Harmonic Mitigation Techniques For Low and Medium Voltage Drives ISA Chapter Meeting Denver, CO January 20th, 2009 Kelvin J. Hurdle Art Kerchner

Harmonic Mitigation
Techniques for Low and

Medium Voltage Drives
ISA Chapter Meeting

Denver, CO
January 20th, 2009
Kelvin J. Hurdle
Art Kerchner
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

OVERVIEW
• Linear vs. Non- Linear Load Definitions
• AC Drive Input Current Harmonics
• Potential Affects of Harmonics
• Application of Harmonic Industry Standards, IEEE Std. 519-1992
• How to Tackle Harmonics
• Harmonic Mitigation Techniques

Drive System
Transformer AC Drive Motor
Line Current Harmonics

PWM AC Drive with 6-Pulse Rectifier
6 Pulse Link PWM

R e c tifie r Id In v e rte r
IGBT INVERTER
Rectifier Choke
Input L p S1 S3 S5
Output
Sinewave D 1 D 3 D 5 480 V,
480 V,
a b c V/Hz,
60 Hz
C V bus 5 - 90 Hz
SMPS
D 2 D 4 D 6
n S2 S4 S6
Fixed DC voltage
Utility Input current to a 6-pulse rectifier is non-sinusoidal and

produces current harmonics which flow back into the power system

What are Harmonics?
0 10.00m 20.00m 30.00m 40.00m

150.0 Rfund.V =...
• A sinusoidal waveform
• does
A sinusoidal waveform
not contain has no harmonics
any harmonics
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0
• This
This isisan
anexample
exampleof aoflinear
a linear
load load -150.0
0 10.00m 20.00m 30.00m 40.00m

What is a Linear Load?
Time Domain Analysis

Linear Load:
Current waveshape linearly
Voltage
follows the Utility sinewave Current
Voltage waveform 0V time
time
Current can differ in
magnitude & power factor
phase angle Power Factor Angle
Linear Commercial Loads: Frequency Domain Analysis

• Induction motors Current magnitude (RMS)
• Incandescent lights
• Resistance heaters
• Electromagnetic devices 60 Hz or Frequency
• Transformers Fundamental
(non-linear with over-voltage)
What are Harmonics?
0 10.00m 20.00m 30.00m 40.00m

150.0 Rtotal.V =...
• A sinusoidal waveform
• does
A non-sinusoidal
not contain anywaveform
harmonics contains harmonics
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
•• This
This isisan
considered
example of aa linear
non-linear
load load
-150.0 -150.0
0 10.00m 20.00m 30.00m 40.00m

What is a Non-Linear Load?
Harmonics are …... Time Domain Analysis

Deviations from the Ideal Amplitude Input Current
Fundamental AC line voltage and AC
Fundamental Current
current waveforms Drive

Input
time
Current
Non-linear loads contain …..
Current Harmonics which cause
Voltage Harmonic problems for Frequency Domain Analysis
other users 1 pu Current magnitude (RMS)
Harmonics
Frequency [Hz] 60 Hz
Frequency [h] Fundamental 5th 7th 11th 13th 17th 19th

Root Cause of Problems with Other Equipment
Current Harmonics
create
Voltage Distortion

Power Consumer Issues
Associated with non-Linear Loads
Non-linear Commercial loads Non-linear Industrial loads

generally come from: generally come from:
• Fluorescent lights • Welders

• Computers and CRT’s • Arc furnaces
• Fax machines • UPS and DC power supplies
• And other single phase office equipment • DC Drives & AC Drives
* Fastest growing factory related non-linear load issue is with AC drives
* This is due to the ever increasing number of installations

What problems do they cause?
• Increased Utility current requirement inability to expand or utilize equipment

• Component overheating distribution transformers & wires
• Nuisance tripping causing lost productivity sensitive equipment
• Equipment malfunction due to multiple or loss of zero crossing
• Noise transfer to other loads possibly even other utility customers
• Incorrect meter readings, relays malfunction maintenance time
• Communication or Telephone Interference problems
• Excitation of Power System Resonance's creating over-voltage’s
• Voltage Flat Topping Problem

