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Ross Hill Controls, Variable Speed Motor Drives Applications Manual

This document provides a guide specification for medium voltage variable frequency motor drive systems. It outlines 29 sections specifying requirements for the manufacturer, drawings, warranty, codes and standards, service conditions, efficiency, harmonic analysis, construction, cooling system, instrumentation, testing, start-up service, and motor. The specification aims to ensure the drive system meets performance and reliability standards for industrial applications.

Uploaded by

Paulo H Tavares
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
100% found this document useful (1 vote)
940 views158 pages

Ross Hill Controls, Variable Speed Motor Drives Applications Manual

This document provides a guide specification for medium voltage variable frequency motor drive systems. It outlines 29 sections specifying requirements for the manufacturer, drawings, warranty, codes and standards, service conditions, efficiency, harmonic analysis, construction, cooling system, instrumentation, testing, start-up service, and motor. The specification aims to ensure the drive system meets performance and reliability standards for industrial applications.

Uploaded by

Paulo H Tavares
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 158

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IRI I FINMECCANICA
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[ROSS HILL CONTROLS)


IRI I FINMECCANICA I ANSALDO

VARIABLE SPEED
MOTOR DRIVES

APPLICATIONS MANUAL

24 HOUR SERVICE + 1 713 467-2523 (USA)


IROSS HILL CONTROLSI
ROSS HILL CONTROLS CORPORATION
1530 West Sam Houston Parkway Nonlt, Houston, Texas 77043
Tel: (713) 467·9888 Tlx: 77-5659 Fax (713) 827-8460
IAI I FINMECCANICA I AN SAl UO

070794
QUICK FIND INDEX
OVERVIEW

WHAT IS A VFD?

BENEFITS OF VARIABLE FREQUENCY DRIVES

ECONOMIC ANALYSIS

HARMONIC ANALYSIS

POWER CONVERSION EQUIPMENT

CONTROL ELECTRONICS

COOLING SYSTEM OPTIONS

GUIDE SPECIFICATION (MEDIUM VOLTAGE)

GUIDELINES FOR SPECIFYING MOTORS

TECHNICAL PAPERS I NOTES


II
INDEX ,·

ROSS HILL CONTROLS CORPORATION 1-1


RIENCE . . . . . . . . . . . . . . . . 1-2
·FACILITIES . . . . . . . . . . . . . . . . . 1-3
WHY USE VARIABLE SPEED ELECTRIC DRIVES? 1-4
INDUCTION MOTOR DRIVE SYSTEM DESIGN . 1-6
SYNCHRONOUS DRIVE SYSTEM DESIGN . . . 1-7
VARIABLE SPEED DRIVE CONFIGURATIONS 1-8
HIGH SPEED DRIVE > 3600 RPM 1-10
RELIABILITY . . . . . . . . . . . . 1-11
MAINTAINABILITY/AVAILABILITY 1-12
. TESTING . . . . . . . . . 1-13
COST OF OPERATION . . . . . 1-14
FLEXIBILITY/SERVICE . . . . . . 1-15
MOTORS: INDUCTION/SYNCHRONOUS UP TO 35,000 HP . 1-16
GENERATORS: INDUCTION/SYNCHRONOUS UP TO 35,000 KW 1-17

2. WHAT IS A VFD?
' HOW DOES IT WORK? . . . . . . . . . . . . . . . . . . . . . . . 2-2
ARE SPECIAL MOTORS REQUIRED FOR USE WITH A VFD? 2-3
WHAT APPLICATIONS FIT THE VFD? 2-4
APPLICATION EXAMPLES . . . . . . . . . . . . . . . . . . . 2-4

. 3. BENEFITS OF VARIABLE FREQUENCY DRIVES


- -----------------------------
ECONOMY . . . . . 3-1
RELIABILITY . . . . . 3-1
. EMISSIONS . . . . . . 3-1
PROCESS CONTROL 3-1

'4. ECONOMIC ANALYSIS


ECONOMIC ANALYSIS FOR FAN SYSTEM . 4-1
OVERVIEW OF LCONOMIC ANALYSIS FOR FAN SYSTEM . 4-2
EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ECONOMIC ANALYSIS FOR PUMP SYSTEMS . . . . . . . . . . . 4-13
OVERVIEW OF ECONOMIC ANALYSIS FOR PUMP SYSTEMS . 4-14
EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
ii
5. HARMONIC ANALYSIS
EXPLANATION OF HARMONIC ANALYSIS RESULTS
OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM FUNDAMENTAL COMPONENTS . . . . . . . . . . . . . . . . . . .
COMMENTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARMONIC ANALYSIS EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . .
./

6. POWER CONVERSION EQUIPMENT


IDENTICAL POWER BRIDGES . . . . . . . . . . . . . . . . .
REDUNDANT THYRISTOR DESIGN . . . . . . . . . . . . . . . . . . . . . . . ; '
RELIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ::
EASE OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . '..
DIVERTER CIRCUIT AND OUTPUT FILTER . . . . . . . . . . . . . . . . . . .

7. CONTROL ELECTRONICS
VFD DIGITAL CONTROL MODULE . . . . . . . . . . . . .
THE FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ELECTRONICS - DISPLAY SCREENS . . . . . . . . . . . . . . . .
MAIN DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER CONFIGURATION SCREEN . . . . . . . . . . . . . . . . . . . . . . .
ALARM DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRIP DISPLAY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY DEVICES SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . .
SETPOINT CHANGE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . .
DATE AND TIME UPDATE SCREEN . . . . . . . .

8. ROSS HILL CONTROLS CORPORATION


COOLING SYSTEM OPTIONS
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . .
FORCED VENTILATED COOLING SYSTEM . . . . . . . . . . . . . . . . . . . .
CLOSED LOOP LIQUID COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED VENTILATED COOLING SYSTEM . . . . . . . . . . . . . . . . . .
CLOSED LOOP LIQUID COOLING SYSTEM . . . . . . . . . . . . . . . . .

INDEX APPLICATIONS
24 HOUR SERVICE (713) 467-2523
iii
9. VARIABLE FREQUENCY MOTOR DRIVE GUIDE SPECIFICATION
(MEDIUM VOLTAGE)
5-1
5~7 1.0 GENERAL ............... . 9-1
5-1 2.0 MANUFACTURER RESPONSIBILITY . 9-1
5-d 3.0 QUOTATION REQUIIiEMENTS 9·2
5:-d 4.0 SPARE PARTS LIST 9-2
5.0 DRAWINGS .. 9-2
t 6.0 WARRANTY . . . . . 9-3
6-1
6-2
&-2
I
~
F
7.0 EXPERIENCE . . . .
8.0 REFERENCE CODES AND STANDARDS .
9.0 SERVICE CONDITIONS .
10.0 EFFICIENCY . . . . . . . . . . .
9··3
9-3
9-4
9-5
6=-2
n~3
11.0 HARMONIC STUDY .. . 95
12.0 TORSIONAL ANALYSIS . 9 5
13.0 INPUT LINE ISOLATION . 9-6
14.0 CONSTRUCTION . . . . . 9--6
72
15.0 WIRING AND EXTERNAL CONNECTIONS 9-7
-z.3
16.0 POWER BRIDGES . . . . . . . 9-8
7_5
17.0 DRIVE COOLING SYSTEM . . . . . . . 9-9
7_5
18.0 DC LINK REACTOnS (DCLR) . . . . . 9·10
7.-5
19.0 INSTRUMENTATION AND CONTROLS . 9·1 0
L-5
20.0 INPUT AND OUTPl JT INTERFACES . . . . . 9-12
J-6
,-6 21.0 MICROPROCESSOH DIAGNOSTIC SYSTEM 9-12
. -6 22.0 PRINTED ClflCUIT BOARDS . . . . . . . . . 9-13
23.0 OUTPUT FILTER (INDUCTION DRIVE) .. . 9 13
~

. -7
24.0 MOTOR FIELD EXCITATION (LCI synchronous drive) 9-1 Lj
25.0 SWITCHGEAn . . . . 9-14
26.0 TESTING . . . . . . . 9-15
27.0 START-UP SERVICr: . 9-15
-d-1 28.0 CONTROL HOUSE . . 9-16
~d-1
29.0 MOTOR . . . . . . . . 9-19
,d-1
ADJUSTABLE FREQUENCY MOTOR DI11VE SYSTEM EVALUATION SHEET . 9-22
d-2
VARIABLE FREQUENt~Y DRIVE . 9-22
J-2 THYRISTORS . . . . . . . . . . . . . . . . . . . 9-22
J-2 DC LINK REACTOR . . . . . . . . . . . . . . . 9-23
3-2 ISOLATION TRANSFORMER (WHEN 11EOUIRED) 9-23
OUTPUT TRANSFORMER (WHEN REOUIIlED) 9-24
MOTOR (IF SUPPLIED WITH DRIVE) . . . . . . . . 9-25
iv

10. GUIDELINES FOR SfECIFYING MOTORS FOR USE WITH


ADJUSTABLE SPEED DRIVES
-,HE ELECTRIC MOTOR - RELIABLE WORKHOI~SE __ . . . . _. . . . 10-1
GROWTH OF DRIVE USAGE - NEED FOR SPECI;:ICATION GUIDANCE . 10-J
"LARGE" DRIVES AND MOTORS . . . . . . . . . . _ . . . . . . . . . . . . . 10- J
ADJUSTABLE-SPEED MOlOR SPECIFICATION CONG::RNS . . . . . . . . . . 10-t:
COMMON MODE VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-.._
HARMONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 0-'"'-

SWITCHING FREQUENCIES AND STANDING WAVF::.S . . . . . . . . . . . . 10-_


SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-
STARTING CONSIDERAI"IONS . . . 10- --
CONCLUSIONS . . . . . . . . . . . . . . . . . . . . . 10-

11. TECHNICAL PAPERS I NOTES


TECHNICAL PAPERS .. - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- I

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-v

INDEX - - -APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
..
OVERVIEW

1
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1.

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This side of the page 1s intentionally left bla11k.

