www.nidec-asi.com

Variable Frequency DrivesVariable Frequency Drives

PPT2013.01.01.18EN

2www.nidec-asi.com

VARIABLE FREQUENCY DRIVE

• definition

• main components

• applications

• design compliance

VARIABLE FREQUENCY CONVERTER

OUR PRODUCT FAMILIES

Index – Part 1

PPT2013.01.01.18EN

3www.nidec-asi.com

Variable frequency drives (VFDs) belong to a group of equipment called“adjustable speed drive systems” (ASDSs) or “variable speed drive systems”

(VSDSs)

Variable speed drives can be electrical or mechanical, VFDs are electrical only

Variable Frequency DriveDefinition

PPT2013.01.01.18EN

4www.nidec-asi.com

A possible definition of VFD is given by the IEC EN 61800 reference standardthat rules the “adjustable speed electrical power drive system (PDS)” withvoltage above 1 kV a.c.

variable frequency converterinput transformer

induction orsynchronous motor

driven machinemainpowersupply

a.c. adjustable speed power drive system (PDS)as defined by CEI EN 61800-4

Variable Frequency DriveDefinition

PPT2013.01.01.18EN

5www.nidec-asi.com

Input transformer: adaptation of voltage levels, insulation

variable frequency converterinput transformer

induction orsynchronous motor

driven machinemainpowersupply

a.c. adjustable speed power drive system (PDS)as defined by CEI EN 61800-4

Variable frequency converter (VFC): change of fixed frequency power sourceinto variable frequency voltage and current

A.C. motor: conversion of electrical power into mechanical rotating power

Variable Frequency DriveMain Components

PPT2013.01.01.18EN

6www.nidec-asi.com

Motor side connection

• Torque distortion

• Motor thermal stresses

• Train dynamics

• Train operability

Electric Grid interface

•Current & Voltage distortion

• Power factor Improvement

• Flicker Control

Subsystem Design

• Substation

• Power Conversion

• Control System

• Auxiliaries

• Power Quality

Automation

• Process Design

• Algorithm Development

• Greenfield turn-key plants,revampings, expansions

• System Integration

An integrated engineering approach

Understanding the overall system issues allows us to design products andsolutions which fit your needs better.

NIDEC ASI is able supply the whole variable frequency drive system

Variable Frequency DriveMain Components

PPT2013.01.01.18EN

7www.nidec-asi.com

NIDEC ASI designs and supplies electric motors, generatorsand VFDs to fulfill the application requirements optimizingthe overall efficiency and performance.

• Basic & detailed design engineering

• Process engineering

• Engineering and Systems Integration

• Complete project and procurement management

• Hardware manufacturing

• Software development and testing

• Installation tests

• Commissioning and tuning

• Upgrades

• After sales service, support and training

Concept

Design

Construction

Support

Integrated Engineering

PPT2013.01.01.18EN

8www.nidec-asi.com

Our R&D Department conducts advanced research in power devices and is able to work withcustomers on innovative products and prototypes.

Our Engineering team in Milan works in close collaboration with both R&D Department and ourMotors & Generators Engineers in Monfalcone to optimize package configuration.

Through our Lean Manufacturing Teams, Engineering & Manufacturing meet on a regularbasis to optimize product configuration and manufacturing processes.

Our field technicians provide constant feedback to our Engineering Dept. and upgrades aredesigned to guarantee a full life cycle to your components.

Integrated Engineering

PPT2013.01.01.18EN

9www.nidec-asi.com

The VFD is used to

• continuously drive a load

(speed / torque control, ..)

• soft start large motors

(weak network, more than one)

• control the output frequency and voltage

(wind generator, tidal turbine, ..)

Variable Frequency DriveApplications

PPT2013.01.01.18EN

10www.nidec-asi.com

The design of the system complies with the IEC EN applicable standards

Variable frequency converters for the North-American market UL marked byField Evaluation (FE) Services or CSA marked by Special Site Acceptance.

