1

Chapter 1
Principle and Characteristics of
Induction Motors
Chapter 2
Inverter Principle and
Characteristics
Chapter 3
Operation Characteristics
Chapter 4
Inverter Drive Units Selection

Chapter 5
Inverter Functions and Advantages
Chapter 6
Inverter Drives Precautions
Chapter 7
Harmonics, Noise & Surge Voltage
Chapter 8
Maintenance and Inspection

Introduction
Market of General purpose Inverters

Drives Industry Market Growth in Japan

Export
Domestic

350

Drives up to 75 kW
840
767

300
Units x 10,000

644

250

Tens of
thousands

200

202

715

262

751

286

260

225

120

118

109

144

151

166

109

127

2002

2003

2004

2005

2006

Hundred
million

98

150
93
100
50
0

2007

Actual

Hundred million yen

1000
900
800
700
600
500
400
300
200
100
0
2008
Estimate

Shipments by capacity in 2006

3%
15%
Units

31%

24%

23%
51%

up to 0.75 kW
0.75 kW to 4 kW
4 kW to 15 kW
15 kW to 75 kW

Amount

27%

26%
Data from JEMA

Global Share by Region

USA

Europe
12.8%

15.8%

No.1 Global Share

(fiscal year 2006)
Japan
H
1.7%
G
2.8%

Others
15.2%
F
7.8%
E
8.6%

\ 395.9 billion
2006
D
11.4%

17.4%

Yaskawa
14.1%

C
12.5%

A
13.0%
B
12.8%

*Data has been gathered and analyzed by Yaskawa.

China
11.0%

Asia
17.0%

Yaskawa Drives Business

As a drives manufacturer, we provide overwhelmingly
06
powerful products and application solutions.
Worlds 1
Drives Specialists

00

V1000
Release
st Matrix

Converter Drive

Varispeed AC

Our vast engineering skills, we have earned us the reputation Worlds 1st 3-level Control General-purpose Inverter
Varispeed
Varispeed G7
among our customers as specialists who possess
V7 pico
95
progressive technology and build longWorlds 1st Vector Control General-purpose Inverter
VS-616G5
lasting cooperative relationships.
Varispeed F7S

Sales

Varispeed L7

94
Worlds 1st Ultra-compact ASIPM Inverter
Varispeed F7
VS mini C

88

VSVS-606V7
VS mini J7

Worlds 1st IGBT Low-noise Inverter

VS-616G
LN

85
Worlds 1st Digital Control
VS-616H

79

VSVS-606PC3

Worlds 1st Vector Control

VS-626TV

VSVS-616G3
VSVS-616H3

74
Worlds 1st Transistor Inverter
VSVS-616H
VS-616T

VSVS-616G

VSVS-616G

74

80

85

90

95

00

05

Global Sales Offices and

Production Facilities

YASKAWA ELECTRIC UK LTD. (YGB)

YASKAWA ELECTRIC EUROPE GmbH (YEG)

YASKAWA ELECTRIC AMERICA,INC. (YEA)

New Berlin Wisconsin Panel Facility

YASKWA ELECTRIC KOREA

CORPORATION (YEK)
YASKAWA ELECTRIC (SHANGHAI) CO.,LTD.
(SHANGHAI)
SHANGHAI YASKWA DRIVE CO.,LTD. (SYD)
YASKAWA ELECTRIC (HK) COMPANY
LIMITED (YHK)

YASKAWA ELECTRIC
CORPORATION (YEC)
Inverter Plant (V)
Yaskawa Electric Taiwan Corporation
(YTW)

YASKAWA ELECTRIC (SINGAPORE) PTE.LTD.

(YSP)

: Sales office
: Production facility

YASKAWA ELECTRIC
AMERICA,INC. (YEA)
Buffalo Grove Facility

YASKAWA ELETRICO DO BRASIL

COMERCIO LTD.A. (YEB)

Chapter 1
Principle and Characteristics
of Induction Motors

Types of Motors
DC motors
(series, shunt, compound)
Motors for motive
power

Induction motors
(Squirrel-cage, wound rotor type)
AC motors

Motors

Synchronous motors
(Magnet type, field winding type)
Motors with eddy-current coupling
(VS-MOTOR)

Motors for dynamic

response

DC servomotors
Servomotors
AC servomotors
(SM, IM types)

Configuration
frame
Bracket

box

Bearing

Output
shaft

External
fan
Internal
fan
Center height
(Motor frame No.)

(a)

Rotor end
ring

Rotor End ring

Fan cover
Rotor
Iron core

Configuration of Squirrel-cage Induction motor

(Example of Totally-enclosed Externally-cooled Type)

Secondary
Conductor

(b) Squirrel-cage Rotor

(Excluding Iron Core)

10

Flemings Right-hand Rule

Flemings Left-hand Rule

Force(F)
F
Magnetic
Field(B)
B

Magnetic field
(Flux density B (wb/m2) )

Current(I)

F
Force(F)
B
Magnetic
Field(B)

Current(I)

11

Principle
ARAGOs Disc
(Disc rotates following magnet rotation.)

Induction Effect of Rotating

Magnetic Field
S

Permanent Magnet

Iron Disc
N
S

NS
NS

Flux
N

Rotary Shaft

12

Magnetic Flux Generated by Current

Direction of Mag. flux
from front to back of
paper face

Current Direction
Current Direction

Direction of Mag. flux

from back to front of
paper face

Right Screw
Beginning of
Coil Winding

Direction of Magnetic Flux

Direction of
Magnetic Flux

A. Right hand screw Rule

End of Coil
Winding

B. Coil Current and Magnetic Flux Directions

13

Principle of Rotating Magnetic Field (2 Pole)

1 Cycle
Phase U
3-phase AC
(Current)

Phase V

Phase W

U
V

Direction of
Magnetic
Field

Induction Motor

(a) Three-phase Alternating Current (Power Supply) and Magnetic Field Direction

Three-phase motors use three-phase

alternating current to create a rotating
magnetic field.
U, V, W : START of Coil
U,V,W: END of Coil

V
W

14

Number of Poles and Synchronous Speed

S

P o w e r S u p p ly
F re q u e n c y (f)

N o. of
P o le s
(P )

N o. of
C o ils p e r
Phase

50 Hz

60 Hz

3000

3600

1500

1800

1000

1200

750

900

N
4p

2p

N
S

(a) Synchronous Speed (min-1)

6p

8p
S

N
N

(b) Number of Poles (p)

15

Rotating Magnetic Field of a 4-pole Motor

U

Phase U

Phase V

Phase W

(a) Coil Arrangement

(b) Three-phase
Alternating Current

16

Induction Motor Speeds

Synchronous Speed
The speed at which the magnetic field rotates is called synchronous speed (NS), which depends on the
number of magnetic poles p , that depends on the configuration of the motor stator winding, and
power supply frequency f .

NS =

120 f
p

( min-1 )

NS : Synchronous speed ( min-1 )

f : Power supply frequency (Hz)

Rotating Speed
Rotor speed N ( min-1 ) is a little slower than synchronous speed Ns . This amount is called
slip
slip,
slip , which is defined as follows:

NS N
=
NS

The above equation can be changed into the following one.

Ns : Characteristic value depending
on motor specifications
s : Value varying on the load size

N = N S (1 S )
Therefore:

120 f
N=
(1 S )
p

( min-1 )

17

Characteristics
Current (%)
Starting Current
Rated Speed

Rated Current
No-load Current

Stalling Torque

Torque

Starting Torque
Rated Torque
Ns
Slip (Rating)

Reverse Phase Braking Area

( PLU GGING )

Regenerative Braking Area

(Induction Generator)

Motoring Area

[With 4 poles at 60 Hz ( min-1 )] - 1800

1800

3600

18

Control Method
Load Torque

-1

The intersection of the motor

generating torque and the load
torque becomes the operation
speed.

