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How VFDs save energy

Analysis and examples of power conversion by variablefrequency drives.
By Edward Tom, Yaskawa America, Inc. -+ Page 1 of 2 Prev 1 | 2NextView on one page

Variable frequency drives (VFD) are becoming more common place and more widely used in applications. They are capable of varying the output speed of a motor without the need for mechanical pulleys, thus reducing the number of mechanical components and overall maintenance. But the biggest advantage that a VFD has is the ability to save the user money through its inherit nature to save energy by consuming only the power thats needed. The main question now is, How does a VFD accomplish this? The simple answer to this question is power conversion. A VFD is similar to the motor to which its attached, they both convert power to a usable form. In the case of an induction motor, the electrical power supplied to it is converted to mechanical power through the rotation of the motors rotor and the torque that it produces through motor slip. A VFD, on the other hand, will convert its incoming power, a fixed voltage and frequency, to a variable voltage and frequency. This same concept is also the basis to vary the speed of the motor without the need of adjustable pulleys or gearing changes. ADVERTISEMENT White Paper: US Electrical Workplace Safety Compliance Five to 10 times per day in the US, a worker is severely injured or killed in an electrical arc flash accident. Other electrical incidents also can injure workers accidental contact with energized parts for example. Electrical incidents can be devastating to workers & the financial consequences of such events can be very damaging to the company. Download
Electrical

Electrical power is defined as the following: Power (P) = 3 x Voltage (V) x Current (I) x Power Factor (PF) In an ideal VFD, the following would hold true:

Powerin = Powerout But because a VFD has inefficiencies and requires a small amount of power consumption to power the brains of the drive, the input power will be slightly greater than the output power. For this, we will assume that this extra power draw is negligible. With these two equations, we can then define the relationship between the VFDs input and output: Vin x Iin x PFin = Vout x Iout x PFout Taking these equations into account, lets use a 100-hp motor as an example with the following properties: Power = 100 hp Speed = 1,785 rpm Voltage = 460 V FLA = 115 A Power factor = 0.86 A VFD will convert its incoming power, a fixed voltage and frequency, to a variable voltage and frequency. - Edward Tom, Yaskawa America, Inc. Assume that the motor is running at 60 Hz on a VFD, drawing a no-load current of 40 A on the output of the VFD. With this, one would assume that the input current would also be the same, 40 A. However, using an ammeter on the drives input, a person is reading nearly zero amps! How is this possible? Is the drive creating power somehow? The answer simply is no, the drive is not creating power. The power factor causes this discrepancy in current When a motor is running at no load, the motors power factor can be assumed to be zero, not 0.86 86 as stated on the nameplate. The reason the power factor isnt at 0.86 is because this is the motor power factor at full load. Alternatively, mechanical (friction) and electrical (resistive) losses in the motor prevent the power factor from being zero when running no load, but well assume these losses to be zero just like we did for the VFD. Therefore, you would have the following: Pout = 460V x 40A x 0 Pout = 0 Because the output power is zero, the input power also will be zero. With a fixed input voltage, the two variables would be current and power factor. Because current is needed for a power factor to exist, both current and power factor are zero, which means the low input current reading is indeed correct.

This explains why the input current to the VFD is so low when the motor is operating under no load conditions. But what about under load? The same concept still applies when the motor is under load. For example, assume the same motor is now operating at half speed, 30 Hz and producing full motor rated torque and drawing the motors full-load amps (FLA). This means that the electrical power that the motor is drawing is: Pout = 3 x 230V x 115A x 0.86 = 39.4kW Because the VFD is a power converter, this means that the input current is (assuming a 0.89 input power factor from a 3% line impedance): Iin = (39.4kW) / (3 x 460V x 0.89) = 55.6A Because the VFD is operating at half speed and under full load, the input current is less than half of the output current.
Power (kW) Voltage (V) Current (A) Frequency (Hz) Power Factor Input Output 39.4 39.4 460 230 55.6 115 60 30 0.89 0.86

