electric drive
DESCRIPTION
electrical VFDTRANSCRIPT
1Copyright © 2008 Schneider Electric. All rights reserved
Go Green with AC Drives
Make the most of your energySM
Identify Energy Savings opportunities with AC Drives
2Copyright © 2008 Schneider Electric. All rights reserved
I. Energy Opportunities
II. Description AC Drives
III. Affinity Laws
IV. Building Applications
V. Conclusion
Go Green with AC Drives
3Copyright © 2008 Schneider Electric. All rights reserved
Increasing cost of energy, especially oil and gas
World’s expanding energy consumption from developing countries i.e. China, India
World events creating security concerns in oil producing areas of the world
U.S Electrical power grid black-outs Northeast and West Coast
Hurricane effects felt in oil producing Gulf of Mexico region
Oil and gas prices –July 2006 $75.00 dollars per barrel $2.00 / gallonJuly 2008 $150.00 dollars per barrel $4.00 / gallon
Energy Savings Opportunities
4Copyright © 2008 Schneider Electric. All rights reserved
U. S. Department of Energy Energy Star Program
Heating and cooling systems are the largest consumers of energy in buildings.
64% of electricity used in industrial facilitiesFor electric motors to power centrifugal pumps and fans
Source: U.S. Department of Energy
Energy Savings Opportunities
5Copyright © 2008 Schneider Electric. All rights reserved
Where are the savings ?
Industry & infrastructureAverage facility can reduce consumption by 10 to 20%
Data centers & networksPower & cooling can reduce power consumption by 20 to 30%
Buildings
Renovation can yield up to 30% of energy savings
Residential
EE products may save 10% to 40% in electricity
25% savings would save 7% of the world’s electricityMotors, account for over 60% of electricity usage
20% to 25 % of consumedenergy (EU & US)Lighting & appliances over 40%
Consume 20% of total energy 3 key areas: HVAC, lighting & integrated building solutions
Power & cooling systems comprise 50% of electricity usage Saving energy improves DC infrastructure efficiency
6Copyright © 2008 Schneider Electric. All rights reserved
U.S. Green Building Council
36% of total energy consumed in the United States is used for buildings
Includes natural gas, electricity and steam
65% of the electricity consumed in the United States is consumed for buildings
Source: US Green Building Council
Energy Savings Opportunities
7Copyright © 2008 Schneider Electric. All rights reserved
United States Government Single largest user of energy in the world45% of energy consumed by the US government is
used to heat, ventilate and cool buildings.
Energy Bill LegislationEnergy Policy Act 0f 2005 (EPAct 2005) signed into law September 2005
Mandates federal facilities to reduce energy consumption by 2% per year, every yearExtended Daylight Savings time period
Source: NEMA
Energy Savings Opportunities
8Copyright © 2008 Schneider Electric. All rights reserved
International Facility Management AssociationOverall cost of running a facility is 10 percent higher than it
was four years ago
IFMA Benchmarks V StudyUtility costs have jumped 19 percent in two years
Includes electricity, gasoline, fuel oil, steam water and sewageCompared to similar data from 2006.
Source: International Facility Management Association
Energy Savings Opportunities
9Copyright © 2008 Schneider Electric. All rights reserved
Energy used in Healthcare Facilities is for
Ventilation Fan EnergyVentilation Air CoolingReheating / Space HeatingOutside Air / Cooling / Dehumidification / Humidification
Energy for hospital HVAC systems59% to 64% of the annual energy cost (typical healthcare facility based on location)
Source: ASHRAE Winter Meeting 2008
Best Practice HVAC Systems-Healthcare
Energy Savings Opportunities
10Copyright © 2008 Schneider Electric. All rights reserved
15 Steps to a More Sustainable Hospital
Recommends VFDs on all motors 3 hp and higher
Installation of VFDs on smaller motorsReduced cost of drivesIncreased distribution and power of Direct Digital Control (Building Automation Systems)
New drives may be controlled in two modes;Modulate flow based on a variable sensor input (PID feedback control)Controlled to balance a constant speed system
valves fully opened to reduce system head loss.