To change the induction motor speed

Number of
Poles Large

Frequency Small

Voltage Small
Secondary
Resistance Large

Changing p
(Pole change motor)

Changing s
(Primary voltage control)

Changing s
(Secondary resistance control)

Changing f
(Primary frequency control
inverter drives)

19

Types of Inverter Motors

1. Inverter Drive Motors
Totally-enclosed
(With PG)
Model EEK-IM

Fan Cover

Totally-enclosed
Fan-cooled Type
FEQ-X, FEF
FEK-I

Totally-enclosed
Fan-cooled Type
(With electric fan)
FEK-IK

Totally-enclosed
Fan-cooled Type
(With electric fan and PG)
FEK-IKM

Pulse Generator (-M)

External Fan
External Fan (-K)

2. Applied Modification
Geared motors

Output shaft torque increased

Brake motors

Quick brake
AG brake motors

Explosionproof motors

Increased safety explosionproof motors

Explosionproof motors

20

Motor Characteristics at Inverter Drives

The following shows the relation between the magnetic flux, voltage and frequency.

Magnetic Flux

Voltage V
= Constant
Frequency f

Example
When speed is reduced to the half (60 Hz to 30 Hz), according to the above equation, set the
inverter output voltage and output frequency so that the magnetic flux will be constant.
200

V 200( V ) 100( V )
=
=
= Cons tan t
f 60( Hz ) 30( Hz )

Voltage (V)

In actual operation, voltage at low frequency must be increased

by 150% to 200% in order to compensate for voltage drop in the
motor.

100

30
Frequency (Hz)

60

21

Motor Rated Torque

The following shows the equation of motor rated torque.
Rated torque

Rated torque

TM 974

TM

60

P (kW)
Rated speed N (min-1)

Motor rated output

P (W)
Rated speed N (min-1)

Motor rated output

Example
In case of a motor of 7.5 kW, 4 poles, rated speed 1740 min-1

7.5
1740

(kgfm)

Rated torque

TM 974

Rated torque

3
60
7.5

10
TM
41.2 (Nm)

2
1740

4.19

(kgfm)

(Nm)

22

Motor Speed Variation

Output Torque
Torque

When load torque varies

As the load torque becomes greater, the motor speed
decreases (or slip becomes greater).
At this time, the greater the load torque the greater
the motor current.

Load Large
Load Small

Speed

Load Fluctuation and Speed Changes

Voltage Large
Torque

When the motor applied voltage varies

The motor generating torque is in proportion to the
square of voltage.
As the voltage becomes smaller, the speed decreases
(or slip becomes greater).

Voltage
Small

Load Constant

Speed

Voltage Fluctuation and Speed Changes

23

Operations Exceeding 50Hz or 60Hz

Inverter output voltage does not exceed power supply voltage.
Therefore, output voltage becomes constant in the range exceeding frequency
50 Hz or 60 Hz (base frequency).
The following equation shows the relation between motor voltage (V),
frequency (f) and torque.

V
T orque T = K
I
f

K Constant
Current

Since only frequency is changed, torque is reduced in inverse proportion

to frequency if the motor current value is the same
as shown in the above equation.
This area is called constant output area.

24

Chapter 2
Inverter Principle and Characteristics

25

Inverter Configuration

Voltage

Voltage

Voltage

Current

Current

Current

AC
Power

Rectifier Circuit
Converter
Section

DC Intermediate
Circuit
Smoothing
Circuit Section

Invert Conversion
Circuit
Inverter Section

AC
Power

Motor
M

Variable Frequency
/Variable Voltage AC

Commercial
Power

VVVF

Control Circuit Section

26

Actual inverter circuit

Voltage

Voltage

DC

Current

Voltage
AC

Current

Diode

Current
Transister

Register
R
S
T

U
V
W

Capacitor

Contact
input
Forward
Reverse
Multifunction
input
SC

IM

Pulse train output

Digital
operator Analog
monitor

Digital
operator Contact
output
Analog input
Open
collector
Pulse train input
output

Multi-function
analog output
Fault output

Multi-unction
contact output

Output signal

Power
source

Input signal

AC

27

Principle of Single-phase Inverter

Switches
S1, S4

S1
DC
Power
Supply

S3

ON

S2, S3

ON
ON

Ed

+Ed

S1 S4 ON

S1 S4 ON
S2 S3 ON

-Ed

S2

S4

How to Make AC

Current wave

28

Basic Circuit of 3-phase Inverter

Interval a
P
S1

S3

S5

S4

S6

S2

Motor

DC
power
source
N
0
S1
S2
Switching
Pattern

S3
S4
S5
S6
U-V

AC Output

V-W
W-U

60

120

Principle of generating 3-phase

alternating current
180

240

300

360

60

120

180

240

300

29

Basic Circuit of Transistor Inverter

3-phase AC
+Ed

DC
Power
Supply

Ed

IM

Motor

30

Converter Section
and In-rush Current Suppression
MC
P
R
D1

D2

D3

In-rush Current
Suppression Resistor

Ed

V
Vs

D4

D5
E

D6

Vs 1.35

Vs

31

Main Semiconductor Power Elements Used for Inverters

Name

Diode

Thyristor

GTO
(Gate Tum Off
Thyristor)

Bipolar Power
Transistor

IGBT

Power MOS FET

(Power Metal Oxide

(Insulated Gate Bipolar
Semiconductor. Field
Tr.)
Effect Tr.)

Drain

Collector

Symbol

Anode

Gate

Base
Gate
Cathode

Emitter

Features,
Application

Voltage, Current
Waveform

Characteristics

Source

General high-voltage, High-voltage,

large-current rectifier large-current converter
circuits
section
Inverter section, chopper
section attached with
commutation circuit

High-voltage,
large-current inverter
section, chopper
section

Medium voltage,
medium current
high-speed switching,
inverter section

Medium voltage,
medium current
high-speed switching,
inverter section

Low-voltage, smallcurrent high-speed

switching, inverter
section

32

Voltage-type Inverter Control Method

(Ed: DC voltage)
Control Method

Output Frequency

Features
Ed
Ed

PAM Method
(Pulse Amplitude
Modulation)

Output Voltage Waveform

Average Output Voltage
Ed
Ed

PWM Method
(Sinusoidal Wave
Approximate)

PWM:
Pulse Width
Modulation
When the above Output power frequency is 60 Hz, the number of pulses per cycle is
14. Therefore, carrier wave (carrier frequency) is obtained as 6014 = 840 Hz.
Since the actual inverter has this carrier frequency of 15 kHz, the number of pulses
per cycle is 250 pulses (1500060).

Voltage control is
needed for the
converter.
Motor current distortion
is excessive, resulting
in torque ripple.
Frequency and voltage
can be controlled only
in the inverter section.
Smooth operation is
possible at a low speed.

33

V/f Control PWM Inverter

Converter

Inverter

3-phase Power Supply

Current Detector

Motor
IM

Transistor Base Signal

Speed
(Frequency)
Reference

Accel/decel
Interrupt Signal

Voltage/
Current
Detection

Voltage
Reference

N
0

Accel/decel Adjuster

PWM
Signal
Generator

V/f Setter
Frequency Reference

Base
Driver

34

Voltage / Frequency Characteristics

in V/f Control
Rated Voltage

V/f control compensates for the voltage drop value of the motor primary
winding for the constant E/f (magnetic flux).

