YASKAWA SOULTION FOR CEMENT

INDUSTRY

03rd Feb 2021

Sreekumar
Sales & Marketing
@2020 YASKAWA India Private Limited.,
SESSION HIGHLIGHTS

VFD Basics overview.

Advantages of VFD.

Different types of Motor control Algorithm.

Application characteristics.

Energy savings.

Cement Application overview.

Innovative drive architecture U1000 & G7.

Universal intelligent drive GA700.

YASKAWA Drive health monitor.

©2020 YASKAWA India Private Limited., 1

VFD CIRCUIT OVERVIEW.
Pre charge Brake
circuit resistors

T1
L1

T2
L2 M
T3

L3

Diode DC Brake Output

Rectifiers Bus IGBT IGBTs

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RECTIFIER
Diode
Full wave rectifier circuit. Rectifiers

Anode Cathode

It converts 3Ø AC supply to DC voltage.

DC bus voltage = 1.3 * AC voltage

+ Vmax

Input
- Vmax

+ Vmax
Output

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PRE CHARGE RESISTOR & DC CONTACTOR
Pre charging
It will restrict the high initial charging current of capacitor

when power on.

It will be by passed by DC contactor within few seconds

once the capacitor is fully charged.

DC contactor in pre charging circuit helps VFD to work

with AC input as well as DC input.

No additional pre charging circuit for DC input.

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DC BUS CAPACITORS
DC Bus
It will maintain the DC bus voltage generated by the

rectifier circuit and provide stiff input to the inverter.

It will get rid of AC ripples in the DC circuit.

Helps in Power factor improvement.

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BRAKE IGBT
Brake IGBT
Itis used to dissipate the back EMF from the motor to the

braking resistors.

Will trigger only when the DC bus voltage shoots above

780VDC.

Built in till 75kW.

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INVERTER
Output IGBTs
Inverter section consist of six IGBTs (Insulated Gate

Bipolar Transistor) which converts DC voltage to AC

voltage.

By controlling switching of IGBT variable frequency

voltage output is obtained in the form of PWM wave

which is alternating in character.

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IGBT SWITCHING PATTERN

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WHY VFD?
Process control.

Energy Savings.

Controlled starting current.

Reduced power line disturbances.

Controlled start/ Stop.

Improved power factor.

Improved Equipment Life and Reduced Maintenance.

Fast braking (Electrical/ Dynamic)

Energy saving during regeneration time.

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APPLICATIONS CATEGORY

CONSTANT
TORQUE

VARIABLE
TORQUE

CONSTANT
HORSEPOWER

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ENERGY SAVINGS VARIABLE TORQUE APPLICATION

Q1 n1 H1 n P1 n1 3
Flow = = Height = = ( 1 )2 Power = =( )
Q2 n 2 H2 n2 P2 n2

Reducing the flow by 1/2 (speed by 1/2) reduces the power consumption to 1/8
(and the maximum Height to 1/4) !

©2020 YASKAWA India Private Limited., 11

DIFFERENT TYPES OF MOTOR CONTROL
V/F Control
- Speed control with no slip compensation.
- Controls motor by keeping V/f curve as per the selection.
- 150% rated torque at 3 hz.
- Speed accuracy around 2 to 3%.

Open loop vector control.

- Controls the speed or torque of an AC motor by controlling the stator current space vectors.
- 200% rated torque at 0.3 hz.
- Speed accuracy around 0.5%.

Closed loop vector control.

- Encoder feedback is taken in addition to OLV control.
- 200% rated torque at 0 rpm.
- Speed accuracy around 0.01%

EZ Vector control (YASKAWA unique)

- Tuning less control.
- MTPA function to improve the system efficiency.

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 CEMENT APPLICATION
OVERVIEW

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KILN MAIN DRIVE
- Starting torque of 200% at 0 RPM.

Closed loop torque and speed control.

Advanced open loop Vector control for encoder Torque Reference
less operation.

