Eaton VFD Troubleshooting

Eaton VFD Troubleshooting

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Eaton VFD TroubleshootingEaton VFD troubleshooting begins with technicians working with the VFD in production. Eaton VFD troubleshooting can be time consuming, so manufacturers tend to keep spare Eaton drives on hand for production lines that cannot afford downtime.When Eaton VFD troubleshooting cannot be resolved in the plant, technicians in the field are known to send their Eaton VFD to the original equipment manufacturer or Eaton VFD repair centers for repair and replacement options. The original equipment manufacturer of Eaton drives and Eaton VFD repair centers usually only offer a replacement for failed drives, but this isn’t usually the most economical solution for manufacturers.

Eaton VFD troubleshooting and VFD repair centers are an asset to manufacturers who use Eaton drive products, and Precision Electric is the best source for Eaton VFD troubleshooting and Eaton VFD repair.Precision Electric has been performing Eaton VFD Troubleshooting and Eaton VFD Repair since 1983.Precision Electric has helped save manufacturers thousands of dollars by repairing their failed Eaton VFD drives in lieu of of replacing Eaton VFD drives.

When Eaton VFD troubleshooting leads to Eaton VFD repair, the repair process should be taken with extreme caution. Eaton VFD 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 and troubleshooting Eaton VFD equipment.

The troubleshooting techniques for each brand of VFD can be unique, but the overall structure of troubleshooting always remains the same.The ultimate goal when performing Eaton VFD troubleshooting is to diagnose, repair and re-commission the unit as quickly as possible, and these are the steps that Precision Electric follows before anydis-assembly takes place.

1. Take Notes –Eaton VFD Troubleshooting

This is often a subject that is passed by many individuals who are attempting to troubleshoot industrial electrical equipment. Before Precision Electric begins to perform Eaton VFD troubleshooting, qualified technicians take note of many important aspects of the equipment including, but not limited to:

    1. Eaton VFD Model Number
    2. VFD Serial Number
    3. Reason for Service
    4. Urgency (Rush Overtime or Standard)
    5. Visual Inspection of External Device

2.Diode and IGBT Tests –Eaton VFD Troubleshooting

Eaton VFD TroubleshootingWhen Eaton VFD Troubleshooting exceeds parameter changes, Precision Electric tests the input and output power sections of the Eaton VFD. This step is essential prior to applying power to the VFD unit. If for any reason there is a short on the input side or output side of the VFD, 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 Eaton VFD 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.

3. Power Up –Eaton VFD Troubleshooting

If the input and output power sections test healthy during this step of the Eaton VFD troubleshooting and repair process, Precision Electric will power up 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 VFD is achieved.

Depending on whether or not the VFD 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 VFD is likely necessary to further evaluate cause of failure and establish cost and lead time for the Eaton VFD repair.

4. Run A Motor – Eaton VFD Troubleshooting

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

5. Contact Customer – Eaton VFD Troubleshooting

At this point we have determined the cause of failure, estimated lead time and cost of the Eaton VFD troubleshooting and VFD repair. If the VFD has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electricwill 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 depends on a wide variety of variables.

6. Send Service Tech – Eaton VFD Troubleshooting

If the customer cannot establish failure on any other aspect of the machine and the Eaton VFD troubleshooting tests appear to be good, then it may be necessary to send a Precision Electric field service technician on site to establish cause of failure. Precision Electricfield service technicians are trained to troubleshoot any issue ranging from standard VFD repair to advanced robotics, servo systems, electric motor issues and more. Precision Electric field technicians are trained to establish cause of failure and come up with solutions as quick as possible.

To learn more about Eaton VFD Troubleshooting or for Eaton VFD Repair Quotes, contactPrecision Electric, Inc.

 

 

 

 

 

 

HVAC VFD Repair

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HVAC VFD RepairHVAC VFD repair should be taken with extreme caution. HVAC VFD 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 HVAC VFD equipment.

Many HVAC VFD 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 HVAC VFD repair must always take extra precautions to ensure proper safety measures are taken, or injury or even death may occur.

