mv drives north america
DESCRIPTION
Randy Huebner. MV Drives North America. World Market size & growth ABB specific data Applications in Utilities ABB MV Drive Products North America – Competitors. Outline. World Market size and growth 00-04. USD CAGR: 15% CHF CAGR: 6% Unit CAGR 14%. World Market 2004 Industry Segments. - PowerPoint PPT PresentationTRANSCRIPT
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MV Drives North AmericaRandy Huebner
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Outline
1. World Market size & growth
2. ABB specific data
3. Applications in Utilities
4. ABB MV Drive Products
5. North America – Competitors
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MV Drives development World MarketIndex yr 2000
0%
20%
40%
60%
80%
100%
120%
140%
160%
180%
200%
2000 2001 2002 2003 2004
kUSD
kCHF
# Conv
USD/Conv
CHF/Conv
World Market size and growth 00-04
USD CAGR: 15%
CHF CAGR: 6%
Unit CAGR 14%
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Metals
23%
Marine
6%
Cement Mineral
& Mining
8%
Water & Waste
12%
Power
21%
Others
5%
Pulp & Paper
2%
COG
23%
World Market [400 MUSD] I ndustry Segments
World Market 2004 Industry Segments
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Europe29%
China37%
ROW11%
North America23%
World Market Geographically
World Market 2004 geographically (end-user MUSD)
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Unit market shares 2004 -
0.9%
1.1%
1.3%
1.4%
1.4%
1.5%
2.7%
2.9%
3.2%
5.6%
7.6%
9.8%
12.5%
15.0%
16.2%
16.8%
0.0% 2.0% 4.0% 6.0% 8.0% 10.0%
12.0%
14.0%
16.0%
18.0%
GE (Industry)
Chinese - Mingyang, Dongfan & other
Yaskawa
Chinese - Tried
Chinese - AriTime
Hitachi
Fuji
Others (L&T, CTQ, WEG, BHEL)
Alstom /GECELEC /AEG / GEC
Chinese - Harvest
TMEIC Toshiba/Mitsubishi
Siemens
GE-Toshiba
ASI Robicon
ABB
Rockwell/AB
ABB’s position world wide # drives
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Market shares in kUSD - Market size ~400 MUSD
0.5%
0.6%
0.8%
1.3%
1.5%
1.5%
1.7%
2.3%
3.2%
4.5%
6.0%
6.2%
12.4%
13.2%
17.9%
26.3%
0% 5% 10% 15% 20% 25% 30%
Chinese - Mingyang, Dongfan & other
Yaskawa
Hitachi
Fuji
Chinese - Tried
Chinese - AriTime
GE (Industry)
Chinese - Harvest
Others (L&T, CTQ, WEG, BHEL)
Alstom /GECELEC /AEG / GEC
TMEIC Toshiba/Mitsubishi
GE-Toshiba
Rockwell/AB
Siemens
ASI Robicon
ABB
ABB’s position world wide (USD) in 2004
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ABB Drives USA ABB US Drive Headquarters New
Berlin, WI 180M Sales 2004 330 Employees ISO 9001 Facility LV & MV Drives & Motors Power Electronics Ratings: 3 - 135,000HP
TurgiTurgi
ABB MV Drive HeadquartersTurgi Switzerland
MFG Location for MV Drives Products
World leader in MV Drives
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ATAP Projects Business – North America
Ins trum entation L V D rives / L V C ontrol P ro jects E xcitation
A T APP res iden t
G reg S cheu
Bernard Lafrance
Dane Maisel
Rick Hepperla
Pat Hogan
Bernard Lafrance
Joe Maloni
Chuck Clark Mike Wallin
M V M otors / G enerato rsJan-A nders B ergm an
T oron to
M V D rivesR andy H uebner
H ous ton
A dvanced P ow er E lectron icsK ev in D ennis
N ew B erlin
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Project Businesses – U.S. / New Berlin
B usiness C ontro llerJaana S uvanto
E xecu tive A ss is tantD iane H erm ann
M arketingH eather F lanaga n
D ouglas C rockJeff F reis lebenS tephane L evesqueB ob S m onR ick W alm sley
O lli M ans ikka
N orth A m ericanF actory S upport T eam
C huck C lar k
B ill H ejda kH ans K rattigerC hris L arsenT or-E iv ind M oen
A dvanced P ow e rE lectron ics - N .A .
