ABB VFDS Health Check Report

RENAISSANCE INDUSTRIES
ABB VARIABLE FREQUENCY DRIVE
POWER QUALITY ANALYSIS

CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

1
Introduction
Variable Frequency Drives (VFDs) play a pivotal role in modern industrial processes by
providing precise control over motor speed, resulting in improved energy efficiency and
enhanced process control. However, the proliferation of VFDs has brought attention to the
importance of ensuring the quality of electrical power they deliver to the connected loads.
Power quality analysis of VFD output is crucial to identify and mitigate issues such as
harmonic distortion, voltage fluctuations, and transient events, which can adversely affect
equipment performance, reliability, and safety.
In this report, we employ the Fluke 43B Power Quality Analyzer to conduct a
comprehensive analysis of the electrical power output from VFDs. The Fluke 43B offers
advanced measurement capabilities, allowing us to evaluate key parameters such as
voltage, current, frequency, harmonics, and power factor with precision and accuracy.
Through this analysis, we aim to provide valuable insights into the power quality
characteristics of VFD output, highlighting potential challenges and areas for improvement.
By understanding and addressing these issues, organizations can optimize the
performance of their VFD-driven systems, minimize downtime, and enhance overall
operational efficiency.
This report begins by outlining the objectives and scope of the power quality analysis,
followed by a description of the testing setup and methodology employed. We then present
the findings and analysis of key power quality parameters, including harmonic content,
voltage stability, and power factor. Finally, we offer recommendations for mitigating
identified issues and improving the power quality of VFD output, thereby enabling
organizations to achieve greater reliability and productivity in their industrial operations.

2
Plant VFD List
SR NO MAKE KW MODEL DESCRIPTION Remarks
1 ABB 7.5/11 ACS550-01-023-4 C-2 MATERIAL PUMP F_L, Health Normal

2 ABB 7.5/11 ACS550-01-023-4 C-1 MATERIAL PUMP Good Health
3 ABB 7.5/11 ACS550-01-023-4 C-3 MATERIAL PUMP Good Health
4 ABB 18.5 ACS355-03E-38A0-4 C-4 MATERIAL PUMP Good Health
5 ABB 18.5 ACS355-03E-38A0-4 C-4 WATER PUMP Good Health

6 ABB 7.5/11 ACS550-01-023-4 C-2 WATER PUMP Good Health
7 ABB 7.5/11 ACS550-01-023-4 C-1 WATER PUMP F_L, THD_L, PAR
8 ABB 7.5/11 ACS550-01-023-4 C-3 WATER PUMP Good Health
9 ABB 18.5/22 ACS550-01-045A-4 BLENDER-2 Good Health
10 ABB 18.5/22 ACS550-01-045A-4 BLENDER-4 Good Health, PAR
13 ABB 4.0/3.0 ACS550-01-012A-4 FEEDER PUMP-1 F_L, THD_L
14 ABB 4.0/3.0 ACS550-01-012A-4 FEEDER PUMP-2 Good Health
15 ABB 7.5/11 ACS550-01-023-4 FLACKER PUMP F_L, THD_L, NORMAL
16 ABB 18.5/22 ACS550-01-045A-4 M/C 1 ROLL VFD 1 UNLOAD GOOD
17 ABB 4.0/3.0 ACS550-01-012A-4 M/C 1 DAAB VFD 2 UNLOAD GOOD
18 ABB 4.0/3.0 ACS550-01-012A-4 M/C1 CON VFD 3 UNLOAD GOOD
19 ABB 18.5/22 ACS550-01-045A-4 M/C 3 ROLL VFD 1 UNLOAD GOOD
21 ABB 4.0/3.0 ACS550-01-012A-4 M/C 3 CON VFD 3 UNLOAD GOOD
23 ABB 4.0/3.0 ACS550-01-012A-4 M/C 2 CON VFD 3 NO MOTOR

3
Application
Above mention 1 to 8 number VFDs work with pump application for supplying material and
water in the plant for the different columns at the plant. VFDs number 8 to 12 work with a
column blending machine to mix the material in a blender with a gearbox connected. VFDs
13 to 15 application for a pump application only.
4 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

