Drives Save Labor And Reduce Energy Costs

Variable frequency drives save labor and reduce energy costs while extending the lifespan of equipment for industrial applications. In the following ABB case study, afarm owner began looking toralternatives to an old irrigation system, which worked by running the water pumps at constantspeed, with control than being done bymanual opening and closing of valves In the pipelines. The system still worked, but it wascertainly not energy efficient.In addition, the need tor manual opening and closing of valves during startup combined withfrequent power outages and voltage dips from the electrical utility, made the whole process varylabor-intensive. To start one of the six pumping stations could take one person up to an hour andwith sometimes as many as three power outages a day, start ups became almost a full-time job.

The young owner of this farm was not previously a customer of ABB, but upon meetingwith ABB energy efficiency engineers, he decided to test variable frequency drives (VFD)on the water pumps at one of Its six pumping stations. ABB recommended a VFDand working witha system integrator, assisted in thedesign, installation and commissioning of five variable frequency drives running irrigation pumps with 45 to 75 kWmotors, and the sixth variable frequency drive used on the water transfer pump.The results were quite dramatic. With the new VFD installed, Riecor saw a significant drop inelectric energy. Demand from the irrigation system went from 291 kW, 308 kVA down to only 175kW, 186 k:VA. This amounted to 116 kW; an impressive 40 percent reduction in electric consumptionfor just one pumping station.

In financial terms, based on the local crop factor tor this region that Indicates the irrigationpumps would operate at 2,970 hours per year means an annual savings of $19,700 U.S.D. in electricitycosts. The payback time amounted to a short 7 months. The farm quickly made a repeat order and hasinstalled similar drives on a second pumping station

MajorBenefits
In addition to the financial savings on the electricity bill, the farm also had further operationalsavings in both labor hours and troubleshooting the initial start up process. Operators now only need to flicka switch to start, and in the eventof power interruptions the system wouldstart back up automatically at pre-set times.The variable frequency drivesgive a long ramp-up timethat allows for a very smooth pipe filling process, so the previous mechanical stresses on the pumpcouplings during start up were completely eliminated, together with fewer friction losses in thepipes. Additionally water hammering following switching off disappeared and fewer losses on theimpeller were seen due to these extended ramp-up and ramp-down times.

The ABB Energy Efficiency engineers who worked most closelyon the project, says that the Riecor Farming installation is a good example of how energyefficiency projects can also give additional benefits on the operational side.

Cost efficient retrofit

  • 40 percent reduction in energy consumption gave rapid seven- month payback of investment
  • Reduced labor costs, manpower needed for startup process is dramatically reduced
  • Smoother operation and pipe filling, power drops handled easier, water hammer and system shockseliminated

To learn more about applications where drives save labor and reduce energy costs, or for additional information about ABB Drives, visit the ABB Website. For ABB variable frequency drive repair or replacement, contact Precision Electric, Inc.

How To Control How A Motor Starts And Stops

Nearly any three phase motor can be started and stopped with a variable frequency drive.

These motors can easily have different start and stop control methods performed by a variable frequency drive.

If you’re not familiar with the motor and drive industry, controlling a motor can be intimidating. Technology offers us many solutions when controlling motors and electronics, but not all of those solutions are equal. There are a number of different ways you can control how a motor starts and stops, and it all begins with a variable frequency drive.

Variable frequency drives give you complete control over your motor. You can control the start method, stop method, speed, direction and much more. They also offer several layers of protection to make sure your motor doesn’t get damaged in the process.

We would like to help you get exactly what you’re looking for. As a distributor of many variable frequency drives through our online store, we’re here to help you find the exact solution you need. In this instance, we will help you start and stop the motor in different ways.

