The larger the asset, the more critical the lifecycle
How selecting the right large VSD helps keep long-term costs and downtime in check
The role of reliability and longevity of Large Variable Speed Drives (>100kW) and how the SD750 range saves time and money for heavy industrial power users.
Operational efficiency and system reliability are paramount in heavy industrial operations.
Common challenges faced when maintaining heavy industrial VSD include unexpected downtime and maintaining increasingly complex componentry arrangements. These put increasing pressure on the associated time and skills required to maintain and repair them.
Unsurprisingly, reliability and serviceability are major considerations in asset choices. When it comes to Large Variable Speed Drives (VSDs), the right Large VSD can reduce energy consumption, extend equipment lifespan, and optimise performance, which translates into cost savings and operational reliability for heavy industrial applications such as mining and manufacturing.
Considering the full lifecycle is crucial, as downtime can make the initial cost of these assets pale in comparison to the long-term benefits of reliability and efficiency.
The SD750 is our most flexible and extensive VSD series, designed with installation, commissioning and maintenance efficiency in mind.
Reducing wear and tear to maximise the longevity of industrial equipment is crucial for heavy industrial operations. Advanced motor protection features, such as dV/dt filtering, can prevent premature motor failure by mitigating electrical stresses that occur with the rapid switching of insulated-gate bipolar transistor (IGBT). Installing a low dV/dt VSD is now regarded as best practice, especially when long cable runs are used.
The SD750 range of VSDs effectively reduces the dV/dt value to 500-800V/μs, which minimises voltage peaks at the motor windings and high stresses on internal motor insulation.
By controlling dV/dt, these voltage spikes can be minimised, thereby reducing the occurrence of electrical discharge machining (EDM) currents. This helps in protecting the motor bearings and extending the lifespan of the motor.
Less frequent breakdowns mean less downtime and costly emergency repairs in operations that need to be operating 24/7.
Fig 1. No dV/dt Filter vs dV/dt Filter
Ease of servicing has been designed into each product in the range. The entire SD750 range is fully serviceable from the front, which can save hours as there is no need to move or significantly disassemble equipment to access key components. Quicker servicing leads to more effective use of skilled labour.
Simplified diagnostics delivered via a fully customisable, plain English display panel, where any variable of the drive can be monitored, paired with predictive maintenance, dramatically simplifies troubleshooting, making this process faster and allowing maintenance teams to quickly identify and address potential issues before they cause failures.
The SD750s unique cooling system design employs strategic component isolation. By separating the electronic components from the cooling zone and the input filter housing, the system optimises cooling and increases protection from contaminants, which leads to increasing the life of the equipment and less downtime.
The SD750 range is rated to IP54 as standard, providing robust protection against dust and water ingress for greater durability in harsh environments.
Fig 2. Full frontal access
Modularity of the power stage from 110kW means critical components are common and interchangeable, reducing spare part costs and ensuring critical components remain common and interchangeable.
The SD750 range is a cost-effective power solution, delivering installation cost savings too. The range’s ability to use unscreened cable up to 300 metres can reduce expensive screening requirements. A screened cable is more complex and requires additional skills for correct termination.
Also, unscreened cabling weighs less. When it comes to people lifting and manoeuvring cables, lighter cabling is easier and safer to work with.
By choosing a quality large VSD, when upgrading older motor control systems, many facilities can use their existing cabling infrastructure. The savings recognised can significantly reduce payback periods and help get efficiency projects over the CapEx line.
With a less complex installation process overall, commissioning times for SD750s are dramatically faster, and labour requirements are lower. Faster commission times mean operational readiness sooner.
Power quality features that are standard across the SD750 range to enhance site power quality and minimise negative impacts on electronic equipment include AC Line Reactors, RFI and dV/dt filters.
Built-in AC Line Reactors lower harmonic currents. This prevents distortion within the electrical system that might otherwise cause sensitive electronic equipment to malfunction and overheating of critical electrical infrastructure, such as cabling and switchboards.
RFI filters reduce the possibility of radio frequency interference.
The SD750FR model is a specialist low harmonic product. It can reduce harmonic distortion from 30-40% down to less than 5%, making it ideal for situations where engineers and consultants specify very low harmonic distortion levels at the drive.
The SD750 range is suited to high-temperature industrial environments, operating up to 50°C.
Overheating is a leading cause of failure of electronic components; for every 10°C increase, components can deteriorate by a significant amount. Reducing the risk of overheating minimises unexpected downtime that could impact production schedules and revenue.
Reliably operating at these high temperatures is due to the SD750s innovative cooling system, comprises of three-level separation of electronics components, cooling system and input filters. Keeping the electronics separate from the cooling air flow and from other areas of the drive, they may be more exposed to the environment, which keeps key electronic components cool.
Critical components of the SD750 range, such as the rectifiers and IGBT’s are purposely oversized for increased overload resistance and longevity. These components, combined with high-quality, oversized heatsinks, make the SD750 the ideal choice for the harshest environments.
The SD750 series from Power Electronics includes several models tailored to different industrial needs. Here’s a brief overview of the main models:
SD750 series provides the core elements of our range. The entire range addresses such common requirements as low dV/dt, smart mechanical design with greater power density, highly advanced motor-control algorithms and a removable memory unit for easy and advanced maintenance.
The SD750SP is a customised SD750 VSD with an increased DC range, adapted to work with AC or DC or hybrid supply. The SD750SP provides ultimate flexibility for your solar applications.
When space saving is a must, the SD750K or Kompakt series, with up to 2.5 times physical size reduction when compared with the SD750 Standard Series, is your go-to solution.
Based on the latest Active Front End technology, the SD750FR can regenerate the braking energy, reduce the THDi<5%, adjust the cosine phi and keep it constant at any load condition, and keep the motor voltage constant even when high input voltage drops occur.
Beyond supplying the market leading SD750s, Power Electronics keeps more stock in New Zealand than any other VSD supplier. Off-the-shelf stock for both spare parts and complete products being available locally, spread across our North and South Island offices, ensures short lead times for installations, fast part replacements and minimises downtime.
Power Electronics offers a three-year warranty on all AC motor control equipment, provides servicing options and customised on-site training for customers as needed.
Combined with deep expertise in heavy industrial sectors, we offer modular, scalable solutions that simplify integration and reduce upgrade costs.
Choosing the right Large Variable Speed Drive (VSD) to integrate into your operation can deliver long-term operational efficiencies. Reliable solutions designed to optimise performance, reduce maintenance costs, and extend equipment lifespan are critical investments for the smooth running of industrial operations.
If you’re looking for electrical expertise, experienced in heavy industrial applications and market leading large variable drives that save you time and money – talk to us today