Advances in Motor Technology

and Energy Efficiency Initiatives

Demand Next-Generation,
Multiple-Capability Drives

WHITE PAPER

Reduce Total Cost of Ownership

TABLE OF CONTENTS
INTRODUCTION
VFD TECHNOLOGY DRIVES ENERGY SAVINGS
BENEFITS OF VFD USE BEYOND PUMPS AND FANS
INCREASING USE OF INTERIOR PERMANENT MOTORS (IPMS)
IPM MOTORS AND INCREASINGLY CHALLENGING APPLICATIONS
ARE DRIVING VFD DEMAND
THE MITSUBISHI ELECTRIC FR-A800 SERIES
SUMMARY
 Advances in Motor Technology and Energy Efficiency
Initiatives Demand Next-Generation, Multiple-Capability Drives
Introduction VFD technology drives energy savings
This industry Factories and machine builders are seeking ways Specific factors driving the need for VFD technology
demand calls to boost motor efficiency to intelligently maximize to increase energy efficiency include rising energy
energy savings. At the same time, these users prices and stringent energy efficiency regulations
for an all-in are transitioning from induction motors to interior imposed by various regulatory authorities around
permanent motors (IPM). the world. (In the U.S., the Energy Independence
one, variable and Security Act (EISA) mandated upgrades
These trends are propelling the need for higher
frequency performance drives that are facilitated through such
to full-load efficiencies, and the Committee of
European manufacturers of Electrical Machines
inverter that innovations as variable frequency inverter technology. and Electronic Power (CEMEP) also developed its
efficiency classification for induction motors.) Within
delivers Variable frequency drives (VFDs) are electronic
the industrial automation market, these factors are
systems used to control motor speed by changing
outstanding the frequency and voltage supplied to the motor.
compounded by the need for increasing plant and
machinery efficiencies, and the demand for higher
VFDs provide energy savings by matching power
performance consumption to actual power needs.
performance at reduced costs.

in any Any machine or process that can be improved by

Using VFDs for energy efficiency initiatives within
HVAC applications is evident, since these drives
environment. varying speed or flow is a candidate for a VFD.
allow the use of only the power needed to cool or
Variable frequency drives are used in all types of
heat a room or building. Conventional building HVAC
industries to achieve multiple speeds of operation in
applications operate fans and pumps at a constant
induction motors. But, industries that are adopting
speed. Building loads, however, are not constant.
the use of IPMs, such as oil and gas, metals and
In a conventional system, the use of mechanical
mining, power generation, water and wastewater,
throttling can reduce water or air flow in the system.
cement, and wind energy, demand high power, high
The drive motor, however, continues to operate at
performance drives in order to maximize productivity.
full speed, using approximately the same amount of
Original equipment manufacturers (OEMs), end energy regardless of the cooling or heating load on
users and systems integrators are increasingly the system. While mechanical throttling can provide
seeking a multiple-capability VFD that can be a good level of control, it’s not efficient. VFDs offer
used in both induction motors and next-generation an efficient and effective alternative. Since building
interior permanent motors – one that would be systems are sized for peak load conditions, pump and
suitable for both low performance applications such fan motors use more energy than necessary during
as pumps and fans, as well as high performance most of their operating hours. Variable frequency
industrial applications. The drive would have to be drives allow the use of energy as demand increases,
fast, dependable, easy to use, easy to integrate and only in the amounts necessary.
and install, and built for the long run. This industry
Additionally, using VFDs in air handlers, pumps,
demand calls for an all-in one, variable frequency
chillers and tower fans, for example, not only saves
inverter that delivers outstanding performance in any
energy, but reduces the motor starting current.
environment.
Variable frequency drives also reduce thermal and
mechanical stresses on motors and belts during
starts, resulting in a higher power factor and lower
kVA. Consequently, using VFDs not only lowers
energy costs, but can also mean greater operational
savings.