Precision Electric has spent years working with electrical components and HVAC VFD controllers, DC motors and VFD controllers, servo motor and servo VFD systems, and other related industrial electrical equipment. The troubleshooting techniques for each brand of VFD can be unique, but the overall structure of troubleshooting always remains the same.The ultimate goal when performing HVAC VFD repair is to diagnose, repair and re-commission the unit as quickly as possible, and there are steps that should be taken before anydis-assembly takes place.

Precision Electric has been performing HVAC VFD repair since 1983 and all repairs performed by Precision Electric includs a 1-year in-service warranty. The Precision Electric in-service warranty begins the same day that equipment is put into service and ends 1 year later. The Precision Electric in-service warranty was implemented to give manufacturers incentive to keep spare equipment in rebuilt condition to minimize downtime and maximize production.

Here are all the steps illustrating how Precision Electric performs HVAC VFD Repair:

1. Take Notes –HVAC VFD Repair

This is often a subject that is passed by many individuals who are attempting to repair industrial electrical equipment. Before Precision Electric begins to perform HVAC VFD repair, qualified technicians take note of many important aspects of the equipment including, but not limited to:

    1. HVAC VFD Manufacturer
    2. VFD Serial Number
    3. Reason for Service
    4. Urgency (Rush Overtime or Standard)
    5. Visual Inspection of External Device

2. Conduct Diode and IGBT Tests –HVAC VFD Repair

There are a number of methods to test the input and output power sections of HVAC VFD repair orders, and this step is essential prior to applying power to the VFD unit. If for any reason there is a short on the input side or output side of the VFD, 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 VFD 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.

3. Power Up Unit –HVAC VFD Repair

HVAC VFD RepairIf the input and output power sections test healthy during this step of the HVAC VFD 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 VFD is achieved.

Depending on whether or not the VFD 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 VFD is likely necessary to further evaluate cause of failure and establish cost and lead time for the HVAC VFD repair.

4. Run A Motor –HVAC VFD Repair

If the previous three tests have passed during the HVAC VFD repair process, then it is time to run a basic jog function of the VFD with a simple template program. Often when a VFD comes into our facility, we make sure to backup whatever program is currently stored in the VFD 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 HVAC VFD 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 VFD is functioning properly to rotate the motor.

5. Contact Customer –HVAC VFD Repair

At this point we have determined the cause of failure, estimated lead time and cost of the HVAC VFD repair. If the HVAC VFD has tested good entirely, then further underlying issues are communicated with the customer. This is when Precision Electricwill 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.

6. Send Service Tech –HVAC VFD Repair

If the customer cannot establish failure on any other aspect of the machine and the HVAC VFD appears to test fine, then it may be necessary to send a Precision Electric field service technician on site to establish cause of failure. Precision Electricfield service technicians are trained to troubleshoot any issue ranging from standard HVAC VFD repair, to advanced robotics, PLCs and more. Precision Electric field technicians are trained to establish cause of failure and come up with solutions as quick as possible.

To learn more about HVAC VFD Repair or for HVAC VFD Repair Quotes, contact Precision Electric, Inc.

 

 

 

 

ABB DCS800 VFD

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ABB DCS800 VFDThe practical requirements of a modern DC VFD are extremely diverse. A DC drive should be full of features and easy to use which sometimes, isn’t a simple task. The challenge is to find an innovative solution which excels in both, and the solution, is the ABB DCS800 VFD.

The ABB DCS800 VFD offers a simple interface and rich feature set, offering ease of commissioning and smooth adaptation to specific applications. The ABB DCS800 VFD has the widest power ranges in the industry from 10 horsepower through 2,500 horsepower in single VFD module packages and solutions through 1200 volts and 20,000 amps.

The ABB DCS800 VFD has the most advanced digital controller of any DC drive on the ABB power platform. This means that there are 16-bit analog input / output; 5 millisecond response time for overriding control; and integrated speed, torque, PID, and voltage controls as standard features. This makes the automatic tuning feature of the ACS800 simple to commission, macros to simplify setup, and adaptive programming feature that allows ease of custom requirements within the application. The ABB DCS800 VFD is the latest digital technology on a proven power platform.

