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Makethemostof yourenergy Makethemostof - - PowerPoint PPT Presentation

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MusicCityPowerQuality IEEEControlTennesseeSection 2015 Addphotointhisarea Makethemostof yourenergy Makethemostof SM yourenergy

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SLIDE 1

Makethemostof yourenergy Makethemostof yourenergy

SM

Addphotointhisarea

MusicCityPowerQuality IEEEControlTennesseeSection 2015

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SLIDE 2

SchneiderElectric 2 # Division# Name– Date

  • MikeMattingly,CEM

MidwestRegionalTeamLeader– SrDriveSpecialist

  • Mike.Mattingly@us.schneider#electric.com
  • 317#292#4537cell
  • 25yearsintheElectricalIndustry
  • GasturbineSystemsElectricalEngineer(USNavy)
  • IndustrialElectrician– 5years
  • ProductApplicationEngineer– 15years
  • SrDriveSpecialistwithSchneiderElectric– 9years
  • MidwestRegionalTeamLeader– Michigan,Tennessee,Kentucky,

Indiana,Ohio,Chicago,Wisconsin,

  • CertifiedEnergyManager– AssociationorEnergyEngineers
slide-3
SLIDE 3

SchneiderElectric 3 # Division# Name– Date

SchneiderElectricU.S.

SchneiderElectric

TheGlobalSpecialistinEnergy Management

peopleacrossthecountry facilitiesacrossthecountry

  • 40Manufacturingfacilities
  • 6Distributioncenters
  • 6R&Dcenters
  • Business,sales&services
  • !
slide-4
SLIDE 4

SchneiderElectric 4 # Division# Name– Date

Today’sDiscussion

  • "#$% &'( !
  • )) *
  • "$&* +
  • ,-
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SLIDE 5

SchneiderElectric 5 # Division# Name– Date

VariableFrequencyDrives commonnamesare:

  • "#$% &'. "$&
  • /#$% &'( $&
  • "#)*. "*
  • /#)*( *
  • "#)&'. "&
  • /#)&'( &
  • *&'
  • '&'
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SLIDE 6

SchneiderElectric 6 # Division# Name– Date

SoftStartvsVFD

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SLIDE 7

SchneiderElectric 7 # Division# Name– Date

MeansofControllingFlow&Pressure

  • TypicalOutputControlsinclude:
  • Throttlevalves
  • Inletguidevanes
  • Outletdampers
  • Mechanicalspeedchangers
  • EddyCurrentClutch
  • BeltDrive
  • Two#speedMotor
  • Motorrunsatfullspeed
  • Noenergysavings
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SLIDE 8

SchneiderElectric 8 # Division# Name– Date

WhyreplaceamotorstarterwithaVFD?

  • *

*

  • 0'

0'

&' &'

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SLIDE 9

SchneiderElectric 9 # Division# Name– Date

WhyuseVFD’s?

  • Providesubstantialenergysavings# #1
  • BuiltinSoftStart– reducesmechanicalshock
  • Reducesdowntime&improvessystemreliability
  • Reducesmaintenance&operationalcost
  • Improvessystemefficiency
  • Preciseprocessspeed&torquecontrol
  • Providesapplicationflexibility
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SLIDE 10
  • 1'222

+ +3

$3

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SLIDE 11
  • !"

+45 )% +)6

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SLIDE 12
  • !) ')# )

( 7/'8+9

# #)

1 -) )

0.

!"

:;+<

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SLIDE 13

SchneiderElectric 13 # Division# Name– Date

  • Situation– Aerationbasin
  • A500hpcentrifugalblower
  • Supplyair10hours/dayfor250days
  • Costatfullspeedwouldbe:

500hpx0.746kW/hpx2500hoursx$0.08/kWhr=$74,600.00

  • Assumingtheblowerdoesnothavetorunatfullspeedallthetime
  • 25%oftimeat100%speed=625hours
  • 50%oftimeat80%speed=1250hours
  • 25%oftimeat60%speed=625hours
  • CostrunningwithaSchneiderElectricACDrive:
  • 500x(1.0)3 x0.746x625x$0.08

=$18,650.00

  • 500x(0.8)3 x0.746x1250x$0.08

=$19,097.60

  • 500x(0.6)3 x0.746x625x$0.08

=$4,028.40

  • Annualsavings($74,600.00# $41,776.00)is$32,824.00

VFDBasics– EnergySavings

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SLIDE 14

SchneiderElectric 14 # Division# Name– Date

  • ControlsspeedofanACmotor.
  • ControlsinrushcurrentofanACmotor.
  • Generatesfulltorqueofthemotoratverylowspeeds.
  • Protectsthemotorandwiringfromoverloadcurrents.
  • Providesbuiltinpowerfactorcorrection.
  • Allowssimpleconnectiontoacommunicationnetwork.
  • Allowsautomaticsetpointcontrolthroughouttheentire

speedrange.

