AC Drives Basics-1

Why Use A Drive ?

Speed and torque control

Reduce mechanical stress on machines(soft start)
Motor protection
Save energy and improve efficiency of systems
 How to change the speed of Motors ?
Hydraulic

Mechanical
Belt and chain drives , Variable speed gear

Electrical
-slip ring , DC Drives , AC Drives
 DC Drive

Armature voltage =

Motor speed
 Advantages and Disadvantages of DC Motor &Drive

Advantages:
1. Speed control over a wide range both above and below the rated speed
2. High starting torque
3. Constant torque over a given speed range
4. Quick starting, stopping, reversing and acceleration
5. DC drives are less complex

Disadvantages
1. High initial cost
2. Increased operation and maintenance cost due to presence of commutator and brush gear
3. Cannot operate in explosive and hazard conditions due to sparking occur at brush ( risk in commutation failure)
 Why AC Drives ?
rpm = 120 x F
P
F=Frequency ,P=no of poles

P=2 ,4 ,6 ,etc. so RPM = 3000 ,1500 ,1000 , 750 etc.

To get wide range of speed .Frequency must be changed

 Power Electronics

Rectifier:
 How to convert DC to AC ?

H-Bride

+ - - +
Variable Frequency Drive
 Most common terminologies of AC drive

Inverters

Variable Frequency Drive (VFD)

Frequency Converter (FC)

Variable Speed Drive(VSD)

Adjustable Frequency Drive (AFD)

Adjustable Speed Drive (ASD)

AC Drive Manufactures
 AC Drives Basics-2
Drive main component :

1-control unit
Control board , Keypad ,IO terminal ,option card
2-power Unit
Rectifier ,Power board ,DC Link ,inverter

1
AC Drive power circuit :

1-Rectifier
2-DC Link (chagrin circuit+ filter + capacitors)
3-Brake unit
4-Inverter

AC DC
AC Drives Basics-1
AC
1 2 3
4
 AC Drive Power Circuit

1-Rectifier
 AC Drive Power Circuit

2- Intermediate Circuit Capacitors bank

Brake Unit

Charging resistor circuit

A-charging resistor circuit

 AC Drive Power Circuit

B-Brake unit
B-Brake unit
A motor can become a generator and send power back to the main line whenever the
rotor is rotating faster than the stator field. Under such a condition, the load is said
to regenerate. This may occur whenever the VFD attempts to decelerate the motor, or
when the load overhauls the motor.
Transistor Resistor
Transistor Resistor
750 V DC

Sensor
 AC Drive Power Circuit

B-Brake Resistor
B-Brake Resistor
Disadvantages : wasting Energy

Solution : Better to use Active front End (AFE) or Regenerative Unit

AC Drive Power Circuit

3-inverter (PWM) DC AC
AC Drive Power Circuit

3-inverter (PWM)

Pulse width Modulation

This is the most widely-established and best developed method
AC Drive Power Circuit

3-inverter (PWM)

Voltage

Current
AC Drive Power Circuit

Carrier Frequency

The carrier, or switching frequency used for IGBT-based VFD, generally ranges between 3 to 15 kHz
AC Drive Power Circuit

Carrier Frequency
At low Frequency
At lower carrier frequencies VFD losses are lower but due to more
harmonics, motors heat up more and also generate more noise which
can be annoying sometimes

At High Frequency
High frequency advantages : High frequency disadvantages :
1-low noise 1-losses .heating for motor
2-low harmonics 2-derating for cables ,motors
 AC Drives Basics-3
Operation Basics
Control methods
Does changing frequency will affect motor performance ?

the variables of operation are:

1-Voltage controls power output V P
2-Frequency controls speed F S
3- Current and Flux controls torque. I T

Induced voltage =EMF (V)=4.44 * F *N * *cos

=V/F = 460/60= 7.7

1/f
If the flux decrease and that will affect the torque
If frequency the flux will increase and causes motor heating
 Operation Basics

Control methods 1-V/F

Changing F change the width of the wave

 Operation Basics

Control methods 1-V/F

Changing V ON duration time

Operation Basics

Control methods

1-V/F

30HZ 230 V

=V/F =230/30=7.7
Operation Basics
Control methods 1-V/F

Curve of the behavior of the Induction Motor

Operation Basics

Control methods 1-V/F

Curve at different speed

Operation Basics

Control methods 1-V/F

Limitations
1-field weakening 460 V

Above rated speed we can`t increase

the voltage (rated voltage ),so the
torque will decrease
=V/F

50 HZ
Operation Basics

Control methods 1-V/F

Constant torque VS constant power

Motor HP = Torque x RPM

Operation Basics
V
Control methods 1-V/F
Limitations
2- Starting Torque at low speed
F
VD 5-15%
Starting Torque 3 HZ 34.5 V 28 V

B oost
q ue
Tor

40 V
Operation Basics

Control methods 2-Vector control

Why Vector control ?

