Variable speed drive or soft starter?

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1 Hendrik Spies, Product Marketing Manager, May 2013 Variable speed drive or soft starter? 1SFC132018N0201, May 6, 2013 Slide 1

2 Motor Starter Options May 6, 2013 Slide 2

3 Motor Starter Options Variable Speed Drives May 6, 2013 Slide 3

4 Motor Starter Options Soft Starters May 6, 2013 Slide 4

5 Motor Starter Options Soft Starter Functionality May 6, 2013 Slide 5

6 Motor Starter Options Comparison Between Starting Methods May 6, 2013 Slide 6

7 Pump systems Different Pump systems May 6, 2013 Slide 7

8 Pump systems Different Pump systems May 6, 2013 Slide 8

9 Pump systems Different Pump systems May 6, 2013 Slide 9

10 Pump systems Different Pump systems May 6, 2013 Slide 10

11 Pump systems Different Pump systems May 6, 2013 Slide 11

12 The great softstarter offer from ABB PSE - The New Efficient Range PST/ PSTB PSS PSR PSE The Efficient range - Water & Wastewater / Pumps and other applications - Cost and space efficient - All the most important functionality - Torque control May 6, 2013 Slide 12

positions showing values and messages 4 status indication LEDs Green - Ready Green - Run Yellow - Protection Red - Fault

13 PSE - User Interface The first compact softstarter with LCD display! Clear terminal markings Illuminated display Possible to lock the keypad to prevent parameters from being changed Four positions showing values and messages 4 status indication LEDs Green - Ready Green - Run Yellow - Protection Red - Fault User friendly 4-button keypad with clear functions Easy to identify - All data available on the front Icons for showing functions, units etc Language neutrual May 6, 2013 Slide 13

PSE - User Interface Settings / Available functions Available functions (top row from left to right) Setting current Start ramp Stop ramp Initial / end voltage Current limit

14 PSE - User Interface Settings / Available functions Available functions (top row from left to right) Setting current Start ramp Stop ramp Initial / end voltage Current limit Torque control for start Torque control for stop Kick start Available functions (bottom row from left to right) Overload Underload Locked rotor Fieldbus May 6, 2013 Slide 14

15 PSE - General product information Electrical ratings Softstarter size kw-rating (400V) hp-rating (480V) PSE18 7,5 kw 10 hp PSE25 11 kw 15 hp PSE30 15 kw 20 hp PSE37 18,5 kw 25 hp PSE45 22 kw 30 hp PSE60 30 kw 40 hp PSE72 37 kw 50 hp PSE85 45 kw 60 hp PSE kw 75 hp PSE kw 100 hp PSE kw 125 hp PSE kw 150 hp PSE kw 200 hp PSE kw 250 hp PSE kw 300 hp May 6, 2013 Slide 15

16 PSE Torque control Water flow Stop This Softstop function has been developed in close cooperation with a well known pump manufacturer. Time The principle of Torque Control Controlling the motor torque instead of the motor voltage. Possible to control torque both during start and stop. Torque control provides a controlled acceleration and deceleration of the machinery. Torque controlled softstop is especially designed for pumps May 6, 2013 Slide 16

17 PSE Torque control Comparing with normal voltage ramp U Voltage ramp U Torque control 100% 100% time time Linear decrease of the voltage down to end voltage. The voltage is fully controlled (both up and down) making it possible to fully control the motor output torque all the way down to zero speed. May 6, 2013 Slide 17

18 PSE Torque control Comparing with normal voltage ramp T Voltage ramp T Torque control RPM RPM When ramping down it is only possible to control the stop down to the maximum torque, where you will lose control of the motor. Torque control allows you to control the stopping also after passing the maximum torque - all the way down to zero speed. May 6, 2013 Slide 18

19 PSE Torque control Comparing with normal voltage ramp RPM Voltage ramp STOP signal RPM Torque control STOP signal time time No speed reduction during the first part of the stop ramp. Towards the end of the ramp, the motor sometimes stops too quickly, causing water hammering More controlled deceleration of the motor from the beginning of the stop all the way down to zero speed. May 6, 2013 Slide 19

20 PSE Torque control Comparing different starting methods May 6, 2013 Slide 20

21 PSE Torque control Principal solution A closed loop control PSE Softstarter M I V α Pin - Ploss Pmotor Tmotor Tideal May 6, 2013 Slide 21

