AC/DC DRIVES

ABB ACS 2000 drives integrated Active Front End (AFE) technology, without using expensive and dedicated transformer, ACS2000 VFD can minimize the power grid harmonic, and with additional four-quadrant operation and reactive power compensation benefits.

AFE provides low harmonic to meet the various criteria for current and voltage harmonics requirements. Thus, there is no need for harmonic analysis or installing a line filter.

In order to achieve minimize energy consumption, AFE allows four-quadrant operation to make braking energy back to the power grid.

AFE also can provide reactive power compensation. With SVC, the VFD can maintain a smooth voltage characteristic, and avoid the reactive power punishment.

With direct power supply connection technique, to allow the VFD installation and commissioning work faster and more convenient. Installing a VFD, simply use ABB “three in – three out” wiring concept, disconnect the direct power supply running and connect to the VFD, then connect the VFD to the AC motor.

ABB ACS2000 drives were designed with withdrawable phase module for quick replacing all of the VFD’s components from the drive’s front side, the mean time to repair (MTTR) is in leading level of the whole industry.

ABB ACS 2000 drives adopt multi-level voltage source inverter (VSI) topological structure, mature high voltage IGBT power semiconductor technology and Direct Torque Control (DTC) motor control platform. Therefore, ACS2000 VFDs have high reliability, extend the mean time between failures (MTBF) and increased utilization.

ABB ACS 2000 VFD inherited the VSI topological structure and uses a patented IGBT-based multi-level design, provides near-sinusoidal current and voltage waveforms, makes the VFD compatible with standard motor and cable.

ACS 2000 VFD’s control platform uses ABB’s award-winning DTC platform, which provides maximum torque, speed performance and lowest energy loss which never happened in medium voltage variable frequency drives. In all conditions, the VFD’s control is quick and smooth.

Flexible power supply connection, lower harmonics and power consumption, easy installation and commissioning reliability to make ABB ACS 2000 drives have a low total investment cost throughout it’s service life cycle.

1. Perfect match with fan and pump applications
2. Advanced control panel
3. Patented technology to reduce harmonics, swinging choke
4. Loop soft start
5. Multi-point V/F curve
6. Built-in RFI filters as standard
7. CE certification

ABB ACS 510 drives Key Features

1. Perfect match with fan pump.
2. Enhanced PFC application: Control up to 7 (1+6) pumps, it’s able to switch more pumps.
3. SPFC: loop soft start function, each pump can be adjusted in turn.
4. Multi-point V/F curve: freely definable 5 V/F curves for flexible applications.
5. PID regulator: Built-in two separate PID controller, PID1 can set two parameters, PID2 can control an independent external valves.

Intuitive features: noise optimization, when the drive temperature reduced, increase the switching frequency, control cooling fan starts only when needed, can be distributed switching frequency randomly, thus reducing noise, improving the motor noise greatly and improve effect.

Magnetic flux optimization: reduce the motor magnetic flux automatically when the loads decrease, and reduce energy consumption and noise significantly.

Connection: easy wiring, simple install, and can be installed side by side.

More environmentally friendly.

EMC: For the first and second environment RFI filters as standard VFDs, without using additional external filters.

Reactor: swinging chokes, match inductance depending on different loads, thus suppressing and reducing harmonics and reduce total harmonic.

1. Perfect match with fan and pump applications
2. Advanced control panel
3. Patented technology to reduce harmonics, swinging choke
4. Loop soft start
5. Multi-point V/F curve
6. Built-in RFI filters as standard
7. CE certification

ABB ACS 510 drives Key Features

1. Perfect match with fan pump.
2. Enhanced PFC application: Control up to 7 (1+6) pumps, it’s able to switch more pumps.
3. SPFC: loop soft start function, each pump can be adjusted in turn.
4. Multi-point V/F curve: freely definable 5 V/F curves for flexible applications.
5. PID regulator: Built-in two separate PID controller, PID1 can set two parameters, PID2 can control an independent external valves.

