Introduction

In modern industrial and commercial applications, the efficient and precise control of electric motors is paramount for optimizing processes, reducing energy consumption, and extending equipment lifespan. Traditional motor starting methods, such as direct-on-line (DOL), often result in high inrush currents, mechanical stress on machinery, and inefficient operation for variable speed applications. Advanced Motor Control Systems, specifically Variable Frequency Drives (VFDs) and Soft Starters, have revolutionized motor control by offering capabilities ranging from smooth, controlled acceleration and deceleration to precise speed and torque regulation. These intelligent control devices not only mitigate the drawbacks of conventional starters but also unlock significant energy savings and enhance the overall performance and reliability of motor-driven systems. Without a comprehensive understanding of Advanced Motor Control Systems (VFDs & Soft Starters), industries risk suboptimal operational efficiency, increased maintenance costs, and an inability to fully leverage the benefits of modern automation technologies. This comprehensive training course focuses on equipping professionals with the expertise to master Advanced Motor Control Systems (VFDs & Soft Starters).

This training course is meticulously designed to empower electrical engineers, automation specialists, maintenance technicians, control system designers, and project managers with the theoretical understanding and hands-on practical skills necessary to select, install, configure, troubleshoot, and optimize Advanced Motor Control Systems. Participants will gain a deep understanding of motor characteristics, explore the operating principles of VFDs and soft starters, learn about advanced control algorithms for various motor types, and acquire skills in integrating these systems into complex automation architectures. The course will delve into topics such as harmonic mitigation, regenerative braking, industrial communication protocols (e.g., Modbus, EtherNet/IP, PROFINET), energy efficiency calculations, protection features, and advanced troubleshooting techniques. By mastering the principles and practical application of Advanced Motor Control Systems (VFDs & Soft Starters), participants will be prepared to enhance industrial productivity, reduce operational expenditures, improve system reliability, and contribute significantly to the energy efficiency goals of their organizations.

Duration: 10 Days

Target Audience

• Electrical Engineers
• Automation and Control Engineers
• Maintenance Technicians and Supervisors
• Industrial Electricians
• System Integrators
• Project Engineers and Managers
• Application Engineers (Drives & Motors)
• HVAC System Engineers
• Water/Wastewater Treatment Plant Operators
• Machine Builders and OEMs

Objectives

• Understand the fundamental principles of AC motor operation and characteristics.
• Learn about the limitations of traditional motor starting methods.
• Acquire skills in identifying appropriate applications for VFDs and soft starters.
• Comprehend techniques for selecting and sizing VFDs and soft starters.
• Explore strategies for configuring and programming VFDs for various control modes.
• Understand the importance of harmonic distortion and its mitigation in VFD applications.
• Gain insights into energy saving potentials and efficiency calculations with VFDs.
• Develop a practical understanding of industrial communication protocols for drive integration.
• Learn about protection features and troubleshooting methods for VFDs and soft starters.
• Master the installation considerations for drives and associated cabling.
• Acquire skills in commissioning and testing advanced motor control systems.
• Understand the integration of drives into PLC/DCS control architectures.
• Explore advanced control algorithms such as sensorless vector control and direct torque control.
• Develop proficiency in diagnosing and resolving common issues with VFDs and soft starters.
• Prepare to optimize motor-driven processes for enhanced performance and energy efficiency.

Course Content

Module 1: Review of AC Motor Fundamentals

• Induction motor construction and operating principles.
• Synchronous motors and their characteristics.
• Motor nameplate data interpretation.
• Speed-torque characteristics of various motor types and loads.
• Basic motor control circuits and protective devices.

Module 2: Introduction to Motor Starting Methods and Their Limitations

• Direct-On-Line (DOL) starting: advantages and disadvantages.
• Star-Delta (Wye-Delta) starting.
• Auto-transformer starting.
• Resistor and Reactor starting.
• Inrush current, mechanical stress, and power quality issues with traditional methods.

Module 3: Soft Starters - Principles and Applications

• Operating principle of soft starters: SCR control for voltage ramp-up.
• Advantages of soft starters: reduced inrush current, smooth acceleration.
• Internal bypass contactor and braking functions.
• Application considerations: pumps, fans, conveyors, compressors.
• Selection and sizing of soft starters.

