01 Vacon AC Drives Basic Course

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Vacon AC Drives Basic Course

Vacon Training Center

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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. What is an AC Drive?2. Where are AC Drives used?3. What benefits do AC Drives give?4. How can AC Drives be used to save energy?5. Why Vacon NX?6. The Vacon AC Drive Family7. 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 Power Supply

M

Controlled AC Output

DC

BUS

AC DRIVE


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Agenda

1. What is an AC Drive?2. Electrical principles of AC Drives3. Where are AC Drives used?4. How can AC Drives be used to save energy?5. What benefits do AC Drives give?6. Why Vacon NX?7. The Vacon AC Drive Family8. Software applications


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2 Electrical Principles of AC Drives2.1 Principle

6-pulse rectifier

L1L2L3 C M

Rectifier DC-bus Inverter

Id

120 ° 120 ° 120 ° 120 °

Input voltage 3 phase

50 or 60 Hz

Output voltage 3 phase

Variable frequency


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Block diagram


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Vacon: A Large Family of Products

Drive Power range

Micro < 4 kW

Low-End 5-40 kW

Mid-Range 41-200 kW

High-End 201-600 kW

Mega > 600 kW


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Agenda

1. What is an AC Drive?2. Electrical principles of AC Drives3. Where are AC Drives used?4. How can AC Drives be used to save energy?5. What benefits do AC Drives give?6. Why Vacon NX?7. The Vacon AC Drive Family8. Software applications


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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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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

Automation System

Paper mill

<


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Raw Water Pumping

Chemical Dosing

Sludge Pumping

Aeration Fan Control

Water Intake

<


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Escalator

Practice

<

Escalator


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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. What is an AC Drive?2. Electrical principles of AC Drives3. Where are AC Drives used?4. What benefits do AC Drives give?5. How can AC Drives be used to save energy?6. Why Vacon NX?7. The Vacon AC Drive Family8. 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:

• 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

Throttling

M

Bypass control

M

On-Off control

M


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4.3 No mechanical parts are needed with AC Drives

D.O.L +Throttling

FrequencyConverter

Electronics

Mechanics

M1~

~~

D.O.L +On/Off

Traditional methods AC Drive control

M1~

M3~

TANK


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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



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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

00 2525 5050 7575 125125 150150

2525

5050

7575

100100

100100

125125

150150

% Speed% Speed

Pow

er

50% speed = 12,5% power


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5.3 Typical HVAC System Load Requirements

% Flow or Volume

% O

per

atin

g T

ime

0

2

4

6

8

10

12

10050 75255

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



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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 requirementsCompare the difference!

IP 54, 45/55 kW

591x237x257 mm35 kg

716 x 306 x 429 mm50 kg

937 x 495 x 421 mm124 kg

Competitor A

ACS 601 VLT 5060

Competitor D


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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



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Vacon NXLCompact drives

Vacon NXLGeneral purpose drives

Vacon NXSIndustrial drives

Vacon NXP / NXCHigh performance drives

Vacon NXLiquid cooled drives

Vacon Common DC components NXI

7 The Vacon AC Drive Family7.1 Complete product portfolio

0.25 – 1.5 kW 208 – 240V0.37 – 3 kW 380 – 500V

0.75 - 37 kW 380 – 500V

0.55 – 90 kW 208 – 240V0.75 – 200 kW 380 – 500V2.2 – 200 kW 525 – 690V

0.55 – 90 kW 208 – 240V0.75 – 1500 kW 380 – 500V2.2 – 2000 kW 525 – 690V

7.5 – 3700 kW 380 – 500V110 – 2450 kW 525 – 690V7.5 – 2700 kW 465 – 800VDC110 – 2450 kW 640 – 1100VDC

1.5 – 1800 kW 465 – 800VDC3 – 2000 kW 640 – 1100VDC


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Agenda



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8 Software Applications8.1 ”All In One” Application Package

All-in-One Applications

Local / Remote

Multi-step Speed

PID Control

Multi-purpose

Pump and Fan Control

Basic

Standard


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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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Documents

01 Vacon AC Drives Basic Course