Energy saving VSDs

The launch of its Vickers by Danfoss Variable Speed Drive (VSD) solutions in Europe, the Middle East, and Africa has just been announced. The Vickers by Danfoss portfolio features induction motor and servo motor VSD solutions, offering a broad range of power, dynamics, and control options. The VSDs save energy, cut costs, reduce heat and noise, and simplify configuration and commissioning. The modular offering fits most industrial hydraulic application needs and machine types, with particular relevance in discrete and process manufacturing.

Comprising a hydraulic pump, electric motor, and frequency drive with control logic, Vickers by Danfoss VSD systems improve the energy efficiency and performance of hydraulic machines by intelligently varying the speed of the electric motor and pump to precisely match the demands of the duty cycle. This smart control technology eliminates the energy waste associated with traditional constant-speed systems, resulting in energy savings of up to 60%, depending on the machine’s duty cycle. Lowering energy consumption reduces operating costs while helping machine owners meet energy efficiency and/or sustainability targets.

The Vickers by Danfoss induction motor VSD solution features the PVM Code B axial piston pump, Danfoss VLT® AutomationDrive FC 302, and an asynchronous induction motor. Designed for systems with low dynamic and control requirements, the solution is suitable for 3- to 250-kilowatt applications (higher than 90 kW engineered to order). It offers speed and flow on demand with open-loop control. In comparison to traditional constant-speed architectures, the induction motor VSD system can reduce energy consumption by 20 to 40%, depending on duty cycle.

This servo motor VSD solution features the VGPS internal gear pump or PVMX axial piston pump (the latter currently engineered to order), a PMSM (servo) motor, and a Danfoss iC7-Automation drive, including proprietary p/Q control software for closed-loop pressure/flow control. Designed for systems with high dynamic and control requirements, the solution is suitable for 3- to 100-kW applications. It offers pressure and flow on demand with closed-loop control. The easily configurable p/Q control logic offers simple setup and integration, shortening design, installation, and commissioning time. The servo motor system can reduce energy consumption by 30 to 60%, depending on duty cycle. It can also simplify machine architecture and complexity, as the precise and highly dynamic pump speed control enables the elimination of separate pressure and flow control valves.

Both the induction and servo motor VSD solutions lower heat generation and reduce overall noise exposure. By improving energy efficiency, VSDs minimize heat generation, enabling downsizing or elimination of oil coolers and delivering lower total installed costs. Reducing heat also extends the life of seals and oil. When the motor and pump operate at lower speeds, the machine operator and those working nearby are exposed to less noise. Quieter operation enhances workplace safety and operator comfort, offers greater design flexibility in terms of power unit placement, and may reduce secondary noise reduction measures.

Vickers by Danfoss VSDs enable the downsizing of pumps and motors to cut costs and reduce space requirements. Because the system can utilize the full motor speed range rather than running at a fixed speed, pump displacement can be significantly smaller without changing the maximum available oil flow. A pump with smaller displacement requires less torque to deliver the same pressure, and because the high overload capability of electric motors can be used to deal with the short high-torque portions of the duty cycle, a smaller motor size can be selected. The smaller motor and pump shrinks the machine's footprint and installed power while improving the total cost of ownership.

“The superior performance of Vickers by Danfoss Variable Speed Drive solutions is rooted in seamless integration. Danfoss drives are a perfect fit for hydraulic VSD systems, resulting in a harmonized system that is easy to commission and operate,” said Juraj Bittner, Product Manager, Industrial Solutions, Danfoss Power Solutions. “By combining the durability and reliability of Vickers by Danfoss pumps with the intelligent control of Danfoss drives, our VSD systems deliver a powerful, efficient, and cost-effective solution for modern hydraulic applications.” These VSDs are ideal for a wide range of industrial hydraulic applications. They are especially suited to discrete and process manufacturing applications with intermittent duty cycles in which peak power is not required most of the time, such as injection molding, rubber molding, machine tools, presses, die casting, metal forming, and food processing.

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@Danfoss @NapierPR #PAuto

Passive harmonic filter.

Help reduce overheating, mechanical stress, and vibrations in motors and transformers caused by harmonic distortion.

