A B B I N D I A | D R I V E P R O D U C T S | 1 9 TH J U L Y 2 0 2 4

Value Driven Products from Drive Products

Partner Expert Training Days 2024
© 2024 ABB. All rights reserved.
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AGENDA

1. Clean Drives Offer

▪ Ultra-low Harmonic Drives
▪ Regenerative Drives

2. Packaged Drives Offer

3. Premium Efficiency Solution Rajasekhar M Jugal Patnaik

Product Sales Manager Product Manager
Drive Products, ABB India Limited Drive Products, ABB India Limited

[email protected] [email protected]

© 2024 ABB. All rights reserved. Slide 2

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Clean Drives Portfolio
its benefits to Customer
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Drive Products, India
Clean Drives Portfolio

ULH Drives for HVACR

ACH580-31 : 4 to 110 kW, 3Ph 380…480V, 50/60 Hz
ACH580-34: 132 to 350 kW, 3Ph 380…480V, 50/60 Hz
ULH Drives for WWW
ACH580-31 : 4 to 110 kW, 3Ph 380…480V, 50/60 Hz
ACH580-34: 132 to 350 kW, 3Ph 380…480V, 50/60 Hz
ULH Industrial Drives
ACS880-31 : 4 to 110 kW, 3Ph 400V, 500V, 50/60 Hz
ACS880-34 : 132 to 400 kW, 3Ph 400V, 500 V 690V , 50/60 Hz
Regenerative / 4Q Industrial Drives
ACS880-11 : 4 to 110 kW, 3Ph 400V, 500V, 50/60 Hz
ACS880-14 : 132 to 400 kW, 3Ph 400V, 500 V 690V , 50/60 Hz

Wide Portfolio for the Ultra Low Harmonic & Regenerative Drives

© 2024 ABB. All rights reserved. Slide 4

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ABB’s Ultra-low harmonic drives
Features & Benefits

Low Harmonic content, <3% THDi Unity Power Factor, at all loads Reactive Power Control
The drive produces exceptionally low harmonic content and ABB’s ultra-low harmonic drives have been designed to be ABB’s ultra-low Before compensation After compensation

exceeds the requirements of harmonic recommendations, neutral from the network point of view. Drive reaches unity harmonic drives
such as IEEE 519 and G5/4. The total harmonic current power factor. This high power-factor indicates that electrical have the built-in Active power
Active power
distortion is typically <3% in nominal situation and energy is used efficiently. feature for
undistorted network. reactive power
compensation, Reactive power
Reactive power
Diode supply Active supply 0,7 1 without any Q Q
additional
components
P P
Standard 6-pulse drive ABB ultra-low harmonnic drive
cosφ = 0,80 cosφ = 0,95
without input choke

Reduced Demand ~25% Immunity to network variations Improve System Efficiency

ABB’s ultra-low The voltage
Harmonic drives kills stabilization feature in U
+
the cause for the the ultra-low harmonic 100 %
harmonics at the source 1,35 MVA 6-pulse drive drives can boost the
and hence the demand output voltage more Supply voltage < 100 %
for the network also than the source voltage. t
U
reduces by 25% + And ensures 100%
Motor voltage ≥ 100 %
voltage at motor
1,1 MVA Ultra-low terminals consistently 100 %
harmonic despite of input
drive
fluctuations. t

© 2024 ABB. All rights reserved. Slide 5

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ABB’s Ultra-low harmonic drives
Why the THDi matters?

