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Beijing Leader & Harvest Electric Technologies Co. Ltd
Application of Medium Voltage Variable
Frequency Drive (VFD) In the Cement Industry
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Beijing LEADER & HARVEST Electric Technologies
Co., Ltd was established in August 1998. Depending on
advanced technology that is from the national key lab-
power electric lab of Tsinghua University, the company
is a high-technology company focusing on research,
development, manufacture, sales and service of the
medium voltage variable frequency drive (VFD) and
has got the certificates of ISO 9001. The headquarter of
our company lies in Yangfang Industrial Development
Zone of Changping South District. Its registered capital
is RMB 40 million. Now it has 600 employees and
covers the area of 50 acres. The company is the biggest
domestic base of producing medium voltage variable
frequency drive (VFD) at present.
Company Introduction
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Research and Development System
The company possesses a group of high quality
research and development team who are of rich
experience and in pursuit of new technologies, 30% of
which are technical engineers, and more than 10% of
which are upper than master degree, and depends on
advanced technology that is from the national key lab-
power electric lab of Tsinghua University.
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Production System
The Building area of Production workshop is 150 arces, the production system
has 300 employees, 70% of which have technology study experience in college. The
productivity of the medium voltage variable frequency drive (VFD) is two
thousands every year, the company has the biggest base of producing VFD at
present.
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Development of Technology
•2000, the first HARSVERT-A 1000KW/6KV medium voltage VFD was put into use.•2001, the first 10KV medium voltage variable frequency drive in china was put into use.•2003, 1800KW/6KV medium voltage variable frequency drive was put into use.•2004, 2500KW/6KV medium voltage variable frequency drive was put into use.•2006, 3400KW/6KV medium voltage variable frequency drive was put into use.•2006, first Vector Control medium voltage variable frequency drive was put into use.•2006, synchronous motor medium voltage variable frequency drive was put into use.•2006, a great sets of medium voltage variable frequency drives are put into use in thermal power plants of 600MW.•2007, 5600KW/10KV medium voltage variable frequency drive was put into use.•2007, four-quadrant medium voltage variable frequency drive was put into use.•2008, 7500KW/10KV medium voltage variable frequency drive was produced.
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Products Performance1.The company is the biggest enterprise of producing and reseaching the medium
voltage variable frequency drive (VFD). our product has been put into use in inter
national market such as Korea, Russia, India, Kazakhstan and so on.
2.The sale is the most in domestic market, Achieve the sales of total 2300 sets of
VFD by the end of 2008,market occupation near 30%.
the total sales of 100 sets in 2003.
the total sales of 200 sets in 2004.
the total sales of 400 sets in 2005.
the total sales of 1000 sets in 2007.
the total sales of 800 sets in 2006.
the total sales of 2000 sets in 2008.
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The Honor of Company 1.August 2005, awarded as"One of 500 Best New Products " by " World Mangers Weekly".2.December 2005, awarded as " Top Ten VFD Brand Made in China " by " VFD World ".3.June 2006, Leader & Harvest VFD was awarded as " the most satisfactory chinese brand admitted by domestic user in 2006".4.September 2006, Leader & Harvest was awarded as " top ten substantial growth enterprises ". 5.December 2006, Leader & Harvest was awarded as" top 100 growing Chinese small and medium-sized enterprises ". 6.February 2007, Leader & Harvest was awarded as" One of 100 Credit Chinese enterprises”
7.April 2007, Leader & Harvest was awarded " One of Ten most influential national brand in Chinese Automation field in 2006 ".8.September 2007, Leader & Harvest was awarded as " China Top Brand " by National General Administration of Quality Supervision, Inspection and Quarantine.9.June 2008, Leader & Harvest was awarded as" Annual the most satisfactory chinese brand admitted by domestic user ".
