提迈克（tmeic）TMdrive-10 SPR应用指南.pdf提迈克（tmeic）TMdrive-

文件名称: 提迈克（tmeic）TMdrive-10 SPR应用指南.pdf

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详细说明：提迈克（tmeic）TMdrive-10 SPR应用指南pdf,提迈克（tmeic）TMdrive-10 SPR应用指南：SPR的TMdrive-10的转差功率恢复驱动器绕线转子电动机系统的TMdrive-10系列低压系统驱动器设计具有许多节省空间，维护功能，降低拥有成本。We drive industry Slip Power Recovery Wound rotor induction motors have been popular in some industries, particularly cement, for decades. Until about 1985, a wound rotor induction motor(WRIM)was the only large ac motor that allowed controlled starting characteristics and adjustable speed capability A WRIM is a machine with a 3-phase wound stator that is usually connected directly to the power system. The rotor also has a 3-phase winding, usually connected in a wye or star) circuit. The three terminals of the rotor winding are connected to separate slip rings, which are normally connected to a liquid rheostat or resistor bank. Changing rotor resistance changes the motor speed. In the past the power in the resistor was lost as heat. The slip power recovery drive, TMdrive-10SPR, is used to vary the motor speed by varying SAG Mill for grinding ore the power taken off the rotor and returned to the utility supply Slip rings Wound rotor Rotor from WRIM showing Slip Rings Large pumps in a Water Treatment Plant Wound rotor motors continue to be applied in some industries, especially in ore processing, cement, and water/wastewater. Speed control of wound rotor motors has traditionally employed slip power recovery(sPr) drives for cost and energy efficiency reasons. Older implementations of SPR technology saved energy but had disadvantages of low power factor operation and torque puLsations The use of state-of-the-art low voltage PWMconverters eliminates these disadvantages while retaining all the energy savings. This new implementation builds on the standard line of TMEIC low voltage induction motor drives used in process industries such as metal processing and paper machines Therefore the hardware is very reliable and familiar. The TM-10SPR is appropriate for new motors or existing motors Cement Plant C 2011 TMEIC Corporation. All Rights Reserved Page 3 of 12 TMEIC Application 1. Slip Power Recovery Drive System for a water treatment plant Eight large vertical pumps handling wastewater at this Canadian water treatment plant were driven by 4 kv wound rotor induction motors. Four of the motors were 3050 HP, and four were 5158 HP, all controlled by 1975 vintage variable speed controls using diode rectifiers and thyristor converters. Oil-filled rheostats on each motor provided start and speed control The customer need The oil-filled rheostats posed a fire hazard, and parts and service for the old thyristor controls were hard to obtain. the municipality decided to purchase new controls for the original motors and pumps and narrowed the choice down to two systems, a medium voltage drive supplying the Wrim, or a low voltage slip power recovery drive (sPr)connected to the WRIM rotor slip rings, (example on page 5). the new controls were required to fit in the foot print of the old drives The Best Solution: TMdrive-10SPR for each pump The SPr drive carrying slip power is much smaller and less expensive than an Mv drive carrying all the motor power at full speed (4 kv voltage The sPr drive has a smaller footprint than a large stator supply drive Inherent fault tolerance-a failure of the sPr drive will not prevent the motors operation The SPR drive can work with any stator-rated voltage, but an mv drive can be difficult to match with the motor The sPr drive can offer higher overall system efficiency thus saving energy and can perform additional VaR compensation Running at or above synchronous speed is possible if the motors are rated for the higher speeds with the existing cable and conduits buried in the concrete floor o line up The new drive footprint featured a back-to-back configuration to The HMI has one button to switch from English to French displays CSA approval required a special inspection for this non-standard panel One of eight pumps Application 2. Slip Power Recovery Drive System for a grinding mill This new $250 M ore processing facility in Papua New Guinea can process up to 4.7 million tons of ore per year, resulting in about 275,000 ounces of annual gold