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BSI PD IEC TS 60034-25:2022

BSI PD IEC TS 60034-25:2022

$215.11

Rotating electrical machines – AC electrical machines used in power drive systems. Application guide

Published By Publication Date Number of Pages
BSI 2022 110
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PDF Pages PDF Title
2 undefined
4 CONTENTS
11 FOREWORD
13 INTRODUCTION
14 1 Scope
2 Normative references
15 3 Terms and definitions
18 4 System characteristics
4.1 General
4.2 System information
4.3 Torque/speed considerations
4.3.1 General
19 4.3.2 Torque/speed capability
Figures
Figure 1 – Torque/speed capability
20 4.3.3 Electrical machine rating
4.3.4 Limiting factors on torque/speed capability
Figure 2 – Current required by motor
21 4.3.5 Safe operating speed, over-speed capability and over-speed test
4.3.6 Cooling arrangement
Tables
Table 1 – Significant factors affecting torque/speed capability
22 4.3.7 Voltage/frequency characteristics
4.3.8 Resonant speed bands
Figure 3 – Examples of possible converter output voltage/frequency characteristics
23 4.3.9 Duty cycles
4.4 Electrical machine requirements
24 Table 2 – Electrical machine design considerations
25 Table 3 – Electrical machine parameters for the tuning of the converter
26 5 Losses and their effects (for induction electrical machines fed from voltage source converters)
5.1 General
27 5.2 Location of the additional losses due to converter supply and ways to reduce them
Figure 4 – Example for the dependence of the electrical machine losses caused by harmonics Ph, related to the losses Pf1 at operating frequency f1, on the switchingfrequency fs in case of 2 level voltage source converter supply
28 5.3 Converter features to reduce the electrical machine losses
5.3.1 Reduction of fundamental losses
5.3.2 Reduction of additional losses due to converter supply
Figure 5 – Example of measured losses PL as a function of frequency f and supply type
29 5.4 Use of filters to reduce additional electrical machine losses due to converter supply
5.5 Temperature influence on life expectancy
Figure 6 – Additional losses ΔPL of an electrical machine (same electrical machine as Figure 5) due to converter supply, as a function of pulse frequency fp, at 50 Hz rotational frequency
30 5.6 Determination of electrical machine efficiency
6 Acoustic noise, vibration and torsional oscillation
6.1 Acoustic noise
6.1.1 General
6.1.2 Changes in noise emission due to changes in speed
31 6.1.3 Magnetically excited noise
Figure 7 – Relative fan noise as a function of fan speed
32 Figure 8 – Vibration modes of the stator core
33 6.1.4 Sound power level determination and limits
6.2 Vibration (excluding torsional oscillation)
6.2.1 General
34 6.2.2 Vibration level determination and limits
6.3 Torsional oscillation
35 7 Electrical machine insulation electrical stresses
7.1 General
7.2 Causes
Figure 9 – Typical surges at the terminals of an electrical machine fed from a PWM converter
36 Figure 10 – Typical voltage surges on one phase at the converter and at the electrical machine terminals (2 ms/division)
Figure 11 – Individual short rise-time surge from Figure 10 (1 μs/division)
37 7.3 Winding electrical stress
Figure 12 – Definition of the rise-time tr of the voltage pulse at the electrical machine terminals
38 7.4 Limits and responsibility
7.4.1 Electrical machines design for low voltage (≤ 1 000 V)
Figure 13 – First turn voltage as a function of the rise-time
39 7.4.2 Electrical machines designed for medium and high voltage (> 1 000 V)
7.5 Methods of reduction of voltage stress
Table 4 – Operating voltage at the terminals in units of UN where the electrical machines may operate reliably without special agreements between manufacturers and system integrators
40 7.6 Insulation stress limitation
Figure 14 – Discharge pulse occurring as a result of converter generated voltage surge at electrical machine terminals (100 ns/division)
41 8 Bearing currents
8.1 Sources of bearing currents in converter-fed electrical motors
8.1.1 General
8.1.2 Circulating currents due to magnetic asymmetry
8.1.3 Electrostatic build-up
8.1.4 High-frequency effects in converter operation
Figure 15 – Classification of bearing currents
42 Figure 16 – Parasitic impedances to earth of drive system components
43 8.2 Generation of high-frequency bearing currents
8.2.1 Common mode voltage
Figure 17 – Common mode voltage a) determination b) waveform example
44 8.2.2 Motor HF equivalent circuit and the resulting bearing current types
Figure 18 – HF equivalent circuit diagram (a) of a motor (b) geometrical representation of capacitances
45 Figure 19 – Graphical representation of the different high frequency bearing current types in the drive unit highlighting the involved physical components
46 8.2.3 Circulating current
8.2.4 Rotor ground current
Figure 20 – Principle of circulating currents formation