Effects of Harmonics on Power System?
• How are harmonics and power factor related?
– Harmonics increase the required current supplied
– Results in increased power requirement from the utility
– If the total load uses all the utility supplied power, the distribution
system is called unity, or 1.0 power factor.
– If the same load requires more utility supplied power due to
harmonics or other losses, then the power factor decreases.
– Some power utilities may impose penalties to the user if they
oversize their distribution system due to a poor power factor.

Effect of Harmonics on the Power System?
• How do I determine when I will have a Harmonics But how do

Issue with my new or existing Drive Installation ? I know
what is SIGNIFICANT ?
• Drives are part of the Non-Linear Load
• If the Non-Linear Load is SIGNIFICANTLY higher than

the Linear Load, there is a potential for Harmonic
Distortion problems

Effect of Harmonics on the Power System?
PLANT ONE LINE DIAGRAM

Harmonic Currents flowing
through the system
Produce Voltage Distortion at various

Points of Common Coupling ( PCC ) with
other loads
Voltage Distortion depends upon:

– System Impedance's (% Z)
– Amplitude of the Injected Harmonics

Who is your neighbor?
u t ilit y I( T D D ) is m e a s u r e d a t e a c h m e te r in g p o in t
tr a n s fo r m e r
Ih a rm Ih a rm A
PC C 1 C uOs t ho em r e r
C u s tAo m e r
Ifu n d Ifu n d A
2500kVA
5 .7 5 % Z Ih a rm B
480Vsec
C uOs t ho em r e r
C u s tBo m e r
Ifu n d B
G o a l is to
k e e p th e V (T H D ) a t Ih a rm C
PC C1 <= 5% , C uOs t ho em r e r
C u s tCo m e r
Ifu n d C

How to Tackle Harmonics?
• It is not economical or desirable to eliminate all harmonics

• Analysis & guidelines are necessary to determine whether or not there
are problems created by existing harmonics
• Useful Guidelines & Standards available are:

– IEEE- 519 is the Main Standard in North America
– (places limits on voltage distortion & current THD)
– IEC- 555 for Europe & some areas of South America
– (places limits on voltage distortion)
– IEC- 61000-3-12 proposed draft
– (places limits on voltage distortion for input current >16A and < 75A)

Harmonic Distortion Limits of IEEE-519
• Developed by utilities,electrical equipment

manufacturers and power consumers
PLANT ONE LINE DIAGRAM
• Recommended Harmonic Limits are based on

reasonable voltage distortion limits at
( PCC )
– PCC is where two or more customers share a
common utility power source
• Distortion is Relative to the total plant load

– i.e. each plant’s harmonic limit is different
• Specification Harmonic Limits increasingly

common in low voltage systems

Voltage Distortion Limits of IEEE-519
Harmonic Voltage Distortion at PCC in %
< 6.9 kV 6.9 kV- 13.8 kV > 13.8 kV

Maximum
individual
harmonic 3.0 % 1.5 % 1.0 %
component
VTHD 5.0 % 2.5 % 1.5 %
• IEEE 519 Harmonic Standard for power systems has:

 GENERAL limit set at 5% THD
 HOSPITAL , AIRPORT limit set at 3% THD

Current Distortion Limits of IEEE-519
Maximum Harmonic Current Distortion in % of Fundamental
Isc / IL h < 11 11< h < 17 17< h < 23 23< h < 35 THD
• Isc system short circuit current at PCC.