How To Control How A Motor Starts

We begin with our personal favorite, the SMVector Series variable frequency drive. This drive is extremely versatile and cost effective. Once you’ve commissioned the drive, you can easily control how your motor starts and stops. Here’s how you do it:

  1. Press the menu button.
  2. If prompted for the password, use the arrow keys to select 0224 and press themenu button again.
  3. Scroll to parameter P110 and press the menu button again.
  4. Choose from one of the following start methods:
    • 00 – Normal – Drive starts when you press the start button. Start command must be applied at least 2 seconds after power-up; F_UF fault will occur if start command is applied too soon.
    • 01 – Start on Power-up – Drive attempts to start as soon as the unit is powered up. For automatic start / restart, the start source must be the terminal strip and the start command must be present.
    • 02 – Start with DC Brake – When start command is applied, drive will apply DC braking according to P174 and P175 prior to starting the motor.Start command must be applied at least 2 seconds after power-up;F_UFfault will occur if start command is applied too soon. If P175 = 999.99, DC braking will be applied for 15 s.
    • 03 – Auto Restart – Drive will automatically restart after faults, or when power is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present. Drive will attempt 5 restarts; if all restart attempts fail, drive displays LC (Fault lockout) and requires a manual reset.
    • 04 – Auto Restart with DC Brake – Combines Start on Power-up with Start with DC Brake.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.
  5. Once you’ve made a selection, press the menu button.

How To Control How A Motor Stops

Now that you’ve set how you want your SMVector series drive to start, you can select how you want it to react when it is configured to stop. Here’s how you do it:

  1. Press the menu button
  2. If prompted for the password, use the arrow keys to select 0224 and press the menu button again.
  3. Scroll to parameter P111 and press the menu button again.
  4. Choose from one of the following stop methods:
    • 00 – Coast – Drive’s output will shut off immediately upon a stop command, allowing the motor to coast to a stop.
    • 01 – Coast with DC Brake – The drive’s output will shut off and then the DC Brake will activate (refer to P174, P175)
    • 02 – Ramp – The drive will ramp the motor to a stop according to P105 or P126.
    • 03 – Ramp with DC Brake – The drive will ramp the motor to 0 Hz and then the DC Brake will activate (refer to P174, P175)
  5. Once you’ve made a selection, press the menu button

The Alternative Flying Start / Restart Method

The SMVector series also has the option to perform different types of flying starts and restarts. A “flying” start is a start that occurs while the motor is in motion. If you have an application that requires the motor stop and restart without completely stopping the motor, this option may be for you.Here are some things you need to consider.

Warning! Automatic starting / restarting may cause damage to equipment and / or injury to personnel! Automatic starting / restarting should only be used on equipment that is inaccessible to personnel.

  1. Press the menu button.
  2. If prompted for the password, use the arrow keys to select 0224 and press themenu button again.
  3. Scroll to parameter P110 and press the menu button again.
  4. Choose from one of the following start methods:
    • 05 – Flying Start / Restart – Type 1–Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at max frequency (P103). If P110 = 0, a flying start is performed when a start command is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset. If drive cannot catch the spinning motor, drive will trip into F_rF fault. If drive trips into F_OF fault, try P110 = to 07 or 08.
    • 06 – Flying Start / Restart – Type 1–Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at the last output frequency prior to faulting or power loss. If P110 = 0, a flying start is performed when a start command is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip into F_rF fault. If drive trips intoF_OFfault, try P110 = to 07 or 08.
    • 07 – Flying Start / Restart – Type 2– For 2-pole motors requiring a flying restart.Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at max frequency (P103). Type 2 utilizes P280 and P281 to set Max Current Level and Decel Time for restart.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip intoF_rFfault.
    • 08 – Flying Start / Restart – Type 2– For 2-pole motors requiring a flying restart.Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting atthe last output frequency prior to faulting or power loss. If P110 = 0, a flying start is performed when a start command is applied.Type 2 utilizes P280 and P281 to set Max Current Level and Decel Time for restart.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip intoF_rFfault.
  5. Once you’ve made a selection, press the menu button.

The Best Variable Frequency Drive For The Money

The SMVector Series drive is one of the most cost effective and versatile choices for controlling your motors start and stop method.

If you want complete control over every aspect of your motor, we recommend the SMVector Series variable frequency drive.

We offer a wide range of variable frequency drives that will fit your needs at our online store. Don’t hesitate to contact us if you have any questions or concerns when looking to purchase a variable frequency drive. We will get you taken care of.

You’ll likely have the most success, and save the most money, by purchasing an SMVector Series variable frequency drive. The SMVector drives areMade In America, include a 2 Year Manufacturer Warranty and the Price Includes Engineering & Application Support.

The performance and flexibility make the SMVector an attractive solution for a broad range of AC Motor applications and with several communications protocols available, networking drives and components into a system solution can be done now or in the future.

