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JD-BP37/38 High Voltage VFDs

Product Overview

With high speed DSPs as the core, JD-BP37/38 high-voltage VFDs are designed with space vector, multi-level power unit series and other advanced control technologies to be highly reliable, easily operated, highly functional and small in size for regulating speeds of various loads and improving production process. These are high-high voltage source VFDs, with harmonics much lower than the standard specified in IEEEE 519-2014. High input power factor and good output waveform save the use of input harmonic filter, power factor compensation device and output filter. They are free from problems caused by harmonics, e.g. additional heating and torque pulse, noise, common mode voltage and so on, and are suitable to two/four quadrant synchronous motors (including permanent magnetic synchronous motors) and asynchronous motors.
This series was included into national important new products in 2003. High voltage variable frequency and speed adjusting system for hoisting systems was incorporated into national torch plan and received the grant from the Ministry of Science and Technology for technical innovation projects in small and middle enterprises. In September, 2007, JD-BP37/38 series was awarded with “China’s Famous Brand”. From 2009 on, WindSun has been awarded with “Top 10 Satisfactory VFD Brands” by authoritative institutions for many years in a row. 

Product Structure

JD-BP37/38 VFD consists of a switch-gear, a transformer cabinet, a power cabinet and a control-gear, with the power cabinet and control-gear in the same casing. The switchgear can be tailored to different applications.
 
 
 
Transformer cabinet: Inside are a phase-shifting transformer, a temperature sensor and a current/voltage detector. The phase-shifting transformers provide independent three-phase input power supplies for power units; temperature sensors detect the real-time temperature inside transformers, send alarms and provide protection in the case of over-temperature; current/voltage detectors can monitor transformer input currents and voltages to protect the VFD.
Power cabinet: Inside are power units that are identically structured and therefore interchangeable. The cabinet has a plastic casing that is well sealed and suitable to high humidity, dusty and corrosive atmosphere. Power cabinet communicates with the control gear through fiber optics which can effectively suppress electromagnetic interference.  
Control-gear: Inside are HMI and many high-precision chips such as ARM, FPAG and DSP. Providing Chinese and English displayed, the HMI requires less parameters and provides easy operation. Many external ports ease the connection to user system and on-site extension. The main controller is enclosed in a box developed by WindSun that has passed EMC certification and received temperature cycle and vibration test, providing high reliability.
Switch-gear: In the case of VFD failure, the motor can be directly switched to original grid either manually or automatically from the variable frequency circuit to continue its operation. For manual switching, the operation procedures must be followed to switch the main circuit; for the automatic switching, the main circuit can be switched under the control of the system, except for service. Not a standard device, the switch-gear must be tailored to user’s requirements. 

Working Principle

A JD-BP37/38 VFD consists of many units in cascade. For the input side, each unit is powered by a phase-shifting transformer whose secondary coil is connected in an extended delta manner to effectively lower harmonic component of the input current. For the output side, the U and V output terminals of each unit are in series to form a start connection for powering the motor; the PWM waveform from each unit is recombined to output a perfect sine waveform. 

A JD-BP37/38 VFD consists of many units in cascade. For the input side, each unit is powered by a phase-shifting transformer whose secondary coil is connected in an extended delta manner to effectively lower harmonic component of the input current. For the output side, the U and V output terminals of each unit are in series to form a start connection for powering the motor; the PWM waveform from each unit is recombined to output a perfect sine waveform.
 

 

 

Each phase of a 6kV VFD has 5 power units and each phase of a 10 kV VFD has 8 power units. Carrier phase shifting technology is used to superimpose output voltages of all power units, thereby forming a multi-level high voltage output that makes the output filter unnecessary and ensures lower current harmonics and zero damage to cables and motors.
 

The electric circuit of a power unit in a two quadrant VFD is indicated in the figure below。 Six diodes provide a three phase full wave rectifier at the rectifying side; sine SVPWM control is imposed on IGBT inverter bridge at the inverting side。 Should a power unit fails, the unit’s output end can be bypassed through IGBT controlled by the software to ensure the normal operation of the entire VFD。

 


A four quadrant VFD provides energy feedback with the electrical circuit of its power unit indicated as below. Both rectifying side and inverting side use the most advanced IGBT power components and controlled via SVPWM.