Source: Engineered Systems Magazine July 2008
Author: Steven Furgeson, PE
Energy Savings Opportunities
VFDs have the potential to save energy even on smaller motors.
11Copyright © 2008 Schneider Electric. All rights reserved
LEEDLeadership in Energy and Environmental Design Certification for Buildings
Recommends ASHRAE 90.1-2004 to set minimum HVAC requirementsPromotes effective energy conserving designs for
buildings and building systems
ASHRAEAmerican Society of Heating Refrigeration and Air Conditioning Engineers Recommends HVAC systems be equipped with Variable Speed Drives if they have:
Variable Air Volume fan controlIndividual fan motors greater than 5 hp
Energy Savings Opportunities
12Copyright © 2008 Schneider Electric. All rights reserved
Today, variable speed drives are widely used in buildings and are reliable and proven electronic technology.
Energy Savings Opportunities
13Copyright © 2008 Schneider Electric. All rights reserved
I. Energy Opportunities
II. Description AC Drives
III. Affinity Laws
IV. Building Applications
V. Conclusion
Go Green with AC Drives
14Copyright © 2008 Schneider Electric. All rights reserved
Input PowerInput Power
DriveDrive MotorMotor
ControlControl
MachineMachine
Adjustable Frequency Drives are just one piece of the system
Adjustable Frequency Drives are just one piece of the system
33∅∅
Typical Drive System
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ConverterConverter InverterInverter
DC Bus++
__
AC Line
Constant Frequency
Motor Leads
Adjustable Frequency
Typical AC Drive
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i
VVV
AC Line Voltage(non-rectified)AC Line Voltage(non-rectified)
ttt
RectifierRectifier DC Voltage (rectified)DC Voltage (rectified)
Converter uses solid state devices to change AC to DCConverter uses solid state devices to change AC to DC
+++
---
Six Pulse AC to DC Converter
Typical AC Drive
17Copyright © 2008 Schneider Electric. All rights reserved
Typical AC Drive
AC Line Voltage(non-rectified)AC Line Voltage(non-rectified)
RectifierRectifier
VVV
tttttt
DC Voltage (rectified)DC Voltage (rectified)
Converter uses solid state devices to change AC to DCConverter uses solid state devices to change AC to DC
+++
i
Six Pulse AC to DC Converter
18Copyright © 2008 Schneider Electric. All rights reserved
DC to AC InversionDC to AC Inversion
VVV
tt tt
AC Voltage (inverted)AC Voltage (inverted)
InverterInverter
VVDC Voltage (non-inverted)DC Voltage (non-inverted)
Typical AC Drive
19Copyright © 2008 Schneider Electric. All rights reserved
DC to AC InversionDC to AC Inversion
VVV
tttt
AC Voltage (inverted)AC Voltage (inverted)
InverterInverter
VVDC Voltage (non-inverted)DC Voltage (non-inverted)
Typical AC Drive
20Copyright © 2008 Schneider Electric. All rights reserved
Optimized power section
DC bus capacitor section is reduced– 95%-97% less typical AC drive capacitor value
Input current waveform characteristics are optimized
– reduction in current spikes typically observed due to capacitance charging
Total input current draw is reduced– lower input current harmonics
Motor control algorithms and powerful microprocessors − engineered to produce sinusoidal wave form to
the motor
Rectifier D C Link Inverter
Three
Phase Power
+
-
C
New Technology for AC Drives
21Copyright © 2008 Schneider Electric. All rights reserved
Typical AC drive100HP
Typical 6 pulse AC drivewithout line reactor
Input voltage: orange
Input current: cyanLarge current spikes due to capacitors
chargingPeak currents = 300 amps
Harmonic current distortionLarge double humped current waveform
significantly contributes to harmonic content.
