power quality for commercial and industrial customers
TRANSCRIPT
© 2017 Electric Power Research Institute, Inc. All rights reserved.
Mark Stephens, PE, CEM, CP EnMSPrincipal Project Manager, EPRI
October 26, 2017
Power Quality for Commercial and Industrial Customers
2© 2017 Electric Power Research Institute, Inc. All rights reserved.
Seminar Agenda8:00 am to 9:00 am Registration and Continental Breakfast
9:00 am to 9:10 am Welcome and Introductions
9:10 am to 10:45 am Session 1:
Understanding Power Quality
How Voltage Sag Impacts on Industrial and Commercial Equipment
Embedded Solution Approaches through equipment design strategy
Embedded Solutions through targeted power conditioning (with demos)
10:45 am to 11:00 am Break
11:00 am to 12:30 pm Session 2:
EPRI PQ Investigator
Machine and Panel Level Solutions
Chillers PQ Issues and Solutions
Air Compressor PQ Issues and Solutions
Relevant Case Studies
Economics of Downtime
12:30 pm Adjourn/Lunch
3© 2017 Electric Power Research Institute, Inc. All rights reserved.
Who is EPRI?
Founded by and for the electricity industry in 1973
Independent, nonprofit center for public interest energy and environmental research
Collaborative resource for the electricity sector
Work with Utilities, Industry, and Government
Major offices in Palo Alto, CA; Charlotte, NC; Knoxville, TN
Collaborative Value
Thought Leadership
Industry Expertise
4© 2017 Electric Power Research Institute, Inc. All rights reserved.
PQ & EE On-Site
Assessment Team
Mark Stephens, PE, C.E.M., CP EnMSPrincipal Project Manager
Bill Howe, PE, C.E.M.PQ Program ManagerTeam Advisory Role
James Owens, C.E.M., C.P.Q.PQ and EE Team Member
Logistics, Scheduling, Process
Baskar Vairamohan, PE, C.E.M.Specialists: Project Management, & Industrial Process Heating
Alden Wright, PE, C.E.M., CP EnMSTechnical Lead, PQ & EE Assessments
Jason Johns, C.P.Q.Technologist, PQ Monitoring & Assessments
Scott Bunton, C.E.M., C.P.Q.Technical Lead
PQ Proposals & Assessments
5© 2017 Electric Power Research Institute, Inc. All rights reserved.
EPRI’s Industrial Energy Efficiency and Power Quality Work
Headed up primarily from Knoxville, we specialize in solving EE & PQ Problems In all Manufacturing Sectors
Our Primary mission is to Focus on Reducing End Use Customer Losses by improving process Energy Efficiency and PQ through:
– Energy Efficiency Assessments Traditional Areas Process Heating Energy Management
– Power Quality Assessments Voltage Sags Harmonics Flicker Wiring and Grounding
– Common Areas to PQ and EE Testing (lab and field) Consulting with OEMs Training
6© 2017 Electric Power Research Institute, Inc. All rights reserved.
EPRI Industrial Site Assessments 1996-2017
Industry Sites PercentageSemiconductor 31 12%
Plastics 29 11%Food & Beverage 28 11%
Automotive 23 9%Paper/Printing 20 8%
Machining 12 5%Aviation/Aerospace 13 5%
Fibers/Textile 11 4%PetroChem/Nat Gas 11 4%
Chemical 10 4%Commercial 8 3%
General Industry 7 3%Glass 8 3%
Heavy Industry 7 3%Metals/Wire 9 4%
Govt 5 2%Electronic 4 2%
Medical/Hospital 13 5%Pharma 5 2%
Power Gen 1 0%Total Sites 255
Average/Year 13
Site Investigations 1996‐2016
© 2017 Electric Power Research Institute, Inc. All rights reserved.
UnderstandingPower Quality
8© 2017 Electric Power Research Institute, Inc. All rights reserved.
Transmission Substation
Farm Service
120/240 Volts
Split Phase
Home Service
120/240 Volts
Split Phase
Commercial Service
120/208 Volts
3 Phase
Distribution Substation
Distribution Grid
7.2kV to 34.5kV
Industrial Service
2,400 Volts and
277/480 Volts
3 Phase
Sub-Transmission Grid
35kV to 138kV
Industrial Service
4,160 Volts
3 Phase
Transmission Grid
69kV to 765kV
Generation
Step-Up
Transformer
Generator Plant
20kV
9© 2017 Electric Power Research Institute, Inc. All rights reserved.
Power Quality
Transients– Impulse– Oscillatory– Irregular
Short Duration Variations– Sags/Swells– Interruptions
Interruptions– Momentary/Sustained
Waveform Distortion– Harmonics
Voltage Fluctuations
10© 2017 Electric Power Research Institute, Inc. All rights reserved.
Transients
Impulse Transients Lighting
Oscillatory Transients Irregular Transients
11© 2017 Electric Power Research Institute, Inc. All rights reserved.
Short Duration Variations
Momentary Interruption– Less than 10% of the voltage Protective device operation with
automatic reclosing
SagsSwells Time Period
12© 2017 Electric Power Research Institute, Inc. All rights reserved.
Short Duration Variations
Momentary InterruptionSags
– A decrease in voltage of 10% to 90% for durations less than 1 minute Electrical Faults Large load additionsMotor startingCapacitor banks turning
off
Swells
Voltage sag
13© 2017 Electric Power Research Institute, Inc. All rights reserved.
Short Duration Variations
Momentary InterruptionSagsSwells
– An increase in voltage to more than 110% for durations less than 1 minute Electrical Faults Large load sheddingCapacitor banks turning
on
Voltage swell
14© 2017 Electric Power Research Institute, Inc. All rights reserved.
Long Duration Variations
Overvoltage– Sustained voltages, longer than
1 minute, outside range A. Load variations Temporary switching
conditions Voltage regulating equipment
Under voltageSustained Interruptions
15© 2017 Electric Power Research Institute, Inc. All rights reserved.
Long Duration Variations
OvervoltageUnder voltage
– Sustained voltages, longer than 1 minute, outside range A.Overloaded equipment Load variations Temporary switching
conditions Voltage regulating equipment
faultsSustained Interruptions
16© 2017 Electric Power Research Institute, Inc. All rights reserved.
Long Duration Variations
Overvoltage Under voltage Sustained Interruptions
– Decreases in supply voltage, to less than 90% of nominal voltage for more than 1 minute.
– Protective Device Operation– Faults
17© 2017 Electric Power Research Institute, Inc. All rights reserved.
Fuse Save vs. Fuse Sacrifice Protection Strategy
® ®
Fuse Sacrifice2.1 mi of Exposure
Fuse Save18.6 mi of Exposure
Customer Customer
18© 2017 Electric Power Research Institute, Inc. All rights reserved.
Fuse Save: Allows automatic devices, like relays and reclosersto clear temporary faults without damaging the fuse. Reduces overall outage duration (SAIDI) Increases “blinks” or momentaries (MAIFI)
Fuse Blow: The fuse clears the fault before relays or reclosersoperate. Often used to protect underground systems – UG faults are
generally permanent. Used in commercial/industrial areas where customers
complain most about momentaries. Some utilities block the instantaneous trip on the relay to
ensure that the fuse will clear
19© 2017 Electric Power Research Institute, Inc. All rights reserved.
Fuse Sacrifice (Fuse Blow)
• The fuse-sacrifice strategy delays the initial operation(s) of the recloser, giving downstream fuses time to sense faults and operates.
• i.e., For any fault down-stream of tap-fuse A, the recloser is delayed enough to allow tap-fuse A time to operate before the recloser operates.
20© 2017 Electric Power Research Institute, Inc. All rights reserved.
Fuse Save
In a fuse-saving strategy, reclosers are set to operate one or more times on a “fast” time-current characteristic, more quickly than downstream fuses can operate, then and subsequently one or more times on a “slow” characteristic which provides ample time for downstream fuses to sense and operate. i.e., For a fault downstream of tap-fuse A, the station recloser operates one or
more times more quickly than the tap fuse will operate.
21© 2017 Electric Power Research Institute, Inc. All rights reserved.
Advantages of each Strategy
Fuse Sacrifice– The number of temporary outages
to all customers on the circuit is minimized
– Permanent faults on lateral taps are cleared in one operation (the fuse blowing), minimizing fault-duty.
