Digital Active Power Conditioner (DAPC)

Written and Compiled by

Shivaji Waghmare
Addl. Gen. Manager - (R & D) DB Power Electronics (P) Ltd. Pune
2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

Table of Contents
INTRODUCTION............................................................................................................................ 3 HARMONIC DISTORTION SOURCES AND EFFECTS ............................................................................. 3 HARMONIC FILTERING AND REACTIVE POWER COMPENSATION ....................................................... 3 PASSIVE FILTER........................................................................................................................... 3 (A) 3-PHASE LINE REACTORS ......................................................................................................... 3 (B) TUNED SINGLE ARM PASSIVE FILTER ......................................................................................... 4 (C) PHASE MULTIPLICATION METHOD ............................................................................................ 4 ACTIVE FILTER ............................................................................................................................ 5 SHUNT ACTIVE FILTER .................................................................................................................... 5 COMPARATIVE STUDY OF DIFFERENT FILTERS.............................................................. 6 DIGITAL ACTIVE POWER CONDITIONER (DAPC) FROM DB......................................... 7 INTRODUCTION ............................................................................................................................... 7 OPERATING PRINCIPLE .................................................................................................................... 7 POWER CIRCUIT .............................................................................................................................. 7 PROTECTIONS.................................................................................................................................. 7 ALARMS AND PARAMETER DISPLAY .................................................................................................. 8 LOCAL ALARMS .............................................................................................................................. 8 INDICATIONS .................................................................................................................................... 8 FEATURES AND SPECIFICATIONS.......................................................................................... 8 FEATURES ....................................................................................................................................... 8 SPECIFICATIONS .............................................................................................................................. 8 TEST RESULT ................................................................................................................................ 9 120 KVA UPS TESTED WITH AF-150 A......................................................................................... 9 C. PF + HARMONIC CORRECTION ..................................................................................................... 9 APPLICATION AREAS ............................................................................................................... 10 ACTIVE FILTER SIZING CALCULATOR.............................................................................. 10

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

INTRODUCTION
Harmonic distortion sources and effects
Events over the last several years have focused attention on certain types of loads on the electrical system that results in power quality problems for the user and utility alike. Equipment which has become common place in most facilities including Computer Power supplies Solid state Lighting ballast Adjustable Speed Drives (ASDs), Uninterruptible Power Supplies (UPSs) are the examples of non-linear loads. Non-linear loads generate voltage and current harmonics which can have adverse effects on equipments, designed for operation as linear loads (i.e. Loads designed to operate on a sinusoidal waveform of 50 or 60 Hz.). Effects of Non-linear load Higher heating losses in the Transformers. Harmonics can have a detrimental effect on emergency generators, telephones and other sensitive electrical equipments. When reactive power compensation (in the form of passive power factor improving capacitors) is used with non-linear loads, resonance conditions can occur that may result in even higher levels of harmonic voltage and current distortion, thereby causing equipment failure, disruption of power service, and fire hazards in extreme conditions. The electrical environment has absorbed most of these problems in the past. However, the problem has now reached a magnitude where Europe, the US, and other countries have proposed standards to responsibly engineer systems considering the electrical environment. IEEE 519-1992 and IEC 555 have evolved to become a common requirement cited when specifying equipment on newly engineered projects. The broad band harmonic filter was designed in part, to meet these specifications. The present IEEE 519-1992 document establishes acceptable levels of harmonics (voltage and current) that can be introduced into the incoming feeders by commercial and industrial users. Where there may have been little cooperation previously from manufacturers to meet such specifications, the adoption of IEEE 519-1992 and other similar world standards now attract the attention of everyone.

Harmonic filtering and reactive power compensation

Various techniques of improving the input current waveform are discussed below. The intent of all techniques is to make the input current more continuous so as to reduce the overall current harmonic distortion. The different techniques can be classified into four broad categories; (a) Introduction of Line reactors and / or DC link chokes (b) Passive Filters (Series, Shunt, and Low Pass broad band filters) (c) Phase Multiplication (12-pulse, 18-pulse rectifier systems) (d) Active Harmonic Compensation. The following paragraphs will briefly discuss the available technologies, their relative advantages and disadvantages. The term 3-phase Line Reactor or just Reactor is used in the following paragraphs to denote 3-phase line inductors.

