General Intro To Drives

Welcome to Danfoss Drives
Target group: VIP-guests, customers and internal use
Updated: 2006-03-07
Contact: Anette Uldall / Irene Krog Hansen
Confidential / Property of 15 June, 2006

Danfoss Drives A/S 1
Confidential / Property of
Danfoss Drives A/S
welcomes
NALCO SMELTER TEAM…
Danfoss Drives A/S
Danfoss Drives A/S
List Of Content
1. Introduction to Danfoss –Global....

2. Danfoss-India...
3. Danfoss Products & solutions....
4. Some basic issues related to use of VFD’s….
5. Various Applications......

Danfoss headquarters, Denmark

Executive Committee
Hans Kirk Niels B. Christiansen Jørgen M. Clausen Ole Steen Andersen
Executive Vice President, CDO Executive Vice President, COO President, CEO Executive Vice President, CFO
Corporate Corporate
Functions Ventures
Danfoss
Refrigeration &
Air Conditioning Danfoss Heating Danfoss Motion
Division Division Controls Division
Vagn Helberg Nis Storgaard Sven Ruder
President President President
Danfoss Refrigeration and Danfoss Comfort Controls Danfoss Drives Owner

A/C Controls • • share
• Danfoss District Heating Danfoss Gearmotors
Danfoss Commercial 38.5%
•
Compressors Danfoss Burner Components
• •
Danfoss Household Danfoss Floor Heating
Compressors
•
Danfoss Industrial &
Danfoss Water Controls
Appliance Controls

Danfoss Services 7
Danfoss Drives A/S
Sales distributed across divisions 2004

mill EUR
2,500
Danfoss
Refrigeration & Air
Conditioning
2,000 Division
Danfoss Heating
Division
1,500
Danfoss Motion
Controls Division
1,000
Other activities,
including Mobile
500 Hydraulics (2000)
00 01 02 03 04
Group figures
Danfoss is a family-owned, global company
(no public shares, but approx. 1% employee shares)
Net sales 2004: EUR 2,200 mill
Employees: 18,000 worldwide (May 2005)
Production of 250,000 items per day
Europe North Latin Africa Asia Pacific Total

America America
Manufacturing sites 39 8 3 1 3 0 54
Sales companies 76 8 7 3 15 2 111
Agents and distributors 107

Group sales
mill EUR
2,500
Mobile Hydraulics
2,200
2,100 The Danfoss Group
2,000 1,900 2,000 2,000 1,900
2,000
1,850 150*
300
300
1,800
1,600 300
1,700
1,500
1,600
300
1,500
1,500
300
1,300
1,300
200
1,200
1,100
1,000
900 200
1,100
Calculated average
growth, total: 8.5%
500 Calculated average
growth, Danfoss
Group excl. MH: 8.5%
* 1 January 2000 to 3 May
2000
93 94 95 96 97 98 99 00 01 02 03 04
Ten largest markets 2004

mill EUR
350
RA
300
HE
250
MC
200
150
100
50
Germany Great Denmark China Spain

Britain
Italy France USA Russia Sweden
Motion Controls Division 2004
1 Drives
2 Silicon Power 1 2
3 Low Power
4 Gearmotors
3 4

Motion Controls sales split 2004
Gearmotors 16%
Drives 81% Silicon Power 3%

Incl. Low Power
Danfoss Drives

Headquarters, Graasten Denmark

History
1968 The first 28 pcs. of VLT® are sold 1997 Danfoss Drives be-
comes an inde-
1983 Acquires Hampton Products in Rockford (now pendent limited
Danfoss Drives, Loves Park) company within the
Danfoss Group
1989 Centralization of the Danfoss Drives division
in the Graasten facility, DK 1999 Acquires Bauer,
Germany.
1995 Graham joins the Drives division
2000 Establishment of
Danfoss Silicon
Power, Schleswig,
Germany
2001 Acquires IWT Power
Electronics GmbH,
Kahlsruhe, Germany
2003 Acquires 51%
Proexpert, Estonia
2004 Danfoss Drives opens

new factory in
Graasten, Denmark
Danfoss Drives Business Unit

Sven Ruder
President
Danfoss Drives
Hans Peter Boisen Business Boards

Director
Business Development & Com Danfoss Drives Ventures
Jens Dam Mikkelsen Peter Simson

Vice President Vice President
Marketing & SBA Fin, Adm, IT & HR
Kim Christensen Morten B. Sørensen

Sales & Service Supply Chain
Charles Manz Finn Jäger-Rasmussen

Danfoss North America Product Development

Facts about Danfoss Drives

• Danfoss Drives is no. 1 in EU and no. 3 worldwide (<160 kW )
• In 1980 we produced approx. 6000 frequency converters, in 2005 we
produced this quantity every 3 days on an average
• Approx. 15-20% yearly growth in frequency converter quantity
produced
• Sales price between 745 and 33,500 EUR per frequency converter
• We produce on customer order, supported by regional assembly in
Europe, US and China. This means no inventories of finished goods in
the factories
• More than 90% is delivered directly to customers in Europe
• Own printing works: more than 300,000 pages per day
• Total employees Graasten: approx. 1,000
• Total employees Globally: approx. 2,000

Production in Europe, China and USA

Denmark
Graasten
Germany
Schleswig
USA
Loves Park, IL
Milwaukee, WI
China
Haiyan, Zhejiang Province

International sales and service
Global network
Local support
24 hours service:
- Spare parts
50 Danfoss sales and service companies
- Hotline More than 200 partner companies, distributors,
agents and serviceshops
DANFOSS INDUSTRIES PVT LTD, INDIA
•100% Wholly owned subsidiary of

Danfoss- Denmark
• Corporate Headquarters : Chennai
• Factory/Testing Centre:Chennai.
•Regional /Branch Sales and Service

offices at Delhi,Ludhiana, Chennai ,
Coimbatore, Hyderabad Bangalore
Mumbai, Ahmedabad, Kolkata.
• Distributors and System –Integrators
spread over the country.