K evin D ennis
C aro l C am pbel lD uane H oernem an nT om K lennerM arko K ukkam aaA rlene M anderyS andy M itchellL ars -E rik T handB ryan W ethere d
L ow V oltageM otors - U .S.
J im C lark
R ichard M aton ic h John D ulasR obert N elsonT im Trum boA aron W ood
M edium V oltageM otors - U .S.
R ay D oran
D om inic C olam eo
L V M otorsD om in ique B inet
M V M otors / L V M otorsA B B C anad a
Jan-A nders B ergm an
A drian G uggisbergB enjam in M agw eC anada (O pen )S teve S chefusD avid T illerB us iness D evelopm ent(O pen)C algary (O pen)H ouston (O pen)R & D (O pen)
M edium V oltageD rives
R andy H uebner
D eepika K othem bak a
C handreka B allm ic kD avid B anksR avi D odballapu rB ruce H ear dR avi K uret iB eau L ow errE rik M artenssonG ary M orrisA li N ilch ia nB ob S chm idtJoe V on S ebo
P ro jectM anagem ent
A nders T roedson
B rian B aldw inT om H arperM ichael K irschnerD ale N em itzB rian O ng
S ystem & D es ignE ngineeringP eter R eind l
O perationsA nders T roedson
P ro ject B us inessesC huck C lar k
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Fields of Application
Cement, Mining and Minerals Conveyors, crushers, mills, fans and pumps
Chemical, Oil and Gas Pumps, compressors, extruders, mixers and blowers
Metals Pumps and fans
Pulp and Paper Fans, pumps, refiners and chippers
Power Generation Fans, pumps, conveyors and coal mills
Water and Waste Water Pump applications, fresh water and waste water
Other Applications Test stands and wind tunnels
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Large Motors Applied in Power Generation
Circulating and Cooling Water Pumps
Boiler Feed Water Pumps
Fans
Compressors
Coal Mills
LCI Starters for Generators
Any of these Motors can use a Drive!!
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Fans
Boiler
Desulfurization Electric precipitator
Chimney
Air preheater
ID FanID Fan Primary fanPrimary fan Secondary fanSecondary fan
Cooling tower fanCooling tower fan
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Visualization of power flow
Source: Hugo Stadler, Lohr GmbH
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Common Applications
ID Fans and Scrubber Upgrades Scrubber upgrade requires
larger ID Fan
Power supply is not large enough to start motor
Matched ID fans to to balance the load
ID fans and FD Fans on swing plants help turn down ratio of the plant
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315
2’000
P (kW)
U (kV)
27’000
5’000
7’000
50’000
Motor Voltage
1.0 2.41.5 4.16 6.03.3
Mo
tor
Po
wer
9’000
10’000
16’000
13.88.06.91.8
ACS 6000cLCI
ACS 1000 Step-Up
ACS 1000A
CS
600
0
AC
S 5
000
MV Drives Portfolio (standard converters)
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Reliability and Availability
Robustness and Performance
Efficiency
Compatibility
ACS 1000, ACS 5000 , ACS 6000
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Reliability - Semiconductors
IGCT semiconductors and 3-level VSI design
Low part count
Least complex and most robust design
No series or parallel connection of power semiconductors
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Reliability – 3 level VSILs1
Ls2
Cdc1
Cdc2
Ccl1
Ccl2
Rs1
Rs2
Vcl1
Vcl2
V1u
V2u
V3u
V4u
V2Nu
V1Nu
V1v
V2v
V3v
V4v
V2Nv
V1Nv
V1w
V2w
V3w
V4w
V2Nw
V1Nw
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Reliable Components
Fuseless design Faster and better protection than medium voltage power fuses
Long-life capacitors Advanced, self-healing, environmental friendly,
foil capacitors have a substantially longer lifetime than electrolytic capacitors
Lower lifetime costs
Built-in input surge protection Surge arresters at the isolation transformer primary side Tolerant to network disturbances
