Derate Three Phase VFD for Single Phase Power

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There are many customers who want to derate their three phase Variable Frequency Drive (VFD) for single phase power.

Some manufacturers offer products that are designed for single phase input, three phase output. The products that are available for single phase input, three phase output max out at 3hp or 5hp. If the electric motor available is three phase and is larger than 5 horsepower, and only single phase power is available, you’ll have to derate the three phase VFD for single phase power.

The formula we use to derate variable frequency drives for single phase power is as follows: AC electric motor current multiplied by 1.73, then size three phase (vfd) variable frequency drive with the corresponding amps. Most times to derate a three phase VFD for single phase power can be done by going up one size. Typically, a 10hp three phase motor would need at least a 15hp or 20hp vfd in order to run off single phase power.

For example. Lets say I have a 7.5hp motor that pulls approximately 23 amps; I want to use a vfd, however I only have single phase 230V line voltage. I need to multiply the 23 amps by 1.73 which gives me the new revised current (39.73 amps) Now I know I need a three phase 230V drive that is rated at 40 amps or higher. A vfd that is rated at approximately 40 amps is about 15hp, and for this particular application would run a 7.5hp 240V drive perfect on 240V single phase power.

Precision Electric, Inc highly recommends contacting someone with experience to safely install variable frequency drives and/or electric motors. Call Precision Electric today to derate a three phase vfd for single phase power.

 

Sausage Slicing Application: PositionServo 940 & SMD Series by Lenze-AC Tech Cuts Pricing

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Lenze – AC Tech has worked closely with a specialist ultrasonic engineering company to solve the problem of making the perfect sliced sausage quickly and with minimal waste. A traditional cured continental sausage is difficult to cut very finely in an automated process because of the adhesive qualities of the meat, when a slice is made with a normal blade it tends to stick to the blade surface after the cut is complete.

The ultrasonic company, more used to sieving and sorting fine powders than chopping sausages has applied it’s high frequency vibration technology to ensure the slices drop away from the blade neatly into the correct place each time. The challenge was to integrate this high-end technology into a slicing machine and still meet the low-cost demands of the food processing industry.

The solution was simple, using a 4 amp PositionServo 940 with encoder feedback to control the position of the blade; the knife could be reciprocated in minimal time and with maximum speed and accuracy. Driving through a precise Lenze MCS servo motor and gearbox combination and a cogged belt drive, the thickness of the slices can be controlled along the entire length of the sausage.

The PositionServo is controlled via a Lenze drive PLC unit and an HMI, in this case a 4” Lenze LCD grey scale touchscreen display. By using an smd drive to power the conventional AC motor that actuates the blade, the machine can be operated with domestic 110 – 240 V supply and still supply a super cost effective combination. Using CANopen to link all the machine control components also allowed minimal wiring to be used and resulted in a highly compact machine that is easy to program and very easy to use.

Features:

Integrated servo, inverter, gearbox

and HMI solution

Complete component compatibility

High speed accurate position control

Precise automation within a low budget

CANopen compatibility

Easy to use

PositionServo Key Ingredient in Successful Recipe for Flat Bread Press Machines

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Lawrence Equipment headquartered outside of Los Angeles CA, designs and manufactures state-of-the art flat bread and fried snack equipment used in single small scale and multi-national large scale operations throughout the United States and Europe. The company’s tagline – “The edge on automation” summarizes their commitment to advanced technology and superb customer service.

As part of their continuous improvement program, Lawrence Equipment searched for the most efficient automation solution for their Mega Series Press. With a capacity of up to 3,000 dozen, 6” diameter tortillas, chapati, roti or wraps per hour, the Mega Series press is designed for large wholesale and supermarket production. In the demanding and competitive market of food processing equipment, machine yield, quality and uptime are non-negotiable. Customers from across the globe rely on the performance of Lawrence Equipment’s high-end presses. When designing the Mega Series, the Lawrence engineering team focused on specifying components that provide value, improve ease-of-use and ensure dependability. They especially appreciated the PositionServo’s outstanding programmability and flexibility as well as the expert support provided globally by Lenze – AC Tech.

With the PositionServo, servo-actuated indexing is now a standard feature of the Mega Series press; It accurately arranges the array of dough balls on a Teflon mesh conveyor belt with the exact speed, acceleration and distance so they are fed continuously and evenly into the oven. The servo drive monitors feedback signals from the motor and continually adjusts for deviation from expected behavior. Also, PositionServo drive parameters are stored in the drive’s EPM (Electronic Programmable Module), allowing Lawrence Equipment engineers to create programs once and then simply copy them in seconds, saving time and avoiding errors. According to Lawrence Equipment, since the inclusion of the PositionServo in the Mega Series Press it has contributed to a significant increase in throughput. Lawrence Equipment is currently considering  incorporating the 940 PositionServo across all its machine platforms.

