general intro to drives
TRANSCRIPT
Welcome to Danfoss Drives
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Target group: VIP-guests, customers and internal use
Updated: 2006-03-07
Contact: Anette Uldall / Irene Krog Hansen
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WelcomeWelcome to Danfoss Drivesto Danfoss Drives
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welcomes
NALCO SMELTER TEAM…
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List Of Content
1. Introduction to Danfoss –Global....
2. Danfoss-India...
3. Danfoss Products & solutions....
4.4. Some basic issues related to use of Some basic issues related to use of VFDVFD’’ss……..
5. Various Applications......
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Danfoss headquarters, Denmark
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Danfoss Refrigeration &Air Conditioning
DivisionVagn Helberg
President
Danfoss Motion Controls Division
Sven RuderPresident
Corporate
Functions
Corporate
Ventures
Executive Committee
Danfoss HeatingDivision
Nis StorgaardPresident
Ownershare
38.5%
Danfoss Services
Danfoss Comfort Controls•
Danfoss District Heating•
Danfoss Burner Components•
Danfoss Floor Heating
Danfoss Water Controls
Danfoss Drives•
Danfoss Gearmotors
Danfoss Refrigeration andA/C Controls
•Danfoss Commercial
Compressors•
Danfoss HouseholdCompressors
•Danfoss Industrial & Appliance Controls
Ole Steen AndersenExecutive Vice President, CFO
Hans KirkExecutive Vice President, CDO
Jørgen M. ClausenPresident, CEO
Niels B. ChristiansenExecutive Vice President, COO
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Sales distributed across divisions 2004
2,500
2,000
mill EUR
1,500
1,000
500
00 01 02 03 04
Danfoss Refrigeration & Air Conditioning Division
Danfoss Heating Division
Danfoss Motion Controls Division
Other activities, including Mobile Hydraulics (2000)
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Europe North Latin Africa Asia Pacific TotalAmerica America
Manufacturing sites 39 8 3 1 3 0 54
Sales companies 76 8 7 3 15 2 111
Agents and distributors 107
Danfoss is a family-owned, global company (no public shares, but approx. 1% employee shares)
Net sales 2004: EUR 2,200 mill
Employees: 18,000 worldwide (May 2005)
Production of 250,000 items per day
Group figures
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Group sales
* 1 January 2000 to 3 May
2000
2,500
2,000
1,500
1,000
mill EUR
97 98 99 00 0193 94 95 96 02
Calculated average growth, total: 8.5%
Calculated average growth, Danfoss Group excl. MH: 8.5%
03
Mobile Hydraulics
The Danfoss Group
04
500
1,300
300
1,500
300
1,600
300
1,700
300
1,850150*
1,200
300
1,100
200
900
200
1,8001,900 2,000 2,000 1,900
1,6001,500
1,300
1,100
2,0002,100
2,200
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Ten largest markets 2004
350mill EUR
50
300
150
100
250
200
RA
HE
MC
Germany
Italy
DenmarkGreatBritain
France USA
China
Russia
Spain
Sweden
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Motion Controls Division 2004
4
1
2
3
1
Drives
Silicon Power
Low Power
Gearmotors
3 4
2
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Motion Controls sales split 2004
Drives 81%Incl. Low Power
Silicon Power 3%
Gearmotors 16%
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Danfoss Drives
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Headquarters, Graasten Denmark
History
1968 The first 28 pcs. of VLT® are sold
1983 Acquires Hampton Products in Rockford (now Danfoss Drives, Loves Park)
1989 Centralization of the Danfoss Drives division in the Graasten facility, DK
1995 Graham joins the Drives division
1997 Danfoss Drives be-comes an inde-pendent limited company within the Danfoss Group
1999 Acquires Bauer, Germany.
2000 Establishment of Danfoss Silicon Power, Schleswig, Germany
2001 Acquires IWT Power Electronics GmbH, Kahlsruhe, Germany
2003 Acquires 51% Proexpert, Estonia
2004 Danfoss Drives opensnew factory in Graasten, Denmark
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Danfoss Drives Business Unit
Peter SimsonVice President
Fin, Adm, IT & HR
Charles ManzVice President
Danfoss North America
Morten B. SørensenVice President
Supply Chain
Kim ChristensenVice President
Sales & Service
Finn Jäger-RasmussenVice President
Product Development
Jens Dam MikkelsenVice President
Marketing & SBA
Sven RuderPresident
Danfoss Drives
Hans Peter BoisenDirector
Business Development & Com
Business Boards
Danfoss Drives Ventures
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Facts about Danfoss Drives
• Danfoss Drives is no. 1 in EU and no. 3 worldwide (<160 kW )
• In 1980 we produced approx. 6000 frequency converters, in 2005 weproduced this quantity every 3 days on an average
• Approx. 15-20% yearly growth in frequency converter quantityproduced
• Sales price between 745 and 33,500 EUR per frequency converter
• We produce on customer order, supported by regional assembly in Europe, US and China. This means no inventories of finished goods in the factories
• More than 90% is delivered directly to customers in Europe
• Own printing works: more than 300,000 pages per day
• Total employees Graasten: approx. 1,000
• Total employees Globally: approx. 2,000
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Production in Europe, China and USA
Denmark
Graasten
Germany
Schleswig
USA
Loves Park, IL
Milwaukee, WI
China
Haiyan, Zhejiang Province
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International sales and service
Global network
Local support
24 hours service:
- Spare parts
- Hotline
50 Danfoss sales and service companies
More than 200 partner companies, distributors,
agents and serviceshops
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DANFOSS INDUSTRIES PVT LTD, INDIADANFOSS INDUSTRIES PVT LTD, INDIA
••100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of 100% Wholly owned subsidiary of DanfossDanfossDanfossDanfossDanfossDanfossDanfossDanfoss-------- Denmark Denmark Denmark Denmark Denmark Denmark Denmark Denmark
•• Corporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : ChennaiCorporate Headquarters : Chennai
•• Factory/Testing Factory/Testing Factory/Testing Factory/Testing Factory/Testing Factory/Testing Factory/Testing Factory/Testing Centre:ChennaiCentre:ChennaiCentre:ChennaiCentre:ChennaiCentre:ChennaiCentre:ChennaiCentre:ChennaiCentre:Chennai........
••Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service Regional /Branch Sales and Service offices at offices at offices at offices at offices at offices at offices at offices at Delhi,LudhianaDelhi,LudhianaDelhi,LudhianaDelhi,LudhianaDelhi,LudhianaDelhi,LudhianaDelhi,LudhianaDelhi,Ludhiana, Chennai , , Chennai , , Chennai , , Chennai , , Chennai , , Chennai , , Chennai , , Chennai , CoimbatoreCoimbatoreCoimbatoreCoimbatoreCoimbatoreCoimbatoreCoimbatoreCoimbatore, Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore , Hyderabad Bangalore Mumbai, Mumbai, Mumbai, Mumbai, Mumbai, Mumbai, Mumbai, Mumbai, AhmedabadAhmedabadAhmedabadAhmedabadAhmedabadAhmedabadAhmedabadAhmedabad, Kolkata. , Kolkata. , Kolkata. , Kolkata. , Kolkata. , Kolkata. , Kolkata. , Kolkata.
•• Distributors and System Distributors and System Distributors and System Distributors and System Distributors and System Distributors and System Distributors and System Distributors and System ––––––––Integrators Integrators Integrators Integrators Integrators Integrators Integrators Integrators spread over the country.spread over the country.spread over the country.spread over the country.spread over the country.spread over the country.spread over the country.spread over the country.
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Drive Testing Centre in Chennai
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Drive Testing Centre in Chennai
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Drive Testing Centre in Chennai
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Engineered Panel at Danfoss-Chennai Shop floor
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Vision
We will be recognized by our customers as the most respected drives solutions provider world wide
• customer driven
• global
• innovative
• deliver user friendly products
• application focused
• reliable
• quality driven
• ethical
• profitable
• the leader
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Mission
Danfoss Drives offers electronic variable speed drives and related
products and services to the global market. We fulfil our
customers’ needs for drive technology, automation, energy
savings and comfort.
The cornerstones of our unique offering to the market are:
• Unmatched knowledge of our customers’ processes
• The scale advantages resulting from a focused approach
• High performing quality products
• Our global reach
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Goals
• 10% growth a year
• To be number 1 on the worldmarket
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Danfoss Drives guiding strategies
Sales and marketing
• Global reach
• Application know-how
• SBA market and product
approach
Product Development
• Leader in technology and innovation
• Platform based product approach • Integrated product developmentprocess
Supply Chain
• Lean manufacturing
• Mass customization
• One product – one factory
• Integrated manufacturing
People
• Value based people management• Performance based companyculture
• Open communication culture
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One year’s production of advancedpower electronics can save onepower plant a year
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History - products
1968 The first 28 pcs. of VLT® are sold
1983 We become a self-supporting product line
1989 Introduction of VLT® 3000/3000 HVAC series
1992 Introduction of VLT® 3500 HVAC series
1993 Introduction of VLT® 2000 series
1996 Introduction of VLT® 5000 series
1997 Introduction of VLT® DriveMotor FCM 300 series.
1998 Introduction of VLT® 6000 HVAC
1999 Introduction of VLT® 2800 series
2001 Introduction of VLT® 5000 FLUX
2002 Introduction of VLT® 8000 AQUA
2002 Introduction of VLT® Decentral FCD300
2002 Introduction of Decentral Motors Switch DMS
2004 Introduction of VLT® AutomationDrive
VLT® 5, The first VLT
VLT® Decentral FCD 300, year 2002
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VLT® product range
VLT® 2800
0.25 – 18.5 kW
VLT® 5000
0.55 – 1200 kW
VLT® 5000 Flux
0.55 – 400 kW
VLT® 6000 HVAC
0.75 – 500 kW
MCD 3000 Soft Starter
1 – 800 kW
VLT® 8000 Aqua
0.75 – 500 kW
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Decentral solutions
VLT® DriveMotor FCM 300 series
0.55 – 7.5 kW
VLT® Decentral FCD 300
0.37 – 3.0 kW
EtaSolution series K
0.12 – 7.5 kW
VLT® Decentral DMS 300
0.18 – 3.0 kW
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Low Power inverter
Cost-effective motor controllers for OEM customers
Dedicated solutions
Target markets
• Appliance (residential and commercial washing machines)
• Pumps (fresh water, hot water, etc.)
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Silicon Power modules
Standard packagesCustom specific highcurrent Sixpack
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Variable speed solutions
Variable Speed Drive Compressors
BPI: Battery Powered Inverter
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The new VLT® AutomationDrive program
• User-Friendly
• Flexible
• Reliable
• Intelligent
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HVAC & Refrigeration
• Mærsk Container
• York
• Mycom
• Gea Grasso
• Ingersol Rand
• Atlas Copco
Our customers:
• Honeywell
• Johnson
• Trane
• TAC
and many more
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Food & Beverage
Our customers:
• Krones
• Tetra-Pak
• Coca-Cola
• Carlsberg
• Heineken
• Nestlé
and many more
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Water & Wastewater
Our customers:
• Grundfos
• Pentair
• KSB
• ITT
and many more
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Material Handling, Chemical & Textile
Our customers:
• FKI Logistex • BASF • Fong’s
and many more
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Cranes, Lift & Hoist
Our customers:
• Liebherr
• IBA
• Stahl
• DaimlerChrysler• BMW
• Eisenmann
and many more
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Why Use Frequency Converter ?
�Process Optimization
�Control
�Flexibility
�Energy Saving
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Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?
• Avoid Product damageAvoid Product damageAvoid Product damageAvoid Product damage• Reduced Wear & TearReduced Wear & TearReduced Wear & TearReduced Wear & Tear• No Mechanical ResonanceNo Mechanical ResonanceNo Mechanical ResonanceNo Mechanical Resonance• Avoid downtimeAvoid downtimeAvoid downtimeAvoid downtime• Added flexibilityAdded flexibilityAdded flexibilityAdded flexibility• Energy SavingsEnergy SavingsEnergy SavingsEnergy Savings
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Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?Why Use Frequency Converter?
• Reliable Stopping & SynchronizationReliable Stopping & SynchronizationReliable Stopping & SynchronizationReliable Stopping & Synchronization• Reduction in Maximum DemandReduction in Maximum DemandReduction in Maximum DemandReduction in Maximum Demand• Starting Current restricted to 100% Starting Current restricted to 100% Starting Current restricted to 100% Starting Current restricted to 100% ----180%180%180%180%
of full load current.of full load current.of full load current.of full load current.• Improved Power Factor.Improved Power Factor.Improved Power Factor.Improved Power Factor.
