2010

ASHRAE Rocky Mountain Chapter

VFD Fundamentals
April 16, 2010
Jeff Miller - ABB

© ABB
Month DD, YYYY | Slide 1
What is a Drive / VFD/ AFD?
460 460 V V
= 7.67
60 Hz Hz
Volts

230
If 230 VAC Power Line:
230 V V
= 3.83
60 Hz Hz

0
30 60
Hertz
 What is a Drive?
L
+
+ + +

L1
C
L2 Motor

L3

_ _ _
_
Input Converter DC Bus Output Inverter
+ (Diode Bridge) (Filter) (IGBT’s)
+
_ _
What is a Drive?
 VFD Fundamentals
A variable frequency drive converts incoming 60 Hz utility
power into DC, then converts to a simulated variable voltage,
variable frequency output

AC DC AC

RECTIFIER INVERTER
(AC - DC) (DC - AC)
60 Hz Power Zero - 120 Hz
60 Hz

ABB
VFD
To
Motor
Zero - 120 Hz
Electrical Energy
VFD
 Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
 Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
Positive
+
DC Bus

Negative -
DC Bus

RECTIFIER INVERTER
 Area Under The Square-Wave Pulses
Approximates The Area Under A Sine Wave

Positive
+
DC Bus

Voltage
Negative -
DC Bus

RECTIFIER INVERTER Frequency

 How Often You Switch From Positive
Pulses To Negative Pulses Determines
The Frequency Of The Waveform

Positive
+
DC Bus

Voltage
Negative -
DC Bus

RECTIFIER INVERTER Frequency

Frequency = 30Hz

Frequency = 60Hz
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
RECTIFIER INVERTER

Positive
+
DC Bus

Negative -
DC Bus

Motor
 Non-Linear Loads?
• Loads which draw non-sinusoidal
current from the line:
– Non-incandescent lighting
– Computers
– Uninterruptible power supplies
– Telecommunications equipment
– Copy machines
– Battery chargers
– Electronic variable speed drives
– Any load with a solid state AC to DC
power converter
 Typical AC Drive Configuration

460VAC M
3-phase

Simulated AC

650VDC (PWM)

All AC Drives rectify AC to DC, then convert to simulated AC

(PWM) to provide the motor Variable voltage and Frequency. The
AC to DC conversion generates harmonics.
 Harmonics — Definitions

• Non-linear loads draw current in a non-sinusoidal or

distorted manner
• Harmonics or harmonic content is a mathematical
concept implemented to allow quantification and
simplified analysis of non-linear waveforms
• Harmonics are typically present in both network
currents and network voltages
• Non-linear current draw creates non-linear voltage as it
flows through the electrical network
– Current harmonics  Voltage harmonics
Harmonic Frequencies
Fundamental 60 Hz
5th Harmonic 300 Hz
7th harmonic 420 Hz
11th Harmonic 660 Hz
13th Harmonic 780 Hz
17th Harmonic 1020 Hz
19th Harmonic 1140 Hz
f5 = 300 Thew Theory:
= 2p × f 5 t) = 0.32 × cos ( w × t - p )
i (Fundamental,
5 5 5th and 7th 5

f7 = 420 w = 2p × f 7 t) = 0.09 × cos ( w × t - p )

i (Harmonics 7 7 7
Fundamental
1
5th
0.5
i 1 ( t)

i 5 ( t)
Components
0
i 7 ( t)
0.5 7th

iT ( t) = i1 (1
t) + i5 ( t) + i7 ( t)
0 0.005 0.01 0.015 0.02 0.025 0.03
1.5
t
1

0.5

i T( t) 0
Summation
0.5

1.5
0 0.005 0.01 0.015 0.02 0.025 0.03
t
Harmonic Content, 6- Pulse Drive
PWM Drive Harmonic Input Spectrum

Fundamental

5th

7th
11th
13th
 Harmonics — Why worry?
– Harmonic Current Distortion —
• Added heating in transformers and
cables, reduces available capacity
• May stimulate a resonance condition
with Power Factor Correction
Capacitors
–Excessive voltage
–Overheating of PF correction capacitors
–Tripping of PF protection equipment
Voltage Distortion interfering w/ sensitive
equipment. Largest Concern!
 Harmonics — A System Issue!

– Harmonics produced by an individual load are only

important to the extent that they represent a significant
portion of the total connected load
– Linear loads help reduce system harmonic levels
– TDD equals the THD of the nonlinear load multiplied by
the ratio of nonlinear load to the demand load:
NL
Where TDD = THD NL ×
DL
TDD = TDD of the system
THDNL = THD of the nonlinear loads
NL = kVA of nonlinear load
DL = kVA of demand load
(nonlinear + linear)
 Harmonics — By the Numbers
IEEE 519 - 1992
Table 10.2
Low-Voltage System Classification and Distortion Limits

Special General Dedicated

Applications System System
Notch Depth 10% 20% 50%
THD (Voltage) 3% 5% 10%
Notch Area, mVs 16,400 22,800 36,500

