Welcome. Yaskawa Training Café Through the Combined Efforts of Drives Engineering and Technical Training Services

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1 Welcome Welcome to Yaskawa Electric America s Training Café Express Today s Topic is Selecting E7/P7/F7 Drives for Single-Phase Input Applications To make this Café enjoyable for all, please follow these tips on web class etiquette. Please do not put us on hold. Others will hear the hold music. Do not use a speaker phone. Background noise can be heard. Don t be shy, we welcome comments and questions. (Press *6 to mute and unmute your phone) Questions not answered during the Café can be ed to training@yaskawa.com or can be entered into the survey sent to you at the end of the class.

2 Single-Phase to Three-Phase Conversion Why the need for single-phase to three-phase power conversion? Areas not originally designated for industrial manufacturing with only single-phase power subject to increased demand to support small manufacturing operations Small start-up companies Custom manufacturing (specialty) operations Residential/ Commercial expansion needing increased water demands Remote pumps (submersible/booster) Increased pump HP (moving water further distances) Increased activity in energy sector Oil/Natural gas wells De-watering pumps Need three-phase power to support increased demand!

3 Single-Phase to Three-Phase Conversion Methods of converting single-phase to threephase power: Phase Converters Rotary Phase Converters (RPC) Static Phase Converters (SPC) Motor-Generator (M-G) Sets Variable Frequency Drives (VFDs) Single-Phase input models Three-Phase input models (with appropriate derating)

4 Single-Phase to Three-Phase Conversion Methods of converting single-phase to three-phase power: Phase Converters Rotary Phase Converters (RPC) Use idler motor to generate third phase Static Phase Converters (SPC) Use inductors/capacitors to generate third phase Unbalanced phase impedance Difficult to balance phase voltages especially with varying load Requires de-rating applied motor (by as much as 50%)!

5 Single-Phase to Three-Phase Conversion Methods of converting single-phase to three-phase power: Motor-Generator (M-G) Sets Uses multiple sets of windings on single rotor to generate three individual new phases Good voltage balance suitable for three-phase motors Easily convert voltage level and frequency from incoming supply Commutators require high maintenance Expensive and bulky

6 Single-Phase to Three-Phase Conversion Methods of converting single-phase to three-phase power: Variable Frequency Drives (VFDs) Single-phase input models Three-phase input models (with appropriate derate) Provide balanced three-phase voltage Can easily vary the voltage and frequency No tuning of capacitors to varying loads Soft start feature, PI control, extensive flexibility/programmability Provides superior protective features (overload, under-voltage, etc.) Reliable/maintenance-free operation

7 Single-Phase Motors Single-Phase Motors: Readily available up to 5HP Available up to and above 15HP but much less common Expensive Long lead times Frequent maintenance Trend is to use three-phase motors (even below 5HP)!

8 Single-Phase Applications Common Single-Phase Applications: Submersible Well Pumps Irrigation Pumps Fountain Systems Pump Jacks (oil/natural gas well pumps) Machining Centers/Lathes Vacuums/Blowers

9 Single-Phase Input Products Yaskawa Single-Phase Product Offering: VS-Mini (GPD205) 115Vac, 1/8 HP to 1 HP, 0.8 Arms to 5 Arms J7 (GPD305) Available through March Vac, 1/8 HP to 2 HP, 0.8 Arms to 8 Arms V7 (GPD315) Obsolete (subject to inventory on-hand) 230Vac, 1/8 HP to 5 HP, 0.8 Arms to 17.5 Arms V Vac, 1/8 HP to 5 HP, 0.8 Arms to 17.5 Arms J1000 (use caution output phase loss cannot be disabled) 230Vac, 1/8 HP to 3 HP, 0.8 Arms to 9.6 Arms (ND)

10 Single-Phase Input Products Yaskawa Single-Phase Product Offering: VS-Mini (GPD205) 115Vac, 1/8 HP to 1 HP, 0.8 Arms to 5 Arms J7 (GPD305) Available through March Vac, 1/8 HP to 2 HP, 0.8 Arms to 8 Arms V Vac, 1/8 HP to 5 HP, 0.8 Arms to 17.5 Arms J1000 (use caution output phase loss cannot be disabled) 230Vac, 1/8 HP to 3 HP, 0.8 Arms to 9.6 Arms (ND) Single-Phase models up to 5 HP only! All models run 230V three-phase motors!

