Do you have ac motors in your facility? Do these motors need a variable output?

Do you use mechamical means to vary the output? If you anwsered yes to these questions, you need to install variable frequency drives on these ac motors. If you are not using VFD's you are wasting energy and throwing money out the window. Many utilities are now offering rebates for the installation of VFD's or retro-fitting existing equipment with variable frequency drives. ontact your local utility or search VFD rebate. What is a VFD? y! Dave "ol#a $ou can divide the world of electronic motor drives into two categories! %& and D&. % motor drive controls the speed, torque, direction and resulting horsepower of a motor. % D& drive typically controls a shunt wound D& motor, which has separate armature and field circuits. %& drives control %& induction motors, and'li#e their D& counterparts'control speed, torque, and horsepower. Application As An Example (et's ta#e a brief loo# at a drive application. In Fig. ), you can see a simple application with a fi*ed speed fan using a motor starter. $ou could replace the +'phase motor starter with Variable Frequency Drive ,VFD- to operate the fan at variable speed. .ince you can operate the fan at any speed below its ma*imum, you can vary airflow by controlling the motor speed instead of the air outlet damper.

Figure 1, Fixed Speed Fan Application % drive can control two main elements of a +'phase induction motor! speed and torque. /o understand how a drive controls these two elements, we will ta#e a short review of %& induction motors. Fig. 0 shows the construction of an induction motor. /he two basic parts of the motor, the rotor and stator, wor# through magnetic interaction. %

motor contains pole pairs. /hese are iron pieces in the stator, wound in a specific pattern to provide a north to south magnetic field.

Figure 2, Basic Induction Motor Construction

Figure 3, Operating Principles of Induction Motor 1ith one pole pair isolated in a motor, the rotor ,shaft- rotates at a specific speed! the base speed. /he number of poles and the frequency applied determine this speed ,Fig. 2-. /his formula includes an effect called 3slip.3 .lip is the difference between the rotor speed and the rotating magnetic field in the stator. 1hen a magnetic field passes through the conductors of the rotor, the rotor ta#es on magnetic fields of its own. /hese rotor magnetic fields will try to catch up to the rotating fields of the stator. 4owever, it never does '' this difference is slip. /hin# of slip as the distance between the greyhounds and the hare they are chasing around the trac#. %s long as they don't catch up to the hare, they will continue to revolve around the trac#. .lip is what allows a motor to turn. Motor Slip: .haft .peed 5 )06 7 F ' .lip

" .lip for 89:% :otor 5 + to ;< of which is )=66 >": at Full (oad F 5 Frequency applied to the motor " 5 8umber of motor poles Example: )06 7 ?6 ' .lip .haft .peed 5 4@ 2

ase .peed

Figure 4, Induction Motor Slip Calculation 1e can conveniently adAust the speed of a motor by changing the frequency applied to the motor. $ou could adAust motor speed by adAusting the number of poles, but this is a physical change to the motor. It would require rewinding, and result in a step change to the speed. .o, for convenience, cost'efficiency, and precision, we change the frequency. Fig. ; shows the torque'developing characteristic of every motor! the Volts per 4ert@ ratio ,VB4@-. 1e change this ratio to change motor torque. %n induction motor connected to a 2?6V, ?6 4@ source has a ratio of C.?C. %s long as this ratio stays in proportion, the motor will develop rated torque. % drive provides many different frequency outputs. %t any given frequency output of the drive, you get a new torque curve.

Figure 5, olts!"ert# $atio How Drive Changes Motor Speed Dust how does a drive provide the frequency and voltage output necessary to change the speed of a motor? /hat's what we'll loo# at ne*t. Fig. ? shows a basic "1: drive. %ll "1: drives contain these

main parts, with subtle differences in hardware and software components.

Figure %, Basic P&M 'ri(e Co)ponents %lthough some drives accept single'phase input power, we'll focus on the +'phase drive. ut to simplify illustrations, the waveforms in the following drive figures show only one phase of input and output. /he input section of the drive is the converter. It contains si* diodes, arranged in an electrical bridge. /hese diodes convert %& power to D& power. /he ne*t section'the D& bus section'sees a fi*ed D& voltage. /he D& us section filters and smoothes out the waveform. /he diodes actually reconstruct the negative halves of the waveform onto the positive half. In a 2?6V unit, you'd measure an average D& bus voltage of about ?;6V to ?=6V. $ou can calculate this as line voltage times ).2)2. /he inductor ,(- and the capacitor ,&- wor# together to filter out any %& component of the D& waveform. /he smoother the D& waveform, the cleaner the output waveform from the drive. /he D& bus feeds the final section of the drive! the inverter. %s the name implies, this section inverts the D& voltage bac# to %&. ut, it does so in a variable voltage and frequency output. 4ow does it do this? /hat depends on what #ind of power devices your drive uses. If you have many .&> ,.ilicon &ontrolled >ectifier-'based drives in your facility, see the .idebar. ipolar /ransistor technology began superceding .&>s in drives in the mid')EC6s. In the early )EE6s, those gave way to using Insulated Fate ipolar /ransistor ,IF /technology, which will form the basis for our discussion. Switching !s With "# $s