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 Variable Benefits of VFD use beyond pumps and fans Additionally, the majority of heavy equipment is
Beyond its use for energy and cost savings in designed and manufactured so that it can operate
frequency HVAC applications, VFD technology facilitates efficiently at peak loads. However, user demand
energy efficiency in all types of motors used in doesn’t always necessitate running equipment at
drives allow industrial plants. Electric motors represent nearly 50 peak levels. In fact, in many instances, companies
the use of percent of industrial energy consumed in the U.S., keep equipment running even when it’s not needed
according to the Natural Resources Defense Council. because of the effort it takes to shut machines down
energy as Consequently, controlling the speed of these motors completely, and then ramp them up again. VFDs
can have a dramatic impact on a plant’s ability to allow the option to put equipment in idle mode.
demand optimize energy use, as well increase machinery
VFDs also help to achieve tighter process control.
increases, efficiencies and meet the demand for higher
No other AC motor control method compares to
performance.
and only in variable speed drives when it comes to accurate
Variable frequency inverters are extremely valuable process control. Variable frequency drives can be
the amounts in applications that require precise speed control. programmed to run the motor at a precise speed,
And, by operating motors at the most efficient speed stop at a precise position, or apply a specific amount
necessary. for the application, fewer mistakes occur, and thus, of torque. In addition, VFDs also extend equipment
production levels increase. life and reduce downtime. Because of the variable
speed drive’s optimal control of the motor’s frequency
Variable frequency drives, by controlling the speed and voltage, the VFD will offer better protection of the
of a motor in real time, are able to adjust energy motor from issues such as electrothermal overloads,
use according to need. By varying motor speed to phase protection, under voltage and overvoltage.
meet the exact process demand, VFDs eliminate
the excess energy used when running a motor at a Also, single-speed starting methods activate motors
fixed speed. Consequently, VFDs can lower energy abruptly, subjecting the motor to a high starting
consumption by allowing a motor’s power level to be torque and current surges. VFDs, on the other hand,
adjusted exactly to performance needs. gradually ramp the motor up to operating speed. This
lessens mechanical and electrical stress, reducing
In a pipeline, for example, the motor runs at the same maintenance and repair costs, and extending the
speed and consumes virtually the same amount of life of the motor and the driven equipment. Variable
energy whether it’s 20 percent or 100 percent full of frequency drives can also run a motor in specialized
fluid. By installing a VFD, the motor can be slowed to patterns to further minimize mechanical and electrical
20 percent speed, thus saving money by consuming stress. For example, an S-curve pattern can be
less energy. applied to a conveyor application for smoother
deceleration/acceleration control, which reduces the
Variable frequency drives offer many advantages
backlash that can occur when a conveyor accelerates
beyond energy savings, thus their adoption in
or decelerates.
industrial applications continues to grow. One such
advantage is that VFD driven motors respond rapidly Factory automation professionals are continuously
to changing load conditions, for example, in response pressured to increase productivity by improving
to shock loads. VFD-driven motors also provide equipment reliability and plant availability. However,
precision torque output. with the realities of increasing operations costs,
decreased operating budgets and rising energy
FIGURE 1, VFD Benefits
costs, these goals can be at odds with one another.
Reduced Because of their high performance and lower power
Reduced
mechanical mechanical consumption, VFDs can help end users achieve
stresses positioning these goals in a variety of demanding industrial
applications.

Energy Savings

Precise Efficient
torque speed
control Dynamic load control
adjustment

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 IPM motors Increasing use of interior permanent motors IPM motors are gaining increasing popularity in
(IPMs) demanding motion control applications because
provide As adjustable speed drives increase in popularity, of their high efficiencies and energy‑reduction
interior permanent magnet (IPM) motors are gaining potential across various torque and speed ranges.
improved more recognition for highefficiency performance. In These next‑generation IPM motors, when paired
motor principle, there are no size limitations to IPM designs; with variable frequency drives, are ideally suited
they can be developed from fractional horsepower to to the most complex and challenging industrial
performance very high HP ratings, making them ideally suited to applications.
complex, demanding applications.
and integrity.
A relatively new design, an IPM motor uses
reluctance through magnetic resistance in addition to
magnetic torque by embedding a permanent magnet
in the rotor itself. Because the magnets are mounted
within the rotor structure, unlike conventional
permanent magnet motors where magnets are
mounted on the rotor surface, IPM motors provide
improved motor performance and integrity. IPM
motors are particularly beneficial when used in
conjunction with vector control, in which case, the
electronic controller tracks the rotor position with
respect to the stator field and injects the current to
optimize torque production and efficiency.

In an application requiring constant torque, such as

a conveyor, factory energy savings can be achieved
by replacing induction motors with IPM motors. IPM
motors are more efficient because the current doesn’t
flow to the rotor, so there is no secondary copper
loss. Magnetic flux is generated by the permanent
magnets, so less current is required to drive a motor.
Thus, an IPM motor used in a conveyor can maintain
a constant carrying speed, while saving energy.

