Installation Considerations When Applying Variable Frequency Drives

CT337
Installation Considerations When Applying Variable

Frequency Drives
PUBLIC INFORMATION
Rev 5058-CO900E Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Today You Will Learn:
• How to correctly size your VFD
• How to properly install to minimize problems.
• How to mitigate Reflective Wave voltage spikes
• How to dampen the effects of Common Mode Current
PUBLIC INFORMATION Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 2
Collect the Motor Data
Select Your VFD Based

on Motor Nameplate
Amps
Record:
Volts
Amps
RPM
Hz
PUBLIC INFORMATION Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Read the Nameplate
Confirm the Input Voltage

Confirm the Output Current
Current needs to be greater than
or equal to the motor nameplate
value
Always Select the VFD Based on
Motor Nameplate Current!
Horsepower is a nominal rating
Plan the Installation
UVW RST
PE
A PE
ASD Output ASD Input
Conduit / Armor Conduit / Armor
bond to cabinet Bond to cabinet
Cabinet Back Plane

ASD - 1 ASD - 2
B A Transient Common
Mode Current on Armor
PLC or
PE PE
Electronics
ASD - 3 ASD - 4
B Transient Common
Mode Current on PE Wire
PE PE Optional PE to
Building Structure
PE Copper Bus
B
Pay Attention to Clearances
Pay Attention to Clearances?
Heat Is Your Enemy!
Just because it fits in the
box, doesn’t make the
enclosure the correct
size!
5.98”
Think of it as a 100 watt light bulb!

Don’t bake your VFD in an Easy
Bake Oven!
3.15”
Heat Is Your Enemy!
Heat rises, give it a

path to flow.
Install the unit vertically to

allow airflow through the heat-
sink cooling fins.
Don’t block the cooling fan!
Pay Attention to Clearances?
Power to Power
Motor to Motor
Pay Attention to the Control Voltage
Don’t let the Magic Smoke out!

Proper Grounding is a Must!
Is Your Input Power Grounded or
Floating?
L1
L2
L3
Ungrounded Power Systems may require the removal of the Input

MOV jumper
AC Drive and Motor Installation Practices
Line Transients
A little protection
and good
technique
ACME INCORPORATED go a long way to
insure a good
drive installation
Common Mode
&
Capacitive Coupling
Tell me again
why I’m using
drives?
? Harmonics
Reflected Wave
Grounding
&
Bonding
Why Should I use a DRIVE ?
• To improve process control though speed and torque

control
• To improve system efficiencies
• To extend life of equipment by reducing mechanical

stress
• Reduce power demand –Save Energy
Why Develop the Variable Frequency Drive?
• The Promise:
• To be able to electronically vary the speed and

torque of any constant speed AC Motor.
• Torque is proportional to applied Voltage.

• Speed is proportional to applied Frequency.
A Little Motor Fodder?
• Most Common Enclosure

is “TEFC”
• Totally Enclosed, Fan Cooled
• Fan attached to motor shaft
rotates at same speed as
motor shaft
• Blows air over outside of motor
frame to dissipate internal heat
• Designed to provide sufficient
cooling on line power to keep
motor from overheating
• Remember: HEAT KILLS
What Do We Know About Fans?
• Governed by the “Laws of Affinity”

• It’s a LAW, which means it applies under all
circumstances
• Law # 1
• The volume of air moved by a fan is directly proportional to its speed.
• Faster = More Air
• Slower = Less Air
• If That Fan is Being Used to Cool an AC Motor, and the
AC Motor is Operating at Less than Nameplate Speed,
the Fan is Moving Less Air and Providing Less Cooling!
A Little History Lesson About AC Motors
• Late 1980’s/Early 1990’s

• No general supplier of “Inverter Rated” motors
• VFDs applied to motors caused failures due to overheating!
• A few niche suppliers modified general purpose motors to keep
them cool when operating at reduced speeds.
• De-rated Higher Horsepower Motors
• Larger metal mass = better heat transfer
• Added Constant Speed Blowers
• Constant cooling regardless of motor speed
• Addressed Only the Motor Thermal Issues
• IGBT Start to be Used By VFD Manufacturers
• Motor Service Centers Started Seeing Increased Volume of Motor Winding
Failures
What is an IGBT?
• Insulated Gate Bipolar Transistor

