W3 - Introduction To VFD AC Drives

ME155P
INDUSTRIAL AUTOMATION AND

CONTROL
INTRODUCTION TO VARIABLE FREQUENCY
DRIVE (VFD) AC DRIVES
INTRODUCTION TO VARIABLE FREQUENCY AC DRIVES
TABLE OF CONTENTS
Segment 1: Variable Speed AC Drive Basics
Objective 1 – Describe the Function and Operation of Two Common Types of Variable Speed AC Drives
Objective 2 – Describe the Advantages and Disadvantages of Using an AC Drive Instead of a DC Drive
Objective 3 – Describe the Advantages of Starting a Motor with an AC Drive Instead of Line Starting
Self Review 1
Segment 2: Variable Speed AC Drive Basics
Objective 4 – Describe the External Control Capabilities of a Variable Frequency AC Drive
Self Review 2
Segment 3: Jogging Control

Objective 5 – Describe How Motor Jogging is Accomplished with a Variable Frequency AC Drive
Self Review 3
Objective 1 - Describe the Function and Operation of Two Common Types of Variable Speed AC Drives
Variable AC Drive Description

When AC Power drives a motor, the input voltage creates a moving magnetic field that turns the rotor. The
speed of the magnetic field depends on the frequency of the AC power. The higher the frequency, or cycles per
second, the faster the motor turns.
Most utility power cycles at 60 Hz, which powers motors at one speed. Variable speed drives switch the utility
power to other frequencies to vary motor speeds.
Variable AC Drive Function
Variable speed AC drives change the

frequency and voltage supplied to an AC motor.
Changing the frequency changes the rotation
of the magnetic field, which turns the motor faster
or slower. However, when motor turn faster, they
need higher voltage to deliver the same amount of
torque.
Single Phase Input Power 3-Phase Output Power
General-Purpose Drive
Description
One common type of variable
speed AC drive is the general-
purpose drive. This drive has three
stages to convert AC power into DC,
boost and filter it, and then turn back
into AC power at different
frequencies and voltage.
Rectifier
The rectifier section uses silicon-controlled rectifiers (SCRs) or diodes to convert the
incoming AC Power into DC Power. The DC output contains ripple voltage that is smoothed
out in later gain stages.
When incoming AC power is first applied, most AC drive rectifiers precharge, or ramp up,
the voltage. Precharging avoids a large inrush current that can blow fuses or damage diodes. A
precharge time of more than a few seconds indicates the rectifier has failed.
DC Link
The DC link is a filtering and gain stage that flattens the ripple of the rectified DC signal. It
also boosts (increases) or bucks (decreases) the DC voltage to the level needed for the overall
output frequency.
Some AC drives call this stage the DC bus.
Inverter
The inverter section converts the DC back into an AC signal that feeds a 3-phase motor.
Simple inverters consist of six high-powered transistors that produce square pulses.
More complicated inverters reduce the distortion of square waves using a process called
pulse-width modulation (PWM).
Inverter Drive Switching
The switching of these devices is

typically controlled by a microprocessor,
which is contained in the control section of
the drive.
The microprocessor is programmed to
turn transistors on and off in a specific
sequence to produce the AC signal that runs
the motor.
The rate at which the switching devices
are switched controls the frequency of the AC
output and, therefore, the speed of the
motor.
Vector Drive Description
Vector drives have feedback added and use more complex control logic than general-purpose
drives do.
Vector drives use an encoder or resolver to provide speed and direction feedback from the motor
to the control section of the drive.
Vector Drive Advantages
Because of the feedback capabilities of vector drives, they can provide more accurate control of a
motor’s speed and torque. Therefore, vector drives are usually more expensive than general-purpose
drives.
Some of the recent vector drives developed do not require encoder or resolver feedback. For example,
Allen Bradley has developed a vector drive that can be programmed for a specific motor. Many of the
operating parameters of the motor are pre-programmed and the vector drive controls the motor based on
those parameters. These vector drives are called sensorless vector drives.
KNOWLEDGE CHECK: Identify the Components of an AC Drive

Click and drag the components of an AC motor drive to put them in the correct order.
RECTIFIER INVERTER DC LINK

KNOWLEDGE CHECK: Identify the Components of an AC Drive

Click and drag the components of an AC motor drive to put them in the correct order.
ANSWER:
RECTIFIER DC LINK INVERTER

Objective 2 - Describe the Advantages and Disadvantages of Using an AC Drive Instead of a DC Drive
Objective 2 - Describe the Advantages and Disadvantages of Using an AC