Variable Frequency DriveDesign Compliance

PPT2013.01.01.18EN

11www.nidec-asi.com

VARIABLE FREQUENCY DRIVE

VARIABLE FREQUENCY CONVERTER

• main assemblies

• design criteria

• converter & inverter

• d.c. link

• air cooling

• water cooling

• controller

OUR PRODUCT FAMILIES

Index – Part 2

PPT2013.01.01.18EN

12www.nidec-asi.com

The variable frequency converter consists of several standard assemblies:converter, inverter, d.c. link, cooling system, controller

~

=

=

~

converter inverter

cooling system

from input transformer to a.c. motor

controller

d.c. l ink

Variable Frequency DriveVCF Main Assemblies

PPT2013.01.01.18EN

13www.nidec-asi.com

Converter: change of a.c. power with fixed frequency into d.c. power

~

=

=

~

converter inverter

cooling system

from input transformer to a.c. motor

controller

d.c. l ink

Inverter: change of d.c. power into a.c. power with variable voltage and frequency

D.C. link: energy storage

Cooling system: removal of the heat

Controller: control of the motor, monitor and protection of the system

Variable Frequency DriveVCF Main Assemblies

PPT2013.01.01.18EN

14www.nidec-asi.com

NIDEC ASI manufactures with the same design criteria differentproduct lines

Variable Frequency DriveVCF Design Criteria

PPT2013.01.01.18EN

15www.nidec-asi.com

+

0

-

Proven design• VSI and LCI solutions• multi-phase diode and active front-end configurations

State-of-the-art technology

• Thyristor/SCR: Current controlled device, Semi-controlled(turn-on only), Highest V-I rating @ lowest cost, Maturetechnology

• IGBT: Voltage controlled device, Fully controlled, Fasterswitching, Module (mature) or press-pack (emerging), proventechnology.

• IGCT: Current controlled device, Fully controlled, Lowerconduction loss, Press-pack packaging, Proven technology

Reliability of operation:• device selection• sizing (application, load cycle)• full load current test

Variable Frequency DriveConverter & Inverter

PPT2013.01.01.18EN

16www.nidec-asi.com

• Complexity @ highpower

• Complex failuremodes

• Use IGBT and IGCT

VSI (Multi Level H-bridge)LCI

• High distortion

• More subsystems toget high performances

• Use SCR

VSI (3-Level NPC)

• Extensively adopted inSteel industry

• Easy & flexible tocontrol

• Use IGBT, IGCT

Variable Frequency DriveInverter Topology

PPT2013.01.01.18EN

17www.nidec-asi.com

Modularity

• stack (diode and thyristor), phase module (IGBT and IGCT)

• compactness and robustness

• fast change

Switching

• insulation HV/LV by optical fibres

• monitoring

Safety

• HV and LV circuits separation

• key interlock

• IP20 with open doors

Variable Frequency DriveConverter & Inverter

PPT2013.01.01.18EN

18www.nidec-asi.com

d.c. link

Integrated in the phase assembly together with thecapacitors (VSI)

Integrated in the cabinet together with the iron-corereactance (LCI)

Insulation monitor

Earth switch (safety)

+

0

-

Variable Frequency Converter

PPT2013.01.01.18EN

19www.nidec-asi.com

Air cooling system

• forced, in open loop (T environment ≤ 45°C, size)

• draft fan on top

• low pressure inside the cabinet

• suction from the front

• fan redundancy

Variable Frequency ConverterAir Cooling

PPT2013.01.01.18EN

20www.nidec-asi.com

Water cooling system

• deionized, in closed loop (T raw water ≤35°C)

• water pump, redundancy

• filter cartridges

• monitoring (pressure, temperature, flow,conductivity)

• piping (PVC, stainless steel)

• water cooling unit integrated in the cabinet

• fast connections to easily remove the power assemblies

Variable Frequency ConverterWater Cooling

PPT2013.01.01.18EN

21www.nidec-asi.com

Water-to-water heat exchanger

• integrated in the cooling unit (VFC cabinet)

