anos How to sect a VED | Contra Engineering CE m Can itt iin Wiobcasts Newalatlrs Magazine ee cre Subseribe ‘Manage Account How to select a VFD ‘Those guidlines dispo the confusion about matching variable frequency drives (VFD) and motors to fans and pumps that aro ‘yplealy encountered in commatcil buiing applications. While the motivation to increase anergy affciney could be financial {troduced energy costs) or sthical (reduce greenhouse gas emissions associated with power production), is takon for granted that VEDS are an easy way to improve energy efficiency ina motor application. And with these noble intentions in mind, the ‘engineer wil specify a VED for hs cllent. Oftentimes that Isnt the end ofthe story forthe engineer. rw20%0 : ‘Shar ines lolli He BN ed ee ‘Ask an enginer the purpose o variable requency dive (VED), and a common answer would be Yo save energy" While the oniir ‘molvation to ncrease energy effency could be franca reduced ene'gy cosls) or ethical educe greenhouse gos emissions [seouateu wih power productor, t's ake fr granted that VEDs are ant cas) way ioimproweenelgyeliceney ammator | Spptatn. And wih hese noble ntnton In mind ne engheer vl specy 9 VED for his len. ‘Oftentimes, that sri the end ofthe story forthe engineer. : ‘The try sometimes ends badly witha dead motor oa bing wih power quality issues, an understandably angry cnt, and alstof mgerportng, These oticomes are often te rest fs poor understantig of Mow VFS and motors work Eerjencn hfe ea hey serv. The ermaton sr cae fom maafecies and vendors oft servo rr Srhe the sues Fotoung ae ow bel guiang connie GapeTamne affus conhsionsureurarg me machrg of ’ {GfDs and mots fo an an punps pay encore hi commerce Bung opricaons Reta : re ~ Anatomy of an induction motor : Ceca put robotics Electic motors conver electical energy into rotatlonal mechanical energy. : within reach Wotors may ave sums, ans compressors, or ary tverrumoer lenge tat OG Maybe thd batpeelcuicieg tha scent ote cing ukerewel + Molorbaacs i neckesay io dsstnd haw\ESeopamte sn aahowtny | Can destroy a motor a Vg i wae Gener tan eooled maucnen motor ‘The most common motor encountered in commercial bulding multhorsepower applications is a $-phase ac induction moter, ‘The motor consists of wo primary assemalles”aslationary stalor and afotating rotor. Allemating current fows through windings inthe state, ereaing a Foating magnate field around the rotor. The frequency of hs rotating magnetic feds decty elated tothe frequency of the ac vollage source, Ths rotating magnetic ele interact wan rotor, Indueng current inthe rotor fad an associated tangential force, which ullmataly causes the rota totum. In an induction motor, the speed of he rotors always slower than that of te rtaing fel. The torque of the motors roughly proportional othe power ofthe motor and Inversely proportional tothe speed of rotation, This operational characteristics important when considering f a varable torque Toad (cantrfugal fan, pup. of compressor) ofa constant torque load (postive displacement scravr, scroll or recipracaling ‘compressor wallbe connected tothe motor. “The most common type of duction motor isthe squire cage motor (also called short-circuit rotor type motor. The stator consists of doughnut shaped sheets of steal called laminatons. These laminatons have slats punched in them and then are aligned and stacked together. Conductors are then wound though tse slots fo form cols. These cal conductors are leceally insulated from the laminations. The characteristics of ths ineulation system are importrt later nour ciscussion ‘The eyindsieal rotor isn the veld inthe idle of te stator. Like the stator, te oto is made fom stacked steal laminations. pura cortrolenn.comindustry-newsmore-nevssinle-artcethw-to-seect vlBATI7366%0a ebSIO088ESNBCE TAH! wanos How lo sect a VED | Contra Engineering ‘These laminations are pressed onto a center shat. Bars of aluminum or copper are inserted through sols athe outer edge of the lamination and are connected athe ends wth shoring rings at either end to form a cage-tke stucture. The rotors Supported with