HYDRAULIC INSTITUTE

KNOWLEDGE SERIES:
MOTORS & VFDS
Variable Frequency
Drives
May 15, 2009
Prepared by the HI
Drivers And Driver Controls Committee
2

 Purpose:
 To provide and overview on Variable Frequency Drives
in support and for the pump industry and define
the basic operating principles and selection
considerations.

 Scope:
 VFD applications for low voltage, 3 phase induction
motors (up to 690Vac).
PRESENTER
3
Julian A. Atchia
Julian A. Atchia is the Business Development Manager for SJE-Rhombus® - Controls
Group in Detroit Lakes, and the Chairman of the HI Monitoring Device and
Instrumentation technical committee. Julian began his career as a controls and
instrumentation engineer and has been employed a diverse group of industries. During
his career, Julian has designed control systems utilizing VFDs from 1/4HP to 600HP for
pumps, mixers, cranes, conveyor belts, mills and fans. Since working at SJE Rhombus ®,
Julian has designed pump control systems for water and wastewater applications, and
developing new products utilizing VFD technology. He has authored several articles for
industry publications. Julian earned his Bachelor of Science in Electrical Engineering at
the University of North Dakota, Grand Forks.
AGENDA
4

1. Definition
2. Benefits
3. Architecture
4. Motors
5. Operating principals
6. Application Considerations
7. Built-in features
8. Pump application considerations
9. VFD selection considerations
 Definitions
5

Variable Frequency Drives (VFD)

Adjustable Frequency Drives (AFD)
Inverter Drives
Variable Speed Drives (VSD)
Drives

A VFD is an electronic device used to control the rotational

speed of an AC motor. Speed control is achieved by
controlling the frequency of the electrical power supplied to
the motor.
 Benefits
6
When properly applied, VFDs can generate great benefits in pumping systems. Benefits include:

1. Accommodate for varying operating conditions.

2. Possibility to reduce and/or optimize system components
3. Potential of energy savings and life cycle cost reduction,
both mechanical and electrical
1. Can convert single-phase power to three-phase power
2. Reduces inrush current at start-up
Basic System
7
VFD SYSTEM ARCHITECTURE
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Basic VFD Diagram

RECTIFIER
9
At the front end of a VFD is a full wave diode bridge rectifier. The
function of this module is to convert AC voltage into DC voltage (to
rectify). A 460 Vac input will be rectified to 650Vdc (460 x√2).
INVERTER
10
By utilizing six or more transistors, the inverter module is able to convert DC
voltage into a simulated sinusoidal output waveform. This method of power
conversion is called Pulse Width Modulation (PWM). There are 2 transistors per
phase, one for the positive switching and one for the negative.
The frequency of these pulses is significantly higher than the frequency of the
simulated sinusoidal output, and is known as the carrier frequency .

Basic IGBT configuration in an Inverter module. Pulse Width Modulation output

CONTROLS – Operator Interface
11
Control of the VFD can be accomplished by various methods. A typical operator
interface, such as a keypad integral with the VFD (see figure below), provides a means
for an operator to start and stop the motor and adjust the output frequency.
CONTROLS – I/O + Com.
12
 13

QUESTIONS
MOTOR
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Variable frequency drives operate under the principle that the synchronous
speed of an AC motor is determined by the frequency of the AC supply and the
number of poles in the motor’s stator winding, according to the following
relationship:

RPM = 120 x F (f)

P
RPM = Revolutions per minute of the rotating magnetic field of the motor
(synchronous speed).
F (f) = AC power frequency (hertz).
P = Number of poles (an even number).
MOTOR: 60Hz
15
The number of motor poles is typically fixed by the motor design and can be
calculated from the motor nameplate data. For example for 60Hz rated motors the
number of poles for typical motors is shown below:

TYPICAL ACTUAL SYNCHRONOUS NUMBER OF

SPEED SPEED POLES
3530 3600 2
1750 1800 4
1175 1200 6
880 900 8
MOTOR: 50Hz
16

Typical Full Load Synchronous

Number of Poles
Speed Speed
2930 3000 2
1450 1500 4
975 1000 6
730 750 8

The operating speed, or typical motor full-load speed, is usually indicated on the motor nameplate and is
the value that should be used when estimating pump performance. Additionally, there may be a difference
in the motor slip when operating from a VFD supply when compared to utility fixed frequency power.
Motor data sheets that include performance data when operated from a VFD are recommended for
determining actual operating speeds.
 17

QUESTIONS
Operating Principles
18
When a VFD starts a motor, it initially applies a minimum low frequency and voltage to the motor. The initial
starting frequency is typically 2 Hz or less. The VFD will then ramp up the output frequency and voltage to
a desired set point.
VFD Built-in features
19

– Adjustable electronic motor overload

– Under current (no flow / dry run)
– Instantaneous over-current protection (Short Circuit)
– Under/over voltage protection / phase imbalance
– Ground fault (motor)
– Surge arrestors
– Fwd/Rev operation without the use of contactors
– Multiple Acceleration and Deceleration ramp rates
– Critical frequency avoidance (skip frequencies)
– Multiple ways of stopping the motor: Coast, Ramp or DC-Brake
– Process control
– Programmable Logic Controller
 20

QUESTIONS
PUMP APPLICATION CONSIDERATIONS
21
Pump selection and operating Speed range:
Verify the that the operating points throughout the speed range meet the desired
head and flow conditions. For pressure control applications, the larger the range
the better the control (35-60Hz).

Max and min speeds:

Verify that the pump and motor can safely operate at these speeds.

Motor Selection considerations: (Consult the motor manufacturer)

Winding insulation class
Bearings type.
Protection: Temperature, vibration,
Hazardous locations

Vibration:
Which frequency to avoid
VFD SELECTION CONSIDERATIONS
22
Voltage:
What is the available incoming power on site?
Single phase input?
Does the VFD rated output voltage match the motor voltage?

Amps:
Motor Full Load Amps: Is the VFD output rating sufficient?
Motor Service Factor Amps: Will the motor run into the SF?
Load type: Variable Torque (120%) or Constant Torque (150%)?

Environment:
Temperature: Enclosure cooling? Heating?
Ingress protection: Dust, moisture, corrosive gas?
Elevation: More than 1000m above sea level?
Hazardous location: Explosion proof?
VFD SELECTION CONSIDERATIONS
23

Controls:
Stand alone or external control? Both?

Motor cable length: Filters required? Voltage drop?

Harmonic level: IEEE 519

Line reactor
DC choke
Active / Passive filter
12, 18 or 24 pulse rectifier
Active front end.

EMI/RFI noise: Filters required?

SUMMARY
24

Variable frequency drives have become a very popular and cost-effective

method of realizing energy savings, process control, and speed
adjustment of AC motors. This presentation has outlined the general
concepts for use of a VFD in pumping applications and covers the
fundamental principles of operation. Proper application and use of VFDs
requires a more detailed examination and analysis of the desired results
and considerations. Please review any VFD application with a VFD
supplier to ensure correct selection and application.
 25

QUESTIONS
 Contact
26

Gregg Romanyshyn, PE
Hydraulic Institute Technical Director
[email protected]
 27

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