‘aare020 Power Distibston in Indust —Al You Need to Know ‘SPONSORED SEARCHES how to calculate earthing cable size earthing lead siz« calculation of earthing conductor size Q earth wire size How to Find the Size of Earth Conductor, Earthing Lead & Earth Electrodes? @clectrical Technology 10 MS minutes read Find TDK here Wecanp solutic of products i TDK Corporation Calculate the size of Earth Continuity Conductor, Earthing Lead & Earth Electrodes? For earhing or grounding purposes, the size of earth continuity conductor, earthing lead and earth electrodes depend on wiring cables used in the system. Solved example given below will make the point easy to understand that how to determine the proper size of earth conductor, earth lead and earth electrodes in a specific installation. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 17rsr020 Power Distbution in Industries — All You Need to Know How to Find the Size of Earth Conductor, Earthing Lead & Earth Electrodes? Table of Contents 1. Finding the Size of Earth Conductor, Earth Lead & Earth Electrode in Factory (Solved Example) 2. Finding the Size of Earth Conductor: 3, Finding the Size of Earth Leads: 4. Finding the Size for Earth Plates & Earth Electrodes Finding the Size of Earth Conductor, Earth Lead & Earth Electrode in Factory (Solved Example) Below is the solved example for earthing & grounding installation in factory. The layout is shown below in fig 1. Example: © wancelectrcatlechnology. org Transformer ‘Main & Sub main Cable runs ‘ecoming Supply Factory Layout as Detailed in Example hlpe:ihwwnelectcaltechnology.org/2015)1Tipower-dstbutionsn-indusries him! 27‘aare020 Power Distibston in Industies —Al You Need to Know Find the proper size of earth conductor, earth lead and earth electrode for earthing and grounding system in the factory installations. Details and description of the given load (electric devices and equipment in the factory) as follow: 1. Motors 2.No of 50hp, 415V three phase induction motors and size of the cable connected to the motors is 19/,064. + 1No of 20hp, 415V, three phase induction motor and size of the cable connected to the motor is 7/.064. + 2.No of 15hp, 415V, three phase induction motor and size of the cable connected to the motor is 7/.052. + 3.No of 10hp, 240V, single phase induction motor and size of the cable connected to the motor is 19/.052. + 12.No of 2hp, 240V, single phase induction motor and size of the cable connected to the motor is 7/.036. 2. Transformer There is a 250kVA, three phase 11kV/400V (Step down) transformer installed in the factory which neutral have to be earthed. Size of the cables connected to LT (Low Tension) is 37/.083. 3. Water Level Water level is deep about 30f. Solution: htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him!rsr020 Power Distbution i Industries — All You Need to Know IEC 6089: Category 1&2 flash protectio Alsico USA Finding the Size of Earth Conductor: Layout of the complete factory earthing and grounding system is shown in fig 2 below. Here, the biggest possible source of fault current is transformer, therefore, at least one earthing plate should be installed near to the transformer and the proper location for earth plate installation (for transformer) is shown in fig 2 (Position A). Since the water level is deep about 30ft, therefore, we have to dig about 30ft coined and both of the plate can be installed in the same pit then (By doing so, we don't need two pits as well as, it reduce the installation cost as well). However, for better safety purposes, another pit about 12f can be dug (on Position B) near to position A for second earth plate installation, Also, make sure that water purring is possible when needed. A connecting point near to main switch board is made at point C. The second point at D and third one at E which is tight below the combination switch fuse board and above the cable ducting, These points are connected via wires flowing through cable ducts. Since the example is fully related to the earthing of electrical apparatus only, therefore, there are two separately earth continuity conductor in whole factory (earth continuity conductors of other metalwork i.e. distribution fuse boards, switch fuses and other electrical wiring ete are not shown in the fig due to complexity) htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! a7rsr020 Power Distbution in Industries — All You Nees to Know * Also read: Types of Electrical Wiring After proper selection of plates and connecting points, now we can find the proper size of earth continuity conductor and earth lead with the help of the following table no 1. In this table, suitable size of earth continuity conductor is given for each size of cable. For simplicity, the whole earthing scheme of the factory is divided in three sections. Transformer LAYOUT OF COMPLETE FACTORY EARTHING & GROUNDING SYSTEM Explanation of each section is as follow: Section