bearings atthe ends of the shat. There's no dreet electncal connecion between the rotor and tne windings in the stator. The only paint of cortac Isa the bearings, which wil be important ina later section Induction motors are not 100 percent effcient. Motor energy loss is caused by several actos, including I°R power losses, ‘maghelle core losses, icon fsses, and stray load losses. These losses generally rest in heal generation, whch must be dissipated to preserve the motor winding insulation, Far common totaly enclosed far-cooled motors (TEFC), ths heat dissipation is accomplished using a fan coupled tothe rotor shat. The speed ofthe mator wil drecy affect volume of coating 2a produced by this fan. As such, the speed of the motor fs an important consideration when variable speed motor operation fs desired, As & rule of thumb, @ 10 increase In winding temperature wil halve the Ife expectancy. Conversely, 2 10 C decrease in wnding temperature wll double the life expectancy. ‘Standard insulation classes for squiel cage induction motors a + 8 (800): general purpose 1 F (1086) industal use 1 (125.6): special use, heavy duty ‘These ratings reflect internal temperature rise only. The maximum recommended temperature limit for any mator also factors in ambient ermperalure and an extra 10 C hot-spat temperature wihin the whdings. Therefore, a motor wih Class B insulation ‘designed to operate In a 40 C ambent would have a maximum recommended operating temperature of 730 C. Motor Using Figher rated insulation systems may run hotter to take advantage of te mproved insulation, ut also would pack mare power into a smaller package. Premium motors ‘The government has legislate effciency standards for electrical motors, beginning with the Energy Policy Act of 1982 (EPAct- 1912), Subsequent legislation, the Energy Independence & Secury Act of 2007 (EISA-2007), requires that al general purpose, 110 200 hp, phase motors rated fo 600 V manufactured afer Dec. 18, 2010, must moet NEMA Premium motor Standards (as defined by NEMA MG! Table 12-12). Nominal ulload efficiency ofthese motors ranges anywhere from 77% to 196.2% depending on a numberof factors. This represen alow. to mid-single-cigi acioncy improvement aver pre-EPAct 1982 requirements (see Table 1). While these efficiency provements may not seem lke much, ita motor is fun 12 hours a day for 5 days a week, this energy savings during the 3,000 hours of runtime aver the course ofa year wll 6d Up Table 1: Motor Eficiency Sizo (np) EPAct! EPAct? NEMA Promium? 10 787 m5 855 18 794 4088S 20 808 4088S 30 ana 75805 50 833. 875895 78 ass. 5 oo 109 857 5 OF 160 856 9.092 200 885. 910930 250 893 24 038 300 296 24 998, 400 902 0 4s 50.0 ona m0 4s. 600 918. 5 950 pura cortolenn comindustry-newsimore-nevssingle-atcethow-to-seect 2 vfBATIC7366%0a ebSHO088EENBCOTAHm!anos How lo sect a VED | Contra Engineering 759 917 1854 tooo 823 m5 054 1250 822 45 054 100 83.0 50 958 2000 © 38 960 962 EDS or premium motors? ‘As described above, a NEMA Premium motor wil see single-digit efficiency improvements over pre-EPAct motor designs under {ullload operating conditions. However, 'n commercial building applications, load requirements change dramatically for HVAC Systeme based on occupancy and outdoor ar temperature. Design day conditions generally represent only a fraction of otal ‘ntime for any system, Polenial energy savings ascociated wit variable speed pumping for hydronic systems and variable ai Volume HVAC systems dramatically exoeed that associated with NEMA Premium motor. For centrifugal loads such as fans and pumps, tis turndown relationship canbe roughly simplified as. HP) = HP; (REMgRPM)® ‘So a 100 hp load at +750 pm operating at hal speedilow would only require 12.5 hp, while the magnitude of torque would ‘ary roughly asthe square of tne rato of speeds at each load. This nonlinear speed/pawerrelatonstip for centrifugal loads ‘can be expe for energy saving the speed af the motor ean be changed. Por pose dsplacement loads, such a8 screw {and scroll compressors that require a consistent torque throughout an operation speed