Recent advances in IPM motor technology have

resulted in motors that are markedly more efficient
over a broad operating range compared with AC
induction motor designs. These advances, combined
with modern control methods, are fueling the
acceptance of IPM motors in the most challenging
applications. The power density of an IPM motor
is greater than an induction motor, so it produces
more power at a smaller size. IPM motors can also
continuously deliver high torque at low speed. The
high power density of IPM motors combined with the
ability to deliver high continuous torque over their
entire speed range eliminates the need for gearing
or other mechanical transmission devices in some
applications. They can also reduce maintenance
costs and space requirements, while increasing
reliability.

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 Variable IPM motors and increasingly challenging In some applications, such as material handling,
applications are driving VFD demand speed is just as important as reliability. For mail and
frequency As adjustable speed drives increase in popularity, package delivery, especially in December when
The union of IPM motors and VFDs in high services can increase by as much as 13 percent,
drives are performance industrial applications creates the need a delivery company’s reputation is contingent upon
also seeing for even greater advances in variable frequency ontime delivery. Moving thousands of letters and
technology to ensure performance, reliability, packages on a large conveyor, scanning bar codes,
increased use precision, speed, and networking capabilities. looking up the bar code information in a database,
then sending the signal via the VFD to the diverter
in high-speed While the number of applications suitable for requires an extremely high rate of speed. There’s a
early generation VFDs was limited based on the
winding, horsepower of the motor, innovations in variable
very small window in which the diverter takes that
signal and reacts. Only a variable frequency drive
because of frequency technology now make them well suited offers both the high rate of speed, and the ability
to high performance industrial applications. Early to control the speed required in such a demanding
the precision generation systems also suffered from low power application. Similarly, in the food and beverage
factor. Today’s VFDs operate at a nearly constant
required power factor over the entire speed range of the motor.
industry, where speed is critical to throughput and
productivity, using a combination of IPM motors and
in such As VFDs continue to evolve, they are proving to be VFDs can help companies stay competitive.
more useful and powerful.
applications.
For most end users of high performance drives,
reliability is an absolute necessity. This is especially
true for operations where machines far outnumber
personnel, such as in a sawmill. For one employee in
a control room loading trees on a conveyor, a failed
drive means the entire operation shuts down. In the
process of loading trees on a conveyor, analyzing
lumber sizes for optimum yield, then cutting up the
log, drive reliability is imperative. If the drive trips from
overuse or if there is a hiccup in the system, there’s a
big price tag to find the problem and fix or reset it.

FIGURE 2, Typical AC Motor

Motor Housing/construction

Concentrated windings

Insulation
Fan
IP54 Protection

Shaft

Motor terminal block

NEMA or IEC mounting

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 Engineers can Variable frequency drives are also seeing increased The Mitsubishi Electric FR-A800 Series
use in high-speed winding, because of the precision Most variable frequency drives provide improved
now specify required in such applications. In the intricate and process control, energy savings and reduced
complex printing process, for example, in order to maintenance. Competitive pressures within
one VFD for achieve a crisp image, unfolding the paper and manufacturing and other industries require that
all their motor feeding it through the printing press requires tight they also provide high performance, reliability,
synchronization. The VFD must control speed and precision and network compatibility, as well as a
control needs. accuracy, and maintain tension as the paper is fed lower total cost of ownership, reduced spares and a
through the machine so the ink is properly distributed smaller footprint. This can only be achieved with a
and doesn’t create a smeared image. Using a VFD multi-capability VFD that can be used in induction
with sensorless vector control can further ensure motors as well as next generation IPM motors, and
precision because it minimizes speed fluctuations of in low performance applications as well as the most
the ink roller axis and water roller axis to eliminate demanding industrial applications.
print unevenness.
Until now, engineers had to consider many
factors in choosing a VFD or motor controller.
FIGURE 3, IPM Solution Benefits
Motor variables such as horsepower, full load
amps, voltage, RPM, and service factor had to be
Accuracy
considered. In addition, other information specific
Reliability to the needs of the system and application, such
as type of load (constant torque or variable torque),
Speed
speed range, control method, and special enclosure
needs, would have to be matched to the drive
IPM Solution specifications.

The Mitsubishi Electric FR-A800 all-in-one

variable frequency inverter enables engineers to
Communication Precision specify a single VFD solution for all their motor
control needs. The FR-A800 VFD is designed for
maximum capacity, to optimize motor efficiency
Modern VFDs must also provide advanced in peak situations and ensure that there are no
networking capabilities. Today’s automated failures at times of highest demand. While the FR-
enterprises are connected and collaborative. An A800 provides high performance in severe duty
automotive manufacturer, for example, consists of situations, it can be scaled to fit any environment,
various departments using different technologies eliminating the need for multiple solutions to
from a myriad of manufacturers. A variable frequency address various motor control challenges. It’s also
drive that could be used interchangeably by welding, designed for flexibility to grow with an application.
painting and other departments, can act as a bridge
connecting the departments, with the drive acting as
one common hardware component. Only the option
card for the network would be different. The drive
would have to offer numerous networking options
allowing compatibility to various open networks.