A: According to table 1 + Earth continuity conductor to SOhp motor (19/.064 cable) = 4 SWwG + Earth continuity conductor to 20hp motor (7/.064 cable) = 10 swe + Earth continuity conductor to 1Shp motor (7/.052 cable) = 12 swe + Earth continuity conductor to 10hp motor (19/.052 cable) = 6 swe htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! s7rsr020 Power Distribution in Insts — Al You Need to Know In this section, the biggest motor is 50hp, therefore, the central pair of earth continuity conductor should able to pass any value of fault current produce in the motor. In this section, since each motor of 50hp is installed on the far end of the distribution system, therefore, the size of each earth continuity conductor around this section ASWG, The proper sizes of earth continuity conductors for other small motors to the main pairs also given in table 2.2. Section B: ‘SPONSORED SEARCHES how to calculate earthing cable size Q earthi calculation of earthing conductor size Q earthing c According to the table, the earth conductor sizes are as follow for this section. + Earth continuity conductor to 10hp motor (19/.052) = 6 SWG + Earth continuity conductor to 2hp motor (7/.036) = 14 SWG The distribution system in this section is designed such a way that the size of each earth continuity conductor (from 10Hp motor to the connecting point E) is 6 SWG but, for 2Hp motors, the size of earth conductor is 14SWG. There would be a safe path, if fault occurs at 10Hp motor side. Section C: The size of earth continuity conductors for this section is as follow: + Earth continuity conductor to Shp motor (7/.052) = 12 SWG + Earth continuity conductor to 10hp motor (7/.036) = 14 SWG The size of earth continuity conductor from 15Hp to connecting point D is 12SWG while for 2Hp (each) motor, the conductor size would be 14SWG, Related Posts htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! earrsr020 Power Distibston in Industies —Al You Need to Know * How to Find the Proper Size of Circuit Breaker? Breaker Calculator & Examples + How to Find Voltage & Ampere Rating of Switch, Plug, Outlet & Receptacle * How to Find The Suitable Size of Cable & Wire for Electrical Wiring Installation Finding the Size of Earth Leads: Now we can find the proper size of earthing leads. Since the cable size of transformer on L.T side is 37/.083. So we can use 3/0 SWG copper wire (or 3/16 x % or 1/8 in) Copper strip. If fault occurs at transformer, then fault current will flow through the earth plat A or B or both at once and it depends on the earth resistance as well. Therefore, the earth leads should able to pass the fault current. For this purpose, we should use 3/0 SWG for all earth leads from transformer to C, C to A, C to D, and D to B. Since the Transformer fault current will not flow in wires between E to D, therefore, it size should be 4SWG (which is equal to the big earth continuity conductor connected to E). Finding the Size for Earth Plates & Earth Electrodes Since both earth plates are below from water level, therefore, 2ft x2ft x 1/8 plate size is most suitable for each main and secondary plate. Continuity should be well after testing the system but also consider the earth resistance as well. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 87rsr020 Power Distbution i Industries — All You Need to Know IEC 6089: Category 1&2 flash protectio Alsico USA If the earth resistance increases than 19, in that case, additional plates can be used in parallel with secondary plate to minimize the total resistance of earthing and grounding system. Table 1. Earthing Conductors Size of copper wire and Strip for earth continuity conductor and earth leads. Table 2. Size of Earth Wire in SVG and Earth Electrode for Motors and Other Electrical Apparatus, Devices and Equipment. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! arrsr020 Power Distbution in Industries — All You Need to Know Nos xem x 8mm 600m x 60m x rm Coe Nos ‘em x 30em x en No2erste tonne = steams iam de Note: Perform a continuity test for earthing installation to make sure everything is working as expected. Related Posts: ‘* Difference Between Grounding, Earthing and Bonding ‘« Difference between Real Ground and Virtual Ground? * Difference Between Neutral, Ground and Earth * How to Find the Size of Earth Conductor, Earthing Lead & Earth Electrodes? ‘« Design of Grounding / Earthing System in a Substation Grid * Different Types of Electrical Wiring ‘Step by Step Home Electrical Wiring Installation Tutorials ‘The purpose of Earth or Ground wire in overhead Transmission lines. Electrical UKs largest Ce Cleveland Cable Company ‘© toos | Earth Conductor ath Electode Earhing Earhing Lead hlpe:ihwwnelctcaltechnology.org/2015)1Tipower-dstbutionsn-ndusries him! 97rsr020 Power Distbution in Industries — All You Nees to Know Electrical Eerthing & Grounding Types of Earthing SHOW ALL COMMENTS lp: elacrcaltechnology.org/201 