range, the associated power to speed {Umdown relationsnip isnot gute as atractve but sl represents a potential for Increased energy efficiency. i cen et Penna docmannt Induction motor, the speed ofthe rotor can be varied with the frequency ofthe voltage applied to the stator an take 39¢ ofthese turdovm powerlspeed relalonships, Given this information lt shouldbe clear why the term VED is interchangeable wih the term acjustable speed drive (ASD), What is a VED? ‘AVFD changes output volage frequency and magnitude to vary the speed, power, and torque ofa connected induction motor {fo meet load conaitons. A ypical VED consists of three primary sectons: 4. Rectifier 2 Intermediate ercuise bus 3 verter pura cortolenn comindustry-newsimore-nevssingle-atcethow-to-seect 2 vfBATIC7366%0a ebSHO088EENBCOTAHm!How lo sect a VED | Contra Engineering ‘You may notice that Figure 3 looks suspiciously simlar to thal for a double conversion UPS. n fac, the primary dference between the two is thatthe controls for iverter section in a UPS altempl fo maintain consistent volage and frequency output regardless of current output as opposed ta varying voltage and frequency win generally consistent curren output to speed up fr slow down a mator load. Consequently, VEDS are ypically rated intr of maximum curent output, while UPS are rated interms of power output ‘Although the exact configuration ofeach section ofthe VED may vary from manufacturer to manufacturer, the basic structure fomains the sama. The rectifier section consists of an array of fast-acting swiches thal convert an incoming ac voltage Supply {oa pulsating de vollage. The ntormodiate excul consisis ofa de bus and agsocialed crouly to sabiize and smooth the pulsating recter output. The de bus voltage Is roughly 1.414 times greater than the incoming ac supply voltage, depending on {design type. This de bus vollage ie made avaliable fo the inverter secton, which synthesizes an ac sine wave volage Cutput ftom the de bus votage. ‘The inverer section ouput nota tue sine wave but an approximation based on {he principles of pulse wath madulaton (PVM), wich iste predominant inverter technology. An aay of fast-acting switches in hverte secion produces votage pulses ata constant magnitude proportional tothe de bus voltage. Ina 3-phase ‘VeD, there are sx swtenes wit a par of svtehes for each phase. In each parr of switches, one switch generates the positive component ofthe sine wave and the Second generates the negative component of he sine wave from the de Bus votage. The longer thatthe switch i "on," the higher the output votage: ‘onwersely, the longer thatthe switch I of" the Tower the output vliage, Ths duration of ontime foreach pulse Is called pulse wietn. The hme dduratorvintervals of these postive ang negative dc valage pulses determine the synthesized ac output voltage and frequency ‘The speed at which these switches can tum on and offs called the carrier ‘raquency. When the cartier frequency Is increased, the associates output can hhave much higher resoluton, resulting ina smoother output waveform with less "ippleldstorion. This smoother output can imprave motor torque performance at Tow speed and decrease aucble mator lamination raise. In additon, faster ‘Swilehing has the potential for better inverter output controllably with assocated improved dynamic response. (Older VED inverter designs typical used sicon controled rectifers (SCR) of bipolar junction transistors (27) as the ‘swifching components. SCRS can operate inthe 250 to 600 Hz range, whe 84s can operate inthe 1 to 2 KHZ range. Most ‘modem VFDSs use insilated gate bipolar transistors (IGT) for the verter section. IGBTs can tum on and of at much higher {fequency, up to 20 kz. The higher cari frequencies associated wi IGBTs offer some key advantages over alder SCR and BUT Inverers, but also have a severe trade-of! fo be aiscussed later, IGBTS typically are not used in VFD rectifier front-ends. VFD rectifiers typically use SCRs or similar slower switching ‘components. SCRs offer an advantage in that ther simpler designs mare fobust given variable input vltage