VFD HVAC controller reducing fan power draw

VFD HVAC Buying Guide: Cut Energy and Boost Comfort

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VFD HVAC: An Efficient Upgrade

Rising utility rates have forced building owners to hunt for fast, low‑risk efficiency measures. A vfd hvac retrofit sits at the top of that list because the technology lets motors slow down whenever the load is light. In contrast, traditional starters slam fans on at full speed and then waste energy while dampers choke airflow by brute force. Industry studies show that dropping fan speed from 100 percent to 80 percent can halve electrical consumption, yet comfort actually improves.

Engineers might also call this an HVAC variable frequency drive or variable speed drive HVAC solution. This guide explains the root causes of wasted energy, shows how variable‑speed control fixes them, and highlights the Optidrive Eco series from Invertek alongside respected peers such as ABB and Yaskawa. By the end, you will know how to select, install and maintain the drive that suits your facility.

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Yaskawa Variable Speed Drives

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The Yaskawa A1000 variable speed drives provide outstanding quality, performance, flexibility, and environmental friendliness. The Yaskawa A1000 variable speed drives offer closed loop vector technology and is used in applications where precise speed regulation is required. The Yaskawa A1000 variable speed drives come in fractional horsepower through 1000 horsepower. The Yaskawa A1000 variable frequency drives offer network communications, speed feedback, and expandable I/O to control anything from simple fans and pumps to complex machines. The Yaskawa A1000 variable speed drives can be used on induction motor applications and permanent magnet servo motor applications. For new installations or retrofits, the Yaskawa A1000 variable speeddrives provide a single solution, regardless of the application.

Yaskawa V1000 Series

Yaskawa Variable Speed DrivesYaskawa V1000 variable speed drives pays off the promise of being in control with products that make businesses move. Yaskawa V1000 variable speed drives can be used in v/hz (volts per hertz), or vector mode. The optimum balance of energy input, product output, maintenance risk, and long life is reached with Yaskawa V1000 variable speed drives. The Yaskawa V1000 variable speed drives can operate at up to 1000 hertz output for spindle applications. The Yaskawa V1000 variable speed drives are only available for 1000 hertz output by request upon purchasing from a Yaskawa distributor.

The Yaskawa V1000-4X variable speed drive is a version of the standard Yaskawa V1000 variable speed drive in an integral enclosure that meets NEMA type 4X/12 indoor use requirements, UL type 4X/12 standards, and the IP66 rating of IEC 529. This enclosure provides the protection required in tough washdown or dust-tight environments, common in Food and Beverage Processing, Packaging, Metal Machining, Woodworking, Pumping, Refrigeration, Printing, and other related manufacturing industries. The Yaskawa V1000-4X variable speed drives’ enclosure is coated to protect against the harmful effects of sanitizing chemicals commonly used in food processing industries.

Yaskawa G7 Series

Yaskawa Variable Speed DrivesYaskawa G7 variable speed drives are designed for applications where the motor distance from the drive is significant. The Yaskawa G7 can be up to 1000 feet away from the motor it’s controlling. The Yaskawa G7 variable speed drives utilize 3 level control to offer the best solution for challenging installations. Yaskawa is the only manufacturer to offer a low voltage drive with this architecture. 3 level technology minimizes drive induced problems associated with long motor cables and premature motor bearing failures. The Yaskawa G7 variable frequency drives reduce overall electrical noise, resulting in the most problem free installations. The Yaskawa G7 variable speed drives also provide high flexibility and excellent vector performance for control of speed, torque, and position.

The Yaskawa G7 variable speed drives have three auto-tuning methods to optimize motor control, including the new static auto-tuning which does not require load decoupling, or motor rotation. The LCD operator displays 5 lines x 16 characters, in 7 languages. The G7 keypad includes memory for parameter settings that makes it easy to transfer settings from one drive to another.

