2. AN ISO 9001: 2008 COMPANY WITH TUV AUSTRIA CERTIFICATION
QUALITY MANAGEMENT SYSTEM
24 X 7 TECHNICAL ASSISTANCE
ELECTRICAL & MECHANICAL SOLUTIONS UNDER ONE ROOF
FABRICATION EXPERTEEFABRICATION EXPERTEE
PROJECT MANAGEMENT & PLANNING
ERECTION & COMMISSIONING SUPPORTS
TURNKEY PROJECTS
ENERGY SAVING SOLUTIONS
AC DRIVE APPLICATIONS FOR PLASTIC INJECTION MOULDING
FREE AMC FOR ONE YEAR *
95 % CUSTOMER SATISFACTION RATIO
TECHNO SUPPORT ENGINEERS
3. WE ARE THE LEADER IN ELECTRICAL AUTOMATION WHO
SUCCESSFULLY APPLY AC VARIABLE FREQUENCY DRIVES IN INJECTION
MOLDING OPERATIONS WITHOUT DISTURBING PROCESS PARAMETERS.
WE CAN IMPLEMENT THESE DRIVES FOR ANY
HYDRAULIC PLASTIC INJECTION MACHINE. THESE DRIVES HAVING
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HYDRAULIC PLASTIC INJECTION MACHINE. THESE DRIVES HAVING
ADVANTAGES NOT TO SAVE YOUR ELECTRICITY BILLS BUT SAVES
MAINTENANCE COST ALSO.
4. TECHNICAL ADVANTAGES
OF VARIABLE FREQUENCY
DRIVES & ACTUALLY HOW
IT WORKS ?
VFDs (Variable Frequency Drives)
are basically a green energy
savings product that matches the
amount of work or load on a motor
to the amount of energy it needs to
power that amount of work. This
reduces excess energy from being
wasted.
We use a lot of energy in this
country and most of that energy is
used to move air and water around
a building. About half the
electricity in commercial
a building. About half the
electricity in commercial
companies just used to move air
and water around, so a VFD is a big
way to save energy there. If you
look at a typical pump motor the
life cycle cost of a pump, 90% of its
life cycle costs is the energy it
consumes and only 10%
TECHNO SUPPORT ENGINEERS
5. Variable frequency drives (VFD) are becoming more common
place and more widely used in applications. They are capable
of varying the output speed of a motor without the need for
mechanical pulleys, thus reducing the number of mechanical
components and overall maintenance. But the biggest
advantage that a VFD has is the ability to save the user money
through its inherit nature to save energy by consuming only thethrough its inherit nature to save energy by consuming only the
power that’s needed. The main question now is, How does a
VFD accomplish this? The simple answer to this question is power
conversion.
A VFD is similar to the motor to which it’s attached, they both
convert power to a usable form. In the case of an induction
motor, the electrical power supplied to it is converted to
mechanical power through the rotation of the motor’s rotor and
the torque that it produces through motor slip. A VFD, on the
other hand, will convert its incoming power, a fixed voltage and
frequency, to a variable voltage and frequency. This same
concept is also the basis to vary the speed of the motor without
the need of adjustable pulleys or gearing changes
TECHNO SUPPORT ENGINEERS
6. Electrical
Electrical power is defined as the following:
Power (P) = √3 x Voltage (V) x Current (I) x Power Factor (PF)
In an ideal VFD, the following would hold true:
Powerin = Powerout
But because a VFD has inefficiencies and requires a small amount of
power consumption to power the brains of the drive, the input powerpower consumption to power the brains of the drive, the input power
will be slightly greater than the output power. For this, we will assume
that this extra power draw is negligible.
With these two equations, we can then define the relationship between
the VFD’s input and output:
Vin x Iin x PFin = Vout x Iout x PFout
Taking these equations into account, let’s use a 100-hp motor as an
example with the following properties:
Power = 100 hp
Speed = 1,785 rpm
Voltage = 460 V
FLA = 115 A
Power factor = 0.86
TECHNO SUPPORT ENGINEERS
7. “A VFD will convert its incoming power, a fixed voltage and frequency, to a variable
voltage and frequency.”
Assume that the motor is running at 60 Hz on a VFD, drawing a no-load current of 40 A
on the output of the VFD. With this, one would assume that the input current would also
be the same, 40 A. However, using an ammeter on the drive’s input, a person is reading
nearly zero amps! How is this possible? Is the drive creating power somehow? The
answer simply is no, the drive is not creating power. The power factor causes this
“discrepancy” in current When a motor is running at no load, the motor’s power factor
can be assumed to be zero, not 0.86 86 as stated on the nameplate. The reason thecan be assumed to be zero, not 0.86 86 as stated on the nameplate. The reason the
power factor isn’t at 0.86 is because this is the motor power factor at full load.
