Vacon NX6 Design Manual
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Vacon NX6 Design Manual

Vacon NX6 Design Manual

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Summary of Contents for Vacon NX6

  • Page 1 ® ac drives design guide hybridization...

  • Page 3: Table Of Contents

    REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site http://drives.danfoss.com/knowledge-center/technical-documentation/ 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 4: Basics

    • 2 BASICS BASICS The basic idea is always to achieve energy and/or power management of Common Point of Coupling. Typical use cases are • time shift for production • peak load shaving for distribution • smoothen load for average energy •...

  • Page 5: Power Or Energy Storage

    • Dynamic requirements: o Grid support functions (Harmonics, FRT) o Bulk energy time shift Power: Energy MW: MWh Power Applications Energy Applications Time [h] Time [h] Time [h] Figure 2. Power vs. energy 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 6 • 4 BASICS 1,000 10,000s 1,000s 100s 0.1s 0.01 1,000 10.000 Power density in W/kg Reference Reference Batteries Li-ion Double layer capacitors NiCd Electrolytic capacitors NiMH Figure 3. Comparision of battery systems Table 1. Comparision of battery systems Energy density...

  • Page 7: Battery Current Dimensioning

    In some cases, the below rated currents are marked as 0.5C = C5. In that case, for example a 10Ah rated current used with a 1A current would mean 0.1C or C1. In the same example, 2C would mean 20A. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 8: Basic Topologies For Connection

    • 6 BASIC TOPOLOGIES FOR CONNECTION BASIC TOPOLOGIES FOR CONNECTION The basic connections are divided into multible possibilities. Table 2. Basic connections Use case Topology Pros Cons • No competitive "technology" when DC-grid connec- Common DC energy tion needed storage connection •...
  • Page 9 600-1100 load and AC-grid with • Efficiency direct DC-link connection • Size • System expansion • Power vs. energy later with dimensioning is additional independent from batteries difficult each other 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 10 • 8 SPECIAL CHARACTERISTICS AFFECTING THE SPECIAL CHARACTERISTICS AFFECTING THE SELECTION Different chemistry causes different behavior in cell voltage as a function of charge/discharge and SOC (State of Charge). This creates "voltage window" requirement similar to the solar inverter.

  • Page 11: Special Characteristics Affecting The Selection

    30 min resulting in 0,2 V/s. This way the SOC (State of Charge) behavior is observed. Below is a case where same sized of DC-power units are charged/discharged from the battery. Figure 7. Battery string number effect on voltage change using the spring analogy 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 12 • 10 SPECIAL CHARACTERISTICS AFFECTING THE The difference in the cases is that the battery size in energy is changed from 6 strings in parallel to one string in parallel. This will lead in higher C-rates in the battery having smaller amount of strings when the same amount of power is taken out of each battery setup (current going from 1C -->...

  • Page 13: Galvanic Isolation Requirement

    Table 3 presents all possible common mode voltages produced by different switching states. Used reference point is in the middle of the DC-link. Table 3. Common mode voltage as function of modulation sequence Switching vector 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 14 • 12 SPECIAL CHARACTERISTICS AFFECTING THE U [V] CM voltage Common mode -200 -400 -600 40.10 40.20 40.30 40.40 40.50 40.60 40.70 40.80 40.90 Time [ms] U DC /6 U DC /2 CM voltage Curve info ..---- CM voltage -512 Figure 10.
  • Page 15 LC filter (sine) to avoid additional voltage drop in the grid side choke. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 16: Balance Or Maintenance Charge

    • 14 SPECIAL CHARACTERISTICS AFFECTING THE -L2.1 -L2.2 -L2.3 -C1.1 -C1.2 -C4.1-C4.2 -C2.1 -C2.2 -C5.1 -C5.2 no HF -C3.1 -C3.2 -C6.1 -C6.2 Figure 13. LCL ground capacitor must be disconnected Balance or maintenance charge The maximum voltage of the battery is needed only when charging the battery at the fullest level.

  • Page 17: System Control Principles

    The Power Conversion System of this list is the system relevant to the product. The PCS includes Power Conversion Control and Power Conversion Hardware, which is the VACON® hardware. It is to control power conversion between the energy storage and the system. Normal time scales are from micro seconds to grid cycles.
  • Page 18 • 16 SPECIAL CHARACTERISTICS AFFECTING THE Energy Management System (EMS) Power Management System (PMS) Power Conversion System Storage System Power Conversion Control Battery Management (PCC) System Power Conversion Battery Hardware Figure 15. Typical system layers Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 285...

