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YASKAWA YASKAWA YASKAWA YASKAWA 1 Inverter Inverter Inverter Inverter Control Control Control Control Chapter 1 Principle and Characteristics of Induction Motors Chapter 2 Inverter Principle and Characteristics Chapter 3 Operation Characteristics Chapter 4 Inverter Drive Units Selection Chapter 5 Inverter Functions and Advantages Chapter 6 Inverter Drives Precautions Chapter 7 Harmonics, Noise & Surge Voltage Chapter 8 Maintenance and Inspection

Yaskawa Inverter Basic Control Training in Vietnam (Saigon)

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  • 1

    Chapter 1Principle and Characteristics of Induction MotorsChapter 2Inverter Principle and CharacteristicsChapter 3Operation CharacteristicsChapter 4Inverter Drive Units Selection

    Chapter 5Inverter Functions and AdvantagesChapter 6Inverter Drives Precautions Chapter 7Harmonics, Noise & Surge VoltageChapter 8Maintenance and Inspection

  • 2

    Market of General purpose Inverters

    Introduction

  • 3

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    127127127127

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    250250250250

    300300300300

    350350350350

    2002200220022002 2003200320032003 2004200420042004 2005200520052005 2006200620062006 2007200720072007 2008200820082008

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    500500500500

    600600600600

    700700700700

    800800800800

    900900900900

    1000100010001000

    202225

    262 260

    Drives Industry Market Growth in Japan

    Actual Estimate

    Hu

    ndred

    millio

    n ye

    n

    U

    n

    i

    t

    s

    x

    1

    0

    ,

    0

    0

    0

    Drives up to 75 kW

    Hundred million

    Tens of thousands

    ExportDomestic

    23% 24%

    27% 26%

    3%

    51%

    15%

    31%up to 0.75 kW0.75 kW to 4 kW4 kW to 15 kW15 kW to 75 kW

    Units Amount

    Shipments by capacity in 2006

    Data from JEMA

    286

  • 4

    Yaskawa14.1%

    A13.0%

    B12.8%

    C12.5%

    D11.4%

    E8.6%

    G2.8%

    F7.8%

    H1.7%

    Others15.2%

    \ 395.9 billion2006

    17.4%

    15.8%12.8%

    17.0%11.0%

    Japan

    USAEurope

    China Asia

    *Data has been gathered and analyzed by Yaskawa.

    No.1 Global Share(fiscal year 2006)

    Global Share by Region

  • 5

    Yaskawa Drives BusinessAs a drives manufacturer, we provide overwhelmingly

    powerful products and application solutions.

    Drives SpecialistsOur vast engineering skills, we have earned us the reputation

    among our customers as specialists who possess

    progressive technology and build long-

    lasting cooperative relationships.

    74Worlds 1st Transistor InverterVS-616T

    747474

    74 808080

    80 909090

    90858585

    85 000000

    00959595

    95 050505

    05

    85Worlds 1st Digital ControlVS-616H

    79Worlds 1st Vector ControlVS-626TV

    88Worlds 1st IGBT Low-noise InverterVS-616GLN

    94Worlds 1st Ultra-compact ASIPM InverterVS mini C

    95Worlds 1st Vector Control General-purpose InverterVS-616G5

    00Worlds 1st 3-level Control General-purpose InverterVarispeed G7

    06Worlds 1st Matrix Converter DriveVarispeed AC

    VS

    VSVS

    VS-

    --

    -616H

    616H616H

    616H

    VS

    VSVS

    VS-

    --

    -616G

    616G616G

    616G

    VS

    VSVS

    VS-

    --

    -616G

    616G616G

    616G

    VS

    VSVS

    VS-

    --

    -616G3

    616G3616G3

    616G3

    VS

    VSVS

    VS-

    --

    -616H3

    616H3616H3

    616H3

    VS

    VSVS

    VS-

    --

    -606PC3

    606PC3606PC3

    606PC3

    VS

    VSVS

    VS-

    --

    -606V7

    606V7606V7

    606V7

    VS mini J7

    VS mini J7VS mini J7

    VS mini J7

    Varispeed F7S

    Varispeed F7SVarispeed F7S

    Varispeed F7S

    Varispeed L7

    Varispeed L7Varispeed L7

    Varispeed L7

    Varispeed

    Varispeed Varispeed

    Varispeed

    V7 pico

    V7 picoV7 pico

    V7 pico

    Varispeed F7

    Varispeed F7Varispeed F7

    Varispeed F7

    S

    a

    l

    e

    s

    V1000Release

  • 6

    YASKAWA ELECTRIC UK LTD. (YGB)YASKAWA ELECTRIC EUROPE GmbH (YEG)

    YASKAWA ELECTRIC AMERICA,INC. (YEA)Buffalo Grove Facility

    Global Sales Offices and Production Facilities

    YASKAWA ELECTRIC AMERICA,INC. (YEA)New Berlin Wisconsin Panel Facility

    YASKWA ELECTRIC KOREA CORPORATION (YEK)

    YASKAWA ELECTRIC (HK) COMPANY LIMITED (YHK)

    YASKAWA ELECTRIC (SHANGHAI) CO.,LTD. (SHANGHAI)

    SHANGHAI YASKWA DRIVE CO.,LTD. (SYD)

    Yaskawa Electric Taiwan Corporation (YTW)

    YASKAWA ELECTRIC (SINGAPORE) PTE.LTD. (YSP)

    Inverter Plant (V)

    YASKAWA ELECTRIC CORPORATION (YEC)

    YASKAWA ELETRICO DO BRASIL COMERCIO LTD.A. (YEB)

    : Sales office: Production facility

  • 7

    Chapter 1Principle and Characteristics

    of Induction Motors

  • 8

    Motors

    Motors for motive power

    Motors for dynamic response

    DC motors (series, shunt, compound)

    AC motors

    Induction motors(Squirrel-cage, wound rotor type)

    Synchronous motors(Magnet type, field winding type)

    Motors with eddy-current coupling(VS-MOTOR)

    ServomotorsDC servomotors

    AC servomotors(SM, IM types)

    Types of Motors

  • 9

    Configuration

    Rotor end ring

    SecondaryConductor

    (b) Squirrel-cage Rotor(Excluding Iron Core)

    (a) Configuration of Squirrel-cage Induction motor(Example of Totally-enclosed Externally-cooled Type)

    Outputshaft

    frame box

    Externalfan

    Bearing

    Internalfan

    Rotor End ring

    Fan coverRotor

    Iron core

    Center height(Motor frame No.)

    Bracket

  • 10

    Magnetic field (Flux density B (wb/m2) )

    N

    SBBBB

    FFFF

    IIII

    Force(F)Force(F)Force(F)Force(F)

    Magnetic Magnetic Magnetic Magnetic

    Field(B)Field(B)Field(B)Field(B)

    Current(I)Current(I)Current(I)Current(I)

    F

    I

    B

    Force(F)Force(F)Force(F)Force(F)

    Magnetic Magnetic Magnetic Magnetic

    Field(B)Field(B)Field(B)Field(B)

    Current(I)Current(I)Current(I)Current(I)

    Flemings Right-hand Rule Flemings Left-hand Rule

  • 11

    ARAGOs Disc(Disc rotates following magnet rotation.)

    Induction Effect of Rotating Magnetic Field

    Rotary Shaft

    Principle

    N

    S

    Permanent MagnetIron Disc

    S

    N

    NS

    NSFlux

  • 12

    Current Direction

    Direction of Magnetic Flux

    Right Screw

    A. Right hand screw Rule

    Current Direction

    B. Coil Current and Magnetic Flux Directions

    Direction of Magnetic Flux

    Beginning of Coil Winding

    End of Coil Winding

    Magnetic Flux Generated by CurrentDirection of Mag. flux from front to back of paper face

    Direction of Mag. flux from back to front of paper face

  • 13

    Three-phase motors use three-phase alternating current to create a rotating magnetic field.

    U

    V

    W

    U

    Phase U Phase V Phase W

    VWU

    V W

    0 pi 2pi

    Principle of Rotating Magnetic Field (2 Pole)

    U, V, W : START of Coil

    U,V,W: END of Coil

    1 Cycle

    3-phase AC (Current)

    Direction of Magnetic

    Field

    (a) Three-phase Alternating Current (Power Supply) and Magnetic Field Direction

    Induction Motor

  • 14

    P o w er S u pp ly F re quency (f) N o . o f P o les

    (P )

    N o . o f C o ils pe r

    P hase 50 H z 60 H z

    2 1 3 000 3 600

    4 2 1 500 1 800

    6 3 1 000 1 200

    8 4 7 50 9 00

    S NS N

    N S2p 4p

    8p6p(a) Synchronous Speed (min-1)

    (b) Number of Poles (p)

    Number of Poles and Synchronous Speed

    S N

    S N

    N S

    S NN

    NNS

    S

    S

  • 15

    Rotating Magnetic Field of a 4-pole Motor

    (a) Coil Arrangement(b) Three-phase

    Alternating Current

    U

    V

    W

    Phase U Phase V Phase W

  • 16

    The above equation can be changed into the following one.

    Therefore:

    Synchronous SpeedThe speed at which the magnetic field rotates is called synchronous speed (NS), which depends on the number of magnetic poles p , that depends on the configuration of the motor stator winding, and power supply frequency f .

    Rotating SpeedRotor speed N ( min-1 ) is a little slower than synchronous speed is a little slower than synchronous speed is a little slower than synchronous speed is a little slower than synchronous speed Ns . This amount is called . This amount is called . This amount is called . This amount is called slipslipslipslip, which is defined as follows:, which is defined as follows:, which is defined as follows:, which is defined as follows:

    S

    S

    NNN

    S

    =

    ( )SSNN = 1

    (((( ))))N fp

    S==== 120 1

    pfN S 120= NS : Synchronous speed ( min-1 )

    f : Power supply frequency (Hz)( min-1 )

    ( min-1 )

    Ns : Characteristic value dependingon motor specifications

    s : Value varying on the load size

    Induction Motor Speeds

  • 17

    360018000[With 4 poles at 60 Hz ( min-1 )] - 1800

    Characteristics

    Torque

    Rated Current

    Stalling Torque

    Rated Torque

    Slip (Rating)

    Motoring Area

    Rated Speed

    ( PLU GGING )

    No-load Current

    Current (%)

    Starting Current

    Starting Torque

    (Induction Generator)Regenerative Braking AreaReverse Phase Braking Area

    Ns

  • 18

    -1

    Control Method

    Load Torque

    The intersection of the motor generating torque and the load torque becomes the operation speed.