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IROSS HILL CONTROLSI
IRI I FINMECCANICA I ANSALDO


l!l ROSS HILL CONTROLS CORPORATION
l&
• Supplier of Large HP I Variable Voltage I Variable Frequency Drives

L.
• Location - Houston, TX, USA
L
1
• Manufactured Oil Well Drilling SCR Systems Since 1970
L
- Industry Leader
1:
L
e 1984- Supplied First High HP I
L
High Voltage Induction Motor
L
Drive
=:- Industry Leader

• 1988 - Began Supplying


Synchronous Drives - LCI's
1

J,
• Industries Served: - ":. ''
• ......_
""!'~,. •.
,.,,..._......,."!-~

J
- Oil Well Drilling
J
- Petrochemical
J
- Electric Utility
.J
- Pulp & Paper
J
- Pipeline
J
- Water Utility
J
- Marine
- General Industry

_J
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~I
Focused on Equipment & Industries
-I
l IANSALDOI
~.I
~,I Anru li"""'AIIr'\P\.IC"' l.Ait.~IIIAI
.
>

1-2

IROSS HILL CONTROLSI


IRI I riNMECCANICA I ANSALDO

EXPERIENCE
• World Leader in Large Induction Motor Dri\ms
• Manufactured:
- Over 5,000,000 HP - Rectifiers and Large SCR Drives
- Over 350 Systems 8!>0,000 HP - Large AC Drives
(Induction & Synchronous)
- Over 300 Systems 700,000 HP - Large Induction Motor Drives

• Voltages Supplied
6.9 kV
- 4.16 kV
- 2.3 kV
- 0.6 kV
• Drive Frequency - From 0- 300Hz
• Leader in Liquid Cooling Systems

.ot'"f

~
ROSS Hill COtJ!•:oLS CORPORATION
,OA MINERALS CORPORAL CUSTOMF P USF.R liST:
VARIABLE SPEFoD DRIVE SYSTEMS
1005)
scription:
,he Model Vr480 ·· SOOHP, 48<1V, 6/6 pulse, cap;\
tompressors. 60 Hz., hot transfer of rnotor for Rtt
;Minerals, Rocky Mountain ~huse, Central Alh•Jr\
( Delivered: June 1981 'i
I, SOUTHWEST PUBLIC SEllVICE I ··.i:
I, (#1013) /
\Description: ·
'\wo Model VF4000 - 2000IIP, 4161 tV, 616 pulo:

~
need draft fans Drives were selected over loa•·
tailed at Southwest l'ubli<; Service's Nich•
"!red: October 198•1
~'
.'
r.HEMICAL CU.

~
~
Most Experienced Variable Frequency Drive Supplier) ~ .,

~·NSALDOf J

-t
~-·
_IN_Tf=lQ_QU(;TION _ _ _ _ _ __
(713) 467-2523
f1PPLICAriONS MANUAL~.·.
24 HOUR SERVICE
1

1-3

IROSS HILL CONTROLSI


IRI I FINMECCANICA I ANSALDO

J FACILITIES
• Over 200,000 Sq. Ft. Manufacturing Facilities
~~/
. I
• Vertically Integrated _/~

l - Card Assembly & Test


-1
I
_J

'
-I
l
-I - Sheet Metal House Manufacturing

• Full System Testing with Test Stands

• ISO 9000 - > Early 1995 Approval

• Dedicated Project Engineering and Field Service Staff

(Committed to Customer Satisfaction and ON-Time Delivery

IANSALDOI
1· 1

IROSS HILL CONTROLS]


IRI I FINMECCANICA I ANSALDO

WHY USE VARIABLE SPEED ELECTRIC DRIVES?


• Efficiency
- Eliminates Valve (Flow Device Losses)
- Operates Compressor/Pump/Fan at Best Efficiency Point

• Reliability
- Eliminates Mechanical Flow Control Device
- Reduces Wear on Motor & Compressor/Pump/Fan

• Maintainability
- Minimum Maintenance Required
- Mean Time to Repair Less Than 1 Hour

""T""'"··+.·-···
r- ..,

...... --· - -
.•

( VFD's an Excellent Solution

IANSALDOI

II' I TRODUCTION
~ - - · · · - - - - - - · -·
-~
APPLICATIONS
. .
M1\Nl'
-

24 HOUR SERVICE (713) 467-2523


1-5

IROSS HILL CONTROLSI


IRI I FINMECCANICA I ANSALDO
"" I -

=> i WHY USE VARIABLE SPEED ELECTRIC DRIVES?


• Emissions
- No Emissions
- Reduces Boiler Emissions

• Environmental Noise Reduction

• Cost of Operation
- No Costly Rebuilds Required

• Large Motor Starting on Soft Systems

~··
:.~~ .. -t:::;p.-+-PE),W ER
.!

~Jjl ' --j


.u ~~ .
~~-­
~a- .· .. - . -1
i

I
!
·······················j

i
...... !

~FLOW ..).

c VFD's an Excellent Solution

[ANSALD~Ql
----~ __ __./
)
1-6

IROSS HILL CO~fROLSI


IRI I FINMECCANICA I ANSALDO

INDUCTION MOTOR DRIVE SY!iTEM DESIGN


• Suitable for Retrofit Applications

• Uses Thyristor Devices

• Reliable Current Source Inverter Technology

• Patented Diverter Technology

• Ratings Up to 6.9kV and Greater than 1 !J,OOO HP

• No Motor Derating Required

• Uses Standard Induction Motor

• System Capable of Speed:. in Excess of 10,000 RPM

Converter Inverter ExistiPg I New ~


Transformer Induction
Motor

DC Link
l>rt--.--1
6-Pulse 6-Pulse Motor

T r ilter

( - - Prove~ 8. Tested lnducti~~ -M~tor Drive Tech,.;-~~~~~ ~J


IANSALDOI

INTRODUCTION
------~------·-- - ---- --- ---...,---- -~-
APPLICATIOiJS MANUAL
24 HOUB SERVICE (713) 467-2523
1-7

IROSS H.ILL CONTROLSI


IRI I FJrJMECCANICA I ANSALDO

SYNCHRONOUS DRIVE SYSTEM DESIGN (LCI)


• Simplest AC Drive System

• High Reliability Design

• High Efficiency System

• Reliable Current Source Inverter Technology

• System Capable of Speeds Greater than 10,000 RPM

• Requires Synchronous Motor Designed for Application

New
Converter Inverter Synchronous
Transformer Motor

r>r
6-Pulse
r>r
6-Pulse

. - -- - - - -- -

ven & Tested Synchronous Motor Drive Technology


-~------- ---- -----·----· ----·--- --------- --- --~----- - · - - - - - -------····-------- ---------- ______ /

[ANSALDOI
r
1-8

!ROSS HILL CONTROLSI


IRI I FINMECCANICA I ANSALDO

VARIABLE SPEED DRIVE CONFIGURATIONS

6/6 Dual Channel 12/6 12/12

IANSALDOJ

INTRODUCTION APPLICAIIONS M1\I\JAL


·----'--"-----'-=-=-
24 HOUR SERVICE (713) 467-2523
ll ,..-· ---- -
-

1-9

IRoss:j-ttLL cPNTROLsl
IAI I FINMECCANICA I ANSALDO

VARIABLE SPEED DRIVE CONFIGURATIONS

Multiple Motors

.···.·..."·:: ... ·.··,.·.:.:

/~~It~~

IANSALDOI
l
1-10
I
!ROSS HILL CONTROLS!
IRI I FINMECCANICA I ANSALDO

HIGH SPEED DRIVE > 3600 RP~II

Eliminates Gear- Increases Efficiency 2°/o

Synchronous New
Converter h··,rerter Synchronous
Transformer Motor

6-Pulse 6-Pulse

New
Converter Induction Inverter Induction
Transformer Motor
<

N'
6-Pulse
...
N'
6-Pulse T Motor
~
Q) Filter
.1!
0

(ANSALDQ)

INTRODUCTION APPLICATIONS MANU/ .


----
24 HOUR SERVICE (713) 467-2523
1-11

IROSS HILL CONTROLSI


IRI I FINMECCANICA I ANSALDO

RELIABILITY
• System
- MTBF Over 3 Years
- Conservative Rated Components
- Rated for 50° C
• Power Conversion
- Uses only SCR's - No GTO's
- Derated Thyristors -Temperature Margin
- N-1 Cell Redundancy
- Liquid Cooled System
• Control
- Mil Grade Devices for Critical Components -
JAN-TX (-55 to 125° C)
- Module 70° C Burn-In with Power On for 168 Hours·
- Comprehensive Computer Tested with Full Operations Testing
• Cooling
- Redundant Pumps

.
It

Most Reliable High HP Induction Motor Drive in The Industry

IANSALDOJ
1-12

IROSS HILL CONTROLS!


IRI I FINMECCANICA I ANSALDO

MAINTAINABILITY I AVAILABILITY
• Designed for Easy Maintenance

• Quickly Replace Entire Control Module


Conservative Rated Components
- Eliminates Searching for Problerns

• Remote Annunciation of Malfunctions


- Includes Single Cell Failures

• Thyristors can be Replaced without Disconnecting Cooling System

• Cooling Pumps Replaceable while Drive is in Operation

Minimum MTTR because of Maintainable Drive Design

IANSALDOI

INTRODUCTION APPLICATI( )NS MANUAL


I
I

24 HOUR SERVICE
(713) 45-7--2-52_3_ ~--~··-·~'
1-13

(ROSS HILL CONTROLSJ


IRI I FINMECCANICA I ANSALDO

TESTING
e 1 00°/o Component Testing

• Military Grade Testing on Critical Control Card Components

• Control Module Burn-In

• Hi-Pot Testing on Power Conversion Equipment

• Eight (8) Hour Operations Test


- Completed Control
- Full Voltage
- Full Current

• Operation of> 500 HP Motor During Tests

• Standard Industrial Test on Transformers & Inductors

( Comprehensive Testing of All Systems

IANSALDOI
1-14

IROSS HILL CONTROLS!


IR! I FINMECCANICA I ANSALDO

COST OF OPERATION
• Minimize Maintenanr.e with Long MTBF I Short MTTR

• 1/2 - 1 Percentage Point Better in System Efficiency over


Other Technologies

• Cost of Spares - Significantly Less Per Item

• Service- Competitiv·~ Hates

--------------·---··------ -- --- ------ ----~---~----- ----

(Minimized Cost of Operation With a Ross Hill Induction Motor Drive)

IANSALDOI

INTRODUCTION APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
---
1-15

IROSS HILL CONTROLSI


IRI I FINMECCANICA I ANSALDO

FLEXI 81 LITY
• Project Engineering will Provide What You Need I Require

• Vertical Integration Allows for Efficient Design Modification

SERVICE
e DEDICATED Field Service
- 20 Engineers Supporting Equipment
- Available in Less than 24 Hours
- 24 Hour Service Line

Flexability & Service Support Makes Project


Coordination Easy With Ross Hill Controls
IANSALDOI
1-16

IRoss HILL co~rRoLsl l!ll I FINMECCANICA I ANSALDO

MOTORS
INDUCTION I SYNCHRONOUS UP TO 35,000 HP
• Design Flexibility
- Ability to Meet Most Specifications
- Ability to Satisfy Demanding Customers

• Low Vibration
- Tight Interference Fit Rotor Bars (Induction)
- Dynamic Balancing At, or Near, Rated Speed
- Heavy Steel Frame & Stiff Shaft Design/Construction
- Double End Cooling for Even Temperature Distribution

• High Reliability
- Proven Insulation System (Cias~; F, r~1ica-Epoxy VPI System)
- Meets API Standards

• Variable/High Speed Motor Applicvtions


- Direct Drive Com1 >ressor w/o Gearbox
- Low Cost Alternative to Gas Turbine Drives

• Quality
- ISO 9001
- Thorough In-Process Testing
... On-Time Response

IANSALliQ]
INTRODUCTION
------------------------------------~----- -- ---· -- ·------------------~--·- ----·-- ·--
APPLICATIONS MANUAL
---------------- -----~~--

24 HOUR SERVICE (713) 467-2523


1-17

IROSS HILL CONTROLS)


IRI I FINMECCANICA I ANSALDO

GENERATORS
INDUCTION I S'YNCHRONOUS UP TO 35,000 KW

• Competitive Price Levels


- OEM Market Orientation
- Standard Designs Customized to Customer Specifications

• High Efficiency

• On-Time Delivery

• High Reliability
- Proven Insulation System (Class F, Mica-Epoxy VPI System)
- Heavy Steel Frame Construction & Double End Cooling
.... Easy Maintenance
.... Low Vibration

• Quality
- ISO 9001
- Thorough In-Process Testing
- On-Time Response

IANSALDOI
This side of the page 1s intentionally left blank.
WHAT IS A VFD?
This side of the page 1s intentionally left blank.
----------------------------------------, .,l

2-1

WHAT IS A VFD?

