Variable frequency drive and faults detection using

Microcontroller
Engineer Iftekhar Ahmad
University of Engineering and Technology Peshawar
Peshawar, Pakistan
Iftikhar6pk@yahoo.com

Abstract—This paper will explore the benefits of VFD

A. VARIABLE FREQUENCY DRIVE
operation and motor protection through microcontroller
while providing guidance on proper application. Variable The term VFD is often used interchangeably with AC drive,
Frequency Drives (VFDs) are the preferred method of inverter, or adjustable-frequency drive (AFD). The two most
controlling AC drive (AC motor). AC motor drives are common circuits for adjusting the speed of an AC squirrel
widely used to control the speed of conveyor systems, cage induction motor are the inverter and the cycloconverter.
blower speeds, pump speeds, machine tool speeds, and Using an inverter, the VFD does two things: First, it takes the
other applications that need variable speed with variable incoming AC signal and converts it to a DC signal through a
torque. By, VFDs can significantly reduce energy process known as rectification; next, it takes the rectified DC
consumption and operating costs of the entire system while signal and inverts it back to a variable voltage and variable-
providing operational benefits to the owner. The circuit frequency AC signal. An inverter takes a waveform like a
will take the full control of the motor and it will protect the rectified DC signal and generates an equivalent time-varying
motor from the several faults such as short-circuit, waveform resembling a sinusoidal[3]. A block diagram for an
overload, and overheat, under voltage, over voltage, phase inverter type VFD is shown in the Figure.
failure. The protection of induction motor with
microcontroller has flexibility to switch off at the required
time, monitors every fault of motor at every time and
every motoring action is known through the LCD display.
In our project we are using the popular 8 bit
microcontroller AT89C52. It is a 40 pin microcontroller.
The VFD using A cycloconverter (CCV) or a cycloinverter
Keywords-component; Variable frequency drive (VFD); converts a constant voltage, constant frequency AC waveform
Microcontroller; Magnetic contactor; circuit breaker; switching to another AC waveform of a lower frequency by synthesizing
relay (common 220, 14 pin relay); phase failure relay; overload the output waveform from segments of the AC supply without
relay an intermediate DC link The cycloconverter type of VFD is
normally used with larger motors or groups of motors[4].
I. INTRODUCTION When an induction motor is connected to a full voltage supply,
You can divide the world of electronic motor drives into two it draws several times (up to about 6 times) its rated current.
categories: AC and DC. A motor drive controls the speed, As the load accelerates, the available torque usually drops a
torque, direction and resulting horsepower of a motor. A DC little and then rises to a peak while the current remains very
drive typically controls a shunt wound DC motor, which has high until the motor approaches full speed[5][6].
separate armature and field circuits. AC drives control AC By contrast, when a VFD starts a motor, it initially applies a
induction motors, and-like their DC counterparts-control low frequency and voltage to the motor. The starting
speed, torque, and horsepower[1]. frequency is typically 2 Hz or less. Thus starting at such a low
A modern adjustable speed AC machine system is equipped frequency avoids the high inrush current that occurs when a
With an adjustable frequency drive that is a power electronics motor is started by simply applying the utility (mains) voltage
device for speed control of an electric machine[2]. It controls by turning on a switch. After the start of the VFD, the applied
the speed of the electric machine by converting the fixed frequency and voltage are increased at a controlled rate or
voltage and frequency to adjustable values on the machine ramped up to accelerate the load without drawing excessive
side. current. This starting method typically allows a motor to
This research interest in Motor control by Variable frequency develop 150% of its rated torque while the VFD is drawing
drives (VFD) and how easily finds motor faults through the less than 50% of its rated current from the mains in the low
microcontroller. speed range. A VFD can be adjusted to produce a steady 150%
starting torque from standstill right up to full speed[5][6][7].