Using a complex mathematical motor model and proprietary internal computer algorithms
vector control is able to exert the necessary control over an AC motor so that its performance is
equal to that of a DC motor.

Flux Vector control flux current control Field oriented control

Advantage of Vector control over V/F

1-Flux current control automatically adapts the drive output to the load.
2-The motor is always operated at optimum efficiency.(Energy saving)
3- Speed remains reliably constant even under varying load conditions
4-Full torque at low speed (200% torque at zero speed)
5-high dynamic performance including fast acceleration and deceleration.
 Operation Basics

Control methods 2-Vector control

Stator current =Active current +Reactive current

current component references from the flux and

torque references given by the drive's speed control.
Operation Basics

Control methods 2-Vector control

In vector control, an AC induction or synchronous motor is

controlled under all operating conditions like a separately
excited DC motor

when torque is controlled, the field flux linkage is not

affected
 AC Drives Basics-4
Operation Basics
Control methods
Control
Methods

Vector control
Scalar control

DTC (Direct
FOC (Field-
V/F without V/F with torque
oriented
Feedback Feedback control)
control)

Direct self Space vector

sensorless Closed Loop
control) modulation
 Operation Basics

Control methods
V/F control mode
V/F without Feedback
No Feedback
Low Starting torque
Low speed accuracy
Torque boost =torque compensating=voltage boost Increase Starting torque
Slip Compensating Increase speed accuracy and response

V/F with PG
45 HZ
45 HZ
to increase speed accuracy
VFD
Operation Basics

Control methods
V/F without Feedback:
Advantage Disadvantage Specs
Auto tuning not required No guarantee motor shaft is Speed Accuracy : 2 to 3% of max.
responding due to lack of frequency
feedback
Several motors controlled from one VFD
Speed response: 3 Hz
Starting torque is 150% at 3Hz

No encoder required Speed control range: 1:40

Output voltage determined by: V/f

Good for motors with unknown data pattern
Operation Basics

Control methods
V/F with Feedback:
Advantage Specs
Auto tuning not required Disadvantage Speed Accuracy :0.03% o max. frequency
Encoder required

Better speed control than V/F withou PG

Speed response: 3 Hz
Starting torque is 150% at 3Hz
Speed control range: 1:40

Output voltage determined by: V/f pattern

 Operation Basics

Control methods
V/F control mode

V/F Pattern
a ratio of voltage-to-frequency for the motor to
follow
a VFD can have only one V/f pattern programmed at
a time.
The V/f patter, or curve, determines what voltage is
output to the motor based on a given speed
reference Constant torque

Variable torque

High Starting torque

Operation Basics

Control methods
Vector control mode
Open Loop Vector control (Sensorless Vector control )

Sensorless vector control calculates rotor speed based on the motor model,
When motor speed is calculated at very low speeds,, slight variations in stator resistance and other
parameters will have an effect on speed calculation.
This makes vector control without a Feedback impractical below a few hertz.

Closed Loop vector control

-To increase speed accuracy ,torque response

VFD
Operation Basics

Control methods
Vector control mode

. Auto tuning: A process in which the VFD tests an attached and unloaded motor to
determine the best tuning parameters

Auto tuning
Rotational
Auto-Tuning

Stationary
Auto-Tuning
Operation Basics

Control methods
Vector control mode

Speed Mode
Fix speed and change torque
Tension control
Torque Mode
Fix torque and change speed
Operation Basics

Control methods
Open Loop Vector control (Sensorless Vector control )
Specs
Advantage
Disadvantage Speed Accuracy : 0.2% of max.
No encoder required
Auto-tuning required for best
performance
frequency Speed response:>10 Hz
Good starting torque: 200% of rated toque
at 0.3 Hz No guarantee motor shaft is
responding due to lack of
Four-quadrant torque limits possible feedback Speed control range: 1:200

Good for impact loads

Operation Basics

Control methods
Closed Loop vector control
Advantage Disadvantage Specs
Can operate in torque-control mode Speed Accuracy : 0.02% of max.
Auto-tuning required for best Frequency
performance
Excellent starting torque: 200% of rated torque
at 0 rpm Speed response >60 Hz

Four-quadrant torque limits possible Encoder and feedback card required

Speed control range: 1:1500

Best for impact loads

Zero-speed operation possible

Operation Basics
Control methods
 AC Drives-5 Hardware
AC Drive Hardware:

1-control unit
Control board , Keypad ,IO terminal ,option card
2-power Unit
Rectifier ,Power board ,DC Link ,inverter

1
 AC Drives-5 Hardware
AC Drive Hardware:
Power Wiring :
1-Supply side
2-DC Bus connection
3-Motor side
AC Drive Hardware:
Power Wiring : Circuit breaker or
Fuse
System component :
Line contactor

Supply side
Line Reactor

Zero phase
reactor

EMI filter

Motor reactor

Motor side dv/dt filter

Sine wave filter

AC Drive Hardware:
Power Wiring :
Motor Connections :

Delta
Star connection
connection
: :
AC Drive Hardware:
Power Wiring :
Motor Connections :

How to read nameplate of motor ?

