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YASKAWA1
Training ManualTraining Manualfor Advanced Sales Stafffor Advanced Sales Staff
SubjectSubject Inverter BasicsInverter BasicsChapter 1Chapter 1Principle and Characteristics of Principle and Characteristics of Induction MotorsInduction MotorsChapter 2Chapter 2Inverter Principle and Inverter Principle and CharacteristicsCharacteristicsChapter 3Chapter 3Operation CharacteristicsOperation CharacteristicsChapter 4Chapter 4Inverter Drive Units SelectionInverter Drive Units Selection
Chapter 5Chapter 5Inverter Functions and AdvantagesInverter Functions and AdvantagesChapter 6Chapter 6Inverter Drives Precautions Inverter Drives Precautions Chapter 7Chapter 7Harmonics, Noise & Surge VoltageHarmonics, Noise & Surge VoltageChapter 8Chapter 8Maintenance and Inspection Maintenance and Inspection Chapter 9Chapter 9Reference Reference
YASKAWA2
Training for Advanced Sales StaffTraining for Advanced Sales Staff
Inverter BasicsInverter Basics
YASKAWA3
Market of General purpose InvertersMarket of General purpose Inverters
IntroductionIntroduction
YASKAWA4
(General-purpose inverters up to 75 kW)Marketing of 2,200,000 units worth \73,000,000,000
Inverter Market TrendInverter Market Trend
\ (Hundred million)
Unit(×10000)
Actual Record Estimation*Actual record is in accordance with “Statistics Investigation on Production Trends” of Ministry of Economy, Trade and Industry.
The data of 2003 is an estimation made by Japan Electrical Manufacturers’ Association (JEMA).
(Hundredmillion)
Transition of Market Scale Tens of thousands
YASKAWA5
TotalTotal1.813million1.813million
FujiFuji24.3%24.3%
MitsubishiMitsubishi30.5%30.5%
ToshibaToshiba9.5%9.5%
HitachiHitachi5.9%5.9%
OthersOthers6.0%6.0%
TotalTotal2,342M US$2,342M US$
YaskawaYaskawa12.8%12.8%
FujiFuji9.6%9.6%
MitsubishiMitsubishi9.8%9.8%
OthersOthers25.8%25.8%
WorldWorld
YaskawaYaskawa23.7%23.7%
ABBABB10.0%10.0%
Rockwell Rockwell 12.1%12.1%
SiemensSiemens7.9%7.9%
※Data estimated by Sales Promotion Section
ToshibaToshiba--SchneiderSchneider7.2%7.2%
C.TC.T4.8%4.8%
Inverter Market Shares Inverter Market Shares (FY 2001 )(FY 2001 )
JapanJapan
unitsunits
※This share represents No. of unitsproduced in Japan.
YASKAWA6
VS-610
VS-610B
VS-616T
Thyristor inverter (current type)
Thyristor inverter (current type)
PWM transistor inverter (analog)
Varispeed G7
Varispeed F7
VS mini V7
VS mini J7
World’s First
World’s First
77thth GenerationGeneration
* 3-level
World’s First
Year of 1968
1974
1980
VS-616HⅡ PWM transistor inverter (digital)1984
VS-616GⅡ, GⅡLN PWM transistor inverter (IGBT, low-noise type)1987
3rd Generation
VS-616G3, etc.PWM transistor inverter
1989
5th Generation
VS-616G5, etc.PWM transistor inverter
1995
1969
World’s First
VS-616G, H PWM transistor inverter (analog)
Year of 2000
2000
1998
1998
Year of 2000 to 2003
History of Yaskawa GeneralHistory of Yaskawa General--purpose Inverterspurpose Inverters
YASKAWA7
Global Sales and Production NetworkGlobal Sales and Production Network
Yaskawa Inverter BusinessYaskawa Inverter Business
● : Sale office□ : Production facility
Taian Technology SDN (YTM)
Yaskawa HongKong (YHK)
YE America Inc. (YEA)
YE Do Brazil Co. LTDA (YEB)
YE Taiwan Corp. (YTW)
YE Korea Corp. (YEK)
Inverter Plant (V)
Yaskawa Electric (YEC)
YE UK Ltd. (YGB)
YE Singapore Pte. (YSP)
YE Shaghai Co Ltd Shanghai Yaskawa-Tongji M&E Co. Ltd (SSC)
YE Europe Ltd. (YEG)
YE Shaghai Co Ltd (SYD)
YASKAWA8
Typical Industrial ApplicationsTypical Industrial ApplicationsMachine Names
Industrial Field Other Machines
Iron, steel making ○ ○ ○ ○ ○ Rolling mill, Steel plate processorWire drawing ○ ○ ○ ○ ○ Winder, Rolling millChemical ○ ○ ○ ○ ○ ○ ○ ○ Film processorTextile ○ ○ ○ ○ ○ ○ Spinning machine, WeaverAutomobile ○ ○ ○ ○ PressMachine tool ○ Lathe, Surface grinder, Machining center, PressFood ○ ○ ○ Noodle maker, Confectionery maker, PackerPaper, Pulp ○ ○ ○ ○ Paper machine, Paper processor, PrinterCement ○ ○ ○ ○ -
Loading, Feeding ○ ○ ○ Automatic warehousePlant, Building ○ ○ ○ ○ ○ Elevator, Water-supply tower
Primary industry ○ ○ ○ ○Shed, Henhouse, Processing M/c for Tea,Processing M/c for Sea Weed
Pum
p
Fan,
Blo
wer
Cra
neFe
edin
g ca
rrie
r
Con
veyo
r
Ext
rude
r
Mix
erC
entri
fuga
l se
para
tor
Com
pres
sor
Air
cond
ition
er
YASKAWA9
FunctionsFunctions
Functions Subject to Variable Speed Drives
Needs for Production Facility Application, Facility
Reduction of drive power by speed changes ○ ○ ○
Power reduction mode at run (light load, no load) ○ ○ ○ ○
Improvement of machine stop position accuracy ○ ○ ○ ○ ○ ○
Improvement of line speed control accuracy ○ ○ ○ ○ ○
Automation of flow rate control ○ ○ ○
Improvement of productivity by increasing line speed ○ ○ ○ ○ ○ ○ ○ ○
FMC of facility ○ ○ ○ ○ ○ ○ ○ ○
Optimum operation by no-step speed changes ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Optimum operation for product quality ○ ○ ○ ○ ○ ○ ○
Optimum operation for product processing ○ ○ ○ ○
Matching of speed between units in line ○ ○ ○ ○ ○ ○
Optimization of reaction time ○ ○ ○ ○ ○ ○
Smooth start, accel/decel, stop ○ ○ ○ ○ ○ ○ ○ ○
Extension of facility lifetime by speed reduction at no load ○ ○ ○ ○ ○ ○
Reduction of maintenance by using no brushes ○ ○ ○ ○ ○ ○
Reduction of maintenance by using no contacts ○ ○ ○ ○ ○ ○
Installation in explosionproof area ○ ○ ○ ○ ○ ○ ○
Noise reduction of facility ○ ○ ○
Machine downsizing by increasing speed ○ ○ ○
Facility downsizing compared to mechanical speed changes ○ ○ ○ ○
Ene
rgy
savi
ng
Impr
ovem
ent o
f pr
oduc
t qua
lity
Upg
radi
ng o
f fac
ility
Faci
lity
dow
nsiz
ing
Cor
resp
onde
nce
to
envi
ronm
ent
Fan,
Pum
p
Com
pres
sor
Mix
erC
entri
fuga
l se
para
tor
Ext
rude
r
Con
veyo
r
Feed
er
Trav
elin
g ca
rrier
Ele
vato
r
Grin
der,
San
der
Pre
ss
Prin
ter
Impr
ovem
ent o
f m
aint
aina
bilit
y
YASKAWA10
(%)
低速運転時の運転性能
0 10 20 30 40 50 60 70 80 90 100
品質・性能
振 動
保護機能
騒 音
耐久性・寿命
ブレーキ特性
寸法・質量
始動トル ク
高調波対策
(Item)
User’s EvaluationUser’s EvaluationSatisfaction Level
Investigated in 1987Investigated in 1999
[by Japan Electrical Manufacturer’s Association (JEMA)]
Quality, Performance
Vibration
Protective functions
Noise
Durability, lifetime
Brake characteristics
Size, weight
Starting torque
Operation characteristics at low-speed operation
Prevention from harmonics
YASKAWA11
Chapter 1Chapter 1Principle and Characteristics Principle and Characteristics
of Induction Motorsof Induction Motors
YASKAWA12
Flange-mounted type
Induction MotorsInduction Motors
Foot-mounted type
YASKAWA13
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 MotorsTypes of Motors
YASKAWA14
① ④ ③ ⑧
⑤
⑦
⑥⑨⑧⑩
⑦
②
⑪
⑫
① Stator frame ⑦ Bearing② Output shaft ⑧ Bracket③ Stator coil ⑨ Internal fan④ Stator iron core ⑩ External fan⑤ Rotor End ring ⑪ Terminal box⑥ Rotor iron core ⑫ Center height (motor frame No.)