/oday's inverters use Insulated Fate ipolar /ransistors ,IF /s- to switch the D& bus on and off at specific intervals. In doing so, the inverter actually creates a variable %& voltage and frequency output. %s shown in Fig. C, the output of the drive doesn't provide an e*act replica of the %& input sine waveform. Instead, it provides voltage pulses that are at a constant magnitude.

Figure *, 'ri(e Output &a(efor) /he drive's control board signals the power device's control circuits to turn 3on3 the waveform positive half or negative half of the power device. /his alternating of positive and negative switches recreates the + phase output. /he longer the power device remains on, the higher the output voltage. /he less time the power device is on, the lower the output voltage ,shown in Fig.=-. &onversely, the longer the power device is off, the lower the output frequency.

Figure +, 'ri(e Output &a(efor) Co)ponents /he speed at which power devices switch on and off is the carrier frequency, also #nown as the switch frequency. /he higher the switch frequency, the more resolution each "1: pulse contains. /ypical switch frequencies are +,666 to 2,666 times per second ,+G4@ to 2G4@-. ,1ith an older, .&>'based drive, switch frequencies are 0;6 to ;66 times per second-. %s you can imagine, the higher the switch frequency, the smoother the output waveform and the higher the

resolution. 4owever, higher switch frequencies decrease the efficiency of the drive because of increased heat in the power devices. Shrin%ing cost and si&e Drives vary in the comple*ity of their designs, but the designs continue to improve. Drives come in smaller pac#ages with each generation. /he trend is similar to that of the personal computer. :ore features, better performance, and lower cost with successive generations. Hnli#e computers, however, drives have dramatically improved in their reliability and ease of use. %nd also unli#e computers, the typical drive of today doesn't spew gratuitous harmonics into your distribution system'nor does it affect your power factor. Drives are increasingly becoming 3plug and play.3 %s electronic power components improve in reliability and decrease in si@e, the cost and si@e of VFDs will continue to decrease. 1hile all that is going on, their performance and ease of use will only get better. Side'ar: What i( )o! have SC*s? 1ith the large installed base of .&>s, you might want to #now how these operate. %n .&> ,originally referred to as a thyristor- contains a control element called a gate. /he gate acts as the 3turn'on3 switch that allows the device to fully conduct voltage. /he device conducts voltage until the polarity of the device reverses'and then it automatically 3turns off.3 .pecial circuitry, usually requiring another circuit board and associated wiring, controls this switching. /he .&>'s output depends on how soon in the control cycle that gate turns on. /he IF / output also depends the length of time the gate is on. 4owever, it can turn off anytime in the control cycle, providing a more precise output waveform. IF /s also require a control circuit connected to the gate, but this circuitry is less comple* and doesn't require a reversal of polarity. /hus, you would approach troubleshooting differently if you have an .&>'based drive. This information has been provided by: ABB Inc. - rives and !o"er #lectronic How to Maintain a Variable Frequency Drive? Many utilities are now offering rebates for the installation of VFD's or retro-fitting existing equipment with variable frequency drives. ontact your local utility or search VFD rebate.

How $o Maintain a VFD y! Dave "ol#a Do you #now how to maintain Variable Frequency Drives ,VFDs-? Doing so is easier than you might thin#. y integrating some simple, logical steps into your preventative maintenance program, you can ensure your drives provide many years of trouble'free service. efore loo#ing at those steps, let's quic#ly review what a VFD is and how it wor#s. A +!ic% ,verview % VFD controls the speed, torque and direction of an %& Induction motor. It ta#es fi*ed voltage and frequency %& input and converts it to a variable voltage and frequency %& output. .ee /raining 8ote 3!hat is a VFD"# for a more detailed description of VFD concepts and operating principles. In very small VFDs, a single power pac# unit may contain the converter and inverter. 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. % microprocessor or Digital .ignal "rocessor ,D."- meets all the internal logic and decision requirements. From this description, you can see a VFD is basically a computer and power supply. %nd the same safety and equipment precautions you'd apply to a computer and to a power supply apply here. VFD maintenance requirements fall into three basic categories!