Total Harmonic Distortion Current (THDI) = 80%
New Technology for AC Drives
22Copyright © 2008 Schneider Electric. All rights reserved
New Technology for AC Drives
AC drivewith line reactor
100HP
Typical 6 pulse AC driveWith 3% line reactor
Input voltage: orange
Input current: cyanLower current spikes due to
capacitors chargingPeak currents = 190 amps
Harmonic current distortionSignificant double humped current
waveform contributes to harmonic content
Total Harmonic Distortion Current = 38%
23Copyright © 2008 Schneider Electric. All rights reserved
Optimized power section100HP
Input voltage: orange
Input current: cyanLow current spikes due to capacitors chargingPeak currents = 190 amps
Harmonic current distortionInput current is a square shaped waveform Eliminating the large double humped
waveform Reducing harmonic content
Total Harmonic Distortion Current = 33%
New Technology for AC Drives
24Copyright © 2008 Schneider Electric. All rights reserved
E-FlexS-Flex M-Flex PowerGard
Range:208/230V 1-40hp460V 1-100hpTarget Market:Residential high riseCommercial office buildingsGovernment facilitiesSchools and Universities
Range:208/230V 1-50hp460V 1-100hpTarget Market:Commercial buildingsHospitalsGovernment facilitiesSchools and Universities
Range:460V 50-500hpTarget Market:IndustrialMunicipal pumping
Range: 208/230V 1-50hp460V 1-500hpTarget Market:Government facilitiesHospitalsPharmaceuticalIndustrialMunicipal pumping
Enclosed AC Drives Products
25Copyright © 2008 Schneider Electric. All rights reserved
MCC Total Solution
UpstreamElectricalNetwork
208-480V
AccuSinePCS
M
VFD
M
VFD
MM
Corrected Loads
MCC Enclosure
Schneider Electric applied and packaged solution for single point
of responsibilityReduced installation costsCan be used for active harmonic filtering of non-linear loads both within and outside the MCC (based on CT installation)
Multiple units can be paralleled for larger RMS ratingsNo harmonic study required to size Accusine PCS for a particular
application
26Copyright © 2008 Schneider Electric. All rights reserved
AC Drives Products
Range:208/230V 1-40hp460V 1-100hpApplicationsCentrifugal PumpsFansTarget MarketOEMsControl Panel Builders
Range:208/230V 1-125hp460V 1-900hp600V 1-900hpApplicationsCentrifugal PumpsFansTarget Market:OEMsSystem IntegratorsControl Panel Builders
Altivar 61Altivar 21
27Copyright © 2008 Schneider Electric. All rights reserved
I. Energy Opportunities
II. Description AC Drives
III. Affinity Laws
IV. Building Applications
V. Conclusion
Go Green with AC Drives
28Copyright © 2008 Schneider Electric. All rights reserved
Affinity Laws for Centrifugal Loads
Adjustable Speed Drives increase system efficiency provide means to reduce motor speed for pumps and fans based on the needs of the building environment
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Significant energy savings at lower motor speeds can be realizedbased of the Affinity laws;
Flow = f (motor speed)
Pressure = f (motor speed)2
Horsepower = f (motor speed)3
Affinity Laws for Centrifugal Loads
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Affinity Laws for Centrifugal Loads
Lower motor speed = less energy consumption
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Affinity Laws for Centrifugal Loads
A motor running at 90% of full speed requires 73% of the electricity of a motor running at 100% speed. (.9 x .9 x .9 = .729)
Lower motor speed = less energy consumption
32Copyright © 2008 Schneider Electric. All rights reserved
Affinity Laws for Centrifugal Loads
A motor running at 80% of full speed requires 51% of the electricity of a motor running at 100% speed. (.8 x .8 x .8 = .512)
Lower motor speed = less energy consumption
33Copyright © 2008 Schneider Electric. All rights reserved
Affinity Laws for Centrifugal Loads
A motor running at 50% of full speed requires 12.5% of the electricity of a motor running at 100% speed.(.5 x .5 x .5 = .125)
Lower motor speed = less energy consumption
34Copyright © 2008 Schneider Electric. All rights reserved
Customer Benefit Calculation
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Customer Benefit Calculation
Cost Savings
Drives pay for themselves in a relatively short period of time.
