Drives Basics

Problems often occur because of

the words we use to describe a
project.

A Drive System is not a Motor

Speed Control
Minding Your P’s & Q’s
With BEZ now offering drives, we must fully understand ASD’s, which have also been called VSD’s
and VFD’s. Some ASD’s are VVI type and some are CSI type but many are being replaced with
PWM. This is possible now with new devices replacing SCR’s with GTO’s or IGBT’s.

We do this to control our RPM’s and reduce KWH through higher EFF. Many ASD’s must also
connect to PLC’s in a LAN which should also be backed up with a UPS.

Now, ASD’s can readily be applied to TEFC or ODP motors with simple rules. However, using
ASD’s on XPF motors will require special approvals from UL or ETL in the USA. CSA in Canada or
IEC in the EEC.

You must also be careful to watch your EMF with a true RMS meter as well as your FLA and I R.
To get SPL down to lower dBA, we push to higher KHz. This can, however, cause problems with
excessive dV/dT and PIV that MOV’s can not fix and then your THD could exceed IEEE.

Obviously, in all ASD applications there are many things to consider, but the single most important
item is your TLA’s (Three Letter Acronyms).
A Drive System is not a Motor Speed
Control
A drive system is defined by all of the
components that are used to transmit
power to the load.
– The power source

– The Control Circuit

– The Prime Mover

– The Drive Train

– The Coupling Devices

– The Feedback Devices

A Drive System is not a Motor Speed
Control
The Power Source

…Incoming Power
Stability
…Grounding
…Cable Distance
…Electrical Noise
The Power Source
Incoming Power Stability

460 VAC RMS

650V “Three Phase AC”

0V
-650V

Peek Voltage = RMS x 1.414

120° degrees out of phase
High and Low Lines
The Power Source

Grounding

Good Grounding results in a

successful installation
Avoid ground loops
use adequate wire size
The Power Source
Cable Distance

Line Load

Each wire has resistance

The cables have capacitance
the result is a bell circuit
The Power Source
Electrical
Noise
Contactors
MC
Use snubber Circuit
snubber

Electronic Controls
Use Reactors and Filters
A Drive System is not a Motor Speed
Control
The Control Circuit

…The basic Control Scheme

…Load Control
…Speed Control
…Closed Loop Control
…Logic Control
The Control Circuit
The basic Control
Scheme
The Control Circuit
Load Control

Soft start
wound rotor
eddy current
The Control Circuit
Speed Control

AC & DC ASD
MG SET
The Control Circuit

Closed Loop Control

SPEED
LOAD
FLOW
PRESSURE
TORQUE
The Control Circuit

Logic Control

PLC
MOTION
PROCESS
A Drive System is not a Motor Speed
Control
The Prime Mover

The AC Induction Motor

…most common motor used
in industry today.
…designed to convert
electrical power into
mechanical work.
…As designed it is a fixed
speed device.
The Prime Mover
The AC Induction Motor most
common motor used in industry
today
Rugged
Low Cost
Requires Little or No Maintenance
Easily Controlled
Good Efficiency
The Prime Mover
Name Plate Data
• NEMA (National Electrical BALDOR
INDUSTRIAL MOTOR
R

Manufacturing Association) THREE PHASE

provides guide lines for the CAT. NO VM3546
SPEC 35A13-87 LOW

data that is used on a motor FRAME 56C SER. F491

VOLTAGE
6 5 4

name plate. This insures that H.P. 1 9 8 7

VOLTS 208-230 / 460

a motor can be built by AMPS 3.7-3.4 / 1.7
3 2 1

many different R.P.M. 1725

HIGH
VOLTAGE
5 4
HZ 6
manufactures. If the proper 60 PH. 3 B
CLASS

SER. F 1.15 DES B CODE J 9 8 7

data is supplied to the motor NEMA NOM.

77.0 % P.F. 74 %
EFF. 3 2 1

manufacturer then a RATING 40C AMB-CONT

replacement can be BALDOR ELECTRIC CO.

supplied. FT. SMITH, ARK.
MFD. IN U.S.A.
NP0005
SA
The Prime Mover
The AC Induction Motor is designed to
convert electrical power into mechanical
work.