22 PSE - Technical product information Current limit Current With current limit Without current limit Speed Used to keep the starting current on a pre-set maximum level Especially useful for heavy duty starts such as fans and conveyor belts, where the starting times are long Possible to set the level (1,5 7 xie) Active during start May 6, 2013 Slide 22

23 PSE - Technical product information Kick start U t Set initial voltage Uini Time Normal ramp Ramp with kick start Used to start for instance jammed pumps or conveyor belts Provides enough torque during start but still ensuring a soft start Possible to set level / time (30% 100%) 30% Ue => 0,3 sec 35% Ue => 0,35 sec 100% Ue => 1,0 sec May 6, 2013 Slide 23

24 PSE - Technical product information Electronic overload protection Time I e Class 30 Class 20 Class 10 Class 10A Current Used to protect the motor from overheating No need for external thermal or electronic overload 4 different classes available 10A Very light start 10 Normal start 20 Medium start 30 Heavy duty start Active both during start/stop and continuous run Needs to cool down to 60% before reset is possible May 6, 2013 Slide 24

25 PSE - Technical product information Underload protection I Rated operational point OK Trip rpm Used to detect for instance broken belts and pumps running dry Active after reaching TOR Possible to set level (0,2 1,0 xie) Time delay of 10 sec Low or Unloaded motor May 6, 2013 Slide 25

26 PSE - Technical product information Locked rotor protection Time Class 30 Class 20 Class 10 Class 10A Current Used to detect for instance jammed pumps, conveyor belts etc Active after reaching TOR Provides faster protection than OL for high currents Possible to set level (0,5 7,0 xie) Time delay of 1 sec May 6, 2013 Slide 26

27 PSE Technical product information Example application diagram Fuses for short circuit protection 2-wire or 1-wire control of the softstarter Internal 24 V DC for control circuit Line contactor Functional ground for most reliable operation PSE Softstarter Softstarter in line connected with the motor May 6, 2013 Slide 27

PSE - Technical product information Accessories Fieldbus

(same accessory as for PSR) All the common protocols available

accessorie Modbus-RTU DeviceNet CANopen Full control of the

28 PSE - Technical product information Accessories Fieldbus communication Fieldbus communication available as an option (same accessory as for PSR) All the common protocols available Profibus DP/V0, DP/V1 ABB Field Bus Plug Field Bus Plug accessorie Modbus-RTU DeviceNet CANopen Full control of the softstarter Parameter settings Start/stop Read status information May 6, 2013 Slide 28

29 Different types of control 3-phase control Benefits Soft start / soft stop Symmetrical voltage and current Lowest starting current Possible to connect inside delta Torque control and current limit possible Disadvantages Largest dimensions Highest cost when used in line L1 L2 L3 M May 6, 2013 Slide 29

30 Different types of control 2-phase control Benefits Reduced price Reduced dimensions Good price / performance ratio Softstop possible Torque control now possible (ABB patent) Current limit possible Reduced inrush current Disadvantages Assymetrical voltage and current during start Not possible to connect the softstarter inside delta DC-current during start (without ABB patent) L1 L2 L3 M May 6, 2013 Slide 30

31 Consequences of 2-phase control Torque control now possible The worlds first compact softstarter with Torque Control! No other softstarter manufacturer has torque control in a 2-phase controlled softstarter. A special ABB algorithm makes it possible to have torque control also on a 2-phase controlled softstarters. (Patent protected) The performance of the torque control is just as good as for a 3- phase controlled softstarter Water flow Stop Time May 6, 2013 Slide 31

Consequences of 2-phase control Algorithm to eliminate DC-component ABB has developed an algorithm to fire the thyristors in a special way to compensate for the DC-component.

32 Consequences of 2-phase control Algorithm to eliminate DC-component ABB has developed an algorithm to fire the thyristors in a special way to compensate for the DC-component. (Patent protected) The elimination of the DC-component will give symmetrical current and increased torque, ensuring a successful start. This algorithm is implemented in both PSR and PSE softstarters. Very few competitors have the same performance on 2-phase controlled softstarters and thereby having the defects mentioned above. Without ABB patent With ABB patent Current (AC) Current (AC) Assymetrical current time Symmetrical current time May 6, 2013 Slide 32

33 May 6, 2013 Slide 33

ABB Softstarter Benefits Charnchanok Thongprad

ABB Softstarter Benefits Charnchanok Thongprad tomation Technology Products AB Control - 1 - - Why Softstarters? Benefits for the Electrical network Reduces voltage drops on networks Minimizes starting