In Case of Variable
Torque Load

Voltage (V)

In Case of Constant
Torque Load
E/f Constant
(Constant Magnetic Flux)
Compensation for Motor
Primary Winding Voltage Drop

Voltage
Bias

V/f Constant
Frequency f (Hz)

Rated Frequency

35

Vector Control PWM Inverter

Speed
Reference

Torque
Reference

Torque Current
Current Reference
Speed Controller Reference Calculator
Current Amplitude Reference

N
I1
t
I1

I2
Current Phase Reference Each Phase Current
Accel/decel

IM

Reference
Speed/Torque
Adjuster
f
Control Switch

Slip Frequency
Calculation

PWM
fdt

Control
I2

Multiplier
IM
f
f
s

Exciting
Current
Reference

3-phase
Power Supply

Converter

Inverter

Instantaneous
Current
Control Circuit
3- (or 2-) phase Current
Feedback Signal

Current Detector
M
Motor

Speed Feedback Signal

PG (Speed Detector)
(Pulse Generator)

36

Equivalent Circuit and Vector Diagram

l1
r1
I&22
II2&
I1 I&1

V
V&

V
r1
E
r2
I1
l1
I2
M
IM
S

I&IMM

EE&

I&11

I2

II&11

r2
1 s
r2
s

: Motor terminal voltage

r2
: Primary winding resistance
s
: Motor (internal) induced voltage
: Secondary winding resistance
: Motor primary (stator) current
: Primary winding leak inductance
: Motor secondary (rotor) current
: Exciting inductance
: Exciting current (exciting current component of primary current)
: Slip

(a) Equivalent Circuit for Motor One Phase

I1 l1

I1 r1

(b) Vector Diagram

I&MM

37

Open
Loop Vector Control

Flux Observer Block Diagram

Motor Current
Actual Value

Voltage
AC

Inverter

Actual Motor
+

Motor Control

Error

Virtual Motor
Motor Current
Estimated Value

Flux
Estimated Value

Speed
Estimated Value

Observer Gain

38

Auto-tuning

Input the basic numerical values such as motor NP into the inverter so that the motor
determines the motor constants required for the vector control by measurement and
calculation. This function is called Auto-tuning.

In Case of V/f Control

V/f control suitable for the motor
load characteristics is needed in
order to obtain low-speed torque.

In Case of Vector Control

Constant calculation using the
motor test report or combination by
manufacturer is needed.

Varispeed G7
Incorporates the auto-tuning program as standard so that no
complicated adjustment is needed.
The following three methods are available for the auto-tuning.
1. Stop-type tuning only for line resistance
2
Stop-type tuning

3. Stop-type tuning2
4
Rotation-type tuning

39

Features of Control Mode

Varispeed G7

Specifications

V/f Control

V/f Control
with PG Feedback

Open-loop
Vector Control

Flux Vector
Control

Basic
Control

Voltage/frequency control
(open-loop)

Voltage/frequency
control with speed
compensation

Current vector control

without PG

Current vector control

with PG

Speed
Detector

Not needed

Needed
(pulse generator)

Not needed

Needed
(pulse generator)

Option Card for

Speed Detection

Not needed

Needed

Not needed

Needed

Speed Control
Range

1:40

1:40

1:200

1:1000

Starting
Torque

150% at 3 Hz

150% at 3 Hz

150% at 0.3 Hz

150% at 0 min-1

Speed Control
Accuracy

2 to 3%

0.03%

0.2%

0.02%

Torque Limit

Disabled

Disabled

Enabled

Enabled

Torque
Control

Disabled

Disabled

Enabled

Enabled

Typical
Applications

Multi-drives
Replacement for existing
motor of which motor
constants are unknown
Auto-tuning is enabled
only for line resistance.

Simplified feedback
control
Applications where
pulse generator is
attached on the
machine shaft

Any variable speed

drives

Simplified servo
drives
High-accuracy speed
control
Torque control

40

Chapter 3
Operation Characteristics

41

Acceleration
Output Frequency f

Motor speed N
0

Excessive Slip
0
Overload capacity when inverter
capacity is increased

Overload capacity when inverter

capacity is equal to motor capacity

Rated Current
0

Rated Current
0

(a) Proper Acceleration Time

(b) Short Acceleration Time

42

Stall Prevention during Acceleration

Inverter Output Frequency

[Dotted line shows the set
accel. ratio.]

Accel. time becomes

longer automatically.
t

Motor Speed
Peak current is limited to
within the specified value.
Motor Current

43

Stall Prevention during Running

To avoid overloading by rapid
fluid temperature in hydraulic
machines.

Avoid overloading by
decreasing output frequency.

Inverter
Output
Frequency
t

Load

44

Actual Stall Prevention Function

RUN Signal

DC Voltage
Inverter Output Frequency

Edc.

OVOA
Motor Current

45

Deceleration
Motor Operation Mode

Deceleration Time td

N,

Slip

tdCoasting to a stop time

Motoring (Motoring area)

Plus

tdCoasting to a stop time

Regeneration (power generation area)

Minus

Rapid deceleration
Slip: Minus
f

N
Slow deceleration
Slip: Plus

Slip
(Minus)

t
Set Decel. Time td

46

Stall Prevention during Deceleration

Inverter Output Frequency
[Dotted line shows the
set decel. ratio.]

Decel. time becomes

longer automatically.

t
Motor Speed

DC Voltage

DC bus voltage is limited to

within specified value.

47

DC Injection Braking
N, f

N, f

N, f

DC Injection
Braking Time

Free Run

F
DC
Current

DC
Current

DC Injection Braking
Starting Frequency

(a) Frequency Deceleration

(Example of DC Injection
Braking Before Stop)

DC Injection
Braking Time

(b) All-area DC Injection Braking

(c) Coasting to a Stop

48

Input Voltage / Current Waveform

Power Factor =

Active Power
Active Power
=
Apparent Power Active Power + Reactive Power
=

Inverter Input Power

3 Power Supply Voltage Inverter Input Current

INV input current is a distortional wave current including harmonics. Unified effective current
including harmonics is INV input current. Therefore, the power factor expressed by the above
equation is not always equal to the value measured with general power factor meter.
V
I

(a) Commercial Power Operation

(b) Inverter Operation

49

The mechanism of harmonics

current generating
er

et

es

Phase voltage of
power source
er-s
V
Line voltage of
power source

er-s

er-t

es-t

es-r

et-r

et-s

er
r

es

et

EDC

Phase
PhasePhase-R
current
PhasePhase-S
PhasePhase-T

Converter

50

Typical Connection of DC Reactor

Effect of power factor improvement: power supply factor 93 to 95% (at 100% load)*3
Power Factor Improvement Reactor*2
UZDA-B
U

Wiring distance:*3
5 m or less.

Be sure to remove the connected piece

between terminals.

+1+2
NFB
Power
Supply

R
S
T

Inverter

U
V
W

Motor

*1. The connection cable between the

reactor and the inverter must be 5
m or less, the shorter the better.
The size must be equivalent to the
power supply cable or larger.
*2. Models of 18.5 to 75 kW (200-V
class) and 18.5 to 160 kW (400-V
class) are incorporated with DC
reactors. The power factor
improvement is more than 93%.

IM
*3. The inverter power supply power
factor is normally approx. 60 to
90%, which differs depending on
the power supply impedance.