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Motion ControlsMotion ControlsMotion ControlsMotion Controls
••95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.95 % of AC Motors have no Controls.
••50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps. 50% of above are used in Fan and Pumps.
••Majority of them are over sized. Majority of them are over sized. Majority of them are over sized. Majority of them are over sized. Majority of them are over sized. Majority of them are over sized. Majority of them are over sized. Majority of them are over sized.
••Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .Typical controls are Dampers and Valves .
••Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts Applications like Compressors, Pumps and Fans use vast amounts of of of of of of of of
Energy. Energy. Energy. Energy. Energy. Energy. Energy. Energy.
••An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40An average Motor consumes its own value in Energy in approx. 40 days days days days days days days days
of running. of running. of running. of running. of running. of running. of running. of running.
CONSIDER THISCONSIDER THISCONSIDER THISCONSIDER THISCONSIDER THISCONSIDER THISCONSIDER THISCONSIDER THIS
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.
What is a frequency converter ?What is a frequency converter ?
Control
V & FSpeed
Reference
AC / DC
Rectifier
3-Phase
400V,50Hz
Input Motor
3 phase Output
0-400V,0-50Hz
Fixed AC - DC- Filter DC -Variable AC
DC / AC
Inverter
DC/DC
Filter
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.
What is a frequency converter ?What is a frequency converter ?
Control
V & FSpeed
Reference
AC / DC Rectifier
DC LinkHarmonic
Choke
400V,50Hz
Input
IGBT
Output
Stage
Motor
Output
0-400V,0-50Hz
Fixed AC - DC- Filter DC -Variable AC
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.
What is a frequency converter ?What to specify in a AC VFD ?
Control
V & FSpeed
Reference
EMC/RFI
Filters ?
AC / DC Rectifier(with built in Surge suppressors?)
2 Limb DC LinkHarmonic
chokes?
AC
Input
Supply
IGBT
Standard Motor ?
De rating ?
DC / AC Conversion
Motor Cable Length ?3x 380- 500V+/-10%
wide range?
Long life DC filter
capacitors?No need to
have AC
Line
chokes?
Built in Safety stops standards?
Unlimited o/p switching?
( when output contactor drops?)
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AC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUES
MOTOR EQUIVALENT CIRCUIT
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LOAD TYPESLOAD TYPES
• CONSTANT TORQUE
• VARIABLE TORQUE
AC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUES
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CONSTANT TORQUE LOAD
60%
70%
80%
90%
100%
110%
120%
130%
140%
150%
0% 5% 10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
SPEED
T
O
R
Q
U
E
AC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUES
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VARIABLE TORQUE
0
%
5
0
%
1
0
0
%
1
5
0
%
0% 5% 10% 15% 20%
25%
30%
35%
40% 45%
50% 55% 60%
65%
70%
75%
80%
85%
90% 95%10
0%
SPEED
TO
RQ
UE
AC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSAC DRIVES & MOTORSSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUESSOME BASIC ISSUES
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“The True Potential Lies Beneath The Surface”
Below the surface Below the surface Integration approach minimize operating & maintenance costs, optimize savings typically realize ROI within 1-3 years.
On the surfaceOn the surface
VFD is often viewed as a pure capital expenditure item.
However,best cost efficiency is realized when drive is fully integrated into the system.
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• RELIABILITY OF THE DRIVE
• CORROSIVE ENVIRONMENT
• MOTOR-VFD CABLE DISTANCE
• LIFE OF THE DRIVE
• SERVICE SUPPORT
• RESPONSE TIME
• SPARES AVAILABILITY
• USER FRIENDLY KWH MONITORING
SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF SOME BASIC ISSUES RELATED TO USE OF VFDVFDVFDVFDVFDVFDVFDVFD’’’’’’’’ssssssss
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How critical is the environment
One cannot “see” how critical an environment is.
It essentially depends on 4 factors:
Concentration of pollutants present
Dirt (which becomes conductive in the presence of
moisture)
Relative Humidity
Temperature
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Examples of critical applications
Different constituents attack metals,
• e.g, Sulphur Di-Oxide attacks all metals except Noble metals• Nitrogen, Ammonia and Ammonia Salts attack copper and brass• Hydrogen Sulphide attacks Silver and copper
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How to plan for such installations
Danfoss Drives can support long Motor cables up to 300 meters in length without use of output chokes
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How to plan for such installations
Supply the cabinet with fresh clean air as corrosion process is slow at low humidity and low temperature
It is important to maintain low Humidity and temperature
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How to plan for such installations
IP 66
Protection
OR IP66 Stand alone module upto 90 KW Web_DKDDPB91T102.pdf
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Enclosure
Enclosure
• Side-by-side
mounting
• IP00/chassis
• IP20/chassis
• IP21/NEMA Type 1
• IP55/NEMA Type 12
• IP66
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IP 55 & 66 – stand alone
Enclosure
• Disconnection
switch
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How to plan for such installations
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Coated PPCB’s for VLT’s
• For harsh environments e.g. aggressive gasses
• Protects against environmental pollution, moisture and dust
• Confirms to International standards and Marine approval standards
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Ventilation and cooling tips
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Intelligent heat management
Two different cooling modes can take place in ways to offer sets of benefits:
• Conventional cooling
with speed controlled fan
• Air not passing electronic
components
• Cold plate cooling
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FEATURES YOU SHOULD EXPECT
FROM A COST SAVINGCOST SAVING DRIVE
IP 54/66 ENCLOSURE INBUILT TRANSMITTER ISOLATED
NO-NEED OF PANEL POWER SUPPLY I/Os
STANDARD MOTOR AUTO MANUAL INBUILT TRANSMITTERCOMPATIBILITY SWITCH POWER SUPPLY
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FEATURES YOU SHOULD EXPECT
FROM A RELIABLERELIABLE DRIVE
USER FRIENDLY SELF PROTECTING WITH STAND MAINS
FLUCTUATIONS
DIAGNOSTIC SKIP FREQUENCIES FLYING STARTFUNCTIONS
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VECTOR CONTROL AUTOMATIC ENERGY VARIABLE
OPTIMISATION TORQUE
AUTOMATIC MOTOR PID CONTROLLER HARMONIC
ADAPTATION FILTERS
FEATURES YOU SHOULD EXPECT FROM A ENERGY SAVINGENERGY SAVING DRIVE
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TWO (2) SET POINT PIDTWO (2) SET POINT PID
• Ideal for Retrofit with no requirement
of PLC
• Energy Savings are
- Precise
- Process Specific
- Consistent
IN A CLOSED LOOP
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TWO (2) SET POINT PID (Contd)TWO (2) SET POINT PID (Contd)……
• Calculation on 2
feedback signals:
� Minimum
� Maximum
� Sum
� Difference
� Average
• 2 Zone control
with 2 feedback's and 2 set-points
1. Minimum
2. Maximum
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Built-in harmonic filter
Low harmonic emission: THID < 48%
No voltage drop => full output voltage
Built-in DC link filters
Reduces installation cost
Fulfils EN 61000-3-2/3-12
Displacement power factor (cos φ ≈ 1)
True power factor 0.9
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System protection
Protecting the motor
• Thermal monitoring (ETR) / thermistor
• Overload current and torque
Protecting the drive
• Short circuit on motor
• Switching on mains and motors
• Earth fault on motor
• Control I/O short circuit
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Connections
Digital/analogue/
RS 485
Spring loaded
Looping
Thin or thick wires
Pluggable terminals
PC connections
USB 1.1
RS 485
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Plug & Play
Plug & Play connection
to PC via USB
Easy upgrade via plug-
in options
(automatic
configuration)
Modular design makesfor real plug & play operation
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VLT® style design
Smaller footprint
Allocation to same terminal numbers
VLT FC 301 is replacing VLT® 5000
VLT FC 302 is replacing VLT® 5000 Flux
Backwards compatible
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SENSOR POSITIONING THE KEY TO ENERGY SAVINGSSENSOR POSITIONING THE KEY TO ENERGY SAVINGS( for closed loop systems)( for closed loop systems)
System curve:The theoretical squared curve showing the pressure required for any flow
Control curve : The squared curve between the sensor setpoint and the max. operating
point. This curve dictates the actual operating points with variable speed.