Electronic copy available at: http://ssrn.com/abstract=2398246

Internal characteristic of the VFD: C: Magnetic contactor

Automatic reset and restart, carrier frequency, DC injection For motor safety purpose Magnetic contractor is a very
braking, Electronic thermal overload, 4-step speed change, necessary part. Normally we are controlling motor in
frequency/current meter calibration, Full-range automatic cement industry by star delta connection. In this research
torque boost, jog operation, Local/remote selection, Motor we are also like this.
stall prevention, Motor torque adjustment, Multifunction
analog output monitor, multifunction contact input. D: LCD
This research interest in LCD is less expensive as
Advantages: compared to other display. We can monitor every fault of
motor at every time on the LCD.
Actually VFD offers many benefits including energy saving,
better motor control, reduce maintenance, adjust motor speed E: Detective Faults components
and reverse motor rotation. a) Circuit Breaker
 A VFD may be used for control of process temperature, Circuit breaker does two things in this research, first it
pressure or flow without the use of a separate controller. controls power and second it detects a short circuit. To use the
Suitable sensors and electronics are used to interface the auxiliary contact of circuit breaker detects a short circuit fault
driven equipment with the VFD[8]. and give signal to switch the relay.
 Maintenance costs can be lower, since lower operating b) Overload relay
speeds result in longer life for bearings and motors. For motor safety purpose thermal overload relay is very
 Eliminating the throttle valves and dampers also does away necessary. To use auxiliary contact (NO and NC contact) of
with maintaining these devices and all associated controls[9]. overload relay detects an overload fault and give signal to
 a soft starter for the motor is no longer required. switch the relay.
 Controlled ramp-up speed in a liquid system can eliminate c) Phase sequence
water hammer problems.
Three phase induction motor use phase failure relays for
 The ability of a VFD to limit torque to a user-selected level correction of phases. It is very necessary because some time
can protect driven equipment that cannot tolerate excessive needs motor to use in forward direction. If due to any reason
torque change phases then it will detect and save the motor in reverse
direction. To use NO and NC contact to detect faults and give
Disadvantages: signal to switch the relay. The red LED "ON" indicates phase
sequence incorrect and relay is de-energized. The green LED
The most common disadvantage is Noise. "ON" indicates phase sequence correct and relay is energized.
We are using phase sequence for incorrect phrases.
Future point:

In my point of view if we install output noise filter on the

output side of the inverter then we can effectively reduce
inductive noise (noise coming on the signal line). d) Resistance temperature detector (RTD)
Some time motor overheat due to unbalance condition so it’s a
greater chance to overheat its bearing and body. Resistance
B: Microcontroller temperature detector is used for motor overheat RTD detect
This research interest in Microcontroller is less expensive faults and give signal to switch the relay.
as compared to Programmable logic controllers (PLCs) and e) Switch relay (common 220,14 pin relay)
Distributed control system (DCS). If any fault occurs in This research interest in switch relay is just used for
microcontroller we can change easily without much expense. microcontroller. To use NO and NC contact for a
The function of microcontroller in our project is to microcontroller.
automatically detect the faults and display on LCD connected Relay socket is used to hold relay. Pin 13 and 14 are cool. Pin
to port1 of the Microcontroller. 1,2,3,4 are normally closed contacts, pin 5,6,7,8 is normally
open contacts, and pin 9,10,11,12 is common.
We are using the common 14 pin relay just for on-off
switching. Whenever fault is come common relay are
energized and show us a fault. Switch relay have take a signal
from detective faults component and give on off signal to the
microcontroller.

Electronic copy available at: http://ssrn.com/abstract=2398246

 TEST3: Overheat
Formula
How to measure speed…..
Ns=120f/p
Ns=synchronous speed
f=supply frequency
P=poles

Example:

2-pole motor at different frequencies

Speed= 60 hertz x 120 / 2 = 3600 RPM
Speed= 50 hertz x 120 / 2 = 3000 RPM
Speed= 40 hertz x 120 / 2 = 2400 RPM

TEST
Before practical implementation we tested our design
PROTEUS

TEST1: Overload

TEST4: Phase failure

TEST2: Short circuit

 Conclusion ACKNOWLEDGMENT
VFD is the ideal soft starter. Unlike all other types of starters, The author is deeply grateful to her supervisor Engineer
the VFD can use frequency to limit the power and current Munaza Sher, Lecturer of computer system Engineering
Department, Peshawar College of Engineering for his closed
delivered to the motor. The VFD will start the motor by guidance, accomplished supervision and suggestion for this
delivering power at a low frequency. At this low frequency, paper.
Lastly, I thank almighty, my parents, brother, sister and
the motor does not require a high level of current. The VFD friends for their constant encouragement without which this
incrementally increases the frequency and motor speed until assignment would not be possible.
the desired speed is meeting. The current level of the motor
Reference
never exceeds the full load amp rating of the motor at any time
[1] Technical note What is A VFD? - HSL Automation
during its start operation. In addition to the benefit of low
starting current, motor designs can now be optimized for high
[2] Analysis of Variable Frequency Three Phase
efficiency.
Induction Motor Drive
Energy savings up to 35 to 50 percent is achieved over Thida Win, Nang Sabai, and Hnin Nandar Maung
.
conventional constant speed applications and 100% at full
[3] Vidal is president of Joseph J. Vidal & Sons, Inc.,
speed.
Throop, Pa.
We achieve protection of the motor through a differential
protective relay. [4] IED (EEC-604) - Prasad Institute of Management and
Technology
Microcontrollers quickly identify the faults by the instant it
[5] Variable Speed / Frequency Drives - Absolute Energy
occurred so we don’t have to check the whole system for a Solutions
single fault
[6] CR4 - Thread: DTC Torque and Power

[7] http://cooper-electric.net/industrial/variable-speed-drives/

[8] Variable Frequency Drive Basics - Crane Buzz

[9] Why Use Variable Frequency Drive? - Paddock

Industries