EUROTHERM DRIVES
‘ The practical
Application of AC
Variable Speed Drives ’
ENERGY SAVING
ANALYSIS
Application : Cooler Fan - Cement Factory
Motor Power: 168 kW
AC Drive : Eurotherm 584SV - 132 kW
S. Speed Freq Output Motor Output Input
No. (in %) (in Hz) Power Current Voltage Current
(kW) (Amp.) (V) (Amp)
1 100 50 162 245 445 200
2 95 47.5 138 220 408 170
3 90 45 115 204 369 148
4 85 42.5 97 192 328 125
5 80 40 82 180 295 100
6 75 37.5 65 165 255 85
7 70 35 52 152 223 65
8 60 30 28 110 163 33
9 50 25 11 61 113 20
ENERGY SAVING
ANALYSIS
Power Consumption at 100% Speed = 162 kW
Power Consumption at 80% Speed = 82 kW
Total Power Saved at 80% Speed = 162 kW - 82 kW
= 80 kW = 80 Units
TOTAL ENERGY SAVED PER YEAR = 80 Units x 24 Hrs x 300 days
= 5,76,000 Units
(If Drive is running at 80%
Speed)
BASIC AC MOTOR
PRINCIPLES
FUNDAMENTALS OF MOTOR OPERATIONS
All
motors work on the principle that when two
magnetic fields interact, a force occurs
The force is maximized when the fields are at 900
to each other
BASIC AC MOTOR
PRINCIPLES
SLIP / TORQUE CURVE
BASIC AC MOTOR
PRINCIPLES
V / H CHARACTERISTICS
Drive Comparisons -
ADVANTAGES OF EACH
DC Drive AC Inverter Vector Drive
Motor Complexity /
Maintenance
Controller
Complexity/ Size
Dynamic
Performance
Drive Comparisons -
PERFORMANCE / BAND WIDTH
B’less Servo
50 Hz
vector
DC tacho
20 Hz
S’less
AC vector
Inverter
ENERGY SAVING
INTRODUCTION
CONSIDERATIONS
CONTROLLING THE PROCESS
PRACTICAL DEMONSTRATION
CASE STUDY
Introduction to
ENERGY SAVING
ECONOMIC CONSIDERATIONS:
• 45% of Electricity Bill is accountable to AC Motors
• 70% of Electricity Bill to industry is accountable to
AC Motors
• 3% reduction in power consumption for each
motor would yield substantial savings in electricity
cost
Introduction to
ENERGY SAVING
ENVIRONMENTAL CONSIDERATION
• Less emissions damaging environment
ENERGY SAVING -
CONSIDERATIONS
CONSIDER THE SYSTEM OR PROCESS
AS A WHOLE
CONTROL OF A PROCESS GIVES
CONTROL OF POWER CONSUMPTION
IMPROVEMENTS IN COMPONENT
EFFICIENCY
CONTROLLING THE
PROCESS (FLOW)
TRADITIONAL METHODS
• DAMPER / REGULATOR VALVE
• EXHAUST / RETURN TO SUPPLY
• STOP / START
• 2 SPEED MOTORS
CONTROLLING THE
PROCESS (FLOW)
INVERTER CONTROL
• CONTINUOUS & PRECISE CONTROL
• FLEXIBILITY
• REDUCED SYSTEM LOSSES
• PRODUCT IMPROVEMENT
• REDUCED POWER CONSUMPTION
SYSTEM COMPONENTS
VARIABLE SPEED ENSURES REQUIRED
FLOW IS ACHIEVED WITHOUT EXCESS
VOLTAGE CONTROL IMPROVES
EFFICIENCY OF MOTORS
IMPROVED POWER FACTOR
DEMONSTRATION
FLOW CONTROL AIR HANDLING SYSTEM
Damper Control Characteristic
DEMONSTRATION
FLOW CONTROL AIR HANDLING SYSTEM
Inverter Control Characteristic
COMPARISON
5% REDUCTION IN FLOW
• Inverter control gives 14% reduction in power
• Damper control gives 0% reduction in power
15% REDUCTION IN FLOW
• Inverter control gives 38% reduction in power
• Damper control gives 0% reduction in power
EXAMPLES
CASE STUDY
PROCESS WATER RING MAIN
• ORIGINAL SYSTEM
• REASONS FOR CHANGE
• MODIFIED SYSTEM
• BENEFITS
ORIGINAL SYSTEM
REASON FOR CHANGE
MODIFIED SYSTEM
CASE STUDY BENEFITS
• REDUCED MAINTENANCE
• 25% REDUCTION IN POWER
CONSUMED BY Pump 1
• 85% REDUCTION IN POWER
CONSUMED BY Pump 2
SUMMARY
• STRONG ECONOMIC ARGUMENT TO CONSIDER
ENERGY SAVING
• CONSIDER SYSTEM / PROCESS AS A WHOLE
• IF YOU ARE IN CONTINUOUS CONTROL OF YOUR
PROCESS, YOU CAN CONTROL POWER CONSUMED
