01 Vacon Ac Drives Basic Course
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Vacon AC Drives Basic Course
17/12/2011
1
Vacon Training Center
Upon completion of this course, students will be able to:
• Explain in a simple way what an AC Drive is • State the main benefits of using AC-Drives • List the most common environments in which AC Drives are used • Understand the electrical principles of AC Drives
17/12/2011
2
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7.
What is an AC Drive? Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Electrical principles of AC Drives
17/12/2011
3
Vacon Training Center
1 What is an AC Drive? 1.1 The Standard Electric AC Motor • A standard electric squirrel cage motor is the most simple and reliable of all electric motors • Only one moving part: the rotor • Essentially a fixed speed machine • Speed depends on the electrical power frequency (50 or 60 Hz)
17/12/2011
4
Vacon Training Center
1.2 The AC Drive • An AC Drive provides the ability to fully control the speed of a motor from zero to maximum frequency and beyond. • It also provides the ability to control the torque produced by the motor. • Very simply, AC Drive takes an AC power supply and converts it to DC. Then it converts it back to AC. During this process it is able to adjust the output to the exact frequency needed and supply the power to suit every load condition.
17/12/2011
AC DRIVE
Controlled AC Output
DC AC Power Supply
5
M BUS
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
6
Vacon Training Center
2 Electrical Principles of AC Drives 2.1 Principle Input voltage 3 phase
Output voltage 3 phase
50 or 60 Hz
Variable frequency
6-pulse rectifier 120 °
120 °
120 °
Id L1 L2 L3
M
C
Rectifier
DC-bus
17/12/2011
Inverter
7
120 °
Vacon Training Center
Block diagram
17/12/2011
8
Vacon Training Center
Vacon: A Large Family of Products
Drive
Power range
Micro
< 4 kW
Low-End
5-40 kW
Mid-Range
41-200 kW
High-End
201-600 kW
Mega
> 600 kW
17/12/2011
9
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
10
Vacon Training Center
>
3 Where are AC Drives used? •
•
•
Material handling – Cranes – Conveyors – Warehouse automation – Packaging machines – Textile drying machines People movement – Elevators – Escalators Flow control – Compressors – Fans – Pumps – High speed compressors
•
•
Plastics – Extruders – Cable manufacturing lines – Plastic lines – In-line drives – Winders Marine & offshore auxiliary drives – Winches, winch systems – Steering – Oil drilling – Pumps – Compressors
Practice 17/12/2011
11
Vacon Training Center
<
Paper mill Automation System
Speed control; Torque control; Load control; Position control
17/12/2011
Applications
Measurements
Stock pumps; Water Pumps; Vacuum; Refiners; Screens; Mixers; Compressors; Conveyers; Winders; Fans ;Cranes; Line Drives;
Speed; Flow; Pressure; Level; Freeness; Position; Temperature; Humidity; Quality
12
Vacon Training Center
<
Water Intake
Chemical Dosing
Raw Water Pumping
Sludge Pumping
17/12/2011
13
Aeration Fan Control
Vacon Training Center
<
Escalator Escalator
17/12/2011
14
Practice
Vacon Training Center
<
Main engine cooling pumps Cooling water flow in continuously changing conditions needs to be controlled. Vacon solution is based on pressure or flow measurements from the cooling water flow to the machine to establish sufficient cooling regardless of engine speed or load. Alternatively the steering of converters can be done by engine control.
17/12/2011
15
Vacon Training Center
<
Cargo pumps Cargo pumps on a chemical tanker need to discharge the cargo at highest possible flow rate at any temperature or viscosity. These variations require a large scale in rotation speed as well as high starting torque. Hydraulic alternative is inefficient in energy consumption, noisy, heavy and requires more expensive piping.
17/12/2011
16
Vacon Training Center
<
Cranes Vacon in crane control means reliability, redundancy and space savings compared to other products available on the market. Liquid cooled converters provide additional space savings as well as less audible noise. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide crane suppliers since 1996.