47 8.2.5 Electrostatic Discharge Machining (EDM) currents
Figure 21 – Rotor ground current principle
48 8.3 Consequences of excessive bearing currents
Figure 22 – Example of measured EDM-current pulses for a 400 V and 500 kW induction motor in converter operation
49 Figure 23 – Photographs of damaged motor bearings
50 Table 5 – Different grades of roller bearing damages
52 8.4 Preventing high-frequency bearing current damage
8.4.1 Basic approaches
53 8.4.2 Other preventive measures
54 Table 6 – Effectiveness of bearing current counter measures
56 8.4.3 Other factors and features influencing the bearing currents
8.5 Additional considerations for electrical motors fed by high voltage source converters
8.5.1 General
8.5.2 Bearing protection of cage induction, brushless synchronous and permanent magnet electrical motors
8.5.3 Bearing protection for slip-ring electrical motors and for synchronous electrical motors with brush excitation
57 8.6 Bearing current protection for electrical motors fed by high-voltage current source converters
9 Installation
9.1 Earthing, bonding and cabling
9.1.1 General
9.1.2 Earthing
9.1.3 Bonding of electrical machines
58 9.1.4 Electrical machine power cables for high switching frequency converters
Figure 24 – Bonding strap from electrical machine terminal box to electrical machine frame
59 Figure 25 – Examples of shielded electrical machine cables and connections
60 Figure 26 – Parallel symmetrical cabling of high-power converter and electrical machine
61 Figure 27 – Converter connections with 360º HF cable glands showing the Faraday cage
Figure 28 – Electrical machine end termination with 360º connection
62 Figure 29 – Cable shield connection
63 9.2 Reactors and filters
9.2.1 General
9.2.2 Output reactors
9.2.3 Voltage limiting filter (du/dt filter)
9.2.4 Sinusoidal filter
9.2.5 Electrical machine termination unit
64 9.3 Power factor correction
Figure 30 – Characteristics of preventative measures
65 9.4 Integral electrical machines (integrated electrical machine and drive modules)
10 Additional considerations for permanent magnet (PM) synchronous electrical machines fed by voltage source converters
10.1 System characteristics
10.2 Losses and their effects
66 10.3 Noise, vibration and torsional oscillation
10.4 Electrical machine insulation electrical stresses
10.5 Bearing currents
10.6 Particular aspects of permanent magnets
11 Additional considerations for cage induction electrical machines fed by high voltage source converters
11.1 General
67 11.2 System characteristics
Figure 31 – Schematic of typical three-level converter
Figure 32 – Output voltage and current from typical three-level converter
68 11.3 Losses and their effects
11.3.1 Additional losses in the stator and rotor winding
11.3.2 Measurement of additional losses
11.4 Noise, vibration and torsional oscillation
69 11.5 Electrical machine insulation electrical stresses
11.5.1 General
11.5.2 Electrical machine terminal overvoltage
11.5.3 Stator winding voltage stresses in converter applications
Figure 33 – Typical first turn voltage ΔU (as a percentageof the line-to-ground voltage) as a function of du/dt
70 Figure 34 – Medium-voltage and high-voltage form-wound coil insulating and voltage stress control materials
71 11.6 Bearing currents
12 Additional considerations for synchronous electrical machines fed by voltage source converters
12.1 System characteristics
12.2 Losses and their effects
12.3 Noise, vibration and torsional oscillation
12.4 Electrical machine insulation electrical stresses
72 12.5 Bearing currents
13 Additional considerations for cage induction electrical machines fed by block-type current source converters
13.1 System characteristics (see Figure 35 and Figure 36)
Figure 35 – Schematic of block-type current source converter
Figure 36 – Current and voltage waveforms of block-type current source converter
73 13.2 Losses and their effects
74 Figure 37 – Influence of converter supply on the losses of a cage induction electrical machine (frame size 315 M, design N) with rated values of torque and speed
75 13.3 Noise, vibration and torsional oscillation
13.4 Electrical machine insulation electrical stresses
13.5 Bearing currents
76 13.6 Additional considerations for six-phase cage induction electrical machines
14 Additional considerations for synchronous electrical machines fed by LCI
14.1 System characteristics
Figure 38 – Schematic and voltage and current waveforms for a synchronous electrical machine supplied from a current source converter
77 14.2 Losses and their effects
14.3 Noise, vibration and torsional oscillation
14.4 Electrical machine insulation electrical stresses
14.5 Bearing currents
78 15 Additional considerations for cage induction electrical machines fed by pulsed current source converters (PWM CSI)
15.1 System characteristics (see Figure 39)
Figure 39 – Schematic of pulsed current source converter