AC Drive Hardware:
Power Wiring :
AC power supply

110 V
Single phase
220 V
AC Drive power
220 V
Three phase
380 V

The output of AC Drive always three phase

AC Drive Hardware:
Power Wiring :
how to read nameplate of AC Drive?
why input current of VFD is different than output ?

The input current may be less than the output current because the output voltage of
the drive may not be equal to the input voltage.
AC Drive Hardware:
Power Wiring :
AC power supply

1- VFD 1 PH 220V

220 V 1 D/Y
PH 0-220 V 3 PH
220/380

2- VFD 3 PH 220V
220 V 3
PH 0-220 V 3 PH D/Y
220 V 1 220/380
PH
AC Drive Hardware:
Power Wiring :
AC power supply
VFD 3 PH 380 V
D/Y
220/380

380 V
3PH 0-380 V 3 PH

22 ax v
D/Y

0V
M 380/690
In this case we
should double the
D/Y
power of drive 220/380
AC Drive Hardware:
Power Wiring :
DC power supply

Common DC Bus
Dc source

Solar Panel

Battery
Rectifier AFE
AC Drive Hardware:
Power Wiring :
Power Terminals

-1 +/B1~ B2
R/L1 U/T1

S/L2 V/T2

T/L3 W/T3
AC Drive Hardware:
Power Wiring : B2
Power Terminals B1

-1 +1

R/L1 U/T1

S/L2 V/T2

T/L3 W/T3
AC Drive Hardware:
Power Wiring :
CAUTION!

2-It is recommended to add a magnetic contactor (MC) in the power input wiring to cut off
1-Connect these terminals (R/L1, S/L2, T/L3) via a no-fuse breaker or earth leakage
power quickly and reduce malfunction when activating the protection function of AC motor drives.
breaker to 3-phase AC power
Both ends of the MC should have an R-C surge absorber.

3-Do NOT run/stop AC motor drives by turning the power ON/OFF. Run/stop AC motor
drives by RUN/STOP command via control terminals or keypad

4-Do NOT connect 3-phase models to a 1-phase power source.

5-Take care of DC bus terminal while connection

 AC Drives-6 Hardware-2
AC Drive Hardware:
Control Hardware:
Control card concept

I
n
p
u
t
Control card
o
u
t
p
u
t
AC Drive Hardware:
Control Hardware:
AC Drive control board component
AC Drive Hardware:
Control Hardware:

DI DO AI AO

Output Com terminals

relay

Option cards Keypad

AC Drive Hardware:
Control Hardware:
1-Keypad

=Operator Panels=Control Panel

Main Function :Parameter Entry and Monitoring
Fixed or Detachable
7-Segemnt or LCD
AC Drive Hardware:
Control Hardware: 2-Digital input
Multi-Function Digital Input
ON/OFF signal
Energizing : positive edge /negative edge
Type DI :PNP/NPN ,Source/Sink
Source of DI :NO/NC(Push button ,Relay ,sensor ,PLC..etc)
Function : Run ,FWD ,REV .REST ,Emergency ..etc
Digital Input Connection

Photocouplers Is a component that transfers electrical signals between two isolated circuits
by using light
+

-
AC Drive Hardware:
Control Hardware: 2-Digital input

PNP or NPN ?

+
-+
AC Drive Hardware:
Control Hardware: 2-Digital input

Internal power supply

NPN
PNP

0V
24V

DI1 DI2 CM 24 v
AC Drive Hardware:
Control Hardware: 2-Digital input

External power supply

PNP

0V
24V

DI1 DI2 CM 24 v

24v
AC Drive Hardware:
Control Hardware: 2-Digital input

External power supply

NPN

0V
0V 24V 24V

DI1 DI2 CM 24 v

0V 24v
AC Drive Hardware:
Control Hardware: 2-Digital output
Multi-Function Digital Output
Type DO:Transistor or Relay
Function : Run ,Fault ,Torque Detection ,Frequency agree ..etc

A-Transistor output

TC T1 T2
AC Drive Hardware:
Control Hardware: 2-Digital output

B-Relay output

RC R1
AC Drive Hardware:
Control Hardware: 3-Analog input
Multi-Function Analog Input(Programmable)
Type: 0-10 V ,4-20 mA
Source :Potentiometer ,PLC ,Sensors
Function : Frequency Reference ,Torque reference

Source
Source :PLC or Sensors
:Potentiometer

10V AI1 AI2 AC

0-10 V OR 4-20 mA
AC Drive Hardware:
Control Hardware: 4-Analog Output
Multi-Function Analog output (Programmable)
Type: 0-10 V ,4-20 mA
Function : Speed Meter ,current meter ,power meteretc

AM FM AC

0-10 V OR 4-20 mA
AC Drive Hardware:
Control Hardware: 5-Communication terminals

Modbus RS485/RS422
SEND /RECIVE data
Control /mentoring

R+ R- S+ S- GS

PLC-HMI
AC Drive Hardware:
Control Hardware: 5-Pulse train IN/OUT
AC Drive Hardware:
Control Hardware: 6-Saftey Terminals
STO function
STO function is a High Integrity Pulse disablement unit which isolates power of firing pulses to
Semiconductor devices (IGBTs) in the drive.

to be sure that the power stage is disabled.