    To change the induction motor speed

    Changing p(Pole change motor)

    Changing s(Primary voltage control)

    Changing s(Secondary resistance control)

    Changing f

    Number of Poles Large

    Secondary Resistance Large

    Voltage Small Frequency Small

    (Primary frequency controlinverter drives)

  • 19

    2. Applied ModificationGeared motors Output shaft torque increased

    Brake motorsQuick brakeAG brake motors

    Explosionproof motorsIncreased safety explosionproof motorsExplosionproof motors

    Types of Inverter Motors

    Fan Cover External FanExternal Fan (-K)

    Pulse Generator (-M)

    1. Inverter Drive Motors

    FEQ-X, FEFFEK-I FEK-IK FEK-IKM

    (With electric fan) (With electric fan and PG)

    Totally-enclosed

    Model EEK-IM(With PG)

    Totally-enclosedFan-cooled Type

    Totally-enclosedFan-cooled Type

    Totally-enclosed Fan-cooled Type

  • 20

    The following shows the relation between the magnetic flux, voltage and frequency.

    ExampleWhen speed is reduced to the half (60 Hz to 30 Hz), according to the above equation, set the inverter output voltage and output frequency so that the magnetic flux will be constant.

    ttanCons)Hz(30)V(100

    )Hz(60)V(200

    fV

    ===

    200

    100

    0 30 60Frequency (Hz)

    In actual operation, voltage at low frequency must be increased by 150% to 200% in order to compensate for voltage drop in the motor.

    Motor Characteristics at Inverter Drives

    Voltage (V)

    Magnetic Flux Voltage VFrequency f = Constant

  • 21

    The following shows the equation of motor rated torque.

    ExampleIn case of a motor of 7.5 kW, 4 poles, rated speed 1740 min-1

    Rated torque TM 974 Motor rated output P (kW)

    Rated speed N (min-1) (kgfm)

    Rated torque TM 974 7.51740 (kgfm) 4.19

    Rated torque TM Motor rated output P (W)

    Rated speed N (min-1) (Nm)602pi

    Rated torque TM 7.5103

    1740 (Nm) 41.2602pi

    Motor Rated Torque

  • 22

    When load torque variesAs the load torque becomes greater, the motor speed decreases (or slip becomes greater).

    At this time, the greater the load torque the greater the motor current.

    When the motor applied voltage variesThe motor generating torque is in proportion to the square of voltage.As the voltage becomes smaller, the speed decreases (or slip becomes greater).

    Voltage Fluctuation and Speed Changes

    Load Fluctuation and Speed Changes

    Motor Speed VariationOutput Torque

    Speed

    Load Large

    Load Small

    Speed

    Voltage Large

    Load Constant

    T

    o

    r

    q

    u

    e

    Voltage Small

    T

    o

    r

    q

    u

    e

  • 23

    Inverter output voltage does not exceed power supply voltage.

    Therefore, output voltage becomes constant in the range exceeding frequency 50 Hz or 60 Hz (base frequency).The following equation shows the relation between motor voltage (V), frequency (f) and torque.

    IfV

    KTorque T = K ConstantConstantConstantConstant CurrentCurrentCurrentCurrent

    Since only frequency is changed, torque is reduced in inverse proportion to frequency if the motor current value is the same as shown in the above equation.

    This area is called constant output area.

    Operations Exceeding 50Hz or 60Hz

  • 24

    Chapter 2Inverter Principle and Characteristics

  • 25

    Rectifier CircuitConverter Section

    DC IntermediateCircuit

    Smoothing Circuit Section

    Invert ConversionCircuit

    Inverter Section

    Commercial Commercial Commercial Commercial

    PowerPowerPowerPower

    AC Power

    VariableVariableVariableVariable FrequencyFrequencyFrequencyFrequency

    /Variable Voltage AC/Variable Voltage AC/Variable Voltage AC/Variable Voltage AC

    Control Circuit Section

    M

    Motor

    VVVF

    Inverter Configuration

    AC Power

    VoltageVoltageVoltageVoltage

    CurrentCurrentCurrentCurrent

    VoltageVoltageVoltageVoltage

    CurrentCurrentCurrentCurrent

    VoltageVoltageVoltageVoltage

    CurrentCurrentCurrentCurrent

  • 26

    Voltage

    Current

    Voltage

    Current

    Voltage

    Current

    IMUVW

    Power source

    Contactinput

    ForwardReverse

    Multi-functioninput

    Analog input

    Pulse train input

    I

    n

    p

    u

    t

    s

    i

    g

    n

    a

    l

    O

    u

    t

    p

    u

    t

    s

    i

    g

    n

    a

    l

    Actual inverter circuit

    Diode Transister

    Register

    Capacitor

    Digitaloperator

    Pulse train output

    Analog monitor

    Multi-unction contact output

    Multi-function analog output

    Contact output

    Open collector output

    Fault output

    RST

    SC

    Digitaloperator

    AC DC AC

  • 27

    0

    Current wave

    R

    S4

    S3S1

    S2

    DC Power Supply

    S1 S4 ON S1 S4 ON

    S2 S3 ON

    How to Make AC

    ON ON

    ON

    SwitchesS1, S4

    S2, S3

    Ed

    Principle of Single-phase Inverter

    +Ed

    -Ed

  • 28

    Basic Circuit of 3-phase Inverter

    S1S2S3S4S5S6

    U-V

    V-W

    W-U

    0 60 120 180 240 300 360 60 120 180 240 300

    MotorU

    WV

    PPPP

    NNNN

    S3S1 S5

    S4 S6 S2

    DCpowersource

    Principle of generating 3-phase alternating current

    SwitchingPattern

    AC Output

    a

    Interval a

  • 29

    IM

    Motor

    3-phase AC

    EdDC Power Supply

    Basic Circuit of Transistor Inverter

    +Ed

  • 30

    ~

    P

    N

    C

    MC

    R

    D3D2D1

    D6D5D4

    V

    V

    Ed

    Vs

    In-rush Current Suppression Resistor

    Vs1.35Vspi

    23dE =

    Converter Sectionand In-rush Current Suppression

    V

  • 31

    Name Diode Thyristor GTO

    (Gate Tum Off Thyristor)

    Bipolar Power Transistor

    IGBT (Insulated Gate Bipolar

    Tr.)

    Power MOS FET (Power Metal Oxide

    Semiconductor. Field Effect Tr.)

    S

    y

    m

    b

    o

    l

    C

    h

    a

    r

    a

    c

    t

    e

    r

    i

    s

    t

    i

    c

    s

    V

    o

    l

    t

    a

    g

    e

    ,

    C

    u

    r

    r

    e

    n

    t

    W

    a

    v

    e

    f

    o

    r

    m

    F

    e

    a

    t

    u

    r

    e

    s

    ,

    A

    p

    p

    l

    i

    c

    a

    t

    i

    o

    n

    General high-voltage, large-current rectifier circuits

    High-voltage, large-current converter section Inverter section, chopper section attached with commutation circuit

    High-voltage, large-current inverter section, chopper section

    Medium voltage, medium current high-speed switching, inverter section

    Medium voltage, medium current high-speed switching, inverter section

    Low-voltage, small- current high-speed switching, inverter section

    Main Semiconductor Power Elements Used for Inverters

    Anode

    Cathode

    Gate

    Collector

    Base

    Emitter

    Drain

    Gate

    Source

  • 32

    Control Method Output Frequency Features

    PAM MethodPAM MethodPAM MethodPAM Method

    (Pulse Amplitude Modulation)

    Voltage control is needed for the converter.

    Motor current distortion is excessive, resulting in torque ripple.

    PWM MethodPWM MethodPWM MethodPWM Method

    (Sinusoidal Wave Approximate)

    PWM: Pulse Width Modulation

    When the above Output power frequency is 60 Hz, the number of pulses per cycle is 14. Therefore, carrier wave (carrier frequency) is obtained as 6014 = 840 Hz. Since the actual inverter has this carrier frequency of 15 kHz, the number of pulses per cycle is 250 pulses (1500060).

    Frequency and voltage can be controlled only in the inverter section.

    Smooth operation is possible at a low speed.

    EdEd

    (Ed: DC voltage)

    Output Voltage Waveform

    Ed

    Ed

    Average Output Voltage

    Voltage-type Inverter Control Method

  • 33

    3-phase Power SupplyIM

    Voltage/Current

    Detection

    N

    0 t

    Accel/decelInterrupt Signal

    V

    0f

    PWM Signal

    GeneratorBaseDriver

    VoltageReference

    Accel/decel Adjuster V/f Setter

    Frequency Reference

    Speed (Frequency)Reference

    Transistor Base Signal

    Current DetectorMotor

    InverterConverter

    V/f Control PWM Inverter

  • 34

    Rated Voltage

    Voltage (V)

    In Case of Variable Torque Load

    In Case of Constant Torque Load

    E/f Constant(Constant Magnetic Flux)

    Compensation for Motor Primary Winding Voltage Drop

    VoltageBias

    Frequency f (Hz)Rated Frequency

    V/f Constant

    V/f control compensates for the voltage drop value of the motor primary winding for the constant E/f (magnetic flux).