• Hybrid cross between a MosFET and a Darlington Power Transistor
An Insulated Gated Bipolar Transistor is a power

switching device capable of interfacing with low signal
level logic control.
RMOD
C1
POWER OUTPUT
Power Bipolar
SIGNAL INPUT G1
RBE
Power MOSFET
E1
Conventional model of IGBT
IGBT Advantages in AC drives
• Higher Switching (Carrier) Frequencies than Bipolar

Transistors
– Lower Motor Noise
– Higher Switching Frequency
– 4kHz Typical
– Lower Motor Heating
– Motor Friendly Current Waveform Due to Higher Switching Frequency
producing Less Waveform Ripple
– Better Field Oriented Control
– Higher Switching Frequency Allowing for Faster Response Time
IGBT vs. Bipolar
Transistor Current
7.5HP MOTOR
1336 @ 60HZ NO LOAD

SWITCHING FREQUENCY
Bi-Polar 1.26KHZ
1336 PLUS @ 60HZ

NO LOAD SWITCHING
FREQUENCY 8KHZ
IGBT
IGBT Advantages in AC drives
• Drive Size Reduction

– High Input Impedance – IGBT
– Voltage “Gated (Switch on/off)” Device
– Reduces Base Driver Power Consumption
– Reduces Base Driver Board Size
5Hp 1333
Darlington Pwr
5Hp PowerFlex40
IGBT
4” x 8.4” x 5.4”
10.2” x 13.6” x 7”
IGBT’s in VFDs
• IGBT Associated Phenomenom

• Reflective Wave or dv/dt
Energy stored in distribution system
Long Wires Runs to Motor between drive and motor is released
Input Power during switching and produces voltage
spikes.
AC DRIVE Output Power
[PWM]
typical
Hotter motors Distribution network

IGBTs can stress motor insulation
because of faster rise times
The Physics of it All
• Rapid voltage rise times

• The cable surge impedance does not match
the motor surge impedance----
– Voltage reflection WILL occur !! Physics! Agh!
Just tell me what
I need to do!
Reflected Wave Investigation
• FACT: Reflected wave voltage at motor is a function of :

• Cable Length
• Cable distance between VFD and Motor
• Output Voltage Risetime

• When you turn on the switch (IGBT), how long does
it take the voltage being sent to the motor to go from
0 to Max (DC Bus Voltage).
• Typically in Micro/Nano seconds.
Reflected Wave
VLL @ Drive
Drive
Motor
VLL @ Motor
Effect: Peak voltage levels that search
and find insulation voids
Breakdown, Corona or Partial Discharge of motor windings
Eventual motor turn-to-turn, winding-to-winding or winding-to-

motor frame shorts
Reflected Wave Result
Motor Manufacturers Step to the Plate
• Most Manufacurers Now Provide a “Inverter Duty” Product

Offering
• Motors are built with “Spike Resistant” Wire
• Special Coating on Wire to Resist Voids Caused by Their
Manufacturing Process, Handling for Forming Prior to Stator
Insertion
Protect the Motor
• Output Reactor between drive & motor

– Slopes off the waveform (lengthens rise time)
– Reduces destructive force for same amplitude
– Allows longer lead lengths
– Does create Voltage drop
• Output Filters
– dV/dt
• 1204-RWR2, 1204-RWC-17A
• 1204-TFA1, TFB2 “terminator”
• Third party devices
– Sine Wave Filter
– Distances Beyond 1000’
– Expensive Solution
GENERATION OF COMMON MODE
or
LINE-GROUND ELECTRICAL NOISE
Common
Mode
Issues
What is Common Mode Current &
How is it Generated?
DRIVE FRAME MOTOR

C FRAME
MODULE
MOTOR
WINDINGS
LOGIC C CONDUIT
MODULE
DRIVE FRAME
C
MODULE
MOTOR
FRAME
PE
X INCIDENTAL
CONTACT OF
X CONDUIT TO
BUILDING STEEL
MOTOR
LOGIC C WINDINGS
MODULE
IGBT Switching Creating Common Mode Current
Occurs at every IGBT switching
Top Vl-l output voltage vs. I line-ground stray cable & motor current
How to Measure Common Mode Current
Current to motor = current from motor.