Drive Testing Centre in Chennai

Danfoss Drives A/S 21 34


Engineered Panel at Danfoss-Chennai Shop floor

Vision
We will be recognized by • customer driven
our customers as the • global
most respected drives • innovative
solutions provider world • deliver user friendly products
wide
• application focused
• reliable
• quality driven
• ethical
• profitable
• the leader

Mission
Danfoss Drives offers electronic variable speed drives and related
products and services to the global market. We fulfil our
customers’ needs for drive technology, automation, energy
savings and comfort.
The cornerstones of our unique offering to the market are:

• Unmatched knowledge of our customers’ processes
• The scale advantages resulting from a focused approach
• High performing quality products
• Our global reach

Goals
• 10% growth a year
• To be number 1 on the world

market

Danfoss Drives guiding strategies

Sales and marketing Product Development
• Global reach • Leader in technology and
• Application know-how innovation
• SBA market and product • Platform based product approach
• Integrated product development
approach
process
Supply Chain People

• Lean manufacturing • Value based people management
• Mass customization • Performance based company
• One product – one factory culture
• Integrated manufacturing • Open communication culture

One year’s production of advanced

power electronics can save one
power plant a year

History - products
1968 The first 28 pcs. of VLT® are sold
1983 We become a self-supporting product line
1989 Introduction of VLT® 3000/3000 HVAC series
1992 Introduction of VLT® 3500 HVAC series
1993 Introduction of VLT® 2000 series
1996 Introduction of VLT® 5000 series VLT® 5, The first VLT
1997 Introduction of VLT® DriveMotor FCM 300 series.

1998 Introduction of VLT® 6000 HVAC
1999 Introduction of VLT® 2800 series
2001 Introduction of VLT® 5000 FLUX
2002 Introduction of VLT® 8000 AQUA
2002 Introduction of VLT® Decentral FCD300
2002 Introduction of Decentral Motors Switch DMS
2004 Introduction of VLT® AutomationDrive VLT® Decentral FCD 300,
year 2002
VLT® product range
VLT® 2800 VLT® 6000 HVAC

0.25 – 18.5 kW 0.75 – 500 kW
VLT® 5000 MCD 3000 Soft Starter

0.55 – 1200 kW 1 – 800 kW
VLT® 5000 Flux VLT® 8000 Aqua

0.55 – 400 kW 0.75 – 500 kW

Decentral solutions
VLT® DriveMotor FCM 300 series VLT® Decentral FCD 300
0.55 – 7.5 kW 0.37 – 3.0 kW
EtaSolution series K VLT® Decentral DMS 300

0.12 – 7.5 kW 0.18 – 3.0 kW

Low Power inverter

Cost-effective motor controllers for OEM customers
Dedicated solutions
Target markets
• Appliance (residential and commercial washing machines)
• Pumps (fresh water, hot water, etc.)
Silicon Power modules
Custom specific high

current Sixpack Standard packages

Variable speed solutions
Variable Speed BPI: Battery Powered Inverter

Drive Compressors

The new VLT® AutomationDrive program
• User-Friendly
• Flexible
• Reliable
• Intelligent

HVAC & Refrigeration
Our customers:
• Honeywell • Mærsk Container • Gea Grasso • TAC
• Johnson • York • Ingersol Rand
and many more
• Trane • Mycom • Atlas Copco

Food & Beverage
Our customers:
• Krones
• Tetra-Pak
• Coca-Cola
• Carlsberg
• Heineken
• Nestlé
and many more

Water & Wastewater
Our customers:
• Grundfos
• Pentair
• KSB
• ITT
and many more

Material Handling, Chemical & Textile
Our customers:
• FKI Logistex • BASF • Fong’s
and many more
Cranes, Lift & Hoist
Our customers:
• Liebherr • Stahl • BMW
• IBA • DaimlerChrysler • Eisenmann
and many more
Why Use Frequency Converter ?
Process Optimization
Control
Flexibility
Energy Saving

Why Use Frequency Converter?

• Avoid Product damage
• Reduced Wear & Tear
• No Mechanical Resonance
• Avoid downtime
• Added flexibility
• Energy Savings

Why Use Frequency Converter?
• Reliable Stopping & Synchronization

• Reduction in Maximum Demand
• Starting Current restricted to 100% -180%
of full load current.
• Improved Power Factor.

CONSIDER THIS
Welcome to Danfoss Drives Motion Controls
•95 % of AC Motors have no Controls.
•50% of above are used in Fan and Pumps.
•Majority of them are over sized.
•Typical controls are Dampers and Valves .
•Applications like Compressors, Pumps and Fans use vast amounts of

Energy.
•An average Motor consumes its own value in Energy in approx. 40 days
of running.

What is a frequency converter ?
Fixed AC - DC- Filter DC -Variable AC
DC/DC 3 phase Output

3-Phase Filter 0-400V,0-50Hz
400V,50Hz
AC / DC DC / AC
Input . Motor
Rectifier Inverter
Speed Control
Reference V&F
Fixed AC - DC- Filter DC -Variable AC

DC LinkHarmonic Output
Choke StageIGBT
Output
0-400V,0-50Hz
400V,50Hz
Input . Motor
AC / DC Rectifier
Speed Control
Reference V&F
What to specify in a AC VFD ?
No need to
EMC/RFI
2 Limb DC Link
Harmonic
Long life DC filter
capacitors?
Unlimited o/p switching?
have AC Filters ? ( when output contactor drops?)
Line chokes?
chokes?
Standard Motor ?
De rating ?
AC
Input .
Supply
3x 380- 500V+/-10%
Motor Cable Length ?
wide range? AC / DC Rectifier DC / AC Conversion
(with built in Surge suppressors?) IGBT
Speed Control
Reference V&F
Built in Safety stops standards? 15 June, 2006
AC DRIVES & MOTORS
SOME BASIC ISSUES
MOTOR EQUIVALENT CIRCUIT

AC DRIVES & MOTORS
SOME BASIC ISSUES
LOAD TYPES
• CONSTANT TORQUE
• VARIABLE TORQUE

AC DRIVES & MOTORS
SOME BASIC ISSUES
CONSTANT TORQUE LOAD
150%
140%
130%
120%
T
O
110%
R
Q
100%
U
E
90%
80%
70%
60%
0%
5%
0%
%
%
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
10
SPEED

AC DRIVES & MOTORS
SOME BASIC ISSUES
VARIABLE TORQUE
1
5
0
%
1
0
0
TORQUE
5
0
%
0
%
0%
5%
%
0%
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
10
SPEED

“The True Potential Lies Beneath The Surface”

On the surface
VFD is often viewed as a pure capital expenditure item.
However,best cost efficiency is realized when drive is fully integrated into the
system.
Below the surface

Integration approach minimize
operating & maintenance costs,
optimize savings typically realize ROI
within 1-3 years.