Sensor setpoint : The pressure needed to keep the system "primed" for design conditions.
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Energy savings
The area between the control curve and the pump or fan curve graphically represents the savings.
A) Incorrect sensor placement results in linear savings
B) Correct sensor placement results in near cubic savings
A B
SENSOR POSITIONING IMPACT ON ENERGY SAVINGSSENSOR POSITIONING IMPACT ON ENERGY SAVINGS
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PAYBACK !PAYBACK !
AN EXAMPLE AN EXAMPLE
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PAYBACK !PAYBACK !
AN EXAMPLE AN EXAMPLE
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PAYBACK !PAYBACK !
AN EXAMPLE AN EXAMPLE
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Harmonic distortion by nonlinear loads
Non-linear LoadNon-linear Load
Current DistortionCurrent Distortion Voltage DistortionVoltage DistortionSystem
Impedance
Disturbance to
other users
Disturbance to
other usersContribution to
system losses
Contribution to
system losses
� Current distortion is apparatus level performance
� Voltage distortion is system level performance
HARMONICSHARMONICS
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Harmonic Limitings Standards - Overview
Hong KongrecommendationHK Code of Practice
EuropeStandardEN 61000-3-2
EuropeFuture StandardEN 61000-3-12
UKRecommendationG5/4
NetherlandsRecommendationEnergieNed
North AmericaRecommendationIEEE 519-1992
CountriesTypeName
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1
~
~
~
a
b
c
2 3
64 5
IDC
IDC
Vab Vac Vbc
Ia
Ib
Ic
� Non-sinusoidal currents are drawn from the supply� Pulsating power from the supply source
Harmonic current of a basic 6-pulse rectifier
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Europe: IEC 61000 - 2 -4
USA: IEEE 519 - 1992
Planing level of voltage distortion
10 %5 %3 %THvD
Dedicatedsystem
General systemSpecial/Critical
application
10 %8 %5 %THvD
Class 3Class 2Class 1
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01 2 3 4 5 6 7
-1
-0.5
0
0.5
1
01 2 3 4 5 6 7
-1
-0.5
0
0.5
1
All periodic signals can be
represented as a sum of sine-
functions with periods equal to
integer numbers of the
fundamental component
∑= )sin()( 1thatf h ω
Harmonics is decomposition of a
signal into different (integer of
fundamental) frequencies
Harmonic Analysis
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HARMONIC CURRENT ANALYSIS
---------------------------------------------
Fund. Current38.57 ATHD 104.52%RMS current 55.79 A
5’th Harmonic 30.41 A
7’th Harmonic 23.64 A
11’th Harmonic 10.01 A13’th Harmonic 5.07 A---------------------------------------------
Input Current of a basic rectifier without Input choke
Input current of rectifier with dcInput current of rectifier with dc--link inductorlink inductor
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current36.22 ATHD 42.51%RMS current 39.47 A
5’th Harmonic 12.91 A7’th Harmonic 7.03 A11’th Harmonic 3.06 A13’th Harmonic 2.10 A------------------------------------------------
Input current for rectifier with acInput current for rectifier with ac--side inductorsside inductors
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current36.84 ATHD 43.84%RMS current 40.22 A
5’th Harmonic 14.71 A7’th Harmonic 5.74 A11’th Harmonic 2.66 A13’th Harmonic 1.34 A------------------------------------------------
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Harmonics ReductionPrice
Performance
Optimum
Solution!
DC Coils
DC+AC No Coils
PassiveFilter
12 Pulse18 Pulse
Active Filter
Active Frontend
Harm. trap
5%
10%
Harmonic Reduction Techniques
Advance Harmonic filters ( AHF)-A Cost effective solution !!!
AlsoAlso-- Harmonic Analysis softwareHarmonic Analysis software--MCT 31 is available MCT 31 is available ––Free!!!Free!!!
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0
200000
400000
600000
800000
1000000
1200000
1yr 2yr 3yr 4yr 5yr
Cost
Rs. save
1 x 30 kW CT Fan VLT6042
Installed cost of Rs.
1,80,000/-
Annual energy savings
of Rs. 2,19,000/-
Payback period : 10 months
Cumulative Cost vs Cumulative Savings
Energy Savings ...