VFD is an acronym for Variable Frequency 5. An Output Filter system is used to limit
Drive. A v a r i a b I e f r e q u e n c y d r i v e i s the voltage and current harmonics of
essentially a "black box" which is capable the output electrical waveform to the
of taking power from a cunstant, three induction motor. The filter also providos
phase, 50 or 60 Hertz, Alternating Current VAn's at speeds above approximat8ly
power source and convertinn it to variable 60% of rated motor speed, so that tl1e
voltage and variable frequency (Hertz) diverter circuit is not needed.
power. This variable voltage, variable
6. Control and Diagnostics Section to
frequency power is then used to operate
allow adjustments of certain operating
a standard squirrel cage induction motor,
parameters by the End User's
or a standard synchronous motor.
operating personnel and the ability to
The basic building blocks involved in a locate problems by means of "usor
variable frequency drive system are: friendly" indicating lights, display
1. A Rtlctifier Unit which converts utility screens, or plain English paper
powor from Alternating Current (AC) to printouts.
Direct Current (DC). 7. Switchgear Section consisting of a11y
2. DC Link Reactors which are used to combination of input, output, atHJ
smooth DC current ripple. bypass contactors, switches, or circuit
breakers. The Switchgear Section
3. An Inverter Unit which converts the DC allows the VFD to be turned off (tripped)
power to variable frequency AC power. during a Fault condition, isolated from
4. A Diverter or Commutating Circuit, t h e m o to r ( s ) be i ng o p e rate d , o r
which is used to provide forced bypassed entirely for constant speed
commutation of the inve11er during low operation of the motor(s).
speed operation of the induction motor.

DIVEIHER I 4i
I
SMOOTIIING

INPUT BREAKER
REACTOR
j OUTPUT BREAKER

INCOMINGAC
"(7
·. )
·" AC-DC
flECTIFIER
~:

() (\ /
DC-AC
INVERTER
OUTPUT
LINE .
1
AC
FIXED FILlER \.MOTOR
FREQUENCY
( 1) (31 ( 5)

lI VARIABLE

ELECTRONIC CONTROL MODULE


AC POWEH

16 .i
1 l
!
'
LOCAL CONTROL
AND
INSTBUMENTATION
6

Figure 2-1. Basic Building Blocks of a VFD System


rI
2-2

HOW DOES IT WORK? By delaying the firing signals to the SCRs


the average output DC voltage, current, ano
power can l1e controlled even though th~::­
The heart of the VFD is a small marvel called
input is a fixod frequency and fixed voltag6
the Thyristor, a.k.a. Silicon Controlled
Rectifier, commonly known as the SCR. DC power from the Rectifier Bridge is passeu
This device, like a diode, has the basic through the DC Link Reactors to providL
characteristic of allowing electrical current smoothing _of the currcmt ripple associater'
to flow through the device in only one with the conversion process. This procesf"
direction. In the opposite, or reverse, provides relatively smooth power to the
direction, the SCR will block the flow of Inverter Bridge. The better designed drivt.
current and will support a substantial systems incorporate two DC Link Reactor,
voltage. The forward flow of current through in the syst;)m. One DC Link Reactor i
the SCR can be started only uy applying applied to the positive and one to thr
a small current into a third terminal of the negative sides of the bridge assemblies.
device called a gate. Thus, an SCR can This design provides the maximun,
block the flow of current in both directions, protection during fault situations. (Se ..
but may conduct current in the forward Figure 2-4, opposite.)
direction, if supplied with the proper gate
The function of the Inverter Bridge is k
current, called the firing signal. (See Figure
receive DC power and convert this int
2-2, below.)
vari;1ble frequency AC power. Thr
l3y lllO<lllS of switching tlw SCR devices convnrsion process involves the same SCR
in the VFD rectifier bridge "on" and "off", device which is used in the Rer.tifier Bridge.
the incoming three phase AC power can The entire inverter bridge is constructe~..
be converted to DC power. (See Figure 2-3.) exaclly the same as a rectifier bridge. A'"
of th1J principles of operation are identical-
with the exception of the firing signals.

ll!nFE PHASF
INPUT VOLTAGE

ANODE~- _ __ A PHASE B PHASE C PHASE

/( ( . "·v ~---- / . / ··,


1. \'
---·--,-I
\ I \ I \ I
\ / \ I \ I

( ~- /!, __
OIFFf-nFNCF BETWEEN MOST POSiliVE AUP , .. l<:, I NFGATIVE

~-
CATHODE ~ '----GATE
I ~- 11j'[~~~~\~~~~'''!~-~-~~;::;l~S) T' U''UTRAL

I - - - ------ --- ---~----- .. ---- --


or OUJf'1JT
vnr IAr.F

Figure 2-2. An SCR Figure 2-3

WHAT IS A VARIABLE FREQUENCY DRIVE? APPLICAliONS MANUA.


24 HOUR SERVICE (713) 467-2523
2-3

RECTIFIER OUTPUT WITHOUT RECTIFIER OUTPUT WITH


t
en
SMOOTHING INDUCTOR
t
en
SMOOTHING INDUCTOR

w w
a:
~ 3000
:::!
<{
a:
~
~
3000 AVERAGE VALUE
2000 AMPERES 7
~ -~---
l-

L
iE 2000 2000· ----------
a:

~
a:
:::>
0 1000 0 1000

,_ --------- ~ --------------~------- __ ,_
TIME ---j 60' f-- TIME

------------ -------
Figure 2-4. Unfiltered and Filtered DC Waveforms

By sequentially turning "on" and "off" the ARE SPECIAL MOTORS


SCRs in the Inverter Bridge and directing
the current through the appropriate motor REQUIRED FOR USE WITH
windings, the winding current interacts with A VFD?
the motor magnetic field and motor torque
is produced. Normally, in an induction motor Many variable frequency drive systems use
drive the voltage and frequency are directly conversion methods which produce very
related to provide optimum flux. This is choppy, harmonic-filled output waveforms.
known as a constant Volts per Hertz
system. As an example, a motor operating These drives require that the squirrel cage
at 85% frequency will require about 85% induction motors used with them be
of rated voltage. Thus, to provide for variable especially designed for the operating
speed operation of an induction motor, the characteristics of that drive. If such a drive
inverter bridge is commanded to increase is applied to an existing motor, the motor
or decrease the output voltage and must be derated; that is, if the motor is
frequency to correspond to the required normally rated for continuous operation at
motor speed. 1000 HP at a 1.0 Service Factor, it can
be operated continuously in the variable
frequency mode at no more than 800 HP.
(See Figure 2-5.)
Drives which produce large amounts of
VOLTS ~~lllilllllll!ruiiii 1 1 JH]miiiJ~ harmonics in the output waveform cause
excessive heating within the motor. This
heating effect will eventually cause an
insulation break down within the motor and

~--
lead to premature motor failure. This same
AMPS f type of failure will not occur with new motors
"designed" for operation with the drive.

Figure 2-5. PWM Drive Waveforms


2-4

(+) ()
t
DC tr!PUT
POWER
I
I
t
(-) 0 --

Figure 2-6. RHCC VFD Output Waveforms

Whether your project will use existing twenty APPLICATION EXAMPLES


year old motors or new, factory fresh motors,
there is a means of assuring a long motor
• Forced Draft and Induced Draft Fans
life in a variable frequency drive application.
The VFD can be provided with an output • Kiln Fans
filter system to smooth the output waveforms • Wind Tunnel Fans
and reduce the Total Harmonic Distortion • Wastewater Plant Aeration Blowers
(THO) of the motor current to less l11an !.i% • Boiler Feed Pumps
at full load and 60 Hertz.
• Slurry Pumps
This output filter system results i11 the drive • Condensate Pumps
having a near sinusoidal waveform (for
• Heactor Cooling Water Pumps
which the induction motor is designed). The
low harmonic content of this waveform • Pipeline Product Pumps
mel.lns that excessive heating due to • W:1stewater Influent and Effluent Pumps
han nonics does not exist, thus no motor • Vertical and Hori 70ntal Water Pumps
der:1ting is required. The low current • CPntrifugal and Reciprocal Compressors
distortion means low output torque
• Hiqh Speed Compmssor Operations at -
han nonics. (See Figure 2-6, above.)
grr)ater than 60 H;
WHAT APPLICATIONS FIT
THE VFD?

The VFD is perfectly suited fo1 almost all


applications which require the speed of an
AC motor be varied. The requirement for
speed variation may be due to load cycling,
such as fans and boiler pumps i11 an electric
generating plant, to meet pe<1ks and lulls
in demand, or it may be due to a process
requirement such as a centrifugal
compressor on a pipeline pumping gases
of differing Mohl Weights.

WHAT IS A VARIABLE FREQUENCY DRIVE?


-· ----~-----
AI'PLICATIONS MANUAL
24 HOUR SERVICE (713) 467-2523
f -
I

BENEFITS OF VARIABLE
FREQUENCY DRIVES
This side of the page 1s intentionally left blank.
3-1

BENEFITS OF VARIABLE FREQUENCY DRIVES

ECONOMY • Flow control by VFD and AC electric motor


will afford power savings over alternate
• Power savings methods of flow control (i.e. dampers,
throttles, bypass, etc.). These power
• Reduced operating costs
savings will be roughly equivalent to the
• Reduced maintenance costs energy loss across the flow control device.
This savings in power will result in
RELIABILITY reduction in fuel costs of electric power
consumption, thereby reducing operating
• Eliminates high mainter1ance, costs over the life of the equipment.
high failure mechanical flow
devices • A VFD requires less frequent preventative
maintenance than mechanical flow control
• Reduced down time devices. The VFD also has a higher
• Longer MTBF MTBF. Couple these benefits with the
ease of maintenance of the Ross Hill
EMISSIONS Controls Corporation VFD and you have
significantly greater equipment availc-tbility.
• Electric motors will allow removal • Processes which utilize steam or gas
of gas or steam turbines turbines will eliminate the emissions
• Reduced NOx emissions associated with this method of process
control. Recent studies have shown that
PROCESS CONTROL the more accurate flow control afforded
by a VFD can reduce NOx and hydrocarbon
• More accurate flow control emissions from boilers (refer to September
1993 article by 0. C. Smith, in Power
• Faster response to changing
Magazine).
demand
• Improved process efficiency • A VFD will afford faster and more accurate
responses to changing flow requirements
than other methods of flow control. This
faster and more accurate response will
result in improved procf:.ss 8fficir:r,cy ir1
critical processes.
r
I
I

This side of the page ts intentionally left blank.