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Products Introduction
Product Specification
◆ HARSVERT-A medium voltage variable frequency drive
——application in asynchronous motor with fans and pump in the
load side
◆ HARSVERT-S medium voltage variable frequency drive
——application in synchronous motor
voltage level 2-11kV application motor 300-8000KW
◆ HARSVERT-FVA medium voltage variable frequency drive（ energy feedback
, vector control） ——application in asynchronous motor 4-quadrant operation
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Products Introduction
The HARSVERT series of variable frequency AC motor drives (voltage source inverter) include phase-shifting transformer, power cells and controller. These power cells are cascaded to provide operating voltages of 3kV(or 6kV,or10kV) directly.
System Structure
A1
A2
An
B1
B2
Bn
C1
C2
Cn
主控制器
U V W
变压器柜 功率柜 控制柜
M
高压三相交流输入
人机界面
PLC
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Products Introduction
Topology of HARSVERT –A VFD
4 cells in series-12 cells total,3kV
■ 3KV
The groups of power cells are wye connected with a floating neutral. Motor voltage 3kV can be provided directly.
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Products Introduction
■ 6KV
The groups of power cells are wye connected with a floating neutral. Motor voltage 6kV can be provided directly.
5 cells in series-15 cells total,6kV
Topology of HARSVERT –A VFD
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Products Introduction
Topology of HARSVERT –A VFD
8 cells in series-24 cells total,6kV
■ 10KV
The groups of power cells are wye connected with a floating neutral. Motor voltage 6kV can be provided directly.
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The transformer secondaries that supply the power cells in each output phase are wound to obtain a small difference in phase angle between each other. This cancels most of the harmonic currents drawn by the individual power cells, so that the primary currents are nearly sinusoidal. The power factor is typically 95% at load.
Products Introduction
Theory-Transformer Cabinet
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Power Cell Cabinet
Each cell is powered by an isolated secondary winding of the integral isolation transformer. No harmonic filters required.The drives cause no additional stress to the motor insulation.
Product Introduction
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Waveforms of Output Voltage
T
T
1) Ref A: 200 Volt 5 ms
T
T
1) Ref A: 200 Volt 5 ms
Products Introduction
All cells are electrically and mechanically identical, so that they are interchangable. The three-phase diode rectifier, fed by the secondary, charges a DC capacitor bank. The DC voltage feeds a single-phase H-bridge of IGBTs, controlled by PWM method.
Each power cell is a AC-DC-AC converter.
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Hardware Overview
Customer benefits:
Cabinets are combination of parts, easy to production
Compact in structure
Fewer Spare parts
Small footprint
Easy to install
Put into production quickly
变频模块柜变压器柜
控制器柜
Products Introduction
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Inside View of Typical Transformer Cabinet
Products Introduction
The Transformer Cabinet houses a dry
phase-shifting transformer which
cancels most of the harmonic currents.
185 ℃ Insulation Class
The windings use NOMEX® insulator
The transformer has three-phase
temperature detector.
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Inside View of Typical Cell Cabinet
Products Introduction
Each cell can be removed from
the cabinet along the slide rails.
Each cell communicates with the
control system through an
isolated link using fiber optic
cables.
The low-voltage power cells are
built in high volume.
Single side maintenance
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Inside View of Typical Control Cabinet
Products Introduction
The Control Cabinet houses the controller, built-in HMI, PLC, UPS, control power source DC24V,terminals,buttons,etc.
