1(800)900-2220 PSI Pump Systems

Variable Frequency
Drives
Presented by
PSI Pump Systems Inc.
Your
Solutions Experts for
Pumps & Water Treatment

1(800)900-2220 PSI Pump Systems

 The Purpose
of
VFDs

1(800)900-2220 PSI Pump Systems

 The Purpose
1. Energy savings on most pump and fan
applications.
2. Better process control and regulation.
3. Speeding up or slowing down a machine or
process.
4. Inherent power-factor correction
5. Emergency bypass capability
6. Protection from overload currents
7. Safe Acceleration

1(800)900-2220 PSI Pump Systems

 Electric & Power Basics
All VFDs must:
Run a machine or process at a desired
speed.
Produce adequate torque to handle the
load.
Use power efficiently to produce the
necessary torque at a given speed.
Effectively monitor the application or
process.

1(800)900-2220 PSI Pump Systems

 Electric & Power Basics

The typical waveform consists of the

frequency portion (time based) of the
wave and the amplitude portion (the
magnitude). This wave is actually in
sine-wave form, commonly referred
to as the fundamental.

1(800)900-2220 PSI Pump Systems

 Electric & Power Basics
Sinusoidal Waveform With Frequency &
Amplitude Components

1(800)900-2220 PSI Pump Systems

 AC-Induction-Motor
Theory

1(800)900-2220 PSI Pump Systems

AC Induction Motor Theory

AC Induction Motor Squirrel Cage Design

1(800)900-2220 PSI Pump Systems

 AC Induction Motor
Theory

Three-phase
motor operation.

1(800)900-2220 PSI Pump Systems

AC Induction Motor Theory

How a motor shaft rotates

Torque is produced as the
induction motor generates flux in
its rotating field.
This flux must remain constant to
produce full-load torque.

1(800)900-2220 PSI Pump Systems

 AC Induction Motor
Theory
As shaft torque load increases, the
slip increases and more flux lines
cut the rotor windings, which in
turn increases rotor current, which
increases the rotor magnetic field
and consequently the rotor torque.

1(800)900-2220 PSI Pump Systems

AC Induction Motor Theory

Typical speed
versus torque
curve for a
NEMA design B
motor.

% Synchronous Speed
1(800)900-2220 PSI Pump Systems
 AC Induction Motor Issues
Starting Induction Motors
The starting current is very high, between 3 to
8 times the full load current. Depending on the
size of the motor, this can result in voltage
sags in the power system.
The full torque is applied instantly at starting
and the mechanical shock can eventually
damage the drive system, particularly with
materials handling equipment, such as
conveyors.
In spite of the high starting current, for some
applications the starting torque may be
relatively low, only 1.0 to 2.5 times full load
torque.

1(800)900-2220 PSI Pump Systems

 AC Induction Motor Theory
The speed of the rotating electric field within
the induction motor.

Synchronous Speed = 120 x frequency

# of motor poles

1(800)900-2220 PSI Pump Systems

 AC Induction Motor Theory
AC motor speed change can be
accomplished in three ways:

(1) Change the number of poles in the motor; this

means separate windings;
(2) Change the slip characteristics of the motor;
this is done with varying resistors, such as is
done with a wound-rotor motor or by varying
the stator voltage; or
(3) Change the frequency of the power supplied to
the motor. This is the method of choice .

1(800)900-2220 PSI Pump Systems

 Components of VFDs
Power electronics is that field of
electronics which covers the
conversion of electrical energy
from one form to another for high
power applications.

1(800)900-2220 PSI Pump Systems

 Components of VFDs
Vacuum tubes
Thyristors (SCRs)
provided the standard method for
rectifying AC. Also referred to as a
diode.

1(800)900-2220 PSI Pump Systems

 Components of VFDs
Transistors provide fast switching
capability for a relatively low cost.
The general types of transistors are:
The bipolar transistor;
The gate turn off transistor (GTO)
The field-effect transistor (FET);
The insulated gate-field-effect transistor
(IGFET);
The insulated gate-bipolar transistor (IGBT).

1(800)900-2220 PSI Pump Systems

 VFD Basics

A VFD in a
block
diagram.

1(800)900-2220 PSI Pump Systems

 Components of VFDs

All VFDs need a power section

that converts AC
power into DC power.
This is called the converter bridge.
Sometimes the front end of the
VFD, the converter is commonly a
three- phase, full-wave-diode bridge.