Load sharing for Master- Slave VFD kiln. Slave VFD

Torque Control Mode

PG Feedback
Load drooping for Multi motor Kiln.
Master VFD
Intelligent deceleration function for safe stop. Speed Control Mode

PG Feedback
Redundancy to resume operation.
Drying
High Ambient operation of 50degC and deration
up to 60DegC. Calcining

Clinker Sintering

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CONVEYOR & FEEDERS
Reduced starting current for enhanced conveyor
life.

S- Ramp start to reduce belt stretching.

DOWNHILL CONVEYOR APPLICATION
Smooth reversing function during rotational
change.

Master slave operation for long distance

descending conveyors

YASKAWA Unique Low harmonic regenerative

drives for long distance descending conveyors.
Torque
Speed Control Torque control
Automatic and manual torque boost function.
MasterReference
VFD Salve VFD

Mechanical brake control function.

Speed Control Torque control
Electrical DC braking in the event of mechanical Master VFD Salve VFD
brake failure.

Regenerative braking unit for feeding braking

back emf to grid and for high braking torque.

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COOLER AND CLASSIFIER FANS
Starting torque of 200%.

Energy Savings by replacing damper/valve.

Speed search function to catch spinning rotor.

Flux optimization for better energy savings.

Over voltage suppression for cooler and classifier fans.

Momentary power loss function to avoid voltage dips.

Input/ Output phase loss protection.

Predict the filter clogging.

Maintenance monitor to reduce the down time.

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SEPERATOR AND BAG HOUSE FAN
- EZ Vector control for dynamic torque regulation.

Better voltage bandwidth to overcome fluctuations.

Intelligent deceleration for high inertia fans.

For high power drives power input prepared for 12

pulse systems allowing reduction of harmonics within

the limits of IEE519.

Extractable rectifier and inverter modules allowing for

easy extraction and maintenance.

Reduced load operation in rare case of unit failure.

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CRUSHER
Reduced starting current there by low power
- demand during starting.
Automatic reverse operation for blocked
crusher.

Two phase operation with deration.

Smooth rotational change.

Automatic and Manual toque boost function.

Load and speed sync for multi motor operation.

Dust, humidity and conformal coated PCB to
make the VFD to work robust in harsh
environments.
High ambient operation capacity ease the drive
to be robust.

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BUCKET ELEVATOR

Master- Slave configuration to control Head &

Boot pulley motors.

Head drive under speed control and boot drive Speed Control Mode Speed Trim Mode
Master VFD Slave VFD
with torque control ensure the smooth operation.
Speed Reference
Advanced open loop vector control to start with
Torque Reference
full load.

Regenerative braking unit for high braking torque.

Enhanced mechanical life improvement.

Motor rotor locking function in case of emergency.

Safe torque off function.

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DRAFT FAN STANDBY FUNCTION
Smooth transfer to the standby Draft fan VFD in
the rare event of main drive trip.

Voltage based speed search enables system to

transfer without pressure drop.

Advanced speed search algorithm catch the MAIN VFD- 1 MAIN VFD- 2 STANDBY VFD
spinning rotor much faster.

CHANGEOVER LOGIC

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PRODUCT POWER RANGE

POWER (KW)
Power (kW)

11000VAC 9000kW

6600VAC 6000kW

3300VAC 3000kW

690VAC 1900kW

400VAC 1200kW

200VAC 110kW

0 2000 4000 6000 8000 10000 12000

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PRODCUT SERIES RANGE

Medium
voltage drive
MV1000

R1000
Regenerative
low harmonic D1000
system

U1000

Application Z1000
specific drive

L1000
3 level 12
pulse drive
G7

Advanced
vector drive GA700

High
performance A1000
vector drive

Sensor less V1000

vector drive

V/F Drive J1000

0.1kW 5.5kW 22kW 45kW 185kW 300kW 560kW 630kW 1900kW 9910kW

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 Innovative Drive Architecture

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U1000- INDUSTRIAL MATRIX REGENERATIVE DRIVE
-
Ultra-Low Harmonics
IEEE519-1992 Compliant

Near Unity Power Factor

True PF: 0.98 or higher

Greater Efficiency

~ M

Power Regeneration

Compact Size

Permanent Magnet Control

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U1000- INDUSTRIAL MATRIX REGENERATIVE DRIVE

Conventional drive U1000

S11
S21
S31
T1
R S12 U
L1
S S22 V
M
T2
L2 IM
T3
T S32 W
L3
S13
S23
Harmonic Filter S33

Diode DC Output Bidirectional Switch

Rectifiers Bus IGBTs
AC → AC

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U1000- INDUSTRIAL MATRIX REGENERATIVE DRIVE
Full Regeneration

Low Input Current Harmonics at All Speeds/Loads.