VFDs Load and Unload Readings As per below
F POWER READING -1 V/F HARMONICS POWER READING -2 V/F HARMONICS
TESTI VOLTS(T WATTS VOLTS(T AMPS(T WATTS(T

SR NG K KV KVA COS AM HD%/RM AMPS(TH (THD%/ KV KVA COS AM HD%/RM HD%/R HD%/RM
NO MAKE KW MODEL DESCRIPTION ON F1 F2 W A R PHY P S) D%/RMS) RMS) KW A R PHY P S) MS) S)
3.
2 3.6 0.87 11.8/394. 1.9 15.1/270.
1 ABB 4.0/3.0 ACS550-01-012A-4 FEEDER PUMP-1 LOAD 34 50 3 9 1.78 5 5.55 431.8/50 2 3.4/5.43 1.05/62 1.6 3 1.07 0.829 4.18 347/34 6 3.5/4.16 0.63/57
0.
0 0.3 0.35 0.22 0.80 16.2/278. 0.208/1 39.5/196. 9.9/0.68
2 ABB 4.0/3.0 ACS550-01-012A-4 FEEDER PUMP-2 LOAD 43 30 8 63 5 0 3 352.5/43 6 7.6/0.764 2 224 269 150 0.833 0.96 276.5/30 4 9 0.111/22
7.
C-2 MATERIAL 37 9 0.90 16.7 1.4%/16.7 1.29/13 4.6 11.0 320.4/30 34/260_8 2.5/10.9
3 ABB 7.5/11 ACS550-01-023-4 PUMP LOAD .7 30 5 8.8 3.77 3 8 364/37.5 6.1/306.4 1 8 3.86 4 2.58 0.832 1 .1 .5/207.1 3 1.583/55
1.
C-1 MATERIAL NO 43 5 4.2 0.36 402.4/43 2.8 328.1/30
4 ABB 7.5/11 ACS550-01-023-4 PUMP LOAD .7 30 4 8 3.99 0 6.95 .7 4.3/6.86 2.34/20 0.99 3 2.65 0.350 6.59 .1 5/6.51 1.59/19
1.
C-3 MATERIAL NO 1 3.6 0.31 2.3 290.6/25
5 ABB 7.5/11 ACS550-01-023-4 PUMP LOAD 37 25 4 3 3.45 4 7.32 360.4/37 8/294.7 2.8/7.23 2.0/21 0.91 7 2.19 0.384 6.97 .0 9.2/200.8 3.0/6.92 1.29/22
2.
1 2.1 0.99 3.36 0.6 0.066/10
6 ABB 7.5/11 ACS550-01-023-4 C-2 WATER PUMP LOAD 47 30 7 8 0.27 5 6 412/47 5/370 10.8/3.374 0.14/82 0.62 2 0.06 1.000 1.75 325/30 20/244.4 40/1.59 0
3.
8 3.8 0.98 0.6 21.3/1.8
7 ABB 7.5/11 ACS550-01-023-4 C-1 WATER PUMP LOAD 50 30 3 9 0.71 5 5.78 426/50 7.5/390 4.2/5.81 0.36/80 0.66 7 0.12 0.985 1.84 327/30 33/252 1 0.05/96

5
8.
9 9.4 0.94
8 ABB 7.5/11 ACS550-01-023-4 C-3 WATER PUMP LOAD 50 4 9 3.2 2 14.1 433/50 10/396 2.5/13.94 2.0/70
1.
2 2.1 0.57 1.017/3 1.2 3.5/2.97
9 ABB 7.5/11 ACS550-01-023-4 FLACKER PUMP LOAD 50 30 4 5 1.76 7 3.3 430/50 9.6/395.3 3.2/3.118 6 0.662 1 1.02 0.547 3 322/30 19.6/240 3 0.592/31
4.
C-4 MATERIAL 6 6.4 0.72 11.8 3.8 24.3/255.
10 ABB 18.5 ACS355-03E-38A0-4 PUMP LOAD 40 30 6 4 4.44 4 2 383.8/40 13/330.6 2.5/11.2 2.56/46 1.81 3 3.38 0.473 8.71 330/30 0 4.7/8.57 1.93/25
8.
4 9.3 0.90 14.6 4.8
11 ABB 18.5 ACS355-03E-38A0-4 C-4 WATER PUMP LOAD 45 35 7 2 3.88 9 6 410/45 5.6/366.4 2.2/14.53 2.34/65 3.96 1 2.72 0.823 9.84 355/35 18/290.6 3.2/9.7 1.66/54
UNLO 1. 11. 0.16 15.6 15.5 4.3/15.3

