Variable Frequency Drive

(VFD)
Fundamentals
 VFD Subjects and Topics

After this session you should be familiar with

the following common topics related to VFD…

Motor Characteristic
Design of VSD - Building Block
Operation of VSD – How
Load Characteristic
Starting Torque
VSD Functions & Features
VSD Enclosure
How to size a drive (VSD)
What is in its name?
Inverter
Adjustable frequency drive
(AFD)
Variable frequency drive (VFD)
Adjustable speed drive (ASD)
Variable speed drive (VSD)
Frequency Converter
AC Drive
Motor Drives
VLT (Danfoss Drives)
…or just plain “Drive”
Motor Characteristics

Motors Use Magnetic Fields

AC motors are electromagnetic energy converters,

converting electrical energy (e.g. 415V, 50Hz) into
mechanical energy by means of electromagnetic
induction
 2-Pole / 4-Pole Motor

2-Pole Motor

Alternating current applied to S N

the stator produces rotating
N S
magnetic field which induces
voltage in the rotor. Interaction
between two magnetic field
cause the rotor to turn 4-Pole Motor
Electrical Motor Family Tree
Electrical Motor Family Tree
Motor Technology Trends
PM Technology
 Induction Motor Exploded View

Stator Winding leads

Terminals
Core
Al. Diecast Rotor
Fins
Terminal
Block
Greasing Facility
Bearing
DE Bearing
Cooling Fan NDE

Fan Cowl
Shaft

Winding Overhang
Inner
Bearing
Stator Housing
Covers
Efficiency and Losses : Induction Motor
Frequency Controls Motor Speed
Changing Frequency Changes
Motor Speed

n motor speed in rpm

P number of motor poles
f frequency of AC

The speed of the motor is dependant on the number of poles in the motor and the
supplied frequency.
Motor rpm = Frequency x 120
(no. of pole)

4 pole motor rpm = 50 x 120 = 1500 rpm

4
What does VFD do?
Variable Speed Drive or VSD is used to start
and control an AC induction motor by varying
the speed.

VSD Motor
Basic Design of AC Drives
VSD is designed to control
speed while maintaining
? motor torque (T) by varying
voltage and frequency at
the same time.
Torque = Power x 9.55
speed

Pwr x 9.55 solving for Pwr is V I Cos O

T=
n and n is 120 f / p

v xI
T=k
f
VSD:Varies both Voltage and Frequency (V/F)

High voltage

Variable Frequency
Variable Voltage

Fixed Voltage
Fixed Frequency

Low Voltage
Why Frequency Converter
Main block diagram
Basic Structure of 6 Pulse VSD

It is a an electric device which provides infinitely variable speed control of three phase AC motors

by converting the fixed mains voltage and frequency into a variable quantities
Rectifier

Uncontrolled?

or

semi controlled rectifier?

Rectifier- working principle

UDC

IDC

L1 L2 L3

3-PHASE SUPPLY Voltage

 Power Section- frequency converter

VDC

L1 L2 L3 U V W

3-PHASE SUPPLY

MOTOR
 Intermediate circuit- frequency converter

The intermediate curcuit (DC-bus)

UDC UDC

VDC IDC
IDC
 Inverter section- frequency converter

UU
UDC
Uv
IDC UW
UU-V

U V W

MOTOR
IGBT (Isolated Gate Bipolar Transistor)
 Inverter-six step voltage

110 UU
Uo*

010 100
UV

αo=ωot

UW

011 101
UU-
V
001
101 100 110 010 011 001
 Pulse Amplitude Modulation (PAM)

Pulse amplitude modulation (PAM) is the transmission of data by varying the

amplitudes (voltage or power levels) of the individual pulse
Pulse Width Modulation - PWM
 Pulse Width Modulation - PWM

How does a frequency inverter produce this

variable voltage and frequency output?

Most frequency inverters today use a method of “creating” an AC

voltage from the fixed DC voltage called PWM (pulse width
modulation):
Output transistors switched on/off at a fast rate (typically ≥3.5KHz)
according to a “switching” pattern which creates a series of
rectangular pulses of fixed amplitude and varying pulse width
This pulse width modulation simulates a sinusoidal voltage at the
fundamental operating frequency plus harmonic voltages
Only the voltage at fundamental frequency (e.g. 0 – 60Hz) creates
useful torque
 Standard PWM

Majority of drives on the market use this type of switching pattern:

Also called “sine coded” or “sine weighted” PWM
Main limitation of Standard PWM is that the maximum output voltage
to the motor is limited to 87% of the drive’s input voltage:
Enhanced PWM

Unlike sine weighted PWM, VVC is based on a digital generation of

the output voltage.
Ensures output voltage reaches rated value of input voltage, motor
current is sinusoidal and the motor operates as it does on the mains.
Operation of VFD
What does VFD do?
Takes fixed AC voltage and frequency supply
and converts it to DC; then Back to variable
AC voltage and frequency
HOW?
AC DC AC

R e c tifie r In v e rte r

DC Bus
Load Characteristics / Torque Curves
VFD Application Terminology
Constant Torque (CT)
loads require:
150% Overload