qualty and have a relatively low cost. However, jut as twas alluded that the higher carer flequency of the IGBT on the inverter can cause Issues, s0.can a lover frequency of SCRs on the rectfir front end. These slower switching requencles on the Font end can ‘cause excessive harman distortion inthe voltage source. Depending on the magnitude ofthe total harmonic distortion ifoduced by the VFO and what other loads (ighting, computers, etc) are sharing the same service, miigalion may be required in atcordance IEEE 516-1992. Some mtgaiion may be achieved by using a 12-pulse inverter Instead af @ B-pulse, or ‘ding ine reactors o” a phase shift zig-zag type transformer used for dive isolation. Drive isolation transformers were ‘designed to protect tne VFD from interference from upstteam power disturbances. They do very ite to milgate the magnitude ‘ofharmonie currents thal VFOs reflect back into the power system. How to kil a motor Motors are commonly klled by one of twa things: insulation fallure or bearing fale. The dramatcaly simplified cause of these failures is heat andor excessive voltage. The question is: How does use of & VFO confnbte to these faire modes, and how ‘can these contibuting factors be mitigated? Motors are not 100 percent efficient and require cooling. TEFC motors are cooled by a shaft-mounted fan. Ita particular load application has a elavely high turndown ratio resulting in avery slow shaft speed, the coaling fom the fan may be adversely ‘atfected. I cannot be assumes that a mator wil accommodate an ifinte turndown fatto without overheating fs ineulation System. Remember the "10 degree” rule of thumb dgcussed earler. Motor manufacturers have recammendes operation speed igs for thet motors. Operation restrictions onthe turngoum ofthe equipment connected fo the motor should reed these ‘operation speed range recommendations. {As slated earler, IGBTs can switch on and off extremely fast. The speed with which they can switch from 0 Vf full de bus ‘Yoiage is refered to as se time, or dyidt. Theres a phenomenon called refleced vrave" Mats exacerbated by the IGBTs ‘characteristic fast ise te (around 0.1 microseconds). Tha stuaton occurs when thee Is a mismatch between the Intereonnectina cable Imoedance and the motor. The motor terminals tlc the vollaae rise back onthe cable. Ths relecton pura cortrolenn.comvindustry-newesmore-nevssingle-artictethw-t-seect 2 vlBATICt7266%0a ebSHOO88ESNBCETAHm!anos How to sect a VED | Contra Engineering ‘on longer cable lengths can reinforce subsequence pulses, resulting in increasing electrical resonance asthe carer frequency ‘Sinereased. Ths refected wave can result n a voltage transient Up to tw times te de bus vallage. Again, ths de bus vokage ‘can be 1.414 times the ac input voltage. In a 480 V system, this can result in ansients in excess of 1200 V. Faster ise imes educe the eable length at which tis phenomenon fs experienced. One manufacturer's general rule of thumé fs hat his can become an issue if eabe engin between tne VFD and motor exceeds 16. In real-world applications, having this short of Tengths pretty amotious, Other manufacturers have recommendations forthe maximum acceptable carer frequency. Another recommended solution isto provide fering devices between the VFD and motor to mitigate the vallage overshoot, bu that flso add cost and complexty {VED manufacturers’ instalation recommendations aside, how much voltage can a motors winding insulation reall tolerate? ‘The winding insulation system on existing general purpose motors may generally witnstand pulses of 1000 V, wien f totally Inadequate for G31 deves on 480 V systems. Ite ae inp valiage [athe VED fs 240 V of ess, the de bus voltage fs Kept ow ‘and the magnitude of hese “rellectes waves" generally isnot an issue, However, wih higher motor oveepower, hese lower lization votages are not always feasible. the ac input volage is 480.V veih possible higher transient overvliage, "inverter duty ated" motors became an option. Sut what is an “inverter duly rated” motor? The definton varies depending on whom you ‘ask NEMA MG1 Part 30 species