Magnetek VFD Repair

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

Connections
Checkingconnections is a step many people miss or do incorrectly during the Magnetek VFDrepair process. Heat cycles and mechanical vibration can lead to sub-standard connections, as canpoorroutine maintenancepractices. Reusing torque screws is not a good Idea on connections, and further tightening an already tight connection can ruin the connection.Bad connections eventually lead to arcing. Arcing at the VFDinput can result in nuisance over voltage faults, clearing of input fuses, or damaging protective components. Arcing at the VFDoutput could result in over-current faults or damage to the power components.

Loose connections can also cause erratic operation. Loose START/STOP signal wires can cause uncontrollable inverterstarting and stopping. A loose speed reference wire can cause the VFDspeed to fluctuate, resulting in scrap, machine damage, injury or death.

Conduct Diode and IGBT Tests
There are a number of methods to test the input and output power sections during Magnetek VFD repair processes, and this step is essential prior to applying power to the VFDunit. If there’s a short on the input or output side of the VFD, further damage to the VFD may result if power is applied to it.

For this reason, Precision Electric uses meters to properly test the input and output power sections of the VFDprior to applying power to the 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 offeredto the customer.

Power Up Unit
If the input and output power sections test healthy during this step of the Magnetek VFDrepair 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 VFDis achieved.

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

Run A Motor
If the previous tests have passed during the Magnetek VFDrepair process, Precision Electric willrun a basic jog function of the VFDwith a simple template program. Often when Magnetek VFD repair jobscome into our facility, technicians will backup operation programs that are stored in the VFD prior to inputting a template program and running test procedures. Backing up the operation program will ensure that Precision Electric canreinstall the program once the Magnetek VFD repair is complete.

The best method for backing up an operation program depends on the manufacturerof drive, but after it has been backed up, Precision Electric will either reset the VFDto factory defaults through the keypad and recommission a basic start, stop function. If the VFD is closed loop requiring an encoder, the encoder is tested for faults prior to running the start, stop test function. If the motor will not run in factory default mode, the motor output voltages and motor current ratings are checked to see if the VFD is functioning properly for motor rotation.

Magnetek VFDrepair should be taken with extreme caution. VFDrepair should only be performed by technicians who have required training and experience to work with electrical equipment. Precision Electric strongly recommends consulting an expert in the field when repairing or installing industrial electrical equipment.Many VFD units have an internal DC bus that retains an electrical charge after power to the drive is turned off, which means it’s unsafe to work with. Technicians performingMagnetek VFD repair should always take extra precautions to ensure proper safety measures are taken to prevent injury or death.

For Magnetek VFDrepair and Magnetek VFDreplacement quotes, contact Precision Electric.

Eaton Overcurrent Protection

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Eaton overcurrent protection and Eaton current control for the Eaton9000X drive is based on motor current measurement in all three phases. In the Frame 9/ Chassis 61 Eaton drives, the current sensors are built into the IGBT SKIP modules, and the current signals are combined and fed into a 14-bit A/D converter on the lower ASIC board. The ASIC board sends the current levels to the control board via a fiber optic serial link. In the smaller Eaton Frame 8 / Chassis 5 drives (and below), the measured current signal is fed directly to the control board. The EatonSVX9000drive has a 10-bit A/D converter and the EatonSPX9000drive has a 14-bit A/D converter.

Eaton overcurrent protection for the 9000X air-cooled frequency converter ratings are based on a High Overload (IH) capability. This means the drive can provide 150% rated output current for 1 minute if the drive was operating at rated output current (IH) for at least 9 minutes. To get continued 150% overcurrent capability, the average current over the duty cycle cannot exceed the rated output current. The maximum drive output current (IS) for starting produces approximately 200% rated motor torque but because the currents are vector sums, IS is less than 200% IH. The drive can deliver IS for 2 seconds every 20 seconds. The drive current limit can be set to 200% (2 x IH) to deliver IH but to reduce the chance of an overcurrent or IGBT over temperature trip, it is better to set the current limit to 150% (1.5 x IH) or less.