AC Drive Hardware:
Control Hardware: 7-Communication terminals

MEMOBUS/Modbus Termination
AC Drive Hardware:
Control Hardware:
8-Option cards
AC Drive Hardware:
Control Hardware:
Overview
AC Drive Hardware:
Control Hardware:
Tips &tricks

1-IF you have 4-20 mA sensor and you want to use analog input 01-10 v ?

2-if you have PNP signal from PLC and VFD accept only NPN ?

3-if you want same digital input energized with FWD and REV

FW REV DI
 AC Drives-7 Programming-1
Programming basics : Numbers Letters
Initializing/basic 00 A
Monitring 01 B
Motor
02 C
03 F
DI/DO
etc H
AI/AO I
Parameter groups Multi-step etc
02(H)-05
Protection

Communication
Group number 2
Auto-tune or H
Option cards Parameter number 5 in
group 2
Programming basics :
keypad

Arrows

Menu/mode

Enter/Prog/Data

Loc/Rem or Hand/Auto

Run

Stop/Rest

Jog
 1-Digital(Keypad-pre set
Programming basics : speed)
V/F pattern mAcc
2-Analog
1-Motor KW
,Dec .S-curve. toque
1-Constant torque1-V/F without PG
2-Motor RPM or no of3-Communication
1-Keypad poles
Overload ,over voltage
compensation
4-Pulse,Auto-
train
2-terminals 1-Multi-function
2-Variable torque 2-V/F with PG 3-rated current
tune under voltageDI/DO
,stall
3-sensorless Vector
3-High starting torque 4-Base 3-Communication
control(Open
frequency loop)
2-Multi
prevention
function,over
AI/AO
4-Closed loop vector
5-..ect.
control torque ,under toque
Programming basics :
Type of Applications
When applying an AC drive and motor to an application it is necessary to know
the KW, torque, and speed characteristics of the load.
1. Constant Torque
2. Quadratic torque
3. Constant power
4. Constant power/torque
5. Starting/breakaway torque demand
1-Constant Torque

A constant torque load type is typical when fixed

volumes are being handled. For example hoists. ,
feeders and conveyors are typical constant torque
applications.
Programming basics :
1-Application
2. Quadratic torque

The torque is quadratically, and the power

is cubically proportional to the speed like centrifugal pumps
and fans

3. Constant power
A constant power load is normal when material is being
rolled and the diameter changes during rolling. The power is
constant and the torque is inversely proportional to the
speed like winder
Programming basics :
1-Application
4-Constant power/torque

This load type is common in the paper industry. It is a

combination of constant power and constant torque load
types. This load type is often a consequence of
dimensioning the system according to the need for certain
power at high speed.

3. High starting torque

In some applications high torque at low frequencies is

needed. This has to be considered in dimensioning. Typical
applications for this load type are for example extruders and
screw pumps.
Programming basics :
1-Application
Programming basics : Start-up parameter
2-Control mode
0: V/f Control without PG
1:V/F with PG
2: Open Loop Vector (OLV) or sensorless Vector control
3:Closed loop vector control (CLV)or FOC
4: PM Open Loop Vector (PM)
5:PM closed loop vector control
3-Motor data

1-Motor KW
2-Motor RPM or no of poles
3-Rated current
4-Base frequency
5-..ect.
Programming basics : Start-up parameter
4-Run command

1-Keypad
2-terminals
3-Communication

5-Frequency reference

1-Digital(Keypad-pre set speed)

2-Analog
3-Communication
4-Pulse train
Programming basics : Start-up parameter

Input Voltage
Max. Operation Frequency
Maximum Output Voltage
Middle Output Frequency
Middle Output Frequency Voltage
Min. Output Frequency
Min. Output Voltage
Programming basics : Start-up parameter
6-Ramp setting

Acceleration the time required by output frequency from 0 Hz to the maximum frequency,

deceleration time is from maximum frequency dropped to 0 Hz.

Acc/dec mode selection : 1-Linear Mode

Max speed
DE
E C
I M TI
T M
C E
AC
Programming basics : Start-up parameter
6-Ramp setting
Acc/dec mode selection :

2-Mult-ACC/DEC
E 1

DEC
C TIM Speed2

TI
AC

ME2
DE
E CT
I M Speed1 IM
C T Speed3 E
AC

3-s-curve DE
CS
ta
rt
n d
CE
AC DE
CE
nd
rt
sta
C
AC
Programming basics : Start-up parameter
6-Ramp setting

Acceleration time Tips :

1-limits the speed up current below the VFD's over-current capacity, make the over current speed
loss don't cause the VFD drives tripped;

2-The deceleration time set point is to prevent smoothing circuit voltage excessive, make
regeneration overvoltage don't cause the variable frequency drive tripped.