Drive Instead of a DC Drive
Page 9: Title Page

Page 10: Advantages of Using an AC Drive Instead of a DC Drive
Page 11: Three Advantages of an AC Drive with a 3-Phase Induction Motor
Page 12: Disadvantages of Using an AC Drive Instead of a DC Drive
Page 13: Knowledge Check – Identify the Motor Needed for a Given Application
Advantages of Using an AC Drive Instead of a DC Drive
AC induction motors and DC brush motors

work by similar principles, but their construction
and control are very different. Thus, using an AC
or DC drive depends solely upon the type of
motor used.
AC drives shift the AC power’s frequency to
affect an AC motor’s speed.
DC drives vary DC current to adjust the
speed of a DC motor.
Three Advantages of an AC Drive with a 3-Phase

Induction Motor
AC motors use AC power to drive a

squirrel-cage induction rotor.
This design keeps the motor
smaller and lighter than a DC motor of
equal power. Parts do not run by
friction, so this design is very efficient in
converting input power to torque. They
require little maintenance, costless, and
run quieter and cooler.
AC Induction Motor
Disadvantages of Using an AC Drive Instead of a

DC Drive
DC motors use brushes to touch the rotor’s

commutator and deliver DC power. These
brushes require constant maintenance.
The design directly powers the rotor so it
has more accurate speed control than an AC
motor. DC motors also have much higher starting
torque.
Dc motors also deliver constant torque at
low speeds and can run overloaded for brief
periods. AC motors cannot do this without
feedback systems.
KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

Determine the more suitable motor for the following scenario. A fan in a ventilation shaft is
difficult to reach. It needs to be quiet and have a long life with minimal maintenance.
AC Motor
DC Motor

Determine the more suitable motor for the following scenario. A rotary saw blade
requires a variable torque load from 9800 rpm to 1750 rpm.
AC Motor
DC Motor

Determine the more suitable motor for the following scenario. An industrial blower
requires a motor that uses little power at startup and is highly efficient.
AC Motor
DC Motor

Determine the more suitable motor for the following scenario. A transformer coil winder
needs a motor that provides constant torque between 500 and 1300 rpm and is capable
of running 125% overload throughout the speed range.
AC Motor
DC Motor

Determine the more suitable motor for the following scenario. A process control system
needs a tank agitator that can run using battery power in the event of an emergency.
AC Motor
DC Motor
Objective 3 - Describe the Advantages of Starting a Motor wit an AC Drive instead of Line Starting
Objective 3 - Describe the Advantages of Starting a Motor with an AC Drive

instead of Line Starting
Page 14: Title Page

Page 15: Advantages of AC Drive Motor Starting
Page 16: Soft-start Drives
Page 17: Use of Single-Phase Power
Page 18: Disadvantages of AC Drive Motor Starting
Page 19: Knowledge Check – Detect the Dilemma
Objective 3 – Describe the Advantages of Starting a Motor wit an AC Drive instead of Line Starting
The simplest way to start a motor is using a direct on line, or

DOL, starter. This method applies full line voltage directly to the
motor terminals to power up the motor.
However, using an AC drive to start a 3-phase motor offers

several advantages over using a DOL starter.
Better control of Acceleration

Control o Inrush Current
Smaller Drive Motors
Reduced Mechanical Stress
Motor Operation
Multiple Motor Control
Built-in Braking
Using a DOL abruptly powers up a motor. This causes the

motor to accelerate to its maximum speed uncontrollably.
Using an AC drive allows the user to set a software-

programmable acceleration rate to bring the motor up to
speed. The shorter the rate is, the faster the motor accelerates.
The longer the rate is, the slower the motor accelerates.
Using a DOL to start a motor causes an inrush current of up to

six times its full-load current. Large motors can cause dips in
AC supply systems or trip circuit breakers.
There are methods of controlling the inrush current of DOL

starters by reducing voltage, but this also reduces starting
torque.
By comparison, an AC drive can provide up to 150% of the full-

load torque during startup.
Unlike line-started motors, high inertial loads started with an

AC drive can be accelerated slowly.
This practice allows the use of a smaller motor.

