What To Check When Commissioning

Variable Speed Drives

Posted A PR 22 2015 by E DVA RD in MOT OR , TE STI NG AN D CO MMI SSI ON IN G , VAR I A BL E SP E ED D RI VE S
with 11 C OMM EN TS

What To Check When Commissioning Variable Speed Drives (on photo: Control
techniques drives at Michelin; by emersonindustrial.com)

The purpose of commissioning VSDs

The main purpose of commissioning VSDs is to ensure that:
1. The AC converter and motor have been correctly installed and meet the wiring and
safety standards such as IEC 60364 or Australian standard AS 3000.
2. The power and motor cables are correctly sized, installed and terminated.

3. All power cable shields have been correctly earthed at both ends, to the
PE terminal at the converter, at the motor and at the DB or MCC.
4. The control cables have been installed according to the control system design.
5. All control cable shields have been correctly earthed at one end only, preferably at
the process control system end (cleaner earth).
6. There are no faults on the cables prior to energization for the first time.

Selecting the correct application settings

Once all the basic checks have been completed and the commissioning test sheet
completed, the VSD is ready for energization.
It is recommended that, when energizing the converter for the first time, that the motor
cables should be disconnected until all the basic parameter settings have been
installed into the converter.
This will avoid problems with starting the motor in the wrong direction , starting with an
acceleration time which is too fast, etc. There is no danger in running a PWM converter
with the output side completely open circuit.

Danfoss variable
frequency drive setting/operation
Once all the initial settings and on-load checks have been completed, the motor cable
can be insulation tested and connected for the final on-load commissioning tests.

Selecting the correct parameter settings

A variable speed drive will only perform correctly if the basic parameters have been
correctly set to suit the particular application.
The following are the basic parameters that must be checked before the VSD is
connected to a mechanical load:

The correct base voltage must be selected for the supply voltage and to suit the
electric motor connected to the output. In Australia, this standard voltage is usually
415 V, 3-phase. This will ensure that the correct output volts/Hz ratio is presented
to the motor.

The correct base frequency must be selected for the supply voltage and to suit
the electric motor connected to the output. In Australia, this standard frequency is
usually 50 Hz. This will ensure that the correct output volts/Hz ratio is presented to
the motor.

The connections to the cooling fan should be checked to ensure that the correct
tap on the transformer has been selected.

Thereafter, the remaining parameters settings can be selected as follows:

1. Maximum speed
Maximum speed, usually set to 50 Hz, but often set to a higher speed to suit the
application. Ensure that the maximum speed does not take the drive beyond the
loadability limit.

2. Minimum speed
Minimum speed, usually 0 Hz for a pump or fan drive, but often set at a higher speed
to suit constant torque applications. Ensure that the minimum speed does not take the
drive below the loadability limit.

3. Rated current of the motor

Rated current of the motor, this depends on the size of the motor relative to the rating of
the converter. The current rating of the converter should always be equal to or higher
than the motor rating. For adequate protection of the motor, the correct current rating
should be chosen.

4. Current limit
Current limit, determines the starting torque of the motor. If a high breakaway torque is
expected, a setting of up to 150% will provide the highest starting torque.

5. Acceleration time
Acceleration time, determines the ramp-up time from zero to maximum speed. This
should be chosen in relation to the inertia of the mechanical load and the type of
application. For example, in a pumping application , the acceleration time should be slow
enough to prevent water hammer in the pipes.

6. Deceleration time
Deceleration time, determines the ramp-down time from maximum speed to zero. This
setting is only applicable if the ramp to stop option is selected. Other alternatives are
usually coast to stop and DC braking.
On high inertia loads, this should not be set too short. If the deceleration time is below
the natural rundown time of the load, the DC voltage will rise to a high level and could
result in unexpected tripping on over-voltage.
The deceleration time can only be shorter than the natural rundown time if a dynamic
braking resistor has been fitted.

7. Starting torque boost

Starting torque boost, can be selected if the load exhibits a high breakaway torque. This
feature should be used cautiously to prevent over-fluxing of the motor at low speeds.
Too high a setting can result in motor over-heating.
Only sufficient torque boost should be selected to ensure that the VSD exceeds the
breakaway torque of the load during starting.

Final words //
There are also many other settings commonly required on modern digital VSDs.
The above are the most important and must be checked before starting. The remaining
parameters usually have a default setting which will probably be adequate for most
applications. However, these should be checked and adjusted for optimum operation.

Reference // Practical Variable Speed Drives and Power Electronics Malcolm Barnes
(Get hardcopy from Amazon)