51

Typical Inverter Input Current Waveform

in Each Power Supply Method (1)
Circuit Pattern

Input Current Waveform

Input Current Spectrum

Harmonics
Content

No countermeasures taken
P
+

88%
N

Harmonics Order
AC reactor inserted
P
+

38%
N

5 7

11

DC reactor inserted
P

33%

+
N

11

52

Typical Inverter Input Current Waveform

in Each Power Supply Method (2)
Circuit Pattern

Input Current Waveform

Input Current Spectrum

Harmonics
Contents

12-phase rectification
P
+

12%
N

Harmonics Order
PWM control converter
P
+

3%
N

53

Chapter 4
Inverter Drive Units Selection

54

General-purpose Inverter Series

From General Industrial-use to Consumer Equipment
High-graded Function Current
Vector Control (0.4 to 300 kW)

Varispeed G7
General-purpose Vector Control (0.4 to 300 kW)

Varispeed F7
Small-size Voltage Vector Control (0.1 to 7.5 kW)

VS mini V7
Super Small-size Contactor Type (0.1 to 3.7 kW)

VS mini J7

55

Features of Each General-purpose Inverter

Speed Control
Torque Control

Braking
Method

1:40

2 to 3

VS mini C

Single-phase: 100 V 0.1 to0.75

Single-phase,3-phase: 0.1 to 1.5

3-phase: 0.2 to 1.5

1:40

2 to 3

VS mini V7

Single-phase: 0.1 to 3.7

3-phase: 0.1 to 7.5

3-phase: 0.2 to 7.5

1:40

3-phase: 0.4 to 110

3-phase: 0.4 to 300

Varispeed G7

3-phase: 0.4 to 110

3-phase: 0.4 to 300

VS-616R3

3-phase: 3.7 to 37

VS-686SS5

3-phase: 0.4 to 75

3-phase: 7.5 to 75
3-phase: 0.4 to 160
3-phase: 0.4 to 300

1:40

2 to 3

1:100

0.2

1:40

0.2

0.02

2 to 3
0.2

0.02

1:200
1:1000

2 to 3
1

Varispeed F7

Accuracy (%)

3-phase: 0.2 to 3.7

V/f

Control Range

Single-phase: 0.1 to 1.5

3-phase: 0.1 to 3.7

400V Class

Flux Vector

VS mini J7

200V Class

Open-loop

Power
Regeneration

Control Method

Resistor
Discharge

Capacity (kW)

1:40
1:10
1:500

2 to 3

56

Power
Regenerative
Unit

Power
Regenerative
Converter

For Machine
Tool Spindle

For System

Exclusive-use Inverter Series

Model

Features

VS-676H5

High-graded function type

VS-686HV5S
VS-686HV5
VS-626M5/MR5
VS-626MC5

High-voltage super energy

saving
Exclusive for machine tools
spindle
(high accuracy)
Exclusive for machine tools
spindle (simplified type)

Output Range
200 V: 0.4 to 75 kW 400 V: 0.4 to 800 kW
575 V: 300 to 1200 kW
3300 V: 132 to 1250 kW
6600 V: 250 to 2500 kW
3300 V: 225 to 1800 kW
6000 V: 450 to 3000 W
200 V: 2.2 / 3.7 to 22 / 30 kW
400 V: 3.7 / 5.5 to 37 / 45 kW
200 V: 2.2 / 3.7 to 11 / 15 kW
200 V: 15 to 75 kW
400 V: 15 to 300 kW

Sinusoidal wave PWM

VS-656DC5

Harmonics: 0
Power factor: 1

200 V: 3.7 to 37 kW
400 V: 3.7 to 75 kW
VS-656RC5

Low cost type

57

Capacity Selection
Check Item

Load type and characteristics

What to Decide

Motor Type

Machine specifications
Operation method
Motor selection
Inverter capacity selection

Motor Output
Inverter Output

Inverter model selection

Inverter selection

Inverter Model

Peripheral units, options

Peripheral units, Options

Investment effect

Enclosure

Investment effect
Final specifications

58

Typical Load Torque Characteristics

Loads of which output

becomes constant for the speed

Loads of which load torque

varies depending on the speed
Loads having the nature
between the low output load
and the constant torque load

Fan
Blower
Pump
Other fluid loads

Constant tension
force winder of
center drive
Spindle motors of
machine tools
Veneer rotary laths

Torque, Output

1.0

Load Torque
Load Output
0

Torque, Output

Loads of which load torque is

decreased as the speed is
reduced

Conveyor
Crane
Winch
Other friction loads
and gravity loads

Speed Torque Characteristics

Torque, Output

Load torque is constant for

speed.
General friction loads

Typical Load

Torque, Output

Reduced
Power

Constant
Power

Reduced
Torque

Control
Torque

Load Characteristics

1.0

Speed

Load torque is constant regardless of

speed.
Output power is in proportion to speed.
T=k
T: torque
P = kN
P: Output
k: Proportional constant

Load Torque

Load Output
Speed
2.0

Load Torque
1.0

Load Output
Speed
2.0

2.0

Load torque is in proportion to the

square of speed.
Output is in proportion to the
cube of speed. T = kN2
P = kN3
Output power required by the load is
constant.
Load torque is in inverse
proportion to speed.
T = k/N
P=k
Speed torque/output
characteristics between the
constant torque load and constant
output load

Load Torque

1.0

Load Output
2.0

59

Difference between Inverter Exclusive-use Motor

and Standard Motor
Standard Motor

Motor may be overheated

in a low-speed area.

Motor can operate properly even

in a low-speed area.
The motor is designed for inverter drives,
therefore, the temperature is within the
specified value even if the motor is used at a
low speed.
Example:
Allowable Load Torque
(%)

Allowable Load Torque

(%)

Since the min-1 of the external fan becomes

lower in a low-speed area, the cooling
capability is deteriorated. Therefore, the
motor may be overheated unless the load is
reduced in a low-speed area.

Exclusive-use Motor

60

3 20

Standard Motor Output

1:10
Const. Torque Motor

55

0.5

Inverter Exclusive-use Motor Output

<Important>
The above characteristics show the torque that can be allowed at continuous operation. There is no
difference in the torque that the motor can generate in a short time, such as at starting, between the
standard motor and the constant torque motor.

60

Operation Pattern and Calculation of Load Torque

Can accelerate?
Motor torque exceeding the torque required
for acceleration (Ta+TL) must be available.
Can start?
Motor starting torque must be
greater than load starting torque.
ta
Load Torque

TL

Accel Torque

Ta

Is motor temperature proper?

Temperature rise must be within the specified value.
Can decelerate?
Brake torque required for deceleration
must be available.
Energy at deceleration can be consumed or
regenerated to the power supply.
td

Time

f
V

TL

Td

Ta

Decel Torque

N
Td
2J
60
td

2J
N
60
ta

Required Motor Torque

N
m

Ta
TL

The inverter regeneration capability is a

key point. The regeneration capability
depends on selection of the inverter
output and braking unit type.

Ta
TL

Required Brake Torque

The volume of the motor output torque is a key point.

Torque depends on the motor output, inverter output,
control method or boost amount.

TB=
Td
TL

61

Power Flow and Regenerative Braking

(a) Motor Mode
Power Flow

Power Flow
i

Commercial
Power

IM

Mechanical Energy

S0
(Motor power factor cos0)

(b) Generator (Regeneration) Mode

Thermal Energy
*1

Power Flow
i

R
Commercial (i =0
Power

IM
*2
(ON)

Mechanical Energy
Kinetic Energy
Potential Energy

S0
(Motor power factor cos 0)

*1 Discharge resistor = braking resistor

*2 Monitors DC voltage and turns ON the transistor when DC voltage exceeds the specified level.
The inverter built-in braking transistor or braking unit is used.

62

Peripheral Devices and Their Connections

(1) Power supply transformer
(7) DC reactor
(2) Circuit breaker or
(3) Leakage breaker

(4) Contactor

(6)
Noise filter

(5) AC reactor

(8) Noise filter

(12) Zero phase reactor

(9) Contactor

(11) Contactor for commercial

power backup
(10) Braking resistor unit

(13) Thermal
relay
(14) Motor

63

How to Select Peripheral Devices

No.

Name

Purpose and Selecting Points

Power transformer

Transformer capacity Inverter capacity 1.5

Circuit breaker

Breaks accidental current (shortcircuit current).

