Reactors and VFD's

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jinglis

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Wth the installation of VFD's it is not uncommon to see line and/or load reactors installed in conjunction with the drives. It is also not uncommon not to see either reactor installed. My questions relate to what are these reactors protecting.
It is my understanding that the line reactor is to protect the drive but some drives these days have some of this protection built into them. I have also been told that the distance from the drive to the motor is another factor which determines the need for reactors.
Load reactors, what do they protect?
I understand that the manufacturer of the drive will determine this need for you but I would like some other opinions as well.
 
Reactors

Reactors

Line Reactors also help in the midigation of harmonics on the electrical system, square d on their site has some good information.
 
The load reactors are to help eliminate the high voltage spikes that can damage the motor winding insulation. Most manufacturers recommend them if the motor is more than 50-75 wire feet from the drive. That being said I have hooked up a 100 or more drives with the minimum motor lead length of over a 100' feet and have not used load side reactors and we have not experienced any problems with the motors. We also do not use line side reactors for drives of less than 100hp.
Don
 
If the load reactors help to protect the motors further from the drives would these load reactors also help to reduce the chance of failure with older motors being retrofited to drives from across the line starting?
 
Long lead issues are discussed below:
"The use of IGBT's, while offering significant cost and performance benefits, has led to motor failures. The problem that has been occurring is a breakdown in the motor insulation, which causes the motor to go to ground or across windings. This is caused by the high voltage spikes that occur when the transistor in a VFD switches on. When the transistor switches on, there is a high voltage spike (as high as 1600 volts) for a very small period of time. The switching speed of IGBTs is very high, typically 8khz or even 16khz. This results in a much smoother output sine wave and significantly lower audible noise of the motor. This increase in switching speed has also increased the rate of voltage change over time, or the dv/dt. These high voltage peaks and short voltage rise times can cause premature breakdown of the motor insulation if it is not selected for these conditions. NEMA (National Electrical Manufacturers Association) has issued a new standard for VFD motors. This standard is NEMA MG1-1993, Part 31.40.4.2. This standard states that the motor should be designed for a peak voltage of 1600 volts and a minimal rise time of 0.1 microseconds for motors rated less than 600 volts. This standard should always be specified when using motors with VFD' which utilize IGBT's.
Another factor that is causing motor insulation to break down is motor lead length (the length of wire between the VFD and the motor). This is a problem because if the impedance of the motor is much larger than the impedance of the wiring a reflected wave can be established. When this reflected wave is added to the transmitted wave from the VFD, the voltage spike can exceed what the motor can withstand and motor insulation breakdown will occur. Because the impedance of motors is larger in smaller motors, this problem is most likely to occur in smaller motors. All VFD manufacturers should have published data on the allowable motor lead lengths for their VFD's."

http://www.gorhamschaffler.com/vfds.htm
 
Reactors are also found designed in with VFDs in jurisdictions with stringent utility requirements. Every CE and Japanese installation I've seen, uses a reactor to keep possible VFD spikes, harmonics, etc., out of the surrounding network.
 
First off, if the motor is 230V, the issues that load reactors protect against are pretty much non-starters because the spikes and reflected waves they are referring to being higher than the motor insulation voltage rating are not going to be high enough to worry about for 230V motor designs. On most new 230V motors, they are dual voltage, so the insulation is rated for the higher voltage to start off with. That's why a lot of people never see any problems; they are primarily working on commercial and light industrial projects where they use 208V or 230V supplies. If you are putting a VFD on an old 220 or 240V single voltage motor, or any really old motor for that matter, a reactor is an absolute must, but even that may not help in the long run. Older motor insulation is already partially breaking down, the VFD will likely hasten it.

Line reactors protect the incoming line from crap coming out of the VFD. We can debate all day as to the worth, but even if the VFD has an internal DC choke, a reactor will serve to add mitigation of harmonics back into your line.

Load reactors serve 2 functions. They do protect 380 and 460V motors from spikes and reflected waves as mentioned above, but on all motors, they also serve to limit the rise time of any load fault so that the VFD's electronic protection systems can act to shut down the transistors and prevent catastrophic failure of the VFD. When you get a load fault, i.e. a motor winding going to ground or a damaged/failed cable, all of the available power in the VFD tries to flow to that fault in an instant. This creates a high dI/dt (delta(change) in I (current) over delta time) in the transistors feeding the affected phase(s) which can cause other adjacent transistors to fire at the wrong time, causing catastrophic failures some or even all of them. In modern drives, individual transistors are no longer replaceable, so in effect the drive is toast. By adding a reactor, you add an inductive time constant to the rise of the current flowing to the fault in each phase circuit. This can allow the VFD's microprocessor that few extra milliseconds it needs to detect the fault and block the bases of all of the transistors, which prevents them from misfiring in the first place. One save like that is worth 3-5 times the cost of the reactor, so in effect they are always "cheap insurance".

Also, if you have multiple motors off of one VFD, a load reactor is a must, not only for that reason but also to absorb any transients from harmonics and capacitive coupling effects in the multiple motor leads and motors.
 
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