PASSIVE FILTER
(a) 3-Phase Line Reactors
Line reactors offer significant magnitudes of inductance, which can alter the way that current is drawn by a non-linear load such as an input rectifier bridge. The reactor makes the current waveform less discontinuous resulting in lower current harmonics. Since the reactor impedance increases with frequency, it offers larger impedance to the flow of higher order harmonic currents. It is thus instrumental in impeding higher frequency current components while allowing the fundamental frequency component to pass through with relative ease. On knowing the input reactance value, one can estimate the expected current harmonic distortion. A table illustrating the expected input current harmonics for various amounts of input reactance is shown in table below. Input reactance is determined by the accumulated impedance of the AC reactor, DC link choke (if used), input transformer and cable impedance. To maximize the input reactance while minimizing AC voltage drop, one can combine the use of both AC input reactors and DC link chokes. One can approximate the total effective reactance and view the expected harmonic current distortion from the above chart. The effective impedance value in % is based on the actual loading as derived below;

Percent Harmonics vs. Total Line Impedance Harmonic 3% 5th 40 7th 16 11th 7.3 13th 4.9 17th 3 19th 2.2 %THID 44.13 4% 34 13 6.3 4.2 2.4 2 37.31 5% 32 12 5.8 3.9 2.2 0.8 34.96 6% 30 11 5.2 3.6 2.1 0.7 32.65 7% 28 10 5 3.3 0.9 0.4 30.35 8% 26 9 4.3 3.15 0.7 0.3 28.04 9% 24 8.3 4.2 3 0.5 0.25 25.92 10% 23 7.5 4 2.8 0.4 0.2 24.68

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

(b) Tuned single arm passive filter

The principle of a tuned arm passive filter is shown in Figure 1. A tuned arm passive filter should be applied at the single lowest harmonic component where there is significant harmonic generation in the system. For systems that mostly supply an industrial load this would probably be the fifth harmonic. Above the tuned frequency the harmonics are absorbed but below that frequency they may be amplified.

(c) Phase Multiplication Method

By increasing pulse, numbers of harmonics in the line current can be reduced. 6-pulse rectifier without inductor Manufacturing cost 100% Typical harmonic current components. Fundamental 100% 5th 63% 7th 54% 11th 10% 13th 6,1% 17th 6,7% 19th 4,8%

6-pulse rectifier with inductor

Figure 1 - Tuned single arm passive filter.

Manufacturing cost 120%. AC or DC choke added. Typical harmonic current components.

Detuned - Single tuning frequency Above tuned frequency harmonics absorbed Below tuned frequency harmonics may be amplified Harmonic reduction limited by possible over compensation at the supply frequency and network itself This kind of filter consists of an inductor in series with a capacitor bank and the best location for the passive filter is close to the harmonic generating loads. This solution is not normally used for new installations. Tuned multiple arm passive filter The principle of this filter is shown in Figure 2 This filter has several arms tuned to two or more of the harmonic components, which should be the lowest significant harmonic frequencies in the system. The multiple filter has better harmonic absorption than the one arm system.

Fundamental 100%

5th 30%

7th 12%

11th 8.9%

13th 5.6%

17th 4.4%

19th 4.1%

Figure 3

12-pulse with double wound transformer Typical harmonic current components.

Figure 2 - Tuned multiple arm passive filter.

Fundamental Capacitive below tuned frequency/Inductive above Better harmonic absorption Design consideration to amplification harmonics by filter Limited by KVAr and network The multiple arm passive filters are often used for large DC drive installations where a dedicated transformer is supplying the whole installation. 100%

5th 3.6%

7th 2.6%

11th 7.5%

13th 5.2%

17th 1.2%

19th 1.3%

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

Shunt Active filter

Fundamental only Supply
idistortion

Load
icompensation

Active Filter

Figure 5 - External active filter principle diagram.

Figure 4

24-pulse rectifier Typical harmonic current components.

The active filter compensates the harmonics generated by nonlinear loads by generating the same harmonic components in opposite phase as shown in Figure 6. External active filters are most suited to multiple small drives. They are relatively expensive compared to other methods.

A passive tuned filter introduces new resonances that can cause additional harmonic problems. New power electronics technologies are resulting in products that can control harmonic distortion with active control. These active filters, see Figure 5, provide compensation for harmonic components on the utility system based on existing harmonic generation at any given moment in time.

Load current

Active filter current

Clean Feeder current

Harmonics

Figure 6

There are different types of active filter configurations. Series active filter Shunt active filter Hybrid active filter. Active front end IGBT based PWM rectifier Most popular is Shunt Active filter.