11 Single-Phase Input Products What about single-phase applications at 480V or applications larger than 5 HP? Use E7/P7/F7 and three-phase motor with appropriate derating as outlined in application note AN.AFD.15 Applying E7/P7/F7 Drives To Single-Phase Input Applications What does document AN.AFD.15 contain? Let s take a look!

12 Single-Phase Input Power Application Specifications Important Considerations When Using a Three-Phase Drive with Single-Phase Input Drive Specifications (w/ derating) Drive HP Output Current Input Current DC Link Choke Selection Input Voltage Specifications Different than three-phase Output Voltage Limitation Effect on motor power Overload Rating Limited to low speeds Wiring & Branch Circuit Recommendations DC Link Choke Dimensions

13 Single-Phase Input Drive Derating Why is Drive derating required? Three-phase VFD designed to accommodate 300/360Hz DC bus ripple (3-phase full wave rectification at 50/60Hz)

14 Single-Phase Input Drive Derating Why is Drive derating required? Single-phase 60Hz input results in 120Hz DC bus ripple! DC bus capacitors need to provide more power DC bus level will decrease a larger amount than with threephase input during this time

15 Single-Phase Input Drive Derating Why is Drive derating required? Duration between bus peaks is longer in single-phase case Dc bus circuit will have to supply power for longer period More stress on input and DC bus components t3 Time t1 > t3 Tt1

16 Single-Phase Input Drive Derating Why is Drive derating required? Drive components subject to greater stress with single-phase input DC bus circuit (capacitors, DC link choke, bus bars) Increased ripple voltage and current Capacitors need to deliver more of the power to the load Input diode rectifier Increased input current Input terminals» Higher harmonic content» Using only 2/3rds of the rectifier Increased input current» Higher harmonic content» Using only 2 of 3 input terminals

17 Single-Phase Input Drive Derating Therefore, derating of Drive HP and output amperage will be required so that the Drive components operate within their ratings! Table 1 contains single-phase ratings for 240V and 480V models

18 Selecting the Proper Drive Select Drive that meets or exceeds both motor HP and motor FLA requirements When making selection be sure to take into account operation using the service factor of the motor if required by the application Drive must be selected to accommodate motor S.F. amps and motor S.F. horsepower if applicable!

19 Selecting the Proper Drive Select Drive that meets or exceeds both motor HP and motor FLA requirements. Include Service Factor if required. Example: Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms Application Requirements: Case 1) No SF required: 20Arms Case 2) SF is required: 23Arms Note: 8.6HP = 7.5HP x 23A/20A Select Drive according to load requirement!

20 Selecting the Proper Drive Example: Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms Application Requirements: No SF required: 20Arms SF is required: 23Arms Note: 8.6HP = 7.5HP x 23A/20A Model 2011: No SF Required

21 Selecting the Proper Drive Example: Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms Application Requirements: Case 1) No SF required: 20Arms Case 2) SF is required: 23Arms Note: 8.6HP = 7.5HP x 23A/20A Model 2011: No SF Required

22 Selecting the Proper Drive Example: Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms Application Requirements: Case 1) No SF required: 20Arms Case 2) SF is required: 23Arms Note: 8.6HP = 7.5HP x 23A/20A Mo del 2015: SF is required

23 Selecting the Proper Drive Example: Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms Application Requirements: Case 1) No SF required: 20Arms Case 2) SF is required: 23Arms Note: 8.6HP = 7.5HP x 23A/20A Mo del 2015: SF is required

24 Selecting the Proper Drive Select Drive that meets or exceeds both motor HP and motor FLA requirements Drive must be selected to accommodate motor S.F. amps and motor S.F. horsepower if applicable!

