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VFD Theory
Craig Hartman, P.E.
www.emcsolutions.com
www.emcsolutions.com
Answer: a - 1969
The microprocessor was invented by Ted Hoff, at Intel, for Busicom, a
Japanese calculator manufacturer. It was first advertised in November of
1971 and cost thousands of dollars. It is fascinating to note that the first
manned landing on the moon was also in 1969. Apollo 11 launched from
Kennedy Space Center on July 16, 1969. Neil Armstrong became the
first man to walk on the moon, stepping on its surface on July 20th.
Twelve people have landed on the moon.
ENIAC
Electronic Numerical Integrator And Computer
VFD Theory: 4
VFD Theory: 5
VFD Theory: 6
6-pulse Converter
AC to DC
Converter
480 V
A
B
C
VFD Theory: 7
Add DC bus
AC to DC
Converter
DC
Bus
+650Vdc
480 V
A
B
C
+
0Vdc
VFD Theory: 8
Pre-Charge Circuit
A
B
C
+
-
VFD Theory: 9
Add Inverter
AC to DC
Converter
DC
Bus
+650Vdc
DC to AC
Inverter
480 V
A
B
C
+
-
0Vdc
VFD Theory: 10
VFD Theory: 11
650V
240 V
30 Hz
VFD Theory: 12
650V
240 V
30 Hz
650V
80 V
10 Hz
VFD Theory: 13
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PWM
Waveforms
VFD Theory: 15
VFD Theory: 16
VFD Theory: 17
VFD Theory: 18
PWM frequency
VFD Theory: 19
PWM frequency
VFD Theory: 20
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VFD
Construction
VFD Internals
Cooling Fan
AC to DC Inverter
(2 transistors per module)
Heat Sink
DC Bus
Capacitors
DC Bus
AC to DC Converter
(2 diodes per module)
AC Power Input
Power Output
to Motor
VFD Theory: 22
VFD Internals
Transistor
Snubber
Control
Board
Capacitor
discharge
resistors
Capacitor
pre-charge
circuit
VFD Theory: 23
VFD
No Harmonic Mitigation
AC to DC
Converter
Filter
DC Filter
Capacitor
TH
DC to AC
Inverter
Free-wheeling
diodes
VFD Theory: 24
Internals
VFD Theory: 25
VFD
(with line reactor)
6-Pulse
VFD
Line
Reactor
3-Contactor
Bypass
VFD Theory: 26
VFD
(2-reactor harmonic filter)
6-Pulse
VFD
Harmonic Filter
Capacitor
Harmonic Filter
Reactors
3-Contactor
Bypass
VFD Theory: 27
VFD
VFD Theory: 28
VFD Theory: 29
VFD Theory: 30
VFD
VFD Theory: 31
Dual VFDs
(harmonic filter with dc-link and ac rectors)
6-Pulse
VFD
Dc-link
reactor
Harmonic filter
capacitors
dV/dt
filter
Harmonic filter
reactors
VFD Theory: 32
VFD
(3-reactor harmonic filter with dc link reactor)
6-Pulse
VFD
Harmonic filter
capacitors
Dc-link
reactor
dV/dt
filter
Harmonic filter
reactors
VFD Theory: 33
VFD Theory: 34
VFD Theory: 35
VFD Theory: 36
VFD Theory: 37
VFD Theory: 38
VFD Theory: 39
VFD Theory: 40
VFD Theory: 41
VFD Theory: 42
Speed Range
VFD Theory: 44
Control Methods
F700
A500
A700
A700/
V500
Speed Control
Torque Control
Position Control
VFD Theory: 45
Braking
Resistor
Chopping
Transistor
DC Link
Inverter
Control Logic
Converter
L1
L2
L3
VFD Theory: 46
Power-Down Braking
Keeps the motor under control even if supply power is lost.
VFD Theory: 47
VFD Theory: 48
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dV/dt
Reflective Wave Phenomenon
Voltage wave reflection is a function of
the voltage rise time (dV/dt) and the
length of the motor cables. Impedance
mismatches cause voltage pulses to be
reflected back in the direction from which
they arrive. As these reflected waves
encounter incoming waves, their values
add, causing higher peak voltage. As
wire length or carrier frequency
increases, the overshoot peak voltage
also increases. This causes motor
insulation degradation and failure.