– The number of recloser operations is minimized.
– Lateral temporary faults result in outages to small zones, reducing the area to be investigated for temporary outage causes.
Fuse Saving– Temporary faults on fused lateral taps
can be cleared and restored by fast-operating reclosers, minimizing permanent outages.
– Quicker clearing of temporary faults by the recloser can minimized though-fault duty.
– Lower total fault energy (I2T) for permanent main-line faults
22© 2017 Electric Power Research Institute, Inc. All rights reserved.
• LG/LL Faults Occur on the Utility System due to: Weather/Trees/Public Interference
• Internally induced plant events (starting of large high inrush load)
• Although the utility can reduce the number of events (tree trimming, root cause analysis) it is impossible to eliminate all voltage Sags.
Why Voltage Sags Occur...
23© 2017 Electric Power Research Institute, Inc. All rights reserved.
How Common are Sags and Interruptions?
Results of EPRI TPQ-DPQ III Study
Key results:
•For every interruption, you may experience 8 to 20 voltage sags depending on what voltage level that you are fed from by the utility.
•The number of events that will be seen at your site is dependent on what type of connection you have from the utility.
24© 2017 Electric Power Research Institute, Inc. All rights reserved.
How many phases “sag”?
Ref: EPRI TPQ-DPQ III Study, June 2014
25© 2017 Electric Power Research Institute, Inc. All rights reserved.
Outage or Sag ?
26© 2017 Electric Power Research Institute, Inc. All rights reserved.
Typical Recloser Screens
27© 2017 Electric Power Research Institute, Inc. All rights reserved.
Targeting by Cause
Florida
Northwest US
EPRI Fault Study
Other
Construction activity
Vandalism
Ice/snow
Vehicle accident
Dig−in
Wind
Animal
Equipment failure
Tree contact
Lightning
0 5 10 15 20 25
Percent of faults by cause
0 5 10 15 20 25
FIGURE 7.1Tom Short, Electric Power Distribution Handbook, CRC Press, 2004
28© 2017 Electric Power Research Institute, Inc. All rights reserved.
Who’s “Fault” is it?
29© 2017 Electric Power Research Institute, Inc. All rights reserved.
Important Realization
Utilities Share Responsibility– Tree Trimming, Lighting Arrestors, Grounding, Maintenance,
Provide PQ information to industrials, etc– Circuit patrols, Reviewing customer complaints and device
operations, INST/QT setting reviews.
Industrials Share Responsibility– Understanding Equipment Vulnerability, PQ Specifications, Power
Conditioning, Proper Wiring/Grounding, etc
Most effective solutions are reached when both sides work together to see what can be done
© 2017 Electric Power Research Institute, Inc. All rights reserved.
How Voltage Sags Impacts on Industrial and Commercial Equipment
Mark Stephens, PE, CEM, CP EnMSPrincipal Project Manager, EPRI
31© 2017 Electric Power Research Institute, Inc. All rights reserved.
Effects of Voltage Sags
Lights may or may not flicker Equipment shutdown or malfunction Can result in production downtime an/or
product loss
-1
-0.5
0
0.5
1
0 1 2 3 4 5 6 7 8
Duration (4 Cycle)
Magnitude (50% of nominal)
(MagDur)
For every 1 momentary interruption a customer will see 8 to 20 voltage sags (EPRI TPQ-DPQ III Study)
32© 2017 Electric Power Research Institute, Inc. All rights reserved.
Interrelated Processes
Air Compressor
PowerSource
ProcessExhaust
PCWPump
PowerProcess
Mechanical
AutomatedProcess
InterlockedAutomated
Process
Is CompressedAir Present?
Is ProcessCooling Water
Present?
Are the ExahaustSystems Running?
Is PowerPresent?
Is InterlockedProcess Running?
Ok to RunAutomated
Process
CONTINUALLYREPEATED
StopAutomated
Process
NO
YES
NO
NO
NO
NO
YES
YES
YES
YES
33© 2017 Electric Power Research Institute, Inc. All rights reserved.
Why is PQ Important - Impacts
What happens to a manufacturing process when a power quality problem occurs?Who is to blame? How do we work together to fix the problems?
34© 2017 Electric Power Research Institute, Inc. All rights reserved.
Typical Reported Per Event Cost of PQ Disturbance
No. Process Reported
Cost Service Voltage Load 1 Semiconductor $1,500,000 69 kV 25 MW 2 Semiconductor $1,400,000 161 kV 30 MW 3 Semiconductor $ 700,000 12.5 kV 10 MW 4 Metal Casting $ 200,000 13.8 kV 16 MW 5 Chemical Plant $ 160,000 12.5 kV 5 MW 6 Pulp and Paper Mill $ 110,000 161kV 100 MW 7 Aerospace Engine Machining $ 100,000 13.8kV 10 MW 8 Food and Beverage $ 87,000 12.5 kV 5 MW 9 Chemical Plant $ 75,000 66kV 3 MW 10 Chemical Plant $ 75,000 66kV 5 MW 11 Electronic Components $ 75,000 12.5 kV 5 MW 12 Crystal Growth $ 60,000 12.5 kV 1 MW 13 Chemical Plant $ 46,175 66kV 30 MW 14 Wiring Manufacturing $ 34,000 12.5 kV 2 MW 15 Chemical Plant $ 18,000 12.5 kV 2 MW 16 Fibers Plant $ 15,000 12.5 kV 1 MW 17 Paper and Packaging $ 10,000 12.5 kV 4 MW 18 Plastic Bag Manufacturing $ 10,000 480V 4 MW 19 Plastics $ 7,500 12.5 kV 4 MW 20 Stainless Steel Manufacturing $ 5,500 12.5 kV 2 MW
Automotive Reported as high as $700,000.
35© 2017 Electric Power Research Institute, Inc. All rights reserved.
Goal – Extending the Operating Envelope
“Extending the operating envelope” of equipment means that we have to reduce the area of equipment malfunctions by enabling the equipment to ride through deeper and longer voltage sags.
36© 2017 Electric Power Research Institute, Inc. All rights reserved.
Sag Generator
37© 2017 Electric Power Research Institute, Inc. All rights reserved.
−50 0 50 100 150 200 250 3000
0.2
0.4
0.6
0.8
1
Time (ms)
rms
Vol
tage
(pe
r un
it)
A
B
C
0.0
0.2
0.4
0.6
0.8
1.0
1 10 100 1000
Duration (ms)
Mag
nitu
de (p
er u
nit)
−20 −10 0 10 20 30 40 50−1
−0.5
0
0.5
1
Time (ms)
Vol
tage
(pe
r un
it)
A
B C
90%Approximation Used in Plotting Events
38© 2017 Electric Power Research Institute, Inc. All rights reserved.
3
Voltage Tolerance Curve: Ice Cube Relay
How many potential shutdown events would be caused by the relays?
39© 2017 Electric Power Research Institute, Inc. All rights reserved.
Voltage Tolerance Curve: Small Contactor
What happens during a voltage sag down to 50% of nominal for 5
cycles ?
40© 2017 Electric Power Research Institute, Inc. All rights reserved.
Voltage Tolerance Curve of Motor Starters
Which motor starters are the most susceptible to voltage sags?
41© 2017 Electric Power Research Institute, Inc. All rights reserved.
Emergency Off (EMO) Circuit
Q1. What happens if the EMO relay or Main Contactor are extremely vulnerable to voltage sags?Q2. What if the plant voltage is low?Q3. What if the transformer rated output voltage does not match the relay and contactor?
42© 2017 Electric Power Research Institute, Inc. All rights reserved.
Master Control Relay Example
What happens when an operator hits the E-Stop?
What happens if 1CRM1 is a sensitive relay?
43© 2017 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supplies
DC Power supplies range from single-phase linear to switch-mode designs and are used to power user interface PCs, tool controllers, and instrument I/O applications. The voltage sag ride-through of most power
supplies designed for PC, tool controllers, and instrument I/O applications is directly related to the amount of stored energy and power and/or topology. PQ Performance Varies based on topology and
loading An example is 120 volts to 24Vdc. The
"secondary" voltage is a lower, control level voltage.
