6120 Eng C W

Measurement of
Adjustable Speed Drives

with Fluke Meters
Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 1

Table of Contents
Introduction ..................................................................................................................................... 3
Troubleshooting Philosophy ...................................................................................................... 3
Making Safe Measurements (Sidebar) ..................................................................................... 4
Safety Ratings for Electrical Test Equipment .............................................................................. 4
Adjustable Speed Drive Theory ................................................................................................. 6
Simple Things First ...................................................................................................................... 8
Resistance Measurements ............................................................................................................. 8
Voltage Drops .................................................................................................................................. 8
Temperature Measurements .......................................................................................................... 8
Motor Measurements .................................................................................................................... 9
Temperature Measurements .......................................................................................................... 9
Overloading ..................................................................................................................................... 9
Voltage Measurements ................................................................................................................... 9
Current Imbalance Measurements .............................................................................................. 10
Single Phasing .............................................................................................................................. 11
Overvoltage Reflections - Theory (Sidebar) .............................................................................. 12
Overvoltage Reflections - Troubleshooting ............................................................................... 14
Bearing Currents ........................................................................................................................... 17
Leakage Currents .......................................................................................................................... 17
Measurements at the Inverter .................................................................................................. 18
Control Circuit Noise ..................................................................................................................... 18
Volts/Hertz Ratio ........................................................................................................................... 18
Inverter Drive Circuits .................................................................................................................. 18
Voltage Source Inverters .......................................................................................................... 18
PWM Inverters ........................................................................................................................... 19
The DC Bus .................................................................................................................................... 20
DC Voltage Too High ................................................................................................................. 20
DC Voltage Too Low ................................................................................................................. 21
AC Line Input ................................................................................................................................. 22
Diode Bridge .............................................................................................................................. 22
Voltage Notching ....................................................................................................................... 23
Voltage Unbalance .................................................................................................................... 23
Harmonics and IEEE-519 Compliance ................................................................................... 24
ASD Measurement Guide for Fluke Test Instruments ......................................................... 26
2 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Introduction
Most experienced motor
technicians are well prepared
to deal with traditional three
phase motor failures caused
by water, dust, grease, failed
bearings, misaligned motor shafts,
or even just old age. However,
modern electronically controlled
motors, more commonly referred
to as adjustable speed drives,
present a unique set of problems.
This application note will focus
on electrical measurements that
can be used to diagnose bad
components and other conditions
that may lead to premature
motor failure in adjustable speed
drives (ASDs).
Troubleshooting Philosophy
There are many different ways Make accurate measurements. Current clamps that put out
to go about troubleshooting an Of course nobody makes inaccu- 10 mV/amp or 100 mV/amp will
electrical circuit, and a good rate measurements on purpose, have better signal to noise ratio
troubleshooter will always find but this is easier to do than you than 1 mV/amp clamps when
the problem - eventually. The think when working in a high making current measurements
procedure set forth in this energy, noisy environment like less than 20 amps.
application note will begin ASDs. Dont use grounded test Finally, document electrical
looking at the motor and work instruments if it can be avoided. measurements at key test points
back towards the electrical They can introduce noise into in the circuit when the system
source. Additionally, it will a measurement where none is functioning properly. If a good
emphasize checking the simple existed before. Avoid touching drawing doesnt exist - make
and easy things first. A lot of instruments and probes if one. A simple one-line, or even
time and money can be wasted possible while taking the block diagram will do. Write
replacing perfectly good parts reading, as electrical noise down voltage and temperature
when the only thing wrong is can get coupled through your measurements at key test
a loose connection. hands which may also affect points. This will save lots of
the reading. Use current clamps time and head-scratching later.
which are well shielded and
terminated with BNC connectors.

Making Safe Measurements
Before any electrical measure- voltage displayed above the as the transient voltage gets
ments are made, be sure you rating, or see the overload (OL) dampened considerably as it
understand completely how being displayed, disconnect makes its way into the building,
to make them safely. No test the measurement device and through the internal
instrument is completely safe immediately. distribution system.
if used improperly, but you Probably the most confusing The measurement environment
should also be aware that many issue is when the voltage rating for an adjustable speed drive
test instruments on the market is coupled with a category is not always straight-forward
are not appropriate for testing rating. The category ratings and may vary from installation
adjustable speed drives. The below in Figure 1 show the to installation. For example, a
following information is measurement environment 100 HP drive instal-led 25 feet
explained in more detail in the expected for a given category. from the switchgear would be
Fluke application note, ABCs of The main criteria for the considered a CAT III measurement
Multimeter Safety and the video different categories is the environment, but if that same drive
with the same name.1 The main transient voltage that the test was installed 70 feet from the
points are summarized below. instrument can withstand, and switchgear and had an isolation
If you install or maintain maybe even more importantly, transformer or line reactors
modern adjustable speed drives how much energy (volt/amps) preceding it, it could be argued
(ASDs), then please dont skip is available to feed any short that it is more like a CAT II
this section as there could be circuit that may occur as environment. If you are working
hazardous voltages that exist in a result of the transient. in both environments, be safe
your measurement application Transients may originate from and use only CAT III rated test
that you are not aware of. sources outside the building, instruments.
i.e., lighting strikes, utility What may not be readily
Safety ratings for electrical switching and power line fault obvious from the looking at Table
test equipment clearing activity, or they may 2 is the difference between a
The International Electro- originate from inside the build- 1000V CAT II rated meter and a
technical Commission (IEC) ing for example, as a result of 600V CAT III rated meter. At first
is the primary independent load switching. The measure- glance, you might think the 1000V
organization that defines safety ment is considered to be safer CAT II meter is the better choice
standards for test equipment the further the test instrument is because it has a higher working
manufacturers. There is much away from the transient source, voltage than the 600V CAT III
confusion about what these
standards mean and how they
should be used to determine
the right instrument for the
right application. The following
section will help clarify this
selection process.
The IEC 1010 standard for
test equipment safety states two
basic parameters; a voltage rat-
ing and an overvoltage category
rating. The voltage rating is the
maximum continuous working
voltage that can be measured.
This is fairly straightforward
and simple, although Im sure
many of you have noticed that
your DMM or scope will often
give a reading higher than its
maximum voltage rating. Your
test instrument should never
be operated above its voltage
rating. Most test instruments
are designed to have a 10%
overvoltage safety margin, but
if for some reason you see a
1
ABCs of Multimeter Safety Application Note,
Literature code BO317UEN Rev. A. The ABCs of
Figure 1. IEC-1010 category ratings diagram for various measurement locations
Digital Multimeter Safety Video, P/N 609104.

meter and it can handle the flame resistant clothing and Use the old electricians trick
same level of high voltage remove jewelry). of keeping one hand in the
transient, which is true. Do not measure voltages pocket to lessen the chance
However, the 600V CAT III above the working voltage of a closed circuit across the
meter can safely handle six rating of the test instrument chest and through the heart.
times the power as the 1000V or in high energy measure- WARNING: To avoid electric
CAT II meter, should a transient ment environments for which shock or other injury, when
cause a fault within the meter. its not rated. making measurements on CAT
The bottom line recommen-
dation for test instruments used Use the three-point test III circuits do not use divider
method: probes (e.g. 10:1, 100:1,
on ASDs is they should be 600V 1. Test a known live circuit. 1000:1, etc.) that are only rated
or 1000V CAT III rated. Some 2. Test the target circuit. IEC 1010 CAT I or CAT II. Make
manufacturers have dual rated 3. Test the live circuit again sure the scope probe you use
600V CAT III/1000V CAT II test to be sure the meter is still is rated for the measurement
instruments and probes which functioning properly. category environment in which
are the next best thing to a you work.
1000V CAT III test instrument. Hook on the ground lead first,
One final word on safety
CAT II instruments should then connect the hot lead.
Then reverse the procedure is covered in the section on
be avoided altogether unless Over-voltage Reflections
you are certain to be making by taking off the hot lead
first, then the ground second. Troubleshooting as it will
measurements only on be much better understood
fractional horsepower drives Hang or rest the meter if and appreciated after the
that are plugged into a wall possible to avoid holding it
in your hands. possible condition is explained
receptacle. As the design in more detail.
guidelines for CAT IV have
yet to be defined and adopted,
there are no official CAT IV Overvoltage
Category Examples
test instruments available.
Also, avoid meters that CAT IV Refers to the origin of installation, i.e. where low-voltage connection
claim to be designed to meet is made to utility power.
IEC-1010 specifications or that Electricity meters, primary overcurrent protection equipment.
do not carry the test certification Outside the building and service entrance, service drop from the pole to
building, run between the meter and panel.
of an independent testing lab Overhead line to detached building, underground line to well pump.
such as UL , CSA, VDE, TUV
or MSHA, as they do not always CAT III Equipment in fixed installations, such as switchgear and three phase motors.
meet the specifications for which Bus and feeder in industrial plants.
they claim to be designed. Feeders and short branch circuits, distribution panel devices.
Always look for independent
Lighting systems in larger buildings.
Appliance outlets with short connections to service entrance.
certification of test instruments
for ASD measurements.
CAT II Appliance, portable tools, and other household and similar loads.
See Table 7 at the end of this Receptacle outlets and long branch circuits.
application note for recommended
Outlets at more than 10 meters (30 feet) from CAT III source.
Outlets at more that 20 meters (60 feet) from CAT IV source.
Fluke instruments.
Once youve selected a test
CAT I Protected electronic equipment.
instrument with an adequate
Equipment connected to source circuits in which measures are taken to
limit transient voltages to an appropriately low level.
safety rating, then its up to Any high-voltage, low-energy source derived from a high-winding
you to follow the measurement resistance transformer, such as the high-voltage section of a copier.
safety practices as outlined
Table 1. Measurement environment examples
below, as even a meter
designed with safety in mind
can be unsafe if misapplied. Overvoltage Working Voltage Peak Impulse Transient Test Source
Category (dc or ac-rms to ground) (20 repetitions) (Ohm = V/A)
Work on de-energized CAT I 600V 2500V 30 ohm source
circuits whenever possible
using proper lockout/tag-out CAT I 1000V 4000V 30 ohm source
procedures. CAT II 600V 4000V 12 ohm source
Use protective gear when CAT II 1000V 6000V 12 ohm source
working on live circuits
(insulated tools, safety CAT III 600V 6000V 2 ohm source
glasses, insulated mat, CAT III 1000V 8000V 2 ohm source
Table 2. Transient test values for overvoltage installation categories

