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The Purpose
1. 2. 3. 4. 5. 6. 7. Energy savings on most pump and fan applications. Better process control and regulation. Speeding up or slowing down a machine or process. Inherent power-factor correction Emergency bypass capability Protection from overload currents Safe Acceleration
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AC-Induction-Motor Theory
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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.
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Components of VFDs
Vacuum tubes Thyristors (SCRs) provided the standard method for rectifying AC. Also referred to as a diode.
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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).
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VFD Basics
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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 threephase, full-wave-diode bridge.
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Components of VFDs
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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 Inc.
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 basedrive 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 Inc.
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 Inc.
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.
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VFD Basics
By switching the inverter-transistor devices on and off many times per half cycle, a pseudosinusoidal current waveform is approximated.
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VFD Basics
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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 Inc.
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 Inc.
VFD Basics
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 voltagesource, current-source of variablevoltage 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 Inc.
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).
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VFD Basics
Volts-perHertz Control
The area within each pulse is the power delivered to the motor in voltmicroseconds.
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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.
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VFD Basics
VFD Basics
Advantages
Sometimes getting a little more speed out of the motor can increase the flow just enough to satisfy the demand. When there is capacity in the motor and the VFD can be programmed to do this, a new, larger motor does not have to be purchased and installed. The VFD can run 10 to 20% higher in speed and make up for lost capacity in a flow-and-demand type of system. However, many motors as built are not balanced for these speeds.
1(800)900-2220 PSI Pump Systems Inc.
VFD Basics
Functions & Features
Set-up Parameters The Control Method Acceleration or Accel-Ramp Rate Automatic Restart Stopping Method Automatic Signals
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VFD Basics
Conclusion
Significant energy savings Easy setup & programming Retrofits Space Better design Competitive edge
1(800)900-2220 PSI Pump Systems Inc.