SOME BASIC ISSUES RELATED TO USE OF VFD’s
• RELIABILITY OF THE DRIVE
• CORROSIVE ENVIRONMENT
• MOTOR-VFD CABLE DISTANCE
• LIFE OF THE DRIVE
• SERVICE SUPPORT
• RESPONSE TIME
• SPARES AVAILABILITY
• USER FRIENDLY KWH MONITORING

How critical is the environment
One cannot “see” how critical an environment is.
It essentially depends on 4 factors:
Concentration of pollutants present

Dirt (which becomes conductive in the presence of
moisture)
Relative Humidity
Temperature

Examples of critical applications
Different constituents attack metals,
• e.g, Sulphur Di-Oxide attacks all metals except Noble metals

• Nitrogen, Ammonia and Ammonia Salts attack copper and brass
• Hydrogen Sulphide attacks Silver and copper
How to plan for such installations
Danfoss Drives can support long Motor cables

up to 300 meters in length without use of
output chokes
Supply the cabinet with fresh clean air as

corrosion process is slow at low humidity and
low temperature
It is important to maintain low Humidity and
temperatureConfidential / Property of 15 June, 2006
66 n
IP tectio
Pro
OR IP66 Stand alone module upto 90 KW Web_DKDDPB91T102.pdf

Enclosure
Enclosure
• Side-by-side
mounting
• IP00/chassis
• IP20/chassis
• IP21/NEMA Type 1
• IP55/NEMA Type 12
• IP66

IP 55 & 66 – stand alone
Enclosure
• Disconnection
switch


Coated PPCB’s for VLT’s
• For harsh
environments e.g.
aggressive gasses
• Protects against
environmental
pollution,
moisture and dust
• Confirms to
International
standards and
Marine approval
standards

Ventilation and cooling tips

Intelligent heat management
Two different cooling modes can take

place in ways to offer sets of benefits:
• Conventional cooling
with speed controlled fan
• Air not passing electronic
components
• Cold plate cooling

FEATURES YOU SHOULD EXPECT
FROM A COST SAVING DRIVE
IP 54/66 ENCLOSURE INBUILT TRANSMITTER ISOLATED

NO-NEED OF PANEL POWER SUPPLY I/Os
STANDARD MOTOR AUTO MANUAL INBUILT TRANSMITTER

COMPATIBILITY SWITCH
POWER15SUPPLY
June, 2006
FEATURES YOU SHOULD EXPECT
FROM A RELIABLE DRIVE
USER FRIENDLY SELF PROTECTING WITH STAND MAINS

FLUCTUATIONS
DIAGNOSTIC SKIP FREQUENCIES FLYING START

FUNCTIONS Confidential / Property of 15 June, 2006
FEATURES YOU SHOULD EXPECT FROM A ENERGY SAVING DRIVE
VECTOR CONTROL AUTOMATIC ENERGY VARIABLE

OPTIMISATION TORQUE
AUTOMATIC MOTOR PID CONTROLLER HARMONIC

ADAPTATION Confidential / Property of FILTERS
15 June, 2006
TWO (2) SET POINT PID
• Ideal for Retrofit

with no requirement
of PLC
• Energy Savings are

- Precise
- Process Specific
- Consistent
IN A CLOSED LOOP

TWO (2) SET POINT PID (Contd)…
• Calculation on 2
feedback signals:
Minimum
Maximum
Sum
Difference
Average
• 2 Zone control
with 2 feedback's
and 2 set-points
1. Minimum
2. Maximum

Built-in harmonic filter
Low harmonic emission: THID < 48%

No voltage drop => full output voltage
Built-in DC link filters
Reduces installation cost
Fulfils EN 61000-3-2/3-12
Displacement power factor (cos φ ≈ 1)
True power factor 0.9

System protection
Protecting the motor
• Thermal monitoring (ETR)
/ thermistor
• Overload current and
torque
Protecting the drive

• Short circuit on motor
• Switching on mains and
motors
• Earth fault on motor
• Control I/O short circuit

Connections
Digital/analogue/
RS 485
Spring loaded
Looping
Thin or thick wires
Pluggable terminals
PC connections
USB 1.1
RS 485

Plug & Play
Modular design makes

for real plug & play
operation
Plug & Play connection

to PC via USB
Easy upgrade via plug-
in options
(automatic
configuration)

Backwards compatible

VLT® style design
Smaller footprint
Allocation to same terminal numbers
VLT FC 301 is replacing VLT® 5000

VLT FC 302 is replacing VLT® 5000 Flux

SENSOR POSITIONING THE KEY TO ENERGY SAVINGS
( for closed loop systems)
System curve:The theoretical squared curve showing the pressure required for any flow
Control curve : The squared curve between the sensor setpoint and the max. operating
point. This curve dictates the actual operating points with variable speed.
Sensor setpoint : The pressure needed to keep the system "primed" for design conditions.