ABB drives are continuous improvement in user interface. Startup Wizard makes ACS800 VFD debugging becomes very easy.

Compare with traditional parametric programming, ABB ACS800 VFD’s custom programming has better adaptability. As a standard configuration of all range drives, it’s like the drive built-in a small PLC, and do not need to add any additional hardware and software.

As standard component, ABB ACS800 VFD has built-in reactor. In addition, you can install additional three modules in ABB ACS800 VFD: I/O extension modules, fieldbus adapter module, pulse encoder interface module or PC interface module. For these modules, no need additional space and cable.

ABB is the business member of ICC (International Chamber of Commerce) sustainable development, ABB drives follow the 16 provisions of the ICC, and follow the ISO14001 standard in the production process.

Using ABB’s patented DTC (Direct Torque Control) technology, ACS1000 series VFD provides precise process control, DTC can provide the most rapid response for any motor torque control platform. Without using encoder, it can guarantee the best control precision even if the input power changes and load sudden changes.

Through the fluid mechanics’ basic principles, we know the fans and pumps are belong to square torque loads, the rotation speed n, flow Q, pressure H and shaft power P relation: Q∝n, H∝n2, P∝n3, i.e., the flow is in proportion to its rotation speed, the pressure is in proportion to the square of its rotation speed, and the shaft power is in proportion to the cube of its rotation speed.

We now take the fan as an instance of the principle in energy conservation. As show in following fig, when the fan in its rated rotation speed, the air volume and air pressure change as curve 1, which intersects with the pipe network resistance curve 2 at the rated working condition point N when the air door is full opened; the air volume of the fan is Qn and the pressure is Hn. Normally, the working condition point is moved to point E by closing the regulation air door and increasing the resistance in ventilation pipe network. At this moment, the air volume is decreased to Qe and the generated pressure head is He. If the air volume is regulated by reducing the rotation speed of the fan, the fan will operate as curve 4, and re-generate required air volume Qe, it will intersect with the pipe network resistance curve 2 at the working condition point C when the air door is full opened.

According to the similar principles between fan and water pump, the air volume, rotation speed and power accordance with the following formula:

Fan And Pump Formula

According to similar principles, when the rotation speed of the fan reduce to n2 from n1, the shaft power of the fan N2 will be reduced to N1 multiply (n1/n2)3; the shaded area in the FIG – the area covered by JECF represents the saved electric quantity by reducing rotation speed compared with closing the air door to regulate the same amount of air volume. Both theory and actual measurement prove that it will cause waste of electric energy by manual increasing ventilation resistance (closing the valve) to regulate the air volume, which is unacceptable.

If variable frequency technology is adopted to change the rotation speed of pumps and fans to control other process control parameters on the field such as pressure, temperature and water level, the comparison results mentioned above can also be obtained by drawing the relation curve in accordance with the system control characteristics. In other words, the method to adopt VFD to change the rotation speed of ac motor is more energy and cost efficient than by using valve and damper, and the operating condition of the equipment is also significantly improved.

Keep the original system but add the variable frequency drive part, All motors in the system are driven by corresponding VFDs, and when the VFD failed, the system can working in power frequency as the original control system to ensure continuous production in the factory.

Control Circuit

A. Manual regulate (open-loop regulation) system, adjust output frequency of the VFD in manual control mode to change the rotation speed of the fan & pump to regulate air volume & water volume. It’s same as original method of regulating the air door (gate valve).

B. Automatic regulate (closed-loop regulation) system:
VFD automatic regulate system. The automatic control system adopts closed-loop regulation which is consisted of the VFD’s built-in PID function with external pressure sensor or pressure gage. The sensor detects air pressure or water pressure in real time and transforms it into 4-20mA current signal (or 0-10V voltage signal), and sends it to the PID regulator, and through internal calculation of the variable speed drive, automatic regulate the frequency of the VFD to stabilize the air volume or water pressure at the set value.