Increased reliability
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Worldwide Service and Support
Installation and commissioning
Training
On-board diagnostics
Remote diagnostics
Customized service programs
Local technical support
Local service support
Spare parts and logistics network
24 x 365 support line
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Robustness and Performance - DTC
Direct Torque Control (DTC) Most powerful control platform
Power loss ride-through of one second
Flying start and automatic restart
Flux optimization
Critical speed avoidance bands
Typical torque response (t) of a DTC drive, compared with flux vector control and open loop pulse width modulation (PWM)
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Robustness and Performance – Power Ride Through
MotorRectifier DC-link Inverter Output filterInputtransformer
Inputsection
U_in
I_s
Udc
M
U
t
ride through
U
t
ride through
n
tride through
T
I
t
ride through
load current
magnetizingcurrent
Vs1
Vs2
S1
At least
1sec f
or main
power and auxil
iary power
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24-pulse or 12-pulse diode rectifiers, fulfilling IEEE 519
No active switching elements on line side interface (only for 4 Q operation)
No filter at the line side No oscillation problems
No power factor compensation
Compatibility – Input / Network
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Compatibility – Fieldbus adapters
Control System Connection to higher-level process controllers
Flexible hardware I/Os for remote control, allowing easy customization
Large variety of available fieldbus interfaces Profibus
Modbus
DeviceNet
LonWorks
CANopen
InterBus-S
Ethernet
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StandardAC Induction
Motor
DCLink
3-level Voltage Source Inverter (VSI)
Sine W aveFilter
IGCT w ith in tegrated gate driver and freew eeling d iode
NPC Diode (N eu tra l C lam p ing D iode)
Legend
ACS 1000 Main Features
Inverter design
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ACS 1000 Sine Filter
Output sine filter Actively controlled LC low pass filter Eliminates virtually all inverter switching harmonics to the motor Keeps motor and bearings common mode voltage free
Inverter output voltage Drive output voltage to the motor
Output Sine Filter
MotorSide
InverterSide
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Compatibility – Common Mode
The produced common mode voltage is only seen by the transformer secondary windings against ground
The Common Mode is keept inside the Drive System
Motor
Input transformerOutput sinefilter
MCB
Converter
Grounding network
Cable
I_Cfuvw_G
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35A
0 5 10 15 20 25 30
ms
Normal common mode current path
Stray capacitance to ground of:•Transformer•Cables•Converter
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ACS 1000
Air cooled or Water cooled
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ACS1000 Air Cooled Front View
3ft
6.5ftexcl.
air outletcover
10ft
Air Cooled Range:
0.4 - 2 MVA;
2.3, 3.3 and 4kV;
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3ft
6.5ft
15ft
Water Cooled Range:
2 - 6 MVA;
3.3 and 4kV;
ACS1000 Water Cooled Front View
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ACS 1000 Water Cooled Cooling Circuit Overview
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ACS 1000i
Special features: Full integrated solution, including
transformer, input switch and disconnector
Easy to install
Standard 24-pulse rectifier bridge
Small footprint
No auxiliary power required
Three cables in – three cables out!