44© 2017 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supply Susceptibility Example 1: Single-Phase 120Vac Input Switch Mode
Heavily Loaded Power Supplies will typically have less immunity to voltage sags than lightly loaded supplies.
Astrodyne SCN-600-12 Voltage Sag Ride Through Curve
30%35%40%45%50%55%60%65%70%
0.000 0.200 0.400 0.600 0.800 1.000
Duration (in seconds)
Volta
ge (%
of N
omin
al)
48% Load 72% Load 94% Load
Input:120Vac
45© 2017 Electric Power Research Institute, Inc. All rights reserved.
DC Power Supply Susceptibility Example 2: Universal Input Types
Idec PS5R-A12, 7.5W
0
10
20
30
40
0 10 20 30 40 50 60
Cycles
%Vn
omin
al
Vin=208Vac
Vin=120Vac
CM50 (208 Volts)
0%20%40%60%80%
100%
0 0.2 0.4 0.6 0.8 1 1.2
Duration (in seconds)
Volta
ge (%
of N
omin
al)
100% Load SEMI F47
46© 2017 Electric Power Research Institute, Inc. All rights reserved.
PLC BasedControl Systems
47© 2017 Electric Power Research Institute, Inc. All rights reserved.
PLC System Wiring (Typical)
E-Stop
48© 2017 Electric Power Research Institute, Inc. All rights reserved.
AC Powered PLC Power Supply
From Typical PLC Literature:
What that means to you:- Oversensitive Power Supply- Process Shutdown due to voltage Sags
What can be done about this?
49© 2017 Electric Power Research Institute, Inc. All rights reserved.
PLC Voltage Sag Response Demo!
AB PLC-5 AC I/O
– AC output Card drives AC Relay (CR1) with contact feed back to PLC AC Input Card Corresponding Pilot Light
DC I/O– DC output Card Drives DC Relay
(CR3) with contact feedback to PLC DC Input Card Corresponding Pilot Light
Various Test Sequences for demonstrating Technologies
Sequence State Set to “0”AC P/S Switch OnDC P/S Switch OFF
50© 2017 Electric Power Research Institute, Inc. All rights reserved.
Discrete Inputs (DI)
24 VOLTS AC/DC
48 VOLTS AC/DC
120 VOLTS AC/DC
230 VOLTS AC/DC
TTL LEVEL
NON-VOLTAGE
ISOLATED INPUT
5-50 VOLTS DC (SINK/SOURCE)
PROXIMITY SWITCHES
PUSH BUTTON/SELECTOR
SWITCHES
LIMIT SWITCHES
MOTOR STARTER AUX. CONTACTS
RELAY CONTACTS
PRESSURE SWITCHES
ZERO SPEED SWITCHES
FLOW SWITCHES
DRY CONTACT OUTPUT CARD OF ANOTHER PLCAC Input ON to OFF detection time is ~11ms!
51© 2017 Electric Power Research Institute, Inc. All rights reserved.
DESCRIPTION 115 VAC inputNUMBER OF POINTS 16OPERATING VOLTAGE 80-130 VAC/47-63 Hz“ON” CONDITION THRESHOLD VOLTAGE 60 +/- 15 VRMSMAXIMUM RESPONSE TIMEOFF to ON 6 ms (4 ms typical)ON to OFF 18 ms (11 ms typical)
Example AC Input Card Specification
52© 2017 Electric Power Research Institute, Inc. All rights reserved.
START
STOP
LOCAL CONTROL PUSHBUTTONS
INPUTS
ProgrammableLogic Controller(PLC)
OUTPUTS
MOTORSTARTER
MOTOR
PLC Applications: Motor Control
Motor Control using conventional "seal-in" technique with motor starter auxiliary contact. | Start Stop | Energize | | motor 1 motor 1 | Motor 1 | | Pushbutton Pushbutton| Starter | | | Coil | | I:1 I:1 O:2 | |-+----] [-----+----] [------------------------------------------------( )-----| | | 0 | 1 0 | | | Motor | | | | Starter 1 | | | | Auxiliary | | | | Contact | | | | I:1 | | | +----] [-----+ | | 2 |
53© 2017 Electric Power Research Institute, Inc. All rights reserved.
RED
WHITE
BLUE
WHITE w/ Blue Stripe (if grounded)
AC and DC DI Cards
54© 2017 Electric Power Research Institute, Inc. All rights reserved.
Discrete Outputs (DO)
12-48 VOLTS AC
120 VOLTS AC
230 VOLTS AC
12-48 VOLTS DC
120 VOLTS DC
230 VOLTS DC
CONTACT (RELAY)
ISOLATED OUTPUT
TTL LEVEL
5-50 VOLTS DC
(SINK/SOURCE)
MOTOR STARTERS
DISCRETE ON/OFF VALVES
SOLENOIDS
RELAYS
PILOT LIGHTS
BINARY CODED DECIMAL (BCD) DISPLAYS
ALARMS HORNS/BUZZERS
INPUT CARD OR ANOTHER PLC
Output Devices Can be Susceptible to Voltage Sags.
55© 2017 Electric Power Research Institute, Inc. All rights reserved.
Suitcase Demo PLC
56© 2017 Electric Power Research Institute, Inc. All rights reserved.
PLC Voltage Sag Response Demo!
AB PLC-5 AC I/O
– AC output Card drives AC Relay (CR1) with contact feed back to PLC AC Input Card Corresponding Pilot Light
DC I/O– DC output Card Drives DC Relay
(CR3) with contact feedback to PLC DC Input Card Corresponding Pilot Light
Various Test Sequences for demonstrating Technologies
Sequence State Set to “0”AC P/S Switch OnDC P/S Switch OFF
57© 2017 Electric Power Research Institute, Inc. All rights reserved.
Adjustable Speed Drives
58© 2017 Electric Power Research Institute, Inc. All rights reserved.
AC PWM Drive
RectifierDiode Bridge
DC BusCapacitor
IGBTInverter
60 65 70 75 80 85-800
-600
-400
-200
0
200
400
600
800
Time (mS)
Voltage (V)
60 65 70 75 80 85 0
100
200
300
400
500
600
700
Time (mS)
Voltage (V)
60 65 70 75 80 85-800
-600
-400
-200
0
200
400
600
800
Time (mS)
Voltage (V)
Source Voltage DC Bus Voltage Motor Input Voltage
MOTORACINPUT
SECTION
ENERGY STORAGE SECTION
OUTPUT SECTION
59© 2017 Electric Power Research Institute, Inc. All rights reserved.
Voltage Sag Impact on ASD
Drive Trips on Undervoltage
InductionMotor
Rectifier Inverterdc Link
dc Bus Voltage
trip level
660V
420V
60© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example Drive Response
61© 2017 Electric Power Research Institute, Inc. All rights reserved.
VSI AC Drive During a Single-Phase Sag (Van = 100%, Vbn = 100%, Vcn = 0%)
0
100
200
300
400
500
600
700
0 0.005 0.01 0.015 0.02Time (in Seconds)
DC
Bus
Vol
tage
(in
Volts
)
DC Bus Voltage Bridge Rectifier Output Trip Level
Why Do ASDs Sometimes Trip During Minor Voltage Sags?
62© 2017 Electric Power Research Institute, Inc. All rights reserved.
Line-Side and Motor-side Contactors
63© 2017 Electric Power Research Institute, Inc. All rights reserved.
ASD Enable/Run Signal
Contact on
120 V AC relay
DriveEnable/Run
© 2017 Electric Power Research Institute, Inc. All rights reserved.
Embedded Solution Approaches through equipment design strategy (with demos)
65© 2017 Electric Power Research Institute, Inc. All rights reserved.
Mitigation Levels
Embedded Solutions
66© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 1: Design with DC Power
One of the best methods of increasing the tolerance of control circuits is to use direct current (DC) instead of alternating current (AC) to power control circuits, controllers, input/output devices (I/O), and sensors. DC power supplies have a “built-in”
tolerance to voltage sags due to their ripple-correction capacitors, whereas control power transformers (CPTs) and AC components do not have inherent energy storage to help them ride through voltage sagsMany OEMs are moving in this
direction to harden their equipment designs
DC Powered Emergency Off Circuit
67© 2017 Electric Power Research Institute, Inc. All rights reserved.