12 ABB 18.5/22 ACS550-01-045A-4 BLENDER-2 AD 50 30 8 1 11 2 5 452/50 8/420 2.7/15.5 6.36/10 1.21 6.6 6.49 0.183 5 336/30 20.8/266 2 3.79/10
3.
UNLO 2 9.3 0.34 13.1 6.5 13.0 4.3/12.9
13 ABB 18.5/22 ACS550-01-045A-4 BLENDER-4 AD 50 35 4 2 8.73 8 3 452/50 9/417 3/13 5.13/20 2.74 8 5.98 0.416 9 367/35 10/295 1 3.45/25
UNLO 2. 0.29 11.6 4.35/16 4.9 11.7 3.7/11.6

14 ABB 18.5/22 ACS550-01-045A-4 BLENDER-3 AD 50 30 3 7.9 7.53 1 6 436/50 11.3/400 3.6/11.61 0 1.75 3 4.6 0.355 7 326/30 34/263 2 2.52/157
15 ABB 18.5/22 ACS550-01-045A-4 BLENDER-1 LOAD

4.
UNLO 5 7.2 0.63 432.9/49 3.07/13 4.6 12.8/239. 2.3/11.2
16 ABB 18.5/22 ACS550-01-045A-4 M/C 1 ROLL VFD 1 AD 50 30 7 1 5.51 4 9.75 .7 4.3/395.2 4.2/9.72 9 3.53 1 2.92 0.766 5 3 1.75/130
M/C 1 DAAB VFD UNLO 16 211.4/16.

17 ABB 4.0/3.0 ACS550-01-012A-4 2 AD .2 8.94 2
0.
3
UNLO 43 5 0.25 2.25 410.6/43 0.776/1
18 ABB 4.0/3.0 ACS550-01-012A-4 M/C1 CON VFD 3 AD .9 6 1.4 1.35 4 5 .9 10/360.7 2.4/2.247 64
1.
UNLO 0 6.8 0.14 459.3/49 34.0/277.
19 ABB 18.5/22 ACS550-01-045A-4 M/C 3 ROLL VFD 1 AD 50 30 1 5 6.78 7 9.43 .7 4.3/423.9 7.4/9.35 3.93/9 0.86 4.4 4.32 0.195 9.78 341.8/30 7 6.1/9.70 2.47/10
3
M/C 3 DAAB VFD UNLO 3 0.49 1.57 16.5/257. 0.342/3 1.1 1.65 4.0/1.64
20 ABB 4.0/3.0 ACS550-01-012A-4 2 AD 30 50 5 679 590 3 6 337.5/30 5 4.2/1.555 1 0.6 9 1.03 0.504 9 453.5/50 9.2/419.3 9 0.600/31
1.
UNLO 3 1.6 0.84 3.96 325.8/30 13.8/243. 0.501/1
21 ABB 4.0/3.0 ACS550-01-012A-4 M/C 3 CON VFD 3 AD 30 50 7 3 874 0 3 .4 4 2.8/3.876 21 2.7 3.6 2.35 0.750 5.23 434/50 7.8/397.7 2.8/5.17 1.29/129
0.
6
M/C 2 DAAB VFD UNLO 7 1.7 0.38 2.57 0.944/1
22 ABB 4.0/3.0 ACS550-01-012A-4 3 AD 50 8 7 1.63 3 6 437.2/50 9.3/399.3 3.5/2.571 56
NO
MOTO
23 ABB 4.0/3.0 ACS550-01-012A-4 M/C 2 CON VFD 3 R 50