Rated current inverter rated current 1.5 Described in the inverter catalog.
Grounding protection
High frequency leak current protection for electric shock accident & leakage current fire.
1. Use a breaker provided with countermeasures for high frequency leakage current.
2. Increase sensitivity current.
3. Decrease inverter carrier frequency.
Since the inverter has the contactor function, any contactor is not needed except for special
cases.
When a braking resistor is used, insert a contactor to make thermal trip circuit.
Perform RUN/STOP at the inverter side and set the contactor to Always ON to use.

Leakage breaker

Contactor

5
7

AC reactor
DC reactor

For high frequency current suppression and improvement of power factor

Install a reactor to protect the inverter when the power supply capacity is large.

6
8

Noise filter or
Zero-phase reactor

Prevent radio noise generated by inverter section

9
10

Braking unit
Braking resistor unit

Used when an electrical brake is needed (when the required braking torque exceeds 20%).

11
12

Contactor for
commercial power
backup

Used for backup at inverter failure or when commercial power supply is used for normal
operations.

13

Thermal relay

Not needed when one motor is driven by one inverter.

(Connected when more than two motors are used.)

64

Chapter 5
Inverter Functions and Advantages

65

Advantages of Inverter Applications (1)

No.

Advantage

Technical Details

Main Precautions

Can control speeds

of the specified
constant-speed
type motors.

Number of revolutions changes

when squirrel-cage-type motor
terminal voltage and frequency
are changed.

Since a standard motor has

temperature rise that becomes
greater at a low speed, torque must
be reduced according to frequency.

Soft start/stop enabled.

Accel/decel time can be set freely

from a low speed.
(0.01 to 6000 seconds).

Set proper accel/decel time after

performing load operation.

Little motor heat generation since

smooth accel/decel is enabled with
little current.

Motor or inverter capacity frame

must be increased depending on the
accel/decel capacity. Check the
accel/decel time and load J.

Because of phase rotation changes

by transistor, there are no moving
parts like conventional contactors
so that interlock operation can be
assured.

When applying the inverter to an

elevating unit, use a motor with a
brake to hold mechanically for
stand still.

2
t

Cushion Start

Highly frequent
start/stop enabled.

Cushion Stop
f

FWD/REV run enabled without main

Inverter
circuit contactor.
4

FWD
Run

REV
Run

RUN Command
FWD
Run
REV
Run

66

Advantages of Inverter Applications (2)

No.

Advantage

Technical Details

Main Precautions

Can apply an electrical brake.

Since mechanical energy is converted into

electrical energy and absorbed in the
inverter at decel, the motor can automatically provide braking force.
DC current is applied to the motor around
zero-speed so that it becomes dynamic
braking, to completely stop the motor.

Braking force is approx. 20% when

only the inverter is used.
Attaching a braking resistor
(optional) externally can increase
the braking force.
Pay attention to the capacity of the
resistor.

Can control speeds of the

motor under adverse
atmosphere.

Since the inverter drives squirrel-cage

motors, it can be used easily for
explosionproof, waterproof, outdoor or
special types of motors.

An explosionproof motor in
combination with an inverter is
subject to explosionproof
certification.

High-speed rotation enabled.

Commercial power supply can provide up

to 3600 min-1 (2-pole at 60Hz) or 3000 min1 (2-pole, at 50Hz).
A general-purpose inverter can increase
frequency up to 400 Hz (12000 min-1) while
a high-frequency inverter can increase it
up to 3000 Hz (180000 min-1).

The speed of a general-purpose

motor cannot be increased by
simply increasing the frequency.
(It can be applied without being
changed if frequency is approx. 120
Hz.)
Mechanical strength and dynamic
balance must be examined.

5
t
Electrical Braking

60Hz

120Hz

400Hz

67

Advantages of Inverter Applications (3)

No.

Advantage
The speeds of more than one motor
can be controlled by one inverter.
IM

8
IM

Inverter

Technical Details

Main Precautions

The inverter is a power supply unit

to the motor, therefore, as many
motors as the capacity allows can
be connected.
These motors do not have to be the
same capacity.

The number of motor revolutions

differs depending on each motor
characteristics or load ratio even at
the same frequency.
(Among general-purpose motors,
speed deviation of 2 to 3% can be
considered.)
Synchronous motors have the same
number of revolutions.

IM

Power supply capacity can be small

when the motor is started up.

Large current (5 or 6 times larger

Transformer capacity (kVA)
than the motor rating) does not
= 1.5 inverter output capacity
flow as with a commercial power
supply start.
Current can be limited to at most
100 to 150% by low-frequency start.

Number of revolutions becomes

constant regardless of power supply
frequency.

Output freq. can be set regardless

of power supply freq. 50/60Hz.

10

68

Motor and Power Supply Current

in Inverter Drives
100% Voltage (100% Speed)

Inverter Output
Voltage

t
150%
100% Current

Inverter Output
Current

t
Inverter Input
Current

150%
100% Current

69

Minimize the Energy Consumptions

Energy Saving for

General Industrial Machines & Systems
(1)Energy Saving for Mechanical Systems by Means of Variable Speed Drive of Motors
A . Variable Torque Load
B . Constant Torque Load
C . Constant Power Load
(2)High Efficiency Motors
A . High Efficiency Induction Motor
B . IPM(Interior Permanent Magnet Motor)
(3)Change to High Efficiency Drive for Existing Variable Speed Drive
A . Primary Voltage Control of Induction Motor
B . Secondary Resistor Control of Wound Rotor Induction Motor
C . VS-Motor (Eddy Current Coupling Motor)
D . Variable Frequency Drive of Induction Motor
E . Variable Frequency Drive of IPM
(4)Regeneration of Braking (Kinetic)Energy
A . Regenerative Converter
B . Drive Regenerated Energy To Another Inv. Drive
(5)Others
A . ON-OFF Control for Mechanical Systems
B . Inverter Energy Saving (Voltage) Control Method

70

Optimum Energy-saving Plan for Facility

Applied Load
Fans
Pumps
Blowers
(Any Variable Torque
Load)
Extruders
Conveyors, etc.
(Any Constant Torque
Load)
Cranes
Elevators, etc.
Rewinders
General Machines

Concept of Energy-saving
Replace with a more efficient motor.
Reduce a redundancy of the facility for the actual loads.
Abate the head loss at valves or dampers.
Change to more efficient drives.
Replace the primary voltage control, secondary resistance
control, eddy-current coupling (VS motors) with a more efficient
control method(Frequency Control).
Collect the regenerative energy at lowering by using the inverter
power supply regenerative function.
Collect the regenerative energy of the rewinders.
Replace with a more efficient motor.
Reduce the starting energy.
(Use the inverter as a starter to stop the operations positively
whenever the load ratio is low.)

(2)
(1)
(1)

(3)

(4)
(4)
(2)
(5)a

71

Air Volume and Wind Pressure

Characteristics of Fan
R50
Hd

( p.u.)
1.0

R
A

Ad

H1.03N0.56NQ0.59Q
RQ

Hi
H0
0

Ai
N50

Rated air volume: 250m3/sec

Rated wind pressure: 433mmAq
Fan efficiency at rated air volume: 0.7
Fan efficiency at 50% air volume: 0.6

Q50
0.5
Air volume (Q)

1.0 ( p.u.)