Typically < 2 years depending on applications through savings on electricity bills.
36Copyright © 2008 Schneider Electric. All rights reserved
A fan with a 20 horsepower motor supplies air12 hours a day260 days a year Energy cost is of $0.09 cents per kilowatt-hour.
Cost of running a 20hp motor full speed 12 hours per day:20 hp x 0.746 kW/hp x 3120 hours x $0.09/kWhr = $4190 per year
Typical Average Annual Utility Rates ($/kWh):*San Francisco $0.1419Los Angeles 0.1266Dallas 0.0900Richmond 0.0689New York 0.2037Average $0.1262
*Source: Syska Hennessy Consulting Group Atlanta, GA
Customer Benefit Calculation
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Assuming the fan does not need to run at full speed all of the day:Running full speed (100%) for 25% of the day 80% speed for 50% of the day50% speed for the remaining 25% of the day
Cost of running with an AC drive controlling the motor:20 hp x (1)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $1,047 per year20 hp x (0.8)3 x 0.746 kW/hp x 1560 hours x $0.09/kWhr = $1,07320 hp x (0.5)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $131
Total = $2,251 per year
Annual savings: $4,190 - $2,251 = $1,939 savings per year
20hp drive typical cost: $2,709 installed cost
(2709 cost per drive / 1939 savings per year) x 12 months = 17 months payback
Customer Benefit Calculation
Payback for the cost of the drive is less than two years
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Energy Savings Calculator
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Energy Savings Calculator
www.squaredleantools.com
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Case Study
Actual Cost Savings Example
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Customer replaced motor soft start device with AC Drive
Actual measurable savings in cost of electricity achieved was $148.00 dollars per week
$7,696.00 dollars electricity saved per year
Cost of drive and metering: $4,500 installed cost
Case Study – Food Manufacturer, Tennessee
Payback for the cost of the drive and meter - 7 months
46Copyright © 2008 Schneider Electric. All rights reserved
BackgroundAir distribution system for 155,000 square foot clothing store provided by five air handling units located in penthouse equipment room.Two return fans vented air from first and second floors through ductwork to air handling unitsAir handling units provided conditioned air through out the building through ductwork to diffusers.Fans operated at two speeds, high and low, adjusted manually.Fans usually operated at high speed setting, occasionally at low speed setting.
Testing was conducted to determine airflow at high speed.Data collected indicated actual airflow from each AHU was less than designed airflow;
therefore fans were larger than necessary for this facility.Accumulation of dirt on the cooling coils in AHU 1 and 2 restricted airflow and wasted fan energy.Measurements of each motor indicated maximum load was less than horsepower rating.
Potential energy saver – minimize outside air for ventilation. Outside air has to be heated or cooled which require energy.By monitoring carbon dioxide levels in building – air intake could be reduced to minimum quantity necessary.
Case Study – JC Penney, Atlanta, GA*
*Energy Star® Building Manual - Fan System Upgrades
47Copyright © 2008 Schneider Electric. All rights reserved
SolutionInstall variable frequency drives on supply air and return air fans to bring fan capacity nearer to actual load.Install carbon dioxide sensors to minimize intake of outside air.Space thermostats were used to regulate fan speeds directly.Before VFD installation, fans cycled on at maximum speed with high motor inrush currents, then cycled off regularly. VFDs eliminated inefficient constant cycling. Peak power was therefore less than maximum. Projected electric demand savings was 36 kilowatts per month.
Cost of VFDs and carbon dioxide sensors: $17,000 installed costProjected electricity savings: 138,833 kilowattsProjected annual savings: $9,726.00
Payback period for project: 1.75 yearsProject internal rate of return: 56.6%
JC Penney was able to realize substantial annual savings – almost $10,000 per yearwith relatively low investment.
