Rockwell Automation 1519 MV User Manual
Medium Voltage
Drive Harmonic
Filter and Power
Factor Correction
Units
Bulletin 1519
2300 - 4160 volts
250 - 3500 hp
User Manual
Important User Information
IMPORTANT
Read this document and the documents listed in the Additional Resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
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use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
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WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
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voltage may be present.
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Introduction Chapter 1
1519-IN050B-EN-P June 2013
Functional Description................................................................................ 1-1
Theory of Operation ................................................................................... 1-1
Application Considerations......................................................................... 1-2
Protective Features ..................................................................................... 1-3
Reactor Overtemperature.................................................................. 1-3
Reactor/Capacitor Overload ............................................................. 1-3
Short-Circuit Protection for Capacitors ............................................ 1-4
Blown Capacitor Fuse Detection ...................................................... 1-4
Schematic Diagrams
Typical Schematic • 5th Filter Fed from Drive Input Contactor
(Figure 1.1) .................................................................................. 1-5
Physical Layout and Chapter 2
Component Identification
Component I.D. and Functional Descriptions............................................. 2-1
Filter Reactor ................................................................................... 2-1
Filter Capacitor ................................................................................ 2-1
Current Transformer ........................................................................ 2-1
SMP-3 Overload Relay .................................................................... 2-1
592 Overload Relay ......................................................................... 2-2
Reset Relay/Pushbutton ................................................................... 2-2
Surge Suppressor ............................................................................. 2-2
Cooling Fans .................................................................................... 2-2
Strip Heater and Thermostat ............................................................ 2-2
Component Identification (Figure 2.1)....................................................... 2-3
Control Components (Figure 2.2).............................................................. 2-4
Overall Dimensions (Figure 2.3) ............................................................... 2-5
Table Of Contents
Performance Specifications Chapter 3
and Design Assumptions
Installation Chapter 4
Performance Specifications and Design Assumptions............................... 3-1
Handling .................................................................................................... 4-1
Power and Control Wiring......................................................................... 4-1
Routing ............................................................................................ 4-1
Cable Terminal Access .................................................................... 4-2
Ground Bus ...................................................................................... 4-2
Auxiliary Components ..................................................................... 4-2
ii Table of Contents – Medium Voltage Drive Harmonic Filter and Power Factor Correction Units User Manual
Commissioning Chapter 5
Pre-start-up Inspection............................................................................... 5-1
Settings ...................................................................................................... 5-2
Annual Inspection Chapter 6
Physical Inspection .................................................................................... 6-1
Bolts ................................................................................................. 6-1
Structure .......................................................................................... 6-1
Cable ................................................................................................ 6-1
Components ..................................................................................... 6-2
Interlocks ......................................................................................... 6-2
Foreign Material .............................................................................. 6-2
Troubleshooting and Repair Chapter 7
Troubleshooting ......................................................................................... 7-1
Harmonic Filter Fault ...................................................................... 7-1
SMP-3 Relay ................................................................................... 7-1
592 Thermal Overload Relay........................................................... 7-2
Component Replacement Instructions........................................................ 7-2
Current Transformers ...................................................................... 7-2
Filter Reactors.................................................................................. 7-3
Cooling Fans .................................................................................... 7-3
Capacitors and Capacitor Fuses ...................................................... 7-3
Renewal Parts Chapter 8
Control Components .................................................................................. 8-1
Power Components .................................................................................... 8-2
Reactors (5th filter only – 6-pulse drives) • Table 8.B ..................... 8-2
Reactors (5th, 7th & 11th filters – 12-pulse drives) • Table 8.C......... 8-2
Current Transformers (5th filter only – 6-pulse drives)
• Table 8.D ................................................................................. 8-3
Current Transformers (5th, 7th & 11th filters – 12-pulse drives)
• Table 8.E .................................................................................. 8-3
Capacitors (5th filter only – 6-pulse drives) • Table 8.F................... 8-4
Capacitors (5th, 7th & 11th filters – 12-pulse drives) • Table 8.G ........ 8-4
Capacitor Fuses (5th filter only – 6-pulse drives) • Table 8.H ............ 8-5
Capacitor Fuses (5th, 7th & 11th filters – 12-pulse drives) • Table 8.J ... 8-5
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Chapter 1
1519-IN050B-EN-P June 2013
Introduction
Functional Description A harmonic filter consists of one or more tuned inductor/capacitor circuits. A
three-phase, iron core reactor is wired in series with three single-phase
individually fused capacitors. These harmonic filters are designed for use with
Bulletin 1557 Medium Voltage Drives.
There are two basic types of standard harmonic filters. Filter Type 1 consists
of an inductor/capacitor combination tuned to the 5th harmonic (5 times the
fundamental power system frequency) which is designed to reduce harmonics
and provide power factor correction when used in conjunction with a drive
with a 6-pulse rectifier. These Type 1 filters may also be used in conjunction
with drives that have 12-pulse rectifiers. When a 5th harmonic filter is applied
with a 12-pulse drive it will primarily provide power factor correction and may
provide some degree of harmonic reduction.