(a) Configuration of Squirrel-cage Induction Motor (Example of Totally-enclosed Externally-cooled Type)
(b) Squirrel-cage Rotor (Excluding Iron Core)
Rotor End Ring
Secondary Conductor
ConfigurationConfiguration
YASKAWA15
Force ( F ) Magnetic field (Flux density B (wb/m2) )
Current ( I (A) )
Force (F)Magnetic field (Flux density B (wb/m2) )
Current ( I (A) )
Length of conductor ( (m) )
Fleming’s LeftFleming’s Left--hand Rulehand Rule
¯sin´BIF ã [N]
θ
´
´
YASKAWA16
ARAGO’s Disc(Disc rotates following magnet rotation.)
Induction Effect of Rotating Magnetic Field
N
S
Permanent Magnet
Rotary Shaft
Iron Disc
PrinciplePrinciple
YASKAWA17
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 CurrentMagnetic 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
:
YASKAWA18
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 π ωt2π
Principle of Rotating Magnetic Field (2 Pole)Principle of Rotating Magnetic Field (2 Pole)
U, V, W : START of CoilU’,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
YASKAWA19
Rotating Magnetic Field of a 4Rotating Magnetic Field of a 4--pole Motorpole Motor
(a) Coil Arrangement
Phase U Phase V Phase W
(b) Three-phase Alternating Current
N
N
S
S1
1
YASKAWA20
P o w e r S u pp ly F re que ncy (f)
N o . o f P o le s
(P )
N o . o f C o ils pe r
P h as e 5 0 H z 6 0 H z
2 1 3 000 3 600
4 2 1 500 1 800
6 3 1 000 1 200
8 4 750 900
S N
S N
N S
2p 4p
8p6p(a) Synchronous Speed (min-1)
(b) Number of Poles (p)
Number of Poles and Synchronous SpeedNumber of Poles and Synchronous Speed
S N
S N
N S
S NN
N
NS
S
S
YASKAWA21
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 Ns . This amount is called
“slip”, which is defined as follows:
S
S
NNN
Só
ã
ø ÷SSNN óã 1
ø ÷N fp
Sã ó120 1
pfN S
120ã 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 SpeedsInduction Motor Speeds
YASKAWA22
360018000[With 4 poles at 60 Hz ( min-1 )] - 1800
CharacteristicsCharacteristics
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
YASKAWA23
Slot Form and Torque Characteristics of Induction MotorsSlot Form and Torque Characteristics of Induction Motors
Normal Squirrel-cage Type
Speed
Special Squirrel-cage Type Class 1
Special Squirrel-cage Type Class 2
Low Starting Torque Type
High Resistance Squirrel-cage Type
High Starting Torque Type
Aluminum die-castCopperBrassHigh-resistance alloy die-cast
Torq
ue
Speed
SpeedSpeed
Speed
Torq
ue
Torq
ueTo
rque
Torq
ue
Torq
ueSpeedStandard
Particular
YASKAWA24
(min-1)
Control MethodControl 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)
YASKAWA25
Number of poles : 4 / 8( 8P ) ( 4P )
Example of Pole Change MotorExample of Pole Change Motor
(Example at 60 Hz)
8P 4P
Load Torque
N900 1800(min-1)
[For Low Speed]
[For High Speed]
[For Low Speed]
Pole Change Motor
Low Speed High Speed
1THR
2THR
0
YASKAWA26
ASR
Nfb
NrefPhase Shifter
Speed Reference
Unit
-+
TG
Induction Motor
3-phase PowerSupply
Thyristor Type Primary Voltage Thyristor Type Primary Voltage Control CircuitControl Circuit
T ∝ V2
Load Torque
1800(min-1)
Voltage
Large
0
Speed DetectionGenerator
Example with 4 Poles at 60 Hz
PS
YASKAWA27
(a) Conceptual Diagram
(b) Symbol
(Slip Ring)
Secondary Resistor
R2’
Secondary Resistor
R2’
Wound Rotor Induction Motor Wound Rotor Induction Motor Secondary Resistor ControlSecondary Resistor Control
(Example with 4 Poles at 60 Hz)
1800(min-1)
(Stalling torque constant:Proportional Transition)
Load Torque
Large
Secondary Resistance Small
3-phase PowerSupply
3-phase PowerSupply
0
YASKAWA28
-
+
Speed Reference
Thyristor Exciter
Power Supply
Speed DetectionGenerator
EddyEddy--current Coupling Motorcurrent Coupling Motor
(Example with 4 Poles at 60Hz)
1800(min-1)
Load Torque
Small
LargeExciting Current
Induction Motor Characteristics
Phase Shifter
Speed Deviation Amplifier
3-phase Power Supply
Drum
Load Machine
Induction Motor
Spider
Slip Ring
Exciting Current
0
YASKAWA29
* “BODY” is added in front of the protection symbol for any configuration without terminal box.
Type Configuration Operational Environment
Protection Symbol
(Representative Example)
Protection Type
Provided with ventilation openings in the housing. Theseopenings protect against round bars of 12 mm diameter or more.
・Ordinary environment (indoor) BODY
JP 20
Dripproof Type
The open-type with water dripping within 15 degrees verticallydoes not enter the motor interior directly or along the motorsurface.
・Ordinary environment・Under special ambient temperature・Exposed to water splashes
JP 12
Dripproof Protection
TypeSatisfies the conditions of both protection type and dripproof type. JP 22
Dripproof Dripproof Protection TypeProtection Type
YASKAWA30
Type Configuration Operational EnvironmentProtection
Symbol (Representative
Example)
Totally-enclosed Type
The housing is enclosed so that the outer air does not enter the motor interior.
・Ordinary environment (indoor)・Under special temperature・Under high temperature・Use in tropical area・ Exposed to excessive amount of dripping water or dust
BODYJP 44
Totally-enclosed, Fan-cooled Type
In addition to the totally-enclosed configuration, the housing surface is cooled by the fan mounted on the rotary axis.
