VSD Advantages, Disadvantages, Selection Criteria and Installation Tips and Tricks
VSD Advantages, Disadvantages, Selection Criteria and Installation Tips and Tricks
VSD Advantages, Disadvantages, Selection Criteria and Installation Tips and Tricks
A Simple adjustment of the time required to accelerate the motor from rest to full speed (Starting), normally 50 Hz and
from full speed to rest (Stopping), ensures a smooth controllable start and stop sequence. This reduces mechanical wear
on the machine. Various types of starting and stopping curves are available by setting the correct parameters in the
Variable Speed Drive as illustrated in figure 1a to c.
Accel
Time
Decel
Figure 1a
Figure 1b
Time
Accel
Decel
Backlash Compensation
f1
f2
Figure 1c
t1
t2
Figure 1: Acceleration and Deceleration curves
Energy Saving
Accel
Time
Decel
We all know that a Direct On Line (DOL) starter will supply full voltage to the motor at the supply frequency with the
current uncontrollable. The motor will use as much current as the load requires normally between 600 to 700% of the
full load current of the motor.
Before the days of Soft Starters and Variable Speed Drives our alternative to control the starting current was with Star
Delta starters, which reduced the starting current to approximately 200%. Our next best device today to limit the
starting current is to fit a Soft Starter, With Soft Starters we use the Phase Angle principal to control the voltage and
therefore reduce the starting current while at the same time producing a smooth controllable start. The limitation is that
these units are very basic and have limited adjustable time settings, normally from 0 to 60 Seconds.
The current limiting features on Variable Speed Drives ensure that when you accelerate a motor from rest, you will not
exceed more than 100% of the Full Load Current of the motor. By replacing DOL starters with Variable Speed Drives
will reduce the Current Demand when starting motors. Variable Speed Drives will deliver maximum torque at the motor
shaft while limiting the current to the Full Load Current setting of the motor in the Variable Speed Drive.
It is the responsibility of every individual to use forms of energy, effectively and efficiently.
It is already well known in the Heating and Ventilation industry that volumes, flows and pressures of centrifugal fans,
pumps and compressors can be controlled by mechanical means to match the demands of the system, many of them do
not consider the immense amount of energy, hence watts, hence money that can be saved by using modern reliable
electronic technology.
If the efficiency of the system can be improved the power demand drops proportionally with the increased efficiency.
Almost all fans, pumps and compressors are over kilowatt powered (just in case) and seldom do they work at their
maximum designed efficiency point.
Fitting an Inverter to a fan, pump or compressor motor varies the motor speed which then varies the characteristics of
the fan, pump or compressor to operate at a different efficiency to produce massive energy savings.
Because of the Affinity Laws, which say that: Flow is proportional to Speed and Kilowatt varies as the cube of the
speed.
Flexibility
100%
Output Voltage
Output Voltage
The flexibility to set-up and configure a Variable Speed Drive for various applications i.e.: Constant torque, Variable
torque, Hoisting and many others, allow users to customise units to suite their needs. See illustrations in figures 2 and 3
100%
Base frequency
Output Frequency (Hz)
Base frequency
Output Frequency (Hz)
Lift profile A
Boost for forward rotation
Linear for reverse rotation
Lift profile B
Linear for forward rotation
Boost for reverse rotation
100%
Output Voltage
Output Voltage
100%
Forward
Rotation
Reverse
Rotation
Reverse
Rotation
Forward
Rotation
Base Frequency
Output Frequency (Hz)
Base Frequency
Output Frequency (Hz)
Radio Frequency Interferences generated by Variable Speed Drives can be very problematic by introducing faults on
other equipment in close vicinity of the installed unit. Most drives can be expected to meet the immunity requirements
of the CENELEC generic standard EN50082-2.
Harmonics
Variable Speed Drives, like most other electronic equipment, do not draw their current as a smooth sinusoid. The supply
current waveform is generally referred to in terms of the harmonics of the supply frequency, which it contains. The
harmonic current causes harmonic voltage to be experienced by other equipment connected to the same supply. Because
harmonic voltage can cause disturbance or stress to other electrical equipment connected to the same supply system,
there are regulations in place to control it. If installations contain a high proportion of Variable Speed Drives and/or
other power electronic equipment such as UPS, then they may have to be shown to satisfy the supply authorities
harmonic guidelines before permission to connect is granted. As well as obeying regulations, users of drives need to
ensure that the harmonic levels within their own plant are not excessive.