Water-to-air heat exchanger (fin fans)

• raw water not available, T external air < 50°C

• external to the cabinet

• deionized water loop only

Water chiller unit

• raw water not available, T external air up to 52°C

(higher T on request)

• special machines

waterchiller

Variable Frequency ConverterWater Cooling

PPT2013.01.01.18EN

22www.nidec-asi.com

Drive controller

• full digital

• motor control (V/Hz, sensorless, FOC algorithms)

• monitoring and protecting functions (transformer, VFC, motor)

• auxiliary circuits management

• hardwired and serial interface

• remote monitoring and diagnostic capability

HMI

• graphic display

• indication in full language (user friendly)

• local control of the system

Variable Frequency ConverterController

PPT2013.01.01.18EN

23www.nidec-asi.com

VARIABLE FREQUENCY DRIVE

VARIABLE FREQUENCY CONVERTER

OUR PRODUCT FAMILIES

• SILCOVERT TN

• SILCOVERT GN

• SILCOVERT TH / NH

• SILCOVERT S

• customized solutions

Index – part 3

PPT2013.01.01.18EN

24www.nidec-asi.com

SILCOVERT TN 3300V are medium voltage IGBT based voltage source inverters for variablefrequency supply of induction motors. These modular units are built using standardassemblies that can be customized to the most demanding applications.

~

=

=

~

front end inverter

cooling system

controlunit

input

transfo

rmer

induction

moto

r

ApplicationsExtruders, pumps, fans, mixers, compressors, metals applications, propellers andthrusters for marine applications and wind generators

A single converter with maximum adaptability.A NPC type, Voltage Source, IGBT inverterwith both Diode Front End and Active Front Endconfigurations and easy integration intoautomation solutions with serial communicationcapabilities.

Our Product FamiliesSILCOVERT TNTM

PPT2013.01.01.18EN

25www.nidec-asi.com

+

0

-

Our Product FamiliesSILCOVERT TNTM

Technical CharacteristicsMain Supply 3-phase:DFE(12P) 2 x 1800 V±10%;DFE(24P) 4 x 1800 V±10%; andAFE: 3000 V +/- 10%

Efficiency: ≥ 0.98 (50 Hz, rated load)

Output Frequency: 5 – 70Hz (extended to 140Hz)

Output Voltage: 0 – 3300V (3 phase); PWM

Output power range: Air Cooling 1300-10400 KVA

Water Cooling 3600-21600 KVA

Diode front-end, 12 or 24 pulse (power factor 0,96)

Active front end (regenerative operations)

Induction motor control

Strongly standardized (15 sizes)

PPT2013.01.01.18EN

26www.nidec-asi.com

SILCOVERT GN 3300V are medium voltage IGCT based voltage source inverters.Modular units using standard assemblies: a front end, inverter section, cooling system andcontrol unit.

~

=

=

~

front end inverter

cooling system

controlunit

input

transf

orm

er

induct

ion

moto

r

It provides ultra high efficiency, very high powerfactor (> 0,96), minimum torque ripple and lowinput and output harmonic content and easyintegration into automation solutions.

Our Product FamiliesSILCOVERT GNTM

Applicationsship propulsion, high torque / overload / dynamic requirements (metals), large centrifugalloads (pumps, compressors, fans) …

PPT2013.01.01.18EN

27www.nidec-asi.com

+

0

-

Our Product FamiliesSILCOVERT GNTM

Technical Characteristics

Mains Supply Voltage (3-phase): DFE(12p) 2 x 1850V ± 10%DFE(24p) 4 x 1850V ± 10%

AFE 2850V ± 10%

Efficiency: ≥ 0,98

Output Frequency: 10 – 65Hz normal / 10 – 110Hz extended

Output Voltage: DFE 0 – 3000V / AFE 0 – 3300V

Output power range: water cooling 9000 to 24.000kVA (higher power on request)

Diode front-end, 12 or 24 pulse (power factor 0,96)

Active front end (regenerative operations)

Induction or synchronous motor control

Standardized (6 sizes)

PPT2013.01.01.18EN

28www.nidec-asi.com

Our Product FamiliesSILCOVERT THTM / NHTM

Silcovert H Series are Multi Level Converters with IGBT power devices and a moreefficient and precise control for induction and synchronous motors.