PositionServo Benefits

• Superior Performance

• Quick, Intuitive Programming

• Removable Memory (EPM)

• Seamless Integration Into System

• Global Support

• Multiple Communication Options

• Outstanding Value

• Product Availability

SMVector Pumps Hard-to-Handle Chemicals

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Flomotion Systems develops and manufactures unique sealless peristaltic pumps that eliminate loss-of prime failures in chemical feed applications. Typical markets served include water & wastewater treatment, chemical, food & dairy, pharmaceutical, pulp & paper, energy management, power and irrigation.

A long-time user of Lenze – AC Tech’s MC Series drives; Flomotion has now incorporated the economical, compact and lightweight SMVector drive in the design of their 2001HEC Series pumps.

The Flomotion 2001HEC Series are rugged, reliable and cost effective industrial hose pumps built to succeed in harsh industrial environments. Several features of the SMVector make it a perfect fit for the job, including a removable terminal cover; easy access for control and power wiring and the fact that it can handle a wide range of operating temperatures from -10 to 55ºC. Last but not least, according to Flomotion, the SMVector offers better protection against electrical shock than any other NEMA 1 controller on the market.

Mounting the SMVector controller directly to the pump allows Flomotion to optimize precious panel space and offer its customers outstanding convenience. The unique EPM or Electronic Programmable Module stores the drive’s parameter configuration greatly simplifying initial setup.

Centrifugal and pumping applications especially those moving fluids or a mixture of wet and dry ingredients present a challenge because the speed is affected by the load. Fluid moving applications require ‘variable speed’ – a drive and motor that can produce the necessary horsepower to move the load at a constant speed. The motor will draw from the drive the amount.

of current it needs to ‘do the job’. The SMVector drive works well in this type of application because the speed can be controlled tightly in vector mode (more torque/less speed) or loosely in V/Hz mode to determine just the right amount of speed.

SMVector Benefits

• Multiple enclosure options available

including washdown

• Wide temperature range: -10 to 55ºC

• Removable memory (EPM)

• Multiple operational modes

(V/Hz, Enhanced V/Hz, Open Loop Vector)

• Lightweight, compact design

• Intuitive programming

• Multiple communication options

• Economical

AC Tech MCH Series Controls Climate of Oyster Habitat

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As a result of over-harvesting, environmental pollution and two new parasites, the famous native Chesapeake Bay oyster population has dramatically decreased. In an attempt to bolster the population, the University of Maryland is conducting a study to assess the effects of introducing the Suminoe oyster, an Asian species that has shown to be resistant to the prevalent parasites.

A University of Maryland 24-month study will examine the Suminoe oysters’ eating and reefing habits as well as their vulnerability to the known native oyster predators. The tests will be conducted at the University’s Center for Environmental Science Aquaculture and Restoration Ecology Lab. This new facility has the unique advantage of both closed aquatic system as well as a secure, flow-through system plus experimental temperature and carbon dioxide controls for climate change research and a quarantine laboratory for the safe study of non-indigenous species.

Through their mechanical contractor, J.M. Zimmer, Inc., the University of Maryland chose the Lenze – AC Tech MCH variable frequency drive to control their pumps, cooling towers and building HVAC system. The MCH drive features a built-in PID set-point controller function as well as the automatic 3-contactor drive bypass, which assures full isolation of the VFD electronics and allows the motor to transfer from ‘drive’ operation and continue running across the line in ‘bypass mode’.

“The advantage of the MCH 3-contactor bypass in strictly controlled testing laboratories,” explains Joe Zimmer Jr. of J.M. Zimmer, “is an increase in reliability, making sure we maintain uninterrupted performance of the laboratory’s entire HVAC system, so research results are not compromised.” Having the power and control wiring easily accessible and ample wiring space, the MCH is considered one of the simplest to install, set up and use of all the HVAC variable frequency drives on the market. A single-point connection makes the MCH drives less error-prone and easy to support.

Process systems often require a system-controlled parameter, such as motor speed, to be able to react to variable situations in order to keep other system attributes constant, such as pressure, flow or temperature. Lenze – AC Tech builds the set point controller function into the MCH drive to compare the set-point value to the actual value and generate a speed command to the drive to correct the variance or error.

