Solutions with Frequency Converters
Festive Day at Gronbech & Sonnner
16 June 2016
Contents
1. Frequency Converter Basics
2. Impacts of the FC
3. Selected Applications
Modulating Duty Applications
UPS Applications
4. Additional Product Information
Frequency Converter
Basics
– integrated frequency converter
Conventional actuator
The „kitchen“
SUPPLY PROCESSING CONSUMPTION
– speed & tripping torque variation
Speed variation Tripping torque variation
Flexibility for Sizing and Planning
7 speeds and 8 torques = 56 possible operation points
– break-away torque reserve
Start-up current
Conventional actuators have a high start-up current
SEVEN actuators are equipped with integral frequency converters,
no start-up current is created.
VFD – rpm control
star/delta
direct starting
Conventional actuators
– integrated frequency converter
No direct connection to the power supply…
Impact of the Frequency Converter
Features
Tripping torque and output speed are adjustable
Minimum stress on the valve due to speed reduction
in the end position range (soft start – soft stop)
Speed variation during operation
The output torque is always constant
at -30% undervoltage to +20% overvoltage
from 40 Hz to 70 Hz
No start-up current
SEVEN actuators always have 3-phase motors
depending on size, power supply can be 1-phase or 3-
phase
Motor temperature is measured and monitored
No over-torque will be created in any case
(no tripping delay!)
– basic things to remember…
Benefits
Planning simplification
Wear on mechanical components is reduced
Valve maintenance/downtime reduced
Precise positioning, pipeline surge reduction
No oversizing is required to compensate
No danger of overtorque
Increased reliability
Cost savings for wiring, UPS and solar applications
Robust & cost efficient technology,
proven performance, no coasting
Secure operation, motors do not burn
No danger of creating stall torque,
valve sizing can be optimized, safe operation
– soft-start & soft-stop
Speed reduction in the end positions – go easy on the valve
Driving a valve at full speed into or out of its end position can cause
seat damage,
additional maintenance costs,
plant downtime.
The SEVEN with its integrated frequency controller automatically
reduces the motor speed
controls the torque
“gentle” operation – reduces wear
Speed changing – standard functions
Standard speed control
The output speed can be adjusted at any time
in 7 steps in the chosen speed range.
Customize what’s needed - when it’s needed !
Adjust the valve operating time to process necessities
Analog speed control option
Process oriented speed controlAdjust valve operating time – anytime!
With the "External analog speed setpoint“ function, the SEVEN can be operated
at different speeds without changing parameters:
Stipulate output speed by
a 0/4..20 mA signal
Can be combined with positioner
– option Positioner
Positioneroptimizes the process and relieves the valve
adaptive three-step controller
dead zone is constantly adapted to the quality
of the setpoint and feedback signal
greatest possible control accuracy
minimum switching frequency
optimizes the process and protects the valve
and pipeline from wear due to fewer switching cycles
Features:
Soft starting and electronic braking
Speed reduction before reaching the setpoint
Possible motor after-running is evaluated and optimized
Basic data:
Accuracy: ± 0.4%
Repeatability: ± 0.2%
Hysteresis: 0.4%
Adaptive positioner – when EMC „hits the fan“
Upward adaption
Minimizes switching cycles
caused by “noise”
control loop remains stable
Downward adaption
Minimizes deadband
Minimizes control deviation
t
sig
na
l
Stroke-time-curve
Define time for a certain stroke
Can be defined independently for
OPEN and CLOSE direction.
This function is often used to minimize
water hammer.
Process oriented speed control
Stroke-speed-curve
Define speed for a valve position
Up to 10 different speed regions can be
specified along the length of the stroke.
Retry Torque Block
Function:
If a torque block occurs, the actuator can be programmed to
perform up to 5 retries in order to pass the block.
Standard: Retry stroke length is calculated automatically
Customized: Retry stroke length can be defined
– impact of the frequency converter
Resume: Speed variation – software features
Soft-start & soft-stop
Programmable for OPEN, CLOSE & EMERGENCY
Analog speed control
Positioner - speed reduction before reaching new setpoint
Stroke-Speed curve
Stroke-Time curve
Adjustable Rise Time (Acceleration)
Selected applications
Eefde lock, Netherlands – soft stop
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20
40
60
80
100
0 10 20 30 40 50 60 70 80 90
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Time [sec]
SIPOS 5 Flash actuators on pump discharge valves
Water hammer prevention
Examples:
Booster pump station Colorado, USA Söder-City, Fortum, Sweden
Water hammer prevention & UPS systems…
This customer had three reasons to chose FC actuators:
No start-up current
Use of single phase actuators (low cost UPS)
Water hammer prevention with variable speed
Special setup for a pump station in Colorado
Pressure control and water hammer prevention
Customer comment:
“We have 7 SIPOS actuators
automatically controlling pressure
upstream of 7 valves during
sequential pump starts and stops.
It’s almost like a valve ballet.”
Reducing maintenance and down time - Denmark
Power plant customer :
”Costs on maintenance of expensive valve spindles is heavily reduced
with SIPOS due to soft start/stop”
Valve maintenance cycles have been extended from
once a year to once in 5 years. This saves costs and down-time.
Interesting applications - Denmark
Floodage and pollution prevention using SIPOS below the city of Aarhus.
1-phase power supply
UPS
SIPOS blocked in move variable travel functionality
Additional Product Information
Product range
SIPOS SEVEN rotary actuators are available
from simple ON-OFF to CONTINUOUS DUTY modulating actuators.
The actuators are designed according to EN 15714-2:
Duty classification SIPOS type
ON-OFF operation (Class A) 2SA70..
INCHING duty (Class B) 2SA73..
MODULATING duty (Class C) 2SA75..with up to 1,200 c/h
CONTINUOUS MODULATING duty (Class D) 2SA78..with up to 3,600 c/h
Product range
2SA70.. 2SA73.. 2SA75.. 2SA78..
Excerpt from EN 15714-2
SEVEN type
– the fact sheet
Ease of use:
A single control button for all functions
Simple upload / download of parameters via the USB port
Intuitive menu navigation via large color display
User selectable language
Efficient installation:
Process control set-up doesn’t require a mains power supply
Easy cloning of actuator parameters via the USB port
Reliable operation:
Temperature measurement and monitoring of motor and electronics
Long life with proven reliability – gear design according to stringent KTA standard
Multi-level password controlled access
Fully sealed electronics
– Details
Metal coverLarge Display window
(Makrolon or glass)
Improved ambient protectionCorrosion Class C5 I
IP68-3; Double Sealed
External USB A interface PROFITRON and HiMod
USB B internal for all actuators
Signaling gear or
encoderPrecision potentiometer or
absolute position encoder
Drive ControllerPush-turn user interface
– Mechanical Design
Features - benefits
Steel worm gear and steel worm shaft practically no wear
Low tolerance toothing accuracy
Torque monitoring without axial moving parts
Worm wheel and output hollow shaft are one piece no tolerances
Motor shaft and worm gear are joined form-fit no tolerance
Operating concept: Display & Drive Controller
Drive Controller features and benefits:
Single multi-functional control button:
Easy and intuitive actuator operation
Non-intrusive commissioning (electronics)
100% leak tight for long term reliability:
PROFITRON and HiMod display:
Large display in full color: easy to read from a distance
Screen orientation can be changed in 90° steps
Various display layouts, according to situation
Multi-lingual instructions with animations
ECOTRON: Clearly arranged segment display
and 6 status LEDs.
Operating concept: Display & Drive Controller