17/12/2011
17
Vacon Training Center
<
Lifts Vacon in lift control means reliability, redundancy and space savings compared to other products available on the market. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide lift suppliers.
17/12/2011
18
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
19
Vacon Training Center
4 What benefits do AC Drives give? • • • •
AC Drives control the rotation and speed of motors They make considerable savings in energy They reduce the load on the electricity network When starting a motor, they reduce the mechanical stress
17/12/2011
20
Vacon Training Center
4.1 Variable volumes require some form of control
17/12/2011
21
Vacon Training Center
4.2 Simple Control Methods Here is an everyday pumping example:
M
Throttling
• • • • • •
M
M
Bypass control
On-Off control
Simple construction Optimal capacity is difficult to achieve An increase in capacity means reconstruction of the system Control is by throttling, recirculation or start and stop Risk of damage at start-up Operating costs are high 17/12/2011
22
Vacon Training Center
4.3 No mechanical parts are needed with AC Drives Traditional methods D.O.L + Throttling
AC Drive control
D.O.L + On/Off
Frequency Converter
~
Electronics
~
M
M
M
1~
1~
3~ T A N K
Mechanics
17/12/2011
23
Vacon Training Center
4.4 The best control method is the AC Drive In this situation, what would you do? • Keep your foot on the gas and control your speed with a brake? • Change to a lower gear and reduce the engine revolutions?
Practice 17/12/2011
24
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
25
Vacon Training Center
5 How can AC Drives be used to save energy? 5.1 Opportunities
• Over 60% of industrial electrical demand is for powering electric motors. • A large proportion of this total is for driving fans & pumps • Typical energy savings on fan & pump applications using AC Drives is 50% - giving a pay-back time of less than 1 YEAR!
17/12/2011
26
Vacon Training Center
5.2 Centrifugal pumps and fans operate like this • Power requirement decreases sharply with small speed decreases 150 125 Power
100 75 50 25 50% speed = 12,5% power
0
25
50
75
100
% Speed 17/12/2011
27
125
150
Vacon Training Center
5.3 Typical HVAC System Load Requirements
% Operating Time
12 10 8 6 4 2 0
5
25
75
50
% Flow or Volume
100
Data Supplied by the U/K Dept of Trade & Industry
17/12/2011
28
Practice
Vacon Training Center
5.4 Other benefits
• Improved control • Reduced noise & vibration • Simpler installation & commissioning • Lower maintenance costs • Fewer complaints!
17/12/2011
29
Vacon Training Center
5.5 Environmental issue
• With every 1 kW/h of electricity generated – over 0.6 kg of CO2 is produced. • Carbon dioxide emissions decrease significantly when using AC drives!
17/12/2011
30
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
31
Vacon Training Center
6 Why Vacon NX? 6.1 Common features
• A very small package for its power • Reliable and robust technology • Simplicity and high functionality • User friendly
17/12/2011
32
Vacon Training Center
6.2 A small power package
• Compact enclosures IP00 to IP54 + NEMA 1 and NEMA 12 • Slim, space-saving design • Side-by-side installation • All sizes up to 400 kW (500 Hp) can be wall-mounted • Best possible power/volume-ratio achieved by using "Super Cooling” heat sink technology
17/12/2011
33
Vacon Training Center
6.3 Vacon AC Drives greatly reduce space requirements Compare the difference! IP 54, 45/55 kW
Competitor D
Competitor A 591x237x257 mm 35 kg
716 x 306 x 429 mm 50 kg
937 x 495 x 421 mm 124 kg
ACS 601
VLT 5060
17/12/2011
34
Vacon Training Center
6.4 Reliable and Robust Technology • AC-choke built-in – in all but the smallest NXL – filters and protects from over voltage.
• Metal enclosures for power modules (plastic for the smallest NXL). – Reliable and environmentally friendly – good EMC performance.