Module 4: Variable Frequency Drives (VFDs) - Basic Principles

• Fundamentals of VFD operation: rectifier, DC bus, inverter sections.
• Pulse Width Modulation (PWM) techniques for voltage and frequency control.
• Relationship between voltage, frequency, and motor flux.
• V/Hz control (scalar control) for basic applications.
• Advantages of VFDs: precise speed control, energy saving, soft start/stop.

Module 5: VFD Topologies and Motor Types

• VFD topologies: Volts/Hz, Vector Control, Direct Torque Control (DTC).
• VFDs for Induction Motors (IM).
• VFDs for Permanent Magnet Synchronous Motors (PMSM).
• VFDs for Synchronous Reluctance Motors (SynRM).
• Multi-drive systems and common DC bus configurations.

Module 6: Advanced VFD Control Algorithms

• Sensorless Vector Control (Field-Oriented Control - FOC): principles and benefits.
• Direct Torque Control (DTC): principles, accuracy, and dynamic response.
• Closed-loop vector control with encoder feedback.
• Tuning VFD auto-tune functions for optimal performance.
• Advanced control features: flux braking, flying start.

Module 7: VFD Sizing and Selection

• Factors influencing VFD sizing: motor horsepower, load type, ambient temperature, altitude.
• Overload capacity and service factor.
• VFD types: standard duty, heavy duty, regeneration.
• Input and output filtering requirements.
• Matching VFD to motor and application.

Module 8: Energy Efficiency and Savings with VFDs

• Fan and pump affinity laws.
• Energy saving potential of VFDs in variable torque applications.
• Calculating energy savings and ROI for VFD installations.
• Power factor improvement with VFDs.
• Regenerative VFDs: principles and applications (e.g., elevators, cranes).

Module 9: Power Quality and Harmonic Mitigation

• Sources of harmonics in VFDs: non-linear rectifiers.
• Effects of harmonics on the electrical system (transformers, capacitors, cables).
• Harmonic mitigation techniques: DC link chokes, AC line reactors, multi-pulse rectifiers, active front end (AFE) VFDs, passive and active filters.
• IEEE 519 standard and harmonic limits.

Module 10: VFD Installation and Wiring Best Practices

• Input and output wiring considerations: proper cable sizing, shielding, grounding.
• EMC/EMI considerations and mitigation.
• Filter installation (line filters, dV/dt filters, common mode chokes).
• Control wiring and segregation from power wiring.
• Enclosure selection and cooling for VFDs.

Module 11: Protection Features and Safety

• Motor protection functions integrated in VFDs: overload, overcurrent, overvoltage, undervoltage, ground fault.
• Drive protection features: overtemperature, short circuit, phase loss.
• Safe torque off (STO) and safe stop functions.
• Integration with emergency stop circuits.
• Arc flash safety considerations in VFD panels.

Module 12: Industrial Communication Protocols and Integration

• Overview of common industrial communication protocols: Modbus RTU/TCP, EtherNet/IP, PROFINET, DeviceNet.
• Integrating VFDs into PLC/DCS control systems.
• SCADA system integration for VFD monitoring and control.
• Data exchange between VFDs and higher-level control systems.
• Remote access and cloud connectivity for drives.

Module 13: VFD Commissioning and Troubleshooting

• Pre-commissioning checks and initial power-up.
• Parameter setting and configuration.
• Motor auto-tune procedures.
• Common VFD faults and alarm codes.
• Systematic troubleshooting methodologies for VFD and motor issues.

Module 14: Soft Starter Commissioning and Troubleshooting

• Soft starter parameter settings and adjustments.
• Bypass contactor functionality testing.
• Common soft starter faults and diagnostics.
• Troubleshooting soft starter issues during acceleration and deceleration.
• Practical considerations for soft starter maintenance.

Module 15: Advanced Applications and Future Trends

• Multi-motor control systems.
• Regenerative drives and energy recovery applications.
• High-voltage VFDs for large motors.
• Condition monitoring and predictive maintenance for drives.
• The role of VFDs in smart manufacturing, Industry 4.0, and digital twins.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 10 working days before commencement of the training.