MV Drive Specification
Specification for
2.4 kV and 3.3 kV
MV VSD
Specification for ALTIVAR 1000 2.4 & 3.3 kV
Motion & Drives – REV 01 – Juin 2009
1 / 14
MV Drive Specification
Table of Contents
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
INTRODUCTION……………………………………………… P03
GENERALITY ………………………………………………… P03
2.1 Power supply
2.2 Environmental conditions
STANDARS COMPLIANCE…………………………………. P04
VFD GENERAL DESCRIPTION…………………………….. P05
. Reliability
. Availability
. Efficiency
. 2 quadrants operation
. 4 quadrants operation
. Harmonics mitigation on network side
. Power factor on network side
. Wave form on motor side
. Maintainability
VFD PERFORMANCES……………………………………… P07
5.1 Speed performances
5.2 Overload capacity
5.3 2 or 4 quadrants operation
5.4 Torque control
5.5 Audible noise level
VFD PREFERED TECHNOLOGIES………………………... P07
VFD CONTROL UNIT………………………………………… P08
7.1 Hardware
7.2 Software
7.3 Main functions available
7.4 Interface with the operator
7.5 Optional interface
7.6 Optional expansion board
VFD PROTECTIONS and FAULTS MANAGEMENT……. P09
VFD INPUT / OUTPUT CONFIGURATION………………... P10
VFD LOCAL-REMOTE CONTROL…………………………. P10
VFD COOLING SYSTEM…………………………………….. P11
ENCLOSURE………………………………………………….. P12
INPUT STEP DOWN TRANSFORMER……………………. P13
QUALITY ASSURANCE…………………………………...P14
STANDARD SERVICES…………………………………... P14
OPTIONAL SERVICES ON REQUEST (Optional)…..... P14
Specification for ALTIVAR 1000 2.4 & 3.3 kV
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MV Drive Specification
1 INTRODUCTION
1.1 This specification impact the design of medium voltage AC drive including input step down
transformer. Supplier offer will be in accordance with data mentioned in attached document.
(Inquiry form)
1.2 This inquiry form will be filled in by the Purchaser. The VSD supplier will complete and submit
it with the proposal.
1.3 The VFD shall be factory pre-wired, assembled and tested as a complete package, Drive +
Transformer, by the VFD supplier. Customer specific drive, motor, and application data should be
pre-loaded into the operator interface and tested prior to shipment.
1.4 Experience
The VFD supplier shall demonstrate experience in manufacturing VFDs at medium voltage for
similar applications at the desired voltage and power ratings.
1.5 Acceptable Manufacturers
1) Schneider Electric
2)
2 GENERALITY
2.1 Power supply
2.1.1 Whatever the power supply voltage in the plant, the drive will be able to supply 2.4kV or
3.3kV Asynchronous motor
2.1.2 The Drive shall accept nominal voltage up to 36 kV (more on request) 50Hz or 60Hz. The
supply input voltage tolerance shall be +/- 10% of the nominal line voltage.
2.1.3 3 phase auxiliary power supply has to be provided by the customer to power The Precharge
circuit of capacitor bank, the VFD cooling system and VFD control circuits. The auxiliary power
voltage shall be 400V. Auxiliaries shall be supplied with single phase 230V when UPS line
voltage is available.
2.2 Environmental Conditions
2.2.1 The VFD shall operate in an ambient temperature range of 0°C to 40°C (32°F to 104°F)
with a relative humidity of up to 95% (non-condensing
2.2.2 The equipment shall be capable of being stored in an environment with an ambient
temperature range of -20°C to 65°C (-4°F to 149°F).
2.2.3 The equipment shall operate at altitudes from 0 to 1000 m (3,300 ft.) above sea level,
without de-rating.
For applications above 1000 m, and/or out of ambient temperature limits mentioned above, VFD
shall be de-rated according to the Customer specification (data in Inquiry form)
Specification for ALTIVAR 1000 2.4 & 3.3 kV
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MV Drive Specification
The VFD shall be designed to withstand the following conditions:
Environment
Power transformer installation
Variable frequency drive installation
industrial, non-hazardous, safe area
indoor, pollution degree 2 or better (EN 61800-5-1)
indoor, pollution degree 2 or better (EN 61800-5-1)
3.0 STANDARDS COMPLIANCE
3.1 The Supplier’s equipment shall comply with the applicable requirements of the latest
standards published by the following organizations:
As a standard:
 International Electrotechnical Commission (IEC) 61800-5 AC Drives Standard
 European Directives for Safety and EMC
 Guide for Harmonic Control and Reactive Compensation of Static Power Converters
(IEEE 519-1992)
 Russian standard (GOST)
As an option:
 Canadian Standards Association (CSA)
 American National Standards Institute (ANSI)
 National Electrical Manufacturers Association (NEMA)
 Underwriters Laboratories, Inc. (UL)
On request according to the project:
 Australian standards
 Customer specification (DEP Shell ….)