5/1 ipower-dstbutionsn-ndustries him! 10187rsr020 Power Distbution in Industries — All You Nees to Know SPONSORED SEARCHES cable size calculator Q 12 volt power distributi distribution board price list Q entertainment power c Power Distribution in Industries — All You Need to Know @ Electrical Technology 3 M7 minutes read See TDK’: here With a wide va we offer suitak applications TDK Corporation Power Distribution in Industries — Everything You Need to Know Table of Contents 1, Structure of Power Distribution in Industries Low Tension (LT) Panel Al Circuit Breaker (ACB) Bus Bar and Connections Bus Coupler Capacitor Bank Metering and indication 8. Sub-LT Panels hitpsiwuuelectricatechnology.org 2015! /power-dribution-nindusties him! ser NOBEONrsr020 Power Disibstion in Industries ~ Al You Nee to Know 9. Sub-Distribution Boards 10, Power Distribution Boards (PDBs) 11. Lighting Distribution Boards (LOBs) Today we are intended to take you to the industrial environment by giving the picture of how an electric power distributed in industries. In industries, electrical panels play a major role in distributing the power that houses various equipments such as bus bars, circuit breakers, meters, ete These panels are distributed over various sections of an industry in order to supply the power to individual installed systems and are connected through cable ducts. Let's look on this concept in brief INDUSTRIES Structure of Power Distribution in Industries In an industrial electric power system, electric power is supplied from either private utilities or public utilities, or both. The supplied voltage is in the range of 11KV, 33KV, 66KV or 132KV. These high voltages are stepped down to a low voltage using step-down transformers, The voltages in the range of 440 volts or below are called as low tension systems. This stepped voltage is further supplied to various panels and equipments through a switchgear arrangement that consisting of clecirical switches, circuit breakers, fuses, protection equipment, metering boards, etc, htpshwwa electicatechnology.org2018/11/power-dstributon-n-industies him! varrsr020 Power Disbution in Industries — All You Nees to Know a F rae) The figure below shows a schematic diagram of the power distribution. This model scheme is mostly employed for large and medium scale industries. In some cases, sub-LT panels are not found; instead power is supplied directly from LT panels to SDBs depending upon the size of distribution area where the number of units (or sections) to be supplied is the major consideration. In the above figure, the elements in this power distribution model included LT panel, sub-LT panel, SDB (sub-distribution board), PDB (power distribution board) and LDB (lighting distribution board). Various transformers supply is given to the LT panels, which acts as a main switching system for entire power distribution scheme and carries the total load demand. We will discuss the elements inside of the LT panels in brief later in this article. The output feeders of the LT panel are connected to sub-LT panels which are placed for a group of loads over a given section to supply the demand. The sub-LT panel incomer is applied at SDB which are placed for supplying the power to loads that consists of a group of machineries hlpe:ihwwnelctcaltechnology.org/2015)1Tipower-dstbutionsn-ndusries him! 13197asa2020 Power Disibstion in Industries ~ Al You Need to Know such as electrical furnaces, hoists, etc. (that are connected to various PDBs). PDBs acts like an actual power connection of load to source where individual machinery is connected directly to the supply. And part of the power from PDB is supplied to LDBs where it supplies the power to lighting equipment such as street lights (See simple Street light project here), lighting in the working area, plug boards etc. All the panels in the distribution system are ground with a proper grounding & earthing to protect the appliances as well as operating personnel. Low Tension (LT) Panel LT Panel & Power Factor Panel with Change-Over Swit The switchgear arrangement on each distribution side is housed in metalenclosed structures called as LT (low tension) panels. These LT panels are responsible for distributing the power to various sub LT panels by receiving it from the transformer. These are rated for 430 V, 3-phase, S0Hz three or four wire system htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! warrsr020 Power Distbution in Industries — All You Nees to Know It is a floor mounted free standing unit and it is totally closed and extensible type. Its design includes all provisions for safety of operation as well as for maintenance personnel. The internal connection for the LT panel is shown in figure below. Air Circuit Breaker (ACB) It makes or breaks the circuit either manually or remotely controlled during normal operating condition and break the circuit during fault condition automatically. These