01
A new drive
Selection and technical assessment, configuration preparation and commissioning, taking the motor, control system and installation conditions into account.
Motor → selection → commissioningEnergy / Control / Motion
Variable frequencydrive setup
From a PLC command to motion in a real machine.
Setup and commissioning of variable frequency drives for industrial equipment. Motor, drive, PLC, communication and mechanics are treated as one system, not as unrelated tasks.
Selection · Setup · Replacement · Integration
100+frequency drive commissionings
One system — a shared result
The drive turns commands into motion.
The PLC determines what the installation should do. Drive setup determines how the motor carries out that command, with appropriate dynamics and an agreed response to changes in load.
SensorsInstallation state
↓HMI / SCADAOperation and diagnostics
↕PLCLogic and commands
Command ↔ status↔
Power supplyPower circuit↓
Frequency driveMatched to the motor and task
Controlled power→
MotorTorque and speed
Rotation / force→
MechanismWork in the process
Feedback: state, actual values and deviations↩
More than Start / Stop
Drive setup defines machine behaviour.
Setting up a drive means matching the motor, load and control logic. Starting is only part of the task: acceleration, working speed, braking and responses to deviations matter too.
- Motor and load
- Motor data, current, torque, load and the mechanism’s characteristics.
- Dynamics
- Speed range, acceleration, deceleration and braking behaviour.
- Control
- Operating mode, setpoint source, enables and the PLC connection.
- Response and diagnostics
- States, faults, agreed reactions and available diagnostic information.
Speed
AccelerationWorking speedBraking
Time →
100+
frequency drive commissionings
Hands-on experience that connects individual parameters to the behaviour of the machine.
Experience across platforms
The drives I work with
A key technical focus
Siemens SINAMICS
Siemens SINAMICS forms a significant part of my hands-on experience. The appropriate solution is still determined by the task, the motor and the existing control system.
Further hands-on experience
- SEW
- Danfoss
- ABB
- Schneider Electric
- Mitsubishi
- Emotron
- Lenze
The exact series, functions and integration options are checked against the device documentation. Drives from the same brand do not necessarily have the same capabilities.
From first start to replacement
What does your drive need?
02
Replacing an old drive
Analyse the existing function, identify a suitable replacement and integrate it into the current electrical system and PLC program.
Existing function → new solution03
Matching the mechanism
Coordinate setpoints, dynamics and braking with the real load. Behaviour is checked not only unloaded but also in the working process.
Dynamics → load → result04
PLC and communication
Integrate control and status words, setpoints, actual values and diagnostic messages into the control system.
Command ↔ state05
Diagnostics
Find the cause in the interaction of drive, motor, electrical system, PLC and mechanics — rather than repeatedly resetting the same fault.
Cause → solution → verificationKeep the function. Renew the technology.
The old drive is no longer manufactured?
That does not automatically mean replacing the entire machine. I first examine the motor, electrical system, interfaces and the drive’s role in the process. A technically justified replacement can then be selected.
- Motor, power and current
- Braking and mechanical task
- Inputs, outputs and interfaces
- Fieldbus and PLC logic
Real project · Case 001
12-ton harbour crane. Drive technology renewed.
5frequency drivesMannesmann → Emotron
- Task
- The obsolete Mannesmann drives were no longer supported and spare parts were unavailable. A failure could have left the crane out of service for an indefinite period.
- Work
- Equipment selection with the manufacturer, adaptation of electrical drawings and installation documentation, STEP 7 changes, drive integration and on-site commissioning.
- Result
- The crane was modernized and commissioned. An engineering PG was prepared for subsequent remote diagnostics and support.
Drive + PLC
The drive must understand the PLC — and vice versa.
In an industrial installation, communication often goes beyond a digital Start/Stop signal. The available interface carries commands, setpoints, states and diagnostic information.
PLCDrive
PLC → drive
- Start / Stop
- Speed setpoint
- Commands and enables
Drive → PLC
- Actual values
- Current, speed, state
- Faults and diagnostics
PROFINET, PROFIBUS, Modbus RTU/TCP or CAN — depending on the drive, its options and the controller. Not every device supports every listed protocol.
For the machine — not just the cabinet
Start with the mechanism.
Motor, load, gearing, inertia and the required dynamics jointly determine how the drive should operate. This distinguishes real commissioning from simply entering a few parameters.
- Conveyors
- Pumps and fans
- Crane mechanisms
- Screw conveyors
- Production machines
Checked in real operation
Start-up is not the finish. Behaviour under load matters.
Commissioning a frequency drive is a closed engineering process: data and commands are checked on the installation, and the results inform further adjustments.
- 01
Motor data
Initial characteristics and the task.
- 02
Configuration
Motor parameters and the selected mode.
- 03
Control
Command sources, setpoints and status.
- 04
Testing
Function checks under agreed conditions.
- 05
Working load
Mechanism behaviour in the process.
- 06
Optimization
Refine dynamics and reactions.
- 07
Diagnostics
Check states and the result.
Deviations lead back to the relevant stage. This describes an engineer’s workflow, not instructions for setting up a drive yourself.
After setup: a clear handover.
Within the agreed scope, I provide parameters and backups, updated drawings, change descriptions and explanations for personnel. The customer should understand the system version they continue to work with.
Another example · Case 005
Siemens SINAMICS: the cause was in the motor.
Water ingress into the servo motor had damaged its built-in encoder. Diagnostics confirmed the hardware cause. This case shows why the drive and the motor need to be investigated together.
A servo drive is a distinct drive-system task, not an example of a standard VFD setup.
FAQ
Questions about the task
What does frequency drive setup include?
Analysis of the motor and mechanism, operating-mode selection, coordination of setpoints and dynamics, and checks of PLC communication and loaded operation. The exact scope depends on the equipment and the task.
Can a drive be replaced with another brand?
This is assessed after checking electrical data, motor, braking, interfaces and PLC logic. Compatibility and adaptation requirements must be established before replacement.
Can a frequency drive be set up remotely?
With suitable access, configuration, communication and diagnostic data can be checked. Measurements, wiring changes and physical checks are performed by qualified personnel on site. Remote-work options are agreed beforehand.
What information helps with an initial discussion?
Drive and motor types, a short description of the mechanism and task, existing electrical drawings and control-system details. For faults, saved messages and information about previous work are useful.
A task involving a frequency drive?
A new drive, replacement of an obsolete unit, matching it to the mechanism or PLC integration: send the device type, motor data and a short description. I will review the information and suggest the next technical step.
— Wladimir Poljakov
Call · +7 (928) 455-05-22