Motro & Drives - Spring Edition

MOTORS
& DRIVES
SP R I N G E D I T I O N
Contents
3 — Your questions answered: Motors and drives: Tips and
tools for efficient motor management
16 — British Motor Manufacturer since 1947
17 — XPlanar transports workpiece during plasma surface
treatment process
23 — Benefits and limitations of ac generator motors
26 — Motion Control: Beckhoff XPlanar — The Flying Motion
27 — Materials handling equipment
29 — Smartphones help with VFD configuration: Your questions
answered
37 — MOVISUITE® Engineering Software EN
38 — SEW-EURODRIVE’s MOVI-C Modular Automation System
41 — The ABCs of VFDs
2
Your questions answered: Motors
and drives: Tips and tools for Your questions answered:
Motors and drives: Tips and
tools for efficient motor
efficient motor management management
British Motor Manufacturer since

1947
Webcast presenter answers additional questions on motor management XPlanar transports workpiece
tips and tools. during plasma surface treatment
process
M otor-driven systems account for about half of all electricity generated in the Benefits and limitations of ac
generator motors
world and are likely the biggest energy users at your facility. Reducing energy
Motion Control: Beckhoff XPlanar
costs by improving these systems can be simple with improved motor management
— The Flying Motion
practices.
Materials handling equipment
Smartphones help with VFD

In a recent Plant Engineering webcast, available in its on-line archives, Michael Lyda,
configuration: Your questions
motor and drive engineer, Advanced Energy Corp. shared his expertise with attendees. answered
He discussed how to streamline motor management practices, quickly improve process MOVISUITE® Engineering Software
reliability and reduce energy costs. EN
SEW-EURODRIVE’s MOVI-C
Modular Automation System
Following the presentation, Michael answered questions from the audience. Below are
the questions, and Michael’s responses, that he was unable to address during the web- The ABCs of VFDs
cast because of time constraints.
The audience asked about purchase specifications and lifecycle cost analyses for elec-
tric motors, and operation and maintenance best practices. Variable frequency drives
(VFDs) were also covered, including basic operation, energy efficiency benefits and
potential applications.
3
Your questions answered: Motors and drives: Tips and tools
Your questions answered:

management

1947
XPlanar transports workpiece

during plasma surface treatment
process
Benefits and limitations of ac

generator motors


answered
MOVISUITE® Engineering Software

EN
Question: Please elaborate a bit on what Figure 1. A typical client witness test at
Advanced Energy. Clients witness testing at SEW-EURODRIVE’s MOVI-C
you referred to as the life of the VFD. Modular Automation System
the lab and multiple engineers participate.
Image courtesy: Advanced Energy The ABCs of VFDs
Lyda: Like motor life, VFD life depends on both
environmental and operating conditions. Keep the VFD in an ambient temperature
within its specification. Keep the cooling vents unblocked. Make sure the fan works as
it is supposed to. One thing to note on the VFD fan is that it may cycle on and off in
operation depending on current draw. Higher current will cause the VFD heatsink to
heat up more, so the fan may not be running at lower loads. There are also mainte-
nance best practices to follow for your VFDs, and I recommend consulting the manu-
facturer on those. 4

Question: Please compare the lifecycles of induction and PMAC invert- Motors and drives: Tips and
er-driven motors. tools for efficient motor
management

Lyda: Commercially available permanent magnet alternating current (PMAC) motors 1947
are relatively new in this market. Although the designs have been around for many
years, they have typically been built by special order only. Many manufacturers will during plasma surface treatment
have them in their catalogs these days, but they can be quite expensive and have very process
long lead times. We have completed testing at our lab on some PMAC motors but only Benefits and limitations of ac
generator motors
for efficiency-mapping and not for lifecycle or reliability. I would also be interested in
those results if test data is out there. Motion Control: Beckhoff XPlanar

Question: Is there a software tool for efficiently figuring real power
consumed by a motor? configuration: Your questions
answered
Lyda: Most measurement devices should come with some type of software. We use MOVISUITE® Engineering Software
Yokogawa high accuracy precision power analyzers in our lab with National Instruments EN
data acquisition hardware and LabVIEW software. One meter I like to use in the field SEW-EURODRIVE’s MOVI-C
for metering and verification is a Fluke 355. It will give you voltage, current and pow-
er factor. It is more expensive than a standard multimeter, but you can get real power The ABCs of VFDs
data since you are acquiring the power factor also.
Question: We have acquired a 250 HP AHU that will be equipped with

a VFD. Is there any maximum distance that applies from the VFD to
motor? Also, do I need filters for the harmonics?
Lyda: For this specific application, I would recommend consulting the VFD manufac-
5

management

1947

process

generator motors


answered

EN
turer. They can best advise on cable length and Figure 2. Large dynamometer used for The ABCs of VFDs
testing. It is rated for up to 300HP output
ancillary equipment needed, whether it be a line
at 1800 rpm. The motor coupled to the
filter, DC choke, load filter or other. dynamometer in this photo is a 200HP
engine. Image courtesy: Advanced Energy
Question: What is the maximum cable

distance between an ac motor and a VFD?
Lyda: This is all relative to the application. The shorter, the better, since longer cable
6

lengths will lead to higher peak voltage at the motor terminals. Consult the VFD manu-
facturer on a case-by-case basis. tools for efficient motor
management
Question: What are the differences between a “motor management British Motor Manufacturer since
1947
relay” and a “motor protection relay”?
Lyda: I have limited experience with these, but I think motor protection relay refers to process
a current overload relay that focuses on current alone. A motor management relay is Benefits and limitations of ac
generator motors
more involved and may have capabilities to monitor current and voltage. Thus, phase
sequence, overvoltage, undervoltage and voltage unbalance could all be monitored by Motion Control: Beckhoff XPlanar
this type of device. Advanced Energy has completed testing and research on two types
of these devices in the past: phase monitors and overload relays. If you would like
more information, please contact me. Smartphones help with VFD
answered
Question: Should we consider service factor for calculation of overload? MOVISUITE® Engineering Software
EN
Lyda: Service factor is meant for short-term overloading. If you run a motor at its SEW-EURODRIVE’s MOVI-C
service factor (e.g., 1.15 or 1.25) continuously, it will not likely last as long as it will at its
rated load. The ABCs of VFDs
Question: Please address motor cooling fans on VFDs. What is the

minimum speed before needing a separate fan motor to cool the VFD
motor? Does installing VFDs impact plant power factor?
Lyda: This will need to be looked at for each application. Inverter-duty motors should
have constant torque (CT) and variable torque (VT) ratings on their nameplates. As long
7

as your load is within these limits, additional
external cooling should not be needed. If tools for efficient motor
management
operating the motor outside of these speed/
torque ranges, the motor manufacturer British Motor Manufacturer since
1947
should be consulted. Installing VFDs adds
capacitance to the system, so if you have a during plasma surface treatment
primarily inductive load at the moment (i.e., process
a lot of motors), your power factor would Benefits and limitations of ac

generator motors
likely be improved by adding VFDs. If your
main loads are lighting, other capacitive Motion Control: Beckhoff XPlanar
sources or purely resistive sources, then
VFDs will not improve the power factor, and
could even make it worse. Smartphones help with VFD
answered
Question: Will an over-dimen- MOVISUITE® Engineering Software
sioned motor, driven by VFD, also EN
exhibit a low power factor? SEW-EURODRIVE’s MOVI-C