Adjustable Speed Drive Theory
The term adjustable speed of these sections has a job to The control circuitry
drive (ASD) includes a wide perform, and for most ASDs the of the ASD performs a variety
variety of mechanical, task is the same: of tasks. It times the switching
pneumatic and electronically The input converter of the input and output
controlled motors whose speed transforms ac sinusoidal devices. It carries out
is adjustable. Another term, current to dc, as dc is commands from the operator
variable frequency drive (VFD) what is required for the control panel. It also monitors
is used for electronically electronically controlled for and reports malfunctions
controlled ac induction motors power transistors in the and improper operating
as they vary the frequency output inverter. conditions to the operator
of the voltage to the motor to or troubleshooter. Control
change its speed. The term ASD The dc link is the source of circuits shut down the ASD,
power for the output inverter. if necessary, to protect the
will be used from here on out The larger horsepower drives
as this is the conventional term motor or output inverter
as used in the IEEE standards. will have a large bank of and prevent unsafe operating
capacitors to store voltage conditions.
DC motors and other methods from the sine wave input.
of adjusting motor speed and
torque will not be discussed This section may also (V x I x Eff)
x 5250
contain a series inductor Horsepower 746
in this application note. to help regulate the voltage Torque = =
Figure 2 shows a simplified Speed 120 x Hz
block diagram of a typical ASD. and current. no. of poles
There are four main sections. The output inverter
The three sections that are provides a variable ac You can see from the formula
in-line between the ac line voltage and frequency. above that varying the ratio of
inputs and the motor are the Voltage and frequency (V/Hz) horsepower to speed will alter
Input Converter, dc Link and are either varied together to the torque. Therefore, changing
the Output Inverter. The fourth provide a constant torque the volts/hertz (V/Hz) ratio will
section, the Control Circuitry, with varying speed, or the change the motor torque. For
is the brains of the drive. Each V/Hz is varied at different constant torque applications,
rates to provide variable the V/Hz ratio is held constant
torque at different speeds. by varying the voltage and
frequency together; or for
variable torque applications,
DC Link
the voltage and frequency are
varied at different rates to
DC Voltage accomplish variable torque.
Input Converter Output Inverter
The speed and torque of the
motor are usually controlled by
Line Voltage
To Motor 0-5 Vdc, 0-10 Vdc, 0-20 mA,
Current or 4-20 mA control signals
applied to the control input
block of the ASD. These control
signals may come from feed-
back sensors and encoders or
Process from a control panel.
Control Circuits Feedback/
Control Signal
The following paragraphs
describe in more detail the two
most common variations of
ASDs, the voltage source
Display
Operator inverter, and the pulse width
Controls
modulated (PWM) inverter.
Figure 2. Block diagram of a typical ASD

3 AC Input Induction Motor
Controlled Rectifier Six-Step Inverter
Figure 3. Simplified diagram of a voltage source inverter with output current and voltage waveforms
Figure 3 shows a simplified Figure 4 shows a simplified distorted (non-sinusoidal),

diagram of a voltage source diagram of a PWM drive. Notice the large motor inductance
inverter. The input section uses the input section is using diodes will smooth out the current
thyristors to rectify all, or part of which provide full rectification waveform so to the motor,
the incoming line-to-line phase of the ac line input, thereby it looks more like the dashed
voltages to produce varying charging the dc link capacitor to lines superimposed on the
levels of dc voltage at the dc 1.414 times the input RMS voltage waveform in Figure 4.
link capacitor. The dc voltage phase-phase voltage (unloaded The nearly sinusoidal current
determines the peak voltage of bus). Unlike the voltage source waveform in the bottom of
the drives output to the motor. inverter, the dc voltage remains Figure 4 shows that the motor
The frequency of the drives at a constant level. is in fact only responding to
output voltage is determined by However, to provide varying the RMS voltage of the pulses.
the control signals applied to levels of RMS voltage, the To summarize, the voltage
the SCRs in the output section. voltage waveform is a series of part of the V/Hz ratio is controlled
To summarize, the voltage part constant magnitude pulses that by varying the pulse width of
of the V/Hz ratio is controlled by vary in width. To the motor, one the pulses, thereby varying
full or partial rectification of the group of positive pulses looks the RMS voltage, even with a
ac to dc in the input section, like the positive half of a sine constant peak-to-peak voltage.
while the frequency part of the wave, while the negative pulses The frequency part of the
V/Hz ratio is controlled by the look like the negative half. V/Hz ratio is controlled by the
frequency of the control signals The wider the pulses, the modulation frequency which
applied to the inputs of the higher the RMS voltage. is the time period comprising one
SCRs (or transistors) in the Therefore if narrow pulses are positive set of pulses and one
output section. at the beginning of the positive negative set of pulses. It is the
cycle, and wide pulses are modulation frequency that the
towards the middle, it will motor is responding to and only
produce a nearly sinusoidal a very small amount of the high
RMS voltage. Although the frequency pulses can be seen in
voltage waveform looks very the motor current waveform.
indicates VRMS
Figure 4. Simplified diagram of a pulse width modulated inverter with current and voltage waveforms taken at the motor terminals

Simple Things First
Be sure all connections are good. to maintain a low resistance Resistance measurements
Seems obvious doesnt it? connection between conductors.
However, honest troubleshooters Visually inspect all connection This is probably the least
will admit to having overlooked points for looseness, corrosion, preferred of the three methods,
this condition at least once in or conductive paths to ground. but will still detect completely
their career right?! This Even if the visual inspection open circuits or leakage paths
troubleshooting step should looks okay, you should use at to ground that are resistive.
always be done before anything least one, or some combination Keep in mind however, that
else. Periodic tightening of of the following three methods most ohmmeters use small
connections is often required for checking the connections. amounts of current in their
measurements and may read
a good connection, when in
fact the connection may open
circuit when a large amount
of current attempts to conduct
through it. This is also known
as contact resistance.
Voltage drops
Check for voltage drops
across the various connections.
Compare with the other two
phases. Any significant variation
between phases, or more than
2-3% (depending on motor
current and supply voltage)
at each connection, should
be suspect.
Temperature
measurements
An inexpensive infrared
temperature probe used
with a handheld DMM is a
fast and easy way to check
for bad connections. Any
significant increase in
temperature at the connection
terminal will indicate a bad
connection or contact resistance
due to I2R heat loss. If the
temperature of the terminal
was not previously recorded
onto your system diagram,
compare with the other two
phases. More on how to use
temperature measurements
to diagnose motor and drive
problems is discussed in the
Figure 5. The 1 mV/degree output of the Fluke 80T-IR can be used with any DMM following sections.
capable of reading millivolts. The Fluke ScopeMeter instruments can read out
directly in Fahrenheit or Celsius.