MCH Series Benefits

• Automatic Transfer to Bypass Option

• PID Setpoint Control

• Program Controller: Direct or Reverse-Acting

• Keypad Option for Local & Remote Operation

• Simple to Install

• Proven Performance & Reliability

Dynamic Brake Selection for Sub-Micro & SMV Series Drives

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Dynamic braking is used when an overhauling load causes regeneration from the motor to occur, especially in situations where the required deceleration time to stop the motor cannot be achieved due to High Voltage nuisance tripping. Most Lenze-AC Tech DB circuits are rated for light-duty use only. The dynamic braking (DB) control circuit is connected to and monitors the fixed DC bus line. When the DC bus reaches 114% of the maximum tolerance, it triggers the chopper circuit in the dynamic brake. The DB circuit will be active whenever the voltage rises on the DC bus. This can occur while the drive is running, while it accelerates or decelerates or even when it is stopped. Using dynamic braking allows a faster deceleration time of a high inertia load. However, fast deceleration of a high inertia load may sometimes cause regeneration and trip the drive into a High Voltage fault. To avoid this, a dynamic brake chopping circuit is switched on when the voltage levels exceed the rated tolerance and brake resistors dissipate the regenerated voltage as excess energy.

Thermal Protection from Overload for the DB Module

Lenze-AC Tech brake modules rated at 0.33 to 10 HP have resistors that are internally mounted. In these modules there is a thermistor that monitors the resistor’s temperature and can be connected back to the drive to trigger a drive fault.

Using a Lenze-AC Tech DB with Another Manufacturer’s Drive

Applications Support is often asked if the Lenze-AC Tech DB module can be used with a non-Lenze AC Tech drive. This is not possible. The Lenze-AC Tech sub-micro drives have specific inputs that are set to trigger the Lenze-AC Tech DB modules. Other VFD manufacturers may encounter problems trying to trigger the DB chopper properly. 1 For the SMVector drives, the dynamic braking module includes a small connector that plugs onto the drive’s DC Bus Board for the B+ and B- connections. A set of mounting instructions is included.

Specifications for these Dynamic Brake Kits and diagrams are available on AC Tech Lenze manual#AN 0039A which can be viewed via PDF at our website at:

http://actech.com/documents/techlib/AN0039A.pdf

SMV Parameter Setup & High Frequency Output

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Setting up SMV Drive Parameters

1. Enter the “edit parameter mode” by:

a. With the drive powered up the display should read “Stop”.

b.  Press the M key once.  The drive will flash “PASS” then display “0000”

c.  Using the arrow keys change the display to read the default password “0225”

d.  Press the M key once.  You can now use the arrow keys to navigate to the parameter you want to change.

Changing the SMV to high frequency mode above 120hz:

1. Enter the “edit parameter mode”

2. Navigate to parameter P103 (Maximum Frequency Output)

3. Press the M key once.

4.  Use the arrow keys to change the maximum frequency to the desired value.  The range of adjustment is 7.5 hz to 500 hz.  When changing this parameter to a value higher than 120 hz you must stop first at 120 hz.  The drive will flash “Hi Fr”.  Release the button for one second.  Press the key again to proceed to the desired value higher than 120 hz.

5.  Press the M key once.  The maximum frequency is now set to the desired value.

 

Lenze AC Tech EPM – Electronic Programming Module

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The EPM contains the drives operational memory. Parameter settings are stored in the EPM and setting changes are made to the “User Settings” in the EPM.

An optional EPM Programmer (model EEPM1RA) is available that allows:

  • An EPM to be copied directly to another EPM
  • An EPM to be copied to the memory of the EPM Programmer
  • Stored files can be modified in the EPM Programmer
  • Stored files can be copied to another EPM

As the EPM Programmer is battery operated, parameter settings can be copied to an EPM and inserted into a drive without power being applied to the drive. This means that the drive will be fully operational with the new settings on the next application of power.

Additionally, when the drives parameter settings are burned into an EPM with the EPM Programmer, the settings are saved in two distinct locations; the “User Settings” and the “OEM Default Settings”. While the user settings can be modified in the drive, the OEM settings cannot. Thus, the drive can be reset not only to the “factory” drive default settings (shown in all Lenze-AC Tech owner’s manuals), but can be set to the Original Machine settings as programmed by the OEM

While the EPM can be removed for copying or to use in another drive, it must be installed for the drive to operate (a missing EPM will trigger an F_F fault)

Additional information and documentation can be found at our website technical library:

https://www.precision-elec.com/technical-documentation/

Experienced Nationwide Motor and Drive Repair, Just One Phone Call Away

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We’ve Been Servicing the Industrial World Since 1983.
Minimize Your Downtime. Maximize Your Productivity.

Sample Servo Motors and Drives

Call Toll Free: 1.877.625.2402

Precision Electric often expands it’s services when customers demand it. With the wide array of Servo Motors and Drives in the market – a substantial need for the repair of these devices has been generated. There have always been three primary issues with Servo Motors and Drives:

  1. Servo Motors and Drive Combinations are Often Proprietary and Difficult to Replace.
  2. Original Equipment Manufacturers (OEMs) Retire Older Series Drives and Motors with Newer.
  3. The Cost of Replacement Servo Motor and Drive Combinations can be Extremely High.