#eep it cleanI #eep it dryI and #eep the connections tight.

(et's loo# at each of these. -eep it Clean :ost VFDs fall into the 89:% ) category ,side vents for cooling airflowor 89:% )0 category ,sealed, dust'tight enclosure-. Drives that fall in the 89:% ) category are susceptible to dust contamination. Dust on VFD hardware can cause a lac# of airflow, resulting in diminished performance from heat sin#s and circulating fans ,"hoto )-.

$hoto %& Fan 'n(ecting Dust into Drive )nclosure Dust on an electronic device can cause malfunction or even failure. Dust absorbs moisture, which also contributes to failure. "eriodically spraying air through the heat sin# fan is a good ": measure. Discharging compressed air into a VFD is a viable option in some environments, but typical plant air contains oil and water. /o use compressed air for cooling, you must use air that is oil'free and dry or you are li#ely to do more harm than good. /hat requires a speciali@ed, dedicated, and e*pensive air supply. %nd you still run the ris# of generating electrostatic charges ,9.D-. % non'static generating spray or a reverse'operated 9.D vacuum will reduce static build'up. &ommon plastics are prime generators of static electricity. /he material in 9.D vacuum cases and fans is a special, non'static generating plastic. /hese vacuums, and cans of non'static generating compressed air, are available through companies that speciali@e in static control equipment. -eep it Dr) In "hoto 0 you can see what happened to a control board periodically subAected to a moist environment. Initially, this VFD was wall'mounted in a clean, dry area of a mechanical room and moisture was not a problem. 4owever, as is often the case, a well'meaning modification led to problems. In this e*ample, an area of the building required a dehumidifier close to the mechanical room. .ince wall space was available above the VFD, this is where the dehumidifier went. Hnfortunately, the VFD was a 89:% ) enclosure style ,side vents and no seal around the cover-. /he obvious result was water dripping from the dehumidifier into the

drive. In si* months, the VFD accumulated enough water to produce circuit board corrosion.

$hoto *&

orrosion on +oard ,races

aused by Moisture

1hat about condensation? .ome VFD manufacturers included a type of 3condensation protection3 on earlier product versions. 1hen the mercury dipped below +0 degrees Fahrenheit, the software logic would not allow the drive to start. VFDs seldom offer this protection today. If you operate the VFD all day every day, the normal radiant heat from the heatsin# should prevent condensation. Hnless the unit is in continuous operation, use a 89:% )0 enclosure and thermostatically controlled space heater if you locate it where condensation is li#ely. -eep Connections $ight 1hile this sounds basic, chec#ing connections is a step many people miss or do incorrectly ' and the requirement applies even in clean rooms. 4eat cycles and mechanical vibration can lead to sub'standard connections, as can standard ": practices. >etorquing screws is not a good idea, and further tightening an already tight connection can ruin the connection ,see .idebar-. ad connections eventually lead to arcing. %rcing at the VFD input could result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. %rcing at the VFD output could result in over'current faults, or even damage to the power components. "hotos + and 2 show what can happen. (oose control wiring connections can cause erratic operation. For e*ample, a loose ./%>/B./J" signal wire can cause uncontrollable

VFD stops. % loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel inAury.

$hoto -& .rcing

aused by /oose 'nput

ontacts

$hoto 0& .rcing

aused by /oose 1utput

ontacts

*e.tor/!ing . A Screw) 0ractice %lthough 3re'torquing3 as a way of chec#ing tightness is common in many ": procedures, it violates basic mechanical principles and does more harm than good. % screw has ma*imum clamping power at a torque value specific to its si@e, shape, and composition. 9*ceeding that torque value permanently reduces the clamping power of that screw by reducing its elasticity and deforming it. (oosening and then re' torquing still reduces elasticity, which still means a loss of clamping power. Doing this to a loc# washer results in a permanent ;6< loss. 1hat should you do? Hse an infrared thermometer to note hot connections. &hec# their torque. If they have merely wor#ed loose, you can try retightening them. 8ote which screws were loose, and be sure to give them an I>

chec# at the ne*t ": cycle. If they are loose again, replace them. Finally, don't forget the 3tug test.3 /his chec#s crimps, as well as screw connections. Don't do this with the drive online with the process, though, or you may cause some very e*pensive process disturbances. Additional Steps ). %s part of a mechanical inspection procedure, don't overloo# internal VFD components. &hec# circulating fans for signs of bearing failure or foreign obAects ' usually indicated by unusual noise or shafts that appear wobbly. 0. Inspect D& bus capacitors for bulging and lea#age. 9ither could be a sign of component stress or electrical misuse. "hotos ; and ? show fan and capacitor stress problems.