Constant Power (CP)

Usually exceeds
nominal full speed of
motor

Variable Torque (VT)

Loads has low starting
torque
110% Overload
Load Types Equipment/Starting Torque
Variable torque(Sq. Law) Starting Torque
Axial fans 40% FLA
Centrifugal fans 30% FLA
Centrifugal pumps 50% FLA

Constant torque
Most compressors 150% FLA
Conveyors 150% FLA
Mixers 175% FLA

Constant Power
Machine Tools (milling & lathe) 100% FLA
Electric Saws 50% FLA
Basic Drive Functions
Motor Starter and Starting Currents
The main function of VSD is to start a motor
Basic Drive Functions

VSD’s work by controlling the

frequency a motor gets
voltage.
When using Normal Starters
with an AC Induction motor,
when we reduce voltage, the
current will increase.
Too much current can damage
motors and their cables.
By using VSD, the VSD control
both the frequency and
voltage (v/f) to control the
motor torque (current)
Basic Drive Functions

Motor & VSD Protections

Current Limit Function

Overcurrent Protection
Overvoltage Protection
Undervoltage Protection
Earth fault
Loss of Phase Protection
Thermal Overload protection
Over Temperature Fault
Fieldbus & Serial Communication
Integrated communication
protocols via RS 485:
FC Protocol
Johnson’s Metasys N2
Landis/Staefa’s FLN
Modbus

Optional Fieldbus
protocols
Profibus
Lonwork
Devicenet
Bacnet
VSD Enclosure – IP/NEMA Rating
Purpose of Drive Enclosure
Protect people (from dangerous voltage)
Protect the drive (from contaminants)
Keep the drive cool (ensure good performance)
Chassis IP 00
NEMA 1 IP 20/21
NEMA 12 IP 54
NEMA 4 IP 55
 IP standards
IP
No protection
0
No protection
0 Protection against Protection against
solid objects liquids
Protected against vertically
Protected against solid objects 1 falling drops of water e.g.
1 up to 50mm e.g. accidental condensation.
touch by hands
Protected against direct sprays
2
Protection against solid objects of water up to 15° from vertical
2 up to 12.5mm e.g. fingers
Protected against direct sprays
3
of water up to 60° from vertical
Protected against solid objects
3 over 2.5mm (tools + wires) Protected against low pressure
4
jets of water from all directions

Protected against solid objects

Protected against low pressure
5
4 up to 1mm (tools, wires + small
jets of water from all directions
wires)
Protected against strong jets of
6
Protected against dust
water from all directions.
5 (no harmful deposits)
Protected against the effects of

7 immersion between 15cm and

Totally protected against dust
1m.
6

Protected against long periods of …m

8
immersion under pressure.
Finn Jonasson / DKDD-KKS
VSD Enclosure – IP Rating
Chassis — IP 00
Provides no protection for the drive or people
around the drive
Must generally be mounted in another enclosure

NEMA 1 — IP 20
“Finger proof”
Cooling air flows through the
inside of the drive – no dust filter

NEMA 12 — IP 54
“Dust proof” & water splash proof
Cooling air flows along the exterior heat sink,
gaskets seal the interior of the drive
 Ventilation for VSD
For Installation in enclosed cabinets, sufficient ventilation of the VSD’s to extract
the HOT air must be considered to prevent tripping on Over Temperature
and premature failures of components.
Steps to calculate the min. air flow required :-
:-
Sum up the total heat losses in Watts of all the VSD’s installed in the same
cabinet.
The highest inlet cooling air temperature (tin) must be lower than 40°
40°C and
the outlet temperature of the air must not exceed 45°
45°C.
Calculate the difference between the temperature of the cooling air and its
outlet temperature (∆
(∆t = 45°
45°C – tin ).
The required air flow (in m3/h) is
(Power Loss x 3.1)
∆t
Be sure to provide enough extra cooling fan capacity to
handle other losses
How do you size a Drive?

Hp/Kw?
FLA?
CT vs. VT?
Starting Current/Torque
Motor Cable Distance?

Hp/Kw is a good rule of thumb,

but you need to look at what
current (FLA) is drawn by the
Motor
Current is what a drive produces
Hp/kW is just a “guide”
VSD FLA must be equal or bigger
than FLA of Motor.
Drive Sizing

Ensure Drive can handle maximum current of motor.

Pump/Load < Motor < or = VSD
What can an AC drive (VFD) do?