JP 44
TotallyTotally--enclosed Fanenclosed Fan--cooled Typecooled Type
YASKAWA31
Type Configuration Operational EnvironmentProtection
Symbol (Representative
Example)
Outdoor TypeDurable for outdoor use.(Totally-enclosed type or totally-enclosed fan-cooled type)
・Ordinary environment (indoor)・Under special temperature・Under high temperature・Use in tropical area・ Exposed to excessive amount of water or dust
JPW 44
Totally-enclosed, Fan-
cooled Type
Can operate properly in a place exposed to corrosive acid, alkali or any other hazardous gases. (Totally-enclosed type or totally-enclosed fan-cooled type)
JPC 44
Outdoor TypeOutdoor Type Anticorrosion TypeAnticorrosion Type
YASKAWA32
Type Configuration Operational Environment
Protection Symbol
(Representative
Example)
Explosionproof Type (Increased Safety,
Pressure Proof, Internal Pressure)
Durable for outdoor use.(Totally-enclosed type or totally-enclosed fan-cooled type)
・Exposed to explosive gases
JPE 44
Dustproof, Explosionproof Type
Can operate properly in a place exposed to corrosive acid, alkali or any other hazardous gases. (Totally-enclosed or totally-enclosed fan-cooled type)
・Exposed to dust JPE 44
Explosionproof TypeExplosionproof Type
YASKAWA33
2. Applied Modification2. Applied Modification・Geared motors Output shaft torque increased
・Brake motorsQuick brakeAG brake motors
・Explosionproof motorsIncreased safety explosionproof motorsExplosionproof motors
Types of Inverter MotorsTypes of Inverter Motors
Fan Cover External FanExternal Fan (-K)
Pulse Generator (-M)
1. Inverter Drive Motors1. Inverter Drive Motors
FEQ-X, FEFFEK-I FEK-IK FEK-IKM
(With electric fan) (With electric fan and PG)
① Totally-enclosed
Model : EEK-IM(With PG)
② Totally-enclosedFan-cooled Type
③ Totally-enclosedFan-cooled Type
④ Totally-enclosed Fan-cooled Type
YASKAWA34
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 DrivesMotor Characteristics at Inverter Drives
Voltage (V)
Magnetic Flux ∝ Voltage VFrequency f
= Constant
YASKAWA35
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) (kgf・m)
Rated torque TM = 974 × 7.51740 (kgf・m)= 4.19
Rated torque TM =Motor rated output P (W)
Rated speed N (min-1) (N・m)602π ×
Rated torque TM =7.5×103
1740(N・m)= 41.260
2π ×
Motor Rated TorqueMotor Rated Torque
YASKAWA36
■ When load torque variesWhen 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 variesWhen 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 VariationMotor Speed VariationOutput Torque
Speed
Load Large
Load Small
Speed
Voltage Large
Load Constant
Torq
ue
Voltage Small
Torq
ue
YASKAWA37
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.
If
VKTorque T ××= K : Constant
I : Current
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 60HzOperations Exceeding 50Hz or 60Hz
YASKAWA38
Chapter 2Chapter 2Inverter Principle and CharacteristicsInverter Principle and Characteristics
YASKAWA39
Rectifier CircuitConverter Section
DC IntermediateCircuit
Smoothing Circuit Section
Invert ConversionCircuit
(Inverter Section)
Commercial Power
AC Power
Variable Frequency/Variable Voltage AC
Control Circuit Section
M
Motor
(VVVF)
Inverter ConfigurationInverter Configuration
AC Power
YASKAWA40
+
-
0
Current wave
R
S4
S3S1
S2
DC Power Supply
R S1 S4 ON S1 S4 ON
S2 S3 ON
+
- +
-
How to Make AC
+
-
ON ON
ON
SwitchesS1, S4
S2, S3
Ed
Principle of SinglePrinciple of Single--phase Inverterphase Inverter
+Ed
-Ed
YASKAWA41
S1
S4
DC Power Supply
S3
S6
S5
S2
U Motor
WV
+
-Ed
Basic Circuit of 3Basic Circuit of 3--phase Inverterphase Inverter
+Ed
-Ed
YASKAWA42
IM
Motor
3-phase AC
EdDC Power Supply
+
-
Basic Circuit of Transistor InverterBasic Circuit of Transistor Inverter
+Ed
YASKAWA43
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.)
Sym
bol
Cha
ract
eris
tics
Volta
ge, C
urre
nt
Wav
efor
m
Feat
ures
, A
pplic
atio
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 InvertersMain Semiconductor Power Elements Used for Inverters
Anode
CathodeGate
Collector
Base
Emitter
Drain
Gate
Source
YASKAWA44
Control Method Output Frequency Features
PAM Method (Pulse Amplitude Modulation)
・ Voltage control is
needed for the converter.
・ Motor current distortion is excessive, resulting in torque ripple.
PWM 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 60×14 = 840 Hz. Since the actual inverter has this carrier frequency of 15 kHz, the number of pulses per cycle is 250 pulses (15000÷60).
・ 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
VoltageVoltage--type Inverter Control Methodtype Inverter Control Method
YASKAWA45
~
P
N
C
MC
R
D3D2D1
D6D5D4
V
V
Ed
Vs
In-rush Current Suppression Resistor
Vs1.35≒ Vs π
23dE ã
Converter SectionConverter Sectionand Inand In--rush Current Suppressionrush Current Suppression
(V)
YASKAWA46
Primary Frequency Control of Induction MotorsPrimary Frequency Control of Induction Motors
0-900-1800600 1800 3600
Load Torque
-30 Hz 0Hz(DC) 20 Hz 60 Hz
Speed(min-1)
<Example of 4 Poles>: In case of vector control(Torque –min-1 curve moves
horizontally.) : In case of V/f control(Torque is reduced at low speed.)
Torque
YASKAWA47
3-phase Power SupplyIM
Voltage/Current
Detection
N
0 t
Accel/decelInterrupt Signal
V
0f
PWM Signal
Generator
BaseDriver
VoltageReference
Accel/decel Adjuster V/f Setter
Frequency Reference
Speed (Frequency)Reference
Transistor Base Signal
Current DetectorMotor
InverterConverter
V/f Control PWM InverterV/f Control PWM Inverter
YASKAWA48
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 Voltage / Frequency Characteristics in V/f Controlin V/f Control
YASKAWA49
úI2r1 l1
úEúVúI1
úIM
Mr2
12
óss
r
(b) Vector Diagram
ú ~I2ú ~I1
úI1
úI M
~¯¯
I2 I2’
I2
I1’
I1
IM
E
IM
EI1V
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 DiagramEquivalent Circuit and Vector Diagram
V 1l
1r1I
1I
sr2
(a) Equivalent Circuit for Motor One Phase
YASKAWA50
tN-
+I I I
II
M
M
12
22
1 2
ã õ
ã ó¯ tan
PWM Control÷
rM
2 fdt ×
×
×
Speed Reference
Torque Reference
Accel/decel Adjuster
Speed Feedback Signal
Speed ControllerCurrent Reference Calculator
Current Amplitude Reference
Torque Current Reference
Each Phase Current Reference
Multiplier
Instantaneous Current Control Circuit
Slip Frequency Reference
IIM
2
IM
Exciting Current Reference
Speed/Torque Control Switch
I 2
IM
Current Phase Reference
f s
fn
+
+
φ
3- (or 2-) phase Current Feedback Signal
PG (Speed Detector) (Pulse Generator)
Motor
Current Detector
Inverter
Converter
3-phase Power Supply
θ
I 2
M
Vector Control PWM InverterVector Control PWM Inverter
YASKAWA51
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 resistance2.Stop-type tuning3.Rotation-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.
AutoAuto--tuningtuning
YASKAWA52
Varispeed G7
Specifications V/f Control V/f Control with PG Feedback
Open-loop Vector Control
Flux Vector Control
Basic Control
Voltage/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 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 ModeFeatures of Control Mode
YASKAWA53
Chapter 3 Chapter 3 Operation CharacteristicsOperation Characteristics
YASKAWA54
Induction Motor 4Induction Motor 4--quadrant Operationquadrant Operation(a) Speed Pattern
(b) Speed-Torque Characteristics
(FWD Run)
Speed
(REV Run)
Time
(REV Run) (FWD Run)
Speed
TorqueForward Phase Rotation
Reverse Phase Rotation (REV)
(FWD)
YASKAWA55
(a) Proper Acceleration Time (b) Short Acceleration Time
AccelerationAcceleration
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
YASKAWA56
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 AccelerationStall Prevention during Acceleration
t
YASKAWA57
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 DecelerationStall Prevention during Deceleration
t
YASKAWA58
Inverter Output Frequency
Load
Stall Prevention during RunningStall Prevention during RunningTo avoid overloading by rapid fluid temperature in hydraulic machines. Avoid overloading by
decreasing output frequency.
t
YASKAWA59
DC Voltage
Inverter Output Frequency
Motor Current
RUN Signal
Actual Stall Prevention FunctionActual Stall Prevention Function
Edc.