SENSOR POSITIONING IMPACT ON ENERGY SAVINGS
Energy savings
The area between the control curve and the pump or fan curve graphically represents the
savings.
A) Incorrect sensor placement results in linear savings
B) Correct sensor placement results in near cubic savings
A B

PAYBACK !
AN EXAMPLE

PAYBACK !
AN EXAMPLE

PAYBACK !
AN EXAMPLE

HARMONICS
Harmonic distortion by nonlinear loads
Non-linear
Non-linearLoad
Load
System
Current
CurrentDistortion
Distortion Voltage
VoltageDistortion
Distortion
Impedance
Contribution
Contributionto
to Disturbance
Disturbanceto to
system
systemlosses
losses other
otherusers
users
Current distortion is apparatus level performance
Voltage distortion is system level performance

Harmonic Limitings Standards - Overview
Name Type Countries
IEEE 519-1992 Recommendation North America
EN 61000-3-2 Standard Europe
EN 61000-3-12 Future Standard Europe
G5/4 Recommendation UK
HK Code of Practice recommendation Hong Kong
EnergieNed Recommendation Netherlands

Harmonic current of a basic 6-pulse rectifier
Vab Vac Vbc

IDC
1 2 3
~ a
~ b IDC
~ c
4 5 6
Ia
Ib
Ic
Non-sinusoidal currents are
drawn from the supply
Pulsating power from the supply
source Confidential / Property of 15 June, 2006
Planing level of voltage distortion
USA: IEEE 519 - 1992
Special/Critical Dedicated
General system
application system
THvD 3% 5% 10 %
Europe: IEC 61000 - 2 -4
Class 1 Class 2 Class 3
THvD 5% 8% 10 %

Harmonic Analysis
1 All periodic signals can be

represented as a sum of sine-
0.5
functions with periods equal to
0 integer numbers of the
-0.5
fundamental component
-1
0
1 2 3 4 5 6 7 f (t ) = ∑ ah sin( hω1t )
1
0.5 Harmonics is decomposition of a

signal into different (integer of
0
fundamental) frequencies
-0.5
-1
0
1 2 3 4 5 6 7

Input Current of a basic rectifier without Input choke
HARMONIC CURRENT ANALYSIS

---------------------------------------------
Fund. Current38.57 A
Welcome to Danfoss Drives THD 104.52%
RMS current 55.79 A
5’th Harmonic 30.41 A

---------------------------------------------
Input current of rectifier with dc-link inductor

------------------------------------------------
THD 42.51%
RMS current 39.47 A

------------------------------------------------
Input current for rectifier with ac-side inductors

------------------------------------------------
THD 43.84%
RMS current 40.22 A

Confidential / Property of 7’th Harmonic 5.74 A 15 June, 2006
Danfoss Drives A/S 13’th Harmonic 1.34 A 86
------------------------------------------------
Harmonic Reduction Techniques
Advance Harmonic filters ( AHF)-

A Cost effective solution !!!
Also-
Also- Harmonic Analysis software-
software-MCT 31 is available –Free!!!
Harmonics Reduction
Price Active Front Optimum
end Solution!
18 Pulse Filter
12 Pulse Active
5%
Harm. trap 10% Passive
Filter
DC+AC
No Coils
DC Coils
Performance
Energy Savings ...
1 x 30 kW CT Fan VLT6042
1200000
Installed cost of Rs. 1000000
1,80,000/-
800000
Annual energy savings 600000 Cost

of Rs. 2,19,000/- 400000
Rs. save
200000
Payback period : 10 months
0
1yr 2yr 3yr 4yr 5yr
Cumulative Cost vs Cumulative Savings

SOME APPLICATIONS(-CONTD)
ENERGY SAVINGS ON COMPRESSOR

EnCon in Compressed Air Systems-BHEL-MAR05.ppt

Automotive Components Factory,IKKT,TN
Motor/VFD Rating : 37KW
Details of Compressor : 210 CFM (Retrofit)
Date of commissioning : Aug-2003
Unit consumed per hour W/O VLT : 32units (a)
Energy consumed per hour with VLT : 24 units (b)
Energy saved/ hour : 8 units
Cost of energy : Rs.5.00
Operation Hours & Days /year : 16*300
Energy saved / Year : Rs.192,000/-
Danfoss Drives A/S
Automotive Components Factory,Chennai
Motor/VFD Rating : 45KW
Details of Compressor : 224 CFM (New comsing)
Date of commissioning : Feb-2003
Unit consumed per hour W/O VLT : 37units (a)
Energy consumed per hour with VLT : 28 units (b)
Energy saved/ hour : 9 units
Cost of energy : Rs.5.00
Operation Hours & Days /year : 24*300
Energy saved / Year : Rs.324,000/-
Danfoss Drives A/S
ENERGY SAVING some POTENTIAL Applications
a) Pumps
b) Fans & Blowers
c) Air compressors ( Rotary screw & Recip)
d) Cooling tower ( Fans & Pumps)
e) HVAC system (Various VT Loads)
f) Roots blowers,Aerators etc.,
g) Agitators/Reactors
..\Introduction\5_Retrofitting Drives.ppt

HVAC APPLICATIONS – Energy saving potential
Supply Air Fan

Return Air Fan
Secondary Pump
Cooling Tower Fan
Condenser Pump
Exhaust Fan
Fume Hood
Primary Pump
Soft Start Types
A.C.Switch Type
• SCR - Diode
• SCR - SCR
Number Of Phases Controlled

• 1 Phase Control
• 2 Phase Control
• 3 Phase Control
Control Method
• Open Loop Control
• Closed Loop Control
Single Phase Control
T1
T2
Motor
T3
Two Phase Control
T1
T2
Motor
T3

Open Loop Control
T1
L1
T2
L2 Motor
T3
L3
Closed Loop Control

T1
L1
T2
L2 Motor
T3
L3
..\..\My Documents\Soft Starter Share Folder\MCD 3000\MCD3000 - Product Familiar
Danfoss MCI LH4N2

PAYBACK !
• Payback varies with
- Application
- Hours of operation
- Cost of energy
- Speed reduction
• Typical payback…
- 1 - 2 yrs on air side

