Presented By: Muhammad Asim Mirza

MSEC01101002
Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

The Concept The purpose Industrial Utilization Life without VSD Work flow for VSD/VFD Selection of VSD Types of VSD Operation of VSD Advantage and Disadvantage of VSD
Prepared By: Muhammad Asim Mirza

In this situation What Would you do? Keep your foot on the gas and control your Speed with the brakes. Change to the lower Gear and reduce engine Revolutions.

Prepared By: Muhammad Asim Mirza

The best control method for most systems is VSD. Imagine you are driving a car for example. If you are driving on a highway and entering a populated area, you need to reduce speed so that you dont risk your own and other peoples lives. The best possible way to do this is of course to reduce motor rotation speed by taking your foot off the gas pedal and, if necessary, changing to a lower gear. Another possibility would be to use the same gear, keep your foot on the gas and reduce speed simply by braking. This would not only cause wear on the engine and brakes, but also use a lot of fuel and reduce your overall control of the vehicle. Furthermore, the original goal of reducing speed without risking your own and other peoples' lives would not have been achieved.
Prepared By: Muhammad Asim Mirza

For example, in air conditioning applications (part of HVAC), air flow requirements change according to the humidity and temperature in the room. These can be met by adjusting the supply and return air fans. These adjustments are carried out with VSDs.

Prepared By: Muhammad Asim Mirza

Rising energy prices create a need for energy-efficient motor control solutions. To help reduce energy losses, process engineers are turning to variable frequency drives (or adjustable speed drives) as an alternative to fixed speed controllers and throttling devices such as dampers and valves.

Prepared By: Muhammad Asim Mirza

Energy savings on most pump and fan applications. Better process control and regulation. Speeding up or slowing down a machine or process. Inherent power-factor correction Emergency bypass capability Protection from overload currents Safe Acceleration Adjust the process

Prepared By: Muhammad Asim Mirza

Chemical industry Pulp, paper, printing Foodstuff, beverages Power plants Mining Metal industry Machine shop Plastics Textile Water treatment Packages
Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

Historically, there have been a number of different methods of controlling processes without changing the fixed speeds of the motors driving them. For example: The flow rate produced by fans and pumps can be controlled by opening and closing dampers and valves The speed of winders and stirrers can be controlled by gears and pulleys.

Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

Things to consider when choosing a motor control solution include: peak-demand charges operating at optimized efficiency power factor Isolation transformer cost and losses regeneration capabilities synchronous transfer options and specialized intelligent motor control energysaving features.
Prepared By: Muhammad Asim Mirza

 Mechanical

o Belt & Pulley

Hydraulic

o turbine principle, Oil

DC

Drive o DC converter Frequency drives o frequency converter

Prepared By: Muhammad Asim Mirza

Motor Starting Operation: When a VFD starts a motor, it initially applies a low frequency and voltage to the motor. The starting frequency is typically 2 Hz or less. Starting at such a low frequency avoids the high inrush current that occurs when a motor is started by simply applying the utility (mains) voltage by turning on a switch. When VFD starts, the applied frequency and voltage are increased at a controlled rate or ramped up to accelerate the load without drawing excessive current. This starting method typically allows a motor to develop 150% of its rated torque while drawing only 50% of its rated current. When a motor is simply switched on at full voltage, it initially draws at least 300% of its rated current while producing less than 50% of its rated torque. As the load accelerates, the available torque usually drops a little and then rises to a peak while the current remains very high until the motor approaches full speed. A VFD can be adjusted to produce a steady 150% starting torque from standstill right up to full speed while drawing only 50% current.
Prepared By: Muhammad Asim Mirza

SYSTEM WORKS BY CONTROLLING SPEED, NOT RESTRICTING AIRFLOW !

Transducer

VARIABLE SPEED DRIVE i

Speed Set point

Pressure or Volume Feedback

Prepared By: Muhammad Asim Mirza

Motor Stopping/decreasing Operation With a VFD, the stopping sequence is just the opposite as the starting sequence. The frequency and voltage applied to the motor are ramped down at a controlled rate. When the frequency approaches zero, the motor is shut off. A small amount of braking torque is available to help decelerate the load a little faster than it would stop if the motor were simply switched off and allowed to coast. Additional braking torque can be obtained by adding a brake circuit to dissipate the braking energy or return it to the power source Fairly involved control circuitry coordinates the switching of power devices, typically through a control board that dictates the firing of power components in the proper sequence. A microprocessor or Digital Signal Processor (DSP) meets all the internal logic and decision requirements. From this description, you can see a VFD is basically a computer and power supply.

Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

A VFD converts 60 HZ power, for example, to a new frequency in two stages: the rectifier stage and the inverter stage. The conversion process incorporates three functions; Rectifier the rectifier changes the incoming alternating current (AC) supply to direct current (DC). The type of rectifier used can vary depending on the type of performance required from the drive. The rectifier design will influence the extent of the harmonic content present in the incoming supply. It can also control the direction of power flow. Intermediate circuit the rectified DC supply is then conditioned in the intermediate circuit, normally by a combination of inductors and capacitors. Over 98% of drives currently in the marketplace use a fixedvoltage DC link. Inverter2 the inverter converts the rectified and conditioned DC back into an AC supply of variable voltage and frequency. This is normally done with a semiconductor switch. Control unit An electronic circuit receives feedback information from the driven motor and adjusts the output voltage or frequency to the selected values. Usually the output voltage is regulated to produce a constant ratio of voltage to frequency (V/Hz). Controllers may incorporate many complex control functions.
Prepared By: Muhammad Asim Mirza

A line reactor is an impedance device. Its benefits are reduction of drive cross talk, and interference.

Input reactors will limit the waveform distortion and harmonic voltages. This will help improve the power factor due to reduction of the root mean square (RMS) currents in the system. Output reactors are generally good up to 100 feet in distance (drive to motor). The benefits are the damping of peak voltage overshoots, which will reduce internal motor heating and lessen the noise that a motor can produce when it is run by a drive. On installations where the distance is greater than 100 feet, filters are recommended for motor protection
Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

This control can be achieved using a frequency converter. As the name suggests, frequency converter changes the frequency of the alternating current and voltage. A frequency converter consists of three parts. Regular 50Hz 3-phase current is fed in to the rectifier part, which converts it to direct current. The DC voltage is fed into the DC bus circuit, which filters the pulsating voltage. The inverter unit then connects each motor phase either to the negative or the positive DC bus according to a certain order. To receive the flux direction shown in the diagram, switches V1, V4 and V5 should be closed. To make the flux rotate counterclockwise, switch V6 has to be closed but V5 has to be open. If switch V5 is not opened, the circuit will short circuit. The flux has turned 60 counterclockwise. The diagram shows these six switching positions and the flux directions.
Prepared By: Muhammad Asim Mirza

The motor itself also has various internal losses and, if it is attached to a transmission system of some sort (for example, a gearbox or pulley), then this introduces further losses in the form of friction. So, typically, only 7580% of the energy supplied to the motor system is transmitted to the enduse equipment. The majority of these losses appear as heat.

Prepared By: Muhammad Asim Mirza

Energy consumption in centrifugal fan and pump applications follows the affinity laws, which means that flow is proportional to speed, pressure is proportional to the square of speed, and horsepower is proportional to the cube of speed. That means if an application only needs 80 percent flow, the fan or pump will run at 80 percent of rated speed and only requires 50 percent of rated power. In other words, reducing speed by 20 percent requires only 50 percent of the power.

Flow (Speed) Pressure (Speed) Horsepower (Speed)

Prepared By: Muhammad Asim Mirza

Beat peak-demand charges VFDs also affect peak-demand electricity prices that the utility charges to companies that exceed a preset limit, such as when industrial motors started across-the-line draw large peaks of current. VFDs help reduce the peaks by supplying the power needed by the specific application, and gradually ramping the motor up to speed to reduce the current drawn. VFD can also be programmed w.r.t desired results.

Prepared By: Muhammad Asim Mirza

Harmonics are Reduced using filters.

Prepared By: Muhammad Asim Mirza

(Diodes)

(DC Bus) (IGBTs)

AC Line

Motor Filter

Input Rectifier

Inverter

Input Rectifier converts AC line voltage to fixed voltage DC. DC voltage is filtered by Capacitors to reduce ripple caused by rectification. Inverter changes fixed voltage DC to adjustable AC voltage and frequency which is fed to the motor.
Prepared By: Muhammad Asim Mirza

Prepared By: Muhammad Asim Mirza

Advantage
o o o o o o o o o

Disadvantage
o o o o o

o
o o

Energy Savings Improved Process Control Reduced Voltage Starting Lower System Maintenance Bypass Capability Multi-motor Control Reduced mechanical stress Instantaneous over-current protection Programmable operation as per requirement Wide range of speed, torque and power output Improve power factor. Energy savings in many applications

Initial Cost Motor Heating at low Speeds Maintenance Output Harmonics Induced Power Line Harmonics The waveform distortion created by ASDs consists of both harmonic distortion and line notching.

Prepared By: Muhammad Asim Mirza