• IL maximum load demand at PCC.
• THD Total Harmonic Current Distortion allowed at PCC.
• Higher (Isc / IL) measure of power system “stiffness”

Isc / IL h < 11 11< h < 17 17< h < 23 23< h < 35 THD
< 20 4.0 2.0 1.5 0.6 5.0
20 - 50 7.0 3.5 2.5 1.0 8.0
50 - 100 10.0 4.5 4.0 1.5 12.0
• Higher (Isc / IL) “stiff” power system more

 THD allowed
•Designing a system with a strong power source diminishes the impact of
harmonics, however, if a back-up generator is utilized, this should be taken into
consideration.


Isc / IL h < 11 11< h < 17 17< h < 23 23< h < 35 THD
< 20 4.0 2.0 1.5 0.6 5.0
20 - 50 7.0 3.5 2.5 1.0 8.0
50 - 100 10.0 4.5 4.0 1.5 12.0
• Worst Case Application of IEEE - 519  (Isc / IL) < 20 Category

What are the IEEE 519-1992 standards?
Harmonic Voltage Limits Table 10.2
Low-Voltage Systems
Application Maximum THD (%)
Special Applications - hospitals and airports 3.0%
General System 5.0%
Dedicated System - exclusively converter load 10.0%
Current distortion Limits for General Distribution Systems (120V through 69,000V)
Maximum Harmonic Current Distortion in Percent of Iload
Isc/Iload <11 11<=h<17 17<=h<23 23<=h<35 35<=h TDD (% )
<20 4.0 2.0 1.5 0.6 0.3 5.0
20<50 7.0 3.5 2.5 1.0 0.5 8.0
50<100 10.0 4.5 4.0 1.5 0.7 12.0
100<1000 12.0 5.5 5.0 2.0 1.0 15.0
>1000 15.0 7.0 6.0 2.5 1.4 20.0
Even harmonics are limited to 25% of the odd harmonic limits above
Table 10.3
Isc=maximum short circuit current at PCC
Iload=maximum demand load current (fundamental frequency component) at PCC
Harmonic Mitigation Techniques
When Non-Linear Loads exceed 30% - 50% of Total Load,

an harmonic analysis of the plant one-line load
diagram should be performed.
Rockwell Automation
can assist in performing a software harmonic analysis,
recommend specific Harmonic Mitigation Solutions
and provide hardware quotations.

How can we reduce the harmonic current?
• DC link choke within the drive

• line reactor
• passive filter
• active filter
• multi-pulse converters
• active front-end

Input Current of 6-Pulse Rectifier
Standard Configuration -
T current
 “no” DC link Choke
• Current THD= 80% @ full load
• THD depends on source impedance(%Z)
• Rectifier diode turn off causes

 voltage spikes on voltage waveform
TT
• For Drives < 5 HP, no impact on utility
1) Ref A: 100 A 2 ms
2) Ref B: 10 V 2 ms
Voltage
current
Standard Configuration -
“with” DC link Choke
• Current THD= 32% @ full load
• THD independent of source %Z
• Good power factor = 0.93
• Minimizes input voltage distortion
Drive w/o DC Link Choke
D r iv e
• Typical I(THD) of 80 to T r a n s fo r m e r
120% x fm r
% Z AC DC
• Sensitive to line voltage
DC AC
transients
• High peak line currents
Common
configuration for M
drives < 5hp hp
M o to r
150.0m 162.5m 175.0m 187.5m 200.0m
400.0 La.I = f( ... Load
200.0 200.0
0 0 NOTE: Ipk about 3x Irms
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Drive with DC Link Choke
• Typical I(THD) of 30 T r a n s fo r m e r
D r iv e
D C L in k
to 40% x fm r C hoke
% Z AC D C
• Less sensitive to line D C AC
transients
M
hp
150.0m 162.5m 175.0m 187.5m 200.0m

M o to r
400.0 La.I = f(t... Load
200.0 200.0
0 0 NOTE: Ipk about 1.5x Irms
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Line Reactor, Drive w/o DC Link Choke
D r iv e
• Typical I(THD) of 30 to T r a n s fo r m e r
45% x fm r
% Z AC DC
• Big help for drives without
DC AC
DC link choke
L in e R e a c to r
Typical values are