Note:
According to the EU Machinery Directive 98/37/EC (2006/42/EC) or outside EU applicable laws,
the VFD is not a complete machine and it shall be incorporated into a system before to be
operated. All the functional safety relating functions needed by the system shall be guaranteed by
the System Integrator.
3.2 Standards
Variable frequency converter in cabinet
IEC EN 61800-_
Part 3
Part 4
Part 5-1
IEC EN 60146-1-_
Part 1
IEC EN 60204-_
Part 1
Part 11
IEC EN 60529
Adjustable speed electric power drive system
EMC requirements and specific test methods
General requirements – Rating specifications for AC power
drive systems above 1000 Vac and not exceeding 35 kV
Safety requirements – Electrical, thermal and energy
Semiconductor converters
General requirements and line commutated converters
Basic requirements
Safety of machinery – Electrical equipment of machines
General requirements
Requirements for HV equipments for voltage above 1000
Vac and 1500 Vdc and not exceeding 36 kV
Degree of protection provided by enclosures (IP code)
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MV Drive Specification
Step-down power transformer
IEC EN 61378-1
Part 1
IEC EN 60076-_
IEC EN 61800-
Part 3
Converter transformer
Transformers for industrial applications
Power transformers
EMC requirements and specific test methods
4 VFD GENERAL DESCRIPTIONS
4.1 The drive shall be of modular design to provide for ease and speed of maintenance. Metal
barriers shall be provided between each vertical section and between the low voltage
compartment and the power cell. Personnel shall have access to the low voltage compartment,
with the VFD energized, without being exposed to any medium voltage.
4.2 The VFD shall produce a variable voltage and variable frequency output to provide
continuous operation over the application speed range. The VFD shall be capable of operating
with the output short circuited at full current or with the output open circuited at rated voltage.
4.3 VFD shall be capable of operating the following motor of equivalent power and speed rating
over the speed range specified in Inquiry form:
=> Standard AC squirrel cage induction motor
4.4 According to the application and to the Customer requirement, VSD shall have an adapted
architecture to give the best performances on these points:
 Reliability
 Availability
 Efficiency
 2 quadrants operation
 4 quadrants operation
 Harmonics mitigation on network side
 Power factor on network side
 Wave form on motor side
 Maintainability
The final solution will be the best compromise between the technical choice and the cost
4.4.1 Impact of the VSD on network side
The supplier shall provide the best solution according to the points mentioned above:
 Constant power factor > 0,95 whatever the power level and speed level this performance will
be reached without any special device (reactor, capacitor…)
 Control of harmonics distorsion
- For 2 quadrants operation (variable torque application) the supplier shall provide the right
solution for the input rectifier bridge “DFE”: 12 or 24 pulse, the choice will be made to reach
the distorsion level expected. With 24 pulses the solution will meet the G5/3 and IEEE1992
harmonic limits (THDI< 5%) without the need of harmonic filter which would introduce
additional losses.
- For 4 quadrants operation (Constant torque application) the supplier shall provide a full
controlled rectifier bridge “AFE” with additional input filter who will provide an THDI <5%
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MV Drive Specification
4.4.2 Wave form on motor side
The VFD shall provide near sinusoidal voltage and current waveforms to the motor at all speeds
and loads. Output current THD shall be less than 5%. The motor insulation system shall not be
compromised thermally or due to dV/dt stress. dV/dt at the motor terminals shall be limited. The
supplier shall provide data regarding:
 Harmonic spectrum
 Maximum dV/dt
 Maximum peak voltage according to motor and cable length
To reach the customer requirement, VSD could be equipped with an output sinus filter
 If sinus filter is required:
- VSD Control will be able to adjust the switching frequency in order to optimize the sinus filter
design and to eliminate potential harmonic resonance in the operating speed range
 In any case the solution shall reduce torque pulsation to the output of the mechanical system
and minimize the possibility of existing resonance.
4.4.3 Reliability
This parameter is mainly link to the number of power components use for the rectifier bridge and
the inverter bridge. To reach the best result the supplier has to propose the most adapted
solution.
M.T.B.F. will be better than 50 000 H
4.4.4 Efficiency
This parameter is mainly link to the number of power components use for the rectifier bridge and
the inverter bridge. Losses are produced during the commutation of these components. To reach
the best result the supplier has to propose the most adapted solution.
