INTRODUCTION OF VFD AND

ITS PROGRAMMING ,FAULTS,

TROUBLESHOOTING
Arial – 48t AND
MAINTENENCE
VARIABLE FREQUENCY DRIVE
I. INTRODUCTION TO VFD
I. What is VFD
II. BLOCK DIAGRAM OF VFD
III. DIFFRENT VFD MANUFACTURER IN MARKET
IV. BENEFITS OF USING VFD
II. CONNECTIONS
 BASIC component of VFD Panel
 Types of Circuit
 Power Board of VFD
 Function of DBR
 Control Board of VFD
 Type of Signal
 Sink & Source
III. HMI DESCRIPTION
IV. PARAMETERS IN VFD
 Structure of Parameter table in manual
 General parameter for hoisting
V. FAULT AND TROUBLESHOOTING
VI. MAINTENANCE
I. INTRODUCTION TO VFD
What is V F D ?

Variable Frequency Drive

• A variable frequency drive (VFD) is a type of motor controller that drives an electric motor by varying
the frequency and voltage supplied to the motor itself.
• Or we can say a variable frequency drive is an electronic device used to control an AC induction motor
or synchronous motor. A VFD controls the torque, speed, and direction of the motor, smoothly starting
and accelerating the motor to the desired speed at a controlled acceleration rate.
I. INTRODUCTION TO VFD
• BLOCK DIAGRAM OF VFD
I. INTRODUCTION TO VFD
• DIFFRENT VFD MANUFACTURER IN MARKET

Available from Available from 0.12KW Available from Available upto

0.18KW to 800KW to 2700KW 0.75KW to 355KW 2250hp
Model: Altivar 12 Model: Sinamics V20 Model: ACS550 Model: FP605
Altivar 310 Sinamic G120C ACS580 GA800
Altivar 320 Sinamic G120 ACS880 GA1000
Altivar 340 Sinamics G130 ACS1000 U1000
Altivar 600/610 Sinamics G150 G7
Altivar 900
I. INTRODUCTION TO VFD
• BENEFITS OF USING VFD

• Energy Savings
• Reduces Peak Energy Demand
• Fully Adjustable Speed
• Controlled starting, stopping, and acceleration
• Dynamic Torque Control
• Provides smooth motion for applications
• Versatility
• Low motor starting currents
• Reduction of thermal and mechanical stresses on motors and belts during starts
• Simple installation
 LED Light

II. CONNECTIONS Relay

• BASIC COMPONENT IN VFD PANEL MCCB

Control Transformer

MCB

VFD

Contactor

Socket Board Main Contactor

Terminal Block

Wireway
Cable Entry Plate
 TYPES OF CIRCUIT

II. CONNECTIONS

POWER CIRCUIT CONTROL CIRCUIT

• Circuit shows • Circuit shows
wire connection connection
between motor, terminals for
circuit breaker actuating the relay
(MCB, MCCB, switches,
MPCB) and contactor’s coils,
contactors. NO/NC contacts.
• Size of wire • Voltage levels that
depends upon used in circuit are
the load which is 110VAC, 110VDC,
connected to it. 24VDC
• Voltage levels
that are used in
circuit are
440VAC,
220VAC.
 • POWER CIRCUIT
II. CONNECTIONS
B Y R DISPLAY WITH KEYPAD

MCCB CONTROL TERMINAL BOARD

MAIN CONTACTOR

MOTOR

DBR
II. CONNECTIONS
• POWER TERMINAL BOARD OF VFD
II. CONNECTIONS
• FUNCTION OF DBR

• DBR stands for Dynamic Brake Resistor

• Connected to DC bus in VFD
• When motor deaccelerates, supply disconnect to stator winding.
However, rotor rotates due to inertia until brake applies, therefore
the delay between disconnect supply and rotor blockage, motor acts
as generator and feed voltage back to vfd.
• The reverse voltage would damage the vfd if not dissipated.
• DBR is connected across the terminals (DC bus), the reverse
feeding voltage is dissipated in resistance.
II. CONNECTIONS
• CONTROL TERMINAL BOARD OF VFD