72

Energy saving Effect in the Fan Application

In the case of damper control
The wind pressure in 50% air volume is Hd = 1.03 + 0.56 0.5 - 0.59 0.52 = 1.16
QH
0.5 1.16
P
=
=
The power becomes D 6120 6120 0.6 0.9 250 433 = 19.0kW
f m

m = 0.9 is the motor efficiency

In the case of inverter control

The wind pressure in 50% air volume is Hi = 0.52 = 0.25

The power becomes Pi =

QH
0.5 0.25
=
250 433 = 3.7kW
6120fmi 6120 0.7 0.9 0.95

i = 0.95 is the inverter efficiency

The electric-power saving quantity

PS = PD Pi = 15.3kW

On the assumption of electric power unit price: \15/kWh and annual continuous running:
8000hours,We can save the electric charge as follows. 15.3 15 8000 = \ 1,836,000

73

Flow Rate and Head Characteristics of Pump

R50

1.5

Squeeze volume

Head (P.U)

HB
1

N
R0
Low speed

Hi
0.5

N50

0.5

Flow rate (P.U)

74

Energy saving Effect in the Pump Application

In the case of valve control
The head in 50% flow rate is HB = 1.25 0.25 0.52 = 1.188

The power becomes PB =

QH
0.5 1.188
=
6 25 = 28.9kW
6.12pm 6.12 0.56 0.9

m = 0.9 is the motor efficiency

In the case of inverter control

The head in 50% flow rate is Hi = 0.7 0.1 0.52 = 0.725

The power becomes Pi =

QH
0.5 0.725
=
6 25 = 13.7kW
6.12pmi 6.12 0.76 0.9 0.95

i = 0.95 is the inverter efficiency

The electric-power saving quantity

PS = PB Pi = 15.2kW

On the assumption of electric power unit price: \15/kWh and annual continuous running:
8000hours,We can save the electric charge as follows. 15. 2 15 8000 = \ 1,824,000

75

Outline of Software Functions (1)

Function Name
MultiMulti-step Speed
Operation

Applications
Feeders, etc.
etc.

Accel/decel Changing
Operation

Automatic panel
feeders, etc.

S-curve Time
Characteristics

feeders such as
conveyors, carts,
etc.
Pumps
Blowers
General machines

Frequency Upper/lower
Limit Operation
Specified Frequency
Setting Prohibition
(Frequency Jump Control)
DWELL Function
HeavyHeavy-inertia loads
such as centrifugal
separators etc.
Speed Search
Inertia load drives
such as blowers,
winders
Compensation for
General machines
Momentary Power Loss
Fault Retry

AirAir-conditioning,
etc..
etc

Purpose
Schedule operation
at specified speed

Description
By combining signals, operation is performed at frequency stored
internally (up to 99-step speeds). Connection with the sequencer is easy;
simplified positioning by using limit switch is also possible.
Changing external
Using an external signal can change the accel/decel rate. This function
signal of accel/decel is effective when two motors are driven alternately by one inverter or
time
when smooth accel/decel is needed only in the highhigh-speed area.
Prevention of
Smooth movement can be achieved by setting SS-curve delay when
start/stop shock
accel/decel starts or finishes.
Limit of motor
revolutions
Prevention of
machine system
vibration
Smooth accel/decel
of heavyheavy-inertia
loads
Starting of coasting
motor

Frequency reference upper/lower value, bias and gain can be set

individually without adding any peripheral devices.
In order to prevent vibration of the machine system, the oscillation point
is avoided automatically during constantconstant-speed operation. This function
can also be used for dead zone control.
Prevents the motor from stalling by holding output frequency temporarily
during accel/decel.

Continuing operation
at a momentary
power loss
Improvement of
operation reliability

Restart the motor automatically after recovery from a momentary power

loss by using the remaining control power supply to continue the motor
operations.
Resets the fault automatically after the inverter detects a fault and
performs selfself-analysis and restarts the operation without stopping the
motor. Up to 10 retry operations may be selected.

Performs pullpull-in operation automatically into the set frequency without

stopping the coasting motor.
motor. Motor speed detector is not needed.
needed.

76

Outline of Software Functions (2)

Function Name
Applications
Carrier Frequency Setting General machines

Load Speed Display

General machines

Purpose
Noise reduction

Improvement of
monitor function
Pulse Train Input
General machines
Improvement of
operability
Pulse Train Output
General machines
Improvement of
monitoring
performance
Stopping Method
General machines
Stopping method
Selection
suitable for the
machine
characteristics
3-wire Sequence
General machines
Simple configuration
of control circuit
Frequency Hold Operation General machines
Improvement of
operability
UP/DOWN Operation
General machines
Improvement of
operability
Frequency Detection
General machines
Frequency detection
to be used for
interlock
Machine protection,
Overtorque Detection and Machine tools
Undertorque Detection
Blowers, cutters, improvement of
reliability for
extruders
continuous operation

Description
Sets the inverter carrier frequency to any arbitrary value to reduce
noise oscillation from the motor and machine system.
system. This function is
also effective for reducing noise.
noise.
Can display the motor speed (min-1), load machine rotating speed (min-1)
or line speed (m/min).
(m/min).
In addition to the function as frequency reference, PID aimed value and
PID feedback value at PID control can be input as a pulse train.
Frequency reference, output frequency, motor speed, output frequency
after softsoft-start, PID feedback amount and PID input value can be output
in pulses.
Selects deceleration to a stop, coasting to a stop or DC injection
braking stop according to the braking torque or machine inertia.

Operation is enabled using automaticautomatic-recoveryrecovery-type pushbutton switch.

Holds frequency increase/decrease temporarily during acceleration or
deceleration.
Speed setting is enabled remotely by ON/OFF operation.
Specifies the set value of output frequency, and outputs to the multimultifunction output terminal when frequency exceeds the range or becomes
short.
"Closed" when motor generating torque exceeds the overtorque
detection level. Can be used as an interlock signal for machine
protection such as cutting loss or overload detection of machine tools.

77

Outline of Software Functions (3)

Function Name
Stall Prevention

Applications
General
machines

Electronic Overload
Thermal Relay

General
machines

Torque Limit (Droop

Pumps,blowers,
Characteristics Selection) extruders, etc.
etc.

Purpose
Machine protection,
improvement of
reliability for
continuous operation
Detection of motor
overload
Machine protection
Improvement of
reliability for
continuous operation
Torque limit
Automatic operation
with maximum
efficiency
Automatic process
control

EnergyEnergy-saving Control

General
machines

PID Control

Pumps,
airair-conditioning,
etc.
etc.
Conveyors of
Proper distribution of
distributed drives load
MultiMulti-drive
motors
Elevators, carts ZeroZero-speed stop to
lock the motor

Droop Control

Zero Servo Function

Description
Interrupts accel/decel when frequency reaches each set value during
acceleration, deceleration or running, and continues operation when it
becomes lower than the set value.
Set the motor rated current value and select the allowable load
characteristics for each motor type, and the electronic overload thermal
relay performs overload protection.
Adjusts output frequency according to the load status when the motor
generating torque reaches a certain level.
level.
Optimum for tiptip-less operation for pumps or blowers.
blowers.

Supplies sufficient voltage for the motor to reach maximum efficiency

according to the load or rotating speed.
Calculates the PID in the inverter and uses the result of the calculation
as its own frequency reference to perform constant control of pressure,
flow rate, wind amount, etc.
etc.
Sets motor speed regulation to an arbitrary value.
value.
Making highhigh-resistance characteristics distributes the loads of several
motors properly.
properly.
Holds a motor in the locked status at zero speed whether external force
is applied in the forward or reverse direction.
direction.