3- Acc/dec time can be calculated according to the load, but to practical experience
Programming basics :
5-Control/Multifunction I/O

Function of digital input

Run parameter (Forward and revere direction)

Run command :
2 wire operation(method1)
Terminal

FW REV CM
Programming basics :
5-Control/Multifunction I/O
Function of digital input
Run parameter (Forward and revere direction)

Run Rev
Fwd CM
Programming basics :
5-Control/Multifunction I/O
Function of digital input
Run parameter (Forward and reverse direction)

FWD REV latch CM

 AC Drives-8 Programming-2
5-Control/Multifunction I/O
Programming basics : 1-Digital(Keypad-pre set speed)
Function of digital input 2-Analog
3-Communication
Multi-step speed
4-Pulse train
5-Keypad potentiometer

Step-1 Step-2 Step-3

CM
Programming basics :
5-Control/Multifunction I/O

Function of digital input

Multi-step speed
Step-1 Step-2 Step-2 speed

0 0 0 S1

1 0 0 S2

0 1 0 S3

0 0 1 S4

1 1 0 S5

1 0 1 S6

0 1 1 S7

1 1 1 S8
Programming basics :
5-Control/Multifunction I/O
Function of digital input
Jog operation(no direction)

Jog has priority over all other reference sources.

AI AC

FWD REV s1 Jog CM

Programming basics :
5-Control/Multifunction I/O
Function of digital input
Jog operation(with direction)

Frequency reference:
Digital or analogue or Fwd/rev Jog
communication

FWD REV F jog R jog CM

Programming basics :
5-Control/Multifunction I/O
Function of digital input
Up/Down speed

Frequency reference:
Up/Down
UP/Down

FWD REV UP dOW CM

Programming basics :
5-Control/Multifunction I/O
Function of digital input
Up/Down speed

Parameter related to UP/Down speed

UP/down rate : ACC/Dec or by constant ration

Frequency Reference Hold/save frequency
Reference Limit
Programming basics :
5-Control/Multifunction I/O Function of digital input

Offset frequency
Fast stop
Multi ACC/Dec
2nd motor operation
Emergency stop/Baseblock DI5 CM
External fault
Analog Hold
PID enable/Disable
Switch between frequency reference
Switch between torque and speed mode
Switch between control modes(V/F,OLV,FOC)
Programming basics :
5-Control/Multifunction I/O
Function of digital Output

During Run
RC R1
During Frequency Output

Fault

Zero speed

Frequency detection /Desired frequency

attained

DC Bus Undervoltage

Torque Detection

Drive Ready

Certain fault
Programming basics :
5-Control/Multifunction I/O 50 Hz
Analog input
25Hz
0-10V
-10 to +10 V
4-20 mA
0v 5v 10 v

Bias and Gain

Noise
50 Hz
50 Hz

5 Hz
0v 1v 10 v
0v 10 v
Bias=10% Gain=100% Bias=-10% Gain=100%
Programming basics :
5-Control/Multifunction I/O
Analog Input Bias and Gain

50 Hz 45 H 50 H

0v 5v 10 v 0v 5v 10v 0v 5v 10v
Bias=0% Gain=200% Bias=0% Gain=90% Bias=100% Gain=0%

FWD
Reference -10 0 +10 v 50 Hz

-10v 10v

50 Hz Rev
Programming basics :
5-Control/Multifunction I/O
Analog input function

Reference operation :
Add
Subtract
Multiply
Programming basics :
5-Control/Multifunction I/O 10v
Analog Output
5v
0-10V
-10 to+10 V
4-20 mA
0 50% 100%

Bias and Gain

10v
10v

1v
0v 10% 100%
0 100%
Bias=10% Gain=100% Bias=-10% Gain=100%
Programming basics :
5-Control/Multifunction I/O
Analog output Bias and Gain

10v 9v

0 50% 100% 0 100%

Bias=0% Gain=200% Bias=0% Gain=90%

Programming basics :
5-Control/Multifunction I/O
Analog output function

speed

Current

voltage

Power
 AC Drives-10 Programming-3

Programming basics :
1-Ramp to stop
Braking Parameters 1-Ramp
2-coast to to stop
stop
2-coast
3-DC to stop
injection braking
3-DC injection braking

Dynamic braking
Dynamic braking is adjusting the VFD AC output so as to slow the motor, and recover the energy onto the
DC bus. The braking resistor then dissipates that energy, preventing the DC bus from rising.
Programming basics :
Braking Parameters
DC injection braking
is a method of slowing AC electric motors. A DC voltage is
injected into the winding of the AC motor after the AC voltage is
disconnected, providing braking force to the roto