The actual drive output current available to the motor is dependent on ambient temperature at the intake to the drive, restrictions in airflow to the drive, and the drive frame size. Drive frames FR4FR9 can deliver rated current (IH) at 50C. Drive frames FR10 and above can deliver rated current (IH) at 40C except for the highest ratings of a drive frame, which may be limited to 35C. The Low Overload (IL ) rating is typically used for variable torque loads where an overload is not necessary even though a 1 (out of 10) minute overload of 110% is allowed. All drive frames are limited to 40C or less for the IL rating. The rated currents of each frame depend on a reduction of switching frequency when unit temperature reaches the warning level.

Eaton overcurrent protection in the liquid-cooled drive has a Thermal maximum continuous rms current (Ith). Use this value for continuous or any overload requirements of the process. The liquid-cooled drive does not have a 1-minute overload current rating. The thermal current rating is dependent on proper coolant flow to each module and a module coolant inlet temperature of 30C. Current limit (software-function) The drive will attempt to limit drive output current to the current limit setting by overriding and lowering the frequency reference until current is within the current limit setting. If unit temperature nears the warning level, the drive will reduce the output frequency in an attempt to bring drive output current down to a continuous current that is approximately the Low Overload (IL ) current rating. The control will not allow any further overcurrent conditions until the average current over the duty cycle is less than the drives current rating. The liquid-cooled drive control will attempt to limit the output current to the current limit setting up to the drives thermal rating. The application should be designed to avoid using the current limiter for control.

The safest way to operate an Eatondrive is to keep the drive output current within ratings with appropriate ramp times or a controlled reference to the drive. If the drive software cannot prevent output current from exceeding 200% IH, a current cutter stops firing the IGBTs when the measured instantaneous value of the current exceeds 360% IH to reduce current quickly before an overcurrent trip occurs. They are re-fired on the next top of the triangle wave. The current cutter is active on select units FR8/CH5 and smaller. If the measured instantaneous value of current exceeds the trip limit value (260400% depending on drive size), all IGBTs are switched off and the drive displays an F1, overcurrent trip. The drive is protected from a short circuit at the motor if the motor leads are greater than 16 feet (5m) in length.

Only trained and experienced electricians should work withEaton overcurrent protection. For more safety information about Eaton overcurrent protection, visit the Eaton Website. For Eaton drive repair and Eaton drive replacement quotes, contact Precision Electric.

Eaton Low Voltage Drives

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Eaton low voltage drives (also known as variable frequency drives) adjust an electric motor’s speed to closely match output requirements, resulting in a typical energy savings of 10 to 50 percent.

Eaton’s SVX9000 adjustable frequency drive offers sensorless vector control technology coupled with an adaptive motor model and sophisticated ASIC circuit features. This technology allows for steady speed error, fast torque rise time, high immunity to resonance vibrations and high starting torque and current. The SVX9000 is suitable for multiple motor drive systems and high-speed applications.EatonSPX9000 drives are designed specifically for high-performance applications. Eaton SPX9000 drives feature high processing power and the ability to use information from an encoder or a resolver to provide precise motor control. In addition, a fast microprocessor provides high dynamic performance for applications where good motor handling and reliability are required.

The Eaton DG1 General-Purpose drives are part of the Eaton next-generation PowerXL series of adjustable frequency drives specifically engineered for todays more demanding commercial and industrial applications. With an industry-leading energy efficiency algorithm, high short-circuit current rating and robust design, the Eaton DG1 General-Purpose drives offer increased efficiency, safety and reliability.Eaton’s LCX9000 drives are liquid-cooled products that utilize potable water or a water-glycol mixture as a cooling medium. Their compact size and low heat transfer rates allow the enclosure size to be greatly reduced, which is especially beneficial in UL Type 4X applications.

Eaton offers industry-leading technology for applications where harmonics are a concern. Eaton’s clean power drives significantly reduce line harmonics at the drive input terminals and provide some of the purest sinusoidal waveforms available.EatonPowerXL Enclosed Drivesis a next generation enclosed drive platform that packages Eatons PowerXL DG1 and SVX drive families in a versatile, fast, and reliable design solution.

EatonCFX9000 Clean Power Drivesuse tuned passive filters to significantly reduce line harmonics at the drive input terminals. These drives are an excellent choice for small and midsize applications where harmonics are a concern. EatonCPX9000 Clean Power Drivesare the clear choice for applications in the water, wastewater, HVAC, industrial and process industries where harmonics are a concern. They offer one of the purest sinusoidal waveforms available.