9 Bi-directional
Facilitates IEEE 519 Compliance.
circuits for a
No additional filters on line side.
total of
18 IGBTs
Near Unity True Power Factor at Full Load R U

S V
Higher Efficiency than Conventional Low harmonic
T
W
solutions.

Low Surge there by suitable for long distance cables.

High Reliability with MTBF in Excess of 28 Years.

Motoring Power Flow
Induction and Permanent Magnet Motor Control
Regenerative Power Flow
Instantaneous
motoring & regeneration

©2020 YASKAWA India Private Limited., 26

ECO MODE- BYPASS TROUGH
Matrix Can Run Line Power Directly to the Motor

Automatically!

Line voltage is passed directly to the motor for across

With conventional AC Drive
the line operation
Contactor

Full line voltage passes to the motor Power Supply Motor

Contactor Contactor
M
Near zero input harmonic current operation* Phase Phase
AC Drives
detector detector
Drive Switching Losses Eliminated U1000 Matrix Drive

High carrier frequency motor noise eliminated Power Supply No Motor

Peripheral M
Devices
High frequency Common mode/Differential Mode noise Required!
U1000

reduced (EMC)

* Actual Results dependent on existing power supply

conditions.

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HARMONIC MITIGATION COMPARISON

Configuration Current Waveform Current Spectrum iTHD

100％

Total Harmonic
Distortion
(Current)
50％

0％ 5 7 11 13 17 19 23 25
Harmonics

100％

Total Harmonic
Distortion
(Current)
AC drive
 5%
50％

with AFE 0％ 5 7 11 13 17 19 23 25
Harmonics

Total Harmonic
100％
AC drive

Distortion
(Current)
with multi-pulse 50％

0％ 5 7 11 13 17 19 23 25
6 - 12%
Harmonics
100％

Total Harmonic
Distortion
AC drive

(Current)
50％
with DC reactor
0％
~ 40%
5 7 11 13 17 19 23 25
Harmonics

Total Harmonic
100％

Distortion
(Current)
AC drive
without reactor 50％

0％ 5 7 11 13 17 19 23 25
~ 80%
Harmonics

©2020 YASKAWA India Private Limited., 28

AFE vs U1000
Active Front End (AFE)
AC reactor

Eliminate Components:
• Extra Regenerative Drive
Power Supply Motor • AC Reactors
Reactor for
AC drive
• Capacitors
Harmonic Filter AFE • Additional Fusing
Capacitor for
Harmonic Filter

ALL IN Reduce Reduce SIZE

ONE WIRING by by

U1000 Matrix Drive

COMPACT 70% 65%
U1000 UNIT!
Reduce Reduce POWER
WEIGHT by
19%
81%
by

Power Supply Motor

Example: 415V 40HP
3 in ↔ 3 out

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LESS FOOT PRINT

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U1000- WAVEFROM

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G7- 12 PULSE 3 LEVEL INVERTOR

“The G7 drive has the world’s first

480V 3-level inverter architecture for
total system protection.”

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G7- 12 PULSE 3 LEVEL INVERTOR
Conventional Drive (2-level) G7 (3-level)
P P
Reduction
Reduction
of Surge
of Audible
Voltage
Inverter Noise
Circuit O

G7 Drive Motor

N Reduction or
N Reduction of
T1 T2 T3 Elimination of
T1 T2 T3 Common-mode Bearing
Noise Currents
+ +
VPN VPN /2
Phase
Voltage _ O

Line
Voltage

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G7- ADVANTAGES

Built-in 12 pulse diode bridge to minimize the ThiD.

Low electric and acoustic noise.

Low surge voltage.