 
When the motor is driving, energy flows to the motor through rectifier circuit and inverter circuit and the VFD is working in the first and third quadrants. The input voltage and current waveforms are indicated as below:


When the motor is generating, the energy it produces is sent back to the bus voltage through the diodes at inverting side. When the DC bus voltage exceeds a certain value, the energy feedback control at rectifying side is started to invert DC to AC, which is provided back to the grid by controlling the inverter voltage phase and amplitude. At this time, the VFD is working in the second and fourth quadrants. The input voltage and current waveforms are indicated as below:

 


 

Performance and Properties

Vector control
The current vector of AC motor’s stator is measured and controlled to control the exciting current and torque current of the AC motor under field orientation principle, thereby controlling AC motor’s torque. The faster the starting quarter, the faster the torque dynamic response, the higher the speed regulation and the higher the loading capacity. Asynchronous and synchronous motors can be driven.
 

 
 
Multi-VFD master/salve control
The VFD provides master/salve control function. Multiple VFDs can form a master/slave control network through data buses with one of them as the master and other salves. The master connects the real-time states of salves and send frequency and torque commands to slaves, a way that balances powers and provides comprehensive control of all VFDs. This control technology is suitable to applications that require balanced power, such as belt conveyor and friction hoist.
 

 
 
 
Easy Industrial/Variable Frequency Switching
Variable frequency to industrial frequency: The VFD drives the motor to industrial frequency and adjusts its own output voltage by detecting the frequency, phase and amplitude of industrial frequency grid. After that, the motor is detached from VFD and connected to grid. Industrial frequency to variable frequency: After the motor is detached from grid and connected to VFD, VFD directly outputs voltage vector by detecting frequency, phase and amplitude of industrial frequency grid. This technology can satisfy the requirements for comprehensive motor control and soft-starting of large-capacity motors.
 

 
 
High/low Voltage Ride Through
If the main power source fails or dips abruptly or the industrial power grid is switched, the VFD is able to continue operating within a certain time after the grid recovery by its high/low voltage ride through technology that increases grid adaptability.
 

 

 
Waveform Display and Analysis
Main control system monitors input current, input voltage, output voltage and output current and displays their waveforms in a real-time manner, and also performs harmonics analysis for the voltage and current of each phase, a way that helps users get electrical parameters of the device.
  

 

 
Black Box
The VFD is able to record operating state and display data automatically, through which, output voltage, output current, preset frequency, operating frequency, input current and input voltage at 200 points (100 ms) can be checked, easy for daily maintenance.
 

 
 
Unit Temperature Alarm
Main control system monitors and displays each power unit’s temperature in a real-time manner. When two or more units exceed the preset warning temperature, a combined optical and audible alarm will be sent to the user who will then time settle problems that cause the over-temperature, such as air blower trip or blocked filter.  
 

Other Technical Information

Dual Power Supply Circuit
Secondary coil of the transformer is used as a backup control power supply to ensure safety when the system is operating.
Multiple controls
Multiple controls are available, including local control, remote box control and DCS control, supporting MODBUS, PROFIBUS and other communication protocols. Frequency can be set either locally or through communication. Frequency presetting and acceleration/deceleration are supported.

High Power Density
Small unit volume and modularized design; compact device that requires a small space.
DC Injection Braking
When the motor is rotating (10Hz or lower frequency), direct current is injected for braking to change the motor from rotation to stop.
Current Limiter
If the current exceeds the preset limit when the VFD is operating, the current can be decreased by lowering frequency until it is lower than the preset limit; then, the normal operating frequency will be recovered.
Over-Voltage Stall Protection
The VFD can increase extend the frequency lowering time if the motor generates electricity or the bus voltage is increased during the frequency lowering period, in order to prevent stall caused by bus over-voltage.
Adaptive Acceleration/Deceleration
The VFD adjusts acceleration time or limits motor’s operating frequency given motor’s load current in order to limit the current, protecting against over-current during acceleration. The VFD adjusts the frequency lowering time given the bus voltage to protect against over-voltage during frequency lowering. 