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

Waveforms

ACTIVE FILTER

Comparative Study of Different Filters

Parameters
Type

Capacitor filter
Passive Only compensates power factor Passive

Tuned filter

Active filter
IGBT based digitally controlled Compensates PF and Harmonics. One filter can compensate multiple harmonics simultaneously Performance remains constant over frequency and voltage variation. Suitable in any type of environment No possibility of resonance. Stable operation Light weight. Size does not change even if required to compensate more harmonics Longer life, since performance remains constant and resonance is avoided Initial cost is more as compared to both the filters No capacitive PF at no load. Smooth PF compensation. No problem to Generator source. Performance remains constant over load variation Same filter can be used to compensate 3rd harmonic without increasing the size Stability through software. Cost vs. performance is easily possible. This makes it more cost effective and flexible More units can be added later on for increasing capacity

Compensation

Compensates Harmonic Multiple tuned filters are required, one for each harmonic Performance varies over frequency variation and variation in voltage distortion. Performance is dependent on load level Possibility of resonance if tuned at higher frequency. Performance depends on source impedance Bulky in size when multiple harmonics are to be compensated

Suitability

Not suitable in case of more voltage distortion and current distortion Possibility of resonance. This results in premature failure of capacitor. Bulky in size

Resonance

Size and weight

Life

Limited life in case of more voltage and current harmonics

More life as compared to capacitor filter

Cost

Cheap

Costlier as compared to capacitor filter Imposes leading PF at fundamental frequency. So not suitable for generator source. Compensated filter is required for generator. Performance is tuned at full load Becomes very bulky

No load condition

Imposes capacitive PF when load is reduced. Contactors are required to compensate for leading pf.

3rd harmonic compensation Selectivity And harmonic Compensation

Not possible

No selectivity

Physical components are required to be changed

Capacity increase

Possible by adding more capacitor To take of resonance problem, lot of fuses must be used. Also resonance causes failure of other sensitive circuits Low loss

Redesigning is required for change of load. Breakers and fuses must be added per tuned filter. Also transient voltage absorbers must be used to avoid of other circuitry in case of resonance More loss

Safety

Only one set of Breakers and fuses are required for all harmonics Moderate losses

Power loss

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

Digital Active Power Conditioner (DAPC) from DB

Introduction
This filter works in shunt with the load. Due to this it is easier to add it in the existing setup, even without taking load shutdown. Also it facilitates to use it at the source end with higher currents and lower harmonics. It is based on 32 bit DSP with full digital control. Digital control makes it more stable, easy upgradeable, more flexible and no variation or degradation of performance over a long period of operation. Total operational technology can be changed without changing any hardware component.

Selectivity User can select whether to compensate both harmonics and PF or to compensate either harmonics or power factor (Displacement factor).

Power Circuit
It is based on High speed IGBT working at higher switching frequencies. Due to which the required inductor value is reduced. This helps in making corrections even at higher input voltages without increasing DC operating voltages. Also it helps to reduce losses in IGBT. Optimized switching performance of IGBT inverter helps to reduce EMI noise as well as improve efficiency of the inverter.

Figure 8 - Single Line Diagram for DAPC Figure 7

Protections
DAPC is protected against Slow protection and Fast Protection

Operating principle
It is based on source current harmonic sensing. Source current is fed to high speed AD converter of DSP. Source current harmonics are extracted by the DSP. These harmonics are injected to the load by the filter. This in turn takes only fundamental harmonic current from the mains. Harmonic compensation Selective harmonic elimination method helps it to use it cost effectively. Compromise in cost and performance can be easily achieved. These can be set on field easily either by the trained user or DB service engineer with the help of switches on the control board. 5th, 7th, 11th, 13th, 17th and 19th harmonics can be easily selected for their compensation. Also Programmable harmonic reduction is possible. Reactive compensation Along with harmonic compensation DAPC can compensate for lagging or leading power factor. This compensation is also programmable. User can have precise required PF correction set as per his requirement. This also helps in compromising cost vs performance. User can have PF compensation up to 0.95 or more to reduce required capacity of Active filter. PF up to unity is possible from 0.6 lag to 0.6 lead.

Slow protection It is for slow variations in input voltages and load. This is done by sensing RMS values of load currents and input voltages. Each input phase voltage is sensed independently and if, any phase voltage is out of limit, DAPC is automatically isolated from input. Overload and over temperature Filter RMS load current and Heat sink temperature of IGBT is continuously monitored. At any instant the filter load or IGBT temperature is exceeded than its preset level, current limit is automatically reduced. This prevents tripping of the filter due to overload or over temperature. It keeps filter running at reduced capacity level (10% capacity reduction). This can happen in the event of elevated ambient temperature.

Fast acting protections These are achieved by using; 1. 2. High speed semiconductor fuses High speed protection to IGBTs.