Usage
DC Injection is good when all that is needed is a small amount of injection braking to stop
the load.
In bake sequence for Elevator and cranes

Advantage Disadvantage
1. Low cost 1. Working under 15 HZ
2. Faster and higher stop 2. In cause of miss use may be cause
torque motor damage (Heating)
3. Precision 3. noise
Programming basics :
DC Braking Parameters

DC Injection Braking Start Frequency

DC Injection Braking Current
DC Injection Braking Time at Start
DC Injection Braking Time at Stop

Max speed
DE
C Frequency at stop
Minimum output
E TI
frequency
I M M
T E
C
AC

Time at
Time at
start
start
Programming basics :
Protection and troubleshooting

1. Is what I am about to do safe for me?

2. Is what I am about to do safe for those people around me?
3. Is what I am about to do safe for the equipment?
Programming basics :
Protection and troubleshooting
Faults
Alarms

Under
voltage

Over
Overload
current

Over voltage
Programming basics :
Protection and troubleshooting
Overcurrent >200%

Check motor insulation

NO
Insulation Ok ?
Change motor
YES

Replace damaged cables. NO Motor cables

-shorten the cable length or install ok?
filter at output

YES

NO Disconnect
Disconnect cable
cable from
from
the
the drive and see
drive and see ifif the
the
Check motor load and fault
fault persist
persist ??
check parameters

YES
Short circuit Check IGBT and replace
VFD
Programming basics :
Protection and troubleshooting
1-check if motor capacity match Load is heavy Check motor load and
drive capacity check parameters
2-reduce load
3-sudden shock on load
Parameters need to be adjusted

ACC OC during DEC

Acceleration Time too ACC or DEC Deceleration Time too short
short or too high or SS

SS

Torque boost is Carrier frequency is The motor control

V/f pattern signal interference
high high method and motor do
not
match
Drive starts while
motor is running
Programming basics :
Protection and troubleshooting
Overload 100%-150% for 60 sec

Motor Drive and parameters

check if motor
capacity match Load is too heavy Acceleration or
drive capacity deceleration time Torque boos is high V/f setting
is too short

The base frequency

is set incorrectly

Output current operating at low

fluctuation Speeds or High
speed
 AC Drives-11 Programming-4

Programming basics :
Protection and troubleshooting

A current short to ground exceeded 50% of

Ground Fault rated current on the output side of the
drive

Motor Drive and parameters

Check motor
Check cable
insulation Check carrier
insulation
frequency

Check IGBT
Programming basics :
Protection and troubleshooting Voltage in the DC bus has exceeded the overvoltage
detection level.
Over voltage For 200 V class drives: approximately 410 V
For 400 V class drives: approximately 820 V

Supply side Drive and parameter Motor and load

NO NO

DEC Acc SS
Drive input power Ground fault in the
voltage is too high output circuit
causes the
Increase the DC bus capacitor to
deceleration time overcharge
Surge voltage at input Install a dynamic Fast acceleration time causes
braking resistor or a the motor to The motor is driven
dynamic braking overshoot the speed reference by another load
resistor unit Excessive braking
NO load

Check The braking transistor or braking resistor (wiring and value)

Programming basics :
Protection and troubleshooting Voltage in the DC bus fell below the under voltage
detection level
Under voltage For 220 V class drives: approximately 190 V
For 38 0 V class drives: approximately 380 V

Supply side Drive Hardware

Drive input power The main circuit

voltage is too low capacitors are worn

Phase loss or or
terminal losse
High starting current of
another load on supply
linw
Charger contactor
The power has been
damaged
interrupted
Increase momentary
power loss time
Programming basics :
Protection and troubleshooting
The heatsink temperature exceeded the
Overheat drive overheat level.

Surrounding Hardware Load is heavy

temperature is too
high
Cooling fan damaged

Improve panel cooling Measurement circuit Reduce load

Adjust V/F or Reduce torque

change control boost or carrier
method frequency
Programming basics :
Protection and troubleshooting

Overcurrent Overload :

Overload :
Udervoltage
Overcurrent

Overvoltage GF
Programming basics : PID
Concept of PID control

PID control or Proportional-Integral-Derivative control

is a control principle which works in a closed loop
feedback system

Why PID ?

uses the difference between the target value and the feedback value to adjust the drive output
frequency to minimize deviation and provide accurate closed loop control of system variables
such as pressure or temperature.
Programming basics :
PID Parameters
Programming basics :

PID
Open Loop control Output

Target VFD Motor

value

Closed Loop control

Output

Target PID Input VFD Motor

value
Programming basics : Application Sensor used
PID System Speed control Tachometer

Pressure Pressure sensor

Fluid control Flow rate sensor

Temperature control Thermocouple,

Thermistor
Pressure
bar
Pressure
bar
F
Programming basics : PID System
PID Wiring