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SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(SOME APPLICATIONS(--------CONTD)CONTD)CONTD)CONTD)CONTD)CONTD)CONTD)CONTD)
ENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSORENERGY SAVINGS ON COMPRESSOREnConEnConEnConEnConEnConEnConEnConEnCon in Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systemsin Compressed Air Systems--------BHELBHELBHELBHELBHELBHELBHELBHEL--------MAR05.pptMAR05.pptMAR05.pptMAR05.pptMAR05.pptMAR05.pptMAR05.pptMAR05.ppt
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Automotive Components Factory,IKKT,TN
Motor/VFD Rating : 37KW
Details of Compressor : 210 CFM (Retrofit)Date of commissioning : Aug-2003
Unit consumed per hour W/O VLT : 32units (a)
Energy consumed per hour with VLT : 24 units (b)
Energy saved/ hour : 8 unitsCost of energy : Rs.5.00Operation Hours & Days /year : 16*300
Energy saved / Year : Rs.192,000/-
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Danfoss Drives A/S
Automotive Components Factory,Chennai
Motor/VFD Rating : 45KW
Details of Compressor : 224 CFM (New comsing)Date of commissioning : Feb-2003
Unit consumed per hour W/O VLT : 37units (a)
Energy consumed per hour with VLT : 28 units (b)
Energy saved/ hour : 9 unitsCost of energy : Rs.5.00Operation Hours & Days /year : 24*300
Energy saved / Year : Rs.324,000/-
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ENERGY SAVING some POTENTIAL Applications
a) Pumps
b) Fans & Blowers
c) Air compressors ( Rotary screw & Recip)
d) Cooling tower ( Fans & Pumps)
e) HVAC system (Various VT Loads)
f) Roots blowers,Aerators etc.,
g) Agitators/Reactors..\Introduction\5_Retrofitting Drives.ppt
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HVAC APPLICATIONS HVAC APPLICATIONS –– Energy saving potentialEnergy saving potential
�Supply Air Fan
�Return Air Fan
�Secondary Pump
�Cooling Tower Fan
�Condenser Pump
�Exhaust Fan
�Fume Hood
�Primary Pump
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Soft Start TypesSoft Start Types
A.C.Switch Type
• SCR - Diode• SCR - SCR
Number Of Phases Controlled
• 1 Phase Control• 2 Phase Control• 3 Phase Control
Control Method
• Open Loop Control• Closed Loop Control
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Single Phase Control
T1
T2
T3
Motor
T1
T2
T3
Motor
Two Phase Control
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Danfoss MCI LH4N2
L1
L2
L3
T1
T2
T3
Motor
Open Loop Control
L1
L2
L3
T1
T2
T3
Motor
Closed Loop Control
..\..\My Documents\Soft Starter Share Folder\MCD 3000\MCD3000 - Product Familiarisation.ppt
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PAYBACK ! PAYBACK !
• Payback varies with
- Application
- Hours of operation
- Cost of energy
- Speed reduction
• Typical payback…
- 1 - 2 yrs on air side
- 1- 2 yrs on water side
- 1-2 yrs for compressor
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User Friendliness
Operational Flexibility
Compliance to Norms
Enhancement of total system efficiency
Upgradability
Safety
Desirable Requirements For Effective Usage
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Points to consider while procurements Points to consider while procurements
of Drives or Soft starters of Drives or Soft starters
� Suppliers Profile/background
� Product Technology
� Application/Process knowledge
� User Friendliness of the product
� After sales support
� Spares Availability even if the
product is obsolete
� AMC support availability
� Faster/Quality service support
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Thanks Thanks
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What is a frequency inverter?
• It is an electronic device that takes a fixed AC supply and converts this into a variable output voltage and frequency to control the speed of a standard induction motor.
• The speed of the motor is dependant on the number of poles in the motor and the supplied frequency.
Motor rpm = Frequency x 60
(no. of pole pairs)
4 pole motor rpm = 50 x 60 = 1500 rpm
2
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.
Control
V & FSpeed
Reference
AC / DC Rectifier
Fixed
380V,
60Hz
Input
IGBT
Output
Stage
Motor
DC
LinkVariable voltage
and frequency
output
What is a frequency inverter?
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How does a frequency inverter produce this
variable voltage and frequency output?
• Most frequency inverters today use a method of “creating” an AC voltage from the fixed DC voltage called PWM (pulse width modulation):
• Output transistors switched on/off at a fast rate (typically ≥4.5KHz) according to a “switching” pattern which creates a series of rectangular pulses of fixed amplitude and varying pulse width
• This pulse width modulation simulates a sinusoidal voltage at the fundamental operating frequency plus harmonic voltages – together they equal the total voltage
• Only the voltage at fundamental frequency (e.g. 0 – 50Hz) creates useful torque
• The harmonic voltage components produce heat in the motor, torque ripple and increased acoustic motor noise
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• The switching on/off of the transistors applies a series of varying width pulses with a magnitude of either +Vdc or –Vdc to the phase outputs (U, V, W)
• The switching pattern which creates the varying width of these pulses has can affect the motor performance
• There are “standard” and “enhanced”switching patterns
• “Enhanced” = better motor performance and compatibility
+Vd
c
-Vdc
PWM switching principle
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• Many frequency inverters use this type of switching pattern
• Also called “sine coded” or “sine weighted” PWM
• Main limitation of Standard PWM is that the maximum output voltage to the motor is limited to 87% of the inverter’s input voltage:
Standard PWM
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.
Motor
V1dc = Vpeak = (Vin x √2)
+V2dc = -V2dc
= (V1dc / 2) = ((Vin x √2) / 2)
Phase-to-Phase
(rms) input
voltage:
Vin = (Vpeak / √2)
Maximum phase to earth peak output voltage = V2dc
Therefore maximum phase to earth rms output
voltage Vpout = (V2dc / √2)
Therefore, maximum phase-to-phase
rms output voltage = (√3 x Vpout))
= (√3 x (V2dc / √2))
= (√3 x ((Vin x √2) / 2) x √2))
= (√3 / 2) x Vin = 0.866 x Vin
Standard PWM – why only 87% mains input voltage
available at output?
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“YES!!”
Does having reduced motor voltage at full speed/full load affect motor performance?