  • Page 19: Choosing A Correct Topology

    Filter Filter Filter Filter Island Grid Converter uGrid needed in Control all cases Application modes Customer Customer Control ref system primary P / Udc /Idc tailoring reference Figure 16. Selection diagram 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 20: Allowed Topology Configurations

    • 18 CHOOSING A CORRECT TOPOLOGY Allowed topology configurations In the following table, example of allowed and not allowed configurations are given. These configurations are valid for both with DC/DC converter or with a direct battery connection into the DC-link. Options shown below are DC/DC configurations A), B) and C) and Direct to DC connection D).
  • Page 21 Options A, B, C, D Options Not OK if grid A, B, C, D selectivity is needed, specially for uGrid Options A, B, C, D 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 22: Basic Variants

    • 19 BASIC VARIANTS BASIC VARIANTS Direct to DC AFE DC INU AC AFE AC Grid AC Grid converter GRID Filter Rectifying Filter Transformer Grid nominal DC/AC and voltage voltage ratio value and AFE control drop and drop voltage...

  • Page 23: Control Structure

    - Useful in situations where PMS is not fast enough or is unable to control. o Upper system needs to give charging and discharging limit to the drive o Upper system needs to give minimum and maximum voltage limits to the drive (DC-Link voltage). 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 24 • 21 BASIC VARIANTS • AFE-operation mode o Power control possible trough DC voltage reference. Needs controller if customer input is power reference (instead of DC voltage reference). o Cannot make or maintain grid by itself, needs existing grid •...

  • Page 25: Dc To Dc

    Battery fixed AFE reference voltage operation DC/DC & filter current ripple Figure 21. DC to DC 5.2.1 Filter The filter topologies in focus are: 1. Interleaved Figure 22. Interleaved filter topology 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 26 • 23 BASIC VARIANTS 2. Independent output control (not yet supported) Figure 23. Independent output control Interleaving is a method to cancel partially or completely certain harmonics from the spectrum. With a standard 3-phase inverter unit, a natural way is to have a 120 degree phase shift with each triangle carrier.
  • Page 27 I = 100A/leg, L= 2050 uH, Udc = 1025V The ripple current for the filter choke can be calculated as follows: It is important to note that the ripple depends on duty cycle which is defined as follows: 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 28 • 25 BASIC VARIANTS The maximum value for the ripple of the choke is obtained when d = 1/2 For the output current ripple there are three segments. When d < 1/3, two switches are always at low state and one switch is either low or high. When 1/3 < d < 2/3, one switch is low, one high and one is either low or high.
  • Page 29 35-45% of the nominal current. A bigger ripple in the choke also directly increases the output side ripple which in this case would be approximately 4-5% peak-to-peak. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 30 • 27 BASIC VARIANTS In most cases, a duty cycle d = 0,5 should be used in calculations. This will guarantee that worst case ripple is taken into consideration. For example, if the application operates with duty cycles 0.7-0.9, it could be possible to decrease the inductance, and in that way increase the choke ripple (see Figure 27 below).
  • Page 31 Tolerances also increase/decrease individual peak-to-peak ripple currents of chokes (Figure 29 and Figure 30). Temperature tolerances are not typically a concern with the above mentioned choke types if all chokes are of the same temperature. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 32 • 29 BASIC VARIANTS I [A] Currents Interleaved 40.10 40.20 40.30 40.40 40.50 40.60 40.70 40.80 40.90 Time [ms] I Battery Curve info peak to peak 100.4 116.0 83.9 32.1 100.3 113.0 87.0 26.0 100.3 113.0 87.0 26.0 I Batteri 300.0...
  • Page 33 Figure 30. Example simulation with interleaved control and d = 1/2: leg currents and sum current. I = 100 A/leg, L = 2050 uH, Udc = 1025V. Leg U has 20% less and leg W 20% more inductance. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 34 • 31 BASIC VARIANTS The filter consists of three separate chokes, one for each leg (Figure 31). It is not possible to use a traditional 3-phase choke because the current is DC (common mode) and the magnetic flux does not have a natural return path in the core structure.
  • Page 35 Because battery properties are usually not well known, it is recommended to dimension the optional capacitor as follows: 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 36 • 33 BASIC VARIANTS This will give some idea what could be expected to work, but because the battery properties are not taken into account in the design, it is not possible to guarantee a safe operation. If the filter does not operate as expected, the capacitance value can be increased for example by adding another capacitor in parallel.