What is THDi?
– THDi is the total harmonic distortion of the current waveform
– The total amount of harmonics is expressed as a THD% value
Why lower THDi is better?
– Less heating, less losses, lower energy cost
– Less heating, less premature component failures, longer
lifetime
– Less disturbances on the network, less interference with other
components, more reliable and stable system
What it says in the spec and how to comply?
– referring to standards IEEE519:2014 or G5/4
– THDi limit < 8% → Offer majority as ULH drives
– 8%< limit < 40% → Offer minimum amount of ULH, Calculate
system harmonics
– If limit >40% → Use 6-pulse units

AVR – active voltage regulator

© 2024 ABB. All rights reserved. Slide 6
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ABB’s Ultra-low Harmonic Drives
Harmonic mitigation built-in

4.5 %

4.0 %
Line Active
supply unit
filter 3.5 % THDi <
3.0 % 3%
2.5 %

2.0 %
M
1.5 %

1.0 %

0.5 %

0.0 %
50 150 250 350 450 550 650 750 850 950 1050 1150 1250 1350 1450 1550 1650

40% THDi means 1,16 times higher energy losses, and

~10% to 20% reduction in installation cost
if using ABB’s Ultra-low Harmonic Drives 60% THDi means 1,36 times higher energy losses.

© 2024 ABB. All rights reserved. Slide 7

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ABB’s Ultra-low Harmonic Drives
True Power Factor as Unity

❑ ABB’s ultra-low harmonic drives have been designed to be neutral from the network point of view.
• Drive reaches unity power factor. This high power factor indicates that electrical energy is used efficiently.

❑ The lower the power factor, the more reactive power the network needs to provide.
• Larger equipment (cables, switchgears, transformers) is required to supply power 1
• Operating costs are higher PFtotal =  cos  fundamental
THD + 1 2

0.7 1

Standard 6-pulse drive without input choke ABB ultra-low harmonic drive

© 2024 ABB. All rights reserved. Slide 8

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ABB’s Ultra-low Harmonic Drives
Reactive Power Compensation built-in

Before compensation After compensation

Active power
Active power

Reactive power
Reactive power

Q Q

P P

cosφ = 0,80 cosφ = 0,95

Avoid Power Factor penalties

if using ABB’s Ultra-low Harmonic Drives

© 2024 ABB. All rights reserved. Slide 9

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ABB’s Ultra-low Harmonic Drives
Avoid oversizing of Transformer
𝐏𝐧 𝟏 𝟏 𝟏 𝟏 𝟏. 𝟎𝟓
Standard 6-pulse drive with 1000 kW motor
𝐒𝐧 ≥ × × × × ×
𝛈𝐦 𝛈𝐫 𝐤 𝛈𝐟 𝐜𝐨𝐬 ∝ 𝟎. 𝟗𝟓
• Due to harmonic content, transformer load ability is 0.85. When also
efficiencies, power factor and voltage drop are taken into account,
apparent power required to be supplied by the transformer is Transformer loadability
1
Sn ≈ 1.35 x Pmotor ≈ 1.35 x 1000 ≈ 1350 kVA 0.9

Ultra-low harmonic drive with 1000 kW motor 0.8

• Due to low harmonic content, transformer load ability is 1. When also 0.7
efficiencies, power factor and voltage drop are taken into account,

k - factor
0.6
apparent power required to be supplied by the transformer is
0.5

Sn ≈ 1.1 x Pmotor ≈ 1.1 x 1000 ≈ 1100 kVA 0.4

0.3

• Drivesize software uses these formulas for transformer 0.2

dimensioning. 0.1
0
500 1000 1500 2000 2500 3000 4000

ULH drive
Up to 25% smaller transformers sizing Sn (kVA)

Up to 50% smaller generator sizing 6 pulse drive

© 2024 ABB. All rights reserved. Slide 10

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ABB’s Ultra-low Harmonic Drives
Switchgear / circuit breaker/ fuse sizing

Reactive currents increase current in power network

components, meaning higher losses, overheating,
malfunctioning and premature failure
Even small harmonic currents may lead to a step up in a
+
switchgear size or result in an extra busbar per phase in a
circuit breaker 6-pulse drive
Circuit breakers can unexpectedly trip and fuses blow up