78

Application for Dust Collection Blowers

Similar Machines
Air-conditioning fans for buildings
Fans for cooling tower
Dust collection blowers
Fans for boilers
Heat treating furnace blowers

Functions Available
Changing of commercial power supply
and inverter operations
Restart from coasting status
Energy-saving control mode at light load
Fault retry
Blower

Dust Collector
Damper

MCB

MC

MC
Inverter
MC

Motor

79

Application for Chemical Feeding Pumps

Raw Water
Flow Rate
Detection

Pump
Chemical

Adjuster

Similar Machines
Chemical feeding
pumps
Cool/warm water
circulation pumps
Water supply/ discharge
pumps
Hydraulic pumps
Submersible pumps

Speed Reference
(4 to 20 mA)
MCB
Inverter

Functions Available
Energy-saving control mode at low speed
4-20mA reference by instrumentation

Motor

PID control
Minimum speed setting

80

Conveyor Follow-up Operation

Similar Machines
Raw material supply conveyors
Shuttle conveyors
Chain conveyors
Steel pipe feeding conveyors

Functions Available
Improvement of constant position stop accuracy
Increasing the starting torque Smooth accel/decel
Changing accel/decel time
Simultaneous control of several motors by one inverter
Hopper
Feeder
Conveyor
Geared
Motor

MCB

Inverter

Power Supply

Geared
Motor

Inverter

MCB
Power
Supply

Pulse Train
Input
PG Pulse Encoder

Main Speed
Setting

81

Example for Crane Exclusive-use

Software ( V/f Control )
Speed Reference
Closed
(FWD) Run Command (F)

Released

BF

Output Frequency
IOUTIF
Brake Release Command BR
Brake Release Check BX

Brake Operation

FTF
HF

FRF
Closed

Released
BT
Released

HT
Closed

BDT

BDT
Released

Closed

IOUT : Inverter Output Frequency (Actual)

FRF : Brake Release Frequency (Set)
BF : Brake Operation Stand By Frequency (Set)
BT : Brake Operation Delay Time (Set)
IF : Brake Release Current (Set)

BDT : Brake Operation Delay Time (Actual)

FHF : Brake Make Up Frequency (Set)
HF : Slip Down Prevention Frequency (Set)
HT : Slip Down Prevention Time (Set)

82

Connection Diagram for Cranes

()

Braking Resistor Unit (Optional)

OFF

ON

MB MC

FWD
Run

REV
Run

MS Master Switch

MC Main Circuit Conductor

Stop

Emergency

Main
Switch

Fault
Reset

Brake
Release Check

Multi-speed
1Ref 1
Multi-speed
2Ref 2

External
Baseblock *

Multi-speed
3Ref 3
Not
Used

Accel/decel
Time Selection 1
1
(a)
Emergency
Stop (NO Contact)
External Fault

REV Run Command

F FWD Run Command

B Brake Conductor

Brake Self-holding

Brake
Applying Command

9 M2
10
M1

* External baseblock signal

baseblock at closed.

2k

BBX Brake Applying Command

BX Brake Release Check

2k
2k

P P

P
*

()

Note *

: Twisted pair-shielded cable

1 2
Varispeed
Varispeed
G7

R(L1)
S(L2)
T(L3)

U(T1)
V(T2)
W (T3)

S1
FWD Run/Stop
S2
REV Run/Stop

2 2
Analog
Monitor
S3
S4

1 1
Analog
Monitor
S5
S6
S7
Multifunction Terminal
S8
S9
S10
S11
S12
SC
BR M 1
Sequence Common
(0V)
Insulated from (0V)
terminal.
M2
E(G)
Shielded
Sheath Cable

Terminal
Connection
FLT
PR
MA
A1
MB
A2
MC
A3
AC
0V

(3)

AM
AF

Class 3 Grounding
(100 or more)

Multifunction
Analog Output

AC

()
AC250V1A
DC30V1A

Brake Release Command

(Brake released at closed)
250 VAC, 1 A or less
30 VDC, 1 A or less

AC250V1A
DC30V1A

Fault Contact Output

250 VAC, 1 A or less
30 VDC, 1 A or less

P1
P2
PC
Multifunction PHC Output
A
48 V, 50
mA or less
P3 48V50m
C3
P4
C4

83

Principle Diagram of Lathe

Similar Machines
Polishers
Grinders
Small lathes
Plano miller feeders
Milling machines
Drilling machines
Presses

Functions Available
Blade cutting loss prevention
Control by digital inputs

Wide range of constant output power

Vibration control

Spindle

X-axis

Z-axis

Motor

Core
Clamper

84

Elevator Application
Functions Available
Improvement of cage landing frequency
Soft-start with S-curve function
Slip prevention at start/stop
Battery operation at a power failure

Converter Section

Braking Resistor, Braking Transistor

(Externally Mounted)
Inverter Section
Induction Speed
Reducer
Motor

AC
Reactor

Elevator Controller
Cage Calling
Signal
Entrance
Calling Signal

Operation
Control
Torque Ref.
Generated
Position
Calculation
Speed Ref.
Generated

Run Operation
PWM Control
Signal
Status Signal AC Current
Fault Signal
Controller
Torque Compensation
Speed Controller

Speed
Ref.

Vector Control
Speed Feedback

Speed/Position Detection
Load Detection

Cage
Balance Weight

Sheave
Current Detection

3-phase AC Power
Supply

Vector Control PWM

Inverter

Load Detector

Similar Machines
Escalators
Rope ways
Cable cars
Electric railcars
Electric
automobiles

85

Chapter 6
Inverter Drives Precautions

86

Installation

(a) Vertical

(b) Horizontal

(b) Side by Side

87

Mounting
Ambient temperature:
50mm or more

Air
120mm or more

-10 to 40
Ambient humidity:
90% RH or less
Vibration:
Less than 20 Hz
9.8 m/s2 or less
20 to 50 Hz
2 m/s2 or less

30mm or more 30mm or more

50mm or more

(a) Right and Left Space

120mm or more
Air

(b) Top and Bottom Space

88

Totally-enclosed Type Control Panel Installation

Remove the unit top and bottom covers for the 20HP (15 kW)
or less models (200-V class, 400-V class).
Totally-enclosed Type
Control Panel
Top Cover
In-panel Air
Temperature at Top:
10 to +55

Top Cover(One-touch)
(
)

Ambient temperature:
+14 to 113F

Cooling
Fin

Cooling Fin

(-10 to 45 )
Ambient humidity:

Open chassis Type

Inverter

90% RH or less
Vibration:

Bottom Cover
Inverter Intake Air
Temperature :
10 to +45

Ambient Temperature 40

Less than 20 Hz
9.8 m/s2 or less

20 to 50 Hz
2 m/s2 or less
Bottom Cover
Bottom Cover Mounting Screw

89

Multiple Inverters Grounding

Inverter
(1)

Inverter
(2)

Inverter
(3)

(a)

Best Grounding

Inverter
(1)

Inverter
(2)

Inverter
(3)

(b)

Good Grounding

Inverter
(1)

Inverter
(2)

Inverter
(3)

(A loop must not be made.)

(c)

Wrong Grounding

90

Allowable Load Characteristics of

Standard Motors
25%ED (or 15 minutes)
40%ED (or 20 minutes)
60%ED (or 40 minutes)
100
90

Run

Run

80
Torque (%)

70
60

Continuous

50

Stop

60

20
Frequency (Hz)

R
ED 100

91

Chapter 7
Harmonics, Noise & Surge Voltage

92

Difference between Harmonics and Noise

Frequency Band

Harmonics
40th to 50th harmonics (up to several kHz)

Main Source

Inverter section

Converter section

Transmission Path

Electric wire (conduction)

Space (radiation)
Induction (electrostatic,
electromagnetic

Electric wire

Influence

Distance, wiring distance

Line impedance

Generating Amount

Voltage variation ratio

Switching frequency
Sensor malfunction
Radio noise
Change the wiring route.
Install a noise filter.
Install INV. in a screened
box

Current capacity

Failure
Corrective Actions

Noise
High frequency
(10 kHz or more)

Overheat of capacitor for P.F improvement

Overheat of generator
Install a reactor.
12-phase rectification
Sinusoidal wave power regeneration
converter