  • Providesasimplemeanstocontinuouslymonitor&

diagnose.

VFD– Whatdoesitgiveyou?

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SLIDE 15

SchneiderElectric 15 # Division# Name– Date

VFDDrivenLoads

  • ConstantTorque– 150%overcurrentfor1minute
  • Positivedisplacementpumps
  • Extruders
  • Centrifuges
  • Mixers
  • Agitators
  • Conveyors
  • Cranes
  • Papermachines
  • VariableTorque– 110%overcurrentfor1minute
  • Centrifugalpumps
  • Fans
  • Blowers
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SLIDE 16

SchneiderElectric 16 # Division# Name– Date

Applications

  • +)
  • 1'
  • 1=$
  • 1'
  • *+)
  • $

'

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SLIDE 17

SchneiderElectric 17 # Division# Name– Date

TypicalBuildingApplications

*!$

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SLIDE 18

SchneiderElectric 18 # Division# Name– Date

VFDBasics

*

  • )

&

  • *'

&*

  • !

' * 0)

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SLIDE 19

SchneiderElectric 19 # Division# Name– Date

Voltz/HzRatio

  • Whencurrentisappliedtoaninductionmotoritgeneratesmagneticfluxin

itsrotatingfieldandtorqueisproduced.

  • Thismagneticfluxmustremainconstantinordertoproducefull#load

torque,whichismostimportantwhenrunningamotoratlessthanfull speed.

  • SinceACdrivesareusedtoprovideslowerrunningspeeds,there mustbe

ameansofmaintainingaconstantmagneticfluxinthemotor.Thismethod

  • fmagneticfluxcontroliscalledthevolts#per#hertzratio.
  • Withthismethod,thefrequencyandvoltagemustincrease/decreaseinthe

sameproportiontomaintaingoodtorqueproductionatthemotor.

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SLIDE 20

SchneiderElectric 20 # Division# Name– Date

PulseWidthModulation

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SLIDE 21

SchneiderElectric 21 # Division# Name– Date

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SLIDE 22

SchneiderElectric 22 # Division# Name– Date

ControlSignals

  • >

*++ *

  • )

*++

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SLIDE 23

SchneiderElectric 23 # Division# Name– Date

) )

&' &'

  • *

*

Drivesarejustone pieceoftheprocess Drivesarejustone pieceoftheprocess # #∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅ !) &' + $ +)

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SLIDE 24

SchneiderElectric 24 # Division# Name– Date

ApplicationConsiderations

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SLIDE 25

SchneiderElectric 25 # Division# Name– Date

Power# WhatkindofPower?

  • Animportantpoint,tocontrolthespeedofamotoritmustbea 3

PhaseMotor!!!

  • TypicalVFDsonthelowvoltagesidecancontrol208V,230V,

380V,460V,575Vmotors!

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SLIDE 26

SchneiderElectric 26 # Division# Name– Date

SelectingACDrives

  • SizebyMotorFLA.
  • Voltage,HPandLoad

Type/Application

  • It’salsousefultoknowthe

motorbasespeed,service factor,enclosuretype, insulationClassofthe motorandNemadesign.

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SLIDE 27

SchneiderElectric 27 # Division# Name– Date

WhattypeofEnclosure?