Lyda: Tough to say. A motor that is over- The ABCs of VFDs

Figure 3. Although many induction motors
sized for an application will generally exhibit a low
may be similar, the quality of the build will
power factor since the magnetizing current plays dictate reliability and life cycle. Motor build
a larger role in the total current draw. However, inspection analysis analyzes the quality of
the motor build and make recommendations
when you add a VFD, the capacitance of the sys-
on potential improvements. Image courtesy:
tem is greatly increased, so the power factor will Advanced Energy
be increased across all loads. I am not sure by how
much, though. We really could use some test data for a better answer.
8

Question: If there is a redundant motor & pump installed, what is best Motors and drives: Tips and
practice for operating the backup motor/pump? tools for efficient motor
management

Lyda: Lead lag process is popular for this. If you have a redundant or standby motor/ 1947
pump, you can alternate with the main to ensure even wear of both machines over
time. Each of the motor/pump combinations can take a turn as the standby and then during plasma surface treatment
pick whatever time period you think is applicable, by week, month or otherwise. process

generator motors
Question: Do belt-driven motors need needle bearings as opposed to
standard roller bearings? Motion Control: Beckhoff XPlanar

Lyda: Needle bearings would typically be used for either very high-speed or very low-
load applications. They are more common in the automobile industry. For belt-driven
motors, you should use roller bearings as opposed to standard ball bearings. answered

Question: Is it typical to see complaints of electrical noise (e.g., prob- EN
lems with controls, etc.) related to the deployment of VFDs? SEW-EURODRIVE’s MOVI-C
Lyda: Yes, this can be quite common. This is one reason you should use VFD-specific The ABCs of VFDs
cables for any VFD-to-motor connections. Most VFD manufacturers recommend this
anyway, and the cables are more expensive than standard ones, but you can mitigate
some noise issues by using them.
Question: How do we derate a motor for 115°F Texas ambient + 10°F

inside a boiler room? (I need a 55°C motor, but they are not normally
available.)
9

Lyda: I would think if you Motors and drives: Tips and
are running above the rated tools for efficient motor
management
ambient then you should
derate the motor tempera- 1947
ture rise. In other words,
if you had an Insulation during plasma surface treatment
Class F motor at 40°C, the process
temperature rise should Benefits and limitations of ac

generator motors
typically be 105°C or less.
Bringing the ambient up to Motion Control: Beckhoff XPlanar
55°C would mean the tem-
perature rise should be der-
ated to 90°C or less. As far
as derating the horsepower answered
Figure 4. When grid power is fed to an
output, I have no idea. I think the manufacturer MOVISUITE® Engineering Software
electric motor a clean sine wave is seen.
should give you advice on that. Here is one other EN
Once a variable frequency drive (VFD) is
thing that may work: If you are currently using a added to the circuit, the capacitive nature SEW-EURODRIVE’s MOVI-C
of the VFD will lead to voltage and current Modular Automation System
Class F insulated motor, upgrading to a motor that harmonics in the system. This is a waveform
is Class H insulation may give you a higher allow- The ABCs of VFDs
taken at the input VFD terminals with a fully
able running temperature. loaded electric motor connected to the
VFD output (size unknown). Image courtesy:
Advanced Energy
Question: My utility is supplying unbal-
anced phase voltages (5% at times). Any advice on how to convince
them to fix this and what the cost of the present situation may be in
terms of premature motor failure?
10

Lyda: Per the power purchase agreement, a utility should be held to a higher stan- Motors and drives: Tips and
dard than 5% unbalance (most that I have reviewed state 2-3%). I would contact them tools for efficient motor
management
directly to send a licensed professional to meter and verify the voltage at your facility.
If they refuse, you will need to measure and verify yourself or hire a third party. If your 1947
motors are running at this high of an unbalance for long periods of time, it is definitely
costing money in the long run. A common industry adage is “7% current unbalance for during plasma surface treatment
every 1% voltage unbalance.” At 5% voltage unbalance, it is likely that at least one of process
your three-phase line currents is well beyond the rated amount at each actual motor. Benefits and limitations of ac
generator motors
Question: For a 50HP motor, how much energy does the motor con- Motion Control: Beckhoff XPlanar
sume when running no load? Does it make sense to shut down the mo-
tor when it is not running? What about the wearing that comes from
frequent restarts? configuration: Your questions
answered
Lyda: At no load, a 50HP motor will likely still consume 1-2kW (at very low power MOVISUITE® Engineering Software
factor). However, you likely do not want to shut the motor off completely if you have EN
a frequent restart application. This is where a VFD and process control can really help SEW-EURODRIVE’s MOVI-C
you out. When a load is not needed, the VFD will slow the motor to stop, and when it
is needed, the VFD can ramp the motor up without an extreme inrush current (like what The ABCs of VFDs
happens at line-starting).
Question: At what point does a soft-start on a motor pay for itself?

Is there a break point for applying soft starters based on motor
horsepower?
Lyda: Not sure. I think this is facility- and application-specific, depending on incoming
11

transformer size and frequency of motor starts plantwide. Soft starters can be benefi-
cial if all you are trying to do is reduce inrush current. For real energy savings, spend tools for efficient motor
management
extra capital upfront and install (and program) a VFD instead.
1947
Question: You mentioned that an oversized electric motor is ineffi-
cient. Does a VFD overcome this inefficiency for load matching? during plasma surface treatment
process
Lyda: For a variable load application, a VFD can be programmed to reduce the speed Benefits and limitations of ac
generator motors
of the motor while lower loads are required. Reducing the speed of the machine
provides energy savings based on the affinity laws. However, if you are starting from Motion Control: Beckhoff XPlanar
scratch, the VFD and motor should match the necessary load as close as possible for
maximum energy efficiency. Keep in mind, a larger motor will have higher magnetizing
current than a smaller one. For instance, if you have a 5HP application and use a 10HP Smartphones help with VFD
motor, you are not getting the efficiency you should be at only 50% load, and you’re answered
getting higher kW usage due to the higher current draw. MOVISUITE® Engineering Software
EN
Question: What will be the power factor when we measure at line side SEW-EURODRIVE’s MOVI-C
of the VFD?
The ABCs of VFDs
Lyda: VFDs generally improve power factor of the system since the capacitance of
the VFD “offsets” inductance of the motor and distribution lines. If the VFD is proper-
ly sized and the motor is running close to full load, the power factor should be high.
However, not all VFDs are created equal. I have witnessed multiple VFDs over the years
that show poor line side power factor.
Question: How do VFDs reduce motor life? Should motors with a spe-
cific insulation class be used with VFDs? 12

