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Industrial Motor Drives and Soft Starters Industrial motor drives and soft starters Industrial Solutions REV0819 1 Variable frequency drives (VFD) and soft starters in industrial applications: help improve motor life and energy efficiency HVAC/Chiller Fan Electric Hoist Variable Frequency Soft Drives Starters Pump Conveyor Compressor Confidential and Proprietary | Littelfuse, Inc. © 2019 2 VFDs and soft starters work on same principles, but have different architectures and are used in different applications Variable Frequency Drives Soft Starter ▪ Controls AC motor speed and torque by varying motor input ▪ Offers smooth start and stop operation for a motor voltage and frequency ▪ Gets bypassed by a contractor overload circuit as motor ▪ Can be programmed to vary the speed of the motor based reaches its full speed on factors such as flow, pressure, etc. ▪ Initial cost is lower than a variable frequency drive ▪ Complete control over motor speed can be achieved ▪ Effectively reduces inrush current during motor start. ▪ Performance more important than cost and size ▪ No harmonics are generated ▪ Energy saving is principle advantage ▪ Examples of applications: conveyors, pumps and other belt- ▪ Examples of applications: elevators, escalators, crushers, driven applications mixers, etc. Confidential and Proprietary | Littelfuse, Inc. © 2019 3 Variable frequency drives and soft starters market overview Market Trends Market Projections Variable Frequency Drive (VFD): ▪ The global VFD market is projected to grow @ 6% CAGR between 2018 -2023 ▪ Market is expected to reach $27.6B by 2023 ▪ 35% growth will come from APAC ▪ A key factor driving the growth is the need for more energy efficiency. ▪ Energy savings estimated to be over 20% ▪ Integrating IoT with VFDs for remote monitoring and controlling the devices Soft Starter: ▪ The global soft starter market is expected to grow at 6% CAGR between 2018 -2023 ▪ Market is expected to reach $2.0B by 2023 ▪ Increased use of industrial pumps and fans are key driving factors Source: Marketsandmarkets.com ResearchAndMarkets.com, Technavio.com Confidential and Proprietary | Littelfuse, Inc. © 2019 4 Protection and control solutions used VFD systems AC Input Protection: ⚫ AC Fuses ⚫ MOVs Input Rectifier Circuit: ⚫ Rectifier Module Inverter: ⚫ High speed fuse ⚫ TVS Diode ⚫ IGBT Module ⚫ Temperature sensor TVS: Transient-Voltage Suppression MOV: Metal Oxide Varistor IGBT: Insulated-Gate Bipolar Transistor Protect Control Sense Confidential and Proprietary | Littelfuse, Inc. © 2019 5 Illustration of typical three-phase VFD topology highlighting key protection and control components PSR Technology Product Series IV AC Fuses for higher JLS, JLLS, VI III TVS IGBT interrupt ratings LDC,L70QS Diodes Module I AC Fuses 606, 504, 505 I Fuse holder LFT, LFJ L1 II MOV TMOV L2 VII L3 NTC III Rectifier module MDD, VUO,VUB Fuses IV High speed fuse PSR V V TVS Diode AK3-380C II VI IGBT Module MIXA, MIXG MOVs PSR VII NTC USUR1000, SM IV Note: Ground Fault detectors should be used for AC Input Rectifier Inverter resistive grounded systems. Suggest: EL731. Confidential and Proprietary | Littelfuse, Inc. © 2019 6 Benefits of Littelfuse components recommended for VFDs Technology Function in Application Series Benefits Features AC Fuse for higher JLS, JLLS, Extremely current-limiting; Small footprint Reduces damage to equipment caused by interrupt ratings AC line fuses for overcurrent or short LDC,L70QS 200kA interrupting rating heating and magnetic effects of short circuit circuit protection I AC Fuses 606, 504, 505 currents; Compact design Smallest available package Fuse holder Supports fuse protection LFT, LFJ DIN Rail Mountable Low resistance connection Protect against damage due to Integrated thermal disconnect enhances TMOVs are UL Recognized Type 4 Surge lightning-induced surges or harmonic safety by disconnecting during MOV EOL Protection Devices. Integrated thermal MOV TMOV II voltage disruptions from the pow er caused by continuous abnormal overvoltage disconnect reduces risk of MOV overheating line. from miss w iring or loss of neutral and catastrophic failures Converts AC line voltage supplied to Package w ith DCB ceramic ;Very low Rectifier module MDD, VUO,VUB Compact design, better electrical isolations III the drive to DC. forward voltage drop & low leakage current, IV High speed fuses Overcurrent protection PSR Best in class DC Performance Buss Bar Mount Bi-directional, high pow er TVS Diode rated Secondary overvoltage protection Offers accurate low voltage clamping for 3kA (8/20µs) w ith a standoff voltage of TVS Diode especially for high pow er line voltage AK3-380C capability to provide differential protection to V 380V. Maximum clamping voltage of the tw o applications of 600V or higher the rectifier diodes, capacitor, and