Variable Frequency Motor Drives

Variable frequency motor drives are also known as motor drives,variable frequency drives, VFD’s, variable speed drives, adjustable frequency drives, AFD’s, adjustable speed drives and ASD’s. Motordrives are solid state motor control systems used to regulatethe speed of alternating (AC) electric motors. Motordrives are mainly used to reduce energy consumption on electric motors for industrial manufacturers.

Motordrives operate as load controls within applications that may accomplish up to 50% reduction in energy costsby speed reduction on applications where the full speed (RPM) of the electric motor is not required. Motor drives are used in AC Servo Systems, Air Compressors, Conveyor Systems, Lathes, Mills, Plastic Extrusion, Slitter Lines, Food Processing, Waste Water Treatment Systems, Submersible Pumps, HVAC Fans and Blowers, and many more AC motor applications.

Many manufacturers apply motor drives withrotating equipment toreduce amperage spikes upon start up of large electric motors.Choosing the right motordrive for an application will benefit rotating equipment by providing less wear on the electric motor where applied. This is accomplished by adjusting the acceleration and deceleration time of electric motors. Adjusting the acceleration and deceleration time of an electric motor will greatly increase the lifespan of an electric motor. Motor drives provide the ability to control the frequency of starting and stopping of an AC electric motor.This ability provides a means by which an AC electric motor is only operating when needed for the equipment it’s rotating, and electric motors have a longer lifespan if they are not continuously operating when they don’t need to be.

Approximately one third of the world’s electrical energy is supplied by electric motors in fixed-speed centrifugal pump, fan, and air compressor applications. These fixed-speed applications hardly ever require the full load speed (RPM) of the electric motor they’re operating. By integrating motor drives to these applications, the motor speeds are reduced, and power costs can be reduced by 50% or more. Technology has reduced cost and physical size of motordrives, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, and control hardware and software.

Power Savings With MotorDrives

The majority of motordrives in the market today contain electronic circuitry that converts 60 Hertz Line power into direct current. The motordrive converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency (speed).A properly applied motordrive when paired with an AC electric motor, will significantly reduce operating costs. This is particularly true for variable torque loads such asFans,Blowers, andPumps.Blowers, for example, are often used with dampers to control air flow. These dampers may operate either manually or automatically. When dampers are closed, 50% of the electric motor current will drop to approximately 60% of Full Load nameplate current. By utilizing a motor drive in this application, current draw in the motor will be reduced 30% for every 10% drop in speed. The same electric motor operating froma motor drive at 50% speed, will draw approximately 20% of the full load current.

Types Of Motor Drives

Volts Per Hertz motordrives are the most common type of drive and areknown as a V/Hz drives, or volts by hertz drives. V/Hz motordrives are used inapplications such as fans, pumps, air compressors, and other related applications wherehigh starting torque is not required. V/Hz drive applications typically do not require full torque when the AC motor is operating at less than the base speed (RPM) of the electric motor. V/Hz drives are the most inexpensive type of motor drive. V/Hz drives do not provide full motor torque at low RPM.

Open-Loop vector motordrives are also known as “sensorless vector” drives. Open loop vector drives adapted the name “sensorless vector” because they do not use an external encoder for speed feedback to the motor.Open loop vector drives are used in applications where high starting torque and full torque at low speed (RPM) is required. Open-Loop vector drives operating a motor a zero RPM should not be used on crane or hoist applications. Most open-loop vector drives are used on CNC machines, mixers, mills, lathes, and other applications where high starting torque or full torque at low RPM is needed.Open loop vector drives are usually more expensive than V/Hz inverterdrives.

Closed-Loop vector motor drives are used in applications where precise speed control (0.01%) is needed, or in applications where extensive programming is needed. Closed-Loop vector drives use an encoder on the motor to provide constant shaft position indication to the drive’s microprocessor. The encoder feedback allows the drive microprocessor to constantly control torque no matter how many RPM the motor is operating at. Closed-Loop vector motor drives are used to provide the motor to operate at full torque even at zero RPM. Closed-Loop vector drives are commonly used on hoist and crane applications because crane and hoist motors must produce full torque prior to it’s brake being released, or the load will drop and it will not be able to stop.

To learn more about motordrives or for motordriverepairs and replacement quotes, contact Precision Electric, Inc.

ABB VFD Drives

ABBVFD drives are designed formotor-driven applications in any industry and all power ranges. ABB VFDdrives are compatible with virtually all processes, automation systems, users and business requirements. The innovation behind ABB VFD drives is architecture that simplifies operation, optimizes energy efficiency and helps maximize process output.