…The Speed/Torque curve

…Frequency is Speed
…Voltage is torque
 The AC Induction Motor
The Speed/Torque curve
300% BD
T

200%
torque

LRT

100% PUT
FLT

0 100%
speed
 The AC Induction Motor
The Speed/Torque curve
300%
Design b

200% Design c
torque

Design D
100%

0 100%
speed
 The AC Induction Motor
Frequency is Speed

Where:
N = Speed in RPM
Fq = Frequency in Hz
P = The number of motor poles
120 is a constant for time conversion

Note:
This formula is the synchronous speed of an induction motor
 The AC Induction Motor
Frequency is Speed
Speed control has been achieved by the
changing the poles.

2 pole 3600 = 60 x 120 / 2

4 pole 1800 = 60 x 120 / 4
6 pole 1200 = 60 x 120 / 6
8 pole 900 = 60 x 120 / 8
 The AC Induction Motor
Frequency is Speed
…The motor manufacturer controls the
speed of the motor by controlling the
number of poles.
…Multi speed motors can be built by
designing multi pole motors.
The AC Induction Motor

Voltage is torque
300%

200%
Amps

No load saturation curve

100%

0 100%
voltage
The AC Induction Motor

Voltage is torque

Where:
N = Speed in RPM
Fq = Frequency in Hz
P = The number of motor poles
120 is a constant for time conversion
Note:
For lb/in of TQ use 63025
A Drive System is not a Motor Speed
Control
The Drive Train

…Torque transmission
…Speed Changer
…enclosed Gearing
The Drive Train
Torque transmission

2:15 LB/FT INPUT RESULTS IN 10 LB/FT OUT

10” dia 5” dia

The Drive Train
Speed Changer

2:1 100 rpm INPUT RESULTS IN 50 rpm OU

10” dia 5” dia

The Drive Train
Speed Changer
Torque transmission
1:2 50 rpm INPUT RESULTS IN 100 rpm OU
10 LB/FT INPUT RESULTS IN 5 LB/FT OUT

10” dia 5” dia

The Drive Train
enclosed Gearing

Also known as speed reducers

Worm… Right angle… 60 to
80% eff
Helical… in line… 90 to 98% eff
Planetary… in line… 95 to 98%
eff
A Drive System is not a Motor Speed
Control
The Coupling
Devices

…Flex
…Mill Duty
…Universal
A Drive System is not a Motor Speed
Control
The Feedback
Devices
…Load
…Speed
…Temperature
…Vibration
…Process
How Does an Electronic Variable Frequency
Control Work
An INVERTER is a motor control that adjusts the speed of an A.C.
Induction motor.

The INVERTER adjusts the SPEED of a motor by varying the

FREQUENCY of the A.C. Power to the motor.
120 X Frequency
Synchronous Speed =
Motor Poles
or

Frequency =Synchronous Speed x Motor Poles

120

MOTOR POLES RATED SPEED SYNCHRONOUS SPEED

2 3450 3600
4 1750 1800
6 1150 1200
8 850 900
How Does an Electronic Variable Frequency
Control Work
An INVERTER adjusts the VOLTAGE and the
FREQUENCY.
There is a relationship between VOLTAGE and
FREQUENCY Known as the VOLTS PER HERTZ
RATIO (V/hz Ratio)
By Controlling the VOLTAGE to hertz ratio the
motor will.
• Draw nearly full load current during operation (if full load is
required).
• Eliminate high locked rotor currents at start-up.
• Maintain constant torque output up to base speed OR:
• Reduce output torque at low speeds on pumps and blowers.
How Does an Electronic Variable Frequency
Control Work
Motor TORQUE control

Motor TORQUE is directly related to the

amount of current flow into a motor, the
INVERTER will limit the peak TORQUE output
to the current capability of the INVERTER.

Typically, the motor will be capable of

providing 150% RATED TORQUE at startup
with a matched control.
Motor TORQUE Control
Typical constant torque speed ranges:

Motor Type Service Inverter Type CT Speed

Factor Range

Standard (pre-EEPact) 1.0 PWM 3:1

Standard (post-EEPact) 1.0 PWM 6:1

Super - E 1.0 PWM 20:1

Vector Duty 1.0 PWM 1000:1

Motor HORSE POWER Control
HP = T x RPM
5250

If the motor’s torque stays constant as the speed is

changed, the motor’s horsepower capacity will change
directly with speed.
Variable Frequency CONTROL
BLOCK
DIAGRAM VARIABLE
AC LINE FREQUENCY
POWER DC LINK AC VOLTAGE