Lyda: There are many ways VFDs
| AT11-20USA |

reduce motor life. I covered quite tools for efficient motor
: Gain unrivaled a few in the presentation. One
management

flexibility and throughput! way is by overheating the motor.
From experience in the lab, when
1947
Flying 2D product transport with up to 6 degrees of freedom XPlanar transports workpiece

running a motor at 60Hz grid during plasma surface treatment
power and then running the same process
motor at 60Hz from a VFD, a 10 Benefits and limitations of ac

generator motors
to 15° temperature rise is expect-
ed. I advise using at least Class F Motion Control: Beckhoff XPlanar
insulation, and maybe even Class
H, with VFD-driven motors. Also,
make sure the motor is invert-
Levitating
planar movers
6D
motion
er-duty. answered
kg
Scalable
payload
Velocities
up to 2 m/s
Individual Free system
Question: Are VFD manu- EN
product transport layout
facturers able to give the SEW-EURODRIVE’s MOVI-C
harmonics configuration to
simulate the harmonic dis- The ABCs of VFDs
www.beckhoff.com/xplanar
XPlanar enables new dimensions of freedom in product and material handling: Levitating planar movers
tortion reports for utilities?
fly over flexibly arranged planar tiles accommodating nearly any track layout and path planning.
Individual 2D transport at up to 2 m/s
Lyda: Harmonics will be greatly

Processing with up to 6 degrees of freedom
Transport and processing in one system
Wear-free, hygienic and easy to clean
Free arrangement of planar tiles enabling totally customized machine and process layouts
Multi-mover control enables parallel and individual product handling
impacted by the size of the power
Fully integrated into the powerful and standardized PC-based Beckhoff control system
(TwinCAT, PLC IEC 61131, Motion, Measurement, Machine Learning, Vision, Communication, HMI) supply at your facility as well as
For use across all industries: assembly, packaging, food/bev, pharma, laboratory, entertainment, …
your incoming voltage. If a VFD

manufacturer knows the size and
13

impedance of your incoming transformer and your precise input voltage, they should
be able to supply the harmonic content of their product. Consult the AHRI Certified tools for efficient motor
management
list for VFD manufacturers if you want to see harmonic values submitted for actual VFD
products. British Motor Manufacturer since
1947

Question: What is the definition of “short” with regard to cable during plasma surface treatment
length? process

generator motors
Lyda: Unfortunately, this is all relative. The shorter, the better in every case. NEMA
MG-1 lists recommendations for dv/dt limits. Dv/dt is a better way to judge the VFD Motion Control: Beckhoff XPlanar
quality to a specific motor application than just cable length.
Question: Do you know of good general data for motor efficiency at Smartphones help with VFD
various loads and speeds when driven by a VFD? answered

Lyda: Motor efficiency data with a VFD is hard to find, although we do this type of EN
testing often in our lab. Unfortunately, most of the results are proprietary. If you look SEW-EURODRIVE’s MOVI-C
at the AHRI Certified list for VFD manufacturers, you will find system efficiencies that
these manufacturers have submitted for their products with motors: The ABCs of VFDs
Question: Can a VFD be connected to any 3-phase motor with 3

leads?
Lyda: Generally speaking, yes. However, make sure the VFD matches the voltage,
current and frequency ratings of the motor. Just installing a VFD into an application will
not do much for you, though. I would advise the motor should be inverter-duty before
14

using a VFD. It is also good practice to use shaft grounding and have at least a Class F
insulation rating. Finally, the VFD will need to be correctly programmed after installa- tools for efficient motor
management
tion to verify you are achieving proper process control and desired energy savings.
1947
Question: We are finding a large number of equipment sets that use
multiple induction motors in situations that range from no load to full during plasma surface treatment
load, applied in short time frames on a frequent basis. Metering shows process
terrible power factor, voltage irregularities, and undesired harmonics. Benefits and limitations of ac
generator motors
Solutions that fit within the existing control scheme and physical spac-
es are a challenge. Any thoughts? Motion Control: Beckhoff XPlanar

Lyda: Are you currently using VFDs? If not, this could offset some of the power factor
and voltage irregularities while also keeping the inrush current of individual motors Smartphones help with VFD
lower. Using one VFD to control multiple motors or using many VFDs and a program- answered
mable logic controller (PLC) are both options. MOVISUITE® Engineering Software
EN
Advanced Energy offers trainings throughout the year. We work with electric utilities, SEW-EURODRIVE’s MOVI-C
government and a wide variety of private organizations in the residential, commercial
and industrial, solar, motors and drives, and electric transportation markets. Our cus- The ABCs of VFDs
tomized services include research, testing, training, consulting and program design.
To be notified of upcoming trainings, feel free to send me your email address and I will
add you to our newsletter list.
Michael Lyda
Michael Lyda, motor and drive engineer at Advanced Energy Corporation.
15
British Motor Manufacturer since 1947

and drives: Tips and tools for
efficient motor management
British Motor Manufacturer

since 1947

process

generator motors

 Smartphones help with VFD

answered

EN
The ABCs of VFDs

British Motor Manufacturer since 1947
16
XPlanar Floating planar system from Beckhoff helps
Plasmatreat simplify transportation of sensitive
workpieces
transports
workpiece during P lasmatreat GmbH, a Steinhagen, Germany-based
manufacturer of plasma systems for high-efficiency
surface treatment and environmentally friendly production
plasma surface
processes, recently unveiled a new plasma treatment unit.
A key innovation with this treatment unit is that it uses
XPlanar, a planar motor system from Beckhoff Automation,
treatment process to transport workpieces with high precision and flexibility.

XPlanar replaces prior systems used to move often sensi-
tive workpieces such as PCBs and eliminates the need to
install complex six-axis robots
and linear motors.
The plasma treatment unit

can surface-treat a variety of
material samples in a two-
stage process, according
to Jochen Stichling, Head
of Design at Plasmatreat.
Jochen Stichling, Head of Design
“During the first stage, the at Plasmatreat: “When it came
substrate is moved under a to custom-programming mover
Uwe Prüßmeier, Senior Product travel routes, there was no
nozzle for cleaning and acti-
Manager Drive Technology, XTS, vation. During the second, a
real alternative to XPlanar.” (©
Plasmatreat, Germany)
XPlanar, Beckhoff Automation
XPlanar transports workpiece during plasma surface treatment process

separate nozzle applies a func- and drives: Tips and tools for
tional coating,” Stichling says. efficient motor management
This, he explains, is where the British Motor Manufacturer since

1947
company focused its innova-
tion efforts: “We wanted a fast, XPlanar transports workpiece
during plasma surface
fully programmable, wear-free treatment process
system to transport the work-
pieces. And when it came to generator motors
custom-programming of tracks Motion Control: Beckhoff XPlanar
and travel there was no real — The Flying Motion
alternative to XPlanar.” Materials handling equipment