VSD efficiency will be better than 0,98 (without transformer and 96% with transformer) at 100%
speed and 100% load. According to the full package solution Transformer, Drive, Sinus filter if
required, the supplier will provide total losses calculation.
4.4.5 Availability
The VFD system shall be designed for a minimum availability of 99.9%.
4.5 Maintainability
M.T.T.R (medium time to repair) not more than 30 minutes
Specification for ALTIVAR 1000 2.4 & 3.3 kV
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MV Drive Specification
5 VFD PERFORMANCES
5.1 Speed performances
The drive system shall provide controlled speed over the range specified. Speed accuracy within
this range, expressed as a percent of top speed, shall be equal or better than :
=> 0.1% of base speed without encoder or pulse tachometer feedback
=> 0.01% with encoder or pulse tachometer feedback
5.2 Overload capacity
The VFD shall have a “normal duty” rating of 100% continuous current.
According to the application, it shall be able to manage:
=> 110% overload (Class 1) for one minute, once every 10 minutes suitable for variable torque
loads according to IEC146-1-1
=> 150% overload (Class 2) for one minute, once every 10 minutes suitable for constant torque
loads according to IEC146-1-1
All these performances are reached without speed feedback.
5.3 2 or 4 quadrants operation
According to load inertia or to process requirement, a preference shall be given to VFDs capable
of regenerative motor braking.
5.4 Torque control
The VFD shall utilize sensorless direct vector control or full vector control, with pulse tachometer
feedback, for optimum performances.
5.5 Audible Noise Level
Maximum audible noise from the VFD or associated VFD system shall be limited to 85dB(A). with
air Cooling system and 75 dB(A) with water cooling system
6 VFD PREFERED TECHNOLOGIES
VSD Power Inverter bridge shall be built with the newest power component technology like IGBT
and the selected semiconductors with adapted characteristics. This choice will have an impact on
=> Inherent short circuit protection: the IGBT can be switched off under short circuit conditions
=> Low power for the gate driver circuit
=> High switching frequency: PWM modulation works at a higher frequency than for other power
semiconductors ensuring a cleaner motor waveform.
=> Standard components.
=> IGBT can be easily paralleled in order to increase the power delivered by the drive.
=> Snubberless design: IGBT doesn’t need any RC damping network in parallel to control the
over-voltage during commutation.
=> Less components, less losses and better reliability.
=> Firing of Power semiconductors shall be done by means of optic fiber
=> Commutation control and feedback for fault management shall be done by means of optic
fiber.
Specification for ALTIVAR 1000 2.4 & 3.3 kV
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MV Drive Specification
7 VFD CONTROL UNIT
7.1 Hardware
The control system shall be based on a dedicated microprocessor card with a fast DSP controller
designed for motor control including:
=> The basic motor controller board;
=> The PWM modulator board;
=> The expansion board for an easy customisation of the application.
The motor controller card shall include:
=> Analog/Digital input interfaces for signal conditioning (Encoder pulse, Current and Voltage
transducers);
=> A digital set with two processors and an analog sub-system for A/D conversion. The first one
is a high speed 16 bits microcontroller for process control tasks, communication diagnoses and
user interface. The second one is a customized processor (DSP) for the high speed control loops,
peripheral functions for PWM generation and sensors evaluation;
=> Dedicated HW for handling the interfaces with the other devices.
7.2 Software
The motor control system shall contain two options that can shall be selected during
commissioning:
=> V/Hz control mode,
=> Flux Vector control mode without sensor
=> Flux Vector control mode with sensor
7.3 Main functions available with the standard control system
The VSD Control shall be able to manage the following fonctions
=> Catch on the fly
=> Capability of driving the motor in torque mode, with an external speed loop
=> + / - speed built in
=> Ramp switching can be selected in a different way
=> Under-voltage management without tripping
=> Three preset speed set points
=> Jog operation.
7.4 Interface with the operator
Control system shall be programmable by means of a key-pad, with an LCD display. As an
alternative, a Software running on a personal computer shall be available to achieve a better man
machine interface and a better display area.
By means of the interface (key-pad or PC) the following operations shall be done:
=> Inserting, changing, reading the parameters
=> Reading value of analog / digital quantities
=> Archiving data, on a printer with the key-pad or on a disk with the PC.
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MV Drive Specification
7.5 Optional Interface with the automation system
The connection to the automation system shall be possible by means of dedicated ports, installed
on the control board and available on customer request. (As to be mention in Inquiry form)
By means of the serial communication it will be possible to make many of the operations
explained in the previous paragraph and also to send / receive data from to the control system.