can be 3/4 pole type with a rating decided by the load current (or breaking capacity) and can be either drawn out or fixed type. ACBs (Air Circuit Breaker) consist of necessary bus bars to connect the terminals with bolted type neutral links. These are provided with microprocessor systems to enable protection systems like overload, earth fault and short circuits. ACB also gives the necessary indication and meterina requirements with the use of CTs, lamps, ammeter, hitpsiwuucelectricatechnology.org 2015! /power-dtribution-n-industies him!rsr020 Power Distbution i Industries — All You Nees to Know voltmeters, etc. Bus Bar and Connections Bus bars are made with high conductivity copper (in some cases, aluminum bus bars are used to reduce the cost). LT panel consists of a system of main horizontal bus bars and auxiliary vertical bus bars in bus bar alleys on which panel could be arranged with front access to connect cables. The outgoing cables are connected to the bus bars either as a solid or flexible connection depends on the panel manufacturer. All bus bars are suitably insulated / sleeved in approved manner. Bus bars collect the supply from transformer terminals and supply it to the various elements in the panel such as ACBs, capacitor bank switch gear, and other connected loads. The bus bars can be run at either top or bottom, or both sides of the panel, but mostly top side bus bars takes the transformer supply while bottom side bus bars take the supply from DG (Diesel Generator) set. Bus Coupler It couples one bus bar with other bus bar of different source (but the rating should be same) without creating any arcs or interruption to the supply system. In case of maintenance of other circuit breakers on the same panel this bus coupler diverts the supply source to the other. It is also a switchgear arrangement with ACB and provided with interlocking facility, It is a separate panel that consisting of bus bars, \CCBs, tuned reactors, capacitor units, contactors, metering equipment, and cables, It is also called as automatic power factor correction panel (APFC). This panel is connected to the LT panel with ACBs and other switchgear arrangements through cables. The capacitors and reactors are of an indoor type with air cooled units. The capacitor banks are connected across the supply to htpshwwa electicatechnology.0rg2018/11/power-dstribution-n-industios him! 1697rsr020 Power Distbution in Intros — All You Nees to Know improve the power factor 0 f the system. Capacitors are switched automatically (through programmable devices) or manually (by switches) depending on the amount of reactive power to be compensated. Metering and indication Voltmeters, ammeter and power factor meters in LT panel indicate various parameters and these are protected with CBs. On all LT panels, indicating lamps (mostly LED lamps) are provided for each phase for indicating live or fault condition, Start and stop push buttons also provided on metering panel to give input commands such as turn ON supply and emergency stop. Sub-LT Panels These panels are similar to the LT panels, however rating of these panels is somewhat less than LT panels and also these are placed in a particular section of an industry (such as assembling section or htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! werrsr020 Power Distibston in Industies —Al You Need to Know dispatching section) instead near the transformer as in case of LT panel. These are acts as mains for various SDBs, because these panels distribute the power to the SDBs by receiving it from LT panels. The internal circuitry is same as that of LT panel such as bus bars, capacitor bank connections, ACBs, metering panels (bus couplers may not be included in most cases). These panels also consist of utilities bus bar chamber as well as DG (diesel generator) set bus bar chamber so that some loads (SDBs) can be switched to DG supply during less amount of power supplied from utilities. However, most cases DG chamber may not be included in sub-LT panels instead it is placed in LT panel itself. Sub LT panels also include capacitor banks or APFC unit to improve the power factor. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 1897rsr020 Power Distbution in Industries — All You Nees to Know Sub-l ution Boards These are available in standardized and customized designs from various manufacturers. SDBs consist of bus bars (copper or aluminum) that receive power supply from either sub-LT panels or main LT panels and then distribute it to various heavy rated machineries (such as furnaces, chillers, water pumps, ovens, etc.) and PDBs (power distribution boards). It receives the power (i.e., incomer) through ACB or MCCB and distributes through outgoing MCCBs or SDFUs (Switch-Disconnect- Fuses). The SDFUs consists of switches in series with fuse links (high breaking capacity HRC fuses) with mechanical structure for manual operation. These switching units are used for load switching, isolation and short circuit protection. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 19097rsr020 Power Distbution in Industries — All You Nees to Know Switeh Disconnector Fuse Unit (SDFU) Some SDBs also consists of capacitor banks especially that (SDBs) are provided to supply heavy inductive loads in order to improve the power factor, SDBs use bus bars to enable connection of all the SDFUs and other devices inside of it through the bus bar chamber, also enables the outgoing connections though high capacity cables in the cable chamber. Each load switching compartment is provided with permanent identification labels, indication lights and metering equipment (if necessary). The figure below shows the schematic diagram of an SDB. ‘Schematic diagram of an SDB. Power Distribution Boards (PDBs) These ara desianed to distribute the nawar ta varinus machines and htps:hwwa electicatechnology.org2018/11/power-dstributon-n-industios him! 20197rsr020 Power Distbution in Industries — All You Need to Know equipment, even in big building we can observe such arrangement of power distribution through PDBs. PDBs are built with short circuit as well as overload protection systems. These are fitted with different protective relays that can trip the different CBs (of high capacity) against various types of faults. PDBs are metal enclosures that consist of various MCBs that are mounted on a metal fixture which connects the various power equipments like motors and also distributes the power to various LDBs. PDBs receives the power from various SDBs and correspondingly supplies to the loads adjacent to it. So these are placed near the application concemed, such as conveyor switching, lift and hoist machinery, pump control sets, etc. htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! 2097rsr020 Power Distbution in Industries — All You Nees to Know * Also read: Three Phase ectrical Wiring Installation in Home These can be wall mount or floor mount depends on the customer requirement as well as power it is rated for. In addition to SDBs incomer, some PDBs are supplied with UPS (uninterrupted power supply) as an auxiliary power source to enable continuity of service of the equipment during power outages. Lighting Distribution Boards (LDBs) These are the final switch boards (In electrical wiring & installation) and are located at small electrical loads switching areas including lighting, air conditioners, small motors switching, distribution boards for plugging portable devices like blowers, etc. We can also observe these LDBs in our homes and offices as they are employed in low switching operations. Click here to view the wiring diagram of lighting distribution board LDBs consist of various MCBs where each MCB acts as a switch for individual loads (some cases two or more lights can be connected to single MCB). These MCBs protects the loads against overload as well as short circuit conditions. These MCBs are mounted or fixed to htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! 2aa7Power Distibston in Industies —Al You Need to Know the metal racks. These boards receive the power from PDBs and then supplies to the lighting loads, Mostly these are of wall mounted type boards. Also read: Different methods of Electrical Wiring Controling Electrcal Wiring Electrical Wiring Systems Fuses HT Panel Industial Power Electrical Wiring LT Panel MCB MCCB Power Distioution Protedtion SDB Switches Switchgear htpshwwa electicaltechnology.org2018/11/power-dstributon-nindustis him! 2aa7rsr020 Power Distbution in Industries — All You Nees to Know What is DC Drive? Working and Types of DC Drives @loctrical Technology 7 M9 minutes read What are DC Drives? Analog and Digital DC Drives DC drive technology is efficient, reliable, cost effective, operator friendly and relatively easy to implement. DC drive provides many advantages over AC drives, especially for regenerative and high power applications. DC drives have been widely used in industrial drive applications in order to offer very precise control * Also read: htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 2ars7rsr020 Power Distbution in Industries — All You Nees to Know Of course, variable frequency drives (VFDs) and AC motors are now offering an alternative to DC drives and motors, but there are many other applications where DC drives are extensively used including crane and hoists, elevators, spindle drives, winders, paper production machines, crushers, etc. due to the advantages of DC drives. Table of Contents 1. What are DC Drives? Components of a DC Drive? Working Principle of DC Drives Digital and Analog DC Drives Analog DC Drives Digital DC Drives What's inside of Power Conversion make SCR DC Drives? NOAEON What are DC Drives? DC drive is basically a DC motor speed control system that supplies the voltage to the motor to operate al desired speed. Earlier, the variable DC voltage for the speed control of an industrial DC motor was generated by a DC generator. By using an induction motor, the DC generator was driven at a fixed speed and by varying the field of the generator, variable voltage was generated. Soon after this Ward Leonard set was replaced by a mercury arc rectifier and later by thyristor converters. Nowadays, the thyristor family of devices is used widely to control the speed of the htpshwwa electicatechnology.org2018/11/power-dstribution-n-industies him! 28197rsr020 hitpsuwouelecticltecnology.orgi2015!