    Voltage / Frequency Characteristics in V/f Control

  • 35

    tN

    PWM Controlfdt

    Speed Reference

    Torque Reference

    Accel/decel Adjuster

    Speed Feedback Signal

    Speed ControllerCurrent Reference Calculator

    Current Amplitude Reference

    Torque Current Reference

    Each Phase Current Reference

    MultiplierInstantaneousCurrentControl Circuit

    Slip FrequencyCalculation

    IM

    Exciting Current Reference

    Speed/Torque Control Switch

    I 2IM

    Current Phase Reference

    f s fn

    3- (or 2-) phase Current Feedback Signal

    PG (Speed Detector) (Pulse Generator)

    Motor

    Current Detector

    Inverter

    Converter

    3-phase Power Supply

    I 2

    M

    Vector Control PWM Inverter

    I1

    I1

    f

  • 36

    &I2r1 l1

    &E&V&I1

    &IMM

    r2

    12

    s

    sr

    (b) Vector Diagram

    & I 2 & I 1

    &I 1

    &I M

    I2 I2

    I2

    I1

    I1

    IM

    E

    IME

    I1V

    V : Motor terminal voltager1 : Primary winding resistanceE : Motor (internal) induced voltage r2 : Secondary winding resistanceI1 : Motor primary (stator) current l1 : Primary winding leak inductanceI2 : Motor secondary (rotor) currentM : Exciting inductanceIM : Exciting current (exciting current component of primary current) S : Slip

    Equivalent Circuit and Vector Diagram

    V 1l

    1r1I

    1I

    s

    r2

    (a) Equivalent Circuit for Motor One Phase

  • 37Open Loop Vector Control

    Actual MotorInverter

    Motor Control

    Virtual Motor

    VoltageACMotor CurrentActual Value

    Error

    Motor CurrentEstimated Value

    Observer GainFluxEstimated ValueSpeedEstimated Value

    +

    -

    Flux Observer Block Diagram

  • 38

    In Case of V/f Control In Case of Vector Control

    V/f control suitable for the motor load characteristics is needed in order to obtain low-speed torque.

    Constant calculation using the motor test report or combination by manufacturer is needed.

    Varispeed G7Incorporates the auto-tuning program as standard so that no

    complicated adjustment is needed. The following three methods are available for the auto-tuning.

    1. Stop-type tuning only for line resistance2Stop-type tuning3. Stop-type tuning24Rotation-type tuning

    Input the basic numerical values such as motor NP into the inverter so that the motor determines the motor constants required for the vector control by measurement and calculation. This function is called Auto-tuning.

    Auto-tuning

  • 39

    Varispeed G7

    Specifications V/f Control V/f Control with PG FeedbackOpen-loop

    Vector ControlFlux Vector

    ControlBasic

    ControlVoltage/frequency control

    (open-loop)Voltage/frequency control with speed

    compensation

    Current vector control without PG

    Current vector control with PG

    Speed Detector Not needed

    Needed (pulse generator) Not needed

    Needed(pulse generator)

    Option Card for Speed Detection Not needed Needed Not needed NeededSpeed Control

    Range 1:40 1:40 1:200 1:1000

    Starting Torque 150% at 3 Hz 150% at 3 Hz 150% at 0.3 Hz 150% at 0 min

    -1

    Speed Control Accuracy 2 to 3% 0.03% 0.2% 0.02%

    Torque Limit Disabled Disabled Enabled EnabledTorque Control Disabled Disabled Enabled Enabled

    Typical Applications

    Multi-drives Replacement for existing

    motor of which motor constants are unknown

    Auto-tuning is enabled only for line resistance.

    Simplified feedback control

    Applications where pulse generator is attached on the machine shaft

    Any variable speed drives

    Simplified servo drives

    High-accuracy speed control

    Torque control

    Features of Control Mode

  • 40

    Chapter 3 Operation Characteristics

  • 41

    (a) Proper Acceleration Time (b) Short Acceleration Time

    Acceleration

    Output Frequency f

    Motor speed N

    Overload capacity when inverter capacity is equal to motor capacity

    Rated Current

    Excessive Slip

    Overload capacity when inverter capacity is increased

    Rated Current

    0

    0 0

    0

  • 42

    Inverter Output Frequency[Dotted line shows the set

    accel. ratio.]

    Motor Speed

    Motor Current

    Accel. time becomes longer automatically.

    Peak current is limited to within the specified value.

    Stall Prevention during Acceleration

    t

  • 43

    Inverter Output Frequency

    Load

    Stall Prevention during RunningTo avoid overloading by rapid fluid temperature in hydraulic machines. Avoid overloading by

    decreasing output frequency.

    t

  • 44

    DC Voltage

    Inverter Output Frequency

    Motor Current

    RUN Signal

    Actual Stall Prevention Function

    Edc.

    OVOA

  • 45

    Set Decel. Time td

    Slip(Minus)

    N Rapid decelerationSlip: Minus

    f

    fN,

    t

    NSlow decelerationSlip: Plus

    Deceleration Time td Motor Operation Mode SliptdCoasting to a stop time Motoring (Motoring area) PlustdCoasting to a stop time Regeneration (power generation area) Minus

    Deceleration

    0

  • 46

    Inverter Output Frequency[Dotted line shows the set decel. ratio.]

    Motor Speed

    DC Voltage

    DC bus voltage is limited to within specified value.

    Decel. time becomes longer automatically.

    Stall Prevention during Deceleration

    t

  • 47

    t

    DC Injection Braking Time

    t

    DC Current

    N

    N

    t

    DC Injection BrakingStarting Frequency

    N, f

    DC Current

    DC Injection Braking Time

    N

    FF

    F

    (a) Frequency Deceleration(Example of DC Injection

    Braking Before Stop)

    (b) All-area DC Injection Braking (c) Coasting to a Stop

    DC Injection Braking

    0 0 0

    N, f N, f

    Free Run

  • 48

    (a) Commercial Power Operation (b) Inverter Operation

    VI

    INV input current is a distortional wave current including harmonics. Unified effective current including harmonics is INV input current. Therefore, the power factor expressed by the above equation is not always equal to the value measured with general power factor meter.

    Input Voltage / Current WaveformPower Factor =

    Active Power Active PowerActive Power + Reactive Power=

    3Inverter Input Power

    Power Supply Voltage Inverter Input Current=

    Apparent Power

  • 49

    er es et

    er-s er-t es-t es-r et-r et-s

    Phase voltage of power source

    Phasecurrent PhasePhasePhasePhase----RRRR

    The mechanism of harmonics current generating

    EDC

    Converter

    Ver-s

    er

    es

    et

    r

    s

    t

    Line voltage ofLine voltage ofLine voltage ofLine voltage ofpower source

    PhasePhasePhasePhase----SSSS

    PhasePhasePhasePhase----TTTT

  • 50

    *1. The connection cable between the reactor and the inverter must be 5 m or less, the shorter the better. The size must be equivalent to the power supply cable or larger.

    *2. Models of 18.5 to 75 kW (200-V class) and 18.5 to 160 kW (400-V class) are incorporated with DC reactors. The power factor improvement is more than 93%.

    *3. The inverter power supply power factor is normally approx. 60 to 90%, which differs depending on the power supply impedance.

    Effect of power factor improvement: power supply factor 93 to 95% (at 100% load)*3

    IM

    NFBPower Supply Inverter

    1+ 2+

    Be sure to remove the connected piece between terminals.

    Wiring distance:*35 m or less.

    Motor

    UZDA-B

    Power Factor Improvement Reactor*2

    U X

    Typical Connection of DC Reactor

    RST

    UVW

  • 51

    Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics ContentNo countermeasures taken

    Harmonics Order

    88%

    AC reactor inserted

    38%

    DC reactor inserted

    33%

    P

    N

    P

    N

    P

    N

    +

    +

    +

    Typical Inverter Input Current Waveformin Each Power Supply Method (1)

    1 5

    1 5 7 11

    1 5 7 11

  • 52

    Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics Contents12-phase rectification

    Harmonics Order

    12%

    PWM control converter

    3%

    P

    N

    P

    N

    +

    +

    1

    1

    Typical Inverter Input Current Waveformin Each Power Supply Method (2)

  • 53

    Chapter 4Inverter Drive Units Selection

  • 54

    From General Industrial-use to Consumer EquipmentGeneral-purpose Inverter Series

    Varispeed G7

    Varispeed F7

    VS mini V7

    VS mini J7

    High-graded Function Current Vector Control (0.4 to 300 kW)

    General-purpose Vector Control (0.4 to 300 kW)

    Small-size Voltage Vector Control (0.1 to 7.5 kW)

    Super Small-size Contactor Type (0.1 to 3.7 kW)

  • 55

    Capacity (kW) Control Method Braking Method Speed Control

    200V Class 400V Class V/f

    VS mini J7 Single-phase: 0.1 to 1.53-phase: 0.1 to 3.7 3-phase: 0.2 to 3.7 1:40 2 to 3

    VS mini C Single-phase: 100 V 0.1 to0.75Single-phase,3-phase: 0.1 to 1.5 3-phase: 0.2 to 1.5 1:40 2 to 3

    VS mini V7 Single-phase: 0.1 to 3.73-phase: 0.1 to 7.5 3-phase: 0.2 to 7.5

    1:402 to 3

    1

    Varispeed F7 3-phase: 0.4 to 110 3-phase: 0.4 to 300

    1:40 2 to 3

    1:100 0.2

    Varispeed G7 3-phase: 0.4 to 110 3-phase: 0.4 to 300

    1:40 2 to 3 1:200 0.2

    1:1000 0.02 VS-616R3 3-phase: 3.7 to 37 3-phase: 7.5 to 75 1:40 2 to 3

    VS-686SS5 3-phase: 0.4 to 753-phase: 0.4 to 160

    1:10 0.2

    3-phase: 0.4 to 300 1:500 0.02 O

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    Features of Each General-purpose Inverter

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  • 56

    Model Features Output Range

    VS-676H5 High-graded function type 200 V: 0.4 to 75 kW 400 V: 0.4 to 800 kW575 V: 300 to 1200 kW

    VS-686HV5SHigh-voltage super energy

    saving

    3300 V: 132 to 1250 kW6600 V: 250 to 2500 kW

    VS-686HV5 3300 V: 225 to 1800 kW6000 V: 450 to 3000 W

    VS-626M5/MR5Exclusive for machine tools

    spindle(high accuracy)

    200 V: 2.2 / 3.7 to 22 / 30 kW400 V: 3.7 / 5.5 to 37 / 45 kW

    VS-626MC5 Exclusive for machine tools spindle (simplified type)200 V: 2.2 / 3.7 to 11 / 15 kW

    Sinusoidal wave PWMVS-656DC5

    Harmonics: 0Power factor: 1

    200 V: 15 to 75 kW400 V: 15 to 300 kW

    VS-656RC5 Low cost type

    200 V: 3.7 to 37 kW400 V: 3.7 to 75 kW

    Exclusive-use Inverter SeriesF

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  • 57

    Motor Type

    Motor Output

    Inverter Output

    Inverter Model

    Peripheral units, Options

    Enclosure

    Check ItemWhat to Decide

    Capacity Selection

    Machine specifications

    Operation method

    Load type and characteristics

    Inverter capacity selection

    Inverter model selection

    Motor selection

    Peripheral units, options

    Investment effect

    Investment effect

    Inverter selection

    Final specifications

  • 58

    Load Characteristics Typical Load Speed Torque CharacteristicsLoad torque is constant for speed.General friction loads

    ConveyorCraneWinchOther friction loads

    and gravity loads

    Load torque is constant regardless of speed.Output power is in proportion to speed.