I
1-
1-
1-
L
I

ECONOMIC ANALYSIS

"
L

l'

l
J

1
J
I

This side of the page rs intentionally left blank.


1
4-1

ECONOMIC ANALYSIS

ECONOMIC ANALYSIS FOR opening. The fans may be operated


individually or in parallel.
FAN SYSTEM
The system proposed for this retrofit
The attached economic analysis is performed application consists of two variable
for a generating unit with two forced draft fans frequency drives with input isolation
each rated 6000 HP. transformers to independently control the
speed of two fan motors.
- The combustion air for the boiler is supplied
by two forced draft fans. The fans are From the customer furnished fan curves and
load profile, the input data for the analysis
equipped with variable inlet vanes on the
~ suction side of the fan. The variable inlet is generated and the flow rates and
~ vanes are electrically operated. The output corresponding hours of operation are
of each fan is controlled by the inlet vane calculated for different megawatt loads.

VARIABLE VARIABLE
FREQUENCY - - - FREQUENCY
INVERTER CONVERTER
II
r- J

l_- l
POWER\

--~-;miNoL INDUCTION
MOTOR
-------- - - -
Figure 4-1

ECONOMIC ANALYSIS
4-2

OVERVIEW OF ECONOMIC indicating power required at the input of the


ANALYSIS FOR FAN SYSTEM variable frequency drive.

l'd!Jt:J •1•1 y u( :_,i\Vh llj0


0UIIIIIIdl ENERGY ANALYSIS: The information
corresponding to the flow rates and numb<.n provided by the power analysis is used along
of fails operating is provided basr>d on llle with duty cycle (hours of operation) to
results of the economic analysis. Tile generate thE~ data for energy consumption.
estimated payback time is calculated with The energy savings is the difference
refe1 ence to the cost of the system scope between the energy consumed by existing
of supply consisting of two vnriable system and r l1e energy used by variable
frnqtwnr.y rfrives, two input isolation frequency dr ;ve system.
lr all! lon11ut s and one control house. ECONOMIC Ati.-\L YSIS: The information
Pagn 4-5 Customer furnished fan curves generated by llle energy analysis is utilized
for •'Xisting constant speed operation with with the cost of energy (cents per KWH)
inlet vane control. information r ovided by the customer. The
calculations r weal the cost of operatio11 for
PagrJ 4-6 Results of the Power. Enerqy existir 19 syst 'tn and for proposed variable
a n c! E c o n o m i c a n a I y s e s f o r o n e ran speed oper; :ion. 1 he cost savings is the
ope1 ation. The information generated is differnnce in d1e cost of operation of existing -~
grot •ped into the following three catagories: system and cost of variable speed operation. _
1. Plant Parameters Page 4-7 Computer generated curves for -
2. Existing one fan operation based on input data -
3. Floss Hill Controls VFD derived from customer provided curves.
The Head vs. Flow curves are plotted for -
P0~1EH ANALYSIS: The information unuer
different spoeds in 10 !Jercent decrements. ~
the i 'LANT PARAMETERS column indicates
the air horsepower requirement The static efficiency curve, the power c1trve
and the sy~.tem resistance or system load -
corresponding to flow and head. fhe flow
rates refer to the selected analysis points. curve are plotted IJased on customer
furni:;hed information. The analysis points -
The information under EXISTING pertains are indicated by small squares on sy~;tem _
to the constant speed operation. The load line.
information about the variable speed
The dashed curves originating from the
operation is listed under ROSS HILL
origin are constant efficiency lines generated
CONTROLS VFD column. The unit
by tile computer. ThP second power curvE:
efficiency represents the efficiency of the
starting from the origin is the power
fan. The motor efficiencies at constant speed
consumption curve of lhe variable frequr0ncy-
and at variable speed operntion ;ue
estimated based on the motor efficiency drive system.
information supplied by the cw;tomer. Page 4-8 Power, Energy and Economic-
analyses for two fan operation. The anvlysis_
The existing power in KW is the ir 'put power
required at the motor terminals laking into is performed on a per fan basis.
account the motor and fan efficiencies. The Page 4-9 Compute1 generated curves for
power requirements for variable speed two fan operation c 1se.
operation are tabulated in the last column

ECONOMIC ANALYSIS
---~--~---~-- ~-~ ~·----~------~----- - - - - - - - APPLICATIONS M/\NU.A.'-
24 HOUR SERVICE (713) 467~2523
,...

4-3

EXAMPLE:
Note that the analysis results c:md the calculated values may not be exactly same
due to program approximations and rounding of numbers:
AIR HORSEPOWER = 0.000157 x Flow in ACFM x Head
in Inches of Water

I =
=
HORSEPOWER REQUIRED FHOM POWER CURVE
0.000157 X 256,000
277.33 HP
X 6.9

(FOR VANE CONTROL) = 1880 HP


277,33 X 100
UNIT EFFICIENCY = 1880

ASSUMING MOTOR EFFICIENCY OF 92.8%


188!1__x_ 0. 7A6
EXISTING POWER IN KW =
0.928
= 1511.3 KW
EXISTING ENERGY IS MWH - 1511.3 X 2190 X 10-3
3309.747 MWH
EXISTING ENERGY COST = 3309.747 X 1000 X 0.0312
= $ 103,264
AIR HORSEPOWER = 282 HP
POWER IN KW = 282 x 0.746
= 210.37 KW
CONSTANT EFFICIENCY CORRESPONDING TO SYSTEM LOAD LINE IS 91.7%
MOTOR EFFICIENCY = 85.8% (Assumed)
VFD I 1RIVE EFFICIENCY = 82.4% (Estimated)
210.37
VFD INPUT POWER = (0.917) X (0.858) X (0.824)
= 324.5 KW
VFD ENERGY IN MWH = 324.5 X 2190 X 10-3
= 710.655 MWH
ENERGY SAVINGS = 3309.747 - 710.655
;
= 2599.092 MWH
t.~· VFD ENERGY COST = 710.655 X 1000 X 0.0312
I = $ 22,172
COST SAVINGS = $ 103,264 - $ 22,172 ''
I
= $ 81,092 !

ECONOMIC ANALl s,s I


4-4
-----~-

ECONOMIC ANA LYSIS - FANS


6000 HP FORCED DRAFT FAN

SAVINGS PER FAN:


------------------- --- ---

FLOW PER FAN NO. ( 1F FANS


1000 HOUR/YEAR OPERATI! IG $/YEAR
--~- ----
256 2190 1 $ 80,971.00
39H 438 1 13,225.00
502 876 1 18,893.00
584 4:11.3 1 5,114.00
TOTAL $ 1"18,203.00
-------- ---------------- - - - ------- ------ ---------1

342 4~18 2 14,760.00


393 4:38 2 13,308.00
449 17!)2 2 15,801.00
493 1752 2 ·m,451.oo
656 438 2 425.00
TOTAL $ ; 13,835.00

TOTAL SAVINGS FOR ONE FAN: 118,203 1- 113,835.00 == $ :32,038.00

TOTAL SAVINGS FOR TWO FANS: 118,2( 13 + (2 X 113,f' :35) = $ 345,873.00

TOTAL COST - TWO DniVf~S AND ONE CONTROL H'JUSE . $1,420,000.00

TOTAL SAVINGS PER YEAil $ 345,873.00 ,_


I
DRIVE PAYBACK TIME . . . . 49.3 MONTHS
l-
1-
I-
I
,_
,_

/_

I
--- -~- - _ _ _ _ _ _ _ _ _ ______j

Table 4-1

ECONOMIC ANALYSIS APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
I .a;-, . 1 td'''; a mfsr l,. bld'llii't, rl''fll I ..... ,~>;!~-·····:"*I n.Jhf t!l,dl $#P'... : ·-~·] . . ., ••- - . . . . . . . '":fiili!l!~---
I
.. lflj. II. .

USER - THE BABCOCK & WILCOX COMPANY


THE .AIR PP.::HEATER COMPANY SITE - DALLAS, TEXAS
WELLSVILLE, NEW YORK ?JR?OSE - rORCE DRAFT rANS
HOWDEN-APCO FANS TYPE - ZM3-11700
OUR REF - PO-E-098-D
CURVES PLOTTED AT 105°F, 850 RPM
INLET DENSITY= ,0683 /CU, FT
I C:::fi
T - - --1 - - -~ -
i
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STATile PRES$URE ---< I

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4-6
.-------------------------
r
6000 HP - 850 RPM - FD FAN - VANE CONTROL

--------
f-----·- -
PLANT PARAMETERS
POWER ANALYSIS
·-~--·--------

-·------
EXISTING
-----
---~- ~---
AVU - TUELHF1-900!:J::O:I

ROSS Hll..L CONTROLS VFD


. ----~--

------
I
# FLOW HEAD POWER UNIT MOT POWEH SPD UNIT MOT VFD POWER
ACFM IN HP EFF EFF KW RPM EFF ElF EFF KW
----- --·------~
- --- ------ -
1 256 6.9 282 15.0 92.8 1510 319 91.7 85.8 82.4 325
2 898 16.4 1035 42.1 93.9 1950 492 91.6 92 2 93.0 982
3 502 25.9 2045 G:J.8 9tl.6 2528 G19 91.6 93.9 96.6 1836
4 584 34.9 3184 l(l.4 94.9 3192 719 91.6 91.5 97.4 28111
------- ---------· ~--- -----------·-

6000 HP - 850 RPM - FD FAN - VANE CONTROL


ENERGY ANALYSIS AVH - TUELHF1-900924
---- --------- · - - - - - - - - - -
PLANT PARAMETERS EXISTING flOSS HILt CONTROLS VFD
----I--
# FLOW HEAD POWER DUTY ENERGY SAVINGS
ACFM IN HP H/1/YR MW-H/1 MW-HR
256 6.9 282 2190 25.0 3307 712 2595
2 398 16.4 10:35 tl38 G.O 854 430 424
3 502 25.9 20,l5 (l76 10.0 2214 1609 606
4 584 34.9 3184 438 5.0 1398 1234 164
- ~ ~ ~ ~

---- ~-- - - ---


TOTALS :1942 45.0 7774 3985 3789
-------- ------

6000 HP - 850 RPM - FD FAN - VANE CONTROL


ECONOMIC ANALYSIS * AVf: - TUELHF1-900924
t
--------- --.--------- ----·--- ---------- t
PLANT PARAMETERS EXISTII''G
------------
# FLOW HEAD POWER DUTY DUTY COST
ACFM IN HP HRIH1 % $/YR.
L
1 256 6.9 282 2190 25.0 103,189 22,218 80,971
2 398 16.4 1035 438 5.0 26,645 13,420 13,225
3 502 25.9 2045 876 10.0 69,084 50,191 18,893
4 584 34.9 3184 438 5.0 43,624 38,509 5,114
-- ------
TOTALS 3942 45.0 242,542 124,338 118,204
--------------------- . -· ------
*(NOTE: ECONOMICS BASED ON 3.12 CENTS PER KILOWATT-HOUR)
l

fable 4-2

ECONOMIC ANALYSIS APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
~;('>,,;:.:;-··--
..$-~:-'!"~.---·

