We will talk about

• Pre-Installation checks

• Installation – What should be looked at

Presentation on • Maintenance

“Best Installation and Maintenance practices for Drives (VFD)” • Advantages of following best practices

Energy Efficiency in Electrical System

8th and 9th December 2008: Chennai Trade Centre, Chennai

9 December 2008

Pre-Installation checks

• Compare VFD model received to what was ordered

• Be sure that input supply, VFD and motor voltages are all same

• VFD rated current should be greater or equal to the total full load current of
all motors driven at once

• If a disconnect (or contactor) is used between VFD and motor, it should be

Pre-Installation checks interlocked with VFD start command else VFD can trip when disconnect is
closed with VFD in RUN mode.

• No power factor capacitors are installed between VFD and motor

• Cable distance between VFD and motor is within VFD specfication.

• Input and Motor power cable dimensions – should match with VFD terminals

• Individual motor protection is provided in case of multimotor applications.

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Installation checks - What should be looked at

• Environment
• Ambient temperature
• IP category
• Mounting clearances
• Cooling and VFD heatloss
• Harmonics

• Drive Connections
Installation checks •
•
Earthing
Layout of control and power cables
• EMC correct wiring
• Input protection
• Power factor correction capacitors

• Drive Configuration
• Parameters as per the application

• Startup
• Balanced voltage, Motor direction

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 Installation checks - Environment
• VFDs available in market have an operating ambient temperature
between 40 to 50 deg C. If VFD surrounding ambient is beyond the
specifications, derating should be considered.
 Correct ambient temperature avoids VFD getting overheated
• IP00, IP20, IP21, IP54, IP66 are the different IP categories of VFD.
Select the location for installing VFD based on IP.
 IP00 VFD can be installed in panels and IP66 in areas where there is a
possibility of water splash.
Installation checks - Environment
• Calculate the total heatloss from VFDs to be installed and make
appropriate cooling arrangement so that VFD ambient requirement
is maintained.
• If many VFDs with high power rating are installed at one location,
provision of supply and return air duct directly connected to VFD (or
panel) can help reduce the air conditioning capacity requirement.

• VFD manual specifies clearances required on the sides, top and

bottom. Adhere to these instructions.
 Natural flow of airflow will be blocked if this is not followed which results in
overheating of VFD.

• Environment should be free from corrosive gases and dust

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Installation checks - Environment Installation checks – Earth and control cables

• If VFD input supply is also connected to many other power electronic
equipments, there is a possibility that large amount of harmonics are
present in the system. Use one of the harmonic reduction techniques
to reduce harmonics in the system
• Earth connections should be properly secured. VFDs have a high leakage
current and must be earthed appropriately for safety reasons.
• Control and communication cables should be shielded

Passive:

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DC-inductors AC-inductors Multi-pulse Passive Filters

Active:

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PWM-rectifier Active filter

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Installation checks – Input protection & PF

Installation checks – EMC correct wiring capacitors
• Use screened/armoured motor cables and
screened/armoured control cables. • Use input disconnect / SFU / MCCB and semiconductor fuses. Fuses
should match I2t rating of rectifiers used at VFD input section and
• Installations using rigid metal conduits are not hence use recommended fuse type and ratings.
required to use screened cable, but the motor
cable must be installed in conduit separate • To satisfactorily operate the PF Correction systems under harmonic
from the control and mains cables. conditions it is important to find a solution to the problems of resonance.
Detune the system from the resonating frequencies which can be
• Connect the screen/armour/conduit to earth at effectively done by installing detuning reactors in series with the
both ends for motor cables as well as for
capacitors.
control cables.

• Avoid terminating the screen/armour with

twisted ends (pigtails). It increases the high
frequency impedance of the screen, which
reduces its effectiveness at high frequencies.

• Avoid using unscreened/unarmoured motor or

control cables inside cabinets housing the
VFDs
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 Installation checks – VFD configuration &
Installation checks – Energy Savings
Startup
• Parameter settings • Regenerative v/s Dynamic braking
• Setting correct parameters for the required application is a key to • If the load is regenerative, go for regenerative scheme (but this is
applicable if VFD selection is not done yet)
smooth startup (commissioning).
• Minimum parameter settings : • Where are the sensors installed ?
• Motor data
• In retrofits, keep dampers and throttling valves open.
• Ramp up/down time
• Torque characteristics • Use squirrel cage motors instead of slipring motors
• Mains voltage
• Network – Address, Baud rate
• Max / Min frequency reference
• Digital and Analog IO configuration

• Startup
• On applying power and start command to VFD, check the balanced
output voltages and direction of motor rotation.

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VFD maintenance

When maintenance is scheduled, be prepared with :

• Tools required
• Checklist with time frame
• Capability of personnel doing maintenance work
• Whether VFD supplier’s presence is required ?
Maintenance

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VFD maintenance - Tools VFD maintenance - Tools

• Ensure that proper tools required for carrying out maintenance are
available at site before shutdown is taken.
• These tools can be spanners, pliers, torque wrench, Screw driver, blower,
cable ties, Infra red thermometer, multimeter, clampmeter, voltmeter.
• Before taking shutdown, check temperature of all power connections in
the panel with thermometer. One can know if there is any abnormality in
connection (loose) or lugs not crimped properly with cables.
• True RMS voltmeter or analog voltmeter can give exact value of VFD
output voltage as the output waveform is PWM. Other multimeters can
give indication whether output 3 phase are balance or not.
• Blower or vacuum cleaner can be used to clean the panel, filters and VFD.
It should be a dry air.

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 VFD maintenance - Checklist VFD maintenance – Person handling VFD

• Prepare checklist for carrying out maintenance work. Include checks to

• Person handling VFD or panel should be a trained personnel.
be carried out with timeframe.
• If maintenance requires dismantling of parts from VFD and re-assembling,
• Some checks needs to be done quarterly and some half yearly. Depending
it is recommended to call a VFD supplier technician.
on the environment, some checks like panel cleaning can be done monthly.
• Most VFD manufacturers also offer maintenance programs. By utilizing these
• Include following points as minimum in checklist : services, customer gets benefit of best attention to the VFDs.
 Cleaning – panel, filters, VFD
 Temperature of power connections
 Physical inspection of VFD – DC capacitors, accumulation of foreign particles
 Cooling fan in panel & VFD are functioning
 VFD heatsink temperature
 VFD output voltage and current balance in all phases
 Input supply conditions and VFD input current balance
 Indications on panel and LCP on VFD
 Logic test…..changeover scheme is functioning ?
 Motor – megger value
 Check that the spares available are in working condition
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Benefits
Best Installation practices
• Reduces commissioning time
• No surprises……like, tripping of VFD after startup
• Smooth operation for long periods

Benefits of using best practices for Best Maintenance practices

Installation and Maintenance • Continuous smooth functioning
• Early detection of breakdowns and hence avoid production loss
• MTBF claimed by VFD manufacturers are as high as (or even higher than)
200,000 hrs (=23 years) and it is easy to achieve if the best practices are put in
place.

9 December 2008

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Thank You

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