Technical Specifications



Model Description

 

 

Product classification
Generation 7 high voltage VFDs basic series

 

 
Power level (two quadrants)
6kV:200kW-5000kW
10kV:200kW-9000kW
Power level (four quadrants)
6kV:200kW-2000kW
10kV:200kW-3250kW
Cooling method:
Forced air cooling
Performance:
Two/four-quadrant synchronous (including permanent magnetic motor) motor platform, unit tightness design and modernized concept ensures the high productivity.
Competitiveness
Module-based control system results in small harmonics and provides accurate speed regulation. Power units are well sealed for good environmental adaptability.
Typical loads
Air blowers and pumps; hoists and belt conveyers.
Generation 7 high voltage VFDs integrated series
 


Power level
6kV:200kW-560kW
10kV:200kW-1000kW
Cooling method:
Forced air cooling
Performance:
Based on two-quadrant synchronous (including permanent magnetic synchronous motor)/asynchronous motor platform, this series has its control-gear, power cabinet, transformer cabinet and switchgear integrated for easy installation.
Competitiveness:
Small size saves space; overall transportation ensures easy installation
Typical loads:
Air blowers and pumps
Generation 7 high voltage VFDs water cooling series
 

 
 
Power level:
6kV:6000kW-11500kW
10kV:10500kW-19000kW
Cooling method:
Forced water cooling
Performance:
Based on two-quadrant synchronous (including permanent magnetic synchronous motor)/asynchronous motor platform, and with reliable large power electric and electronic components and water cooling, this series provides high power density and strong environmental adaptability.
Competitiveness:
Highly reliable design, water cooling, low noise, high efficiency and stronger environmental adaptability
Typical loads:
Blast furnace blowers, oxygen-generation compressor, induced draft fans for boilers, main exhaust fans for sintering furnaces, fans and pumps

Two-quadrant high voltage VFDs

Two-quadrant high voltage VFDs (basic series)
With high speed DSPs as the core, JD-BP37/38 high-voltage VFDs are designed with sensorless vector control, multi-level power unit series and other advanced control technologies and are high-high voltage source VFDs. Harmonics indicators are much lower than the standard specified in IEEEE 519-2014. High input power factor and good output waveform save the use of input harmonic filter, power factor compensation device and output filter. They are free from problems caused by harmonics, e.g. additional heating and torque pulse, noise, common mode voltage and so on, and are suitable to conventional asynchronous motors.
This series was included into national important new products in 2003. In 2005, high voltage variable frequency and speed adjusting system for hoisting systems was incorporated into national torch plan and received the grant from the Ministry of Science and Technology for technical innovation projects in small and middle enterprises. In 2007, this series was awarded with “China’s Famous Brand”, one of the two brands that receive such honor among China’s high VFD producers. From 2009 on, WindSun has been awarded with “Top 10 Satisfactory VFD Brands” by authoritative institutions for many years in a row.
A JD-BP37/38 VFD consists of a phase-shifting transformer, power units and a controller. Its front end is powered by an isolation phase-shifting transformer with many windings. A 6kV transformer has 15 secondary windings and uses a 30-pulse rectifier. Each phase of the power unit consists of 5 low voltage power units in series, which makes 15 units for the 3 phases. A 10 kV transformer has 24 secondary windings and uses a 48-pulse rectifier. Each phase of the power unit consists of 8 low voltage power units in series, which makes 15 units for the 3 phases. Input harmonics comply with the requirements relating to voltage and current distortions as described in GB/T 14549-93. High speed microprocessor provides control and communication with sub-microprocessors in the controller. WindSun high voltage VFDs are based on module-design that ensures good interchangeability, easy maintenance, low noise, small harmonics component and zero torque pulse of the motor which therefore imposes no special requirement on motors. 