    T = k T: torqueP = kN P: Output

    k: Proportional constantLoads of which load torque is decreased as the speed is reduced

    FanBlowerPumpOther fluid loads

    Load torque is in proportion to the square of speed. Output is in proportion to the

    cube of speed. T = kN2P = kN3

    Loads of which output becomes constant for the speed

    Constant tension force winder ofcenter drive

    Spindle motors of machine tools

    Veneer rotary laths

    Output power required by the load is constant. Load torque is in inverse proportion to speed.

    T = k/NP = k

    Loads of which load torque varies depending on the speedLoads having the nature between the low output load and the constant torque load

    Speed torque/output characteristics between the constant torque load and constant output load

    Load Torque

    Load Output

    SpeedTo

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    Load Torque

    Load OutputSpeedT

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    Typical Load Torque Characteristics

    0

    1.0

    1.0

    2.0

    Load Torque

    Load Output

    1.0

    2.0

    2.0

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    Load Output

    Load Torque

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    Speed

    1.0

    2.0

  • 59

    Motor may be overheated in a low-speed area.

    Since the min-1 of the external fan becomes lower in a low-speed area, the cooling capability is deteriorated. Therefore, the motor may be overheated unless the load is reduced in a low-speed area.

    Motor can operate properly even in a low-speed area.

    The motor is designed for inverter drives, therefore, the temperature is within the specified value even if the motor is used at a low speed.

    The above characteristics show the torque that can be allowed at continuous operation. There is no difference in the torque that the motor can generate in a short time, such as at starting, between the standard motor and the constant torque motor.

    Standard Motor Output Inverter Exclusive-use Motor Output

    60606060

    3333 20202020

    0.50.50.50.5

    55555555

    Difference between Inverter Exclusive-use Motor and Standard Motor

    Standard MotorStandard Motor Exclusive-use MotorExclusive-use Motor

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    Example:1:10 Const. Torque Motor

  • 60

    Load Torque

    Accel Torque

    Decel Torque

    Td 2piJN60td

    Required Brake TorqueTB=TdTL

    Required Motor Torque

    TaTL

    Ta 2piJN60ta

    TL fVpiN

    Nm

    The inverter regeneration capability is a key point. The regeneration capability depends on selection of the inverter output and braking unit type.

    Operation Pattern and Calculation of Load Torque

    Can start?Motor starting torque must be greater than load starting torque.

    Is motor temperature proper?Temperature rise must be within the specified value.

    Time

    Can accelerate?Motor torque exceeding the torque requiredfor acceleration (Ta+TL) must be available.

    The volume of the motor output torque is a key point.Torque depends on the motor output, inverter output, control method or boost amount.

    Can decelerate?Brake torque required for deceleration

    must be available. Energy at deceleration can be consumed or

    regenerated to the power supply.

    TL

    Ta

    Td

    TaTL

    ta td

  • 61

    (a) Motor Mode

    (b) Generator (Regeneration) Mode

    IMCommercial

    Power Mechanical Energy

    Power FlowPower Flowi

    S 0(Motor power factor cos0)

    *1 Discharge resistor = braking resistor *2 Monitors DC voltage and turns ON the transistor when DC voltage exceeds the specified level.

    The inverter built-in braking transistor or braking unit is used.

    IMCommercial

    Power

    Mechanical EnergyKinetic EnergyPotential Energy

    Power Flow

    (i =0i

    *1R

    *2(ON)

    Thermal Energy

    S 0(Motor power factor cos 0)

    Power Flow and Regenerative Braking

  • 62

    (1) Power supply transformer

    (2) Circuit breaker or(3) Leakage breaker

    (4) Contactor(6)Noise filter

    (5) AC reactor

    (10) Braking resistor unit

    (7) DC reactor

    (8) Noise filter

    (9) Contactor

    Peripheral Devices and Their Connections

    (11) Contactor for commercial power backup

    (12) Zero phase reactor

    (13) Thermalrelay (14) Motor

  • 63

    No. Name Purpose and Selecting Points1 Power transformer Transformer capacity Inverter capacity 1.5

    2 Circuit breaker Breaks accidental current (shortcircuit current). Rated current inverter rated current 1.5 Described in the inverter catalog.

    3 Leakage breaker

    Grounding protectionHigh frequency leak current protection for electric shock accident & leakage current fire.

    1. Use a breaker provided with countermeasures for high frequency leakage current. 2. Increase sensitivity current.3. Decrease inverter carrier frequency.

    4 ContactorSince the inverter has the contactor function, any contactor is not needed except for special cases.When a braking resistor is used, insert a contactor to make thermal trip circuit.Perform RUN/STOP at the inverter side and set the contactor to Always ON to use.

    57

    AC reactorDC reactor

    For high frequency current suppression and improvement of power factorInstall a reactor to protect the inverter when the power supply capacity is large.

    68

    Noise filter orZero-phase reactor Prevent radio noise generated by inverter section

    910

    Braking unitBraking resistor unit Used when an electrical brake is needed (when the required braking torque exceeds 20%).

    1112

    Contactor for commercial power backup

    Used for backup at inverter failure or when commercial power supply is used for normal operations.

    13 Thermal relay Not needed when one motor is driven by one inverter. (Connected when more than two motors are used.)

    How to Select Peripheral Devices

  • 64

    Chapter 5Inverter Functions and Advantages

  • 65

    No. Advantage Technical Details Main Precautions

    1

    Can control speeds of the specified constant-speed type motors.

    Number of revolutions changes when squirrel-cage-type motor terminal voltage and frequency are changed.

    Since a standard motor has temperature rise that becomes greater at a low speed, torque must be reduced according to frequency.

    2

    Soft start/stop enabled. Accel/decel time can be set freely from a low speed.(0.01 to 6000 seconds).

    Set proper accel/decel time after performing load operation.

    3

    Highly frequent start/stop enabled.

    Little motor heat generation since smooth accel/decel is enabled with little current.

    Motor or inverter capacity frame must be increased depending on the accel/decel capacity. Check the accel/decel time and load J.

    4

    FWD/REV run enabled without main circuit contactor.

    Because of phase rotation changes by transistor, there are no moving parts like conventional contactors so that interlock operation can be assured.

    When applying the inverter to an elevating unit, use a motor with a brake to hold mechanically for stand still.

    Advantages of Inverter Applications (1)

    Cushion Start

    t

    f

    FWD

    Run

    REV

    Run

    Cushion Stop

    Inverter

    RUN Command

    FWD

    Run

    REV

    Run

    t

    f

  • 66

    No. Advantage Technical Details Main Precautions

    5

    Can apply an electrical brake. Since mechanical energy is converted into electrical energy and absorbed in the inverter at decel, the motor can auto-matically provide braking force.DC current is applied to the motor around zero-speed so that it becomes dynamic braking, to completely stop the motor.

    Braking force is approx. 20% when only the inverter is used. Attaching a braking resistor (optional) externally can increase the braking force.Pay attention to the capacity of the resistor.

    6

    Can control speeds of the motor under adverse atmosphere.

    Since the inverter drives squirrel-cage motors, it can be used easily for explosionproof, waterproof, outdoor or special types of motors.

    An explosionproof motor in combination with an inverter is subject to explosionproof certification.

    7

    High-speed rotation enabled. Commercial power supply can provide up to 3600 min-1 (2-pole at 60Hz) or 3000 min-1 (2-pole, at 50Hz). A general-purpose inverter can increase frequency up to 400 Hz (12000 min-1) while a high-frequency inverter can increase it up to 3000 Hz (180000 min-1).

    The speed of a general-purpose motor cannot be increased by simply increasing the frequency. (It can be applied without being changed if frequency is approx. 120 Hz.)Mechanical strength and dynamic balance must be examined. 60Hz 120Hz 400Hz

    Electrical Braking

    Advantages of Inverter Applications (2)

    f

    t

    V

    f

  • 67

    No. Advantage Technical Details Main Precautions

    8

    The speeds of more than one motor can be controlled by one inverter.

    The inverter is a power supply unit to the motor, therefore, as many motors as the capacity allows can be connected.These motors do not have to be the same capacity.

    The number of motor revolutions differs depending on each motor characteristics or load ratio even at the same frequency.(Among general-purpose motors, speed deviation of 2 to 3% can be considered.)Synchronous motors have the same number of revolutions.

    9

    Power supply capacity can be small when the motor is started up.

    Large current (5 or 6 times larger than the motor rating) does not flow as with a commercial power supply start.Current can be limited to at most 100 to 150% by low-frequency start.

    Transformer capacity (kVA)= 1.5 inverter output capacity

    10Number of revolutions becomes constant regardless of power supply frequency.

    Output freq. can be set regardless of power supply freq. 50/60Hz.

    Inverter

    Advantages of Inverter Applications (3)

    IM

    IM

    IM

  • 68

    Inverter Output Voltage

    Inverter Output Current

    Inverter Input Current

    150%

    150%100% Current

    100% Current

    100% Voltage (100% Speed)

    t

    Motor and Power Supply Currentin Inverter Drives

    t

    t0

  • 69

    Energy Saving for General Industrial Machines & Systems

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    (1)Energy Saving for Mechanical Systems by Means of Variable Speed Drive of Motors

    (2)High Efficiency Motors

    (3)Change to High Efficiency Drive for Existing Variable Speed Drive

    (4)Regeneration of Braking (Kinetic)Energy

    (5)Others

    A . Variable Torque LoadB . Constant Torque LoadC . Constant Power Load

    A . High Efficiency Induction Motor B . IPM(Interior Permanent Magnet Motor)

    A . Primary Voltage Control of Induction MotorB . Secondary Resistor Control of Wound Rotor Induction MotorC . VS-Motor (Eddy Current Coupling Motor)D . Variable Frequency Drive of Induction MotorE . Variable Frequency Drive of IPM

    A . Regenerative ConverterB . Drive Regenerated Energy To Another Inv. Drive

    A . ON-OFF Control for Mechanical SystemsB . Inverter Energy Saving (Voltage) Control Method

  • 70

    Applied Load Concept of Energy-saving Fans Pumps Blowers (Any Variable Torque Load)

    Replace with a more efficient motor. Reduce a redundancy of the facility for the actual loads. Abate the head loss at valves or dampers.

