Sinus Penta Variable Speed Drive

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1 Sinus Penta Variable Speed Drive Advanced solutions for specialised applications motor control Sales 1300 NHP NHP Sales 0800 NHP NHP nhp.com.au nhp-nz.com

2 SINUS PENTA VARIABLE SPEED DRIVE SPECIALISED SOLUTIONS NHP products that are simple and easy to maintain Our Elettronica Santerno range of Variable Speed Drives has become recognised as a reliable and easy to use solution, with strong capabilities in specialised industrial applications. These industrial solutions include: Active Front End technology for low harmonics and regenerative braking HVAC solutions including firemode, IP 54, BACnet and LonWorks Multi-pump control logic offering multi-master control A wide 690 V range for mining applications. NHP provides the world s best electrical engineering products in the major market categories of power distribution, automation systems and motor control. These quality products are backed by our local technical support experts so as to ensure you get what you need and that it works reliably and consistently. To connect with any NHP branch in Australia call 1300 NHP NHP. or NHP New Zealand on 0800 NHP NHP.

3 The Specialised Solutions Active Front End Technology Heating, Ventilation and Air-Conditioning Solutions (HVAC) Multi Pump Solutions 690V Solutions

4 Active Front End Technology Low Harmonic and Regenerative Solution Regenerative benefits: energy savings Energy savings can be achieved with the regenerative functionality as excess electrical energy reduces overall power consumption, lowers operating costs and excess energy can be recycled instead of being dissipated as heat when using conventional braking resistors. A common application of the Active Front End (AFE) Technology solution is its regenerative functionality for use with high inertia loads. This allows the recovery of kinetic energy of the connected load and transfers this into electrical energy which can be sent back into the mains power grid. Reduce harmonic distortion An extremely low level of harmonic distortion is produced by the Sinus Penta AFE solution with the level being produced independent of the operating conditions of the load. The power regenerated back into the mains power grid is a near perfect sinusoidal current waveform which reduces operating costs and increases drive efficiency. The use of the Sinus Penta AFE solution removes the need for expensive and complex active harmonic mitigation equipment which produces excess heating during normal operation. This makes the AFE solution perfect for users with limited installation space and reduces overall cost of installation. Increase dynamic braking performance without resistors. The Sinus Penta AFE solution has the ability to provide extremely high levels of dynamic braking in excess of 150 % braking torque. This is much more than what can be achieved when using standard braking resistors with a Variable Speed Drive (VSD). The advantage of using the Sinus Penta AFE solution is that no additional space is required to house the brake resistors and additional ventilation is not required to manage the excess heat loss during their operation. Other Benefits of AFE Ability to use 100 % capacity of backup generators without de-rating due to reduced harmonic line currents Suitable for use in areas which exhibit wide line voltage fluctuations Unity power factor Instantaneous drive performance between motoring and regenerative operation Energy recovery while minimising your carbon footprint. 3

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6 Active Front End Technology The SINUS PENTA AFE utilizes standard off the shelf drives complete with all its features which ensures that the same familiar programming style, keypad controls, features and functionality are maintained. The SINUS PENTA is available over a large range as it is available in both 415 V AC and 690 V AC from 2.2 kw to 2.0 MW. Because the AFE solution utilises the tried, proven and tested SINUS PENTA drives, the complete AFE system is covered by a three warranty plus it is fully compatible with the Remote Drive software which offers tools for the control of the AFE system, trending functions, setting and storing of parameters and online monitoring. AFE - How does it work? The AFE is located on the supply side of a standard Sinus Penta VSD and consists of a second Sinus Penta drive which is loaded with integrated control firmware to perform the AFE function. Some ancillary equipment is also installed to ensure synchronisation with the mains supply. A typical waveform of the Sinus Penta AFE solution is shown below: Standard drive non-active front end solution Sinus Penta active front end solution Inductors (otherwise known as chokes) are used between the AFE and the mains power in order to filter the Pulse Width Modulated (PWM) voltage on the inverter output terminals and make the current exchanged with the mains sinusoidal. Suitable applications Cranes Centrifuges Conveyors Rolling Mills Elevators 5

7 AFE and multiple drives / common DC bus The AFE has a stabilised direct voltage (DC Link) as an output that can be also used to power one or more SINUS PENTA inverters through a direct DC connection. This removes the need for expensive individual cabling runs to the connected drives plus provides you the full regenerative function for all connected drives. Enclosed systems NHP have a vast amount of experience designing and engineering enclosed drive solutions which can be tailored to suit your specific requirements or application. The system can be customised to include options such as contactors, chokes, semiconductor fuses, communication options and much more. Ordering Due to a wide range of options and accessories available with the AFE drive system, please contact NHP so we can custom design a solution specifically to suit your application. 6