Some of the practical problems, which may arise from excessive harmonic levels, are:
An important property of harmonics is that they tend to be cumulative on a power system, i.e. the contributions of the
various harmonic sources add up to some degree. This is different from other high-frequency electromagnetic
compatibility (EMC) effects, which are generally localized and not significantly cumulative. It is important to
differentiate harmonics from high-frequency EMC effects, which tend to cause interference to sensitive data and
measuring circuits by stray coupling paths. With few exceptions, if harmonics cause disturbance it is through direct
electrical connection and not through stray paths. Screening is rarely a remedial measure for harmonic problems.
Knowledge
The biggest disadvantage is to understand Variable Speed Drives and their ability to improve our lives and of course the
unwillingness to change, because, My motors worked for the last 20 years with Direct On Line starters, why should I
complicate my life and let something, that I do not understand, and is very expensive, control my process? Even worse,
now I need to employ a highly qualified Technical Engineer to maintain my plant. These remarks, and by not reading
the instructions manual, create a bad image of a product that improves life for all of us.
Selection criteria
Summarised is some of the basic criteria to successfully install a Variable Speed Drive
Supply Voltage
380VAC
Always ensure that the correct voltage is available. In many cases users interpretation of a Variable Speed Drive is that
you could supply the unit with single-phase 220VAC and control a three-phase motor rated for 380VAC. Most standard
induction motors could operate with three phase 380VAC with all six leads from the windings available and connected
in a Star configuration. The same motor could operate with 3 Phase 220VAC if the leads from the windings are
connected in a Delta configuration. However consult with the motor manufacturer if it is not indicated on the motor
nameplate.
220VAC
190VAC
380VAC
190VAC
220VAC
Delta Connection
Star Connection
Kilowatt size
It is not totally correct to select an Inverter according to motor capacity in kW. It is better to select an Inverter based
on the rated current of a motor. If the Inverter and the motor have the same capacity (kW), an increase in the number of
motor poles reduces the efficiency and power factor of the motor increasing the rated current value.
Torque requirements
If we look at the following calculations we will understand why torque loss happens when running a motor above base
speed. This will also explain some of the basic requirements why torque is an important factor when selecting a Variable
Speed Drive.
Motor speed:
60 f
P
Where:
n
60
= Seconds (s)
(1)
Motor Torque:
2 M n
60
(2)
Where:
W
= Watts
= Torque (Nm)
Example:
A Mechanical Engineer designs a machine that requires 405 Nm and a speed range from 100 to 175 rpm. By fitting a
10/1 ratio gearbox to the machine he reduces the input torque required to 40.5 Nm, the minimum and maximum input
speed increases to 700 and 1750rpm respectively. A four-pole 7.5kW motor (1500 rpm @ 50Hz) produces 47.8 Nm. We
need to calculate if he will produce enough torque at the maximum speed.
To reduce the speed to 1000 rpm is not a problem, as long as he keeps the motor speed above 50% of the base speed to
produce enough cooling.
A Variable Speed Drive will produce the full load torque of the motor up to the base frequency by changing the voltage
to produce the necessary torque. Once the motor reaches its base speed and supply voltage the Variable Speed Drive can
only change the frequency supplied to the motor to increase the speed as the Variable Speed Drive cannot supply a
higher voltage than the supply voltage.
To calculate the torque produced by the 7.5kW at 1750 rpm we have to manipulate the above formula.
M
W 60
2 n
7500 60
2 3.142 1750
M 40.9 Nm
Therefore the 7.5kW motor with a Variable Speed Drive fitted can produce the necessary torque at the correct speed.
From this we can see that it is always necessary to check if the speed / torque range is within the capability of the
Inverter and motor.
DC Injection Braking
In most hoisting applications, the motor must be kept at zero speed and in position for a short period of time allowing
the mechanical brake to open or close. To keep the motor in this position the Inverter injects DC into the motor that
causes it to produce torque at standstill (Zero Speed), This type of braking is sometimes misunderstood as DC Bus
braking, which is explained in the next section. When selecting a Variable Speed Drive, and the applications requires
this function, ensure that it is the function required.
