Variable Frequency Drives

Saqib Saeed
Graduate Trainee Engineer
(E&I) - Electrical
Contents

• Introduction
• Block Diagram
• Building blocks
• Modes of operation
• VFD Parameters
• Some Potential Problems
• Harmonics and THD
• Recent Improvements in the FFCL system
Variable Frequency Drives

– Standard motors are constant speed and when they

are energized they run at a 100% speed no matter
the load.

– What if the speed of the driven machine (Fan, Pump)

is to be changed?
What is a VFD?
– Variable Frequency Drive (VFD)

– Governing Equation of motor speed

Speed= 120 x f /P

• P=No. of poles Constant

=50Hz
• F=Line Frequency

– How to change line frequency?

 VFD Fundamentals

Block Diagram

AC DC AC

RECTIFIER INVERTER
(AC - DC) (DC - AC)
50 Hz Power 50 Hz
Variable Frequency

ABB
VFD
To
Motor
Variable Frequency
Electrical Energy
VFD
VFD Explored

 First, the Converter (usually a diode rectifier) converts three-phase AC power to DC

power.
 Next, the DC Bus stores and filters the DC power in a large bank of capacitors.
 Last, the Inverter (usually a set of six IGBTs) switches or inverts the DC power in a
Pulse Width Modulated (PWM) AC waveform to the motor.
Rectifier

• Basic Building blocks of rectification

– Diodes (Uncontrolled)
Thyristors

Gate Pulse
• Controlled

Conduction
after Gate
Pulse

• Output voltage can be controlled

Three Phase Rectifiers
Output Voltage

3× 3×𝑉𝑚
• Output Voltage (dc) = x cos 𝐴
∏
– Vm=Peak Value of voltage
– A= Firing Angle

• Firing at zero gives maximum output dc

voltage
IS it a perfect Direct Current?

• Conversion of AC into DC a perfect process?

– Ripples

• How to eliminate the ripples?

– Filters

DC bus in VFD
Inverter Action
• Switching DC voltage ON and OFF will make it
AC

• Filtered output from DC bus is sent to inverter

in VFD
How switching can convert DC into AC?

Positive
+
DC Bus

Negative
-
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative
-
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative
-
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative
-
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative
-
DC Bus

RECTIFIER INVERTER
Pulse width modulation

• Such a waveform is not acceptable

– Nowhere near Sine wave

• Contains harmonics
– Multiples of fundamentals

• Solution
– Pulse width modulation
 How Often You Switch From Positive
Pulses To Negative Pulses Determines
The Frequency Of The Waveform

Positive
+
DC Bus

Voltage
Negative
-
DC Bus

RECTIFIER INVERTER Frequency

Area Under the Curve
Basic Purpose achieved

• Speed of the motor now can be controlled

• Is changing motor frequency alone enough?

𝑉
Φ=
𝐹
V/F Control Mode

• Flux = V/F

400 400 V V
= 8
50 Hz Hz
Volts

230
If 230 VAC Power Line:
230 V V
= 4.6
50 Hz Hz

0
25 50
Hertz
V/F Control Mode

• Scalar mode
• Drive is unaware of what is happening in the motor

Example:
• A 400V scalar drive is told to run a 400V, 50 Hz motor at 50%
speed Following V/F pattern, Voltage applied by the drive will
also be half.
• Perfect when at no load.
• After loading, motor will run at less than 50% speed
• Drive is unaware of it

Vector
Solution
Control
 Load increase

Drive Motor

Speed setting=50% Speed at no load=50%

 No idea what
is happening

Drive Motor

Speed setting=50% Speed=40%

Vector Control Mode

• Sensor less vector control mode

– No feedback through speed sensor
– Feedback is derived through motor terminals
– Drive need to go through “Auto tuning”

• Vector control with sensor

– Feedback through encoder
– Better speed regulations up to 0.01%
– Faster response to load variations
VFD input Parameters

• Max./Base frequency setting

• Motor rated output

• Motor rated voltage

• Motor rated current

• Carrier frequency
VFD input Parameters

• Frequency Reference setting methods

• Stop Command method

• Start frequency

• Stop frequency (DC Braking starts)

