Variable Frequency Drive in Focus

What is the function of a variable frequency drive in a temperature control unit?

The variable frequency drive controls the pump speed by transforming the mains frequency into variable frequencies. Our innovative IRIS control system opens up entirely new use cases by fully integrating the VFD into the temperature control algorithm. In ECO mode, the control system can now automatically operate the unit at the optimal operating point. Alternatively, precise flow control or direct pump power settings are possible. The user can even configure a maximum pressure. 

The clue behind all this is: The pump does not run constantly at full load, but at the frequency required for a specific application. When the required heating or cooling capacity is low, the speed can be reduced – when high heating or cooling capacity is needed, the pump speed is increased to the optimal operating speed.

What are the concrete advantages for the customer?

The key advantages are the following: 

• Efficiency: Energy consumption drops significantly because the pump doesn't always run at full load
• Service & Comfort:  less wear, extended maintenance intervals, and significantly lower noise levels
• Performance: All pumps can now be operated up to 60Hz – there are no more mains frequency-dependent designs. This is particularly useful when pump wear occurs during the temperature control unit's lifetime. Now, performance losses from worn components can be partially compensated by increasing the frequency.  Our VFD thus ensures that close to full pump capacity is available throughout the entire service life
• Electrical: a smooth pump startup without current spikes, which increases service life and reduces stress on the power grid
• Controls: We can now precisely control the flow rate

Are there typical applications where variable frequency drives are particularly beneficial?

Yes – wherever dynamic processes take place. Changing temperatures, variable flow rates, or fluctuating heating and cooling capacity…..this is where the variable frequency drive demonstrates its full potential.  But even in "simpler" processes, the variable frequency drive pays off. Think of fast heating with full power, followed by energy-saving temperature maintenance with reduced pump power. 

The key advantage materializes whenever pumps are “too strong” for specific situations. This happens a lot since standard engineering practice implies that pumps are always sized with safety margins for peak demands. 

Typical applications include plastics processing, rubber, and die-casting applications, as well as specialized solutions in pharmaceutical or food industries. 

Are variable frequency drives standard equipment on all Tooltemp units?

All units in our «MATIC» product line are standardly equipped with the latest variable frequency drive technology. Demand-based pump performance is ensured by the variable frequency drive being fully integrated into our innovative IRIS control system.

Temperature control units from the «CLASSIC» product line do not include VFDs. These conventional temperature control units reliably fulfill many standard applications. For more demanding processes, the temperature control units from the «MATIC» product line with variable frequency drives offer clear advantages in terms of efficiency, control accuracy, and flexibility.

What do you recommend to customers who are unsure whether to invest in a CLASSIC or MATIC temperature control unit for their production process?

We recommend discussing the specific requirements in detail with our sales experts – preferably in a consultation meeting. Whether a unit from the «CLASSIC» or «MATIC» product line is the appropriate choice depends heavily on the production process, on-site conditions, control requirements, and desired flexibility. Together with the customer, we can quickly find the most suitable and cost-effective solution for stable and precise temperature control, high energy efficiency, and reliable production safety.