OV,OA
YASKAWA60
Set Decel. Time td
Slip
(Minus)
N Rapid decelerationSlip: Minus
f
fN,
t
NSlow decelerationSlip: Plus
Deceleration Time (td) Motor Operation Mode Slip
td>Coasting to a stop time Motoring (Motoring area) Plus
td<Coasting to a stop time Regeneration (power generation area) Minus
DecelerationDeceleration
0
YASKAWA61
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 BrakingDC Injection Braking
0 0 0
N, f N, f
Free Run
YASKAWA62
Inverter Load
Motor Output
Inverter OutputPower
Inverter Input Power
Power Supply
PowerPower SupplyMotor Loss
Motor Efficiency
IM
Inverter LossInverter Efficiency
Motor
● Inverter Efficiency =――――――― = ―――――― Inverter Output Output
Inverter Input Output + Loss
● Total Efficiency = ――――――― = Inverter Efficiency × Motor Efficiency Motor Output
Inverter Input
● Motor Efficiency = ――――――――――――― Motor Output
Motor Input (Inverter Output)
I/O Power Flow DiagramI/O Power Flow Diagram
YASKAWA63
(a) Commercial Power Operation (b) Inverter Operation
VI
φ
※ 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 WaveformInput Voltage / Current Waveform
Power Factor = Active Power Active PowerActive Power + Reactive Power=
3Inverter Input Power
× Power Supply Voltage・ Inverter Input Current=
Apparent Power
YASKAWA64
*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 ReactorTypical Connection of DC Reactor
RST
UVW
YASKAWA65
Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics Content
No countermeasures taken
Harmonics Order
88%
AC reactor inserted
38%
DC reactor inserted
33%
P
N
P
N
P
N
+
+
+
Typical Inverter Input Current WaveformTypical Inverter Input Current Waveformin Each Power Supply Method (1)in Each Power Supply Method (1)
1 5
1 5 7 11
1 5 7 11
YASKAWA66
Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics Contents
12-phase rectification
Harmonics Order
12%
PWM control converter
3%
P
N
P
N
+
+
1
1
Typical Inverter Input Current WaveformTypical Inverter Input Current Waveformin Each Power Supply Method (2)in Each Power Supply Method (2)
YASKAWA67
Chapter 4Chapter 4Inverter Drive Units SelectionInverter Drive Units Selection
YASKAWA68
From General IndustrialFrom General Industrial--use to Consumer Equipmentuse to Consumer EquipmentGeneralGeneral--purpose Inverter Series 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)
YASKAWA69
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
○○ ― 1:40
±2 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
pen-
loop
Flux
Vec
tor
Features of Each GeneralFeatures of Each General--purpose Inverter purpose Inverter
Pow
er
Reg
ener
atio
n
Res
isto
r D
isch
arge
Acc
urac
y (%
)
Con
trol
Ran
ge
Torq
ue C
ontr
ol
YASKAWA70
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 kW
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
ExclusiveExclusive--use Inverter Seriesuse Inverter SeriesFo
r Sy
stem
Pow
er
Reg
ener
ativ
eC
onve
rter
For
Mac
hine
Tool
Spi
ndle
Pow
er
Reg
ener
ativ
eU
nit
YASKAWA71
Motor Type
Motor Output
Inverter Output
Inverter Model
Peripheral units, Options
Enclosure
インバータの機種選定
Check ItemWhat to Decide
Capacity SelectionCapacity 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
YASKAWA72
Load Characteristics Typical Load Speed –Torque Characteristics
・Load torque is constant for speed.・General friction loads
・Conveyor・Crane・Winch・Other 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 constant
Loads of which load torque is decreased as the speed is reduced
・Fan・Blower・Pump・Other fluid loads
・Load torque is in proportion to the square of speed. ・Output is in proportion to the
cube of speed. T = kN2
P = 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 speed・Loads 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
SpeedTorq
ue, O
utpu
t
Load Torque
Load OutputSpeedTo
rque
, Out
put
Typical Load Torque CharacteristicsTypical Load Torque Characteristics
0
1.0
1.0
2.0
Load Torque
Load Output
1.0
2.0
2.0Torq
ue, O
utpu
t To
rque
, Out
put
Red
uced
To
rque
Con
trol
To
rque
Load Output
Load Torque
Con
stan
t Po
wer
Red
uced
Po
wer
Speed
1.0
2.0
YASKAWA73
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.
<Important><Important>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
60
3 200.5
55
Difference between Inverter ExclusiveDifference between Inverter Exclusive--use Motor use Motor and Standard Motorand Standard Motor
Standard MotorStandard Motor Exclusive-use MotorExclusive-use Motor
Allo
wab
le L
oad
Torq
ue(%
)
Allo
wab
le L
oad
Torq
ue(%
)
Example:1:10 Const. Torque Motor
YASKAWA74
Relation between Frequency and Motor Speed Relation between Frequency and Motor Speed at Accel/Decelat Accel/Decel
During AccelNS > N
During Constant SpeedNS > N
During Decel(A): NS< N(B): NS > N
f・N
①+
②+
③+ ④―――
④ ⑤―――
⑤
Inverter Frequency Motor Speed
During Decel(A) Small Load Torque, Short Decel Time (NS < N) (B) Large Load Torque, Long Decel Time (NS >
N)
+① +②
+③
+④
+⑤
0N
T
+① +②
+③
+⑤
0N
T
+④
+⑤
’
’
’’
’
YASKAWA75
Load Torque
Accel TorqueDecel Torque
TL
Ta
Td
Ta
TL
Td= J・N9.55×td
Required Brake TorqueTB=(Td-TL)
Required Motor Torque(Ta+TL)
Ta= J・N9.55×ta
TL= f・V2πN
1× (N・
m)η
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 TorqueOperation Pattern and Calculation of Load Torque
① Can start?Motor starting torque must be greater than load starting torque.
④Is motor temperature proper?Temperature rise must be within the specified value.
Time
② 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.
Accel time Decel time
③Can decelerate?・Brake torque required for deceleration
must be available. ・Energy at deceleration can be consumed or
regenerated to the power supply.
2π609.55 ≒
YASKAWA76
Selection of Motor and InverterSelection of Motor and InverterCalculation of Motor and Inverter Capacities
η1
Nπ2Vf
TL •••
=
aa
t55.9NJ
T•
=
dd
t55.9NJ
T•
=
Load torque
Accel torque
Decel torque
(N・m)
① Calculate torque at accel, constant speed or decel.
②Select the motor that satisfies TL+Ta<1.5TM (TM: motorrated torque, P:Motor Cap.(W)).
NP55.9
T M = (N・m)
③Select the inverter suitable for the motor output.In details, calculate the required apparent power (kVA) according to the motor efficiency and power factor to select the inverter output (kVA).
④Select the braking resistor (braking unit) according to Td- TL .
Drum Gears IM PowerSupply
t
t
Td-TL
N2(N2 = 0)
Load
Tor
que
Spee
d N
W (kg)
f (N)V(m/min)
INV
η : Machine EfficiencyJM : Moment of Inertia
(Rotating Part)μ: Friction Coefficient
Wμ8.9f •= 22
L )Nπ2
V(W
4GD
J ==(N)
ta tdtc
Total Inertia
(kg・m2)
LM JJJ +=
(N・m)
(N・m)
N1(N1 = N)
N1 = N (min-1)
TL+TaTL
YASKAWA77
(a) Motor Mode
(b) Generator (Regeneration) Mode
IMCommercial
Power Mechanical Energy
Power FlowPower Flowi
S > 0(Motor power factor cosθ>0)
*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 =0)i
+
*1R
*2(ON)
Thermal Energy
S < 0(Motor power factor cosθ < 0)
Power Flow and Regenerative BrakingPower Flow and Regenerative Braking
YASKAWA78
Actual Measured Braking FunctionActual Measured Braking Function
RUN Signal
Inverter Output Frequency
DC Bus Bar Voltage
Braking Resistor Current
STOP RUN/STOP Reference
EDC
60Hz
0Hz
YASKAWA79
IM
(1) Power supply transformer
(2) Circuit breaker or(3) Leakage breaker
(4) Contactor
(6)Noise filter
(7) DC reactor
(8) Noise filter(11) Contactor
(13) Thermal relay
(9) Braking unit
(10) Braking resistor unit(12) Contactor for commercial
power backup
(5) AC reactor
Peripheral Devices and Their ConnectionsPeripheral Devices and Their Connections
YASKAWA80
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 protection・High 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 Contactor・Since 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 factor・Install 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 DevicesHow to Select Peripheral Devices
YASKAWA81
Chapter 5Chapter 5Inverter Functions and AdvantagesInverter Functions and Advantages
YASKAWA82
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)Advantages of Inverter Applications (1)
Cushion Start
t
f
FWD Run
REVRun
Cushion Stop
Inverter
RUN Command
FWD Run
REVRun
t
f
YASKAWA83
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)Advantages of Inverter Applications (2)
f
t
V
f
YASKAWA84
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)Advantages of Inverter Applications (3)
IM
IM
IM
YASKAWA85
Inverter Output Voltage
Inverter Output Current
Inverter Input Current
150%
150%100% Current
100% Current
100% Voltage (100% Speed)
t
Motor and Power Supply CurrentMotor and Power Supply Currentin Inverter Drivesin Inverter Drives
t
t0
YASKAWA86
Energy Saving for Energy Saving for General Industrial Machines & SystemsGeneral Industrial Machines & Systems
Min
imiz
e th
e En
ergy
Con
sum
ptio
ns
(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
YASKAWA87
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 EnergyOptimum Energy--saving Plan for Facilitysaving Plan for Facility
YASKAWA88
AN
Hd
1.0
0 0.5 1.0 ( p.u.)Air volume (Q)
R
Hi
( p.u.)