93

Harmonics and Noise Sources

Harmonics Current Generated
by Rectifier Circuit

Noise Generated
by High-speed Switching

Motor
+

Smoothing
Capacitor

Commercial Power

Bridge Rectifier

Converter Section

Inverter Section

94

Fundamental Wave + Harmonics = Distorted Wave AC

(Harmonics Superimposed on Fundamental Wave)
A
2

Fundamental Wave Current

(at 50 or 60 Hz) 0

Harmonics Current
(Example of 5th Level Harmonics)
(Amplitude Ratio: 0.3)

A+B

Distorted Wave Current

95

Generation of Harmonics Current

er

es

et

Power Supply
Phase Voltage
er-s
V
EDC (Without Capacitor)

Power Supply
Line Voltage
Power Supply
Current Waveform
Phase R
ir
Phase S
is
Phase
it

er-s

er-t

es-t

es-r

et-r

et-s

er
r

es

et

EDC

Converter

96

Reactor Connection
(Harmonics Current Suppression)
Inverter

AC Reactor

Motor

Commercial
Power

(a) AC Reactor

DC Reactor

(b) DC Reactor
Inverter

Motor
Commercial
Power

97

Noise Transmission Paths

Conductive noise
: Noise that flows out through the power supply line or grounding line

Induction (electromagnetic, electrostatic)

: Noise transmitted by electromagnetic or electrostatic integration for the signal
lines provided for the inverter main circuit wiring

Radiation
: Noise radiated into the air through the inverter, motor unit, main circuit wiring
that work as antenna.

Radio

Power Supply
Transformer
Inverter

Machine

Amplifier

Electronic
Device

Sensor

98

Induction Noise Suppression and

Metallic Raceway
Signal Line

Shielding (Steel) Plate

Power Line

Wiring Separation by
Rack or Duct

Metallic Raceway

Metallic Raceway
Inverter

99

Conductive Noise Suppression

Inverter
Power Supply

Inverter

Power Supply

(a) Capacitive Filter

(b) Inductive Filter (Zero-phase Reactor)

Inverter

Power Supply

(c) LC Filter

100

Inverter Noise Prevention

(Shielded Sheath Wire)
Junction Terminal

Inverter

Inverter

0V

0V

(Common)

(Common)

101

Progress and Reflection of Surge Voltage

(Leading Edge of One Pulse)

(Twice Surge Voltage

Applied to Terminals)

Progressive Wave
Inverter

Reflected
Wave

Progressive
wave reflects at the rapid changing

point
(motor terminal section) of line impedance.

Motor

102

Surge Voltage Suppression by Filter

PWM
Inverter

(a) Test Circuit

IM
Filter
Expanded Diagram

Expanded Diagram
[Inverter Output]

[Motor Input]

(b) Result of Waveform Observation

(5s/div, 250/div)
Without Filter

With Filter

Inverter Output

Motor Input

103

Motor Surge Voltage Suppression by Filter

Motor Terminal Voltage
(Without Filter )
Filter

~~~

PWM Inverter
Motor
Unless any filter is installed, surge
voltage may be generated at the
motor terminal, which may affect
motor insulation.

104

Features of 3-level control

The solution to 400V class inverter drive problems
1. Low surge voltage
Suppresses motor surge voltage, eliminating the
need for the motor surge voltage protection.
2. Low electrical noise (Radiated, Conductive)
3. Low acoustic noise
4. Electrolytic corrosion of motor bearings due to shaft voltage

105

Actual Measurement of Shaft Voltage

(Rotor)
(Opposite to Directcoupling Side)

(Direct-coupling Side)
(Stator)

V: Measuring Device
R: Non-inductive Resistor (1k)

Shaft Voltage
(mV)

(a) Example of Shaft Voltage Measuring Circuit

Inverter: PWM
Motor: 3.7 kW, 200 V, 4 poles
V/f characteristics: Constant torque

Inverter
Commercial Power
Drives

Commercial Power Supply Drives

(Hz)
Inverter Drives

(b) Example of Shaft Voltage Measurement (between Shafts)

(c) Shaft Voltage Waveform

106

Chapter 8
Maintenance and Inspection

107

Failure
Ratio (t)

Failure Patterns
Service Lifetime

Specified Failure
Ratio
0

ta

tb
t
Accidental Failure Period

Initial Failure Period

Wear-out Failure Period

108

Daily Inspection and Periodical Inspection

(From JEMA Information)

Place

Item

Checking Item

Whole

Peripheral environment
Whole unit
Power supply voltage

Ambient temperature, humidity, dust, hazardous gases, oil mist, etc.

No excessive vibration or noise.
Check that main circuit voltage or control voltage is normal.
Megger check between main circuit terminal and ground terminal
No loose connections
No traces of overheating in components
Clean.
No distortion in conductor
No breakage or deterioration (cracks, discoloration, etc.) in cables
No odor, excessive beats or noise
No damages
No liquid leakage
No projection (safety valve) or bulge
Measure electrostatic capacity and insulation resistance.
No chattering at operations
Timer operation time
No roughness on contacts
No crack in resistor insulating material
No disconnection
Balance of output voltage between each phase by inverter single-unit operation
No failure in protective or display circuit by sequence protection test
No odor or discoloration
No excessive corrosion
No traces of liquid leakage or deformation
No excessive vibration or noise
No loose connections
Clean the air filter.
All lamps lights correctly.
Clean.
Indicated values are correct.

Whole

Main Circuit

Connected conductor,
Power supply
Transformer, Reactor
Terminal stand
Smoothing capacitor
Relay, Contactor
Resistor

Control Circuit,
Protective
Circuit

Operation check
Component
check

Whole
Capacitor

Cooling System

Cooling fan

Display

Display
Meter

Schedule
Periodical
Daily
1-yr 2-yr

109

Component Replacement Guidelines

Name
Cooling fan
Smoothing capacitor

Standard
Replacement Period
2 to 3 years

Method
Replace.

5 years

Replace on investigation.

Breaker, relay

Determine what to do on
investigation.

Timer

Determine after checking the

operation times.

Fuse

10 years

Replace.

Aluminum capacitor on
PC board

5 years

Replace on investigation.

Note : Operational Conditions

Ambient temperature : Annually 30
in average
Load ratio : 80% or less
Operation ratio : 12 hours or less per day

110

Precautions on Measurement
Inverter
Input

Output

Approximate Waveform

Element

Meter

Voltage

All effective
values

Moving iron type

voltmeter

Current

All effective
values

Moving iron type

ammeter

Voltage

Fundamental Rectifier type

wave effective voltmeter (Model
value
YEW2017, etc.)

Current

All effective
values

Moving iron type

ammeter *

* Clamp meters available on markets have differences in characteristics between manufacturers.

Especially, measured values tend to be extremely small at low frequency.

111

Purpose and Types of Protective Functions

Inverter Protection

Overcurrent OC
Overvoltage OV

Protection

Grounding GF
Main circuit undervoltage UV1
Cooling fin overheat OH
Braking transistor error rr

Warning

Inverter overload OL2

Motor Overheat Protection

Motor overload OL1

Others

Overtorque detection OL3/OL4 lit

CPU error CPF

Operation status is not proper.

Overtorque detection OL3/OL4 (blinking)

Undertorque detection UL3/UL4 (blinking)

Prediction of protective
function operation

Inverter overheat prediction OH2

Radiation fin overheat prediction OH

112

Level at Which Protective Function Operates

Current
200%

160%
150%

100%

DC Voltage
Inverter output
overcurrent : OC

Approx. 410 V
(Approx. 820 V)

Overload anti-time-interval Approx. 380 V

characteristics
(Approx. 760 V)
Stall prevention level
during running
Approx. 365 V
Stall prevention level
during acceleration

Inverter rated
output current

Can be changed.

(Approx. 730 V)

Approx. 190 V
(Approx. 380 V)

Main circuit overvoltage : OV

Voltage at stall prevention
during deceleration

Voltage at braking

Main circuit
undervoltage : UV1

Voltage in the parentheses shows 400-V series.