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Two major issues that should be paid attention to at the installation site of the inverter
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Two major issues that should be paid attention to at the installation site of the inverter

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  • Time of issue:2020-07-01
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Two major issues that should be paid attention to at the installation site of the inverter

The inverter feedback unit supplier reminds you: In the current state of my country’s industrialization, inverters, as a part of power and electrical equipment, are increasingly involved in industrial production, and most users are concerned about the environment and safety of inverter installation. If you don’t understand, this causes unstable cost and safety, and understanding the installation options of the frequency converter can help users save costs, reduce downtime, and improve the safety of the motion control system.

When choosing where and how to install low-voltage inverters, cost is often the decisive factor. However, putting cost before the key decision about installing the frequency converter can lead to higher cost of ownership. It will also increase the possibility of unplanned downtime and cause potential safety issues.

Regardless of whether the user plans to install the inverter in a new or existing facility, the following environmental and safety issues should be considered first. Only when the user understands the inherent risks and benefits of the installation options can the performance of the inverter be optimized.

1. The environmental issues of the inverter

High temperature is the biggest enemy of inverter reliability. If the management is ineffective, heat can accumulate on the junction layer of the power transistor of the drive. This may cause the fuse or melting of the strata. Overheating can also harm the intelligent power module of the inverter. That will affect hundreds of small discrete components and components that work together inside the inverter.

From an environmental point of view, installing a frequency converter in a motor control center (MCC) is an ideal choice. UL-845: Requirements and test procedures for motor control centers to solve the problem of overheating management of the entire MCC arrangement. This means that MCC manufacturers need to prove that the inverter installed in the MCC will not be damaged, or that the heat generated by the inverter will not damage other equipment in the MCC.

However, the important thing to remember is that proper thermal management and assembly equipment on the UL-845 list can only be done by the MCC manufacturer. Even panel manufacturers certified under UL-508a cannot add frequency converters to the MCC and cannot maintain their UL-845 list. If a unit in the MCC is not in the UL-845 list, the entire list of MCC arrangements is invalid.

If a set of inverters are installed in an industrial control cabinet (ICP) instead of in an MCC, the end user will bear the burden of thermal management. If the ICP must be sealed, a set of air-conditioning equipment is usually needed to keep the internal temperature within the design limit of the inverter (or the limit of other ICP components). A general rule of thumb is that the inverter will release approximately 3% of the total power flowing through it as heat radiated to its surrounding environment.

When ventilating the ICP, the total air exchange volume during the highest outdoor temperature must be sufficient to keep the internal temperature within the design limit of the inverter. Moreover, if the circulating outside air contains dust or moisture, a filter must be used to eliminate the pollution. Maintenance failures and regular filter replacement can cause components to overheat.

For the inverter installed in the ICP, another key heat-related problem is to leave enough headroom around the inverter to achieve normal air flow. The design of each inverter has requirements for minimum headroom, including above, below, and side to side, which are essential for the cooling of internal boards and components. It is often seen that some inexperienced panel manufacturers mistakenly assume that the slotted cable duct will not be an obstacle, and therefore arrange it too close to the frequency converter. However, it becomes an obstacle to normal air flow and cannot leave enough headroom, which often leads to premature failure of the inverter.

Wall-mounted inverters are usually equipped with fans, which drive air to flow through the enclosure of the inverter to achieve cooling. And also consider other substances that may exist in the surrounding air, including water vapor, oil, dust, chemicals, and gas. These substances may enter the inverter and cause damage, or cause residue to accumulate and reduce cooling efficiency. Preventing obstacles from obstructing air flow is equally important for wall-mounted inverters. Certain gases, such as hydrogen sulfide, should be avoided because it can corrode printed circuit boards and connecting parts. Moreover, the relative humidity must be kept above the lowest value when using certain drives, because if it is too low, static electricity will become a problem when the air flows through the components.

This is particularly important for low-voltage inverters that do not use conformal coating on their circuit boards. For the inverter with a motor model of more than 400 horsepower, it is too big to be installed on the wall, and can only be installed in an independent structure that can be fixed on the floor. These so-called cabinet-mounted inverters require a separate air channel to cool the heat sink.

Users should understand the inherent risks and benefits of different installation options, so as to optimize the performance of the inverter.

2. Proper inverter safety

When deciding how and where to install the inverter, the safety of arcing requires special attention. The most convincing reason for installing a frequency converter in an MCC is that its safety is consistent with the overall design of the MCC. When installing the inverter in the MCC, all personnel safety issues are related to the entire MCC decision-making process. If you want MCC to have arc resistance, the cabinet of the frequency converter must also be arc resistant.

In addition to arc flash protection, there are some other personnel safety issues related to MCC installation: In a UL-845 MCC unit, the inverter must be in a series combination that has been tested and is on the list (should be determined by MCC Manufacturer to implement), its level must meet or exceed the MCC short-circuit rating.

As long as the overall specifications of the MCC meet the field conditions, this will ensure that every unit within the MCC is certified to be connected to the system. The human-machine interface (HMI) required by the user to access the inverter is usually moved to the outside of the equipment unit cabinet door in the form of MCC, unless there are other special regulations. This means that when operators want to read, adjust, program or troubleshoot the inverter on their display, they do not need to open the equipment unit cabinet door and expose it to safety hazards in the cabinet.

If you install a frequency converter inside the ICP, you also need to consider multiple safety issues. If the user does not require a short-circuit current rating (SCCR) in the purchase instructions, some ICP manufacturers will kindly provide an ICP with a 5kA rating. This means that the user cannot connect the ICP to a power system with a possible fault current (AFC) above 5kA. But in fact, 5kA AFC is unlikely to be achieved in industrial applications, especially when using 480V power supply. Moreover, the requirements of arc flash safety and lockout and tagout usually mean that the main circuit breaker of the ICP must be disconnected, and lockout and tagout operations must be performed before any operation is performed inside the ICP or before the ICP is connected.

It is extremely difficult to manage multiple circuit breaker devices running through the cabinet door. When a part of the system is shut down and the entire system must be shut down, ICP is more sensible than MCC or a separate inverter. At the same time, SCCR is also very important for wall-mounted and cabinet-type inverters. If possible, try to buy the frequency converter in the form of a combined unit, because the main circuit breaker and overcurrent protection device will be integrated into the frequency converter complete set of equipment. This solves the SCCR problem and other electrical safety issues.

Another problem associated with large frequency converters is that they are usually heavy. For example, maintenance technicians often use tools, cranes, and even forklift trucks, which puts the frequency converter and workers at risk. A push-out chassis design uses a special truck-like assembly design that can be matched with the internal rails located at the bottom of the inverter cabinet, which can provide a simple and safe method for moving heavy equipment parts. The accessibility, safety, maintenance, and suitability of the inverter installation will have long-term effects, which will not be immediately apparent during the design and planning stages. By understanding the inherent risks and benefits of different installation options, users can optimize the performance of the inverter throughout its life cycle, while also reducing downtime and safety risks.

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