production. This variable speed drive application is a dual-pinion Sag mill driven by two 5,000 kW wound rotor induction motors. Two TMdrive-10SPRs control motor speed by recovering rotor current and returning the power to the utility supply The customer need Reliability, power dependency and logistics were a challenge for this project. Limited access to the mine's extremely remote location required power recovery and stellar reliability in its operations. The best solution tMdrive-10SP for each mill motor The TMdrive-10SPR has high reliabil ity and a good track record Configured in a twin motor arrangement, the motors share load in the tandem mill. The first motor provides speed control, the second motor provides torque control Continuously recovers an estimated 770 kW Inherent fault tolerance- a failure of the spr drive will not prevent the motor s operation The SPr drive offers high overall system efficiency thus saving energy, and can perform additional VAR compensation SAG Mill and motor Page 4 of 12 C 2011 TMEIC Corporation. All Rights Reserved We drive industry Application 3. Energy Savings using Slip Power Recovery Drive System The example below compares the case of an induction motor driven by a large standard drive, with the case of a Wri controlled by a small SPR drive, and calculates the energy savings. In the larger standard drive system all the motor power passes through the drive. With the spr drive, only a fraction of the motor power passes through the drive For a rated pump load of 5,000 hp, running at 90% speed, the power saving using the SPr drive is 88 kW. With an electrical cost of 7c/kWh, the annual savings amount to $53, 960. At lower speeds the savings are even higher Compared to a WriM using only a rheostat to control speed where all of the slip power is wasted as heat, the sPr drive saves $176,000 annually P1 Utility supply P5 Slip power recovery flow after Power flow transformer MV Variable Speed Drive (larger capacity) Power flow to P2 Power flow to motor stator Transformer motor stator P4 Power supply flow to sPR TMdrive-10SPR Induction (smaller drive Motor power Tlow P3 Wound r Motor shaft Induction motor power flow Pump shaft power flow Pump P2=P1- Drive losses dmp P3-P2- Motor losses P2=P1+P P4=P2-P3- Motor losses P5=P4- Drive tfr mr losses Standard drive induction motor Slip power recovery Drive and Wound rotor Motor Power Standard Drive Operating Conditions Slip power Recovery Drive Wound Flow Induction motor Rotor motor Pump load at full speed shaft kw 3730kW(5,000hp)3730kW(5,000hp) Pump load at 9o% speed shaft kW P3 2720kW 2720kW Utility supply power flow P1 2980kW 2892kW Power flow to motor stator P2 2863kW 3180kW Power flow to Slip power recovery drive P4 300kW P5 Slip power recovery after transformer 0 288kW Difference in uti lity power flows 88 KW P1(Induction motor)-P1 (WRIM) $53, 960 per year SPR system savings with 7c/kWH electrical power C 2011 TMEIC Corporation. All Rights Reserved Page 5 of 12 TMEIC A Look Inside TWo-Level Phase Leg Assembl The cabinet style inverters have modular two-level phase leg assemblies. Each phase leg cludes. IGBTs with flyback diodes Heat pipe assembly IGBT gate driver circuit board oa0o00040t自 0060000d Control Functions Each inverter and regenerative converter shares a common set of control boards. The primary control board performs several functions: Speed and torque regulation · Sequencing 10 mapping Diagnostic data gathering A mounting bracket is provided for an optional Lan interface board Incoming Power The converter in each lineup is fed 3-phase ac power. In addition, 3-phase ac control power is fed to each converter and inverter in the lineup. A control power disconnect is provided in each cabinet NIA!LA !MM1!!!!!!