How to Size, Wire, and Program a VFD to Convert Single Phase Power Into 3 Phase Power

hey guys my name's Thea bald headman and you're watching Southern Ingenuity in today's video I'm going to cover how to use a variable frequency drive or vfd to convert single phase power in the three-phase power like I did for my milling machine I'm going to go over some things that you'll want to consider before starting your project it can help you avoid a mistake that I made and I'm going to show you how I wired everything up on my machine and program the drive now this particular Drive is one of the Hy series drives from Hong Yang more specifically the hy02d223b and so far since I've had it running I've had no problems whatsoever however getting it to run by trying to decipher the manual that it came with that was another story I had to watch a lot of YouTube videos and confer with some of the electrical professionals where I work get everything figured out and run it so I wanted to make this video to share what I've learned and help others out there who are trying to do the same thing with this particular brand of drive and we'll get started on that in just a minute so don't go away [Music] before making this video I put considerable time and effort into researching the information to try to make sure it was as accurate as I could possibly get it however it may not be applicable to every single situation or scenario it works just fine with my machine and the variables that were associated with my setup and please keep in mind that working with electricity can be extremely dangerous so if you don't know what you're doing please seek the services of a qualified electrical professional now for those who may not know a variable frequency drive is an electronic device used to control the speed of an electric motor and it does that by varying or controlling the frequency of the electricity that it sends to the motor and a lot of them can also convert single phase power into three-phase power don't use my drive for controlling the speed of the motor to control the speed of the spindle this machine has a mechanical means for doing that I use mine strictly as a phase converter but I will briefly touch on speed control a little bit later on in the video now there's a few things you're going to want to consider before starting your project the environment to which your drive is going to be exposed the compatibility of your motor with this particular setup what size Drive you're going to need and you need to make sure you correctly size your supply wire and circuit breaker you don't want a lot of excessive dust moisture or humidity causing your drive to malfunction so if you have an environment like that you're probably going to want to put inside some sort of enclosure or housing now my shop there's definitely a lot of dust a lot of grind and dust in particular a lot of small fine metallic particles so I didn't want any of that getting inside my drive so I didn't actually go out and buy an enclosure I took an old storage cabinet that I had here in the shop modified it and made it into a housing to protect my drive if you'd like to see how I did that there's a link to that video in the description now for this setup to work your motor is going to have to be able to run on 240 volts or less the drive is not going to act as a Transformer to increase the voltage for your motor so you're going to be limited to no more than the 240 volt that you get from your breaker panel now I actually had to change the motor that came on my machine when I bought it because it ran on 575 volts now a lot of Motors can be configured to run on multiple voltages if that's the case the acceptable voltages should be indicated on the motor's nameplate there should also be a diagram showing how to configure the wiring for each particular voltage next you need to make sure that you size your drive correctly now remember we're using it to convert single phase power in the three-phase power now your motor is going to require a certain amount of current to run regardless and then a normal three-phase system is supplied by three lines of power or three phases so that basically means that your drive is going to have to work harder to supply a three-phase motor from a single phase power source you're going to have to oversize your drive so to figure out what size Drive you're going to need you have to know how much current is going to be required look at the name plate on the side of your motor and find the amp rating now it may be listed as fla which stands for full load amps it may be listed as FL amps or it may just be simply listed as amps or the letter A now keep in mind that if your motor has multiple operating frequencies or voltages you've got to be sure to use the values that are going to correspond with your setup once you find out the amp rating for your motor multiply it times 1.73 and this will give you the output current that your drive is going to have to be able to deliver we'll use my motor for an example my motor list values for 200 and 400 volts at 50 and 60 hertz or Cycles now it's set up to run on 208 volts at 60 hertz so I take 6.5 amps and multiply it times 1.73 I get a value of 11.245 amps so that means that the proper size Drive should be rated to deliver at least this much current or more I didn't know about this calculation when I purchased my drive and as you can see from this sizing chart my drive is slightly underrated from what I actually needed I should have purchased a drive that was the next size up now so far I haven't had any problems or issues with it but if I do start to run into that I'm just going to have to buy a bigger Drive and now that we know how much current is going to be required we need to make sure that we correctly size our supply wire and our circuit breaker never use a supply wire that is underrated for the breaker that's supplying it doing so can cause a fire now here's a chart showing several different wire gauges in their rated amp capacity we need to make sure that the supply wire has an amp rating that is higher than the output of our Drive so again using my setup as an example the full load current coming from my breaker panel should be 11.245 amps and we can see in the chart that 14 gauge wire is rated for 15 amps so that means I can safely use a 14 gauge Supply wire connected to a 15 amp breaker and that's exactly what I did well now that we've gone over the basic things to consider for the project I'm going to show you how I wired everything up for my machine the power wire coming from the breaker panel to the vfd cabinet is 14 3 solid copper inside the breaker panel the black and red wires are connected to a 15 amp double pole circuit breaker the white wire is connected to the