The TPQH3411 passive harmonic filter from EMIS is designed and manufactured to provide a cost-effective solution for harmonic mitigation in Power Systems by maintaining THID in compliance with the current and voltage requirements of IEEE 519.

Three-Phase Passive Harmonic Filters are used to minimise harmonic distortion, especially in installations with high levels of non-linear loads such as variable frequency drives (VFDs), UPS units and rectifiers. They function by using passive components resistors, inductors and capacitors in a filter network to suppress unwanted harmonic currents and voltages.

They are typically tuned to specific harmonic orders (e.g.,3rd, 5th, 7th, 11th….), providing low-impedance paths at those frequencies to effectively divert harmonic content. The capacitive elements in these filters offer reactive power compensation, enhancing the system’s power factor.

Key specifications include:

• Operating Voltage - 415 VAC
• Operating Frequency - 50HZ
• Power Rating - 1.1KW to 250KW
• Mounting - Floor/wall

Passive harmonic filters are recognised for their simple and robust design, making them a popular and cost-effective solution for mitigating harmonics in power systems. In addition to assisting with compliance to harmonic distortion limits set by standards such as IEEE 519, the filters also help reduce overheating, mechanical stress, and vibrations in motors and transformers caused by harmonic distortion.

Applications for the EMIS TPQH3411 passive harmonic filter include:

• Variable Frequency Drives (VFDs), induction furnaces, robotics, conveyors.
• High-power pumps, blowers, motor drives
• UPS systems and switch-mode power supplies.
• Crushers, rolling mills, large motors.
• Compressors, offshore drilling systems, pumps
• Elevators, lighting with electronic ballasts
• Inverter-based wind/solar systems
• Cement, Paper, and Steel Industries
  

@proactivefleet #EMIS #PAuto #Electronics

Communicating sustainability.

Schneider Electric has been honoured with the 10,000,000th Anybus Module award by HMS Networks. The award ceremony took place at the Schneider Electric headquarters in Paris. Present at the ceremony were Magnus Jansson, Product Marketing Director at HMS Networks, Jean-Louis Guillou, VP Drives at Schneider Electric, and Peter Greenfort, Strategic Account Manager at HMS Networks (see pic)

By integrating Anybus network connectivity interfaces into its line of variable speed drives, Schneider Electric empowers its customers with a diverse range of drives that can be fine-tuned for both performance and energy efficiency. This dual benefit not only enhances customer operation performance but also contributes to a greener planet.

Sustainability lies at the heart of Schneider Electric’s mission. The company employs multifaceted strategies to promote a sustainable world. One key approach involves assisting customers in reducing energy consumption while maximizing the impact of the energy they use. As a trailblazer in the transition to a cleaner and more equitable industry, Schneider Electric’s significant contributions to carbon emissions reduction are publicly disclosed every quarter.

Jean-Louis Guillou, VP Drives - Industrial Control & Drives, highlights the remarkable impact of Variable Speed Drive. Currently, 42% of the total avoided carbon emissions in the Schneider Electric carbon emission report can be attributed to Variable Speed Drives and the more efficient utilization of electrical motors—an achievement that Jean-Louis describes as “absolutely fantastic.”

He observes that the trends in drives align with broader industry shifts. Intelligence is increasingly embedded in products, and with each new drive generation, processing power doubles—a deliberate effort to improve monitoring and control to further improve overall efficiency. To achieve optimal motor performance, continuous monitoring and adjustment are crucial. This necessitates smart automation equipment that can be intelligently controlled. In certain industries, up to 50% of total energy consumption is attributed to electrical motors. By employing smart drives to regulate these motors, energy consumption can be reduced by up to 20%..

Schneider Electric and HMS Networks have maintained a strategic partnership for two decades. During this time, HMS Networks has been instrumental in developing network connectivity solutions for Schneider Electric’s popular variable speed drives, enabling seamless connectivity to industrial control networks. These networks span various protocols, including PROFINET, EtherNet/IP, EtherCAT, Modbus TCP, and more. The collaboration between Schneider and HMS Networks has been essential in achieving a solution for supporting multiple industrial communication protocols.