Air Volume and Wind Pressure Air Volume and Wind Pressure Characteristics of FanCharacteristics of Fan
H=1.03N2+0.56NQ-0.59Q2
R=Q2
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
N50
Q50H0
YASKAWA89
Energy saving Effect in the Fan ApplicationEnergy saving Effect in the Fan Application① 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 becomesηm = 0.9 is the motor efficiency
② In the case of inverter controlThe wind pressure in 50% air volume is Hi = 0.52 = 0.25
The power becomesηi = 0.95 is the inverter efficiency
③ 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=433×250×0.9×0.6×6120
1.16×0.5=
6120QH
=Pmf
D ηη
3.7kW=433×250×0.95×0.9×0.7×6120
0.25×0.5=
6120QH
=Piimf ηηη
YASKAWA90
Flow Rate and Head Characteristics of PumpFlow Rate and Head Characteristics of Pump
Squeeze volume
Low speed
1.5
HB
1
Hi
0.5
0 0.5 1
Flow rate (P.U)
Hea
d (P
.U)
R50
R
NR0
N50
YASKAWA91
Energy saving Effect in the Pump ApplicationEnergy saving Effect in the Pump Application① In the case of valve control
The head in 50% flow rate is HB = 1.25 - 0.25 × 0.52 = 1.188
The power becomesηm = 0.9 is the motor efficiency
② In the case of inverter controlThe head in 50% flow rate is Hi = 0.7 + 0.1 × 0.52 = 0.725
The power becomesηi = 0.95 is the inverter efficiency
③ 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=25×6×0.9×0.56×6.12
1.188×0.5=
6.12QH
=Pmp
B ηη
13.7kW=25×6×0.95×0.9×0.76×6.12
0.725×0.5=
6.12QH
=Piimp ηηη
YASKAWA92
Outline of Software Functions (1)Outline of Software Functions (1)Function Name Applications Purpose Description
Multi-step Speed Operation
Feeders, etc. Schedule operation at specified speed
By combining signals, operation is performed at frequency stored internally (up to 9-step speeds). Connection with the sequencer is easy; simplified positioning by using limit switch is also possible.
Accel/decel Changing Operation
Automatic panel feeders, etc.
Changing external signal of accel/decel time
Using an external signal can change the accel/decel rate. This function is effective when two motors are driven alternately by one inverter or when smooth accel/decel is needed only in the high-speed area.
S-curve Time Characteristics
feeders such as conveyors, carts, etc.
Prevention of start/stop shock
Smooth movement can be achieved by setting S-curve delay when accel/decel starts or finishes.
Frequency Upper/lower Limit Operation
PumpsBlowers
Limit of motor revolutions
Frequency reference upper/lower value, bias and gain can be set individually without adding any peripheral devices.
Specified Frequency Setting Prohibition (Frequency Jump Control)
General machines Prevention of machine system vibration
In order to prevent vibration of the machine system, the oscillation point is avoided automatically during constant-speed operation. This function can also be used for dead zone control.
DWELL Function Heavy-inertia loads such as centrifugal separators etc.
Smooth accel/decel of heavy-inertia loads
Prevents the motor from stalling by holding output frequency temporarily during accel/decel.
Speed Search Inertia load drives such as blowers, winders
Starting of coasting motor
Performs pull-in operation automatically into the set frequency withoutstopping the coasting motor. Motor speed detector is not needed.
Compensation for Momentary Power Loss
General machines Continuing operation at a momentary power loss
Restart the motor automatically after recovery from a momentary power loss by using the remaining control power supply to continue the motor operations.
Fault Retry Air-conditioning,etc.
Improvement of operation reliability
Resets the fault automatically after the inverter detects a fault and performs self-analysis and restarts the operation without stopping the motor. Up to 10 retry operations may be selected.
YASKAWA93
Outline of Software Functions (2)Outline of Software Functions (2)Function Name Applications Purpose Description
Carrier Frequency Setting General machines Noise reduction Sets the inverter carrier frequency to any arbitrary value to reducenoise oscillation from the motor and machine system. This function isalso effective for reducing noise.
Load Speed Display General machines Improvement of monitor function
Can display the motor speed (min-1), load machine rotating speed (min-1)or line speed (m/min).
Pulse Train Input General machines Improvement of operability
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.
Pulse Train Output General machines Improvement of monitoring performance
Frequency reference, output frequency, motor speed, output frequency after soft-start, PID feedback amount and PID input value can be output in pulses.
Stopping Method Selection
General machines Stopping method suitable for the machine characteristics
Selects deceleration to a stop, coasting to a stop or DC injection braking stop according to the braking torque or machine inertia.
3-wire Sequence General machines Simple configurationof control circuit
Operation is enabled using automatic-recovery-type pushbutton switch.
Frequency Hold Operation General machines Improvement of operability
Holds frequency increase/decrease temporarily during acceleration or deceleration.
UP/DOWN Operation General machines Improvement of operability
Speed setting is enabled remotely by ON/OFF operation.
Frequency Detection General machines Frequency detection to be used for interlock
Specifies the set value of output frequency, and outputs to the multi-function output terminal when frequency exceeds the range or becomes short.
Overtorque Detection and Undertorque Detection
・Machine tools・ Blowers, cutters,extruders
Machine protection, improvement of reliability for continuous operation
"Closed" when motor generating torque exceeds the overtorque detection level. Can be used as an interlock signal for machine protection such as cutting loss or overload detection of machine tools.
YASKAWA94
Outline of Software Functions (3)Outline of Software Functions (3)Function Name Applications Purpose Description
Stall Prevention General machines
Machine protection, improvement of reliability for continuous operation
Interrupts accel/decel when frequency reaches each set value during acceleration, deceleration or running, and continues operation when it becomes lower than the set value.
Electronic Overload Thermal Relay
General machines
Detection of motor overload
Set the motor rated current value and select the allowable load characteristics for each motor type, and the electronic overload thermal relay performs overload protection.
Torque Limit (Droop Characteristics Selection)
Pumps,blowers,extruders, etc.
・Machine protection・Improvement of reliability for continuous operation・Torque limit
Adjusts output frequency according to the load status when the motorgenerating torque reaches a certain level.Optimum for tip-less operation for pumps or blowers.
Energy-saving Control General machines
Automatic operation with maximum efficiency
Supplies sufficient voltage for the motor to reach maximum efficiency according to the load or rotating speed.
PID Control Pumps,air-conditioning,etc.
Automatic process control
Calculates the PID in the inverter and uses the result of the calculationas its own frequency reference to perform constant control of pressure,flow rate, wind amount, etc.
Droop Control ・Conveyors of distributed drives・Multi-drive motors
Proper distribution of load
Sets motor speed regulation to an arbitrary value.Making high-resistance characteristics distributes the loads of severalmotors properly.
Zero Servo Function Elevators, carts Zero-speed stop to lock the motor
Holds a motor in the locked status at zero speed whether external forceis applied in the forward or reverse direction.
