How do VFDs enable energy savings and demand response in industrial and commercial facilities?

1 Energy savings with VFDs

One of the main advantages of using VFDs is that they can reduce the energy consumption and costs of electric motors, which account for about half of the global electricity demand. By adjusting the motor speed to match the load requirements, VFDs can avoid wasting energy and improve the power factor of the system. For example, a fan running at 50% speed consumes only 12.5% of the power required at full speed, thanks to the affinity laws that govern the relationship between speed, flow, and power. VFDs can also eliminate the need for mechanical devices such as throttles, valves, dampers, or gears, which can cause losses and maintenance issues.

2 Demand response with VFDs

Another benefit of using VFDs is that they can enable demand response, which is a strategy to manage the electricity demand and supply in response to grid conditions, such as peak periods, price signals, or emergencies. By participating in demand response programs, industrial and commercial facilities can receive incentives or lower rates for reducing or shifting their electricity consumption when the grid is stressed or congested. VFDs can facilitate demand response by providing flexibility and control over the motor loads, allowing them to modulate, ramp up, or ramp down as needed, without compromising the quality or productivity of the processes.

3 Benefits of VFDs for your business

By implementing VFDs in your industrial and commercial facilities, you can enjoy several benefits for your business. These include lower energy bills and carbon footprint, as well as improved power quality of motor systems. Additionally, VFDs can optimize motor speed and torque for different applications and conditions, resulting in higher performance and reliability. Furthermore, VFDs can enhance process control and automation, leading to greater operational efficiency and productivity. Finally, they can help access incentives and savings from demand response programs while meeting environmental and regulatory standards for energy efficiency and emissions, improving competitiveness and compliance.

4 How to choose and install VFDs

If you are interested in installing VFDs in your industrial and commercial facilities, there are a few factors to consider. Firstly, the type and size of the motor and the load must be compatible with the VFD. You will need to select a VFD that matches the motor specifications, such as voltage, current, frequency, and horsepower, and can handle the load characteristics, such as constant or variable torque, and starting and stopping requirements. Secondly, you must ensure that the VFD is properly installed and protected from dust, moisture, heat, vibration, and electromagnetic interference in its location. Additionally, adequate ventilation and cooling must be provided for the VFD as it generates heat during operation. Lastly, you must follow manufacturer instructions and electrical codes for wiring and grounding the VFD and motor to avoid potential hazards or problems. Appropriate cables, connectors, filters, and shields should also be used to reduce voltage spikes and losses in long cable runs between the VFD and motor.

5 How to operate and maintain VFDs

Once you have installed VFDs in your industrial and commercial facilities, it is essential to operate and maintain them properly for optimal performance and longevity. You should set up and program the VFD parameters according to motor and load specifications, and the desired speed and torque control modes. This can be done using the VFD keypad, display, or software to configure settings like frequency, acceleration, deceleration, current limit, voltage boost, slip compensation, and protection functions. It is important to monitor and troubleshoot the VFD operation and performance with the indicators, alarms, and fault codes provided. This will involve checking the VFD status, output, and input regularly to identify any issues or errors such as overvoltage, undervoltage, overcurrent, overload, overtemperature, or communication failure. Additionally, you should clean and inspect the VFD components periodically to prevent dust accumulation, corrosion or damage. Use a soft brush or a vacuum cleaner to remove dust or debris from the VFD enclosure, fans, filters, heat sinks, terminals and boards. Also examine the parts for any signs of wear or loose connections and replace or tighten them as needed.