VFD Theory: 50
Voltage Stress
ALL MOTORS
VFD MOTORS
Vpeak
1kV
3.1 * Vrated
Rise time
2s
0.1s
2.04 * Vrated
2.04 * Vrated
1s
1s
VFD Theory: 51
Vpeak
Voltage
Steady-state voltage
100%
90%
dV
dt
V
t
10%
t
Rise time
Time
VFD Theory: 52
Courtesy TCI
VFD Theory: 53
dV/dt
Courtesy TCI
VFD Theory: 54
dV/dt
Courtesy TCI
VFD Theory: 55
dV/dt
VFD Theory: 56
dV/dt
(proprietary solution)
PWM
Frequency
1 hp
and below
2hp
3 hp
and above
2 kHz
300 meters
500 meters
500 meters
3-15 kHz
200 meters
300 meters
500 meters
VFD Theory: 57
VFD Theory: 58
dV/dt filter
dV/dt filter
Recommendations
VFD Theory: 59
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460 VAC
60Hz
A number of
different wave
forms may be
present
64
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Bearing Discharge
~50 nano sec.
Creates EDM pitting
65
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
66
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Electron Microscope
(SEM) Image
1000x Magnified
EDM Pit
EDM Pitting
67
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Mitigation Techniques
VFD Waveform
Mitigation
Bearing
Insulation
Alternate
Discharge Paths
Bearing Insulating
Sleeve
Ceramic Bearings
Conductive Grease
Grounding Brush
Shaft Grounding Ring
Sine-wave filter
Ceramic Bearing
VFD Theory: 68
*IEEE paper, September 2007: Design Aspects of Conductive Microfiber Rings for
Shaft Grounding Purposes, by Dr. Annette Muetze et. Al.
69
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Easy to install
Maintenance free
Improves VFD motor bearing reliability
Best ROI - Small investment
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
AEGIS SGR
Bracket Mounted Shaft Grounding Ring
Fits most motor end brackets
Drill and tap for mounting brackets
and small screws
Ring slides over shaft
Easy Installation
Applications
OEM installations
All VFD driven Motors
HVAC
Industrial Process
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Split Ring
Shaft diameters: 0.311 to 6.02 (8mm to 153mm)
4 to 6 mounting brackets, screws and washers
Installs without decoupling motor
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
AEGIS SGR
Conductive Epoxy Mounting
Split ring or solid ring
Installs with Conductive Epoxy to
clean metal surface
No drilling holes or tapping for screws
Best solution for field installation
Applications
Pump motors
Fan Motors
Mechanical Rooms
Coupled Equipment
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
AEGIS CS015
Colloidal Silver Shaft Coating
Enhances shaft surface conductivity
lowers residual shaft voltage
Can be used in all AEGIS Bearing
Protection Ring installations
Required for vertical motors and roller
bearings
Helps prevent oxidation
Applications
For shaft grounding ring
installations in harsh areas
Included in all iPROs
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Stator
Shaft
Rotor
V
F
D
Ground
75
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
Insulated
bearing on
ODE
Stator
Rotor
Shaft
V
F
D
Ground
76
Copyright 2010 Electro Static Technology-ITW Patented Technology All Rights Reserved
IEGT
4.5kV-4kA
IEGT = Injection
Enhanced Gate
Transistor
Slide #77
We drive industry
Q1
E
Q2
Q1
E
Q2
+E
Q3
Q4
Q2
0V
E
Q3
Q4
-E
Q3
Q4
Slide #78
We drive industry
3 Level
0V
3 Level Inverter
Q1
Q1
Q1
Q2
Q3
Q4
-E
E
Q2
+E
E
Q2
0V
Q3
Q4
-E
Q3
Q4
Line to Line
3 / 5 levels
Including zero
Slide #79
We drive industry
Progress of Inverter
Circuits to High Capacity
5 Level Inverter
3 Level Inverter
2 Level Inverter
3
Large capacity
3kV - 15MVA
Low voltage application
460V, 690V
Copyright TM GE Automation Systems March 2011
Slide #80
6kV
7kV, 8MVA
120MVA
High voltage, large capacity,
clean waveform
We drive industry
INCOMING
POWER
INVERTER
SECTION
BYPASS
CONTACTOR
[option]
TRANSFORMER &
DC CONVERTER
Slide #81
DRIVE
CONTROL
We drive industry
Slide #82
We drive industry
VFD Theory: 83
VFD Theory: 84
VFD Inventory
VFD Theory: 85
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Thank You!
Questions?