8 Heating, Ventilation and Air Conditioning Solutions 7

9 The SINUS PENTA variable speed drive has unique features that allow it to be readily applied to many applications, including heating, ventilation and air conditioning (HVAC). IP 54 Enclosure offers High Degree of protection against dust and water sprays Ability to wall mount without the need for additional enclosures and ventilation PID functionality for automatic control Extensive communications options allowing control and monitoring for most BMS networks Inclusion of a firemode function for extended operation during critical periods Robustness and reliability Ability to start on a rotating load to ensure trip free operation A whisper quiet mode operation. Save Energy and Money As shown below the affinity law demonstrates the power consumed in proportion to speed cubed. Therefore a reduction in speed by 10 % can result in a reduction of power approximately by 25 %. A further reduction in speed by 50 % can further reduce power by approximately 85 %. Since many applications do not need to run at full speed, the reduction in speed offers significant opportunity for energy savings while meeting the exact flow requirements. 11

10 Heating, Ventilation and Air Conditioning Solutions The SINUS PENTA can be used in a number of HVAC applications with some of the benefits listed below: Air handler Reduce energy costs - Variable torque load characteristics use less energy as speed is reduced Reduce supply demand - Drives reduce starting current by 8-10 times Reduce noise in buildings - Airflow noise decreases by eliminating starts and stops and optimising flow rates Reduce shock and vibration - Drive avoids running at speeds near resonant frequencies and provides controlled acceleration Increased life of motor belts - Drives provide low torque starts reducing stress on belts, pulleys and keys. Cooling tower fan Energy savings and reduced energy costs - Motors use less energy as speed is reduced Reduce maintenance requirements and reduce operating costs - Robust construction and energy efficient Precisely control water temperature using in-built control functions designed for fans. Water condenser chiller Reduce energy consumption - Provide improved efficiency and reduce energy requirements Provide continuous operation - Restart a spinning motor after momentary power loss. Pump Reduce energy costs - Variable torque load characteristics uses less energy as speed is reduced Reduce demand charges - Drives reduce motor starting current by 8-10 times Control of pressure of flow using PID - The drive can automate the pressure flow with just a single pressure transducer Wide power range for different pump sizes - Interface commonality throughout the range Network communications - Supports all major communication protocols Prevention of water hammer, pipe stress, valve, pump seals and cavitation prevention extends the life of the entire system. 9

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12 Heating, Ventilation and Air Conditioning Solutions Sinus Penta BACnet solution for HVAC 11

13 The BACnet solution available for the SINUS PENTA range of Variable Speed Drives is simply a plug-in expansion card, which mounts directly into the Santerno range of VSDs. Both BACnet IP and BACnet MSTP are available on the same card at no extra cost to the user providing flexibility in the BACnet protocol. Major benefits The Santerno BACnet communication offers the ability to provide BACnet IP directly to the Santerno VSD without the need to use B-BC (BACnet Building Controller) or B-AAC (BACnet Advanced Application Controller) devices as shown below. BACnet configuration software Configuration of the BACnet fieldbus solution for use with the Santerno VSD range can be completed with ease by using the Santerno Automation Suite which includes configuration tools for use with the BACnet communication card. Users can program the BACnet communication card for BACnet IP or BACnet MSTP plus configure other parameters relevant to the chosen BACnet medium. The data transferred over the BACnet fieldbus is identical with the existing data that can be transferred over the existing fieldbus networks available with the Santerno range of VSDs. This includes: Analogue inputs, analogue outputs, digital inputs, digital outputs, status and alarms and a selection of customer defined motor measured values (e.g. current, speed). Also available: Ethernet / IP LonWorks Most other protocols. 12

14 Multi-pump Solutions The SINUS PENTA Variable Speed Drive when combined with special software becomes a high level integrated pump control system. This software can be added to any SINUS PENTA drive and is field loadable using the Remote Drive PC software package or can be supplied, pre-installed on request. The software provides a high level of control with flexible options for configuration, control and monitoring. PID implementation The Sinus Penta incorporates PID loop control which provides integrated control of an external process (such as level, flow, pressure or temperature) and allows the drive to continually respond to changing demands by adjusting the output speed of the motor. The PID loop takes an input from the field and in addition to an external set-point or reference; the drive takes care of the rest and continually matches the feedback to the reference value to ensure continuous operation. Multi-pump control The multi-pump system can be used to control a system of up to five pumps including the master. The drive can be used to control this system without any additional hardware. The drive utilises the internal PID loop and control functionality to control the operation of not only the master but the slave drives also. Fixed Speed Operation The fixed speed operation provides an economical multi-pump solution where the master Sinus Penta drive is used to control the process and the slaves are operated at fixed speed and brought on-line by the master when the capacity of the master is exceeded. When demand reduces, the master sheds the pumps off the system to maintain the process demand. A fixed speed system can be configured using a combination of Direct On-Line (DOL), Star-Delta or Soft Starters. 17

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16 Multi-pump Solutions Save energy using Variable Speed Drives in multi-pump applications. 13

