How to Specify a Variable Frequency Drive

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Table of Content
Load Type for Variable Frequency Drives
Motor Information
Supply Power
Control Methods for Variable Frequency Drives
Speed Reference Alternatives
Efficiency and Power Factor
Protection and Power Quality
Harmonics

Load Type for Variable Frequency Drives

Does your Variable Frequency Drive application require a variable torque or constant
torque drive?

If the equipment being driven is centrifugal, such as a fan or pump, then a variable
torque drive will be more appropriate.

One primary VFD Benefit and usually the primary motivation for installing Variable
Frequency Drives for centrifugal applications is energy savings, and variable torque
drives offer the greatest energy savings.

For example, a fan needs less torque when running at 50% speed than it does when
running at full speed. Variable torque operation allows the motor to apply only the
torque needed, which results in reduced energy consumption. Conveyors, positive
displacement pumps, punch presses, extruders, and other similar type applications
require constant level of torque at all speeds. In which case, constant torque variable
frequency drives would be more appropriate for the job.

A constant torque drive should have an overload current capacity of 150% or more for
one minute. Variable torque variable frequency drives need only an overload current
capacity of 120% for one minute since centrifugal applications rarely exceed the rated
current. When buying a VFD for a system needing tight process control, then you may
need to look into purchasing a sensorless vector, or flux vector Variable Frequency Drive,
which allow a high level of accuracy in controlling speed, torque, and positioning.

Motor Information
The following motor information will be needed to select the proper variable frequency
drive:
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 Full Load Amp Rating. Using a motor's horsepower is an inaccurate way to size
variable frequency drives.
Voltage Rating.
Speed Range. Generally speaking, a motor should not be run at any less than 20%
its specified maximum speed allowed. If it is run at a speed less than this without
auxiliary motor cooling, the motor will overheat. Auxiliary motor cooling should be
used if the motor must be operated at slow speeds.
Multiple Motors. To size a variable frequency drive that will control more than one
motor, add together the full-load amp ratings of each of the motors. All motors
controlled by a single drive must have an equal voltage rating.

Supply Power
If continuous operation is a must, then the following should be specified:

+/- 10% voltage fluctuation

+/- 3% frequency variation
Voltage sag ride-through for the following:
0% voltage for 1 cycle
60% voltage for 10 cycles
87% voltage continuous

If you need to supply a 3-phase drive with single-phase power, then the drive should be
derated by 25% to 50% of its current-handling ability, which may require you to specify a
larger-sized drive.

Control Methods for Variable Frequency Drives

With 2-wire control, only one switch is used to run the variable frequency drive. An open
switch stops the drive, and a closed switch starts the drive. Two-wire control is
predominately used in HVAC applications since t is able to maintain the RUN command
to the drive during a loss of power, which enables Variable Frequency Drives to
automatically restart when power is restored. Plus, 2-wire control allows drives that have
"power loss ride-through" to operate during a power drop that is 2 seconds or less in
duration.

With 3-wire control, two switches are used to run the drive. One switch is needed to stop,
and another to start the variable frequency drive. This allows an auxiliary contact from
the start to "seal in" the RUN command, just like your more conventional motor starters.

Speed Reference Alternatives

Speed Potentiometer. Allows the operator to set motor speed with pot.

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 Digital Programming / Display Unit. Allows the operator to program and
troubleshoot the drive by inputting values through a keypad with an LED or LCD
display unit. Drive operation can also be monitored through this display.
Analog Signal Follower. 4-20mA or 0-10VDC; must provide variable frequency drives
with an isolated input; must use a twisted/shielded pair and keep wire away from
3-phase AC.
Selector switch speed selection. Allows operator to select from several preset
speeds. Can also be used if the speed is being set via a PLC, and an analog output
is not available.
Serial Communications. Allow variable frequency drives to communicate on a
network, such as MODBUS, PROFIBUS, DEVICENET, or METASYS, enabling drive
operation to be coordinated and monitored from a PC.

Efficiency and Power Factor

A drive should have an efficiency rating of 95% or better at full load. Variable frequency
drives should also offer a true system power factor of 95% or better across the
operational speed range, to avoid penalties from the power utility, save on energy bills,
and to protect you equipment (especially motors).

Protection and Power Quality

Motor overload for instantaneous trip and motor over current.
Additional Protection: Over voltage, under voltage, over temperature, ground fault,
control or microprocessor fault. These protective circuits should provide an orderly
shutdown of the VFD, provide indication of the fault condition, and require a
manual reset (except under voltage) before restart. Under voltage from a power
loss shall be set to automatically restart after return to normal. The history of the
previous three faults shall remain in memory for future review.
If a built-up system is required. there should also be externally-operated short
circuit protection, door-interlocked fused disconnect, circuit breaker or motor
circuit protector (MCP) rated at a minimum of 65,000 AIC, and a door-interlocked
handle capable of being locked.

Harmonics
The drive/system should be compliant with IEEE 519-1992. The IEEE 519-1992 Table
of Current Distortion Limits for general distribution systems (120V through
69,000V) is given below:

Current Distortion Limits for General Distribution Systems

(120V through 69,000V)

Maximum Harmonic Current Distortion in Percent of IL

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ISC/IL Individual Harmonic Order (Odd Harmonics)
(Load)
< 11 11 < h < 17 17 < h < 23 23 < h < 35 35 < h TDD

< 20 4.0 2.0 1.5 0.6 0.5 5.0

20 < 50 7.0 3.5 2.5 1.0 0.5 8.0

50 < 100 10.0 4.5 4.0 1.5 0.7 12.0

100 < 1000 12.0 5.5 5.0 2.0 1.0 15.0

> 1000 5.0 7.0 6.0 2.5 1.4 20.0

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