Motor Measurements
Temperature
measurements What next?
Temperature is a key indicator
of a failing, or overloaded motor. If mechanical load requirements and behavior seem normal, then its
Use an infrared temperature possible some of the motor windings have become shorted and are the
probe such as the 80T-IR from source for increased current, heat and loss of torque. Things to check
Fluke to measure motor tem- for now are current imbalance, single phasing, voltage imbalance and
peratures at key points includ- something unique to PWM drives, overvoltages caused by reflected
ing; bearing locations and motor voltage waves. High motor shaft voltages, a problem also associated
terminal block connections (if with PWM drives, could explain excessive bearing temperatures and
one exists), as well as the motor premature bearing failure. How to test for these conditions is described
housing itself. Are the readings in the following paragraphs.
close to what was measured
when the motor was operating
normally? If these readings
werent taken before, is the
motor operating temperature Voltage measurements However, it should be noted that
within the NEMA classification even though the motor
for that motor? If the answers As the voltage applied to the is not responding to the higher
to these questions are yes, motor terminals by the ASD is frequencies in terms of torque
then you may want to move to non-sinusoidal, the voltage or work being done, high
the ASD controller for the next readings given by an analog frequency currents may be
measurements, or you can go meter, an average responding flowing outside of the windings
ahead and make the following digital multimeter (DMM) and a due to various capacitances
measurements just to be sure. true RMS DMM will all be in other parts of the motor. This
different. Many troubleshooters will be discussed in more detail
Overloading prefer using an analog meter later on.
because the coil in the meter The reason for making voltage
If the motor is trying to deliver movement responds in the same measurements at the motor
more torque/power to the way as the motor, i.e., to terminals is to verify that the
mechanical load than for which the low frequency component voltage is not too high, too low,
it is rated, an overload condition of the waveform, not the high or is unbalanced. A DMM/Scope
will exist, i.e., the motor draws frequency switching component. with a low pass filter probe or
current above its nameplate The analog meter will also Fluke 41B, can be used to verify
rating. Measure the motor correspond to the ASDs that the voltage at the motor
current and check it against programmed V/Hz ratio and terminals corresponds with the
the nameplate rating. Be sure to the voltage displayed on the calculated voltage readout at the
multiply the service factor (SF), ASD housing if one exists. ASDs display. Using a scope
if one is shown on the name- Most digital multimeters or 41B has the advantage in
plate, times the rated current. (DMMs) will respond to the that a simultaneous frequency
If the motor is at or above its high frequency component measurement can be made which
rated capacity and the overload of the motor drive waveform is much more meaningful. This is
is intermittently tripping the and will therefore give a discussed further in the Volts/Hz
drive, the solution is not to higher reading. Even though ratio section. If the voltage at
adjust the overload on the drive a true-RMS DMM will give an the motor is too low, then bad
higher to prevent the tripping! accurate reading of the heating connections are a likely cause,
Find out if the motor is rated effect of the non-sinusoidal or the dc bus voltage at the ASD
properly for the application. voltage applied to the motor, is too low. If the motor terminal
Sometimes a cheaper, lower quite often the analog meter voltages are too high, then the
rated motor is substituted; or reading is preferred since dc bus voltage may be too high,
perhaps a miscalculation of the it gives a (lower) voltage which in turn could be due to the
load requirement accounts for reading similar to the motors ASD input voltage being too high.
the mismatch. Its also possible response to the voltage applied.
that the mechanical load being
driven by the motor has been
increased by an operator
or process supervisor who
doesnt understand that doing
so will put the motor into an
overload condition.

Next measure the phase- Current imbalance As the current measurement
to-phase voltage between measurements will be made in a high energy,
the three motor terminals for electrically noisy environment,
voltage imbalance. Voltage Motor current should be be sure the proper current
imbalances of as little as 3% measured to ensure that the clamp is used as well as good
can cause excessive heating continuous load rating on measuring technique. An ac
due to unbalanced currents in the motors nameplate is not only current transformer (CT)
the stator windings and loss of exceeded and that all three style current clamp will usually
motor torque. However, some phase currents are balanced. work best as it is a low imped-
motor installations are more If the measured load current ance device and less likely to
forgiving towards imbalances exceeds the nameplate rating, capture electrical noise across
so be sure to check out the or the current is unbalanced, it. Most ac/dc current clamps
entire motor system for other the life of the motor will be are the hall effect style which
causes should an imbalance reduced by the resulting high have a high impedance and
exist. As the relative difference operating temperature. If the are therefore more susceptible
between phase voltages is voltage imbalance is within to noise. Either style clamp
what is being measured, not acceptable limits, then any can have problems with noise
absolute voltages, the DMM excessive current imbalance if not properly shielded and
will give more accurate detected could indicate shorted terminated. Clamps using
readings with better resolution motor windings. Generally, coaxial cable terminated with
than an analog meter. Use the current imbalance for three- BNC connectors work best.
following procedure to calculate phase motors should not Clamps with higher select-
voltage imbalance. exceed 10%. able output ranges for current
measurements less than 10
or 20 amps will help get the
Percent Voltage Maximum deviation from the average voltages signal-to-noise ratio of the
Imbalance = x 100 clamp to an acceptable level.
Average voltage
The integrity of the
measurement can sometimes
For example, voltages of 449, 470 and 462 gives an average be enhanced by not touching
of 460. The maximum deviation from the average voltage is the clamp or the meter while
11 and percent unbalance would be: 11 taking the reading.
x 100 = 2.39%
460 To calculate current imbal-
ance, use the same formula as
above for voltage but substitute
Possible causes of voltage current in amps. For example,
imbalance are: one of the currents of 30, 35 and 30 amps
phase drive circuits is only would give an average current
partially conducting, or there of 31.7 amps. The maximum
is a voltage drop between the deviation from the average
ASDs output and the motor current would be 3.3 amps with
terminal on one of the phases a current imbalance of 10.4%.
due to a poor connection.
There are other concerns about
the motor terminal voltages with
regard to distortion, but they
must be measured and viewed
using an oscilloscope and will
be discussed in a later section.

Single phasing is a fairly
mA common cause of failure for
A three phase induction motors
FLUKE 87 T1 A 30A as the other two phase wind-
A T2 B 35A ings must conduct more current,
T1
A mA
mA AA COM
COM
T3 C 30A and therefore produce more
T3 T2 80i-400 heat, which eventually leads
10A MAX
FUSED
400mA MAX
FUSED
1000V MAX to premature failure of the motor.
What makes single phasing a
B
tricky problem to detect is that
C the motor will continue to run
normally, although there will be
Figure 6. Measure the motor phase currents. an increase in heat, and possibly
loss in torquesubtle conditions
that may go unnoticed. Another
T1 Rolled Phases clue to a possible single phasing
C condition is if the motor is
T3 Unbalanced caused Unbalanced caused
by supply by motor stopped and restarted, it may
A run backwards.
T1 C 30A T1 C 30A
The measurement side
B T2 A 30A T2 A 35A
T2 of detecting this problem
T3 B 35A T3 B 30A is also a little tricky. When
the voltage measurement is
Figure 7. Rotate phase connections to determine whether problem is in the made at the motor terminals,
motor or the drive. the voltages will read close
to normal as motor action is
inducing voltage into the open
If the current in the motor is Single phasing winding. The best way to
unbalanced (Figure 6), you can reliably detect this condition is
determine if the unbalance is Single phasing results from the
total loss of one of the phase to make current measurements
caused by the motor or the ASD on all phases until the open
by rotating the phase connec- voltages applied to a three
phase ac induction motor and phase is detected through an
tions on the motor terminals. absence of current flow.
But first, measure the current in can be a tricky problem to
all three phases with the motor detect. In an ASD application,
under load. Next, rotate the this would usually be caused by
phase conductors from the ASD an open connection at either
to the motor terminals. end of the cabling between the
If the phases A, B and C motor and drive, or an open in
are connected to motor termi- one of the conductors in the
nals T1, T2 and T3 respectively, cable itself. Its also possible
then change the connections so one of the insulated gate bipolar
that phases A, B and C are transistors (IGBT) which are
now connected to terminals T2, the devices that drive each
T3 and T1 (Figure 7). Now phase of the motor, could have
measure the phase currents with become open circuit, although
the motor under load again. some ASDs are able to detect
Lets say the first measurement this condition.
found the current imbalance
was on the B/T2 connection.
If the imbalance moved to the
B/T3 connection in the second
measurement, then the imbal-
ance is coming from the ASD. If
the current imbalance in the
second measurement was on
the A/T2 connection then the
imbalance is due to the motor.

Overvoltage Reflections Theory
For those not interested in the

theory of how this phenomenon
occurs, skip ahead to the next
section on troubleshooting the
problem.
The trend with PWM drives
has been to make the rise time
of the pulses as fast as possible
to reduce switching losses and
increase the efficiency of the
drive. However, fast rise times,
coupled with long cable lengths
produce an impedance
mismatch between the cable
and the motor causing reflected
waves, or ringing as shown
in Figure 8. If the rise times
are slow enough, or the cable
short enough, the reflected
Figure 8. Reflected voltages (ringing) on the
waves will not occur. The main modulated pulse
problem with this condition
is that ordinary motor winding The relationship between
insulation can break down cable length, rise time and
quickly. Additionally, higher the resultant increase in peak
than normal shaft voltages voltage is illustrated in Figure 9.
can develop causing premature Basically, the peak voltage
failure of bearings and at the motor terminals will
excessive common mode noise increase above the dc bus voltage
(leakage currents) can interfere of the ASD as cable length
with low voltage control signals increases and the rise time of
and cause GFI circuits to trip. the ASD output pulse gets faster.
Figure 9. Impact of rise time and cable length on magnitude of reflected voltages

