Principles VFD Basics

Wiring Connection Diagram

• I/O is used for the control and monitoring of
the VFDs operation and status.
Examples….
• Start/Stop
• Speed control (analog or digital)
• Analog meter (speed monitoring)
• Communications
• Output contacts for fault, run, speed status,
etc.

• The I/O terminals typically consist of and

interface with 24VDC, 4-20mA, 0-10VDC, and
other low voltage signals.
Principles VFD Basics
VFD Sections
Hey, G100!
• The control panel of the VFD is used for Go faster!
programming and monitoring.
• The main power sections of the VFD are
necessary to convert constant frequency and
voltage to variable frequency and voltage.
• This allows us to control motor speed and
torque!

Input Converter DC Voltage Inverter Output

Non-Regulated Voltage Controlled
AC Input Rectifier • Variable
Voltage Frequency
• Variable Voltage
• Constant V/f
Principles VFD Basics
Principle 1 – Main Components
• The VFD changes (rectifies) AC power to DC power and
then changes (inverts) it back to AC power.

AC DC AC
Principles VFD Basics
Converter Section
• The converter section is made up of diodes that convert the
AC input voltage to DC voltage.

+
Cathode (-)

Anode (+)

-
Schematic diagram
Principles VFD Basics
DC Bus Section
• The DC bus consists of capacitors used to smooth and store DC
voltage.
• DC Bus Voltage = Vin*1.414

AC to DC Conversion

+ +
Principles VFD Basics
DC Bus Section
• The DC bus is protected by a soft charge circuit. The circuit
utilizes a resistor and contactor to “softly” charge the DC
bus capacitors on power up.

Soft Charge Sequence

Soft Charge Contactor 1. Current flows through the resistor which limits
inrush to the capacitors.
2. The under-voltage level is reached and the
contactor closes. This bypasses flow through the
Output Transistors contactor instead of the resistor.
Input Diode Soft Charge Resistor

3 phase
input DC Bus Capacitors

Fuse

Simplified VFD Circuit

Principles VFD Basics
DC Bus Section
• Some VFDs have a DC bus fuse which is used to protect the
power components when then output shorts or fails.

Soft Charge Contactor

Output Transistors
Input Diode Soft Charge Resistor

3 phase
input DC Bus Capacitors

Fuse

Simplified VFD Circuit

Principles VFD Basics
Inverter Section
• The inverter section consists of rapid firing insulated gate
bipolar transistors (IGBTs). The IGBTs are utilized as
switches to switch the voltage ON and OFF to the
connected motor.
Principles VFD Basics
Inverter Section
• The rapid firing IGBTs “chop” up the DC bus voltage to
reconstruct a pseudo sine wave. This is called Pulse Width
Modulation (PWM)
• The rate at which the IGBTs switch is called the carrier
frequency.
Principles VFD Basics
Principle 2 - PWM
• The output voltage to the motor is adjusted by modulating the
width of the output pulses which make up the output voltage
waveform via PWM.
• The higher the ratio of ON time as compared to the switching
time results in a higher voltage. Ton
Tc
= 50%

Ton
Tc

Ton: Length of time the transistor is on

Tc: Switching time
Principles VFD Basics
Principle 2 - PWM
• More ON time means higher output voltage.

Ton Ton
Ton = 75% = 90%
= 50% Tc Tc
Tc

Ton Ton Ton

Tc Tc Tc

Ton: Length of time the transistor is on

Tc: Switching time
Principles VFD Basics
Principle 2 - PWM
Question: How can an AC motor possibly run on this PWM output?

Answer: An induction motor is…an inductor! An inductor resists the change in

current. Even though the output voltage waveform is a PWM square wave, the
current is sinusoidal!
Principles VFD Basics
Principle 3 – Speed Torque Curve
• Speed Torque Curve for an “across the line” start.
(300%) (600%)
Slip

TORQUE CURRENT
Breakdown
(300%) Torque
(200-250%)
(200%)

Pull Up Torque
Locked Rotor (125%)
Torque (150%)

Full Load
Torque (100%)

No Load
Current
(30%)

SPEED Rated Speed Synch Speed

Principles VFD Basics
Principle 3 – Speed Torque Curve
• Torque production when connected to an inverter.

TORQUE

Locked Rotor Torque

(150%)

Full Load Torque

(100%)

Freq. Out (Hz) 60

Principles VFD Basics
Principle 3 – Speed Torque Curve
• Torque can be controlled at any speed with an inverter to
meet application demands!