1(800)900-2220 PSI Pump Systems

 Components of VFDs

Rectifier is that special type of converter

that converts AC to DC.

1(800)900-2220 PSI Pump Systems

 VFD Basics
DC Bus
The DC bus is the true link
between the converter and
inverter sections of the drive. Any
ripple must be smoothed out before
any transistor switches on. If not,
this distortion will show up in the
output to the motor. The DC bus
voltage and current can be
viewed through the bus terminals.

1(800)900-2220 PSI Pump Systems

 VFD Basics
Simplified Circuit showing DC bus components:

The DC link is an important section of the drive as it provides much of the

monitoring and protection for the drive & motor circuit. It contains the base-
drive fusing and pre-charge capacitor network, which assures steady
voltage DC voltage levels prior to the inverter bridge and allows a path for
over-voltage dissipation.

1(800)900-2220 PSI Pump Systems

 VFD Basics
Input Waveforms
The voltage that is not stepped down is
rectified through the diodes, and a DC bus
voltage should be present.
The DC + and DC terminals will
typically read approximately 325 volts
DC on a 230 volts AC supplied drive
and 650 volts DC on a 460 volts AC
supplied drive.
This waveform, when viewed, is straight
DC, possibly with some rippling effect
from the AC input.
1(800)900-2220 PSI Pump Systems
 VFD Basics
Power-Module
The inverter section is made up
primarily of modules that are each
made up of a transistor and diode
in combination with each other
which inverts the DC energy back to
AC.

1(800)900-2220 PSI Pump Systems

 VFD Basics

Simplified
Inverter
Section of a
VFD

1(800)900-2220 PSI Pump Systems

 VFD Basics
The DC waveform looks more like
an AC waveform but the voltage
waveform is much different.
The power semi-conductors in the
inverter section act as
switches, switches of the DC bus,
and therefore, are pulsing the
motor with some voltage.

1(800)900-2220 PSI Pump Systems

 VFD Basics
A typical square wave takes its shape
on the square-wave look due to this
switching function ( which explains
the sharp rise to peak) rather than a
rotational, changing state of
amplitude.
This frequency and amplitude
pattern is sometimes called the
carrier frequency of a PWM drive.

1(800)900-2220 PSI Pump Systems

 VFD Basics

Pulse-width-modulated voltage and

current waveforms.
1(800)900-2220 PSI Pump Systems
 VFD Basics
The VFD changes the DC energy
into three channels of AC energy
that an AC induction motor can
use to function properly.
Inverters are classified as voltage-
source, current-source of variable-
voltage types. This has to do with
the form of DC that the inverter
receives from the DC bus.

1(800)900-2220 PSI Pump Systems

 VFD Basics

Types of VFDs
Solid-state AC VFDs can be
named for their use, by their DC
bus/inverter voltage or current
source, by their waveform (PWM or
PAM), by the type of power
device used in their inverter section,
or by their performance
characteristics.
1(800)900-2220 PSI Pump Systems
 VFD Basics
The main objective of the VFD is to
vary the speed of the motor while
providing the closest approximation
to a sine wave for current (while
pulsing DC voltage to the motor).

1(800)900-2220 PSI Pump Systems

 VFD Basics

Volts-per-
Hertz
Control
The area
within each
pulse is the
power
delivered to
the motor in
volt-
microseconds.

1(800)900-2220 PSI Pump Systems

 VFD Basics
How VFDs Operate

The PWMs drive ability to maintain

the AC levels through all types of
load conditions at given speeds is the
factor which separates one drive
manufacturer from the other.

1(800)900-2220 PSI Pump Systems

 VFD Basics
Functions & Features

Set-up Parameters
The Control Method
Acceleration or Accel-Ramp Rate
Automatic Restart
Stopping Method
Automatic Signals

1(800)900-2220 PSI Pump Systems

 VFD Basics

Functions & Features

Jump, Skip or Critical Frequencies
Fault Logs and On-Board
Diagnostics
Power Loss Ride Through
Slip Compensation
Catch a Rotating Motor, Speed
Search or Pick-Up a Spinning Load
1(800)900-2220 PSI Pump Systems
 VFD Basics
Conclusion
Significant energy savings
Easy setup & programming
Retrofits
Space
Better design
Competitive edge
1(800)900-2220 PSI Pump Systems