The Yaskawa G7 variable speed drives have a large programming feature set to handle sophisticated industrial applications. If the standard feature set does not meet specific requirements, the Yaskawa G7 can be programmed using software called DriveWorksEZ™. The Yaskawa G7 variable speed drives are available in ratings through 500 horsepower.

Inverter Repair

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Most inverter repair can be prevented with routine maintenance. Inverter repair costs and lead times can also be reduced with routine maintenance. Inverter repair can be expensive and also cost manufacturers production downtime while the inverter repair is in process. Most manufacturers stock spare inverter modules to prevent production downtime in the event of an inverter failure. Components used for inverter modules are often cheaply made and prone to failure. Knowledgeable inverter repair shops should replace cheaply made components with high quality components during the inverter repair process. Using high quality components in an inverter repair ensures a higher chance of success and a longer lifespan during production.

Connections
Checking connections is a step many people miss or do incorrectly during the inverter repair process. 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 inverter input could result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the inverter output could result in over-current faults or even damage to the power components.

Loose connections can cause erratic operation. Loose START/STOP signal wires can cause uncontrollable inverter 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 of an inverter, and this step is essential prior to applying power to the inverter unit. If for any reason there is a short on the input side or output side of the inverter, 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 inverter 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 repair is too costly, then a replacement is offered to the customer.

Power Up Unit
If the input and output power sections test healthy during this step of the inverter repair process, Precision Electric will power the unit and perform amp reading and output frequency tests. Precision Electric prefers to slowly increase power voltage to the unit until the rated input voltage of the inverter is achieved.

Depending on whether or not the inverter provides a display will determine what further action(s) will be taken. If display is unavailable, dis-assembly and diagnosis of the internal power supply of the control section of the inverter is likely necessary to further evaluate cause of failure and establish cost and lead time for the inverter repair.

Run A Motor
If the previous three tests have passed during the inverter repair process, then it is time to run a basic jog function of the inverter with a simple template program. Often when an inverter comes into our facility, we make sure to backup whatever program is currently stored in the inverter prior to inputting a template program and running a test procedure. This ensure 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 inverter 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 inverter is functioning properly to rotate the motor.

Contact Customer
At this point we have determined the cause of failure, estimated lead time and cost of the inverter repair. If the inverter has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electric will gather application specific information from the customer to establish whether or not it may be some outside issue associated with the system including, but not limited to, PLC communications, faulty IO, bad wiring or even bad cabling. There is no single way to do this step, as it really depends on a wide variety of variables.

Send Service Tech
If the customer cannot establish failure on any other aspect of the machine and the inverter appears to test fine, then it may be necessary to send a field service technician on site to establish cause of failure. Field service technicians should be trained to troubleshoot any issue ranging from standard inverter repair, to advanced robotics, PLCs and more. Field technicians should also be trained to establish cause of failure and come up with solutions as quick as possible.

Inverter repair should be taken with extreme caution. Inverter repair should 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 or installing inverter equipment. Many inverter 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 with inverter repair must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

For inverter repair and inverter replacement quotes, contact Precision Electric.

Variable Frequency Drive Information

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Variable Frequency Drives (VFDs) are electronic devices used to control the speed of an Alternating Current Motor (AC Motor).  Variable Frequency Drives (VFDs) are also commonly known as adjustable frequency drives, adjustable speed drives, AC drives and inverters.
Variable Frequency Drives (VFDs) have a wide range of application use that include, but are not limited too:
Variable Air Volume Systems
Circulating Pumps for Hot Water Heating Systems
Chilled Water Circulating Pumps
Geothermal Heat Pump Systems
Injection-molding Equipment
Air Compressors
Conveyors
Chillers
Cooling Towers
Variable Frequency Drives (VFDs) operate as load controls within these applications that may accomplish up to a 50% reduction in energy costs.  In general, an electric motor will turn at a rate proportional to the frequency of the alternating current (AC) applied to it.  The majority of Variable Frequency Drives (VFDs) in the market today contain electronic circuitry that converts a 60Hz Line power into direct current.  The VFD converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency.
Advances in technology over the past decade have allowed for Variable Frequency Drives (VFDs) to become a very cost efficient way to reduce energy costs and increase system efficiencies.  More and more companies within a wide range of industries are finding more ways to apply Variable Frequency Drives (VFDs) to their applications.
For an even more in depth explanation of Variable Frequency Drives (VFDs), it is highly recommended that you visit: http://en.wikipedia.org/wiki/Variable-frequency_drive