Line starting places a great deal of mechanical stress on the

machinery being driven.
Because the AC drive allows controlled acceleration, the

mechanical drive system of a machine can be downsized and,
in some cases, eliminated.
Most common line-started motors can only operate at their

base speed.
AC drives allow continuous operation of these motors both

below and above their base speed.
AC drives can control multiple motors and accelerate them at

the same time,
This allows machines that have multiple motors to be

controlled with one AC drive.
Most AC drives have built-in braking capabilities that can be

programmed.
On the other hand, line starters require additional contractors

and circuitry for braking.
Smaller AC drives are used in many applications in place of

regular magnetic motor starters.
These drives are often referred to as soft-start drives.
Soft-start applications include pumps, conveyors, grinders, and

fans.
Another important feature of some AC drives is that

3-phase power is not needed to control a 3-phase
motor.
Some AC drives can use single-phase power and

produce the 3-phase signal to operate a 3-phase
motor.
This allows locations that do not have-phase power

readily available to use 3-phase motors.
DOL starters do have some advantages over AC drives

regarding startup torque and cost.
Line-started motors develop approximately 200% of rated full-

load torque at startup. AC drives usually produce only 150%.
The complex electronics and higher operational costs make AC

drives more expensive. Maintaining and troubleshooting AC
drive lines is also more difficult than DOL lines.
DOL starters do have some advantages over AC drives

regarding startup torque and cost.
Line-started motors develop approximately 200% of rated full-

load torque at startup. AC drives usually produce only 150%.
The complex electronics and higher operational costs make AC

drives more expensive. Maintaining and troubleshooting AC
drive lines is also more difficult than DOL lines.
An example system uses a DOL motor starter, but it does not

KNOWLEDGE CHECK: Detect the Dilemma work correctly. Read through the power requirements and
indicate why an AC drive is needed.
A conveyor system uses an AC induction motor to drive a load.

Three-phase power is not available, so sing-phase power must
be used. The motor must output no less than 150% of rated
torque at startup to get load moving.
Why is an AC drive a better choice to drive the motor than a

DOL starter?
DOL starters develop lower torque at startup
DOL starters require 3-phase power to start AC motors.
DOL starters can not drive AC induction motors.

Segment 1: Self Review
Self Review
1. Two common types of variable speed

AC drives are ______ and vector drives. Alternating Electrical Outputs
2. The ______ section of a general-purpose Armature General-purpose Phases

drive uses rectifiers to convert AC to drives
DC. Brushes Half-load Reverse
Chord Hertz Schematic
3. A(n) ________ drive includes a feedback
device to provide speed and direction Converter Horsepower Silence
feedback. Current Inrush Size
4. One of the disadvantages of using an DC link Inverter Starting
AC drive and motor instead of a DC Direct Lineup Stopping
drive and motor is that the AC motor
cannot match the DC motor’s ________ Distance Load Transformer
torque. Drive Looping Vector
5. DC motors are usually heavier and

larger than 3-phase motors of
equivalent ________.
Objective 4 - Describe External Control Capabilities of a Variable Frequency AC Drive
Objective 4 - Describe External Control Capabilities of a Variable Frequency

AC Drive
Page 21: Title Page

Page 22: Variable Speed AC Drive Control
Page 23: VFD Inputs and Outputs
Page 24: Control Settings
Page 25: Knowledge Check: Set Up a VFD for 3-Wire Control
Although most programmable AC drives can operate a motor

using built-in keypad, many applications need external controls.
The simplest method of control is the 2-wire circuit. This

control scheme simply energizes a motor for on/off operation.
Three-wire control schemes are similar but the add a parallel

circuit that seals in he starter circuit and keeps the motor
running automatically
Input for 2-wire and 3-wire controls include

pushbuttons, switches, potentiometers, sensors, and
PLCs. Most AC drives can accept combinations of
several devices.
AC drives also contain terminals for inputs to line

power and outputs for motor power. Some drive also
have output relays that can turn on indicator lights to
signal a fault condition.
Display Options P036 [Start Source] P037 [Stop Mode] P038 [Speed Reference
0 Keypad Ramp, Clear Faults Built-In Potentiometer
1 3-Wire Coast, Clear Faults Internal Frequency
2 2-Wire DC Brake, Clear Faults 0-10 V Input
3 2-Wire Level Sensor Auto DC Brake 4-20 mA input
Programmable AV drives often allow users to set the input mode between manual and automatic
inputs.
Also, the user selects the signal that sets the speed command. This can be an internal
frequency (based on the maximum frequency output), an external 0-10V signal, an external
4-20 mA signal, or from the built-in potentiometer.
KNOWLEDGE CHECK: Set Up a VFD for 3-Wire Control
Click and drag the components of a variable frequency drive to set up a 3-wire control scheme
Self Review
1. In many applications, ___________

controls are required to controls a 1-wire Clutch Maximum
variable speed drive.
2 Common Minimum
2. Common inputs to a variable 2-wire Current Output relays
frequency drive include manual inputs,
________ devices, potentiometers, and 3 Digital Outputs
PLCs.
3-wire Drive Pilot
3. Variable frequency drives provide 6 External PLC
inputs for line power _________ for the
Automated Frequencies Proximity
motor.
Brake Information Schematic
4. Some drives include ___________ that can
Calls Inputs Speed
be used to turn on external devices
such as an indicator light. Capacitor Keypad voltage
5. The user of a variable frequency drive

can select what signal will provide the
___________ command.
Objective 5 –How Motor Jogging Is Accomplished with a Variable Frequency AC Drive
Objective 5 –How Motor Jogging Is Accomplished with a Variable Frequency