YASKAWA95
■ Similar Machines・Air-conditioning fans for buildings・Fans for cooling tower・Dust collection blowers・Fans for boilers・Heat treating furnace blowers
Application for Dust Collection BlowersApplication for Dust Collection Blowers■Functions Available・Changing of commercial power supply
and inverter operations・Restart from coasting status・Energy-saving control mode at light load・Fault retry
Inverter
BlowerDust CollectorDamper
Motor MCMCMCB
MC
YASKAWA96
Application for Chemical Feeding PumpsApplication for Chemical Feeding Pumps
Inverter
Raw Water
PumpFlow Rate Detection
Adjuster
Motor
Chemical
Speed Reference
(4 to 20 mA)MCB
■ Similar Machines・Chemical feeding pumps・Cool/warm water circulation pumps ・Water supply/ discharge pumps ・Hydraulic pumps・Submersible pumps
■Functions Available・Energy-saving control mode at low speed ・PID control・4-20mA reference by instrumentation ・Minimum speed setting
YASKAWA97
Conveyor FollowConveyor Follow--up Operationup Operation
HopperFeeder
Conveyor
Geared Motor
Geared Motor
MCBMCB
PG Pulse Encoder
InverterInverter
Power SupplyMain
Speed Setting
Pulse Train Input
Power Supply
■ Similar Machines・Raw material supply conveyors ・Shuttle conveyors・Chain conveyors・Steel pipe feeding conveyors
■ Functions Available・Improvement of constant position stop accuracy ・Increasing the starting torque ・Smooth accel/decel・Changing accel/decel time・Simultaneous control of several motors by one inverter
YASKAWA98
Application for Chain ConveyorsApplication for Chain Conveyors
■Functions Available・Synchronous operation (linking operation) of 2 inverters・Proportional operation with other machines
Chain Conveyor for Painting Line
Drive Section
MCB
Power Supply
Power Supply
Power Supply
MCB
Geared Motor (Sub)
Adding
Position Controller
Phase Meter
Main Speed Setting
Soft Starter
Take-up
Drive Section
Take-up
Inverter
Synchronizer Transmitter
Synchronizer Receiver
Hunting Signal
Inverter
Geared Motor (Main)
YASKAWA99
(b) Lifting/Lowering Operations
To Incinerator
Hopper
Grab Trolley
No.1 Hopper No.2 Hopper No.3 Hopper No.4 Hopper
Pit
No.2 CraneNo.1 Crane(Stopping Position)
Pit
Garbage Carry-in
Crane Operation Room
Traveling Traverse
Garbage Carry-in
Crane Operation Room
Application for Garbage CranesApplication for Garbage Cranes
(a) Traverse/Traveling Operations
■ Similar Machines
・Cranes・Hoists・Stacker cranes・Elevators
■Functions Available・Prevention from slipping・Use of brake motors・Prevention from shock when a horizontal traveling motor starts・Changing operation of 2 horizontal traveling motors by one inverter・Energy-saving of existing winding-type motors
YASKAWA100
(Example where One Inverter Used Both for Traverse and Fork)
Application for Stacker CraneApplication for Stacker Crane(Automatic Warehouse)(Automatic Warehouse)
Upper Guide Roller
Traveling Unit
Carriage
Hoisting Unit
Fork
Suspension Chain
TrolleyMCB MC
MC
Incorporated Control Panel
MC
MC
MC
MC
For Fork
Brake
Brake
Brake
For Traveling
Elevating Motor
Inverter
Inverter
YASKAWA101
Example for Crane ExclusiveExample for Crane Exclusive--use use Software ( V/f Control )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
IOUT>IF
HT
BDT
HF
FTF
Speed Reference
(FWD) Run Command (F)
Output Frequency
Brake Release Command BR
Brake Release Check BX
Brake Operation
YASKAWA102
非常主幹
切入
MSMS
MC
FLT
MS 主幹
MS 主回路コンダクタ
F 正転指令
R 逆転指令
B ブレーキコンダクタ
BBX ブレーキ締め指令
BX ブレーキ緩み確認
はツイストペアシールド線はシールド線(注)
R
F
BRXF
R
B
BR
ブレーキ自己保持
ブレーキ締め指令
逆転
停止
正確
MB MC
9 10
B
多機能アナログ出力
MB
IM
R
S
T
MC
R(L1)
S(L2)
T(L3)
F
R
外部異常
異常リセセット
ブレーキ緩み確認
多段速指令1
多段速指令3
外部ベースブロック*
*外部ベースブロック信号は、“閉”でベースブロック解除です。
BX
MS
2kΩ
2kΩ
2kΩ
P P
P
S1 正転運転/停止
S2 逆転運転/停止
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
SCシーケンスコモン(0V)端子とは絶縁されている
E(G)シールド被膜線接続端子
多機能端子
PR
A1
A2
A3
AC
0V
C4
P4
C3
P3
P2
P1
PC多機能PHC出力48V 50mA以下
異常接点出力AC 250V 1A以下DC 30V 1A以下
FLT
BRブレーキ緩め指令(閉でブレーキ緩め)AC 250V 1A以下DC 30V 1A以下
MA
MB
MC
M1
M2
アナログモニタ 1
アナログモニタ 2
AF
AC
AM
(第3種接地)
U(T1)
V(T2)
W(T3)
B
B1
B21[ 2[
制動抵抗器ユニット(オプション)
Varispeed G7
未使用
加減速時間選択1
非常停止(a接点)
多段速指令2
Connection Diagram for CranesConnection 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 (100Ω or more)
Multifunction Terminal
External Fault
Fault Reset
Multi-speed Ref 1
Multi-speed Ref 2
Multi-speed Ref 3
Not 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
REV
R
unSt
op
FWD
R
un
Brake Applying Command
Brake 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 *
YASKAWA103
Spindle
X-axisCore Clamper
Z-axis
Motor
■ Similar Machines
・Polishers・Grinders・Small lathes・Plano miller feeders・Milling machines・Drilling machines・Presses
■Functions Available・Blade cutting loss prevention ・Wide range of constant output power・Control by digital inputs ・Vibration control
Principle Diagram of LathePrinciple Diagram of Lathe
YASKAWA104
Mechanism of NC LathesMechanism of NC LathesX-axis
Coupling Ball Screw
Z-axis Motor
CouplingBall Screw
Blade
Turret (Tool Base)
Spindle Position Sensor
Belt
Speed Changing
Timing Belt Spindle Motor
Motor for Core Clamper
Coupling
Core Clamper
WorkpieceS
pind
le
Ball Screw
YASKAWA105
Elevator ApplicationElevator Application
Sheave
Vector Control PWM Inverter
Braking Resistor, Braking Transistor (Externally Mounted)Inverter Section Converter Section
Induction Motor
Cur
rent
Det
ectio
n
AC Reactor
Cage Calling Signal
Entrance Calling Signal
Speed Feedback
Vector Control
Run Operation Signal
Load
Det
ecto
rC
age
Bal
ance
Wei
ght
Elevator Controller
Operation Control
Torque Ref. GeneratedPosition
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 Machines・Escalators・Rope ways・Cable cars・Electric railcars・Electric automobiles
■Functions Available・Improvement of cage landing frequency・Soft-start with S-curve function ・Slip prevention at start/stop・Battery operation at a power failure
YASKAWA106
Chapter 6Chapter 6Inverter Drives Precautions Inverter Drives Precautions
YASKAWA107
○ × ×
(a) Vertical (b) Horizontal (b) Side by Side
InstallationInstallation
YASKAWA108
(a) Right and Left Space (b) Top and Bottom Space
MountingMountingAmbient 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 more
50mm or more
120mm or more
120mm or moreAir
Air
YASKAWA109
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).