$hoto 2& Foreign 1b(ect in Fan +. /a#e voltage measurements while the VFD is in operation. Fluctuations in D& bus voltage measurements can indicate degradation of D& bus capacitors. Jne function of the capacitor ban# is to act as a filter section ,smoothing out any %& ripple voltage on the us-. %bnormal %& voltage on the D& bus indicates the capacitors are headed for trouble. :ost VFD manufacturers have a special terminal bloc# for this type of measurement and also for connection of the dynamic bra#ing resistors. :easurements more than 2V%& may indicate a capacitor filtering problem or a possible problem with the diode bridge converter section ,ahead of the bus-. If you have such

voltage levels, consult the VFD manufacturer before ta#ing further action. 1ith the VFD in ./%>/ and at @ero speed, you should read output voltage of 26V%& phase'to'phase or less. If you read more than this, you may have transistor lea#age. %t @ero speed, the power components should not be operating. If your readings are ?6V%& or more, you can e*pect power component failure. 2. 1hat about spare VFDs? .tore them in a clean, dry environment, with no condensation allowed. "lace this unit in your ": system so you #now to power it up every ? months to #eep the D& bus capacitors at their pea# performance capability. Jtherwise, their charging ability will significantly diminish. % capacitor is much li#e a battery'it needs to go into service soon after purchase or suffer a loss of usable life.

$hoto 3&

apacitor Failure

;. >egularly monitor heat sin# temperatures. :ost VFD manufacturers ma#e this tas# easy by including a direct temperature readout on the Geypad or display. Verify where this readout is, and ma#e chec#ing it part of a wee#ly or monthly review of VFD operation. $ou wouldn't place your laptop computer outside, on the roof of a building or in direct sunlight, where temperatures could reach )); degrees Fahrenheit or as low as ')6 degrees Fahrenheit. % VFD, which is basically a computer with a power supply, needs the same consideration. .ome VFD manufacturers advertise 066,666 hours'almost 0+ years'of :ean /ime etween Failures ,:/ F-. .uch impressive performance is easy to obtain, if you follow these simple procedures.

/his information has been provided by! A 9lectronics

"nc1 ' Drives and "ower

(Programmable Logic Controller) What is a 0rogramma'le 2ogic Controller 302C4? :any years before the "(& was invented, machine controllers used combinational circuits, li#e a combination of many relays, timers or any other devices, mechanical controller li#e cam shafts and drums, including electronic circuits to ma#e a sequence process ,logic control system-. 1ith this old sequential controller, the circuit loo#s very crowded and usually it's hard to find the malfunctioning part, or to even modify the sequence, also requires more time and cost. /he old sequential controller was implemented only in small scale or medium scale systems and was specific to a system or machine. ecause in large scale systems, it is hard to test the ability and the efficiency of the entire system. /his system also cannot be implemented in the process that needs a high speed control. .o that's why the "(& was invented. :any new industries have already implemented "(& systems to control their machines. "(& is operated by the instruction input from the input devices ,li#e push button switch, selector switch, digital switch, etc. provided on the operation panel, or sensors input from the limit switch, pro*imity switch, etc.- used to detect the operation condition of the equipment, and serve to control the driving loads, output devices ,such as solenoid valve, motor, electromagnetic clutch, etc. and indication loads such as pilot lamp, digital indicator, etc.-. /he transmission of output signal against these input signals is determined by the contents of "(& program to be provided to the "(&. /he light loads such as small type solenoid valve, pilot valve, pilot lamp, etc. can be directly driven by the "(&, however, the heavy loads such as +'phase motor, large capacity solenoid valve, etc. need to be driven through the contactor or the intermediate relay. .uch contactor, intermediate relay, power brea#er, etc. are installed in the control panel together with the "(&. /he "(& will play an important role as a small type, high'reliability and fle*ible brain when designing the automated product machining, assembling, transfer, inspection, pac#ing, etc.

