AC DC Industrial Electric Motors

AC DC industrial electric motors operate by applying alternating current (AC) or direct current (DC) power to itscorresponding AC or DC motor. AC DC industrial electric motors are seen in manufacturing equipment and other industrial rotating machinery.

The main parts of an AC electric motor arethe stator and rotor. The AC electric motor stator consists of wound coils that are supplied with alternating current power and produce a rotating magnetic field. The rotor will then rotate inside the electric motor coils and the output shaft produces torque via the rotating magnetic field. There are two different types of AC electric motors:

AC induction motors use a magnetic field on the rotor of an induction motor that’s created by an induced current. AC synchronous motors rotate at precise supply frequency or on a sub-multiple of the supply frequency.AC synchronous motors are able to operate with precision supply frequency because it doesn’t reply on an induced current. The magnetic field on an AC synchronous motor is generated by current delivered through slip rings or a permanent magnet. Most AC motors seen today are controlled by AC variable frequency drives (VFDs). Running a motor from a VFD can extend the lifespan of its corresponding motor increase energy efficiency within a manufacturing plant.

DC industrial electric motors are powered from direct current (DC) power and are mechanically commutated. DC electric motors have a voltage induced rotating armature windings and non-rotating armature field frame coils that are a static field or permanent magnet. DC electric motors use different motor connections of the field and armature winding to produce variable speed and torque outputs.DC industrial electric motor speed can be controlled within the winding by changing the voltage sent to the motor armature or by adjusting field frame current. Most DC electric motors today are manufactured to be controlled with DC drives. DC electric motors are used in many applications across the globe such as paper producing machines, steel mill rolling machines and other applications that require variable speed and torque output. Some obsolete machinery can be retrofitted with updated equipment by replacing a DC industrial electric motor with an AC industrial electric motor and AC variable frequency drive. Energy savings, increased production, increased quality control,anddecreased downtime are some of the benefits of integrating an AC motor and VFD to replace a DC motor.

Additionalinformation on AC DC industrial electric motors is available viathe linkswithin this post.Precision Electric integrates new applications and retrofits outdated equipment for manufacturers worldwide. Contact Precision Electric for AC DC industrial electric motors or other related equipment.

ABB Drive Repair

ABB drive repair is less expensive and has a quicker turnaround time than ABB drive replacement. ABB will sometimes recommend replacing failed drives instead of repairing them but ABB drive replacement is very expensive.

Checking the motor and drive terminal connections is a step many people miss or do incorrectly during an ABB drive repair. Heat cycles and mechanical vibration can lead to sub-standard connections, as can standard preventative maintenance practices. 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 nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the drive output terminal could result in over-current faults or even damage to the power components.Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable drive starting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections during an ABB drive repair, and this step is done prior to applying power to the drive unit. If for any reason 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, Precision Electric uses meters to properly test the input and output power sections of the drive prior to applying power to the actual unit. If a short is found, the unit can be disassembled and the cause of the short can be diagnosed and quoted for repair. If the ABB drive repair is too costly, then an ABB replacement is offered to the customer.

Power Up Unit
If the input and output power sections test healthy during the ABBdrive repairprocess, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electricslowly increases the power voltage to the ABB unit until the rated input voltage of the drive is reached. Depending on whether or not the ABBdrive provides a display will determine what further action will be taken. If display is unavailable, disassembly 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 for the ABB drive repair.

Run A Motor
If the previous three tests have passed during an ABB drive repair process, Precision Electric willrun a basic jog function of the drive with a simple template program. Often when a drive comes into our facility, we make sure to backup all existing programs stored in the drive prior to inputting a template program and running a test procedure. This ensures that we have a backup copy of the program.The best method for backing up depends on the brand of drive, but after it has been backed up, we either reset the ABB drive to factory defaults through the keypad and recommission a basic start, stop and job application or closed loop if an encoder is involved. If the motor will not run, it will be necessary to check the output voltages and current ratings going to the motor to see if the drive is functioning properly to rotate the motor.

Routine Maintenance
Most ABBdrive failure can be prevented with routine maintenance. ABB drive repair cost and lead times can also be reduced with routine maintenance. ABBdrive repair can be expensive and cost manufacturers production downtime during the repair process. Most manufacturers keep spare drives in stock to prevent production downtime when their equipment repairs are in process.