Main features of vector control VFD in Fan and Water Pump application

The VFD is a product special designed for load with square torque like in fan and water pump applications, cost effective and reliable, it’s an ideal choice for your energy saving system.

Wide range operation voltage, fluctuation range in 304 – 456V AC.

Special rotation speed tracking technology with no impact.

Several V/F curves in setting.

Multi-function input/output terminals with Multi-path definable function.

Re-start function in instant power off.

Built-in RS 485, support MODBUS-RTU communication protocol.

Stable start, suitable for high-inertia load’s speed regulation.

Easy to realize closed-loop automatic operation with advanced built-in PID algorithm.

1. Realize AC motor’s soft start/stop by adopting VFD control, to increase the equipment’s service life and avoid impact on the power system.
2. Control the AC motor’s rotation speed by the variable speed drive, remove the damper adjustment to decrease failure rate of the application, and increase electricity saving significantly.
3. The ac motor operates below rated rotation speed, to decrease impact of noises to the environment.
4. Do not affect original power facilities & environment during installation to allow continuous production.
5. Enhance overload, overvoltage, overcurrent, undervoltage and voltage phase lack protection functions, and audible and visual alarm function.
6. Due to keep the original system wiring and make the system have two working modes in normal power frequency & variable frequency power, the whole system operate in a more reliable situation.

Can I control multiple motors on one VFD

Multiple motors operation is quite common application. There are many applications like textile, printing etc where multi motor operation is very common. I have seen many VFD manufacturers recommending multiple motor operation. Say in a textile loom, there could be scores of Motors running spinning pumps, godets, winders etc. If there are some 40 Motors of say 0.5 HP, then one can certainly go in for one single variable frequency drive of say 25 hp rating. That would be the best and most economical and practical solution.

But, certain conditions, considerations and safety must be met. First each motor must be individually protected, consider the load, speed, torque, etc on EACH motor. Now this is tricky if the gearboxes are used. You have to consider are they new? Are they used and if so how much “SLACK” does each have as all these things play into the “LOAD” of each individual motor amp draw! Also, I would use 2 OL on each 3 phase load on the load side. Most of the time the cost of the motor is miniscual compared to the VFD. So protect it at all cost. Here’s a novel idea, “Ask the Manufacturer”! Not being a smarty pants, just want my fellow peer to do as good a job as he or she can and sometimes that means reading the instructions. Hope all this helps and if you will let me know the layout and how it works out for you.

VFD reactor

Quality VFD’s incorporate either an AC Reactor or DC Reactor (choke). Their inclusion in the basic design of the VFD allows the design engineer to maximize the advantages of the choke. Their function is to reduce the current distortion caused by the input stage rectifiers by slowing the rate of change of current, and thus charging the internal capacitor at a slower rate over a longer time.

Some VFD’s allow aftermarket fitment of DC chokes but access to the DC bus is required. While it is easy to add AC chokes to the input stage, there is a disadvantage of voltage drop to the VFD that may have to be considered.

The Harmonic Distortion caused by a VFD is related to its size & load, choke size, and the supply network parameters.

With no AC Reactor or DC Choke, the harmonic distortion will be greater.

Another consideration should be a properly sized source transformer that provides enough impedance. The sized source transformer used as an isolation transformer (although a bit more of an investment) should provide 3 to 5% impedance yet also provides Voltage Transient mitigation with ten to one reduction in impulse peaks, as well as noise reduction through the use of a Delta primary to Wye secondary with center tap ground. As Joe above states it provides additional protection for the VFD drives front (Converter) end while proper ground of the Source to Drive, Drive to Motor and Motor to Voltage Source assists in mitigating high frequency noise, especially when flat braid is used as the grounding straps. This protects your investment and assists in keeping the VFD’s from generating noise into the supply that can compromise your nearby instrumentation, and PLC power supplies, etc. As well you can tap up the transformer giving you a higher input voltage mitigating the voltage drop issues resulting from the higher impedance.

