Danfoss Drives PDF

A shortcut to energy savings
Advantages of infinitely variable speed adjustment
Energy savings on centrifugal pumps, fans and compressors
Total cost of ownership
Xavier Poupeleer ing. / Danfoss KAM

www.Danfoss.be/drives 5 Feb 2007
Advantages of infinitely variable
speed adjustment
400 V 50 Hz
Energy savings
Process optimisation
0 400 V, 0 50+ Hz
Smooth machine operation
l s ignal
tro
Con Less maintenance
Improved working environment
0-100+% Speed Higher productivity

Advantages of infinitely variable
speed adjustment
Energy savings (Typical load characteristics)
Winding
conveyor belts, cranes, positive

displacement pumps, compressors
rollers, smoothing machines
centrifugal pumps and fans.

Centrifugal pumps, fans and compressors
Considerably energy savings

Short payback time
Easy retrofit
Long lifetime of the investment
No disadvantages or eliminate them
Do you need permanently 100% of the installed capacity?
no! less or more

Simplified Brewery Refrigeration System:
Brine pump speed Constant suction pressure Condenser fan control
according to actual load
or floating pressure depending Floating head pressure control
on actual load
Set point = Wet bulb (Ambient
PID temp, RH) + 10 C
PID
Minimum 20 C
P Pe Pc
PID
Compressor
Brine pump
T+P
P
Heat exchanger
Condenser
Evaporator
Tc
M
T Throttling device
Pe Pc
Compressors and centrifugal pumps and fans
1.Centrifugal pumps and fans
2. Compressors

But we already regulate the capacity of
centrifugal pumps and fans
Flow (*) Pressure
PID
(*)
PID
M M
-The motor of the pump is connected Direct Online ( DO; star-delta; softstarter )
-The pump runs continously at full speed.
-The valve adjust the flow.
A look at the pump caracteristics
40%
50%
60%
70%
50
75%
77%
%
45
79
%
80
Total Head (Pressure)
40
%
80
%
35 79
7 5 7%
%
7
30 70
%
25 %
60
20 50
%
15
10 # diameters
5 (#)
0
0 100 200 300 400 500 600
Flow
What happens when we change the position of the valve ?

convensional vs frequency drive
Diagramme : flow/pressure
1 = pump curve
2 = system curve
3 = system + valve curve
4 = pump curve at lower speed
VI= pump losses
VT= valve losses
green area = guides losses
Ps= outlet power
throttle valves, bypass systems

or inlet guide vanes frequency drive
When we change the valve position we move from system curve 2 to 3. Other working point.
For the same pressure (same flow ) the needed power (colored surface) is less than the half.
Look at the pump losses, they are lower due to lower pressure in the pump.

convensional vs frequency drive
Transformer Transformer
Motor VSD
Pump Motor
Throttle valve Pump
Utilized output Utilized output

The utilized output at the pump is 100% in each case. In the case of throttle control, 2,86 times the
utilized power has to be fed in. With electronic speed control, in contrast 1,6 times the utilized power
has to be fed. The losses losses are reduced to 1/3
Drives are no cost
If for example we double the speed, the flow is doubled. The pressure loss is quadrupled because the
pressure is a quadratic function of the flow. To run the machine 4 times more couple is needed.
The power is the result of the product of the couple and speed. At double speed a power X 8
corresponds!
Payback time mostly less than one year.

Compressors and centrifugal pumps and fans
1.Centrifugal pumps and fans
2. Compressors

Compressor capacity regulation
100
80
%Power
60
40
20
0
0 50 100
% Capacity
Throttle valve On-Off

L-NL Variable Speed
Slide valve

Reduced average system header pressure, 0,1 bar = 1%.
Pressure stability
Load / NoLoad 2 bar
Modulation 1 bar
Variable Speed Drive 0,2 bar
Bar 120
100
80
60
40
20
0
time


Total Cost of Ownership
Expansion and upgrade Hardware

Downtime and repair Software
Set Up and Admin Cabeling

Operation Efficiency Labour
The Danfoss solution is a Hardware that eliminates or considerably reduces all other costs

Hardware Dilemma for a drive manufacturer
Protection
Danfoss Solution
Harmonic reactors
Cabinet IPxx
RFI filter
Options
Inverter
Motor inductor (du/dt)

common mode FC-102P11KT4E66H1BGC8XXSXXXXA0BKCXXXXD0
suppression Danfoss std
Danfoss options
PLC +
Safety Cascade
Free Software (USB-port)
Plug and play connection of a PC

Easy use of
VLT Set-up Software
MCT 10
VLT Energy Box
Syncpos MC0 305
Saves Time and money
Commissioning is Child's play

Installation costs
Safety Cat. 3 (EN 954-1)

Stopping Cat. 0 (EN 60204-1) Buid-up options
Simple (one-wire) cabling IP00 up to IP66
No contactor on output
Free space in cabinet
Smalest footprint on the market

Smart Logic Controller Highest ambient temp.
Cascade Controller 50C-55C
Build in filters have less heat
dissipation
Save on cabinet cooling

Operation costs
The new VLT HMI fits all VSD needs
220Vac / 400Vac / 690Vac

0,25 kW up to 1.2 mW
IP00 / IP20 / IP21 / IP55 / IP66
Global player (24/7 service)