    (2) (1) (1)

    Extruders Conveyors, etc. (Any Constant Torque Load)

    Change to more efficient drives. Replace the primary voltage control, secondary resistance control, eddy-current coupling (VS motors) with a more efficient control method(Frequency Control).

    (3)

    Cranes Elevators, etc.

    Collect the regenerative energy at lowering by using the inverter power supply regenerative function.

    (4)

    Rewinders Collect the regenerative energy of the rewinders. Replace with a more efficient motor. (4) (2)

    General Machines Reduce the starting energy. (Use the inverter as a starter to stop the operations positively whenever the load ratio is low.)

    (5)a

    Optimum Energy-saving Plan for Facility

  • 71

    AN

    Hd1.0

    0 0.5 1.0 ( p.u.)Air volume (Q)

    R

    Hi

    ( p.u.)

    Air Volume and Wind Pressure Characteristics of Fan

    H1.03N0.56NQ0.59QRQ

    Rated air volume: 250m3/secRated wind pressure: 433mmAqFan efficiency at rated air volume: 0.7Fan efficiency at 50% air volume: 0.6

    Ad

    Ai

    R50

    N50Q50H0

  • 72

    Energy saving Effect in the Fan Application In the case of damper control

    The wind pressure in 50% air volume is Hd = 1.03 + 0.56 0.5 - 0.59 0.52 = 1.16

    The power becomesm = 0.9 is the motor efficiency

    In the case of inverter controlThe wind pressure in 50% air volume is Hi = 0.52 = 0.25

    The power becomesi = 0.95 is the inverter efficiency

    The electric-power saving quantityPS = PD Pi = 15.3kWOn the assumption of electric power unit price: \15/kWh and annual continuous running:

    8000hours,We can save the electric charge as follows. 15.3 15 8000 = \ 1,836,000

    19.0kW=4332500.90.661201.160.5

    =6120QH

    =Pmf

    D

    3.7kW=4332500.950.90.761200.250.5

    =6120QH

    =Piimf

  • 73

    Flow Rate and Head Characteristics of Pump

    Squeeze volume

    Low speed

    1.5

    HB

    1

    Hi0.5

    0 0.5 1

    Flow rate (P.U)

    H

    e

    a

    d

    (

    P

    .

    U

    )

    R50

    R

    NR0

    N50

  • 74

    Energy saving Effect in the Pump Application In the case of valve control

    The head in 50% flow rate is HB = 1.25 0.25 0.52 = 1.188

    The power becomesm = 0.9 is the motor efficiency

    In the case of inverter controlThe head in 50% flow rate is Hi = 0.7 0.1 0.52 = 0.725

    The power becomesi = 0.95 is the inverter efficiency

    The electric-power saving quantityPS = PB Pi = 15.2kWOn the assumption of electric power unit price: \15/kWh and annual continuous running:

    8000hours,We can save the electric charge as follows. 15. 2 15 8000 = \ 1,824,000

    28.9kW=2560.90.566.121.1880.5

    =6.12QH

    =Pmp

    B

    13.7kW=2560.950.90.766.120.7250.5

    =6.12QH

    =Piimp

  • 75

    Outline of Software Functions (1)Function Name Function Name Function Name Function Name ApplicationsApplicationsApplicationsApplications PurposePurposePurposePurpose DescriptionDescriptionDescriptionDescription

    MultiMultiMultiMulti----step Speed step Speed step Speed step Speed

    OperationOperationOperationOperation

    Feeders,Feeders,Feeders,Feeders, etcetcetcetc.... Schedule operation Schedule operation Schedule operation Schedule operation

    at specified speedat specified speedat specified speedat specified speed

    By combining signals, operation is performed at frequency stored By combining signals, operation is performed at frequency stored By combining signals, operation is performed at frequency stored By combining signals, operation is performed at frequency stored

    internally (up to 9internally (up to 9internally (up to 9internally (up to 9----step speeds). Connection with the sequencer is easy; step speeds). Connection with the sequencer is easy; step speeds). Connection with the sequencer is easy; step speeds). Connection with the sequencer is easy;

    simplified positioning by using limit switch is also possible. simplified positioning by using limit switch is also possible. simplified positioning by using limit switch is also possible. simplified positioning by using limit switch is also possible.

    Accel/decel Changing Accel/decel Changing Accel/decel Changing Accel/decel Changing

    OperationOperationOperationOperation

    Automatic panel Automatic panel Automatic panel Automatic panel

    feeders, etc.feeders, etc.feeders, etc.feeders, etc.

    Changing external Changing external Changing external Changing external

    signal of accel/decel signal of accel/decel signal of accel/decel signal of accel/decel

    timetimetimetime

    Using an external signal can change the accel/decel rate. This function Using an external signal can change the accel/decel rate. This function Using an external signal can change the accel/decel rate. This function Using an external signal can change the accel/decel rate. This function

    is effective when two motors are driven alternately by one inverter or is effective when two motors are driven alternately by one inverter or is effective when two motors are driven alternately by one inverter or is effective when two motors are driven alternately by one inverter or

    when smooth accel/decel is needed only in the highwhen smooth accel/decel is needed only in the highwhen smooth accel/decel is needed only in the highwhen smooth accel/decel is needed only in the high----speed area.speed area.speed area.speed area.

    SSSS----curve Time curve Time curve Time curve Time

    CharacteristicsCharacteristicsCharacteristicsCharacteristics

    feeders such as feeders such as feeders such as feeders such as

    conveyors, carts, conveyors, carts, conveyors, carts, conveyors, carts,

    etc.etc.etc.etc.

    Prevention of Prevention of Prevention of Prevention of

    start/stop shockstart/stop shockstart/stop shockstart/stop shock

    Smooth movement can be achieved by setting SSmooth movement can be achieved by setting SSmooth movement can be achieved by setting SSmooth movement can be achieved by setting S----curve delay when curve delay when curve delay when curve delay when

    accel/decel starts or finishes.accel/decel starts or finishes.accel/decel starts or finishes.accel/decel starts or finishes.

    FrequencyFrequencyFrequencyFrequency Upper/lower Upper/lower Upper/lower Upper/lower

    Limit OperationLimit OperationLimit OperationLimit Operation

    PumpsPumpsPumpsPumps

    BlowersBlowersBlowersBlowers

    Limit of motor Limit of motor Limit of motor Limit of motor

    revolutionsrevolutionsrevolutionsrevolutions

    Frequency reference upper/lower value, bias and gain can be set Frequency reference upper/lower value, bias and gain can be set Frequency reference upper/lower value, bias and gain can be set Frequency reference upper/lower value, bias and gain can be set

    individually without adding any peripheral devices.individually without adding any peripheral devices.individually without adding any peripheral devices.individually without adding any peripheral devices.

    Specified Frequency Specified Frequency Specified Frequency Specified Frequency

    Setting Prohibition Setting Prohibition Setting Prohibition Setting Prohibition

    (Frequency Jump Control)(Frequency Jump Control)(Frequency Jump Control)(Frequency Jump Control)

    General machinesGeneral machinesGeneral machinesGeneral machines Prevention of Prevention of Prevention of Prevention of

    machine system machine system machine system machine system

    vibrationvibrationvibrationvibration

    In order to prevent vibration of the machine system, the oscillation point In order to prevent vibration of the machine system, the oscillation point In order to prevent vibration of the machine system, the oscillation point In order to prevent vibration of the machine system, the oscillation point

    is avoided automatically during constantis avoided automatically during constantis avoided automatically during constantis avoided automatically during constant----speed operation. This function speed operation. This function speed operation. This function speed operation. This function

    can also be used for dead zone control.can also be used for dead zone control.can also be used for dead zone control.can also be used for dead zone control.

    DWELL FunctionDWELL FunctionDWELL FunctionDWELL Function HeavyHeavyHeavyHeavy----inertia loads inertia loads inertia loads inertia loads

    such as centrifugal such as centrifugal such as centrifugal such as centrifugal

    separators etc.separators etc.separators etc.separators etc.

    Smooth accel/decel Smooth accel/decel Smooth accel/decel Smooth accel/decel

    of heavyof heavyof heavyof heavy----inertia inertia inertia inertia

    loadsloadsloadsloads

    Prevents the motor from stalling by holding output frequency temporarily Prevents the motor from stalling by holding output frequency temporarily Prevents the motor from stalling by holding output frequency temporarily Prevents the motor from stalling by holding output frequency temporarily

    during accel/decel. during accel/decel. during accel/decel. during accel/decel.

    Speed SearchSpeed SearchSpeed SearchSpeed Search Inertia load drives Inertia load drives Inertia load drives Inertia load drives

    such as blowers, such as blowers, such as blowers, such as blowers,

    winders winders winders winders

    Starting of coasting Starting of coasting Starting of coasting Starting of coasting

    motormotormotormotor

    PerformsPerformsPerformsPerforms pullpullpullpull----inininin operationoperationoperationoperation automaticallyautomaticallyautomaticallyautomatically intointointointo thethethethe setsetsetset frequencyfrequencyfrequencyfrequency withoutwithoutwithoutwithout

    stoppingstoppingstoppingstopping thethethethe coastingcoastingcoastingcoasting motormotormotormotor.... MotorMotorMotorMotor speedspeedspeedspeed detectordetectordetectordetector isisisis notnotnotnot neededneededneededneeded....

    Compensation for Compensation for Compensation for Compensation for

    Momentary Power LossMomentary Power LossMomentary Power LossMomentary Power Loss

    General machinesGeneral machinesGeneral machinesGeneral machines Continuing operation Continuing operation Continuing operation Continuing operation

    at a momentary at a momentary at a momentary at a momentary

    power losspower losspower losspower loss

    Restart the motor automatically after recovery from a momentary power Restart the motor automatically after recovery from a momentary power Restart the motor automatically after recovery from a momentary power Restart the motor automatically after recovery from a momentary power

    loss by using the remaining control power supply to continue the motor loss by using the remaining control power supply to continue the motor loss by using the remaining control power supply to continue the motor loss by using the remaining control power supply to continue the motor

    operations. operations. operations. operations.