上部カバー (ワンタッチ )
TotallyTotally--enclosed Type Control Panel Installation enclosed Type Control Panel Installation
CoolingFin
Totally-enclosed Type Control Panel
Top CoverIn-panel Air Temperature at Top: –10 to +55℃Cooling Fin
Open chassis Type Inverter
Bottom Cover
Inverter Intake Air Temperature : –10 to +45℃
Ambient Temperature 40℃Bottom Cover
Top Cover(One-touch)
Ambient temperature:
+14 to 113ºF
(-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
YASKAWA110
(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 GroundingMultiple Inverters Grounding
YASKAWA111
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 Allowable Load Characteristics of Standard MotorsStandard Motors
RunRun
StoptR
T
%ED = ―― ×100%tR
T
Torq
ue (%
)
YASKAWA112
Chapter 7 Chapter 7 Harmonics, Noise & Surge VoltageHarmonics, Noise & Surge Voltage
YASKAWA113
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 主な
Difference between Harmonics and NoiseDifference between Harmonics and Noise
YASKAWA114
Com
mer
cial
Pow
er
+Sm
ooth
ing
Cap
acito
r
Converter Section
Motor
Bridge Rectifier
M
Harmonics Current Generated by Rectifier Circuit
Noise Generated by High-speed Switching
Harmonics and Noise SourcesHarmonics and Noise Sources
Inverter Section
YASKAWA115
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 ACFundamental Wave + Harmonics = Distorted Wave AC(Harmonics Superimposed on Fundamental Wave)(Harmonics Superimposed on Fundamental Wave)
0 °°2
YASKAWA116
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
ir
is
it
EDC (Without Capacitor)
Power Supply Line Voltage
Power Supply Current Waveform
Phase R ir
Phase Sis
Phase Tit
Generation of Harmonics CurrentGeneration of Harmonics Current
YASKAWA117
(Harmonics Current Suppression)
(a) AC Reactor
+
Inverter
Motor
AC Reactor
Com
mer
cial
Pow
er
(b) DC Reactor
+
Inverter
Motor
DC Reactor
CommercialPower
Reactor ConnectionReactor Connection
YASKAWA118
Radio
Machine
Inverter
Power Supply Transformer
Amplifier
①②③ Conductive noise : Noise that flows out through the power supply line or grounding line④ Induction (electromagnetic, electrostatic)
: Noise transmitted by electromagnetic or electrostatic integration for the signal lines provided for the inverter main circuit wiring
⑤ Radiation : Noise radiated into the air through the inverter, motor unit, main circuit wiringthat work as antenna.
Noise Transmission PathsNoise Transmission Paths
Electronic Device
Sensor
YASKAWA119
Shielding (Steel) Plate Power LineSignal Line
Inverter M
Metallic Raceway Metallic Raceway
Wiring Separation by Rack or Duct
Induction Noise Suppression and Induction Noise Suppression and Metallic RacewayMetallic Raceway
YASKAWA120
インバータ
(a) Capacitive Filter (b) Inductive Filter (Zero-phase Reactor)
Power Supply
Pow
er S
uppl
y
(c) LC Filter
Conductive Noise SuppressionConductive Noise Suppression
InverterInverter
Power Supply
Inverter
YASKAWA121
InverterInverter
0V(Common)
0V(Common)
Junction Terminal
Inverter Noise Prevention Inverter Noise Prevention (Shielded Sheath Wire)(Shielded Sheath Wire)
YASKAWA122
Motor
線路インピーダンスの急変点(モータ端子部)で進行波の反射がおきる。
Progress and Reflection of Surge VoltageProgress 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)
YASKAWA123
Without Filter →
(a) Test Circuit
[Inverter Output] [Motor Input]
(b) Result of Waveform Observation
(5μs/div, 250/div)
Expanded Diagram
With Filter →
Inverter Output Motor Input
IM
Surge Voltage Suppression by FilterSurge Voltage Suppression by Filter
Filter
Expanded Diagram
PWM Inverter
YASKAWA124
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 Motor Surge Voltage Suppression by Filter
PWM Inverter
~ ~~
~ ~~
YASKAWA125
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 3Features of 3--level control level control
YASKAWA126
(b) Example of Shaft Voltage Measurement (between Shafts) (c) Shaft Voltage Waveform
(Hz)
Commercial Power Supply Drives
Actual Measurement of Shaft VoltageActual Measurement of Shaft Voltage
Commercial Power Drives
(Direct-coupling Side)(Opposite to Direct-coupling Side)
Shaf
t Vol
tage
(m
V)
Inverter
Inverter Drives
V: Measuring DeviceR: Non-inductive Resistor (1kΩ)
(Stator)
(Rotor)
(a) Example of Shaft Voltage Measuring Circuit Inverter: PWMMotor: 3.7 kW, 200 V, 4 polesV/f characteristics: Constant torque
YASKAWA127
Chapter 8Chapter 8Maintenance and Inspection Maintenance and Inspection
YASKAWA128
Failure PatternsFailure Patterns
Initial Failure Period
Accidental Failure Period Wear-out Failure Period
t
Specified Failure Ratio
Service Lifetime
Failu
re
Rat
ioλ
(t)
0ta tb
YASKAWA129
Place Item Checking Item
Schedule
DailyPeriodical
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
① Megger check between main circuit terminal and ground terminal② No loose connections③ No traces of overheating in components④ Clean.
○○○
○
Connected conductor, Power supply
① No distortion in conductor② No breakage or deterioration (cracks, discoloration, etc.) in cables
○○
Transformer, Reactor No odor, excessive beats or noise ○
Terminal stand No damages ○
Smoothing capacitor① No liquid leakage② No projection (safety valve) or bulge③ Measure electrostatic capacity and insulation resistance.
○○
○
Relay, Contactor① No chattering at operations② Timer operation time③ No roughness on contacts
○○○
Resistor① No crack in resistor insulating material② No disconnection
○○
Control Circuit, Protective
Circuit
Operation check① Balance of output voltage between each phase by inverter single-unit operation② No failure in protective or display circuit by sequence protection test
○○
Component check
Whole① No odor or discoloration② No excessive corrosion
○
Capacitor No traces of liquid leakage or deformation ○
Cooling System Cooling fan① No excessive vibration or noise② No loose connections③ Clean the air filter.
○
○○
DisplayDisplay
① All lamps lights correctly.② Clean.
○○
Meter Indicated values are correct. ○
(From JEMA Information)
Daily Inspection and Periodical InspectionDaily Inspection and Periodical Inspection
YASKAWA130
NameStandard
Replacement PeriodMethod
Cooling fan 2 to 3 years Replace.
Smoothing capacitor 5 years Replace on investigation.
Breaker, relay -Determine what to do on investigation.
Timer -Determine after checking the operation times.
Fuse 10 years Replace.
Aluminum capacitor on PC board
5 years Replace on investigation.
Note : Operational Conditions・Ambient temperature : Annually 30℃ in average ・ Load ratio : 80% or less・ Operation ratio : 12 hours or less per day
Component Replacement Guidelines Component Replacement Guidelines
YASKAWA131
* Clamp meters available on markets have differences in characteristics between manufacturers.Especially, measured values tend to be extremely small at low frequency.
Precautions on MeasurementPrecautions on MeasurementInverter Approximate Waveform Element Meter
Input Voltage All effective values
Moving iron type voltmeter
Current All effective values
Moving iron type ammeter
Output Voltage Fundamental wave effective value
Rectifier type voltmeter (Model YEW2017, etc.)
Current All effective values
Moving iron type ammeter *
YASKAWA132
(a) Connection in Double Wattmeter Method
(b) Connection in Triple Wattmeter Method
Pow
er S
uppl
y
Motor Load Machine
Torque Meter Speed Meter
Motor Load Machine
Torque Meter Speed Meter
Inverter I/O MeasurementInverter I/O MeasurementPo
wer
Sup
ply
Inve
rter
Inve
rter
Torque meterLoardTachometer
MotorRecifier type voltmeterMoving iron type voltmeter
Electrodynamometer type wattmeterMoving iron type ammeter
YASKAWA133
Indications by Voltmeters Indications by Voltmeters with PWM Inverterwith PWM Inverter
Frequency (Hz)
Volta
ge (V
)
0.5-class Moving Iron Type Voltmeter
Digital ACpower meter
Tester(General-purpose)
Basic Wave Voltage (FFT)
0.5-class Rectifier Type Voltmeter
Inverter : 200V class 7.5kWMotor : 200Vclass 3.7kW, 4 poles
at no-load
Tester (in conformance to JIS C12-2 Class AA)
YASKAWA134
Hardware Block DiagramHardware Block Diagram
3-ph
ase
Pow
er S
uppl
y
External Sequence Signal
External Frequency Reference
Digital Operator
Motor
Frequency Meter
GateAlley
Base Drive Circuit
Inverter SectionDC IntermediateCircuit
Converter Section
ControlPower Supply
Ref
eren
ce In
put
Circ
uit S
eque
nce
Inpu
t Circ
uit
Freq
uenc
y R
efer
ence
VoltageDetection
CurrentDetection
Non-volatile Memory
Sequ
ence
Sig
nal O
utpu
t C
ircui
t
YASKAWA135
Purpose and Types of Protective FunctionsPurpose and Types of Protective FunctionsInverter Protection
Prot
ectio
nW
arni
ng
Motor Overheat Protection
Others
Operation status is not proper.
