INABB/ATDPL1/ac drive basics 1

AC Drives Basics
 Course content

Topics covered in this section -

AC Drive (Variable Frequency Drive) subsystems

Rectifier,
Inverter,
Motor,
Control Interface,
Cable
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Software tools, Efficiency,

Applications of AC Drives(VFD)
 Variable Frequency Drive ( VFD ):

An adjustable frequency AC drive converts an input line

constant voltage and frequency to an adjustable voltage
and frequency output .

Normally speed and current control are provided.

More sophisticated drives also provide torque control.

INABB/ATDPL1/ac drive basics 3
 Main components of AC Drive :

Equipment Waveform Operation

Line
Line voltage

Line Supply
Rectification
Unit

DC bus,
capacitor Smoothing
and choke

Inverter
Inversion
Unit
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Motor M Motor
3

Functional principle of the drive system

INABB/ATDPL1/ac drive basics 5
Output waveform of AC Drive
 Variable Frequency Drive ( VFD )Panel:

FREQ. CONVERTER
SEMICON MODULE
I/P SWITCH
& FUSE(OPTIONAL) FUSE O/P CONTACTOR

3 PHASE
SUPPLY

3 PHASE
dU/dT SC IM
I/P CONTACTOR FILTER
(OPTIONAL) (OPTIONAL)
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Plus: CONTROL TRAFO,

CONTROL FUSES, METERS, DOL BYPASS CONTACTOR
PUSH BUTTONS, INDICATIONS, (OPTIONAL)
CABLES,AUX. CONTACTORS ETC.
 AC Drive Technology

AC Drive Types
Current Source Invertors (CSI)
Constant current principle
Large inductor in DC link
Types
Six Step
Voltage Source Invertors (VSI)
Constant voltage principle
Large capacitor in DC link
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Types Our Focus

Six Step (Variable Voltage)
Pulse Width Modulated (PWM)
 AC Drive Control principles

AC Drive Control Principles

Scalar (simple constant volts per hertz i.e. V / f )

Vector (field oriented)
Sensorless Vector
Direct Torque Control (ABB exclusive)
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 AC Drives Control principles
Flux vector control
Flux vector control can calculate torque
control only at 1-3 ms intervals.
A modulator is needed to calculate
switching times
Control response is around 10 ms

Direct Torque Control DTC

DTC can calculate torque control at 0.025
ms intervals
Each switching is directly activated by
INABB/ATDPL1/ac drive basics 9

torque control
Control response is around 1 ms
 AC Drives

AC Drive Capabilities:
Controllable Speed
Controllable Acceleration / Deceleration
Electronic Reversing
Current Limiting
Torque Limiting
Intelligent Process Interfacing
Integral Process Control Possible
Multiple Motors Possible
INABB/ATDPL1/ac drive basics 10

Bypass Possible
Programmable Settings
 AC Drives

AC Drive Performance Advantages:

Accurate Speed Regulation

Dynamic Speed Response
High Process Efficiency
High Input Power Factor
Low Operating Cost
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 Application Types

Constant Torque Applications

Constant Torque (CT) Constant Power (CP)

Torque
100

%
Torque HP Torque
& HP
50
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50 100 150
(Base)
% Speed
 Constant torque applications

Example: Positive Displacement

Pumps,Conveyors,Mixers,
Extruders, Cranes,etc.
Features
High starting torque
Intermitent overloads
Typical kW Range - 0.12 to 2800
Typical Speed Range - 10 to 100%
Speed Controlled with Coast to Stop/ Regeneration /braking
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Chopper
Typical Speed Regulation is 1 to 5%
Acceleration Time From 2 to 90 Seconds
Breakaway Torque From 150% to 225%
 Application Types

Constant Power (CP)

HP
100
%
Torque
& HP
HP
50 Torque
INABB/ATDPL1/ac drive basics 14

100 150 200

(Base)
% Speed
 Application Types

Example: Winders (Center Driven)

Speed is Slow Speed is Low

Speed is High

Low
Torque Required

High Torque Required

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 Application Types

Variable Torque (VT)