The SMVector NEMA 1 (IP31) is the most common and cost effective drive enclosure for a wide range of applications including packaging, material handling / conveying, positive displacement pumping, and HVAC systems.

The SMVector Series can be used with 3-phase AC induction motors and is available in NEMA 1 (IP31) , NEMA 4X (IP65) and NEMA 4X (IP65) with an integral disconnect switch. Filtered input versions of the SMV are available in NEMA 4X (IP65) models for compliance with the CE EMC directive.

Programmable digital and analog I/O allow the drive to be configured for many application specific tasks such as multiple preset speeds, electronic braking and motor jogging to name a few. Like all Lenze AC Tech sub-micro drives, the SMVector uses EPM memory technology for fast and efficient programming.

Technical documentation for the SMVector Series Drive, and all AC Tech brand drives, is available in our Technical Library.

 

Industrial Packaging Systems Using Variable Frequency Drives

D&D Engineering (Hull) Ltd is a manufacturer ofconveyors and product handling equipment. Eighty percent ofits customers are in the food industry, mainly in the preparedproduce sector, with some involved in the production ofchilled products and bakery goods.One of D&D Engineerings recent customers is John BaardaLtd, a company specializing in the growing of tomatoes.John Baarda Ltd needed to replace its current tomatohandling conveyor system, which used inefficient chainsand sprockets, with a solution that would allow it to packtomatoes more quickly and accurately while allowing qualityinspection of the tomatoes.The company was experiencing difficulties with themechanically interfaced conveyors, as their coordinatingseries of chains and sprockets are subject to wear andstretch. This causes maintenance problems, with any timingadjustments having to be made mechanically, leading toproduction interruptions and reduced output.Gavin Walker, Engineering Sales Manager of D&D Engineering(Hull) Ltd explains: The speed of the conveyor must becoordinated with the speed and timing of the wrapper toensure that the tomatoes are delivered to the flow-wrapperat exactly the right time.

Quick And Accurate Industrial Packaging Systems Using Variable Frequency Drives

Integrating their industrial packaging systems using variable frequency drives was the goal for this application. The conveyor systemthat uses ABB servo motors and ABB high performancemachinery drives to control the speed of the tomato handlingconveyors, matching the speed of the packing machineand ensuring that the tomatoes are packed quickly andaccurately. An ABB component drive runs rollers on theconveyors, allowing the tomatoes to be turned automaticallyand inspected for quality.The two feeder conveyors are each driven by an ABB highperformance machinery drive in master-slave configuration,with the master receiving an encoder signal from the wrapper.This ensures that the drive knows where the wrapper is in itscycle and can control the speed of the conveyor precisely toensure the tomatoes arrive at the wrapper at the correcttime. If the speed of the wrapper changes, the drive canalter the speed of the conveyor accordingly to maintain thecorrect timing.

Challenges:

  • Accurate co-ordination of tomato handling conveyor withwrapping machine to allow quicker packing of tomatoeswhile providing quality inspections

Solution:

  • ABB servo motors controlled by ABB high performancemachinery drives match the speed of the tomato handlingconveyors to the speed of the packing machine
  • ABB component drive controls rollers on the conveyors,allowing the tomatoes to be turned for inspection

Benefits:

  • Tomatoes are packed quickly and accurately
  • Packing rate has doubled from 40 packs per minuteto up to 80 packs per minute
  • The drives programmed product menus allow different
  • products to be run on the conveyor with quick changeovers
  • Easier to build thanthe previous mechanical interfaced systems
  • Operation and maintenance costs reduced

Doubling The Packing Rate

Tim Howarth, Business Development Manager with JohnBaarda says: With mechanical systems, we can achievea maximum rate of around 60 packs per minute. Withstoppages, this averages around 40 packs per minute.The ABB machinery drive based electronic control systemgives us an average of 70 to 80 packs per minute.The ABB high performance machinery drives can be used withboth synchronous and induction motors and their modulardesign and flexible software make them suitable for use in arange of machinery applications, including those of the foodand beverage industry, material handling and packaging.

To learn more about ABB Low Voltage Drives or for ABB Repair and Replacement Quotes, contact Precision Electric, Inc.

Information References:

www.abb.com/drives
www.abb.com/drivespartners