1. Feed Pump -1 VFD

● Trial Taken on load
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS for the FEED PUMP on
Load and above mention
WATT CO
CO VOLTS( AMPS(T S(TH S VOLTS AMPS( WATTS
reading achieved for two
SR TESTI KV KVA S AM THD%/ HD%/R D%/R K KV KVA PH A (THD% THD%/ (THD%
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) number of frequency set
ACS550-01- FEEDER 3.2 0.87 431.8/ 11.8/39 1.05/6 0.8 4.1 15.1/27 3.5/4.1
34 & 50.
1 ABB 4.0/3.0 012A-4 PUMP-1 LOAD 34 50 3 3.69 1.78 5 5.55 50 4.2 3.4/5.43 2 1.6 1.93 1.07 29 8 347/34 0.6 6 0.63/57
● The power factor of VFDs is above 0.855 in both frequency testS, good in nature on
load conditon
● Ampere value is within rated ampere and found okay.
● Harmonics in lower frequency test show compare to full speed test.
Recommendation:
Identify a lower Frequency limit for making low harmonic at the time of lowering speed.
Output Chock Require to connect between motor and vfd due to distance above 50 meters. (optional)
The health of VFD and pump is Good.

2. Feed Pump -2 VFD

● Trial Taken on
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS load for the Feeder
Pump 2 on Load and
WATT CO
above mention reading
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) achieved for two
ACS550-01- FEEDER 0.0 0.36 0.35 0.22 0.80 352.5/ 16.2/27 7.6/0.76 0.208/ 22 0.8 0.9 276.5/3 39.5/19 9.9/0.6 0.111/2
number of frequencies
2 ABB 4.0/3.0 012A-4 PUMP-2 LOAD 43 30 8 3 5 0 3 43 8.6 4 12 4 269 150 33 6 0 6.4 89 2
set 43 & 30 Hz.
● The power factor of VFDs is different than due to the connection to a 1

hp motor.
● Harmonics is normal in 43Hz speed tests & in 30Hz tests.
Recommendation:
The motor connected is 1hp so it is suitable.


3. Column -2 Material Circulation Pump

● Trial Taken
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS on load for the
Material
WATT CO
Circulation pump
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) on Load and
34/260
above mention
ACS550-01- C-2 MATERIAL 37 7.9 0.90 16.7 364/3 6.1/306. 1.4%/16. 1.29/1 3.8 0.8 11. 320.4/3 _8.5/20 2.5/10. 1.583/5
reading achieved
3 ABB 7.5/11 023-4 PUMP LOAD .7 30 5 8.8 3.77 3 8 7.5 4 71 38 6 4.64 2.58 32 01 0.1 7.1 93 5
for two number of

frequencies set 37.7 & 30 Hz.
● The power factor of VFDs is unity on load condition.
Recommendation:
The motor connected is in good condition, but lower frequency needs to be identified.
The health of VFD and pump is normal.


● Trial Taken
POWER READING
Material
WATT CO
Circulation pump
ACS550-01- C-1 MATERIAL NO 43 1.5 0.36 402.4/ 2.34/2 0.9 0.3 6.5 328.1/3
above mention
4 ABB 7.5/11 023-4 PUMP LOAD .7 30 4 4.28 3.99 0 6.95 43.7 4.3/6.86 0 9 2.83 2.65 50 9 0.1 5/6.51 1.59/19
reading achieved
for two number of
frequencies set 43.7 & 30 Hz.
● The power factor of VFDs is half due to inductive application on load.
● Harmonics is normal in 43.7Hz speed tests & in 30Hz tests.
Recommendation:
The motor and vfd condition are good.



● Trial Taken
POWER READING
Material
WATT CO
Circulation Pump
ACS550-01- C-3 MATERIAL NO 1.1 0.31 360.4/ 0.9 0.3 6.9 290.6/2 9.2/200 3.0/6.9
above mention
5 ABB 7.5/11 023-4 PUMP LOAD 37 25 4 3.63 3.45 4 7.32 37 8/294.7 2.8/7.23 2.0/21 1 2.37 2.19 84 7 5.0 .8 2 1.29/22
reading achieved
for two number of
frequencies set 37 & 25 Hz.
● The power factor of VFDs is half due to inductive application on load.
● Only 1st Harmonics present very good condition of vfd and motor
pump.
Recommendation:
The VFD health is very good

