01 Vacon AC Drives Basic Course

Vacon AC Drives Basic Course
17/12/2011
Vacon Training Center
Upon completion of this course, students will be able to:
Explain in a simple way what an AC Drive is State the main benefits of using AC-Drives List the most common environments in which AC Drives are used Understand the electrical principles of AC Drives
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Agenda
1. 2. 3. 4. 5. 6. 7.
What is an AC Drive? Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Electrical principles of AC Drives
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1 What is an AC Drive? 1.1 The Standard Electric AC Motor

A standard electric squirrel cage motor is the most simple and reliable of all electric motors Only one moving part: the rotor Essentially a fixed speed machine Speed depends on the electrical power frequency (50 or 60 Hz)
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1.2 The AC Drive

An AC Drive provides the ability to fully control the speed of a motor from zero to maximum frequency and beyond. It also provides the ability to control the torque produced by the motor. Very simply, AC Drive takes an AC power supply and converts it to DC. Then it converts it back to AC. During this process it is able to adjust the output to the exact frequency needed and supply the power to suit every load condition.
AC DRIVE DC AC Power Supply
Controlled AC Output
M
BUS
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
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2 Electrical Principles of AC Drives 2.1 Principle

Input voltage 3 phase 50 or 60 Hz Output voltage 3 phase Variable frequency
6-pulse rectifier
120 120 120 120
Id
L1 L2 L3
Rectifier
DC-bus
Inverter
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Block diagram
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Vacon: A Large Family of Products
Drive Micro Low-End Mid-Range High-End Mega
Power range < 4 kW 5-40 kW 41-200 kW 201-600 kW > 600 kW
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
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10
>
3 Where are AC Drives used?

Material handling Cranes Conveyors Warehouse automation Packaging machines Textile drying machines People movement Elevators Escalators Flow control Compressors Fans Pumps High speed compressors Plastics Extruders Cable manufacturing lines Plastic lines In-line drives Winders Marine & offshore auxiliary drives Winches, winch systems Steering Oil drilling Pumps Compressors
Practice
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<
Paper mill
Automation System
Speed control; Torque control; Load control; Position control
Applications Stock pumps; Water Pumps; Vacuum; Refiners; Screens; Mixers; Compressors; Conveyers; Winders; Fans ;Cranes; Line Drives;
Measurements Speed; Flow; Pressure; Level; Freeness; Position; Temperature; Humidity; Quality
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<
Water Intake
Chemical Dosing
Raw Water Pumping
Sludge Pumping
Aeration Fan Control
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<
Escalator Escalator
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Practice
<
Main engine cooling pumps

Cooling water flow in continuously changing conditions needs to be controlled. Vacon solution is based on pressure or flow measurements from the cooling water flow to the machine to establish sufficient cooling regardless of engine speed or load. Alternatively the steering of converters can be done by engine control.
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<
Cargo pumps
Cargo pumps on a chemical tanker need to discharge the cargo at highest possible flow rate at any temperature or viscosity. These variations require a large scale in rotation speed as well as high starting torque. Hydraulic alternative is inefficient in energy consumption, noisy, heavy and requires more expensive piping.
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<
Cranes
Vacon in crane control means reliability, redundancy and space savings compared to other products available on the market. Liquid cooled converters provide additional space savings as well as less audible noise. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide crane suppliers since 1996.
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<
Lifts
Vacon in lift control means reliability, redundancy and space savings compared to other products available on the market. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide lift suppliers.
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
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4 What benefits do AC Drives give?

AC Drives control the rotation and speed of motors They make considerable savings in energy They reduce the load on the electricity network When starting a motor, they reduce the mechanical stress
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4.1 Variable volumes require some form of control
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4.2 Simple Control Methods

Here is an everyday pumping example:
Throttling
Bypass control
On-Off control
Simple construction Optimal capacity is difficult to achieve An increase in capacity means reconstruction of the system Control is by throttling, recirculation or start and stop Risk of damage at start-up Operating costs are high
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4.3 No mechanical parts are needed with AC Drives

Traditional methods
D.O.L + Throttling D.O.L + On/Off
AC Drive control
Frequency Converter
Electronics
~ M
1~
M
1~
T A N K
M
3~
Mechanics
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4.4 The best control method is the AC Drive

In this situation, what would you do? Keep your foot on the gas and control your speed with a brake? Change to a lower gear and reduce the engine revolutions?
Practice
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
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5 How can AC Drives be used to save energy? 5.1 Opportunities
Over 60% of industrial electrical demand is for powering electric motors. A large proportion of this total is for driving fans & pumps Typical energy savings on fan & pump applications using AC Drives is 50% - giving a pay-back time of less than 1 YEAR!
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5.2 Centrifugal pumps and fans operate like this

Power requirement decreases sharply with small speed decreases
150 125 100
Power
50% speed = 12,5% power
75 50 25 0
25
50
75
100
125
150
% Speed
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5.3 Typical HVAC System Load Requirements