In this example, the input current is less than half of the output, a result of having a higher power factor on the input side. The difference in power factor between the input and output side of the motor is what makes it possible to have a higher output current than input current. Assuming the motor is now running at full load and using the same power factor values, your input current now becomes: Iin = (3 x 460V x 115A x 0.86) / (3 x 460V x 0.89) = 111A which is 4 A lower than the output current.
If Then

PFin < PFout Iin < Iout PFin = PFout Iin = Iout PFin > PFout Iin > Iout Mechanical

The current a VFD draws on the input side also can be related to the mechanical power a motor is delivering. The basic relationship for motor power is:
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Powermechanical Speed x Torque This means that if the motor is operating at half the speed and producing full torque, the motor is outputting half of its rated power. Consequently, if the motor is running at full speed and producing half torque, the motor is also outputting half of its rated power.\ Because of motor losses, the power relationship between the electrical power going into the motor and the mechanical power is: PowerElectrical = (Powermechanical) / (EfficiencyMotor) Revisiting the above example, if the motor is operating at 30 Hz, half the motors rated speed and producing full torque, then the mechanical power being produced is 50 hp. Assuming that the motor is 95% efficient, the electrical power thats required is: PowerElectrical = (50HP x 0.746) / 0.95 = 39.3kW which means that the current on the input side of the VFD will be approximately 55 A. This same current will also hold true even if the motor is operating at full speed and producing half torque. Table 1. Operating points for examples*
Motor speed (rpm) Motor torque (ft-lb) Motor power (hp) Input power (kW) Input current (A) 0 0 900 900 1800 1800 0 100 0 295 0 295 0 0 0 50 0 100 0 0 0 39.3 0 78.8 0 0 0 55 0 111

*Motor is rated for 100 hp with a rated torque of 295 ft-lb.

Ultimately, a VFD is merely a power conversion device that converts the fixed voltage and frequency of incoming power to a variable voltage and frequency output to provide the variable speed capabilities for which it was designed. Keep in mind the variables associated with electrical power (voltage, current and power factor) and their relationships when comparing the VFDs input to its output. This also will hold true when using the motors mechanical power (speed and torque) to determine the amount of input power/current to the VFD. Taking all the variables into consideration, one can be pleasantly surprised to find the input current lower than the output current
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What are the factors that affect VFD rangeability?

In the ISA Automation Week Mentor Program, I am providing guidance for extremely talented individuals from Argentina, Brazil, Malaysia, Mexico, Saudi Arabia, and the USA. We will be sharing a question and the answers each week. If you would like to provide additional answers, please send them to Susan Colwell at ISA. The eighteenth question is from Muhammad Khalifah in Saudi Arabia: What are the factors that affect Variable Frequency Drive (VFD) rangeability for flow control? Greg Shinskey in his study Flow and Pressure Control Using Variable Speed Drives (Control Conference, Chicago, 1980, pages 161167) found that rangeability of flow control by variable speed pumping exceeded the rangeability of the magnetic flow meter in the test. In general, the rangeability of VFD can be 40:1 or better if the following guideline is followed: Guideline to maximize VFD rangeability for flow control

1. Pulse Width Modulation to improve low speed performance reducing torque pulsation (cogging) 2. Totally enclosed fan cooled (TEFC) motors with constant speed fan or booster fan as necessary with class F insulation (inverter duty) and 1.15 service factor to prevent overheating 3. Totally enclosed water cooled (TWEC) motors for high temperature fluids to prevent overheating 4. NEMA frame B motor to prevent steep torque curve 5. Proper pump sizing to prevent operation on flat part of pump curve 6. Use of recycle valve to keep pump discharge pressure well above static head at low flow (see article Watch out with variable speed pumping)