3% and 5% M
impedance hp
M o to r
150.0m 162.5m 175.0m 187.5m 200.0m
400.0 La.I = f(t... Load
200.0 200.0
0 0 NOTE: shown is 3% LR
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Line Reactor
D r iv e
D C L in k
to 35% x fm r C hoke
% Z AC D C
• Big help for drives D C AC
without DC link choke

L in e R e a c to r
Typical values are
3% and 5% M
impedance hp
150.0m 162.5m 175.0m 187.5m 200.0m

M o to r
400.0 La.I = f(t... Load
200.0 200.0
0 0 NOTE: shown is 3% LR
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Harmonic Mitigation Technique - Passive & Active
Filters
Passive Filters:
eliminate/reduce specific harmonics (tuned 5th, 7th filters)
reduce higher order harmonics (low pass, 5th thru 17th)
Active Filters:
using switching converters to compensate for specific
harmonics and/or improve Power Factor
It injects equal and opposite of Drive harmonics into AC
line
Let’s, look at these solutions in more detail !

Passive Harmonic Filter
D r iv e
D C L in k
to 8% x fm r
% Z
C hoke
AC DC
DC AC
M
hp
P a s s iv e F ilt e r
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m

M o to r
150.0 Ia = f( S,... Load
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Passive Harmonic Filter

Passive Harmonic Filter - Dual
D r iv e
D C L in k
to 7% x fm r C hoke
% Z AC D C
D C AC
M
hp
P a s s iv e F ilt e r
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
M o to r
150.0 Ia = f( S,... Load
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Passive Filter: Harmonic Trap Filter
6-pulse rectifier with tuned 5th & 7th filter
VSI
FEED
UTILITY AC DRIVE
XFMR.
5th Filter 7th Filter
Consists of one or more tuned 5th or 7th LC filters in shunt with power system.
Usually connected at the primary of the isolation transformer or line reactor.
Filters interact with other plant non-linear loads, can sink for unknown load.
Need overload and fuse blown detection (usually individually fused).

Active Filter Concept
I source = I rectifier + I filter

I rectifier
I source I rectifier
I filter
I filter
I source
1st 5th 7th 11th 13th
• High Filter Converter ratings: ~ 1/3 of Drive kVA

• Multi-functional: reactive power factor compensation,
voltage and load balancing

Active Harmonic Filter
• Typical I(THD) of 3 to 6% T r a n s fo r m e r
D r iv e
D C L in k
x fm r C hoke
% Z Ifu n d Ifu n d + Ih a rm AC DC
DC AC
Ih a rm
AC
DC
M
A c t iv e F ilte r hp
Current from Transformer
M o to r
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m Load
150.0 Ia = f( S,...
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
A C D r iv e
T r a n s fo r m e r D C L in k
x fm r C hoke
% Z Ifu n d Ifu n d + Ih a rm
AC DC
DC AC
M
Ih arm
A C D r iv e
AC D C L in k
C hoke
DC
AC DC
A c tiv e F ilte r DC AC
M
D C D r iv e
AC
DC
M


Harmonic Mitigation Technique
Rectifier’s with Higher Pulse Number
12-Pulse Rectifier
Auto-Transformer OR Isolation Transformer
18-Pulse Rectifier
• 18-pulse drives produce less THD, but are larger & more expensive
• Isolation transformers produce less THD, but larger & more expensive

Multi-Pulse Converters
• 12-Pulse Typical T r a n s fo r m e r
D r iv e
D C L in k
I(THD) of 9 to 12% x fm r
% Z 3 9
C hoke
AC DC
• 18-Pulse Typical DC AC
I(THD) of 4 to 5%
M u lt i- P h a s e
T ra n s fo rm e r
M
hp
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m

M o to r
200.0 Ia = f( S,... Load
100.0 100.0
0 0
-100.0 -100.0
-200.0 -200.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
18-Pulse, Parallel
DC
M
AC
• Auto-transformer with polygon windings (480V primary for 480V drive)