EatonCP to CPX Retrofit Kitsprovide an alternative to a complete drive and enclosure replacement for our existing CP customers. They provide a cost effective and time efficient solution only Eaton can provide. EatonAGSVX Irrigation Drive Panelis a single-phase to three-phase irrigation drive panel is an efficient and clean solution for three-phase power. EatonHVX9000 HVACvariable frequency drives use the most sophisticated semiconductor technology and a highly modular construction to provide flexibility for HVAC applications.

EatonMVX9000 Micro Drivesare sensorless vector variable frequency drives are designed to provide adjustable speed control of three-phase motors. EatonSLX9000 General Purposedrives are compact, yet powerful drive is based on the more robust SVX9000. It is designed to be the next generation of drives specifically engineered for modern commercial and light industrial applications.

To learn more about Eaton low voltage drives or for Eaton low voltage drives repair and replacement quotes, contact Precision Electric.

 

 

Lenze Frequency Inverter

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Lenze frequency inverter drives are used in a wide variety of industries including materials handling, packaging, robotics and automotive. Lenze frequency inverterproducts are carefully coordinated and matched and can be combined as required to provide the right solution for mostneeds. Lenze frequency inverter drivescombine reliability with quality to enable Lenze to help increase the productivity for mechanical engineers and machine operators.

Lenze frequency inverterdrives are used for electronic speed control of AC induction motors. The needs of the market are wide and varied, and Lenze offers a broad range of standard products for everything from simple speed control to complex; each with a wide range of functionality, small physical size and exceptional performance. Lenze frequency inverterdrivesare reliable, flexible to apply, easy to commission, and meet the highest standards of quality. Lenze frequency inverter drives provide solutions to fulfill nearly any variable frequency drive needin the power range between 0.25 kW and 400 kW.

SMVector Lenze Frequency Inverter

The SMVector of Lenze frequency inverter drives is Lenze’s most advanced product. Lenze’s tradition of innovative compact design, performance and flexibility make the SMVector an attractive solution for a broad range of AC Motor applications. Lenze drives feature several communications protocols, networking drives and components into a system solution that can be done now or in the future.The Lenze SMVector NEMA 1 drives are 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 Lenze SMVector NEMA 4X drives are available in two enclosure types– one is for indoor only use and one is 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 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.

MC1000 And MCH Lenze Frequency Inverter

The MC Series Lenze frequency inverter is an AC Tech legacy product and has been being used in production since the late 1970’s. The MC series Lenze frequency inverter drives are made in the United States and are an inexpensive solution for standard volts per hertz applications. MC Series drives are a common drive solution for pumps, conveyors, and other applications where high starting torque and full torque at low speed (RPM) is not required.

The MC series Lenze frequency inverter drives are built in rugged steel enclosures that hold up to wear and tear in factories across the globe. The AC Tech MC series drives have an easy to read 16 character LCD display above the drive keypad that allows for simple set up and daily operations. MC series Lenze frequency inverter drives are a constant horsepower drive and can be set up for simple applications requiring slow start and slow stop of an AC electric motor.MC series Lenze frequency inverter drives can also be applied in applications that require PID set-point control.

MC series Lenze frequency inverter drives come in two different models; the M1000 Series and the MCH Series. Most industrial applications will use the MC1000 series drive with a keypad that includes start, stop, up, down, forward/reverse, Program/Run, Auto/Manual and Enter buttons.MCH series drives are used in non-reversing industrial applications that require independent switching of start and stop from local to remote. MCH series Lenze frequency inverter drives are also used in applications where speed control from auto to manual is required. The MCH series keypad replaces the forward/reverse button with Local/Remote. Technical documentation for the MC1000 and MCH series Lenze frequency inverter drives can be found on the Lenze Americas Website.

To learn more about Lenze frequency inverter drives or for Lenze Repair and Replacement quotes, contact Precision Electric.

What Is A VFD?

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VFD is an abbreviation that stands for Variable Frequency Drive. VFD’s arealso known as variable frequency drives, variable speed drives, adjustable speed drives, electronic motor controllers, orinverters.

VFD’s aresolid 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 costsup to 50% by speed reduction on electric motorswhere the full speed (RPM) of the electric motor is not required.VFD’s 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 will apply a VFD to rotating equipment to reduce amperage spikes upon start up of large electric motors.Choosing the right VFDfor 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. Variable frequency drives provide 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 it’s rotating, and electric motors have a longer lifespan if they are only running when they 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 a VFD 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 variable frequency drives, and has improved performance through advances in semiconductor switching devices, simulation, control techniques, and control hardware and software.