Converter Inverter

CONVERTS 50/60 HZ INVERTS DC POWER

LINE POWER Control INTO ADJUSTABLE
INTO DC FREQUENCY AC POWER
Variable Frequency CONTROL
SOLID STATE
BLOCK INVERTER

CONVERTER Dc capacitors
Variable Frequency CONTROL
converter
Converts AC power to DC power

DC Bus = RMS x 1.414

VFC Sections
DC Bus

…FILTERS THE VOLTAGE

…STORES POWER FOR
LOAD
VFC Sections
Inverter
• Inverts the DC Bus Voltage
into a PWM AC sine wave
• Monitors the motor Back
EMF to determine the load

PWM wave
VFC Sections
Soft Charge Circuit

Soft charge circuit

…At start up the the
discharged caps look
as a dead short to the
AC line.
… The resistor allows
the caps to charge
softly and prevent
fuse faults.
VFC Sections
Dynamic braking
Diode
Current flow

Shunt brake circuit

…Diodes are one way valves.
…Motors regenerate during stopping
and deceleration.
…Brake Circuits re-channel the
regenerative energy
Tools & Safety Issues
Test Equipment
• Electronic Multi-meters
– Used to Measure Voltage, Current &
Resistance

• “Clamp” Current Meter

– Used to Measure Large AC & DC
Currents

• Digital Oscilloscope
– Required for “real time” voltage &
Current Measurements
Tools & Safety Issues
Electronic Multi-meters
• Minimum Required Features
– Category III 1000v Tektronix TX1
– AC to 750v ~$325.00
– True RMS w/Crest Factor = 3
– DC to 1000v
– Resistance
– Diode Check
– Min/Max/Avg. Record
– Optional
• Frequency Fluke 87-III
• Temperature
~$350.00
Tools & Safety Issues
“Clamp” Current Meter
• Minimum Required Features
– Category III 600v
–
Fluke 36
AC current - 45 to 400hz
– True RMS w/Crest Factor = 3 ~$225.00
– Optional
• Connect to DMM/Oscilloscope
• Min/Max/Avg. Record
• Frequency
• DC Current

Tektronix A621
$400.00
Tools & Safety Issues
Portable Oscilloscopes
• Minimum Required Features
– UL Listed Device
– Electrically Isolated Input Channels!
– 50Mhz Bandwidth or Greater
– Digital Storage Capability Tektronix THS-730A ~$2,200.00
– AC to 600v
– DC to 1000v

– Optional
• Built-in Multi-meter
• Complex Power & Math

Tektronix THS-720P ~$3,000.00

Tools & Safety Issues
Don’t do it!

…Don’t take short cuts

– Always measure
– use good test leads and other tools
– know the power rating of the equipment
– be sure you use the right tool
– lock-out Tag-out
– know who’s around the equipment
– inspect for broken parts before starting
– walk the equipment to insure your safety, the safety
of others and the equipment.
What Makes a Drive Application Successful?
The Load
• There are four load types
– Constant Torque
• LOAD IS NOT A FUNCTION OF SPEED. (CONVEYORS, POSITIVE DISPLACEMENT
PUMPS.)

– Constant Horse power

• MOTOR TORQUE ABOVE BASE SPEED WILL DECREASE. (GRINDERS, WINDERS)

– Variable Torque
• TORQUE INCREASES WITH THE SQUARE OF SPEED. (CENTRIFUGAL PUMPS &
FANS)

– Impact Load
• TORQUE LOADING IS INTERMITTENT. PEAK TORQUE REQUIREMENTS MUST BE
CONSIDERED. (PUNCH PRESS)
The Load

Constant torque
The Torque remains constant
from a low speed to base speed
torque
torque

H P
or
H z
V/

Speed
The Load
Constant Horse
power
The Horse power remains constant
from base speed to max speed

HP
torque

to
r qu
e

Speed
The Load
Variable torque

The Torque Varies by the Square of the speed

The HP Varies by the Cube of the speed
torque

que
r
to P
r H
o
/Hz
V

Speed
The Load
Inverters for Variable Torque

• Adjustable speed drives are the state of the art for

flow control
– Variable Speed Fan
– No air restrictions
– Volume varies directly with the speed
– Pressure varies with the square of the speed
– Power varies with the cube of the speed
The Load
Impact
Load
The Torque is a function of the RMS value

motoring
torque

Regeneration

time
The Load

REGENERATION
When the rotor frequency is greater then the
stator frequency the motor will begin to act like
a GENERATOR. This will occur during
deceleration and when the load drives the
motor shaft. This GENERATED power is called
REGENERATIVE ENERGY.
The Load
REGENERATION

