Sunplus Vfd Tool Kit

Share • LinkedIn • Facebook • Twitter 0 As a Wisconsin based company that supplies and services variable frequency drives in the HVAC, Irrigation, Entertainment, Water and Waste Water industries for the last 25 years, we are called into projects that face various installation and product problems. Each industry has it's own 'traditions' for mounting VFD's. MCC mounted VFD's are almost never seen in hospitals, labs, or universities. It is common in waste water plants to see VFD's mounted motor control centers.

Space limitations and 'habits' are the common motivations. The issues that we see are several. One of the most common issues is the impact for the end-user regarding the life cycle cost and serviceability. Small HP VFD's (20HP and less) are small enough that they fit into a standard MCC bucket. Larger VFD's are placed into custom buckets that do not have the tabs for the power connections and are direct cabled.

I have an end user with a 100HP VFD (about 5 years old) with a failed main cooling fan. The entire MCC line-up had to be shut down for several hours because the fan was mounted on the back of the VFD heat sink that was flanged mounted.

This meant that the drive was mounted (bucket was not removable) through a cut out and the fan was about 1/2' from the vertical bus bars. With the arc flash protective gear, the technician was not able to remove the small screws, etc.

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Required to change the fan. Another end user was concerned that his VFD's only lasted 5-7 years before a catastrophic failure and had to be replaced. This was due to the inadequate cooling and dust build-up on the VFD heatsink. The VFD's needed to be completely removed from the MCC so proper access to the heatsink in order for it to be cleaned.

A 10C rise over the VFD rated temperature typically will reduce the VFD's lifespan by 50%! I have yet to see a VFD that is mounted in an MCC that does not operate at elevated temperatures compared to a stand alone VFD due to restricted and recirculated airflow. I have also seen high frequency noise issues generated by the VFD motor cabling in a MCC as it is very difficult to 'isolate' the motor cable (which is like a transmitter of high frequency noise) that can interfere with communication systems for SCADA, transmitters, etc). Note the output wiring intermingled with control wiring and motor filter (heat generator) underneath the VFD A MCC structure also limits the options for harmonic filtering, motor filters (mounting VFD's in MCC typically increases cable runs between the VFD and motor) as well as increases the cost of the system.

Most of the companies that market MCC's do not manufacture their own VFD's. They are brand labeling a third parties product and have little control over quality and design of future models.

This causes many issues for the end users that are looking for technical support, repair parts and retrofit VFD's (the new VFD design doesn't fit into the existing MCC). As a result, creative and expensive retrofits result. An example of a MCC retrofit. Note the door modification 'bump-out' to accommodate the new VFD. Motor control center mounted VFD's are but one tool in the tool kit.

The tool should be used when it fits the need (severe space limitations and small HP's), but not as a standard practice. Most designers that we work with are not aware of the challenges that the end users have 5 years + down the road maintaining the operation, reliability and cost of their systems, and they paid a higher price for the equipment.