Variable Frequency Drive Basics

Variable Frequency Drive Basics 50% of the total electrical energy generated in the United States is used my rotating equipment. 65% of this total is consumed by centrifugal or flow related applications such as fans, blowers, compressors, and pumps .With using Variable Speed Drive technology the advantage gained in both productivity improvements and reduced energy consumption has been widely documented in the past few years. For example, by lowering fan or pump speed by 15% to 20%, shaft power can be reduced by as much as 30%. The main reason variable speed drives are used is to reduce energy costs and prolong the life of equipment by adjusting motor speed to meet load requirements. What is a Variable Frequency Drive A variable frequency drive is an electronic controller that adjusts the speed of an electric motor by regulating the power being delivered. Variable-frequency drives provide continuous control, matching motor speed to the specific demands of the work being performed. Variable-frequency drives are an excellent choice for adjustable-speed drive users because they allow operators to fine-tune processes while reducing costs for energy and equipment maintenance. How it Works Single-speed drives start motors abruptly, subjecting the motor to high torque and current surges up to 10 times the full-load current. Variable frequency drives offer a soft start, gradually ramping up a motor to operating speed. The variable frequency lessens mechanical and electrical stress on the motors and can reduce maintenance and repair costs and extend the motor life. Variable frequency drives also allows more control of processes such as water distribution, aeration and chemical feed. Wastewater treatment plants can consistently maintain desired dissolved oxygen concentrations by using automated controls to link dissolved oxygen sensors to variable frequency drives on the aeration blowers. Energy savings from variable-frequency drives can be significant. For example with a centrifugal pumps even a small reduction in motor speed can reduce a pump’s energy use by as much as 50%. For a 25 horse power motor running 23 hours per day (2 hours at 100% speed; 8 hours at 75%: 8 hours at 67%; and 5 hours at 50%) a variable frequency drives can reduce energy use by 45%. Because benefits varies depending on system variables its important to calculate benefits for each application before specifying a variable frequency drive. We have been discussing the cost saving variable frequency drive but we have not spoken about the cost of a variable frequency drive. Installed drives can range from about $3000 for a 5 housepower motor to almost $45,000 for a custom-engineered 300 horsepower motor, and more for larger version. Installation can take from 10 to 70 labor-hours, depending on the system and the complexity of the system. However, payback for a variable frequency drive can range from just a few months to less than three years for a 25-250 horsepower models. Remember also they can drive more than one motor, so some costs can be consolidated. Savings from reduced maintenance and longer equipment life can significantly contribute to a rapid payback and long term saving. Many utilities offer financial incentives that can help reduce the

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installation cost of variable frequence drive. Understanding Variable Frequency Drives A thorough understanding on how to match the variable frequency drive to the driven load is the key to a successful application. When applied properly, it is the most effective motor controller in the industry today. Variable frequency drives are affordable and reliable, and having flexibility of control, plus offering significant electrical savings through reducing electric bills. Variable Frequency Drives are used in a wide variety of applications for various reasons. They are the most effective energy savers in pump and fan application. In most facilities, centrifugal pumps and fans run at one speed. An automatic value, or some mechanical means varies fluid flow rates. With a variable frequency drive you can change motor speeds electronically. By being able to adjust a pump or fan speed to get the desired rate you can significant reduce energy cost. Variable frequency drive has been successfully applied to large boiler feedwater pumps in power plants, hot water circulation pumps in commercial buildings and for waste water treatment plants. Variable Frequency Drives provide soft-start capabilities, which decrease electrical stresses and line voltage sags associated with full voltage motor start-ups, especially when driving high-inertia loads. Variable-frequency drives are reliable, easy to operate, increase the degree of flow control, and reduce pump noise. But despite the benefits, problems are common and we should be aware of them.. Variable frequency drives can produce harmonic distortion, which adversely affecting power quality and other electrical machinery. Manufacturers have developed many solutions to correct this problem. By installing an isolation transformer with a variable frequency drive can reduce distortion to an inconsequential level. Applying a variable frequency drive to a specific application you need a clear understanding of the basic theory and should gain a working knowledge of the variable frequency drive. Our article on AC Variable Frequency Drive can give you this information and also discuss loads types, sizing and specifications. Contact our experienced variable frequency drive specialists at Variable Frequency Drive Co at 510-490-2187 to get your quote, place your order and arrange for shipping. Our electrical specialists are standing by and ready to help

Baldor Variable Frequency Drives & AC Controls Baldor Drives offers a complete selection of AC Motor Controls. Starting at 1/100 HP going up to 800 HP with custom controls build up to 1500 HP. From basic analog soft starts to full fledged Vector technology. Baldor invests in the latest technology to ensure the highest level of quality in all our products. Baldor technician uses an optical comparator to test a motor lamination to an

accuracy of 1/100th of an inch. Each control is designed and manufactured to be the most reliable you can buy. Read more about all of the Baldor Variable Frequency Drives & AC Controls.