If you have found Precision Electric on the web chances are you need a variable frequency drive replaced, serviced, or maybe you don’t even know what a variable frequency drive is.

Variable Frequency Drives are electronic devices used to control the speed of an Alternating Current Motor; typically these AC electric motors are used for industrial manufacturing. Variable Frequency Drives can also be known as inverters, electronic soft start devices, VFDs, adjustable speed drives and/or AC drives.

Variable Frequency Drives have a wide range of application use in several different industries. Here are a few of the more common applications and industries drives are used in:

Variable Frequency Drives operate as load controls within these applications that may accomplish up to 50% reduction in energy costs.  In general, an electric motor will turn at a rate proportional to the frequency of the alternating current (AC) applied to it.  The majority of Variable Frequency Drives in the market today contain electronic circuitry that converts a 60Hz Line power into direct current.  The VFD converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency.

Advances in technology over the past decade have allowed for Variable Frequency Drives to become a cost efficient way to reduce energy costs and increase system efficiencies.  Today manufacturing around the globe within a wide range of industries are finding more ways to apply Variable Frequency Drives to their manufacturing equipment.

For an even more in depth explanation of Variable Frequency Drives go to Wikipedia.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]

ABB Frequency Converters for Waste Water Treatment Plants

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ABB now offers the ACQ550 Series variable frequency converter to protect, supply and recycle water. System reliability, pump efficiency and a suite of industry-specific controls enable waste water treatment plants to successfully maintain a reliable water cycle management system. With this in mind, ABB designed a variable speed AC drives specifically for Water/ Wastewater environments and applications. These devices are available, as standard, for panel-mounting or factory direct NEMA-1, drip-proof NEMA-12 or outdoor-rated NEMA-3R enclosures.

A water industry start-up assistant resides within the intuitive, full graphic display panel to aid in commissioning submersible, centrifugal or positive displacement pumps. This control panel can also be mounted remotely, or on the cover of the drive, and used to upload, store and download parameters in multiple drive setups.

Application Control

The extensive library of pre-programmed, water-specific application macros allows rapid configuration of inputs, outputs, and parameters to maximize convenience and minimize start-up time. To simplify troubleshooting, the drive uses a real-time clock, which allows for accurate time stamps on faults, resets and more. Two integral option slots, that can be configured for additional relay outputs (i.e. drive status indications, timed or pump staging applications) or a variety of different communication bus adapters, are at your disposal.

Cost savings

ABB Frequency Converters for Waste Water Treatment PlantsThe ABB ACQ550 variable frequency converter is designed for solutions to give wastewater treatment plants the most flexible motor control performance through two standard modes: Scalar (V/Hz) for typical pumps; and Sensorless Vector for the more demanding applications. By using either these modes, the drive will have accurate speed control of any standard induction motor.

ABB designed the ACQ550 to save save energy by applying variable electronic speed control to pumps and pumping systems. These savings can be achieved over bypass or valve-operated flow control, traditional diesel driven systems or across the line operations. The Affinity Laws of physics define the relationship between pumps and the power they require. On centrifugal pump applications, the power requirement of the pump varies by the cube of the speed. Electronically reducing the pump speed by 20% will typically cut energy costs in half. Designed for water The ACQ550 – which ranges from 1 to 550HP – is well-suited to meet customer demands, from the simplest pumping applications, through the most demanding. Introducing an industry-driven approach, a growing network of Water and Wastewater experts, and the new ACQ550 industry-specific variable frequency converter.