6000 HP- 250 ;::,PM - FD FAN- VANE CONTROL

60 8000
I , 1

1
-CONSTANTEFFIClENCY(d-~shkd curve~) I .
I I I I : STATIC
·~ ~FFI'CIENCY
I \ ' 0

I ?ft.
t-------+--~~0
0 \ I ok
0~
I
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54 CX) I )
7200
]0\~ C) ~ I
: ___ct) • I
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48 ' ! ~~'----+--~ 6400
i I I o . \.. /
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.I I
--:--~·-POWER "·· !
42 ~c::-----,- 5600
i ~',
1I
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850RPM
,
1/
y HEAD VS. FLOW
I I t \ ' J I I
1" 00 -/---,-,----'--------t~~~;--;-;.::.:_; I 480:J
1"
:I:
m /I
~
rv'·,~ 1
l is4 RPM . ""C
., l>
a 30
I .· .;; H:EAD vs. FLOW I
4000
0
=:m
(.0
c
- ~ ~PM
ro
~I
z
:I: ~
;:rJ/ 1 679
~ HEADVS:-FLOW--'-----~---
-
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-"'+
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24 ; ,,:

~~ I
'I 3200
-+
""C

/r /
1/

----}., :..---------r , , ~d:_L 594 RPM


18 71 ' . r 17 Y~ / v HEAD·vs:-Ft.::OW 2400
/"'.../! ,· ft
/509 RPM / I//
12 ,__-+-=-r~----~-L----7''---__,.--+-/HEAD-VS. F L O W - - - - , - - - - + - - - - - i - - - 1600
1 i i

I
~VFDPOWER
I 11

6 800
m
0
0
z 0
I I -~ ' 0
0
s: 0 100 200 300 400 500 600 700 800 900 1000
0
)>
z)> +- FLOW (ACFM x 1000} -+
~
AVB- TUELHF1-900924
(/)
(]j
I~
~----------------------------------------------~·~
4-8

6000 HP - 850 RPM - FD rAN - VANE CONTROL


POWER ANALYSIS
PLANT PARAMETERS R( ISS HILL · :ONTROLS VFD
# FLOW HEAD UNIT SPD UNIT ,vfOT VI D POII\IER
ACFM IN. lTF RPM EFF EFF ElF I~W
--
342 12.1 661 :10.4 93.5 1737 423 91.6 90.6 90.4 657
393 16.0 995 '11.0 93.9 1928 486 91.6 g2.1 92.8 948
449 20.8 1473 ~i3.0 94.3 2200 554 91.6 13.2 911 5 1 ~\62
493 25.0 1939 94.6 2467 608 91.6 'i1.8 9G 5 1745
656 44.0 4475 iJ8.7 95.0 3962 807 91.6 91.8 3931
--------------~---'--- --------------- ----------------- ------------- ---~

6000 HP - 850 RPM - FD FAN - VANE CONTfiOL


E!·~ERGY ANALYSIS AVB - TUELHF2-900924
PLANT PARAMETEn.'; EXISTING ROSS HILL CONTROLS VFD
# FLOW HEAD POWER I JUTY DUTY ENERGY ENERGY SAVINGS
ACFM
----~-----------

342
IN.
12.1
--
HP l'fl!YR
661
%
--~-------~--------

438 5.0
MW-111?
761
----1 MW-HR
288
MW-HR
473
2 393 16.0 995 438 5.0 84!) 415 429
3 449 20.8 1473 1752 20.0 3855 2387 1468
4 493 25.0 1939 1752 20.0 4322 3057 1264
5 656 44.0 4475 1\38 5.0 1735 1722 14
TOTALS 1\818 55.0 1151 B 7869 3649

6000 HP - 850 RPM - FD FAN - VANE CONTF\OL


ECONOMIC ANALYSIS * AVB - TUELHF2-900924
-- ------- ----,-------~ - - - --~-----
PLANT PARAMETERS EXIS11NG ROSS HILL CONTROLS VFD
----- -- ------~----·-- --- ------- ------- -------- -~--- -----------~-- -------- ~~------

# FLOW HEAD POWER DUTY DUTY COST COST SAVINGS


ACFM IN. HP IJR/YR % $/Y/1. $/YR. $/YR.
342 12.1 661 438 5.0 23,732 8,972 14,760
2 393 16.0 995 438 5.0 26,3[·1 12,952 13,398
3 449 20.8 1473 17!52 20.0 120,2/7 74,475 45,801
4 493 25.0 1939 175:2 20.0 134,8,14 95,393 39,451
5 656 44.0 4475 4313 5.0 54,1r\8 53,72' 42L•
TOTALS 4818 !)5.0 359,3~)1 245,515 i 13,835

*(NOTE: ECONOi'v11CS BASED ON 3.12 CENTS PER KILOWA r T-IIOUR) -~·

-------~------------ ------

ECONOMIC ANALYSIS
Table 4-3

APPLICATIONS MANUAL
••
24 HOUR SERVICE (713) 467-2523 ~
~
'YJ~-~"":·:·~~~?~~····
~-·",)l "'O:j(~:<~i~P"";E~~-~:·~~~~-~:; ·!J.t~·~~;, J:;.~+'o/f-~:f_k~·g~y"fi?t~: ~ --..,' ,
6000 HP- 850 RPM - FD FAN -VANE CONTROL

60 I ' 8000
---1-- CONSTANT EFFICIENCY (dashed curves) !

~
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p
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1. l ~
_----<--------E-~(CA'~t?.cv
! l'""il it:"
! i

54 I ----i-----0~ ~ o- ~ · 7200
~
I
I
o'""'
w
'
r a: '
1 "'-1 ~
I

I I ~/1 1\ I 1 ~STE~ ,I ,
4 8I. ----7"'~-- ----~--- I .. o;;_ 6400
~/I I /! ! I I ~.II g
1//1 I·~~ 1.
,.------j-__:;:::=-· P0 WE R \
42 I I 5600
'850 RPM
. I
( HEAD VS. FLOW

36 7
~1 i i 4800
1'
!

, I . . . ~
:I:
m ~~~ / !/// I 764 RPM I '"0
)> 1 :I [ / ~""' / 1; H,EAD VS. FLOW 0
"Tl 30 4000 :E
-z
0 !-----:?-"'---t----f-r--~ I / '""' '
c.O"
m
;.X~~
c i i
ro
f>
..,. :I: . 1 ~ I
I[
·
~ 1:/
• I
I
/ /
/ /
1/ i 679 ~PM
1
!
·

i -
:IJ
:I:

I
I
N

-
0

~
24 =~ ~""~ .. HEAD-VS:-FLOW 3200
-
'"0

~
!
18 2400
- v~
/
/ [/ / //509 RPM )
12 ~ r=T J 7 ·i ~ 7\ /: HE~D-VS.-FLOyv''----i---___:__ __.__ _ _j 1600
--, / 1/ ' I I

6
~JFDPOvJER 800

0 0
0 100 200 300 400 500 600 700 800 900 1000

+- FLOW (ACFM x 1000) -+


~

I~
') AVB · TUELHF2-900924

') t.:)
I
t
l
!' 4-10

This side of the page 1s intentio11ally left blank.

ECONOMIC ANALYSIS
·------
24 HOUR-SERVICE ____(713)
APPLICA !IONS MANU/
467-i523____ -------_ f~
~
'
---------. --- --------
--·------------------- "-- .. -----:

4-1 t

INFORMATION TO BE SUPPLIED BY THE USER


FOil FAN ECONOMIC ANALYSIS

NAME OF COMPANY:
ADDRESS: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
CITY: _____________ STATE: _ _ _ _ _ __ ZIP: - - - -
CONTACT NAME·
PHONE NO.: ___________ _ _ _ FAX NO.: _ _ _ _ _ _ _ __

ANALYSIS INFORMATION:

PLANT OR STATION: ___________


APPLICATION: _________________ NO. OF UNIT: _ _ __
TVPE OF FAN: - - - - - - ------'-------- ---------
EXISTING CONTI"lOL:
MOTOR DATA: HP SPEED _ _ _ _ _ VOLTAGE _ _ _ _ _
COST OF ENERCiY: $ PFR KWH _ __
LOAD PF10FILE: (LOAD POINT (FLOW OR MW)/HOURS OF OPERATION):

-------------------------

(OVER)
~
4-12 t!
INFORMATION TO BE SUPPLIED BY THE USER FOR FAN ECONOMIC ANALYSI::; t
(Cont'cf.) (

FAN PERFORMANCE DATA:

Inlet Temperature: -------~- Degrees r


Performance Curves:
a. Static Pressure in inches of WG vs. FloV\ or Volume in ACFM
b. Static Efficiency in percent vs. Volume in ACFM
c. Horsepower vs. Vo!t.ll11e in ACFM (PreferaiJiy wj:h existing control)
d. System Resistance <;r Load Characteristic~ -
Pressure in inches of WG. vs. Volume in ACF~.1
e. Test block (TB) or Uesign Rating - Volume and Pressure
f. Maximum Continuou:. Ral1ng (MCR) - Vol11me and Pressure

* If the performance curves are not available in units specified above, information
should be provided to convert tile <.Jata to the iJbove units for analysis.
* If performance curves arn not available, followinrJ infortnation is required to
generate default curves.
• Flow or Volume at maximum efficiency • Head offse at zero flow or zero volume
• Head or Pressure at maximurn efficiency • Maximum Efficiency
• Flow of Volume at Test Block

ADDITIONAL INFORMATION:

------------ --- -------------------------


- - - --- ---- ----------------

------------

---------. - - - - - - - - - - - - ----------
----------------------- -----------------------

- - - -----------

- - - - - ------ --------- -----------

ECONOMIC ANALYSIS APPLICATIONS MANUAL


-------'--
24 HOUR SERVICE (71 :]) 467-2523
4-13
pump is driven by two (2) 3500 HP induction
ECONOMIC ANALVSIS FOR ~otors in tandem. The output of each pump
PUMP SYSTEMS 1s controlled by the throttle valve opening.
The system proposed for this application
The attached economic an<tlysis is consists of two variable frequency drives
perfornwd for a power generating plant with each rated 7000 HP with input isolation
two boiler feed p11mps each rated at 7000 transformers to independently control the
liP. boiler feed pumps. Each drive will operate
The 60%, capacity boiler ked purnps take two (2) 3500 HP motors in unison.
suction from the heater. [- ach pump is a From the customer furnished pump curves
rnulti. sta~1e, barrel type, contrifuual pump and load profile, the input data for the
and IS rated at t ,650,000 lbs. per hour at analysis is generated and the flow rates and
2770 psi and 330 degrees r:. Undt;r normal corre~;ponding hours of operation are
conditions, two pumps will be in operation calculated for different megawatt loads.
when the: load is above 50 percent. At lower
loads one pump will be in operation. Each
--··---

!
j_ VARIABLE VARIABLE
FREQUENCY
FREQUENCY
INVERTER CONVERTER

POWER\

--~--- /
- ---- - - - - - --~:0..