+
Ultra-low
harmonic drive

~10% to 30% component sizing reduction

if using ABB’s Ultra-low Harmonic Drives

© 2024 ABB. All rights reserved. Slide 11

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ABB’s Ultra-low Harmonic Drives
Mains Cable Sizing

Sometime installers complain that cables are of poorer

quality today – they get warmer, their insulation ages
faster, hardens and cracks
It is however more likely due to the cable dimensioning for TDD Oversize
the fundamental current, which does not include the 10% 1.00
harmonics load
20% 1.02
30% 1.04
There's a dimensioning guideline depending on TDD for 40% 1.08
cables:
50% 1.12
60% 1.17
70% 1.22

Up to 30% cable size down

if using ABB’s Ultra-low Harmonic Drives

© 2024 ABB. All rights reserved. Slide 12

— 2
U 
ABB’s Ultra-low Harmonic Drives Maximum Torque: Tmaxmot  n
 f 

Electrical motor sizing Max. torque ratio:

Tmaxmot

nn  U n2
TN 2  n s  PN  X k

Un
Flux:  
… voltage drop is critical because the motor may not have enough f
torque to start the load!

Motor torque ≈ f(U²)

NOTE: Exponent may be between 2.0 and 2.5, depending on
saturation Constant flux range Field weakening range
Terminal Motor
Voltage Torque
100% 100%
90% ≤ 81%
80% ≤ 64%
65% ≤ 42%
50% ≤ 25% 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Voltage Flux Torque max

Up to 30% optimized motor size
if using ABB’s Ultra-low Harmonic Drives Relative speed

© 2024 ABB. All rights reserved. Slide 13

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ABB’s Ultra-low Harmonic Drives
Voltage drop compensation

Supply voltage Voltage drop over supply cables Input voltage Motor voltage
400 V 370 V 370 V
Transformer 6-pulse drive Motor

Supply voltage Voltage drop over supply cables Input voltage Motor voltage
400 V 370 V 400 V
Transformer ABB ULH drive Motor

No need of Step-up trafo. or oversized motors

if using ABB’s Ultra-low Harmonic Drives

© 2024 ABB. All rights reserved. Slide 14

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ABB’s Ultra-low Harmonic Drives
System efficiency over component efficiency

10%
harmonic
content
Network Passive filter 6-pulse drive Actual motor efficiency due to drive Motor voltage after Network eff x PF eff x Drive eff x Motor eff
Supply voltage
efficiency efficiency efficiency waveform and lower motor voltage system losses = 0.98 x 0.985 x 0.98 x 0.92 =
400 V/480 V
~ 98% 98.5%1 98% 92% ~ 370 V/ 450 V 87%

5%
harmonic
content
Supply voltage Network Active filter 6-pulse drive Actual motor efficiency Motor voltage after Network eff x AF eff x Drive eff x Motor eff
400 V/480 V efficiency rated efficiency efficiency at nominal motor voltage system losses = 0.98 x 0.97 x 0.98 x 0.92 =
~ 98% 97% 98% 92% ~ 380 V/ 460 V 85.7%

3%
harmonic
content
Network ABB AFE drive Actual motor efficiency Motor voltage after Network eff x Drive eff x Motor eff
Supply voltage
efficiency efficiency at nominal motor voltage system losses = 0.98 x 0.97 x 0.925 =
400 V/480V
~ 98% 97% 92.5% ~ 400 V/ 480 V 87.9%

1. Full harmonic performance only in full load

Note: Standard drive has higher efficiency than AFE, but the efficiency drop in the passive or active filter and the lower motor voltage make the system efficiency
lower meaning higher operating costs.
© 2024 ABB. All rights reserved. Slide 15
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Selecting a drive technology for buildings
Effect on capital investments with ABB ULH drives
Distribution transformer
10% size
6-pulse drives need transformer
down with AFE
oversize by 1.35 x motor kVA.
With AFE drives, the factor is 1.1.
Cabling
Oversizing depends on the
20% size harmonics content in the grid
down with AFE
TDD Oversize
10% 1.00
~10-30% 50% 1.12
size down with AFE
70% 1.22

