SEPTEMBER 2020 MAINTENANCE
Automated
pumps can
perform
their own
maintenance
the wasted energy as heat. In
a fan application for instance,
VSDs reduce the airfl ow as per
requirements, rather than simply
cutting off the airfl ow while
remaining at maximum capacity.
While the current regulation
states that IE2 motors must be
used with a VSD, this has been
diffi cult to enforce. This explains
why the regulations are becoming
stricter. As of July 1, 2021, three
phase motors will need to meet
IE3 standards, regardless of any
VSD additions.
The 2021 changes are
also holding VSDs to higher
standards, assigning this product
group IE ratings too. They will
be expected to meet an IE2
standard, although an IE2 drive
does not represent the equivalent
effi ciency of an IE2 motor; these
are separate rating systems.
Installing a VSD is one thing;
using it to its full potential is
another. Many VSDs are packed
with useful features that plant
managers don’t know exist.
Pump applications are a good example. Fluid
handling can be turbulent, between leakages and
low fl uid levels, there’s a lot that can go wrong.
Built-in control, such as Pump Genius in WEG
VSDs, enables more eff ective use of motors based
on production demands and fl uid availability.
Automatic broken pipe detection in the VSD
can identify fl uid leakage zones and adjusts motor
performance accordingly. Additionally, dry pump
detection means if fl uid runs out, the motor is
automatically deactivated and a dry pump alert is
issued. In both cases, the motor reduces its energy
consumption when less energy is required to
handle available resources.
If using multiple motors in the pump
application, jockey pump control can also optimise
the use of diff erent sized motors. It may be that
demand requires just a small motor to be in use,
or a combination of a small and large motor.
VSDs can even perform automatic cleaning
of the motor impeller, to ensure deragging is
carried out consistently. This keeps the motor in
optimal condition which has positive eff ects on
energy effi ciency.
If you’re not happy to pay 30 times the motor
price in energy bills over a decade, it’s time to
make changes. They won’t happen overnight, but
a strategic plan that targets your most ineffi cient
pain points will result in signifi cant benefi ts.
slam your foot down on the gas
pedal when the light turns green,
you know this is an ineffi cient
and mechanically stressful way
to drive — as well as dangerous.
Similarly, for machine
equipment, a slower start
uses less energy and results
in less mechanical stress on
the motor and shaft. Over the
lifespan of the motor, a soft
starter provides cost savings
attributed to reduced energy
costs. Some soft starters also
have built in automatic energy
optimising. Ideal for compressor
applications, the soft starter
judges the load requirements
and adjusts accordingly to
keep energy expenditure to a
minimum.
Use a variable speed drive
VSDs adjust the speed of an
electric motor, based on the
application requirements.
Without this control, the
system simply brakes when
less force is required, expelling
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