An installation of 3 of our FRENIC-Ace inverters and an HMI with connection via MODBUS was implemented in a restaurant in Croatia to offer customers a 360º view of the city. The task was to control the motors that are simultaneously rotating the restaurant platform, avoid any failures, and analyze and collect feedback of the application.
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Our inverters control 3 of their motors, offering power control, protection against failures, speed control and maintenance warnings. Meanwhile, our HMI gives access to analytic data like current, temperature, and more at any moment.
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Industrial Hygiene SolutionsCleaning machines for kitchens, heaters, and air conditioners have an electric brushing solution which enters deep into ventilation ducts. Their rotating, flexible shafts must adapt perfectly to their environment without causing any damage. Fuji Electric installed our FRENIC-Mini C2 inverters into those cleaning machines, as well as our Monitouch Technoshot HMI screens.
The HMI replaced all manual keypads and push buttons and therefore modernized the machines significantly. With the FRENIC-Mini C2 and its quick response torque limitation, the cable inside the hose as well as the duct is well protected. In addition, the StopGo system stops the motor way before any breakdown can occur!
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Recycling Industry SolutionsWe installed our FRENIC-MEGA inverters in a garbage recycling shredder that has 2 motors of 132 kW, mechanically coupled in the same axis. The main requirements in this application were a high starting torque (overload up to 200%), a control in the load imbalance and the maintenance of speed during the process.
With our FRENIC-MEGA and its “droop-control” function, we can keep the load unbalance to a minimum. This represents a machine process control without stops, thus prolonging its maintenance!
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Textile Machine SolutionsWe installed our FRENIC-Ace, 3-phase 400 V, 1.5 to 2.2 kW into a textile machine in Italy. The challenge was to control a permanent magnetic synchronous motor (PMSM) in open loop and to find a function to stop the machine with PID function in case of input phase loss.
Our solution provides a low voltage ride-through function, a best PMSM control with static pole-tuning at starting, and which has CANopen built-in.
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Irrigation SolutionsFor this installation, Fuji Electric developed a complete cabinet with EPLAN schematics. 2 FRENIC-Ace inverters with our special software for solar pumping (CLI-SOL) were installed: 1 inverter of 7.5 kW for submersible pumps (irrigation pump) and 1 inverter of 2.2 kW for water rotation pump of the lake.
A third standard FRENIC-Ace inverter was also installed for synthetic main supply, which allows the connection of any other external 230/400V AC load.
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Cutting & Processing SolutionsOur HMI Monitouch Technoshot allow a remote connection through VNC, so you can watch, read and save the information of the inverter and PLC of your installation or machine. This is an installation of diamond wire saw machine for cutting and processing natural stone in quarries, such as granite, marble, slate, onyx, etc.
As well as for industrial materials such as metals, composites, glass, PVC. Now our customer could upgrade and go from a totally manual process (with buttons) to a more automated and visual process!
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UPS MaintenanceWhen doing maintenance on an Uninterruptible Power Supply and its auxiliary equipment, keeping it clean is one of the main objectives. Dirt, dust, sawdust, and metal filings are just some of the pollutants that technicians see in UPSs, even when installed in seemingly clean environments. These substances can cause failures when they contaminate the contacts of relays and contactors, and conductive material can cause short circuits and malfunctions on printed circuit boards (PCBs).
At least once a year, make sure your UPS gets cleaned including a good vacuuming with a non-conductive hose and attachments. Never use a blower or compressed air! These methods can blow contaminants deeper into the unit, causing real troubleshooting headaches if and when they finally do cause issues.
Use lint-free rags lightly damp with a nonflammable and fast-drying solvent for heavy deposits, and soft brushes around delicate components and connectors. Always perform cleaning work on equipment that is offline, and de-energized and with the proper personal protective equipment (PPE) such as goggles, gloves, aprons, and respirators as necessary. Lastly, always use a torque wrench on copper and lead connectors
Know Your Pipe and Don't Guess
Know your pipe and don't guess! This includes the customer knowing their liner and its thickness. Many customers don't know their pipe's exact specifications, but by measuring circumference and looking for a schedule embossment on a fitting, as well as referencing a pipe resource is usually a good solution.
It is also something they can research with a system engineer ahead of a flow survey or fixed installation. To that point, they could even program the measurement point(s) on the bench in air conditioning before going in the field.