    Fault RetryFault RetryFault RetryFault Retry AirAirAirAir----conditioning,conditioning,conditioning,conditioning,

    etcetcetcetc....

    Improvement of Improvement of Improvement of Improvement of

    operation reliabilityoperation reliabilityoperation reliabilityoperation reliability

    Resets the fault automatically after the inverter detects a fault and Resets the fault automatically after the inverter detects a fault and Resets the fault automatically after the inverter detects a fault and Resets the fault automatically after the inverter detects a fault and

    performs selfperforms selfperforms selfperforms self----analysis and restarts the operation without stopping the analysis and restarts the operation without stopping the analysis and restarts the operation without stopping the analysis and restarts the operation without stopping the

    motor. Up to 10 retry operations may be selected.motor. Up to 10 retry operations may be selected.motor. Up to 10 retry operations may be selected.motor. Up to 10 retry operations may be selected.

  • 76

    Outline of Software Functions (2)Function Name Function Name Function Name Function Name ApplicationsApplicationsApplicationsApplications PurposePurposePurposePurpose DescriptionDescriptionDescriptionDescription

    Carrier Frequency SettingCarrier Frequency SettingCarrier Frequency SettingCarrier Frequency Setting GeneralGeneralGeneralGeneral machinesmachinesmachinesmachines NoiseNoiseNoiseNoise reductionreductionreductionreduction SetsSetsSetsSets thethethethe inverterinverterinverterinverter carriercarriercarriercarrier frequencyfrequencyfrequencyfrequency totototo anyanyanyany arbitraryarbitraryarbitraryarbitrary valuevaluevaluevalue totototo reducereducereducereduce

    noisenoisenoisenoise oscillationoscillationoscillationoscillation fromfromfromfrom thethethethe motormotormotormotor andandandand machinemachinemachinemachine systemsystemsystemsystem.... ThisThisThisThis functionfunctionfunctionfunction isisisis

    alsoalsoalsoalso effectiveeffectiveeffectiveeffective forforforfor reducingreducingreducingreducing noisenoisenoisenoise....

    Load Speed DisplayLoad Speed DisplayLoad Speed DisplayLoad Speed Display General machinesGeneral machinesGeneral machinesGeneral machines Improvement of Improvement of Improvement of Improvement of

    monitor functionmonitor functionmonitor functionmonitor function

    CanCanCanCan displaydisplaydisplaydisplay thethethethe motormotormotormotor speedspeedspeedspeed (min(min(min(min

    -

    --

    -1

    11

    1

    ),),),), loadloadloadload machinemachinemachinemachine rotatingrotatingrotatingrotating speedspeedspeedspeed (min(min(min(min

    -

    --

    -1

    11

    1

    ))))

    orororor linelinelineline speedspeedspeedspeed (m/min)(m/min)(m/min)(m/min)....

    Pulse Train InputPulse Train InputPulse Train InputPulse Train Input General machinesGeneral machinesGeneral machinesGeneral machines Improvement of Improvement of Improvement of Improvement of

    operabilityoperabilityoperabilityoperability

    In addition to the function as frequency reference, PID aimed value and In addition to the function as frequency reference, PID aimed value and In addition to the function as frequency reference, PID aimed value and In addition to the function as frequency reference, PID aimed value and

    PID feedback value at PID control can be input as a pulse train.PID feedback value at PID control can be input as a pulse train.PID feedback value at PID control can be input as a pulse train.PID feedback value at PID control can be input as a pulse train.

    Pulse Train OutputPulse Train OutputPulse Train OutputPulse Train Output General machinesGeneral machinesGeneral machinesGeneral machines Improvement of Improvement of Improvement of Improvement of

    monitoring monitoring monitoring monitoring

    performanceperformanceperformanceperformance

    Frequency reference, output frequency, motor speed, output frequency Frequency reference, output frequency, motor speed, output frequency Frequency reference, output frequency, motor speed, output frequency Frequency reference, output frequency, motor speed, output frequency

    after softafter softafter softafter soft----start, PID feedback amount and PID input value can be output start, PID feedback amount and PID input value can be output start, PID feedback amount and PID input value can be output start, PID feedback amount and PID input value can be output

    in pulses.in pulses.in pulses.in pulses.

    Stopping Method Stopping Method Stopping Method Stopping Method

    Selection Selection Selection Selection

    GeneralGeneralGeneralGeneral machinesmachinesmachinesmachines Stopping method Stopping method Stopping method Stopping method

    suitable for the suitable for the suitable for the suitable for the

    machine machine machine machine

    characteristicscharacteristicscharacteristicscharacteristics

    Selects deceleration to a stop, coasting to a stop or DC injection Selects deceleration to a stop, coasting to a stop or DC injection Selects deceleration to a stop, coasting to a stop or DC injection Selects deceleration to a stop, coasting to a stop or DC injection

    braking stop according to the braking torque or machine inertia. braking stop according to the braking torque or machine inertia. braking stop according to the braking torque or machine inertia. braking stop according to the braking torque or machine inertia.

    3333----wire Sequencewire Sequencewire Sequencewire Sequence General machinesGeneral machinesGeneral machinesGeneral machines SimpleSimpleSimpleSimple configurationconfigurationconfigurationconfiguration

    ofofofof controlcontrolcontrolcontrol circuitcircuitcircuitcircuit

    Operation is enabled using automaticOperation is enabled using automaticOperation is enabled using automaticOperation is enabled using automatic----recoveryrecoveryrecoveryrecovery----type pushbutton switch.type pushbutton switch.type pushbutton switch.type pushbutton switch.

    Frequency Hold OperationFrequency Hold OperationFrequency Hold OperationFrequency Hold Operation General machinesGeneral machinesGeneral machinesGeneral machines Improvement of Improvement of Improvement of Improvement of

    operabilityoperabilityoperabilityoperability

    Holds frequency increase/decrease temporarily during acceleration or Holds frequency increase/decrease temporarily during acceleration or Holds frequency increase/decrease temporarily during acceleration or Holds frequency increase/decrease temporarily during acceleration or

    deceleration. deceleration. deceleration. deceleration.

    UP/DOWN OperationUP/DOWN OperationUP/DOWN OperationUP/DOWN Operation General machinesGeneral machinesGeneral machinesGeneral machines Improvement of Improvement of Improvement of Improvement of

    operabilityoperabilityoperabilityoperability

    Speed setting is enabled remotely by ON/OFF operation. Speed setting is enabled remotely by ON/OFF operation. Speed setting is enabled remotely by ON/OFF operation. Speed setting is enabled remotely by ON/OFF operation.

    Frequency DetectionFrequency DetectionFrequency DetectionFrequency Detection General machinesGeneral machinesGeneral machinesGeneral machines Frequency detection Frequency detection Frequency detection Frequency detection

    to be used for to be used for to be used for to be used for

    interlockinterlockinterlockinterlock

    Specifies the set value of output frequency, and outputs to the multiSpecifies the set value of output frequency, and outputs to the multiSpecifies the set value of output frequency, and outputs to the multiSpecifies the set value of output frequency, and outputs to the multi----

    function output terminal when frequency exceeds the range or becomes function output terminal when frequency exceeds the range or becomes function output terminal when frequency exceeds the range or becomes function output terminal when frequency exceeds the range or becomes

    short.short.short.short.

    Overtorque Detection and Overtorque Detection and Overtorque Detection and Overtorque Detection and

    Undertorque DetectionUndertorque DetectionUndertorque DetectionUndertorque Detection

    MachineMachineMachineMachine toolstoolstoolstools

    Blowers,Blowers,Blowers,Blowers, cutters,cutters,cutters,cutters,

    extrudersextrudersextrudersextruders

    Machine protection, Machine protection, Machine protection, Machine protection,

    improvement of improvement of improvement of improvement of

    reliability for reliability for reliability for reliability for

    continuous operationcontinuous operationcontinuous operationcontinuous operation

    "Closed" when motor generating torque exceeds the overtorque "Closed" when motor generating torque exceeds the overtorque "Closed" when motor generating torque exceeds the overtorque "Closed" when motor generating torque exceeds the overtorque

    detection level. Can be used as an interlock signal for machine detection level. Can be used as an interlock signal for machine detection level. Can be used as an interlock signal for machine detection level. Can be used as an interlock signal for machine

    protection such as cutting loss or overload detection of machine tools.protection such as cutting loss or overload detection of machine tools.protection such as cutting loss or overload detection of machine tools.protection such as cutting loss or overload detection of machine tools.

  • 77

    Outline of Software Functions (3)Function Name Function Name Function Name Function Name ApplicationsApplicationsApplicationsApplications PurposePurposePurposePurpose DescriptionDescriptionDescriptionDescription

    Stall PreventionStall PreventionStall PreventionStall Prevention General General General General

    machinesmachinesmachinesmachines

    Machine protection, Machine protection, Machine protection, Machine protection,

    improvement of improvement of improvement of improvement of

    reliability for reliability for reliability for reliability for

    continuous operation continuous operation continuous operation continuous operation

    Interrupts accel/decel when frequency reaches each set value during Interrupts accel/decel when frequency reaches each set value during Interrupts accel/decel when frequency reaches each set value during Interrupts accel/decel when frequency reaches each set value during

    acceleration, deceleration or running, and continues operation when it acceleration, deceleration or running, and continues operation when it acceleration, deceleration or running, and continues operation when it acceleration, deceleration or running, and continues operation when it

    becomes lower than the set value. becomes lower than the set value. becomes lower than the set value. becomes lower than the set value.

    Electronic Overload Electronic Overload Electronic Overload Electronic Overload

    Thermal RelayThermal RelayThermal RelayThermal Relay

    General General General General

    machinesmachinesmachinesmachines

    Detection of motor Detection of motor Detection of motor Detection of motor

    overloadoverloadoverloadoverload

    Set the motor rated current value and select the allowable load Set the motor rated current value and select the allowable load Set the motor rated current value and select the allowable load Set the motor rated current value and select the allowable load

    characteristics for each motor type, and the electronic overload thermal characteristics for each motor type, and the electronic overload thermal characteristics for each motor type, and the electronic overload thermal characteristics for each motor type, and the electronic overload thermal

    relay performs overload protection.relay performs overload protection.relay performs overload protection.relay performs overload protection.

