August 04

VFD 101 for Water

Lesson 1
Functions of an Variable Frequency Drive (VFD)

This lesson covers the basic functions of a Variable

Frequency Drives (VFD) used with pumps.
August 04

Here is the basics outline for this lesson.

Outline:
Functions of a VFD in pumping
1. Start/Stop
2. Change Speed
3. Constant Speed
4. Limits
5. Ramping
6. Forward/Reverse
7. Save Energy

Note: There are other names for a VFD such as Adjustable Frequency Drive
(AFD); Variable Speed Drive; Adjustable Speed Drive; Inverter and
Frequency Converter. The name VFD is consistently used through out this
lesson.

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 August 04

To understand the functions of a VFD better,

an example of a pump is used but the same
function apply to aerators and blowers.

What must the pump system do?

August 04

The pump system in the picture above must maintain a certain pressure
perhaps 70psi (480kPa). Looking at this example, see if you can identify
some of the functions that must be performed by the VFD, AC motor and
pump? In other words, what must the pump do? Take a couple of minutes
to think about its functions.

The pump must …

_________________ ______________________

_________________ ______________________

A few of the basic functions of a VFD in controlling the AC motor and

pump are covered on the pages that follow.

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 August 04

Function #1 – Start and Stop

The VFD must be able to START and STOP

the pump.
August 04

Function #1 Start and Stop

START
One function of the VFD is to start the pump. This could be done
locally through the keypad of the drive or remotely from a switch as shown
above. The difference between these 2 control arrangements, local and
remote, are covered in the next lesson.

STOP
In the picture above, the same switch is used to stop the pump. If there
is only 1 switch to start/stop the VFD it is known as a 2-wire Start/Stop. If
there are 2 separate momentary (push button) switches, one to Start and
one to Stop, this arrangement is known as a 3-wire Start/Stop.

On the next page 2-wire and 3-wire start/stop arrangements are explained in
more detail.

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 August 04

Function #1 – Start and Stop

A 2-wire switch uses a continuous switch

A 3-wire switch uses momentary switches
August 04

2-wire
The picture on the left shows a 2-wire start/stop. The remote switch is a
continuous single-pole-double-throw (SPDT) switch. In stays in the ON or
OFF position. If the VFD is started with only 1 switch it is a 2-wire.

3-wire
The picture on the right shows the 3-wire start/stop. This is considered as a
standard motor starter configuration. Two momentary or push-button
switches are used to start and stop the VFD. A normally-open (NO) push-
button switch is used to start the VFD. A normally-closed (NC) push-button
switch is used to stop it. If the VFD is started with one switch and stopped
with another, it is a 3-wire.

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 August 04

Function #2 – Change Speed

The VFD must be able to Change the Reference, Hz.

The Reference could also be PSI if a transmitter
were attached to the VFD.
August 04

Function #2 Change Speed

The speed of the pump must be variable to allow for a slower speed
when there is little demand for water and a higher speed when water is
needed. This allows the operator to match the speed of the pump to a
particular demand. The setting of this speed is known as the Reference. In
most examples, reference refers to speed in Hertz (Hz), maximum reference
of 60Hz, and minimum reference of 18Hz for pumps. It could also be used in
regards to a pressure setting, maximum reference of 100psi (690kPa),
minimum reference of 40psi (275kPa), if a transmitter were attached to the
VFD.
In the picture above, the display of a VFD, a Danfoss VLT 8000, is
shown. Speed in Hz is the reference. The plus (+) key is used to increase
the reference making the pump go faster and the minus (-) is used to
decrease the reference point slowing the pump down.

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Function #3 – Maintain a Constant

Speed

Light load or heavy, the drive should

maintain the same speed.
August 04

Function #3 Maintain a Constant Speed

Another function of the VFD is to maintain the speed of the pump
regardless of the type of liquid in the lines. In the example above 100 gpm
(380 l/m) is pumped whether it is clear water or sludge. The VFD
automatically compensates for the current and torque needed to
accommodate changes in the texture of the load.

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 August 04

Function #4 – Limits

Limits on current, torque, speed, heat and voltage, to

name a few, protect the VFD & motor.

August 04

Function #4 Limits
It is important that limits be placed on a VFD. Speed limits can be
placed in the program of the VFD so an operator can not go beyond a
maximum speed or less than a minimum speed. The maximum speed of the
pump should not exceed 60Hz in North America (50Hz in the rest of the
world), due to excessive power consumption. For lubrication purposes the
pump should have a minimum speed of at least 18Hz. Because of the
possibility of overheating, fans and blowers should not be run less than 6Hz.
For the same reason as the pump, fans should not be run more than 60/50
Hz.
If the pump gets stuck, there are torque limits that the VFD monitors
stopping the motor if they are exceeded. Current limits are also important for
protection of the drive and motor. In the picture above the maximum
reference is set to 60/ 50 Hz. Notice that in the diagram there is a minimum
reference of 18Hz.