TORQUE

Locked Rotor Torque

(150%)

Full Load Torque

(100%)

3.0 Freq. Out (Hz) 60

General Topics VFD Basics
Topics of Discussion

• MCCB Current Rating and Selection • High Altitude Derating

• Single Phase Input • Input/ Output Reactors

• Motor Overload Protection • DC Link Chokes

• Operating Multiple Motors • NEMA Enclosure Ratings

• Input / Output Contactors

MCCB Current Rating and Selection VFD Basics

• Rule of Thumb:
MCCB  150% of drive input current rating

Vinv x Pfm x Iinv

• Iin= Vin x Pf

Where: Iin = Input fuse/MCCB Rating

Vinv = Inverter rated output voltage
Iinv = Inverter rated output current x 150%
Vin = Nominal input voltage
Pfs = Power system power factor
Pfm = Motor power factor
Single Phase Input VFD Basics

• VFD series can operate on a single-phase input. The VFD acts as a phase
converter to run a three-phase motor.

• Some VFD series are dedicated for three-phase input use.

• For standard three-phase input VFDs, a general 50% derate can be applied
when sizing.
Tested single-phase derate tables are available!

But why do we
have to derate?
Motor Overload Protection VFD Basics

• VFDs include electronic thermal overload protection for

the motor.

• The overload is adjusted to the motor current via

parameters. 140
Trip/minutes at 0Hz
120

• This eliminates the need for an external overload for 100

Trip/minutes at
6.7Hz
motor protection.

Time/Minutes
Trip/minutes at
80 13.4Hz

60

40

20

0
60% 85% 110% 135% 160% 185%
Percent Load
Operating Multiple Motors VFD Basics

• When more than one motor is driven in parallel with a

single VFD, select the capacity so that…
OLR

OLR

VFD Output Current  Total Motor FLA x 1.1 OLR

OLR

• Operating multiple motors requires separate overloads

for each motor and the VFD must be programmed for V/f.

T1-Temp

Proportional (PID) Control

VFD
Excessive Switching VFD Basics

Switching Limit

Transformer

The recommended maximum switching of the input of the VFD is 2 times per
minute.
Pre-charge circuits can heat up causing premature failure when exceeding this
recommendation.
Input/Output Contactors VFD Basics

Input Contactors
• A VFD can be operated without an input contactor.
• Do not use an input contactor to start and stop the VFD.
• Instead use terminal run commands or alternative start/stop
controls through the VFDs I/O.

Output Contactors
• A VFD can also be used without an output contactor.
• Opening or closing an output contactor while the VFD is
running can cause damage and failure to the VFD.
High Altitude Derate VFD Basics

• Power conversion equipment must be derated above a certain

altitude.
• Some VFDs are rated to 3300 feet (1000 meters) in altitude
and 40 degrees C. Derate is about 3% for every 1000ft (300M)
above that. Hey! I hope
you derated
• VFD's manufacturers claim on altitude derating is due to
that drive!
thinner air at higher altitude that compromises the heat
dissipation from the electronics.
Input Reactors VFD Basics

Problem
• Stray voltages, spikes, and transients can damage a VFD.
• Imbalanced phases can also cause stress on filter capacitors or
trigger various faults.
• The closer your application is to the maximum load of the VFD
the more sensitive it becomes to a voltage imbalance.
• Current Harmonics.

Solution
• Use a three-phase input reactor when the power source
transformer (KVA) is very large compared VFD capacity (KVA).
• Also used when the power factor needs to be improved.
• Can reduce current harmonics from 85% down to 30-35%.
Output Reactors VFD Basics

Problem
• Long lead lengths causing reflective (standing) waves.
• Low impedance motor is used.

Solution
• Use a three-phase output reactor to filter the spikes on the
output PWM waveform. And output reactor will also add
additional impedance.

M
DC Reactors VFD Basics

• DC Reactors (DC link chokes) are used when the power source
transformer (KVA) is very large compared to the VFD capacity
(KVA).
• DC Reactors improve VFD power factor and mitigate bus ripple
caused by a single phase input.
• Larger VFDs tend to have built in DC reactors while smaller
VFDs would need one installed.

A 150HP H100 with two

built-in DC link chokes.
NEMA Ratings VFD Basics

Enclosure Rating Characteristics

Intended for indoor use primarily to provide a degree of
protection against contact with the enclosed
1
equipment or locations where unusual service
conditions do not exist
Intended for outdoor use primarily to provide a degree
3R of protection against falling rain and sleet; undamaged
by the formation of ice on the enclosure
Intended for indoor or outdoor use primarily to provide
a degree of protection against windblown dust and
4
rain, splashing water and hose-directed water; iS7 with NEMA 1 Kit
undamaged by the formation of ice on the enclosure
Intended for indoor or outdoor use primarily to provide
a degree of protection against corrosion, windblown
4X dust and rain, splashing water and hose-directed
water; undamaged by the formation of ice on the
enclosure
Intended for indoor use primarily to provide a degree of
12 protection against dust, falling dirt and dripping
noncorrosive liquids

S100 NEMA 4X
Closing VFD Basics

Thank You!