*1/power-distribution Power Distbution in Industries — All You Nees to Know DC motor. Components of a DC Drive? The main components of a DC drive system are shown in figure below. DC Drive Input: Some thyristor based DC drives operate on a single phase supply and use four thyristors for full wave rectification. For larger motors, three phase power supply is needed because the waveforms are much smoother. In such cases, six thyristors are needed for full wave rectification. Rectifier Bridge: The power component of a controlled DC drive is a full wave bridge rectifier which can be driven by three phase or single phase supply. As mentioned above the number of thyristor may vary depends on the supply voltage. A six-thyristor bridge (in case of three phase converter) rectifies the incoming AC supply to DC supply to the motor armature. The firing angle control of these thyristors varies the voltage to the motor. Field Supply Unit: The power to be applied to the field winding is much lower than the armature power, so, most often single phase supply is provided. A separate thyristor bridge or diode rectifier is used for supplying the power to the field winding of the motor. In many cases a two-phase supply is drawn from the three phase 26097rsr020 Power Distbution in Inustries — All You Need to Know Input (Inat supplies power to ine armature) ana nence tne mela excner is included in the armature supply unit. The function of the field supply unit is to provide a constant voltage to the field winding to create a constant field or flux in the motor. In some cases, this unit is supplied with thyristors to reduce the voltage applied to the field so as to control the speed of the motor above the base speed In case of permanent magnet DC motors, the field supply unit is not included in the drive. Speed Regulation unit: It compares the operator instruction (desired speed) with feedback signals and sends appropriate signals to the firing circuit. In analog drives, this regulator unit consists of both voltage and current regulators. The voltage regulator accepts the speed error as input and produces the voltage output which is then applied to the current regulator. The current regulator then produces required firing current to the firing circuit, If more speed is required, additional current is called from the voltage regulator and hence thyristors conducts for more periods. Generally, this regulation (both voltage and current) is accomplished with proportional-integral-derivative controllers. The field current regulator is also provided where speed greater than the base speed is required. htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! 20e7rsr020 Power Distbution in Industries — All You Nees to Know In modem digital microprocessor based drives, the speed control is achieved with a lookup table to determine the current for the firing circuit with additional digital circuitry. Firing Circuit: it supplies the gate pulses to thyristors so that they turned ON for particular periods to produce variable armature voltage. Isolation is also provided in this gate drive circuit Working Principle of DC Drives In DC motors, the speed is proportional to the armature voltage and inversely proportional to the field current. And also, the armature current is proportional to the motor torque. Therefore, by increasing or reducing the applied voltage, the speed of the motor is varied. However, it is possible up to the rated voltage. If the speed greater than the base speed is required, the field current of the motor has to be reduced By reducing the field current, the flux in the motor reduces. The reduction of field current reduces the armature counter emf. The more armature current flows if there is less counter armature emf. Further, this armature current increases the motor torque and hence htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 27rsr020 Power Distbution i Industries — All You Nees to Know the speed. These are the two basic principles employed in DC drives to control the speed of the motor. In armature controlled DC drives, drive unit provides a rated current and torque at any speed between zero and the base of the motor, By varying the armature voltage, variable speed is obtained as shown in figure. Generally, a fixed field supply is provided in these DC drives. As the torque is constant (which describes