Switchgear and breakers Generator 50% size

down with AFE
Even small harmonic currents may lead to Generator supplying 6-pulse
a step up in the switchgear size or result in drives to be derated by 40-50%.
an extra busbar per phase in the circuit breaker Avoided if using AFE drives

© 2024 ABB. All rights reserved. Slide 16

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ABB’s Regenerative Drive
Reduced Component

ABB regenerative drives have all inside: line filter, active supply unit and
inverter come in one extremely compact package Resistor braking
• Small footprint Drive Chopper Resistor Cooling
• No need for additional engineering
• No need for additional braking choppers or resistors + + +
• No need to add cooling to remove the heat generated
by mechanical or resistor braking
• Possibility for cabinet free installation
Regenerative braking
Line Filter Active Supply Unit Inverter Unit

+ +

ABB’s regenerative braking solution

Upto 85% space savings Everything integrated One module

if using ABB’s Ultra-low Harmonic Drives

© 2024 ABB. All rights reserved. Slide 17

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ACS880 Regenerative or ULH drives common DC solution
Energy efficient and Ultra low harmonic system

Regenerative drive in Common DC system

One ACS880-11/14 connected to AC supply with multiple DC
connected ACS880-01 drives Supply network

Benefits
• Share braking energy in DC link
• Return excess braking energy to the supply
Common DC link
• ACS880-11/14 rated for continuous full power regeneration
• Voltage stabilization feature maintains constant DC link voltage
even if AC supply voltage is unstable
• Connection to supply network is clean; Meets IEEE519,
IEC61000-3-12 and G5/5 harmonic standards at all load
conditions
• Unity power factor reduces supply losses

*ACS880-31/34 can also be used as AC sourced drive, which will

them make a low harmonic system without regeneration. ACS880 Regen or ACS880-01 ACS880-01
ULH

© 2024 ABB. All rights reserved. Slide 18

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ACS880 Regenerative or ULH drives in common DC system
Applications

Crane benefits with regenerative drive and common DC system

ACSS880-11 used on vertical movement (Hoist)

• Regenerative braking, no brake chopper and resistor, no losses

• Hoist braking energy returned to supply
• Clean supply connection and unity power factor
• DTC motor control
• Integrated Crane control program
• Integrated Functional safety; Safe Brake Control, Safe Stop, STO
• IEC and adaptive programming

ACS880-01 used on Horizontal movements (Bridge, Trolley)

• Integrated crane control features
• Integrated Functional safety; STO
• Master follower arrangement can be used for Parallel Bridge
motors
• IEC and adaptive programming

© 2024 ABB. All rights reserved. Slide 19

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Tool for Harmonic
Comparision
 CONFIDENTIAL

—
Harmonic Estimator
Results

Harmonic result summary Colour coding

Real time calculation summary is shown in Colour coding makes it easy to wether
right side of the main view. the total values meet the requirements
or not
Calculated Current Total Demand
Distortion (TDD) compared to limit / Green colour and symbol indicates that
recommendations. calculated value is under the limit
Calculated Voltage Total Harmonics
Red colour and symbol indicates that
Distortion (THD) compared to limit /
calculated results are exceeding the
recommendations.
limits
Short circuit current and load current
ratio Limit/Recommendation is shown next
after calculated value and valid for short
Primary side summary is always visible circuit ratio
Secondary side summary is shown if the
PCC is at secondary side of transformer

S
l ©July
202424,
ABB.2024
All rights reserved. Slide 21
i
 CONFIDENTIAL

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Harmonic Estimator
Report sheet

Project data, results, Harmonics content in Harmonic components in Network, loads and details
statements and notes graphical form numerical form

© 2024 ABB. All rights reserved. Slide 22

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Packaged Drives offer
its benefits to Customer
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ACx580 Packaged Drive offering
(Built-in Fuse + Disconnect variants)