To learn more about the ABB ACQ550 product, visit the ABB Website.

Information Sources:

 

 

 

Food And Beverage Manufacturing

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Modern food and beverage manufacturing from the 19th and 20th centuries began mainly to serve military needs. In 1809 Nicolas Appert invented an airtight bottling technique used to preserve food for French troops that contributed to the development of tinning, followed by canning by Peter Durand in 1810. Canning was expensive and hazardous because lead was used in cans but later became a standard around the world. Louis Pasteur discovered Pasteurization in 1864; this process improved the quality of preserved foods and was introduced to preserve wine, beer, and milk preservation. In western Europe and North America, the second half of the 20th century witnessed a rise in the pursuit of convenience. Food processing companies in western Europe and North America marketed their products during the second half of the 20th century to middle class working wives and mothers. Frozen foods were a sales success in juice concentrates and TV dinners. Food and beverage manufacturing utilized the value of time to appeal to the postwar population and today, this same appeal contributes to the success of convenience foods.

Benefits And Risks Of Food And Beverage Manufacturing

The benefits of food and beverage manufacturing today is the removal of toxins, preservation, increased food consistency, and simple marketing & distribution.  Food and beverage manufacturing also increases yearly availability of many foods, allows for transportation of perishable foods across long distances and makes many foods safe to eat by removing micro organisms that cause spoiling. Modern grocery stores only exist as a direct resuld of modern food and beverage manufacturing techniques. Modern food and beverage manufacturing techniques are also credited for transportation food and beverage products across long distances. Modern food and beverage manufacturing techniques also play a role in the improvement of the quality of life for people
with allergies, diabetics, and other people who cannot consume some common foods.

All processing of food affects its nutritional density. The amount of lost nutrients will depend on the food and processing methods. Using food additives raises another safety concern; the health risks of any additive will vary from person to person; take for example using sugar as a food additive could affect persons with diabetes. Certain additives can also result in addiction to particular foods. As these effects are discovered, laws are changed to regulate these issues and practices constantly change to make food and beverage manufacturing safer.

Food and beverage manufacturing is a mechanical process that utilizes mixing, chopping, grinding, and integration of equipment in the production process. These processes do introduce a number of potential contamination risks. As mixing bowls or grinders are used over long periods of time, the food contact parts will eventually fracture and fail. This type of failure introduces brings small and large metal contaminants into the production line. Continuing food and beverage manufacturing with these metal fragments can result in equipment failure and the risk of ingestion by consumers. Food and beverage manufacturers utilize industrial-grade metal detectors to automatically locate and reject any metal fragments during production. Large food and beverage manufacturing processors utilize several metal detectors within the production line to prevent consumer health risks and reduce the damage of industrial equipment.

To learn more about food and beverage manufacturing or for food and beverage manufacturing equipment repair and replacement, contact Precision Electric.

 

Robotic Automation: ABB Robots For The Packaging Industry

Robotic Automation: ABB Robots For The Packaging Industry

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ABB robotic automation ensures shorter product life cycles, new packaging designs, product variants and batch manufacturing. Compared to dedicated hard automation, robot lines are shorter and allow far better utilization of floor space. In addition to increased up-time and total throughput of production, fewer accidents and increasingly demanding workplace laws are compelling reasons to make the transition to ABB robotic automation. Robots are usually associated with handling repetitive tasks in a process – either in high volume production roles or where flexible handling systems are needed for frequent changes. In the packaging industry, robots generally fall into three main areas:

 

  • Pick and Place Applications (where products are packed into trays or secondary packages)
  • Feed Placement (where products are prearranged on a conveyor to ease future packaging procedures)
  • Palletizing (pallet loading and unloading)

 

