Industrial Pumps Division

BASICS OF KIRLOSKAR VARIABLE

SPEED
DRIVES AND INTRODUCTION TO
ELECTRICAL DEVICES

17th Jun 2006 This is a Proprietary Document of Kirloskar Brothers Ltd. 1

 Industrial Pumps Division

WHAT IS VFD
VARIABLE FREQUENCY DRIVE

AN ELECTRONIC POWER DEVICE FOR CHANGING SPEED OF 3 PHASE

AC INDUCTION MOTORS

SPEED CHANGE METHOD - BY FREQUENCY VARIATION,PULSE WIDTH

MODULATION.

RANGE OF FREQUENCY - 0 - 400 HZ(DEPENDS ON MODEL OF DRIVE)

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 Industrial Pumps Division

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 Industrial Pumps Division

TYPICAL VFD
RECTIFIER AND FILTER
THE RECTIFIER CONVERTS AC INPUT INTO DC AND FILTER FILTERS IT
FURTHER .
PFC
The PFC(POWER FACTOR CORRECTION) CIRCUIT HELPS TO MAINTAIN AN
APPROXIMATE UNITY PF.BY EXECUTING COMPLEX ALGORITHEM IN REAL-
TIME USING THE MICROCONTROLLER,THE USER CAN EASILY LIMIT FLOW OF
HARMONICS FROM LINE TO MOTOR AND HENCE,NEAR UNITY PF POWER CAN
BE DRAWN BY LINE.
SMPS
THE SMPS(SWITCH MODE POWER SUPPLY) PROVIDES DC POWER TO ALL
CONTOL CIRCUITS AND DISPLAY UNIT.

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 Industrial Pumps Division

TYPICAL VFD
INVERTER SECTION
INVERTER CONVERTS DC INPUT TO AC AGAIN AND FED TO MOTOR. IT IS IN THE
FORM OF PWM(PULSE WIDTH MODULATED)

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 Industrial Pumps Division

TYPICAL VFD

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 Industrial Pumps Division

TYPICAL VFD
INVERTER PRICIPLE
INVERTER CIRCUITARY GENERATES AN ALTERNATING
CURRENT(AC) BY SEQUENTIALLY SWITCHING A DIRECT
CURRENT(DC) IN ALTERNATE DIRECTIONS.
THE ILLUSTRATION ABOVE SHOWS THE GENERATION OF POSITIVE
PULSE AND A SINGLE NEGATIVE PULSE (GREEN) WHICH
OCCURES 180 ELECTRICAL DEGREES LATER.
TRANSISTORS 1A AND 2B ARE TURNED ON & OFF BY
MICROCONTROLLER & CURRENT FLOWS FROM THE DC BUS
POSITIVE THROUGH THE MOTOR WINDINGS AS SHOWN BY RED
ARROWS.
TO GENERATE NEXT HALF CYCLE TRANSISTORS 1B & 2A WILL BE
TURNED ON & OFF & THE CURRENT FLOW WILL REVERSE
THROUGH MOTOR WINDINGS SHOWN BY GREEN ARROWS.

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 Industrial Pumps Division

TYPICAL VFD
DRIVER CIRCUIT
DRIVER CIRCUIT WITH MICROCONTROLLER BASICALLY CONTROLS SWITCHING
ON-OFF OF THE TRANSISTORS HENCE SWITCHING PATTERN OF PWM
MICROCONTROLLER
MICROCONTROLLER IS A BRAIN OF VFD.ALL DECISIONS ARE TAKEN BY
MICOCONTROLLER CONSIDERING USER PARAMETERS & VARIOUS FEEDBACKS
FROM DEVICES.
ALL CONTROL TERMINALS ON TERMINAL STRIPS (DIGITAL INPUTS,DIGITAL
OUTPUTS,ANALOG INPUTS,ANALOG OUTPUTS) ARE CONNECTED TO
MICROCONTROLLER.
ACCORDING TO INPUT STATUS & USER SETTINGS MICOCONTROLLER DRIVES
MOTOR AS WELL AS OUTPUTS.
ADDITIONAL FEATURES ARE PROVIDED LIKE THE DC BUS VOLTAGE SENSING,OV
AND UV TRIP,OVERCURRENT PROTECTION,ACCURATE SPEED/POSITION
CONTROL,TEMPERATURE CONTROL,EASY DISPLAY SETTING FOR MONITORING
PROCESS PARAMETERS.

