Solutions with Frequency Converters

Festive Day at Gronbech & Sonnner

16 June 2016

Contents

1. Frequency Converter Basics

2. Impacts of the FC

3. Selected Applications

Modulating Duty Applications

UPS Applications

4. Additional Product Information

Frequency Converter

Basics

– integrated frequency converter

Conventional actuator

The „kitchen“

SUPPLY PROCESSING CONSUMPTION

– speed & tripping torque variation

Speed variation Tripping torque variation

Flexibility for Sizing and Planning

7 speeds and 8 torques = 56 possible operation points

– break-away torque reserve

Start-up current

Conventional actuators have a high start-up current

SEVEN actuators are equipped with integral frequency converters,

no start-up current is created.

VFD – rpm control

star/delta

direct starting

Conventional actuators

– integrated frequency converter

No direct connection to the power supply…

Impact of the Frequency Converter

Features

Tripping torque and output speed are adjustable

Minimum stress on the valve due to speed reduction

in the end position range (soft start – soft stop)

Speed variation during operation

The output torque is always constant

at -30% undervoltage to +20% overvoltage

from 40 Hz to 70 Hz

No start-up current

SEVEN actuators always have 3-phase motors

depending on size, power supply can be 1-phase or 3-

phase

Motor temperature is measured and monitored

No over-torque will be created in any case

(no tripping delay!)

– basic things to remember…

Benefits

Planning simplification

Wear on mechanical components is reduced

Valve maintenance/downtime reduced

Precise positioning, pipeline surge reduction

No oversizing is required to compensate

No danger of overtorque

Increased reliability

Cost savings for wiring, UPS and solar applications

Robust & cost efficient technology,

proven performance, no coasting

Secure operation, motors do not burn

No danger of creating stall torque,

valve sizing can be optimized, safe operation

– soft-start & soft-stop

Speed reduction in the end positions – go easy on the valve

Driving a valve at full speed into or out of its end position can cause

seat damage,

additional maintenance costs,

plant downtime.

The SEVEN with its integrated frequency controller automatically

reduces the motor speed

controls the torque

“gentle” operation – reduces wear

Speed changing – standard functions

Standard speed control

The output speed can be adjusted at any time

in 7 steps in the chosen speed range.

Customize what’s needed - when it’s needed !

Adjust the valve operating time to process necessities

Analog speed control option

Process oriented speed controlAdjust valve operating time – anytime!

With the "External analog speed setpoint“ function, the SEVEN can be operated

at different speeds without changing parameters:

Stipulate output speed by

a 0/4..20 mA signal

Can be combined with positioner

– option Positioner

Positioneroptimizes the process and relieves the valve

adaptive three-step controller

dead zone is constantly adapted to the quality

of the setpoint and feedback signal

greatest possible control accuracy

minimum switching frequency

optimizes the process and protects the valve

and pipeline from wear due to fewer switching cycles

Features:

Soft starting and electronic braking

Speed reduction before reaching the setpoint

Possible motor after-running is evaluated and optimized

Basic data:

Accuracy: ± 0.4%

Repeatability: ± 0.2%

Hysteresis: 0.4%

Adaptive positioner – when EMC „hits the fan“

Upward adaption

Minimizes switching cycles

caused by “noise”

control loop remains stable

Downward adaption

Minimizes deadband

Minimizes control deviation

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sig

na

l

Stroke-time-curve

Define time for a certain stroke

Can be defined independently for

OPEN and CLOSE direction.

This function is often used to minimize

water hammer.

Process oriented speed control

Stroke-speed-curve

Define speed for a valve position

Up to 10 different speed regions can be

specified along the length of the stroke.

Retry Torque Block

Function:

If a torque block occurs, the actuator can be programmed to

perform up to 5 retries in order to pass the block.

Standard: Retry stroke length is calculated automatically

Customized: Retry stroke length can be defined

– impact of the frequency converter

Resume: Speed variation – software features

Soft-start & soft-stop

Programmable for OPEN, CLOSE & EMERGENCY

Analog speed control

Positioner - speed reduction before reaching new setpoint

Stroke-Speed curve

Stroke-Time curve

Adjustable Rise Time (Acceleration)

Selected applications

Eefde lock, Netherlands – soft stop

2217 11 5

0

20

40

60

80

100

0 10 20 30 40 50 60 70 80 90

Po

sit

ion

[%

]

Time [sec]

SIPOS 5 Flash actuators on pump discharge valves

Water hammer prevention

Examples:

Booster pump station Colorado, USA Söder-City, Fortum, Sweden

Water hammer prevention & UPS systems…

This customer had three reasons to chose FC actuators:

No start-up current

Use of single phase actuators (low cost UPS)

Water hammer prevention with variable speed

Special setup for a pump station in Colorado

Pressure control and water hammer prevention

Customer comment:

“We have 7 SIPOS actuators

automatically controlling pressure

upstream of 7 valves during

sequential pump starts and stops.

It’s almost like a valve ballet.”

Reducing maintenance and down time - Denmark

Power plant customer :

”Costs on maintenance of expensive valve spindles is heavily reduced

with SIPOS due to soft start/stop”

Valve maintenance cycles have been extended from

once a year to once in 5 years. This saves costs and down-time.

Interesting applications - Denmark

Floodage and pollution prevention using SIPOS below the city of Aarhus.

1-phase power supply

UPS

SIPOS blocked in move variable travel functionality

Additional Product Information

Product range

SIPOS SEVEN rotary actuators are available

from simple ON-OFF to CONTINUOUS DUTY modulating actuators.

The actuators are designed according to EN 15714-2:

Duty classification SIPOS type

ON-OFF operation (Class A) 2SA70..

INCHING duty (Class B) 2SA73..

MODULATING duty (Class C) 2SA75..with up to 1,200 c/h

CONTINUOUS MODULATING duty (Class D) 2SA78..with up to 3,600 c/h

Product range

2SA70.. 2SA73.. 2SA75.. 2SA78..

Excerpt from EN 15714-2

SEVEN type

– the fact sheet

Ease of use:

A single control button for all functions

Simple upload / download of parameters via the USB port

Intuitive menu navigation via large color display

User selectable language

Efficient installation:

Process control set-up doesn’t require a mains power supply

Easy cloning of actuator parameters via the USB port

Reliable operation:

Temperature measurement and monitoring of motor and electronics

Long life with proven reliability – gear design according to stringent KTA standard

Multi-level password controlled access

Fully sealed electronics

– Details

Metal coverLarge Display window

(Makrolon or glass)

Improved ambient protectionCorrosion Class C5 I

IP68-3; Double Sealed

External USB A interface PROFITRON and HiMod

USB B internal for all actuators

Signaling gear or

encoderPrecision potentiometer or

absolute position encoder

Drive ControllerPush-turn user interface

– Mechanical Design

Features - benefits

Steel worm gear and steel worm shaft practically no wear

Low tolerance toothing accuracy

Torque monitoring without axial moving parts

Worm wheel and output hollow shaft are one piece no tolerances

Motor shaft and worm gear are joined form-fit no tolerance

Operating concept: Display & Drive Controller

Drive Controller features and benefits:

Single multi-functional control button:

Easy and intuitive actuator operation

Non-intrusive commissioning (electronics)

100% leak tight for long term reliability:

PROFITRON and HiMod display:

Large display in full color: easy to read from a distance

Screen orientation can be changed in 90° steps

Various display layouts, according to situation

Multi-lingual instructions with animations

ECOTRON: Clearly arranged segment display

and 6 status LEDs.

Operating concept: Display & Drive Controller