• Isolated galvanized inputs and outputs – Safe and considerably less noisy connections
17/12/2011
35
Vacon Training Center
6.5 Comprehensive motor drive protection, which includes protection against • • • • • • • •
Over current Short circuit Over voltage/under voltage Earth fault Stalled motor Over loaded/under loaded motor Over temperature unit/motor Phase fault (in/out)
17/12/2011
36
Vacon Training Center
Vacon Global Customers
17/12/2011
37
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
38
Vacon Training Center
7 The Vacon AC Drive Family 7.1 Complete product portfolio Vacon NXL Compact drives
0.25 – 1.5 kW 0.37 – 3 kW
208 – 240V 380 – 500V
Vacon NXL General purpose drives
0.75 - 37 kW
380 – 500V
Vacon NXS Industrial drives
0.55 – 90 kW 0.75 – 200 kW 2.2 – 200 kW
208 – 240V 380 – 500V 525 – 690V
Vacon NXP / NXC High performance drives
0.55 – 90 kW 0.75 – 1500 kW 2.2 – 2000 kW
208 – 240V 380 – 500V 525 – 690V
Vacon NX Liquid cooled drives Vacon Common DC components NXI
7.5 – 3700 kW 110 – 2450 kW 7.5 – 2700 kW 110 – 2450 kW
380 525 465 640
1.5 – 1800 kW 3 – 2000 kW
17/12/2011
– – – –
500V 690V 800VDC 1100VDC
465 – 800VDC 640 – 1100VDC
39
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
40
Vacon Training Center
8 Software Applications 8.1 ”All In One” Application Package Local / Remote
Multi-step Speed
PID Control
Standard
Multipurpose
Basic
All-in-One Applications
Pump and Fan Control
17/12/2011
41
Vacon Training Center
8.2 The Basic Application • For simple applications with direct frequency reference. • Covers most general requirements. • The Basic Application is set as default when the drive leaves the factory. • The basic application has one small group of parameters, all with default values. • Very straight forward commissioning.
17/12/2011
42
Vacon Training Center
17/12/2011
43
17/12/2011
1
Vacon Training Center
Upon completion of this course, students will be able to:
• Explain in a simple way what an AC Drive is • State the main benefits of using AC-Drives • List the most common environments in which AC Drives are used • Understand the electrical principles of AC Drives
17/12/2011
2
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7.
What is an AC Drive? Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Electrical principles of AC Drives
17/12/2011
3
Vacon Training Center
1 What is an AC Drive? 1.1 The Standard Electric AC Motor • A standard electric squirrel cage motor is the most simple and reliable of all electric motors • Only one moving part: the rotor • Essentially a fixed speed machine • Speed depends on the electrical power frequency (50 or 60 Hz)
17/12/2011
4
Vacon Training Center
1.2 The AC Drive • An AC Drive provides the ability to fully control the speed of a motor from zero to maximum frequency and beyond. • It also provides the ability to control the torque produced by the motor. • Very simply, AC Drive takes an AC power supply and converts it to DC. Then it converts it back to AC. During this process it is able to adjust the output to the exact frequency needed and supply the power to suit every load condition.
17/12/2011
AC DRIVE
Controlled AC Output
DC AC Power Supply
5
M BUS
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
6
Vacon Training Center
2 Electrical Principles of AC Drives 2.1 Principle Input voltage 3 phase
Output voltage 3 phase
50 or 60 Hz
Variable frequency
6-pulse rectifier 120 °
120 °
120 °
Id L1 L2 L3
M
C
Rectifier
DC-bus
17/12/2011
Inverter
7
120 °
Vacon Training Center
Block diagram
17/12/2011
8
Vacon Training Center
Vacon: A Large Family of Products
Drive
Power range
Micro
< 4 kW
Low-End
5-40 kW
Mid-Range
41-200 kW
High-End
201-600 kW
Mega
> 600 kW
17/12/2011
9
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? How can AC Drives be used to save energy? What benefits do AC Drives give? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
10
Vacon Training Center
>
3 Where are AC Drives used? •
•
•
Material handling – Cranes – Conveyors – Warehouse automation – Packaging machines – Textile drying machines People movement – Elevators – Escalators Flow control – Compressors – Fans – Pumps – High speed compressors
•
•
Plastics – Extruders – Cable manufacturing lines – Plastic lines – In-line drives – Winders Marine & offshore auxiliary drives – Winches, winch systems – Steering – Oil drilling – Pumps – Compressors
Practice 17/12/2011
11
Vacon Training Center
<
Paper mill Automation System
Speed control; Torque control; Load control; Position control
17/12/2011
Applications
Measurements
Stock pumps; Water Pumps; Vacuum; Refiners; Screens; Mixers; Compressors; Conveyers; Winders; Fans ;Cranes; Line Drives;
Speed; Flow; Pressure; Level; Freeness; Position; Temperature; Humidity; Quality
12
Vacon Training Center
<
Water Intake
Chemical Dosing
Raw Water Pumping
Sludge Pumping
17/12/2011
13
Aeration Fan Control
Vacon Training Center
<
Escalator Escalator
17/12/2011
14
Practice
Vacon Training Center
<
Main engine cooling pumps Cooling water flow in continuously changing conditions needs to be controlled. Vacon solution is based on pressure or flow measurements from the cooling water flow to the machine to establish sufficient cooling regardless of engine speed or load. Alternatively the steering of converters can be done by engine control.