Connectivity: A Vital Requirement for Efficiency and Sustainability
As the world moves toward greater efficiency and sustainability, digitalization is becoming ubiquitous. Connectivity is no longer a luxury—it’s a necessity. In the future, everything will be interconnected. Schneider Electric and HMS Networks share a vision of continued collaboration to drive this transformation forward. Jean-Louis Guillou sums it up: “Digitalization is happening all around us. Connectivity isn’t just nice to have; it’s an essential requirement. Let’s continue working together to shape a connected and sustainable future.” 

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@hmsnetworks @SchneiderElec @mepaxIntPR #PAuto

DOL damper-fan system replaced by variable frequency drives.

Energy use was reduced from 19,423kWh to 7,789kWh as a result of the VFDs being installed.

Replacing an inefficient damper-based fan system with Invertek variable frequency drives has helped a Brazilian ceramics producer reduce energy use in part of its process by 60%, while increasing the quality of its products at the same time.

Ceramica Tomazia, located in Canelinha in Brazil, produces a range of ceramic brick and tile products used mainly in the construction industry. The production process involves mixing raw materials, before they are pressed, dried, glazed, and then undergo firing in a kiln.

Before the ceramics are glazed and fired, moisture has to be removed from the product in a drying room. An industrial exhaust fan was used to pull the heat source from the kiln into the drying room where it was then spread through seven industrial damper-based fans.

“To control the heat in the room dampers were used on the fans. This meant the fans were operating constantly at full speed unnecessarily, wasting energy and making it difficult to maintain the correct temperature accurately,” said Gabriel Robert of G2R Engenharia e Automacao,  "the company brought in to create a cost-effective solution. The damper-fans are simply inefficient and ineffective. We introduced Invertek Drives's Optidrive E3 and Eco drives to accurately control the fans, varying their speed depending on the products being dried and the temperature required.”

An Optidrive E3 IP66 / NEMA 4X rated VFD was used on the 15HP motor exhaust fan pulling the heat from the firing room. The outdoor rated enclosure was required due to the dust and heat in the industrial environment.

The seven 3HP (total 21HP) fans used in the drying room are now controlled by a single Optidrive Eco drive. The 22kW (30HP), 46A, 380-480V, IP20 rated drive is housed in a control panel, while all motors used on the fans have individual thermal protection.

Energy use was reduced from 19,423kWh to 7,789kWh as a result of the VFDs being installed.

“The introduction of VFD controlled fans has created significant savings in energy costs. Additionally, the quality and standardization of the products has been improved thanks to the improved control of the circulation of heat inside the drying room. The customer is very happy with the outcome,” added Gabriel.

Marcus Silva, Head of Sales in Latin America for Invertek Drives, said the result was another demonstration of how Optidrive VFDs are benefiting businesses and the environment by lowering emissions created through efficient energy use. “This can be just as important in areas such as agricultural buildings where the health and welfare of animals can be improved through such accurate ventilation and temperature control, or in environments where ventilation is important.”\

@Invertek_Drives #PAuto #Ceramics #VSD

Appointment for HVAC sector.

Mike Carman has been appointed as Executive Business Development Manager for the HVAC-R sector with Invertek Drives. His role is to focus on the development of Invertek’s growing position as an innovator and manufacturer of energy efficient variable frequency drives (VFD) used to control and optimise the performance of AC electric motors used in BLDC compressors for applications such as Heat Pumps, CDU’S and refrigeration food retail display cases.

Mike Carman

He has worked in the VFD industry for more than 20 years, including a total of six years at Invertek Drives.

Mike has been heavily involved in Invertek’s work in the refrigeration sector in recent years with the launch of Optidrive Coolvert, a VFD designed specifically for OEMs to optimise the performance of BLDC compressors using natural refrigerants such as R744 and R290.

Rhydian Welson, Sales and Marketing Director, said: “Globally there is a push, indeed a need, to reduce energy consumption and associated emissions. Our VFDs are already being used in the HVAC-R sector and our overall market share of the industry has grown significantly in recent years having witnessed record orders and growth.

“We are in a commanding position through our innovation and drives products, including Coolvert, to support ever more efficient AC motor controlled systems, including BLDC compressors used in HVAC-R applications. These markets are growing rapidly and we are ready to support that.

