Machining a New Fan Hub
Machining a New Fan Hub
Layne preparing a bearing housing for a sleeve insert.
What are the drive differences between an ABB ACSxxx-01E/03E/01 and ACSxxx-01U/03U/U1
Answer: The ABB ACSxxx-01E/03E/01 drive’s motor information parameters default to the following MOTOR NOM FREQ to “50Hz”, MOTOR NOM POWER is in “Kw”, REF1 MAX to “50Hz”, MAXIMUM SPEED to “1500RPM” and MAXIMUM FREQ to “50Hz”. The EMC metal screw is installed activating the EMC filter. 50 Hertz default output and power ratings in Kilowatt are standard for drives and other industrial electrical equipment in Western Europe, the United Kingdom and most countries located outside the United States of America. This is because electric motors are sized in Kilowatt ratings outside the USA; and, electric motors manufactured outside the USA run at full load speed when operating at 50 hertz.
The ACSxxx-01U/03U/U1 drive’s motor information parameters default to the following MOTOR NOM FREQ to “60Hz”, MOTOR NOM POWER is in “Hp”, REF1 MAX to “60Hz”, MAXIMUM SPEED to “1800RPM” and MAXIMUM FREQ to “60Hz”. The EMC plastic screw is installed deactivating the EMC filter, but the drive ships with the metal screw to activate the EMC filter. 60 Hertz default output and power ratings in Horsepower are standard for drives and other industrial electrical equipment in the United States of America. This is because electric motors are sized in horsepower ratings in the USA; and, electric motors manufactured in the USA run at full load speed when operating at 60 hertz.
There are several ways to build an ABB multi-motor setup with ABB micro drives. Master-slave control, parallel control of motors and combinations of these two ways. The most typical ABB multi-motor setup for compact drives is the parallel control, which means that several motors are powered by one inverter (parallel connection of motor windings). The benefits of such approach are that there is only one inverter to startup, and that less time and effort is needed for the installation work. Multi-motor setup is possible only with asynchronous motors.
Correct selection of drive is critical with this kind of ABB multi-motor setup. This is due to the fact that increased amount of common mode current will reduce the loading current capability of the drive. Factors that affect drive load ability and the amount of common mode current:
The drive is selected based on the sum of the connected motor powers. See the table below to indicate the drive type depending the total motor power. Typically, also the use of external output chokes is recommended and the maximum motor cable length is more limited than with a single motor connection. When one drive controls several motors, only scalar control should be used. Motor parameters (PN, I2N) are given as the sum of the nominal values of the motors. Nominal speed is given as an average of the motor rated speeds. It is recommended to limit the maximum current according to the actual need and it should not exceed 1.1 × I2N (parameter 2003 MAX CURRENT). Only 4 kHz switching frequency is allowed to be used. When multiple motors are connected, the sum of the output cable lengths must not exceed the maximum allowed cable length (see table below). Cables should be separated as close to the drive as possible. If motor contactors are used, switching the contactors during operation is not recommended.
The ACS880-07 of ABB Inverter Drives is a cabinet-built single drive. The ACS880-07 is built-to-order to meet customers’ needs and the drive can meet any technical challenge partly through its built-in array of options. The features and options include: extended I/O, fieldbus options, du/dt filtering, EMC filtering, a brake resistor, fuses and a main switch. Induction motors, synchronous motors and induction servo motors are all supported as standard, without any additional software. The drive can control them in either open loop or closed loop, through its high precision motor control platform, direct torque control (DTC).
Built-in safety features reduce the need for external safety components. The drive supports the programming environment based on IEC 61131-3. The common drives architecture features the same control panel, parameter menu structure, universal accessories and engineering tools. The control panel is equipped with an intuitive and high-resolution control display that enables easy navigation. Many flexible data visualizations including bar charts, histograms and trend graphs help users to analyze processes, with assistants available to simplify setup. The menus and messages are customizable for the specific terminology of different applications. An integrated USB port allows easy connection to PC tool – Drive composer, which offers fast and harmonized startup, commissioning and monitoring. The built-in energy calculators, including used and saved kWh, CO2 reduction and money saved, help the user fine-tune processes to ensure optimal energy use. The energy optimizer control mode ensures the maximum torque per ampere, reducing energy drawn from the supply. The drive also offers built-in service features.
The ACS880-07 of ABB inverter drives is available in power ratings from 60 horsepower through 3000 horsepower (45 to 2800 Kw), and is compatible with a broad range of industries. Typical applications include conveyors, kilns, extruders, pumps and fans. The drive configuration contains a rectifier, DC link and an inverter, all built into a compact cabinet.