Alternatively, mechanical (friction) and electrical (resistive) losses in the motor prevent
the power factor from being zero when running no load, but we’ll assume these losses to
be zero just like we did for the VFD. Therefore, you would have the following:
Pout = 460V x 40A x 0
Pout = 0
Because the output power is zero, the input power also will be zero. With a fixed input
voltage, the two variables would be current and power factor. Because current is
needed for a power factor to exist, both current and power factor are zero, which
means the low input current reading is indeed correct.
This explains why the input current to the VFD is so low when the motor is operating
under no load conditions. But what about under load? The same concept still applies
when the motor is under load. For example, assume the same motor is now operating at
half speed, 30 Hz and producing full motor rated torque and drawing the motor’s full-
load amps (FLA). This means that the electrical power that the motor is drawing is
TECHNO SUPPORT ENGINEERS
8. Pout = √3 x 230V x 115A x 0.86 = 39.4kW
Because the VFD is a power converter, this means that the input current is (assuming a
0.89 input power factor from a 3% line impedance):
Iin = (39.4kW) / (√3 x 460V x 0.89) = 55.6A
Because the VFD is operating at half speed and under full load, the input current is less
than half of the output current.
Power Voltage Current Frequency PF
In this example, the input current is less than half of the output, a result of having a
higher power factor on the input side.
The difference in power factor between the input and output side of the motor is what
makes it possible to have a higher output current than input current. Assuming the motor
is now running at full load and using the same power factor values, your input current
now becomes:
Iin = (√3 x 460V x 115A x 0.86) / (√3 x 460V x 0.89) = 111A
TECHNO SUPPORT ENGINEERS
Power
KW
Voltage
V
Current
A
Frequency
Hz
PF
Input 39.4 460 55.6 60 0.89
Output 39.4 230 115 30 0.86
9. which is 4 A lower than the output current.
If Then
PFin < Pfout Iin < Iout
PF = Pf I = IPFin = Pfout Iin = Iout
PFin > Pfout Iin > Iout
Mechanical
The current a VFD draws on the input side
also can be related to the mechanical
power a motor is delivering. The basic
relationship for motor power is as below .
TECHNO SUPPORT ENGINEERS
10. Powermechanical ∝ Speed x Torque
This means that if the motor is operating at half the speed
and producing full torque, the motor is outputting half of
its rated power. Consequently, if the motor is running at full
speed and producing half torque, the motor is also
outputting half of its rated power.outputting half of its rated power.
Because of motor losses, the power relationship between
the electrical power going into the motor and the
mechanical power is:
PowerElectrical = (Powermechanical) / (EfficiencyMotor)
Revisiting the above example, if the motor is operating at
30 Hz, half the motor’s rated speed and producing full
torque, then the mechanical power being produced is 50
hp. Assuming that the motor is 95% efficient, the electrical
power that’s required is:
PowerElectrical = (50HP x 0.746) / 0.95 = 39.3kW
TECHNO SUPPORT ENGINEERS
11. which means that the current on the input side of the VFD
will be approximately 55 A. This same current will also hold
true even if the motor is operating at full speed and
producing half torque. Ultimately, a VFD is merely a power
conversion device that converts the fixed voltage and
frequency of incoming power to a variable voltage and
frequency output to provide the variable speed
frequency of incoming power to a variable voltage and
frequency output to provide the variable speed
capabilities for which it was designed. Keep in mind the
variables associated with electrical power (voltage,
current and power factor) and their relationships when
comparing the VFD’s input to its output. This also will hold
true when using the motor’s mechanical power (speed
and torque) to determine the amount of input
power/current to the VFD. Taking all the variables into
consideration, one can be pleasantly surprised to find the
input current lower than the output current.
TECHNO SUPPORT ENGINEERS
12. We are having one year AMC free with installation of above control
panel (replacement of electrical components will be at customer’s
scope)
Improves Power Factor
Improves life of motor & bearings
Reduces maintenance cost
24 X 7 technical assistance24 X 7 technical assistance
Saving electricity approximately 40- 50% of your previous energy bills.
Easy for maintenance* ( 40 % to 50 % depends of HP capacity of motor )
Technical future adaptation possible if you need to change the process
parameters
Safety of your electric motor
Provision of Auto & Manual modes
RPM reading, voltmeter analog meter, phase indicators, emergency
stop
Aesthetical look of control panel with standard provision
TECHNO SUPPORT ENGINEERS
13. We firstly visit the factory premises to see
the actual technical requirements
Trial installation to the plastic injection
machine if requiredmachine if required
Total calculated difference of energy
saved
Provision of standard electrical
automation solutions
TECHNO SUPPORT ENGINEERS
14. Contact Us :
Email : info.techsuppen@gmail.com
sales.techsuppen@gmail.comsales.techsuppen@gmail.com
Facebook :
https://www.facebook.com/Techsuppen?fr
ef=nf
Linkedin
:https://in.linkedin.com/pub/techsuppen-
enterprises/b9/b22/b1a
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