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General overview ACS 1000i
MotorRectifier DC-link Inverter Output filterInputtransformer
Inputsection
M
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ACS 5000 and ACS 6000
High power drives (5000HP – 40’000HP) Suitable for induction, synchronous and permanent magnet motors
ACS 5000 General drive for pump, fan and compressor applications 6.0 – 6.9kV output voltage
ACS 6000 High performance drive Active front end or diode bridge input Reactive power compensation Single drive and Multi drive topology
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ACS 6/5000Inverter Unit
INU
PowerStack(s)
ACS 5000 and ACS 6000 Common Platform
Pow
er
Mot
or V
olta
ge3k
V6k
V3MVA
5MVA
7MVA
9MVA
12MVA
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Technology Basis 3 level IGCT phase
ACS 6000: One 3 level phase module per motor
phase -> 3.3kV output voltage
ACS 5000: two 3 level phase modules per
motor phase (in series) -> 6.9kV output voltage
To motor
To “converter starpoint”
To motor
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ACS 6000 VSI ”System topology”
Phase modules EMC Filter
DC (-)
DC (+)
DC (NP)
Clamping circuit
Motor
Supplytransformer
LSULine Supply Unit
INUInverter Unit
CBU
Motoring modePower flow
2Q drive
Resistor BrakingUnit (RBU)
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ACS 5000 VSI - MF ”System topology”
Scope of ACS 5000
COU
Auxiliaries
Control
UPS PowerSupply
Auxiliary Power Supply
MCB (Standard)(Pre)TripOpen/Close
Main Power Supply
Control Interface Options:- Oil level Alarm- Overtemp /FLT/Alarm- Gas relay /FLT/Alarm- Transformer supervision FLT/Alarm
MotorIM
1U 1V 1W
Options forcontrol Interface:
- Tacometer- Winding Temp /FLT/Alarm- Bearing Supervision /FLT/Alarm- Cond. Water Det.- Space Heater FB- Cooling Fans FB
T
WCU
Cooling Water
Converter Starpoint
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ACS 5000 12 MVA unit
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North American Market
Market Size
Competitors
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North America – Sales Channel values
DOMESTIC
GE
GE-Toshiba
Rockwell
Robicon
IMPORTED DRIVES
ABB
Siemens
Alstom
Other marginal players (WEG..)
This is our perception of the North American Market.
NA Market - Sales Channel values ~ 150 MUSD (Domestic+Export) ABB
2%
Alstom2%
Other8%
Siemens2%
Rockwell30%ASI Rob
30%
TMEIC&GE26%
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North America – the main players
DOMESTIC
GE
GE-Toshiba
Rockwell
Robicon
IMPORTED DRIVES
ABB
Siemens
Alstom
Other marginal players (WEG..)
This is our perception of the North American Market.
NORTH AMERICA End-User ~100 MUSD (Domestic only)
Alstom2%
Siemens3%
Other2%
ABB4%
ASI Rob34%
Rockwell32%
TMEIC&GE23%
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A closer look at the individual competitors
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Main Competitors
ASI Robicon
AB Rockwell
GE Toshiba
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Robicon
Fighting for time and money
Expressed strategic focus: COG – (Exxon projects)
New HV IGBT module with less parts
New capacitors of “self-healing” film type (developed and used by ABB for 10 years)
We are eagerly waiting for news on who will buy them. Until then – customers are taking a certain risk dealing with them. (Many want to bail out)
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ASI Robicon
Main Products: Baby Harmony and Perfect Harmony
Messages: Company Under chapter 11
Availability ACS 1000 reduces the maintenance required on the drive. There are no
components in the power circuit to be changed and maintained. Robicons Harmony drives requires extensive maintenance work. According
to the user manual:
This results in 8 inspections in the first year, taken 8 to 12 hours per shut-down (increased maintenance and lost production output).
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ASI Robicon
Reliability and Lifetime cost: Capacitors ACS 1000 is designed to minimize lifetime cost. There are for
example no electrolyte capacitors used in the power circuit of the drive.
Robicon use electrolyte capacitors, which have to be changed all 5 years according to their manual.
By changing the capacitors the core of the drive (inverter) has to be disassembled. This brings a high risk of failure (No burne in after reassembly).
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ASI Robicon
Reliability and Lifetime cost: Fuses / Fuseless In ABB medium voltage drives are no power fuses to protect the
converter. The converters are based on a fuseless design.
In Robicon’s Harmony drives all the power cells are protected with fuses.
Fuses
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ASI Robicon
Ride Through ACS 1000 offers a ride through of at least 1s due to DTC. In many
practical situations a ride through of at least 500ms is required (Example: main bus transfers).
Harmony offers a ride through capability of only 6 cycles. -> see flyer
Common tools ABB offers a wide range of automation products. For the different
product, the same tools are used to monitor and configure. ABB’s medium voltage drives use exactly the same tools as ABB’s low voltage drives.
Robicon is only offering a small range of products with automation technologies. This means that product specific tools and skills are required.