a load type) over the speed range, the motor output horsepower is proportional to the speed (HP = T x N/ 525). The motor characteristics of this drive are shown below. In case of armature and field controlled drives, the armature voltage to the motor is controlled for constant torque-variable HP operation up to the base speed of the motor, And for the above base speed operation, drive switches to the field control for constant HP- reduced torque operation up to maximum speed as shown in figure below. In this case, reducing the field current increases the speed of the motor up to its maximum speed as shown in figure htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 207rsr020 Power Distbution in Industries — All You Nees to Know ital and Analog DC Drives Nowadays, digital implementations have replaced analog circuitry of electric drive system in all forms of industrial control. Digital controllers offer greater flexibility to produce the precise control, setf- tuning, and ease of interfacing with host computers and other drives. However, a basic understanding of analogue version DC drive makes less difficult to understand its digital equivalent. Let us look on both of these DC drives. Analog DC Drives A standard analog DC drive with speed and current control is shown in figure below. The objective of this system is to provide speed control and hence the speed reference becomes the input to the system and speed of the motor is the output of the system which is measured by the tachometer. The working of this drive goes like this; consider that motor is running at a set speed. Now, the speed reference signal has increased to somewhat greater than the actual speed. So there will be an error speed signal at left-hand summing junction as shown in figure. This speed error indicates the required acceleration by the motor, which htpshwwa electicaltechnology.org2018/11/power-dstributon-nindustios him! 307rsr020 Power Distibuston in Industies —Al You Need to Know means the torque and hence more current. The error is amplified by the speed controller (which is basically a speed-error amplifier) and its output is given as current input reference to the inner control system, As the current reference increases, the inner current controller drives the more current to the motor thereby extra torque is provided The inner current loop is responsible for maintaining the zero current error between the actual motor current and current reference signal which means to make actual motor current to follow the reference current. The amplified current error signal from the current controller controls the firing angle of the bridge and hence the output voltage of the converter, The current feedback is achieved either by DC transformer or by AC transformer (with rectifier) in the main supply lines. This entire operation is performed by a current error amplifier with a high gain. In most cases, this amplifier is of proportional plus integral control (Pl) type circuit that maintains the actual and desired currents exactly equal under steady-state conditions, This current controller also limits the current through the motor by considering the minimum and maximum currents of the motor. The outer loop provides the speed control by comparing the actual speed obtained by the DC tachogenerator with desired or required speed from the speed reference. These two inputs are fed into the speed-error amplifier, and then resulted error is amplified and applied as an input to the current controller. The speed amplifier produces the current output proportion to the cnaed arr Far thie amniifiar alen 2 Bl rantenl ie amnlavad fh tisina htpshwwa electicatechnology.org2018/11/power-dstributon-nindustios him! sus7rsr020 Power Disbbution in Industries — All You Nees to Know SPEEU CHIE UE so aiiM HE! aHOW GFF SUrME iO UremMyoM Wy Moni analog electronics) in order to achieve zero steady state error, Using this, the actual speed of the motor is maintained exactly at reference speed for all loads. igital DC Drives With the advancements in digital control, DC drives become more flexible and faster (due to faster response times) compared with analog drives. A schematic arrangement of digital DC drive is shown in below figure; of course it is similar to the analog scheme, but here analog circuit (analog amplifiers) is replaced by digital circuitry. A speed reference signal given as the drive's input compared with the feedback speed in the summing circuit. If the output of the summing hipswnnlaccatechnoloy.og/2015!1 power dstrbutonnndusties Mim 3207rsr020 Power Distibston in Industies —Al You Need to Know circuit is positive error, indicating that a speed increase is required and if it generates a negative error, indicating that a speed decrease is required (because motor is operating at faster than desired speed). The error speed is given to the speed controller in the microprocessor which determines