Planar motor system configuration: Your questions
answered
with floating movers
The XPlanar system consists EN
of planar tiles that can be
XPlanar eliminates the need to move the SEW-EURODRIVE’s MOVI-C
arranged in any pattern, combined with contact- plasma jet; instead, a floating planar mover
less movers that float over them and provide ex- carries the workpiece exactly into position The ABCs of VFDs
ceptionally fast, flexible and precise positioning. for precise surface treatment.
(© Plasmatreat, Germany)
The movers operate jerk-free and are capable of
traveling at speeds of up to 2 m/s; they can also
accelerate at 2 g and be positioned with a repeatability of 50 µm – silently, and without
wear or abrasion. The system not only supports movement within the x-y space, but it
also provides additional functions to allow mover positioning with up to six degrees of
freedom when necessary:
18

• raising and lowering by up to 5 and drives: Tips and tools for
mm (unloaded), with weighing ca- efficient motor management
pabilities available as an option British Motor Manufacturer since

1947
• tilting by up to 5° when transport- XPlanar transports workpiece

ing and handling liquids treatment process
• rotation of 360° over all planar tiles generator motors

The XPlanar system in the Plasmatreat — The Flying Motion
machine consists of six 240 x 240 mm Materials handling equipment

planar tiles and a single planar mover. Smartphones help with VFD
answered
XPlanar increases flexibility
while reducing mechanical EN
complexity SEW-EURODRIVE’s MOVI-C
A major advantage Plasmatreat gained Modular Automation System
by implementing XPlanar is that the plasma jets used to Plasmatreat’s new plasma The ABCs of VFDs
treatment unit is highly compact
treat surfaces no longer need to be moved and, as a re-
as it no longer requires a six-axis
sult, can now be installed in fixed mountings. The jets are robot or additional linear axes. (©
complex, both mechanically and electrically, and the abil- Plasmatreat, Germany)
ity to move the workpieces rather than the plasma jets

themselves reduces wear to the feed lines. Stichling sees additional benefits from the
increased flexibility too: “We can attach a variety of material samples to the mover for
treatment using just simple adapters. We can easily add processing stations alongside
the plasma jets – markers for good parts, for instance, or optical sensing heads to con-
19

duct full part inspections – and
| AT11-20USA |

carry workpieces to them flexibly efficient motor management
: Gain unrivaled as needed. And XPlanar’s rapid British Motor Manufacturer since
1947
flexibility and throughput! acceleration also lets us move
material samples at high speeds; XPlanar transports workpiece
Flying 2D product transport with up to 6 degrees of freedom during plasma surface
with thin samples, for instance, treatment process
this helps minimize treatment
time with the fixed jet.” generator motors

According to Stichling, XPlanar’s — The Flying Motion
functional benefits are proving Materials handling equipment

valuable in a range of applica- Smartphones help with VFD
tions: “Conventional setups use configuration: Your questions
answered
Levitating 6D a six-axis robot or linear motors
planar movers motion
Scalable Velocities
to move a plasma jet around a EN
kg payload up to 2 m/s
stationary workpiece. From a cost
Individual
product transport
Free system
layout
perspective, XPlanar comes in Modular Automation System
somewhere between linear-axis The ABCs of VFDs
and robotic systems. With flat
www.beckhoff.com/xplanar parts that don’t require much
XPlanar enables new dimensions of freedom in product and material handling: Levitating planar movers
fly over flexibly arranged planar tiles accommodating nearly any track layout and path planning.
Individual 2D transport at up to 2 m/s
vertical travel on the z-axis, where
robotic systems are usually ideal,
Processing with up to 6 degrees of freedom
Transport and processing in one system
Wear-free, hygienic and easy to clean
Free arrangement of planar tiles enabling totally customized machine and process layouts
Multi-mover control enables parallel and individual product handling
XPlanar offers an excellent alter-
native to gantry-type systems.
Fully integrated into the powerful and standardized PC-based Beckhoff control system
(TwinCAT, PLC IEC 61131, Motion, Measurement, Machine Learning, Vision, Communication, HMI)
For use across all industries: assembly, packaging, food/bev, pharma, laboratory, entertainment, …
XPlanar’s advantages in terms of
lack of wear, easy cleaning and
20

clean-room compatibility also play and drives: Tips and tools for
out here.” efficient motor management

1947
For Stichling, XPlanar has the po-
tential to optimize plasma surface XPlanar transports workpiece
treatment in two key areas, going treatment process
forward: direct integration of in-line
testing for full inspections during generator motors
the treatment process, and cus- Motion Control: Beckhoff XPlanar
tom-programmable mover travel — The Flying Motion
routes for end customers. Materials handling equipment

Another advantage for Plasmatreat was that it took less Christian Buske (right), CEO of configuration: Your questions
answered
than two months to integrate the XPlanar system into Plasmatreat, and Hans Beckhoff
(left), owner and Managing MOVISUITE® Engineering Software
its machine – not least because Beckhoff was quick to Director of Beckhoff Automation, EN
supply the 3D data and the electrical connection infor- were delighted by the successful
unveiling of the XPlanar-based
mation that enabled the company to rapidly incorporate Modular Automation System
plasma treatment unit at the K 2019
the XPlanar starter kit into its machine design. XPlanar, trade show in Düsseldorf, Germany. The ABCs of VFDs
according to Jochen Stichling, has proved to be both ro- (© Plasmatreat, Germany)
bust and reliable. And another advantage, he points out,

is that the entire plasma treatment cell has now been fully automated using PC-based
control, making it a complete system solution from a single source.
Further information:
www.plasmatreat.com
www.beckhoff.com/xplanar
21
generator motors Your questions answered: Motors
AC generator motors have advantages such as simple design and not British Motor Manufacturer since
1947
requiring matching voltages, but they do have some drawbacks such as
higher levels of insulation. during plasma surface treatment
process
M ost commercial areas rely on ac to power a wide range of electrical appliances

and pieces of equipment. AC results from the movement of the electrical charge
through a medium. The direction of movement varies over time. This variation is not
generator motors
the case with DC since it only involves a single direction for its movement.
AC generator basics Smartphones help with VFD

An ac generator is a type of electromagnetic device, responsible for converting me- answered
chanical energy into electrical power, essential in electromagnetic induction applica- MOVISUITE® Engineering Software
tions. This device comes with a rectangular coil of wire, and this component rotates EN
on an axis. Moreover, this coil lays between the poles of the two permanent magnets. SEW-EURODRIVE’s MOVI-C
With the rotation of the coil, this leads to the changes in the magnetic field. Thus, the
process generates an electromotive force between the coil’s ends. The ABCs of VFDs
Benefits of ac generators
AC generators provide several benefits to a user’s facility including:
Simple design
For the most part, an ac motor comes with a simple design since it only contains a sin-
gle moving part, the rotor. AC motors are easier to maintain as a result. They are also
cheaper to own and have quieter operation. They also have a longer life compared to 23
Benefits and limitations of ac generator motors

dc motors. In fact, dc motors and drives: Tips and tools for
have carbon brushes and a com- efficient motor management
mutator that tend to wear out British Motor Manufacturer since

1947
over time. These have to be re-
placed throughout the life of the XPlanar transports workpiece
motor. There is also a loud noise process
and a distinct smell typical with
a dc motor due to the friction generator motors
produced by its components. Motion Control: Beckhoff XPlanar
Matching voltage not neces- Materials handling equipment
sary Smartphones help with VFD