ABB DCS800 VFD Programming and Communications

ABB DCS800 VFDAdaptive Programming (AP) offers the ability to customize the drive to needs without installation of additional hardware to the ABB DCS800 VFD. Adaptive Programming within the ABB DCS800 VFD also allows the user to change how a digital output works, add a PI Controller, and filter an analog input. The DCS800 can be programmed with the control panel or by using the ABB PC-Based software, DriveWindow Light, which is included with every ACS800 VFD. Adaptive Programming features the flexibility users need to make the drive work to required specifications.

ABB offers a wide range of software to make accessing, programming and diagnostics easier to communicate with the ACS800 than ever before. DriveWindow Light is a powerful PC-Based tool to start up and interface with the ACS800, and DriveWindow Light is included with every ACS800 drive module. More complex applications and systems use High Speed DriveWindow Tool with a host of features, high speed data, and clear graphical presentation of the application operations that make it a valuable addition to any DC Drive System.

For Control Builder users, ABB CoDeSys offers all t he tools needed to create and modify applications. If additional programming or software is needed beyond the CoDeSys, ABB will provide control builders with its own web page with full internet access.

ABB DCS800 VFD Adaptability

The ABB DCS800 VFD functionality increases according to the requirements of the DCS800 user. The user has the ability to include plug-in options such as field bus modules, input / output extension modules, and fiber-optic communication modules. ABB’s field bus alternatives feature full access to drive control and status words to system diagnostics. This makes the choice of automation systems completely independent from the choice of using an ABB DCS800 VFD versus the competition. The ABB DCS800 VFD also offers the adaptability of Control Builder; Control Builder is a tool that puts fully programmable PLC (prgrammable logic control) inside the drive. Control Builder can modify the drive operation, interface, or create entirely new functions for the application equipment.

To learn more about the ABB DCS800 VFD, please visit the ABB Website or contact Precision Electric, Inc.

 

Information References:

 

  • http://new.abb.com/us
  • http://www.abb.com/product/us/9AAC113388.aspx?country=US
  • http://www05.abb.com/global/scot/scot204.nsf/veritydisplay/7e9e66c8d3dea67ec1257a090044cea7/$file/3adw000192r0601%20dcs800%20technical%20catalog%20e%20f.pdf

 

 

 

 

 

 

 

 

VFD Manufacturers in the United States - ABB

VFD Manufacturers

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When choosing VFD manufacturers for motor speed control equipment in production, it is recommended by Precision Electric to choose VFD manufacturers who offer extensive technical support for their products.Precision Electric recommends using VFD manufacturers in the United States, such asABBorLenze Americas. VFD manufacturers in the United States such as ABB and Lenze Americas have a reputable past for providing extensive technical support and troubleshooting for their VFD products.

USA VFD Manufacturers – ABB Low Voltage Drives

VFD Manufacturers in the United States - ABBABBlow voltage AC and DC VFD products are manufactured in the United States and are used across all industries and applications.ABBVFD products offer application specific functionality control for different types of motors as well as flexible connectivity to automation networks. ABB VFD products, inverters and converters are proven and reliable solutions backed by global production and life cycle services.

ABB VFD products provide scalable motor control from standard to demanding applications for a wide range of industries, especially in the process industries such as pulp and paper, metals, mining, cement, power, chemical, oil, gas, and more.

ABB VFD products are packed with advanced drive technology developed by ABB engineers and are capable of tackling even the most demanding requirements. A wide voltage and power range with various drive configurations and options enable one drive platform to be used for all needs.Precision Electric works closely with VFD manufacturers such as ABB.

Precision Electric offers retrofit solutions with the integration ofABBlow voltage VFD products to increase production time, and to increase energy efficiency for manufacturers across the nation. Precision Electric also offers ABB low voltage VFD distribution, technical telephone support, repair services and certified ABB VFD start up solutions. The ABB VFD Certified Start Up adds an extra one year warranty to anyABBVFDproduct that is installed by qualified Precision Electric service technicians.