Start and Stop motor by Local or Remote

Able to adjust the speed of a motor to match what is
required: Flow, Pressure, Level…etc.
Provide a gentle ramp up or down in speed to
eliminate the surges, mechanically, electrically, and
hydraulically, caused by starting a motor
Smooth operation and process improvement
Set speed or current limit
Less wear & tear and less maintenance
Monitor and Protect the motor and cables
Able to have Fieldbus communication
Save energy
What can’t a drive do?
Boost the output voltage
significantly above the input
voltage
Run a motor of different
voltage rating eg. 415V
supply running 220V motor or
vise versa
Used as a power supply for
non inductive load
Increase the output power of
the motor
Solve all system design
problems
How to control VSD

Motor speed are controlled by:

Hand Mode, directly from the LCP
Potentiometer, 10 Volt supply for the potentiometer available
Voltage signal, 0-10Volt or +/- 0-10 Volt
Current signal
Field bus signals

Motor speed are controlled in open or closed loop:

Open loop as mentioned above
Closed loop using
The build in PID controller function
Using an external PID controller
How to control the VSD

Functionality are controlled by:

Keys on the LCP
Switches connected to the digital inputs
24 Volt signal
Field bus signals

VLT can inform about status via

Reading on the LCP
Digital outputs
Relays
Analogue signals, current or voltage
Field Bus signals
Summary

Change AC to DC back to AC
Use Solid State components like SCR & IGBTs
Change frequency to change the motor’s
speed
Applied motor voltage will change along with
frequency ( v/f )
Reduced starting current to <110%
Output of inverter is based on pulse width
modulation (PWM)
Danfoss Chemical
Solutions Selection Criteria of VFD

May 2007
How to select VFDs ?
Purchase criteria ?
Concerns while selecting VFD

Over load capacity Use freindly

RFI
dv/dt ( Voltage spikes)/Motor life
Temperature
Reliability in Harsh environment Efficiency
Heat loss
IP standard
Harmonics
VSD features to meet the standards and help save cost….

No Need to
have AC
Input Line
chokes

VFD to Motor
Cable distance
can be upto
300 meters
Wide Dual Limb
w/o need of
voltage DC Choke
motor coils
range Harmonic
342v-550v Filters High Ambient
& 690v Temp. 50
Dec.C
 Over load capacity

Over load capacity : 160% over load

110% over load ??

• Depends on the application.

• for fan & pump applications : 110%
• For other applications : 160% over load capacity for one minute.
• Continuous current capacity : Focus on continuos current & not
on KW or HP.
• Some of the drive mention 90% of full load current is coninuous
current.
Motor Current Performance
Conventional PWM Output
•Motor does not get 100% fundamental
voltage
•Stress on motor insulation and winding
•High heat generation
VVC grade
•Need for higher frame or inverter
motor

VVCPLUS Output
•Increased motor life- motor gets
100% fundamental voltage
•Less heat generation
•Motor works as if it is working on
Mains
•No need of inverter grade motor
Radio Frequency Interference (RFI)

Noise RFI

CE EN 55011

1A Filter

1B Filter

Grounded Delta
 Harmonic Distortion

Summation of all
Multiples, mainly the 5th & 7th
harmonic frequencies harmonics of the
fundamental sine wave (50
Hz), caused by the
switching current flow
through the VFD’s input
rectifiers,
causes interference in the
incoming power.

Fundamental
Harmonic Current Distortion increases the RMS current and can result in
overheating of the supply transformer and cables.

Harmonic Voltage Distortion can interfere with other equipment attached to

the same line.

Total Harmonic Distortion (THD) at the point of common coupling is

discussed in IEEE 5-19.
Built-in DC choke ( in both limbs)

Low harmonic emission: THID < 35%

No voltage drop => full output

voltage

Built-in DC link filters

Reduces installation cost

Fulfils EN 61000-3-2/3-12

Displacement power factor(cos φ≈ 1)

True power factor 0.9

Built-in DC choke ( in both limbs)

Benefits of built in DC choke.

Harmonic distortion under control

Improves the life of DC capacitor by 5

times higher.

Harmonic level in motor is reduced,

less heating in the motor.
EMC-Services
Analyses of the customer
mains through measurements
in the production line

Analyses of harmonic-wave-
stress through own HCS-
Software
Criteria for selecting the right drive

Application Data. Type of Application? (Find the right segment

drive). Bus communication. Options. torque curve, Multi motor?

Motor data : Current , voltage. Frequency, Speed, Temperature

protection

Drive installation data. IP class., Air quality (Corrosion, Moisture,

Dust) ,Cooling , Motor Cable length, Vibration. Supply voltage.

Derating: Ambient temperature , Altitude, Switching frequency.

Type of Application? Torque curve. VT or CT
Motor data :

Current

Speed

Voltage
Mec. Brake

Temp. Sensor
Motor data : Current , voltage. Frequency,
Speed, Temperature protection.
Voltage
Current

1.8Amp x 1.6 =2.9

1 min every 10 min.

Motor data sheet
Motor starting current is not relevant when using VLT
Drive installation data. Supply voltage IP class., Air quality
(Corrosion, Moister, Dust) ,Cooling , Motor Cable length, Vibration.
Drive installation data. IP class., Air quality (Corrosion, Moisture, Dust) ,
Cooling , Motor Cable length, Vibration. Supply voltage.
Drive installation data. IP class

Air quality (Corrosion, Moisture, Dust) ,Cooling , Motor Cable

length, Vibration. Supply voltage
Temperature Derating,Switching frequency, Altitude
Temperature Derating:Altitude, Ambient temperature,
Switching frequency.
Thank You