The control cabinet:
Has reliable built-in processor
Deals with Data & pulses
Positions protection & fault
Communicates by Using fiber optic
cables
Has friendly user interface
Has Back-up battery
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Products Introduction
Operation Interface
嵌入式人机界面
Main interface
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Production Introduction
Function interface
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Production Introduction
Parameter Interface
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Production Introduction
Operation Record Interface
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Products Introduction
Fault Information Inquiry Interface
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Main Performance Parameter
Input Frequency （ Hz ） 50±10%
Rated input voltage （ kV ） kV±10%
Voltage Tolerance -35% ～ +15%
Input Power Factor 0.95 （＞ 20% Load ）
Efficiency ＞ 0.96(Rated Load)
output frequency range （ Hz ） 0.5 — 120
Output Frequency Resolution （ Hz ） 0.01
Overload Capability 120% for 1min ； 150% for 3s ；200% immediately
Analog Signal Input 4 — 20mA/0 — 10V
Analog Signal Output 4 — 20mA/0 — 10V
Acceleration/Deceleration Time range （ S ）
0.1— 3200
Enclosure Protection Grade IP20
Products Introduction
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Production Introduction
Benefits-Easy to wire
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Production Introduction
A variety of control mode
DCS
4~20mA/0~10V analog signal
SIEMENS
6SE7016- 1EA30WR 2,2 kWNr. 467321
SIMOVERT SC
RS485上位机
Closed loop
Operation box
本机
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Production Introduction
The input voltage tolerance is ±10%.The input voltage tolerance is ±10%.
Under this voltage, the VFD could continue to run . Under this voltage, the VFD could continue to run . When the input voltage decrease less than 35% of the When the input voltage decrease less than 35% of the rated value, the drive will run derated.rated value, the drive will run derated.
Input voltage tolerance
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Production Introduction
High Input Power Factor
HASVERT-A drives maintain a high power HASVERT-A drives maintain a high power factor –typically better than 95%.factor –typically better than 95%.
The three-phase diode rectifier, fed by The three-phase diode rectifier, fed by the secondary, charges a DC capacitor the secondary, charges a DC capacitor bank. There is nearly no phase difference bank. There is nearly no phase difference between the input voltage and current.between the input voltage and current.
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Production Introduction
Clear power input
The THD of the input The THD of the input current is always less current is always less
than 4%.than 4%.
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Production Introduction
Multi-level PWM OutputThe voltage stress on the motor is dramatically reduced and the quality of the motor currents is dramatically increased.
The THD of the output currents The THD of the output currents with a HARSVERT-A series drive with a HARSVERT-A series drive
is always less than 2 percent.is always less than 2 percent.
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Production Introduction
Advanced cell bypassThrough a redundant bypass control, the drive ensures Through a redundant bypass control, the drive ensures automatic bypass of a failed power cell in 10 milliseconds.automatic bypass of a failed power cell in 10 milliseconds.Balance of line output is retained.Balance of line output is retained.
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The VFD system is capable of automatically The VFD system is capable of automatically
restarting in the event of a momentary loss of restarting in the event of a momentary loss of
power(20s default)power(20s default)
Production Introduction
Auto-restarting
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Production Introduction
When we start the VFD, the motor may still When we start the VFD, the motor may still
rotating or even at reverse direction. The VFD, rotating or even at reverse direction. The VFD,
which is controlled by DSP, can automatically which is controlled by DSP, can automatically
identify the track and drag the motor to the identify the track and drag the motor to the
setting speed.setting speed.
Rotating start
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Production Introduction
Full Protections Available
Output OverloadOutput OvercurrentLine Over voltageLine low voltageMain power supply lossDC over voltageDC under voltageTransformer overheat
Loss of one phase of
input powerControl power source
failureDrive signal failureDCS speed demand
signal lossGround failureOptic fiber fault
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电力行业45%
冶金行业20%
石化行业15%
水泥行业10%
其他10%
电力行业 冶金行业 石化行业 水泥行业 其他
HARSVERT-A Product Applications
The HARSVERT-A drives, the best-selling medium-voltage AC drives in China, deliver an
impressive combination of benefits:
Lower operating costs & maintenance costs
Precise process control
Increased production efficiency
High performance
Employed in applications ranging from
power plant to oil and gas, water,and
steel,the HARSVERT-A drive is a versatile
performer that can help you significantly
enhance energy efficiency, and reduce
operating costs.