Picking

This is an area in which ABB services a multitude of products, applications and packaging line set-ups. Frozen food, bakery and confectionery, ice cream, meat and fish, cheese, pet food, medical products, shampoo and perfume bottles are a few examples. The ABB IRB 360 is the first 2nd generation delta robot; The FlexPickerTM . The new robot family will initially see three models available. Stainless steel versions are available for wash down duties such as in meat and dairy handling applications. Apart from even greater performance, the new delta robot has a significantly increased payload of up to 3 kg – opening up further application possibilities, especially at the end of line. For full 6-axis flexibility, less demanding cycle times and payloads of up to 5 kg, ABB recommends the IRB 140.

Palletizing

Placing boxes, trays, bags, bottles or other items on a pallet seems easy enough. But, when you’re dealing with the rigorous demands of multiple feeder lines, quick box-pattern changes and high up-time, nothing compares to ABB robotic automation. The ABB IRB 660 has the versatility, reach and handling capacity needed for most palletizing applications. For even greater payload requirements, ABB standard 6-axis robots are the largest and are built to handle as much as 1,433 lbs.

The IRB 660 is a refinement of the well established, proven, ABB IRB 640 palletizer, with more than 1,800 installations worldwide. The new version of this robot blends speed, reach and payload like no other. Exceptionally fast, this 4-axis performer combines a 3.15 meter reach with a 250 kg payload, making it ideal for palletizing bags, boxes, crates, bottles and more. The new palletizer comes in two versions; a high throughput version designed for 250 kg and a high-speed version built to handle 180 kg payloads at full speed. The IRB 660 has the versatility, reach and handling capacity to meet the demands of just about any palletizing application. And it’s robust enough to perform steadily in the toughest environments.

Tailor Made Robots For Demanding Packaging Industries

ABB robotic automation includes specialized robots for picking, packing and palletizing. In addition, ABB provides a wide range of standard 6-axis robots which allows customers to meet the demands of nearly all applications in the packaging industry. What’s more, ABB’s unique packaging software, including vision technology and conveyor tracking, facilitates continuous production flows and packing on-the-fly. This allows for efficient handling of food and beverages, pharmaceuticals, cosmetics, electronics or personal care products.

High Speed Packing

The ABB FlexPicker IRB 360 is a unique parallel-arm robot designed for the most exacting high-speed picking and packing applications. The new robot succeeds ABB’s widely used FlexPickerTM IRB 340 system and is the result of 10 years’ experience and research and development combined with proven packaging technology. ABB has over 2000 delta robots installed globally and is the leader in this state of the art picking and packing technology. The newest version of the IRB 340 is called the FlexPickerTM IRB 360.

Cost Efficient Packing

The 4-axis IRB 260 houses all the necessary features for placing items in boxes, tray handling and more. Optimized for packing applications this robot can work closely to its own base, allowing very compact packing cells and integration into tight packing machines. IRB 260

features a 30 kg payload capacity and short cycle times to meet the packing industry requirements. Like all ABB robots, the IRB 260 is compatible with PickMaster, our dedicated software for packaging applications, including vision guidance and easy programming.

Food Safety & Pharmaceutical

ABB builds robots to meet the most demanding work conditions – as well as the highest hygiene standards. In addition, all ABB robots are IP67 certified, ensuring tightly sealed joints and connectors. The IRB 360, which is most likely to handle open food, is available in wash-down and stainless steel and is IP69K certified.

The demands on quality validation and traceability are extremely high in pharmaceutical production. The absolute accuracy, repeatability and high up-time of ABB robots result in massive improvements over manual operation or dedicated production equipment. All ABB smaller robots are suited to primary packing and are verified for clean-room operation.

To learn more about ABB Robotic Automation, visit the ABB Website. For ABB robot integration or replacement quotes, contact Precision Electric. Precision Electric can retrofit obsolete packaging machines / inefficient packaging systems with ABB Robotic Technology. We also offer servo drive repair and servo motor repair for All industrial robots.