17/12/2011
15
Vacon Training Center
<
Cargo pumps Cargo pumps on a chemical tanker need to discharge the cargo at highest possible flow rate at any temperature or viscosity. These variations require a large scale in rotation speed as well as high starting torque. Hydraulic alternative is inefficient in energy consumption, noisy, heavy and requires more expensive piping.
17/12/2011
16
Vacon Training Center
<
Cranes Vacon in crane control means reliability, redundancy and space savings compared to other products available on the market. Liquid cooled converters provide additional space savings as well as less audible noise. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide crane suppliers since 1996.
17/12/2011
17
Vacon Training Center
<
Lifts Vacon in lift control means reliability, redundancy and space savings compared to other products available on the market. Motion control becomes silent and more efficient with Vacon AC Drives and provide less space requirements than traditional hydraulic solutions. Vacon has a long time experience with world wide lift suppliers.
17/12/2011
18
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
19
Vacon Training Center
4 What benefits do AC Drives give? • • • •
AC Drives control the rotation and speed of motors They make considerable savings in energy They reduce the load on the electricity network When starting a motor, they reduce the mechanical stress
17/12/2011
20
Vacon Training Center
4.1 Variable volumes require some form of control
17/12/2011
21
Vacon Training Center
4.2 Simple Control Methods Here is an everyday pumping example:
M
Throttling
• • • • • •
M
M
Bypass control
On-Off control
Simple construction Optimal capacity is difficult to achieve An increase in capacity means reconstruction of the system Control is by throttling, recirculation or start and stop Risk of damage at start-up Operating costs are high 17/12/2011
22
Vacon Training Center
4.3 No mechanical parts are needed with AC Drives Traditional methods D.O.L + Throttling
AC Drive control
D.O.L + On/Off
Frequency Converter
~
Electronics
~
M
M
M
1~
1~
3~ T A N K
Mechanics
17/12/2011
23
Vacon Training Center
4.4 The best control method is the AC Drive In this situation, what would you do? • Keep your foot on the gas and control your speed with a brake? • Change to a lower gear and reduce the engine revolutions?
Practice 17/12/2011
24
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
25
Vacon Training Center
5 How can AC Drives be used to save energy? 5.1 Opportunities
• Over 60% of industrial electrical demand is for powering electric motors. • A large proportion of this total is for driving fans & pumps • Typical energy savings on fan & pump applications using AC Drives is 50% - giving a pay-back time of less than 1 YEAR!
17/12/2011
26
Vacon Training Center
5.2 Centrifugal pumps and fans operate like this • Power requirement decreases sharply with small speed decreases 150 125 Power
100 75 50 25 50% speed = 12,5% power
0
25
50
75
100
% Speed 17/12/2011
27
125
150
Vacon Training Center
5.3 Typical HVAC System Load Requirements
% Operating Time
12 10 8 6 4 2 0
5
25
75
50
% Flow or Volume
100
Data Supplied by the U/K Dept of Trade & Industry
17/12/2011
28
Practice
Vacon Training Center
5.4 Other benefits
• Improved control • Reduced noise & vibration • Simpler installation & commissioning • Lower maintenance costs • Fewer complaints!