The magnitude of the voltage There are two different for- For example, if we have a
that is reflected at the motor mulas for determining the peak 480 Vac L-L voltage with a
terminals back to the ASD and voltage that can be expected at 648 Vdc bus, 50 feet of cable,
added to the peak voltage, then the motor terminals, depending and RL = 0.9 we can see the
driven back to the motor, is on whether the transit time of effect of the peak voltage
determined by something called the pulse (traveling at half the calculation using two different
the reflection coefficient, which speed of light) is greater than rise times.
is a function of the motor resis- or equal to 1/3 the rise time With a rise time of 0.5 s, the
tance, the cable inductance and (dv/dt) or less than 1/3 the rise transit time (0.1 s) is less than
cable capacitance as shown in time. First lets look at how to 1/3 the rise time (0.16 s) so we
the formula below: determine the transit time (tt) use the first Vpeak formula that
RM - RC with regard to cable length (lc). takes into account the effect
L =
RM + RC lc (ft) of rise time and the calculation
tt = = 2x10-9 * lc becomes:
where L is the reflection coeffi- 500 (ft/sec)
cient of the load, RM is the .3
If the transit time of the cable x 0.9 + 1* 648 Vdc = 998 Vpeak
motor resistance and RC is the is less than 1/3 the rise time .5
characteristic cable resistance then use the following Vpeak With a rise time of 0.1 s, the
expressed by the formula: formula: transit time (0.1 s) is greater
than 1/3 the rise time (0.033 s)
RC = L/C Vpeak =
3tt
* L +1 * VDCB so we use the second Vpeak
tr
(see cable manufacturers. formula which is:
specifications for inductance (L) When the transit time is 0.9 + 1 * 648 Vdc = 1,231Vpeak
and capacitance (C) per foot) greater than or equal to 1/3
Most motors less than 10 HP the rise time, then the rise time (See the Acknowledgments at
have an L between 0.9 - 1.0. portion of the first Vpeak formula the end of this application note
Some larger horsepower motors is not used and the calculation for additional information and
may have an L as low as 0.8, becomes: references)
occasionally less. The curves in Vpeak = L +1 * VDCB
Figure 9 use an L of 0.9 in the
calculation.

Overvoltage reflections Figure 10 shows the ASD
troubleshooting L-L voltage measurement at the
motor terminals with six feet
As mentioned earlier, fast rise of cable, while Figure 11 shows
times on the ASD output pulses the ASD L-L voltage with
and long cable runs between 100 feet of cable. Notice the
the ASD and the motor will difference in peak voltage
cause overvoltage reflections measurements about 210
approaching double the DC volts. Also notice that there is
bus voltage and even higher. only 5 Vrms difference between
An oscilloscope is required to the two waveforms (small digits
discover the full extent of this on the display). This means
problem, as seen in Figures 10 your voltmeter will not find
and 11 below. this problem.
Very few scopes will trigger
Figure 13. Leading edge of PWM pulse with
as nicely and easily as the Fluke reflected voltage (ringing)
ScopeMeter 123 Test Tool did
for the measurements in Figures The signals in Figures 12 and
10 and 11. For other scopes 13 were captured by triggering
use the procedure outlined on a single pulse using single
below to measure the extent shot mode with cursors enabled
of the overvoltages. to make the peak voltage
measurement along with rise
time. While this measurement
requires more button pressing
and scope know how,
the automated rise time
measurement may be worth the
trouble. Manually resetting the
Figure 10. Normal PWM signal single shot trigger periodically
will give you a sampling of
various peak voltages for the
different pulses. Also, slowly
raising the trigger voltage
will give you an idea of the
maximum peak when the
scope stops triggering.
Figure 12. Leading edge of PWM pulse with
no reflected voltage
Figure 11. Overvoltages due to reflected waves

Assuming you have identified The real danger of this If your motor has already
a true overvoltage, or ringing overvoltage condition is the failed and has to be rebuilt,
problem, then something must damage it can do to the motor better insulated wire such as
be done about it. The simplest windings over a period of time, Thermaleze Qs, or TZ Qs (by
solution is to shorten the cable. which may not show up as a Phelps-Dodge), should be used
Table 3 shows the maximum problem when the PWM drive is to rewind the motor. The main
length of the cable before the first installed. Many PWM drives advantage is that it provides
peak voltage goes beyond 1.15 are installed without taking into significantly more protection
times the dc bus, (highest safe consideration the overvoltage against overvoltages without
motor voltage) for various rise effects of long cabling between adding insulation thickness
times and reflection coefficients the PWM output and the motor. and the same stator can be
( L ) of 0.9 and 0.8 (see previous And while improved efficiency used without modification.
section for more details). of the newest and latest PWM If the motor has been damaged
The table only shows where drives are achieved by making beyond repair then a motor
the peak overvoltages start the rise times faster on the designed to meet NEMA MG-31
for a given rise time and length output pulses, this can make specifications (sustained Vpeak
of cable. The peak overvoltages the overvoltage problem even 1600 volts and rise time
will continue to increase to worse, and the need for shorter 0.1 s) should be used as a
almost double the dc bus cabling even greater. replacement motor for PWM
voltage as the cable lengthens applications where sustained
or rise time gets faster. The overvoltages may be occurring.
peak voltages can even exceed
voltage doubling if the reflected
voltage occurs on top of existing
ringing due to the distributed
leakage inductance and
coupling capacitance.
Length where Vpeak Length where Vpeak

>1.15 x DC bus voltage >1.15 x DC bus voltage
PWM Pulse Rise Time and L = 0.9 and L = 0.8
0.1 s 2.8 feet 3.1 feet
0.2 s 5.5 feet 6.3 feet
0.5 s 14 feet 16 feet
1 s 28 feet 31 feet
2 s 55 feet 63 feet
3 s 83 feet 94 feet
4 s 111 feet 125 feet
Table 3. Maximum cable lengths for various rise times and reflection coefficients before peak
voltages begin to exceed 1.15 times the DC bus voltage

Filter Remedy 1: Typical Filter Remedy 2: Filter Remedy 3: Typical
effect of a low pass filter Typical effect of the effect of an R-C impedance
at the inverter output as series reactor measured matching filter measured at
measured at the motor at the motor terminals the motor terminals
terminals
Figure 14
Motor Terminal Filter Inverter Output Filter Series Reactor

Parallel connected at the Series connected to the Series connected to the
motor terminals. PWM output terminals. PWM output terminals.
Designed to match the Designed to slow rise Acts as current limiter
characteristic cable time (dv/dt) below a and also slows rise time.
impedance. critical value.
Not cable length Dependent on cable Dependent on size of
dependent. length. system.
Losses are more or less Losses dependent on Losses dependent on
fixed. motor kVA motor kVA
Size/cost more or less Size/cost dependent on Size/cost dependent on
fixed. motor kVA. motor kVA.
Table 4.
If the cabling in your PWM 3. In some applications, such All the solutions suggested
application cannot be shortened as submersible pumps or above should be designed for
then use one of the three ways drilling machines, it is not your specific application by a
to fix the problem as shown possible to access the motor qualified engineer.
in Figure 14: terminals and other methods
of minimizing overvoltages Safety Note: Reflective voltage
1. An external add-on low phenomenon can mean peak
pass filter can be installed are required. One way is
to apply series reactors voltages 2-3 times the DC bus
between the PWM output voltage. For 480V line voltage
terminals and the cable to between the PWM output
terminals and the cable to this means a DC bus voltage
the motor, as one way to of 648V and possible peak
slow the rise time. the motor. While this is a
fairly simple solution, the overvoltages of 1300V-2000V
2. Another approach is to install and possibly higher given
an R-C impedance matching reactors may be fairly large,
bulky and expensive for large +10% line voltage variance.
filter at the motor terminals Therefore it is recommended
to minimize the overvoltages, horsepower applications.
that the measurement at the
or ringing effect. The trade-offs between motor terminals be made
these three alternatives for with the highest rated probe
minimizing overvoltages can available and for the shortest
be summarized in Table 4. time possible where reflected
voltages are likely to be present.