For optimal use, it is important for a dc generator to produce a voltage at a certain answered
level. The ac generator allows the user to convert the current to another voltage using
a transformer. In fact, transformers are compatible with ac, but not with dc. EN
Limitations Modular Automation System
While ac generators have benefits, there are also some limitations to consider including: The ABCs of VFDs
Greater insulation required

There is a higher level of insulation due to the massive voltages required to supply a
fixed amount of power from an ac motor. As a result, there is the challenge in the safe
handling of ac generators. Working with ac may pose some difficulties and risks, as
compared to what you can expect from dc motors.
Transformer use 24
Benefits and limitations of ac generator motors

While it may also be an advantage, the need for a transformer can also be a limitation and drives: Tips and tools for
for ac generators. For instance, the motors need a special design that prevents the efficient motor management
discharge of the higher voltage generated on one side. Since it is not possible for an British Motor Manufacturer since
1947
efficient way to generate high voltages, it is necessary to use a transformer to ease
long distance transmission. This transmission occurs once the low voltage converts to a XPlanar transports workpiece
much greater level necessary. process

Issues involved generator motors
AC power may be susceptible to sparks and overheating due to its production of high Motion Control: Beckhoff XPlanar
currents. Such phenomenon results in electric shock and fires. These fires are detrimen-
tal to properties and lives of your employees. Besides these safety risks, ac generators Materials handling equipment
appear to be less durable considering its need to produce massive currents resulting in Smartphones help with VFD
such hazards. answered

Bottom line EN
Just as with dc, there are benefits and drawbacks involved in the use of an ac genera- SEW-EURODRIVE’s MOVI-C
tor. Overall, though, the advantages of ac appear to outweigh the limitations involved. Modular Automation System
The ABCs of VFDs

David Manney
David Manney is a marketing administrator at L&S Electric. This article originally ap-
peared on L&S Electric Watts New Blog. L&S Electric is a CFE Media content partner.
25
Motion Control: Beckhoff XPlanar — The Flying Motion


1947

process

generator motors
Motion Control: Beckhoff

XPlanar — The Flying Motion


answered

EN
Motion Control: Beckhoff XPlanar — The The ABCs of VFDs
Flying Motion
Beckhoff is revolutionizing drive technology with the eXtended
planar motor system. Free-floating planar movers move jerk-free
and without contact over arbitrarily arranged planar tiles, thus
enabling the wear-free transport of products – noiselessly and
without mechanical abrasion and the generation of particles.
26
Materials I f your business involves manufacturing, warehousing or
distribution, materials handling is something you proba-
bly live and breathe every day. The smooth running of any
handling warehouse or factory operation depends on raw, compo-

nent and finished materials being processed efficiently and
equipment safely and getting this right can help a business gain a real
competitive advantage.
We live in a 24-hour economy and intrinsic to a successful

‘always-on’ operation is an efficient process supported by
the right equipment. Materials handling equipment comes
in many varieties; from hand-operated units through to spe-
cialised motorised systems for handling drums, reels, pack-
ages and glass. The right handling equipment, positioned
correctly in a process workflow, can save a business time,
increase productivity and maintain health and safety.
Packline Materials Handling has been designing and manu-

facturing lifting and handling equipment since 1993 from its
headquarters in Poole, UK. The company’s ‘Compac’ range
of stainless-steel roll, reel and drum handling equipment
is ideally suited to clean room environments and Packline
has established itself as the leading supplier of materials
handling equipment to the food, drinks, dairy, pharmaceu-
tical and medical processing industries. The company has
earned an enviable reputation around the world for devel-

oping custom materials and drives: Tips and tools for
handling solutions that efficient motor management
enable Packline custom- British Motor Manufacturer since

1947
ers to improve productiv-
ity and enjoy a real com- XPlanar transports workpiece
petitive advantage. process

Packline initially contact- generator motors
ed Parvalux during 2006 Motion Control: Beckhoff XPlanar
seeking a new drive sys- — The Flying Motion
tem partner. To meet the Materials handling equipment

performance specifica- Smartphones help with VFD
tion needed in Packline’s configuration: Your questions
answered
product range, a number
of modifications were made to the Parvalux PM50-63 DC motor and GB4 gearbox com- EN
bination and a sample was built and sent to Packline for testing and evaluation by their
development team. This combination has proven to be highly successful, underlining Modular Automation System
the capability and reliability of the Parvalux drive unit and it remains specified by Pack- The ABCs of VFDs
line to this day.
Packline’s Managing Director, Paul Winter, says; “We’ve worked with Parvalux for a num-
ber of years now and they are a partner we trust. They take the time to understand what
we’re trying to achieve and have developed excellent drive solutions that enhance the
‘reliability comes as standard’ message every Packline customer has come to expect
from our brand.”
To find out more about Packline, please visit the company’s website: www.packline.co.uk 28
configuration: Your questions Your questions answered: Motors
answered British Motor Manufacturer since

1947

Additional answers provide more details about smartphone programming for during plasma surface treatment
variable frequency drives (VFDs). process
V ariable frequency drive (VFD) configuration by using a smartphone was the topic generator motors
of a recent webcast from Control Engineering and Plant Engineering, and the pre- Motion Control: Beckhoff XPlanar
senter provided additional answers to questions asked during the event, “VFD Config-
uration and Troubleshooting with a Smartphone: 10 Tips, 3 Applications, and a Demo.” Materials handling equipment

Michael Hall, product manager for mobile applications and technical communications, answered
Yaskawa America Inc., was the presenter for the webcast and answered the questions
below. EN
Question: What is Yaskawa DriveCloud, and what products does it Modular Automation System
support? The ABCs of VFDs
Answer: Yaskawa DriveCloud is free storage for your specific configuration informa-
tion pertaining to your drives. It allows you to store things like parameter sets, appli-
cation notes, photos, etc., unique to each of your Yaskawa drives with their own serial
number and your account credentials. Your information is secure and only accessible
by you. New products such as GA800 are supported in Yaskawa DriveCloud. Previous
generation products are not supported.
29
Smartphones help with VFD configuration: Your questions answered

Q: Why do I need an account for DriveWizard Mobile? and drives: Tips and tools for
A: Yaskawa DriveWizard Mobile offers parameter or application backup in the Yaska- British Motor Manufacturer since
1947
wa Drive Cloud so that data is available anytime and anywhere with internet access.
Parameter back-ups are connected to the drive serial number and your personal login,
which can only be done with a user account. Additionally, the account allows DriveWiz- process
ard Mobile to gain access to the latest drive parameter data and manuals. Benefits and limitations of ac
generator motors
Q: How do I register for Yaskawa Drive Cloud account? Motion Control: Beckhoff XPlanar

A: Yaskawa DriveWizard Mobile requires a personal user account in the Yaskawa Drive
Cloud. The account can be created from a browser using the registration form or from Smartphones help with VFD
the DriveWizard Mobile App on your mobile device. answered

