York MILLENIUM 351-46, Operating Instructions Manual, Page: 8 / 24

JOHNSON CONTROLS
8
FORM 160.00-O1 (1020)
to form a capacitor “bank”. In order to assure an equal sharing
of the voltage between the series connected capacitors and
to provide a discharge means for the capacitor bank when the
VSD is powered off, “bleeder” resistors (3RES and 4RES) are
connected across the capacitor banks.
The DC to AC inverter section of the VSD (See Fig. 2), serves
to convert the rectified and filtered DC back to AC at the mag -
nitude and frequency commanded by the VSD Logic board.
The inverter section is actually composed of three identical
inverter output phase assemblies. These assemblies are in
turn composed of a series of Insulated Gate Bipolar Transistor
(IGBT) modules (Q1-Q4) mounted to a liquid cooled heatsink, a
filter capacitor “bank” (C13-C20) and a VSD Gate Driver board
(031-01476) which provides the On and Off gating pulses to
the IGBT’s as determined by the VSD Logic board. In order
to minimize the parasitic inductance between the IGBT’s and
the capacitor banks, copper plates which electrically connect
the capacitors to one another and to the IGBT’s are connected
together using a “laminated bus” structure. This “laminated
bus” structure is a actually composed of a pair of copper bus
plates with a thin sheet of insulating material acting as the
separator/insulator. The “laminated bus” structure forms a
parasitic capacitor which acts as a small valued capacitor,
effectively canceling the parasitic inductance of the busbars
themselves. To further cancel the parasitic inductances, a se-
ries of small film capacitors (C43-C51) are connected between
the positive and negative plates of the DC link. To provide
electrical shielding for the VSD Gate Driver board, an IGBT
driver “shield board” (031-01627) is mounted just beneath the
VSD Gate Driver board.
The VSD output suppression network is composed of a
series of capacitors (C61-C66) and resistors (5RES-10RES)
connected in a three phase delta configuration. The param -
eters of the suppression network components are chosen
to work in unison with the parasitic inductance of the DC to
AC inverter sections in order to simultaneously limit both the
rate of change of voltage and the peak voltage applied to
the motor windings. By limiting the peak voltage to the motor
windings, as well as the rate-of-change of motor voltage, we
can avoid problems commonly associated with PWM motor
drives, such as stator-winding end-turn failures and electrical
fluting of motor bearings.
Various ancillary sensors and boards are used to convey
information back to the VSD Logic board. Each liquid cooled
heatsink within the DC to AC inverter section contains a
thermistor heatsink temperature sensor (RT1 - RT3) to provide
temperature information to the VSD logic board. The AC to
DC semi-converter heatsink temperature is also monitored
using thermistor temperature sensor RT4. The Bus Isolator
board (031-01624) utilizes three resistors on the board to
provide a “safe” impedance between the DC link filter capac -
itors located on the output phase bank assemblies and the
VSD logic board. It provides the means to sense the positive,
midpoint and negative connection points of the VSD’s DC link.
A Current Transformer (3T - 5T) is included on each output
phase assembly to provide motor current information to the
VSD logic board.
Harmonic Filter Option
The VSD system may also include an optional harmonic filter
designed to meet the IEEE Std 519 -1992, “IEEE Recom-
mended Practices and Requirements for Harmonic Control
in Electrical Power Systems”. The filter is offered as a means
to “clean up” the input current waveform drawn by the VSD
from the power mains, thus reducing the possibility of causing
electrical interference with other sensitive electronic equipment
connected to the same power source.
Figure 3A is a plot of the typical input current waveform for
the VSD system without the optional filter when the system
is operating at 50% load. Figure 3B is a plot of the typical
input current waveform for the VSD system with the optional
harmonic filter installed when operating at the same load
conditions. The plots show that the input current waveform
is converted from a square wave to a fairly clean sinusoidal
waveform when the filter is installed. In addition, the power
factor of the system with the optional filter installed corrects
the system power factor to nearly unity.
The power section of the Harmonic Filter is composed of four
major blocks: a pre-charge section, a “trap” filter network,
a three phase inductor and an IGBT Phase Bank Assembly
(See Fig. 4).
The pre-charge section is formed by three resistors (11RES
- 13RES) and two contactors, pre-charge contactor 2M, and
supply contactor 3M. The pre-charge network serves two pur-
poses, to slowly charge the DC link filter capacitors associated
with the filter Phase Bank Assembly (via the diodes within the
IGBT modules Q13-Q18) and to provide a means of discon-
necting the filter power components from the power mains.
When the drive is turned off, both contactors are dropped out
and the filter phase bank assembly is disconnected from the
mains. When the drive is commanded to run, the pre-charge
resistors are switched into the circuit via contactor 2M for a
fixed time period of 5 seconds. This permits the filter capac -
itors in the phase bank assembly to slowly charge. After the
5 second time period, the supply contactor is pulled in and
the pre-charge contactor is dropped out, permitting the filter
Phase Bank Assembly to completely charge to the peak of the
input power mains. Three power fuses (11FU -13FU) connect
the filter power components to the power mains. Very fast
semiconductor power fuses are utilized to ensure that the
IGBT modules do not rupture if a catastrophic
failure were to