Bearing currents Care must be taken when Leakage currents
making this measurement.
When motor shaft voltages Connect the probe tip to a piece Leakage currents (common
exceed the insulating capability of twisted stranded wire, or mode noise) capacitively coupled
of the bearing grease, flashover a carbon brush which in turn between the stator winding
currents to the outer bearing makes contact with the motor and frame ground will increase
will occur, thereby causing shaft, while the common is with PWM drives as the capacitive
pitting and grooving to the connected to the motor frame reactance of the winding
bearing races. The first signs ground. As the shaft voltages insulation is reduced with the
of this problem will be noise are caused by fast rise times high frequency output of the
and overheating as the bearings of the PWM drive pulses, drive. Therefore, faster rise times
begin to lose their original the voltages will appear as and higher switching frequencies
shape and metal fragments mix inconsistent peaks and should be will only make the problem
with the grease and increase measured using an oscilloscope worse. It should also be noted
bearing friction. This can lead to and not a DMM. Even if the the potential increase in leakage
bearing destruction within a DMM has peak detect, there is currents should warrant close
few months of ASD operation enough variation between peaks attention to established and
and is thus expensive in motor to render the reading unreliable. safe grounding practices for the
repair and downtime. Another measurement tip is to motor frame. The increase in
There is a normal, unavoidable make the shaft to frame ground leakage currents can also cause
shaft voltage created from the voltage measurement after the nuisance tripping of ground fault
stator winding to the rotor shaft motor has warmed to its normal protection relays, override 4-20
due to small dissymmetries of operating temperature as shaft mA control signals, and interfere
the magnetic field in the air gap voltages may not even be with PLC communications lines.
that are inherent in the design present when the motor is cold. Measure common mode noise
of the motor. Most induction The most simple solution to by placing the current clamp
motors are designed to have a this problem is to reduce the around all three motor conduc-
maximum shaft voltage to frame carrier (pulse) frequency to less tors. The resultant signal will be
ground of < 1 Vrms. than 10 kHz, or ideally around the leakage current.
Another source of motor 4 kHz if possible. If the carrier A common mode choke along
shaft voltages are from internal frequency is already in this with a damping resistor can be
electrostatic coupled sources range than alternative solutions used to reduce leakage currents
including; belt driven couplings, can be employed such as: shaft (Figure 15). Also, special EMI
ionized air passing over rotor grounding devices, bearing suppression cables can be used
fan blades, or high velocity air insulation, faraday shield in between the drive output and
passing over rotor fan blades the motor, conductive grease, the motor terminals. The copper
such as in steam turbines. the use of ceramic bearings or conductors of the cable are
Under 60 Hz sine wave filtering between the ASD and covered with ferrite granules
operation, the bearing break- the motor. which absorb the RF energy
down voltage is approximately and convert it to heat. Isolation
0.4-0.7 volts. However, with transformers on the ac inputs will
the fast edges of the transient also reduce common mode noise.
voltages found with PWM
drives, the breakdown of the
insulating capacity of the grease
actually occurs at a higher
voltage about 8-15 volts.
This higher breakdown voltage 3 AC Input Induction Motor
creates higher bearing flashover
M
currents, which causes increased
damage to the bearings in a Common Mode
shorter amount of time. Choke
Research in this area has
shown that shaft voltages
Diode Rectifier PWM Inverter
below 0.3 volts are safe and
would not be high enough for Figure 15. Common mode choke with dampening resistor to reduce leakage currents
destructive bearing currents to
occur. However, voltages from
0.5-1.0 volts may cause harmful
bearing currents (>3A) and
shaft voltages > 2 volts may
destroy the bearing.
Measurements at the Inverter
Control circuit noise Noise on the line inputs filter such as the PM 8918/301
caused by SCR controlled dc low pass filter probe from Fluke,
Induced electrical noise can drives, current source inverters, can give similar results.
significantly affect sensitive six-step drives, and other noisy If the frequency of the reading
control circuits such as speed, loads in the building can also is stable, but the voltage is low,
torque and control logic, induce unwanted noise in high or unstable, it could indicate
position feedback sensors, adjacent control wiring. The a problem with the dc bus circuit.
as well as outputs to display high energy, fast switching If the frequency is unstable,
indicators and system control PWM signals on the motor but the voltage is okay, then
computers. As many of the cabling will also contribute to something might be wrong with
control inputs are scaled 0 to this problem if it is unshielded the IGBT control circuit. If the
5 or 10 Vdc maximum, with and within close proximity of V/Hz are fluctuating together,
typical resolutions of one part control wiring. The best way or the speed of the motor is off,
in 1,000, only a few millivolts to minimize this problem is but the V/Hz ratio is correct,
can cause improper operation. to be sure line input wires and then one of the speed inputs to
Significant amounts of noise motor cabling are contained the control board may be bad.
can actually damage the drive in separate grounded, rigid Vector drives that employ torque
and/or motor. metal conduit. control by regulating current
A common source of Verifying whether noise in a nonlinear fashion over
electrical noise is from the problems exist in control circuit the entire speed range are an
coils of relay and contactor wiring will require the use of a exception to this however,
coils. Transients caused by scope. Special care should be as the V/Hz ratio will vary
the opening of the coil circuits taken when using a scope to considerably, be hard to predict,
can generate spikes of several make low voltage measurements and should therefore not be
hundred volts which in turn so that noise is not coupled into used for diagnostic purposes.
can induce several volts of noise the scope and is then mistaken
in adjacent wiring. Follow good as noise on the control signal Inverter drive circuits
installation practices by using wiring. Using 10x probes with
twisted pair, shielded wiring short ground leads will minimize Voltage source inverters
for sensitive control circuits noise introduced by the scope While PWM drives are becoming
and separate them from relay probes into the measurement. more and more popular, and are
and contactor coil circuit wiring. commonly being used to replace
Additionally, adding Volts/hertz ratio the voltage source inverters
snubber circuits to the relay (more commonly called the
and con-tactor coils will As discussed earlier, the six-step drive because of the
eliminate arcing and reduce ratio of voltage to frequency stepped shape of its output)
noise induced in adjacent determines the amount of motor there are still many of these
wiring. For most ac coils, a torque produced by a given six-step drives in operation that
33 k resistor connected in ac induction motor. If the motor require maintenance. While all
series with .047 F capacitor experiences a loss in torque, the other checks outlined in this
can be connected across each then this measurement may sectionvoltage and current
ac relay and contactor coil. give some clues as to what imbalance, single phasing
For dc coils, use a reverse is happening. and overheatingcertainly apply
biased diode across the coil to While the V/Hz ratio is not to six-step drives, there are
achieve similar results as the something that normally needs problems unique to this kind
RC snubber for ac coils. to be adjusted after installation, of drive as well.
this measurement can be quite A shorted transistor on
useful for diagnostic purposes. some six-step drives can be
The Fluke 39 or 41B power detected by measuring across
meters work well for this the transistor with a scope.
RC snubber + measurement as they have a A good transistor will have
built-in low frequency response a nicely formed square wave
which gives a voltage reading with sharp edges, while a bad
0.47 F
AC Coil DC Coil Diode comparable to what the motor transistor will be rounded at
33 K responds to. Additionally, the the peak of the leading edge.
frequency can be viewed on
_
the same screen as the voltage.
Using an oscilloscope with a
built-in, or an external low pass
Figure 16.ACand DC coil noise suppression

If the shorted transistor is
causing the drives protection Anode
circuit to trip, then the converter 87 TRUE RMS MULTIMETER
section that rectifies the ac into P 0 1 2 3 4 5 6 7 8 9 0

40
dc can be disconnected and the MIN MAX RANGE HOLD H
inverter circuit can be run with N PEAK MIN MAX

REL Hz
SCR
the 10 volts or so of leakage P Gate V
mV
mA
A
voltage that is present on the dc V A
bus. The input driver circuit will N OFF
still turn on the transistors but A mA A COM V
at a much lower voltage level Cathode 400mA MAX
and the bad transistor is easily 10A MAX

FUSED
FUSED
!
1000V MAX
detected.
Likewise, the inverter section
can be disabled while trouble-
shooting the ac to dc converter
circuit. The speed control can Figure 17. Setup for testing SCRs
be varied while monitoring the
dc bus voltage to see if it varies
with the speed control. 4. This should turn on the SCR 1. To check the positive
Important note: The voltage and a voltage drop of about conducting IGBTs, connect
feedback resistors must remain 1.0 volt should be measured the scope common lead to
connected to the dc bus to across it. If the SCR is not the DC+ bus and measure
insure the converter section conducting, you will continue each of the three phases at
is still controlled with the speed to see OL on the DMMs the inverters motor output
potentiometer. Be sure to display. Note: some SCRs may terminals. Check for nice,
disconnect the ac inverter section require a higher voltage to clean-edged square waves
after the voltage feedback turn on. If this is the case, without any visible noise
resistors. If this procedure is then connect a test lamp in inside the pulses, and that
not followed, the dc converter series with the SCR and all three phases have the
will turn full on immediately connect a 9 or 12 Vdc battery same appearance.
upon starting the drive. across the test lamp and SCR.
If the converter section is not 2. To check the negative
Connect the resistor between conducting IGBTs, connect
functioning properly SCRs can the gate and the anode of the
be checked individually, out of the common lead to the
SCR. The SCR is conducting if DC- bus and perform
circuit, using the following the lamp turns on.
procedure (Figure 17). the same measurements
as in step one above, on
1. Put the DMM or ScopeMeter PWM inverters each of the three phases
in Diode Test. Many of the newer fractional at the inverters motor
2. Place the red lead on the horsepower PWM drives are output terminals.
Anode and the black lead on integrated to the point where 3. Check for leaky IGBTs by
the Cathode. This puts about the input diode block and IGBTs measuring the voltage from
3.5 Vdc across the device. are potted into a single throw- earth ground to the inverters
3. Solder some alligator leads to away module that is bolted to motor output terminals with
a 1 K resister and connect the heat sink. The cost of these the drive powered on, but
one end to the anode and the units rarely justify the time to the speed set to zero (motor
other to the gate. repair, if replacement parts stopped). Some drives may
are even available. However, have a normal earth ground
the larger horsepower drives to motor terminal voltage
starting in the 5-25 horsepower of about 60 volts, with a
range, have components that reading of over 200 volts
are accessible and become indicating a leaky IGBT.
economically feasible to repair. Perform this measurement
If it has been determined that on a known good drive to
the drive inverter is the source determine what is normal
of an improper voltage being for that drive.
applied to the motor, then use
the following procedure to
isolate which IGBT(s) is failing
in the output section.