EN
Q: What drive products are supported by DriveWizard Mobile?
A: New products such as GA800 are supported by DriveWizard Mobile. Previous gen-
The ABCs of VFDs
eration products are not supported.
Q: Are these Bluetooth-enabled devices verified to any security

standards? Are there any industries that have specific recommenda-
tions/requirements for security, such as NIST?
A: The Bluetooth interface for the GA800 ac drive is compliant with Bluetooth Stan-
dard Ver. 4.1 Single Mode (Smart). The device has a Bluetooth SIG Registered Certi-
30

fication. This is Yaskawa’s Cyber Security Statement from the product manual for the and drives: Tips and tools for
GA800 Bluetooth interface: efficient motor management

1947
“Users are responsible for network security regarding connectivity between this prod-
uct and the customer network or some other network. Users are responsible for es- XPlanar transports workpiece
tablishing and maintaining appropriate systems (such as firewalls, authentication, data process
encryption, and antivirus software) to protect the product, networks, systems, and
interfaces against any kind of security breaches, unauthorized access, interference, generator motors
intrusion, and loss/theft of data or information.” Motion Control: Beckhoff XPlanar
The National Institute of Standards and Technology (NIST) has published NIST Special Materials handling equipment
Publication 800-121 Revision 2 Smartphones help with VFD
answered
Guide to Bluetooth Security available here at this URL. There are other resources in
addition to NIST. EN
Q: Which version of Android OS, and smartphone modes can be Modular Automation System
used with Yaskawa app? The ABCs of VFDs
A: Yaskawa DriveWizard Mobile v3.1.0 requires Android 5.0 (Lollipop) or greater.
Q: If I don’t have an Android smartphone available can I use a USB

power pack to power the VFD?
A: DriveWizard Mobile for Android can use a Bluetooth or USB on-the-go (OTG) for
connection to the GA800 ac drive. No other connection method is approved by the 31

manufacturer. An Android phone has the ability to provide power to access the mem- and drives: Tips and tools for
ory of the drive so that you can read and write parameters, similar to accessing a flash efficient motor management
drive. The USB port is not intended to power the drive’s control circuit or provide pow- British Motor Manufacturer since
1947
er to program the drive via the keypad.
Q: How well do VFD manufacturers support VFD backup files from process
older firmware versions to the latest on the same drive model? Benefits and limitations of ac
generator motors
A: We can’t speak in any detail to the capabilities of other VFD manufacturers. Each Motion Control: Beckhoff XPlanar
manufacturer has its own strategy for VFD backup files. Yaskawa has various tools to as-
sist in restoring backup files from older firmware versions to the latest firmware for the
same drive model. The choice of tool varies for Yaskawa drive products. Smartphones help with VFD
answered
Q: How far can the Bluetooth signal send out? MOVISUITE® Engineering Software
EN
A: The Bluetooth interface distance for the Yaskawa GA800 ac drive is 10 m or nearer SEW-EURODRIVE’s MOVI-C
to the GA800 keypad. This distance may be limited by the smartphone or tablet speci-
The ABCs of VFDs
fications or shielding, such as a metal enclosure around the GA800 keypad.
Q: Is the Dr. Wizard mobile application usable with other Yaskawa

drives, IQ and P1000 VFDs? Is it usable with a USB cable connec-
tion?
A: DriveWizard Mobile is provided for use with GA800 Series ac drives and also for fu-
32
ture ac drives offered by Yaskawa. It is not compatible with iQ or P1000 series ac drives.

Q: Can we use this and drives: Tips and tools for
Bluetooth display in a
closed cabinet? British Motor Manufacturer since
1947

A: Our experience is that during plasma surface treatment
some customers have had process
success connecting by Blue- Benefits and limitations of ac

generator motors
tooth to a GA800 ac drive that
is totally enclosed (including Motion Control: Beckhoff XPlanar
keypad) inside a metal cabi-
net. Distance may be severely
limited to only a few feet or Smartphones help with VFD
less in such cases. There are answered
many factors, such as enclo- MOVISUITE® Engineering Software
sure material or enclosure EN
integrity type, that can affect SEW-EURODRIVE’s MOVI-C

Accessing the VFD’s HMI via a wireless or Modular Automation System
the radio signal strength. We recommend install-
Bluetooth connection to adjust settings
ing the GA800 keypad on the cabinet door for The ABCs of VFDs
or collect diagnostic data can negate the
best performance. need to suit up with personal protective
equipment (PPE). This is because the
operator can access the HMI without
Q: Would this app notify you of a fault opening the enclosure containing the VFD.
Courtesy: Yaskawa
when it happens?
A: DriveWizard Mobile can monitor drive status including fault conditions for the
GA800 when it has an active Bluetooth connection to the smartphone or tablet. Smart
devices with Android OS additionally support a wired USB-OTG connection. Remote 33

monitoring beyond the Bluetooth or USB connections is not supported. and drives: Tips and tools for
Q: How long will V1000 Microdrive be around, versus, GA800? British Motor Manufacturer since
1947

A: Yaskawa continues to make ac drives available for at least 5 years after a new gener- during plasma surface treatment
ation for that drive series becomes available. Spare parts are available for an additional process
5 years after production is stopped and repair for 10 years after that. Technical support Benefits and limitations of ac
is always available. A new series micro-drive that will improve upon the V1000 is on the generator motors
horizon for Yaskawa customers. GA800 series was recently released in January 2019. Motion Control: Beckhoff XPlanar

Q: Is there any effort underway to standardize an app for numerous
VFDs? Smartphones help with VFD
answered
A: DriveWizard Mobile is provided for use with the GA800 Series ac drives and new MOVISUITE® Engineering Software
EN
series ac drives we offer. Mobile app compatibility for previous generation drives is not
currently planned. However, at Yaskawa we are always evolving our designs to meet SEW-EURODRIVE’s MOVI-C
our customer needs. Thank you for this valuable feedback that we can consider for
The ABCs of VFDs
future development.
Q: Can I download parameters to my phone, and store them in a csv file?
A: DriveWizard Mobile exports a *.dwbkp file that can be opened directly by Drive-
Wizard Industrial PC tool and then it can be saved as Microsoft Excel file. Alternately,
the .dwbkp file can be unzipped as an XML file and opened by Excel with the default
Excel schema in tabular format.
34

Note: The *.dwbkp backup files only contain parameter settings that differ from the and drives: Tips and tools for
factory default settings. efficient motor management

1947
Q: Power over USB can be done from your laptop as well, correct?
A: Correct. The DriveWizard Industrial PC software can be used for power over USB process
programming for the GA800 ac drive. Benefits and limitations of ac
generator motors
Q: Can pre-programming via USB be done from a PC without Motion Control: Beckhoff XPlanar
3-phase power just like with an Android phone?