STANDARD
INDUCTION
MOTOFl
--~--·- ----·-- ---
Figure 4-5
4-14
OVERVIEW OF ECONOMIC The existing power in KW is the input power
ANALYSIS FOR PUMP SYSTEMS required at the motor terrninals taking into
account the motor and pump efficie• 1Cies.
Page 4-16 Summary of savings The power requirements for varia:Jie · peed
corresponding to the flow rates and number operation are tabulated in the laf~t C'llumn - j

of pumps operating is provided based on indicating power requirPd at the input of the
the results of the economic analysis. The variable frequency drive.
estimated payback time is calculated with
ENEflGY ANALYSIS: The inform,, t ion
reference to the cost of the system scope
provided by l11e power a11alysis is used along
of supply consisting of two variable
with duty cycle (hours of operation) to
freLJuency drives, two input isolation
genrrate tho data for energy consumrtion.
transformers.
Tho eneryy savings is the difference
Page 4-17 Customer furnishud pump between the energy consumed by e'<isting
curves for existing constant speed system and the energy used by v;1riable
operation. frequency drive system.
Page 4-18 Customer furnished load ECONOMIC ANALYSIS: The information
profile data. genorated by the energy analysis is ulilized
with the cost of ener~IY (cents per KWH)
Page 4-19 Results of the Power, Energy
infonnation ·Ill ovided by the cw: tomer. The
and Economic analyses for one pump
calcttlation mveal the cost of operation for
operation. The information generated is
existing system and for proposed variable
grouped into following three categories:
speed operation. The cost savings is the
1. Plant Parameters difference in the cost of operation of existing
2. Existing system and cost of vari;Jble speed operation.
3. Ross Hill Controls VFO
Page 4-20 Computer generated curves
for one pump operation based on input data
POWER ANALYSIS: The information under
derived from customer provided curves.
the PLANT PARAMETERS column indicates
the hydraulic horsepower requirement The Head vs. Flow curves are plotted for
corresponding to flow anrl head_ Thn flow differert spGeds in 10 percent decrements.
rates refer to the selected analysis points. The static efficiency curve, the power curve
and the sy:-;tem resistance or system load
The information under EXIS-llf'JG pertains
curve are plotted b:1sed on customer
to the constant speed operation. The
furnished information. The analysis points
information about the variable speed
are indicatt:d by small squares on systPm
operation is listed under f-lOSS HILL
load line.
CONTROLS VFD column. The unit
efficiency represents the efficiency of the Tho dashed curves originating from the
pump. The motor efficiencie~-; at constant origin are constant efficiency lines generated
speed and at variable speed operation are by the computer. The second power curve
estimated based on the motor efficiency (lower curve) is the power consump"tion
information supplied by the customor. curve of the variable frequency drive system.

ECONOMIC ANALYSIS --·---·--·--· ---- ---~·-·


APPLICATIONS MANUAL
24 HOUR SERVICE (713) 467-2523
-
4-15
-EXAMPLE:
Note that the analysis results and the calculated values may not be exactly same
due to program approximations and rounding of numbers.

HYDRAULIC = f !ow in GPM x Head in feet of water x specific gravity


HORSEPOWER 3960
~·818 X 6861.R X 0.902
= 3960
= ·1404.5 HP
HORSEPOWER nEQUIRE[' FROM POWER CURVE - 6260
4404.5 X 100
UNIT EFFICIENCY = 6:~60

= 70.35%
ASSUMING MOTOR EFFICIENC)' OF 95. 1%
6260 X 0.746
EXISTING POWER IN KW ==
0.951
= 4910.6 KW
EXISTING ENERGY IN MVVH == 4910.6 X 552 X 10-3
= 2710.65 MWH
EXISTING ENERGY COS1 = 2710.65 X 1000 X 0.021
.:: ::::f=: O'!'l.
= - --·~-- ...

HYDRAULIC HORSEPOWER = 4404.5 HP


= 44045 X 0.746
= 3285.76 KW
CONSTANT EFFICIENCY CORRESPONDING TO SYSTEM LOAD LINE IS 79.2%
MOTOR EFFICIENCY = 95.1% (Assumed)
VFD DRIVE EFFICIENCY = 97.8% (Estimated)
3285.76
VFD INPUT POWER =
(0.792) X (0.951) X (0.978)
= 4461 KW
3
VFD ENERGY IN MWH = 4461 X 552 X 10-
= 2462.47 MWH
ENERGY SAVINGS = 2710.65 - 2462.47
= 248.18 MWH
VFD ENERGY COST == 2462.47 X 1000 X 0.021
= $ 51,712
COST SAVINGS = $ 56,923 - $ 51,712
= $ 5,211
4-16
·------- ~--- ------ ----- - - - - -

ECONOMIC ANALYSIS - PUMPS


7000 t-IP BOILER FEED PUMP

-·- -· - - - - - - - - - - ---------- - -----·----- ---- - - - - - --1


NO. MW NO. FLOVl PER NO. $AVINGS PEH YEAR
OUTPUT OF PUMP OF BASED ON 2.1 CENT PER KWH
PUMPS GI'M HOURS TOTAL
f'ER PUMP
$ $
400 2 2,818 552 5,116 10,232

2 350 2 2,tFi5 1,419 20,156 40,312

3 300 2 2,113 2,059 35,()53 71,306

4 250 2 1 ,I ; 1 1,314 24, 1191 48,982

5 200 2 1,4WJ 1,314 24,;'93 48,586

6 150 1 ?. ! 1:1 587 10,1 ·I 10,164

7 100 1 1.·10() 1,428 26, 11 IQ 26,400

----- -----
-·---- - ___ ]
- - - ·----- ---- --- - ------ - ---- ------------- - - ---

TOTAL $ 146,213 $ 255,982

I
TOTAL COST OF TWO DHIVES: $ 1.1 06,00Q_()Q

TOTAL SAVINGS PER YEAR: $ 255,982_00 I

DRIVE PAYBACK TIME: . 51.8 Months J


_j

Table 4-4

ECONOMIC ANALYSIS APPLICATIONS M/\NUJ


---- ----
24 HOUR SERVICE (713) 467-2523
T
1_.
. ___ .-_:_·_ .

~- ,•

4-17
'-}
-- -~----··------------------

BOILER FEED PUMPS

,----.-- --
-P,ER'C l~·NUF.FI €1 ENCY
0 0 0 C> Ci 0 0 0 0
m co ,-.~ (l) l1) o::t M N ,- 0

-- ......
- '-- -
0 0
0 0
0 0
BRAKE HP ,- tn 0
1--- f--

-- ~- r---

- - f- --- ~---- ·----· ---- - - - - - -~


-- w
I-
:>
0
0
z
- -- -- ·-
:2
~
a:
w
a.
I en
0 z
0 g
f - f-- -1---- f--

v
f-- f---

/
I~ ..J
~
<!J

~,~
~
q,
'If :;::> "'Oi
0
0

-~~ '~l
0
t--- t-1-~ r-c----0
I
0
M
II

LiJ
f- --
a:
;l:-
~\ 9
h:
~ en 0

?o---*" f~-
I 0
f--- t-------- 1-------
~ ~
a.
::c
' r'-,f-- -

~
m
0
~ --
0
·o
......... ,-
I'- I

1---- t------ --

1.-.
0 0 0 0
0 0 0 0
0 0 0 0
0') ...... c.o tn

TOTAL HEAD IN FEET


-------------------------------
Figure 4-6
4-18 ~------

PCC UNIT 2 MEGAWATT READINGS


(1/31/92 to 2/6/9;')

26.0%----------- ---- ------- --

24.0%
22.0%
20.0%
~
UJ 18.0% -
16.2"n
UJ
16.3%
~ 16.0% --
15.0%
LL
0 14.0% -
1-
zUJ 12.0% -
(.)
a: 10.0% -
UJ
a.
8.0% --

6.0%
4.0%
2.0%
0.0%
0.0%
50 100 150 200 250 Jl)Q 350 400

. . MEGAWATTS

I~:
~
Figure 1-7
1 "!!
£Z

i
ECONOMIC ANALYSIS
24 HOUR SERVICE ---(7-1J-)-467-2523
1\PPLICATIONS MANUAL
______ j
~-
4-HJ
7000 HP - 3570 RPM - PUMP - THROTTLE CONTROL
POWER ANALYSIS AVB - FPLK1BP2-9:10113
------- ------ -~- ---- --- ------ --~--~--------- -----
- - - PLANTPARAMEniiis---, ----
EXISTING ROSS HILL CONTROLS VFD
---~ --·-----·----------·- ------------ ---·----- ---------------------- ---
FLOW HEAD POWEFI UNIT MOT POWER SPD UNIT MOT VFD POWER
GPM FT HP EFF- EfF KW RPM EFF EFF EFF f(W
2818 6861.9 4404 70.4 95 1 4096 3426 79.2 95.1 97.8 4465
2 2465 6726.4 3777 63.3 95.2 467B 3344 75.9 95.0 97.7 4001
3 2113 6609.4 3181 56.5 95.2 4410 327G 71.5 94.9 97.6 3fi86
4 1761 6510.3 2611 50.0 95.2 4097 3222 65.7 94.8 97.5 3210
!) 1409 6429.3 2063 43.2 95 1 3750 3182 58.2 94.7 97.3 2869
6 2113 6609.4 3181 56.5 95.2 4410 327f) 71.5 94.9 97.6 3586
7 1409 6429.3 2063 43.2 95.1 3750 318:> 58.2 94.7 97.3 2869
ENERGY ANALYSIS AVB - FPLK1BP2-030113
PLANT PARAMETE:RS EXISTING ROSS HILL CONTROLS VFD
----------------- ·---- --- -·------- --------- - -

# FLOW HEAD POWER DUn DUrY ENERGY ENERGY SAVINGS


GPM FT HP HRIYJI Ol
!u MW-HR MW-HR MW-f-1R
2818 6861.9 4404 552 6_3 2708 2465 244
2 2465 6726.4 3777 1419 16_2 6638 5678 960
3 2113 6609.4 3181 2059 23_:1 9081 7383 16~8

4 1761 6510.3 2611 1314 15 0 5384 4218 1166


5 1409 6429.3 2063 1314 15 0 4927 3770 1157
6 2113 6609.4 3181 587 6_7 2589 2105 484
7 1409 6429.3 2063 1428 16.3 5354 4097 1257
-/; JTALS 8673 99 0 36681 29715 6965
ECONOMIC ANALYSIS * AVB - FPLK1 BP2-93011 :3
PLANT PARAMETERS EXISTING ROSS HILL CONTROLS VFD
-~ ------ -------------------------- -------- -·- ----------------------·- --------------------
# FLOW HEAD POWER DUT'r' DUTY COST COST SAVING8
GPM FT HP HRIYJ; % $/YR. $/YR. $/YR.
2818 6861.9 4404 552 6.:1 56872 51756 5116
2 2465 6726.4 3777 1419 16_2 139392 119236 20156
3 2113 6609.4 3181 2059 23.5 190697 155044 35653
4 1761 6510.3 2611 1314 15_0 113066 88575 24491
5 1409 6429.3 2063 1314 15.0 103464 79171 24293
6 2113 6609.4 3181 587 6.7 54366 44201 10164
7 1409 6429.3 2063 1428 16.3 112440 86040 26400
TOTALS 8673 99.0 770297 624024 146274
---- -------- ---------- ·- ---------- ---------
*(NOTE: ECONOMICS !lASED ON 2.1 CENTS PER KILOWATT-HOUR)

- - - - --------------- --------------------
Table 4-5
'm
0
0
z
I 7000 HP- 3750 RPM- PUMP- THROTT~~~ONTRO:-------- - -- - -~ ~
0 . I
s: 9000 ! I 10000
0 --- . I I II J

CONSTANT EFFICIENCY ! 1 1-,-STATIC


)>
z)> (dash~d curve~)--\, G ~ ~ ~ :. I\ EFFICIENCY,
8100 ~==~===t=====~==='-<.a~ 0 ~ . I 9000
~ • ! I
(j)
(j)
:1
I1 I
I ~~:
'
~i\
0 I .. II !