USA VFD Manufacturers – Lenze Americas

VFD Manufacturers in the United States - Lenze AmericasLenze AmericasVFD products are manufactured and stocked in the United States.Lenze AmericasVFD and automation technology is used in a wide variety of industries; including materials handling, packaging industry, robotics and automotive. Lenze Americas products are carefully coordinated and matched, and can be combined as required to provide the right solution for production needs. Lenze Americas automation solutions with integrated software and system engineering, and a global customer service, makes Lenze Americas a leader in their industry.

Lenze Americas reliability combined with the quality of their products and services consequently increases the productivity of industrial manufacturing. Precision Electric has been working with Lenze Americas for over 25 years. Precision Electric offers Lenze VFD retrofit solutions to industrial manufacturers to increase energy efficiency and production for manufacturers across the nation. Precision Electric offers Lenze VFD repair services, distribution, and technical support forLenze Americasproducts.

Precision Electric aims to increase production time, while maximizing energy efficiency to manufacturers across the nation.ContactPrecision Electric today for free VFD Repair or VFD Replacement Quotes.

 

 

 

 

SVX9000

SVX9000 VFD

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Eaton SVX VFDEatonsSVX9000VFD (variable frequency drive) is thecompact, modular solution to adjustable speed applications. The SVX9000 VFD enables a broad range of new application capabilities, and option cards allow the to configurethe VFD to meet any requirement. With its wide voltagerange, high overload ability, and user-friendly alphanumericalkeypad,SVX9000VFD Drivesare the smart decision forevery user.

There are just three screws that link thecontrol module to the powermodule on the SVX9000 VFD. SVX9000 VFD controlunits are interchangeable withinframe sizes while software,control panels, I/O andcommunication cards arecommon throughout the line.Separating the power andcontrol units provides installationadvantages and reduced spareparts requirements. Forconvenience, theSVX9000VFD isfield convertible from Type 1 toType 12 (frames 46). Itsreduced size equates to lesspanel space used and easyretrofits.

Even when the drive isunpowered, theSVX9000VFDcanbe programmed and tested.The control logic module can bepowered from an external +24Volts DC source so youre ready totrain, test and go live wheneverneeded. Whether you chooselocal or remote operations viathe keypad, simple copy/pastefunctions streamline processes.

TheSVX9000may be configuredwith several differentcommunication protocols,making it easy to communicatewith all commonly used controlsystems. The control unitspowerful microprocessor can beused for local control tasks,thereby freeing resources of thecontrol system for other controltasks. 9000XEngine, Eaton’sversatile block-programmingtool, eliminates the need for aPLC and significantly simplifiesthe control system.

SVX9000 VFD Programming Software

SVX90009000XLoad For SVX9000 VFD

9000XLoad is an easy-to-usetool for the SVX9000 VFD, to upload system,application and option cardsoftware intended for use byengineering, commissioning andservice personnel. 9000XLoad isalso suitable for loading customapplications to the SVX9000 VFD.

9000XDrive For SVX9000 VFD

9000XDrive is a software toolthat allows uploading anddownloading SVX9000 VFD parameters.Parameters can be changed,saved, and uploaded to anynumber of SVX9000 VFD drives.The tool has the ability to printparameters or save them to afile for future use and reference.Parameters can be compared todefault values to determine drivesetup. Operator functions includethe ability to set references,start and stop the drive, andto monitor signals and actualvalues. These values can bedisplayed via a graphic display.

9000XEngine For SVX9000 VFD

Create IEC 1131-3 compliantcustom applications with9000XEngine for the SVX9000 VFD. This graphicaldesign tool customizes thecontrol logic and parameters inthe SVX9000 VFD. Functional BlockDiagram (FBD), Ladder Diagram(LD) and Structured Text (ST)are all part of the functionset. 9000XEngine enables thecreation of parameters, faultmessages and other application relatedfeatures.

To learn more about the Eaton SVX9000 VFD, visit the Eaton Website or contact Precision Electric, Inc.

 

 

Information References:

http://www.eaton.com/Eaton/ProductsServices/Electrical/ProductsandServices/AutomationandControl/AdjustableFrequencyDrives/IndustrialDrives/SVX/index.htm

 

 

 

Excellent Versus Horrible Packaging When Shipping A VFD

Shipping A VFD

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When Shipping A VFD, These Are Examples Of Perfect Packaging Versus Terrible Packaging.