100%
torque

-100%

0 speed
The Load
Stopping the load

…Dynamic Braking
—Shunt Brake
…Line Regenerative Braking
…DC Injection braking
Stopping The Load

LINE REGENERATIVE

A LINE REGENERATIVE motor control will route the

REGENERATIVE energy from the motor back onto the
input power line. Yes, this is desirable in applications
where a significant amount of REGENERATIVE energy
will be present such as engine dynamometers.
Stopping The Load
DC INJECTION BRAKING

DC INJECTION BRAKING of an AC Induction Motor is

accomplished by sending the motor DC power rather
than AC power. An Induction motor rotates because of
the Alternating Current (AC) power supplied to the
motor leads. When the Direct Current (DC) power is
supplied to the motor leads, the motor’s magnetic
poles will try to align themselves in a stationary
position, causing the motor to stop.
 David
DavidRuehle:
Applications
Total
Ruehle:
Totalcost
cost10084.00
10084.00
Labor
Labor16
16hours
hours@@200/hr
200/hr
• The
VFC application
VFCabout
abouttwice
twicemotor
motor
is
a 3600 RPM centrifugal pump. The pump
requires a 20 horse power motor with a C-face and feet. The
application will have a speed pot to set the operating point.

2 HP 2 Pole motor $ 1814.00

pressure transducer $ 200.00
speed pot $ 56.00
Variable Frequency $ 3536.00
Control
$ 988.00
Input & output Reactors
$ 290.00
Start/Stop Station
$ 3200.00
Installation & Start-Up
Applications

Vector Control

DC - Like Performance with an Induction Motor

Field Weakening Above Base Speed for Higher Speeds

with Constant HP

Microprocessor Controls All Simultaneously

Applications

Vector Control
Performance
Speed Regulation = 0.1% (Analog Signal)
= Exact (Digital Mode)
(Closed Velocity Loop with Encoder)
Full Rated Torque: Zero to Base Speed

Limitations
System Cost Higher than Inverter
Motor Heating (greater than across the line, much less than an
inverter with similar cooling)
Applications

Vector Control
1. Variable Speed AC Drive Package that Includes:
A. Control (Vector Type)
B. Motor (AC Induction)
C. Feedback Device (encoder or resolver)
2. Control is Microprocessor based.
3. Closed loop communications vs. open loop
communications.

What a Vector control does

1. Converts AC fixed line frequency and voltage into variable
frequency and voltage to control speed and torque of an AC
Induction motor.
2. The encoder senses direction and speed of the shaft. The
encoder signal is fed back to the control.
3. The control compares what the motor is doing vs. what the
motor should be doing and changes the output frequency,
current and voltage to correct for changes such as load,
temperature, friction, etc.
Applications

Vector Control
Comparison with an Inverter
1. The Vector Drive is essentially an enhanced
Inverter Drive and can therefore do anything
an Inverter can do.

2. Additionally, a Vector Drive can have the ability to:

A. Speed regulate (0.1% regulation)
B. Torque follow
C. Provide full torque down to and including 0 speed
D. Wide speed range (6000:1)
E. No cogging at low speeds
F. Homing or Orienting
G. Positioning with Motion Control Card
Applications for Vector Drives

• Cranes • Hobbing Equipment

• Extruders • Winches
• Conveyors • Electric Vehicles
• Winders • Elevators
• Glass Production Lines • Variable Pitch Pulley
• Printers Replacements
• Conveyor Cars
• Stirrers/Mixers
• Precision Pump
• Dynamometers
• Spindles
Vector Drives vs. Inverters
Application Inverter Vector
Conveyor Min. Speed>3Hz Any Speed
(90 RPM w/4 pole)
Fans & Blowers Any Speed Overkill
Pumps, Centrifugal Any Speed Overkill
Cranes, Hoists Possible, Size for Starting Superior to Inverter,
Torque & Regen Full torque at Zero Speed
Slip Comp Preferred Less Jerk with S-Curve
Spindle Drives Yes, No orientation Yes, Orientation included
Feed to Length No Yes with External Motion
Controller
Indexer No Yes, with External Motion
Controller
Presses - Cyclic Load Yes, Size for Torque Yes
Requirement
Extruder Possible, Size for Starting Yes, Cost Premium
Torque
Some Application Considerations

• Line Impedance
– If the impedance is less than 3 % then consider
• Line Reactors
• Isolation Transformers
– If the impedance is greater than 10 % then consider changing
transformers
• Long Cable Runs
– If you have long cable runs – consider some type of filtering
Other Application Considerations

• Does the Drive need to run on a Generator?