Baldor VS1SP Inverter Drive The VS1P AC Drive is one of the most popular variable speed motor controls because of it's easy out- of- the-box applications, it uses a traditional inverter V/Hz control methods. Typical applications where multiple motors are operated simultaneously from one motor control, including pumps, fans, and general machinery applications. Read more about the Baldor VS1SP Inverter Drives. Baldor VS1SP Washdown Inverter Drive The VS1SP AC Drive offers easy setup, quick startup with a traditional inventor V/Hz control method. Available in horsepower from 3/4 to 10 HP and voltages ranges from 180-660 volts, this drive offers a variety of features and designs that insure dependable performance. Read more about the Baldor VS1SP Washdown Inverter Drives. Baldor VS1GV Vector Drive The VS1GV is a high performance vector drive. By offering three modes of control, in which to controls motor speed and torque with precision and the responsiveness needed to accomplish the most demanding application. Read more about the Baldor VS1GV Vector Drives. Baldor VS1GV Washdown Vector Drive VS1GV Washdown Vector Drive offers three mode of controls-closed-loop, encoderless or the traditional V/Hz to meet the most demanding applications. Additionally, it provides the same interface as the Baldor V*S Drives sensorless vector products so that commonality is maintained within your facility for both closed loop and open loop applications. Read more about the Baldor VS1GV Washdown Vector Drives. Blador VS1PF Pump and Fan Drive The Baldor VS1PF provides energy savings by controlling centrifugal loads with a variable frequency drive while implementing unique algorithms that further reduce energy consumed by your application. The Baldor V*S Drives VS1PF is a feature rich AC drive targeted at the pump and fan markets but with functionality that rivals more sophisticated general purpose products. Read more about the Baldor VS1PF Pump and Fan Drives. Baldor VS1MD Microdrive The VS1MD Microdrive is the most powerful and cost competitive in its class with its capability up to 10HP (7.5) kW. Because of its compact size, userfriendly interface, higher horsepower and superior motor torque makes its ideal for a wide uses of application. Read more about the Read more about the Baldor VS1PF Pump and Fan Drives.

Baldor VS1MX Microdrive The VS1MX Microdrive is the ultimate drive for harsh conditions with its IP55/NEMA 12 rating makes it ideal for use in wet, dry and harsh-duty conditions. This AC variably speed drive is easy to use, available in switched or non-switched enclosures and has a compact design which makes its ideal for a wide use of application. Read more about the Baldor VS1MX Micro Drives. Baldor VS1SM Microdrive The Baldor VS1SM is a V / Hz and Sensorless Vector product with optional built-in EMC/RFI Filter and configurable PNP/NPN Digital Inputs, this single phase 230V AC microdrive is ideal for OEM Applications that require a compact, cost-effective, feature-rich product. Read more about the Baldor VS1SM Micro Drives. Baldor H2 Inverter Drive Baldor's new H2 Inverter drive offers open loop speed control and V/Hz mode for multiple motors or Encoderless Vector for higher performance in one easy to use package. V/Hz mode allow out of the box setup and operation. H2 Inverter drive are used in a variety of applications that require adjustable speed operation and good speed regulation including pumps, fans and general machinery applications. V/Hz is the control method for applications where multiple motors are operated simultaneously from one motor control. Read more about the Baldor H2 Inverter Drives. Baldor H2 Washdown Inverter Drive Baldor's new H2 Washdown Inverter drive offers open loop speed control in one easy to use NEMA 4x/IP65 package. Used for a variety of applications that require adjustable speed operation and good speed regulation including pumps, fans and general machinery applications The Easy to Use keypad is incorporated into the cover in order to prevent “voids” whereby food or other contaminants can collect. V/Hz is the control applications method of choice where multiple motors are operated simultaneously from one motor control. Read more about the Baldor H2 Washdown Inverter Drives. Baldor H2 Vector Drive Baldor’s new line of H2 Vector Drives provides the ultimate control of AC induction motors. Setup is accomplished by using the one touch rotational or stationary auto tune feature. But the control doesn’t stop there, adaptive tuning will also automatically adjust the control loop while the motor is running. By using a motor mounted encoder, or similar feedback sensor, the control is able to precisely control motor torque and speed. Full torque at zero speed, ability to directly command motor torque, tight speed regulation and high-speed motor operation are all available. Read more about the Baldor H2 Vector Drives. Baldor H2 Servo Drive Baldor’s new line of H2 Servo Drives provides control of 3-phase AC induction servomotor in an industrial package and design. These NEMA 1 controls with Baldor’s easy to use Smart Keypad makes for easy setup and flexibility. The H2 keypad follows the same easy to use menu structure as that of its companions, the H2 Inverter and H2 Vector drives. Read more about the Baldor H2 Servo Drives.