Get Your Installation Right
Surveying the intended installation location for straight run, and selecting a valid installation point is one of the most important tips we could offer. That is after vetting Transit Time Ultrasonic technology for the macroscopic application. This is by far the biggest battle we have in the field, even when we try to get this information upfront in our application work.
It seems that people use the basic rule of 10D up/5D down and apply it to all situations, or make no straight run considerations at all. I would highlight the need for additional straight runs for the plumbing situations that poses the biggest obstacles for us. The biggest being pumps, two elbows out of plane, valves, and T fittings. The trick is to portray this without evoking fear, just to bring them to conscious thought.
Ring Compressors & Blowers for Pressure, Vacuum, and Airflow
Pressure
Systems for Waste Water Treatment and Aquaculture rely on Fuji Electric Regenerative Blowers to provide reliable pressure. For Waste Water applications, our blowers provide airflow and pressure for aeration of Waste Water Systems. In Aquaculture, our blowers provide airflow for pressure application in the aeration tanks for Shrimp and Fish.
Vacuum
Applications for Pneumatic Tube Systems and Hold Down Applications for Milling & Cutting utilize Fuji Electric Regenerative Blowers for its vacuum capabilities. Fuji Electric Blowers provide reliable pressure and vacuum as the driver for Tube systems. Our regenerative blowers also provide vacuum for hold down applications for milling and cutting applications.
Airflow & Aeration
When it comes to efficient and reliable airflow, industries such as Metal Plating and Commercial Spas & Hot Tubs use our blowers. Fuji Electric Regenerative blowers provide aeration for plating tanks, mixing tanks and rinsing tanks. Our blowers also provide aeration for commercial spas and hot tubs.
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AC Drives for Residential Elevators
We understand you need products to be reliable and manufactured to the highest quality standards. In this case, when a large volume manufacturer of residential elevators was experiencing widespread field failures with their current supplier of the VFD used in their application, they immediately sought out an alternative solution.
Our engineering team and resources at the customer worked in concert to provide a comprehensive solution that required meeting the highest quality standards in their industry. A solution was provided and tested over 800,000 cycles. Several competitor’s products failed during the testing process. Fuji Electric was selected as their primary source for their production requirements and adopted as their standard of choice. At Fuji Electric, we pride ourselves on manufacturing products that exceed our customers expectations.
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HMI for Oil & Gas
Compact size and shallow mounting depth make Fuji Electric operator interfaces ideal for installation in harsh environments, and for many factory automation applications. Did you know Fuji Electric HMI’s are utilized in the Oil and Gas – Test and Measurement industry? We work with companies who selected several manufacturers to test; several of those failed to pass their stringent harsh duty requirements.
After months of field operation, Fuji Electric was chosen as their preferred choice to meet their application requirements. Since then, we have deployed several thousand units in the field, operating in the most extreme temperature climates. When choosing Fuji Electric for your HMI requirements, you can be assured of receiving a product that is suitable for just about any industrial environment!
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Regenerative Blowers for Spas & Hot Tubs
Most spas and hot tubs require regenerative blowers to provide the pressure and flow needed to agitate the water. Here are your Do’s & Don’ts for your Commercial Spa to operate smoothly:
Do’s
1. Use a licensed electrician to install your blower.
2. Use a Pressure relief valve.
3. Use a Hartford loop at least 18 inches above the water level of the spa.
4. Install the blower as close to the spa as possible.
5. Install the blower in a weatherproof house or enclosure.
6. Install a check valve as close to the spa as possible.
7. Install an Inlet Filter on the blower.
Don’ts
1. Don’t install the unit lower than the water level of the spa.
2. Don’t allow water into the blower. Water will damage the blower and void the warranty
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Semiconductors that Keep Your Production Line Moving
Welding is a critical activity used on many modern production lines. So, when downtime hits, your entire line can go down. Our IGBT modules have been specifically designed to maximize uptime so you don't miss a step.
Low Loss
Reduce inverter loss by 10% and chip temperature by 1 OC compared with the 6th generation V series EP3 Package (75A at fc = 8kHz).
Miniaturization
An approximately 36% smaller footprint has been achieved by reducing power loss and improving heat transfer
High Temperature Operation
Up to 35% more output than the previous generation. A 2x improvement in power cycle capability.