Figure 40 – Voltages and currents of pulsed current source converter
79 15.2 Losses and their effects
15.3 Noise, vibration and torsional oscillation
15.4 Electrical machine insulation electrical stresses
15.5 Bearing currents
16 Wound rotor induction (asynchronous) electrical machines supplied by voltage source converters in the rotor circuit
16.1 System characteristics
16.2 Losses and their effects
80 16.3 Noise, vibration and torsional oscillation
16.4 Electrical machine insulation electrical stresses
16.5 Bearing currents
17 Other electrical machine/converter systems
17.1 Drives supplied by cyclo-converters
Figure 41 – Schematic of cyclo-converter
81 Figure 42 – Voltage and current waveforms of a cyclo-converter
82 17.2 Wound rotor induction (asynchronous) electrical machines supplied by current source converters in the rotor circuit
18 Special consideration for standard fixed-speed induction electrical machines in the scope of IEC 60034-12 when fed from voltage source converter and motor requirements to be considered a converter capable motor
18.1 General
83 Figure 43 – Diagram comparing converter capable motor to converter duty motor
84 18.2 Torque derating during converter operation
18.2.1 General
Figure 44 – Fundamental voltage U1 as a function of operating frequency f1
85 18.2.2 Self-cooled motors
Figure 45 – Torque derating factor for cage induction electrical machines of design N, IC 411 (self-circulating cooling) as a function of operating frequency f1 (example)
86 18.2.3 Non self-cooled motors
18.3 Losses and their effects
18.4 Noise, vibrations and torsional oscillation
18.5 Electrical machine insulation electrical stresses
18.5.1 General
87 18.5.2 Converter capable motor
18.6 Bearing currents in converter capable motors
88 18.7 Speed range mechanical limits
18.7.1 General
18.7.2 Maximum speed
18.7.3 Minimum speed
89 18.8 Overload torque capability
18.9 Excess overload current limits
18.9.1 General
18.9.2 Converter capable motor
18.10 Volts/Hz ratio and voltage boost
18.11 Resonance
18.12 Hazardous area operation
18.12.1 General
90 18.12.2 Converter capable motor
91 18.13 Unusual service conditions
18.13.1 Converter capable motors
18.13.2 Unusual converter-fed applications
19 Additional considerations for synchronous reluctance electrical machine fed by voltage source converters
19.1 System characteristics
19.2 Losses and their effects
19.3 Noise, vibration and torsional oscillation
19.4 Electrical machine insulation electrical stresses
19.5 Bearing currents
92 19.6 Particular aspects of synchronous reluctance electrical machines
93 Annex A (informative) Converter characteristics
A.1 Converter control types
A.1.1 General
94 A.1.2 Converter type considerations
A.2 Converter output voltage generation (for voltage source converters)
A.2.1 Pulse width modulation (PWM)
95 A.2.2 Hysteresis (sliding mode)
A.2.3 Influence of switching frequency
Figure A.1 – Effects of switching frequency on electrical machine and converter losses
96 A.2.4 Multi-level converters
Figure A.2 – Effects of switching frequency on acoustic noise
Figure A.3 – Effects of switching frequency on torque ripple
97 A.2.5 Parallel converter operation
98 Annex B (informative) Output characteristics of 2 level voltage source converter spectra
Figure B.1 – Waveform of line-to-line voltage ULL for voltage source converter supply with switching frequency fs = 30 × f1 (example)
99 Figure B.2 – Typical output voltage frequency spectra for a constant frequency PWM control versus hysteresis control
Figure B.3 – Typical output voltage frequency spectra for random frequency PWM versus hysteresis control
100 Figure B.4 – Typical output voltage frequency spectra for a two-phase modulated control versus hysteresis modulation
Figure B.5 – Typical time characteristics of electrical machine current for a Constant frequency PWM control versus hysteresis control
101 Figure B.6 – Typical time characteristics of electrical machine current for a two-phase modulated control versus hysteresis modulation
102 Annex C (informative) Voltages to be expected at the power interface between converter and electrical machine
Figure C.1 – Example of typical voltage curves and parameters ofa two level inverter versus time at the electrical machine terminals (phase to phase voltage; taken from IEC TS 61800-8)
106 Annex D (informative) Speed and harmonic capability of converter capable induction motor
D.1 General
D.2 Harmonic capability of converter capable motors
107 D.3 Speed capability and derating in variable torque application
D.4 Speed capability and derating in a constant torque application
Figure D.1 – Derating curve for harmonic voltages
108 Figure D.2 – Torque capability at reduced speeds due to the effects of reduced cooling (applyies to 50 Hz or 60 Hz design N)
109 Bibliography

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BSI PD IEC TS 60034-25:2022
$215.11