The DC link assists in mitigating DC Bus Ripple and increasing the input impedance enabling a slower inrush for power on and sudden demand current requirements furthering the life of your capacitors, while a sized supply transformer protects the front end of the drive by providing voltage noise protection and adding input impedance for smoother current and adding a capability to change taps to prevent a voltage drop, while input reactors slow inrush current furthering the life of your input components and capacitors but add no protection from Voltage impulses or noise to the variable frequency drive converter components, and add voltage drop increasing stress on those components. The important thing to remember is that “Proper” systemic design protects your drive(s) and system components investment.

Through the fluid mechanics’ basic principles, we know the fans and pumps are belong to square torque loads, the rotation speed n, flow Q, pressure H and shaft power P relation: Q∝n, H∝n2, P∝n3, i.e., the flow is in proportion to its rotation speed, the pressure is in proportion to the square of its rotation speed, and the shaft power is in proportion to the cube of its rotation speed.

We now take the fan as an instance of the principle in energy conservation. As show in following fig, when the fan in its rated rotation speed, the air volume and air pressure change as curve 1, which intersects with the pipe network resistance curve 2 at the rated working condition point N when the air door is full opened; the air volume of the fan is Qn and the pressure is Hn. Normally, the working condition point is moved to point E by closing the regulation air door and increasing the resistance in ventilation pipe network. At this moment, the air volume is decreased to Qe and the generated pressure head is He. If the air volume is regulated by reducing the rotation speed of the fan, the fan will operate as curve 4, and re-generate required air volume Qe, it will intersect with the pipe network resistance curve 2 at the working condition point C when the air door is full opened.

According to the similar principles between fan and water pump, the air volume, rotation speed and power accordance with the following formula:

Fan And Pump Formula

According to similar principles, when the rotation speed of the fan reduce to n2 from n1, the shaft power of the fan N2 will be reduced to N1 multiply (n1/n2)3; the shaded area in the FIG – the area covered by JECF represents the saved electric quantity by reducing rotation speed compared with closing the air door to regulate the same amount of air volume. Both theory and actual measurement prove that it will cause waste of electric energy by manual increasing ventilation resistance (closing the valve) to regulate the air volume, which is unacceptable.

If variable frequency technology is adopted to change the rotation speed of pumps and fans to control other process control parameters on the field such as pressure, temperature and water level, the comparison results mentioned above can also be obtained by drawing the relation curve in accordance with the system control characteristics. In other words, the method to adopt VFD to change the rotation speed of ac motor is more energy and cost efficient than by using valve and damper, and the operating condition of the equipment is also significantly improved.

Keep the original system but add the variable frequency drive part, All motors in the system are driven by corresponding VFDs, and when the VFD failed, the system can working in power frequency as the original control system to ensure continuous production in the factory.

Control Circuit

A. Manual regulate (open-loop regulation) system, adjust output frequency of the VFD in manual control mode to change the rotation speed of the fan & pump to regulate air volume & water volume. It’s same as original method of regulating the air door (gate valve).

B. Automatic regulate (closed-loop regulation) system:
VFD automatic regulate system. The automatic control system adopts closed-loop regulation which is consisted of the VFD’s built-in PID function with external pressure sensor or pressure gage. The sensor detects air pressure or water pressure in real time and transforms it into 4-20mA current signal (or 0-10V voltage signal), and sends it to the PID regulator, and through internal calculation of the variable speed drive, automatic regulate the frequency of the VFD to stabilize the air volume or water pressure at the set value.

Main features of vector control VFD in Fan and Water Pump application

The VFD is a product special designed for load with square torque like in fan and water pump applications, cost effective and reliable, it’s an ideal choice for your energy saving system.

Wide range operation voltage, fluctuation range in 304 – 456V AC.

Special rotation speed tracking technology with no impact.

Several V/F curves in setting.

Multi-function input/output terminals with Multi-path definable function.

Re-start function in instant power off.

Built-in RS 485, support MODBUS-RTU communication protocol.

Stable start, suitable for high-inertia load’s speed regulation.

