What do Dust Collectors, Control Panels, Industrial Fans and Filter Cartridges have in common? They all contribute to creating an efficient dust collector that can solve your dust collection needs.
There are many different types of dust collector controls, but the most efficient is an accurately programmed VFD Control panel.
VFDs ensure that a dust collector operates as efficiently as possible, and in this blog, we’ll discuss why they’re the smart choice for every dust collection application.
What Are VFDs?
VFDs are electrical devices that control the frequency of the power being supplied to another electrical device.
Regulating the frequency of the incoming power is an effective way to change the fan motor speed since their relationship is directly proportional. For example, a VFD can change a motor that runs at 3,600 revolutions per minute (RPM) at 60 hertz (Hz) to run at 1,800 RPM at 30 Hz.
The fan draws only the amount of power required for the set speed. For instance, a fan that runs 25 percent slower than 100 percent would use 42 percent of the power that would be required for full speed. The same fan running 50 percent slower would use 12 percent of the full speed power.
Benefits of Using VFDs in Dust Collectors
When used in dust collectors, VFDs provide many more benefits than basic motor starters, including the following:
VFDs Allow You to Soft-Start a System
If you immediately start up a dust collector at full speed, the fan could draw very high power. However, when the process gets up to a steady rate (i.e., a higher operating temperature than ambient air), the power level will go down significantly. With a VFD, you can avoid this power decrease by slowly ramping up the fan speed as the temperature increases. In turn, you won’t have to oversize your motor to compensate for startup.
WHY THIS MATTERS: Electrical costs will be reduced due to the lower amp draw at startup, as well as the ability to reduce the speed of the fan according to filter conditions and changes in process or cubic feet per minute (CFM) requirements.
VFDs Take the Human Interaction Out of Fan Adjustment
Because VFDs automatically manipulate the frequency and power consumption supplied to the fan motor, routine human interaction is no longer required. The VFD, equipped with an airflow or static pressure sensor, will automatically sense changes in airflow and pressure drop, and will adjust the fan speed to return the system to optimal airflow.
New filters = the drive decreases fan speed to obtain the desired airflow
Dust-filled filters = the drive speeds up the fan to keep the airflow consistent
Without VFDs, you have to manually open or close dampers, creating high manual labor costs. Additionally, if there are multiple dampers on the system, tampering with the opening and closing of any one damper can cause the airflow balance to be off and can increase the static pressure of the system.
WHY THIS MATTERS: The automatic speed adjustment decreases the amount of labor needed to maintain the dust collector since no one has to change an outlet damper routinely. The VFD also ensures the dust collection system is regularly operating at the ideal air-to-cloth ratio.
Make Your Dust Collector More Efficient
VFDs have been proven to save energy over the life of the filters. The additional capital cost savings made possible by installing a VFD on a dust collection system will vary with different applications. However, the ROI is typically achieved within less than a year.
A.C.T. Dust Collectors offers solutions for all dust collection needs and will assist with making sure your dust collection system operates efficiently. Our industrial dust collector parts are tested, approved and can improve performance and extend the life of your system.
For more information on variable frequency drives or to discuss your specific dust collection needs, please contact us.