Tomorrow’s Automation, Today

A Symposium on Virtualization For the Process & Manufacturing Industries

TR03B Variable Frequency Drives

Omar Javed – Manager Sales Oct. 20, 2015 |15:00 PM – 15:30 PM

Variable Frequency Drives

AgendaThis session explains very brief overview

of Variable Frequency Drives; general introduction followed by industrial examples, applicable industries and

operations to be focused.

What is VFD?

What are the concerns?

Solutions

What is VFDElectrical/electronic pieceof equipment that variesthe speed of a 3 phase ACmotor.

Also Called:

VSD [ Variable Speed Drive]

ASD [Adjustable Speed Drive]

AFD [Adjustable frequency drive]

4

Basic VFD Operations

Convert AC power to DC power.

Filter DC power.

Invert DC power to variable voltage and variable frequency AC power

5

VFD Block Diagram

Motor Load Groups: Constant Torque Load

100

Horsepower Demanded by the Load %

Speed %

100

Torque Demanded by the Load %

Speed % 100 100

7

Constant Torque “CT” Applications

Positive Displacement Pumps

Reciprocating Compressors

Rotary Compressors

8

Variable Torque Load

Torque Demanded by the Load %

Speed % 100

100

Horsepower Demandedby the Load %

Speed %

100

100

9

Variable Torque “VT” Applications

Centrifugal Fans

Centrifugal Pumps

Centrifugal Blower

10

Affinity Law

𝐵𝐻𝑃1𝐵𝐻𝑃2

=𝑁1

𝑁23

BHP = Brake Horsepower

N = Speed

Example

N1 = 3,550 N2 = (3,550 x .9) = 3,195

BHP1 = 3.53

BHP2 = [3.53 x (3,195/3,550)3 ] = [3.53 x (.9 x .9 x .9)] = (3.53 x .729) = 2.574

11

Speed Reduction by 10% Achieve savings up to 30 %

12

Output or Cable Device Termination

AC Drive

Input Filter**

Line Reactor

Input fusing & circuit breakers

AC

Sup

ply So

urce

AC Motor

13

Normal Duty or Heavy Duty

If a normal duty overload characteristic is chosen, an oversize motor allows up to 110% torque performance for up to 1 min. in both CT and VT.

This function is used mainly for pumps and fans, since these applications do not require an overload torque.

If a heavy duty overload characteristic is chosen, a rated motor with the frequency converter obtains up to 160% torque for 1 min. in both CT and VT

14

What do You Need to Know to Select a Drive?

Current rating (A) of the motor

kW rating of the motor

Type of Machine (Application)

IP Rating

• IP20 = Clean Switch room, Switchboard

• IP54 = Dust/Damp Wall Mount

• IP66 = Washdown

Functionality

• How is the drive being controlled?

• I/O?

• Communications?.

Most Important

Least Important

15

What Rockwell Automation is Offering

PowerFlex Family of Low Voltage Drives

PowerFlex Drives meet worldwide standards out of-the-box, achieving EMC, global voltage and safety requirements.

PowerFlex Compact Drives offer cost-effective motor control for machine-level and stand-alone applications (PowerFlex 523, 525, 527, 40, 40P)

PowerFlex Standard Drives are designed for application flexibility and control system integration (PowerFlex 400, 70, 700, 753)

PowerFlex Premium Drives are designed for advanced applications with tight control system integration and extended Power Ranges (PowerFlex 700L, 700H, 700S, 755)

Power Flex MV Drives (7000 & 600) Designed for Medium Voltage Applications

17

Power

Pe

rfo

rman

ce

Compact

Standard

Premium

PowerFlex Family of Low Voltage Drives

18

PowerFlex 750 Series AC Drives

PowerFlex 755Premium Integration

AC Drive

PowerFlex 753General Purpose

AC Drive

Panel Mount Drives0.75 to 250 kW @ 400V1.0 to 350 Hp @ 480 V.5 to 300 Hp @ 600V5.5 to 250 kW @ 690V

Panel Mount Drives0.75 to 250 kW @ 400V1.0 to 350 Hp @ 480V.5 to 350 Hp @ 600V5.5 to 250 kW @ 690V

Floor Mount AC Drives315 to 1400 kW @ 400V400 to 2000 Hp @ 480V250 to 1500 Hp @ 600V200 to 1500 kW @ 690V

PowerFlex 750-Series AC Drives

Ratings to 250 kW/350 Hp Ratings to 1500 kW / 2000 Hp

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PowerFlex MV (7000, 6000)

Rockwell’s 3rd generation MV Drive

Incorporates leading-edge technology, embedded communications, and significant commonality across multiple platforms, networks, operator interface programming and hardware.

Designed for end users, solution providers and OEMs

Air-cooled and Liquid-cooled drives

Applications ranging up tov9000 horsepower (6340 kW).

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Value Delivered

Faster Time to Market

$ $$

Lower Total Cost of Ownership

Improved Asset Utilization

Enterprise Risk Management

Timeline Review

Original Hardwired SystemTypically configured using:

Two different software tools

Two different cables or converters

Sometimes by two different people

23

Early NetworksSame as hardwired system

Typically configured using two different software tools

Two different cables or converters

Sometimes by twodifferent people

24

Use of Dual NetworksTypically configured using two different software tools

25

Integrated Software TodaySingle Software Tool

Configure network i/o connection to the drive One time, in One place & by One person

Eliminates potential for user error when configuring network i/o

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Success StoryLalpir Power Plant & Nestle

4

Question & AnswersThank You for Your Valuable Time

Lahore, Pakistan

Headquarters South East Asia

19 Km Main Multan Road

Lahore, Punjab 54660

Pakistan

Phone : + 92 42 111 940 940

Dubai, UAE

Headquarters Middle East And Asia

Office FZS1 BD04, Jebel Ali Free Zone

PO Box 18590, Dubai

United Arab Emirates

Phone: +971 4 88 60 277

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Headquarters Americas

180 Sheree Boulevard, Suite 1400

Exton, PA 19341

United States of America

Phone +1 610 458 8700

Regional Offices and Global Headquarters