Type 2 harmonic filters consist of series inductor/capacitor combinations tuned
for approximately the 5th, 7th, and 11th harmonics and are designed specifically
for use with 12-pulse drives. Drives with 12-pulse rectifiers do not produce
significant amounts of 5th or 7th harmonic current, however, the 5th and 7
filters are designed to prevent a potentially detrimental resonance condition
from occurring. Type 2 filters provide harmonic reduction as well as power
factor correction.
Harmonic filters of Type 1 or Type 2 are designed to correct the power factor
to between 0.95 lagging and 0.95 leading over the 50-60% to 100% speed
range for a typical variable torque load.
A particular harmonic filter may or may not allow compliance with the
harmonic current limits specified in IEEE Std 519-1992 (IEEE Recommended
Practices and Requirements for Harmonic Control in Electrical Power
Systems). Calculations need to be carried out which take into account specific
power system data in order to assess compliance with IEEE 519 harmonic
limits for a particular drive application.
th
Theory of Operation Operating the rectifier of any drive will create harmonic currents that flow
back towards the power source and to other plant loads. These harmonics
result from the non-linearity of the rectifier, which draws a non-sinusoidal
current from a sinusoidal voltage source. The magnitude of the harmonic
currents generated by the rectifier is primarily related to the pulse number of
the rectifier.
1519-5.0 – May 1998
1-2 Introduction
Theory of Operation (cont.) These harmonic currents can result in distortion of the voltage waveform. In
rare instances, excessive voltage distortion on the power system can have ill
effects on the system. These effects can include overheating of motors or
transformers, capacitor failure, misoperation of relays, computer system
disruption, and telephone system interference.
The purpose of a harmonic filter is to shunt certain harmonic currents that are
produced by the rectifier away from the power system. The result is a
reduction in distortion of the voltage waveform on the power system and a
reduction in the likelihood of harmonics affecting plant or utility system
components.
Application Considerations Switching with Drive Input Contactor versus Dedicated Harmonic Filter
Contactor
To simplify the system and reduce capital cost, a harmonic filter can be
switched using the same contactor or breaker that feeds the input power to the
associated drive. In this configuration, the harmonic filter is energized as long
as the drive input contactor is closed. The input contactor is usually configured
to close when the Emergency Stop string is completed. The contactor would
then stay closed regardless of whether the drive is running or stopped.
If the system is configured as described above, the user should consider
whether the leading kilovolt-ampere rating (kvar) provided by the filter when
the drive is not running (and thus not drawing any lagging kvar) result in an
acceptable system power factor. In this configuration it is necessary to shut
down the drive in the event of a harmonic filter fault condition since the drive
input contactor is the only means by which the filter can be taken off line. If a
harmonic filter fault were to occur and it was necessary to operate the drive
without the filter it would be necessary to physically disconnect and isolate
power cables from the harmonic filter while the drive system is shut off. It is
necessary to prevent reclosure of the drive input contactor within approximately
five minutes of opening to prevent energizing a harmonic filter capacitor
which may still have a DC charge on it.
Alternatively, a harmonic filter can be switched with a dedicated vacuum
contactor. In general, the vacuum contactor would be configured to energize
the filter when the associated drive receives a start command. The vacuum
contactor would be configured to de-energize the filter when the drive has
stopped. In this way the leading kvar from the filter is only present when the
drive is operating and power factor correction is required.
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NOTE: Re-energization of the harmonic filter should be delayed until the
filter has had adequate time to discharge – typically 5 minutes.
Introduction 1-3
1519-IN050B-EN-P June 2013
Application Considerations (cont.) In this scheme, energizing the filter can be a permissive to allow starting the
drive or the drive can be configured to operate independently of the harmonic
filter. Similarly, a harmonic filter fault can be configured to shut down the
drive or it can be configured to create an alarm only and allow the drive to
continue to operate. The isolation switch associated with the harmonic filter
contactor can be opened to allow servicing of the filter without necessarily
affecting operation of the associated drive.
Protective Features There are a number of protective features that are incorporated in each tuned
circuit of the harmonic filter to cover the following functions:
• reactor overtemperature
• reactor/capacitor overload
• short-circuit protection for capacitors
• blown capacitor fuse detection
Reactor Overtemperature
Reactor overtemperature is implemented in the form of a normally closed
thermal switch, one of which is embedded in each of the three windings of a
particular harmonic filter reactor. The thermal switches operate at a temperature
somewhat below the maximum allowable temperature for the reactor
insulation. The three switches are wired out individually to a terminal strip on
the top of the reactor where the switches are then connected in series. These
contacts are typically configured to open a dedicated harmonic filter contactor
and/or shut down an associated drive.
Reactor/Capacitor Overload
An Allen-Bradley Bulletin 592 Thermal Overload relay is driven by windowtype current transformers which are installed on each of the phases feeding
each set of three capacitors. The heater elements are factory selected to
protect the filter reactors and capacitors from an overload condition. If there is
one capacitor per phase in a particular harmonic filter then the heater elements
are selected on the basis of the root-mean-square (rms) current rating of the
reactor in the filter. This heater element sizing also allows protecting the
capacitors against overload. If there are two identical capacitors per phase in
the harmonic filter then the heater elements are chosen based on half of the
rms current rating of the associated reactor. A contact from the 592 overload
relay is wired to either open a dedicated harmonic filter contactor and/or shut
down the associated drive.