VFD Power Savings

The majority of 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 VFD when paired with the correct 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 variable frequency drives in blower applications, the current draw of the motor will be reduced 30% for every 10% drop in speed. The same electric motor operating froman AC variable frequency drive at 50% speed, will draw approximately 20% of the full load current.

VFD 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 is usually 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/orthe KWH charge is higher, the savings will quickly compound.

The energy saved on a utility bill from using a variable frequencydrive is often significant enough to pay for the variable speed frequencywithin a couple of months from installation date.Increasing and/or decreasing the start up time on an AC current electric motor via a variable frequencydrive can add years to the motor’s overall lifespan. Using a variable frequencydrive can also improve efficiency on production demands.

VFD Types

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

Open-Loop vector drives are also known as “sensorless vector” variable frequencydrives. 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 frequency 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 VFD’s, please watch our YouTube Videobelow this post. For VFD repair and replacement quotes, contact Precision Electric, Inc.

Eaton HVAC Frequency Drives

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Eaton HVAC frequencydrives were specifically engineered for HVAC, pump and fluid control applications. The power unit makes use of the most sophisticated semiconductor technology and a highly modular construction that can be flexibly adapted to the customers needs. The input and output configuration (I/O) is designed with modularity in mind. The I/O is compromised of option cards, each with its own input and output configuration. The control module is designed to accept a total of five of these cards. The cards contain not only normal analog and digital inputs but also field bus cards.

The HVX series of Eaton HVAC frequencydrives are obsolete and replaced by Eaton H-MAX drives.The HMAX series of Eaton HVAC frequency drives are designed to the HVAC market for fan, pump, and fluid control applications. The patented energy savings algorithm, high short-circuit current rating and intuitive user interface provide customers an energy efficient, safe, and easy to use solution for adjustable frequency drive needs.The H-MAX drive supports the increasing demand for energy savings in buildings, systems and facilities. Built in capabilities and unique features provide a competitive solution that can add value to any end user.

MVX9000 And M-MaxEaton HVAC Frequency Drives

The MVX9000 series of Eaton HVAC frequency drives are microprocessor-based, sensorless vector drives that provide adjustable speed control for three-phase motors. MVX9000 drives come with standard features that can be programmed to customize the drive’s performance to suit a wide variety of applications, and they include a digital display with operating and programming keys on a removable keypad.

MVX9000 series of Eaton HVAC frequency drives are obsolete and replaced by Eaton M-MAX drives.The M-Max Drive is a compact micro drive with a broad power range. The M-Max series of Eaton HVAC frequency drives feature conformal board coating, unique mounting characteristics, simple programming, and 50C Rating to makethe M-Max perfectly suited for machinery applications in many industries. Typical applications for the M-Max Eaton drive include Food and Beverage, HVAC, Packaging, Pumping, Textile, OEM, and more.

The M-Max series of Eaton HVAC frequency drives key features include:

  • Global acceptance
  • 50C ambient temperature environments
  • Conformal coating standard
  • Modbus-RTU as standard serial fieldbus
  • Side-by-side mounting and orientation flexibility to maximize panel space
  • Temperature controlled cooling fan to increase efficiency and extend life
  • On-board start-up wizard and preset macros to simplify commissioning
  • NEMA 1 kits available

To learn more about Eaton HVAC frequency drives or for Eaton HVAC drives repair and replacement quotes, contact Precision Electric.

Eaton SV Repair

Eaton SV Repair

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Eaton SV repairshould be taken with extreme caution andonly be performed by technicians who have required training and experience with electrical equipment. Alwaysconsult an expert in the field when repairing or troubleshooting industrial electrical equipment. Most drive controllers have an internal DC bus that retains a charge after power has been cut to the drive, as a result, the power being cut doesn’t mean that the drive issafe to work with. Technicians working with variable frequency drives and other electrical equipmentmust always take extra precautions to ensure proper safety measures are taken to prevent injury or even death.

Variable Frequency Drives (VFD’s) have over the past decade allowed to become a cost efficient way to reduce power costs and increase system efficiency. Manufacturers around the globe within a wide range of industries are finding more ways to apply VFD’s to their rotating equipment.From past experience, smaller horsepower VFD’s typically fail in eight years and are more often replaced rather than repaired.Larger horsepower VFD’s last longer by virtue of repairs that often require replacement of circuit boards and other electrical components.