Resultant should be zero!
Current seen is real current going somewhere?
Common Mode to Ground grid.
Oscilloscope
The Paths of Common Mode Current and
it’s affect on Sensitive Electronic Equipment
Input Transformer AC Drive Ilg Motor Frame

A R U
Ilg (+)
XO B S V
Vdc Motor Tach
Ilg bus W
T
(-) C lg-m
PE C Ilg
Logic
Ilg
C lg-c I
Common Mode PE lg
Current Path Vng
EARTH Potential #1 Potential #2 Potential #3

GROUND Interface Electronics
0-10V, communication,
4-20 ma,sensor interface,etc
Potential # 4 True Earth Ground (TE)

Common Mode Noise Current Path causing ground EMI
Interference
Containing Common Mode Current
Input Transformer AC Drive Conduit Motor Frame

A R U
(+)
Ilg
XO B S V Ilg s
Vdc t Motor
bus W r
Ilg T a
p C lg-m
PE C (-)
Ilg PE
Motor PE
Ilg PE GND wire
Ilg Accidental Ilg
Common Mode Current Path Contact of
conduit
Potential #1 Potential #2 Potential #3

EARTH GROUND
Potential 4
CONDUIT PROVIDES GOOD WIRING NOISE CONTROL

BUT ACCIDENTAL CONDUIT CONTACT TO GROUND MAY
ALLOW Ilg NOISE PATH BACK TO GROUND
Additional Containment
Shielded Cable / Armor

Input Transformer AC Drive with PVC Jacket Motor Frame
A R U
(+)
Ilg
XO B S V
Vdc Motor
bus W PVC
Ilg T
C lg-m
PE C (-)
Ilg PE
Ilg
Ilg PE
Ilg Additional
Common Mode Current Path Motor PE
GND wire
EARTH GROUND Potential #1 Potential #2 Potential #3

Potential 4
Shielded output cable/armor with PVC jacket

PROVIDES BETTER WIRING & NOISE CONTROL WITH NO ACCIDENTAL ARMOR
CONTACT TO GROUND. BUT IF NOT USED ON INPUT MAY ALLOW Ilg NOISE PATH
BACK TO GROUND
Additional Containment
Transformer Cable / Armor Cable / Armor

Cabinet Frame & PVC JacketAC Drive & PVC Jacket Motor Frame
A
R U
Ilg
XO
B
S V Motor
Ilg PVC PVC
T W C lg-m
C PE
PE
PE Ilg
HRG or
Ilg Common Mode
SOLID GND Current Path Additional
Motor PE
GND wire

Potential 4
Shielded input & output cable/armor with PVC jacket

PROVIDES BETTER WIRING & NOISE CONTROL WITH NO ACCIDENTAL ARMOR
CONTACT TO GROUND. Prevents Ilg NOISE inteference PATH BACK TO GROUND.
Common mode cores and
common mode capacitors as a solution
Common Mode
AC Drive Choke Motor Frame
A R U
Vdc bus
(+)
XO B S V Ilg
Motor
T W
(-)
C lg-m
PE C Common Mode PE
Bus Capacitors Ilg Motor PE
PE GND wire
C lg-c Ilg
IlgCommon Mode
Current Path

Potential 4
Implementation of CM core in drive output, CM

cores are smaller than output line reactors.
Common mode core solution
Inverter 70 nS
output
Voltage
Vu-v
Ipeak
6 MHz Oscillation
Common
Mode
Ilg Current
Ilg Current
With Slower 1.5 us to 5 us risetime
Common
Mode Lower 200 kHz to 63 kHz Oscillation
Chokes
Lower 1/3 Ipeak

CM ferrite cores attenuate the high frequency noise peak
amplitude and more importantly the ILG noise current
rise time that develops CM noise ground voltage
CE or RFI filter solution
Main Plant Xfmr.LISN Drive EMI Filter AC Drive Motor Frame

A R U
XO B
S
Ilg
V Motor
Lf W
T C lg-m
C PE
Cf PE Motor PE
HRG GND wire
Unit C lg-c Ilg
Ilg

Potential 4
* EMI filters re-direct noise current back to drive input leads
and out of ground , must be used with shielded output
cables.
* (+) and (-) DC Bus capacitors to Ground also perform the
same function
Isolation transformer solution
Main Plant Xfmr. Drive Isolation Xfmr. AC Drive Motor Frame

A A
R U
B Ilg Ilg
XO XO B
S V Motor
Ilg W C lg-m
C T PE
C Ilg PE Motor PE
HRG GND wire
Unit to other Ilg C lg-c Ilg
plant loads