Demonstration Time – PLC using DC Power Supply Rather Than CPT
DC Powered PLC Circuit
How Much Better is the DC solution?–Depth of Sag–Duration of SagWhat other benefits does DC have?What are some design considerations with DC?
PLC DC P/S On, AC P/S OFFSequence State Set to “0”
68© 2017 Electric Power Research Institute, Inc. All rights reserved.
AC Versus DC Powered PLC Ride-Through Demo
05
10152025303540455055606570758085
0 5 10 15 20 25 30 35 40 45 50 55 60
%Vn
om
Cycles
SEMI F47
Legend
AC PLC
DC PLC
69© 2017 Electric Power Research Institute, Inc. All rights reserved.
DC Powered PLC System in Weld Shop
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 5 10 15 20 25 30 35 40
Duration (cycles)
Mag
nitu
de (P
erce
ntag
e of
Pre
-Sag
Vol
tage
)
Min Phase-to-Phase AB SLC-5/X PLC
70© 2017 Electric Power Research Institute, Inc. All rights reserved.
Summary of Robust Power Supply Strategies
71© 2017 Electric Power Research Institute, Inc. All rights reserved.
Summary of Robust Power Supply Strategies: Relative Power Supply Response at 100% Loading
Ride-Through for Single-Phase Voltage
Sags
72© 2017 Electric Power Research Institute, Inc. All rights reserved.
24Vdc Energy Storage Options
The PQI now has two 24Vdc Energy Storage Options that can harden 24Vdc Based Controls.
73© 2017 Electric Power Research Institute, Inc. All rights reserved.
PULS DC BUFFER Module
DEMO:Sequence “0”PLC DC P/S “ON”Connect Buffer Module to 24VDC
Ref: PULSE Buffer module SLV.20.200 data sheet
74© 2017 Electric Power Research Institute, Inc. All rights reserved.
ABB Ucap DC Power Supply Buffer Module
DC Buffer modules are devices that are installed in parallel with the output of DC power supplies to offer extended voltage sag ride through protection. There are several
manufacturers of DC voltage buffers Most manufacturers assert
that buffers may be used in parallel to supply more energy. These modules can supply
power up to 38 seconds at full load current in the event of an interruption of DC power.
Ref: ABB Buffer module CP-B 24/20.0 data sheet
DEMO:Sequence “0”PLC DC P/S “ON”Connect Buffer Module to 24VDC
75© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method No. 2: Utilize Sag Tolerant Components
If AC Relays and Contactors are used in the machine design, then utilize compliant devices.
Consider response at both 50 and 60 Hz.
We have certified a many relays and contactors to SEMI F47.
76© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example Robust Contactor
Telemecanique LC1F150 Coil LX9FF220Voltage Sag Ride Through Curve
0%
20%
40%
60%
80%
100%
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1Duration (in seconds)
Volta
ge (%
of N
omin
al)
DUT 60HZ SEMI F47 DUT 50HZ
77© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example Voltage Sag Response of Motor Controls Based on Robustness of Components
78© 2017 Electric Power Research Institute, Inc. All rights reserved.
New Solution for an Old Problem: “Nice Cube” Concept
Original “AC Ice Cube”
Drop out ~70% VnomRemove “AC Ice Cube” Insert“Nice Cube” Puck Into Base
Insert “DC Ice Cube”
Drop Out ~ 25-30% Vnom
79© 2017 Electric Power Research Institute, Inc. All rights reserved.
Nice Cube Relay
DEMO PLC DC Powered
Sequence State Set to “2”
80© 2017 Electric Power Research Institute, Inc. All rights reserved.
Nice Cube Relay
MitigatorModel Manufacturer Mfr Part Number MitigatorDescription Mitigator Cost ()Nice Cube Relay 120Vac
Power Quality Solutions Inc. VNC-120Vac Nice Cube, 120Vac Unit, 50/60Hz 85
Nice Cube Relay 24Vac
Power Quality Solutions Inc. VNC-24Vac Nice Cube, 24Vac Unit, 50/60Hz 85
81© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 3: Apply Custom Programming Techniques – Delay Filters
Delay filters can be verify the presence of power and work as a “de-bounce” mechanism for when components drop out due to a voltage sag. The PLC motor-control circuit shown demonstrates how this method can be applied.
The program is designed to detect whether the auxiliary contact is open for more than 250 milliseconds.
If the contact is open for more than that preset time, then the “Timer On Delay Coil” in Rung 2 will be set and unlatch the previous rung to remove voltage from the motor starter.
DEMO • PLC DC P/S “ON” • Sequence State Set to “3” w/o delay• Sag test to 40% Nom, 12 cycles• Set to “4” with filter timer• Repeat Sag Test
82© 2017 Electric Power Research Institute, Inc. All rights reserved.
Motor Control - Auxiliary Contact Drop Out DelayThe next two rungs demonstrate motor control with a time delay used todetermine how long to wait after the motor starter auxiliary contact opens (oris thought to be open by the PLC) before dropping the motor starter. Thiscircuit enhances the ride-through of the motor control circuit.
| Start Stop |Motor 2 | Energize || Motor 2 Motor 2 |Auxiliary | Motor 2 || Pushbutton Pushbutton|Contact | Starter || |open timer| Coil || |done | || I:1 I:1 T4:0 O:2 ||-+----] [-----+----] [--------]/[-------------------------------------( )-----|| | 3 | 4 DN 1 || | Energize | || | Motor 2 | || | Starter | || | Coil | || | O:2 | || +----] [-----+ || 1 |When the motor starter coil is energized, this detects if the auxiliarycontact is open for more than 250 milliseconds. If the contact is open formore than the preset time, then the timer done bit t4:0/dn will be set on andunlatch the previous rung to remove voltage from the motor starter.
| Energize |Motor Motor || Motor 2 |Starter 2 Starter 2 || Starter |Auxiliary Auxiliary || Coil |Contact Contact || Timer || O:2 I:1 +TON---------------+ ||----] [--------]/[----------------------------------+TIMER ON DELAY +-(EN)-|| 1 5 |Timer T4:0+-(DN) || |Time Base 0.01| || |Preset 25| || |Accum 0| || +------------------+ |
83© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 3: Apply Custom Programming Techniques –State Machine Programming
State Machine Programming is based on the idea that manufacturing processes are comprised of a number of steps with the goal of producing and moving a product.
Therefore, machine-state programming keeps track of every sequential process state and associated variables by writing variables to non-volatile memory in the event power is lost.
When power returns, the processing step number and variables can be recalled so that the machine can continue from where it stopped.
84© 2017 Electric Power Research Institute, Inc. All rights reserved.
YMCA BOT Demo State Machine ProgrammingUsing Volatile vs. Non-Volatile Memory
By writing the process step into non-volatile memory, the YMCA Bot is able to remember which letter it was doing before it shutdown and pick up afterwards.
85© 2017 Electric Power Research Institute, Inc. All rights reserved.
YMCA BOT Demo State Machine ProgrammingUsing Volatile vs. Non-Volatile Memory
“YMCA” States Written to Volatile Memory
“YMCA” States Written to Non-Volatile Memory
86© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 3: Apply Custom Programming Techniques – Programming Using Phase/Voltage Sensing RelayA phase monitor or voltage
sensing relay, used in conjunction with programming, can also protect against the effects of voltage says. The relay contacts can be
used to run a check on the system, retrieve past information stored in memory, or hold control parameters constant until the event is over.
Potential Sensing Devices For Voltage Sags
(Left to Right)
Phase Monitoring Relay
PQ Relay
“Original” PQ Relay (AC Ice Cube)
87© 2017 Electric Power Research Institute, Inc. All rights reserved.
PQ Relay Demonstration
PQ Relay is a sensor that detects voltage sags and swells and opens contacts for 3 seconds when detected. Can be picked up by controls
for “evasive action” or logging. Input 100V – 240Vac Contacts N.C., 30Vac/dc max
Demo
$349 each
www.powersensorsltd.com
PLC DC PoweredPQ1 Set to SEMI F47Sequence Set to “6”Sag to 90%, 12 cyclesSag to 50%, 12 cycles
88© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 4 – Examine Configuration Settings
A low-cost or perhaps no-cost method of increasing the tolerance of AC and DC motor drives to voltage sags is through software configuration settings. This method applies to all types
of drives, including, but not limited to, AC pulse-width modulation (PWM), direct-current, AC-pulse, stepper, and servo drives.