Four-quadrant high voltage VDFs

Four-quadrant high voltage VDFs (energy feedback series)
WindSun is among the earliest Chinese producers that started research and development of VFDs (four-quadrant or energy feedback types) uses for hoists. Product voltage and power ranges from 380V to 10,000 V and from dozens of kilowatts to thousands of kilowatts, respectively. WindSun hoist VFD project has been included into national torch plan and received the grant from the Ministry of Science and Technology. WindSun high voltage hoist VFDs have filled the gap that home-produced multi-level VFDs with units in series were not able to operate in four quadrants and rank high among peers in China. Directory of Promoted National Key Energy-saving Technologies (the 1st edition) released by National Development and Reform Commission describes the mine hoist-used VFD technology developed by WindSun.
Advanced vector control that can work without rotary encoder if necessary are used for WindSun high voltage four-quadrant (energy feedback type) VFDs. The main difference between vector control and conventional V/F control lies in that the former can differentiate reactive current from active current (torque current), adjust reactive current relative to the load changes during hoisting process to optimize the output torque which may as high as 2.5 times of the rated value.
WindSun JD-BP37/38T high voltage four-qundrant (energy feedback type) VFD uses several low voltage inverters power units in series to directly obtain high voltage output. The phase-shifting transformer has 15/24 secondary windings; each phase has 5/8 power units, which means three phase have 18/27 units; 30~48 pulse rectifier is used. All these give rise to an input harmonic component much lower than the limit required in national standard.  
The core control function is provided by a 32-bit chip with deliberately designed algorithm that ensures the best motor performance. Human-machine interface provides monitoring and operation pages in Chinese and also supports remote monitoring and networked control. PLC is used for logic processing of switch signals in the cabinet and coordination with operation signals and state signals on site, which enhances system flexibility.  Large scale integrations like state-of-the-art microcontrollers and surface welding technology adopted for the controller and all control unit boards ensures extremely high system reliability.
In addition, the controller and power units communicate through multi-channel fiber optic technology which ensures the complete isolation of low voltage from high voltage, making the system highly safe and resistant to electromagnetic interference. The control power supplies of all power units share a uniform controller independent of the high voltage system, a design that provides convenience for commissioning, repair and onsite training and increases system reliability.
High voltage four-quadrant (energy feedback type) VFD forms a core part of the entire electric control system and has various interfaces that match with the operating system. It receives operation commands from the electrical control system and sends operating states, including working frequency, motor current, power supply voltage and current and fault information to the electrical control system. VFD itself also automatically record working signals and working states for later use and is available to be connected to a printer for printing shift data that form necessary reports. All input and output interfaces of VFD are isolated to avoid introducing interference. Having detected that the motor in negative lift, VFD will provide energy feedback to the grid. 

Application Field

Power generation
Boiler feed-water pump, draft fan, induced draft fan,  condensation pump, circulating water pump, mud pump, compression pump, dust collector fan, boost fan

Petroleum, petro-chemistry, natural gas

Air compressor, induced draft fan, pipe pump, water injection pump, oil delivery pump, water supply pump, submersible pump, circulating water pump, brine pump
Coal, mine

Hoist, counter-rotating fan, axil-flow fan, descaling pump, mixing pump, dust removal fan, mud pump, slurry pump, clean water pump, feed pump, drainage pump, medium pump


Metallurgy
Dust removal fan, air blower for blast furnace, induced draft fan, compressed air fan, oxygen-generation compressor, draft fan, water supply pump, feed-water pump, descaling pump, SO2 draft fan, converter for slag washing machine, electric furnace, blast furnace, coal-gas compressor
Cement and building materials
Induced draft fan for raw material grinding, draft fan for cement grinding mill, sorter draft fan, induced draft fan for kilns, air supply fan for kilns, tail exhaust fan, high temperature fan, coal miller, dust removal fan, circulating fan, pressurized air fan

Municipality

Boost pump, hot water circulation pump, sewage pump, clean water pump, water supply pump, induced draft fan, draft fan

Light industry, chemical engineering

Boost pump, compressor, axil-flow pump, soft water pump, water supply pump, air blower, induced draft fan


Other
Air pump test stand, wind tunnel test device

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