AC Drive
Page 27: Title Page

Page 28: Jogging a Motor with a VFD
Page 29: Jog Settings
Page 30: Knowledge Check: Set Up a VFD for Motor Jog Control
Jogging a motor briefly triggers the contracts to

run at a slower rate than its normal run speed.
This allows a motor to align parts or run a
machine through its sequence of operations for
repair or maintenance.
Most AC drives allow inputs to activate motor

jogging in opposite directions. Often, they allow
programmable settings for speed and
deceleration too,
The programmable settings related to motor jogging are located in the Advanced
Group Parameters.
• Digital Input 1 (A051)/ Digital Input 2 (A052) – This parameter activates the
I/O terminals on the VFD for a range of preset functions.
• Jog Frequency (A078) – This parameter sets the maximum frequency of the
drive output while jogging.
• Jog Acceleration/ Deceleration (A079) – This parameter sets the rate the motor
speeds up when triggered, and the rate the motor stops when released.
KNOWLEDGE CHECK: Set Up a VFD for Motor Jog Control
Drag the components of the variable frequency drive to the terminal block to enable VFD motor jog
control.
Self Review
1. Most variable frequency allow the use

of manual inputs to __________ a motor. 1-wire Common Jog decel
2. When jogging with a variable 2 Computer Maximum

frequency drive, the direction and 4 Current Minimum
__________ of jogging can be controlled
5 Different Outputs
3. Depending on the drive, the inputs
6 Digital Pilot device
used to jog the motor may be
__________ than the inputs used for Automated Drive PLC
standard control.
Brake Frequencies Proximity
4. Common parameters associated with Calls Frequency Schematic
jogging include: Jog _______, Jog Accel,
Capacitor Information Speed
and Jog Decel.
Clutch Jog voltage
5. The _________ parameter establishes the
deceleration rate for a motor when a
jog input is released.

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ME155P

INDUSTRIAL AUTOMATION AND

Segment 3: Jogging Control

Variable AC Drive Description

Variable AC Drive Function

Variable speed AC drives change the

Single Phase Input Power 3-Phase Output Power

Inverter Drive Switching

The switching of these devices is

Vector Drive Description

Vector Drive Advantages

KNOWLEDGE CHECK: Identify the Components of an AC Drive

RECTIFIER INVERTER DC LINK

KNOWLEDGE CHECK: Identify the Components of an AC Drive

RECTIFIER DC LINK INVERTER

Objective 2 - Describe the Advantages and Disadvantages of Using an AC

Page 9: Title Page

Advantages of Using an AC Drive Instead of a DC Drive

AC induction motors and DC brush motors

Three Advantages of an AC Drive with a 3-Phase

AC motors use AC power to drive a

Disadvantages of Using an AC Drive Instead of a

DC motors use brushes to touch the rotor’s

KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

KNOWLEDGE CHECK: Identify the Motor Needed for a Given Application

Objective 3 - Describe the Advantages of Starting a Motor with an AC Drive

Page 14: Title Page

The simplest way to start a motor is using a direct on line, or

However, using an AC drive to start a 3-phase motor offers

Better control of Acceleration

Using a DOL abruptly powers up a motor. This causes the

Using an AC drive allows the user to set a software-

Using a DOL to start a motor causes an inrush current of up to

There are methods of controlling the inrush current of DOL

By comparison, an AC drive can provide up to 150% of the full-

Unlike line-started motors, high inertial loads started with an

This practice allows the use of a smaller motor.

Line starting places a great deal of mechanical stress on the

Because the AC drive allows controlled acceleration, the

Most common line-started motors can only operate at their

AC drives allow continuous operation of these motors both

AC drives can control multiple motors and accelerate them at

This allows machines that have multiple motors to be

Most AC drives have built-in braking capabilities that can be

On the other hand, line starters require additional contractors

Smaller AC drives are used in many applications in place of

These drives are often referred to as soft-start drives.

Soft-start applications include pumps, conveyors, grinders, and

Another important feature of some AC drives is that

Some AC drives can use single-phase power and

This allows locations that do not have-phase power

DOL starters do have some advantages over AC drives

Line-started motors develop approximately 200% of rated full-

The complex electronics and higher operational costs make AC

DOL starters do have some advantages over AC drives