BY YOUR PROCESS
• PAY BACK PERIODS ARE OFTEN LESS THAN 18
MONTHS
The Trouble Free Installation
of Inverters & Vector Drives
• MOTOR / DRIVE SELECTION
• CORRECT SITING AND INSTALLATION
• MULTI MOTOR APPLICATIONS
• RADIO FREQUENCY INTERFERENCE (RFI) AND
ELECTRO MAGNETIC COMPATIBILITY (EMC)
• CABLING
• DATA and SET UP RETENTION
MOTOR / DRIVE SELECTION
• MOTOR SELECTION
• INVERTER / VECTOR DRIVE SELECTION
• STAR and DELTA CONNECTIONS
MOTOR / DRIVE SELECTION
MOTOR SELECTION
DERATE
FACTOR
CLASS ‘F’ 100 C
RISE
100%
80%
CLASS ‘B’ 80 C
RISE
BASE
PER UNIT
FREQUENCY
SPEED
MOTOR / DRIVE SELECTION
INVERTER / VECTOR DRIVE SELECTION
• Select the inverter / vector drive by current
-not kW
• For a given power, the current will vary
according to the motor voltage and number
of poles
MOTOR / DRIVE SELECTION
STAR and DELTA CONNECTIONS
• LOW POWER MOTOR (UP TO Approx. 2.2 kW)
Delta Connection 230 V
Star Connection 400 V
• HIGH POWER MOTOR (typically above 4 kW)
•Delta Connection 400 V
•Star Connection 660 V
MOTOR / DRIVE SELECTION
STAR and DELTA CONNECTIONS
TERMINAL BOX
200 / 240 V
Connected
L Standard
R
TE
ER
3 Phase motor
N
V
0,37 to 2,2 kW
IN
380 / 460 V
Connected
Usually up to
ER
3, 7 kW
RT
VE
IN
Connected
Usually above
3, 7 kW
CORRECT SITING AND
INSTALLATION
Modern Inverters and Vector Drives are
extremely reliable; but consideration should be
given to:
Ambient Temperature
Altitude
Vibration
Environment
CORRECT SITING AND
INSTALLATION
Ambient Temperature:
CORRECT SITING AND
INSTALLATION
ALTITUDE
CORRECT SITING AND
INSTALLATION
VIBRATION
10
TONS
CORRECT SITING AND
INSTALLATION
AGGRESSIVE ENVIRONMENT
CORRECT SITING AND
INSTALLATION
LONG SERVICE
CABLING
When there is a long cable run between the drive
and motor, the following points should be taken in to
account:
VOLTAGE DROP
CABLE CAPACITANCE
SEGREGATION
DATA and SET UP
RETENTION
Long term security of data / drive set up
configuration
Diagnostic / Configuration visual print out
Simple cloning of similar / identical drives
A.C. V.S.D. APPLICATIONS
HAZARDOUS AREAS
LIFTS + HOISTS
MACHINE TOOLS
CONVEYORS
PROCESS CONTROL
PRODUCTION LINES
Variable Speed offers Flexibility
Master / Slave - One speed reference
for complete production line
Ratio Control - Controls Product
spacing on conveyors
RETROFIT
SIMPLE TO RETROFIT INVERTER ON
EXISTING AC MOTOR DRIVEN
CONVEYOR
IP54 INVERTER MODULE
CUSTOMISED CONTROL CUBICLE
CONVEYORS SUMMARY
CONSTANT TORQUE
SIMPLE CONTROLS
SIMPLE TO RETROFIT
PROCESS CONTROL
CLOSED LOOP CONTROL
PID CONTROL
INCORPORATING PID CONTROL
DEMONSTRATION
CLOSED-LOOP
CONTROL
Continuous control of desired
parameter e.g. Flow, Pressure,
pH, etc.
Minimise waste
Improved product specification
PID CONTROL
P - PROPORTIONAL - GAIN
I - INTEGRAL - ZERO STEADY STATE
D - DERIVATIVE -INCREASED
DAMPING
INCORPORATING PID
WITHIN A DRIVE SYSTEM
PID IN TOTAL CONTROL
S/P
PID RAMP PWM M
GENERATOR
F/B
E.G. LEVEL CONTROL SYSTEM
INCORPORATING PID
WITHIN A DRIVE SYSTEM`
PID to TRIM SET POINT
DRIVE RAMP PWM M
S/P
S/
P PID SCALING
F/B
E.G. HIGH INERTIA AIR HANDLING
INCORPORATING PID
WITHIN A DRIVE SYSTEM
PID to TRIM OUTPUT
DRIVE PWM
RAMP M
S/P
PID
S/P
PID SCALER
F/B
E.G. LOW INERTIA PUMP
PROCESS CONTROL
SUMMARY
CloseLoop around parameter of
importance
PID Control to remove steady state error
Consider incorporation of PID
Improved Product
Improved efficiency