Output Chock is required to connect between motor and vfd due to a distance above 50 meters. (optional)

6. Column -2 Water Circulation Pump

● Trial Taken
POWER READING
Water circulation
WATT CO
pump Load and
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) above mention
ACS550-01- C-2 WATER 2.1 0.99 3.36 412/4 10.8/3.3 0.14/8 0.6 1.0 1.7 20/244. 40/1.5 0.066/1
reading achieved
6 ABB 7.5/11 023-4 PUMP LOAD 47 30 7 2.18 0.27 5 6 7 5/370 74 2 2 0.62 0.06 00 5 325/30 4 9 00
for two number of
frequencies set 47
& 30 Hz.
● The power factor of VFDs is unity on both frequency readings.
● Harmonics is very low on both tests. Very good condition drive and
pump motor.
Recommendation:
The VFD connected is a suitable load.

The health of VFD and pump is very Good.


● Trial Taken
POWER READING
Water circulation
WATT CO
pump on Load
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) and above
ACS550-01- C-1 WATER 3.8 0.98 426/5 0.36/8 0.6 0.9 1.8 21.3/1.
mention reading
7 ABB 7.5/11 023-4 PUMP LOAD 50 30 3 3.89 0.71 5 5.78 0 7.5/390 4.2/5.81 0 6 0.67 0.12 85 4 327/30 33/252 81 0.05/96
achieved for two
number of
● The power factor of VFDs is unity on both frequency readings.
● Harmonics is very low on high-frequency tests. But higher in
lower-frequency tests.
Recommendation:
The motor parameter needs to be checked and re-verified & lower speed needs to be set.
The health of VFD and pump is NORMAL.


● Trial Taken
POWER READING
Water Circulation
WATT CO
pump on Load
ACS550-01- C-3 WATER 8.9 0.94 433/5 2.5/13.9

mention reading
8 ABB 7.5/11 023-4 PUMP LOAD 50 4 9.49 3.2 2 14.1 0 10/396 4 2.0/70
achieved for one
number of
frequency set 50 Hz.
● The power factor of VFDs is nearby unity.
● Harmonics is normal in test conditions.
Recommendation:
The motor connected is 10 hp.


9. Flacker Pump VFD

● Trial Taken
POWER READING
Flacker pump on
WATT CO
unload and above
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) mention reading
ACS550-01- FLACKER 1.2 0.57 430/5 9.6/395. 3.2/3.11 1.017/ 0.6 0.5 19.6/24 3.5/2.9 0.592/3
achieved for two
9 ABB 7.5/11 023-4 PUMP LOAD 50 30 4 2.15 1.76 7 3.3 0 3 8 36 62 1.21 1.02 47 3 322/30 0 73 1
number of
frequencies set 50
& 30 Hz.
● The power factor of VFDs is half due to unload condition.
● Harmonics is normal in 50Hz speed tests & in 30Hz tests shown 1st/ 5th
/7th.
Recommendation:
The motor connected is in unloading condition. Lower F needs to be set.



● Trial Taken
POWER READING
ACS355 MATERIAL
WATT CO
CIRCULATION on
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) Load and above
ACS355-03E C-4 MATERIAL 4.6 0.72 11.8 383.8/ 13/330. 2.56/4 1.8 0.4 8.7 24.3/25 4.7/8.5
mention reading
10 ABB 18.5 -38A0-4 PUMP LOAD 40 30 6 6.44 4.44 4 2 40 6 2.5/11.2 6 1 3.83 3.38 73 1 330/30 5.0 7 1.93/25
achieved for two
number of
● The power factor of VFD is normal
● Harmonics is normal in 40Hz speed tests & in 30Hz tests more.
Recommendation:
The VFD is connected to a suitable load.