Effect of voltage variation on induction motor characteristics
-20
-15
-10
-5
0
5
10
15
20
-20 -15 -10 -5 0 5 10 15 20
Percent voltage variation
Pe
rce
nt
ch
an
ge
in
mo
tor
pe
rfo
rma
nc
e
Full Load Amps
Power Factor
Efficiency
Starting and Maximum Torque
Starting Amps
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• For a motor operating from a fixed supply frequency (50Hz), to produce motor nameplate rated shaft torque when the mains supply is -10% below motor nameplate rated voltage results in the following:
21% increase in slip to produce rated torque,
2% decrease in efficiency,
9.5% increase in full load amps,
6 - 7°C temperature rise,
for every +10°C. temperature riserise above rated, the lifelife of the motor is reducedreduced 50%50%
Poor motor performance with Standard PWM
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• Switching pattern modulation index can be increased or third harmonic injection can be used to increase output voltage from standard PWM frequency inverters
• Both methods increase fundamental output voltage however but also increase harmonic voltages = limitations
• Theoretically it is possible to achieve a fundamental output voltage 95% of the input voltage however this still means motor operates at best in a 5% under voltage condition
• If try to increase output voltage any further increases harmonicfrequencies in motor = increased motor temperature + torque ripple + acoustic noise = reduced motor performance and efficiency
Can Standard PWM output voltage be improved?
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• In reality what happens if using a standard PWM frequency inverter to control a motor?
• The motor must be derated
It cannot be used for full load output power/torque (e.g. a
15kW motor can only be used for a load which requires
maximum 13kW shaft power)
Due to over-design of systems and selection of standard frame
size motors this might be OK for some applications but this is
a serious limitation of standard PWM – what if you need full
flow, full power, full torque for only 5% of the time?
• Frequency inverter supplier relies on fact that motor has over design built in as part of the motor’s service factor (i.e. lifetime) to compensate for the inverter performance
• This is often true, but is that what a service factor is for?
Standard PWM – the reality !
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• Not all frequency inverters use Standard PWM switching pattern today
• Some frequency inverters have used an enhanced version of PWM (e.g. Danfoss VVCplus) for many years, others are now introducing this
• Enhanced PWM (e.g. VVCplus) = improved performance
Full motor voltageSinusoidal output currentMinimizes motor heating = same motor temp rise as on mains supply Maximizes inverter efficiency
• Many frequency inverters still use Standard PWM and rely on the over design in the system, over sizing of the motor, or result in reduced performance or lifetime of the motor
Enhanced PWM (e.g. VVCplus)
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• Unlike sine weighted PWM, VVC is based on a digital generation of the output voltage.
• Ensures output voltage reaches rated value of input voltage, motor current is sinusoidal and the motor operates as it does on the mains.
Enhanced PWM (e.g. VVCplus)
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• Enhanced PWM (e.g. VVCplus)
Enhanced PWM vs Standard PWM Motor Voltage Difference !
• Standard PWM14%
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• A motor controlled by a frequency inverter using “enhanced”PWM switching technique:
With rated mains supply voltage applied to the drive input,
full rated fundamental output voltage is applied to the motor at rated frequency.
The motor is able to develop its rated power and torque at rated voltage, current, and speed.
The motor operates within its rated temperature rise allowing full thermal life of the motor to be maintained.
Harmonics in the motor are minimized
• The frequency inverter is compatible with the motor
Enhanced PWM (e.g. VVCplus) – Advantages
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• All frequency inverters are non-linear loads resulting in harmonic currents in the mains supply
• Most frequency inverters have one or two basic solutions to reduce harmonics
DC link reactor OR AC input reactor
Other design factors affecting available motor voltage– harmonic filter solutions
1 2 3
64 5
AC-side inductors
~~~
1
~~~
2 3
64 5
DC-side inductor(s)
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• Both DC reactors and AC reactors give similar reduction in harmonics
Other design factors affecting available motor voltage – harmonic filter solutions
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current 36.22 ATHD 42.51%RMS current 39.47 A
5’th Harmonic 12.91 A7’th Harmonic 7.03 A11’th Harmonic 3.06 A13’th Harmonic 2.10 A------------------------------------------------
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current 36.22 ATHD 42.51%RMS current 39.47 A
5’th Harmonic 12.91 A7’th Harmonic 7.03 A11’th Harmonic 3.06 A13’th Harmonic 2.10 A------------------------------------------------
• DC reactors
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current 36.84 ATHD 43.84%RMS current 40.22 A
5’th Harmonic 14.71 A7’th Harmonic 5.74 A11’th Harmonic 2.66 A13’th Harmonic 1.34 A------------------------------------------------
HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current 36.84 ATHD 43.84%RMS current 40.22 A
5’th Harmonic 14.71 A7’th Harmonic 5.74 A11’th Harmonic 2.66 A13’th Harmonic 1.34 A------------------------------------------------
• AC reactors
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• BUT – AC reactors result in a lower DC link voltage and therefore lower voltage available to the motor
• How much lower voltage?
• Example, a 3% AC reactor for an 11kW frequency inverter with a rated current of 25 amps may have an impedance of 1.2mH
• On 60Hz supply this has an impedance XL=2x∏xfxL = 0.45 ohms
• At 25 amps this equates to a voltage drop across reactor of:
V = I x XL = 11.3 volts = 3% of 380V
• Voltage drop across reactor is 90 degrees out of phase with supply voltage so not full 3% drop (Note: DC reactor has no voltage drop)
• But AC chokes also increase diode commutation time
• Typically results reduction in DC link voltage = 0.5 x % inductance
• e.g. 3% AC reactor = 1.5% reduction in DC link voltage,
5% reactor = 2.5% reduction 1 2 3
64 5
AC-side inductors
~~~
Other design factors affecting available motor voltage –
harmonic filter solutions
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• BUT – AC reactors result in a lower DC link voltage and therefore lower voltage available to the motor
• How much lower voltage?
• Example, a 3% AC reactor for an 11kW frequency inverter with a rated current of 25 amps may have an impedance of 1.2mH
• On 60Hz supply this has an impedance XL=2x∏xfxL = 0.45 ohms
• At 25 amps this equates to a voltage drop across reactor of:
V = I x XL = 11.3 volts = 3% of 380V
• Voltage drop across reactor is 90 degrees out of phase with supply voltage so not full 3% drop (Note: DC reactor has no voltage drop)
• But AC chokes also increase diode commutation time
• Typically results reduction in DC link voltage = 0.5 x % inductance
• e.g. 3% AC reactor = 1.5% reduction in DC link voltage, 5% reactor = 2.5% reduction
1 2 3
64 5
AC-side inductors
~~~
Other design factors affecting available motor voltage– harmonic filter solutions
Statement in inverter supplier’s manual
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Standard PWM and AC reactors – the reality !
4 pole 4kW and 5.5kW motor nominal full load torque
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm
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Standard PWM and AC reactors – the reality !