Note: Notch area for other than 480 V systems should be multiplied by V / 480.
 Harmonics — By the Numbers
(cont.)
IEEE 519 - 1992
Table 10.3
Current Distortion Limits for General Distribution Systems

ISC / IL <11 11£h<17 17£h<23 23£h<35 35£h TDD

<20 4.0 2.0 1.5 0.6 0.3 5.0
20<50 7.0 3.5 2.5 1.0 0.5 8.0
50<100 10.0 4.5 4.0 1.5 0.7 12.0
100<1000 12.0 5.5 5.0 2.0 1.0 15.0

Note: All harmonic current levels are in percent with fundamental current IL as the base.
Harmonics — Attenuation Options
• Reactors (Chokes)
• Passive Filters
– Harmonic Trap
– Hybrid
• High Pulse Count
Rectification
• Active Filters
– Drive Front End
– Stand Alone
 Reactors (Chokes)
• Simplest and least • May be implemented
expensive harmonic with AC line reactors or
reduction technique with DC link reactors
– AC line reactors provide
• May be included in base better input protection
drive package – DC link reactors provide
• Often meet harmonic load insensitive drive
output voltage
needs provided drive
– Both types provide
load is a small portion similar harmonic benefits
of total connected load
• “Swinging” choke
design provides
enhanced light load
harmonic performance
 Reactors, AC Line or DC Link
AC Line • Different design
Reactor
techniques
M • Equal harmonic
reduction for
same normalized
DC Link % reactance
Reactor
• Typical full load
THD (current) at
M drive input
terminals
28%  46%
Hybrid Filter
• Installs in series with
drive input
• May feed multiple
drives
• Improves power factor
(may go leading)
• Typical full load THD
(current) at filter input
terminals
5%  8%
• Relatively unaffected
by line imbalance
 High Pulse Count Rectification
• Typical configurations are either 12 pulse or 18
pulse
• Phase shifting transformer is required
• Additional drive input bridge(s) is needed
• Typical full load THD (current) at transformer
primary 8%  12% (12 pulse), 4%  6% (18
pulse)
• Performance severely reduced by line
imbalance (voltage or phase)
• Excellent choice if step-down transformer is
already required
 High Pulse Count Rectification
(cont.)
• 6 pulse • 18 pulse
rectifier rectifier
DC/AC

DC/AC
• 12 pulse
Transformer and rectifier
cabling simple Transformer and cabling
DC/AC complicated

Transformer and cabling

complicated
Current very distorted Current wave form good
Ithd typically 45% with Ithd 4% to 6% (depending on
3% reactor network impedance)

Current distorted
Ithd 8% to 12% (depending
on network impedance)
Active Filter Front End with LCL Filter
L L M

Line Motor
C
inverter inverter Motor
(rectifier)
LCL filter

 LCL Filter (Sine Filter) removes high frequencies >1 kHz.

(Current and voltage)
 Full output voltage is available with 80% input voltage
(400VIn = 480VOut)
 Full regenerative capability
 No transformer required
 Not affected by line imbalance
 Harmonic Reduction Summary
Effectiveness of Harmonic Mitigation Techniques
(Assuming 100% Nonlinear Loading, ISC / IL = 60)

THD Harmonic
Technique
(Current) Reduction
No mitigation (reference level) 72% 
3% line reactors (or equivalent DC link reactor) 39% 45.8%
5% line reactors (or equivalent DC link reactor) 33% 54.2%
5% line reactors + 5th harmonic trap filter 12% 83.3%
12 pulse input rectifier with 5% impedance transformer 10% 86.1%
Hybrid filter 7% 90.3%
18 pulse input rectifier with 5% impedance transformer 5% 93.1%
12 pulse input rectifier with 5% impedance transformer
4% 94.4%
+ 11th harmonic trap filter
Active harmonic filter 3.5% 95.1%

Remember!
Even an 80% THD nonlinear load with a will result in only 8%
TDD if the nonlinear load is 10% and the linear load is 90%.
(80%•(10%/(10%+90%))=8%)
 Summary – Practical Advice
• With a main distribution transformer, 20-30% of its
load on non-linear loads will typically comply with
IEEE 519-1992
• Voltage distortion causes interference with sensitive
equipment, not current distortion!
• 5% reactors address 90+% of typical applications.
They also provide protection against line transients
and keep input currents low to avoid oversizing power
wiring to comply with NEC.
• Make VFD vendor perform a harmonic distortion
calculation with the submittals.
 PEAK: 1,040 volts
 Peak Voltage all at 50’ of cable

Peak Voltage has Drive Peak Voltage

many Contributing
Factors 1 1040
Inverter Rated
2 1110
Motors Help
Minimize the Issue 3 1180
Less dV/dT
minimizes; problems 4 1290
with RFI/EMI Motor
5 1350
Insulation & Bearing
Current 6 2454
 Recommendations

• Keep cable length short as possible

• Use a NEMA MG1, Part 31 motor (not
“inverter duty” or “inverter ready”
• Ensure that grounding is sound