2006 DB Power Electronics (P) Ltd. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.dbups.com Rev. 2006-1.0

High speed mains abnormal sensing, which includes phase reversal and negative sequence component sensing in the input voltage. Filter will immediately isolate form mains and again reconnect automatically after sensing confirming mains healthiness. This requires no manual intervention. Dual levels with different delays DC Over voltage protection with hardware and software. 300% over current protection for IGBT. (Redundant protections) It is ensured that IGBT is protected against all severe operating conditions. FMECA statistical techniques are used for these protections. Appropriate alarm is provided for all Faults and Alarms conditions.

1. 2. 3. 4. 5. 6.

Mains abnormal Over temperature Over load Phase reversal DC over voltage Filter trip

External Inhibit. (Includes filter off due to hardware protections and ON/OFF switch operation).

Indications
Following LED indications are provided on the display. 1. 2. 3. 4. Filter ON Filter OFF OV/OC Sync OK.

Alarms and Parameter Display

Remote alarms Voltage free contacts are provided for 1. 2.

Figure 9 - Front Panel LCD Display on DAPC

Filter running Filter trip

Monitoring of filter through PC is possible by Remote as well as local alarms are provided for getting the status of DAPC. Following parameters are displayed locally as well as remotely; 1. 2. 3. 4. 5. Input 3 phase voltage Input frequency DC bus voltage Filter currents for all three phases Heat sink temperature 1. 2. MODBUS connectivity Monitoring through (optional features) SNMP and web browser

Features and specifications

Features
1. Closed loop active filter with source current sensing High attenuation upto 96% of individual harmonics Programmable selective harmonic elimination PF compensation, leading as well as lagging Selection between PF and harmonic compensation Remote monitoring and diagnosis IGBT based inverter design 2. 3. 4. 5. 6. 7.

Local Alarms
A user friendly LCD display, along with Keypad is used locally to indicate parameters, alarms and faults. Following alarms are provided on LCD;

Specifications
3 phase / 3 wire non-zero sequence compensation

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Parameter Input Voltage range Frequency Capacity Harmonic Filtering Power loss in filter IP Protection
Dimensions (mm)

DAPC 60 DAPC 100 DAPC 150 400V, 3 Ph +10%, -15%, 50 Hz. 45 to 55 Hz 60 A 100 A 150 A 5th to 19th harmonic compensation. Attenuation ratio up to 96% < 1700 w < 2800 w IP 32 IP42 optional
800 x 600 x 1000+100 P 150 800 x 600 x 1600 + 100 P 275 800 x 600 x 1600+ 100 P 275

B. Only Harmonic Correction Input Current VTHD PF DAPC Current Voltage ITHD Power 146 A 3.7 % 0.92 48 A 221 V 4.0 % 93 kW

< 3500 w

(WxDxH) Weight in kg. Colour Installation Ambient Humidity Option Standards Potential free contacts

Havells Gray Floor mounting. Lifting lugs provided Cable Entry from bottom (From top Optional) -5 to 40 0C Up to 90 0 Rh, non condensing Remote monitoring through MODBUS, SNMP, Web browser Meets IEEE 519 for compensated harmonics. IEC 62040 Part II for conducted emission. Class A, for restricted use. Filter Trip and Filter ON
Figure 11

C. PF + Harmonic Correction

TEST RESULT
120 kVA UPS Tested with AF-150 A
A. Without Active Filter Input Current VTHD PF Voltage ITHD Power 164 A 4.8 % 0.87 217 V 27.4 % 93 kW

Input Current VTHD PF AF Bridge Voltage ITHD Power

135 A 2.2 % 1.00 95 A 223V 3.9 % 93 kW

Figure 12

Figure 10

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Application areas
1. At the Input side of Rectifier, AC Drive, UPS

Active Filter Sizing Calculator

Harmonic & PF compensation

Figure 13

Figure 16

2.

PF Compensation

Active Filter Sizing is a tool developed to find the required size of the DAPC. The data gathered at the site, where the DAPC is required to be installed, need to be inserted in to appropriate fields of Active Filter Sizing calculator. It will then size the DAPC and its output characteristic will also be displayed. Following are the details for the Active Filter Sizing Calculator : Load Current - Here enter the per phase current in Amp of the Load. ITHD % - Enter the Current Total Harmonic Distortion measured on the load side. KW Calculate the total power in KW, consumed by the load. PF The Load power factor.
Figure 14

Nom Volt Ph to Ph Enter the Phase-to-Phase voltage. After entering all this data, please check what type of Power Factor compensation is required at the site. Though Unity is always better, the cost implication for achieving it need to be considered. Click the radio button for the percentage required. (in the above example it is clicked at 50%) Now press calculate button to get the following results; Output Effective Power factor Output Filter Current The filter current field is the required size of the DAPC.

3.

At the source input

Figure 15

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