© 2017 Electric Power Research Institute, Inc. All rights reserved.
Video : Visualizing PQ Drive Parameters for Improved
Voltage Sag Ride-Through
Video 1: Visualizing PQ Drive Parameters for Improved Voltage Sag Ride-Through
90© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 5 – Select Appropriate Trip Curves for Circuit Breakers
Some equipment, especially equipment with AC-to-DC converters, may respond to a voltage sag by drawing inrush current when the voltage supply returns to normal. During a voltage sag, the AC-to-DC converter capacitors
discharge. At the end of the sag, the sudden presence of a full voltage causes the discharged capacitors to rapidly recharge. The magnitude of this inrush of current depends on the depth and
duration of the voltage sag. The resulting current transient may be large enough to trip circuit breakers that have a quick response time. Process machines with any type of AC-to-DC converter—such as
DC power supplies, AC or DC variable-speed drives, and servo drives—can not only cause such transients but may also be susceptible to breaker trips caused by the transients.
91© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 6: Control Power Transformer Tap Adjustments
If CPT output voltage is not at rated output:– Adjust CPT taps up (if available on transformer) 1) Lower Input Tap (i.e. from 460/480 to 440/460) 2) Raise Output Tap (i.e. from 110/115 to 115/120)
– Lowers susceptibility of control components to voltage sags by raising the nominal voltage.
– Check against unloaded condition to insure you do not overvoltage the control power
A B
92© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 7: Coordinate Control Power Transformer Wiring Adjustments
Within a process line with multiple control cabinets, the Control Power Transformers (CPTs) may be derived from various phase-to-phase combinations and be at various output voltages. A voltage sag on most any phase combination will cause the line to trip
somewhere.
A-B
A-B
A-B
B-C B-C B-CA-C
93© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 7: Coordinate Control Power Transformer Wiring Adjustments (2)
Coordinating which phases the CPT wiring is derived from within a line can make it less apt to drop out during a sag on a specific phase or phases. In this case a phase C, A-C, B-C voltage sag is less likely to cause the line
to drop out.
A-B
A-B
A-B
A-B A-B A-BA-B
LINE 1
94© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 7: Coordinate Control Power Transformer Wiring Adjustments (3)
Coordinating between will raise the chances that some lines may ride-through an event. What lines are likely
to ride-through for:– A sag on line A-B?– A sag on line C?
Probability Game!
95© 2017 Electric Power Research Institute, Inc. All rights reserved.
Method 8 – Specify a Voltage Sag Recommended Practice for OEMs!
A new recommended practice for voltage sag immunity to be published October 2017.– Trial Use in 2014– Full Recommended Practice in
2017
IEEE P1668 is based on SEMI F47 but includes requirements for three phase voltage sags.This recommended practice
defines test requirements and test criteria.
96© 2017 Electric Power Research Institute, Inc. All rights reserved.
IEEE P1668 – User Specs Desired Machine Response
Full (normal) operation – equipment performs as expected or intended and all of its relevant parameters are within technical specification or within allowed tolerance limits. Equipment performance should be expressed and measured against the set of relevant/critical “equipment outputs” (e.g. speed, torque, voltage level, etc.), which have to be defined as per the process requirements. Self-recovery – equipment does not perform intended functions, or its outputs
vary outside the technical specification/limits, but equipment is able to automatically recover after the end of voltage sag event without any intervention from the user. Assisted-recovery – equipment does not perform intended functions, or its
outputs vary outside the technical specification/limits, and equipment is not able to automatically recover after the end of voltage sag event. Assisted-recovery criteria should be applied only when there are dedicated and/or trained personnel/staff, who either operate the equipment, or are responsible for supervising the equipment at all times when equipment is in use. If some external control circuit is applied for automatic restarting of equipment, this should be treated as a self-recovery criterion.
97© 2017 Electric Power Research Institute, Inc. All rights reserved.
IEEE 1668
Spec. Sheet format to be used for Single-phase equipment testing requirements.
98© 2017 Electric Power Research Institute, Inc. All rights reserved.
IEEE 1668
Spec. Sheet format to be used for 3-phase equipment testing requirements.
99© 2017 Electric Power Research Institute, Inc. All rights reserved.
Other Considerations
Make sure the device rated voltage matches the nominal voltage. Mismatches can lead to higher voltage sag sensitivities (for example 208Vac fed to 230Vac rated component).Consider Subsystem performance. Vendor subsystems
must be robust for the entire system to be robust. Otherwise, power conditioning may be required for the subsystem. Consolidate Control Power Sources. This will make the
implementation of any required power conditioner scheme much simpler and cost effective.Use a targeted voltage conditioning approach as the last
resort. Apply Batteryless power conditioner devices where possible (next session)
© 2017 Electric Power Research Institute, Inc. All rights reserved.
Mark Stephens, PE, CEM, CP EnMSPrincipal Project Manager, EPRI
Embedded Solutions through targeted
power conditioning with demos
101© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example Cost vs. Coverage
102© 2017 Electric Power Research Institute, Inc. All rights reserved.
Typical PQ Mitigation Devices
1 - 3
3 ProDySC 0% / 2 sec. 30% / 2 sec. 50% / 2 sec. at full load
45% / 30 sec. 45% / 30 sec. 50% / 30 sec.
25% / 30 sec. 25% / 30 sec. 50% / 30 sec.
1 Contrl Ckt PowerRide RTD 0% / 2+ sec. 0% A-B, B-C; 70-80% C-A / 2+ sec. 70-80% / 2+ sec. 3-phase Input, 1-phase Output
1 Contrl Ckt MiniDySC 0% / 0.05 sec. 50% / 2 sec. n/a n/a
1 Contrl Ckt CVT 40-50% / 2+ sec. n/a n/a
1 Contrl Ckt VDC (6T Model) 37% / 2+ sec. n/a n/a
1 Contrl CktCoil Hold-in (CoilLock
and KnowTrip) 25% / 2+ sec. n/a n/a for relays, contactors, motor starters
3AVC (two rated
models) at full load
Comparison of Power Conditioning DevicesCoverage (Vnom) / Duration
Application Device Notes
3
3
1
1
1
1
1
1 - 3
1-phase Supercapacitor UPS 0% /15 sec.
103© 2017 Electric Power Research Institute, Inc. All rights reserved.
The Premise:All equipment power users are not ultra-sensitive.
The Plan:To prop up the single-phase “weak links” only.
The Weak Links:Small, single-phase 100Vac-230Vac, typically power supplies, sensors and controls.
The Benefit: Lower Cost than Macro Solutions.
“Selective” Conditioning
104© 2017 Electric Power Research Institute, Inc. All rights reserved.
Uninterruptible Power Supply (UPS)
Battery Based UPS
Are Often “Overkill”
For Control LoadsSmall 500Va to
3kVAUPS Systems are sometimes Used
“Abandoned in Place” UPS Systems
105© 2017 Electric Power Research Institute, Inc. All rights reserved.
Industrial UPS Example:SDU DIN Rail DC UPS Series
Features Modular, rugged industrial grade design Microprocessor based controls Automatic self-test feature for UPS function
and battery management check Power module wide operation temperature range (-
20 to +50°C) Flexible batteries back-up expansion capabilities Overload protection in normal and battery modes User replaceable batteries Both power and battery modules are UL508 Listed IP-20 rated input and output screw terminals No internal fan, no extra cooling required Sturdy, reliable all metal DIN Rail mounting
connector LED Status Indicators Universal Dry Contact Relay terminals provide
remote signaling Monitoring, diagnostics, and remote turn-on
and shut-off capabilities Limited two-year warranty
Cost/Unit ~$500 USD
106© 2017 Electric Power Research Institute, Inc. All rights reserved.
Supercapacitor UPS New Product from Marathon
Power “Batteryless” UPS Supercapacitors store energy 3kVA, 2100 W 120V, 208V, 230V models Interruption Coverage:
– 15 seconds at full load– 45 seconds at ½ load
15 to 45 Seconds @Full Load
107© 2017 Electric Power Research Institute, Inc. All rights reserved.