No need of output reactor/ sin filter

Capable for long distance cables.

Reduce the common mode voltage.

Reduce the bearing current of the motor.

Reduces the insulation breakdown of the motor.

Compactable to drive general purpose motors.

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3 LEVEL Vs 2 LEVEL:O/P VAC WAVEFORM

3 Level Topology

2- Level Topology

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R1000- POWER REGENERATIVE BRAKING UNIT

Will save the regenerative energy , by just connect R1000 with one Inverter.

Previous R1000
configuration

Braking
Resistor Control Panel R1000 Control Panel

AC Drive AC Drive
Power
Return Coordinating
Reactor

Heat
Braking Unit
Fuse R1000
Braking Resistor Unit Current Suppression
Reactor

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R1000- POWER REGENERATIVE BRAKING UNIT

Compactable with all conventional drives having full power access

to DC bus.

Improved process time by reducing the braking time

Will replace the dynamic braking unit and dynamic braking

resistors.

High braking torque of 150% for 30sec.

-10˚C to +50˚C ambient operation without deration

Energy saved which is currently wasted at Dynamic braking

resistors.

Monitor the amount of energy saved.

Available up to 300kW.

Improves the maintenance factor and down time.

©2020 YASKAWA India Private Limited., 37

Advanced Vector control Intelligent AC
Drive
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GA700- BEST VALUE FOR YOUR APPLICATIONS
Ambient temperature 50 DegC and derating up to 60 DegC.

IP20 Protection class to all capacity.

One drive can control four different motors.

EZ Vector control for tuning less operation.

Conformal coating for PCB’s and separate coated drives for

Oil (N class), Gas (K class), Sticky dust (M).

Anti vibration feature (S class).

Horizontal mount is possible (~75kW).

Safe torque off function.

IOT enabled drive

Gateway connection system

Braking transistor built in till 75kW.

Capable for storing parameters of the four different motors.

©2020 YASKAWA India Private Limited., 39

FAILURE PREDICTION

Predict potential conveyor failures

Detect filter clogging in fan

Predict potential drive failures.

IGBT Main Circuit Soft charge

Cooling Fans
Capacitor bypass relay

Quick recovery in the event of failure

©2020 YASKAWA India Private Limited., 40

VFD REMOTE MONITORING WIZARD
• All drives are connected to Ethernet Hub using Modbus Communication

• Ethernet Hub is located in the Drive panel room and can access all the drives data.

• User can access all the drives data remotely on IP address allocated.

• Can monitor the Status of the VFD on a customized screen which is easy to understand
and troubleshoot problems if necessary.

• User Customer screens are possible

Modbus

Hub

Remote Monitoring

©2020 YASKAWA India Private Limited., 41

VFD REMOTE MONITORING WIZARD : Sample Screen
OPERATION DETAILS
SELECTED DEVICE No. of RUN COMMANDS FAN OPERATION HOURS MOST RECENT FAULT CURRENT FAULT RUNNING HOURS
Machine 2 100 commands 10 hours oL2 (nil) 100 hours

CURRENT STATUS IO Terminal Status

FWD RUN REV RUN FAULT READY ALARM S1 S2 S3 S4 S5 S6 S7 S8

MA-MC M1-M2 M3-M4 M5-M6

Fault During Run Zero Speed Speed Agree

Monitor Data
DC BUS VOLTAGE FREQUENCY REFERENCE HEATSINK TEMP
660VDC 50.0Hz 50 C

Output Frequency = 50Hz Output Current = 50Hz PID Feedback = 50% AI1 terminal input AI2 Terminal Input AI3 Terminal Input
50% 100% 25%

Change Color as per status

Customizable as per
parameter by user
Output frequency, current can
be shown here. More options
as per requirement of cutomer

Rotate clockwise if FWD

Anti Clockwise if REV
Gear shown only for reference

©2020 YASKAWA India Private Limited., 42

“OUR PASSION FOR MANUFACTURING
IS TIMELESS
AND
WILL NEVER CHANGE”

© Private
©2020 YASKAWA India 2020 YASKAWA
Limited., India Private limited., 43