Eaton SV Repair Versus Eaton SV Replacement

Eaton SV repair is common for Sullair Service Centers and manufacturers who use Eaton equipment. Eaton SVrepair is preferred by Sullair service centersand manufacturers because Eaton SV replacement is more expensive than Eaton SV repair.Most companies who offer Eaton SV repair don’t have the capabilities or experience to repair Eaton equipment themselves; so they outsource the VFD repair to third party repair centers, or they send it to Eaton and charge their customer more than the actual repair cost. Eaton offers SV VFD repair services for their products but it’s inefficient because Eaton always has extensive lead times for repairs, and Eaton drive users cannot wait forextensive lead times due toproduction downtime.Precision Electric offerscomplete Eaton SVrepair, and all Eaton SVrepair jobs are performed in house at Precision Electric.

Eaton SV repairis an asset to manufacturers who use Eaton VFD equipment because Eaton usually recommends replacing their equipment when it fails. Eaton SV VFD replacement is more expensive than Eaton SV repair. Eaton SVreplacement also has extensive lead times that aren’t economical when production is down. Eaton SVrepair can be performed by Certified Eaton SV Repair Centers morequickly than waiting for Eaton to produce a replacement SV VFD.

ContactPrecision Electric today forEaton SV repairand Eaton SV replacement quotes.

Variable Frequency Motor Drives

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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

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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

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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

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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.

Lenze i500

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The Lenzei500 is the newest frequency inverter from Lenze and is available in the 0.33 to 60 horsepower power range. The Lenze i500 features a streamlined design, scalable functionality, and exceptional user-friendliness. Lenzei500 provides a high-quality frequency inverter that already conforms to future standards in accordance with the EN 50598-2 efficiency classes (IE). Overall, the Lenze i500 provides a reliable and future-proof drive for a wide range of machine applications.

The functions and power of the new range of Lenze i500 frequency inverters can be tailored to virtually any machine application and industrial environment. Lenze i500 inverters are compliant with efficiency class IE2. Lenze i500 inverters feature a slim design and peak energy efficiency in the 0.33 to 60 Hp power range. Lenze set out to bundle cutting edge control technologies into a customized IE2-compliant package for machine builders. All of the Lenze i500 components are stringently designed for optimal energy efficiency, which boosts the value for machine builders by increasing power density while allowing for a smaller design. The compact, modular Lenze i500 frequency inverter features a lower housing depth along with a sophisticated cooling system to reduce heat losses and allow side-by-side installation with minimal wiring in a smaller control cabinet. Lenze i500 inverters for control cabinet installation feature IP20 and IP31-rated protection. Delivering functional scalability and integrated safety, the Lenze i500 power section is structurally separate from the control unit, and contains different forms of field bus communication, including Ethernet, multiple I/O interfaces, and plug options for a keypad, a USB interface or a wireless LAN module. These interfaces provide users with greater flexibility and ease of commissioning, parameter setting, maintenance and diagnostics. The wireless LAN module can communicate with a PC or via a smart phone keypad application.

Lenze i500 Advantages

  • Space saving design: 2.36 in. (60 mm) wide, 5.12 in. (130 mm) deep, also zero-clearance mounting.
  • Innovative interface options enable set-up times faster than ever before.
  • The wide-ranging modular system enables various product configurations depending on machine requirements.
  • The i500 is recommended in applications for pumps and fans, conveyors, formers, winders, traveling drives, tool and hoist drives.

Lenze is a global manufacturer of electrical and mechanical drives, motion control and automation technology. As a global specialist in Motion Centric Automation, Lenzeoffers products, drive solutions, complete automation systems, engineering services and tools from a single source. Lenze isa leading provider of automation solutions to the packaging industry, and our other focus industries include automotive, material handling and logistics, robotics, and commercial pumps/fans. With a global network of engineers, sales representatives, and manufacturing facilities, Lenze is well-positioned to meet the motion control needs of customers worldwide.

The new Lenze i500 frequency inverters are structured and built to give machine builders the ultimate in energy savings, integration and design flexibility to specify precisely the features they need. To learn more about Lenze i500 frequency inverters, visit the Lenze Website. For Lenze i500 frequency inverter quotes, contact Precision Electric.