+10VDC source
10 mA max.
Programmable Relay
5 A (resistive) or 2A (inductive)
Analog Output
for 250 Vac or 30 Vdc
0 to +10 Vdc
7 ms ± 0.5 ms
Analog Inputs
-10 to +10 Vdc, 2 ms ±
0.5 ms
Terminal for Modbus
external PWR
+24VDC (power removal
source function). Short
circuited with +24V

0V Programmable +24VDC source

Digital Inputs Max current 200
mA
II. CONNECTIONS
• TYPES OF SIGNAL IN VFD

10V
• Analog signal varies with time
• In VFD, analog signal are 4-20mA in
current form and -10VDC to +10VDC in
voltage form.
• Potentiometer is connected to input
variable signal. -10V

24V
• Digital signal does not vary with time
• Either its high or low.
• In VFD, digital signal are +24VDC or 0V
• Pilot devices are connected to send
digital signal.
0V
II. CONNECTIONS
• SINK AND SOURCE

• Sink means 0V is fed as digital input.

• If circuit needs to send 0V as signal to
digital input terminals then sink mode to SINK
be activated
• It is also called as NPN mode

• Source means 24V is fed as digital input

• If circuit need to send 24V as signal to
digital input terminal of VFD then source SOURCE
mode to be activated.
• It is also called as PNP mode.
 HMI DESCRIPTION IN ATV303
1. Value LED (a) (b) 8. MODE button Switches
2. Charge LED between the
III. HMI DESCRIPTION 12
3. Unit LED (c) control/programming
4. ESC button: Exits a menu or parameter, or aborts modes. A 3 s press on
the displayed value to return to the previous MODE button switches
1 value in the memory. In LOCAL configuration, a 2 between the
11
10 2 s press on ESC button switches between the REMOTE/LOCAL
9 3 control/programming modes. Note: In LOCAL configurations.
configuration, the three Leds 9, 10, 11 are 9. CONFIGURATION mode
4 blinking simultaneously in programming mode LED (b)
8 and are working as a Led chaser in control mode. 10. MONITORING mode LED
5. STOP/RESET button: stops the motor (could be 11. REFERENCE mode LED
hidden by door if function disabled). Important: 12. Four "7-segment" displays
5 See instructions for "RUN/STOP" cover removal.
6. RUN button: Starts running in LOCAL
6 configuration and in REMOTE configuration if the
function is configured (could be hidden by door if
function disabled).
7. Jog Dial - Acts as a potentiometer in local mode
in LOCAL configuration and in REMOTE
configuration if the function is configured - For
7
navigation when turned clockwise or
counterclockwise - And selection / validation
when pushed. This action is represented by the
symbol on the right.
• Local Mode: Dial is enabled for speed reference. Mode is not applicable on all
models of VFD.
• Remote Mode: Input is connected at either digital input or analog input to send
speed reference.
 HMI DESCRIPTION ATV71
1. 2 Modbus status LEDs

