2. SPOC Automation and BECI- who are we?
Pump Focused VFD company
Specialists in Optimizing Pump Control
SPOC 15+ Years in business
BECI 16+ Years in business
Both Family Owned
SPOC Based in Trussville, AL
BECI – Based in Conway, AR

3. Efficiency using Automation VFDs
“Power” Basics
AC Motor Basics
AFD Basics
Energy Savings Basics
Discrete Automation Advantages

4. POWER
Basics

5. HP is the measurement of the work that the motor can perform.
The Basics
HP is the measurement of the work that the motor can perform.
33,000 ft/lbs per minute or
746 Watts
1 HP =
Note: comes from (33,000 ft·lbf/min)/(2π rad/rev)

6. The Basics Torque is: directly proportional to HP
indirectly proportional to speed
related to current demand – so, the higher the torque, the higher the HP – the higher the current demand.
To understand Horsepower and Torque better, we need to understand how a motor works……..

7. AC Motor
Basics

8. Electric motors convert electrical energy to mechanical energy
The Basics
                  
Electric motors convert electrical energy to mechanical energy

9. The Basics
The motor stator is made up of a series of windings wound to create a series of magnetic poles when energized

10. The Basics
When 3 phase AC power is applied to the stator winding a rotating magnetic field is created.

11. The Basics Induction causes Rotor rotation
The rotor tries to align itself with the rotating magnetic field.
With no losses, the rotor would rotate at the synchronous speed.

12. The Basics
An induction motor is basically a constant speed device because the stator field rotates based on the frequency of the AC power system
Looking at the equation differently: what would happen to the speed of the AC Motor if the frequency to the stator changed?

13. The Basics
The Basics
300
10 Hz
900
30 Hz
1800
60 Hz

14. VFD
Basics

15. VARIABLE FREQUENCY DRIVES How does a Variable Frequency Drive Work?
THREE SECTIONS
1. CONVERTER - Transforms (Converts) AC Line Power
to DC Voltage
2. DC FILTER - The DC Voltage is Cleaned
3. INVERTER - Tranforms (Inverts) the DC Voltage to
Synthetic AC Voltage

16. DRIVE TERMS Pulse Width Modulation (output)
Definition - DC current is switched on and off quickly
to appoximate an AC sine wave

17. To provide a little more detail, lets look at a simple drive schematic
To provide a little more detail, lets look at a simple drive schematic. The converter or rectifier section usually consists of six diodes. These diodes rectify the incoming line voltage to DC.
The filter section then smooths the DC to a level required by the inverter section. The filter section usually consists only of a filter capacitor. On infrequent occasions an inductor may also be used in series with the rectifier output.
The inverter section switches its IGBTs in the appropriate sequence to provide a three phase output at the desired frequency and voltage to be applied to the motor.
You may note the diodes in parallel with the IGBTs. These diodes provide a circuit path for the motor magnetizing current since it cannot flow backwards through the IGBTs.

18. Energy Savings
Basics

19. Energy savings
50HP Motor running full speed for a year…How much does it cost to run?
@ 10 Cents per kwh, about $30k

20. Typical Variable Torque Loads
Most Pumps
Supply and Exhaust Fans
Aerators

21. HP = K(Operating speed/nameplate speed)3
Variable Torque Application
HP = K(Operating speed/nameplate speed)3
This is THE $$$$
Equation!!!
Max Volts
230/460/575
Variable Torque
Constant HP
V/Hz Ratio
V/Hz Ratio
Output Voltage
V/Hz Ratio
60 Hz
Extended Frequency
Frequency

22. Variable Torque Application
HP = K(Operating speed/nameplate speed)3
Why is this considered to be THE $$$$ Equation? Energy Savings!
HP equals cube of the speed, so
½ speed = (1/2) x (1/2) x (1/2) = 1/8 HP
¼ speed = 1/64 HP
A 100HP motor at ½ speed requires 12.5 HP
HP is directly proportional to $

23. Savings Example-oversized fan
If a zoo runs a 10HP Motor for 24 hours a day at full speed:
10HP x (1)3 x KW/HP = 7.46KW
7.46KW x 24 hours = 179 KWhrs
If a zoo runs a 10HP motor for 24 hours a day at 3/4 speed:
100HP x (3/4)3 x KW/HP = 3.14 KW
3.14 KW x 24 hours = KWhrs
58% Savings simply by slowing the fan down by 25%.
New Reduced airflow through fan is 75% of original

24. Savings Example--
If a zoo runs a 100HP Pump for 12 hours a day at full speed:
100HP x (1)3 x KW/HP = 74.6KW
74.6KW x 12 hours = 895 KWhrs
If a zoo runs a 100HP Pump for 24 hours a day at ½ speed:
100HP x (1/2)3 x KW/HP = 9.4 KW
24 hour day: 9.4 KW x 24 hours = 225 KWhrs
75% energy savings to move the same amount of fluid

25. VFD “Myth Buster” #1 Myth: VFD’s are rated VT and CT
Fact: VFD’s are rated based on over-current capabilites. Typically, drives are rated at
110% overload for 1 minute, or
150% overload for 1 minute.

26. AFD “Myth Buster” #2 Myth: AFD’s are inefficient at low speeds.
Fact: The AFD is typically >96% efficient throughout the speed range.
The concern is the AC Motor:
It is self-cooled
The slower the motor is going, the less cooling from the fan
Most modern motors have specifications for what is allowed

27. AFD “Myth Buster” #3
Myth: I’ll burn up motors if I connect more than one to an AFD
Fact: One of the biggest benefits of an AFD is that more than one motor can be controlled by one drive. All motors will receive the same voltage and frequency.

28. Automation VFD
Basics

29. Pump Automation +
VFD
Controls

30. + Pump Automation Control process Variable Capacity Safety interlocks
Flexibility for rate of flow or compression
Energy Savings
Control process
Safety interlocks
Eliminate manual adjustments to hit targets +

31. Pump Automation
Easy, right?
…..but we forgot a couple things

32. Pump Automation +
VFD startup technician
PLC startup technician

33. A Simpler Way

34. Pump Automation
PLC
VFD
Automation VFD
PLC Technician
SCADA

35. Typical Controls Branch of Electrical Contractor Usually 1 or 2 techs
Exists to support contractor business
Dedicated Controls Company
Typically small company
Can do anything approach
Customized solutions

36. Automation VFD ……..It’s In There Simple Operation
Operator Friendly Startup
Standard Product
Standard Support

37. Automation Drives ……..It’s In There Reduce Electrical Costs
Reduce On-off Cycles
Eliminate Bypass Valves
Simplified Startup
Single Vendor responsibility
Easy System Troubleshooting

38. Automation Drives
Typical savings $10-$15k installed cost advantage of traditional PLC based approach
Optimized for smaller systems with a few pumps or fans per system
Simple setpoint changes
Flow
Pressure
Temperature