- 1- 2 yrs on water side
- 1-2 yrs for compressor
Desirable Requirements For Effective Usage
User Friendliness
Upgradability
Operational Flexibility
Compliance to Norms
Safety
Enhancement of total system efficiency

Points to consider while procurements
of Drives or Soft starters
Suppliers Profile/background
Product Technology
Application/Process knowledge
User Friendliness of the product
After sales support
Spares Availability even if the
product is obsolete
AMC support availability
Faster/Quality service support

Thanks

What is a frequency inverter?
• It is an electronic device that takes a fixed AC supply and converts this

into a variable output voltage and frequency to control the speed of a
standard induction motor.
• The speed of the motor is dependant on the number of poles in the motor
and the supplied frequency.
Motor rpm = Frequency x 60

(no. of pole pairs)
4 pole motor rpm = 50 x 60 = 1500 rpm

2

What is a frequency inverter?
IGBT
Output
Stage
Motor
Fixed
380V,
60Hz
.
Input
DC
Variable voltage
AC / DC Rectifier Link
and frequency
output
Speed Control
Reference V&F
How does a frequency inverter produce this
variable voltage and frequency output?
• Most frequency inverters today use a method of “creating” an AC voltage

from the fixed DC voltage called PWM (pulse width modulation):
• Output transistors switched on/off at a fast rate (typically ≥4.5KHz)

according to a “switching” pattern which creates a series of rectangular
pulses of fixed amplitude and varying pulse width
• This pulse width modulation simulates a sinusoidal voltage at the

fundamental operating frequency plus harmonic voltages – together they
equal the total voltage
• Only the voltage at fundamental frequency (e.g. 0 – 50Hz) creates useful
torque
• The harmonic voltage components produce heat in the motor, torque ripple
and increased acoustic motor noise

PWM switching principle

• The switching on/off of the transistors
applies a series of varying width pulses
with a magnitude of either +Vdc or –Vdc to +Vd
the phase outputs (U, V, W) c
• The switching pattern which creates the

varying width of these pulses has can
affect the motor performance
• There are “standard” and “enhanced”

switching patterns
-Vdc
• “Enhanced” = better motor performance
and compatibility

Standard PWM
• Many frequency inverters use this type of switching pattern

• Also called “sine coded” or “sine weighted” PWM
• Main limitation of Standard PWM is that the maximum output voltage to
the motor is limited to 87% of the inverter’s input voltage:

Standard PWM – why only 87% mains input voltage
available at output?

Maximum phase to earth peak output voltage = V2dc
Therefore maximum phase to earth rms output
voltage Vpout = (V2dc / √2)
Phase-to-Phase Motor
(rms) input
voltage:
.
Vin = (Vpeak / √2)
Therefore, maximum phase-to-phase

V1dc = Vpeak = (Vin x √2) rms output voltage = (√3 x Vpout))
= (√3 x (V2dc / √2))
+V2dc = -V2dc
= (√3 x ((Vin x √2) / 2) x √2))
= (V1dc / 2) = ((Vin x √2) / 2)
= (√3 / 2) x Vin = 0.866 x 15VJune,
in 2006
Does having reduced motor voltage at full speed/full
load affect motor performance?
Effect of voltage variation on induction motor characteristics

20
15
“YES!!”
Percent change in motor performance
10
5
Full Load Amps
Power Factor
0 Efficiency
Starting and Maximum Torque
Starting Amps
-5
-10
-15
-20
-20 -15 -10 -5 0 5 10 15 20
Percent voltage variation
Poor motor performance with Standard PWM
• For a motor operating from a fixed supply frequency (50Hz), to

produce motor nameplate rated shaft torque when the mains supply is
-10% below motor nameplate rated voltage results in the following:
21% increase in slip to produce rated torque,
2% decrease in efficiency,
9.5% increase in full load amps,
6 - 7°C temperature rise,
for every +10°C. temperature rise above rated, the life of the
motor is reduced 50%

Can Standard PWM output voltage be improved?
• Switching pattern modulation index can be increased or third

harmonic injection can be used to increase output voltage from
standard PWM frequency inverters
• Both methods increase fundamental output voltage however but
also increase harmonic voltages = limitations
• Theoretically it is possible to achieve a fundamental output
voltage 95% of the input voltage however this still means motor
operates at best in a 5% under voltage condition
• If try to increase output voltage any further increases harmonic
frequencies in motor = increased motor temperature + torque
ripple + acoustic noise = reduced motor performance and
efficiency

Standard PWM – the reality !
• In reality what happens if using a standard PWM frequency

inverter to control a motor?
• The motor must be derated
It cannot be used for full load output power/torque (e.g. a
15kW motor can only be used for a load which requires
maximum 13kW shaft power)
Due to over-design of systems and selection of standard frame
size motors this might be OK for some applications but this is
a serious limitation of standard PWM – what if you need full
flow, full power, full torque for only 5% of the time?
• Frequency inverter supplier relies on fact that motor has over
design built in as part of the motor’s service factor (i.e. lifetime)
to compensate for the inverter performance
• This is often true, but is that what a service factor is for?

Enhanced PWM (e.g. VVCplus)
• Not all frequency inverters use Standard PWM

switching pattern today
• Some frequency inverters have used an
enhanced version of PWM (e.g. Danfoss VVCplus)
for many years, others are now introducing this
• Enhanced PWM (e.g. VVCplus) = improved
performance
Full motor voltage
Sinusoidal output current
Minimizes motor heating = same motor
temp rise as on mains supply
Maximizes inverter efficiency
• Many frequency inverters still use Standard
PWM and rely on the over design in the system,
over sizing of the motor, or result in reduced
performance or lifetime of the motor

Enhanced PWM (e.g. VVCplus)
• Unlike sine weighted PWM,

VVC is based on a digital
generation of the output
voltage.
• Ensures output voltage

reaches rated value of input
voltage, motor current is
sinusoidal and the motor
operates as it does on the
mains.