III. HMI DESCRIPTION 2. Four 7-segment displays

3. Returns to the previous menu or parameter, or increases the
1 displayed value
4. Goes to the next menu or parameter, or decreases the
2 7
displayed value
3 6 5. Enters a menu or parameter, or saves the displayed parameter
or value
4 5 6. Exits a menu or parameter, or aborts the displayed value to
return to the previous value in the memory
7. 2 CANopen status LEDs
IV. PARAMETERS IN VFD
• STRUCTURE OF PARAMETER TABLES IN MANUAL
IV. PARAMETERS IN VFD
• GENERAL PARAMETER FOR HOISTING
Main Menu Parameter Code Value Remark
ACCESS LEVEL Access Level LAC Epr (expert)  
Micro Configuration CFG HST ( Hoisting ) For Hoisting application only
SIMPLY START ( SIN)
2/3 Wire control TCC 2C L1- Forward, L2- Reverse
Acceleration ACC 3 sec Adjust as required
Deacceleration DEC 2 sec Adjust as required
Low Speed LSP 5-15 HZ Adjust as required
SET ( SETTING )
High Speed HSP 50.00 HZ As per motor nameplate
Motor them current ITH Motor Current Rated Motor Current
Current Limitation CLI Load Current of motor Current At Full Load Trial
SUP (MONITORING) Output frequency RFR   Real time output frequency
Standard Motor Frequency BFR 50 HZ From Motor Name Plate
Rated Motor Power NPR …... From Motor Name Plate
Rated Motor Voltage UNS …... From Motor Name Plate
Rated Motor Current NCR …... From Motor Name Plate
DRC ( MOTOR Rated Motor Frequency FRS …... From Motor Name Plate
CONTROL ) Rated Motor Speed NSP …... From Motor Name Plate
Max Frequency TFR 55  
Auto tuning TUN yes After Tuning Display Will Show
Done
Motor control type CTT UUC/CVC/FVC For closed loop
IV. PARAMETERS IN VFD
• GENERAL PARAMETER FOR HOISTING
Main Menu Parameter Code Value Remark
CTL ( Command ) Reference 1 . Channel FR1 AI1  
Profile CHCF SEP (Separate), SIN  
Reference 2 switching RFC FR2  
Reference 2 . Channel FR2 UPDT(+, - Speed ) To increase and decrease speed from digital
inputs
I-O- (Input/ output) Relay 1 assignment RUN Drive Run Relay's Contact changes once drive in run
mode
Speed (+,-) UPD    
Speed (+) Assignment USP L14 O/P Frequency will increase on feeding digital
FUN ( APPLICATION input on L14
Function ) Speed (-) Assignment DSP L15 O/P Frequency will decrease on feeding digital
input on L14
DC injection assignment DC1 No DC injection braking is disabled
Brake Assignment BLC R2  
Movement Type BST UER  
Brake Contact BCI L13 Feedback to vide for disengagement brake.
Brake Impulse BIP YES  
BLC ( Brake logic
Brake Release Time BRT 0.5 SEC  
control)
Brake Release Frequency BIR Auto  
Brake Engage Frequency BEN Auto  
Brake Engage Time BET 0.5 SEC ,, 0.8 SEC  
Time to restart TTR 0.5 SEC  
IV. PARAMETERS IN VFD
• GENERAL PARAMETER FOR HOISTING

Main Menu Parameter Code Value Remark

FLT ( Fault Fault Reset RST NO Fault would not reset.
Management ) Fault Reset RSF    
External Fault ETF NO External fault is disabled.
External Fault ETF  
Assignment  
V. FAULT & TROUBLESHOOTING
Fault Name Probable cause Remedies

bOF DBR overload The braking resistor is under excessive Check the size of the resistor and wait for it to cool down
stress
brF Brake feedback The brake feedback contact does not Check the feedback circuit and the brake logic control
match the brake logic control • The brake circuit • Check the mechanical state of the brake • Check
does not stop the motor quickly enough the brake linings
(detected by measuring the speed on the
"Pulse input" input).
OCF Overcurrent Parameters in the [SETTINGS] (SEt-) • Check the parameters
and [1.4 MOTOR CONTROL] (drC-) • Check the size of the motor/drive/load
menus are not correct • Check the state of the mechanism.
Inertia or load too high • Mechanical
locking
PrF Power removal Fault with the drive’s "Power removal" Inspect/repair the drive
safety function
ObF Overbraking Braking too sudden or driving load • Increase the deceleration time
• Install a braking resistor if necessary
OPF1 1 output phase loss Loss of one phase at drive output • Check the connections from the drive to the motor
V. FAULT & TROUBLESHOOTING