Silcovert TH – Multi-Level, LV IGBT based, PWM controlled. Available configurations withair cooling systems and water cooling system (power range 500/18700 KVA).

Silcovert NH - The PWM technique with high switching frequency allows an almostsinusoidal motor current with low total losses and ripple-free torque. Its water coolingmethod permits to achieve high output power ranges.

This Series are compatible with your existing motor systems, regardless of brand or age.With our customized retrofit you can achieve increased levels of safety, reliability andefficiency.

Applicationsship propulsion, large centrifugal loads (pumps, compressors, fans) …

PPT2013.01.01.18EN

29www.nidec-asi.com

Technical Characteristics

VSI typeIGBT basedPWM controlled4,16 up to 7,2 kV250 Hz, extended range up to 330 Hz

NH Power range: water cooling 2900/14400 KVAair Cooling 1500/3700 KVA

TH Power range: air cooling up to 8100 KVAwater cooling up to 18700 KVA

Higher power on request for water cooling (NH)Diode front-end, multipulse (power factor 0,96)Input transformer integrated or close to the electric cabinetInduction or synchronous motor controlCentrifugal loads (pumps, compressors, fans), revamping ofExisting motor, high speed applications, …

+

-

+

0

-

Our Product FamiliesSILCOVERT THTM / NHTM

PPT2013.01.01.18EN

30www.nidec-asi.com

=

~

12 pulse diode front end configuration

=

~

24 pulse diode front end configuration

=

~

~

=

active front end configurationmultipulse diode front end configuration

iU1 iU2 iU3

iV1 iV2 iV3

iW1 iW2 iW3

oU

oV

oW

iU1

iU2

iU3

iV1

iV2

iV3

iW1

iW2

iW3

Our Product FamiliesVSI Diagram

PPT2013.01.01.18EN

31www.nidec-asi.com

SILCOVERT S is a medium voltage load-commutated current source inverter (LCI) forsynchronous motors and provides speed regularity, monitoring and braking torque regulation,V/Hz low shaping, Easy integration into automation solutions due to Ethernet communicationcapabilities with digital and analogue interface.

~

=

inductio

nm

oto

r

= ~

rectifier inverter

cooling system

inputtr

ansf

orm

er

DC line reactor

Applicationssoft starter or drive for large centrifugal loads(pumps, compressors, fans), ship propulsion, gasand hydro turbine starter, …

Our Product FamiliesSILCOVERT STM

PPT2013.01.01.18EN

32www.nidec-asi.com

+

-

Technical Characteristics

Mains Supply(3-phase)

Efficiency: >0,99

Output Frequency: 5 - 95Hz

Output Voltage: Air Cooling up to 4500 V

Water Cooling up to 72000 V

6/6 , 12/6, 12/12, 24/12 pulse configurations

4 quadrants operations

Synchronous motor control

Design on project, based on standard stack frames

High reliability (mature technology)

Our Product FamiliesSILCOVERT STM

PPT2013.01.01.18EN

33www.nidec-asi.com

~

6 pulse / 6 pulse configuration

~

12 pulse / 6 pulse configuration

~

12 pulse / 12 pulse configuration

~

24 pulse / 12 pulse configuration

Our Product FamiliesLCI diagrams

PPT2013.01.01.18EN

34www.nidec-asi.com

NIDEC ASI is able to design solutions ad hoc

Our Product FamiliesCustomized Solutions

• auxiliaries (disconnector, switchgear, harmonicfilters, ..)

• ratings

• electric cabinet (overall dimensions, cable i/o, IP,..)

• containerization

• system automation

• serial communication

• ..

PPT2013.01.01.18EN