• 1/3 the size of the isolation xfmr
• Can have isolated primary - larger
• Diode bridges are in parallel – one third current rating
• 9 wires from transformer to bridges
• I(THD) = 3 to 5%

18-Pulse Auto-Transformer Converter
Supply Transformer Line Reactor Auto-Transformer 18 Diode Bridge
H1 X1 H6
+
X2 X9
H1 X1 400 400
X3 X8
H2 X2
H4 H3
X0
X4 X7
H3 X3
H2 X5 X6 H5
-
NOTE: 5 Autotransformer
windings per core leg

Input Waveforms of 18-Pulse Option
FEATURES
• Meets IEEE-519 5% Harmonic Standard at the
18 pulse input current drive input Terminal
• Current THD 3.5% full load (typ.), 6 % no load
• 5th, 7th, 11th & 13th harmonic reduced
• Input power factor improved to 0.99, thus
reducing kVA source requirements
18 pulse Utility input voltage • Input Diode rectifiers & magnetics lead to a
reliable drive system
• More robust and trouble free than
Harmonic Trap filters
• Specified for use on high “Z” Aux-Gen unit
• Lower $ than Active PWM Rectifier approach

18-Pulse Front-End
• 18 pulse
– Diode bridge converter
– Common DC
bus drive
– Auto-transformer

Active Front-End
D r iv e
to 5% x fm r
% Z AC DC
DC AC
M
hp
N o tc h F ilt e r
145.0m
150.0m 162.5m 175.0m 187.5m
195.0m
M o to r
200.0 Lx1.I = ... Load
100.0 100.0
0 0
-100.0 -100.0
-200.0 -200.0
145.0m
150.0m 162.5m 175.0m 187.5m
195.0m
Active Front-End
• Serves as Input to Drive(s) 500.0
54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m
I"LX1" = f(T...
VMRN = f(T...
– Multiple drives on one DC bus

• Regulated DC Bus 250.0 250.0
– Ride Through Capability 0 0
– No loss of motor voltage

• Unity Displacement Power Factor -250.0 -250.0
• Low Harmonics -500.0

54.2m 60.0m 70.0m 80.0m
Motoring
90.0m
-500.0
100.0m 104.2m
– IEEE-519
• Regenerative 54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m
– Energy Saving
500.0 I"LX1" [A] =...
VMRN [V] =...
– 100% Regenerative Capacity 250.0 250.0
0 0
-250.0 -250.0
-500.0
Regen -500.0
54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m

Regenerative AC Drive
R e g e n e r a tiv e A C D r iv e
AC Motor Output
AC Line Input
C o n v e rte r D C In v e rte r
A C to D C Bus D C to A C
F ilt e r

Harmonic Mitigation Technique
Active Front End Rectifier
Input
A dual-direction converter that ... Breaker
• Supplies forward power to a common DC bus

drive system with Sinusoidal input currents
• Regenerates excess power back to the 3-
phase AC line with Sinusoidal input currents Inverter
used as
Front-end
rectifier
Input
choke
Output: 200A DC
Input: 460V AC, 145 kVA
(K-Code)

Liquid Cooled Drive

AFE Converter IGBTs
Input Converter Bridge

Inverter IGBTs
Output Inverter Bridge

Harmonic Mitigation
with MV Drives
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
56
PowerFlex 7000 - Topology
There are three standard designs for the rectifier of the PowerFlex drive:
AFE
6 Pulse 18 Pulse or
Direct-to-Drive
(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 57
Drives with AFE Technology
• Product Mix
– The Active Front End configuration continues to dominate sales by a wide margin
• No isolation transformer
• Best harmonic performance
• Best input power factor
3%
17%
6-Pulse
18-Pulse
AFE
80%
(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 58
MV Drive Topology Comparison
Simple Complex
Very Complex
CSI-PWM 2 Level
•MV SGCT inverter
switch
•Low component count
•Simple power structure
•No phase shifting VSI-PWM Multi-Level
transformer •MV IGBT inverter switch
•High component count VSI-PWM Multi-Level (Series Cell)
•Complex Power structure and •LV IGBT inverter switch
transformer configuration •Very high component count.
•Complex output filter •Very Complex power structure and
transformer configuration