    Torque Limit (Droop Torque Limit (Droop Torque Limit (Droop Torque Limit (Droop

    Characteristics Selection)Characteristics Selection)Characteristics Selection)Characteristics Selection)

    Pumps,blowers,Pumps,blowers,Pumps,blowers,Pumps,blowers,

    extruders,extruders,extruders,extruders, etcetcetcetc....

    Machine protectionMachine protectionMachine protectionMachine protection

    Improvement of Improvement of Improvement of Improvement of

    reliability for reliability for reliability for reliability for

    continuous operationcontinuous operationcontinuous operationcontinuous operation

    Torque limitTorque limitTorque limitTorque limit

    AdjustsAdjustsAdjustsAdjusts outputoutputoutputoutput frequencyfrequencyfrequencyfrequency accordingaccordingaccordingaccording totototo thethethethe loadloadloadload statusstatusstatusstatus whenwhenwhenwhen thethethethe motormotormotormotor

    generatinggeneratinggeneratinggenerating torquetorquetorquetorque reachesreachesreachesreaches aaaa certaincertaincertaincertain levellevellevellevel....

    OptimumOptimumOptimumOptimum forforforfor tiptiptiptip----lesslesslessless operationoperationoperationoperation forforforfor pumpspumpspumpspumps orororor blowersblowersblowersblowers....

    EnergyEnergyEnergyEnergy----saving Controlsaving Controlsaving Controlsaving Control General General General General

    machinesmachinesmachinesmachines

    Automatic operation Automatic operation Automatic operation Automatic operation

    with maximum with maximum with maximum with maximum

    efficiencyefficiencyefficiencyefficiency

    Supplies sufficient voltage for the motor to reach maximum efficiency Supplies sufficient voltage for the motor to reach maximum efficiency Supplies sufficient voltage for the motor to reach maximum efficiency Supplies sufficient voltage for the motor to reach maximum efficiency

    according to the load or rotating speed.according to the load or rotating speed.according to the load or rotating speed.according to the load or rotating speed.

    PID ControlPID ControlPID ControlPID Control Pumps,Pumps,Pumps,Pumps,

    airairairair----conditioning,conditioning,conditioning,conditioning,

    etcetcetcetc....

    Automatic process Automatic process Automatic process Automatic process

    controlcontrolcontrolcontrol

    CalculatesCalculatesCalculatesCalculates thethethethe PIDPIDPIDPID inininin thethethethe inverterinverterinverterinverter andandandand usesusesusesuses thethethethe resultresultresultresult ofofofof thethethethe calculationcalculationcalculationcalculation

    asasasas itsitsitsits ownownownown frequencyfrequencyfrequencyfrequency referencereferencereferencereference totototo performperformperformperform constantconstantconstantconstant controlcontrolcontrolcontrol ofofofof pressure,pressure,pressure,pressure,

    flowflowflowflow rate,rate,rate,rate, windwindwindwind amount,amount,amount,amount, etcetcetcetc....

    Droop ControlDroop ControlDroop ControlDroop Control Conveyors of Conveyors of Conveyors of Conveyors of

    distributed drivesdistributed drivesdistributed drivesdistributed drives

    MultiMultiMultiMulti----drive drive drive drive

    motorsmotorsmotorsmotors

    Proper distribution of Proper distribution of Proper distribution of Proper distribution of

    loadloadloadload

    SetsSetsSetsSets motormotormotormotor speedspeedspeedspeed regulationregulationregulationregulation totototo anananan arbitraryarbitraryarbitraryarbitrary valuevaluevaluevalue....

    MakingMakingMakingMaking highhighhighhigh----resistanceresistanceresistanceresistance characteristicscharacteristicscharacteristicscharacteristics distributesdistributesdistributesdistributes thethethethe loadsloadsloadsloads ofofofof severalseveralseveralseveral

    motorsmotorsmotorsmotors properlyproperlyproperlyproperly....

    Zero Servo FunctionZero Servo FunctionZero Servo FunctionZero Servo Function Elevators,Elevators,Elevators,Elevators, cartscartscartscarts ZeroZeroZeroZero----speed stop to speed stop to speed stop to speed stop to

    lock the motorlock the motorlock the motorlock the motor

    HoldsHoldsHoldsHolds aaaa motormotormotormotor inininin thethethethe lockedlockedlockedlocked statusstatusstatusstatus atatatat zerozerozerozero speedspeedspeedspeed whetherwhetherwhetherwhether externalexternalexternalexternal forceforceforceforce

    isisisis appliedappliedappliedapplied inininin thethethethe forwardforwardforwardforward orororor reversereversereversereverse directiondirectiondirectiondirection....

  • 78

    Similar MachinesAir-conditioning fans for buildingsFans for cooling towerDust collection blowersFans for boilersHeat treating furnace blowers

    Application for Dust Collection BlowersFunctions AvailableChanging of commercial power supply and inverter operationsRestart from coasting statusEnergy-saving control mode at light loadFault retry

    Inverter

    BlowerDust CollectorDamper

    Motor MCMCMCB

    MC

  • 79

    Application for Chemical Feeding Pumps

    Inverter

    Raw Water

    PumpFlow Rate Detection

    Adjuster

    Motor

    Chemical

    Speed Reference (4 to 20 mA)

    MCB

    Similar MachinesChemical feeding pumpsCool/warm water circulation pumps Water supply/ discharge pumps Hydraulic pumpsSubmersible pumps

    Functions AvailableEnergy-saving control mode at low speed PID control4-20mA reference by instrumentation Minimum speed setting

  • 80

    Conveyor Follow-up Operation

    HopperFeeder

    ConveyorGeared Motor

    Geared Motor MCB

    MCB

    PG Pulse Encoder

    InverterInverter

    Power Supply

    Main Speed Setting

    Pulse Train Input

    Power Supply

    Similar MachinesRaw material supply conveyors Shuttle conveyorsChain conveyorsSteel pipe feeding conveyors

    Functions AvailableImprovement of constant position stop accuracy Increasing the starting torque Smooth accel/decelChanging accel/decel timeSimultaneous control of several motors by one inverter

  • 81

    Example for Crane Exclusive-use Software ( V/f Control )

    IOUT : Inverter Output Frequency (Actual)FRF : Brake Release Frequency (Set)BF : Brake Operation Stand By Frequency (Set)BT : Brake Operation Delay Time (Set)IF : Brake Release Current (Set)

    BDT : Brake Operation Delay Time (Actual)FHF : Brake Make Up Frequency (Set)HF : Slip Down Prevention Frequency (Set)HT : Slip Down Prevention Time (Set)

    Closed

    BF

    FRF

    Closed

    Closed

    Released

    BT

    BDT

    IOUTIF

    HT

    BDT

    HF

    FTF

    Speed Reference

    (FWD) Run Command (F)

    Output Frequency

    Brake Release Command BR

    Brake Release Check BX

    Brake Operation Closed

    Released

    Released

    Released

  • 82

    ()

    M B M C

    9 10

    R(L1)

    S(L2)

    T(L3)

    1

    3

    *

    *

    2k

    2k

    2k

    P P

    P

    S1

    S2

    S3

    S4

    S5

    S6

    S7

    S8

    S9

    S10

    S11

    S12

    SC

    (0V)

    E(G )

    PR

    A1

    A2

    A3

    AC

    0V

    C 4

    P4

    C 3

    P3

    P2

    P1

    PC

    48V50m A

    AC250V1A

    DC 30V1A

    FLT

    BR

    ( )

    AC250V1A

    DC 30V1A

    M A

    M B

    M C

    M 1

    M 2

    1

    2

    AF

    AC

    AM

    (3)

    U(T1)

    V(T2)

    W (T3)

    1

    2

    1 2

    ()

    Varispeed

    1

    (a)

    2

    Connection Diagram for CranesEmergency Main Switch

    MS Master Switch

    MC Main Circuit Conductor

    F FWD Run Command

    R REV Run Command

    B Brake Conductor

    BBX Brake Applying Command

    BX Brake Release Check

    : Twisted pair-shielded cable

    Braking Resistor Unit (Optional)

    Varispeed G7

    Class 3 Grounding (100 or more)

    Multifunction Terminal

    External Fault

    Fault Reset

    Multi-speed Ref 1Multi-speed Ref 2

    Multi-speed Ref 3Not Used

    Sequence CommonInsulated from (0V) terminal.

    Shielded Sheath Cable Connection Terminal

    Brake Release Command (Brake released at closed)250 VAC, 1 A or less30 VDC, 1 A or less

    Fault Contact Output250 VAC, 1 A or less30 VDC, 1 A or less

    Multifunction PHC Output48 V, 50 mA or less

    ONOFF

    R

    E

    V

    R

    u

    n

    S

    t

    o

    p

    F

    W

    D

    R

    u

    n

    Brake Applying CommandBrake Self-holding

    M1 M2

    Brake Release Check

    Accel/decel Time Selection 1

    Emergency Stop (NO Contact)

    External Baseblock *

    * External baseblock signal baseblock at closed.

    *

    FWD Run/StopREV Run/Stop

    Analog Monitor 2

    Analog Monitor 1

    Multifunction Analog Output

    Note *

  • 83

    Spindle

    X-axisCore Clamper

    Z-axis

    Motor

    Similar Machines

    PolishersGrindersSmall lathesPlano miller feedersMilling machinesDrilling machinesPresses

    Functions AvailableBlade cutting loss prevention Wide range of constant output powerControl by digital inputs Vibration control

    Principle Diagram of Lathe

  • 84

    Elevator Application

    Sheave

    Vector Control PWM Inverter

    Braking Resistor, Braking Transistor (Externally Mounted)Inverter Section Converter Section

    Induction Motor

    C

    u

    r

    r

    e

    n

    t

    D

    e

    t

    e

    c

    t

    i

    o

    n

    AC Reactor

    Cage Calling Signal

    Entrance Calling Signal

    Speed FeedbackVector Control

    Run Operation Signal

    L

    o

    a

    d

    D

    e

    t

    e

    c

    t

    o

    r

    C

    a

    g

    e

    B

    a

    l

    a

    n

    c

    e

    W

    e

    i

    g

    h

    t

    Elevator Controller

    Operation Control

    Torque Ref. Generated

    Position Calculation Speed Ref. Generated

    Speed/Position DetectionLoad Detection

    3-phase AC Power Supply

    PWM Control

    Status Signal Fault Signal

    AC Current Controller

    Torque Compensation Speed Controller

    Speed Ref.