Case Study – JC Penney, Atlanta, GA*
*Energy Star® Building Manual - Fan System Upgrades
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Maintenance Benefits
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Financial and Maintenance Benefits
Drives provide a soft start control for motors, resulting in HVAC systems that:
Last longer
Reduce mechanical stress
Require less maintenance
Cause fewer instances of unscheduled equipment downtime
Lower inrush current and peak power demand
50Copyright © 2008 Schneider Electric. All rights reserved
Network Communications
Network connectivity with the Building Automation Systems
BACnet®LonWorks®Metasys® N2Apogee® P1Modbus®
allows real time control of pumps and fans
based on climate demands of the building
environment under control and
increases occupant comfort
LonWorks®
51Copyright © 2008 Schneider Electric. All rights reserved
Energy Efficiency Programs
52Copyright © 2008 Schneider Electric. All rights reserved
Energy Efficiency Incentives
Increase bottom line profit utilizing Energy Efficiency Incentive Programs
Many energy efficiency programs offer incentives for motors and adjustable frequency drives in commercial and industrial facilities
Incentives may include rebates as well as funding for feasibility audits and design assistance
53Copyright © 2008 Schneider Electric. All rights reserved
Energy Efficiency Incentive programs
Consortium for Energy Efficiency
Provides information about energy efficiency programs in industrial and commercial facilities
www.cee1.org
Source: CEE Energy Efficient Programs-May 2007
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Energy Star
EnergyStar.gov
Energy audit and energy management information for industrial and commercial facilities
Energy Star Building Manual recommendationsHeating and Cooling System UpgradesFan System Upgrades
www.energystar.gov
Source: energystar.gov website
55Copyright © 2008 Schneider Electric. All rights reserved
I. Energy Opportunities
II. Description AC Drives
III. Affinity Laws
IV. Building Applications
V. Conclusion
Go Green with AC Drives
56Copyright © 2008 Schneider Electric. All rights reserved
Typical Building Applications
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Typical Building Applications
Air Handling Unit
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Typical Building Applications
Exhaust Fans
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Typical Building Applications
Cooling Tower Fans
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Typical Building Applications
Cooling Tower Water Pump
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Typical Building Applications
Hot Water Pumps
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Typical Building Applications
Secondary Loop Chilled Water Pumps
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Typical Building Applications
Domestic Water Pump for High Rise
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Raleigh Convention Center, Raleigh, NC
Raleigh Convention Center$220 million project150,000 exhibit hallMeeting roomsBallroom
Enclosed drives will control: 18 Air handling units 25hp, 30hp, 40hp, 50hp,
60hp, 75hp, 100hp2 Hot water pumps 50hp2 Chilled Water pumps 60hp4 Cooling Tower Water pumps 40hp7 Exhaust fans 7.5hp
Installed Square D® enclosed drives
65Copyright © 2008 Schneider Electric. All rights reserved
Proctor & Gambles headquarters1.5 million square footEnergy Star certified facility
Energy Star CertificationReset supply air for air handling unitsUse outside air to reduce heating and
cooling time by 60 hours per weekUpgrade existing motors to add
variable frequency drives
Installed Square D® enclosed drives
Proctor & Gamble, Cincinnati, Ohio
Source: Sustainable Facility Magazine, June 2008
66Copyright © 2008 Schneider Electric. All rights reserved
Rex Healthcare, Raleigh, North Carolina
Surgical Expansion ProjectThree story addition to hospital12 operating roomsThree new air handling unitsNew boilerNew chillerNew cooling tower