7.5 Optional Expansion board (PLC like)
An expansion board shall be available on customer request to support-specific functions. This
board is programmed by means of a graphical language (in a PLC-like way), and can support
either logic or control function with a timing down to 1 millisecond.
8 VFD PROTECTIONS and FAULTS MANAGEMENT
VSD shall assume protection and faults management as described in the table below
Power transformer protections
Motor overload
Motor over current
Motor over temperature
Motor side ground fault
Motor stall
5% speed deviation from the reference value
Speed  105% of max. operating value
Speed  95% of min. operating value
DC bus over voltage
DC bus under voltage
Converter over temperature
Inverter over temperature
Cabinet high temperature
Single cooling fan / water pump fault
Redundant fan / pump not available
Cooling water pressure / flow low
Cooling water temperature high
Auxiliary power supply line fault
Instantaneous over current (IOC)
Alarm + Trip
Trip
Trip
Trip
Trip
Trip
Alarm
Trip
Trip
Trip
Trip
Trip
Trip
Alarm
Alarm
Trip
Alarm + Trip
Alarm + Trip
Alarm
Trip
available as an option
available as an option
20” delayed
10” delayed
with auto-reset
water cooled systems only
water cooled systems only
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MV Drive Specification
9 VSD INPUTS / OUTPUTS CONFIGURATION
VSD shall provide the following inputs / outputs configuration
Standard
16
16
2
0
Digital inputs
Digital outputs
Analogue inputs
Analogue output
Options
2+2+2
2+2
10 VSD LOCAL – REMOTE CONTROL
10.1 Remote Control
The following signals will be exchanged between the converter via RS-485 Serial link (ModBUSRTU, or other Communication Protocol ETHERNET, PROFIBUS...) and the Plant DCS:
- Permissive to VFD Running (Protections and Process consents)
- kV Input Main Circuit Breaker (on Customer Switchgear) Closed
- VFD Auxiliaries Start / Stop
- Motor Start / Stop
- Motor Running
- Auto – Manual Control Selection
- VFD Fault (Cumulative for Transformer and Converter)
- Emergency Stop (NC Steady, Hardwired)
- Operating Data (Motor Current, Voltage, Power, Frequency or Speed),
- Configuration Parameters, Alarms, Faults for Remote DCS monitoring
10.2 Local Control from HMI
Manual mode will be managed by H.M.I. located on Cabinet front Door for Maintenance and Test.
- Interface signals between VFD Cabinet and Customer HV Main Switchgear shall be hardwired.
- Emergency signals (push-buttons and so on) between VFD Cabinet and Plant shall be
hardwired.
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MV Drive Specification
11 COOLING SYSTEM
Considering that the cooling system of a variable frequency drive is a critical element of the overall
system, it has to be designed taking into account the ability to be easily installed, maintained, and
monitored. The cooling system can substantially impact the reliability and availability of the drive, and
as such, the customer process.
VSD Supplier shall provide the adapted cooling system according to the customer requirement (to be
specified in Inquiry form)
11.1 Air cooling system
Air-cooled VFD shall be provided with a mixed flow cooling fan, mounted integral to the VFD
enclosure. The VFD shall include air-flow pressure switches and temperature detectors to
monitor proper operation of the air cooling system. If a fan fails, the system must generate alarm
indication of the fan failure. Redundant fan shall be installed to guarantee the VSD cooling
If specified on the attached Inquiry form, provision shall be made for ducting VFD exhaust air
outside the control room.
11.2 Water cooling system
The VSD liquid cooling shall utilize a pressurized, closed-loop cooling system where coolant
(deionized water) circulates between the drive power device (diodes and IGBTs) heat sinks and a
liquid-to-liquid heat exchanger.
Auxiliary fans shall be installed on cabinet front doors to remove residual heat produced by input
fuses, DC capacitors, output reactor, power wiring and auxiliary circuits, all devices not cooled by
deionized water cooling system.
The VSD water cooling system shall be built as describe below:
- Plastic pipe
- All drive piping and hosing shall be contained within the cabinet.
- The cooling unit cubicle shall be mechanically segregated from the VSD power and control cubicles.
- Quick-disconnect coolant connections shall be provided for each power module.
- Customer connections to the drive piping shall be typically via AISI flange connection (from the
bottom of the cabinet).
- Pipe diameters shall be selected to ensure no particle erosion due to excessive coolant flow rates.
- Cooling system high points shall be fitted with a ball valve or auto-vent valve to purge air from the
system
- Two 100 % redundant coolant pumps shall be provided standard with the drive system.