1519-5.0 – May 1998
1-4 Introduction
Protective Features (cont.) Short-circuit Protection for Capacitors
Short-circuit protection for harmonic filter capacitors is addressed by
individual fusing of each capacitor. The intent of the capacitor fusing is to
clear a short-circuit-type fault condition on a failed capacitor. The fuses are
chosen to prevent a capacitor from rupturing. The fuses are not designed to
prevent the capacitor from failing. These fuses are generally chosen at 175%
to 200% of the capacitor rms current rating. The thermal overload described
above prevents operation of the fuse in the overload region.
Blown Capacitor Fuse Detection
Blown capacitor fuse detection is performed by an Allen-Bradley SMP-3 relay.
This relay is also fed by window-type current transformers which are used on
each phase for every capacitor. The phase loss function of this relay is used to
detect a blown capacitor fuse. If a capacitor fuse has blown then there will be
no current flow in that particular phase. It is undesirable for a harmonic filter
to continue to operate with a blown fuse on one or more capacitors since this
significantly alters the tuned frequency of the filter. A contact from the SMP-3
relay is wired to open a dedicated harmonic filter contactor and/or shut down
the associated drive. Note that the SMP-3 relay is not used as an overload relay
in this application since it is designed for a sinusoidal waveform. It determines
the rms value of a current waveform by repetitively sampling to find the peak
of the waveform. It then assumes that the rms current is the peak value divided
by the square root of two. This relationship between peak and rms current is
not correct when there is significant harmonic content in the waveform. For
this reason the DIP switches for overload protection are set substantially above
the current ratings of the filter components to prevent nuisance tripping due to
overload and allow phase loss detection to reliably take place.
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Introduction 1-5
1519-IN050B-EN-P June 2013
Schematic Diagrams Figure 1.1
Typical schematic • 5
FROM VFD INPUT CONTACTOR UNIT
2400V, 3, 60Hz
FT2FT1 FT3
0%
0%
95%
95%
100%
100%
105%
105%
CT1 CT2 CT3
C2 C3
C1
5th HARMONIC FILTER
REACTOR
THERMOSTATS
0%
REACTOR
95%
100%
105%
2
3
4
CAPACITO R FUSES
CAPACITO RS
59 2
OVE RL OA D
15 15A
SOLID STATE
PHASE LOSS RELAY
COMM
1A1
L1
2A
3A
L3L2T3
SMP-3592
(40)
(30)
SMP-3
60
50
SMP-3
REMOTE
RESET
T1
T2
15C15B
th
Filter fed from drive input contactor
SMP-3 SWITCH SETTINGS
AUTO
ON
TRIP
CLASS
FOR FLC SETTING
SEE DIMENSI O N DRAWING
FILTER RESET
5HFPR
5HFPR
13A
13A
OFF
GF
MAN
TESTJAM
SS
D
15D
16
D
SS
D
D
13A
5HFPR
5th FILTER
TRIPPED
FAN
55 0 CFM
FAN
55 0 CFM
13
D122
TO VFD CUSTO MER TERMINAL BLOCKS (DCTB)
14
ON VFD DRAWING SHT.4
D123
(CONTROL POWER FROM VFD INPUT CONTACTOR UNIT)
14
14
1519-5.0 – May 1998
1-6 Introduction
1)."%.0*UNE
Chapter 2
1519-IN050B-EN-P June 2013
Physical Layout and Component Identification
Component Identification Refer to Figures 2.1 and 2.2 to identify the functional components described in
and Functional Descriptions this section.
Note: For illustrative purposes, a 5
shown. In a 5th, 7th and 11th configuration, there will be two (2) cabinets as
shown with the 7th and 11th filter legs in the right-hand cabinet. Customer load
terminals and low voltage control components are always located in the 5
filter-leg cabinet (left-hand side).
th
harmonic filter with six (6) capacitors is
th
Filter Reactor
A three-phase, iron-core reactor with ±5% taps on the inductance is wired in
series with capacitors to create a specific tuned frequency for the filter. Each
winding has a normally closed thermal switch that opens when the temperature
reaches an excessive level.
Filter Capacitor
Single phase, individually fused capacitors are used in combination with a
reactor to tune the filter to a specific frequency. The capacitors also serve the
purpose of providing leading kvar to correct the power factor of the associated
drive.
Current Transformer
Window-type current transformers are used around the conductors feeding
each capacitor. The 5A CT secondary drives a 592 thermal overload relay and
an SMP-3 relay.
SMP-3 Overload Relay
Only the phase loss function of this relay is used to detect a blown fuse on a
capacitor. A blown fuse on a capacitor generally indicates that the associated
capacitor has failed in a short-circuit condition. The overload setting on this
relay is intentionally set high since the overload function is not used. The
SMP-3 relay is a manually reset device.
1519-5.0 – May 1998
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