 

What is an HMI

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What is an HMIA human-machine interface (known as an HMI) is an industrial electronics product that’s used to interact the operation and control between humans and machines. An HMI provides feedback from the industrial machine to the end user which helps the user make changes so that the machine is more effective in production. An HMI can also provide a way to control, manage, monitor and visually operation processes during production. HMI’s are used in all sorts of production applications across the world; but are extremely popular in heavy machinery, robotics, process controls, ergonomics, PLC and other related applications.

An industrial HMI system’s processing power determines it’s usability and its ability to render complex screens. An HMI’s fast response time to user input and flexibility to handle multiple levels of operator interactions is also determined upon the processing power within the HMI. HMI’s require dynamically changing graphics that require a high-performance solution that can achieve the 60 frame per second refresh rate that’s required at the right resolution. HMI’s also have to support multiple connectivity and communications protocols to communicate between the operator and various machines and control systems.

HMI’s range from simple displays to high resolution LCD panels and can be mounted on the machine, portable handheld devices, and also in centralized control cabinets. HMI’s are used in machine and process control to connect sensors, actuators and machines on the plant floor to I/O control and PLC systems. An operator control cabinet allows an HMI operator to interact with the machine in a  visual way. With controls and read-outs graphically displayed on the screen, the HMI user can use either external buttons or a touch screen to control the industrial machine it’s connected to.

sources:

http://www.pcmag.com/encyclopedia/term/44300/hmi

https://en.wikipedia.org/wiki/User_interface

 

MotiFlex E180 ABB Servo Drive – Product Overview

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The MotiFlex e180 ABB servo drive delivers versatile motion control performance, capability and dependability to power machine innovations. Flexible connectivity with Ethernet and motor feedback technologies is highly integrated and optimized for demanding motion applications. With the MINT WorkBench PC tool you can quickly and easily customize the drive to the exact control requirements of your machine.

The MotiFlex e180 ABB servo drive delivers capability and performance you can depend on. It combines Ethernet technology, advanced multitasking programming and safety as standard. The MotiFlex e180 can operate from 200 to 480 V AC three-phase with motor RMS current range from 3 to 50 A servo duty. Ethernet and motor feedback interfaces are fully integrated and optimized for demanding motion applications.

Metal Forming and Converting Machinery

The metal industry sets high requirements for motion control. In applications such as pressing, bending, laser cutting, drilling or polishing the motion control system must perform well in tight tolerance levels and changing inertia loads. MotiFlex e180 ABB servo drive adapts to various roles in different metal forming and converting machinery.

  • Dynamic control for rotary and linear servo motors with up to 300% overload modes
  • Highly integrated connectivity to various feedback devices as standard and dual feedback to eliminate mechanical errors
  • Real-time communication over Ethernet ensures optimal machine performance

Textile Machinery:

The textile industry requires high dependability, throughput and performance in harsh environments exposed to dust, humidity and high temperatures. Typically textile machines operate 24/7 with high production speeds and big volumes. An unwanted interruption of a machine turns quickly to big losses in production. MotiFlex e180 ABB servo drive provides dependable performance, accurate speed and tension control to textile machinery such as winding, reeling, spinning, dyeing, stretching, weaving, knitting, finishing and printing.

  • The drive can be used for stand-alone single axis control, in centralized systems for multi-axis control or as the master drive controlling other drives
  • Highly integrated and flexible feedback device connectivity as standard, including rugged resolvers and precise encoders

Plastics Machinery:

  • Plastics machinery requires versatility from motion control. From high starting torque in extrusion to high speed and tension control in winding, and high accuracy and dose control in injection and blow molding.
  • Versatility and flexibility are key attributes for the MotiFlex e180 ABB servo drive
  • A broad operation range with continuous currents up to 90 A, and overloads up to 300%
  • Real-time Ethernet connectivity enables high precision and quality of end-products
  • Highly integrated connectivity to various feedback devices comes as standard, including robust resolvers

Packaging:

Packaging applications, over wrappers and vertical form fill seals, demand high throughput and repeatable quality of product with minimum downtime. MotiFlex e180 ABB servo drive features high performance servo control for dynamic motion, with tightly integrated Ethernet control and feedback devices to match the machine needs of precision and resilience.