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 Industrial Pumps Division

TYPICAL VFD
DISPLAY AND CONTROL PANEL
THIS UNIT IS A COMBINE UNIT INCLUDES LCD DISPLAY & SETTING KEYS.
THE DISPLAY UNT CAN BE USED FOR MONITORING PROCESS
PARAMETERS LIKE SPEED,CURRENT,VOLTAGE,KW AS WELL AS IT
HELPS INITIALLY FOR SETTING UP THE DRIVE & ALSO USEFUL FOR
TROUBLE SHOOTING.
NORMALLY KEYS ARE PROVIDED FOR START/STOP,RESET,SET,SPEED
UP THIS UNIT IS A COMBINE UNIT INCLUDES LCD DISPLAY & SETTING
KEYS.
THE DISPLAY UNT CAN BE USED FOR MONITORING PROCESS
PARAMETERS LIKE SPEED,CURRENT,VOLTAGE,KW AS WELL AS IT
HELPS INITIALLY FOR SETTING UP THE DRIVE & ALSO USEFUL FOR
TROUBLE SHOOTING.
NORMALLY KEYS ARE PROVIDED FOR START/STOP,RESET,SET, SPEED
UP/DN OPERATIONS.

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 Industrial Pumps Division

TYPICAL VFD
RS 232 LINK
MOST OF THE DRIVES PROVIDE THIS PORT WHICH PROVIDES
COMPUTER CONNECTIVITY SO THAT IMPORTANT PARAMETERS CAN BE
LOGGED IN PC .
THIS FUNCTION IS VERY USEFUL FOR ANALYSIS IN CASE OF TROUBLE
AS DATA IS STORED IN COMPUTER DATE & TIMEWISE OR FOR EVEN
FOR KNOWING SYSTEM PERFORMANCE .

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 Industrial Pumps Division

V/F CURVE

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 Industrial Pumps Division

V/F CURVE

AS SEEN IN FIG.21 THE VOLTAGE AND FREQUENCY ARE VARIED AT CONSTANT RATIO
UP TO THE BASE SPEED. THE FLUX AND TORQUE REMAINS ALMOST CONSTANT UP
TO THE BASE SPEED.BEYOND THE BASE SPEED THE SUPPLY VOLTAGE CANNOT
BE INCREASED AND INCREASING FREQUENCY BEYOND THE BASE SPEED
RESULTS IN FIELD WEAKENING AND THE TORQUE REDUCES. ABOVE THE BASE
SPEED THE TORQUE GOVERNING FACTORS BECOME MORE NONLINEAR AS THE
FRICTION LOSS INCREASES.
THIS CONTROL IS MORE POPULAR IN INDUSTRY AND CALLED AS V/F CONTROL.
WHILE OPERATING MOTOR AT VERY LOW SPEED RISTRICTION COMES MAINLY
DUETO INHERENTLOSSES IN THE MOTOR LIKE FRICTION,IRON ETC.THESE LOSSES
ARE ALMOST CONSTANT OVER THE ENTIRE SPEED.THEREFORE TO START THE
MOTOR ,SUFFICIENT POWER MUST BE SUPPLIED TO OVERCOME THESE LOSSES
AND THE MINIMUM TORQUE HAS TO DEVELOPED TO OVERCOME THE LOAD
INERTIA.

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 Industrial Pumps Division

SPEED OF MOTOR
SPEED OF AC INDUCTION MOTOR IS DEPEND ON

NO OF POLES
FREQUENCY
AC MOTOR SPEED = 120F/P
F = FREQUENCY & P = POLE

FOR EXAMPLE SPEED OF 2 POLE MOTOR AT 50 HZ =

120*50/2
= 3000 RPM

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 Industrial Pumps Division

SPEED AND POWER RELATION

AC MOTOR POWER IS DEPENDS ON
TORQUE
SPEED

THE FORMULA IS HP = T x N/5252

HP = HORSEPOWER
T TORQUE IN lbft
N = SPEED IN RPM

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 Industrial Pumps Division

WHAT HAPPENS WHEN MOTOR

CONNECTED TO VFD
SPEED = 120F/P
HP = T x N/5252
T = V/F
VFD VARIES FREQUENCY SO SPEED VARIES
VFD TRIES TO KEEP TORQUE CONSTANT BY MAINTAINING
V/F RATIO
AS A RESULT WHEN SPEED DECREASES AS TORQUE IS
CONSTANT HP REDUCES

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 Industrial Pumps Division

ENERGY SAVING FOR PUMPS

IF WE REDUCE SPEED HP GETS REDUCE AND HENCE WE

CAN SAVE ENERGY WITH THE FELP OF VFD AS PUMPS
NOT NEEDED TO RUN AT FULL SPEED ALL THE TIME.

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 Industrial Pumps Division

ADVANTAGES OF VFD FOR PUMPING

UP TO 50% ENERGY SAVING COMPARED TO

CONVENTIONAL METHOD

MAINTAINS ACUURATE PRESSURE WITH THE HELP OF

BUILTIN PID CONTROL

FLEXIBILITY TO FINETUNE FLOW AS PER

REQUIREMENT SO NO NEED OF MECHANICAL
ALTERATIONS

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 Industrial Pumps Division

ADVANTAGES OF VFD FOR PUMPING

SOFT STARTING AND STOPINGS AVOIDS WATER

HAMMERING IN PIPINGS SO INCREASES LIFE

AVOIDS RESONANCE OF THE SYSTEM

TAKES CARE OF ALL NECESSARY INTERLOCKS LIKE EM

STOP,LEVEL SWITCHES ETC.