Enhanced PWM vs Standard PWM Motor Voltage Difference !
• Standard PWM • Enhanced PWM (e.g. VVCplus)

14%

Enhanced PWM (e.g. VVCplus) – Advantages
• A motor controlled by a frequency inverter using “enhanced”

PWM switching technique:
With rated mains supply voltage applied to the drive input,
full rated fundamental output voltage is applied to the
motor at rated frequency.
The motor is able to develop its rated power and torque at
rated voltage, current, and speed.
The motor operates within its rated temperature rise
allowing full thermal life of the motor to be maintained.
Harmonics in the motor are minimized
• The frequency inverter is compatible with the motor

Other design factors affecting available motor voltage
– harmonic filter solutions
• All frequency inverters are non-linear loads

resulting in harmonic currents in the mains
supply
• Most frequency inverters have one or two basic
solutions to reduce harmonics
DC link reactor OR AC input reactor
1 2 3 1 2 3
~ ~
~ ~
~ DC-side inductor(s) ~
4 5 6 4 5 6
AC-side inductors

• Both DC reactors and AC reactors give

similar reduction in harmonics
• DC reactors • AC reactors
HARMONIC
HARMONICCURRENT CURRENTANALYSIS ANALYSIS HARMONIC CURRENT ANALYSIS
------------------------------------------------ ------------------------------------------------
------------------------------------------------ ------------------------------------------------
Fund.
Fund.Current
Current 36.22
36.22AA Fund. Current 36.84 A
Fund. Current 36.84 A
THD
THD 42.51%
42.51% THD 43.84%
THD 43.84%
RMS current 39.47
RMS current 39.47AA RMS current
RMS current
40.22 A
40.22 A
5’th Harmonic 12.91 A 5’th
5’th Harmonic 12.91 A 5’thHarmonic
Harmonic 14.71
14.71AA
7’th Harmonic 7.03 A 7’th Harmonic 5.74
7’th Harmonic 7.03 A 7’th Harmonic 5.74AA
11’th
11’thHarmonic 3.06
3.06AA 11’th
Harmonic 11’thHarmonic
Harmonic 2.66
2.66AA
13’th Harmonic 2.10 A 13’th Harmonic 1.34 A
13’th Harmonic 2.10 A 13’th Harmonic 1.34 A
------------------------------------------------
------------------------------------------------ ------------------------------------------------
------------------------------------------------

Other design factors affecting available motor voltage –
harmonic filter solutions
• BUT – AC reactors result in a lower DC link voltage and therefore lower voltage
available to the motor
• How much lower voltage?
• Example, a 3% AC reactor for an 11kW frequency inverter with a rated current of 25
amps may have an impedance of 1.2mH
• On 60Hz supply this has an impedance XL=2x∏xfxL = 0.45 ohms
• At 25 amps this equates to a voltage drop across reactor of:
V = I x XL = 11.3 volts = 3% of 380V
• Voltage drop across reactor is 90 degrees out of phase with supply voltage so not full
3% drop (Note: DC reactor has no voltage drop)
• But AC chokes also increase diode commutation time
• Typically results reduction in DC link voltage = 0.5 x % inductance
• e.g. 3% AC reactor = 1.5% reduction in DC link voltage,
5% reactor = 2.5% reduction 1 2 3
~
~
~
4 5 6
AC-side inductors
• BUT – AC reactors result in a lower DC link voltage and therefore lower

voltage available to the motor Statement in inverter supplier’s manual
• How much lower voltage?
• Example, a 3% AC reactor for an 11kW frequency inverter with a rated
current of 25 amps may have an impedance of 1.2mH
• On 60Hz supply this has an impedance XL=2x∏xfxL = 0.45 ohms
• At 25 amps this equates to a voltage drop across reactor of:
V = I x XL = 11.3 volts = 3% of 380V
• Voltage drop across reactor is 90 degrees out of phase with supply voltage
so not full 3% drop (Note: DC reactor has no voltage drop)
• But AC chokes also increase diode commutation time
• Typically results reduction in DC link voltage = 0.5 x
1 2 3
% inductance ~
e.g. 3% AC reactor = 1.5% reduction in DC link
•
~
~
voltage, 5% reactor = 2.5% reduction
4 5 6
AC-side inductors
Standard PWM and AC reactors – the reality !
4 pole 4kW and 5.5kW motor nominal full load torque
30
25
20
Torque Nm
15
10
0
0 300 600 900 1200 1500 1800
Speed rpm
Motor Nominal Torque (4 pole, 4kW) Nm
Motor Nominal Torque (4 pole, 5.5kW) Nm

Standard PWM
Example of available 4kW and 5.5kW motor shaft torque
30 Full torque at full

speed/full load not
available w ith
25
Standard PWM
frequency inverters -
20
Torque Nm
typically best max

90% FLT available
15 (especially if AC input
reactors used for
10 harmonic reduction)
0
0 300 600 900 1200 1500 1800
Speed rpm
Motor Torque available (4 pole, 5.5kW) with Standard PWM Frequency Inverter Nm (Supplier A)
Motor Torque available (4 pole, 4kW) with Standard PWM Frequency Inverter Nm (Supplier A)

Standard PWM
30 Full torque at full

speed/full load not
available w ith
25
Standard PWM
frequency inverters -
20
Torque Nm
typically best max

90% FLT available
15 (especially if AC input
reactors used for
0
0 300 600 900 1200 1500 1800
Speed rpm

Standard PWM
Centrifugal Pump or Fan Application
Requirement to oversize frequency inverter and motor
depending on full flow torque requirement
30 Required full flow
torque not available
w ith standard PWM
25
therefore need to use
5.5kW frequency
20
Torque Nm
inverter and motor to

give required full flow
15 torque = increased
cost
10
0
0 300 600 900 1200 1500 1800
Speed rpm

Centrifugal Pump or Fan load torque Nm

Enhanced PWM and DC reactors – the advantage
Enhanced PWM
Full torque at full

30
speed/full load is
available w ith
25 Enhanced PWM
frequency inverters
20
Torque Nm
(especially if DC
reactors used for
10
0
0 300 600 900 1200 1500 1800
Speed rpm
Motor Torque available (4 pole, 4kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)
Motor Torque available (4 pole, 5.5kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)