  • Safe torque off (STO) as standard eliminates costly power cycles, with immediate restart in the event operators open machine guards
  • High speed registration inputs provide precise registration of product and label for high speed labeling

ABB designs motion control solutions to power machine innovations. From servo motors and drives to complete systems with programmable logic controllers (PLC), motion controllers and safety technology, ABB’s offering is designed to scale and integrate seamlessly to different machines, providing dependable performance, high process quality and productivity. ABB engineers work together with machine builders in a broad range of industries to know what it takes to succeed in this dynamic world of motion control.

For Motiflex e180 ABB servo drive repair and replacement quotes, contact Precision Electric.

Lenze-AC Tech Announces Release of Nema 4x AC Drive up to 30HP

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SMVector frequency inverter – NEMA 4X (IP65)

Lenze – AC Tech’s most technically advanced inverter drive continues it’s tradition of innovative compact inverter design. 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 4X (IP65) is available in two enclosure materials – for indoor only use and for indoor/outdoor use. These rugged enclosure options are ideal for many industries including food / beverage, waste water, chemical metering and processing, and pharmaceuticals.

The power ranges of the SMVector in NEMA 4X include:

  • 120/240V – 1Phase Input, up to 1.5 HP (1.1kW)
  • 200/240V – 1 or 3 Phase Input, up to 3.0 HP (2.2 kW)
  • 200/240V – 3 Phase Input, up to 30 HP (22 kW)
  • 400/480V – 3 Phase Input, up to 30 HP (22 kW)
  • 480/600V – 3 Phase Input, up to 30 HP (22 kW)

The SMVector Series can be used with 3-phase AC induction motors and is available in NEMA 1 (IP31) , NEMA 4X (IP65) ¹ and NEMA 4X (IP65) ¹ 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.

¹ type 4X (IP65) enclosures are available for either indoor use, suitable for most indoor industrial environments; or indoor/outdoor use that offers UV protection and has higher impact strength at low temperatures.

Variable Speed Drive Motors

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Variable speed drive motors, also known as inverter-duty motors, are an asset in the industrial manufacturing world. When using a variable speed drive, variable speed drive motors are less likely to fail during production than general purpose motors. Variable speed drive motors exceed general purpose motors in performance, because variable speed drive motors are manufactured to operate at low speed (RPM) without overheating during production.

Variable speed drives generate high voltage spikes in all electric motors. Variable speed drive motors withstand the high voltage
spikes that are generated by variable speed drives, whereas general purpose motors do not. General purpose motors do not have the insulation required to withstand high voltage spikes, so the motor winding on a general purpose motor used with a variable speed drive begins to breakdown, and ultimately, the winding will burn up.

Variable speed drives used on electric motors that are 100hp (or greater) induce harmful voltage levels on the electric motor shaft. When harmful voltage levels exceed the resistance of the motor bearing lubricant, those voltage levels dissipate to the electric motor’s bearing housings. Harmful voltage levels sent to a motor’s bearing housings eventually leads to bearing failure in the electric motor. Variable speed drive motors use special bearings that are designed to withstand the harmful voltage levels that are induced by variable speed drives.

General purpose electric motors can be driven by variable speed drives, but once the general purpose motor fails, an inverter duty motor should replace the general purpose motor. Precision Electric recommends maintenance technicians who use general purpose motors on variable speed drive applications to keep a spare inverter-duty motor to minimize downtime.