De-Rating ABB Drives for single phase input is possible with the ABB ACS310 and ACS355 Series drives. The ACS3XX-01U drives ratings are supplied in standard ratings for a single-phase supply voltage ranging from 200 to 240 V. They would then be used to operate a three-phase motor. It is also possible to supply 230 V single phase power to some three phase drive ratings but this would require a de-rating of the output current when choosing a drive. Table Showing Drive Rating and Available Output Current When Single Phase Input Power Is Applied:
De-Rating ABB Drives for single phase input should only be performed by electrical technicians. If you’re de-rating ABB drives for single phase input, contact someone with experience before purchasing or installing equipment. To learn more about ABB drives, visit the ABB Website. To purchase ABB drives or for ABB drive repair, contact Precision Electric.
ABB variable frequency drive repair should begin with checking the electric motor connections and drive terminal connections. Motor and drive connections can be missed, installed loosely or wired to the incorrect terminals, so checking all connections is recommended before pulling the drive for a repair evaluation. Heat cycles and mechanical vibration can lead to sub-standard connections. Reusing torque screws is not a good idea, and further tightening an already tight connection can ruin the connection. Bad connections eventually lead to arcing. Arcing at the drive input terminal can result in over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the drive input or output terminals may result in over-current faults or damage to the power components. Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable starting and stopping of the motor. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, and personnel injury.
Diode and IGBT Testing
Prior to applying power during ABB variable frequency drive repairs, the input and output power sections are tested. If there is a short on the input side or output side of the drive, further damage can be caused to the unit if power is applied to it. For this reason, special meters should be used to properly test the input and output power sections of the drive prior to applying power to the drive unit. If a short is found, the drive can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the drive repairs are too costly, drive replacement should be considered.
If the input and output power sections test healthy during the ABB variable frequency drive repairs process, power can be applied to the drive to perform amp reading and output frequency testing. Slowly increasing the power voltage during this step of the drive repairs process is suggested to gather accurate meter readings and to protect the motor. The power voltage is slowly increased on the drive until the rated input voltage of the drive is reached. Depending on whether or not the drive provides a display will determine what further action will be taken. If display is unavailable, disassemble and diagnosis of the internal power supply of the control section of the drive is necessary to further evaluate cause of failure and establish cost and lead time of the drive repairs.
If the previous three tests have passed during the ABB variable frequency drive repairs process, a basic JOG / RUN function of the drive can be performed with a simple template program. When a drive comes into our facility, repair techs will backup all existing programs stored in the drive prior to installing a test template program for testing. Backing up the drive program ensures that we have a backup copy of the program to install after the repair is complete. The best method for backing up drive programs will depend on the series and model of drive that’s being repaired. After the drive programs have been backed up, the drive is reset to factory default through the keypad and then recommissioned to a basic START / STOP function of the drive connected to its motor. Closed loop testing will be necessary when an encoder or tachometer is involved. If the motor will not run, the output voltages and motor current ratings are tested to verify that the drive is functioning properly to rotate the motor.
Manufacturers are encouraged to ensure that their ABB variable frequency drive repairs are being performed at the actual site of whoever is offering the service. Drive repairs should be taken with extreme caution and only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends to consult an expert in the field when repairing all industrial electrical equipment. Many drive controllers have an internal DC bus that retains a charge after power has been cut to the drive, and as a result, electrical current is still present after power is shut down. Technicians performing VFD repairs must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.
Precision Electric receives ABB variable frequency drive repairs everyday from companies who offer drive repair services; those third party repair companies will have Precision Electric perform the repair, and then they will mark up the repair cost to their customers. Going straight to Precision Electric for drive repairs will prevent these added costs and prevent extensive lead times. For ABB variable frequency drive repairs and replacements, contact Precision Electric.
Lenze Price Increase Effective May 1st, 2017, has been a topic of discussion for several months. Lenze Americas (formerly AC Tech Corporation) originally announced this price increase in March of 2017. Lenze is committed to producing the most innovative products in the industry. Lenze latest product offerings of the i500 and the g500 are proving to give customers a competitive edge in their marketplace with motion control solutions.
The Lenze price increase will be applied to SMV products, i500 products, Global drive products, and Sub Micro products that have been in the market for over 15 years. Sub Micro Series products include MC1000 (MC), SMV, SCF, SCM and SCL series products. Some of the products that will see a price increase are beginning their phase-out period. Products in the phase-out period will no longer be available for purchase within two years from today. The chart below has detailed information on all products that will be affected by the Lenze price increase. There is also additional information on this chart regarding products that are in the phase-out period. Products that are not listed, will stay in regular production and stay the same price.
| Product: Increased By:
*These products have been in the market for over 15 years and are beginning their phase-out period. While the phase-out period is two years away, we would like to assist you in the migration process to provide an upgraded replacement. Please contact Precision Electric: 877-625-2402 for any application or migration assistance.
