Square One is the Industry Leader in VFD Motor Controls Replacement and Repair
Variable Frequency Drives, or VFD, are ideal solutions for motor speed controllers. They can be found in every industry, from manufacturing to HVAC.
A VFD is suitable for both single-phase and three-phase AC motor and DC motor speed controls.
Click here to read our blog: "INTRO TO VFD MOTOR CONTROLS"
Square One Electric offers a wide range of AC and DC drives. We serve your needs from small, compact units to replace contactors and starters to more complex units with sophisticated engineering capabilities.
You can shop online for major VFD brands like ABB, Toshiba, Leeson, and Teco at Square One. Plus, you get to enjoy these perks:
- VFD drives with single-phase and three-phase input options
- Various enclosures, from NEMA 1 for cleanrooms to NEMA 4x for outdoors
- Nationwide warehouses stocked with brand new drives ready to ship
- Manufacturer’s warranty with each unit ordered
- Expert support and discount prices
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Need pricing on other brands like Weg, Yaskawa, Eaton Cutler, Hammer, and Century? If you can’t find your brand of choice on our website, please CONTACT US HERE. We’ll send over a quote ASAP!
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Intro to VFDs
Variable frequency drive is a motor speed controller which allows for precise control of a motor’s speed and direction of rotation by varying motor voltage based on user input. They are also known as phase converters because they can convert single-phase AC power into three-phase power and vice versa.
VFD is computer-based and designed for use with motors of all sizes. These speed controllers can be applied to just about any kind of motor, from extremely small (such as those found in microwaves) to very large (those used in industrial manufacturing).
Benefits of VFDs
Motor speed controllers are powerful tools with the ability to increase the efficiency of motors through the following:
Save Energy and Increase Performance
They’re called variable frequency drives because they vary the frequency of the electricity utilized to run your motor, which directly controls its speed. By doing this, VFDs allow you to use only as much power as necessary to get the job done and nothing more. As a result, you reduce your energy consumption by up to 50%!
Easy to Install
Another great thing about VFDs is that installing new or existing machinery is simple. At the same time, it maximizes the efficiency of the equipment. They can also be connected to old motors when you need to convert them into variable speed drives.
This not only helps cut down on energy costs but also reduces carbon emissions from your company’s operations.
Optimum Speed
If you have an electric motor and wish it to run at its perfect speed, a VFD is what you need. It provides increased torque when starting your motor and is able to convert single-phase current into three-phase current as well as utilize induction currents.
VFD Applications
HVAC, refrigeration, conveyor systems, machine tools, and factory automation all use variable frequency drives. They allow for more precise control of motor speed and torque. Their technology uses DC voltage to run AC motors and doesn’t require an inverter.
The most common configuration is a VFD paired with a permanent magnet synchronous motor (PMSM).
Phase converters are typically used on three-phase motors, which have internal copper windings that make their own connection with the power source. The device interfaces between an electric motor and a load, allowing for speed control of induction motors. This type of setup allows three-phase systems to be run at different speeds depending on load.
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How Do VFDs Work?
The short of it is that the electric motor is the muscle while the drive (control) is the brain.
A variable frequency drive helps control the speed of an electric motor, usually based on the power needs of the attached piece of equipment. VFDs are made up of several key components that work together to help machinery operate at peak performance.
The basic principle behind VFDs is fairly simple: When you apply electricity to an electric motor, it starts rotating—that’s just how motors work. However, motors have more torque than horsepower and different performance characteristics at slower speeds than at high speeds. This is where these phase converters come in handy.
Unlike most transformers, they don’t simply change voltage levels. Instead, they adjust voltages in response to load demand. At the same time, they calibrate currents accordingly to prevent dramatic dropoff in efficiency even at slower speeds (it works a lot like your car engine).
This creates smooth rotational motion with minimal losses.
Types of VFD Drives
There are two main types of VFDs: AC motor speed control and DC motor speed control. AC and DC refer to how an electric motor is powered. Although they both perform similar functions, they’re used with different types of motors and equipment.
AC Variable Frequency Drive
An AC VFD uses a standard wall outlet and converts line power into alternating current (AC) in order to run your machinery.
For example, if you have a small compressor or pump with mechanical controls that can be converted to electrical controls with a VFD controller, it would be best suited for an AC motor conversion.
DC Variable Frequency Drive
A DC VFD runs directly off a battery or other power source by converting direct current (DC) into low-voltage AC electricity for use by motors.
As an illustration, if your compressor already has electrical control boards installed with either DC brushless motors or solenoid valves, then it would work best with a DC VFD controller.
Which VFD Type is Better?
You should make sure your motor can handle any additional power demands that a variable frequency drive places on it. If your system requires more energy than what is supplied by the VFD, damage could occur. Hence, when choosing which one to install, it is important to factor that in as well.
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Why is VFD Maintenance Important?
Maintaining your VFD can help it last longer and serve you better over time. In order to increase its life span and effectiveness, it's important to clean its interior regularly and service any damaged parts promptly. Performing preventative maintenance tasks also keep it running smoothly between services.
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5 Tips in Choosing the Right VFD
Replacing a variable frequency drive is not challenging—most people purchase the same brand and model that they already have in place. However, there are times when that unit was not sized properly, or perhaps you are implementing a control into an application that previously had none.
You need to consider a few factors prior to purchase in such cases. Below are the questions to answer to arrive at an informed decision.
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Can your motor handle a VFD?
Not all electric motors are created equally—most NEMA and EPAct motors can run on VFDs, especially if they are inverter capable. Pre-EPAct motors, however, cannot. If you’re not sure about your motor’s compatibility with a VFD, call Square One for a consultation. We’d be happy to answer all your motor and VFD-related queries.
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Are AMPs more important than horsepower?
Yes. Size the drive so that the motor’s maximum current does not exceed it. You’ll also need to ensure that the motor’s AMPs are not higher than the inverter’s AMPs. Sometimes, you may need to choose an inverter higher in HP than the motor to meet this requirement.
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Does your application run on constant torque or variable torque?
In constant torque loads, such as conveyors, torque is independent of speed. On the other hand, in variable torque loads like pumps and fans, the torque varies as a function of speed. Know your application before sizing the drive.
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What are the acceleration and deceleration requirements?
Applications that practically require full torque from near zero speed will need a sensorless vector control. As for deceleration, you must consider brake resistors for energy/heat dissipation and control in constant torque applications. And for very low-speed applications, you may need an encoder.
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Do you need or want to improve energy usage?
If so, then shop for a regenerative drive. It stores unused energy in internal capacitors to apply to the next operation, reducing energy use.
Once you have established these parameters, it will be easier to find the right VFD. Other considerations are price, availability, and ease of use unless you already have a brand preference.
Square One supplies VFD Motor Controls for residential, commercial, and industrial units.
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