17/12/2011
29
Vacon Training Center
5.5 Environmental issue
• With every 1 kW/h of electricity generated – over 0.6 kg of CO2 is produced. • Carbon dioxide emissions decrease significantly when using AC drives!
17/12/2011
30
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
31
Vacon Training Center
6 Why Vacon NX? 6.1 Common features
• A very small package for its power • Reliable and robust technology • Simplicity and high functionality • User friendly
17/12/2011
32
Vacon Training Center
6.2 A small power package
• Compact enclosures IP00 to IP54 + NEMA 1 and NEMA 12 • Slim, space-saving design • Side-by-side installation • All sizes up to 400 kW (500 Hp) can be wall-mounted • Best possible power/volume-ratio achieved by using "Super Cooling” heat sink technology
17/12/2011
33
Vacon Training Center
6.3 Vacon AC Drives greatly reduce space requirements Compare the difference! IP 54, 45/55 kW
Competitor D
Competitor A 591x237x257 mm 35 kg
716 x 306 x 429 mm 50 kg
937 x 495 x 421 mm 124 kg
ACS 601
VLT 5060
17/12/2011
34
Vacon Training Center
6.4 Reliable and Robust Technology • AC-choke built-in – in all but the smallest NXL – filters and protects from over voltage.
• Metal enclosures for power modules (plastic for the smallest NXL). – Reliable and environmentally friendly – good EMC performance.
• Isolated galvanized inputs and outputs – Safe and considerably less noisy connections
17/12/2011
35
Vacon Training Center
6.5 Comprehensive motor drive protection, which includes protection against • • • • • • • •
Over current Short circuit Over voltage/under voltage Earth fault Stalled motor Over loaded/under loaded motor Over temperature unit/motor Phase fault (in/out)
17/12/2011
36
Vacon Training Center
Vacon Global Customers
17/12/2011
37
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
38
Vacon Training Center
7 The Vacon AC Drive Family 7.1 Complete product portfolio Vacon NXL Compact drives
0.25 – 1.5 kW 0.37 – 3 kW
208 – 240V 380 – 500V
Vacon NXL General purpose drives
0.75 - 37 kW
380 – 500V
Vacon NXS Industrial drives
0.55 – 90 kW 0.75 – 200 kW 2.2 – 200 kW
208 – 240V 380 – 500V 525 – 690V
Vacon NXP / NXC High performance drives
0.55 – 90 kW 0.75 – 1500 kW 2.2 – 2000 kW
208 – 240V 380 – 500V 525 – 690V
Vacon NX Liquid cooled drives Vacon Common DC components NXI
7.5 – 3700 kW 110 – 2450 kW 7.5 – 2700 kW 110 – 2450 kW
380 525 465 640
1.5 – 1800 kW 3 – 2000 kW
17/12/2011
– – – –
500V 690V 800VDC 1100VDC
465 – 800VDC 640 – 1100VDC
39
Vacon Training Center
Agenda
1. 2. 3. 4. 5. 6. 7. 8.
What is an AC Drive? Electrical principles of AC Drives Where are AC Drives used? What benefits do AC Drives give? How can AC Drives be used to save energy? Why Vacon NX? The Vacon AC Drive Family Software applications
17/12/2011
40
Vacon Training Center
8 Software Applications 8.1 ”All In One” Application Package Local / Remote
Multi-step Speed
PID Control
Standard
Multipurpose
Basic
All-in-One Applications
Pump and Fan Control
17/12/2011
41
Vacon Training Center
8.2 The Basic Application • For simple applications with direct frequency reference. • Covers most general requirements. • The Basic Application is set as default when the drive leaves the factory. • The basic application has one small group of parameters, all with default values. • Very straight forward commissioning.
17/12/2011
42
Vacon Training Center
17/12/2011
43
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