Variable frequency drive manufacturers offer products to be used with electric motors. A variable frequency drive is also known as a VFD, variable speed drive, adjustable speed drive, electronic motor controller, or an inverter. Every VFD is unique with its own component characteristics; so, how each VFD works is dependent upon components within the VFD. Most VFDs integrate a solid state electronics controller, consisting of a bridge rectifier, a converter, and an inverter module. Properly applied variable frequency drives can significantly reduce production operating costs.
ABB low voltage drives are used globally. ABB low voltage drives are designed specifically for the following industries: textile, material handling, mining, cement, rubber and plastics, food and beverage, consumer goods, automotive, oil and gas, pulp and paper, water filtration, and waste water treatment. ABB manufactures specific products for each of these industries to provide the best possible performance while keeping cost to an absolute minimum.
ABB micro drives include models ACS55 and ACS150. ABB micro drives are very easy to install and set up. ABB micro drives provide flexible mounting alternatives and straightforward configuration for many basic applications. Each drive is tested before it leaves the factory providing high machine availability. ABB local customer and technical support is available no matter where ABB micro drives are delivered and installed. ABB machinery drives include models ACS55, ACS150 and ACS355. ABB machinery drives are designed to meet the production and performance needs of machine builders, system integration specialists, panel builders and end users. ABB machinery drives can be flexibly programmed to meet the demands of different machine solutions. A wide range of features and options provide optimal solutions.
ABB ACS880 single drives are complete drives and can be installed without any additional cabinet or enclosure. ABB single drive modules configuration contains a rectifier, optional EMC filter, reactor, DC link and an inverter in one single AC drive unit. ABB single drives are available as wall-mounted, free-standing and cabinet-built constructions. The key features of ABB single drives are programmability and configurability during both ordering and commissioning, which makes adaptation to different applications easy. ABB’s ACS880 multi-drives are mounted into a cabinet and the complete assembly is offered and delivered as one package. Often, the multi-drives will include additional accessories such as contactors and earth fault protection units. ABB multi-drives are built from ABB industrial drive modules connected to a common DC bus. This enables a single power entry and common braking resources for several drives. This construction simplifies the total installation, and results in many benefits, including: savings in cabling, reduced installation and maintenance costs, reduced line currents and more. ABB multi-drives are built-to-order products. ABB is one of several variable frequency drive manufacturers offered by Precision Electric.
Eaton/Cutler Hammer drives are system drives designed for simple to complex applications. Eaton SVX9000 drives are used in Sullair air compressor applications throughout the United States. Eaton SVX9000 drives are also used globally in oil refineries, marine vessel, power distribution and alternative energy applications. Eaton’s SVX9000 adjustable frequency drive offers sensorless vector control technology coupled with an adaptive motor model and sophisticated ASIC circuit features.. This technology allows for steady speed error, fast torque rise time, high immunity to resonance vibrations and high starting torque and current. The SVX9000 is suitable for multiple motor drive systems and high-speed applications. Eaton SPX9000 drives are designed specifically for high-performance applications. Eaton SPX9000 drives feature high processing power and the ability to use information from an encoder or a resolver to provide precise motor control. In addition, a fast microprocessor provides high dynamic performance for applications where good motor handling and reliability are required. Eaton is one of several variable frequency drive manufacturers offered by Precision Electric.
Lenze Americas drives are mainly used for any application that does not require speed feedback. Lenze drives are built in America and are an inexpensive solution for food processing, packaging machinery, materials handling, conveying systems, and HVAC systems. The SMV series of Lenze drives range from IP31 (NEMA 1) and IP65 (NEMA 4/NEMA 4X) in power ratings from 120V to 240V through 480V and 600V. The SMV series of Lenze drives offer sophisticated auto-tuning, fast dynamic toque response with impressive low-speed operation all from a compact and simple to use package. The SMV range is designed for motor applications where dynamic speed and torque control is demanded, making the units ideal for conveyors, food production lines, packaging equipment plus fan & pump systems.The SMV series of Lenze drives use a price leadership tradition in the highly competitive AC drive market. With the benefit of a two year warranty, the SMV series of Lenze drives offer performance and flexibility make it an attractive solution for a broad range of applications.