1/ I I ·I co I· ' · ·I 00
~ SYSTEM~
I I

N 7200 I
A 1
I I I 80
' ' .

+::-
3570 RPM
:I: HEAD VS. FLOW
0 6300 !
~ ! 7000
c I
I

:0
' I

(/)I 5400 · , · 7 - 6000


~I ~~~ 1
~ ~:;/.3212-RPML--i-

~I "':E
[ / HEADVS.FLO'f'
::z:
,. m ,/~ VFDiPOWER "'C

-m
<
() <0"
c
>
-z
0 4500
.

2ass RPM
5000
0
m
m
:r:
HEAD VS. FLOW
-:r::::0

-
.1>-
Co 3600 4000

-... -
N "'C
0 ,/ I
~ 2498 RPM
' -I ~ /, ~
HEAD VS. FLOW

-
w
+::-
en
2700

/'
I
I/
/
/
~
[ 2141 RI?M
HEAD VS. FLOW
3000

'-I 1800 -----I---IT7'7- /!"',., /


~!)('')
I /
1\.)
CJ1
1\.)
w )>
900 I , 1000
"lJ
"lJ
I : l i
I I
f) 1

I ' Q
0
~
6 0 400 800 1200 1600 2000 2400 2800 3200 3600 4000
z
(j)

s:
)>
+- FLOW (GPM) -+
z lVB- co!..:<~SP:-:~c' ·3

I~ l_
::.~tMt·:emrb1WW»t~se ~··twi<t" ·n~r!f', e • .. ~ ...~·.·--.·i~">fV'~.~$~~~·f"""'""'"'"''''
t
B
'"
:!o:"

t 4-21

INFORMATION TO BE SUPPLIED BY THE USER


FOR PUMP ECONOMIC ANALYSIS

NAME OF COMPANY: ~- _____________________


ADDRESS: __________________ _
CITY: ____ STATE: ZIP: - - -
CONTACT NAME: ----- - - - - - - - - - - - -
PHONE NO.: _________ FAX NO.: _ _ _ _ _ _ _ __

ANALYSIS INFORMATION:
PLANT OR STATION: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
APPLICATION: _ _ _ _ _ _ _ _ _ _ _ _ _ NO. OF UNITS: _ _ _ _ __
TYPE OF PUMP: - - -------------------
EXISTING CONTROL: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
MOTOR DATA: HP SPEED _________ VOLTAGE _ __
COST OF ENERGY: $ PER KWI ~

LOAD PllOFILE: (LOAD POINT (FLOW OR MW)/HOUnS OF OPERATION):


-------- -----------------------
------- ---- -----------------
-- --- - - - - ---------
-------- -- -- -----

--- --- - - - - - - - - - - - - - - - - - - - -

(OVER)

ECONOMIC ANALYSIS
4-22
INFORMATION TO BE SUPPLIED BY THE USER FOR PUMP ECONOMIC ANALYSIS
(Cont'd.)

PUMP PERFORMANCE DATA:


Specific Gravity: _ _ __
Performance Curves:
a. Head in feet of water or psi vs. Flow in GPM.
b. Efficiency in percent vs. Flow in GPM.
c. Horsepower vs. Flow in GPM. (Preferably with existing control)
d. System Resistance or Load Characteristics-
Head in feet of WRter or psi vs. Flow in GPM
e. Test block (TB) or Design Rating - He. 1d and Flow
f. Maximum Continuous Rating (MCR) - Head and Flow

* If the performance curves ate not available i11 uni 1:> specified above, informatior.
should be provided to convert the data to the above units k1r analy:;is.
* If performance curves are not available, following it formation is required to
generate default curves.
• Flow or Volume at maximum efficiency
• Head or Pressure at maxitnum efficiency
• flow of Volume at Test 131ock
• Head offset at zero flow or zero volume
• Maximum Efficiency

ADDITIONAL INFORMATION:

- - - - - - - - - --·-· - - - - - - -

----·-- - - - - - -

-------

------··· ----------------
----------- ------------

ECONOMIC ANALYSIS
-=----- - - - - - - - · · - APPLICATIONS MANL --
24 HOUR SERVICE (713) 467-2523
HARMONIC ANALYSIS
J

This side of the page 1s intentionally left blank.


5-1

HARMONIC ANALYSIS

Power system harmonics have plagued than the preceding Standard IEEE
electric utility companies for many years. 519-198 ·1. The 1992 Standard recommends
The utilities have customarily solved their limits on certain harmonic indices (current
harmonic problems by prescri!)ing a limit on and voltaue) at the point of common couplin\J
the harmonics that a manuf, 1cturiw1 plant to reduce harmonic effects at any point i11
or other users could impose on tho utility the system. Further harmonic limitations
system, and/or mandatinq corrective may be required by power utility
measures or imposing financial penalties. specificntions, company standards, and
local government regulations.
The widespread use of non linear loads has
increased harmonics on iJ tplant power In a thre(1 phase full wave bridge rectifier,
systoms with seriotts it'lplant problems. The the thyristors operate in pairs to convert AC
concerns include, but are not limited to, to DC by switching the load current among
transformer overheating, motor fililures, the variot lS thyristor pairs six times pu AC
cap;1citor fuse blowing, and misoperation of cycle. During commutation a brief short
electronic controls. These concerns cannot circuit ou:urs which produces notches in the
be :~olved by simply paying a penalty to line to linH voltage waveform. Commu1.1tion
_ the utility company. For utilities, harmonic produces two primary notches per eye!.' plus
distc:.rtion taxes the i :ntire distribution ~;ystem four secondary notches of lesser magnitudo
and reduces genet ating car·dCity. which ar& due to notch reflections fron 1 other
legs of the bridge. The line current
Tho harmonic di:.tortion h caused by
waveform is essentially a "quasi square
nonlinear loads including static power
wave" current pulse.
converters, arc fumaces, <tnd saturated
mannetic device:;. The ~;tatic power An analysis of these non sinusoidal
converters are the largest n1 1nlinear loads wavesh:tpes by Fourier transforms will
and are used in tlte industry for a variety resolve the waveshape down to a
of purposes such ci:> variable speed drives, fundamental sinusoidal wave plus a number
and uninterruptiblt: power supplie~>. The of higher frequency sinusoidal wavef()rms.
nonlinear loads chLmge the sinusoidal nature These high frequencies are harmonic
of tile AC power current and consequently multiples of the fundamental and are
the AC voltage drop, result it .g in t11e flow determint~d by h =
kp ± 1, where h is thv
of harmonic currt~nts in tlte AC power harmonic order, p is the number of pt llses
system. These l1armonic currents can (6, 12, etc) and k is any positive i11teger
cause interferencn with cummunication 1,2,3 etr:.
circuits and other types of equipment.
In other \t-JOrds, for a six pulse bridge rectifier
Further, when power factor correction
characteristic harmonics present are of the
capacitors are usc;d with those nonlinear
order of !!th, 7th, 11th, 13th, 17th, 19th, etc.,
loads, resonance conditions can occur
where as, for a twelve pulse bridge rectifier
resulting in high levels of hat monic voltage
the characteristic harmonics are of the order
and current disto11 ion.
of 11th, 13th, 23rd, 25th, 35th, 37th, etc.
The harmonic standards in the U.S. and
Calculation of system harmonic levels
worldwide recommend specific limits on
resulting from harmonic sources requires
harmonic distortion. In tho U.S., many
knowledge of the harmonic source
utilities will adopt the recommenda1ions of
characteristics and a representation of the
harmonic standard IEEE 519. The latest
system response characteristics. The
standard IEEE 51D-1992 is more stringent
' 5-2
important elements of the model used to The harmonic currents from a converte1 C?""'
perform these calculations include system flow into any part of an AC system to whicn
short circuit equivalent impedance, it is conner;ted, as determined by tt •...:
characteristics of lines and cables, load impedances of the sy[;tem at the ham :or.
characteristics and capacitor b;mks. frequcncie[:. Several techniques such r
s e r i o s r e <1 c t o r, s h u n t f i It o r s , p It a$ o
A computer simulation program is used to
multiplication catt be used to contwl the
determine the levels of harmonic distortion
harmonics. ·In reality, some harmonic effec •..,
in a given network. The computer analysis
are unavoidable at some points in tt .
will be performed with available system
system. Aho, economic factors ar 1
characteristic data to ensun~ that the
effecti 1enes~. of the harmonic control rnuct
harmonic distortion limits recom• nended by
be cot tsiderE·u in the selection of the c~~ntrol
the standards and/or requirod I ·y the user
scheP1e.
specification are not excee• led. The
analysis is performed at the point of The shunt filters used for 1ed11cti· •n of
influence or point of common coupling. The harmunic currents flowing into ;Jn i\C 1'OWe-(
interface between sources and load is syste1 n con~;ist of one or more tum·d cit ~:ui, .
described as the point of common coupling. The individual circuits consist tJf ~ ,;ri · ~
The analysis results provide information connucted i:1ductor ;md capacitor tun· ·d f·>r
about total harmonic distortion of current and speciiic harmonics e.g. 5th, 7th, 11th, 13m
voltage as well as individual harmonic levels etc.
of voltages and currents up tu the 49th
The basic 6 pulse C(Jnverter produces 5th,
harmonic. All the information is related to
7th, 11th, ! 3th, 17th etc harmon.~
the point of common coupling. It is
frequencies. I he use of 12 pulse conver. r
important to understand that any analysis
theorE:tically oliminatr:;s 5th, 7th, 17th, 1!"-·,
of system harmonics is dependrmt on the
etc. hmmoni ; frequencies reducing the totL)I
quality of the system network itlformation.
harmonic distortion. Further phase
The harmonic filter, if necessary, will be
multiplicati! )n will reduce other harmo,,.c
designed and selected to provido the best
currents an'l the total harmonic distortic ..
and optimum solution to meet the harmonic
distortion requirements.

HARMONIC ANALYSIS -~·--·--------


APPLICATIONS MANL. ,L
24 HOUR SERVICE (713) 467-2523
5-3

EXPLANATION OF HARMONIC ANALYSIS RESULTS


The results of the harmonic analy~:;is always relate to the analyzed circuit configuration.
A typical circuit configuration is shuwn (on page 5-4) for reference. Please note that all
the components shown are not always present in the circuit to be analyzed.
~ The reference analysis 5-1 dttachod consists of following components of the circuit.
1. Source Impedance - Ls and lls.
This information is always required to perform the analysis.