Baldor H Inverter The adjustable H Inverter controls are available in a variety of rating, input voltages, and enclosure styles. Baldor has a motor control for all your applications, whether you are automating equipment or saving energy on fans and pumps. Ranging in size from small mini inverters to floor mounted cabinets from rating to 1/3 to 480 HP. All units are UL and CUL listed and many are standard with ready to mount NEMA 1 enclosures and easy to use Operator Keypads. Read more about the Baldor H Inverter Drives. Baldor H Washdown Baldor Washdown adjustable speed motors and motor control are designed to take the harshest conditions whether it inclement weather to high pressure washdown. Inverter and Vector Duty are available in paint free and epoxy coated finishes and also available in NEMA 4X enclosure from 1 to 20 HP. All washdown Duty are UL and CUL listed and are recognized and meet NEMA MG1, Part 31. Read more about the Baldor H Washdown Inverter Drives. Baldor H Vector The H Vector are available in a variety of rating, and input voltages. The Baldor Vector Control makes automating industrial equipment easy by using Flux Vector Control Techniques and closed loop motor feedback with the build in motor auto-tuning feature. Baldor stock 1 to 450 HP rating and has custom capabilities in larger horsepower sizes. All units are UL and CUL listed and come standard with ready to mount NEMA 1 enclosures and easy to use Operator Keypads. Expansion capabilities for various I/O and Bus Communications protocols are available with field installable expansion. Read more about the Baldor H Vector Drives. Baldor Vector Line Regen Baldor Line Regen Vector Control with the use of the Flux Vector Control Techniques and close loop motor feedback allows even more capability in slowing a motor and saving energy cost at the same time. No dynamic braking resistors are needed to bleed energy from the motor control. Near unity power factor and ability to meet IEEE-519 (1992) is easy with the built in sine wave input/output converter section. Baldor stocks ratings from 10 to 50 HP and has custom capabilities in larger horsepower sizes. All units are UL and CUL listed and come standard with ready to mount NEMA 1 enclosures and easy to use Operator Keypads. Read more about the Baldor Vector Line Regen Drives. Baldor Series 5 Micro Inverters Baldor Series 5 Micro Inverter is a low cost, compact inverter. Don't let the size fool you, it has the same protection features as a much larger control. With it's build-in current limit which provides motor overload protection and the high peak current available up to 2 minutes and delivers up to 200% starting torque. This inverter reducing nuisance tripping doing overload conditions. Electronic inrush current limit and filtering is standard to reduce transient voltage spikes from dirty power sources. Read more about the Baldor Series 5 Micro Inverter Drives. Baldor Analog Soft-Start & Dynamic Brakes The benefits of Baldor analog soft-start and dynamic brakes units reduce mechanical stress, prolong motor life and lower motor inrush currents. Baldor Soft Start Motor Control includes products from simple torque control design to the easy programmable digital control. Combination, Non-Combination and

control only configurations in panel or NEMA 1, 3R, 12, or NEMA 4 enclosures are available from 1 through 800 HP. Many are available from stock or can be quick shipped in 72 hours or less. UL and CUL Listing along with CE Certification are standard on most designs. Read more about the Baldor Analog Soft Start & Dynamic Break Drives. Baldor Digital Soft-Start Baldor Soft Starts reduces the wear on mechanical gears, chains, sprockets, belts and gearboxes and reduces water hammer in pump application. SoftStart control combines the simplicity of a 6 SCR three phase voltage regulator with the most adaptable soft starting techniques available. In reducing inrush current it can prevent overload of a overall plant, thus preventing penalties change by the utility company. Read more about the Baldor Digital Soft Start Controls. Baldor Baldor SmartMotor® Baldor Smart Motor combines adjustable speed control electronics with a Premium Efficiency industrial motor in one easy to install, easy to use package. Available in sizes from 1-10 HP covering NEMA frames from 56C to 215TC for standard and Washdown Duty designs. Close Coupled Pump units in NEMA 143JM to 215JM frames are also available. UL / CUL Listing and CFace with rigid mounting base is standard and all models are available from stock. Read more about the Baldor SmartMotor Models.

