2025

COMPETENCY-BASED LEARNING MATERIAL

Sector ELECTRICAL AND ELECTRONICS

Module Title VARIABLE FREQUENCY DRIVES

MFI POLYTECHNIC INSTITUTE INC.

JEROME ROMEO D. MORCOZO, RME, LPT

Lecturer
 INFORMATION SHEET No. 1.1

Variable Frequency Drives

Learning Objectives:

After reading this information sheet you should be able to;

1. Identify and describe the core components and their functions

within a Variable Frequency Drive (VFD) system.
2. Explain the fundamental principles of AC motor speed control
using a VFD, specifically detailing the V/Hz ratio and the concept of
Pulse Width Modulation (PWM).
3. Differentiate between Scalar (V/Hz) control and Vector (Field-
Oriented) control methods, and identify appropriate applications for
each.
4. Analyze the significant benefits of VFD implementation,
particularly concerning energy savings (using Affinity Laws) and
reduced mechanical stress on equipment.
5. Recognize common challenges and considerations associated
with VFD installation and operation, such as harmonic distortion,
long motor lead effects, and the importance of motor compatibility.

What is a VFD?

A Variable Frequency Drive (VFD), also

known as an Adjustable Speed Drive (ASD),
Adjustable Frequency Drive (AFD), or
Inverter Drive, is a type of motor controller
that drives an electric motor by varying the
frequency and voltage of its power1 supply.
The purpose of VFDs is to control the speed
and torque of AC electric motors, thereby
optimizing process control and saving
energy.

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 This Photo by Unknown Author is licensed under CC BY-SA

Why Use VFDs?

Energy Savings

Significant reductions in energy consumption, especially in variable torque

applications (pumps, fans) due to the "cube law."

Improved Process Control

Precise control over motor speed, acceleration, and deceleration, leading to

better product quality and system performance.

Reduced Mechanical Stress

Smooth starts and stops (soft starting) minimize wear and tear on mechanical
components (gears, belts, couplings), extending equipment life.

Lower Maintenance Costs

Less stress on machinery means fewer breakdowns and reduced need for
repairs.

Increased Power Factor

VFDs typically maintain a high-power factor, reducing utility penalties.

Noise Reduction

Can reduce system noise in applications like HVAC.

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Basic Principles of AC Motor Speed Control

Synchronous Speed Formula: Ns=(120×f)/P

Ns: Synchronous speed (RPM)

f: Frequency of the AC supply (Hz)

P: Number of poles in the motor

V/Hz Ratio is to maintain constant motor flux and rated torque, the voltage
applied to the motor must be varied proportionally with the frequency.

VFD Components and Architecture

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Block Diagram: Input (AC Power) -> Rectifier -> DC Link (Filter) -> Inverter ->
Output (Variable AC to Motor)

Main Components:
Rectifier (Converter): Converts incoming fixed AC voltage to DC voltage. (e.g.,
diode bridge rectifier)
DC Link (Intermediate Circuit): Filters and smooths the DC voltage using
capacitors and inductors (DC choke).
Inverter: Converts the DC voltage back into variable frequency and voltage AC
using power electronic switches (e.g., IGBTs - Insulated Gate Bipolar
Transistors).
Control Unit (Microprocessor): The "brain" of the VFD, managing the switching
of the inverter, monitoring parameters, and handling communication.

How a VFD Works?

Step 1: Rectification: AC incoming power (e.g., 480V, 60Hz) is converted to DC.

Step 2: DC Bus Filtering: The rectified DC voltage is smoothed to reduce ripple.

Step 3: Inversion (PWM): The DC voltage is "chopped" by the IGBTs to create a

pseudo-sinusoidal AC waveform.

Pulse Width Modulation (PWM): The width of the pulses is varied to

control the effective output voltage and frequency.

Result: The motor receives a variable frequency and voltage supply, allowing its
speed to be precisely controlled.

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Types of VFDs

Voltage Source Inverter (VSI): Most common type. The DC link is a voltage
source.