7. Use of low speed limit to prevent reverse flow for highest possible destination pressure 8. Twelve bit or more signal input cards to improve resolution limit of signal to 0.05% or better 9. For tachometer control, gear teeth for magnetic pickups and discs with holes or bands with mirrors on the shafts for optical pickups to provide more pulses per revolution 10.For tachometer control, keep the speed control in the VFD to prevent violation of the cascade rule where the secondary flow loop should be 5 times faster than the primary (flow) loop as discussed in More Fun with PID Controllers 11.To increase rangeability to 80:1, consider fast cascade control of speed to torque in VFD to provide closed loop slip control as described in The Control Techniques Drives and Controls Handbook, IEE Power and Energy Series 35, Cambridge University Press, 2001
The excerpt Essential-Book-Excerpt-VFD-Performance from the ISA book Essentials of Modern Measurements and Final Elements in the Process Industries documents these and other considerations in maximizing the performance of variable frequency drives for process control. Senior Member

Full Member 253 posts

Gender:Male Location:Midwest, USA

Posted 28 July 2010 - 06:30 AM

QUOTE (mbouknight @ Jul 20 2010, 01:11 PM) <{POST_SNAPBACK}> How do I find the Full Load Amps for a 380 V motor, 3-phase, 200 HP, 1.15 service factor in order to correctly size a VFD?

mbouknight Is it the case that the motor is an older design and no longer has its Rating Plate attached to it ? Advise ..

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#3

GreenDriv

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Gender:Male Location:China Interests:travel, reading, listening to music

Posted 10 February 2011 - 01:37 PM

QUOTE (mbouknight @ Jul 21 2010, 03:11 AM) <{POST_SNAPBACK}> How do I find the Full Load Amps for a 380 V motor, 3-phase, 200 HP, 1.15 service factor in order to correctly size a VFD?

I think you can refer to the name plate of the motor. When you want to apply the VFD, just remember that the power of VFD should be equal or larger than that of motor. That's enough.
Manufacturing & offering variable speed drives, frequency inverters, closed loop AC drives... Let's share and communicate!

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#4

KJF

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Posted 01 March 2011 - 03:20 AM

The motor information you give is confusing. 380 V implies that this is a European motor rated for a 380v, 50 Hz system. If so, the nameplate rating would be in kw not horsepower there would be no service factor. European motors are design with a sf of 1.0 If the motor is a 480V, 60 Hz, 200 hp motor with a 1.15 sf and the nameplate FLA is not available, the conservative approach is to size the VFD drive current capacity from the FLA table in NFPA 70 (NEC). When applying this motor in a VFD application, the s.f. must now be assumed to be 1.0 since the additional heating from the VFD waveform will consume all the additional heat capacity the of the 1.15 s.f.

Other factors that may require consideration is the driven load. If this is a constant torque application such as a compressor or positive displacement pump, a higher thermal capacity drive is require since the drive may have to produce near FLA at low voltages. The VFD vendors can make recommendations. One other caution is that if you need more than a 5:1 speed reduction, you may need to provide additional cooling for the motor. A TEFC motor looses most of the fan effect as the speed drops. As you may expect, this is even more important on constant torque loads. If this is indeed 380V, 50 Hz motor, let me know.

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#5

jOmega

Senior Member

Full Member 253 posts

Gender:Male Location:Midwest, USA

Posted 01 March 2011 - 03:51 PM

QUOTE (GreenDriv @ Feb 10 2011, 07:37 AM) <{POST_SNAPBACK}> I think you can refer to the name plate of the motor. When you want to apply the VFD, just remember that the power of VFD should be equal or larger than that of motor. That's enough.

GreenDriv ..... and when the nameplate (rating plate) is no longer attached to the motor or is missing or isn't able to be viewed ....... what's your advice for determining the motor FLA so that the VFD can be properly selected for the motor...?????