DC Bus braking / Resistive braking
DC Bus braking is to control the deceleration of induction motors without activating the over voltage protection
function on Variable Speed Drives. When applications require a fast deceleration function or the load is very unstable it
could be controlled with this function. There are various methods to solve the problem depending on the application. It
could be done with a regenerative system, feeding energy back to the mains or with a brake unit and brake resistors
dissipating the energy through external resistors.
The main advantages for an A.C. regenerative system are:
Energy saving
Expensive to install
The output voltage for the motor can be higher than the available A.C. mains voltage
The regenerative unit will synchronise to any frequency between 30 and 100 Hz, provided that the supply
voltage is between 380V 10 per cent and 480V + 10 per cent
Under conditions of A.C. mains instability, a Mitsubishi Drive regenerative system can continue to function
down to approximately 270V A.C. supply voltage without any effect on the D.C. bus voltage and hence on the
operation of the motor drives
When using either the internal braking system of the Variable Speed Drive with resistors or an external brake unit with
resistors we waste energy unnecessary. This, however, is the cheapest solution and unfortunately selected by most
customers. In the next section Tips and Tricks, the selection of the correct brake unit and resistors is explained.
Installation tips and tricks
Environmental Requirements
Most Variable Speed Drives are supplied with a protection rating of IP20 (Finger proof). This normally requires that the
Inverter needs to be mounted in a floor standing enclosure or wall mounted panel, to increase the degree of protection.
Refer to Table 1 for standard rating of protection.
DEGREE OF PROTECTION (IP..) IEC529
1st Numeral Digit
No Protection
No Protection
Calculate the minimum required unobstructed surface area Ae for the enclosure as follows:
Ae
P
k (Ti Tamb )
(3)
Where:
Ae
Tamb
Ti
Example
To calculate the size of an enclosure to accommodate the following:
The enclosure is to be made from painted 2mm sheet steel having a heat transmission coefficient of
5.5 Wm-2 C-1. Only the top, the front and two sides of the enclosure are free to dissipate heat.
The minimum required unobstructed surface area Ae for the enclosure is as follows
Ae
P
k (Ti Tamb )
Ae
430
5.5(40 30)
Ae 7.8 m2
If we select an enclosure with a height (H) of 2 m, a depth (D) of 0.6 m, and a minimum width W
Dissipating surfaces
> 7.8 m
Top + Front
> 7.8 m
> 7.8 m2
Wmin
If the enclosure is too large for the available space it can be made smaller by:
Increasing the permissible ambient temperature inside the cubicle if possible by derating equipment in line
with manufacturers recommendations
3kP
m3hr-1
Ti Tamb
Tamb
Ti
= ratio of po / pi
po
pi
(4)
Where:
Where:
Typically, a factor of 1.2 to 1.3 can be used to allow for pressure drops in dirty air filters.
Example
To calculate the size of an enclosure to accommodate the following:
3kP
Ti Tamb
3 1.3 1890
40 30
V 737 m3hr-1
Electronic overload relays
It is important to recognise that the non-sinusoidal waveforms, and variable frequency, associated with Inverters,
invalidate the basis for protection afforded by most electronic overload relays. The use of such devices on the mains
supply of an Inverter is also invalid. Please consult with the manufacturer before using any of these devices.
Fusing
Fuses should not be seen as an overload protection device; Inverters regulate the current flowing in the system and
fusing needs to be designed to cater for catastrophic failure within the Drive or a short circuit between cables. High
rupturing capacity fuses (HRC) act as clearing devices for sustained high currents and are consequently well suited to
this type of duty, and is commonly recommended by most Drive manufacturers.
Typical fuse recommendations for three-phase AC Inverters are given in Table 2.
Inverter rating
Recommended
Power (kW)
Current (A)
0.75
2.1
1.5
1.5
3.8
2.5
10
2.2
5.6
2.5
10
9.5
2.5
16
5.5
12
2.5
16
7.5
16
20
11
25
35
15
34
40
18.5
40
10
50
22
46
10
60
30
60
16
70
37
70
25
80
45
96
35
100
55
124
35
125
75
156
50
160
90
180
70
200
110
202
95
250
Converter circuit
DC Bus
Inverter circuit
CT
CT
R
CT
CT
Voltage Detection
Regenerative
Over voltage shut-off
Under voltage
Stall prevention
Power Supply
Instantaneous
Power failure, over
Voltage and inrush
Protection
Current Detection
Over current shut-off
Output side short circuit
Output side ground fault
Over current
Overload (electronic
Over current protection)
Stall prevention
Main circuit device overheat
Brake transistor
Brake transistor fault
detection
0.75kW
70
1.5kW
100
2.2kW
130
4kW
200
5.5kW 11kW
250
15kW 90kW
300
Table 3: Long motor cables
The above cable lengths are for Mitsubishi FR-A500 series Variable Speed Drives. Please consult with the Inverter
Manufacturer before installing.
