Common VFD Problems, and the Clean Power VFD Solution

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Variable frequency drives (VFDs) are essential devices for motor control, applicable across industries ranging from agriculture and mining to utilities and infrastructure. While they initially result in efficiency gains, traditional VFDs also introduce various challenges to an application. These challenges come in the form of electrical noise, vibrations, harmonic distortion, increased maintenance headaches and costs, and reduced equipment performance and longevity over time.

SmartD Clean Power VFDs serve as innovative alternatives for enhanced motor control. They’re designed to address the problems traditional VFDs experience for more efficient, sustainable operations. Here, we’ll explore some of the more common issues conventional VFDs face and discuss how SmartD VFDs help prevent or mitigate them.

Common Problems With Traditional VFDs

Standard VFDs do increase energy efficiency and help lower costs, but the technology still has inherent limitations when it comes to performance capabilities. SmartD Clean Power VFDs have improved upon this technology to better address issues like insulation degradation, part wear, overvoltage, and electronic noise.

Motor Winding Damage From Voltage Spikes

The Problem

Standard VFDs utilize PWM, or pulse width modulation. PWM generates high peak voltages. The problem is that these voltage spikes cause stress in the insulation of a motor, leading to:

• Insulation degradation
• Motor winding failure
• Costly operational downtime
• Higher maintenance expenditures

The Solution

Alternatively, SmartD Clean Power VFDs produce a pure sine wave output, canceling damaging spikes in voltage. They support dependable, consistent performance in motors. These VFDs are also capable of decreasing electrical stress to better safeguard motor windings, enhancing their longevity.

Bearing Damage From Shaft Currents

The Problem

Shaft currents from traditional VFDs often discharge through a motor’s bearings, causing pitting and fluting. Over time, these currents cause bearings to fail prematurely, leading to unplanned shutdowns and costly repairs.

The Solution

Using pure sine wave technology, SmartD Clean Power VFDs reduce common-mode voltages and shaft currents while preventing harmful electrical discharges. In turn, this technology extends the life span of motor bearings and boosts the reliability of the motor itself.

Overheating at Low Speeds

The Problem

Motors require a mechanism to prevent overheating, which is why they include internal fans. Unfortunately, these fans lose their effectiveness at low speeds, leading to overheating that compromises the lifecycle and efficiency of the motor. Sometimes, the only solution is to invest in costly external cooling systems.

The Solution

SmartD Clean Power VFDs enable optimized energy consumption, producing less heat even when motors are running at lower speeds. By helping keep motors cool, they preclude the need for additional cooling solutions.

Voltage Reflections in Long Cable Runs

The Problem

Long cable runs often result in voltage reflections, which cause overvoltages. These overvoltages stress the motor’s insulation, increasing the likelihood of premature motor or component failure.

The Solution

SmartD’s VFD technology, however, supplies smooth sine wave output that reduces the chance of voltage reflections and the detrimental impact of overvoltages. This makes them ideal for long cable runs, all without requiring added mitigation solutions like filters.

Electromagnetic Interference (EMI)

The Problem

Conventional VRDs give off high-frequency noise in the form of EMI, which can negatively impact other electronic devices in the vicinity. This electromagnetic interference can result in anything from malfunctioning electronics and inefficient operation to actual regulatory compliance concerns.

The Solution

SmartD Clean Power VFDs’ ultra-low harmonic design decreases such EMI, offering a compatible solution for nearby equipment. Even for industrial facilities equipped with complex electronics setups, the SmartD technology helps ensure stable operating conditions.

Accumulation of Dust and Moisture

The Problem

Typical VFDs rely on external filters to operate. However, these filters are prone to dust and moisture build-up. This can result in anything from clogging to contamination, requiring more frequent maintenance to support consistent motor performance.

The Solution

Featuring a filter-less design, SmartD Clean Power VFDs mitigate the risk of dust and moisture accumulation — as well as any resulting contamination. By not using external filters, SmartD technology facilitates VFD maintenance and improves your system’s durability.

The Future of Motor Control is With SmartD

By addressing the most prevalent challenges of traditional VFDs — such as voltage spikes, overheating, and EMI — SmartD technology improves efficiency and reliability, reduces maintenance needs and costly downtime, and enhances sustainability through optimized energy usage.

At MH&W International Corp., we’ve supplied our diverse client base with power conversion and filtration solutions since 1964. We offer SmartD Clean Power VFDs to support enhanced motor control in your equipment and maximize system uptime. We’re continually expanding our product offers to provide you with standard and custom solutions for your most challenging VFD applications. Learn more about our offerings by exploring our catalog, or contact our team for more information.