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Function #5 – Ramping

To avoid water hammer, it is important to

control the acceleration, ramp up and
deceleration, ramp down.
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Function #5 Ramping
The VFD also ramps the pump up and ramps it down. When the pump
starts, acceleration, it is important that there is no sudden jump to the
reference speed, or water hammer occurs. Older pipes have great difficulty
with rapid pressure changes and can break. In the example above, a ramp-
up slowly increases the speed from stopped or 0Hz up to the reference,
34Hz, over a certain amount of time perhaps 10 seconds. If this ramp up is
too short, the drive can trip on an over current alarm or torque limit. If the
VFD is tripped, the pump stops and it might require an operator to manually
reset the VFD. Many VFDs have an automatic reset setting from 1 restart or
reset per alarm, up to an infinite number of resets per alarm.
Many submersible pumps require 2 startup ramps. One very quick
initial start up ramp (say 1 second) for pump lubrication, up to its minimum
speed, say 20Hz. Then a much slower ramp up (say 20 seconds) from the
minimum speed up to the operating speed of 45Hz.

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Function #5 – Ramping

All ramp times are based on motor speed,

60Hz in North America, 50Hz in the rest of
the world.
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A ramp is also present on the stop side. This is referred to as a ramp

down or deceleration. It is important that the pump is NOT stopped abruptly.
A ramp-down of 10 seconds might be entered into the program for this
application. If the ramp is too short, the drive can trip on over voltage.
All ramp times are based on the motor speed, 60Hz in North America
50Hz in the rest of the world. This means if the the ramp time is set for 10
seconds as in the picture above, but the reference is set to 30Hz (1/2 of
60Hz), it takes 30/60 x 10seocnds (½ the time) or 5 seconds to ramp up. In
the rest of the world 50Hz is used for the motor speed. Using the same
ramp up time (10) and reference (30), the motor then takes 30/50 X
10seconds or 6 seconds to ramp up to 30Hz. Calculations for the ramp
down time would be the same.
A special feature of the Danfoss VLT 8000 is automatic ramping. The
VFD automatically extends the ramp times, during ramp up and ramp down,
to avoid tripping of the drive.

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Function #6 – Forward/Reverse

• Change of Direction
• Forward to fill the tank
August 04

Function #6 Forward/Reverse Operation

FORWARD
One function of the VFD is to operate the motor in a forward direction,
to move the supply water to the needed areas. In its default (factory set)
condition the VFD is only allowed to go forward. Some pumps must never
be operated backwards. If driven backwards they have problems, including
unscrewing their impellers.
On startup, if it is discovered that the pump is operating backwards.
Remove power from the drive and swap 2 of the 3 output wires. As an
example exchanging the wire attached to terminal U of the VFD with the wire
on terminal V. This changes its direction. If a Bypass switch, which
bypasses the VFD, is involved you must also check to insure that it operates
the pump in the correct direction.

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Function #6 – Forward/Reverse

• Reverse to clear the impeller

• Be careful – this may unscrew impeller
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REVERSE
If something is stuck in the impeller of the pump, and it is allowed by
the pump manufacturer, it might be of advantage to turn the pump slowly
backwards. From the last page power going to the motor must be changed
between 2 terminals of the motor to move the pump backwards (or Reverse).
When a Reverse command is given to the VFD, it automatically swaps 2 of
the 3 leads of the 3-phase motor to change directions, going backwards.

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Function #7 – Saving Energy

The most important function for the VFD with this

pump application is to save energy.

August 04

Function #7 Saving Energy

In many applications, particularly involving fans, blowers and pumps,
the major function of the VFD is to save energy. Before VFDs, a pump was
turned ON to full speed, 60Hz (50Hz), then perhaps a butterfly valve
downstream from the pump might be used to throttle the pressure back to a
useable level. Or the pump might have been cycled on at full power, until a
pressure setting, 80psi (550kPa), was reached. When 80psi (550kPa) was
reached the pump was turned OFF coming back ON when the pressure
dropped to perhaps 60psi (410kPa). This arrangement uses a great deal of
energy and the frequent cycling causes a great deal of wear on equipment.
A drive is placed on the pump, which slows the pump down to perhaps
30Hz to constantly maintain the required pressure. The pump speeds up or
slows down following demands. On the chart above, if the pump is running
at 30Hz (25Hz), half of the full speed, assuming no friction losses, the energy
level is 1/8th the HP (kW) at full speed.

This concludes Lesson 1. There is a Post-test to review this information.

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