Prediction of protective function operation
Overcurrent OC
Overvoltage OV
Grounding GF
Main circuit undervoltage UV1
Cooling fin overheat OH
Braking transistor error rr
Inverter overload OL2
Motor overload OL1
Overtorque detection OL3/OL4 lit
CPU error CPF
Overtorque detection OL3/OL4 (blinking)
Undertorque detection UL3/UL4 (blinking)
Inverter overheat prediction OH2
Radiation fin overheat prediction OH
YASKAWA136
Main circuit overvoltage : OVApprox. 410 V(Approx. 820 V)
Approx. 380 V(Approx. 760 V)
Voltage at stall prevention during deceleration
Approx. 365 V(Approx. 730 V)
Voltage at braking
Approx. 190 V(Approx. 380 V)
Main circuit undervoltage : UV1 ※
DC Voltage
Voltage in the parentheses shows 400-V series.
Inverter output overcurrent : OC
Overload anti-time-interval characteristicsStall prevention level during running ※
Inverter rated output current
Current
200%
160%
100%
Stall prevention level during acceleration ※
150%
Level at Which Protective Function OperatesLevel at Which Protective Function Operates
※ Can be changed.
YASKAWA137
Chapter 9 Chapter 9 Reference Reference
YASKAWA138
(1) Difference between Inverters and Servos(1) Difference between Inverters and Servos
General-purpose Inverter Servos
What to Control
Mainly number of revolutions (torque) Mainly positions
Output 0.1 to 300 kW 0.003 to 55 kW
Motor General-purpose motors Exclusive-use motors with encoders
Positioning Accuracy
0.1 mm 0.001 mm
Maximum Torque
150% 300%
Start/Stop Frequency
Small Large
Price Less than ½ of servo -
Main Applications
● Fans, pumps, compressors● Conveyors, lifters, carts ● Elevators, electric railcars● Extruders, centrifugal separators● Paper machine● Iron & steel machine
● Semi-conductor manufacturing equipment
● Electronics parts mounting machine● Robots● Machine tools, printing,
material handling machines
YASKAWA139
(2) Principle of DC Motors(2) Principle of DC Motors
Commutator
Brush
Magnetic Field Direction
Magnetic Field Direction
F : Conductor (Rotor) Receiving Force
(View A)
: Current direction from front to back of paper face
: Current direction from back to front of paper face
YASKAWA140
(3) Speed Control of DC Motors(3) Speed Control of DC Motors
Speed Feed Back
Soft-Starter
Thyristor Converter
Speed Detection Generator (TG)
DC Motor
PhaseShifter
Field Power Supply
Current Reference
Speed Controller
Current Controller
Main Circuit Power Supply
FieldSpeed Reference
Speed Control Circuit
YASKAWA141
DC Motor
Current Detector
Thyristor ConverterTachometer-generator
(Phase Shifter)
(Main Circuit)
Motor Impedance
(Motor + Load) Inertia
Current Feed backSpeed
Feed back
LoadTorque
(4) Speed Control of DC Motors(4) Speed Control of DC Motors( Block Diagram )( Block Diagram )
YASKAWA142
(5) Configuration of IPM Motor Rotor(5) Configuration of IPM Motor Rotor
Stator Winding Stator
Permanent Magnet
Stator Winding
Stator
Secondary Conductor
Rotor
IPM Motor Induction Motor
YASKAWA143
(6) Comparison of IPM & Induction Motors(6) Comparison of IPM & Induction Motors
Comparison of Weights Comparison of Volumes
Output [kW] Output [kW]
Wei
ght [
%]
Volu
me
[%]
Induction Motor (100%)
IPM Motor
Induction Motor (100%)
IPM Motor
YASKAWA144
(7) Efficiency of IPM & Induction Motors(7) Efficiency of IPM & Induction Motors
0
50
100
誘導電動機 IPMモータ
100%35%DOWN
65%
Elec
tric
al L
oss
[%]
Motor Loss
Efficiency improved by 5.5% (Example of 37 kW)
IPM MotorInduction Motor70
75
80
85
90
95
100
誘導電動機 IPMモータ
81.2%86.7%
5.5%UP
Effic
ienc
y [%
]Comparison of Efficiencies
IPM MotorInduction Motor
YASKAWA145
(8) Rotor Cross Section of Super Econo(8) Rotor Cross Section of Super Econo--MotorMotor
Rotor Core
Slot
Magnet
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(9) Comparison of IPM (VS(9) Comparison of IPM (VS--686SS5 Drive) and ISM (Super Econo686SS5 Drive) and ISM (Super Econo--motor)motor)Type Motor Configuration Configuration Characteristics Loss Remarks
Induction Motor
Synchronous Motor
Interior Permanent Magnet (IPM) Motor
VS-686SS5
Induction Synchronous Motor (ISM) Super Econo-
motor
Stator Winding
Rotor
Stator
Rotor Conductor
Stator Winding
Rotor
Stator
Braking Winding
Field Winding
Stator Winding
Rotor
Stator
(Example of 6P)
Stator Winding
Rotor
Stator
Permanent Magnet (Example of 4P)
Rotor Conductor
Pow
er C
omm
erci
al
(Speed Feedback)
VS-686SS5 Inverter
Field Power Supply
〕 〔- r/minS)f(1P
120=Nspeed Rated :
Speed
Torq
ue
Load Torque
〕 〔 r/minfP
120=Ns : sSpeedSynchronou
P : No. of poles f : Frequency
〕 〔 r/minfP
120=NsN =
Speed
Pullout Torque
Pull-in Torque
Start Torque by Braking Winding
Speed
〕 〔 r/minfnP
120=NsnNn =
〕 〔 r/minfP
120=NsN =
Pullout Torque
Pull-in Torque
Starting Torque by Rotor Conductor squirrel(Cage)
Speed
Primary (stator) copper lossPrimary iron lossSecondary copper lossSecondary iron lossFloating load lossMechanical loss (Friction loss, windage loss)
Primary copper lossPrimary iron lossSecondary copper loss (Field winding loss)Floating load lossMechanical loss (Friction loss, windage loss)
Primary copper lossPrimary iron lossFloating load lossMechanical loss
Inverter loss
Primary copper lossPrimary iron lossFloating load lossMechanical loss
By applying 3-phase AC to the stator winding, a rotatingmagnetic field (rotating at synchronous speed) is made.Secondary current flows because the rotor rotates slower than synchronous speed (slip). Torque is generated by the rotating magnetic field and secondary current.Therefore, speed regulates by load torque. Torque generated by rotor braking winding is used for starting (acceleration). After completion of acceleration, field current flows to perform synchronous pull-in.
・Since rotating speed regulation is not occurred
Frequency is accelerated after synchronous pull-in by inverter. ・There is no loss at the secondary side. ・Speed control is performed by inverter frequency.
Acceleration is made by torque generated by rotor conductor at starting (acceleration). When speed is increased and closed to synchronous speed, the permanent magnet performs synchronous pull-in.・There is no secondary loss at synchronous speed. ・Field power supply is not needed.・No speed regulation.
Com
mer
cial
Pow
erPo
wer
Com
mer
cial
Pow
er C
omm
erci
al
Torq
ueTo
rque
Torq
ue
Permanent Magnet
(min-1)
(min-1)
(min-1)
(min-1)
(min-1)