Trigger (T=0.00) on 2/26/97 at 13:45:08
150
100
50
capture, time-stamp and reset
single shot measurements.2
0 It is especially well suited for
2/26/97 13:45:08 logging and time-stamping
Volts
-50
elusive transient events. See
-100
Figure 18.
-150 The ScopeMeter 123 can
-200
also time stamp a single shot
event which can later be
-250 retrieved using FlukeView for
-0.04
-0.03
-0.02
-0.01
0.00
0.01
0.02
0.03
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.14
0.15
0.16
ScopeMeter software version
Time
2.0 (this feature only available
with ScopeMeter 123). This
Figure 18. Single shot transient time stamped with ScopeMeter freeware eliminates the need to have a
PC connected to ScopeMeter
properly. Additionally, the 123 while its waiting to trigger
The dc bus on the transient (Figure 19).
buildings grounding system
DC voltage too high must be properly installed If the tripping is caused by
Transients (less than .5 cycle) and functioning to help dissipate a transient, then an isolation
and swells (.5-180 cycles) on lightning strikes safely to earth, transformer or series line reactors
the AC line inputs and motor rather than through some can be placed in series with
regeneration are the two most path in the buildings power the front end of the ASD. An
common causes of nuisance distribution system. Steps can alternate solution would be to
tripping of the overvoltage and should be taken to minimize place a surge protection device
fault circuit on ASD inverters. their effects on your electrical (SPD) at the motor control
Transients and swells can be and electronic equipment, since center, or the primary side
caused by events happening a building that is susceptible of the distribution transformer
outside the building like to transients, sags and swells, feeding the ASD. However, if
lightning or utilities switching is usually a building that is the source of the transient is
KVAR capacitors or transformer deficient in proper wiring coming from another load on
taps, as well as other loads and grounding. the same secondary feed as the
inside the building being If a transient voltage is ASD, then a separate isolation
switched on (capacitive) or off expected, then an oscilloscope transformer or series line reactor
(inductive). To test for this, use like the Fluke ScopeMeter may need to be used directly in
an oscilloscope or power line can be used to measure, and front of the ASD, or better yet,
monitor with at least 10 sec/ more importantly, time stamp put the ASD on its own feed.
div. resolution, and capable of the transient so it can time Voltage swells >30 cycles
time-stamping the event. correlated to whatever event can be monitored using the
The Fluke ScopeMeter 123 caused the ASD fault. A freeware ScopeMeter TrendPlot mode

Test Tool is a good choice for software package is available (see Figure 20) or using some
this measurement as it has which was especially designed other type of line monitor. One
plenty of single shot resolution, for the ScopeMeter B series to way to mitigate the swell is to
and most importantly can time- 2
ScopeMeter freeware available at:
stamp the event so it can be www.fluke.com/scopemeter/
time correlated to whatever
sourcelightning, utility or
electrical equipmentis causing
the problem. Additionally, it has
the IEC 1010-1 600V CAT III
safety rating which should be
an important consideration
when purposely measuring high
magnitude impulses in a high
energy environment.
If the drive is installed in a
part of the country that is prone
to lightning activity, be sure
the building has proper surge
protection that is functioning
Figure 19. Transient time and date stamp retrieved using FlukeView software

install a temporary dropout coasting and begins to spin DC voltage too low
relay for as many cycles as the motor shaft rather than There are several possibilities
the swell, but that can still getting spun by the motor, for nuisance tripping of the
be tolerated by the drive. The which causes the motor to low voltage fault circuit on
viability of this solution will be change into a voltage generator ASD inverters. Voltage sags
determined by the amount of and returns energy to the dc (.5-180 cycles) and undervoltages
ride-through the ASDs input bus. Excessive regeneration can (>180 cycles) on the line
circuit can handle before the be measured by checking for a input to the drive are common
dc bus voltage drops to an change in the direction of the conditions associated with this
undervoltage condition. dc current back into the dc bus problem. Sags are quite often
Another possible solution is to while simultaneously checking caused by another load within
use a voltage regulation device the dc bus voltage for an the buildings distribution
like an uninterruptable power increase above the trip point. system being turned on, or
supply (UPS), but it should If regeneration is causing the perhaps from a neighboring
be noted that most UPSs are overvoltage tripping, something building starting a large
designed to handle voltage sags called dynamic braking can be electrical load.
and momentary interruptions employed which limits how fast Make the measurement with
and may not handle voltage the regenerative current is an instrument that can time
swell conditions unless allowed to feed back into the dc stamp the sag or where the
specifically designed to do bus capacitors. undervoltage causes the ASD
so. Carefully check the UPS If the dynamic braking has low voltage fault to trip. You
manufacturer specifications. already been employed and is may want to start making this
Overvoltages or long term not functioning properly, then measurement at the service
voltage drift can be caused by it can be tested according to the entrance. This way you can
very large loads being turned manufacturers specifications. quickly isolate whether the sag
off within the building or a slow If the brake is the resistor type, is being caused from within the
response of the utilitys voltage it can be visually inspected for building or outside. Be sure to
regulation system to large signs of overheating; discolora- monitor the voltage and current
reductions in demand on the tion, cracking, or even smell simultaneously so you can
power grid. This condition is for that distinctive aroma of tell whether the problem is
easily discovered using the an overheated component. downstream from the service
ScopeMeter TrendPlot feature. The resistance value can also entrance as indicated in Figure
The best way to deal with this be measured against the 21 where the surge in current
problem is to employ local manufacturers specifications. is coincident with the voltage
voltage regulation with a device If the dynamic brake uses the sag. An upstream (outside the
like a UPS that is designed to transistor type, then the silicon building) problem would show
handle overvoltage as well as junctions can be tested using the voltage sag without a
sags and dropouts. diode test as described earlier. corresponding surge in current.
Another common source Also, the braking current can be If the problem is within the
for overvoltage on the dc bus measured and the current building, continue making the
is motor regeneration. This waveform compared with that measurement at different load
occurs when the motor load is of a known good system. centers until you have isolated
the load with the corresponding
voltage sag and current surge.
Another possibility is a motor
that is drawing enough current
to cause the dc bus voltage
to drop below the undervoltage
fault setting, but not enough
to trip the current overload.
You will need to check the
motor current for overloading
(compare with motor name-
plate) as well as verify whether
the program settings of the
drive are correct for the motor
nameplate ratings, including the
application for which the motor
Figure 20. Trend of voltage swell Figure 21. Voltage sag caused by a down- and drive were intended.
stream load

Look at the line input Once power has been reduction in wiring and
voltage waveform to the ASD. completely disconnected from transformer size that would
The wave-shape should be the ASD line inputs, use diode normally be required to handle
a nicely shaped sine wave. test to check from both the -DC the inrush. Some drives will
Severe flat-topping of the and the +DC bus to each of the employ a pre-charge resistor
waveform (see Figure 22) can line input connections. Starting that limits the inrush current
prevent the dc bus capacitors with the positive lead on the until the dc bus charges to
from fully charging to the peak +DC bus, probe each of the about 60%, then a relay cuts in
value, which lowers the dc bus line inputs with the negative to remove the resistor from the
voltage as well as the amount lead. Each reading should circuit. When troubleshooting
of current available to the ASD indicate OL (overload), or a the input circuit, be sure the
output circuit. reverse bias condition. Take pre-charge resistor and relay
the readings again, only now are not overlooked as possible
AC line input with the negative lead on the causes first.
+DC bus and measure each Other drives employ SCRs
Many of the problems line input with the positive on the front end that will chop
associated with the ac line lead. This will forward bias the ac voltage that is allowed
input that have been discussed the diodes and cause them to to be rectified. This slowly
in the previous section, have a conduct with about 0.5-0.7 charges the dc bus capacitors
direct and immediate effect on volts dropped across them. until the dc bus comes up to a
the dc bus. However, there Use this same procedure for the predetermined level, then the
are a few issues unique to the other three diodes connected to SCRs goes into full rectification.
input circuit that still need to the -DC bus. The only difference Use the following procedure to
be discussed. is that the positive lead on the check for a bad SCR or one that
Diode bridge -DC bus will cause the diodes to doesnt go into full conduction
The diode bridges used in PWM conduct, and the negative lead in the pre-charge circuit.
drives are pretty straightforward on the -DC bus will reverse bias Use measurements made on a
to troubleshoot. The normal the diodes and cause an OL known good drive for reference
failure mode for a diode is reading on the DMM. Shorted waveforms.
from transient overvoltages or diodes will read as 0 volts while 1. Connect the scope common
over-current conditions. If the open diodes will read OL when lead to the DC+ bus and
shorted diode trips the breaker they should be conducting. measure each of the three
before it has a chance to burn Most modern ASDs will phases at the line inputs
into an open circuit, then also employ some kind of a one at a time. There will
a DMM with diode test will pre-charge circuit to the dc be a large voltage drop
uncover this problem quite bus capacitors to reduce the across each input SCR at the
easily. Use diode test as the inrush current. This will prevent beginning of the pre-charge
ohms mode may not put out tripping of protection circuits, cycle which will drop down
a high enough voltage to get not to mention significant to nearly zero volts once the
the diode to conduct.
+DC
87 TRUE RMS MULTIMETER
0 1 2 3 4 5 6 7 8 9 0
40
MIN MAX RANGE HOLD H
REL Hz
PEAK MIN MAX
AC Input mV
mA
V A
V A
OFF
A mA A COM V
400mA MAX
DC
FUSED
10A MAX 1000V MAX
FUSED !
Figure 22. Voltage flat-topping caused by