Potential 4
* solidly ground drive isolation XFMR re-directs noise current back

to drive input leads and out of ground. Mount close to drive. Must
be used with shielded output cables.
* NO Ground noise in upstream ground from XFMR
Using common mode (ferrite) cores on signal wires
SEND RECEIVE
Hi
Isignal
Load
Isignal
Lo
Z
Common Mode
Choke on Shield
Interface Leads
Ground Potential #1 Ground Potential #2
Implementation of CM core in signal lines between noisy grounds works
Panel layout is important
U VW RST
B A ASD Output A PE ASD Input
PE Cabinet Back Plane
ASD - 1 ASD - 2
AB
A Transient Common
PLC or
PE PE
Electronics
ASD - 3 ASD - 4
B Transient Common
AB
PE PE
PE Copper Bus
B
B Poor panel layout allows Ilg noise on
output armor to flow back to ground
Wire To System PE behind the PLC ground , causing
of Building Structure possible interference
Better panel layout
UVW RST
PE
A PE
ASD Output ASD Input
Cabinet Back Plane

ASD - 1 ASD - 2
B A Transient Common
PLC or
PE PE
Electronics
ASD - 3 ASD - 4
B Transient Common
PE PE Optional PE to
Building Structure
PE Copper Bus
B
Better panel layout allows Ilg noise on output armor to

flow back to input armor and out of PLC ground
Strategy to Reduce or Eliminate CM Noise Issues
•Follow grounding recommendations to the letter

•Use recommended panel layout
•Keep motor cables short
•Use shielded cable whenever possible
•Route wires intelligently
•Use drives with CM internal cores
or
•Use external CM cores
•Set drives for the lowest carrier frequency
QUESTIONS and ANSWERS

Installation Considerations When Applying Variable Frequency Drives

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CT337

Installation Considerations When Applying Variable

Today You Will Learn:

• How to correctly size your VFD

• How to properly install to minimize problems.

• How to mitigate Reflective Wave voltage spikes

• How to dampen the effects of Common Mode Current

Select Your VFD Based

Confirm the Input Voltage

Cabinet Back Plane

Think of it as a 100 watt light bulb!

Heat rises, give it a

Install the unit vertically to

Don’t let the Magic Smoke out!

Ungrounded Power Systems may require the removal of the Input

• To improve process control though speed and torque

• To improve system efficiencies

• To extend life of equipment by reducing mechanical

• Reduce power demand –Save Energy

• To be able to electronically vary the speed and

• Torque is proportional to applied Voltage.

• Most Common Enclosure

• Governed by the “Laws of Affinity”

• Late 1980’s/Early 1990’s

• Insulated Gate Bipolar Transistor

An Insulated Gated Bipolar Transistor is a power

• Higher Switching (Carrier) Frequencies than Bipolar

1336 @ 60HZ NO LOAD

1336 PLUS @ 60HZ

• Drive Size Reduction

• IGBT Associated Phenomenom

Hotter motors Distribution network

• Rapid voltage rise times

• FACT: Reflected wave voltage at motor is a function of :

• Output Voltage Risetime

Breakdown, Corona or Partial Discharge of motor windings

Eventual motor turn-to-turn, winding-to-winding or winding-to-

• Most Manufacurers Now Provide a “Inverter Duty” Product

• Output Reactor between drive & motor

DRIVE FRAME MOTOR

Occurs at every IGBT switching

Current to motor = current from motor.

Input Transformer AC Drive Ilg Motor Frame

EARTH Potential #1 Potential #2 Potential #3

Potential # 4 True Earth Ground (TE)

Input Transformer AC Drive Conduit Motor Frame

Potential #1 Potential #2 Potential #3

CONDUIT PROVIDES GOOD WIRING NOISE CONTROL

Shielded Cable / Armor

EARTH GROUND Potential #1 Potential #2 Potential #3

Shielded output cable/armor with PVC jacket

Transformer Cable / Armor Cable / Armor

EARTH GROUND Potential #1 Potential #2 Potential #3

Shielded input & output cable/armor with PVC jacket

EARTH GROUND Potential #1 Potential #2 Potential #3

Implementation of CM core in drive output, CM

Lower 1/3 Ipeak

Main Plant Xfmr.LISN Drive EMI Filter AC Drive Motor Frame

EARTH GROUND Potential #1 Potential #2 Potential #3

Main Plant Xfmr. Drive Isolation Xfmr. AC Drive Motor Frame

EARTH GROUND Potential #1 Potential #2 Potential #3

* solidly ground drive isolation XFMR re-directs noise current back

Ground Potential #1 Ground Potential #2