Standard PWM
Example of available 4kW and 5.5kW motor shaft torque
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm
Motor Torque available (4 pole, 5.5kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Motor Torque available (4 pole, 4kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Full torque at full
speed/full load not
available w ith
Standard PWM
frequency inverters -
typically best max
90% FLT available
(especially if AC input
reactors used for
harmonic reduction)
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Standard PWM and AC reactors – the reality !
Standard PWM
Example of available 4kW and 5.5kW motor shaft torque
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm
Motor Torque available (4 pole, 5.5kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Motor Torque available (4 pole, 4kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Full torque at full
speed/full load not
available w ith
Standard PWM
frequency inverters -
typically best max
90% FLT available
(especially if AC input
reactors used for
harmonic reduction)
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Standard PWM and AC reactors – the reality !
Standard PWM
Centrifugal Pump or Fan Application
Requirement to oversize frequency inverter and motor
depending on full flow torque requirement
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm
Motor Torque available (4 pole, 5.5kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Motor Torque available (4 pole, 4kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Centrifugal Pump or Fan load torque Nm
Required full f low
torque not available
w ith standard PWM
therefore need to use
5.5kW frequency
inverter and motor to
give required full f low
torque = increased
cost
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Enhanced PWM and DC reactors – the advantage
Enhanced PWM
Example of available 4kW and 5.5kW motor shaft torque
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm
Motor Torque available (4 pole, 4kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)
Motor Torque available (4 pole, 5.5kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)
Full torque at full
speed/full load is
available w ith
Enhanced PWM
frequency inverters
(especially if DC
reactors used for
harmonic reduction)
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Enhanced PWM and DC reactors – the advantage
Enhanced PWM
Centrifugal Pump or Fan Application
Same motor as for fixed speed application (4kW)
and 4kW frequency inverter required
0
5
10
15
20
25
30
0 300 600 900 1200 1500 1800
Speed rpm
To
rqu
e N
m
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Torque available (4 pole, 4kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)
Centrifugal Pump or Fan load torque Nm
Required full f low
torque is available
w ith enhanced PWM
therefore can use
same 4kW motor as
for fixed speed
application, w ith 4kW
frequency inverter =
low est cost + best
performance
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• By selecting or specifying a frequency inverter which uses an enhanced PWM switching pattern (e.g. VVCplus) and using DC reactors instead of AC input reactors you can be sure the motor will get it’s nameplate rated voltage when operating at full speed, full load and therefore be able to provide full motor shaft torque and power without overloading the motor, or reducing it’s lifetime
• This ensures compatibility with the motor and ensures it operates from the frequency inverter, just as it would if connected to the mains supply
• Inverter duty rated motors, oversized (de-rated) motors are NOT required
• For centrifugal pump and fan HVAC applications – enhanced PWM + DC reactors = standard motors can always be used no matter what the speed/flow range
Motor Compatibility
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• Another important factor to consider is whether the motor’s insulation is compatible with the voltage supply from a frequency inverter
• The voltage supply from a PWM frequency inverter can be very different to the voltage from the mains supply
Motor Insulation – Peak Voltage and Rise Time
• Although not common, this can potentially affect the motor insulation
Voltage Current
Motor Compatibility
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• This is generally NOT a problem with “good” quality standard motors and frequency inverters on mains supplies <500V AC
• It can be a problem on higher voltage mains supplies, with “low cost” motors and on special applications – for these special precautions can be taken to prevent problems
• However, for 220V/380V/480V mains supplies, using motors complying with IEC60034-17 and “good” quality frequency inverters, there should be no problems and no need to use inverter rated motors
• Following slides, explain why potentially there can be problems and how to avoid these problems
Motor Insulation – Peak Voltage and Rise Time
Motor Compatibility
* Following information comes Danfoss internal studies, studies at Dresden University, Germany and from a study into this topic by GAMBICA (UK drives industry association) and REMA (UK motor manufacturers association)
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• It is a fact that motor winding insulation experiences higher voltage stresses when supplied by a frequency inverter than when connected to sinusoidal AC mains supply
• These higher stresses are dependant on motor cable length and are caused by the interaction of the fast rising voltage pulses of the frequency inverter and transmission line effects in the cable
• To ensure compatibility with a motor, it is necessary to ensure the motor terminal peak voltage (voltage and rise time) are below the levels that the motor insulation is immune to
Motor Insulation – Peak Voltage and Rise Time
Motor Compatibility
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• PWM frequency inverters use fast switching IGBTs to create the PWM voltage waveform
• A series of square wave voltage pulses are applied to the motor cable
• The motor draws current and due to the large inductance of the motor this consists of mainly a sinusoidal current waveform at the required frequency of operation
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter – Output Voltage
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• Each pulse of the PWM waveform created by the fast switching IGBTs has a fast rise time (at the output of a typical frequencyinverter this could be approx 100 – 300 ns)
• Rise times are so fast that as it travels along length of the motor cable to the motor it can change the shape of the pulse and may produce voltage overshoot (and change the rise time)
• At the motor, one pulse of the PWM waveform can look very different to the square wave at the frequency inverter output
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
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• To understand this effect, due to the fast rising pulse, it is necessary to consider the motor cable as a transmission line
• Transmission line effects can then be considered = pulse travelsalong the cable and is reflected at the motor like a wave
• A transmission line consists of a long string of inductor/capacitor sections as shown below (only one phase is considered here):
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
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• At each fast rising pulse edge the frequency inverter has to charge the inductance and capacitance of the cable so a pulse of energy is delivered into the cable
• Transmission line theory shows pulse travels at velocity
= [1 / √(LC)] m/s
L and C = inductance (Henries) and capacitance (Farads) per metre
• Velocity of a pulse in typical PVC insulated cable
= approx 1.7 x 108 m/s
= in 100ns the pulse travels 17m
• Different cable types give slightly different velocities, but generally the differences are only small
• With this information can study how the fast rising pulse on output of frequency inverter travels along the cable to the motor and how the motor terminal voltage appears as shown 2 slides ago
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
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• In this theoretical/ideal explanation:
tr = rise time of pulse at frequency inverter output
tp = time taken for pulse to travel length of cable
tr < tp (which is typical for cable lengths >30m)
• Time t = tr• Pulse enters cable at t = 0 and rises to DC link voltage Ud in time tr
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