100
% Torque (square)
Torque,
Flow,
& HP 50

Flow
HP (cube)
INABB/ATDPL1/ac drive basics 16

50 100
(Base)
% Speed
 Application Types

Example: Centrifugal Fan

Move Air or Other Gaseous Materials
Typical kW Range >2.2 to 3000kW
Speed Range From 25 to 100%
Coast To Stop
Speed Controlled With 3 to 5% Speed Regulation
Acceleration From 2 to 90 Seconds
StartingTorque From 50 to 100%
INABB/ATDPL1/ac drive basics 17

No overload requriments
 Application Types

Example: Centrifugal Pump

Move Air or Other Gaseous Materials
Typical kW Range >2.2 to 3000kW
Speed Range From 25 to 100%
Coast To Stop
Speed Controlled With 3 to 5% Speed Regulation
Acceleration From 2 to 90 Seconds
StartingTorque From 50 to 100%
INABB/ATDPL1/ac drive basics 18

No overload requriments
 Application Types

Fan Operation

125
Operating
Point
100
%
Pressure
Fan
50 Curve

System
Curve
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50 100 150

% Flow
 Application Types
Volume Control Methods : Outlet Dampers
: Inlet Guide Vanes
: Variable Frequency Drives
Power Requirements For All Types

%
Input
Power
INABB/ATDPL1/ac drive basics 20
 Energy saving - Example

Throttling by a valve

By-passing by a valve

On-off control of the pump

Variable speed control of the pump

INABB/ATDPL1/ac drive basics 21

Parallel running of Pumps

INABB/ATDPL1/ac drive basics 22 Relative Power consumption

• Software tools - FanSave, PumpSave

 Control Accuracy & Regulation
Speed Regulation
Simple Scalar — 1% to 3%
Scalar with Slip Compensation — 0.5% to 1%
Vector with Encoder — 0.01%
Direct Torque Control (DTC) — 0.1% to 0.5%
DTC with Encoder — 0.01%
Speed Response
Simple Scalar — 3 %s
Scalar with Slip Compensation — 3 %s
INABB/ATDPL1/ac drive basics 23

Vector with Encoder — 0.3 %s

Direct Torque Control (DTC) — 0.4 %s
DTC with Encoder — 0.1 %s
 Application Issues

Other

Drive Efficiency — ≈ 98%

Power Factor — 0.97 (displacement)
Current Harmonics — 35% to 45% THD
(network dependent)
INABB/ATDPL1/ac drive basics 24
 Rectifier Configurations

6-pulse Rectifier 12-pulse Rectifier 12-pulse Rectifier 24-pulse Rectifier

3~
3~
3~
3~

Current Waveforms
INABB/ATDPL1/ac drive basics 25
 IGBT Rectifier

Best is to use an IGBT rectifier.

IGBT can be switched off if the current starts to grow.
It is full regenerative
It can boost the motor voltage when line voltage is low.
The power factor is 1
Current harmonics are lower due to higher switching frequency.

U+

U
V
INABB/ATDPL1/ac drive basics 26

U-
 Thyristor bridge in motoring

We study how U+ (DC) voltage is developed.

Thyristors are controlled to diode mode( Fully fired ) so the bridge
always selects the highest of AC voltages (U,V,W) for U+
Anyway line inductance L slows down the transfer of current from
phase to phase. This transfer is called commutation.

U+
E L
U
V
W
INABB/ATDPL1/ac drive basics 27

U-
 Thyristor bridge in generating

In generating mode the DC bridge is supporting the current so if the

AC voltage disappears, the current will grow high.
A Thyristor cannot be turned of by control, so it will continue
conducting and the current will increase until the the fuses interrupt
the current.