11. Column 4 Water Circulation Pump

● Trial Taken
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS on load for the acs
355 Water
WATT CO
circulation on
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) Load and above
ACS355-03E C-4 WATER 8.4 0.90 14.6 410/4 5.6/366. 2.2/14.5 2.34/6 3.9 0.8 9.8 18/290.
mention reading
11 ABB 18.5 -38A0-4 PUMP LOAD 45 35 7 9.32 3.88 9 6 5 4 3 5 6 4.81 2.72 23 4 355/35 6 3.2/9.7 1.66/54
achieved for two
number of
● The power factor of VFDs is good.
● Harmonics is normal in 45 Hz speed tests & in 35 Hz tests.
Recommendation:
The VFD is connected to a suitable load.


12. Blender -2 Gear Motor

● Trial Taken
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS on unload for the
Blender VFD on
WATT CO
UnLoad and
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) above mention
18.5/2 ACS550-01- UNLO 0.16 15.6 452/5 6.36/1 1.2 0.1 15. 20.8/26 4.3/15.
reading achieved
12 ABB 2 045A-4 BLENDER-2 AD 50 30 1.8 11.1 11 2 5 0 8/420 2.7/15.5 0 1 6.6 6.49 83 55 336/30 6 32 3.79/10
for two number of
frequencies set 50
& 30 Hz.
● The power factor of VFDs is showing inductive application unload.
● Harmonics is normal in 50 Hz speed tests & in 30Hz tests slightly more.
Recommendation:
The VFD is connected to a suitable load,

Output Chock is required to connect between motor and vfd due to a distance above 30 meters. (optional)
The health of VFD and Gear Motor is Good.

13. Blender - 4 with gear motor 30 hp

● Trial Taken
POWER READING
Blender 4 on
WATT CO
unload and above
18.5/2 ACS550-01- UNLO 3.2 0.34 13.1 452/5 5.13/2 2.7 0.4 13. 4.3/12.
achieved for two
13 ABB 2 045A-4 BLENDER-4 AD 50 35 4 9.32 8.73 8 3 0 9/417 3/13 0 4 6.58 5.98 16 09 367/35 10/295 91 3.45/25
number of
frequencies set 50
& 35 Hz.
Recommendation:
The vfd is connected to a 30hp suitable gear motor. Drive parameters need to be verified.


● Trial Taken
POWER READING
Blender 3 on
WATT CO
unload and above
18.5/2 ACS550-01- UNLO 0.29 11.6 436/5 11.3/40 3.6/11.6 4.35/1 1.7 0.3 11. 3.7/11. 2.52/15
achieved for two
14 ABB 2 045A-4 BLENDER-3 AD 50 30 2.3 7.9 7.53 1 6 0 0 1 60 5 4.93 4.6 55 77 326/30 34/263 62 7
number of
frequencies set 50
& 30 Hz.
Recommendation:
The vfd is connected to a 30hp suitable gear motor.


POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS
WATT CO
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS)

16. M/C 1 ROLL VFD

● Trial Taken
POWER READING
MACHINE 1 ROLL
WATT CO
VFD on UNLoad
18.5/2 ACS550-01- M/C 1 ROLL UNLO 4.5 0.63 432.9/ 4.3/395. 3.07/1 3.5 0.7 12.8/23 2.3/11. 1.75/13
mention reading
16 ABB 2 045A-4 VFD 1 AD 50 30 7 7.21 5.51 4 9.75 49.7 2 4.2/9.72 39 3 4.61 2.92 66 9.5 23 0
achieved for two
number of
frequency set 30 & 50.
● The power factor of VFDs is HALF DUE TO UNLOAD CONDITION TRIAL.

● Harmonics is in the allowable range.
Recommendation:
VFD parameter needs to be checked.

The health of VFD and motor good.

17. M/C 1 DAAB VFD 2

● Trial
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS Taken on
load for the
WATT CO
machine 1
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) daab vfd
ACS550-01- M/C 1 DAAB UNLO 16 211.4/

on Load
17 ABB 4.0/3.0 012A-4 VFD 2 AD .2 8.94 16.2
and above
mention
reading achieved for frequency set 16.2.
● Not able to read values.

● Not able to read.
Recommendation:

18. M/C1 CON VFD 3

● Trial
POWER READING
load for the
WATT CO
machine 1
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) conveyor
ACS550-01- M/C1 CON UNLO 43 0.3 0.25 2.25 410.6/ 10/360. 2.4/2.24 0.776/
on Load
18 ABB 4.0/3.0 012A-4 VFD 3 AD .9 56 1.4 1.35 4 5 43.9 7 7 164
and above
mention
reading achieved for 43.9Hz.
● The power factor of VFDs is normal due to the unload condition test.
● Harmonics in allowable range.
Recommendation:
VFD is in good condition.