harmonic currents
Figure 23. Checking for open and shorted diodes in-circuit

dc bus capacitor is charged can be a real problem if this Voltage unbalance
and the SCR is fully conducting. distorted voltage makes its way While voltage unbalance at
The time it takes to go into the distribution system and the motor terminals (discussed
to nearly zero volts can be is applied to other sensitive earlier) can adversely affect
measured and compared electronic loads. motor operation, it can also
against the manufacturers The most common way to cause problems at the line side
specification or a known deal with voltage notching from of the drive. ANSI C84.1-1989
good drive. six step drives is to use line recommends 3% maximum
2. Repeat the same procedure reactors in series with the line voltage unbalance at the point
for the other three SCRs by input to the drive, or use of common coupling (PCC)
placing the scope common an isolation transformer. with the utility under no load
lead on the DC- bus and The advantage to an isolation conditions, while the IEC
make the same measure- transformer is it will also recommends 2% (see previous
ments as explained in step reduce common mode noise. section to determine % voltage
one above. This should be done with unbalance). However, as little
caution however, as the addition as 0.3% voltage unbalance on
Voltage notching of line reactors and isolation the input to a PWM inverter
The older six-step drives usually transformers will increase the can cause voltage notching
use SCRs instead of diodes as source impedance which can and excessive current to
in the PWM drives to rectify the cause problems for other loads flow in one or more phases
input line voltage and convert sharing the same branch circuit. which can cause tripping of
it to dc. The reason for this is The reason for this is the ASD the ASDs current overload
the SCRs can be made to rectify will be drawing nonlinear fault protection.
only a portion of the incoming (harmonic) currents in addition While the 0.3% voltage
sine wave, thereby reducing or to chopping the voltage, and the unbalance is an extreme case
increasing the peak voltage harmonic currents may produce compounded by a lightly loaded
seen by the dc bus capacitor. additional voltage distortion due motor, an oscilloscope will be
Remember, by raising or to the increased line impedance. required to view the notching
lowering the dc bus voltage Additionally, there may be problem. An accurate DMM will
we are raising or lowering the loads such as KVAR correction be needed to make the voltage
peak voltage of the output capacitors that become resonant measurements required for
circuit signal applied to the and draw excessive current at the % voltage unbalance
motor and therefore the RMS a certain harmonic frequency, calculation. The Fluke 87, 863
voltage as well. depending on the inductance and 867B are good choices for
As you can see in Figure 24, of the distribution wiring and this measurement because of
the voltage contains notches other upstream devices that their accuracy and resolution.
caused by the firing of the SCRs may exist like line reactors and A common cause of this
from the control circuit, which isolation transformers (see Fluke problem is single phase loads
Harmonics application note and dropping in or out on the same
video3 for more information). feed as the three phase ASD.
3
Understanding and Managing Harmonics The trend mode of the Fluke
Video, P/N 609096. In Tune With Power ScopeMeter Test Tool can be
Harmonics Application Note Literature used to help isolate which
code BO221C. single phase load is causing
the most problem. Additionally,
providing a stiffer source by
increasing the kVA rating of
the transformer, or by providing
a separate feed for the ASD
will minimize or eliminate
this problem.
Figure 24. Notching of the line voltage caused

by chopping of the line input SCRs

Harmonics and IEEE-519 Compliance
There are two basic issues Remember, harmonic currents

concerning harmonics and are only a problem if they
ASDs: encounter some kind of source
1) the ASD operating in a impedance. In other words, if
harmonic environment created the utility transformer has too
by other loads, and 2) creating little V/A capacity for the level
a harmonic environment for of harmonic currents present,
loads both within and outside the source voltage begins
the building. That is, how the to distort. Since the utility is
ASD is itself affected and how responsible for supplying
the ASD can create problems distortion free voltage to all its
for other loads. The latter customers, they will probably
condition, creating problems let you know, and possibly
for other loads is what the penalize you if your ASDs and
IEEE-519 recommended other nonlinear loads are
Figure 25. Nonlinear (harmonic) currents
practice is all about and cause flat-topping of the voltage waveform
generating more harmonic
is discussed further in the currents than the distribution
following paragraphs. The second condition, system can handle.
The main problem with when the installation of the The IEEE-519 guidelines
installing the ASD in a harmonics ASD creates harmonic problems set limits for harmonic voltage
environment is voltage flat- for other loads, is an issue and current distortion as
topping. As discussed earlier, primarily for large horsepower measured at the point of common
the conversion of ac to dc drives, or a large number of coupling or PCC (usually at the
means that there is current small horsepower drives, an revenue meter), not individual
drawn only at the peak of the increasingly common situation. loads. Some ASD manufacturers
voltage waveform (see Figure If your ASD installation exceeds will promote their drives as
25) as the ac line voltage the capability of your buildings being IEEE-519 compliant.
exceeds the dc bus capacitor distribution transformer and/or This is a rather dubious claim
voltage. This burst of current distribution wiring, then flat- as there is no way to accurately
into the capacitor is what topping may occur and cause predict how even a low
causes the voltage to drop at problems for other nonlinear distortion ASD load will affect
its peak. Flat-topping of the loads in the building such as the buildings ability to meet
line voltage caused by other personal computers and other IEEE-519 guidelines, unless
electronic loads in the building electronic (nonlinear) loads. of course ASD manufacturers
means the dc bus capacitor in Another concern is when a discover a way for the drive
the ASD cannot charge to its large ASD installation generates converters to draw current in
maximum capacity. This can harmonic currents that exceed a sinusoidal (linear) fashion.
make for dramatic drops in the guidelines set forth in the IEEE- No matter which harmonic
DC bus voltage should either 519 document. The purpose problem you are trying to
the motor load suddenly of IEEE-519 is to provide correct, it will be necessary to
increase, or if there is a sudden guidelines for how much use a power harmonics analyzer
sag on the line voltage inputs. harmonic current should be such as the Fluke 41B, or fast
Stiffening the source (increasing allowed to travel outside of fourier transformation (FFT)
transformer kVA and distribution your building onto the utilities software with the oscilloscope
conductors) or adding voltage distribution system. The limits waveform to analyze harmonic
regulation such as with a UPS will depend on the stiffness content and voltage distortion.
should alleviate this problem. of the utility system (see Tables This measurement should be
5 and 6). made at the PCC with the ASD
operating at full load, then with
the ASD powered down, so the
impact of the ASD installation
on the buildings ability to meet
the IEEE-519 guidelines can
be known.

The short circuit current ratio Figure 26 below shows how building would be out of
(SCR), is basically the stiffness of the harmonic voltage distortion compliance with the IEEE-519
the system to which the building data is presented on the Fluke guidelines. However, some
is connected. Table 5 shows both 41B power harmonics analyzer. harmonic cancellation with
the total harmonic distortion limit Two screens are also available other loads in the distribution
as well as the distortion limit for for current and power. This system often occurs which
each individual harmonic for bus measurement was made at the will usually mean lower THD
voltages below 69kV. Table 6 input to the drive and shows readings at the PCC. Refer to
shows what the maximum the total harmonic distortion the Fluke Harmonics application
current distortion is for different (THD) as above 5%. If the same note and video3 for more
SCRs and for the different ranges measurement results had been information on how to solve
of harmonics. made at the PCC, then this your harmonics problems.
3
Understanding and Managing Harmonics
Video, P/N 609096. In Tune With Power
Harmonics Application Note, Literature
Table 5: Voltage Distortion Limits code BO221UEN.
Individual Voltage Total Voltage
Bus Voltage at PCC Distortion (%) Distortion (%)
Below 69 kV 3.0 5.0
Table 6: Maximum Harmonic Current Distortion in % iL (120V - 69 kV)

SCR h<11 11-16 17-23 23-34 h>34 TDD Related Assumption
<20 4.0 2.0 1.5 0.6 0.3 5.0 Dedicated system
20<50 7.0 3.5 2.5 1.0 0.5 8.0 1-2 large customers
A few relatively large
50<100 10.0 4.5 4.0 1.5 0.7 12.0
customers
5-20 medium size
100<1000 12.0 5.5 5.0 2.0 1.0 15.0 customers
>1000 15.0 7.0 6.0 2.5 1.4 20.0 Many small customers
Figure 26. Voltage waveform, harmonics graph and text data from the Fluke 41B Power Harmonics Analyzer

ASD Measurement Guide
The following table summarizes

the ASD measurements discussed
previously and the recommended
Fluke scopes, meters and power
analyzers that can be used for
each measurement.
Fluke 39/41B
Measurement Fluke 87 867 B GMM ScopeMeter B Series ScopeMeter 123 Power Analyzer
Type CAT III 1000V CAT III 1000V CAT III 600V CAT III 600V CAT III 600V
Resistance X X X X
Low Voltage X X X X
Temperature w/accessory w/accessory w/accessory w/accessory
Motor Voltage Use only for X Use PM 8918/301 low pass Use PM 8918/301 low pass X
without voltage filter probe for motor eqv. filter probe for motor eqv.
overvoltages imbalance rms voltage. Use standard rms voltage. Use standard
present probe for waveform detail. probe for waveform detail.
Motor Voltage Use only for X DP120 CAT III 600V/CAT II DP120 CAT III 600V/CAT II X
overvoltages voltage 1000V probe recommended 1000V probe recommended
present imbalance
Motor Current clamps with clamps with 80i-1000s, 80i-500s, or 80i-1000s, 80i-500s, or X
current output current output 80i-110s current probes 80i-110s current probes
only only recommended recommended
Volts/Hz Use PM 8918/301 low pass Use PM 8918/301 low pass X
filter probe for motor rms filter probe for motor rms
voltage. voltage.
DC Bus X X For DC volts > 600 use For DC volts > 600 use
DP120 differential probe - DP120 differential probe -
CAT II measurements only CAT II measurements only
Voltage Limited X X < 2 kHz only
Distortion
Harmonics With FlukeView software With FlukeView software X
Component X X X X
tests
Transients > 1 msec > 1 sec > 40 ns > 40 ns
and Surges
Table 7. Instrument recommendations for various ASD measurements
80i-1000s 80i-500s 80i-110s 80I-400