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Car Wash SolutionsThe nation’s largest manufacturer of turn-key, automated car wash systems chose Fuji Electric as their standard of choice for all of their AC Drives requirements. Our product offering supplies them the efficiency and reliability required for every aspect of automating their processes.
The customer tested several manufacturers over a decade ago and found that Fuji Electric surpassed their expectations in keeping their systems running that impacted their profitability due to low maintenance requirements and longer uptime. Our cost effective, compact solutions met their design requirements to include the 3-year warranty that differentiated Fuji Electric from other manufacturers.
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Commercial Mixer SolutionsA long standing customer that tested several competitors’ products over a decade ago, chose a Fuji Electric product that not only meets their application criteria, but exceeded their expectations regarding: performance, quality and reliability for their commercial mixer product lines.
As their standard of choice, our AC Drives continue to surpass expectations as our product models offer the versatility and flexibility required for any demanding environment. Fuji Electric AC Drives prove to be technically superior compared to other products offered in the market. Our compact design, 3-year warranty, and exceptional torque features is ideal for many recipe requirements that make Fuji Electric their sole supplier for all of their AC drives needs.
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Agriculture Irrigation SolutionsOur products are designed to operate in 50 deg C ambient under full load conditions with no derating factor. The VFDs also maintains a UL rating under single phase power input. Fuji Electric’s ECO-DY model has a standard feature of a simultaneous control of Pump pressure and water table level control. This feature will control a pump’s output pressure and automatically switch to water table level control when the level sensor goes below an adjustable threshold. This prevents costly dry run damage to the submersible pump.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed for Agriculture Irrigation control. For this case, the ECO-DY model achieves the control by switching between two PID loops. Throughout this process, the first loop, PID1, will control the output pipe pressure. The second loop, PID2, controls the water table level. There is a sensor threshold and time that controls the switching between PID1 or PID2. One of the PID sensors will need to be a 0-10v signal and the second will need to be a 4-20ma input.
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Oil Field SolutionsFuji Electric VFDs are a tough, rugged and designed to operate in the harsh conditions of the oil field. Our VFDs are used in thousands of Oil field pump jack applications. For this Oil Field application, they run in 50 deg C ambient at full power without derating.
In this application, our VFDs provided the standard capability to overcome the regeneration portion of the pump jack cycle without needing braking resistors. Our VFD accurately senses the regenerative energy created by the beam pump and precisely increases the speed to eliminate the need for a braking resistor.
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Mixing Extruder SolutionsPeter Pugger is the world’s leading manufacturer of mixing extruders (pugmills). With the growing demand to mix and extrude new and innovative products, Peter Pugger machines require versatility and efficiency as it relates to motor control, speed control, soft start/stop and remote capability. The utilization of Fuji Electric's FRENIC-Mini and FRENIC-ACE drives has allowed their systems to maintain product quality, durability and performance. The durability of our Fuji Electric drives and the three-year warranty has established our drives as the drive of choice for all of our units. With thousands of machines worldwide, Fuji Electric’s dependability has played a key role in their success.
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Hydraulic Pump SolutionsH2O Technologies is a high quality, highly innovative OEM Control Panels fabricator that specializes in the engineering, designing and building of Bypass Control Panels for hydraulic pump related industries that construct fountains, waterfalls and municipal pools. Fuji Electric’s FRENIC -Eco and EcoPAK Bypass Panels quickly became H2OTechnologies’ exclusive offering due to its high quality, product adaptability, and superb technical & support staff. “We have discovered a hidden gem working with Fuji Electric; it’s their ability to take us back to better days, when there was less bureaucracy, where management decisions and issues resolution were local and only a call away. That is a “game-changer” that sets them far apart from almost every other large organization”, exclaims Greg Sills, PPX Central’s President & CEO.
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Wind Turbine SolutionsFuji Electric Power Semiconductors are used in Wind Turbines of major Wind Turbine Manufacturers. The PrimePACK™ 3+ improves power conversion efficiency to reduce power loss and increase output power. Amid the beautiful and expansive natural landscape of northern Denmark, you can see lines of wind turbines. These wind turbines use our large-capacity IGBT module PrimePACK™ 3+. In this wind power generation, the force of wind spins the blades of the wind turbine, which in turn rotates the generator to generate electricity. In order to feed this electricity into transmission lines, the voltage and frequency must be changed, and that power conversion is where our power semiconductors play a vital role.