The SMV series of Lenze drives use price leadership in delivering unparalleled performance and simplicity. The SMV series of Lenze drives is the right choice for performance, power, packaging and intuitive programming. The Lenze SMV series of Lenze drives use an Electronic Programming Module (EPM) for programming. The Lenze EPM makes for ease of hassle-free reconfiguration within each parameter or resetting the drive to factory or user default settings. When drive reset is necessary, reset to factory default or customer settings in seconds with the EPM. When the EPM equipped drive is used on a line containing multiple drives with the identical setup, it takes just minutes to program the entire line. The EPM’s can be replaced with or without power connected. When a drive must be replaced, the parameter configuration is not lost, simply plug in the pre-programmed EPM. Lenze is one of several variable frequency drive manufacturers offered by Precision Electric.
Hitachi AC Variable frequency drives are utilized for an array of applications. Hitachi drives are equipped with several advanced features and deliver unprecedented performance and reliability. Hitachi drives are a result of high degree of commonality between models and user friendly configuration software – making them easy to install, program and maintain. The SJ700D Hitachi inverter is designed with more capabilities and functions of its predecessor, the Hitachi SJ700B Series. SJ700D inverters come with improved sensorless vector (SLV) control algorithm, which allows the SJ700D Series to develop 150% torque at 0.5 Hz, ideal for a wide range of applications. Another key upgrade in the SJ700D Series is the addition of Hitachi’s EzSQ (Easy Sequence) built-in programming function, which provides the functionality of a PLC built into the inverter.
SJ700D inverters offer built in programming functions. Sequence operations are used by downloading programs created with Hitachi’s EzSQ software and then transferred to the Hitachi inverters. Operation of SJ700D inverters can be tailored to meet changing process requirements and SJ700D inverters can replace separate PLC’s in some cases to simplify or eliminate external hardware, which reduces cost and increases performance. SJ700D Hitachi inverters through 150kW have a built-in EMC filter to reduce electromagnetic noise, cost and space. SJ700D inverters have a lifetime warning function to allow preventive maintenance before a failure occurs.
The Hitachi industrial WJ200 Series AC Variable Frequency Drives range from 100-200V single phase input to three phase output, and 200-240V three phase input / output, and 390-480V three phase input / output. The WJ200 Variable Speed Drive comes with an integrated auto-tuning function for easy sensorless vector control that provides high starting torque of 200% or greater, suitable for a variety of applications. Hitachi is one of several variable frequency drive manufacturers offered by Precision Electric.
ABB ACS880-PE Enclosed Drive is the latest offering of ABB configured drives. This product was announced and released by ABB on March 31st, 2017. The ACS880-PE Enclosed Drive features a single ACS880-01 flange-mounted variable frequency drive in a wall mounted or floor standing enclosure and is available in a UL type 1 or type 12 design. It also features a wide selection of optional components including a manual two-contactor bypass with or without a soft start and a variety of power filters.
The ABB ACS880-PE Enclosed Drive is a pre-engineered space-saving solution, with ABB quality inside and out. It can be used in a variety of industries including chemical, oil and gas, mining, material handling, pulp and paper, saw mills and cement. Applications include extruders, winders, conveyors, mixers, compressors, pumps and fans. The ABB ACS880-PE Enclosed Drive is available up to 200 HP and is engineered for indoor locations in industrial environments. The ACS880-PE Enclosed Drive is available in 230VAC from 1hp to 100hp and in 460VAC from 1hp to 200hp.
ABB’s common drive architecture features a user interface, parameter menu structure, accessories and PC tools common across the ACS880 platform. The standard ACS880 part number will just change from ACS880-*** to ACS880-PE-*** everything else in the part number being the same as before, except the added PE suffix. The lead time for ACS880-PE drives as of 4-5-2017 is 8 weeks short term, and 6 weeks long term. For additional information on the ABB ACS880-PE Enclosed Drive, visit the ABB Website. For ABB drive repair and replacement, contact Precision Electric.
AC Tech drive repair can be quicker and less expensive than drive replacement. AC Tech drive repair is most economical for: obsolete drives, out of stock drives, and, drives above 10 horsepower. When a failed AC Tech drive is obsolete or the availability exceeds repair time, AC Tech drive repair can be a better solution than replacement.
AC Tech drives below 10 horsepower typically fail in eight years from their initial installation date. AC Tech drives below 10 horsepower are more often replaced than repaired because the cost of repair will exceed the cost of replacement. AC Tech drives above 10 horsepower have a longer life span, and, are more often repaired than replaced, because the cost of repair is less expensive than the cost of replacement. Depending on the cause of failure, an AC Tech drive repair can cost anywhere from 40%-75% less than the replacement cost.