ABB VFD drives for general purpose applications are designed to control a wide range of applications such as fans, pumps, mixers, conveyors as well as process control in industries including food and beverage, material handling, chemical, rubber and plastics, textile and printing. ABB general purpose drives are easy to select, install, configure and use. ABB VFD drives for general purpose applicationssave users time by standardizing most drive features to be built-in.

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 machineavailability. ABB local customer and technical support is available no matter where ABB micro drives are delivered and installed.

ABB machinery drives include models ACS355 and ACS850. ABB machinery drives are designed to meet the production and performance needs of machine builders, system integration specialists, panel builders and end users in a broad range of applications. 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 series drives are designed for fast, cost-effective installation and integration into a customers own control cabinet. ABB ACS800 VFD drives enable OEMs, system integrators and panel builders to build their own drive while maximizing benefits fromABB drive technology such as DTC motor control, adaptive programming and a wide range of built-in and external options. ABB provides detailed cabinet installation instructions and other support material to help customers buildtheir own solutions.

ABB ACS880 single drives are complete alternating current 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 drivesare programmability and configurability during both ordering and commissioning, which makes adaptation to different applications easy.ABBs ACS880 cabinet-built single drives are drives that aremounted into a cabinet and the complete assembly isoffered and delivered as one package. Often the cabinetwill include additional accessories such as contactorsand earth fault protection units. ABB VFD drives for control cabinets aretypically built-to-order products.

ABBs ACS880 multi-drives are built from ABB industrial drive modules connected to a common DC bus. This enables a singlepower entry and common braking resources for several drives.This construction simplifies the total installation and results in many benefits including savings in cabling, reducedinstallation and maintenance costs, reduced line currents and more.

ABB VFD drivescover a wide power and voltage range, including voltages up to 690 Voltand powers up to 5600 kW. At the core of ABB VFD drives is the Direct Torque Control (DTC), ABBs DTC is premiummotor control technology that enables highly accurate open and closed loop control. ABB VFD drives aredesigned for industrial applications such as those found in pulp and paper, metals, mining, cement, power,chemical, oil and gas, water and wastewater, and food and beverage.

To learn more about ABB VFDDrives, visit the ABB Website. For ABB VFD drives repair and replacement quotes, contact Precision Electric.






Lenze Drives

Rapidly changing times present manufacturerswith new and varied challenges. To succeed in the future, manufacturerswill need to handle more extensive tasks in even shorter time frames. Lenze drives create the best possible solution to set ideas in motion for optimizing an existing machine or develop new machines. Lenzeis one of the leading drive and automation specialists in the field of machine engineering.

SMV Series
The SMV series of Lenze drives range from IP31 (NEMA 1) and IP65 (NEMA 4/NEMA 4X). The SMV series of Lenzedrives 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 Lenzedrives offerperformance and flexibility make it an attractive solution for a broad range of applications including:

  • Food processing machinery
  • Packaging machinery
  • Material handling/conveying systems
  • HVAC systems

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 forperformance, power, packaging and intuitive programming. The Lenze SMV series of Lenze drives use anElectronic 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. And EPMs 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.

MC Series
The MC Series of Lenze drives are the intelligent, versatile and cost-effective choice for industrial applications. From harsh environments to high torque loads, the MC M1000 Series drives meet the toughest requirements with reliability, at a low cost. The MC Series is easy-to-program and offers full features, extensive I/O, and a full array of programmable functions. The M1000 is available in a power range of 1/4 to 150 HP and voltages ranging from 115 to 575 VAC. With its Enhanced Torque System (ETS), a highly efficient sine coding algorithm and auto-voltage boost, the M1000 delivers maximum starting and accelerating torque and tight speed regulation, even under fluctuating load conditions. A built-in, UL-approved thermal overload provides full motor protection. M1000 drives feature manual boost for high starting torque, auto-boost for high torque acceleration at any speed, power-up & auto restart modes, sleep mode with adjustable speed threshold and time. Adjustable units display: Hz, RPM, %, /SEC, /MIN, and /HR. Slip compensation is for tight speed regulation even under fluctuating loads and control configuration uses local, remote, both, serial communications and auxiliary outputs – two open collector outputs and a Form C relay. Dynamic Braking is available for faster stopping or deceleration time. Additional form-C relay and remote keypad is also available (up to NEMA 4X rating).All MC Series options can be factory installed or field installed.

