Hello, I am experiencing an issue with the ice delivery system after transitioning from contactor to VFD control using Danfoss VLT FC001 3kW VFDs to regulate 3-phase asynchronous 2.2kW motors driving augers and scrapers. While the system operates smoothly under light loads, it struggles when faced with clumped ice or excessive ice on the scrapers. Instead of tripping, it appears to lose power. Despite adjusting ramp-up times, torque and current limits, load compensation settings, and frequency levels, the issue persists. Before reverting to contactors, I am seeking advice on other settings that may need adjustment. Thank you.
Hello, it's important to assess the frequency drive output voltage when encountering issues, such as struggling and abnormal currents. If the voltage output of the drive reads 380/400V at 50Hz, there may be a fault in your electric motor. It is crucial to monitor and troubleshoot these factors to ensure optimal performance and prevent potential damages.
Ensure that the drive is configured with the motor nameplate data before proceeding. If the drive is utilizing "SVC Mode" to enhance torque capability, it is crucial to complete the "Autotune" procedure detailed in the manual. Failure to do so may result in inaccurate assumptions about the motor. If your VFD does not have SCV mode, it may be time to upgrade to a better VFD for optimal performance. Additionally, it is important to note that the drive in question is HVAC rated, designed for simpler applications like centrifugal pumps and fans in HVAC systems, and may not be suitable for your specific needs. Consider investing in a "Constant Torque" or "Heavy Duty" rated drive for this application.
You might want to look into the thermals of your motor. The VFD should protect the motor from overload conditions, but if the motor is running hotter due to the heavier loads, it could be causing your power issues. Another possible factor could be the power supply. If it's not stable or well-regulated, this could contribute to the problem. If neither of these are the issue, I'd consider consulting directly with a Danfoss technician for more specialized assistance.
It sounds like you’ve already done a thorough job troubleshooting! Have you looked into the feedback settings for the VFD? Sometimes, adjusting the stall prevention settings or increasing the maximum allowable current can help when the motors face sudden loads, like clumped ice. Additionally, a proper setting for the acceleration and deceleration times can really make a difference. If the VFD has a torque boost feature, that might help with initial starts when the load is heavier. You might also want to double-check that the VFD's parameters match the motor specs correctly; mismatches can lead to performance issues. Good luck, and let us know how it goes!
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Answer: Answer: The issue might be related to the VFD settings not being optimized for handling clumped ice or excessive loads on the scrapers. Despite adjusting various parameters like ramp-up times, torque limits, current limits, load compensation settings, and frequency levels, the problem persists.
Answer: Answer: The power loss issue may be due to the VFDs not being able to effectively regulate the motors under heavy loads. It's possible that the VFD settings need further adjustments to handle these specific scenarios more efficiently.
Answer: Answer: Before reverting to contactors, it's advisable to explore other settings on the VFDs that could help address the power loss issue. This could involve fine-tuning parameters related to motor control, overload protection, or fault handling to better suit the ice delivery system's operational requirements.
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