- These pumps shall be automatically cycled by the drive main control to ensure availability and to
prevent dry-up of the pump seals.
- Strainers shall be provided at the suction of coolant pumps.
- The normal operating pressure of the system shall be approximately 5 bars (70 PSI). The system
shall be factory pressure tested at 8 bars (120 PSI) to check for leaks and assure all connections are
proper. The system coolant tank shall provide space for the coolant volume to expand and contract,
resulting in a nearly constant pressure throughout the system at any times.
- A mixed bed deionizer bottle shall be constantly in service ‘polishing’ the coolant. This bottle can
shall be isolated and replaced with the system in service.
- The standard liquid-to-liquid heat exchanger shall be a stainless steel plate/carbon steel frame type.
To provide a high level of availability, the cooling system includes its own protections by means of:
=> Pressure measuring
=> Temperature measuring
=> Flow measuring
=> Conductivity measuring
Each measure is managed to deliver 1 alarm signal and 1 trip signal
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MV Drive Specification
12 ENCLOSURE
12.1 VFD cabinet shall include the following accessories
DC bus precharge circuit
Manually operated DC bus ground switch
Anti-condensation heaters
Internal service lights and socket
Local and remote control
Door mounted LCD user interface
VFD interface terminal board
PROFIBUS serial communication protocol
12.2 VFD enclosures for air cooled shall provide an IP 42 protection. With Water cooling system
the protection level shall be IP 42 on standard version and IP54 on request
12.3 The VFD shall be designed for front access to all components. For special operation during
maintenance, rear access shall be possible
12.4 Power and control cabling shall be done from the bottom
12.5 VSD supplier shall propose a standard color for the cabinet painting and special color
according to the customer request as an option.
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MV Drive Specification
13 INPUT STEP DOWN TRANSFORMER
To adapt the network voltage to the input voltage of the VFD, the supplier shall provide one of the
following transformers according to the VFD rectifier architecture
=> Indoor, dry type rectifier duty transformer
=> Outdoor, oil-filled rectifier duty transformer
VSD dedicated transformer shall have the following caracteristics
Manufacturer
Design
Type
Duty type
Cooling type
Primary winding rated voltage
Rated frequency
Tap changer / type
Secondary winding rated voltage
Rated power
Connection group
Short circuit voltage
Efficiency at full load
Noise level
Protection degree
Overall dimensions: L x W x H
Weight
Installation / Max. design temperature
kV
Hz
%
V
kVA
%
%
dB(A)
mm
kg
°C
Has to be qualified by the supplier
converter transformer
Dry type or Oil type
continuous
AN
Has to be given by the customer
50 or 60
 5 / off-load
According to the VFD rectifier
2 secondaries for 12 pulse “DFE”rectifier
4 secondaries for 24 pulse “DFE” rectifier
1 secondary for “AFE” rectifier
According to the application power
D / d0 / y11
≥7
 98,5 @ cos = 1
< 80 @ 1 m
IP 31 or IP54
0 / +40°C
Standard accessories shall be monted:
 Electrostatic shield between primary and secondary windings
 Porcelain bushings
 Earthing terminals
 Routine factory tests
 Rating plate
 Bi-directional rollers
 Enclosure cabinet IP31, forced air cooled
 No. 6 Pt100 type probes into the secondary windings
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MV Drive Specification
14 QUALITY ASSURANCE
14.1 All inspection and testing procedures shall be developed and controlled under the guidelines
of the Supplier’s quality system. This system must be registered to ISO 9001 and regularly
reviewed and audited by a third party registrar.
14.2 All incoming material shall be inspected and/or tested for conformance to quality assurance
specifications.
14.3 All sub-assemblies shall be inspected and/or tested for conformance to Supplier’s
engineering and quality assurance specifications.
15 STANDARD SERVICES
VFD Supplier shall provide standard services as following:
=> Routine factory tests according to product Quality Control Plan. This document will be available
=> Documentation package according to the IEC standard, composed of:
. Electrical diagram(1),
. Terminal boards diagram(1)
. Service and maintenance handbook in English (1)
16 OPTIONAL SERVICES ON REQUEST (Optional)
16.1 VFD Supplier shall be able to perform:
=> Commissioning at Customer site
=> Training in its factory
=> Training at Customer site
16.2 VFD Supplier shall be able to deliver:
=> Critical Spare parts for commissioning
=> Maintenance Spare parts
16.3 VFD Supplier shall be able to propose on request :
=> Visual Inspection of Equipment
=> Witness Testing
=> Combination Transformer – Drive - Motor Witness Testing
=> Specific Custom Testing
Specification for ALTIVAR 1000 2.4 & 3.3 kV
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