Comissioning and troubleshooting
My personal menu
Quick setup
Changes made
Loggings
Application set-ups
28 languages
On board manual : Brief help text
for the function in use
MCT10
Design Guide Manuals
Friendly

f1
Expansion and upgrade
Adaptable and programmable
Modules can be applied independently

Buy on need to have basis
Easy upgrade
Easy commissioning
Easy service
Reliability
Flexible

Dias nummer 22
f1 C-optionen
f31685; 17-01-2006
Downtime and repair
Fact : downtime cost of Bottle line = 5000 /h
Case Stella Artois Brewery in Leuven :

No maintenance Install base : 1000 pcs
Danfoss Quality Total failures in 2006 : 32 pcs ( 3,2%)
Global 24/7 Service 50% of 32 pcs,older than 14 Years !
Service stocks (VLT3000)
Application Support 25% in critical environments (bad
Modular concept stock reduction implementation)
25% no info about at this time
Bringing the lowest cost of ownership

Total Cost of Ownership
Std Filtering
Modular concept Build-in intelligence
IP-Range
Expansion and upgrade Hardware options
Hardware
Downtime and repair Software
Quality USB-port
Gobal 24/7 Service Free MCT10
Free Syncpos program
Free Energy Box
Set Up and Admin

IP range
Operation Efficiency Cabeling
Hardware options
One HMI Labour Highest ambient temp
Free MCT10 Small bookstyle
LCP Help Multy languages SLC / Cascade
Danfoss Manuals Safe stop
The Danfoss solution is a Hardware that eliminates or considerably reduces all other costs

A new generation with new standards
Reliable Intelligent
Flexible Friendly

Hammer Mills classic
Feeding variation based
ve
C
PL
Dri
on Current consumption
ter
Rotation Detector Bypass
r
Sta
0
IP2
ft
So
50Hz
Rotation Change
Xavier Poupeleer ing. / Danfoss KAM Cabinet

Hammer Mills VSD
Feeding variation based Proces

on actual Torque Monitoring
Cabinet
Torque
-//-50Hz // 50Hz // +
IP5 ve
5
Dri
Advantages of Frequency drives on
Hammer Mills
infinitely variable speed adjustment, based on different grain types (change of impulse
force on grains)
Better product quality regulation 0-50Hz or more in both directions (possible energy
savings)
Easy and Fastest direction change
Controlled stops ( high inertia 4 to 6 times rotor inertia)
Less components (rotation-, speed detection, contactors, PLC, etc.)
Feeding device regulation based on actual torque in crusher ( Current measures involves
also magnetising current, not linear )
Local cos compensation (energy savings)
No starting current peaks (energy savings, smaller transformer needed)
Exact Feeding device regulation (closed torque PID loop)
Less maintenance, longer mechanical lifetime

Thanks for your attention
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A shortcut to energy savings

Advantages of infinitely variable speed adjustment

Energy savings on centrifugal pumps, fans and compressors

Total cost of ownership

Xavier Poupeleer ing. / Danfoss KAM

Xavier Poupeleer ing. / Danfoss KAM

conveyor belts, cranes, positive

rollers, smoothing machines

centrifugal pumps and fans.

Xavier Poupeleer ing. / Danfoss KAM

Considerably energy savings

Do you need permanently 100% of the installed capacity?

no! less or more

Xavier Poupeleer ing. / Danfoss KAM

1.Centrifugal pumps and fans

Xavier Poupeleer ing. / Danfoss KAM

What happens when we change the position of the valve ?

Xavier Poupeleer ing. / Danfoss KAM

throttle valves, bypass systems

Xavier Poupeleer ing. / Danfoss KAM

Throttle valve Pump

Utilized output Utilized output

Xavier Poupeleer ing. / Danfoss KAM

1.Centrifugal pumps and fans

Xavier Poupeleer ing. / Danfoss KAM

Throttle valve On-Off

Xavier Poupeleer ing. / Danfoss KAM

Xavier Poupeleer ing. / Danfoss KAM

Xavier Poupeleer ing. / Danfoss KAM

Expansion and upgrade Hardware

Set Up and Admin Cabeling

Xavier Poupeleer ing. / Danfoss KAM

Motor inductor (du/dt)

Plug and play connection of a PC

Saves Time and money

Commissioning is Child's play

Xavier Poupeleer ing. / Danfoss KAM

Safety Cat. 3 (EN 954-1)

Smalest footprint on the market

Xavier Poupeleer ing. / Danfoss KAM

220Vac / 400Vac / 690Vac

Xavier Poupeleer ing. / Danfoss KAM

Xavier Poupeleer ing. / Danfoss KAM

Expansion and upgrade

Adaptable and programmable

Modules can be applied independently

Xavier Poupeleer ing. / Danfoss KAM

Fact : downtime cost of Bottle line = 5000 /h

Case Stella Artois Brewery in Leuven :

Bringing the lowest cost of ownership

Xavier Poupeleer ing. / Danfoss KAM

Set Up and Admin

Xavier Poupeleer ing. / Danfoss KAM

Xavier Poupeleer ing. / Danfoss KAM

Feeding variation based

Xavier Poupeleer ing. / Danfoss KAM Cabinet

Feeding variation based Proces

Xavier Poupeleer ing. / Danfoss KAM

You are speaking

Xavier Poupeleer ing. / Danfoss KAM

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