What is the difference between a Regular Freq. Drive and a Pump Drive ?

Cydog

Member
Join Date
Feb 2018
Location
Maryland
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313
Good Morning ,

I have 2 Frequency Drive panels to build and commission . It is for 2 pump systems .

Just wondering , what is the difference between a Regular Frequency Drive and a Pump Duty Frequency Drive ?

Are Pump Duty Drives more expensive ? If so , are they worth the added cost ?

Thanks so much ,
 
"Pump Duty " just means that the transistors are sized differently because in a centrifugal pump (or fan), the load drops off at the CUBE of the change in speed. So for example at half speed, the load on the motor and thereby the VFD is .5 x .5 x .5 or .125 (1/8) of what it would be at full speed. This is called a "Variable Torque" application, meaning the torque requirement of the load varies with speed, where the only time you need full torque is at full speed.

When using transistors to recreate a voltage and frequency pseudo-sine wave to vary the motor speed, as you slow down the speed, the switching losses inside of the transistors increase. In a "regular" drive, also called a "Constant Torque" rated drive, it is expected that the torque will be the same at lower speeds as it is at higher speeds, and current roughly equates to torque. So at lower speeds on a CT rated drive, the transistors have to put put the same current, but the switching losses inside of the transistor increase, so they have to be sized for that worst case scenario of total heat dissipation. In addition, the transistors will be sized to handle short term overloading conditions, typically 150% for 60 seconds, 180-200% for 3 seconds, to handle sudden changes in load.

In a Variable Torque (VT) application, the torque requirement, and thus the current seen by the transistors, DROPS as the speed decreases, so even though the switching losses become a higher percentage at lower speeds, it is a higher percentage of a drastically lower value. So the transistors are sized based on the switching losses at full speed only, resulting in SMALLER transistors on a VT rated drive. Those smaller transistors then can also not handle as much OVERLOAD capability either, but the VDFD mfrs know that the NATURE of a centrifugal machine is such that is it not possible to overload them in a normal operation; you cannot "force" a correctly sized pump to pump more than it is capable of unless there is an accident, like a broken pipe ("open channel flow"), in which case you will WANT to shut it down immediately. So the over Load capability is unnecessary and is typically limited to 115% for 30 seconds, no instantaneous OL capacity at all. This results in a smaller and lower cost VFD. It should also be noted however that under 20A (most) VFD mfrs do not make a VT rated drive because there is no real significance in the sizing of the smaller transistors.

So bottom line, you can use ANY CT rated drive for a VT load, but you should not use a VT rated drive for anything other than a centrifugal pump or fan.
 
Last edited:
In addition to Jraefs excellent explanation, a lot of drives aimed at the pump market have useful built in features if you don't have PLC smarts or want things out the box. Features like fast ramp to minimum speed then normal ramp from there (bore pumps), detection of loss of prime or airlock (low power consumption), built in PID for flow control etc.
 
Thanks so much. Great explanation. Considering the supply chain issues , I'm thinking of going with a WEG CFW500. ABB has some serious issues getting drives out . Below is what I would like to use . Do you think this drive would work ?


WEG CFW500
WEG CFW500 microdrive
Broad offering from 1/4 to 60 hp Scalar, Vector Control (Sensorless and closed-loop with encoder feedback), and VVW PM (suitable for fan, pump and compressor)
200-240V (single-phase/3-phase and 3-phase only models) and 380-480V input voltage
230VAC: three-phase up to 30Hp, single phase input up to 3hp
STO - Safe Torque Off (TUV certified) with option module
460VAC: three-phase up to 3 HP
IP20 with NEMA 1 conduit box options (not required for NEMA 4X IP66)
Speed and torque control down to 0 (zero) rpm
Precision of 0.01% for speed control
DIN rail (35mm), A, B, and C frame, or surface mounting with screws on all frame sizes; Frame F can be flange mounted
Same programming as other WEG VFDs
Built-in SoftPLC
0 to 500 Hz output frequency
2.5 to 15 kHz adjustable switching frequency (5 kHz standard)
PID with sleep mode
Flying start / ride-through
Built-in 24VDC power supply (max. 150 mA)
Built-in RS-485 (Modbus RTU) communication
Plenty of built-in I/O, expandable with option modules
Control features: Linear and "S" ramp acceleration and deceleration, local/remote control, DC braking, torque boost, motor slip compensation, electronic pot, preset speeds, adjustable V/Hz profile, maximum and minimum adjustable frequency limits, two skip frequencies, adjustable output current limit, JOG, ride-thru, flying start and PID regulator
Keypad with backlight, with main display line, secondary display line and bar graph display
CFW500 NEMA 4X drives are available with or without integral, locking disconnect
CFW500 NEMA 4X drives can operate AC induction or permanent magnet AC motors (PMAC).
 

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