  • BrandNames
  • OpenPanel
  • Soldwhenothersmountinanenclosure
  • OEMs,systemintegrators,panelbuilders
  • Soldforwallmountedapplications
  • Enclosed
  • Soldtocustomersneeding

a“readytouse” solution

  • Soldtocustomerswhovalueapackagedesigned

andassembledbyamajorcompany

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SLIDE 28

SchneiderElectric 28 # Division# Name– Date

Altivar61

  • Type1solutionforwallmounting
  • Optionalconduitkit
  • 460Vacrange

– 1to450HP

  • 208/230Vacrange

– 1to75HP

  • Abilitytoorderonepartnumber
  • Add“!” totheendofpartnumber
  • Driveandconduitkitshiptogether

– inonebox – orstrappedtogether

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SLIDE 29

SchneiderElectric 29 # Division# Name– Date

M#FlexVFD(1to500hp)

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SLIDE 30

SchneiderElectric 30 # Division# Name– Date

SeismicQualification

  • 1stDrivemanufacturertomeet

newstandards

  • NewSeismicDesignCategories

replaceSeismicZones

  • TestedtoICCESAC156
  • Uniformacceptancetestprotocol
  • ShakertabletestedatWylieLabs
  • Importancefactorof1.5
  • Operationalafterevent
  • Ss(spectralresponse

accelerationatonesecond period)>2.67g

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SLIDE 31

SchneiderElectric 31 # Division# Name– Date

Reliability&ThermalManagement

  • Thermalmodeling
  • 50°Cde#rating,highaltitude,cloggedfilters

simulations

  • Airflowanddirectionoptimization
  • DesignVerification
  • Extremetoleranceverification
  • 40°C,2%AClinevoltageunbalance
  • 460VAC±10%underfullload
  • Elevatedinputcurrents(lowimpedance

system)

  • Thermalcouplemeasurementsforverification

Stirringfan at60° angle

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SLIDE 32

SchneiderElectric 32 # Division# Name– Date

LongLeadLength– StatorIssues

  • Specialconsiderations
  • Impedancemismatchbetweendrive/cableandmotor
  • Carrierfrequency/switchingfrequency
  • Cableleadlength
  • dV/dT– RisetimeofIGBT’s
  • Voltagespikes
  • Reflectedwaveformcancausevoltagedoubling

atthemotor

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SLIDE 33

SchneiderElectric 33 # Division# Name– Date

StatorFailure

  • TheResult– PhasetoPhase,CoiltoCoilandTurntoTurnFailures

InsulationFailure Highestvoltagestressoccurs betweentheturnsinthefirstone

  • rtwocoilsinaphasegroup
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SLIDE 34

SchneiderElectric 34 # Division# Name– Date

VFDDesignConsiderations– Bearings

  • Specialconsiderations:
  • Rectifiersswitching3Output/Unbalanced
  • FluctuationofMotorVrespecttoGround
  • CommonModeVoltageaprimarycauseofBearingCurrent
  • Voltagebuild#upof5#30VDContheshaftispossible
  • Typicalflashpointisbearings
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SLIDE 35

SchneiderElectric 35 # Division# Name– Date

VFDDesignConsiderations– Motors

  • BearingSolutions
  • Decreasecarrierfrequencyfromdrive
  • Insulatebearings/Groundshaftwithabrush
  • Commonmodefilter
  • SpecifyandpurchaseNEMAMG1,Part31Motors
  • StatorSolutions
  • Lowerthecarrierfrequencyofthedrive
  • Loadreactor/Outputfilters
  • SpecifyandpurchaseNEMAMG#1,Part31motors
  • StandardNEMABmotorswithclassFHPEinsulation
  • 1.15ServicefactororBetter
  • OutputFilterswhererecommended

ConsiderspecifyingNEMAMG1,Part31motors

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SLIDE 36

SchneiderElectric 36 # Division# Name– Date

PowerFactorCorrectionCapacitors

  • Issues
  • InstallonlinesideofVFD
  • Analyzetoavoidharmonicfrequencyresonanceconditions
  • RandomswitchingofPFcorrectioncapacitorsmaycausevoltagetransients
  • ntheAClinethatcouldcausenuisanceovervoltagecontroltripping.
  • Solution
  • Installalinereactortoreducethemagnitudeofthelinetransients,thus

preventingtripping

  • HavePFcorrectioncapacitorstunedtoavoidharmonicfrequency

resonanceconditions

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SLIDE 37

SchneiderElectric 37 # Division# Name– Date

,

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SLIDE 38

SchneiderElectric 38 # Division# Name– Date

* ?

  • Mike.Mattingly@us.schneider#electric.com
  • 317#292#4537cell