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Rockwell
Growing steadily with good profit
Rockwell Control Systems
0
500
1000
1500
2000
2500
3000
3500
4000
4500
2002 2003 2004 2005Q1
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%Control Systems Sales
Earnings
% margin
MUSD
projected based on Q1 -2005 Increasing push into COG (Bohai Bay)
Will be increasing power of PowerFlex 7000 by paralleling drives
Trend-setter in trafo-less drives.
Their technology limits their applications to “less demanding” types like pumps, fans, compressors.. But this is a large market still.
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AB Rockwell
Main Product: PowerFlex7000
Messages: VSI versus CSI
ABB uses voltage source inverters, which allows to use diode rectifiers at the line side.
AB use current source inverters, which requires always active front end (Thyristors or SGCTs).
Today’s state of the art is voltage source inverters -> just consider low voltage
Diodes are much more reliable than thyristors (or SGCTs). Diode rectifiers are causing much less harmonics -> no filter is required,
where for CSI’s always a filter is required (harmonics + power factor)
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AB Rockwell
Active front end An active front end is used to regenerate power to the network – 4Q
operation. Therefore ABB uses active front end drives only if regeneration is required.
AB is pushing active front end also for 2Q operations.
Active front end requires in connection with CSI always a line filter.
The reliability of the active front end is much lower than the reliability of a diode bridge.
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AB Rockwell
Transformer less design ABB uses an insulation transformer on the drive input in order to:
Keep the common mode voltage within the drive system (not seen by the motor and the network)
Cancel harmonics by phase displacement
AB is promoting transformer less design. AB’s topology requires:
Special insulations on the motor, due to high common mode voltage stress.
An input inductor, which has approximately the same impedance like an input transformer.
Higher insulation levels and overvoltage withstand within the converter, because there is no galvanic separation to the network.
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SGCT versus IGCT
IGCT (Reverse Conducting)
SGCT
The SGCT has an integrated diode in series to the GCT, where the IGCT has an integrated diode in parallel to the GCT
It follows that the SGCT has higher on state losses due to the fact that tha current pass through the GCT and the diode.
It is expected that the SGCT creates 20% more losses than the IGCT
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A competitor to consider – growing fast in the low powers. Durabilt, T300MVi and “Built for X-tremes”
Bench-mark on prices up 3000 HP
Also active in Rolling Mill and high power applications
States 16 year MTBF – an unrealistic figure in our opinion. Customers need education on this subject
Their service network may not be as strong as they claim. Not all GE offices are capable.
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Product: Dura-Bilt 5iMV or Tosvert T300MVi
Messages: Ride through
ACS 1000 offers a ride through of at least 1s due to DTC. In many practical situations a ride through of at least 500ms is required (main bus transfers).
Dura Built has a ride through capability of only 100ms. See flyer
Tacho / Speed encoder ACS 1000 doesn’t require speed encoders. DTC is a very powerful control scheme,
proved in many thousands of installations worldwide. Dura-Bilt requires tachometer for several applications. This is due to poor control
accuracy and stability. Torque control without encoder has only an accuracy of +- 30% See application guide, flyer
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Cooling ACS 1000 offers water cooled and air cooled drives. Water and air doesn’t
cause any hazard.
Dura-Bilt 5iMV use heat pipes for the air cooled drives in order to get a lower thermal resistance. As cooling medium Fluorinert is used.
Fluorinert gets poisonous in case of overheating. Overheating may occur in case of a semiconductor failure.
Risk for humans
The air “cooled” Dura-Bilt lose thebig advantage of air cooled drives:
There remains a risk of a leaking
Check home page of GE -> Dura-Bilt presentations
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Overvoltage protection: ACS 1000i has always a transformer primary overvoltage protection (surge arrestors in
front of the transformer). This protects the drive and especially the transformer from overvoltages caused in the network and caused by the input main switch.
Dura-Bilt has surge arrestors only in front of the main switch. This means the transformer is not protected against overvoltages caused by the switch.
The transformer gets a higher insulation stress, which can cause short circuits of the transformer windings.
T1
S1
F1 [u, v, w]S2
Ft(u,v,w)
Protection Relay
300/5A
Surge Arrestors of ACS 1000
Between switch and transformer
ACS 1000i
Dura-Bilt
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