ABBdrive repair 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, as a result, it does not mean it’s safe to work with. Technicians working ABBdrives and other electrical equipmentmust always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

A lot of companies who offerABB drive repairoutsource the ABB drive repair to a third party. Precision Electric often receives ABB drive repair from companies who offer ABB drive repair. Those third party repair companies mark up the ABB drive repair to their customers. The most economical way to get an ABB drive repair is by going directly to a certified ABB drive repair center such as Precision Electric. Precision Electric performs all ABB drive repair in house.

Call Precision Electricfor ABB drive repairquotes.

VFD Controllers

VFD Controllersare 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.

VFDcontrollers 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. VFD controllersare 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 VFD controllerswithrotating equipment toreduce amperage spikes upon start up of large electric motors.Choosing the right VFD controllersfor applications will benefit rotating equipment by providing less wear on the electric motors 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. VFD controllersprovide 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 do not usuallyrequire the full load speed (RPM) of the electric motor they’re operating. By integrating VFD controllersto 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 VFD controllers, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, and control hardware and software.

Power Savings WithVFD Controllers

The majority of VFD controllersin the market today contain electronic circuitry that converts 60 Hertz Line power into direct current. The VFD controller converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency (speed).A properly applied VFD controllerpaired 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 VFD Controllers

Volts Per Hertz VFD controllersare the most common type of VFD and they’re known as a V/Hz drives, or volts by hertz drives. V/Hz VFD controllersare 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 VFD controllersare the most inexpensive type of motor drive. V/Hz VFD controllersdo not provide full motor torque at low RPM.

Open-Loop vector VFD controllersare also known as “sensorless vector” drives. Open loop vector VFD controllersadapted the name “sensorless vector” because they do not use an external encoder for speed feedback to the motor.Open loop vector VFD controllersare used in applications where high starting torque and full torque at low speed (RPM) is required. Open-Loop vector VFD controllers operating a motor a zero RPM should not be used on crane or hoist applications. Most open-loop vector VFD controllersare 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 VFD controllersare usually more expensive than V/Hz.

Closed-Loop vector VFD controllersare used in applications where precise speed control (0.01%) is needed, or in applications where extensive programming is needed. Closed-Loop vector VFD controllersuse 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 VFD controllers are used to provide the motor to operate at full torque even at zero RPM. Closed-Loop vector VFD controllersare 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 VFD controllersor for VFDrepairs and VFD replacement quotes, contact Precision Electric, Inc.

VFD Device

A VFD device is also known as Variable Frequency Drive, variable speed drive, adjustable speed drive, electronic motor controller, or an inverter.

A VFD device is a solid state electric motor control system designed to control the speed of an electric motor. VFD devicesoperate as load controls within electric motor applications; and a VFD devicecan reduce energy costsup to 50% by speed reduction on electric motorswhere the full speed of the electric motor is not needed.VFD devices 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, blowers, and many more electric motor applications.

Many manufacturers will apply a VFD device to rotating equipment to reduce amperage spikes upon start up of large electric motors.Choosing the right VFD device for an application can aid rotating equipment by providing less wear on the electric motors where applied.Adjusting the acceleration and deceleration time of electric motors can extend the lifespan of an electric motor. VFD devicesprovide the ability to control the frequency of starting and stopping of an AC electric motor.This ability allowsan AC electric motor to only operate when needed for the equipment its rotating, and electric motors have a longer lifespan if they are only running when needed.

Approximately one third of electrical energy in the world is supplied by electric motors in fixed-speed centrifugal pump, fan, and air compressor applications. These fixed-speed applications don’t usually needthe full load speed of the electric motor theyre operating. By installing a VFD device to these applications, electric motor speeds are reduced, and power costs can be reduced by 50% or more. Technology has allowed cost and physical size reduction of VFD devices, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, control hardware and software.

A properly applied VFD device and electric motor will significantly reduce energycosts for manufacturers. This is particularly true for variable torque loads such as fans, blowers, and pumps.Blowers 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 VFD devicein blower applications, the current draw of the motor will be reduced 30% for every 10% drop in speed; The same electric motor operating froma VFD device at 50% speed, will draw approximately 20% of the full load current.

To learn more about a VFD device orfor VFD device repair and replacement quotes, contact Precision Electric, Inc.