Marathon Power Supercapacitor UPS Product Matrix
108© 2017 Electric Power Research Institute, Inc. All rights reserved.
Constant Voltage Transformer (CVT)
109© 2017 Electric Power Research Institute, Inc. All rights reserved.
CVT Application & FeaturesOn-line Device. In-Rush Current of load(s)
MUST be considered in sizing.Output of CVT can collapse when in-rush
current gets close too high ( around 4 x rated size). Sub-Cycle Response. Should be oversized to at least 2 times
nominal of load to increase ride-through. Acts as an isolation transformer and protects
against voltage sags.
Inpu
t Vol
tage
Out
put V
olta
ge
110© 2017 Electric Power Research Institute, Inc. All rights reserved.
Sample CVT SizingRecommendations
Specs 250VA 500VA 1kVA 3kVARecommended MaxNominal Load VA/Current @ 120Vac
100 VA / 0.83 A 200 VA / 1.67 A 400 VA / 3.33 A 1200 VA / 10 A
Recommended MaxInrush Load VACurrent @ 120Vac
500 VA / 4.16A 1000 VA / 8.33A 2000 VA / 16.67 A 6000 VA / 50A
Dimensions (inch) 9.88x4.5x7.44 12.69x7.78x6.44 16.75x7.78x6.44 18.69x10.56x9.03Weight (lbs) 27 37 62 142
MIN SIZE = 2.5 X Nominal VAor
1/2 Max Inrush VA*(whichever is larger)
*most critical with contactor loads
111© 2017 Electric Power Research Institute, Inc. All rights reserved.
CVT Typical Costs ($USD)
112© 2017 Electric Power Research Institute, Inc. All rights reserved.
CVT Coverage vs. Sample Historical Data
DemoPLC AC Powered
Sequence Set to “7”
113© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example CVT Application to Avoid: 500VA control power transformer and a NEMA type 6 starter
1/2 Max Inrush VA = 2kVA to 3kVA ~ $3,000 – Not cost effective!2 X Nominal VA = 2 x 500VA = 1kVA – Would Likely Collapse (Inrush around 4 x CVT Size)
114© 2017 Electric Power Research Institute, Inc. All rights reserved.
UPPI PowerRide RTD: CVT on STEROIDS
Power Anomaly ResultLoss of Phase A Output remains constantLoss of Phase B Output remains constantLoss of Phase C Output remains constantLoss of Phase A and B -33% sag on remaining phase
Output remains constant
Loss of Phase B and C -33% sag on remaining phase
Output remains constant
Loss of Phase A and C Output goes to 0Loss of A and 33% Sag on C Output remains constantLoss of C and 33% Sag on A Output remains constant37% Sag on A and C Output remains constant
No need to oversize by factor of 2.5Apply same Inrush caution as with Standard CVT.
115© 2017 Electric Power Research Institute, Inc. All rights reserved.
Power Ride RTD Coverage vs.Sample Historical Data
116© 2017 Electric Power Research Institute, Inc. All rights reserved.
UPPI PoweRide RTD: Example Suggested List Price
http://www.uppi-ups.com
Contact UPPI for accurate Pricing
500VA 500W 0.5kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 10A, 60Hz 1000
1kVA 1kW 1kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 10-15A, 60Hz 1400
2kVA 2kW 2kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 20-35A,60Hz 2400
3kVA 3kW 3kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 15-50A, 60Hz 3200
5kVA 5kW 5kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 20-80A,60Hz 4900
7.5kVA 7.5kW 7.5kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 30-125A,60Hz 5300
10kVA 10kW 10kVA, Input 208, 480,380,400,415 Wye/Del Or 240,480,200 del, Output 1ph, Any Input V Lvl, 40-175A,60Hz 8300
No need to oversize by factor of 2.5Apply same Inrush caution as with Standard CVT.
Mfr Part Number Mitigator DescriptionMitigator Cost ()
117© 2017 Electric Power Research Institute, Inc. All rights reserved.
The Dip Proofing Inverter
No batteries; therefore, no replacement and maintenance costs or hazardous waste. Fast (<700µS) transfer, off-line system
develops little heat & fails to safety. Able to withstand high inrush currents;
no need to oversize as with UPS’s & CVT’s. Lightweight, small & easy to retrofit; no
step-up transformers or batteries. Accurate application control; adjustable
ride through time & variable transfer level. Primarily designed for inductive and low
power factor loads.
118© 2017 Electric Power Research Institute, Inc. All rights reserved.
Typical Connections
119© 2017 Electric Power Research Institute, Inc. All rights reserved.
Sample DPI Specifications (120V Models)
Specs 250VA 500VA 1kVA 3hkVANominal LoadCurrent
2A 4A 8A 25A
Useable StoredEnergy
45J 90J 180J 540J
Ride-ThroughTimer Range
0.01 to 2.56 Seconds
Transfer LevelRange
50% to 80%50% to 90% Recommended (Special Order)
Dimensions (inch) 7.68x12.25x6.4 11.4x12.25x6.4 15.75x12.25x6.4 21x12.25x6.4Weight (lbs) 11 17 22 31
Ride-Through Time = Stored Energy (Watt-Second)/Load (Watts)
Example:500VA DPI Unit has 90 Joules = 90 Watt-Seconds
Circuit Load = 45 Watts
Ride-Through Time = 90 Watt-Seconds/ 45 Watts = 2 Seconds
120© 2017 Electric Power Research Institute, Inc. All rights reserved.
DPI Output
Inpu
t Vol
tage
Out
put V
olta
ge
•1-3 second ride-through based on real power required and sizing.
Square Wave not compatible with some PLC AC Input Cards.
121© 2017 Electric Power Research Institute, Inc. All rights reserved.
DPI Coverage vs. Sample Historical Data
DemoPLC AC Powered
Sequence Set to “7”
122© 2017 Electric Power Research Institute, Inc. All rights reserved.
DPI Product Matrix
MitigatorModel Manufacturer Mfr Part Number MitigatorDescription Mitigator Cost ()
DPIDip Proofing Technologies DPI53S6.6mF120V2A DPI, 0.25kVA, 120V, 2A, 31J, 50/60Hz 1500
DPIDip Proofing Technologies DPI53S13.2mF120V4A DPI, 0.5kVA, 120V, 4A, 68J, 50/60Hz 1900
DPIDip Proofing Technologies DPI53S19.8mF120V6A DPI, 0.75kVA, 120V, 6A, 103J, 50/60Hz 2400
DPIDip Proofing Technologies DPI53S39.6mF120V8A DPI, 1kVA, 120V, 8A, 217J, 50/60Hz 2800
DPIDip Proofing Technologies DPI54L33mF120V25A DPI, 3kVA, 120V, 25A, 181J, 50/60Hz 3200
DPIDip Proofing Technologies DPI54L66mF120V25A DPI, 3kVA, 120V, 25A, 371J, 50/60Hz 3800
DPIDip Proofing Technologies DPI54L99mF120V25A DPI, 3kVA, 120V, 25A, 556J, 50/60Hz 4200
DPIDip Proofing Technologies DPI53S2.04mF230V2A DPI, 0.46kVA, 208 or 230V, 2A, 910J@230V, 50/60Hz 1500
DPIDip Proofing Technologies DPI53S4.08mF230V4A DPI, 0.92kVA, 208 or 230V, 4A, 1820J@230V, 50/60Hz 1900
DPIDip Proofing Technologies DPI53S6.120mF230V6A DPI, 1.38kVA, 208 or 230V, 6A, 273J@230V, 50/60Hz 2400
DPIDip Proofing Technologies DPI53S12.24mF230V8A DPI, 1.84kVA, 208 or 230V, 8A, 584J@230V, 50/60Hz 2800
DPIDip Proofing Technologies DPI54L15mF230V25A DPI, 5.75kVA, 208 or 230V, 25A, 373J@230V, 50/60Hz 3200
DPIDip Proofing Technologies DPI54L30mF230V25A DPI, 5.75kVA, 208 or 230V, 25A, 746J@230V, 50/60Hz 3800
DPIDip Proofing Technologies DPI54L45mF230V25A DPI, 5.75kVA, 208 or 230V, 25A, 1.2kJ@230V, 50/60Hz 4200
DPIDip Proofing Technologies DPI54L90mF230V25A DPI, 5.75kVA, 208 or 230V, 25A, 2.2kJ@230V, 50/60Hz 5900
123© 2017 Electric Power Research Institute, Inc. All rights reserved.