We have worked extensively with a wide array of Servo Motors and Drives, and we are proud to say we can repair from most of, if not all of, the major manufacturers in the industrial market today. Using our proprietary software, we can re-align the servo as necessary to ensure the rewinding of the motor retains it’s full accuracy.  Our electronics department has over 15 years in Drive repair, and can find components and parts for the toughest to repair of drives – and we can do it all at only a fraction of the cost of buying a new one.

One more thing that is important to note – the components built into servo motor and drive combinations often are cheaply made – so parts that are put back into the motors and drives during our repairs often exceed the quality control of the Original Manufacturer. What does this mean?  It means that the product you receive back from us is likely better in quality than the original equipment itself.

These services are available to our customers nationwide.  All that is necessary is arranging for direct shipment to our 31,000 square foot facility.  If desired, the urgency can be labeled as rush, where we will work on it 24 hours a day, 7 days a week until completed to standard repair, where we turn over your product in a reasonable time to save you money.

Do not hesitate to contact us if you have any questions regarding this service. You may also request a free repair quotation for your equipment.

Our Servo Motor and Drive Repair Brochure

Our Servo Motor and Drive Repair Brochure

Delayed Shipments For All AC Tech & Lenze Products

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Precision Electric, Inc has been losing a lot of orders lately due to AC Tech Corporation inventory problems. For the past couple of months AC Tech has not been committing to their normal ‘same day shipping’

“All of our products, including Lenze products have a 4-5 week lead time” This has been the typical response from AC Tech when asked about shipping time for all AC Tech products.

Precision Electric, Inc is not the least bit happy about this problem, however we have been able to come up with ideal solutions for our customers’ immediate needs.

Currently we are stocking AC Tech SMV drives in the 3hp, 5hp, and 10hp in all voltage ranges as well as all enclosure types, including Nema 1, Nema 4, and Nema 4X. This is one of Precision Electric immediate solutions for customers who are in need of a drive that is 10hp or less. We have also been replacing many of the AC Tech drives with competitor’s products, such as Baldor,  and Leeson.

For the past couple of weeks I have noticed that AC Tech has been shipping orders much quicker than promised.  For example, every order I’ve placed with AC Tech has shipped within 5-7 business days from the time I place order. These orders have been promised 4-5 week delivery, yet they have been shipping in 5-7 business days. I speculate by recent transactions that AC Tech is not having actual manufacturing delays, rather AC Tech is having inventory control problems.

I contacted AC Tech to find out about these problems and I was told that AC Tech is currently using new software for inventory control. This new software is causing all of the shipping delays. Unfortunatley AC Tech does not have an immediate solution for these problems. AC Tech is working around the clock trying to fix these issues, and Precision Electric has high hopes these problems are only temporary.

Precision Electric has edited the lead time/ship time on all of our eBay listings for AC Tech and Lenze products. In the meantime Precision Electric will be stocking AC Tech SMV drives available for immediate shipment, and we will also do our best to find comparable products for our customers who are in need of immediate solutions.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]

Leeson Electric & Baldor-Reliance Variable Frequency Drive Solutions

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For the past several months AC Tech/Lenze has had inventory control problems, which in turn has caused Precision Electric, Inc to seek alternative products for customers who are in an immediate need of Nema enclosed drives.

Precision Electric, Inc offers several manufacturer’s products as well as support for their products. Today, Precision Electric recommends Leeson Electric or Baldor-Reliance Electric for Nema 4X through Nema 12 applications.

Precision Electric has experience with all Leeson and Baldor-Reliance products, and have been working close with both Leeson and Baldor for over ten years.

Many of Precision Electric, Inc customers who are broke down cannot wait for AC Tech drives. AC Tech/Lenze will continue to be our number one cost-effective solution for drives, however, Precision Electric continues to seek alternatives for customers who cannot wait for AC Tech’s 4-5 week delivery.

Ryan Chamberlin
Inside Sales, Customer Support
[email protected]

Inverter Duty Motors VS General Purpose Motors

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General purpose AC motors have been around for many years. An inverter-duty motor is a much newer concept that became necessary as motors began to be driven by variable frequency drives.

An inverter-duty motor can withstand the higher voltage spikes producted by all VFDs and can run at very slow speeds without overheating. This performance comes at a cost: inverter-duty motors can be much more expensive than general purpose motors.

General purpose motors can be run with drives in many applications; however inverter-duty motors are designed to handle much lower speeds without overheating and they are capable of withstanding higher voltage spikes without their insulation failing.

With the increased performance associated with inverter-duty motors comes an increase in cost. This additional cost can be worth it if you need greater performance.