New Advances in Variable Frequency Drives

Written by Steven B. Weston and Michael W. Owens, Eaton Corporation

Variable frequency drive technology is more efficient and accurate, which leads to increased energy
savings. Advancements in capacitors and direct current (DC) link reactors, IGBTs, heat management,
processing power and measuring technology are all enabling the development of solutions to problems
that were not even recognized earlier. Additionally, new and advanced algorithms affect energy
efficiency.
High Efficiency Capacitors
In the most advanced drives, the state-of-the-art capacitor uses a new type of plastic film capacitor .
This device stores energy from the rectifier, and is part of a LC filter that reduces ripple on the DC bus
and minimizes current surges. The advancements in capacitor technology are yielding net energy
savings while limiting toxins.
Previous capacitor technology relied on electrolyte capacitors. Today, new capacitors use thin,
metalized film capacitors, which do not contain toxic electrolytes. Capacitors are non-toxic and do not
leak electrolytes into landfills; they are fully Restriction of Hazardous Substances (RoHS) compliant. In
addition, metalized film capacitors are self healing-preventing the occurrence of hot spots and
extending the life of the product, while decreasing heat loss.
State-of-the-art capacitors do not require re-charging, even after years of sitting on the shelf.
Ultimately, these advances in technology allow the newest capacitors to offer 80 percent less power
loss than older capacitor technology. As a result, there are less power losses, increased efficiency and
lower heat output within a drive package. Since heat is the greatest threat to the drive, these drives will
have a longer life span.
DC Choke
In the latest generation of adjustable frequency drives, the internal line reactor is replaced with a built-
in DC link choke. In earlier drives the internal line reactor provided protection for the AC diode and
some amount of harmonic mitigation; the line reactor is most effective at the highest order of the
harmonic spectrum.
The DC link choke performs a similar function as the AC line reactor; that is, it prevents harmonic
distortion from getting back on the line and acts as a filter to smooth the ripple on a DC bus. While it
reduces harmonics similarly to the AC line reactor, the DC link choke reduces harmonics across the
entire harmonic spectrum. In turn, this allows users to meet the more rigid requirements of IEC 61800,
which looks at individual harmonics, not just the total harmonics of the system. The built-in DC link
choke complies with the C2 category both for radiated and conducted emissions specified in EN/IEC
61800-3.2 for commercial and industry environments. In other words, all drive manufacturers will need
to use a DC link choke to meet this emissions standard in the next generation of drives.
Further, the DC link choke has the added benefit of a lower voltage drop than the equivalent AC line
reactor, translating into overall increased efficiency for the drive. Specifically, the AC line reactor
typically resulted in a 2 to 4 percent voltage drop, whereas the DC link choke has a voltage drop of less
than 1 percent; this translates into overall increased efficiency of the drive.
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Heat Management
In HVAC applications, drives are typically used to improve or increase energy savings while providing
system efficiency. VFD manufacturers are now taking their own advice and using the same technology
on the drive.
All drives generate heat, and use fans to cool themselves. Typically, cooling fans used to run at full
speed whenever the drive was energized. Newer drive technology monitors the heat-sink temperature,
and the fans provide only as much cooling as is necessary (0 to 100 percent), based on the ambient
temperature and the drive load. This makes the fans inside the drives another variable speed
application. Essentially, drives in HVAC applications are used to make fans more efficient; now, drive
manufacturers are making the internal fans in the drives more efficient.
Closely matching cooling requirements to fans speed can net a 20 to 60 percent reduction of energy
used to control these fans. Less losses means increased energy savings for the drive users.
Less Power Loss from Semiconductors
New generation power semiconductors-insulated gate bipolar transistors (IGBTs)-are able to operate at
higher switching frequencies, resulting in less power losses and reduced heat within the drive. As this is
a core component of the drive technology, it has a huge impact on overall drive efficiency.
Advanced Power Management Control (Sleep Functionality)
In run mode, a drive consumes a tremendous amount of energy even if a zero speed reference is given.
This is due to the fact that most systems require a minimum speed (12 Hz for example) to keep the
TEFC motor cooled.
Some drive manufacturers now offer an enhanced sleep function, which allows the drive to shut down
(remove run command) when it is not needed. Typically this is used in a fan or pump application with
the drive's internal PID loop controlling speed. A PID loop uses a set point and feedback from the
system to determine the correct speed. When the feedback from a remote sensor indicates a low or zero
speed is required the drive is able to turn itself off, or remove the run command but return to run mode
when the system indicates a higher speed is required. This same function can be performed using a
costly PLC with extensive programming.
Drives can now be better tuned to actual energy needs, tapering system requirements during off hours,
weekends and holidays-allowing customers to see significant cost savings in their energy bill.
Advanced Algorithms Deliver
The product of intensive research, advanced algorithms provide energy savings and stability over
traditional variable frequency control methods. In response to load conditions, the algorithms
dynamically adjust the operating point of the drive and motor system to reduce motor losses and save
energy, thus reducing the users' utility bill. By reducing losses in the motor, the algorithms are designed
to make the motor as well as the entire system (motor, drive and load) more efficient. Further, advanced
algorithms facilitate protective system monitoring and response, and as a result, are able to better able
to help the drive operate in optimal boundaries, providing added stability.
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For example, comparing one new algorithm to older technology, a 50 hp motor setup could see
additional savings of $10,000 to $28,000 through the lifetime of the drive in lightly loaded conditions,
typical of pumping and HVAC applications (see Figure 1). These advanced efficiency algorithms allow
users to save an additional .5 to 10 percent over the savings they realize now, by applying the drive to a
variable torque load.

Figure 1
Conclusion
Drive technology has come a long way. By adding up the new technological advances built into a drive,
users can save more than before. The last 10 years have created advances that allow drives to be more
intelligent; they now control more than a motor-they control themselves.
Pumps & Systems, June 2010
Steve B. Weston is the aftermarket services manager for drives at Eaton Corporation. Michael W.
Owens is the HVAC manager at Eaton Corporation.
Tags: Instrumentation and Controls , June 2010 Issue , Variable Frequency Drives
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