Voltage Dip Compensator (Vdc)
No batteries; no maintenance. Fast compensation. Able to withstand high inrush
currents. Small footprint, easy to retrofit. Support exceeds SEMI F47
standard requirements. Handles inductive and low power
factor loads. 120Vac and 208Vac Models
124© 2017 Electric Power Research Institute, Inc. All rights reserved.
VDC Output
Product by Dip Proofing Technologies
www.dipproof.comwww.measurlogic.com
AC Output is a Sine Waveinstead of a Square Wave
125© 2017 Electric Power Research Institute, Inc. All rights reserved.
VDC Coverage
4T Model – Down to 50%
126© 2017 Electric Power Research Institute, Inc. All rights reserved.
VDC Coverage (4T Model) vs. Sample Historical Data
DemoPLC AC Powered
Sequence Set to “7”
127© 2017 Electric Power Research Institute, Inc. All rights reserved.
VDC Sizing
General Sizing Rule up to existing CPT size.120Vac Sizes – 1kVA, 3kVA208Vac Sizes – 1kVA, 5kVA
128© 2017 Electric Power Research Institute, Inc. All rights reserved.
VDC Product Matrix in PQI
Mfr Part NumberMitigatorDescription Mitigator Cost ()VDC S4T1K 120 VDC, 1kVA, 120V, Output, 8.5A, 50/60Hz, 1900VDC L4T3K 120 VDC, 3kVA, 120V, Output, 24A, 50/60Hz 3000VDC S4T1K 208 VDC, 1kVA, 208V, Output,4.8A, 50/60 Hz 1900VDC L4T5K 208 VDC, 5kVA, 208V, Output, 24A, 50/60Hz 3800
129© 2017 Electric Power Research Institute, Inc. All rights reserved.
Dynamic Sag Corrector
Draws power from remaining sagged voltage down to 50% of nominal voltage, and injects a series voltage to regulate a sinusoidal output voltage Below 50%, draws power from internal
storage capacitorsMega and Pro DySC have on board event
logging.
MiniDySC
Single-Phase Protection
1-50 Amps
ProDySC
Three-Phase Protection
25-200Amps
MegaDySC
Three-Phase Protection
400-3200Amps
130© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example DySC Output
Input Voltage (Van)
Missing Volts
DySC Output Voltage
-500-400-300-200-100
0100200300400500
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t ( s)
-500
-300
-100
100
300
500
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t ( s)
-600
-400
-200
0
200
400
600
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t ( s)
131© 2017 Electric Power Research Institute, Inc. All rights reserved.
Single Phase DySC Topology
LOAD
Static Bypass Switch• On under normal conditions• Highly efficient (>99%)
Voltage-doubling Rectifier• Each dc capacitor charged to
peak of AC source voltage• Idle under normal conditions• Supplies power to inverter at
dc bus during sag correction
Half-bridge Inverter• Idle under normal conditions• Sinusoidal 12 kHz PWM switching
during sag correction• Acts as an AC voltage source
between points A and B, supplying only the missing voltage
Notes• The unique DySC circuit utilizes the same
capacitors for two functions: rectifier and inverter• More “ER” dc capacitors can be added for longer run time
when input voltage <50%. • Series connected inverter requires current path through
AC source.
A B
132© 2017 Electric Power Research Institute, Inc. All rights reserved.
DySC Operation
Normal Conditions:– Capacitors remained fully charged, idle, with no ripple current heating– Output (load) voltage is continuously monitored– Output voltage phase and frequency are tracked
Sag Condition:– A voltage sag is detected at the output of the DySC– Inverter IGBTs apply a reverse voltage to the conducting SCR to quickly force it off (commutate
it)– Inverter regulates the DySC output voltage to produce a sinusoidal output voltage– When input line rms voltage is restored to >90% for one cycle, the SCRs are turned on and the
inverter is shut off– Capacitors recharge to normal condition within a few cycles
133© 2017 Electric Power Research Institute, Inc. All rights reserved.
Example: MiniDySC 60% sag correctionVoltage sag Correction• DC voltage is sufficient to
correct voltage sags if input line voltage remains ≥ 50%.
• Stored Energy in capacitors is not needed unless input drops below 50%.
• Correction for up to 5 seconds or 2 seconds cumulative every minute (design limits).
Example: voltage sag to 60% remaining voltage, at full load• Power in = Power out = Load power (determined by load)
= (voltage) x (current)• Load voltage remains 100%, load current remains 100%• Input volt. dip to 60% causes input current 167% of load• Load energy comes from the AC source, not capacitors
100%
67%
167%
167%
100%
100%
V = 100%V = 60%
(V = 40%)
LOAD
V = 100%
134© 2017 Electric Power Research Institute, Inc. All rights reserved.
Mini-DySC Ride-Through Capability
100%
.001
50%
0%
.01 101.0.10 5.0
SR ER
50ms 200ms
• Ride-Through Times: (Based on 100% load, 0.7PF at 60Hz line frequency)
• Standard Runtime (SR) is 5 seconds for sags from 87% to 50% of nominal voltage every 60 seconds
• 3 cycles for Standard Outage units from 50%-100% (zero voltage remaining)
• 12 cycles for Extended Ride-Through (ER) units from 50%-100% (zero voltage remaining)
Nom
inal
Inpu
t Vol
tage
(%)
Duration/Time (Seconds)
SR
135© 2017 Electric Power Research Institute, Inc. All rights reserved.
MiniDySC Coverage vs.Sample Historical Data
Static Series Compensator with Stored Energy Supply >Coverage out to 5 seconds
DemoPLC AC Powered
Sequence Set to “7”
136© 2017 Electric Power Research Institute, Inc. All rights reserved.
MiniDySC ProductMatrix
http://ab.rockwellautomation.com/Power-Supplies/Voltage-Sag-Protector
Size to CPT or if fed from CB or Fuse:(Rated Voltage x Fuse/CB Size) x 0.8.Pay careful attention to load inrush for units 6A and Below.