“Mike has a wealth of knowledge and experience in this sector and will lead on this global development.”

Earlier this year the European Commission unveiled a revision of its F-Gas Regulation which aims to reduce harmful carbon emissions by at least 55 per cent by 2030 and making Europe climate neutral by 2050. Part of this means refrigeration systems manufacturers are having to turn to alternative “green refrigerants” such as, R744 and R290 natural refrigerants.

Mike Carman, said: “We recently attended Chillventa in Nuremberg, Germany, Europe’s premier refrigeration exhibition, where it became obvious just how well known Invertek and our Optidrive products have become within the industry. Our products could be seen on refrigeration and heat pump machines throughout the show highlighting how we are already making a significant impact.”

He added: “The global refrigeration equipment market was valued at $37.25 Billion (USD) in 2021 and expected to grow by 132% to $58.31 Billion (USD) by 2028. Place this alongside growth of 34 per cent in European heat pump sales in 2021 and it’s quite clear we have a significant role and opportunity to play in this sector. I’m looking forward to developing that opportunity by working with OEMs, our dedicated sales partners to integrate our drive technology into existing and future systems.”

@Invertek_Drives @EUClimateAction #HVAC #F-Gas

New line of variable frequency drives.

A new line of VF1A Doesa variable frequency drives (VFDs) ia available from IDEC Corporation. The line offers versatile control and efficient operation of electrical motors for a wide range of applications. 

VFDs are used to control the speed and torque of AC motors so users can optimize system performance by running equipment at just the speed required to meet the demand of the load. Furthermore, VFDs are configurable to accelerate and decelerate to commanded speed smoothly, reducing the wear and tear on associated mechanical components. Among the greatest of VFD benefits is the energy savings realized by running a motor at any speed below maximum, so long as the equipment needs are met. 

Control options.
IDEC VF1A Doesa VFDs are suitable for speed control of variable and constant torque applications ranging from fans and pumps to specialized equipment. The VFD is capable of driving an induction motor (IM) or a permanent magnet synchronous motor (PMSM). IMs can be driven in open loop or closed loop, while PMSMs can be driven in open loop only

The product family features a compact form factor in a UL open-type construction, with nickel- and tin-plated bus bars and conformal coatings for corrosion protection. The VFD is designed for a long operating life, and provides a maintenance alarm signal.

Electrical input is nominally rated as three-phase low voltage AC 400V (with an allowable input voltage range of 380-480V AC), and the VFDs come in 14 models with a capacity range of up to 139A. Each VFD is quadruple rated for varying duties—normal or heavy overload, and mild 40DegC or high 50DegC temperatures—so users can minimize the number of models needed to handle a wide range of applications.

Other advanced functionality includes control of mechanical brakes, a built-in braking transistor, regeneration avoidance, and low-voltage ride through. Safe torque off (STO) capability ensures the VFD fulfills functional safety standard requirements while eliminating the need for external circuit breakers required by conventional VFDs.

Logic programming with 55 functions, different calculations and sequences, and fast processing intervals lets designers eliminate other small controllers, and adapt the VFD to meet special requirements. The logic is configured via easy-to-use graphical software, enabling users to create customized automation applications of up to 200 steps, including PID control. Online logic, value, and trace monitoring helps users optimize and diagnose applications. Password protection is included.

The VFD also includes seven digital inputs, two analog inputs, three digital outputs, and two analog outputs for added control functionality. A standard option port and RS-485 terminals are included, and the VFD accepts removable terminal cards for standard, 5V, and 12V/15V operation. Optional communication cards are available for easy integration of the VFD with PLCs and other intelligent devices.

An on-board keypad provides convenient status and diagnostic monitoring, along with local configuration and control capability. An optional external keypad makes it easy to set and save parameters in a convenient location—using a PC and software if desired—and then later connect this keypad locally at the VFD for downloading the configuration.

The IDEC portfolio of VF1A Doesa VFDs provide cost-effective, high-performance control for a wide variety of motor applications. IDEC offers free tech support for the VFDs, with no service or support contract required.

@IDECUSA #PAuto #VFD