    Speed Reducer

    Similar MachinesEscalatorsRope waysCable carsElectric railcarsElectric automobiles

    Functions AvailableImprovement of cage landing frequencySoft-start with S-curve function Slip prevention at start/stopBattery operation at a power failure

  • 85

    Chapter 6Inverter Drives Precautions

  • 86

    (a) Vertical (b) Horizontal (b) Side by Side

    Installation

  • 87

    (a) Right and Left Space (b) Top and Bottom Space

    MountingAmbient temperature:

    -10 to 40

    Ambient humidity:

    90% RH or less

    Vibration:

    Less than 20 Hz

    9.8 m/s2 or less

    20 to 50 Hz

    2 m/s2 or less

    50mm or more

    30mm or more 30mm or more50mm or more

    120mm or more

    120mm or moreAir

    Air

  • 88

    Bottom Cover Mounting Screw

    Remove the unit top and bottom covers for the 20HP (15 kW) or less models (200-V class, 400-V class).

    ()

    Totally-enclosed Type Control Panel Installation

    CoolingFin

    Totally-enclosed Type Control Panel

    Top CoverIn-panel Air Temperature at Top: 10 to +55Cooling Fin

    Open chassis Type Inverter

    Bottom CoverInverter Intake Air Temperature : 10 to +45

    Ambient Temperature 40Bottom Cover

    Top Cover(One-touch)Ambient temperature:

    +14 to 113F

    (-10 to 45 ) Ambient humidity:

    90% RH or less

    Vibration:

    Less than 20 Hz

    9.8 m/s2 or less

    20 to 50 Hz

    2 m/s2 or less

  • 89

    (a) Best Grounding

    Inverter(1)

    Inverter (2)

    Inverter(3)

    E E E

    (b) Good Grounding

    (c) Wrong Grounding

    Inverter(1)

    Inverter(2)

    Inverter(3)

    E E E

    Inverter(1)

    Inverter(2)

    Inverter(3)

    E E E

    (A loop must not be made.)

    Multiple Inverters Grounding

  • 90

    0 3 6 20 60

    Continuous

    100

    807060

    50

    Frequency (Hz)

    25%ED (or 15 minutes)40%ED (or 20 minutes)

    60%ED (or 40 minutes)

    90

    Allowable Load Characteristics of Standard Motors

    RunRun

    StopR

    T

    ED 100R

    T

    T

    o

    r

    q

    u

    e

    (

    %

    )

  • 91

    Chapter 7 Harmonics, Noise & Surge Voltage

  • 92

    Noise Harmonics

    Frequency Band High frequency (10 kHz or more) 40th to 50th harmonics (up to several kHz)

    Main Source Inverter section Converter section Transmission Path

    Electric wire (conduction) Space (radiation) Induction (electrostatic,

    electromagnetic

    Electric wire

    Influence Distance, wiring distance Line impedance Generating Amount

    Voltage variation ratio Switching frequency

    Current capacity

    Failure Sensor malfunction Radio noise

    Overheat of capacitor for P.F improvement Overheat of generator

    Corrective Actions Change the wiring route. Install a noise filter. Install INV. in a screened

    box

    Install a reactor. 12-phase rectification Sinusoidal wave power regeneration

    converter

    Difference between Harmonics and Noise

  • 93

    C

    o

    m

    m

    e

    r

    c

    i

    a

    l

    P

    o

    w

    e

    r

    +S

    m

    o

    o

    t

    h

    i

    n

    g

    C

    a

    p

    a

    c

    i

    t

    o

    r

    Converter Section

    Motor

    Bridge Rectifier

    Harmonics Current Generated by Rectifier Circuit

    Noise Generated by High-speed Switching

    Harmonics and Noise Sources

    Inverter Section

  • 94

    Fundamental Wave Current(at 50 or 60 Hz)

    Harmonics Current(Example of 5th Level Harmonics)

    (Amplitude Ratio: 0.3)

    Distorted Wave Current

    Fundamental Wave + Harmonics = Distorted Wave AC(Harmonics Superimposed on Fundamental Wave)

    0 pipi2

    A

    B

    A+B

  • 95

    EDC

    Converter

    er es et

    er-s er-t es-t es-r et-r et-s

    Power Supply Phase Voltage

    Ver-s

    er

    es

    et

    r

    s

    t

    EDC (Without Capacitor)

    Power Supply Line Voltage

    Power Supply Current Waveform

    Phase R ir

    Phase Sis

    Phase it

    Generation of Harmonics Current

  • 96

    (Harmonics Current Suppression)(a) AC Reactor

    +

    Inverter

    Motor

    AC Reactor

    C

    o

    m

    m

    e

    r

    c

    i

    a

    l

    P

    o

    w

    e

    r

    (b) DC Reactor

    +

    Inverter

    Motor

    DC Reactor

    CommercialPower

    Reactor Connection

  • 97

    Radio

    Machine

    Inverter

    Power Supply Transformer

    Amplifier

    Conductive noise : Noise that flows out through the power supply line or grounding line Induction (electromagnetic, electrostatic)

    : Noise transmitted by electromagnetic or electrostatic integration for the signal lines provided for the inverter main circuit wiring

    Radiation : Noise radiated into the air through the inverter, motor unit, main circuit wiringthat work as antenna.

    Noise Transmission Paths

    Electronic Device

    Sensor

  • 98

    Shielding (Steel) Plate Power LineSignal Line

    Inverter M

    Metallic Raceway Metallic Raceway

    Wiring Separation by Rack or Duct

    Induction Noise Suppression and Metallic Raceway

  • 99

    (a) Capacitive Filter (b) Inductive Filter (Zero-phase Reactor)

    Power Supply

    P

    o

    w

    e

    r

    S

    u

    p

    p

    l

    y

    (c) LC Filter

    Conductive Noise Suppression

    InverterInverter

    Power Supply

    Inverter

  • 100

    InverterInverter

    0V(Common)

    0V(Common)

    Junction Terminal

    Inverter Noise Prevention (Shielded Sheath Wire)

  • 101

    Motor

    Progress and Reflection of Surge Voltage

    (Leading Edge of One Pulse)

    Inverter

    Progressive Wave

    Reflected Wave

    Progressive wave reflects at the rapid changing point (motor terminal section) of line impedance.

    (Twice Surge VoltageApplied to Terminals)

  • 102

    Without Filter

    (a) Test Circuit

    [Inverter Output] [Motor Input]

    (b) Result of Waveform Observation (5s/div, 250/div)

    Expanded Diagram

    With Filter

    Inverter Output Motor Input

    IM

    Surge Voltage Suppression by Filter

    Filter

    Expanded Diagram

    PWM Inverter

  • 103

    Filter

    Motor Terminal Voltage(Without Filter )

    Unless any filter is installed, surge voltage may be generated at the motor terminal, which may affect motor insulation.

    Motor

    Motor Surge Voltage Suppression by Filter

    PWM Inverter

    ~ ~

    ~

    ~ ~

    ~

  • 104

    The solution to 400V class inverter drive problems1. Low surge voltage

    Suppresses motor surge voltage, eliminating theneed for the motor surge voltage protection.

    2. Low electrical noise (Radiated, Conductive)3. Low acoustic noise 4. Electrolytic corrosion of motor bearings due to shaft voltage

    Features of 3-level control

  • 105

    (b) Example of Shaft Voltage Measurement (between Shafts) (c) Shaft Voltage Waveform

    (Hz)

    Commercial Power Supply Drives

    Actual Measurement of Shaft Voltage

    Commercial Power Drives

    (Direct-coupling Side)(Opposite to Direct-coupling Side)

    S

    h

    a

    f

    t

    V

    o

    l

    t

    a

    g

    e

    (

    m

    V

    )

    Inverter

    Inverter Drives

    V: Measuring DeviceR: Non-inductive Resistor (1k)

    (Stator)(Rotor)

    (a) Example of Shaft Voltage Measuring Circuit Inverter: PWMMotor: 3.7 kW, 200 V, 4 polesV/f characteristics: Constant torque

  • 106

    Chapter 8Maintenance and Inspection

  • 107

    Failure Patterns

    Initial Failure Period

    Accidental Failure Period Wear-out Failure Period

    t

    Specified Failure Ratio

    Service Lifetime

    F

    a

    i

    l

    u

    r

    e

    R

    a

    t

    i

    o

    (

    t

    )

    0ta tb

  • 108

    Place Item Checking Item

    Schedule

    Daily

    Periodical

    1-yr 2-yr

    Whole

    Peripheral environment Ambient temperature, humidity, dust, hazardous gases, oil mist, etc.

    Whole unit No excessive vibration or noise.

    Power supply voltage Check that main circuit voltage or control voltage is normal.

    Main Circuit

    Whole

    Megger check between main circuit terminal and ground terminal

    No loose connections

    No traces of overheating in components

    Clean.

    Connected conductor,

    Power supply

    No distortion in conductor

    No breakage or deterioration (cracks, discoloration, etc.) in cables

    Transformer, Reactor No odor, excessive beats or noise

    Terminal stand No damages

    Smoothing capacitor

    No liquid leakage

    No projection (safety valve) or bulge

    Measure electrostatic capacity and insulation resistance.

    Relay, Contactor

    No chattering at operations

    Timer operation time

    No roughness on contacts

    Resistor

    No crack in resistor insulating material

    No disconnection

    Control Circuit,

    Protective

    Circuit

    Operation check

    Balance of output voltage between each phase by inverter single-unit operation

    No failure in protective or display circuit by sequence protection test

    Component

    check

    Whole

    No odor or discoloration

    No excessive corrosion

    Capacitor No traces of liquid leakage or deformation

    Cooling System Cooling fan

    No excessive vibration or noise

    No loose connections

    Clean the air filter.

    Display

    Display

    All lamps lights correctly.

    Clean.

    Meter Indicated values are correct.

    (From JEMA Information)

    Daily Inspection and Periodical Inspection

  • 109

    NameNameNameName

    Standard Standard Standard Standard

    Replacement PeriodReplacement PeriodReplacement PeriodReplacement Period

    MethodMethodMethodMethod

    Cooling fanCooling fanCooling fa