• Time t = tr + tp• Pulse travels from inverter to motor
• When reaches motor it is reflected because motor high frequency impedance is > cable impedance
• Reflection causes pulse to rise towards 2 x original peak = 2 x Ud
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• Time t = 2tr + 2tp (i.e. after the pulse has traveled to the motor and back to the inverter)
• Reflected pulse returns to inverter
• Because inverter impedance is low pulse is reflected in a negative sense
• Inverter clamps voltage to Ud resulting in negative pulse as it travels back along cable to motor
Motor Insulation – Peak Voltage and Rise Time
• Time t = 2tr + 3tp (i.e. after the pulse has traveled to the motor, back to the inverter and back to the motor)
• Negative pulse is reflected again at the motor and is doubled again = -2 x Ud
• This counteracts the original motor terminal voltage increase
PWM Frequency Inverter - Motor Terminal Voltage
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• In ideal case of previous 2 slides reflections would cause voltage to oscillate continuously
• In the “real world” voltage rise time is increased due to high frequency losses in the cable and waveforms become rounded
• Also due to high frequency losses peak voltage oscillations over one pulse time decay to and stabilise at the DC link voltage (Ud)
• This diagram shows “real world”motor terminal voltage waveform with 42m motor cable
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
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• Motor peak voltage is therefore a function of cable length and rise time• If the cable length is such that the time for the pulse to travel along
the cable is > the rise time, potentially 2 x Ud peak voltages could occur at the motor
• (Note: Ud is approx the peak voltage of the sinusoidal mains supply at input of the inverter)
• Motor terminal peak voltage will be less with shorter cables (above a certain length – typically >30-50m the peak voltage does not increase)
• Motor terminal peak voltage can be less if the frequency inverter output voltage pulses have a longer rise time for the same motor cable length
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
Measurements with 460V mains supply
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•When considering the effects of these higher motor terminal peak voltages on the motor insulation, the pulse rise time is important
• IEC 600034-17 and NEMA MG1 Part 30 have different definitions of pulse rise time as shown below
• These diagrams show that with exactly the same waveform, the rise time value can be different by a factor of 2
• Important to understand this if using IEC or NEMA motors
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Terminal Voltage
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• Motor terminal peak voltage is an important factor to consider to ensure motor insulation is not damaged
• However, with “good” quality standard motors the peak voltage alone has little effect because the main motor insulation systems between phases and between phases and earth are designed to withstand large over voltages
• However, because of the fast rise time, the peak voltage stresses insulation between turns and especially between randomly touching conductors within a coil or between coil ends
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Winding Voltage
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• The pulse voltage travels around motor winding just as it does along the cable
• Diagram shows how this may result in a large % of the pulse voltage appearing between turns, at random points within a coil or between coil ends
• (With a sinusoidal supply the voltage is distributed evenly in the winding)
Motor Insulation – Peak Voltage and Rise Time
PWM Frequency Inverter - Motor Winding Voltage
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Motor Insulation – Peak Voltage and Rise Time
• Depending on motor (rating, type of winding, number of turns etc.) and the rise time, the % of the peak terminal voltage appearing between turns or randomly within a coil may reach 30%–90%
• This diagram shows possible variations in 1st coil voltage as a % of the motor terminal peak voltage vs rise time
• With a sinusoidal supply the coil ends only experience a fraction of the phase voltage (determined by number of coils)
PWM Frequency Inverter - Motor Winding Voltage
• With a PWM frequency inverter it is a combination of the peak motor terminal voltage and the rise time that can cause considerable increase in voltage stress within a coil
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• That’s the bad news …. now the good news !
• “Good” quality motors have adequate insulation systems to prevent damage or reduced lifetime of the insulation when controlled by PWM frequency inverters
• What is a “good” quality motor?
• How do “good” quality motors prevent insulation failure due to these fast rising, high motor terminal peak voltages?
Motor Insulation – Peak Voltage and Rise Time
Motor Compatibility
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• There are basically two types of motor winding used for low voltage motors up to 690V
Motor Insulation – Peak Voltage and Rise Time
Motor Compatibility
Form wound – often used for higher power motors
Random wound – often used for low power motors
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• Both random wound and form wound motors have similar essential elements in their insulation system
• Phase to earth and phase to phase insulation
In “good” quality motors this is provided by slot liners, slot closures and end winding and will typically consist of polyesterfilm/meta-aramid paperIn low cost, low power motors, this inter-phase “paper”insulation is omitted (PWM frequency inverters should use output LC filters if used with this type of low cost motor)
• Inter-turn insulation
In random wound motors this is provided by multi-layer polyester/polyamide enamel on the conductor
In form wound motors this is provided by mica/polyester wrapped film around the rectangular form wound turns
Motor Insulation – Peak Voltage and Rise Time
Motor Compatibility
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• At each fast rising pulse edge the frequency inverter has to charge the inductance and capacitance of the cable
• Depending on the length of cable, the cable charging currents can be high
• For small motors on long cables, the cable charging current can be similar to the motor full load current
• All frequency inverters have a maximum motor cable length based on the rating of it’s internal components (can vary 10m – 300m depending on supplier)
• If frequency inverter not selected correctly can get nuisance tripping with long motor cables – check maximum motor cable length (shielded/screened and unshielded/unscreened)
Other important issues
PWM Frequency Inverter – Maximum Motor Cable Length
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• With the correct selection of frequency inverter it is possible to ensure full compatibility with standard IEC motors without requiring the use of inverter duty motors
• A frequency inverter can provide full protection of the motor but depending on it’s motor current monitoring and fault protection circuits, the reliability of that protection may differ between different suppliers
• Operation of frequency inverters at full load when total mains loss occurs is very short unless a back-up power supply is provided
• Operation of frequency inverters at full load when voltage sags/dips occur according to Semi F47 can vary depending on the frequency inverter design
Frequency Inverters Motor Compatibility, Protectionand Operation on Mains Voltage Sags/Dips
Conclusion
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Highly accurate controls possible
Less or inaccurate systemAccuracy 6
The life of motor increases.
Maximum 1.5 timesThe motor current is 6-7 timesof Rated current
Starting Current5
Trouble free operationMaintenance freeRegular maintenance requiredMaintenance4
Sizes of Motor & associated switchgearreduces
95-98% based operating speed
50-70% based on operating speed
Efficiency3
Better control option0-100%10-85% Speed Variation range
2
Very high efficient & reliable system as no moving parts
Pure Static electronic device
Electromagnetic coupling between Motor & load
Control technology1
SignificanceInverter DriveEddy Current DriveFeaturesSl
Comparison between Eddy Current Drive & Inverter Drive