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Industrial Refrigeration SolutionsSignificant levels of refrigerants and heating are needed to slow down spoilage and maintain preharvest freshness and flavor of ripe fruit and vegetables. Fuji Electric Variable Frequency Drives (VFD) make it possible to quickly provide the necessary cooling or heating to maintain a uniform temperature, humidity, air-circulation or fresh air requirements in cold storage while at the same time the energy consumption is reduced to a minimum. In standard system designs, electric motors are intended to operate at a fixed speed. This speed is determined by the frequency of the power supply and the motor design (number of poles).
The shaft load on the motor is determined by the product of shaft speed and torque. With a fixed speed, motor power is determined by the torque of the load. With a change in speed the motor load will not only benefit from the speed reduction, but also any reduction in torque with speed. Two types of motor load exist; constant torque and variable torque.
VFDs give better control and more efficiency for compressors, fans and pumps:
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Scheduling a Freight Pick UpA customer was given incorrect information for scheduling a freight pick up and the terms for shipping the item. The shipment was delayed and stuck in a freight branch location. This led our team to coordinate communications between several stakeholders (Customer, Logistics Company, End User, and the freight company shipping the order). Information had to be confirmed for accuracy and ease of understanding to avoid confusion or delays. Our team at Fuji Electric was able to keep the customer informed of status regularly and get the info needed in order to resolve the issue and get the order completed.
Meeting Production SchedulesDue to material challenges, in order to meet our customer's production schedule, our team members participate in weekly meetings, provide status and shipping updates, and facilitate direct shipments from our factories. It requires daily attention and time management skills to keep track of multiple avenues to achieve delivery. However, there is a great sense of satisfaction knowing we are part of a team doing everything possible to meet their expectations!
Did You Know?Did you also know Fuji Electric Corp. of America (FECOA) was established in ? Fuji Electric Corp. of America is happy to celebrate over 50 years in the United States! Fuji Electric now aims to become a leading-edge company in “energy and the environment” by building upon our core platform of five technology fields which unlock the potential of electricity—energy, industrial systems, social systems, power electronics, and electronic devices.
Industrial Laundry SolutionsFuji Electric’s FRENIC-Ace model, Variable Frequency Drives (VFDs) are commonly used in commercial laundry equipment for their ability to control the speed of electric motors. In the context of commercial laundry, VFDs are often employed in various machines and systems to enhance efficiency, reduce energy consumption, and provide better control over operations. Here are some ways VFDs are utilized in commercial laundry equipment.
In summary, Variable Frequency Drives play a crucial role in enhancing the performance, energy efficiency, and operational flexibility of commercial laundry equipment. They contribute to cost savings, reduce environmental impact, and improve the overall reliability of laundry systems.
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Silicon carbide (SiC) is a well-established device technology with clear advantages over silicon (Si) technologies, including Si superjunction (SJ) and insulated-gate bipolar transistors (IGBTs), in the 900 V to over 1,200 V high-voltage, high-switching-frequency applications.1 The recent introduction of the 650 V SiC MOSFET products has further broadened SiC use by easily replacing IGBTs, taking a bite out of the Si SJ application share and offering an alternative to gallium nitride (GaN) in the mid-voltage range.
When replacing Si devices with SiC or designing anew with the latter, engineers must consider the different characteristics, capabilities, and advantages of SiC to ensure success. Here is a list of SiC design tips from the power experts at Wolfspeed.
A key advantage of SiC is a low RDS(ON) that changes as little as 1.3× to 1.4× over a wide temperature range, whereas in Si or GaN devices, RDS(ON) may double to triple from that rated at 25°C to the practical junction temperatures in the 120°C to 140°C range (Figure 1). It is therefore important to carefully check the datasheet and specify the correct I2R or conduction loss.
IGBTs are optimized for a thermal design point at the full rated current. Below that point lies the VCE(sat)exponential “knee” voltage curve (Figure 2). SiC MOSFETs’ VDS characteristics are linear, offering lower conduction loss at any point lower than the full rated current.