Enhanced PWM and DC reactors – the advantage
Enhanced PWM
Centrifugal Pump or Fan Application
Same motor as for fixed speed application (4kW)
and 4kW frequency inverter required Required full flow
30
torque is available
w ith enhanced PWM
25 therefore can use
same 4kW motor as
20
Torque Nm
for fixed speed

application, w ith 4kW
15 frequency inverter =
low est cost + best
10 performance
0
0 300 600 900 1200 1500 1800
Speed rpm
Motor Torque available (4 pole, 4kW) with Enhanced PWM Frequency Inverter Nm (Supplier B)
Centrifugal Pump or Fan load torque Nm

Motor Compatibility
• By selecting or specifying a frequency inverter which uses an

enhanced PWM switching pattern (e.g. VVCplus) and using DC
reactors instead of AC input reactors you can be sure the motor
will get it’s nameplate rated voltage when operating at full
speed, full load and therefore be able to provide full motor shaft
torque and power without overloading the motor, or reducing
it’s lifetime
• This ensures compatibility with the motor and ensures it
operates from the frequency inverter, just as it would if
connected to the mains supply
• Inverter duty rated motors, oversized (de-rated) motors are
NOT required
• For centrifugal pump and fan HVAC applications – enhanced

PWM + DC reactors = standard motors can always be used no
matter what the speed/flow range

Motor Compatibility
Motor Insulation – Peak Voltage and Rise Time
• Another important factor to consider is whether the motor’s

insulation is compatible with the voltage supply from a
frequency inverter
• The voltage supply from a PWM frequency inverter can be very
different to the voltage from the mains supply
Voltage Current
• Although not common, this can potentially affect the motor

insulation
Motor Compatibility
• This is generally NOT a problem with “good” quality standard motors

and frequency inverters on mains supplies <500V AC
• It can be a problem on higher voltage mains supplies, with “low

cost” motors and on special applications – for these special
precautions can be taken to prevent problems
• However, for 220V/380V/480V mains supplies, using motors

complying with IEC60034-17 and “good” quality frequency inverters,
there should be no problems and no need to use inverter rated
motors
• Following slides, explain why potentially there can be problems and

how to avoid these problems
* Following information comes Danfoss internal studies, studies at Dresden University, Germany
and from a study into this topic by GAMBICA (UK drives industry association) and REMA (UK
motor manufacturers association)
Motor Compatibility
• It is a fact that motor winding insulation experiences higher

voltage stresses when supplied by a frequency inverter than
when connected to sinusoidal AC mains supply
• These higher stresses are dependant on motor cable length

and are caused by the interaction of the fast rising voltage
pulses of the frequency inverter and transmission line effects
in the cable
• To ensure compatibility with a motor, it is necessary to ensure

the motor terminal peak voltage (voltage and rise time) are
below the levels that the motor insulation is immune to

PWM Frequency Inverter – Output Voltage
• PWM frequency inverters use fast switching IGBTs to

create the PWM voltage waveform
• A series of square wave voltage pulses are applied to the
motor cable
• The motor draws current and due to the large inductance
of the motor this consists of mainly a sinusoidal current
waveform at the required frequency of operation

PWM Frequency Inverter - Motor Terminal Voltage
• Each pulse of the PWM waveform created by the fast switching

IGBTs has a fast rise time (at the output of a typical frequency
inverter this could be approx 100 – 300 ns)
• Rise times are so fast that as it travels along length of the
motor cable to the motor it can change the shape of the pulse
and may produce voltage overshoot (and change the rise time)
• At the motor, one pulse of the PWM waveform can look very
different to the square wave at the frequency inverter output

• To understand this effect, due to the fast rising pulse, it is

necessary to consider the motor cable as a transmission line
• Transmission line effects can then be considered = pulse travels
along the cable and is reflected at the motor like a wave
• A transmission line consists of a long string of
inductor/capacitor sections as shown below (only one phase is
considered here):

• At each fast rising pulse edge the frequency inverter has to charge
the inductance and capacitance of the cable so a pulse of energy is
delivered into the cable
• Transmission line theory shows pulse travels at velocity
= [1 / √(LC)] m/s
L and C = inductance (Henries) and capacitance (Farads) per
metre
• Velocity of a pulse in typical PVC insulated cable
= approx 1.7 x 108 m/s
= in 100ns the pulse travels 17m
• Different cable types give slightly different velocities, but generally
the differences are only small
• With this information can study how the fast rising pulse on output
of frequency inverter travels along the cable to the motor and how
the motor terminal voltage appears as shown 2 slides ago
• In this theoretical/ideal explanation:
tr = rise time of pulse at frequency
inverter output
tp = time taken for pulse to travel
length of cable
tr < tp (which is typical for cable
lengths >30m)
• Time t = tr
• Pulse enters cable at t = 0 and rises to
DC link voltage Ud in time tr
• Time t = tr + tp
• Pulse travels from inverter to motor
• When reaches motor it is reflected
because motor high frequency
impedance is > cable impedance
• Reflection causes pulse to rise towards 2
x original peak = 2 x Ud

• Time t = 2tr + 2tp (i.e. after the pulse
has traveled to the motor and back to
the inverter)
• Reflected pulse returns to inverter
• Because inverter impedance is low pulse
is reflected in a negative sense
• Inverter clamps voltage to Ud resulting in
negative pulse as it travels back along
cable to motor
• Time t = 2tr + 3tp (i.e. after the pulse

has traveled to the motor, back to the
inverter and back to the motor)
• Negative pulse is reflected again at the
motor and is doubled again = -2 x Ud
• This counteracts the original motor
terminal voltage increase