Shipping a VFD (variable frequency drive) safely is important because electronic components can be easily damaged due to poor packaging. When shipping a VFD, the first step to safely package the VFD is to locate an appropriatesize box for everything you intend to ship. When using larger boxes, keep in mind this will mean higher shipping fees from the carrier, and large boxes are unnecessary if you’re shipping small items.

When shipping a VFD, always either use a box supplied by the VFD manufacturer, specifically designed for the VFD, or a cardboard box with thick sidewalls that will not break during shipment.Once an appropriate box has been located, gently place the items in the box and use plenty of packaging materials within the box to keep the VFD safe during shipment. You can use Styrofoam, newspaper, bubble wrap, or any other type of shipping material that will keep the VFD protected within the box during shipment.Once the variable speed drive has been safely boxed up, seal the box with clear shipping tape. Masking tape and duct tape are not recommended and will not be accepted by most shipping carriers. Clear packaging tape is easy to find and holds cardboard better.

Precision Electric receives VFD Drives that are damaged during shipping nearly every day, but for the most part, VFD Drive users are aware that it’s important to package equipment safely when shipping a VFD, no matter how far of a distance the drive will be shipping. Call Precision Electric for VFD Drive repair quotes or variable speed drive replacement quotes.

 

 

 

Benefits of Using a Variable Speed Drive

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Benefits of Using a Variable Speed DriveApproximately one third of the world’s electrical energy is supplied by electric motors in fixed-speed centrifugal pump, fan, and air compressor applications. This proves thatsignificant energy efficiency improvement opportunities are available by applying variable speed drives to electric motors.

Variable speed drives have over the past decade allowed to become a cost efficient way to reduce energy costs and increase system production efficiency. Today variable speed drive manufacturers around the globe are finding more ways to benefit production processes by applying variable speed drives to manufacturing equipment .

Variable speed drives can reduce energy costs up to 50% by speed reduction on applications where the full speed (RPM) of the electric motor is not required.This energy savings is often significant enough to pay for the variable speed drive within a couple of months.

Variable Speed Drive Applications

Benefits of Using a Variable Speed DriveVariable speed drives are used in many applications such as swimming pool pumps, air compressors, conveyor belts, lathes, mills, food processing production lines, waste water treatment pumps, HVAC fans and blowers, and many more applications in the industrial manufacturing world. Variable speed drivesare often used in manufacturing facilities to increase or decrease the acceleration and deceleration times on alternating current (AC) motors. Adjusting the acceleration and deceleration timeon an AC motor can add years to the lifespan of an AC motor, and can also improve efficiency on production demands. Variable speed drives can also provide the ability to be programmed to control the frequency of starting and stopping an AC motor.This ability provides a means by which an AC electric motor is only operating when needed for the equipment it’s rotating. AC electric motors have a longer lifespan if they are not continuously operating when they don’t need to be.

Variable speed drives have an average lifespan of up to about 8 years from fractional horsepower through about 10 horsepower, but larger horsepower drives have a longer lifespan which creates a market for manufacturers to use variable speed drive repair centers. Variable speed drive repair centers work closely with manufacturers to keep production at a maximum while reducing production downtime.To learn more about variable speed drives or for variable speed drive repair and replacement quotes, contact Precision Electric, Inc.

 

 

ABB Low Harmonic Drives

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Harmonic distortion may disturb or damage sensitive equipment connected to the same circuit of a variable speed drive. Any distorted voltage and current waveform that deviates from the ideal waveform presents the potential to harm electronic components, which can result in expensive repairs and production downtime. Non-linear loads connected to the electrical supply in industrial and commercial facilities insert harmonic distortion on the power distribution system.

A non-linear load application included solid state electric motor soft starts, variable speed drives, personal computers, electronic lighting, welding equipment and other power supplies that are not interrupted. Harmonic distortion can cause distribution transformers and supply cables to overheat; resulting in the breakdown of electrical insulation and failure; electronic display failure, circuit breaker tripping and other damage resulting in distorted readings by metering equipment.