This is particularly useful to bear in mind when designing EV drivetrains, in which the drive cycle is mostly below the full rated power. When used in parallel, the IGBT VCE(sat) curve exacerbates the problem.
Designers must therefore carefully consider where lies their thermal design point and mission profile.
Effective switching frequency (ESF) is defined as the maximum frequency in a hard-switched application that a device can sustain at the rated IC100 with a 50% square-wave duty cycle without exceeding the device’s specified maximum power dissipation at working voltage. Or:
Where:
The theoretical ESF of a 40 mΩ Wolfspeed SiC MOSFET compared with that of a 40 mΩ Si device is 10× higher. While this offers a glimpse into SiC’s capabilities, cooling, magnetics, and cost put practical limits to switching frequency.
Cooling costs increase, but the passive BoM costs for inductors and capacitors decrease with switching frequency. For IGBTs, the optimum frequency is about 18 kHz, where the cooling and passive BoM savings curves intersect. For SiC MOSFETs, with their lower conduction losses, that sweet spot of cost tradeoffs is at about 60 kHz (Figure 3).
Designers must note that there is a limit to minimizing the inductors, particularly if the system is tied to the grid. And while SiC devices themselves are more expensive than IGBTs, a frequency-optimized design sees a 20% to 25% cost savings at the system level.
The figure of merit (FoM) for a MOSFET is defined by the equation below. The idea behind it is that lower RDS(ON) means lower conduction losses, while lower gate charge, Qg, means lower switching losses. Total losses are minimized if their product, FoM, is minimized.
An examination of the output current and output power versus switching frequency characteristics of two of Wolfspeed’s highest-power-density power modules reveals how designers must carefully select the optimal product for their application (Figure 4). The 450 A CAB450M12XM3 module is optimized for very low RDS(ON), but the 400 A CAB400M12XM3 module is optimized for FoM. Over 15 kHz, the 400 A delivers higher current and higher power.
For a motor drive typically operating below 20 kHz, the higher-amperage module is effective, but for solar power inverters switching in the 48 kHz to 60 kHz range, the 400 A module is a better choice.
IGBTs are typically rated at 1.2 kV, with VDS breakdown voltage close to 1.25 kV. Wolfspeed’s SiC MOSFETs, while rated at 1.2 kV, typically have breakdown voltages several hundred volts higher. In aerospace applications, in which designers must derate to account for the effects of cosmic radiation, SiC’s robustness offers an advantage.
Designers may not pay as much attention to it when soft-switching or using asymmetric designs, but reverse recovery (Qrr) is important for symmetrical designs, including buck, boost, and totem-pole PFCs. A Wolfspeed 650 V SiC MOSFET would have an 11-nC Qrr for a reverse-recovery time, Trr, of 16 ns compared with a typical 650 V Si MOSFET that has a 13 μC Qrr for a Trr of 725 ns.
The Kelvin source pin — a Kelvin connection that is as close as possible to the source connection of the MOSFET die — is used to mitigate inductance due to internal bond wires of the MOSFETs. To maintain the high switching frequency advantage of SiC devices, the Kelvin source pin is critical.
The Kelvin source pin also affects switching loss. For instance, at 30 A IDS, the total switching loss in a TO-247-3 SiC MOSFET with no Kelvin pin and 12 nH source inductance is close to 430 μJ (Figure 5). The same product in a TO-247-4 package — with a Kelvin source pin — has merely 150 μJ of switching loss at the same IDS. Moving to a smaller package like the TO-263-7 or the surface-mount D2PAK-7 further reduces the inherent source inductance and the losses.
When driving SiC MOSFETs, designers must remember that a negative gate drive is needed to ensure a hard turnoff, unlike with silicon, in which a positive gate drive is used to turn on the device. Other SiC-specific factors to remember include:
Beyond this, driving SiC devices is much like driving Si-based devices.
Because target switching frequencies are usually higher for SiC devices, and their rise and fall times are much shorter than those of Si products, engineers may be inclined to believe that this would cause greater EMI issues.
However, there is no effect on the low-frequency noise or the differential mode EMI filter size required compared with Si. While there is an effect on the conduction mode noise on the input terminal, it is only in the megahertz range. This high-frequency EMI can be attenuated, just like with Si-based devices, by using high-frequency material and capacitor for EMI suppression.
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