32 n VARIABLE-SPEED DRIVES January 2026 www.drivesncontrols.com Low-harmonic drives ensure efficiency of Finnish heat pumps A pair of heat pump plants that deliver process cooling and heating have been installed at two facilities in Finland, at Turku and Espoo, operated by the pharmaceutical company, Orion. The modular AmbiHeat heat pump plants were supplied by the Finnish heat pump specialist Calefa. They use waste heat from the production processes, combined with outdoor energy, to provide environmentally friendly heating and cooling. “Since the summer of 2024, the 2MW cooling requirement of the [Espoo] tablet production line has been met completely CO2free with five heat pumps in the heat pump plant,” explains Calefa’s supply chain manager, Mikko Rantanen. “The previously commissioned heat pump plant provided the factory area with emission-free heating from outdoor air, reducing the need for purchased energy for heating by more than 50%.” “The waste heat generated from the factory processes is used through the district heating network of the factory area in the heating of properties,” adds Orion’s HVAC engineer, Jaakko Valkama. “The plant’s total heating capacity from waste heat and outdoor air is 3MW, which means up to 19,300MWh of completely carbon-neutral heating energy per year. The heat pump plant reduces CO2 emissions from heating at Orion's Espoo plant by 2,200 tonnes per year.” To operate the heat pump plants reliably and efficiently, the quality of their power supply is important. Disruptions, such as harmonics, could cause the equipment to overheat, as well as resulting in premature wear-and-tear and damage. Good electricity quality ensures that the heat pumps will operate stably in all conditions. This is especially important in cold climates, such as Finland’s, where reliable operation of heat pumps is critical during the winter months, in particular. Heat pumps running on optimal power are efficient and, thanks to their long maintenance intervals, also cost-effective. Orion therefore chose ultra-low harmonic (ULH) drives with active front-ends (AFEs) to control its heat pumps. This technology keeps the voltage of the motors stable, while its high power factor cuts energy costs and improves performance. The drives also enhance the efficiency of the local power grid because all the power supplied is used as active power, without consuming any reactive power. The AFE technology helps to reduce harmonics in the drives, ensuring that the THDi (total harmonic distortion) is less than 3%, and that the nominal voltage is maintained. THDi describes the number of harmonics in relation to the base frequency. A high THDi value can result in electrical system problems, such as overheating equipment, disruptions and energy losses. It is important to keep the THDi as low as possible, especially in sensitive and critical applications. For six-pulse standard drives with chokes, the THDi is 40%, which means 16% higher losses in the electrical system. The harmonic levels of the ULH drives are up to 97% lower than those of conventional frequency converters. The drives reduce the need to over-dimension power grid components, ensure trouble-free power grid operation, cut energy losses, improve equipment durability, and eliminate the risk of network overloads. The more efficient use of energy and reduced grid losses help to cut carbon dioxide emissions. Orion’s heat pumps are being controlled by ABB ACH580 ULH drives, which support a wide range of fieldbus protocols, adding to their flexibility. “At the core of the success of the cooperation project between Orion, Calefa and ABB was comprehensive planning started at an early stage,” recalls ABB sales manager, Pyry-Pekka Lehto. “Challenges caused by harmonics were identified in time, meaning that the design and the equipment selections were carried out specifically from the point-ofview of electricity quality, and the adequacy of transformer power.”n Two heat pump systems that provide heating and cooling for a pair of pharmaceutical plants in Finland, are being controlled by ultra-low harmonic drives that improve the plants’ energy efficiency and ensure that they operate reliably. The ultra-low harmonic variable-speed drives used to control the heat pump plant.
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