Square D® enclosed drives will control3 Supply air fans in AHU3 Return air fans in AHU2 Cooling tower water pumps
LonWorks Communications with Honeywell Enterprise Building Integrator (EBI) building automation system
67Copyright © 2008 Schneider Electric. All rights reserved
Oak Ridge National Laboratory, Oak Ridge, Tennessee
United States Largest Science and Energy Laboratory
58 square mile campus4200 employees
Energy Conservation mandated EPAct 2005Reduce building heating and cooling loss
through laboratory fume hoodsReduce energy usage by adding variable
frequency drives to existing motors
Installed Square D® enclosed drives
“Utilizing variable speeds drives to control motor speeds and reduce energy usage was the first area to implement.”Greg PalkoEnergy Efficiency ManagerOak Ridge National Laboratory
68Copyright © 2008 Schneider Electric. All rights reserved
Acute care and nursing facility with 61 patent beds
15 Square D® brand enclosed drives Circuit breaker disconnect andBypass circuit at460 volt 5hp to 40hp
The enclosed drives will control; Supply air fans 15hp, 30hp and 40hpReturn air fans 5hp, 10hp, 20hp and 30hpHot water pumps 10hpChilled water pumps 20hp
Jefferson County Hospital Fairfield, Iowa
69Copyright © 2008 Schneider Electric. All rights reserved
15 floor high rise hotel 294 rooms Six restaurants53,000 square feet riverboat casino
28 Square D® enclosed drives Circuit breaker disconnect and Bypass circuit at 460 volt, 2 to 40 horsepower
Drive applications include Exhaust fans 40hp eachHot water pumps 2 hp each
Harrah’s East Chicago, Indiana
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26 Square D® enclosed drives with Circuit breaker disconnectBypass circuit460 volt3 to 20 horsepower
BACnet building automation communications
Bothell High School Shoreline, Washington
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Elementary school scheduled to open Fall 2008
47 Square D® enclosed drives Circuit breaker disconnectBypass circuit208 volt1 to 3 horsepower
Installed by Trane partner
Elementary School, Kinston, North Carolina
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AC Drives 24 / 7 technical and application assistance 1-888-SQUARED
Sales and application assistance•Regional Product Application Engineers
Available Resources
Website:www.us.squared.com
• Products and Services- Motor Controls
- Adjustable frequency drives
73Copyright © 2008 Schneider Electric. All rights reserved
4 main
messages
Pump and Fan systems operating with Variable Speed Drives provide:
1. Cost savings and conserve electricity
2. Increase comfort in buildings
3. Reduce equipment maintenance and downtime
4. Additional savings through energy efficiency rebate programs
Energy Savings with Variable Speed Drives
74Copyright © 2008 Schneider Electric. All rights reserved
E-FlexS-Flex M-Flex PowerGard
Range:208/230V 1-40hp460V 1-100hpTarget Market:Residential high riseCommercial office buildingsGovernment facilitiesSchools and Universities
Range:208/230V 1-50hp460V 1-100hpTarget Market:Commercial buildingsHospitalsGovernment facilitiesSchools and Universities
Range:460V 50-500hpTarget Market:IndustrialMunicipal pumpingWastewater
Range: 208/230V 1-50hp460V 1-500hpTarget Market:Government facilitiesHospitalsPharmaceuticalIndustrialMunicipal pumpingWastewater
Enclosed AC Drives Products
75Copyright © 2008 Schneider Electric. All rights reserved
Altivar 61/71 MCC Drive Offering
Single Family Product Line
1-500 HP, 480 volt
1-50 HP, 240 volt
Compact, General Purpose Pkg
UL 845 Listed, 100K Amp Fault rating
NEMA 1, 1A, 12, and 3R (up to 40 HP)
76Copyright © 2008 Schneider Electric. All rights reserved
AC Drives Products
Range:208/230V 1-40hp460V 1-100hpApplicationsCentrifugal PumpsFansTarget MarketOEMsControl Panel Builders
Range:208/230V 1-125hp460V 1-900hp600V 1-900hpApplicationsCentrifugal PumpsFansTarget Market:OEMsSystem IntegratorsControl Panel Builders
Altivar 61Altivar 21
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TT hank you
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Make the mostof Your EnergySM