For other switching frequencies:
Maximum cable length = Maximum cable length at 3kHz x (3kHz / switching frequency)
(5)
Output Chokes
Calculation of the necessary inductance of the choke is complex. However the following guidelines might be helpful.
Estimate the cable capacitance (C), from one line to all others.
Typical values
Screened/Armoured cables where there is a plastic sheath between the phase and the screen: 130pF/m
Screened cables with no plastic sheath between cores and screen, mineral insulated cables: 300pF/m
Add an allowance for the motor capacitance: 1nF is a reasonable estimate
Decide on the available charging current
Ich 1.41In ( 2 k )
(6)
Where:
In
2C
3
Vdc
Ich
(7)
If using standard iron-cored chokes, the inductance at the high frequencies involved will be rather lower than the
specified 50Hz inductance. A good rule of thumb is to specify an inductance of twice that determined by this
calculation.
The acceptable voltage drop at the working frequency determines the maximum value of inductance. Calculate this
from the following expression:
L max
xVA.C .
2 f 0 3In
Where:
x = Acceptable volt drop over the choke
VA.C. = Motor voltage rating (line to line r.m.s.)
f0 = Maximum Inverter output frequency
(8)
If 2Lmin < Lmax then any value between these limits can be used.
If 2Lmin > Lmax then the Inverter cannot operate with this length of cable and a higher rated Inverter must be used.
Consideration must be given to the high frequency losses in the chokes. This can be estimated from the following
expression:
P 0.8 fsCVD .C .
(9)
Where:
fs = Switching frequency
The factor 0.8 is a rough estimate of the fraction of the total losses dissipated in the choke. Note that the loss is
proportional to the switching frequency so the lowest acceptable frequency should be selected
It is now necessary to decide whether the choke is able to tolerate this loss. This is a difficult judgment. As a crude rule,
the loss should not exceed 0.1 VA in the choke at maximum speed, i.e.:
P 0.2 f
0 (max)
LIn
(10)
Where:
fo(max) = Maximum output frequency
If the loss exceeds this limit, and it is not possible to reduce the switching frequency, then a resistor should be connected
in parallel with each choke to extract some of the power. The resistor value is given by:
2L
C
(11)
The value is not critical and variations of 50% are acceptable. The power rating of the resistor should be at least 0.8P.
Provision must be made for the resistor to dissipate this power without overheating itself or nearby equipment. Values
of 100W per phase are not uncommon
Supply impedance
High quality commercial Variable Speed Drives are designed to operate from typical industrial power distribution
systems with a maximum fault level of ten to twenty times the Inverter rated power. Problems can also occur if a Drive
system is installed close to the main power supply or power factor correction capacitors, both of which present low
supply impedance to the drive. A.C. Inverters fitted wit D.C. link chokes are in general unaffected by low supply
impedance.
A good rule of thumb is to ensure a total supply impedance of approximately 4 percent reactance. Where information
about the supply is not known, it is good practice to fit line reactors of 2 percent.
There is no easy solution for high supply impedance as power lines carrying Drive current need to be oversized, as do
transformers used in order to minimize the impedance. This over sizing may need to be as high as five times that
normally considerate adequate.
110
Brake resistor selection
Firstly we need to understand what happens when a motor decelerates to stop under a high inertia load. When the motor
starts to decelerate and the load keeps on rotating the motor, the motor starts to act as a generator sending energy back
to the Variable Speed Drive. With energy from the main supply and from the motor, now acting as a generator, the DC
Bus voltage level starts to rise from approximately 560VDC to levels that will activate a DC Bus over voltage trip. Most
Inverters can sustain levels up to 780VDC before tripping. Some Inverters equipped with internal braking circuits and
resistors will control this rise in DC Bus voltage but only for a short duration. If a lengthy or heavy-duty brake cycle is
required, it is best to fit external units, which could cope with the extra energy safely.
