Variable Frequency

Drives
VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives

What should an SCO be specifically looking for when inspecting a VFD installation
 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.
VFD Explored

EtherNet IP, DeviceNet, ControlNet,

Modbus, LonWorks, Profibus, Can-Open,
Interbus, Metasys, etc.
 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives

What should an SCO be specifically looking for when inspecting a VFD installation
 VFD / Motor Protection

• Drive must be correct size for the motor and programmed

accordingly to ensure motor is protected
– Based on CEC 2-024, 28-300, 28-500
• Motor OL protection on a VFD is provided electronically
• Motor Data to be programmed during commissioning
– Motor Nameplate information
• Power (HP/KW)
• FLA
• SF
• Volts
• RPM
• Frequency
– Select Motor control type
• V/Hz Control
– Motor control is calculated for performance and I²t protection
• Vector Control
– Motor / drive auto-tuning to optimize performance & calculates I²t
protection
 VFD / Motor OL Protection
• For single motor applications the drive shall be programmed to protect
the motor from overload conditions
• An electronic thermal overload I²T function emulates a thermal
overload relay
• Models Class 10 OL
• This operation is based on three parameters;
[Motor NP FLA], [Motor OL Factor] and [Motor OL Hertz]
– [Motor NP FLA] is multiplied by [Motor OL Factor] to allow the user to
define the continuous level of current allowed by the motor thermal
overload
– [Motor OL Hertz] is used to allow the user to adjust the frequency below
which the motor overload is de-rated.
 Short Circuit Protection
28-200, 28-202, 28-206, 28-208, 28-210

• Short Circuit Protection

– Provided by Fuse or Breaker
– Most VFD’s rated at 200kA for short duration
– Fuse preferred by most drive vendors
• Semi-conductor fuse
– Clear time ¼ to ½ Cycle
• Breaker
– Thermal Type
– 1½ to 2 cycles
• VFD provides instantaneous over current
protection
 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives

What should an SCO be specifically looking for when inspecting a VFD installation
 Load Types
Constant Torque vs. Variable Torque
• A constant amount of torque is required to turn the load regardless of the
speed
• Constant torque means constant current
• Heat generated is same at all speeds
• Motor heat is a function of heating losses in the motor
– Power (heat) = I2R
• The cooling system of TEFC motors deteriorates at reduced speed and is
proportional to motor speed
– Fan Cooling  Speed2
– i.e. Cooling effect at 50% speed  0.52  25%
• Motor heating becomes an issue and must be addressed with the type of
motor purchased (motor speed range).
• Typical Ranges: 4:1 10:1 100:1 1000:1
 Speed Range - Constant Torque 4:1

100
Torque
90

80
Torque
70

%Torque 60

50

40

30 Acceptable Region
for Continuous Operation)
20

10

0
0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90

Hz
 VFD Ratings
Constant Torque versus Variable Torque

• Some VFD manufacturers rate their VFD’s differently to

operate on both of the two predominant load types:
– Constant Torque (CT) or “Heavy Duty”
– Variable Torque (VT) or “Normal Duty”

• The ratings are industry standards and basically state the

amount of overload that the load can tolerate, and that
the drive must supply, for a one minute period
– Constant Torque (CT) = 150% current for one minute
– Variable Torque (VT) = 110 - 120% current for one
minute
 VFD Ratings
Constant Torque versus Variable Torque
• These ratings basically qualify the drive
chassis’ thermal rating

• The thermal withstand of the chassis is a

fixed value and is based upon the product
of the square of the current and time (I2t)

• Most VFD Manufacturers rate their drives

to meet the VT specification and then have
to derate them to meet the CT rating

• Some VFD Manufacturers do just the

opposite and rate their drives (usually
230V & 480V Micro drives) for CT and then
can over rate them for VT.
– (1.5 x lower current)2 x t  (1.15 x higher
current)2 x t
 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives

What should an SCO be specifically looking for when inspecting a VFD installation
 The Reflected Wave Phenomenon

• First identified in 1900 with power distribution lines

• Also known as Standing Wave or

Transmission Line Effect

• Well documented in digital communications

• Coming to the forefront in IGBT based drives

• Can cause voltage peaks at the motor

• Presents the possibility for insulation breakdown

 The Physics of it All
• The cable between the drive and motor represents a
substantial impedance to the PWM voltage pulses of the
drive
• Cable impedance is proportional to length

Inductance / unit length

Capacitance / unit length
Z0=

• If the cable surge impedance does not match

the motor surge impedance----
– Voltage reflection WILL occur !!
 What will the amplitude be?
The velocity of the reflection
(Dependent on cable capacitance & inductance)

PLUS

The rise time of the switching device

determine the cable distance at which the
reflected wave will reach maximum amplitude

The amplitude can be 2 - 3 times the DC Bus voltage

( 675VDC X 2 = 1350 Volts typical )
Typical PWM VLL Output Pulse at the Motor
Terminal
+2

+1

-1
 Reflective Wave
Raw output voltage waveform
Drive Motor Match
Drive Motor Match
 Inverter Duty/Rated Motors
• Drives are designed to work with all squirrel cage induction motors

• Inverter duty motors allow longer distances with no degradation or

breakdown

• Per NEMA MG1 Part 31:

Definite-purpose, inverter-fed motors are designed to withstand
maximum repetitive voltage peaks at the motor terminals equal to 3.1
times the motor’s rated rms voltage with a rise time not less than 0.1 μs.

• These motors can be used on a control without additional filters or reactors

provided the particular combination of control and cable does not generate
peak voltages which exceed this requirement at the motor terminals.

• Only where motors are required to meet “Temperature Code Ratings” as per
section 18, they must be Drive/Motor match, tested and labelled
accordingly.

• Non inverter or standard motors can be used provided the necessary

precautions are taken
 Protect the Motor
Installed solution between VFD and Motor
• Output (Load) Reactor
• Output dv/dt Filter
• Sinewave Filter
• Motor Terminating Device
 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives
What should an SCO be specifically looking for when inspecting a VFD installation
 Multi Motor Application
28-108, 28-500(3)(e)

•All motors run at same speed

•Drive size to be sum of all HP
•No limit to number of motors
on one drive
•Motors do not need to be
same HP rating
•All OL Relays to be tied
together in series 20HP

•Drive would run in V/Hz mode

•Motor OL can be disabled in
drive

10HP 5HP 5HP

 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives
What should an SCO be specifically looking for when inspecting a VFD installation
 VFD Explored

Low Voltage Protection as per CEC 28-400

 Power Structure c/w DC Brake
•Drive and brake are separate
components

•Chopper Transistor Voltage Control

regulates the voltage of the DC bus
during regeneration.

•Drive with DC Brake

installed
•Resistor terminates
at drive
 Power Structure c/w DC Brake
•Drive and brake are separate
components

•Chopper Transistor Voltage Control

regulates the voltage of the DC bus
during regeneration.
Wire sized according to resistor size

Caution should be take to

ensure proper

Wire Type
Wire size

Brake resistor wire size CEC 26-640 & 26-642

•Drive with DC Brake

installed
•Resistor terminates
at drive Terminate at
BR1 & BR2
External Brake Resistor Circuitry
 Variable Frequency Drives

VFD Explored
VFD Control Schemes
Over current and over load protection requirements
Load Types – Constant Torque vs. Variable Torque
Motor / VFD compatibility and requirements to be matched
Multi Motor Applications
DC Brake Resistors applied to Drives

What should an SCO be specifically looking for when inspecting a VFD installation
Questions?