Download Selecting E7/P7/F7 Drives for Single-Phase Input

Welcome
Yaskawa Training Café
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 e-mailed to
[email protected] or can be entered into the survey sent to
you at the end of the class.
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase to Three-Phase Conversion
Yaskawa Training Café

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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase to Three-Phase Conversion
Yaskawa Training Café

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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase to Three-Phase Conversion
Yaskawa Training Café

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%)!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase to Three-Phase Conversion
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase to Three-Phase Conversion
Yaskawa Training Café

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
•
•
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Motors
Yaskawa Training Café

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)!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Applications
Yaskawa Training Café

Common Single-Phase Applications:






Submersible Well Pumps
Irrigation Pumps
Fountain Systems
Pump Jacks (oil/natural gas well pumps)
Machining Centers/Lathes
Vacuums/Blowers
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Products
Yaskawa Training Café

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 2010

• 230Vac, 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

V1000
• 230Vac, 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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Products
Yaskawa Training Café

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 2010
• 230Vac, 1/8 HP to 2 HP, 0.8 Arms to 8 Arms

V1000
• 230Vac, 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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Products
Yaskawa Training Café

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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Drive Derating
Yaskawa Training Café

Why is Drive derating required?

Three-phase VFD designed to accommodate 300/360Hz DC
bus ripple (3-phase full wave rectification at 50/60Hz)
DCL
DC link voltage – 360 Hz Ripple
DC
capacitor
Phase voltage
3-phase
input
Rectifer input current
Approximately 40% I-THD
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Drive Derating
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Drive Derating
Yaskawa Training Café

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
DC link voltage – 360 Hz Ripple
Phase voltage
Rectifer input current
Approximately 40% I-THD
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Drive Derating
Yaskawa Training Café

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
» Higher harmonic content
» Using only 2/3rds of the rectifier
• Input terminals
– Increased input current
» Higher harmonic content
» Using only 2 of 3 input terminals
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Drive Derating
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café

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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café

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: 7.5HP @ 20Arms
Case 2) SF is required: 8.6HP @ 23Arms
Note: 8.6HP = 7.5HP x 23A/20A
Select Drive according to load requirement!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café
Example:
Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms
Application Requirements:
No SF required: 7.5HP @ 20Arms
SF is required: 8.6HP @ 23Arms
Note: 8.6HP = 7.5HP x 23A/20A
Model 2011: No SF Required
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café
Example:
Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms
Application Requirements:
Case 1) No SF required: 7.5HP @ 20Arms
Case 2) SF is required: 8.6HP @ 23Arms
Note: 8.6HP = 7.5HP x 23A/20A
Model 2011: No SF Required
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café
Example:
Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms
Application Requirements:
Case 1) No SF required: 7.5HP @ 20Arms
Case 2) SF is required: 8.6HP @ 23Arms
Note: 8.6HP = 7.5HP x 23A/20A
Model 2015: SF is required
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café
Example:
Pump Rating: 7.5HP, 230V, 20Arms cont., SF amperage 23Arms
Application Requirements:
Case 1) No SF required: 7.5HP @ 20Arms
Case 2) SF is required: 8.6HP @ 23Arms
Note: 8.6HP = 7.5HP x 23A/20A
Model 2015: SF is required
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Selecting the Proper Drive
Yaskawa Training Café
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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
DC Link Choke Benefits
Yaskawa Training Café

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)
Therefore, DC
Link Chokes
must always be
DC Link Chokes are listed in Table 1
used!
• Link Chokes selected to optimize performance for
single-phase
• reduces input current
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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
DC Link Choke Benefits
Yaskawa Training Café
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Input Voltage and Frequency
Yaskawa Training Café

Input Supply Specifications:

Standard VFD specifications with three-phase input:
• 208-240/480Vac, +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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Input Voltage and Frequency
Yaskawa Training Café

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!
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Reduced Voltage Motors
Yaskawa Training Café
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Input Voltage and Frequency
Yaskawa Training Café

Input Supply Specifications:

Standard VFD specifications with three-phase input:
• 208-240/480Vac, +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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Current
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Overload Capacity
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
E7/P7/F7 Drives with Single-Phase Input
Yaskawa Training Café

Document AN.AFD.15 also includes wiring and branch circuit
recommendations

Table 2 contains:
• Wire gauge recommendations
• Fuse recommendations
• Circuit Breaker recommendations
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
DC Link Choke Details
Yaskawa Training Café

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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Single-Phase Input Specification Summary
Yaskawa Training Café

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
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Input Phase Loss (PF) Faults
Yaskawa Training Café

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)
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
Input Phase Loss (PF) Faults
Yaskawa Training Café

Final Comments:

Consult factory when using other Yaskawa products with
single-phase
• Other products have not been officially evaluated for singlephase use
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services
That’s A Wrap!
Yaskawa Training Café

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.
Yaskawa Training Café – Through the Combined Efforts of Drives Engineering and Technical Training Services