A: Yes. The DriveWizard Industrial PC software can be used for pre-programming of configuration: Your questions
the GA800 ac drive without three-phase input power. answered

EN
Q: Can you configure the RA800 drive on the phone offline?
A: DriveWizard Mobile can only edit the GA800 parameters during an active Blue-
The ABCs of VFDs
tooth or USB connection to the GA800. The file saved by DriveWizard Mobile (.dwbkp),
can be exported to DriveWizard Industrial for offline editing. DriveWizard Industrial has
an offline editing feature. Subsequently the .dwbkp file can be exported from Drive-
Wizard Industrial and imported back into DriveWizard Mobile. Modified parameters
are the only values contained within the .dwbkp file. The DriveWizard Industrial PC tool
has a full database of drive parameters which allows for offline editing od drive param-
eter files.
35

Q: Will you maintain the application over the product lifecycle? and drives: Tips and tools for
A: The DriveWizard Mobile app is a new evolving product for Yaskawa. There are no British Motor Manufacturer since
1947
plans to discontinue supporting this mobile app. Yaskawa plans to offer DriveWizard
Mobile support for all new generation ac drives.
process
Q: What is the resolution of the monitoring feature? Benefits and limitations of ac

generator motors
A: Trace settings are: Motion Control: Beckhoff XPlanar


• Sample rate: 20 milliseconds with a double sample rate option of 500 microsec-
onds Smartphones help with VFD
• Plots per screen: 1000 answered
• Continuous tracing is not available when double sample rate is selected. MOVISUITE® Engineering Software
EN
Michael Hall SEW-EURODRIVE’s MOVI-C

Michael Hall, product manager for mobile applications and technical communications,
Yaskawa America Inc. The ABCs of VFDs
36
MOVISUITE® Engineering Software EN


1947

process

generator motors



answered
MOVISUITE® Engineering
Software EN
MOVISUITE® Engineering Software EN The ABCs of VFDs
This engineering software for automation projects saves

time and money, and gets you where you want to be
intuitively and with ease. One software suite that can be
used for planning, startup, operation and diagnostics.
37
SEW- Can you please describe one innovative mo-
tor or drive that a machine builder would
EURODRIVE’s
find valuable, as well as the technology that
makes it work?
MOVI-C Modular SEW-EURODRIVES’s MOVI-C® modular automation sys-

tem is a flexible one-software, one-hardware automation
Automation platform that combines fully integrated drive components,

control electronics and automation software – all from one
System
source. The key to the MOVI-C platform is that each of
those components is designed to work together perfectly.
The MOVI-C platform utilizes our newest technologies –

from high efficiency asynchronous gearmotors to ultra-ef-
ficient permanent magnet servomotors. Machine builders
will appreciate the seamless integration and the availability
of proven and value-adding software kits tailored to the
customer’s application.
What specific applications or problems was

MOVI-C designed for?
Today’s engineers can quickly get overwhelmed with au-

tomation complexity. The MOVI-C platform has been de-
signed to simplify motion control and automation challeng-
es from basic to advanced needs and requirements– using
SEW-EURODRIVE’s MOVI-C Modular Automation System

controls and components designed and drives: Tips and tools for
to work perfectly together. efficient motor management

1947
The new MOVI-C product family is
designed to solve a wide range of XPlanar transports workpiece
motion control challenges ranging process
from standard shaft spinning ap-
plications like simple conveyors all generator motors
the way to complex multi-axis kine- Motion Control: Beckhoff XPlanar
matics and robotics - for beginner — The Flying Motion
or advanced level engineers. Our Materials handling equipment

approach: more parametrization, less programming. With this modular automation Smartphones help with VFD
platform, we cover decentralized control architectures as well as centralized approach- configuration: Your questions
answered
es, all the way to highly complex multi-axis systems. From the controller and inverter all
the way to the gearbox: automation made simple. EN
What makes the design of the MOVI-C automation platform Modular Automation System
unique? The ABCs of VFDs
Typically, engineers order control electronics from one source, software from anoth-
er, and drive components from yet another. Getting these building blocks all to work
together is another story. The MOVI-C platform offers a complete automation solution
– without all the headaches of mismatched components and complexity.
As an added benefit, our MOVIKIT® pre-built software modules are available for many
common motion control applications from simple to complex, even robot control. This
39
SEW-EURODRIVE’s MOVI-C Modular Automation System

makes it easy for engineers of all skill and drives: Tips and tools for
levels to do their own automation. efficient motor management

1947
What should users know about
the MOVI-C platform, whether during plasma surface treatment
it’s a rookie who’s unfamiliar process
with it or a veteran in need of a Benefits and limitations of ac

generator motors
refresher?
The MOVI-C platform is easy to deploy
and intuitive to start up. Plus, with standardized MOVIKIT pre-built application mod-
ules, there is very little programming required, even for advanced automation tasks. configuration: Your questions
MOVI-C also integrates with all major PLC manufacturers. answered

EN
Combining MOVI-C’s ease of use and MOVIKIT’s flexible pre-built modules is the most
intuitive way to integrate state of the art drive technology into your machine. Custom- SEW-EURODRIVE’s MOVI-C
ized solutions also include open loop, closed loop, functional safety, and decentralized
The ABCs of VFDs
applications. Communication compatibility includes Ethernet IP, PROFINET®, PROF-
INETSave®, EtherCat®, FSoE, and other standards.
40
The ABCs of VFDs
Find the right application to match the motor need and know the conditions and drives: Tips and tools for
for using a variable frequency drive (VFD).
1947
I nside of plants today, ac motors are becoming the industry standard. Many plants
are shifting to ac motors from hydraulic motors and in some cases dc motors when
powering heavy loads, which were more popular in the past. This shift can be at-
process
tributed to a variety of reasons and most have to do with cost. AC motors are more Benefits and limitations of ac
generator motors
compact and require less maintenance than a hydraulic motor or a dc motor with
brushes. Couple this with the more expensive hardware associated with a hydraulic Motion Control: Beckhoff XPlanar
motor, and it is apparent why more plant managers are moving to ac motors inside of
their operation.
With cost being a driving factor, operators need to have more precise control over the ac answered
motor. They need to be able to optimize its use so that there is not unnecessary, wasted MOVISUITE® Engineering Software
energy. It is important to understand the practical applications of a variable frequency EN
drive (VFD) to an ac motor. SEW-EURODRIVE’s MOVI-C

Among the questions to be asked: The ABCs of VFDs
• When is a VFD beneficial?