The health of VFD and conveyor motor is Good.

19. M/C 3 ROLL VFD 1

● Trial
POWER READING
load for the
WATT CO
machine 3
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) roll vfd on
18.5/2 ACS550-01- M/C 3 ROLL UNLO 1.0 0.14 459.3/ 4.3/423. 0.8 0.1 9.7 341.8/3 34.0/27 6.1/9.7
Load and
19 ABB 2 045A-4 VFD 1 AD 50 30 1 6.85 6.78 7 9.43 49.7 9 7.4/9.35 3.93/9 6 4.4 4.32 95 8 0 7.7 0 2.47/10
above
mention
reading achieved for two number of two frequency sets 30 & 50.
● The power factor of VFDs is above 0.855 in both frequency tests, good cause it is on
unload condition
● Harmonics in allowable range in unload test condition.
Recommendation:
VFD health is very good in unload test conditions.

The health of VFD is Good.


● Trial
POWER READING
load for the
WATT CO
machine 3
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) daab on
ACS550-01- M/C 3 DAAB UNLO 0.49 1.57 337.5/ 16.5/25 4.2/1.55 0.342/ 0.5 1.6 453.5/5 9.2/419 4.0/1.6 0.600/3
unLoad
20 ABB 4.0/3.0 012A-4 VFD 2 AD 30 50 335 679 590 3 6 30 7.5 5 31 0.6 1.19 1.03 04 59 0 .3 49 1
and above
mention
reading achieved for two number of frequency sets 30 & 50.
● The power factor of VFDs is low due to unload trial

● Harmonics in allowable range in unload trial.
Recommendation:
VFD is in good condition and all readings in the allowable range.

The health of VFD and gear motor is Good.

21. M/C 3 CON VFD 3

● Trial
POWER READING
load for the
WATT CO
machine 3
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) conveyor
ACS550-01- M/C 3 CON UNLO 1.3 0.84 3.96 325.8/ 13.8/24 2.8/3.87 0.501/ 0.7 5.2 7.8/397 2.8/5.1 1.29/12
on unLoad
21 ABB 4.0/3.0 012A-4 VFD 3 AD 30 50 7 1.63 874 0 3 30.4 3.4 6 121 2.7 3.6 2.35 50 3 434/50 .7 7 9
and above
mention
reading achieved for two number of frequency sets 30 & 50.
● The power factor of VFDs is good in unload conditions.

● Harmonics in allowable range on unload conditions.
Recommendation:
VFD output PWM signal is in a good range.

The health of VFD and motor is Good.


● Trial
POWER READING
load for the
WATT CO
machine 2
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS) daab vfd
ACS550-01- M/C 2 DAAB UNLO 0.6 0.38 2.57 437.2/ 9.3/399. 3.5/2.57 0.944/
on Load
22 ABB 4.0/3.0 012A-4 VFD 3 AD 50 78 1.77 1.63 3 6 50 3 1 156
and above
mention
reading achieved of frequency 50.
● The power factor of VFD is good in unload test.

● Harmonics is an allowable range in unload test.
Recommendation:
VFD output PWM signal is in a good range.

The health of VFD and motor is Good.

23. M/C 2 CON VFD 3
POWER READING
F POWER READING -1 V/F HARMONICS -2 V/F HARMONICS
WATT CO
NO MAKE KW MODEL DESCRIPTION NG ON F1 F2 KW A R PHY P RMS) MS) MS) W A R Y MP /RMS) RMS) /RMS)
NO
ACS550-01- M/C 2 CON MOTO
23 ABB 4.0/3.0 012A-4 VFD 3 R 50
Motor not connected with drive on machine 2 conveyor.