U+

U
V
W
INABB/ATDPL1/ac drive basics 28

U-
 Improving commutation

Risk for problems can be reduced by higher AC voltage. This gives

more margin for commutation. The alternatives:
The infeed transformer can be selected to give e.g. 20 % higher
voltage.
There can be an autotransformer in the converter boosting the
generating bridge voltage by 20 %
U+
U
V
W

U-
INABB/ATDPL1/ac drive basics 29

U+

M
U-
 Braking to resistor

motor as
line rectifier motor converter
generator

M
Net
3

mechanical
electrical CH braking chopper energy
energy

braking resistor
INABB/ATDPL1/ac drive basics 30
 ACS 600 Power Plates

Basic construction

P1 P2 P3
INABB/ATDPL1/ac drive basics 31
 ACS 600 Power Plates

Power Plate connections, single inverters

R4 - R7 R8, R9
P1 P2 P3 P1 P2 P3 P1 P2 P3
P1 P2 P3

U V W U V W
R10i, R11i

P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3

U V W
R12i
INABB/ATDPL1/ac drive basics 32

Phase module Phase module Phase module

P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3

U V W
 ACS 600 Power Plates

Power Plate connections, parallel inverters

2 x R8,R9
R8, R9 R8, R9
P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3 P1 P2 P3

U V W

4 x R12i
R12i R12i R12i R12i

P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3 P1
P2P3P1
P2P3P1
P2P3
INABB/ATDPL1/ac drive basics 33

U V W
INABB/ATDPL1/ac drive basics 34 Control Cards - Example
INABB/ATDPL1/ac drive basics 35
Control Cards - Example
 MultiDrive

DSU = Diode Supply Unit TSU = Thyristor Supply Unit

INABB/ATDPL1/ac drive basics 36

ISU = IGBT Supply Unit DBU = Dynamic Braking Unit

ACU = Control Unit ICU = Main Switch
INABB/ATDPL1/ac drive basics 37
Efficiency
 AC motor general benefits

Robust and simple construction

=>High reliability
Closed structure
=>Protected against harsh
environment
=>Saves cost of additional
clean air cooling system
No brushes or sliprings in the
motor
=>Minimal maintenance
High efficiency
INABB/ATDPL1/ac drive basics 38

=>Substantial energy
savings
 Motor Torque Speed curve

TORQUE
Tmax

nominal torque
1

motor mode

0
1 2 SPEED
generator mode
INABB/ATDPL1/ac drive basics 39

Typical torque/speed curve of a cage induction motor

 Motor Torque Speed curve with Freq.. Conv.

n
INABB/ATDPL1/ac drive basics 40

Torque curves of a cage induction motor fed by

frequency converter
INABB/ATDPL1/ac drive basics 41
Motor efficiency - Typical (DOL)
INABB/ATDPL1/ac drive basics 42
Motor losses
INABB/ATDPL1/ac drive basics 43 Line harmonics
INABB/ATDPL1/ac drive basics 44
Cabling
INABB/ATDPL1/ac drive basics 45
Recommended cable types
 Fieldbus

Definition of a Fieldbus
INABB/ATDPL1/ac drive basics 46
 Fieldbus
Fieldbus System
Ethernet, TCP/IP Backbone

Operation HMI
level HMI

System Bus

Control
level

PROFIBUS-DP PROFIBUS-PA
INABB/ATDPL1/ac drive basics 47

Device
level
 Software tools

Supporting the lifecycle of drives

DriveSize - Advanced dimensioning
tool for drives
DriveBuilder - Configuration tool
producing cabinet dimensions and
line drawings
DriveWindow - Comprehensive
set of features for
commissioning, maintenance and
training
DriveLink - Communication interface
between Windows-based monitoring
softwares and ABB drives
DriveSupport - Clear, concise service
tool for ABB drives
INABB/ATDPL1/ac drive basics 48
 AC drives are the most eco-efficient products we know of

During the past ten years, ABB AC Drives have been reducing
energy consumption in pumps and fans by about 46 TWh every year.
This corresponds to 38 million tons less CO2 emissions per year.

1999
1998
1997
1996
1995
1994
1993
1992
INABB/ATDPL1/ac drive basics 49

1991
1990
0 1000 2000 3000 4000 5000 6000 7000 8000

GWh
INABB/ATDPL1/ac drive basics 50