neutral bar and the bare wire to the Earth ground at the vfd cabinet the black and red wires are connected to a double pole toggle switch and then to the drive at terminals r and s I also use this toggle switch to control the 120 volt receptacle in the bottom of the cabinet that's why I needed the neutral wire between the vfd cabinet and the breaker panel my digital readout display and x-axis power feed are plugged into this receptacle this allows me to control the power to everything on my milling machine with just one switch the wire going from the drive to the motor is also 14 3 solid copper at the drive the black red and white wires are connected to terminals U V and W the bare wire is connected to the Earth ground at the motor the colored wires are connected to the leads and the bare wire to the motor casing to start stop or reverse the motor I still use the old mechanical switch on the front of the machine but instead of directly controlling power to the motor like it used to it now connects to the control circuit terminals on the drive the green wire is connected to the DCM Port which is the common terminal for the digital and control signals the white and black wires are connected to the forward and reverse control circuit terminals activating the switch completes a circuit between either the forward or reverse control terminal and this is a low voltage low current circuit so the wires don't have to be that big foreign everything together and wired up you're going to have to program your vfd for your setup I've included in the description the parameters that you're going to need to set and directions for doing the programming and this should be compatible across any of the hanyang Hy series drives that are also listed there in the description so to program the drive you're going to use these five buttons on the front of the panel the program button takes you into the programming mode the up and down arrows allow you to navigate through the parameters and change the value of each setting the set button selects the parameter for editing and locks in the new values when you're done the shift button changes the input position from right to left across the display there's over 180 function parameters on this drive but there's only 14 that you're going to need to program for this setup the first one we're going to do is pd013 parameter reset and this restores the drive to the factory default settings and even if you bought it new it's a good idea to go ahead and do it it's not going to hurt anything so we press the program button and then we use the up arrows to get to pd013 press the set button to select this parameter for editing then use the up arrows to get to the value of 8. press set this restores drive to the factory settings the next parameter is pd001 source of run commands this tells the drive how you're going to start or stop the motor a value of 0 means that you'll be using the buttons on the front of the drive to start or stop the motor a value of one here means that you'll be using some sort of external switch something kind of like I've got set up here on my machine and the value of 2 means that you'll be using the rs-485 computer communication port and this is if you were using some sort of CNC program or something like that to control the drive net is pd002 source of operating frequency and this tells the drive how you're going to control the speed of the motor zero means that you'll be using the buttons on the front of the panel to control the speed one means that you'll control the speed with a potentiometer whether it be the onboard potentiometer or an external one and two means the speed will be controlled via the rs-485 port if you have this parameter set at one to use a potentiometer there's a jumper beside the control circuit terminals that'll need to be set to the correct position if you're using the onboard potentiometer the jumper will need to be set on the VR side connecting positions two and three if you're using an external potentiometer the jumper needs to be on the vi side connecting positions one and two and if you need to know how to wire up an external potentiometer I found a YouTube video that gives a pretty good visualization of that and I have it linked in the description as well the next three parameters are pd-003004 and zero zero five and they deal with operating frequencies you have to set pd005 first the maximum operating frequency this is where you set the upper limit on how fast you want your motor to run and I've got mine set at 60 hertz pd-004 is the base frequency and that's just the rated frequency as listed on the motor's nameplate pd003 is the main frequency this is the frequency at which the motor will start if pd002 is set on zero parameter pd008 is the max voltage and this is just the rated voltage as listed on the motor's nameplate I've got mine set at 208 volts pd014 and zero one five are your acceleration and deceleration times and you may have to experiment with this with longer or shorter times based on your setup but mine works just fine with both of them set at 2.0 seconds the next parameter is pd023 reverse rotation select now this is a case to where if you don't want your motor to be able to be ran in Reverse you'd want to set it to zero but if you want to be able to run it in either direction and you set it to one well now we're going to jump all the way forward to parameter PD 141 and that's simply the rated voltage for your motor as is listed on the main plate then the next one would be pd142 and that's the full load amp rating as listed on the nameplate pd-143 is your motor pole number this is where you have to list the number of poles that your motor has if you don't know how many poles your motor has and you'd like to know how to calculate it use the formula listed here at the bottom of the screen but if you're not interested in how to do the calculation just look at the chart on the right hand side of the screen well finally the last parameter we need to program is PD 144 the rated motor revolutions and that's pretty simple and straightforward it's just a rated RPMs as listed on the motor's nameplate well I hope this video was helpful for you like I said it may not be applicable for every situation or scenario but if you're wanting to use one of these types of drives for a phase converter this should get you well on your way to getting your machine running like I did I hope you enjoyed it if you did please give it a thumbs up and share it with your friends and until next time I'm Theobald Heaven thanks for watching Southern ingenuity [Music]

Channel: Southern Ingenuity

Views: 66,590

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Id: eT1eau5y7lk

Length: 14min 12sec (852 seconds)

Published: Sun Jan 29 2023