Current Source Inverter (CSI): DC link is a current source. Used for high-power
applications, often regenerative.

Pulse Width Modulation (PWM) VFDs: The dominant type, offering excellent
control and efficiency.

Other classifications: Single-phase input, three-phase input, low voltage,

medium voltage.

Control Methods: Scalar vs. Vector Control

Scalar Control (V/Hz Control):

• Simple, maintains a constant V/Hz ratio.
• Suitable for general-purpose applications like fans and pumps where precise
torque control isn't critical.
• Less responsive to sudden load changes.
Vector Control (Field-Oriented Control - FOC):
• More complex, independently controls the motor's flux and torque-producing
current components.
• Provides precise control over motor speed and torque, even at low speeds.
• Ideal for high-performance applications like cranes, extruders, and machine
tools.
• Can be open-loop or closed-loop (with encoder

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Key Parameters and Settings

Acceleration/Deceleration Ramps: Control how quickly the motor speeds

up and slows down.

Minimum/Maximum Frequency: Sets the operational speed limits.

Motor Nameplate Data: Input motor parameters (HP, FLA, rated voltage,
frequency) for optimal tuning.

Current Limit: Protects the motor and VFD from overcurrent conditions.

PID Control: For process control (e.g., maintaining constant pressure, flow,
or temperature).

Fault Handling: Settings for overvoltage, undervoltage, overcurrent, motor

overload, etc.

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Advantages and Disadvantages

Advantages (Recap & Expansion): Disadvantages:

○ Energy efficiency ○ Initial Cost: Higher upfront
○ Improved process control investment compared to traditional
○ Reduced mechanical stress motor starters.
○ High power factor ○ Harmonics: Can introduce
○ Soft starting harmonic distortion into the
○ Overload protection electrical system, potentially
affecting other equipment.
(Mitigation: Line reactors, filters,
active front end VFDs).
○ Motor Lead Length: Long
motor leads can cause voltage
reflections and standing waves,
leading to premature motor
insulation failure. (Mitigation:
Output filters, VFD-rated motors).
○ Motor Heating: Motors may
run hotter at low speeds due to
reduced cooling fan effectiveness
and harmonic content. (Mitigation:
Inverter-duty motors with
improved insulation, external
cooling).
○ EMI/RFI: Can generate
electromagnetic interference,
potentially affecting sensitive
electronic equipment. (Mitigation:
Proper grounding, shielded
cables).

Applications of VFDs

HVAC Systems: Fans (air handlers, exhaust fans), pumps (chilled water,
condenser water).

Pumps: Centrifugal pumps (water, wastewater, chemical), positive

displacement pumps.

Fans & Blowers: Industrial ventilation, process air, draft fans.

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Conveyors: Smooth starting, controlled acceleration/deceleration, variable
speed for product flow.

Compressors: Optimizing air or gas compression.

Machine Tools: Lathes, mills, drills requiring precise speed control.

Extruders: Plastic and rubber manufacturing.

Cranes and Hoists: Smooth lifting and lowering, precise positioning.

Textile Machinery: Consistent tension and speed control.

Food & Beverage Industry: Mixers, blenders, conveyors, bottling lines.

Considerations for VFD Installation and Maintenance

Proper Sizing: Matching VFD to motor HP, FLA, and application

requirements.

Environmental Factors: Temperature, humidity, dust, vibrations.

Cabling: Using shielded motor cables, proper grounding.

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Harmonic Mitigation: Considering line reactors, harmonic filters, or active
front-end drives if harmonic distortion is a concern.

Motor Compatibility: Using "inverter-duty" or "VFD-rated" motors for

continuous low-speed operation or long lead lengths.

Maintenance: Regular cleaning, fan checks, capacitor checks, firmware

updates.

Watch video: [Link]

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 Worksheet No. 1.1

Variable Frequency Drives

INSTRUCTION: Draw/sketch a Forward-Reverse Wye-Delta Configuration

Control, Power Circuit.

Criteria:
Cleanliness –5
Clarity -5
Diagram - 10
Labeling -5
Total: 25 points

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