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 Variable A permanent motor auto-tuning function allows The drive system’s energy monitor allows users to
the FR-A800 to operate with all Mitsubishi Electric confirm energy saving at a glance. This provides
frequency induction motors and permanent magnet motors, as the ability to visualize energy usage in real time,
well as virtually all induction motors and permanent rather than waiting for energy bills, allowing the
drives can magnet motors from other manufacturers. This management and optimization of energy use.
significantly requires fewer spare motors to be stocked. Mitsubishi Electric’s energy-optimization software
boosts motor efficiency and intelligently maximizes
FIGURE 4, FR-A800
reduce the energy savings. Meanwhile, optimum control of the
excitation current maximizes motor efficiency for
total cost of additional energy reduction.
ownership The FR-A800 premium VFD offers compatibility
of both the with various open networks. It’s equipped with
USB, RS485 and Modbus®-RTU interfaces.
motor and the Communication options are also available for the
major network protocols such as CC-Link® IE
drive. Field and CC-Link, EtherCat®, and SSCNET III/H
as well as DeviceNet™, PROFIBUS®-DP, and
LONWORKS®. Other Ethernet networks are also
supported. With a 10-year design life, the FR-A800
inverter is built for reliable, long-term operation
and is backed by Mitsubishi Electric’s superior
maintenance and service for the life of the drive.
Its total cost of ownership is not only measured by
amortizing the cost of the drive over its 10-year life,
but by the reduction in energy costs over those 10
The FR-A800 inverter features real sensorless vector years.
control to provide high-precision, fast response
speed control. The inverter also offers a choice of Designed for ease of use anywhere in the
V/F control or advanced magnetic flux vector control, world, the FR-A800 includes a multilanguage
allowing simple replacement of a conventional unit LCD parameter unit and complies with the most
inverter drive. demanding global standards. With unparalleled
drive precision, speed control, powerful startup,
A PLC function has also been added to Mitsubishi ease of use, simple installation and integration,
Electric’s latest generation VFD. Now, when using and long operating life, the FR-A800 all-in-one
sensors to check the presence and arrival of inverter meets the demands of OEMs, systems
goods on a conveyor, for example, the drive can integrators and end users for a multiple-capability
directly receive such signals from sensors and then inverter that can deliver superior performance in
command the speed accordingly. any environment.

Third party marks and brands are the property of their respective owners.

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 FIGURE 5, FR-A800 Features and Benefits

Feature

Real Sensorless Vector (RSV) Control High precision and fast response speed control

PLC Function Sequence control and flexibility for complex applications

Energy Monitoring Real-time confirmation and energy savings at a glance

Open Network Compatibility Simple connection to other devices on the plant floor or facility

Autotuning Optimized control for standard induction and IPM motors

Reliability Built with 10-year design life

Satisfies Global Standards Can be used anywhere in the world

Summary The versatility of the Mitsubishi Electric FR-A800

Historically, motor purchases have essentially been exponentially reduces total cost of ownership of a
based on dollars-per-horsepower costs. Increasingly, typical VFD by decreasing the number of spares
savvy buyers are now looking closely at the true required and providing industry-leading energy-
cost of ownership for both the motor itself and the savings capabilities. However, even more important
drive system. This broad perspective includes the than its TOC advantages, the FR-A800 meets
cost of powering the equipment over its useful life industry demands for a fast, reliable, dependable,
and the opportunity to substantially reduce those multi-capability VFD that can deliver superior
costs. Short-term hardware expense of motors and performance in both induction motors and next-
drives must be evaluated against the long-term cost generation interior permanent motors.
savings. With few exceptions, variable frequency
drives can significantly reduce the total cost of
ownership of both the motor and the drive.

MITSUBISHI ELECTRIC AUTOMATION, INC.

500 Corporate Woods Parkway, Vernon Hills, IL 60061
Ph 847.478.2100 • Fx 847.478.2253
us.MitsubishiElectric.com/fa/en
©2018, Mitsubishi Electric Automation, Inc.
Specifications subject to change without notice. • All rights reserved
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