Variable Frequency Drives - Heat Loss and Required Air

Cooling
Avoid overheated variable frequency drives with adequate ventilation.
Heat Loss from a Variable Frequency Drive
An amount of the power transferred through a variable frequency drive to the motor is lost as
heat. The heat loss from a drive can be expressed as

Hloss = Pt (1 - ηd)         (1)

where

Hloss = heat loss to the variable-frequency drive surroundings (kW)

Pt = electrical power through the variable-frequency drive (kW)

ηd = variable-frequency drive efficiency

The heat loss expressed in imperial units

Hloss = Pt 3412 (1 - ηd)         (1b)

where

Hloss = heat loss to the variable-frequency drive surroundings (btu/h)

Pt = power in to the frequency drive (kW)

ηd = variable-frequency drive efficiency

To calculate maximum heat loss - the maximum power transmission through the variable-
frequency drive must be used.

It is common that the heat loss from a frequency drive is in the range 2 - 6% of the KVA rating.

Necessary Ventilation for Cooling a Variable-Frequency Drive

Maximum ambient temperature for a frequency-drive is approximately 40oC (104oF). Since
frequency-drives often are physical protected in small cabinets or small rooms, ventilation - or
even cooling - may be needed to avoid overheating.

The mass flow of air needed for transporting heat from the variable-frequency drive can be
expressed as

mair = Hloss / cp (tout - tin)         (2)

where

mair = mass flow of air (kg/s)

Hloss = heat loss to the frequency-drive surroundings (W)

cp = specific heat of air (kJ/kg  oC) (1.005 kJ/kg  oC standard air)

tout = temperature of air out (oC)

tin = temperature of air in (oC)

Combined with (1), the mass flow (2) can be expressed as:

mair = Pt (1 - ηd) / cp (tout - tin)         (2b)

The volume flow can be calculated by multiplying (2b) with the specific volume or inverted
density:

qair = (1 / ρair) Pt (1 - ηd) / cp (tout - tin)         (2c)

where

ρair = density of air at the actual temperature (1.205 kg/m3 standard air)

Variable Frequency Drive - Heat Loss Air Cooling Chart

Example - Ventilation and Cooling of a Variable-Frequency Drive

The heat generation by the variable frequency drive with maximum power of 100 kW and
efficiency of 0.95,can be calculate with eq. 1 as

Hloss = (50 kW) (1 - 95 / 100) 

      = 2.5 kW 

The mass of cooling cooling air through the cabinet when the maximum ambient operating
temperature for the frequency drive is 40  oC and outside temperature of the cabinet is 20  oC can
be calculated with eq. 2 as

mair = (2.5 kW) / (1.005 kJ/kg  oC) ((40  oC) - (20  oC)) 

      = 0.125 kg/s   

The volume and density of air depends on the temperature of the air. The density of air
at 20oC is 1.205 kg/m3 and 1.127 kg/m3 at 40  oC.
The volume flow at the inlet (20  oC):

qair = (1 / (1.205 kg/m3)) (0.125 kg/s)

    = 0.104 m3/s

    = 375 m3/h

The volume flow at the outlet (40  oC):

qair = (1 / (1.127 kg/m3)) (0.125 kg/s)

    = 0.111 m3/s

    = 400 m3/h

HOW TO CALCULATE HEAT DISSIPATION

FOR VFDS

When you’re building a panel containing Variable Frequency Drives (VFDs), it’s easy to
underestimate their contribution toward the electrical enclosure’s heat load. Part of the
problem arises from the paucity of information supplied by manufacturers who don’t always
publish power dissipation or efficiency information in brochures.

VFDs generate a significant amount of heat and unless the heat is removed through the use
of enclosure cooling, the drives can overheat and trip, causing plant outages. Here is a
simple guide to calculate the heat dissipation requirements for VFDs.
Drive Efficiency
The efficiency of most VFDs is between 93 to 98 percent and the balance of the energy is
lost as heat. The power dissipated is calculated by subtracting the efficiency from 100
percent and multiplying the result by the power consumption of the drive. The heat loss of a
95 percent efficient, 100 horsepower drive can be estimated as 5 percent of 100
horsepower which equals 5 horsepower or 3729 watts.

In order to make this calculation, it’s essential to obtain the VFD drive efficiency at the
design load from the equipment supplier.
Allow For Other Losses
Take into account the thermal losses of ancillary equipment such as DC reactors, phase
shifting transformers, power supplies and switch gear. Unless these are insignificant, their
losses must be added to the total heat load. The losses from a transformer could be another
4 percent of power consumption.

Again, obtain these figures from the equipment suppliers.

If the drive uses braking resistors and is frequently stopped and started, the power
dissipated by the braking resistor should also be taken into account.

Maximum Operating Temperature

Drive manufacturers specify the maximum allowed operating temperature of their devices. In
some cases, this is relatively low as it allows for the heating effect of power electronics on
the circuit boards inside the drives. Additionally, some manufacturers derate their drives
above temperatures of 104 ºF.
It’s good engineering practice to design the enclosure cooling for a temperature that’s 20 ºF
below the equipment’s maximum temperature; this will promote long life and minimize the
possibility of overheating.

Total Heat Load

The enclosure heat load is established by adding the total heat dissipation of all items of
equipment. Additionally, the calculation needs to take into account heat transfer through the
enclosure walls as a result of the ambient temperature, local heat sources, and solar
radiation. Although there are various ways this can be calculated, the most effective method
is to use an online heat load calculator to establish the enclosure’s total heat load and
associated cooling capacity requirement.
Cooling Solutions
Provided the ambient temperature is lower than the required enclosure temperature,
a filtered fan package may provide sufficient heat removal capacity to adequately cool the
enclosure. Alternatively, should there be a need to use a sealed enclosure, an air-to-air heat
exchanger solution will work well.
However, if the ambient air temperature is close to or above the required enclosure
temperature, then an enclosure air conditioner will be required. This has several advantages.
First, because the enclosure must be sealed, no dust, dirt, or pollutants are able to
contaminate surfaces. Second, an air conditioner dries the air, which ensures that the
maximum humidity requirements of VFD drives are met.
Don’t Underestimate VFD Heat Load
It’s easy to overlook the cumulative heat load of VFDs. This could have serious ramifications in
terms of drives tripping, poor control, and plant outages caused by high temperature. It could also
cause premature drive failure. Although the calculation of enclosure heat load is simple, the effect of
external influences is more difficult to assess: if you need help sizing your enclosure cooling
system, contact our experts at Thermal Edge .