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 Industrial Pumps Division

ADVANTAGES OF VFD FOR PUMPING

USER FRIENDLY DISPLAY USED TO MONITOR SYSTEM

STATUS,FAULTS & PROCESS PARAMETERS LIKE
ENERGY,FLOW PRESSURE

DATA LOGGING OF ENERGY,WORKING HRS ETC.

KEYPAD ENABLES AUTO/MAN MODE,PROGRAMMING

OF PUMP PARAMETERS & CURVES OF
OPTIMISATION

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 Industrial Pumps Division

MOTOR AND VFD EFFICIENCY

FREQUENCY CONVERTERS WITH NON-SINUSOIDAL CURRENT CAN
CAUSE HARMONIC LOSSES IN THE MOTOR AND INCREASE MOTOR
LOSSES BY UP TO 10 PERCENT WHICH TRANSLATES INTO
OVERALL REDUCTION IN MOTOR EFFICIENCY OF UP TO 1
PERCENT
ELECTRICAL SWITCHING WITH TRANSISTORS IS VERY EFFICIENT. SO
THE EFFICIENCY OF A FREQUENCY CONVERTER IS ALSO VERY
HIGH FROM 0.97 TO 0.99
FOLLOWING FIG CAN APPROXIMATELY TELLS YOU THE RELATION
BETWEEN EFFICIENCY SPEED & LOAD.

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 Industrial Pumps Division

MOTOR AND VFD EFFICIENCY

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 Industrial Pumps Division

Motor Contactor

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 Industrial Pumps Division

Motor Contactor
• Three Phase Switching Device used for
Starting/Stopping Motor
• Elements of Contactor
– Power Contacts- For switching power
– Electromagnetic Coil- For command On/Off
– Terminals - For Wiring
– Auxilary contacts - For logic interlocks
• NO - Normally Open
• NC - Normally Closed

When Coil gets energize contacts change

their state.No to NC & Vice Versa
Coil NO NC
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 Industrial Pumps Division

Relay
• Switching Device used for Control logic
• Elements of Relay
– Change over Contacts- For switching controls
– Electromagnetic Coil- For command On/Off
– Terminals - For Wiring Pole

When Coil gets energize contacts change

their state.No to NC & Vice Versa

Coil NO NC
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 Industrial Pumps Division

Over Load Relay

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 Industrial Pumps Division

Over Load Relay

• Motor protection Device - Protection against Overload(over current)
• Principle - Bimetallic Strips.
• Elements
– Change over Contacts- For switching control
– Three phase Studs
– Reset button & current setting dial
Pole

When excess current passes,temp rises &

Strips get separated & contacts change
their state.No to NC & Vice Versa
NO NC

Change-over
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 Industrial Pumps Division

Miniature Circuit Breaker

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 Industrial Pumps Division

Miniature Circuit Breaker

• Motor protection Device - Protection against Overload(over
current) & Short Circuit
• Principle - Bimetallic Strips & Magnetic
• Rating - Up to 63 Amp, 1 - 4 poles
• Elements
– On / Off Lever
– Input & Output Terminals
When excess current passes,temp rises &
Strips get separated & contacts gets open.
In case of short circuit current rise is Rapid
& sensed it & tripped by magnetic coil

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 Industrial Pumps Division

Electronic Timer

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 Industrial Pumps Division

Electronic Timer
• Used for Timed delayed logic
• Elements of Timer
– Change over Contacts- For switching controls
– Source - For Start command Pole
– Terminals - For Wiring & setting dial
• Types
– On Delay -
Off Delay - Source
When source gets energize After preset Delay contacts NO NC
change their state.No to NC & Vice Versa Change-Over

When source gets De-energize After preset Delay

contacts change their state.No to NC & Vice Versa

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 Industrial Pumps Division

Voltage Monitoring Relay

• Used for Mains voltage monitoring, Protection Device
• If supply variations is more than specified/preset
limits, relay operates
• Also monitors phase sequence & phase failure
• Starts Automatically once supply voltage comes in
limit
• If phase sequence gets change we have to change it
manually

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 Industrial Pumps Division

Liquid Level Controller Relay

• Used for controlling liquid levels in tanks
• Operates between two levels - Pump Shut off
below Min Level or Above Max Level & Pump
Start Level
• Includes Three Probes
– Reference Level
– Start Level
– Stop Level
• Principal - Conductivity
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 Industrial Pumps Division

PID Controller
• Controller used to control process by taking
feedback of process by sensor.
From Sensor
PV
O
UT
Set Value by
SV
Keys

Compares Process Value coming from Sensor with

Set Value & accordingly output will be varied or made
on / off

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 Industrial Pumps Division

PID Controller

• P - (Proportional Gain) Determines how fast system

responds to a change in feedback. More Gain - Fast
Response/change of output
• I - (Integration Time) The integrator adds the error
signal over time & uses this to correct output
accordingly. Fast Regulation can be obtained by
setting short integration time

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