10V AI1 AI2 AC

FW REV

Target Value
0-10 V OR 4-20 mA
Feedback
Programming basics : PID System
Parameter setting -Deal with the deviation during stable
Time 4 Frequency limit
Eliminate oscillation and over shoot
Shorter mean means high gain and faster
response
Set point 8

1-Analog input
2-Pulse train
I
7 8
3-Communication 1 PID PID
PID Limit Output
4-user defined P gain Direction Delay frequency

Feedback
Predict the error
used to decrease the Positive or
1-Analog input error and get the faster
Longer time settings will
improve the response but negative(Revers
6
can cause vibrations.
response speed.
2-Two AI(Differential ) 2 Shorter settings will reduce
2-Pulse train 3 the overshoot but also
Reduce the controller
responsiveness.
5
Programming basics : PID System
Parameter setting 5
Positive and negative feedback Negative
Target Feedback

5 Bar 8 bar
Flow
Pressure Pressure Set
point Frequency
Feedback

Positive
Target Feedback

40 30
Air circulation
Temperature Temperature
feedback Set point Frequency
AC Drive Hardware:
Control Hardware:
Tips &tricks

1-IF you have 4-20 mA sensor and you want to use analog input 0-10 v ?

2-if you have PNP signal from PLC and VFD accept only NPN ?

3-if you want same digital input energized with FWD and REV

FW REV DI
 AC Drives-13 Encoders and VFD-1

Rotary Encoder and VFD`S

Why to use encoder with VFD`s ?

Feedback to improve vector control performance (Speed accuracy , Max torque

per ampere)

Encoders(PG) VFD`S
Encoder
What is the encoder ?
provides information
Pulse Generator about the motion of the
Encoder are sensors shaft

Linear
movement
Position
speed
Encoder
Classification of encoders

Incremental
Output signal
Absolute
Encoder
Magnetic
Sensing
technology
Optical
Optical Incremental Encoder Encoder Parts

Light source (LED)

Photo Detector(phototransistor or photodiode)
Disk with slots
Shaft
Housing
Electronic Board
Optical Incremental Encoder How it is work ?

Incremental encoders provide a specific number of equally

spaced pulses per revolution (PPR)
Optical Incremental Encoder

Specifying the Correct Encoder Output Type

Channel Type With or without Interface Circuit

Complementary output

Dual Push-
Single Dual channel Line Pull
Open-
channel channel with Driver
collector
Index
Optical Absolute Encoder Encoder Nameplate:

Data on Encoder name Plate :

1-Resolution
2-Supply voltage
3-Wire assignment(No of Ch)
4-Output Circuit
5-Shaft Type
6-Shaft Diameter (mm)
Optical Incremental Encoder Channel Type

"A" Single channel:

to provide position feedback for unidirectional rotation.
Examples cut-to-length, counting or simple speed control.
Encoder Products Company designates this as channel "A".
Optical Incremental Encoder Channel Type

"Q" Dual channel: Also called quadrature" encoder output,

this option has two output channels, labeled "A" and "B", that
are electrically offset by 90 degrees.
Determining which signal, A or B, is leading the other is used to
indicate rotation direction. bidirectional feedback.
In unidirectional feedback the "B" channel can be used to eliminate
"encoder edge jitter",.
Optical Incremental Encoder Channel Type

"R" Quadrature with Index: In this option an index

pulse, labeled as "Z",
The Index provides a single pulse once every 360 degrees of
rotation.
This feature is typically used to allow a device to locate a home
position. .
Optical Incremental Encoder Channel Type

Complementary
Optical Incremental Encoder Encoder Circuit :

Encoder Output
Circuit

Open collector
With or without Push-up Push Pull Line Driver
Complementary
output
Optical Incremental Encoder Encoder Wiring:

Incremental encoders can be connected with single ended or differential wiring

single-ended wiring is a good fit for cost
Line Driver
applications operating with extremely long runs or in high-noise environments
work better with differential wiring
Optical Incremental Encoder Encoder Wiring:

Wires
Power (DC 5 ,12 ,24 , Free(5-30)V )
Common
Output signal(A ,B .Etc.)

1 Wire A
2 wire A B
No of signal
3 Wire A B Z
wires
4 wire A A* BB*
6 Wire A A* BB* ZZ*
Optical Incremental Encoder Encoder Wiring:

(VFD)
Encoder Encoder
Card

Open collector With or without Open collector With or without

Complementary output Complementary output

Push up With or without Push up With or without

Complementary output Complementary output

Push-Pull With or without Push-Pull With or without

Complementary output Complementary output

Line Driver Line Driver

Optical Incremental Encoder Encoder Wiring:

3-wire Encoder (VFD)

Encoder
Open collector With or without Card
Complementary output

Open collector With or without

Complementary output
Optical Incremental Encoder Encoder Wiring:

6-wire Encoder (VFD)