CSI-PWM MV Drive with Active Front End
rectifier Inverter
load
• The rectifier is the same as the inverter

PowerFlex 7000 – Semiconductors
• Symmetrical Gate Commutated Thyristor

(SGCT) is an ideal switch for Medium
Voltage applications.
• Gate drive close to the device creates low
inductance path
– more efficient and uniform gating
• Low conduction & switching losses
• Low failure rate
– 100 failures per billion hours operation
– 5 X better reliability rating than IGBTs
• High PIV (Peak Inverse Voltage) rating
means less components are required.
• Small, lightweight, and accessible means
easy to replace
• Double-sided cooling
• Non-rupture / non-arc failure mode

Characteristics of an AFE Rectifier Drive
• Output:
– PWM-CSI with SHE patterns, eliminating 5th, 7th and 11th to rated frequency with
switching frequency of 420hz
• Input:
– AFE bridge eliminates 5th, 7th, 11th harmonics (SHE pattern)
– results in low input current THD using 420Hz switching frequency
– input capacitance filtering harmonics above 11th and providing capacitance for
reactive power compensation (improved PF)
– reactor on line side of capacitor isolating the drive from the line
• current limiting features
• further filtering

Control Options for the AFE Rectifier
0.5
Fsw = 420 Hz, (5th,7th & 11th)
• SHE eliminating 5th, 7th and 11th harmonics with phase shifting switching
frequency is 420Hz
• each symmetric switching pattern eliminates one harmonic

PWM Switching Pattern
The Active Front End Rectifier
To comply with IEEE 519 while avoiding the use of a phase shifting isolation transformer,
the active front end uses the SGCT to produce a PWM switching pattern that prevents the
drive from producing high levels of line harmonics.

PowerFlex 7000 - Rectifier Configurations
Active Front End Rectifier

• World’s most common harmonic standard requirements are typically met in
every case
• The THD is approximately:
– 4 - 5% current THD
– 1.5% voltage THD (line-to-line)*
• True input power factor with the AFE rectifier is greater than 0.95 for the
typical speed and load range of variable torque loads.
*THD of line voltage is a function of system impedance
Line current
Line-to-line voltage

PowerFlex 7000 – Power Quality
Typical THD of Different Rectifiers
Input Current
AFE
Input Voltage

PowerFlex 7000 – Features and Benefits
Drive Performance - Motor Friendly
• Near sinusoidal current and voltage @ all speeds and
loads
– no additional motor heating or voltage stress to insulation
compared to sine wave operation
• Compatible with standard motors
– induction or synchronous motors
– no de-rating
– inverter duty motor not required
– new or retrofit applications Typical VFD output waveforms @ full load, full speed
• Virtually unlimited motor cable distance •4160V, 933 kW, 60 Hz
– stable operation up to 15 Km •Top - Motor Current
– no capacitive coupling or dv/dt issues •Bottom - Motor Voltage
• Quiet, smooth motor operation

– High quality of current and voltage waveforms
– Low torque ripple
– Lower switching frequency compared to IGBT drives (no
reflected wave issues)

PowerFlex 7000 – Modern Thinking
Examples include large and heavy energy-wasting multi-level phase-shifting transformers that
required as many as 53 cables connected to the drive rectifier.
Rockwell Automation has changed all of that with its DIRECT-TO-DRIVE Technology!

Can we estimate what the
harmonics will be?

Rockwell Automation Can Help Choose the Right
Solution
“I don’t know where to start!”