  • Page 37: Control Structure

    • Upper system needs to give minimum and maximum voltage limits to the DC/DC converter. o Grid Converter needs also under voltage limit because battery voltage can come directly to DC-Link trough DC/DC converter, if DC-Link voltage goes below battery voltage. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 38 • 35 BASIC VARIANTS • Charging can be achieved by upper system control or simply by Value ID Control functions. Charging will start automatically when the DC/DC converter overvoltage limit is reached even without charging reference. • When the grid converter power flow is parallel to the grid, the DC-Link voltage will go down until it reaches the DC/DC converter undervoltage level, where the voltage remains until the DC/DC converter discharging current limit is reached.

  • Page 39: Product Configuration Examples

    6.1.1 Direct to DC The scope of delivery of VACON includes the typical VACON offering from power modules to system drive or other suitable switchgear. The simplest delivery includes power modules, LCL filters, NXP controls with an application and a license.

  • Page 40: Dc To Dc

    Figure 39. Scope of delivery 6.1.2 DC to DC The scope of delivery of VACON includes the typical VACON offering from power modules to system drive or other suitable switchgear. The simplest delivery includes power modules, NXP controls with an application and a license.
  • Page 41 In tailored customer projects, the scope of delivery may be a switchgear including power modules, chokes, NXP controls with an application and a license but also breakers, fuses, DC pre-charging components and other possible control circuit. Figure 41. Scope of delivery 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 42: Example Configurations

    • 39 PRODUCT CONFIGURATION EXAMPLES Example configurations 6.2.1 DC/DC for supply interruptions The DC/DC converter can be used to prevent grid voltage drops to interrupt essential drives to stop for undervoltage. The DC/DC converter is connected to the AC drive's DC-terminals and used to feed power during the grid voltage drops.

  • Page 43: Direct Dc For Grid Support

    AFE UNIT AFE UNIT -FC2 -FC2 -FC2 -FC2 OEVA OEVA OEVA OEVA SWITCH SWITCH SWITCH SWITCH OUTGOING DC SUPPLY Figure 44. Peak shaving of higher power and high energy AC grid 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 44: Sizing Of The System And Product

    U can be calculated with: The selection is made by choosing an appropriate current size from the VACON products with the above defined voltage class based on the maximum storage voltage level. The output voltage is needed for the transformer dimensioning.

  • Page 45: Dc/Dc

    CE and UL certification is valid. C DC Battery Figure 45. Vacon power converter ratings plate and their corresponding values in DC/DC converter circuit diagram. The second constraint is the thermal limits of the power converter. There are two parts which are thermally stressed in the DC/DC application: •...
  • Page 46 You may roughly calculate the DC/DC converter current rating by multiplying the inverter current rating by 1.2. To have an overview, see the following table where the DC/DC converter current ratings for NX6 are given. Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 285...
  • Page 47 Table 5. DC/DC converter current ratings for NX6 1025 VDC link voltage 1100 VDC 1025 VDC 931 VDC Air cooled NX6 drives 1min nomi- 1min 1min Unit type Frame nal (A) (KW) 5kHz (A) 3.6kHz (A) 5kHz (A) 3.6kHz (A) 5kHz (A) 3.6kHz (A)
  • Page 48 1025 VDC link voltage 1100 VDC 1025 VDC 931 VDC Air cooled NX6 drives 1min nomi- 1min 1min Unit type Frame nal (A) (KW) 5kHz (A) 3.6kHz (A) 5kHz (A) 3.6kHz (A) 5kHz (A) 3.6kHz (A) 5kHz (A) 3.6kHz (A)
  • Page 49 This helps to allow the use of a smaller frame size. Filter size is also proportional to current. Therefore, high energy storage voltage is preferred from the DC/DC converter sizing perspective. 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 50: Information To Acquire From Customers

    • 47 INFORMATION TO ACQUIRE FROM CUSTOMERS INFORMATION TO ACQUIRE FROM CUSTOMERS It is important to find enablers and limiting factors of the customer system. The following list is, in priority order, the information to be acquired from customer system to continue the discussion of the offering.
  • Page 51 Document ID: Vacon Ltd DPD01887A Member of the Danfoss Group Rev. A Runsorintie 7 65380 Vaasa Finland...

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