Variable speed drive motors are more expensive than general purpose motors, but the increase in cost is worth preventing
downtime in variable speed drive applications when low speed is present. Many variable speed drive applications do not need to operate at low speeds, so variable speed drive motors are cost-prohibited in applications where low speed is not required.

Call Precision Electric for free quotes on variable speed drives, variable speed drive motors, servo motors, and all other industrial related equipment. Precision Electric offers free repair quotes on all industrial electronics equipment and industrial electronics field services.

What Is A Variable Frequency Drive

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What is a variable frequency drive? Variable frequency drives are also known as variable speed drives, VFD’s, adjustable speed drives, and inverters.

Variable frequency drives are solid state motor control systems designed to control the speed of an AC (alternating current) electric motor. Variable frequency drives operate as load controls within AC electric motor applications; and variable frequency drives can reduce energy costs up to 50% by speed reduction on electric motors where the full speed (RPM) of the electric motor is not required. Variable frequency 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 electric motor applications.

Many manufacturers apply AC variable frequency drives to rotating equipment because variable frequency drives reduce amperage spikes upon start up of large electric motors. Choosing the right AC variable frequency drive for an application will benefit 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. AC variable frequency drives provide the ability to control the frequency of starting and stopping of an AC electric motor. This ability allows an AC electric motor to only operate 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 in which they’re operating. By installing AC variable frequency drives 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 AC variable frequency drives, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, and control hardware and software.

Power Savings: What Is A Variable Frequency Drive

The majority of AC variable frequency drives in the market today contain electronic circuitry that converts 60 Hertz Line power into direct current. The variable frequency drive converts this line power into a pulsed output voltage that duplicates varying alternating current to a desired frequency (speed). A properly applied AC variable frequency drive when paired with an AC electric motor will significantly reduce operating costs 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 an AC variable frequency drive in blower applications, the current draw of the motor will be reduced 30% for every 10% drop in speed. The same electric motor operating from an AC variable frequency drive at 50% speed, will draw approximately 20% of the full load current.

Example Application:

A 10 horsepower AC electric motor, rated 90% efficient, operating across the line without an AC variable frequency drive, with the dampers operating between 50 – 70%, for 2000 hours per year will require 11,996 KWH.  If the KWH charge is $.08 per KWH, the cost to run this motor will be: $1,248.00 annually. The same 10 horsepower electric motor operating from an AC variable frequency drive, between 50 – 70% speed for 2000 hours per year will require 4,676 KWH.  Operating cost at the same KWH rate will be:  $432.00 per year. This represents a savings of $816.00 per year and should be enough to pay for the AC variable frequency drives investment and installation costs, within the first 12 months of operation. If any electric motor application operates more hours than in the above example, and/or the KWH charge is higher, the savings will quickly compound. The energy saved on a utility bill from using a variable frequency drive is often significant enough to pay for the variable speed frequency within a couple of months from installation date. Increasing and/or decreasing the start up time on an AC current electric motor via a variable frequency drive can add years to the motor’s overall lifespan. Using a variable frequency drive can also improve efficiency on production demands. Variable frequency drives provide the ability to control the frequency of starting and stopping an AC electric motor. This ability provides a means by which an AC electric motor is only operating when needed. AC electric motors have a longer lifespan if they are not continuously operating when they do not need to be.

Types Of Drives: What Is A Variable Frequency Drive

Volts Per Hertz drives are the most common type of variable frequency drive and are known as a V/Hz drives, or volts by hertz drives. V/Hz variable frequency drives are used in applications such as fans, pumps, air compressors, and other related applications where high starting torque is not required. V/Hz variable frequency 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 variable frequency drives are the most inexpensive type of variable frequency drive. V/Hz variable frequency drives do not provide full motor torque at low RPM.

Open-Loop vector drives are also known as “sensorless vector” variable frequency 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 a V/Hz variable speed drives.

Closed-Loop vector 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 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 variable frequency drives or for repair and replacement quotes, contact Precision Electric, Inc.