Skip to learning content
All component labs

Motor drives · intermediate

Variable Frequency Drive

An electronic motor controller that turns fixed mains power into adjustable-frequency power so an AC motor can run at different speeds.

Why it exists

Control speed and torque smoothly, reduce starting current, and expose motor diagnostics to the PLC.

Compact industrial variable frequency drive with keypad, display and power terminals

Quick answer

What is a variable frequency drive?

A variable frequency drive controls an AC motor by converting incoming AC to DC, smoothing it on a DC bus, and switching that DC through an inverter to create a variable-frequency, variable-voltage three-phase output. The PLC can send run, direction and speed commands while reading ready, running, current and fault status.

Inside the control system

How the PLC relates to it

A simple installation uses digital inputs for run and direction plus an analog or pulse reference for speed. A networked drive can exchange commands, reference values, status words, actual speed and fault codes over an industrial protocol. Whichever interface is used, define where control comes from, scale engineering units explicitly, separate normal stop from safety functions, and decide what the sequence should do if communication or feedback is lost. The motor leads belong on U, V and W; switching contactors on the drive output while it is running can damage equipment.

Cause and effect

How it works, step by step

  1. 01

    A rectifier converts incoming AC to DC.

  2. 02

    Capacitors smooth and store energy on the DC bus.

  3. 03

    Fast power transistors rebuild a variable-frequency three-phase waveform.

  4. 04

    Motor speed follows commanded frequency while protection monitors current and voltage.

01 / Open the case

Watch the mechanism do the work

Follow one highlighted causal link at a time, then operate the component and deliberately create the fault.

Unlock all interactive component labs

Create a free account to save your progress, then upgrade whenever you are ready to unlock this.

Create free accountSee plans

Know the terminals

  • L1 L2 L3 — supply
  • U V W — motor
  • +24 V / DI / COM — control
  • Network port — PLC comms

Recognize the faults

  • Motor data not commissioned
  • Ramp too short causes overcurrent
  • Incorrect control source
  • Unsafe isolation of charged DC bus

Read the field guide

Go deeper on sizing, wiring conventions, test procedure, and the mistakes that damage equipment.

Open the complete guide

02 / Ask in context

Ask about this exact component

The Pro AI tutor receives this component’s mechanism, terminals, and common faults so its explanation stays grounded in the lab.

Selection checks

  • Supply voltage, phase and available fault current.
  • Motor current, overload duty and required speed range.
  • Load type: variable torque, constant torque or regenerative.
  • Braking resistor, line reactor, EMC filtering and cable-length requirements.
  • Control I/O, safety functions and communication protocol.

Commissioning sequence

  1. 1Record the motor nameplate voltage, current, frequency, speed and power before entering motor data.
  2. 2Confirm supply, motor, protective-earth and control wiring against the drive manual.
  3. 3Select the intended command source and speed-reference source; do not leave local keypad control active by accident.
  4. 4Test direction at low frequency with the machine uncoupled or otherwise made safe.
  5. 5Prove acceleration, deceleration, current limit, stop behaviour and representative fault recovery under load.

Troubleshooting answers

Frequently asked questions

Does a VFD reduce motor voltage as well as frequency?

Yes. The drive coordinates output voltage and frequency to maintain appropriate motor flux, then applies its control method and current limits across the operating range.

Can a VFD be used as an emergency stop?

A normal run command is not a safety function. Safety designs may use certified Safe Torque Off or external isolation as required by the risk assessment and drive documentation.

Why does a VFD trip during deceleration?

A fast-ramping load can regenerate energy into the DC bus and cause overvoltage. A longer ramp, suitable braking method or regenerative drive may be required.

Now use it in a machine

Recognition is not mastery. Build the control logic, operate the process, and prove the fault response.

Commission a conveyor drive

Free first success

Now control a variable frequency drive in a working machine

Move from recognition to PLC logic, feedback checks and fault recovery. The related guided exercise runs in your browser.

No installNo credit cardImmediate pass/fail feedback

Technical reference and worked-example guide

Variable-frequency drive component guide: field reference

Direct answer

The reader can trace one run and speed request through the drive to motor response and separate source selection, trip, STO, motor and process faults.

Written for pLC and maintenance learners understanding what a VFD controls and how power, commands, references, motor data and diagnostics interact.

a guarded motor-control training cell used to commission contactors, protection, a variable-frequency drive and independent speed feedback while studying VFD power, control, reference, protection and feedback boundaries
System map / 02

NODE 01observable

Definition

Input supply, rectifier, DC bus, inverter, motor data, control source, speed reference, acceleration and deceleration, current limit, braking, STO, feedback and fault history.

NODE 02observable

Signal path

Supply and command through source selection, internal drive state, modulated output, motor torque and speed, machine load and independent feedback.

NODE 03observable

Worked example

A bounded start reaches the requested speed and load, stops predictably and records healthy ready, running and feedback states.

NODE 04observable

Limits

Zero reference, source conflict, overcurrent, undervoltage, overload, motor mismatch, rapid deceleration, STO demand, feedback loss and power return.

NODE 05observable

Common mistake

A supply, protection, command, reference, parameter, drive, motor, mechanical, feedback or process mismatch.

NODE 06observable

Verification

The drive sized, wired, parameterized and commissioned on the target motor and machine under approved procedures.

Answer surface / 07

What does a VFD do?

It converts incoming electrical power into controlled motor voltage and frequency so torque and speed can be managed within drive, motor and process limits.

What must a PLC send to a VFD?

The contract may include enable or run command, direction, speed reference and reset, while ready, running, speed, current and fault feedback provide evidence.

Real vfd plc control simulation footage

See this exact skill in the working simulator.

Watch the real browser product respond to the task on this page, then try the same practical workflow yourself. No slides, concept mockups, install, or credit card.

Try this in the browser
PLC and VFD Speed Control — Command, Reference and Feedback