• In ideal case of previous 2 slides

reflections would cause voltage to
oscillate continuously
• In the “real world” voltage rise
time is increased due to high
frequency losses in the cable and
waveforms become rounded
• Also due to high frequency losses
peak voltage oscillations over one
pulse time decay to and stabilise
at the DC link voltage (Ud)
• This diagram shows “real world”
motor terminal voltage waveform
with 42m motor cable
• Motor peak voltage is therefore a function of cable length and rise time
• If the cable length is such that the time for the pulse to travel along
the cable is > the rise time, potentially 2 x Ud peak voltages could
occur at the motor
• (Note: Ud is approx the peak voltage of the sinusoidal mains supply at
input of the inverter)
• Motor terminal peak voltage will be less with shorter cables (above a
certain length – typically >30-50m the peak voltage does not increase)
• Motor terminal peak voltage can be less if the frequency inverter
output voltage pulses have a longer rise time for the same motor cable
length

Measurements with 460V mains supply 136
Danfoss Drives A/S
• When considering the effects of these higher motor terminal
peak voltages on the motor insulation, the pulse rise time is
important
• IEC 600034-17 and NEMA MG1 Part 30 have different definitions
of pulse rise time as shown below
• These diagrams show that with exactly the same waveform, the
rise time value can be different by a factor of 2
• Important to understand this if using IEC or NEMA motors

PWM Frequency Inverter - Motor Winding Voltage
• Motor terminal peak voltage is an important factor to consider to

ensure motor insulation is not damaged
• However, with “good” quality standard motors the peak voltage

alone has little effect because the main motor insulation systems
between phases and between phases and earth are designed to
withstand large over voltages
• However, because of the fast rise time, the peak voltage stresses
insulation between turns and especially between randomly
touching conductors within a coil or between coil ends

• The pulse voltage travels around

motor winding just as it does along
the cable
• Diagram shows how this may result

in a large % of the pulse voltage
appearing between turns, at random
points within a coil or between coil
ends
• (With a sinusoidal supply the voltage

is distributed evenly in the winding)

• Depending on motor (rating, type of
winding, number of turns etc.) and
the rise time, the % of the peak
terminal voltage appearing between
turns or randomly within a coil may
reach 30%–90%
• This diagram shows possible
variations in 1st coil voltage as a % of
the motor terminal peak voltage vs
rise time
• With a sinusoidal supply the coil ends
only experience a fraction of the
phase voltage (determined by
number of coils)
• With a PWM frequency inverter it is a combination of the peak

motor terminal voltage and the rise time that can cause
considerable increase in voltage stress within a coil
Motor Compatibility
• That’s the bad news …. now the good news !
• “Good” quality motors have adequate insulation systems

to prevent damage or reduced lifetime of the insulation
when controlled by PWM frequency inverters
• What is a “good” quality motor?
• How do “good” quality motors prevent insulation failure

due to these fast rising, high motor terminal peak
voltages?

Motor Compatibility
• There are basically two types of motor winding used for low
voltage motors up to 690V
Random wound – often used Form wound – often used for

for low power motors higher power motors

Motor Compatibility
• Both random wound and form wound motors have similar

essential elements in their insulation system
• Phase to earth and phase to phase insulation
In “good” quality motors this is provided by slot liners, slot
closures and end winding and will typically consist of polyester
film/meta-aramid paper
In low cost, low power motors, this inter-phase “paper”
insulation is omitted (PWM frequency inverters should use
output LC filters if used with this type of low cost motor)
• Inter-turn insulation
In random wound motors this is provided by multi-layer
polyester/polyamide enamel on the conductor
In form wound motors this is provided by mica/polyester
wrapped film around the rectangular form wound turns

PWM Frequency Inverter – Maximum Motor Cable Length
Other important issues
• At each fast rising pulse edge the frequency inverter has to charge
the inductance and capacitance of the cable
• Depending on the length of cable, the cable charging currents can
be high
• For small motors on long cables, the cable charging current can be
similar to the motor full load current
• All frequency inverters have a maximum motor cable length based
on the rating of it’s internal components (can vary 10m – 300m
depending on supplier)
• If frequency inverter not selected correctly can get nuisance
tripping with long motor cables – check maximum motor cable
length (shielded/screened and unshielded/unscreened)

Frequency Inverters Motor Compatibility, Protection
and Operation on Mains Voltage Sags/Dips
Conclusion
• With the correct selection of frequency inverter it is possible to

ensure full compatibility with standard IEC motors without requiring
the use of inverter duty motors
• A frequency inverter can provide full protection of the motor but
depending on it’s motor current monitoring and fault protection
circuits, the reliability of that protection may differ between
different suppliers
• Operation of frequency inverters at full load when total mains loss
occurs is very short unless a back-up power supply is provided
• Operation of frequency inverters at full load when voltage sags/dips
occur according to Semi F47 can vary depending on the frequency
inverter design

Comparison between Eddy Current Drive & Inverter Drive
Sl Features Eddy Current Drive Inverter Drive Significance
1 Control technology Electromagnetic coupling Pure Static electronic Very high efficient &
between Motor & load device reliable system as no
moving parts
2 Speed Variation 10-85% 0-100% Better control option

range
3 Efficiency 50-70% based on operating 95-98% based Sizes of Motor &

speed operating speed associated switchgear
reduces
4 Maintenance Regular maintenance required Maintenance free Trouble free operation
5 Starting Current The motor current is 6-7 times Maximum 1.5 times The life of motor
of Rated current increases.
6 Accuracy Less or inaccurate system Highly accurate controls

possible


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Welcome to Danfoss Drives

Target group: VIP-guests, customers and internal use

Contact: Anette Uldall / Irene Krog Hansen

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NALCO SMELTER TEAM…

Welcome to Danfoss Drives

1. Introduction to Danfoss –Global....

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Motion Controls Division 2004

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2004 Danfoss Drives opens

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Business Development & Com Danfoss Drives Ventures

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Facts about Danfoss Drives

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Production in Europe, China and USA

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The cornerstones of our unique offering to the market are:

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Supply Chain People

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One year’s production of advanced

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1997 Introduction of VLT® DriveMotor FCM 300 series.

VLT® product range