IGBT AK3-380C TVS Diodes is only 1040V Short circuit rated for 10µsec, low gate Rugged XPT design w ith thin w afer IGBT Module Sw itching power supplies MIXA, MIXG charge ,low EMI and competitive low VI technology Vce(sat) USUR is UL Recognized NTC sensor w ith Semiconductor Temperature Rapid thermal response and long time ring lug mounting; SM NTCs is in NTC USUR1000, SM VII Measurement reliability hermetically sealed MELF package suitable for operation up to 220°C Confidential and Proprietary | Littelfuse, Inc. © 2019 7 Protection and control solutions for soft starters AC input protection: ⚫ AC Fuses ⚫ MOVs Phase control: ⚫ SCR Modules ⚫ Discrete SCRs ⚫ Temperature Sensors SCR: Silicon Controlled Rectifier MOV: Metal Oxide Varistor Protect Control Sense Confidential and Proprietary | Littelfuse, Inc. © 2019 8 Protection and control components for soft starter topology Technology Product Series L50QS, L70QS, JLS, AC Fuse Y A I JLLS Fuse Holders LSCR, LFT, LFJ I III II MOV TMOV Dual SCR Module MCC Motor III Y B Discrete SCR N Capsule series IV NTC USUR1000, SM NTC IV Z C Fuses SCR Module MOVs II AC Input Phase Control Confidential and Proprietary | Littelfuse, Inc. © 2019 9 Benefits of Littelfuse components in soft starters Technology Function in Application Series Benefits Features Designed specifically for Reliable interruption of all over currents. Extremely Current Limiting supplementary protection of L50QS, L70QS, JLS, Less heating and pow er consumption Low Watt Losses AC fuses I semiconducting devices SCRs, diodes, JLLS Help reduce semiconductor failures from Controlled Transient Over-voltages IGBTs, and so on over-voltages UL Recognized Fuse holder Supports fuse protection LSCR, LFT, LFJ DIN Rail Mountable Low resistance connection Integrated thermal disconnect enhances TMOVs are UL Recognized Type 4 Protect against damage due to safety by disconnecting during MOV EOL Surge Protection Devices. Integrated MOV lightning-induced surges or harmonic TMOV caused by continuous abnormal II thermal disconnect reduces risk of MOV voltage disruptions from the pow er line. overvoltage from miss w iring or loss of overheating and catastrophic failures neutral Dual SCR Module MCC Space and w eight savings International standard package, JEDEC To control the application of supply Simple mounting w ith two screws TO-240 AA III Discrete SCR voltage to the motor N Capsule series Improved temperature and pow er cycling Isolation voltage 3600 V Reduced protection circuits UL registered USUR is UL Recognized NTC sensor Semiconductor Temperature Rapid thermal response and long time w ith ring lug mounting; SM NTCs is in NTC USUR1000, SM IV Measurement reliability hermetically sealed MELF package suitable for operation up to 220°C Confidential and Proprietary | Littelfuse, Inc. © 2019 10 Safety standards for machinery VFDs and soft starters Standard Title General Scope Region IEC 61800-5-2 specifies requirements and makes recommendations for the design Adjustable speed electrical pow er drive systems - IEC 61800-5-2 and development, integration and validation of safety related pow er drive systems Global Part 5-2: Safety requirements – Functional (PDS(SR)) in terms of their functional safety considerations. Safety of machinery – Electrical equipment of Covers both electrical safety and functional safety, and in respect of the latter it IEC 60204-1 Global machines – Part 1: General requirements specifies requirements for electrical control devices, circuits, and functions. Safety of machinery – Functional safety of safety- Specifies requirements and makes recommendations for the design, integration and IEC 62061 related electrical, electronic and programmable validation of safety-related electrical, electronic and programmable electronic control Global electronic control systems systems (SRECS) for machines Provides safety requirements and guidance on the principles for the design and Safety of machinery – Safety-related parts of control ISO 13849-1 integration of safety-related parts of control systems (SRP/CS), including the Global systems – Part 1: General principles for design design of software Low -voltage switchgear and control gear – Part 4-2: IEC 60947-4-2:2011 applies to AC semiconductor motor controllers and starters, IEC 60947-4-2 Contactors and motor-starters – AC semiconductor w hich may include a series mechanical sw itching device, intended to be connected to Global motor controllers and starters circuits, the rated voltage of w hich does not exceed 1000VAC UL508/CSA Cover industrial control devices, and devices accessory thereto, for starting, stopping, Standard for Industrial Control Equipment North America C22.2 No. 14 regulating, controlling, or protecting electric motors. Devices rated 1500 volts or less Low -voltage
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