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Invertek’s Energy Saving Drives for Demanding Environments

Invertek’s Energy Saving Drives for Demanding Environments

Posted by Morgan Spano on Jan 5th 2024

We have to hand it to Wayne Morris and Owain Betts from Invertek, they’ve created a fantastic guide detailing how Invertek’s line of Optidrive VFDs are an energy efficient solution for a number of applications. Learn how these drives are impacting raceways, golf courses and more all while maintaining durability and energy efficiency below. 

Invertek Drives has become synonymous with energy efficient and durable drives used in some of the most demanding industrial environments.
One reason for this, according to Wayne Morris, Vice-President of Invertek Drives USA, is the significant investment it’s made in product research and development.
Here, Wayne runs through the range of drives used throughout the US in a wide range of industries and sectors, often in demanding applications.
The Optidrive IP66/NEMA 4X outdoor rated range of variable frequency drives have become the VFD of choice in industries involving harsh conditions.

Tough and durable IP66 / NEMA 4X

The tough and durable enclosures are available throughout the Optidrive range, including general purpose E3, high performance P2, and the ECO for HVAC and Pump applications.
Key IP66 / NEMA 4X features include:
  • Frame sizes 1 to 4
  • Up to 30HP
  • NEMA 4X outdoor rated using a tough polycarbonate enclosure
    • Withstanding degradation by Ultraviolet (UV), greases, oils, and acids
  • Robust enough down to -20°C/-4°F
  • Outdoor rated
The drives can also be direct mounted, ensuring protection from dust, contaminants, and high-pressure washdown. 

Additionally, they can be customized locally – flat front terminal cover with mounting points for switches and internal PCBs.

A coated heatsink is included as standard. This makes it ideal for hygiene-based application, such as those in food and beverage (from mixers through to conveyors, cutters, and fan-based processes).

Other key points include:
  • Switched models with local speed potentiometer, run reverse / off / run forward switch, and UL rated lockable mains disconnect / isolator.
  • 2 x RJ45 ports for improved network capability
  • Easily accessible EMC disconnect
  • Removable gland plate
Drives for all industries and applications

General Purpose Optidrive E3

Optidrives are well-known for their ease of use. From installation to connection and commissioning. The Optidrive E3 is unrivalled in this respect and ready in minutes to provide precise motor control.
 
Key features include:
  • 14 basic parameters and application macro functions provide rapid set-up, minimizing start-up time
  • Intuitive keypad control – precise digital control at the touch of a button
  • Simple switching between industrial and pump and fan mode via macro functions
 

Single phase motor control – Optidrive E3

Removing the need for three-phase wiring, the Optidrive E3 for single phase motors uses a revolutionary motor control strategy to achieve the reliable start of single-phase motors.
The E3 is designed specifically for use with Permanent Split Capacitor (PSC) or Shaded-Pole single phase induction motors.
It provides the same performance features as the three-phase E3 and is ideal for energy saving solutions where high-torque is not required, such as fans, blowers, centrifugal pumps, fume extractors, and air flow controllers.

Advanced Fan and Pump Control with the Optidrive ECO

Optimizing fan and pump control cannot only significantly reduce energy costs, but it can also cut downtime and maintenance costs. The Optidrive ECO HVAC is used in these applications to provide maximum efficiency under all conditions.
Its Optiflow technology also ensures intelligent control of multi pump systems. Only using the required number of pumps when demand is needed. This reduces water and energy usage.
 

Key features include:

  • Low Harmonic hardware to ensure minimal effect on system Harmonic distortion
  • New outdoor rated IP66/NEMA 4X enclosures up to 30HP
  • New customizable high-resolution TFT text displays
  • NEMA 12/IP55 available up to 250HP
  • Electronic bypass control built in
  • Optiflow intelligent pump functionality for mutli-pump cascade systems

For Demanding Applications, the Optidrive P2 is a High-Performance Drive

The most demanding applications can be tackled easily by the Optidrive P2. It’s Invertek’s high performance drive. 

Available for three-phase and single-phase operation, 200V to 600V and up to 350HP, it can handle 200% overload situations.