There are special circumstances that would allow a maintenance technician to choose AC Tech drive repair instead of replacement, regardless of the drive cost. For example: If a crucial production line is down due to AC Tech drive failure, a maintenance technician would look at their options: 1.) AC Tech drive replacement or 2.) AC Tech drive repair. If the AC Tech product needed is not in stock and the lead time is several weeks, the quicker solution would be AC Tech drive repair. The cost of the repair in these situations would first depend on the cost of downtime. If the downtime in production loss exceeds the drive repair time, the maintenance tech would go with the drive repair.
AC Tech drive repair PM programs for larger (above 10hp) AC Tech drives, can prevent severe damage to AC Tech drives. Severely damaged drive repair can cost more than drive replacement, depending on the extent of board and component damage. Preventative maintenance consists of cleanup or replacement of circuit boards and all other electrical components – Followed by 100% component test and final test run with motor; PM programs are typically scheduled out once or twice a year – onsite, when necessary.
AC Tech drive repair is an asset to manufacturers, but choosing the right source is crucial. If the manufacturer chooses the wrong repair vendor, the mfg. could end up 1.) paying too much, 2.) waiting too long, or, 3.) paying a repair vendor that’s outsourcing the repair to a third party, and marking up the cost. Precision Electric performs AC Tech drive repair every day for electrical ‘repair shops’ who offer repair services. Precision Electric suggests to all manufacturers: make sure your repair vendor is performing the repair and not outsourcing the repair.
All AC Tech drive repair services are performed in house at Precision Electric. Precision Electric replaces bad components and failed parts with the best available components and parts in the electrical industry. All AC Tech drive repair performed by Precision Electric includes a one year ‘in service’ warranty. The ‘in service’ warranty ensures that all repaired equipment will receive an entire year of warranty – the warranty begins the day your equipment is put into service. The in service warranty is especially attractive for spare drives.
AC Tech drive repair should be taken with extreme caution and only be performed by trained technicians. Most AC Tech drives have an internal DC bus that retains a charge after power has been cut to the drive. An untrained drive user can be injured if they’re unaware that power is still active on the drive. A technician working with variable frequency drives must follow certain steps and take extra precautions during a drive repair – This is to prevent injury or death during the repair.
The three products that make up the ABB acs880 series are: single drives, multidrives, and drive modules. In this article, I will discuss product features and specifications of the ABB acs880 multidrives; which is one-third of the entire acs880 product.
ABB acs880 multidrives are available from 1.5 horsepower to 7,500 horsepower, with power ranging from 200 / 400 / 600 Volt AC (Alternating Current) to 700 Volt AC. The acs880 multidrives are stock products; with the option of built to order customization, to meet every user need. ABB acs880 multidrives come with various types of supply units. The supply units available are diode supply units and regenerative supply units; and these can meet technical challenges through a wide selection of options. A single supply and DC bus arrangement with multiple inverters reduce line power, cabinet size and investment costs.
The ABB acs880 multidrives have built-in safety features to reduce the need for external safety components. The acs880 multidrives support the CODESYS programming environment according to IEC 61131-3. Learn it once, use it everywhere. The ABB acs880 multidrives architecture features the same control panel, parameter menu structure, universal accessories and engineering tools as its predecessor, the acs800.
The acs880 multidrives features and options include extended I/O, fieldbus options, EMC filtering, brake options, fuses and main switch. The new cabinet design is more compact than the acs800, including efficient thermal handling. Several ingress protection (IP) classes with IP22 and IP42 offering cabinet solutions for different environments are also available. Induction motors, synchronous motors and induction servo motors are all supported as standard, without any additional software. The drive can control them in either open loop or closed loop, through its high precision motor control platform, direct torque control (DTC).
The new acs880 control panel is equipped with an intuitive and high-resolution, color control display that enables easy navigation. Many flexible data visualizations including bar charts, histograms and trend graphs help users to analyze processes, with assistants available to simplify setup. The menus and messages are customizable for the specific terminology of different applications. An integrated USB port allows easy connection to the PC tool – Drive composer, which offers fast and harmonized startup, commissioning and monitoring.
The built-in energy calculators, including used and saved kWh, CO2 reduction and money saved, help the user fine-tune processes to ensure optimal energy use. The energy optimizer control mode ensures the maximum torque per ampere, reducing energy drawn from the supply. The ABB acs880 multidrives reduces system size with premium motor control. The ABB acs880 multidrives are used in applications such as: winders, rolling mills, cranes, drilling, processing lines, and many other similar applications.