Offered in ACS580 / ACH580 / ACQ580 Ready to use Plug and Play wall mount unit

Available in IP21 or IP55 ingress protection ABB Standard design and dimensions

Offered in Inline design in R1 to R4 (upto 45kW) Built-in protection devices and disconnect option

Offered with separate IP55 disconnector box in All-Compatible features and parameterization
R5 to R8 (45kW to 160kW)
Fully enclosed design for human and machine safety

Reduce order to installation time

ACX580-PDR-XXXA-4 + XXXX Ease to plan machine design

One stop shop for drive and protection accessories

© 2024 ABB. All rights reserved. Slide 24

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ACx580 Packaged Drive offering
Targeted applications

Tunnel Ventilation, AHU (HVAC)

– Less space & Built-in protection

OEMs Crusher (MH)

– Skid Mounting -Remote site

Air Compressor Ammonia / CO2

(Machinery) Compressor (F&B)
- Fit & forget - Readymade
Solution

Fan (Cement, COG)

– Perfect fit for site Reactors (Pharma)
environment – Easy Installation

Pump (Water, Sugar, Metals)

– Proximity to motor

© 2024 ABB. All rights reserved. Slide 25

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ABB Drive + SynRM
for Premium Efficiency
—
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A complete drive
product portfolio
Optimized package selections
available in the catalogues
ABB offers a range of SynRM motor and drive packages
with verified performance and efficiency!

ACS580/ ACH580 / ACQ580 & ACS880 variable speed

drives
• SynRM optimized drive types in the catalogue
• For all applications including water and wastewater,
HVAC, food and beverage and many more
• Support various motor types including induction,
permanent magnet, and synchronous reluctance motors

© 2024 ABB. All rights reserved. Slide 27

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Practical guidance to an easy comparison
IE5 vs IE3 in VSD duty

How to calculate motor efficiency with VSD supply Performance at nominal speed
if only motor DOL efficiency is known? IE class acc. Motor Typical IE3
to IEC TS efficiency with induction
Add additional losses as given in IEC TS 60034-30-2 60034-30-2 VSD supply motor
• 15% additional losses for motors up to 90kW TN=100% efficiency with
Output kW Type designation Product code nN=100% VSD supply1
• 25% additional losses for motors above 90kW 1500 r/min (50 Hz) 400 V network
15 kW IE3 motor DOL efficiency 92,1% 5.5 M3AL 132SMA 4 3GAL132213-•SC IE5 93.7 88.2
Same motor with VSD supply 91,0% 7.5 M3AL 132SMB 4 3GAL132223-•SC IE5 93.7 89.1

This is the right value to compare against SynRM 11 M3AL 132SMC 4 3GAL132233-•SC IE5 94.2 90.2
94,8% 11 M3BL 160MLA 4 3GBL162413-•SC IE5 94.0 90.2

→ approximate improvement in Drive+Motor 15 M3BL 160MLB 4 3GBL162423-•SC IE5 94.8 91.0

package as whole is 3.8%

Typical IE3 induction motor efficiency with VSD supply are precalculated in SynRM catalogue

1. Additional motor losses acc. to IEC TS 60034-30-2

© 2024 ABB. All rights reserved. Slide 28
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IE5 SynRM + Drive vs. IE3 motor + Drive
Full load and part load efficiency

ABB measurements confirm SynRM efficiency advantage also

at partial load conditions

There is about a 2-3% of benefit at full load, while at partial

load the benefit can be as much as 6-7%

IE5 + VSD vs. IE3 + VSD payback calculation can be done

by comparing nominal point efficiency
Partial load efficiency not critical as the power consumption
is also much less

Using “average power” to assume VSD duty

Payback calculation can be done with nominal point efficiency comparison

Typical behavior based on ABB measurements

© 2024 ABB. All rights reserved. Slide 29