Input Chokes for Danfoss Drive - Heavy Noise and Heating

Has anyone been through with a set of spanners and checked that all connections and supports are as tight as they should be?

we had send a service team to check all the terminations to the chokes are tightened to max level and they said everything is fine. what we doubt is whether the drive is creating more harmionics.

what will be the reason for heat and noise? please help me out...

Has anyone been through with a vacuum cleaner and sucked up any wire trimmings or dropped spare washers?

i think there wont be any dropped washers are trimmers, becoz all the 5 drive panels have the same problems

The maintenence crew should be able to spot something. I agree with previous posts. Check the simple stuff first. Make sure everything has been installed correctly to begin with.

we had only supplied chokes for danfoss , danfoss manufactured the whole control panel, we dont know much about control panel ,what these danfoss people say is everything is perfect from their side(except choke).

what we doubt is whether they using the specified shielded cables or not, or the drive is creating excess harmonics or the input voltage is low

please help us to solve this problem

You need to have the power quality assessed. You may be seeing the choke do it's job quite as designed, but with a greater value in harmonics to deal with than you anticipated, exceeding the current rating of the choke.

i dont know wheather input voltages are correct , but what these danfoss people say is thier drive wont work if the voltages are low,i dont know what they are saying is true or false

if the harmonics devoloped is more then it is the drive problem ,how can i prove them the harmonics devoloped is excessive, if it the problem then i have to design for a more higher rating choke for them

please help me out of this problem

FLUKE meters that evaluate harmonics can record the result, which can be transmitted to your location for evaluation.

Since this is happening to only two of several drives, look for differences in the details. Are they all fed from the same source generator? What are the differences in the controlled motors? Did Danfoss design the controls exactly alike, or are there special adaptations for these 2 controls?

Heat equates directly to energy. A choke is designed to extract energy of specific frequency ranges, and sound specifically requires physical motion. Iron core design and the result of saturation are features you have a handle on as the manufacturer, but you need more information from the site.

I have on occasion received equipment that was mis-marked for polarity and/or rated values. Again you need information.

When you say, we supplied input chokes, were these chokes manufactured by Danfloss?

If not, why wern't they?

Also dont forget that the ambient temperature in India is quite high, the further North you go the higher the ambient temperature, have these chokes have cooling fans connected. If there is no cooling and with the high ambient temperature you may find that the problem is due to heat expansion causing the fault.

The chokes are connected on the line side of the drive arent they?

Are they the correct chokes for the supply frequency?

I know that this is not the right thing to do, how about bypassing the chokes and see how this works.

Also what are the drives running?

If all else fails maby a field trip may be required, I have spent a lot of time in Pakastian, and in my experience it has been easier, just to fly there and sort out the problems myself. You must understand a lot of information can be lost in the translation.

May The Force Be With You!

These chokes are manufactured by us (transtrac electronics pvt ltd) and we supplied the chokes to danfoss drives division ltd and they manufactured the whole control panel and installed it.

They bypassed the chokes the drive is working fine(danfoss people gave these details we are not present at site)

the drives are running 200kw and 132kw motors and ive dont know thier application

dear joe,

we had supplied an alternative choke designed for 200% saturation level and waiting for the result .

"nos" means numbers

my contact number 91-044-09840977368 please feel free to contact me

please give us ur contact details

ru working for some company or an freelancer?

choke heating can be one of the reason unbalanced voltage or that magnetic path disturbed by something else better make site visit and study the physical installation status like check earthing connection of core body earth and whether having adecuate air flow /any blokage in ventilation path

nomally any ion material influenced in this magnetic path it can creat eddycurent circulate then it leads to the choke and heating themself.

regards,

R.Bhashyam

I've been "in motion" for quite a while.

If you have a variable frequency drive, you need to adjust the base frequency of the motor, the PWM carrier frequency and also program maybe one or two skip frequencies to avoid resonant states.

If you have a servo system, you need to adjust the position proportional gain, the velocity feedforward gain (usually lessen = quieter) BE READY TO HIT E-STOP. If all this fails then run "AUTO TUNE" (i don't like it myself but will be fine for most aplications).

Yahlasit

Overheating and noise go together in 95% of these cases and are caused by a poorly tunned drive. Only rarely will be a failure within the drive (unless it's around 10 years old).

Yahlasit

READ ME FIRST !

Before you mess with the adjustments I mentioned before, you have to, at least browse the user manuals of the drive and see what each parameter is intended for.

Arriba muchacho, no te desanimes !

Yahlasit

The problem is we had supplied 5 chokes 200kw - 2nos ,132kw-3nos , all five of them are heating and creates noise . if any one creates problem its ok if all five has these same problems, its hard to find out the problem...

we dont know wat to do...

wat we suspect is some extra harmonics is created somewhere

If these input chokes are sized properly, the excessive noise could be caused by phase imbalance. This can come from line voltage imbalance, a burned fuse, or by a burned diode bridge. Measure the phase current and voltages to verify those.

Good luck

First you must look at the basics, what is the ambient temp?

You add the ambient temp to the heat generated from the chokes, this would be a high value.

Also are the input chokes designed to the input frequency?

Also i dont think you have bothered to answer my previous questions, so why should i bother!

Answer all questions that are posted, to assist in giving us, the people that are trying to help, a better picture of what is going on.

If you dont a field trip will be parmont.

Find out what is going on, get of your butt and do some investigation.

Without your input, and asking questions we are all guessing as to what the problem or problems are.

I am also not familar with the term "nos" means?

If the chokes are heating to 100 degree c, things are going to change.

And you will have problems.

Answer all questions please, otherwise i for one will be of no more assistance.

dear soebfatehi ,

It is an mixed noise electrical humming and chattering noise (dont know the noise level but its slightly higher if u want we can send the audio file of the noise)

only core it getting heat more than 100deg and coils only to the max of 65deg

no forced cooling(just one fan provided at top of the roof of panel)

room tempurature will be 28 deg

ambient temp 35deg

yes vacum impergnated

mechanically everything full tight

tierods where in choke?

electrically cant provide all details

dont know what kind of cables used

we had supplied an alternative choke designed for 200% saturation level and waiting for the result .

my contact number 91-044-09840977368 please feel free to contact me

please give us ur contact details

ru working for some company or an freelancer?

- tierods are vertical rods for holding upper yoke and lower yoke in place

- core overheat means bad news - 100 deg and 65 deg is final temperature? or is it the rise above ambient? what is the insulation class? if you have designed for class B you have a problem but with class F or class H your temperature looks pretty good

- what is the core material you are using? what are the watt losses of the lamination? using thinner gauge can help you -

- importantly - drive manufacturers specify choke linearity and L values for a typical expected harmonic spectrum - at many sites the harmonic spectrum can differ due to a variety of reasons so if the chokes are standard designs performing in service elsewhere and troubling you at one location only then a site conditions analysis is called for - thereafter the drive manufacturer may have to respecify the choke for you to design