/he "(& is composed of electronic circuits with a micro'computer ,micro'controller- centered, however, it can be equivalently regarded as an integrated body of ordinary relay, timer, counter, etc. /he input relay built in the "(& is driven by the e*ternal switch through the input terminal. /he output relay built in the "(& is provided with various internal contacts in addition to the e*ternal output contact. esides, it is incorporated with various types of elements such as timer, counter, au*iliary relay, state, coil and function bloc#, etc. In addition, these elements are provided with many electrically normally'open contacts and normally'close contacts, and can be used optionally within the "(&. 5oliet $echnologies and 0A6.$ECH Engineering7 "nc111 "an'/ech was created in )EE6 as a part time business for building electrical panels. In )EE; the company e*panded into engineering, process control, programming, "(& programming, and machine building and is also currently involved in process integration and data collection. "an'/ech is staffed with talented individuals speciali@ing in manufacturing and process control in the pharmaceutical, food, chemical, and health care industries. Jne of the company's main focuses is personali@ed service to customers. 1or#ing with plant personnel from the visionaries, to the supporters, to the users. "an'/ech strives to develop wor#able solutions to best fit the environment. /hey then provide continuous support for these solutions. "an'/ech benefits from its relationship with Indicom by providing highly organi@ed and efficient turn#ey solutions to any electrical application. %s the company continues to grow, its plans include e*panding into software validation and home automation. "%8'/9&4 9ngineering is dedicated to provide the highest quality equipment and service. 1ith our e*perience, e*pertise and commitment, you will be completely satisfied with our wor#manship and our wor# ethic.

Variable Speed DC Drives DC D*"VES D& drives consist of an .&> ,.ilicon &ontrolled >ectifierbridge, which converts incoming three or single'phase %& volts to D& volts. During this conversion process D& drives then can regulate speed, torque, voltage and current conditions of the D& motor. /his is ideal for industrial processes such as tube mills, e*truders, mi*ers, paper machines and various other controlled applications. Doliet /echnologies can provide several D& Drives from different reputable manufactures. "ac#ages can vary from Jnsite >etrofits to custom multi drive cabinets. Engineering and "ntegration Doliet /echnologies with its highly e*perienced engineers and /echnical staff can provide solutions for e*isting drive problems or new applications. .olutions that may be helpful consist of!

.i@ing a drive to a target horsepower, current and voltage required. "ower and harmonics issues can be addressed and corrected through the use of isolation transformers, reactors and filter pac#ages. &ustomi@ing control and analog circuitry to be integrated in with e*isting engineered specifications. Jperator consoles B Door mounted pilot and metering devices :&& and .witchgear installation type custom pac#aging for growing demands of the industry. "eer to "eer and :asterB.lave drive configurations for Follower and 4igh 4orsepower applications.

9ngineered cabinet cooling system for any environment. /oday's drives are more compact and can be placed in smaller enclosures only if the correct cooling is applied. &ommunication .ystems for advanced :odbus, "rofibus and Data 4igh1ay lin#ing multiple devices such as power management and 4:IB"(& systems.

Service and 0arts Doliet /echnologies can be reached 02BC for any emergency or non' emergency service and parts request. /o ma#e this service wor# better for anyone interested, please pre'qualify your company using this simple form. &lic# here, fill out the form and someone from Doliet /echnologies will contact you. :ore D& Drive information...

/o purchase a drive, contact us at! "hone 389:4 ;<:.=>=>, /oll Free 38>>4 ?=<.=888, Fa* 389:4 ;<:.=@=@ or 9'mail in(oABoliettech1com AC Drives and AC Drive Controllers AC D*"VE C,6$*,22E*S %& Drives and %& control circuits are considered to be part of the high tech electrical controls mar#et. 9ven the more straightforward %&

Fot a question or comment? 8eed a Kuote?

controllers involving contactors, starters, timers, metering and relay logic can become quite technical. Gnowing what is going on with the demands on your electrical machinery through first hand #nowledge and visual inspections can save you a lot of headaches and downtime. /herefore, the importance of using solid state monitoring devices that send valuable information to your electrical maintenance office or provide you with visual information on the door of the cabinet cannot be underestimated in #eeping your equipment up and running L ma#ing money. % customi@ed %& &ontroller from an industrial controls supplier, li#e Doliet /echnologies, can provide you with all the required components from, programming of the "(&, touch screen controls, simple starter or contactor cabinets, all customi@ed for your unique needs. %ll down stream electrical au*iliary equipment controls, such as hydraulic pumps, air pumps, solenoid vales, e*haust fans and blowers can be pac#aged in a single enclosed control system. For :&& ,:otor &ontrol &enter%& &ontroller applications, Doliet /echnologies can add interconnect wire harnessing, "(& sections, and help with engineering and commissioning. From the basic starter panel, to the comple* control system, Doliet /echnologies is prepared to wor# with you, to provide the controls needed to improve the preformance and production of your manufacturing machinery needs. :ore %& Drive information...

/o purchase a drive, contact us at! "hone 389:4 ;<:.=>=>, /oll Free 38>>4 ?=<.=888, Fa* 389:4 ;<:.=@=@ or 9'mail in(oABoliettech1com