阳 Page 6 of 12 C 2011 TMEIC Corporation. All Rights Reserved We drive industry Heat Pipe cooling logy he cabinet st erters and regenerative converters use heat pipes to cool the IBGT power switches and capacitors. This technology reduces the footpr of the power bridge as well as the airflow requirements saving valuable floor space and dramatically reducing the audibl noise Vo Be AllTMdrive-10 products share a common i/o board the l/o board supports an encoder 24 v dc v/O 115V ac inputs, and analog 1/o, standard. In addition a resolver interface option can be provided ◆二 All l/O are terminated to a two-piece modular terminal block for ease of maintenance DC Bus The converter in each lined generates dc power for each of the erters. the inverters then create variable frequency ac power to control the induction motors. this dc power for the lineup is conveyed u on a solid copper bus near the bottom of the cabinets Tin-plated bus may be used C 2011 TMEIC Corporation. All Rights Reserved Page 7 of 12 TMEIC Operator Interface High Function Display LCD backlight gives great visibility and long life Easy-to-understand navigation buttons Bar graphs, icons, menus and digital values combine to allow quick access to information provide concise status information, often eliminating the without resorting to a PC-based tool need for traditional analog meters NAVIGATION Mot d 1431.5的in-1-51 Motor 430.9 % RJ-45 Ethernet port rotor Current is used for the local toolbox connection 米 Es Enter dicates aarm ● READY G RUN . ALARM/ FAULT A so/d LED indicates Fau. CONTROLS TOOL D/A 6666e 的协國 ANALOG CHECK INTERLOCK Instrumentation nterface Two analog outputs are dedicated to motor Interlock button Switch to local current feed back disables the drive mode and operate Five analog outputs can be mapped to the equipment right variables for external data logging and analysis from the keypad How to Apply SPR Application of the TMdrive-10SPR starts with the motor The rating of the converter is determined from the speed speed range, the rated rotor current, the rated rotor range and the power to be recovered from the rotor voltage (at standstill), and any overload requirements. For a variable torque load (pump or fan), the maximum The speed range and the rotor voltage determine the regenerated power is 15% of the motor rating By contrast, maximum operating voltage of the TMdrive-10SPR. Thethe power regenerated from a motor powering a constant rotor voltage is at rated value at standstill and reaches zero torque load is equal to motor rating times the speed range at synchronous speed. Therefore, the voltage at minimum in percent controlled speed is As an example, consider a 3000 HP motor with a 4 kV stator Vc=Rated *(100-Nmin), where a rotor voltage of 1200v, rotor current of 1150 A, speed Vrated= rated rotor voltage, and range of 70-96%, and no overloads exceeding 150% for min minimum controlled speed in percent 60 sec, driving a fan. The maximum rotor voltage is 360 V, so a 460V inverter is applicable. The inverter size is a 1000 The rated rotor current and overloads determine the frame with a current rating of 1506 amps. The regenerated required inverter current capacity. The inverter continuous power is 335 kW, so the line converter is a 700 frame. Other current rating must be equal to the rated rotor current and components such as the utility interface transformer and must be rated for any overloads. rotor contactors must also accommodate these ratings. Page 8 of 12 C 2011 TMEIC Corporation. All Rights Reserved We drive industry Specifications Inverter Specifications for models without DC disconnects 460V ac 575/690Vac Weight Full Load Loss Rotor Current Allowable Rotor Current Frame kg (bs) (kW) A ac Overload A ac 528 100-150 352 395 400 6.3 469 175 302 (869) 411 200 264 753 100-150 486 500 400 75 669 175 417 (880) 586 200 365 960 100-150 586 700 405 9.3 861 175 502 (892) 753 200 440 1130 100-150 720 900 410 13.5 969 175 617 902) 848 200 540 1506 100-150 972 1000 800 14.9 1339 175 883 (1760) 1171 200 729 1920 100-150 1172 1400 810 18.6 1721 175 1005 (1782) 1506 200 879 2260 100-150 40 144 1800 820 27 1937 175 1234 (1804) 1695 200 1080 Source Converter Specifications 460V ac 575/690vac Weight Loss Power Frame Current Allowable Power at Power at Current kg(lbs) kW KW A ac Overload 575V ac 690V ac A ac 475 3.7 236 308 150 196 235 205 300 (1045) 290 200 180 680 8.5 533 697 150 445 534 465 700 (1496 697 200 407 795 709 926 150 590 709 617 900 1749) 895 200 540 1330 17 1067 1394 150 890 1067 929 1400 (2926) 1394 200 813 1560 27 1417 1852 150 1180 1416 1235 1800 3432) 1790 200 1080 C 2011 TMEIC Corporation. All Rights Reserved Page 9 of 12 TMEIC Inverter Specifications Inverter Power Output Motor Control Output Voltage 0-460V,0-690V With Speed sensor(Resolver or Encoder) Output Frequency 0-200Hz Speed regulator accuracy: +/-0.01% 0-400 Hz Optional Maximum speed response: 60 rad/ sec Continuous operation below 0. 