To reduce the cost and physical size of Variable Speed Drives, and the fact that very few applications require DC Bus
braking, manufacturers only provide units with limited DC Bus braking capabilities. Users should consult with
Manufacturers as to the capability of the units before installing them in these applications.
Two important factors to consider are the required braking torque and the duty cycle of the application.
Kinetic energy of the motor and load = 0.5 J 2
(12)
Where:
J = Total inertia (kg m) of the motor, transmission and driven machine
If there is gearing between the motor and the driven machine, J is the value reflected at the motor shaft.
=
angular velocity
As the energy regenerated is proportional to the square of the angular velocity, most of the energy in the system is
concentrated at the higher operating speed, and is delivered to the resistor at the start of the deceleration.
Example:
A system inertia of 10kg m2 is to be decelerated from full load speed to rest. We need to find the braking resistor value
and maximum braking torque
Drive rating
30kW
Motor rating
30kW
1475rpm
191Nm
30 Seconds
660V
Mb J J
J
Nm
tb
30 tb
(13)
Jn
tb
30 Mb
But maximum deceleration occurs at 150% of motor nominal torque. The value to apply for Mb is therefore
1.5 x 191 = 286.5 Nm
So the actual deceleration time tb is:
tb
10 1475
Seconds
30 286.5
tb = 5.39 seconds
This is the minimum deceleration time. For example, let us decide on a more practical deceleration time of 7seconds.
We can now calculate the maximum braking torque to decelerate the load in 7 seconds:
Mb
n
J
Nm
30 td
Mb
10 1475
30 7
= 220.64 Nm
Pb
Mb n
30 103
Pb
224.38 1475
30 1000
=34.65 kW
V
Pb
660
35 1000
= 12.45
(14)
As the braking operates intermittently, the resistor can be selected from a range offering intermittent rather than
continuous power absorption. Advantage can also be taken of the overload rating of the resistor by applying an
overload factor, which will be derived from a set of cooling curves obtained from the manufacturer or supplier of the
resistor. In this example, deceleration time is taken as 7 seconds, repeat cycle time 30 seconds. From typical data the
overload factor is 2.
The power rating of the chosen resistor is:
Pr
Pb
O / L Factor
Pr =
35
2
= 17.5kW
(15)
For practical purposes, it can be assumed that 15% to 20% of energy dissipated during the regenerative braking is due to
electrical losses in the motor and Inverter, and mechanical losses in the motor and load, all of which assist the braking.
In practice, using the recommended resistor value will result in extra braking torque available. However, the rate of
energy feedback from the load inertia is determined by the rate of deceleration.
A braking resistor must be installed in accordance with instructions provided by its supplier or manufacturer. The
braking resistor should incorporate a thermal tripping device, which should be connected, to a trip release mechanism to
stop the Variable Speed Drive.
Resistors intended for braking duty should be capable of tolerating thermal shock Pulse rated resistors are
recommended
Application selection
The following table is a guide of torque requirements in certain applications.
Name of Application
Accelerating
Peak running
Liquid
100
100
100
Slurry
150
100
100
Valve closed
30
50
40
Valve open
40
110
100
40
40
100
Centrifuges (extractors)
40
60
125
40
100
100
150
150
75
50
75
100
Valve closed
25
60
50
Valve open
25
110
100
Valve closed
25
60
100
Valve open
25
200
175
40
110
100
50
125
100
Grinders, metal
25
50
100
Agitators
Blowers, centrifugal
50
75
100
150
150
70
25
50
100
Machines, polishing
50
75
100
50
75
100
Mixers, chemical
175
75
100
Mixers, concrete
40
50
100
Mixers, dough
175
125
100
Mixers, liquid
100
100
100
50
100
100
175
100
100
Mixers, slurry
150
125
100
Mixers, solid
175
125
175
50
40
125
40
100
100
150
200
200
40
150
150
40
150
150
Pumps, propeller
40
100
100
50
100
100
60
100
100
40
60
100
150
60
150
50
110
125
Rolls, flaking
30
50
100
40
60
125
Screens, vibrating
50
150
70
40
100
100
Washers, laundry
25
75
100