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HIVECTOL-HVI

Medium Voltage Multi-Lebel IGBT Drives

Copy Right @ Hitachi Ltd.

Contents

Introduction
4Drive Selection

1Product Overview
1.1
1.2
1.3
1.4
1.5
1.6

Introduction
Evolution of Hitachis Drive
HIVECTOL-HVI Features
Product Lineup
Target Application
Drive Cabinet Layout

2
2
3
3
4
5

2Main Circuit Overview


2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

Circuit Arrangement
Operating Principle
Input and Output Waveform
External Pre-charging Circuit
Film Capacitor
Separation Arrangement of Isolation Transformer
By-pass Circuit to Commercial Power Source
Separated Wiring

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8
9
9
10
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11
11

4.1 Selection Flow Chart


4.2 Drive Capacity Selection
4.3 Energy Savings and CO2 Reduction

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21
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5Data
5.1 Dimensional Outline Drawing
5.2 Structural Diagram
5.3 External Interface Terminals
5.4 Specifications
5.5 Options
5.6 Spare parts
5.7 Efficiency Curve To Rotating Speed
5.8Specification Form for Estimation

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3Control Circuit Overview


3.1
3.2
3.3
3.4
3.5

Sensor-less Vector Control


Control Board Construction
Graphic Panel
Maintenance Tool
External Interfaces

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13
14
15
16

Copy Right @ Hitachi Ltd.

Product Overview

1.1 Introduction
Hitachi was founded as an electrical repair shop for a mining company and had developed its original 5
HP motors in 1910. For over 90 years since then, Hitachi has established a significant install base of
wide range of products. By means of latest motor control technology, Hitachi contributes to improving
product quality and to achieving energy saving in many industries such as Iron & Steel, Water Treatment,
Chemical Processes, Transportation, and Electrical Power.

1.2 Evolution of Hitachis Drive


Hitachis Variable Speed Drive Motor history of 75 years started with the DC motor of Ward Leonard.With the
evolution of power semiconductors, motor drives have evolved from thyristor to GTO to IGBT systems. Based upon
our knowledge and experience from these technologies, we have developed HIVECTOL-HVI as a modern industrial
motor drive. We use proven and well accepted IGBT devices for multilevel inverter in a configuration to adapt to
industry standard voltages such as 2.4kV, 3.3kV, 4.16kV and 6.6kV.

2007

30MVA IGBT Drives for steel rolling mills delivered

2001

8MVA HIVECTOL-HVI for utility thermal power plants delivered

1999

Medium Voltage Multi -level IGBT Drives, HIVECTOL-HVI, delivered8MVA

1995

20MVA GTO Drives for steel rolling millsdelivered

1986

Medium Voltage AC Drives for steel rolling mills delivered

1982

The world's first Digital Thyrister Leonard Drives delivered

1973

DC drive controls, HILECTOL, delivered

Copy Right @ Hitachi Ltd.

Product Overview

1.3 HIVECTOL-HVI Features


High Performance

High Performance

High Performance

Multilevel conversion method reduces input side


harmonics and conforms to the IEEE519-1992
recommended performance without having to use
harmonic filter.
High Function

Installation Flexibility

High Flexibility

Series connected IGBT cell inverter controls the output


waveform distortion and approximates it to a sine
waveform. This reduces stress on the motor insulation
and enables trouble free application with the existing
motors.
High Reliability

Separate installation of the transformer cabinet and


inverter cabinet is possible.

1.4 Product Lineup

Low Loss

User friendly HIVECTOL-HVI-Power/Voltage Map

Reducing the parts count by patented external precharging method.


High Reliability

Low Cost

High Reliability

Patented control method provides smooth starting and


operation with high torque loads and impact loads,
without use of a speed feedback sensor.

Space Saving

Use of long-life film capacitors in the main circuit


reduces maintenance costs.

13.8

Outpu t Voltage (kV)

High Reliability

11.0

Air Cooling Type


6.6
4.16
3.3
2.4

500

1,000
5,000
Drive Capacity (kVA)

10,000

50,000

Product Overview

1.4 Target Application

FDFForced Draft Fan IDFInduced Draft FanGRFGas Recirculation Fan


GMFGas Mixture Fan PAFPrimary Air FanBFPBoiler Feed Pump

Torque Charac
Industries
Oil & Gas
Chemical
Paper & Pulp

Variable Torque (square law)


(Benefit: Energy Saving/CO2 Reduction)
Furnace FDF/IDF, Sulfur Recovery Blower
Charge Pump
Process Fan, Desulfurization Blower,
Flux Process Pump, Refrigeration Machine

Constant Torque, Constant, Constant Output


(Benefit : Flexible and Reliable Production)
Large Gas Compressor
Polymerization Can, Agitator , Extruder,
Cutter, Various type of Compressor

Cleaner Pump, Fan Pump, Refiner

Paper Machine, Pulper

Kiln Air Exhaust Fan, Dust Collection Fan,


Cooling Fan, Extractor Fan
FDF, Furnace Combustion Blower,
Dust Exhaust Fan , Descaling Pump
Combustion Process Blower, Feed Pump,
Refrigeration Machines, Dust Collection Machine
Combustion Air Sending Blower, Feed Pump,
Dust Collection Machine

Kiln, Crusher , Ball Mill, Vertical Crushing Mill,


Grading Machine

Power Generation

FDF, IDF, GRF, GMF, BFP

Coal Mill, Pulverizing Machine

Food & Beverage

Extractor Fan , Air Conditioning Fan

Agitator, etc.