12
% Operating Time
10 8 6 4 2 0
25
% Flow or Volume
50
75
100
Data Supplied by the U/K Dept of Trade & Industry
Practice
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5.4 Other benefits
Improved control Reduced noise & vibration Simpler installation & commissioning Lower maintenance costs Fewer complaints!
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5.5 Environmental issue
With every 1 kW/h of electricity generated over 0.6 kg of CO2 is produced. Carbon dioxide emissions decrease significantly when using AC drives!
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
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6 Why Vacon NX? 6.1 Common features
A very small package for its power Reliable and robust technology Simplicity and high functionality User friendly
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6.2 A small power package
Compact enclosures IP00 to IP54 + NEMA 1 and NEMA 12 Slim, space-saving design Side-by-side installation All sizes up to 400 kW (500 Hp) can be wall-mounted Best possible power/volume-ratio achieved by using "Super Cooling heat sink technology
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6.3 Vacon AC Drives greatly reduce space requirements Compare the difference!
IP 54, 45/55 kW
Competitor D
Competitor A
591x237x257 mm 35 kg 716 x 306 x 429 mm 50 kg 937 x 495 x 421 mm 124 kg
ACS 601
VLT 5060
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6.4 Reliable and Robust Technology

AC-choke built-in in all but the smallest NXL
filters and protects from over voltage.
Metal enclosures for power modules (plastic for the smallest NXL).
Reliable and environmentally friendly good EMC performance.
Isolated galvanized inputs and outputs

Safe and considerably less noisy connections
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6.5 Comprehensive motor drive protection, which includes protection against

Over current Short circuit Over voltage/under voltage Earth fault Stalled motor Over loaded/under loaded motor Over temperature unit/motor Phase fault (in/out)
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Vacon Global Customers
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
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7 The Vacon AC Drive Family 7.1 Complete product portfolio

Vacon NXL Compact drives Vacon NXL General purpose drives Vacon NXS Industrial drives
0.25 1.5 kW 0.37 3 kW 208 240V 380 500V
0.75 - 37 kW 0.55 90 kW 0.75 200 kW 2.2 200 kW 0.55 90 kW 0.75 1500 kW 2.2 2000 kW 7.5 3700 kW 110 2450 kW 7.5 2700 kW 110 2450 kW 1.5 1800 kW 3 2000 kW
380 500V 208 240V 380 500V 525 690V 208 240V 380 500V 525 690V 380 525 465 640 500V 690V 800VDC 1100VDC
Vacon NXP / NXC High performance drives Vacon NX Liquid cooled drives Vacon Common DC components NXI
465 800VDC 640 1100VDC
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Agenda
1. 2. 3. 4. 5. 6. 7. 8.
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8 Software Applications 8.1 All In One Application Package

Local / Remote Multi-step Speed
Standard
PID Control
Basic
Multipurpose Pump and Fan Control
All-in-One Applications
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8.2 The Basic Application

For simple applications with direct frequency reference. Covers most general requirements. The Basic Application is set as default when the drive leaves the factory. The basic application has one small group of parameters, all with default values. Very straight forward commissioning.
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01 Vacon AC Drives Basic Course

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01 Vacon AC Drives Basic Course

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Vacon AC Drives Basic Course

Vacon Training Center

Upon completion of this course, students will be able to:

Vacon Training Center

Vacon Training Center

1 What is an AC Drive? 1.1 The Standard Electric AC Motor

Vacon Training Center

1.2 The AC Drive

AC DRIVE DC AC Power Supply

Vacon Training Center

Vacon Training Center

2 Electrical Principles of AC Drives 2.1 Principle

Vacon Training Center

Vacon Training Center

Vacon: A Large Family of Products

Drive Micro Low-End Mid-Range High-End Mega

Power range < 4 kW 5-40 kW 41-200 kW 201-600 kW > 600 kW

Vacon Training Center

Vacon Training Center

3 Where are AC Drives used?

Vacon Training Center

Speed control; Torque control; Load control; Position control

Vacon Training Center

Raw Water Pumping

Aeration Fan Control

Vacon Training Center

Vacon Training Center

Main engine cooling pumps

Vacon Training Center

Vacon Training Center

Vacon Training Center

Vacon Training Center

Vacon Training Center

4 What benefits do AC Drives give?

Vacon Training Center

4.1 Variable volumes require some form of control

Vacon Training Center

4.2 Simple Control Methods

Vacon Training Center

4.3 No mechanical parts are needed with AC Drives

Vacon Training Center

4.4 The best control method is the AC Drive

Vacon Training Center

Vacon Training Center

5 How can AC Drives be used to save energy? 5.1 Opportunities

Vacon Training Center

5.2 Centrifugal pumps and fans operate like this

Vacon Training Center

5.3 Typical HVAC System Load Requirements

Data Supplied by the U/K Dept of Trade & Industry

Vacon Training Center

5.4 Other benefits

Vacon Training Center

5.5 Environmental issue

Vacon Training Center

Vacon Training Center

6 Why Vacon NX? 6.1 Common features

Vacon Training Center

6.2 A small power package

Vacon Training Center

Vacon Training Center

6.4 Reliable and Robust Technology

Isolated galvanized inputs and outputs

Vacon Training Center