a peak of 1000 V at 2 microseconds rise time, which is OK for SCR and BJT drives but ‘defintely not for IGT crves on 480 V systems. Ideally, inverter duty rated motors shoul conform to NEMA MG'-2006, Par 31. Part 31 species a maximum delectic ‘withstand capably fora peak ine-todie vollage of 1800 V and a ise ime of 0.1 microseconds with Improved bearing Toncant for higher temperature operation. Now thatthe insulation system is now “bulletproof with a NEMA MG1-2006, Part 31 compliant motor. what happened to that anoying high-frequency “reflected wave"? The answer is hat is sll there, creating a capactive coupling between that stator {and oto, Again, the nly place that tne stator and rolor assemblies make contact fsa the bearings. Once the bearing grease ‘experiences delecc breakdown, there isan electrical discharge a the bearing races and flow of current through the bearings {bearing curren), sulting in a phenomenon known as electric discharge macrining (EDM). Al the point of discharge on the bearing rac, the surface ofthe race becomes piled. tr a period of ime, all ofthese tiny pis form grooves or "Nutes" nthe bearing race perpendicular tothe direction of bearing travel. These eventually estoy the motor bear ngs. “There are several ways to address EDM 1. Lower cartier requencies. 2 Keep the VED and motor as close together as possibie forthe shortest possible cable length 5, Install mgulates bearings to prevent the low of current betwoen the Bearing races, However, ths does not necessary ‘adress the root cause. 4 Installa shat grounding device that provides alow impedance path that bypasses the bearings and propery ground the \VED and motor fame, However, typleal shat grounaing brushes wll eventually wear out and become a maintenance tem 5. Install shielded cable that provides alow impedance path for high frequencies between the VED and motor. Each ofthese solutions has a cost associated wit it, As such, a determination that balances life and reliabilty with acceptable ccosthas fo be made for any specie applieaton. Yoon is the senior staf electrical engineer for McGuire Engineers. He has 16 years of experience in the design of electrical ‘isinution systems. His project expenence covers a broad spectrum, including high-ise building infrastructure renewal programs, tenant buit-outs, mission critical deta centers, GMP laborstones, and Industral facies. References: U.S. Department of Energy NEMA Consortium for Energy Eciency Allen-Bradley ABE Industyy Oy—Technical Guide #5, Bearing currents in Modem ac Deve Systems, 1989 GE Industral Baldor Electic Company Danfoss AVS Relate News: A VEDs: Te path to prolonged Ife 18.11 2018 14:4 ‘BHvAC vF0s, bypass panels - 20.01.2011 15°54 B ios Viste Arete onthe Website during November 10.12.2010 10:44 2B ign-siaing HVAC 0.122010 1203 pura cortolenn comindustry-newsimore-nevssingle-atcethow-to-seect 2 vfBATIC7366%0a ebSHO088EENBCOTAHm!anos How lo sect a VED | Contra Engineering Post a comment Log in or creat account to submit your comment for this artic ROBERTO , TX, Brazil, 01/16/13 05:14 PM: Excellent article. t covers a lot of fils rect to the porns, Manel David, CA, United States, 08/14/13 4 39 AM: ‘As a"mechanical-type",| appreciated how the article was formatted witha basic introduction of ae motor design. | also enjoyed the atele a it relates to some ofthe situations that | have seen/experienced as an equipment operator, such as Dearing failure (that was attributed to stray motor cuent). ‘And was interesting to compare the diferent types of mechanical loads wih respect o motor spec-out “Te article has prompted me to research further “Thank you. Davis Yancosky Gon , Nor-USINot Applicable, Zimbabwo, 08/15/13 08:52 AM. ‘This the best article | have ever read regarding VFDS, many thanks Gen ‘Traning, Tole Events and Awards News, Views, Slogs Newsies Advertising pura cortolenn comindustry-newsimore-nevssingle-atcethow-to-seect 2 vfBATIC7366%0a ebSHO088EENBCOTAHm! eranos How lo sect a VED | Contra Engineering pura cortolenn comindustry-newsimore-nevssingle-atcethow-to-seect 2 vfBATIC7366%0a ebSHO088EENBCOTAHm! ”