output voltage to operate the motor at desired speed. At the same time, current controller in the microprocessor determines the firing signals to the SCRs in the bridge converter. SCRs then convert the three phase supply to DC supply in relation to the desired speed. This drive can operate in open loop without any feedback and can achieve a speed regulation of 5-8%. However, a speed regulation less than 5% is required in many applications. In such cases, the speed measuring/scaling unit switches to the EMF feedback measuring circuit. This feedback circuit measures the armature voltage, scales it in proportion to the output voltage (scaling function in microprocessor) and gives to the summing circuit, Further, it is transformed into a speed error signal in speed controller. If the speed regulation less than 1% is required, tachometer generator feedback is used. So the speed measuring/scaling circuit then switches to the tachometer feedback. This feedback achieves very precise control compared with EMF feedback. htpshwwa electicatechnology.org2018/11/power-dstributon-nindustis him! 3307rsr020 Power Distbution in Industries — All You Nees to Know Also for field control (above rated speeds), this drive includes a separate field exciter. A field current regulator in the microprocessor determines the voltage to the field windings by accepting the flux/field reference signal from the operator. This regulator provides the firing signals required by the field converter unit to produce the required DC voltage proportional to the speed. What's inside of Power Conversion make SCR DC Drives? Silicon Controlled Rectifiers (SCRs) are widely used thyristors for large DC motor drives in its power conversion unit. An SCR conducts when a small voltage applied to its gate terminal. Its conduction continues till the starting of negative cycle and it turned OFF automatically once the voltage across the SCR goes through natural zero till next gated signal, The purpose of using these SCRs in DC drives is to convert the fixed AC supply to variable DC supply that controls the motor speed. As discussed earlier, some SCR DC drives are supplied from single phase AC supply and use four SCRs in the form of bridge for the DC rectification, In case of high power DC drives, a three phase supply with six SCRs is used for DC rectification. In case four quadrant operation (forward motoring, forward braking, reverse motoring and reverse braking) of the DC drive, a bridge rectifier of consisting of 12 SCRs with a three phase incoming supply is used. During each quadrant operation, SCRs are triggered at a htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! sarrsr020 Power Distbution in Industries — All You Nees to Know phase angle in order to provide required DC voltage to the motor. The connection of SCRs (for four quadrant operation of the drive) from incoming three phase AC supply to the DC output is shown in figure below. In this, the motoring SCR bridge and regeneration SCR bridge achieve the drive four quadrant operation by receiving the appropriate gate signals from (analog or digital) controller. If the SCRs were gated with a phase angle of zero degrees, then the drive function as a rectifier which feds the full rectified rated DC supply to the motor and by varying the firing angle to the SCRs, a variable DC supply is applied to the motor. The DC output voltage waveform in relation to the AC waveform for above circuit is shown below. This average DC output voltage is obtained for 40°, 32° and 24° firing phase angles. By this way, the average output is controlled by varying the firing phase angles to the SCRs. htpshwwa electicatechnology.org2018!11/power-dstribution-n-industis him! 3997rsr020 Power Distbution in Industries — All You Nees to Know As the field winding also requires the regulated DC supply, only four SCRs are used in the field bridge converter. This is because field never requires a negative current and hence another set of SCRs is not required, which were used in armature for reversing the motor. In modem DC drives, SCRs are completely replaced by MOSFETs and IGBTs in order to achieve high speed switching so that distortion to the AC incoming power and currents during switching is eliminated. Hence, the drive becomes more efficient and accurate. As discussed in AC drives article, DC drives are also available in modular units that consisting analog and digital /Os, multifunctional keypads, remote operator panels in addition to the software programming and configuring capabilities, from —_ various manufacturers such as ABB, Siemens, Rockwell automation, Emerson, etc. These can be connected to the other drives or a computer host via communication cables. htpshwwa electicaltechnology.org2018/11/power-dstributon-nindustis him! 3697rsr020 Power Distbution in Industries — All You Nees to Know htpshwwa electicaltechnology.org2018/11/power-dstributon-nindustis him! srs7