Key features include:
  • Simple PLC functionality
  • Built-in EMC filter
  • Low ambient operation (-10c)
  • Dedicated hoist mode
  • Integral brake transistor
  • Safe Torque Off (STO) built in
  • NEW customizable high resolution TFT text displays
  • NEW outdoor rated IP66/NEMA 4X enclosures up to 30HP

How the Optidrive Eco is Racing Ahead for Customers

One of the latest and most sophisticated vehicle rolling road test facility is producing accurate data for super car engine calibration thanks to the Optidrive Eco.

Fourteen high-output fans are housed in the test cell at Runway 42, part of the new Steller Technical Centre at Tingewick, Buckinghamshire, UK.

The VFDs control 12 of the fans to simulate varying air movement cycles under strict conditions in vehicle test situations. The volumes of air create real world and extreme external ambient conditions against the vehicle cells.

Runway42 is part of Steller Engineering Ltd, a racing team and engineering company specializing in bespoke engine and gearbox calibrations for super, hyper and race cars. The high-powered vehicles are placed in the facility to undergo testing as part of the engine calibration process.

Twelve Optidrive Eco IP66 / NEMA 4X VFDs have been commissioned within the test facility.

The drives included six Size 3, 7.5kW, 400V; four Size 2, 4kW, 400V and two Size 2, 1.5kW, 400V Optidrive Eco VFDs.

Reliable and Accurate Fan Control

“This is a new facility and the thinking behind how to design the systems in place was totally different to any similar outfit currently available,” said Max Daymond of Steller Engineering Ltd.

“We wanted to create a system whereby we could accurately control and monitor a system of high-output fans at varying duty cycles simultaneously for short periods of time under a relatively strict set of conditions. This included monitoring and adjusting cell pressure against external ambient conditions to obtain as close to ambient values as possible whilst flowing a considerable volume of air.”

He said the quality of Invertek’s Optidrive VFDs was a key reason for choosing them.

Optidrive P2 – Shredding Costs and Maintenance

An industrial automation control systems supplier has significantly cut energy costs in the use of an industrial shredder by introducing the Optidrive P2 into the process.

High electrical absorption was being created on start-up by an existing Star/Delta starter. This, combined with a lack of motor speed control, were creating high energy costs and wear on the blades of the shredder.

Gas Automazioni s.r.l. (GAS s.r.l) and Omer Ecology s.r.l., Italian leader OEM in shredders manufacturing, decided to change the existing main line fed Star/Delta starter with Invertek Drives high-performance Optidrive P2.

“The motor control was a particular issue as this meant the speed of the cutting blades couldn’t be adjusted to match the type of material being shredded. This resulted in wear and damage to the blades. 

As a result, they needed to be regularly repaired or replaced,” said Stiven Gheller of GAS s.r.l. “This was impacting on the overall efficiency of the plant.”

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l worked with Invertek Drives and introduced an Optidrive P2, size 8, IP20 drive as part of the motor control method. The P2 is designed for demanding and high-performance applications, such as industrial shredders that require high torque at start-up.

The P2 is capable of up to 200% torque from zero speed which provides accurate speed control under all load conditions. The drive used was a three-phase, 250kW, 350HP, 450Amps VFD to control a 160kW, 300Amps motor.

“Straight away we were able to accurately control the speed of the motor, resulting in reduced energy use. We shredded a range of materials and there was immediately much less wear or damage,” added Manuel Meneghelli, Area Manager at Invertek Drives.

“Just as importantly, the previous high absorption resulting from Star/Delta starter was reduced, cutting energy costs for the plant.”

Optidrive E3 IP66 / NEMA 4X Performance is a Breeze for US Manufacturer

 

The ability to operate high-velocity fans from a mobile generator source without the need for an input line reactor is helping a US manufacturer improve the performance of its portable fans for drying golf courses.

The company is installing the Optidrive E3 IP66 / NEMA 4X outdoor-rated VFDs on its portable generator fans which are used on golf greens throughout the United States.

 

The fans are positioned on a mobile platform capable of being towed to any part of a golf course where they provide high-velocity air movement with a 200ft throw over a green. A generator powers the fan.

The company had previously used a VFD where the manufacturer of the drive stipulated input line reactors to protect the drive from power surges and to reduce harmonics. The Optidrive E3 negates the need for this through its innovative design.

“The portable fans are often operating for hours at a time in high temperatures. This is to ensure greens are maintained and playable by blowing substantial amounts of air on to them to reduce the effects of heat and rainfall, meaning reliability is critical,” said Wayne Morris, Vice-President of Invertek Drives USA.

 
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