FYI - All VFD's are current rated; ......... power is a relative term.. The amps that a VFD can continuously source to its connected load..... is the guiding factor. As an example, consider a 460 vac motor rated at 10 HP .... Would you specify a 10 HP VFD (rated at a nominal 14 amps continuous at 40 deg. C.)? Pretty Standard, right ? So after shipping that VFD off to the customer and proper installation, you start getting phone calls saying the drive is tripping .... How could that be? You supplied a standard 10 HP VFD for his 10 HP motor application, right ? Well, when you dig into it a bit further .... turns out that 10 HP motor is an 8-pole machine in a 284T frame, drawing a rated FLA of 16 amps ...(Marathon Elect. Cat. No. 453) .... So, it looks like that "standard" 10 HP, 14 Amp VFD wasn't a good choice. Probably should have supplied him a 15 HP VFD rated at a nominal 21 amps. The point is ... that selecting a VFD on the basis of HP alone can... and will... get one into trouble. HP is a relative term. NFPA-70 table is not an absolute either. ACTUAL MOTOR NAMEPLATE AMPS is the important parameter when selecting a VFD rating.

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#6

jOmega

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Gender:Male Location:Midwest, USA

Posted 01 March 2011 - 06:57 PM

QUOTE (KJF @ Feb 28 2011, 09:20 PM) <{POST_SNAPBACK}> The motor information you give is confusing. 380 V implies that this is a European motor rated for a 380v, 50 Hz system. If so, the nameplate rating would be in kw not horsepower there would be no service factor. European motors are design with a sf of 1.0 If the motor is a 480V, 60 Hz, 200 hp motor with a 1.15 sf and the nameplate FLA is not available, the conservative approach is to size the VFD drive current capacity from the FLA table in NFPA 70 (NEC). When applying this motor in a VFD application, the s.f. must now be assumed to be 1.0 since the additional heating from the VFD waveform will consume all the additional heat capacity the of the 1.15 s.f. Other factors that may require consideration is the driven load. If this is a constant torque application such as a compressor or positive displacement pump, a higher thermal capacity drive is require since the drive may have to produce near FLA at low voltages. The VFD vendors can make recommendations.

One other caution is that if you need more than a 5:1 speed reduction, you may need to provide additional cooling for the motor. A TEFC motor looses most of the fan effect as the speed drops. As you may expect, this is even more important on constant torque loads. If this is indeed 380V, 50 Hz motor, let me know.

KJF..... With regard to your comment about S.F. and additional heating as a consequence of the VFD output waveform; that was so back in the 1980s with VVi (six-step) and CSI (current source) schemes the output of which were rich in harmonics.....but the technology of VFDs and motors has improved many times over in the last 30 years. Today's VFDs contribute very little (negligible) heat to the motor as a consequence of their vastly improved output waveform. That statement is made as a result of actual test data where a series of motors and VFDs were dynamometer tested on both sine wave power and VFD power and comparing the temperature differences. As a consequence of the testing and improvement to process and materials that motor manufacturers have done, today they offer motors that are 1.15 S.F. at Class F rise and 1.0 S.F. at Class B rise. So when considering the VFDs of today's design and technology, the issue of their contributing additional heating into the motor so as to reduce Service Factor capability is..... a non-issue.

I also must take issue with your statements: "Other factors that may require consideration is the driven load. If this is a constant torque application such as a compressor or positive displacement pump, a higher

thermal capacity drive is require since the drive may have to produce near FLA at low voltages. The VFD vendors can make recommendations." VFDs are designed to operate continuously at their published/nameplated ratings. That means that a 10 HP - 460vac - 14 Amp - 40 deg. C VFD can operate continuously ...... in a 40 deg. C ambient environment, supplying 14 amperes without any derating as a consequence of what the load is doing .... as long as.... the load doesn't cause the motor to exceed the ratings of the VFD and the environment is within the rating of the VFD. VFDs are designed to operate at their ratings..... continuously. They can operate at rated output current at 10 v output just as well as at full rated voltage output without eclipsing the thermal rating of the VFD. It matters not whether the load is a compressor, a conveyor, a fan, a positive displacement pump, an extruder, etc., the thermal capacity of the VFD is NOT affected. The factors that influence thermal properties of a VFD are : Environmental (ambient temperature, altitude, etc) .... and operating continuously overloaded. (i.e., outside their design parameters)

Kind regards,