• Torque Boost

• Frequency Skip
VFD input Parameters

• Max./Base frequency setting

VFD input Parameters

• Motor Rated Output

• Motor Rated Voltage

VFD input Parameters

• Motor rated Current

• Carrier Frequency
Frequency Reference Setting Methods

• Potentiometer

• 0-10V input voltage

• 4-20(mA)
Frequency Reference Setting through Potentiometer

Max

Frequency

Min
Min Max
Centrifuge Main Control Panel

Potentiometer
 Start/Stop Frequency/Acceleration/Deceleration

Frequency
Stop Frequency
Start Frequency

DC Brake

Acceleration Deceleration
Time Time

Time
 Start/Stop Frequency/Acceleration/Deceleration

Frequency
Stop Frequency
Start Frequency

DC Brake

Acceleration Deceleration
Time Time

Time
Stop Command methods

• Coast to stop

• Ramp to stop
 Coast to stop

Frequency Motor speed

Coast to
Stop Command
is removed
Run Command
 Ramp to stop

Ramp to
Stop
Frequency

DC Brake

Run Command Command

is removed
 Torque Boost

Rated
Voltage

Voltage

Rated
Frequency
Voltage
Boost

Frequency
Frequency Skip
Auto Tuning

• Drive familiarizing itself with motor

VFD here I am IM
Auto Tuning

Torque Boost
Primary
Leakage
Slip
DC Brake
compensation
resistance
reactance
Voltage
Voltage

Drive Motor

Start of Auto tuning

 Auto Tuning Procedure
Turn Power ON
Auto tuning procedure Preparation
Start VAT 300

Select the
control mode

Motor ratings

Input 1: Simple No
Can motor
adjustment
rotate?
mode
yes
Input 2: High
adjustment
mode
Auto Tuning Procedure Contd.
Input 1: Simple Input 2: High
adjustment adjustment
mode mode

LED flickers

Start Auto-Tuning
Press Fwd or Rev

10s for V/F mode

RUN LED ON
1min. for vector mode

Auto-tuning End
DC Injection Braking

• No mechanical Contact
• DC is applied at the stator winding
• DC causes stator to be become a magnet with
constant field
• A voltage is induced inside the rotor causing current
to flow
• According to Lens’s law, this current will cause rotor
to stop
Dynamic Braking

• Concept of Braking
– Kinetic energy keeping the object moving
– Energy cannot be destroyed but can be converted

Kinetic Energy Heat Energy

Wear and Tear Mechanical

Brakes
Dynamic Braking

• Some other form of energy

– Electrical

Kinetic Energy Electrical Energy

Utilize Discard

Regenerative Resistive
Electric railcars Elevators
Resistive Dynamic Braking in Elevators
Braking resistor for CAN Elevator

VFD

Braking
Unit
Resistive Dynamic Braking

• A built in dynamic braking resistor (<15Kw)

• An external DB unit
Potential Problems

• Harmonic Distortion

• Bearing Damage
Total Harmonic Distortion

• Harmonic Content
– Deviation of waveform from pure sinusoidal
shape
• Present due to non-linear devices (switching)
– Power electronics
2
(𝐼22 +𝐼32 +𝐼42 + …+𝐼𝑁 )
• THD = x 100
𝐼1
THD Percentage

VFD BUS Non-VFD BUS

Harmonics Spectrum

VFD BUS Non-VFD BUS

Current Waveform Comparison

VFD BUS Non-VFD BUS

519-1992 - IEEE Recommended Practices and Requirements
for Harmonic Control in Electrical Power Systems

• IEEE Std. 519 (1981) – Revision (1992)

• Deals with harmonics introduced by the static power

converters

• Overall THD < 5%

• Any single harmonic < 3%

IEEE standard for THD
AREVA report on THD in MCC (VFD) at NP plant

Voltage (V) R-N Y-N B-N

RMS Voltage
237 237 237

Peak Voltage
362 364 364

THD (%)
4.7 5 5

Harmonics Voltage
11 12 12
AREVA report on THD in MCC (VFD) at NP plant
Harmonic # R-N Y-N B-N

5 3.2 3.5 3.4

7 2.9 3.1 3.2

11 1.0 1.0 1.0

13 0.9 1.0 1.1

Line Reactors

• Installed ahead of the drive

• Protect the drive from sudden disturbances
• Reduces the harmonics content introduced by VFD

VFD
 High peaks
without reactor

Reduction Up to
35% after
reactor
Line reactors installed at NP SS
14 Line reactors are installed, 7 on each side of MCC-VFD
VFD and Line Reactor

Line reactor

Main Breaker

VFD
THD after installation of Line Reactors
Bearing Damage

• Pulse width modulated voltage induces

bursts of shaft currents
• Grounded through bearings
• Eventually bearing failure
Bearing Damage
Pitting of bearing due to Shaft Currents
Solution for shaft currents

• Shaft grounding through carbon brushes

– Wear and corrode
– Need maintenance

• Insulated bearings are used

– Partial solution
– May flow through driven equipment
– Insulation may become a capacitor

• Shaft grounding rings

– A combination of both
Shaft Grounding Ring
Questions