Taking action to solve harmonic distortion provides many benefits beyond managing risk. Industries with high power consumption such as paper and pulp, metals, oil and gas refineries, cement and chemical processing, have the opportunity to optimize the power quality in these facilities by managing the disturbances and losses that are caused by harmonic distortion.

A Single Solution to Harmonic Distortion

ABB Low Harmonic DrivesHarmonic standards are becoming stricter and there is a growing demand for low harmonic drive solutions. The ABB ACS800-U31 variable speed drive offers an easy solution to the problem of harmonics. The solution itself is incorporated within the variable speed drive, eliminating the need for any additional filtering equipment or complicated large multiple pulse transformer installations.

The ABB ACS800-U31 eliminates low order harmonics with the active converter controlled with DTC technology and high order harmonics with an LCL line filter. The result is exceptionally low harmonic content within the network that exceeds the requirements made by IIEEE519 at the drive input terminals. Even on the weakest AC line network the ACS800-U31 can be a solution to harmonic distortion. The ABB ACS800-U31 provides a simple, compact and complete solution to meet power quality standards.

The ABB ACS800-U31 doesn’t require a dedicated multiple pulse transformer so the installation time is significantly reduced with regards to cabling and wiring processes. The ABB ACS800-U31 also requires less physical floor space which also makes ease of installation. The ABB ACS800-U31 always operates with unity power factor of 1 and is impervious to alternating current line voltage imbalances up to and over 3%. The system efficiency also is better than 12 and 18 pulse drive solutions since there isn’t a phase shifting transformer required for applications.

The ACS800-U31 is a ultra low harmonic wall mounted drive and is available in power ratings from 208-240 voltage from 10 horsepower through 60 horsepower; and 380-480 voltage from 20 horsepower through 125 horsepower.

To learn more about ABB ACS800-U31 low harmonic drives, please visit the ABB Website.

 

Information References:

 

 

 

 

 

Variable Frequency Drives for Wastewater

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The flow and pressure of fans and pumps need to be controlled because water consumption varies during a day.The flow and pressure can be adjusted either electrically with variable speed drives or mechanically with fixed-speed solutions such as inlet guide vanes, throttling valves or hydraulic couplings. The most common flow control method is by means of a fixed speed motor regulated with a valve. This method can be compared to adjusting the speed of a car by braking while keeping the foot on the gas pedal. This technique doesn’t only waste a tremendous amount of energy, it also wears out the equipment. With variable frequency drives, changing the flow is achieved by adjusting the motor speed which can be compared to reducing the speed by taking the foot on the gas pedal and switching the automobile into lower gear. Wastewater pumps are operated at best efficiency point under all operating conditions when using a variable frequency drive with the application. Variable speed drives are the most efficient control method because they save energy and they decrease water emissions while minimizing total operating costs.

Variable frequency drives can also reduce maintenance overhead at waste water plants by acting as soft starters when applied to electric motors; because they reduce the stress on bearings, motor windings, housings and other equipment. The variable frequency drive progressively increases the motor speed and accelerates the corresponding load to the rated RPM of the motor. When sized correctly, one variable frequency drive can be setup to operate several wastewater pumps in sequence.

Using a variable frequency drive for soft starting electric motors eliminates high starting currents and voltage dips that normally would cause breakers to trip on overload fault. When a wastewater pump is turned off or if the water demand is reduced, a variable frequency drive can slowly reduce the speed of the pump to avoid water hammering, stress on pumping equipment and electric motor parts, resulting in an extended lifetime of wastewater pumps and electric motors. A pump running at half its rated RPM consumes as little as one eighth of the energy compared to a pump running at full rated RPM.Wastewater pumps usually operate at partial load so a huge potential in energy savings can be achieved by controlling a pump’s RPM with a variable frequency drive. Applying a variable frequency drive to wastewater pumps instead of operating across the line, an energy bill can be reduced by as much as 60 percent and this consequently helps to reduce water emissions.