M3000 Series
The M3000 series of Lenze Drives arefor process control demands with fast acceleration and response. Lenze M3000 series drives are designed expressly for use where the motor control is an integral part of a process, the M3000 is rated for constant torque applications but can easily be configured for variable torque applications. Most process control drives are designed for variable torque applications where the motor is driving a centrifugal fan or pump. As such, these drives are limited to 110% current for overload situations such as acceleration or responding to a feedback change. The MC3000 is a true Constant Torque drive rated for 180% of rated current for 30 seconds and 150% for one minute; this allows faster response to system changes and the ability to apply the MC3000 to non-centrifugal applications such as compressors, conveyors and other constant torque loads. The M3000 is available in the same power ranges and voltages as the M1000.
MCH Series
The MCH series of Lenze drives are available for output power from 1 HP to 250 HP (0.18 to 185 kW).The MCH series of Lenze drives were designed for the HVAC market and the specific requirements of Industrial and Commercial installations.The MCH series Lenze Drives are designed to operate standard polyphase induction motors rated from 200VAC – 575VAC from 0 to 120Hz. The MCH Series Lenzedrives offer intuitive operator interface using simpleprogramming and operational information. The MCH series of Lenze drives allow drive software to adjust the motor speed to maintain a preset pressure, flow, temperature or other variables using PID setpoint control. The MCH Series of Lenze drives are HVAC drives and include UL and cUL approved motor protection for single motor applications. The MCH Series of Lenze drives has been specifically designed for HVAC loads such as fans, pumps and cooling towers. The application specific keypad offers easy operation.

Lenze 8400

Lenze 8400 series invertersare used for cutting-edge machines and plant concepts with the ability to modernize existing equipment. With comprehensive and innovative software, Lenze supports manufacturing product selection decisions, energy efficiency, project planning and commissioning. Lenze 8400 series inverters for control cabinet installation are designed for IP20 and IP31 degrees of protection. Lenze 8400 series drives have the ability to use the cold-plate or push-through installation technique. Lenze 8400 devices can be installed one after the other to save space, and they can be used in a DC bus operation to keep wiring efforts to a minimum. All other control components, like the controller and the I/O system, are mounted right next to the inverter modules.

The Lenze 8400 BaseLine achievescontrolled movement to basic applications. Lenze 8400 BaseLine is usedfor controlled motion with communication, and its power range is from 0.25 through 3.0 kilowatt. The Lenze 8400 BaseLine issuitable for conveyor, pump and fan applications. Lenze 8400 BaseLine I/O consists ofstart/stop, analog input, and freely programmable digital inputs and outputs. Lenze 8400 BaseLine uses optional CANopen for communications and is quick and easy to commission. Lenze 8400 BaseLine also has integrated motor overload protection.

The Lenze 8400 StateLine is ideally suited to drive control with or without speed feedback providing precisely tailored solutions. The Lenze 8400 StateLine is used when communication via bus systems is required. In addition to this, the integrated brake management ensures significant wear reduction on the service brakes. Highlights of the Lenze 8400 BaseLine are VFC eco energy saving function (ensures energy-efficient handling of limited resources), control of synchronous motors without feedback, and 200 % overload current. Typical applications for the Lenze 8400 StateLine include: palletizers, extruders, filling systems or travelling/variable speed drives.

The Lenze 8400 TopLine offers the maximum level of functionality and optimum drive behavior within the 8400 series. Lenze 8400 TopLine provides precisely tailored solutions and represents a cost effective solution for speed-controlled, position-controlled, synchronized and positioning applications. Highlights of the Lenze 8400 TopLine are servo control of synchronous and asynchronous servo motors, integrated resolver input that supports the standard feedback of Lenze servo motors, multiple encoder input extends the range of potential applications; including absolute position measurement systems, and electrical shafts and electronic gearboxes can be implemented using the integrated axis bus. Typical applications for the Lenze 8400 TopLine include handling systems, positioning systems, travelling drives and hoist drives in the most diverse of application areas. The integrated axis bus is also designed for synchronizing drive axes, (e. g. when processing material webs.)

The Lenze 8400 HighLine stands out from the 8400 product range with its integrated point-to-point positioning. This allows up to 15 selectable target positions, including their travel profiles, to be saved in the inverter. Depending on accuracy and dynamic requirements, you can choose to position with or without feedback. Each of the positioning axes is set up for its individual application using the graphic and application-specific entry masks of the Engineer software tool. This makes setting parameters, commissioning and diagnostics quick and easy. Highlights of the Lenze 8400 HighLine are integrated point-to-point positioning reduces the load on the higher-level PLC, precise servo control of asynchronous motors, integrated safety (STO) in line with EN 13849-1 reduces the need for external controls The 8400 HighLine is recommended for applications without feedback, such as dosing drives, pallet systemsor feed units, and other similar applications. Typical applications for the Lenze 8400 HighLine with feedback include: cross-cutters, rotary tables, lifts and hoists.

To learn more about the Lenze 8400 series invertersor for Lenze 8400 repair and replacement quotes, contact Precision Electric.