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HARSVERT Product Application in cement industry
Cement industry status quo
Cement industry is one of the largest energy consumption
area. The energy cost of medium voltage motors occupies 30%
of the end product cost.
Valve is widely used to control air flow in cement industry.
However, the resistance caused by the valve closing waste
energy.
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HARSVERT Product Application in cement industry
Energy saving solution
The VFD can help you saving energy cost. When the medium
voltage VFD is used to control the fan flow, we can save energy
at the range of 30% ~ 50% . Usually the total investment will
get back for less than 2 years.
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HARSVERT Production Application in cement industry
Till the end of 2008， HARSVERT VFD installed 151 sets in cement industry
cycl i ng fans30
hi gh tempfans 50
ki l n head fan 9
coal mi l lfans25
coal mi l ldust fans 11
ki l n end fans26
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HARSVERT Production Application in cement industry
Special demands of cement industry to VFD
1、 sudden change of high temperature fans load due to break down of materials accumulated, this lead to motor overload
measure：Use vector control, the calculation of torque needs less than 100us.
When load changes, the torque of motor is restricted under rated
torque. Over current would never happen.
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Sensorless vector controller
PI
K1
mL
1
PI
PI dq
变频
器
abc
IM
dq
转子磁链观测器
s
*sl
*sdi
*sqi
sdisqi
*sqv
*sdv
*sv
*sv
si
si
svsv
sqcv
sdcv
K2转速给定值
abc
转速估计值
磁链给定
转子磁链角度
转矩给定
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HARSVERT Production Application in cement industry
2.Cement plants can present some environmental challenges for
electronic equipment.
Enclosure style
Abundant design
Rational layout of the components
Several cooling types: air conditioning & air-to-
water cooling & forced air cooling
Special demands of cement industry to VFD
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HARSVERT Production Application in cement industry
针对水泥行业风机应用的主要问题与应对措施
3、 dealing with old liquid coupler or liquid resistor
measures：1、 wound rotor with liquid resistor: short circuit the resistor
2、 liquid coupler: move away the liquid coupler, use a shaft to
connect the motor and the fan.
Special demands of cement industry to VFD
HARSVERT Production Application in cement industry
Energy saving effect
motorpower
voltage
adjust
power（ kW）
Motor current
frequenc
y
fans type （ kW）
（ kV）
（%） before
Use VFD
saving
line VFD（ Hz）
cycling fans 630 6 Valve 80% 500 372 25% 64 36.5 43
mill fans 560 10 Valve 80% 500 382 24% 37 24 37
kiln head fan 710 6 Valve 70% 582 369 36% 70 34.8 39.9
kiln end fan 1000 10 Liquid res80% 840 710 15% 61 42.9 39.7
high temp fan 2500 10Liquid coupler90%
2600 2350 9.6% 155 143 45
cement mill fan 355 10 Valve 45% 190 105 45% 17 6.2 36
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Application effect
1、 energy saving
2、 improve product and quality
with VFD, the air volume and pressure could be
adjusted more smoothly and precisely. This improves the
product quality.
HARSVERT Production Application in cement industry
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3、 decrease the maintenance fee
with the VFD, the users could save the maintenance
fee of the liquid coupler.
HARSVERT Production Application in cement industry
Application effect
1、 energy saving
2、 improve product and quality
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HARSVERT Production Application in cement industry
应用效果
with VFDs’ soft start, the pulse currents during
start is eliminated.
4、 improve the life time of motors and other machines
Application effect
1、 energy saving
2、 improve product and quality
3、 decrease the maintenance fee
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HARSVERT Production Application in cement industry
5、 improve the power factor of the system
The cell-cascaded medium voltage VFD, with low
distortion of input current, power factor higher than 0.95,
compared with old speed regulating methods, greatly
improves the system power factor。
Application effect
1、 energy saving
2、 improve product and quality
3、 decrease the maintenance fee
4、 improve the life time of motors and other machines
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