ABB Drive Solutions for Wastewater Pumps

Variable Frequency Drives for WastewaterThe ABB ACS 2000 ULH direct-to-line configuration combines the cost savings of a variable speed drive systems without using a transformer and features the benefits of a voltage source inverter, including excellent availability, reliability, and high, constant power factor with superior control performance.

The ABB ACS 2000 drive features an active front end combined with multiple levels of control. The result is an ultra-low harmonic design that minimizes line harmonics without the use of expensive, custom transformers. The ABB ACS 2000 also includes a smaller, lighter weight packaged product to minimize the overall space required in the maintenance room while reducing shipping and installation costs.

Power ratings of the ABB ACS 2000 series drives range from 400 kVA through 300 kVA to 2000 horsepower.and 4.16 kV, 6.0 kV to 6.9 kV. The ABB ACS 2000 series drive is commonly used on influent, effluent pumps, aeration blowers, cooling fans, intake pumps and other related wastewater equipment.

To learn more about the ABB ACS 2000 series drive, please visit the ABB Website.

 

Information References:

 

 

 

Difference From AC and DC Electric Motors

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Difference from AC and DC Electric MotorsAC electric motors operate by applying alternating current (AC) power to the electric motor. The main parts of AC electric motors are the stator and rotor. AC electric motors stator consist of coils that are supplied with alternating current power and produce a rotating magnetic field. AC electric motors rotor will rotate inside the electric motor coils and the output shaft produces torque via the rotating magnetic field.

There are two different types of AC electric motors and each of them uses a different type of rotor. The first type of AC motor is called an induction motor. Induction motors use a magnetic field on the rotor of an induction motor that’s created by an induced current. The other type of AC motor is called a synchronous motor and rotates precisely at the supply frequency or on a sub-multiple of the supply frequency. Synchronous motors are able to operate with precision supply frequency because it doesn’t reply on an induced current. The magnetic field on a synchronous motor is generated by current delivered through slip rings or a permanent magnet. Synchronous motors run faster than induction motors because the speed is reduced by the slip of asynchronous motors.

DC Electric Motors

Difference from AC and DC Electric MotorsDC electric motors are powered from direct current (DC) power and are mechanically commutated. DC electric motors have a voltage induced rotating armature windings and non-rotating armature field frame coils that are a static field or permanent magnet. DC electric motors use different motor connections of the field and armature winding to produce variable speed and torque outputs.

DC electric motor speed can be controlled within the winding by changing the voltage sent to the motor armature or by adjusting field frame current. Most DC electric motors today are manufactured to be controlled with industrial electronic DC drives. DC electric motors are used in many applications across the globe such as paper producing machines, steel mill rolling machines and other applications that require variable speed and torque output.

Review

Difference from AC and DC Electric MotorsDirect Current DC motors are usually seen in applications where the motor speed needs to be precision controlled. AC motors work best in applications when performance is needed for extended periods of time. DC motors are single phase and AC motors can be single phase or three phase. AC and DC motors use the same principle of using an armature winding and magnetic field except with DC motors, the armature rotates while the magnetic field doesn’t rotate. In AC motors the armature does not rotate and the magnetic field continuously rotates.

DC electric motors are commonly replaced by pairing an AC electric motor with an adjustable frequency speed drive (also known as variable frequency drives, VFD’s, ASD’s, etc). DC electric motors are replaced with an AC electric motor and an adjustable frequency drive as a more economical and less expensive solution to DC motors. DC electric motors have parts that are either obsolete or expensive, so usually it’s less expensive and more efficient to replace a DC motor with an AC motor paired with an AC speed drive.

 

 

 

Eaton SPI9000 VFD System Drives

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A variable frequency drive (also known as a VFD) adjusts an electric motors speed to closely match output application requirements while also reduces energy savings of 10 to 50 percent. Soft start motor controls lower the demands on a motor during start-up, conserving energy and extending the life of the mechanical system. Whether the application calls for an ultra-compact solution, clean power, or future configurability, Eaton’s Cutler-Hammer drives answer Industrial, HVAC, Water/Wastewater Treatment and other application demands. Eaton offers VFD system drives for nearly every application.