Fault Name Probable cause Remedies

OPF2 3 motor phase loss • Motor not connected or motor power too • Check the connections from the drive to the motor
low
• Output contactor open
• Instantaneous instability in the motor
current
OSF Mains overvoltage • Line voltage too high • Check the line voltage
• Disturbed mains supply
USF Under voltage • Line supply too low • Check the voltage
• Transient voltage dip
• This protection only operates with the
drive running in motor mode
tJF IGBT overheat] • Drive overheated • Check the size of the load/motor/drive.
• Reduce the switching frequency.
• Wait for the motor to cool before restarting
PHF Input phase loss • Failure of one phase • Use a 3-phase line supply.
VI. MAINTENANCE
• VFDs must be regularly maintained.  Maintenance requirements are similar to other electronic components and power supplies.
They need cool, dry environments with minimal dust and interruptions, and connections must remain tight for uniform
performance.
• The three key principles of maintaining VFDs – keeping them clean, dry, and securely connected 

Check and keep VFDs clean

• VFDs are designed for indoor applications and have side vents to allow better airflow. These vents provide some degree of
protection against solid foreign objects but allow dust to collect inside the unit and in the vents themselves. This can prevent heat
sinks and circulation fans from cooling the unit.
• This is why requires regular cleaning so that material does not build up enough to obstruct airflow or compromise performance.

Check and Keep VFDs dry.

• Like most electronic devices, VFDs are not safe in the presence of moisture. The risk of corrosion is a big issue with electronic
components. Protecting VFD storage spaces with moisture free-and ambient humidity levels low enough to reduce the risk of
corrosion. Sealed enclosures are safer against accidental drips and splashes. But should still be monitored regularly to keep water
exposure to a minimum
• VFDs are even more exposed to water because they have open side vents. Open vents and an unsealed cover mean moisture
can easily enter the unit and cause corrosion.
VI. MAINTENANCE

Check for tight VFD connections

• Connections in VFDs require to work properly. While the drives themselves may not move very often, the connections can
loosen over time due to mechanical vibration, heat cycling, or even accidental movement over long periods.

• The concerned team should inspect the connections as per schedule for loose or over-tightened connections. Because over-
tightening and retightening connection bolts can cause malfunctions similar to loose connections.
VI. MAINTENANCE Document No. : QF/P&M/ELE.- 23
Checklist & Preventive maintenance of VFD, Electronic Revision No. : 0
TPL
• CHECKLIST & PREVANTIVE
Panels & PLC panels. Revision Date : 19.09.2020

MAINTENANCE OF VFD,
Project Code: Date of Inspection & preventive Maintenance :

Location : Next due date for Preventive Maintenance.:

ELECTRONIC PANELS & PLC Panel Identification : Frequency of Insp. Fortnightly

PANELS
Sr No Description Yes No N/A Remarks

1 Physical Condition        

  A. Check & rectify whether dusts and debris from fan filters ,PCB cards and heatsinks        
removed? Dedust through Vacuum pump.

  B. Check and rectify for correct enclosure provided for VFD?        

C. Check / rectify any obstacle or block around the air flow and VFD fan? Check and rectify the
  over heating due to exhaust fan of the panel / VFD.        

  D. Check & rectify VFD body & output on display for checking the condition.        

  E. Check & rectify the silica gel packets kept inside the VFD Panel.        

  F.Check & close the additional botton holes for cable entry.        

  G. Check & rectify condition of weather proof compound sealant at panel and motor end.        

  H. Check and rectify & connect the SPD to incoming Switch Gear.        

If Panel is switch off / running for some days during premonsoon/monsoon pl check and rectify for moisture control , Dust control & Heating by following points :

a.Check & recfify and block all the panel holes and incoming & out
2 going cables to be sealed at panel end and motor / pump terminal end        
by weather proof compound before moonsoon starts.

b. Check & rectify the VFD/ Electronic Board/PLC input power terminals
         
before switch on by multimeter.

c.Make arrangement for heating the panel by 100 W bulbs 12 hours

  before start up / switch on of the Control panel.        

d.Check , rectify & replace the Silica Gel packets as per colour of silica
         
Gel.

  e.Check and rectify the exhaust system of the panel .        

f. Check & rectify the motors windings and the gland terminal to be sealed by weather
  proof cement before start up of the panel.        

  g.Check & rectify the connected motors cables up to VFD / Electronic Board/ PLC .        

Electrician Name : Signature:  

Electrical Engineer Name . Signature:  

P&M I/C Name :     Signature:  

THANK YOU !!