Mfr Part Number MitigatorDescriptionMitigator Cost ()
1608N-002A120V2E MiniDySC - 1Ph , 0.24kVA, 2 A, 120 VAC, L-N, Extended, 50/60Hz 16501608N-002A120V2S MiniDySC - 1Ph , 0.24kVA 2 A, 120 VAC, L-N, Standard, 50/60Hz 12001608N-006A120V2E MiniDySC - 1Ph ,0.72kVA, 6 A, 120 VAC, L-N, Extended, 50/60Hz 23001608N-006A120V2S MiniDySC - 1Ph , 0.72kVA, 6 A, 120 VAC, L-N, Standard, 50/60Hz 18001608N-012A120V2S MiniDySC - 1Ph , 1.44kVA, 12 A, 120 VAC, L-N, Standard, 50/60Hz 2500
1608N-012A120V2S-RMiniDySC - 1Ph , 1.44kVA, 12 A, 120 VAC, L-N, Standard, Rack Mount, 50/60Hz 2700
1608N-025A120V2E MiniDySC - 1Ph , 3kVA, 25 A, 120 VAC, L-N, Extended, 50/60Hz 36001608N-025A120V2S MiniDySC - 1Ph , 3kVA, 25 A, 120 VAC, L-N, Standard, 50/60Hz 27001608N-050A120V2E MiniDySC - 1Ph , 6kVA, 50 A, 120 VAC, L-N, Extended, 50/60Hz 68001608N-050A120V2S MiniDySC - 1Ph , 6kVA, 50 A, 120 VAC, L-N, Standard, 50/60Hz 44001608N-002A208V1E MiniDySC - 1Ph , 0.42kVA, 2 A, 208 VAC, L-L, Extended, 50/60Hz 22001608N-002A208V1S MiniDySC - 1Ph , 0.42kVA, 2 A, 208 VAC, L-L, Standard, 50/60Hz 16001608N-003A208V1E MiniDySC - 1Ph , 0.62kVA, 3 A, 208 VAC, L-L, Extended, 50/60Hz 24001608N-003A208V1S MiniDySC - 1Ph , 0.62kVA, 3 A, 208 VAC, L-L, Standard, 50/60Hz 18001608N-012A208V1S MiniDySC - 1Ph , 2.5kVA, 12 A, 208 VAC, L-L, Standard, 50/60Hz 33001608N-025A208V1E MiniDySC - 1Ph , 5.2kVA, 25 A, 208 VAC, L-L, Extended, 50/60Hz 48001608N-025A208V1S MiniDySC - 1Ph ,5.2kVA, 25 A, 208 VAC, L-L, Standard, 50/60Hz 37001608N-050A208V1E MiniDySC - 1Ph ,10.4kVA, 50 A, 208 VAC, L-L, Extended, 50/60Hz 91001608N-050A208V1S MiniDySC - 1Ph ,10.4kVA, 50 A, 208 VAC, L-L, Standard, 50/60Hz 59001608N-012A220V2S MiniDySC - 1Ph ,2.64kVA, 12 A, 220 VAC, L-N, Standard, 50/60Hz 33001608N-025A220V2E MiniDySC - 1Ph ,5.5kVA, 25 A, 220 VAC, L-N, Extended, 50/60Hz 47001608N-025A220V2S MiniDySC - 1Ph ,5.5kVA, 25 A, 220 VAC, L-N, Standard, 50/60Hz 36001608N-050A220V2E MiniDySC - 1Ph ,11kVA, 50 A, 220 VAC, L-N, Extended, 50/60Hz 9100
1608N-050A220V2S MiniDySC - 1Ph ,11kVA, 50 A, 220 VAC, L-N, Standard, 50/60Hz 59001608N-003A230V2E MiniDySC - 1Ph ,0.69kVA, 3 A, 230 VAC, L-N, Extended, 50/60Hz 24001608N-003A230V2S MiniDySC - 1Ph ,0.69kVA, 3 A, 230 VAC, L-N, Standard, 50/60Hz 18001608N-012A230V2S MiniDySC - 1Ph ,2.76kVA, 12 A, 230 VAC, L-N, Standard, 50/60Hz 33001608N-025A230V2E MiniDySC - 1Ph ,5.75kVA, 25 A, 230 VAC, L-N, Extended, 50/60Hz 48001608N-025A230V2S MiniDySC - 1Ph ,5.75kVA, 25 A, 230 VAC, L-N, Standard, 50/60Hz 36001608N-050A230V2E MiniDySC - 1Ph ,11.5kVA, 50 A, 230 VAC, L-N, Extended, 50/60Hz 91001608N-050A230V2S MiniDySC - 1Ph ,11.5kVA, 50 A, 230 VAC, L-N, Standard, 50/60Hz 59001608N-002A240V1E MiniDySC - 1Ph ,0.48kVA, 2 A, 240 VAC, L-L, Extended, 50/60Hz 22001608N-002A240V1S MiniDySC - 1Ph ,0.48kVA, 2 A, 240 VAC, L-L, Standard, 50/60Hz 16001608N-002A240V2E MiniDySC - 1Ph , 0.48kVA, 2 A, 240 VAC, L-N, Extended, 50/60Hz 22001608N-002A240V2S MiniDySC - 1Ph , 0.48kVA, 2 A, 240 VAC, L-N, Standard, 50/60Hz 16001608N-003A240V1E MiniDySC - 1Ph , 0.72kVA, 3 A, 240 VAC, L-L, Extended, 50/60Hz 24001608N-003A240V1S MiniDySC - 1Ph , 0.72kVA, 3 A, 240 VAC, L-L, Standard, 50/60Hz 18001608N-003A240V2E MiniDySC - 1Ph , 0.72kVA, 3 A, 240 VAC, L-N, Extended, 50/60Hz 24001608N-003A240V2S MiniDySC - 1Ph , 0.72kVA, 3 A, 240 VAC, L-N, Standard, 50/60Hz 18001608N-012A240V1S MiniDySC - 1Ph , 2.88kVA, 12 A, 240 VAC, L-L, Standard, 50/60Hz 33001608N-012A240V2S MiniDySC - 1Ph , 2.88kVA, 12 A, 240 VAC, L-N, Standard, 50/60Hz 33001608N-025A240V1E MiniDySC - 1Ph , 6kVA, 25 A, 240 VAC, L-L, Extended, 50/60Hz 48001608N-025A240V1S MiniDySC - 1Ph , 6kVA, 25 A, 240 VAC, L-L, Standard, 50/60Hz 36001608N-025A240V2E MiniDySC - 1Ph , 6kVA, 25 A, 240 VAC, L-N, Extended, 50/60Hz 48001608N-025A240V2S MiniDySC - 1Ph , 6kVA, 25 A, 240 VAC, L-N, Standard, 50/60Hz 37001608N-050A240V1E MiniDySC - 1Ph , 12kVA, 50 A, 240 VAC, L-L, Extended, 50/60Hz 91001608N-050A240V1S MiniDySC - 1Ph , 12kVA, 50 A, 240 VAC, L-L, Standard, 50/60Hz 59001608N-050A240V2E MiniDySC - 1Ph , 12kVA, 50 A, 240 VAC, L-N, Extended, 50/60Hz 91001608N-050A240V2S MiniDySC - 1Ph , 12kVA, 50 A, 240 VAC, L-N, Standard, 50/60Hz 5900
137© 2017 Electric Power Research Institute, Inc. All rights reserved.
• Designed to “Prop Up” individual relays and contactors. Available at 120, 230 and 480Vac.
• Holds in down to 10 to 20% of %Vnominal.• Ideal for Motor Control Center Applications.• Size Based on Voltage and Coil Resistance.• Cost: less than $130 per unit
Coil Hold-in Devices
CoilLock Low VoltageRide Through
Module
138© 2017 Electric Power Research Institute, Inc. All rights reserved.
Coil Hold-In Device Ride-Through Curve
SEMI F47
DemoPLC DC Powered
Sequence Set to “1”8 cycle sag, 40%
139© 2017 Electric Power Research Institute, Inc. All rights reserved.
Coil Hold-In Device Costs
PQSI Coil Lock
Model Coil Resistance Measured with DC Ohmmeter Comments PriceNumber
1000-120V801 to 4.5k Ohms [1]
UL Compliant File E255764 120
1001-120V201 to 800 Ohms [1]
UL Compliant File E255764 120
1002-120V 8 to 200 Ohms [1]UL Compliant File E255764 120
1002-120V-CE 8 to 200 Ohms [1]
UL & CE Compliant (50 ma no load, 0.4 Amp w/8 Ohm Coil) 140
1003-120V 3 to 7.9 Ohms [1]UL Compliant File E255764 120
1001-240V601 to 17.5k Ohms [2]
UL Compliant File E255764 140
1002-240V155 to 600 Ohms [2]
UL Compliant File E255764 140
1003-240V20 to 154 Ohms [2]
UL Compliant File E255764 140
Know Trip
DESCRIPTIONPART NUMBER
LIST PRICE
MODEL 120 8.0 - 35 OHMSMODEL 120 $268
MODEL 120-8.5 36 - 200 OHMSMODEL 120-8.5 $268
MODEL 120A 201 - 800 OHMSMODEL 120A $268
MODEL 120B 801 OHMS and UPMODEL 120B $268
MODEL 120HP .5 - 7.9 OHMSMODEL 120HP $696
MODEL 240 151 OHMS and UPMODEL 240 $417
MODEL 240A 5 - 35 OHMSMODEL 240A $1,006
MODEL 240B 36 - 150 OHMSMODEL 240B $1,006
MODEL 480 151 OHMS and UPMODEL 480 $423
MODEL 480 and RC4 40 - 150 OHMS
MODEL 480 & RC4 $615
140© 2017 Electric Power Research Institute, Inc. All rights reserved.
Up After Break:PQ Investigator - You Can Connect to the PQI V3.0
EPRI has setup PQI on an internal server To access go to….
– Wi-Fi Node Name: PQI– Password: training– http://pqi.training/pqinvestigator/
When connected, you will not have outside internet access.
© 2017 Electric Power Research Institute, Inc. All rights reserved.
10:45 am to 11:00 amBreak