WEG Variable Frequency Drives & Soft Starters WEG CFW-08 Plus ( 1/3-10HP) Variable Frequency Drives The new WEG CFW-08 Plus Series with engineering improvements and the re-design of their successful uLine VFD'S have produced one of the most compact and pack featured microdrives in the marketplace. The features and options in a NEMA1 enclosure allows the CFW-08 to be used in many applications. Read more about the WEG CFW-08 Plus Variable Frequency Drives. WEG CFW-09 ( 1-500 HP) Variable Frequency Drives The CFW-09 Variable Frequency Drive offers the most advance technology in drives for three-phase AC induction motors. The Vectrue Technology and it significant advancement allowing VFD's to combine V/F, Sensorless Vector and closed loop vector (with encoder) all in one control product. A innovated new feature named Optimal Braking was introduced to simplify applications that require braking torque, by eliminating the need for the dynamic braking resistor it means a simpler, more compact and economic solution. Read more about the WEG CFW-09 Variable Frequency Drives. WEG CFW-10 Plus ( 1/4 - 3HP) Variable Frequency Drives With the expansion to the CFW-10 Variable Frequency Drive Product Line, three new HP rating (1,2 and 3 HP) and frame sizes (Sizes 2 and 3) will complement the existing ratings. The benefits of the CFW-10 is its compact size, easily mounted package, with a simplified keypad and bright LED readout, complete diagnostics and fully programmable I/O. The key benefits to

the WEG CFW-10 is that it control three-phase AC motors with a single-phase AC input. Increase flexibility and decreased costs are achieved by eliminating the need for a step-up transformer to operate three phase 230V AC motors when only single-phase 115V or 230V are available. With the new products lines, a single-phase 120 VAC input voltage will produce three phase 230V to drive motors up to 1 HP and single-phase 230VAC input voltage will control motors up to 3HP.The CFW-10 is a perfect solution for many industrial and commercial applications. Read more about the WEG CFW-10 Plus Variable Frequency Drives. WEG Shark Drive™ ( 1 - 10 HP) Variable Frequency Drives The WEG Shark Variable Frequency Drive is an ideal solution with its Stainless Steel NEMA 4X enclosure for high pressure wash down and corrosive environments and is designed to complement the enclosure ruggedness of WEG's Shark Motor Product Line. The Shark Drive's complete package combination of the CFW-09's triple control capability (Volts/Hertz, Sensorless or Closed Loop Vector) matched with the Shark Drive's NEMA4X enclosure rating allows the Shark Drive™ to succeed in virtually all applications in any industrial environment. Read more about the WEG Shark Drive Variable Frequency Drives. WEG Combination Soft Starters-GPH Series (5-500 HP) The WEG Combination Soft Starter, GPH Series packages is a very simple and is designed for quick installation and start up. This package only requires an input and output motor connection. The GPH series is built for ruggedness and reliability and with its NEMA 4/12 enclosure it is ideal for dusty and wet applications. Read more about the WEG Combination Soft Starters-GPH Series Controls. WEG Crusher Duty-TPH Series Soft Starters ( 100-600 HP) WEG TPH Series provides a complete and cost effective AC motor starting and protection solution. The TPH are designed to withstand the most demanding AC motor starting applications. While exceeding the requirements for the highest starting torque requirements, plus with it's NEMA 4/12 enclosure making it ideal for wash down and harsh conditions application. A emergency direct-on-line starting is available at a flip of a switch plus an AC3 full HP rated bypass contactor and motor overload relay is standard in the TPH series which provides full motor protection. Read more about the WEG Crusher Duty-TPH Series Soft Starters. WEG SSW-03 Series Soft Starters ( 50-1000 HP) The SSW-03 provides a complete and cost effective solution with a full microprocessor based control, making adjustments easy with the keypad startup and still provides complete motor protection. With the pump control feature which prevents running pumps at no load and eliminates pipeline waterhammer. Read more about the WEG SSW-03 Series Soft Starters. WEG SSW-04 Series Soft Starters ( 5-75 HP) The WEG SSW-04 are build for ruggedness and reliability and provides a complete solution. With it's full microprocessor based control which allows easy adjustment with the keypad start-up, and complete motor protection.. With the pump control feature which prevents running pumps at no load and eliminates pipeline waterhammer. Read more about the WEG SSW-04 Series Soft Starters.

WEG SSW-05 Series Soft Starters ( 5-75 HP) The WEG SSW-05 is a compact fully digital soft starter with state-of-the-art DSP controller. With the digital construction some of the benefits includes: optimum operations, diagnostics capability and full protection of the motor. The Status LED"s alert the user of the operational status and with the dipswitches and potentiometers simplicity in set-up and operation is assured. The simplicity and the micro size and ease of set up makes it a quick and easy solution. Read more about the WEG SSW-05 Series Soft Starters.