Summary:
● - The file contains power quality measurements for various ABB variable frequency drives (VFDs) connected to
different loads like material pumps, water pumps, blenders, feeders, and machine drives.
● - Parameters measured include voltage, current, power factor, harmonics (voltage THD, current THD), active
power, reactive power, apparent power, etc.
● - Several observations indicate potential issues with some of the VFD installations:
● - High current THD values (>25%) for some drives like entries 6, 7, 8, 11 indicating high harmonic currents
● - Low power factor (<0.5) for some lightly loaded drives like entries 9, 10, 11
● - Some drives showing abnormal current readings like entries 6, 7, 8
● - Comments suggesting need to check drive parameters for some entries like 16, 21

Recommendations:
1. Conduct harmonic analysis and mitigation: The high current THD values indicate excessive harmonic currents which
can cause heating, losses and disturbances. Harmonic filters or multi-pulse drives may need to be considered.
2. Optimize power factor: For lightly loaded drives operating at very low power factors, look at adding power factor
correction capacitors or active front ends to improve power factor.
3. Check VFD parameter settings: As noted, some drives may have incorrect parameter settings leading to abnormal
currents or poor performance. Review and optimize parameter settings.
4. Consider input/output reactors: Adding line/load reactors can help reduce harmonics and electrical stress on the
drives.
5. Conduct power quality audit: A detailed power quality study measuring harmonics, unbalance, transients, etc. at the
plant's incoming supply and load levels can identify other issues.
6. Implement power quality monitoring: Installing permanent power quality monitors can help track issues, detect
trends and take preventive actions.
Overall, addressing harmonics and power factor and ensuring proper VFD setup/integration are key to improving
electrical efficiency, equipment reliability and plant power quality.

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RENAISSANCE INDUSTRIES

ABB VARIABLE FREQUENCY DRIVE

POWER QUALITY ANALYSIS

CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

Plant VFD List

SR NO MAKE KW MODEL DESCRIPTION Remarks

1 ABB 7.5/11 ACS550-01-023-4 C-2 MATERIAL PUMP F_L, Health Normal

4 ABB 18.5 ACS355-03E-38A0-4 C-4 MATERIAL PUMP Good Health

5 ABB 18.5 ACS355-03E-38A0-4 C-4 WATER PUMP Good Health

CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

4 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

VFDs Load and Unload Readings As per below

F POWER READING -1 V/F HARMONICS POWER READING -2 V/F HARMONICS

TESTI VOLTS(T WATTS VOLTS(T AMPS(T WATTS(T

CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

UNLO 1. 11. 0.16 15.6 15.5 4.3/15.3

UNLO 2. 0.29 11.6 4.35/16 4.9 11.7 3.7/11.6

15 ABB 18.5/22 ACS550-01-045A-4 BLENDER-1 LOAD

6 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

M/C 1 DAAB VFD UNLO 16 211.4/16.

7 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

1. Feed Pump -1 VFD

8 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

2. Feed Pump -2 VFD

● The power factor of VFDs is different than due to the connection to a 1

The motor connected is 1hp so it is suitable.

9 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

3. Column -2 Material Circulation Pump

for two number of

10 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

4. Column -1 Material Circulation Pump

The motor and vfd condition are good.

11 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

5. Column -3 Material Circulation Pump

The VFD health is very good

12 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

6. Column -2 Water Circulation Pump

The VFD connected is a suitable load.

13 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

7. Column -1 Water Circulation Pump

14 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

8. Column -3 Water Circulation Pump

ACS550-01- C-3 WATER 8.9 0.94 433/5 2.5/13.9

The motor connected is 10 hp.

15 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

9. Flacker Pump VFD

The motor connected is in unloading condition. Lower F needs to be set.

16 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

10. Column -4 Material Circulation Pump

The VFD is connected to a suitable load.

17 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

11. Column 4 Water Circulation Pump

The VFD is connected to a suitable load.

18 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

12. Blender -2 Gear Motor

The VFD is connected to a suitable load,

19 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

13. Blender - 4 with gear motor 30 hp

20 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

14. Blender - 3 with gear motor 30 hp

The vfd is connected to a 30hp suitable gear motor.

21 CREATED BY: PRADIP GIRI GOSWAMI, +916353237172, resourceatrahul@gmail.com

15. Blender - 1 with gear motor 30 hp