25 DC Link Choke Benefits Using a DC Link Choke allows us to pull more power from the VFD Reduces DC bus ripple Lowers input harmonics (from over 100% to 90% ITHD) Improves input power factor (to approx. 0.7 PF) reduces input current Therefore, DC Link Chokes DC Link Chokes are listed in Table 1 must always be Link Chokes selected to optimize performance for used! single-phase use Note: Models 18kW and smaller use a different link choke than what is normally used with three-phase input Select DC link choke according to Table 1 Caution - DC link chokes are open style (no enclosure)

26 DC Link Choke Benefits

27 Input Voltage and Frequency Input Supply Specifications: Standard VFD specifications with three-phase input: /480Vac, +10/-15% 50/60Hz, +/-5% VFD Specifications with single-phase input: 240/480Vac, +10/-5% 60Hz, +/-5% Thus, strict input voltage tolerance of +10 to -5% and 60Hz applies with single-phase use! Note: Wire input using terminals L1(R) and L2(S) to accommodate units that incorporate AC fans and soft-charge circuits (larger models)

28 Input Voltage and Frequency Why the stricter input voltage tolerance? Average bus voltage is lower with single-phase input than with equivalent three-phase input Therefore, output motor voltage will be reduced Motor power will be reduced with lower motor voltage Output voltage of 207V with input voltage of 228V (240V 5%) Output voltage of 414V with input voltage of 456V (480V 5%) Consider using a 208V or 400V motor if rated power must be developed at base speed to eliminate the effect of voltage deprivation! 208V and 400V motor selections are included in Table 1 Note: Additional impedance at the input of the Drive will cause additional voltage drop!

29 Reduced Voltage Motors

30 Input Voltage and Frequency Input Supply Specifications: Standard VFD specifications with three-phase input: /480Vac, +10/-15% 50/60Hz, +/-5% VFD Specifications with single-phase input: 240/480Vac, +10/-5% 60Hz, +/-5% Thus, strict input voltage of 240V(480Vac) +10 to -5% at 60Hz applies with single-phase use! Note: Wire input using terminals L1(R) and L2(S) to accommodate units that incorporate AC fans and soft-charge circuits

31 Single-Phase Input Current Drive input current will be approximately twice the motor current Single-phase to three-phase conversion accounts for majority of input current increase (factor 3) Overall input Power Factor of 0.7 can be expected Input current is included in Table 1

32 Overload Capacity Overload capacity with single-phase input is limited to 120% of Drive single-phase current rating Increased DC bus ripple means the DC bus level will drop to lower level As output power increases (high torque and high speed) average bus voltage decreases Motor voltage further decreases as load increases Therefore, expect 120% overload maximum for starting purposes only! Consult factory with cyclic applications (repeating overload) or when overload in excess of 120% is required

33 E7/P7/F7 Drives with Single-Phase Input Document AN.AFD.15 also includes wiring and branch circuit recommendations Table 2 contains: Wire gauge recommendations Fuse recommendations Circuit Breaker recommendations

34 DC Link Choke Details Table 3 contains DC Link Choke dimensions DC Link Chokes are open type (no enclosure) DC Link Chokes in Table 3 are different from chokes used for threephase input Wire DC Link Chokes to terminals +1 and +2 (remove factory supplied shorting bar)

35 Single-Phase Input Specification Summary Summary: Input Specifications: Voltage: 240/480VAC +10% / -5%, Frequency: 60Hz +/-5% Drive Ratings must meet or exceed both motor HP and FLA Be sure to include Service Factor operation if required DC Link Chokes are required on models 18kW and smaller Consult factory if Link Chokes cannot be used Maximum Overload of 120% for starting purposes only Expect motor voltage of approx. 207Vac (414Vac) with input voltage of 228Vac (456Vac) Consider a reduced voltage motor (208/400V) if full HP is required with low input voltage Specifications not mentioned in this document remain the same as standard three-phase product

36 Input Phase Loss (PF) Faults Final Comments: When using the Drive with single-phase input the Drive s input phase loss protection must remain enabled If Input Phase Loss (PF) faults are encountered, be sure to check the load current and horsepower along with incoming line voltage levels to insure all are within Drive specification Input Phase Loss faults generally indicate the Drive is undersized for the connected load Disabling input phase loss protection will result in permanent Drive damage and void the warranty Reducing Drive output frequency will reduce HP requirement Limiting the maximum frequency may allow an undersized drive to operate the load (Power = Torque x Speed)

37 Input Phase Loss (PF) Faults Final Comments: Consult factory when using other Yaskawa products with single-phase Other products have not been officially evaluated for singlephase use

38 That s A Wrap! Thank you for attending the Yaskawa Electric America Training Café. Please see the Café Schedule in the partner login section of Yaskawa.com for future classes. Training Café classes are held approximately once per month. Please complete the survey sent to you at the end of the class to help us improve the quality and relevance of the Training Café.