Enjoy Easy, Precise & Reliable Motor Speed Control with Invertek VFDs

Problem

In order to create biogas, animal effluent and food waste must be broken down in cogeneration units.

Solution

Utilizing Optidrive E3 VFDs, the process uses pumping and mixing processes to accurately control waste inflow and outflow and mixing speed.

Theodore Amiridis, the Technical Director at Automation Experts, highlighted the integral role of Optidrive E3 variable frequency drives (VFDs) in a biogas production project in Greece. PK Energy, a company specializing in renewable energy, collaborated with Automation Experts and utilized Optidrive VFD technology from Invertek Drives to construct electricity production units using biogas generated through anaerobic digestion.

The project, located in Kefalovrysos, Trikala, involved the breakdown of animal and food waste into microorganisms within two oxygen-free storage units. The waste material was pumped and mixed to create the biogas. The gas was then converted into electricity through two on-site cogeneration units, generating 3MW per hour, which was fed into the mains grid.

Optidrive E3 VFDs were employed for the pump and mixing processes. These VFDs were specifically IP20 enclosures, ranging from 4kW to 37kW in power. The VFDs played a crucial role in accurately controlling the quantity of waste material and the speed of mixing during the biogas production process.

Theodore Amiridis emphasized that the Optidrive E3 VFDs ensured precise control of the pumping and mixing processes, enabling the optimum production of gas. The VFDs were easy to install, commission, and program. Each drive was connected with a PLC through Ethernet/IP protocol, and the VFD PID function was used for pump control. The expertise of Automation Experts, combined with the functionality of the VFDs, facilitated the correct motor and pump speed for optimal gas production.

The Optidrive E3 is part of Invertek Drives' range of user-friendly VFDs. It offers simple commissioning with basic setup parameters, default settings, and additional flexible parameters for customization. The drive features an intuitive keypad and application macros to switch between industrial, pump, and fan modes based on the specific application requirements.

Problem

An inefficient fixed-speed compressor controlled a supermarket's refrigeration system. The result was higher energy costs and less efficient HVAC and refrigeration systems.

Solution

Falkonair Inc, a specialist HVAC-R software manufacturer, partnered with EcoPower, a contractor in Costa Rica, to retrofit multiple systems at a large supermarket retailer’s sites. The inefficient fixed speed compressors were converted to Optidrive variable speed compressors using Falkonair's Smart Compressor Control.

The partnership between Falkonair Inc and EcoPower in Costa Rica involved retrofitting multiple systems at a large supermarket retailer's sites to improve energy efficiency. They achieved average energy savings of 35% by installing Invertek Drives Optidrive variable frequency drives (VFD) controlled by Falkonair's Smart Compressor Control (SCC).

Falkonair's SCC enabled the conversion of inefficient fixed-speed compressors to variable-speed systems, using temperature sensors instead of pressure control. This approach was unique in the market. The Optidrive Eco, available in 3-phase, 480V, and 230V models with IP55 enclosures, was used on the compressors in the refrigeration rack systems and rooftop packaged units. The drives were compatible with Bitzer and Copeland Discus reciprocating compressors as well as LG scroll compressors.

The installation of Optidrive VFDs demonstrated their compatibility and effectiveness in increasing efficiencies in HVAC-R systems, thereby reducing energy consumption. By reducing energy use and associated costs, the system also contributed to a reduction in emissions, benefiting the environment. Moreover, the system's improved efficiency resulted in less downtime, which is crucial for a retailer with a large refrigeration system.

The Optidrive Eco is specifically designed for HVAC-R and pump systems, available in various frame sizes and enclosures, including IP66/NEMA 4X. It offers models ranging from 0.75kW to 250kW (1HP to 350HP) and operates at voltages ranging from 200V to 600V in both single and three-phase configurations.

Problem

In Piaui, Brazil, Farm Camaratuba is located in a semi-arid region, making production of livestock fodder difficult. Thus, there is a need to transport a large amount of fodder to the farm. A 150KVA diesel generator was used to pump water from a 150ft deep tubular well into an irrigation system feeding 17 hectares of land. There was no control over the amount of water pumped from the well.

Solution

The farm’s owners worked with WM Engenharia on the project. They designed and installed the complete system which consisted of 15 photo-voltaic panels on a six-string system using an Invertek Drives Optidrive P2 Solar VFD which controlled the pump. This fed water into a reservoir and only the required amount of water into the irrigation system.

Farm Camaratuba in Piaui, Brazil, has successfully eliminated the use of an expensive and inefficient diesel generator water pumping system by implementing a solar-powered solution controlled with variable frequency drives (VFD). Situated in a semi-arid region, the farm faced challenges in producing livestock fodder and distributing water for irrigation and livestock needs.

Previously, a 150KVA diesel generator was employed to pump water from a 150ft deep tubular well into a 17-hectare irrigation system. However, the system lacked control over water consumption, resulting in wastage. To address these issues, the farm collaborated with WM Engenharia to design and install a comprehensive solar-powered system.

The system comprises 15 photovoltaic panels connected to an Invertek Drives Optidrive P2 Solar VFD, which effectively controls the pump. Another drive is planned for a future pumping system utilizing a PV system. By implementing this solution, Farm Camaratuba has eliminated the need for the diesel generator, enabling larger areas of land to be irrigated with precise water quantities when required.

Marcus Silva, Head of Sales at Invertek Drives Latin America, explained that the farm previously struggled to produce sufficient fodder without heavy reliance on irrigation or external suppliers. The introduction of the photovoltaic-powered pumping system has allowed the farm to enhance fodder production throughout the year, reducing transportation costs and diesel consumption, as well as minimizing generator emissions.

Moreover, the VFDs offer the advantage of controlling the water flow. Unlike the previous setup that provided a constant flow, the VFDs enable adjustment of the flow and quantity based on specific requirements, thereby preventing water wastage.

The outdated diesel generator has been replaced with a 47.7kW photovoltaic system that powers the existing 35HP submersible pump in the well. Two Optidrive P2 Solar VFDs (380V, 50HP, IP20 enclosure rated) have been installed, with one controlling the system and the other serving as a backup for future expansion. The P2 Solar Pump VFD offers extended DC operative voltage ranges, making it suitable for various applications such as watering, irrigation, agriculture, swimming pools, water treatment, and more, particularly in off-grid or challenging locations.

The Optidrive P2 Solar VFDs are available in IP20, IP55, and IP66/NEMA 4X enclosures, ensuring their adaptability to different environments and conditions. The range covers power ratings from 0.75kW to 250kW (1HP to 350HP) and includes extended DC operative voltage ranges of 345 to 800Vdc (HV) and 185 to 410Vdc (LV), enhancing system operational time and reducing interruptions caused by low array voltages during dawn and dusk.