SPI9000, SPA9000, SPN9000 Drives

Eaton SPI9000 VFD System DrivesEaton SPI9000 VFD system drives offer a comprehensive range of common direct current (DC) bus drive products. The front-end SPI9000 vfd units convert a mains alternating current (AC) voltage and current into a DC voltage and current. The power is transferred from the mains to a common DC bus (and, in certain cases, vice versa). The SPA9000 (active front-end) unit is a bi-directional (regenerative) power converter for the front end of a common DC bus driveline up. An external LCL filter is used at the input. This unit is suitable in applications where low mains harmonics are required. The SPN9000 (non-regenerative front-end) unit is a unidirectional (motoring) power converter for the front-end of a common DC bus drive line-up. The device operates as a diode bridge using diode/thyristor components. A dedicated external choke is used at the input. The unit has the capacity to charge a common DC bus. This unit is suitable as a rectifying device when a “normal” level of harmonics is accepted and no regeneration to the mains is required.

Features and Benefits

  • Comprehensive range available for almost every application
  • UL and cUL listed
  • Meets NEC, NEMA and IEEE standards
  • Alphanumeric keypad available for most drives
  • Air cooling
  • 460 V and 690 V, 1-1/2 to 2000 Hp

Eaton’s common DC bus product portfolio fulfills solution demands with a flexible architecture. Eaton SPI9000 VFD System Drives are built on Eaton SPX9000 technology which product family covers a number of front-end units and VFD units in the many power ranges.

To learn more about the Eaton SPI9000 System Drives or to download technical information, visit the Eaton Website.

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ABB DCS800-EP Drive Updates

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ABB DCS800-EP Drive UpdatesABB is pleased to announce that the DCS800-EP now includes the easy-to-useQuickStart Assistant and the introduction of the ABB DCS800-EP User Manual andwall chart.The ABB DCS800-EP Panel Drive is a DCS800 power module and associated systemcomponents mounted and wired on a sub-panel, ready to be installed into anindustrial enclosure. Standard components include AC input fuses, DC outputfuses (regen), control transformer, AC contactor, plus a variety of optionalcomponents.

QUICKSTART ASSISTANT: The QuickStart Assistant has been added to the control panelsoftware as a new way to commission the drive. It mimics the QuickStart Assistant used inthe Reliance FlexPak 3000 drive and makes commissioning easier by shortening theprocess for the 80% of users who have simple, straightforward applications.

ABB DCS800-EP USER MANUAL: The brand new 120-page User Manual targets these sameusers who have simple, straightforward applications.

The DCS800-EP User Manual:

  • combines the best of the DCS800 Hardware and Firmware Manuals into one shorter
  • document,supports the QuickStart Assistant and the commissioning process in general
  • defines the twelve application macros,defines the most commonly used parameters and signals in the compact set, andclearly explains faults and alarms and the related parameters and signals

In light of the lead time reduction, DCS800-EP drives will be built-to-order only.Stock drives will be discontinued.

Due to more stringent requirements in the EU for the power usage offans, some of the DCS800 drives are transitioning to a design with fansthat use less energy with no reduction in airflow. The new designs will be
rolled out gradually over the next few quarters.

The ABB DCS800 D5 Frame, 500 Volt drives: DCS800-S01-1200-05 throughDCS800-S02-2000-05 become DCS800-S01-1200-05B throughDCS800-S02-2000-05B. These are the first to be transitioned as ofthis release.

Frame D6 & D7, 600 & 700 V drives: To be transitioned at a laterdate. The ABBDCS800-EP Panel Drives are NOT affected. Frames D1 D4 drives arealso NOT affected.

CHANGES TO THE D5 DRIVE: The fan that was used on the D5 drivewas a squirrel-cage blower that extended 2.5 inches below the DC busbars. The fan on the new drive is a box fan that is much thinner. Thisreduces the overall height of the D5 drive from 41.4 inches to 37.4 inches.Both the new fan and old fan are electrically equivalent, requiring 230 Vsingle-phase power.

To learn more about product changes or to download ABB DCS800 literature, please visit the ABB Website.

 

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