• If the drive goes down, would running off the line
be acceptable and beneficial?
• Is there a factory network that the drive needs to
communicate with?
– Device Net
– Profibus
– Modbus Plus
– Can Open
Other Application Considerations

• What environment is the motor and drive in?

– Moisture
– Heat
– Dust and Dirt
– Vibration
– Shock
– Altitude
• Are any agency approvals required
– CSA
– UL
– CE
– Explosion Proof
Trouble Shooting
10 Most Common Problems

1: Lack of Knowledge
– Read and Know the Manual!
– Attend Manufacturer/Supplier Training Courses
– Contact OEM for System Operation Issues

2: Under/Over Voltage
– Check the Incoming Power Line

3: Intermittent Operation
– Check for Loose Wires
Trouble Shooting
10 Most Common Problems

4: Overheating
– Check for Proper Airflow - fans, blowers, etc...
– Check for Contamination

5: Ground Fault
– Check for Failed Motor Conductor Insulation
– Check for Failed Winding Conductor Insulation
Trouble Shooting
10 Most Common Problems
6: Unexplained Nuisance Faults
– Separate Low & High Voltage Wires
– Use Shielded Cable for Signal Wires
Trouble Shooting
10 Most Common Problems

7: Overload
– Check for Mechanical Jams

8: Blown Fuses
– Do Not Just Replace - Determine Cause!
– Check Basic Components

9: Motor Damaged
– Check for Free Rotation of Shaft
– Check for Open Circuit in Windings
Trouble Shooting
10 Most Common Problems
10: Application Considerations
– Environment
• Contamination
• Temperature / Altitude
• Vibration

– Sufficient Motor Torque & HP for the Load

– Match Motor Control Type to Application

• Speed Control
• Torque Control
• etc...
What are the Pitfalls?
Case Study
1 • A customer requires control of a conveyor that
feeds a rock crusher the current design is a motor
that starts across the line. When the load meter
reaches 85% load the operator turns off the
conveyor. When the load meter drops below 45%
the operator is required to turn the conveyor on.
This process needs to be automated. The motor is
a 10 HP 4 pole design. It is exposed to the
elements, wind, rain, heat, cold, etc… The reducer
is a 60 : 1 right angle worm gear. There is a 3 : 1
chain drive from the output shaft of the reducer to
the head pulley.

• How do we address this application?

What are the Pitfalls?
Case Study
2 • An oil field is pumping oil with a walking beam
style pump that is turned on every 45 minutes
and run for 15 minutes. They pump 50 barrels of
oil and 80 barrels of water each hour. The motor
is a 40 HP 6 pole design C with 300% break
down. The control circuit for this motor is a timer
circuit that triggers a coil to start and stop the
motor. They went to the design C motor because
the design B motor was failing.
• What can we do to improve the operation of this
pump?
• Will the design change provide a payback?
What are the Pitfalls?
Case Study
3 • A VFC trips on OVER CURRENT when the start
circuit is activated. The power supply is 480
VAC, 3 Phase. The VFC is a 15 HP unit. The
motor is a 7.5 HP 4 pole 230/460 motor wired
for 230 Volts. The motor is controlling a screen
feed that is designed as a shaker.

• How do we get started?

• How do we find the problem?
• How should the VFC be setup before we leave?
Closing

Recap
• Review of the Drive System

– The power source

– The Control Circuit

– The Prime Mover

– The Drive Train

– The Coupling Devices

– The Feedback Devices

Closing

Recap
• Review of the Inverter Design

– Speed and frequency

– torque and voltage

– AC to DC conversion

– PWM wave forms

– braking circuits

– vector drives
Closing

Recap
• Review of test equipment & safety

– The Multi Meter

– Current measurements

– Advanced measurements

– safety first

– always measure

– lock-out tag-out
Closing

Recap
• Review basic trouble shooting

– 10 common problems

– using the vfc as a tool

• Review basic applications

– How to apply a vfc

– how review a payback

– How to find a problem

Closing

Recap
• Review of the load

– Four types of loads

– stopping the load

• Review of the Application

– Vector Control

– Application consideration