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
Power Consumption at 80% Speed
Total Power Saved at 80% Speed
TOTAL ENERGY SAVED PER YEAR
= 162 kW
= 82 kW
= 162 kW - 82 kW
= 80 kW = 80 Units
= 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