• Under what conditions should a VFD be used?
• What’s the difference between a VFD and a soft starter?
Understanding the answers to these questions will maximize the use and minimize the
cost of operating an ac motor in a plant setting.
41
The ABCs of VFDs

Full voltage starters, and drives: Tips and tools for
soft starters, and efficient motor management
VFDs British Motor Manufacturer since

1947
There are several ways to
power and control an ac mo- during plasma surface treatment
tor. In addition to a VFD, one process
could alternatively apply a full Benefits and limitations of ac

generator motors
voltage starter or a soft starter.
The most basic motor control Motion Control: Beckhoff XPlanar
involves utilizing a full voltage
starter. With this approach, full
voltage is applied to the mo- Smartphones help with VFD
tor and it ramps up to maxi- answered
mum speed as quickly as it can. MOVISUITE® Engineering Software
EN
The problem operators run into with a full voltage starter is the inrush of current can be SEW-EURODRIVE’s MOVI-C
up to seven times the full load current of the motor. For a very short period of time, a
very high in rush of current is applied to the motor and its control components. If a large The ABCs of VFDs
motor needs to do a frequent amount of starting and stopping, it can wear out equip-
ment faster and be a costly burden on the facility’s utilities.
In contrast, a soft starter eliminates this burden by reducing the load and torque output
to the motor. This approach allows the motor to ramp up at a speed that is determined
by a setting on the soft starter itself. An operator can set a specific ramp-up time, and
from the time it is turned on to the time designated, the motor runs at full speed. This al-
lows reduced current inrush, reducing the risk of premature failure and additional burden
42
The ABCs of VFDs

on the facility’s utilities. Soft starters are ideal for applications where speed ramping and and drives: Tips and tools for
torque control are critical components, and in piping systems where fluid changes speed efficient motor management
rapidly to avoid pressure surges. British Motor Manufacturer since

1947
A VFD takes this concept a step further by allowing the operator to always control the inrush XPlanar transports workpiece
current and the speed of the motor. The VFD can control the motor both during the start/ process
stop cycle and throughout its runtime. A VFD is necessary where complete speed control is
required and a key concern is energy consumption. A soft starter will be the less expensive generator motors
option, but in large horsepower situations, savings can be realized over time with a VFD. Motion Control: Beckhoff XPlanar
Basic VFD applications Materials handling equipment
Flow control is one of the most common applications of a VFD inside of a plant setting. Smartphones help with VFD
The ability to change the speed of a pump to control flow is paramount. System conditions answered
will often require a reduced flow rate. Dampers and valves often are used to accomplish
this reduction, but this strategy does not help energy conservation. Conversely, a VFD can EN
control flow rate while at the same time optimizing the energy required to do so. SEW-EURODRIVE’s MOVI-C
There may be a situation where an operator needs to run the motor at less than maxi- The ABCs of VFDs
mum speed at certain times of the day, but then crank it up faster at other times. This
is the real driver with the popularity of VFDs in today’s environment: saving energy and
reducing operational costs. If an operator is simply looking to run an ac motor at a con-
stant speed that is less than the motor’s full speed rating, a gearbox can be used. How-
ever, if an application is such that it is a variable torque load, a VFD is a fitting solution.
On a very basic level, for example, imagine an ac motor is used to run a fan on a cooling
tower. The faster the operator wants the fan to run, the more horsepower and energy it
will require. Due to the external environment shifting throughout the day, temperatures
43
The ABCs of VFDs

may cool. Because of this, perhaps the fan only needs to run at a speed that is less than and drives: Tips and tools for
what was required during a hotter part of the day. Costly energy is being wasted by run- efficient motor management
ning it at full speed when the task can be accomplished at a lower level. British Motor Manufacturer since
1947
Additional benefits XPlanar transports workpiece

In addition to cost savings due to energy conservation, most VFDs will allow the opera- process
tor to set different parameters to limit torque. This is done by limiting the output current Benefits and limitations of ac
on the motor. This desired outcome is completely driven by process. There is a need generator motors
to protect whatever it is that the motor is driving, and many pieces of equipment in the Motion Control: Beckhoff XPlanar
plant setting have mechanical limitations. Because of this, exceeding these limits by over
torqueing can lead to heavy damage or costly malfunction. Materials handling equipment

Most VFDs are manufactured to be extremely flexible so they can be configured to use answered
the inputs and outputs (I/O) that are integrated into them. These I/O can be used for
any number of different functions, including start/stop functionality, direction change, EN
constant speed selection, macro selection, speed adjustment, etc. Additionally, VFDs’ SEW-EURODRIVE’s MOVI-C
analog outputs can be configured to provide feedback to the plant control system for Modular Automation System
parameters, including power consumption, actual speed, frequency, torque, etc. If a The ABCs of VFDs
process changes, for example, and it now needs to be run at a different speed, the plant
control system can adjust the signal to the drive’s designated speed input.
In the case of flow control, VFDs have evolved to the point where many of them can be
integrated with a pump right out of the box using a pre-defined macro. In this case, a
flow meter would connect directly to a drive’s analog input. An operator may adjust the
desired flow remotely and the drive will maintain that flow by executing an internal PID
loop. Some drives allow the operator to set up flow schedules and may also be set up to
44
The ABCs of VFDs

bring additional pumps online as demand requires. and drives: Tips and tools for
A VFD’s built-in I/O is not the only way to control a drive. Many drives offer flexibility that British Motor Manufacturer since
1947
allows for a variety of different communications protocols that can control the VFD from
most manufacturers’ controllers. All standard protocols are available for most VFDs. This XPlanar transports workpiece
allows the operator to have bi-directional communications with one communications process
cable as opposed to multiple wires.
generator motors
Why is this important? By utilizing a single cable, as opposed to multiple wires, installa- Motion Control: Beckhoff XPlanar
tion costs are kept at a minimum and a much larger amount of data can be transmitted. — The Flying Motion
This data does not just apply to advanced control, but monitoring as well. Typically, op- Materials handling equipment
erators are looking to monitor the speed, torque, current, and temperature of the drive. Smartphones help with VFD
Far more data can be communicated over this one cable than a VFD’s built-in I/O can configuration: Your questions
answered
accommodate. When a situation calls for multiple pieces of data, involving numerous
I/O, many VFDs today can handle the requirement. EN
Finally, the maintenance benefits are a major part of the appeal of effectively utilizing a Modular Automation System
VFD for an ac motor in a plant’s operation. Maintenance costs can be lowered significantly The ABCs of VFDs
due to reduced wear and tear on the equipment because of controlled starts. Additionally,
in cases where applying a VFD to a motor eliminates the need for dampers and valves, the
maintenance costs of those pieces of equipment can be eliminated as well.
VFDs are continuing to gain popularity in the industry as the different benefits they provide
grow, most of which will be associated in one way or another with cost and energy savings.
Kevin Goodsell
Kevin Goodsell is an engineering manager at Valin Corporation. 45
Motors & Drives
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MOTORS

efficient motor management management

British Motor Manufacturer since

Smartphones help with VFD

cast because of time constraints.

Your questions answered:

British Motor Manufacturer since

XPlanar transports workpiece

Benefits and limitations of ac

Motion Control: Beckhoff XPlanar

Materials handling equipment

Smartphones help with VFD

MOVISUITE® Engineering Software

Your questions answered:

British Motor Manufacturer since

Materials handling equipment

data since you are acquiring the power factor also.

Question: We have acquired a 250 HP AHU that will be equipped with

Your questions answered:

British Motor Manufacturer since

XPlanar transports workpiece

Benefits and limitations of ac

Motion Control: Beckhoff XPlanar

Materials handling equipment

Smartphones help with VFD

MOVISUITE® Engineering Software

Question: What is the maximum cable

Your questions answered:

Question: Please address motor cooling fans on VFDs. What is the

Your questions answered:

a lot of motors), your power factor would Benefits and limitations of ac

exhibit a low power factor? SEW-EURODRIVE’s MOVI-C

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