AC current clamp 1 mV, AC current clamp AC/DC current clamp AC current clamp
Measurement Type 10 mV or 100 mV/Amp 1 mV/Amp 10 mV, 100 mV/Amp 1 mA/Amp
DC To 100 amps
AC RMS To 1,000 amps To 500 amps To 100 amps To 400 amps
Waveform Details To 100 kHz To 10 kHz To 100 kHz To 5 kHz
Table 8. Recommended Fluke current probes for ASD current measurements

A COM B
1 2
123 SCOPEMETER 20 MHz

43 POWER QUALITY ANALYZER
100ms AVG H
AutoHOLD FAST MN MX LOGGING YES
HOLD MIN MAX REL k

0 1 2 3 4 5 6 7 8 9 0
40
CANCEL SAVE NO
Hz % ms RANGE
SETUP
nS MIN MAX RANGE HOLD H
F REL Hz
ac+dc mV C PEAK MIN MAX
A
ac+dc V mA mV
mA
dB mV A V A F1 F2 F3 F4
F1 F2 F3 ENTER
V A V A A B
dB
mA V Hz A
ac+dc V Hz A
OFF A OFF
ac+dc
VIEW MEM mV mV
CLEAR MEM
TEMPERATURE A mA A COM V s TIME ns

V V
MENU RECORD
mA
A A COM V
HOLD SCOPE
AUTO
RUN MENU
400mA MAX
10A MAX CAT FUSED
FUSED 400mA 1000V 10A MAX 1000V MAX
FUSED FUSED ! USER SAVE HOLD
OPTIONS PRINT SAVE PRINT
RUN
Fluke 89-IV Fluke 87 ScopeMeter190 Series ScopeMeter 123 Fluke 43

50,000-count resolution 0.1% basic dc accuracy Bench-level performance 0.5% basic dc accuracy The Fluke 42 Power Quality
with instant readings 100 mV to 1000V ac & in a rugged, reliable
handheld oscilloscope
5 mV to 600V ac & dc Analyzer performs the
0.025% basic dc dc 20 MHz bandwidth measurements you need
accuracy 0.1 mA to 10A, all fused 200 MHz bandwidth 3 / digit, >5000 count
2
3
to maintain power systems,
troubleshoot power problems
100 kHc ac bandwidth 3 / digit, 4000 count
3
4 2.5 GS/s real time display and diagnose equipment
Internal memory allows digital display sampling
for stand-alone logging 27,500 points record 2 channel Min/Max/ failures. All in a rugged
and storage of up to
Analog bar graph pointer length
Trend Plot recording handheld package.
1000 measurements Min/Max/Avg recording Frequency, duty cycle, Combines the most useful
Frequency, duty cycle, Advanced trigger modes pulse width capabilities of a power
Time-stamped MIN/MAX/ capacitance Up to 1000V isolated Direct readout in amps quality analyzer,
AVG inputs multimeter and scope
Input Alert TM and C/F
Real-time clock 4 hour battery life True-rms, backlit display, Measure power, harmonics,
Temerature readings in True-rms, backlit display, Built-in meter and 40 nS glitch capture and catch intermittents
1 ms peak hold, 41/2 digit
C or F
mode recorder Touch Hold and Relative Monitoring functions help
Lifetime warranty modes track intermittent problems
Touch Hold and and power system
CAT III 1000V safety Relative modes Print Screen capability performance
Optional FlukeView Lifetime warranty Three-year warranty Menus use familiar
software electrical terminology
Complete package with
voltage and current probes,
PC software and cables
Applications manual, power
MAX pk
100A T
INPU
OFF V/A
OL
10m V/A
100m PUT
OUT
ON
quality troubleshooting
RO
ZE
-
+
video and users manual

I
explain measurements
ON
OF
F
step-by-step
80i-110s
Optional accessory.
80i-1000s 80i-500s AC Measures ac and dc
current in two ranges
Optional accessory. AC Included with both the from 50 mA to 100A.
current 100 mA to Fluke 39 and 41B. AC Best accuracy is 3% and
1000A rms continuous, current up to 500A rms, frequency response is
1400A rms peak. BNC 700A rms peak, with dc to 100 kHz. BNC
connection. best accuracy of 2% of connection.
Use with 39/41B or reading from 45 Hz to
ScopeMeter 65 Hz. BNC connection.
80T-IR
For fast non-contact FlukeView Software
temperature measurements. Capture screen images or waveforms to
Range: -18C to 260C (0F to 80i-400 document and archive measurements
500F). Accuracy: 3% of Use data in spreadsheet programs for
reading or 3C (5F) which-
1-400A
detailed analysis
ever is greater. Internal switch 3% of Rdg
selection for C or F. For use 30 mm (1.18 in) Save and retrieve setups for fast
preparation of measurement routines
with DMMs or ScopeMeter. 1 mA/Amp
Supports popular PC file formats (BMP
and PCX) for image storage

Application Notes
In Tune with Power Harmonics
Literature #B0221UEN
Electrical Power Circuit Mea-
surements for ScopeMeter
ABCs of Multimeter Safety
Electrical Troubleshooting with
Fluke Multimeters
Educational Videos
ABCs of Digital Multimeter Safety
P/N 609104
Understanding and Managing
Harmonics
P/N 609096
Acknowledgments
[1] A. von Jouanne, P. Enjeti, V. Stefanovic,
Adjustable Speed AC Motor Drives: Applica-
tion Problems and Solutions, Seminar notes,
pp. 3.1-6.20, PowerSystems World Conf. 1996
[2] IEEE Recommended Practices and Require-
ments for Harmonic Control in Electrical
Power Systems - Std 519, New York, NY: IEEE
Inc., 1992
[3] EC&M, Practical Guide to Motors and Motor
Controllers, pp. 9-16, Intertec Electrical
Group, 1991
Special thanks to Dr. Annette von Jouanne for Fluke. Keeping your world
her assistance preparing this application note up and running.
and to Oregon State University for the use of
their Motor Systems Resource Facility.
Fluke Corporation
PO Box 9090, Everett, WA USA 98206
Fluke Europe B.V.
PO Box 1186, 5602 BD
Eindhoven, The Netherlands
For more information call:
U.S.A. (800) 443-5853 or
Fax (425) 356-5116
Europe/M-East/Africa (31 40) 2 678 200 or
Fax (31 40) 2 678 222
Canada (800) 36-FLUKE or
Fax (905) 890-6866
Other countries (425) 356-5500 or
Fax (425) 356-5116
Web access: http://www.fluke.com
1999 Fluke Corporation. All rights reserved.
Printed in U.S.A. 11/99 1264691 A-ENG-N Rev C
Printed on recycled paper.

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Measurement of

Adjustable Speed Drives

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 1

2 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 3

4 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 5

6 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Controlled Rectifier Six-Step Inverter

Figure 3 shows a simplified Figure 4 shows a simplified distorted (non-sinusoidal),

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 7

8 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 9

10 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 11

For those not interested in the

12 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 13

Figure 11. Overvoltages due to reflected waves

14 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Length where Vpeak Length where Vpeak

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 15

Motor Terminal Filter Inverter Output Filter Series Reactor

16 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

18 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

section that rectifies the ac into P 0 1 2 3 4 5 6 7 8 9 0

dc can be disconnected and the MIN MAX RANGE HOLD H

inverter circuit can be run with N PEAK MIN MAX

voltage that is present on the dc V A

bus. The input driver circuit will N OFF

still turn on the transistors but A mA A COM V

at a much lower voltage level Cathode 400mA MAX

and the bad transistor is easily 10A MAX

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 19

20 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 21

MIN MAX RANGE HOLD H

PEAK MIN MAX

Figure 22. Voltage flat-topping caused by

Figure 23. Checking for open and shorted diodes in-circuit

22 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Figure 24. Notching of the line voltage caused

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 23

There are two basic issues Remember, harmonic currents

24 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

Table 6: Maximum Harmonic Current Distortion in % iL (120V - 69 kV)

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 25

The following table summarizes

80i-1000s 80i-500s 80i-110s 80I-400

26 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

123 SCOPEMETER 20 MHz

87 TRUE RMS MULTIMETER

HOLD MIN MAX REL k

ac+dc mV C PEAK MIN MAX

TEMPERATURE A mA A COM V s TIME ns

Fluke 89-IV Fluke 87 ScopeMeter190 Series ScopeMeter 123 Fluke 43

video and users manual

Measurement of Adjustable Speed Drives with Fluke Meters Fluke Corporation 27

28 Fluke Corporation Measurement of Adjustable Speed Drives with Fluke Meters

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