Easy to realize closed-loop automatic operation with advanced built-in PID algorithm.

1. Realize AC motor’s soft start/stop by adopting VFD control, to increase the equipment’s service life and avoid impact on the power system.
2. Control the AC motor’s rotation speed by the variable speed drive, remove the damper adjustment to decrease failure rate of the application, and increase electricity saving significantly.
3. The ac motor operates below rated rotation speed, to decrease impact of noises to the environment.
4. Do not affect original power facilities & environment during installation to allow continuous production.
5. Enhance overload, overvoltage, overcurrent, undervoltage and voltage phase lack protection functions, and audible and visual alarm function.
6. Due to keep the original system wiring and make the system have two working modes in normal power frequency & variable frequency power, the whole system operate in a more reliable situation.

Can I control multiple motors on one VFD

Multiple motors operation is quite common application. There are many applications like textile, printing etc where multi motor operation is very common. I have seen many VFD manufacturers recommending multiple motor operation. Say in a textile loom, there could be scores of Motors running spinning pumps, godets, winders etc. If there are some 40 Motors of say 0.5 HP, then one can certainly go in for one single variable frequency drive of say 25 hp rating. That would be the best and most economical and practical solution.

But, certain conditions, considerations and safety must be met. First each motor must be individually protected, consider the load, speed, torque, etc on EACH motor. Now this is tricky if the gearboxes are used. You have to consider are they new? Are they used and if so how much “SLACK” does each have as all these things play into the “LOAD” of each individual motor amp draw! Also, I would use 2 OL on each 3 phase load on the load side. Most of the time the cost of the motor is miniscual compared to the VFD. So protect it at all cost. Here’s a novel idea, “Ask the Manufacturer”! Not being a smarty pants, just want my fellow peer to do as good a job as he or she can and sometimes that means reading the instructions. Hope all this helps and if you will let me know the layout and how it works out for you.

VFD reactor

Quality VFD’s incorporate either an AC Reactor or DC Reactor (choke). Their inclusion in the basic design of the VFD allows the design engineer to maximize the advantages of the choke. Their function is to reduce the current distortion caused by the input stage rectifiers by slowing the rate of change of current, and thus charging the internal capacitor at a slower rate over a longer time.

Some VFD’s allow aftermarket fitment of DC chokes but access to the DC bus is required. While it is easy to add AC chokes to the input stage, there is a disadvantage of voltage drop to the VFD that may have to be considered.

The Harmonic Distortion caused by a VFD is related to its size & load, choke size, and the supply network parameters.

With no AC Reactor or DC Choke, the harmonic distortion will be greater.

Another consideration should be a properly sized source transformer that provides enough impedance. The sized source transformer used as an isolation transformer (although a bit more of an investment) should provide 3 to 5% impedance yet also provides Voltage Transient mitigation with ten to one reduction in impulse peaks, as well as noise reduction through the use of a Delta primary to Wye secondary with center tap ground. As Joe above states it provides additional protection for the VFD drives front (Converter) end while proper ground of the Source to Drive, Drive to Motor and Motor to Voltage Source assists in mitigating high frequency noise, especially when flat braid is used as the grounding straps. This protects your investment and assists in keeping the VFD’s from generating noise into the supply that can compromise your nearby instrumentation, and PLC power supplies, etc. As well you can tap up the transformer giving you a higher input voltage mitigating the voltage drop issues resulting from the higher impedance.

The DC link assists in mitigating DC Bus Ripple and increasing the input impedance enabling a slower inrush for power on and sudden demand current requirements furthering the life of your capacitors, while a sized supply transformer protects the front end of the drive by providing voltage noise protection and adding input impedance for smoother current and adding a capability to change taps to prevent a voltage drop, while input reactors slow inrush current furthering the life of your input components and capacitors but add no protection from Voltage impulses or noise to the variable frequency drive converter components, and add voltage drop increasing stress on those components. The important thing to remember is that “Proper” systemic design protects your drive(s) and system components investment.