Water & Waste Water

Water Pump, Waste Water Pump

Transportation & Logistics

Tunnel Ventilation Fan, Wind Tunnel Test Facility

Machinery Manufacturing

Fan Test Facility, Hydraulic Pump

Turbine Balance Machine,


Test Power Supply Facility

Common Industry Functions

Boiler FDF/IDF/GRF/PAF/GMF/BFP,
Seawater Pump, Circulation Water Pump

Coal Mill, Petroleum Coke Mill, Biomass Mill

Others

Parking Garage Ventilation Fan

Others

Ceramic / Earth & Rock


Steel / Nonferrous Metal
Textile
Rubber

Hoisting Machine, Conveyer


Agitator, Extruder, Spinner, Hoisting Machine
Agitator, Extruder, Conveyer

Product Overview

1.6 Drive Cabinet Layout


HIVECTOL-HVI is composed of Isolation Transformer, Inverter Section and Control Unit.
Isolation Transformer

Inverter Section

Control Unit

Depending upon the installation space the


transformer can be set right next to the inverter.
Transformer can also be set separately from
the inverter. There is a fan on the top of the
transformer cabinet.
Input power can be fed from either top or the
bottom.

Inverter cells are mounted in inverter cabinets.


The number of cells depend upon the number
of levels & voltage.
Transformer secondary phase connections are
made from the rear side to each cell.
Each type of control board, fuse, control power
supply is mounted in front of each inverter cell
for easy access and maintenance.

Components inside the control


cabinet, such as relay, electronic
boards, control power supply and
terminal blocks are mounted on the
front side. This facilitates easy
component replacement and
maintenance.

Isolation Transformer

Inverter Section
Power Source
Connector for Fan

Fan

Control Unit

Transformer for
Control Source

Fuse

Fan

Precharge
Resistor

Primary
Terminal
Relay
Control Board
Terminal Block
Fuse
Circuit Breaker
Secondary
Terminal

Main Transformer

Contactor

Driver Board

Drive
Interface
Board

Cell
Output Bus
Inverter

Main Circuit Overview

2.1 Circuit Arrangement


HIVECTOL HVI inverter uses series connected IGBT inverter cells. Each inverter cell is fed from a
separate secondary winding. Each inverter cell has a 6 pulse diode rectifier that supplies DC voltage
to two level IGBT inverter section. Series connected cell inverters are switched in multiplexed mode
and their output step voltages are added to generate a multi-level output voltage that is closer to a
sine-wave form.
The number of inverter cells in a series
connection determine the magnitude of the
output voltage.

Medium Voltage Direct Inverter


HIVECTOL-HVI Series Circuit Arrangement

For example, 4 inverter cells connected in


series per phase (total 12 units for three
phases) will generate 3kV stepped output
and 8 inverter cells connected in series per
phase will generate 6kV stepped output.
The isolation transformer has multiple phase
shifted secondary windings. Viewed from
primary side, there is multi-pulse conversion
of AC to DC voltage (The number of shifted
phase outputs x 2 conversions per cycle).
This offers lesser distortion of the voltage
waveform at transformer primary.

Inverter Section

Isolation
Transformer

Control Circuit

Main Circuit Overview

2.2 Operating Principle

Waveform Phase Voltage

Output Level of Each Drive

HIVECTOL-HVI is composed of inverter section


which connects multiple transformer and cell
inverter, and control circuit section which
controls switching.
Cell inverter consists of three phase input diode
converter and two levels IGBT inverter for one
phase output. Cell inverter generates DC voltage
from three-phase full wave rectification. For
example, for 620V DC per one inverter cell will
generate 2480V instantaneous, for 4 cells in
series. For 3.3kV output voltage, the inverter will
have 4 cells x 3 phases = 12 cell inverters.
By star connecting these multistage connected
inverter cells, line voltage 3,037 volts can be
generated. 3.3 kV output is then achieved by
adding 3rd harmonic vector offset to the output
voltage vector.
Cell inverter can output the waveform which is
very close to the sine wave because of
multilevel addition of voltages and PWM control
by IGBT.