4 Hz Torque linearity: +/-3% with temperature sensor requires derate +/-10%without temperature sensor Maximum Torque current response: 1000 rad/sec Output Chopping 1.5 kHz for 200-1800 frames Torque range: 0-400%of rated motor torque Frequency 2 kHz for 4-125 frames Maximum flux control range: 20%0-100% Up to 6 kHz available with derating Without Speed sensor Inverter Type Modulation Two-level voltage converter Pulse Speed regulator accuracy: +/-0 1% with temperature sensor Width Modulation(PWM +/-0.2% ithout temperature sensor Power semiconductor Insulated gate Bipolar transistor (Using 1% slip motor at rated flux Technology (IGBT) Maximum speed regulator response: 20/rad/sec Minimum continuous speed: 3% Torque linearity: +/-10% Maximum Torque current response: 1000 fad/sec Torque range: 0-150% of rated motor torque Maximum flux control range: 75%-100% Inverter Notes 1. All inverter cabinets are 605 mm(24 in )in depth. All equipment figure in radians/s Speed regulator responses step Respon requires a steel support of at least 50 mm(2 in)under the panel (not shown are maximum available. Actual response included in these dimensions). All shipping splits are 2. 4 m maximum. will be limited by drive train mechanical conditions. :of snal val Reserve an additional 115 mm(5 in. )in height for equipment requiring Accuracy and linearity specifications shown are as a debris hood (UL) measured under controlled conditions in our lab and L includes 2. A minimum of 500 mm(20 in) should be allocated above cabinet for while typical may not be achievable in all systems fan maintenance. No back access is required. Reserve 800 mm(32 in) 9. Air is pulled in through the front and out the front clearance for maintenanc top for all Cabinets. Ras onse 3/Radians/s) 3. Motor power ratings based assume 150% overloads, motor efficiency 10. The dc bus for the lineup has a maximum of 95 %, motor power factor of 0. 85, ambient temperature 0-40C (32 current capacity of 2000 amps. 104 F), an altitude below 2000 m(3280 ft)above sea level. Use actual 11. High temperature current derating: all frames motor data for final inverter selection 25% per oC below0° above40°C 4. The specified current ratings are continuous to which the referenced 12. Inverter doors are electrically interlocked with controls to inhibit overload can be applied for a maximum of 60 seconds. Refer to gating when the doors are open application example on the previous page 13. Low temperature current derating: frames 200 to 1800-1.75%per C 5. Inverters support bottom cable entry. Top cable entry is supported except frame 400 which is.5% perC below0C all other frames with one 600 mm(24 in) auxiliary cabinet between every two inverter no derating cabinets 14. The ratings shown in green in the inverter table for motor currents 6. Each of the inverters requires 2-phase control power and the associated overload percent indicate the maximum peak 7. For high-performance torque regulation a temperature sensor is current that inverter frame can produce mounted in the motor 8. Speed and current regulator responses are computer per the adjacent Environmental (Inverters and Converters) Mechanical (Inverters and Converters) Enclosure NEMA 1(P20)IP32 or IP31 optional Operating Temperature oto40°c(32to104°F) at rat 20 to 50oC(4 to 122F)with derating Bottom is standard Cable entrance Storage Temperature-25to55°C(-13to131°F) Top with optional auxiliary cabinet Humidity 5 to 95% relative humidity Wire colors Per CsA/ul and ce Non-condensing 100 kA for ac and dc buswork 0 to 5000 m(16,400 ft)above sea level Short Circuit Ratings 10 kA for control power Derate current ratings: 1% per 200m Acoustic Noise ≤68dB altitude above 1000 m (3280 ft) Altitude Derate voltage 2. 25% per 200 m(656 ft) Mean Time lo Repair 30 minutes to replace power bridge pl leg for 460V inverters above 4000 m (13120 ft) MTBE >41000 hours for 575 V inverters above 3000 m(9840 ft) for 690V inverters above 2000 m(6560 ft) Applicable IEC, JIS,JEM, UL, CSA and Code Conformance NEMA standards (entire lineup extra cost Vibration 10-50Hz,<49m/s2(0.5G) option) Page10°f12 C 2011 TMEIC Corporation. All Rights Reserved.

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