17 Variable speed operation allows for the most efficient and energy saving option for a pump system. By using Variable Speed Drives on all pumps and varying their speed, the pumps can all be run at the optimum speed to ensure the lowest energy usage level. As a result the operation of a variable speed system provides the same energy savings of a single pump, multiplied across all of the pumps. The master will determine which drives are required in order to maintain the demand based on user defined minimum and maximum operation levels. A complete variable speed system has the added benefit of providing a faster response to changing load conditions and is able to maintain a more stable system. Multiple benefits: Energy is saved by replacing mechanical fluid flow controllers with integrated motor speed control - These energy savings result in cost savings and a reduction in greenhouse gas emissions Reduce motor starting current 8-10 times Prevention of water hammer, pipe stress, valve and pump seals and cavitation prevention and extends system life The controlled start of VSDs eliminates voltage dips and reduces starting shock on motors, couplings, gears and drive equipment, thus reducing maintenance Running at reduced speed reduces wear on drive train components and reduces the need for high maintenance items such as dampers, throttling valves In general, the range of flow control is higher with VSDs when compared to mechanical controllers. This reduces the probability of surges and vibration Some over speeding is possible without the need for additional gearing. 14

18 SINUS PENTA - Multi-pump Solutions Save power, save money When using VSD s in pumping application, the Affinity Laws described below are used to describe the relationship between hydraulic characteristics and rotational speed of centrifugal pumps. The Affinity Law s state: The change in power varies by the cube of the change in speed. In this case, twice the speed requires eight times (2 3 ) the power. Refer to page 8 for further explanation. It is this Law which results in the huge power and financial savings when using VSD s in pumping application. In many instances of flow or pressure control the application does not need to run at full speed, hence a reduction offers significant opportunities for energy savings with little or no reduction in process output. 15

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20 Multi-pump Solutions Option 1: Master with fixed speed slaves - I/O or Modbus/RS485 control Using one drive and fixed speed slaves the master is able to control the operation of the complete system. The master provides fine adjustment and cascades the slaves as required to maintain the required demand. The control of the slaves is all achieved through a choice of two methods: direct connection using I/O control or Modbus. When using fixed speed devices which have the ability to communicate on a Modbus network, such as an AuCom soft starter, the system can be greatly simplified. Option 2: Master with variable speed slaves - I/O or Modbus/RS485 control With both master and slave pumps connected to VSD s, improved control and reduced energy consumption is instantly achieved compared to using fixed speed slaves. As with the fixed speed slave application, the master drive provides complete control of the system but this time, each pump is able to operate at an adjustable speed which is determined by the master drive. The master determines which drives are required to operate and what speed is required to maintain the required demand. The use of a Modbus connection between the variable speed slaves can greatly reduce the complexity of the system wiring. FILLING FILLING AC MAINS EMPTYING AC MAINS EMPTYING SINUS PENTA MUP MASTER FLOW PRESSURE SINUS PENTA MUP MASTER FLOW PRESSURE SLAVE 1 M1 P1 Q SLAVE 1 M1 P1 Q M2 P2 M2 P2 SLAVE 2 SLAVE 2 M n P n M n P n 19

21 Option 3: Multi-Master with fixed or variable speed slaves - I/O or Modbus/RS485 control In addition to the two systems described above, the multi-pump application is also able to operate in a multimaster mode with a combination of fixed speed slave or variable speed slave drives connected with either I/O or Modbus control. Under normal operating conditions, the system will operate as described above however should the primary master drive be removed from circuit for maintenance then the secondary master drive will seamlessly take over operation of the entire multi-pump system. FILLING AC MAINS EMPTYING MUP PRIMARY MASTER FLOW PRESSURE M1 P1 Q MUP SECONDARY MASTER M2 P2 SLAVE 1 M n P n If necessary, the secondary master drive will instruct the system to increase or decrease the slave pump speeds to suit the required flow level when the primary master was removed from service to maintain a constant pressure as required by the system. Should the primary master drive come back on-line in the system, then the secondary master will continue to control the entire multi-pump operation and the primary master will act as a slave drive. 20

22 690V Solutions 21

23 Mining Application A major benefit of the SINUS PENTA is that it s now available as a drive suitable for 690V AC three phase supply connection. The 690V option is proving particularly popular for underground mining as it is a more practical and cost efficient alternative to the conventional 415V AC supply or medium voltage options such as 11 kv. Long feeder runs on larger sized drives in underground mining present unique challenges specifically with regards to conductor size and voltage drop. Traditionally moving to an MV supply has been the only option but this comes with a high switchgear cost. The 690V option presents as a unique middle-ground, allowing cost efficient LV design and switchgear, while almost halving the currents and associated current drops. The Sinus Penta is one of only a handful of VSDs that support this important new supply standard. The SINUS PENTA will suit most standard mining applications such as the following: Crushers Standard duty (140% overload) and Heavy duty (175% overload) ratings to suit cone, jaw and vertical impact crushers. Ability to vary the operating speed to allow optimal feed rate of material into the crusher to match current conditions and increasing throughput. Fans and underground Ventilation PID functionality using external inputs to accommodate unusual ambient conditions and adjust the speed of the fan accordingly for example exhausting CO2 or increasing flow of oxygen. Fire mode to allow continuous operation of the drive under normal fault conditions. IP54 enclosures available to suit underground environments. Conveyors Fixed or variable speed control. Synchronization with parallel conveyors. Regenerative option available in 690V. 22

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