Level 9
Line Voltage Waveform

Main Circuit Overview

2.3 Input and Output Waveform


Along with the development of the power electronics, harmonics generated by the
frequency converters are being strictly controlled. For a simple 6 pulse rectifier a harmonic
suppression filter may be required to limit magnitude of allowable harmonic currents in the
supply line. HIVECTOL-HVI series inverters use phase shifted isolation transformers.
Typical 18 pulse or higher rectifier operation eliminates need for any harmonic filters on
input side.
Inverter section connects single phase IGBT PWM inverter cells to generate a output
waveform that is very close to the sine wave. Generally this enables operation with
existing motors without need for a output filter. Furthermore, the motor noise during
operation is also reduced.
LineLine
-side current distortion content

Current distortion

IEEE-519-1992
Current Distor tion Guideline

Output Voltage

Output Current

Harmonics

Main Circuit Overview

2.4 External Pre-Charging Circuit


Pre-charging circuit charges the DC capacitor before the input medium voltage breaker
is turned on. This is done in order to prevent the inrush current required by capacitor
charging when the medium voltage main power supply turns on.
HIVECTOL-HVI uses a separate LV power source for pre-charging. This power supply is
switched on for about 20 seconds, during which capacitors in the inverter cells charge.
Once capacitor charging is completed, the LV supply is disconnected and the medium
voltage breaker for main supply is turned on.
Compared to a pre-charging
Cell Unit
circuit that uses a thyristor
Inverter
switch and a resistor in each cell
Multiple
Transformer
unit, the arrangement of
DCC
Medium
separated pre- charging circuit
Voltage
Main PS
is simple and easy to maintain.
Induction
This design leads to high
Motor
Medium
Voltage
reliability in inverter operation.
Breaker
Separated pre-charging circuit
method has been patented by
Pre-charging
Hitachi Ltd (Patent
Resistor Circuit
Pre-charge PS
No.3,535,477).
(200V or 400V)

Main Circuit Overview

2.5 Film Capacitor


Capacitors are used to smooth the DC voltage. These capacitors are usually electrolytic
type. However expected life-span of electrolytic capacitors is rather short. This may
cause frequent capacitor replacement and result in higher maintenance costs.
HIVECTOL-HVI inverter uses film capacitors. This type of capacitor has higher durability
and longer life-span.
Use of film capacitors drastically reduce the amount of maintenance cost for capacitors.

Running Cost

Film
Capacitor
Electrolytic Capacitor

Film Capacitor

Tenure of Use

Running
Cost
Deviation

10

Main Circuit Overview

2.6 Separation Arrangement of Isolation Transformer


While considering installation of inverter in an air conditioned electrical room, the
capacity of the air conditioning unit needs to be considered carefully in order to allow
proper air-flow and cooling.
The inverter isolation transformer needs to be installed in the electrical room, as it
generates heat and causes larger capacity air conditioning units to be installed.
The multi-winding isolation transformer can be installed separately from the drive cabinet.
The separately installed transformer can also be oil filled.
This type of installation saves space in electrical room (pre-fabricated or otherwise) and
significantly reduces the required air-conditioning capacity for the electrical room.

Electrical
Room

Isolation
Air
Transformer
Conditioner

Inverter
Section

Control
Unit

Electrical
Room

Air
Conditioner

Inverter
Section

Control
Unit

Isolation
Transformer

11

Main Circuit Overview

2.7 By-pass Circuit to Commercial Power Source


By-pass circuit is useful primarily for two
purposes.
Direct Start of Motor
In case of maintenance or failure of inverter,
the by-pass circuit can start and run the motor
on backup mode.
Soft Starting and Stopping of Motor
Inverters are used only during starting or
stopping of the motor.After the motor starts
up, the by-pass curcuit is engaged to
commercial power source, allowing the motor
and the load to gently start and stop.

By-pass
Circuit
Transformer

Multi-level Inverter

Induction Motor

12

Main Circuit Overview

2.8 Separated Wiring


During site installation, signal cables, power cables and grounding cables need to be separated.This
helps in avoiding any disturbance to field signals and drive control signals from power circuit. Important
reminders are as given below:
Avoid electrical noise from
inductive loads and radio noise
from power cables and ground
cables by separating them.

Transformer
Main
Power Supply

Main Circuit
Output Terminal

Main Circuit
Input Terminal

Main Circuit
If the separation of cables is
Input Terminal
difficult, then use metallic pipe
Earth Terminal
or metallic board as a shield.
Use shielded twisted pair cable
for control and field signals.
Set each grounding wire
A Type
mutually apart.
Grounding
Electrode
Prepare the specific grounding
for the inverter.
Make sure that minimum size
EB : Medium Voltage Earth Terminal
for grounding cable is over
CB : Low Voltage Earth Terminal
38mm2.
E1 : Isolation Transformer Power Cross
Preventing Plate Earth Terminal

Inverter
Section

Control Unit
Main Circuit
Output Terminal

Main
Circuit
Input
Terminal

Earth
Terminal

B Type
Grounding
Electrode
(Less than
10)
for Low V
Circuit

C Type
Grounding
Electrode
(Less than
10)
for Low V
Circuit

A Type
Grounding
Electrode
(Less than
10)
for Low V
Circuit

Exist
Grounding
Electrode
A Type