Encoder
Card

Push Pull : With or without Push Pull : With or without

Complementary output Complementary output
Optical Incremental Encoder Encoder Wiring:
Line Driver(differential )

RS422 (TTL)
circuits provide a constant 5 V signal level that is
not dependent on the supply voltage
The differential outputs have the highest
frequency response capability and the best noise
immunity.
 AC Drives-14 Encoders and VFD-2

Optical Incremental Encoder Encoder Wiring:

Differential
Normal connection Single Ended

4 ,6-wire 4 ,6-wire
4 ,6-wire
3-wire 3-wire 3-wire
A A A
A A A A`
A` A`

B B B
B B B B`
B` B`

Z Z Z
Z Z Z Z`
Z` Z`
Optical Incremental Encoder Encoder Cards:
Optical Incremental Encoder Resolution and Input frequency :

Resolution : is the number of measuring segments or units in one revolution of an

encoder (PPR)

Input frequency of encoder card : no of pulses encoder can accept per second

Encoder= 1000 PPR

Motor =3000 RPM
Motor revolution per second=3000/60=50 RPS
NO of pulses per second =1000 * 50 = 50 KHz

Encoder pulses=10000 PPR

No of pulses per second= 10000*50=500 khz
Encoder(1vp-p) Sin/Cos Incremental encoder

The sin/cos encoder is very similar to an incremental

encoder with the main difference being the quadrature
signals are sinusoidal as opposed to square waves.
sinusoidal signal is that Drive can interpolate off of the
analog signal the degree of resolution that they need.
The SIN/COS index signal may or may not be sinusoidal.
Often times this is an option.(R)
Encoder(1vp-p) Sin/cos Incremental encoder ERN 1387
Optical Absolute Encoder What is Absolute Encoder ?

Every position of absolute encoder is unique

while the output of an absolute encoder is a multi-bit word. This can be transmitted
in either parallel or serial form
If power is lost, its output will be correct whenever power is restored. It is not necessary
to move to a reference position as with incremental type encoders.
Optical Absolute Encoder Absolute Encoder Parts
Optical Absolute Encoder Absolute Encoder Parts

Incremental Encoder

Absolute Encoder
Optical Absolute Encoder How it is Work
Optical Absolute Encoder How it is Work
Single-turn versus Multi-turn

In a single turn encoder, the output codes are repeated for every revolution
of the encoder shaft. There is no mechanism to indicate whether the encoder
had made one revolution or several revolutions.

. In a multi turn absolute encoder, the output is unique for each shaft position
through every rotation up to x number of revolutions.
Optical Absolute Encoder Encoding :
transmission of absolute encoder data

Binary Code
Parallel
Gray Code

Encoding EndDat

HIPERFACE
Serial Profibus
SII+SIN/COS
Interbus
Industrial Bus
Interfaces
Device net

CAN Open
Optical Absolute Encoder Encoding :
transmission of absolute encoder data: EnDat

EnDat
EnDat (Encoder Data) Heidenhain.,
it is synchronous, with clock signals fed to the encoder by the controller.
internal memory
data can include encoder diagnostics, identification, and alarm status.
In addition, the controller can set the encoders zero reference point, which aids in
equipment setup. Depending on version
EnDat can include an analog 1 V p-p sin/cos output that electronics in the controller
interpolate to derive incremental data for real-time control.
EnDat uses a six- to twelve-conductor cable up to 150 m long,
Optical Absolute Encoder Encoding :
transmission of absolute encoder data

HIPERFACE is a proprietary protocol developed by Max Stegmann GmbH.

It uses an eight-wire cable (two for data, two for power and four for 1Vp-p sin/cos)
has two channels: One carries 1 V p-p sin/cos incremental data, while the other is
bidirectional RS-485 link.
Absolute position data is transmitted via the RS-485 link
HIPERFACE can access the encoders memory area for manufacturers data, status,
alarm information, and so on. In addition, the controller can write to certain
memory areas, and can set the
Optical Encoder
Applications : Elevator

Geared Machine Gearless Machine(PM)

Optical Absolute Encoder
Applications : Elevator
Optical Absolute Encoder Encoder Wiring :
Incremental VS. Absolute
Optical Encoder Encoder Parameter :

0: V/f Control
1: V/f Control with PG
Control Method Selection 2: Open Loop Vector Control
3: Closed Loop Vector Control
5: Open Loop Vector Control for PM
6: Advanced Open Loop Vector Control for PM
7: Closed Loop Vector Control for PM

Pulses per Revolution Data sheet and name plate on encoder

PG 1 Rotation 0: Forward = A pulse leads 1: Forward = B pulse leads

Encoder Selection Depend on type of encoder card

Optical Encoder Encoder Parameter :

Communication Speed Selection of Depend on type of encoder card

Serial Encoder

PG Feedback Loss 0: Ramp to stop

1: Coast to stop
PG Deviation
2: Fast Stop
PG Over speed 3: Continue running

Adjust Deviation lever ,Over speed Level