– Rockwell Automation can do an up front software
analysis and make a recommendation.
– What is needed?
• Power distribution drawing showing utility
and feed transformer specifications
• Maximum Short Circuit Current (this
figure comes from the utility)
• Linear and non-linear loads

Visual Basic Version

Wrap-Up

Practical Aids for Harmonic Compliance
• Take time to understand the benefits and drawbacks of each

type of mitigation solution to assure you meet the
requirements of the application and that you can live with any
negative effects created by the chosen harmonic solution.
• Identify the required PCC and apply techniques most cost
effective for that location.
• Perform a preliminary harmonic analysis and explore the
effects of using various harmonic mitigation methods.
• Add a line reactor (or DC link choke if possible) to any un-
buffered 6-pulse drive or group of drives.

• Design the system to isolate linear and non-linear loads and

create two systems with 5% and 10% voltage limits.
• For passive filters on generator power, select a filter with a

dropout contactor terminal block for the filter capacitors. This will
limit the leading power factor under no-load operation and stand-
by operation.
• Never use power factor correction capacitors at the input (or

output) of a drive.

• Consider use of an active filter on a multiple drive system or MCC lineup to

correct for harmonic distortion.
• Consider an active front end if the application requires regenerative

operation and harmonic compliance.
• When conducting a drives-based harmonic analysis, establishing the PCC

at any point other than where the sharing of utility power occurs is not
consistent with the intent of IEEE519-1992 and may lead to the purchase
of unnecessary equipment.

Market Trends
• The 18 Pulse market is firmly established.

• Passive filter are evolving. Recent new designs have surfaced with very
good performance. System resonance with multiple filters needs
investigation. Suitable for smaller horsepowers <100
• Active Filters are technically viable but right now are a more costly solution
for most projects.
• Active Filters fare better on large projects with the PCC specified at
transformer secondary.
• The price of copper and iron is going up while the price of power electronics
is coming down.

Questions?

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Harmonic Mitigation

Techniques for Low and

ISA Chapter Meeting

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

• Linear vs. Non- Linear Load Definitions

• AC Drive Input Current Harmonics

• Potential Affects of Harmonics

• Application of Harmonic Industry Standards, IEEE Std. 519-1992

• How to Tackle Harmonics

• Harmonic Mitigation Techniques

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 2

Transformer AC Drive Motor

Line Current Harmonics

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 3

6 Pulse Link PWM

Utility Input current to a 6-pulse rectifier is non-sinusoidal and

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 4

0 10.00m 20.00m 30.00m 40.00m

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 5

Time Domain Analysis

Linear Commercial Loads: Frequency Domain Analysis

0 10.00m 20.00m 30.00m 40.00m

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 7

Harmonics are …... Time Domain Analysis

current waveforms Drive

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 8

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 9

Non-linear Commercial loads Non-linear Industrial loads

• Fluorescent lights • Welders

* Fastest growing factory related non-linear load issue is with AC drives

* This is due to the ever increasing number of installations

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 10

• Increased Utility current requirement inability to expand or utilize equipment

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 11

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 12

• How do I determine when I will have a Harmonics But how do

• If the Non-Linear Load is SIGNIFICANTLY higher than

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 13

PLANT ONE LINE DIAGRAM

Produce Voltage Distortion at various

Voltage Distortion depends upon:

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 14

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 15

• It is not economical or desirable to eliminate all harmonics

• Useful Guidelines & Standards available are:

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 16

• Developed by utilities,electrical equipment

• Recommended Harmonic Limits are based on

• Distortion is Relative to the total plant load

• Specification Harmonic Limits increasingly

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 17

Harmonic Voltage Distortion at PCC in %

< 6.9 kV 6.9 kV- 13.8 kV > 13.8 kV

VTHD 5.0 % 2.5 % 1.5 %

• IEEE 519 Harmonic Standard for power systems has:

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 18

Maximum Harmonic Current Distortion in % of Fundamental

Isc / IL h < 11 11< h < 17 17< h < 23 23< h < 35 THD

• Isc system short circuit current at PCC.