2. Analysis bus - 4160 V Bus

3. Harmonic Traps

4. Bridge Transformer - Three windinn

5. Drive - Consists of two drives assumed as one bridge.

The circuit is analyzed with both drives operating at 70% speed.


The following exphtnation relates !o the attached analysis.
Line 1 Indicates date and the a1 ialysis identification for disc storage.
Date - 930128
ldentificatir 111 - AMEHAR - 3A 1
Line 2 Indicates the voltage of tlte analyzed bus and KVA base used for calculations.
Bus Voltaue - 4160 V
Base - I 5000 KVA
Line 3 Source
Provides source impedance information in per unit values. This information is derived
from the customer providdd data e.g .. short circuit MVA, transformer impedance,
source impedance etc.
Resistance - Rs = 0.008:'3 p.u.
Inductance - Ls = 0.083 p.u.
NOTE: If X/R ratio is not provided, we assume that the X/R ratio is 10.
Line 4 Bus Adder
Provides information on added inductor La and Ra. In this application input inductor
is not added to thn circt 1it.
Resistance - Ra = 0
Inductance - La = 0
Line 5 Bridge #1
Information on added bridgl3 inductor and DC link reactor is provided. In this application
bridge inductor is not added to the circuit.
Resistance - Rf = 0
Inductance - Lf = 0
DC Link Inductance Ldc = 0.00758 Henries
(continued on page 5-6)

HARMONIC ANALYSIS
I 5-4
-- ---~---~-~~--~---- -----------

Ls } Source Impedance
Rs

Source XFMR

(I(Y' Bus XFMR

~
__) La} Added Reactor
or lndnctor
Ra
,--------1
I #6 #s #4 #3 #2 #1

:1111 JT-:
Harmonic Trap-:
La} Added Bridge

Ra
Reactor or Inductor

,;K---- lconv
___ ! Drive XFMR
----- or Bridge XFMR

(V3, 13)

Drive or Bridge
Parameters
(Ldc, Ide, Vdc)

Figure 5 1
Typical Ci:•:uil Configuration for Distortion Factor Analysis

HARMONIC ANALYSIS APPLICATIONS MANUAL


-- - - - - - - , - - - - - - - - - - c - - - - - , - - · - - - - -
24 HOUR SERVICE (713) 467-2523
________________________________________.
5-5
#930128AVB - AMEHAR-3A1
-----~---- ~--------~-- - - - - - ·------------- -------~-------------·--- -·--------~--- --------·--------
4160 VOLT CIRCUIT ELEMENTS (15000 KVA BASE)
Source: As = .0083 PIJ Ls = .083 PU ( .009576 n + 254 IJH )
Bus Adder: Ra = o PU La = 0 PU ( 0 Q + 0 ~tH )
Bridge #1: Rf =0 PU Lf =0 PU ( 0 n + 0 ~tH ) Lclc = .00758 Hen

-----------
Xfmr:
--------------
10000 I<VA
--------~--- -------
Z =-- .08 FL = .008065
- -- --- --------
1'-IL = --------------
.0015 Pri!Sec = 4160 I 3600
4800 VOLT HARMONIC FILTER COMPONENTS
Circuit # Capacitance Inductance Resistance Circuit Freq. Harmonic
(I<VAR) (~tH) (!.l) Q (Hz) #
---------------------------------· ---- -- ------ -------
C1 = 400 L1 = 6111.54 R 1 = . 1151 100 300 5
2 C2 = 400 L2 -= 311 n. 13 R2 = .0822 100 420 7
3 C3 = 1200 L3 = 420.9
--------- --------------------
R3 = .0174 100
-----------------------------
660 11
OJ>ERATING CONDITIONS:
Bridge # 1: 824 AfJC 331~) VDC A == 45.4" U = :l.47". Rc = .109 (12-Pulse)
-------- ·-----·---- --- ·------ ------ - -- ------------------------------
5 '/STEM FUNDAMENTAL COMPONENTS:
Input Bus: 4116 VAC @ .833° lac = 446.9 Amps @ -30.82° (V1, 11)
VFD Filter: 4116 VAC @ .833° lac = 446.9 Amps @ -30.82° (V2, 12)
Bridge #1: 3473 VAG @ -2.03° lac = 643.3 @ -47.1° (V3, 13)

SYSTEM HAfiMONIC COMPONENTS


_f:i_AR~ __ f::_~_l.ls --::?__De9~ ___ II•LJ_!=::'__!>e9.__ lconv
--·----------
#1 #2 #3
---·-- ----- -
#4 --
#5
-~-
#6
- - - ------
Load
--
2376 -1 4i7 31 557 43 42 125 0 0 0 0
------------ ---------- ----
5 1 135 3 -I '34 12 12 0 0 0 0 0 0
-----+-------· ------- ------- -------- ---- ----- -----· ---------------
7 1 35 126 7 0 7
- - - - - - ----- ---- - - -- -- -
0 0 0 0
- - - - · - - - -------- - - -
0
11
- - - - - - - - -------- - - · · -
23 113 49 0 0 49 0 0 0 0
13 14 16 11 107 36 1 24 0 0 0 0
17 2 9 1 99 3 0 0 0 0 0
- - - - - ------
0
19 2 -86 1 5 2 0 0 0 0 0 0
23 24 -94 11 -4 21 0 1 9 0 0 0 0
25 23 172 10 98 18 0 1 7 0
------ --------
0 0
--------
()

29 2 163 1 -I 06 2 0 0 -
1
--- -- ---
0 0
---------- ----- - - -
-
0 ()

31 2 69 159 ----- 0 0 -- --- ------


0 0
------ ------
0 ()

35 23 61 7 151 12 0 1 - - - -5- - - - -0- - 0 0


------t-------- --------- ----~--- -----~ -- ------ -------

37 22 -33 6 57 11 0- - - - - 1 ---
4
-~--------
0 0 0
------------------
()
-----

41 2
------------- ----
1 48 0 0
--- ---- - -
0
-·------
0
---------
0
-----
0
------- -------
0
43 2 0 46 1 0 0 0 0 0 0 0
-------
47 19 -145 4 54 8 0 0 3 0 0 0 0
19 121 4 -149 7 0 0 3 0 0 0 0
-.--------
2377 447 561 45 4:3 137 0 0 0 0

---·---------
RESULTS: Bus Currt!nt OF== 4 86');,
----------- --------- ------ ---
Bus Potential OF= 2.34%
NOTES: 1. CUSTOMER NAME - PLANT NAME
2. TWO 5000 l-IP 4160 V BOILER FEED PUMP DRIVES AT 70% SPEED
3. CASE 1 - UNIT START UP WITH SOURCE TRANSFORMER

Analysis 5-1
5-6

EXPLANATION OF HABMONIC ANALYSIS BESULTS (Cont'd.)

Line 6 XFMR
Information on bridge trtnsformer or drive transformer is giVf'n.
KVA Rating == 10,000 KVA
Impedance Z .08 P.U. or 8% on 10.000 KVA base
(transformer rated KVA base)
Total Loss - FL .008065 per unit
No Load Loss - NL = .0015 per unit
Primary/secondary voltage - Pri/Sec = 4 160/3600 V
NOTE: The transformer secondary voltn.ge for a tht' ~e winding transfor111er is the
sum of voltages of the two secondary windings.

Table 4800 VOLT HARMONIC FILTER COMPONENTS.


This table provides info1 mation about the harmonic traps used to improve the total
harmonic distortion.

The 4800 volt refers tt, the capacitor rated voltage and relates to the voltage of
the bus on which the traps are connected.
4800V = 4160V (Bus vultage) x 1.15

COLUMN 1 - Indicates circuit number.

COLUMN 2 - Indicates !<VAll rating of each trap capacitor.

COLUMN 3 - Indicates inductance in rnicrohenries 11sed with each trap.

COLUMN 4 - Indicates resistance in ohms associaied with each trap circuit.

COLUMN 5 - 0 facto1 ur Quality factur of lhe tra~, circuit.

COLUMN 6 - Frequencv in het1z (Hz) of the filter trap circwt.

COLUMN 7 - Indicates harmonic number of the trap circuit.


The information is provi1 led here for 5th, 7th, and 11th traps used in the circuit.
Similar information will IJe provided fot additional tr 1p circuits if used.

HARMONIC ANALYSfS APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467~2523
5-7
OPERATING CONDITIONS
The inforrnation provided here relates to the operating conditions of the drive.
The information is given here for bridge NO. 1 and similar information will be provided
for additional bridges if used.
Bridge #1:
DC Link Current = 824 ADC
DC Link Volta~")e = 3319 VDC
Alpha Angle of
the bridge, A = 45.4"
Overlap Angle, u = 3.4r
Rippk: Coefficient, Rc == 0.109
(12 l'ulse) == indicates 12 plllse input
(6 Pulse) == indicates 6 pulse input

SYSTEM FUNDAMENTAL COMPONENTS


Input Bus Fur1uamental values of voltage and current at the input bus.
Voltage (V1) = 4116 VAC @ -.833° represents line to line voltage at a Ltgging
anDie of .83:3° with respect to source voltage.
Current (11) = 446.9 Amps @ -30.82° represents line current in An1ps ut
a I, 1gging angle of 30.82° with respect to source voltage.
VFD Filter: Fundamental values of voltage and current at the input of VFD filter.
Since the bus tran~Jormer and added inductor (La and Ra) is not used in
the circuit, tile voltage and current values are same as input bus values.
Bridge #I Fundamental values of voltage and current at the input of bridge # 1.
Voltage V3 - 3473 VAC @ -2.03° indicated line to line voltage at the input
of converter !>ridge at a lagging angle of ~~.03° with respect to source voltage.
Current /3 - 643.3A @ -47. 1 o indicates line current in Amps at a Llgging
anqle of 47. 1o with respect to source voltage.

NOTE: The leadinu angle is representf;d by + sign and lagging angle is


represented by - ~;ign.

HARMONIC ANALYSIS
5-8
SYSTEM FUNDAMENTAL COMPONENTS (Cont'd.)
Table SYSTEM HARMONIC COMPONENTS
The table provides information on the harmonic content of bu:. voltage, bus current
and individual trap currents.
COLUMN 1 - HAilM - I
Lists individual harmo1 de numbers up to 49lh han nonic.
COLUMN 2 - Ebus --- Degrees
Represent phase to ground voltage of bus and n!lated angle, con ~~sponding to
I
listed individual harmonics.
COLUMN 3 - lbus --- Degrees
I
Represents bus phase cur rent and rela!ed aPgle, c~~rresponding to listed individual
harmonics.
COLUMN 4 - lconv
Represents input current at the primary of the br1dye or drive transformer conosponding
to listed individual harmonics. J
COLUMNS 5 throuyh 10 - # 1, #2, 113, #4, 115, 1/G i
Represents phase current in the corresponding trap circuits at listed individual
harmonics.
COLUMN 11 - Load
Represents phase current in the parallel load cor :11ected al the drive input.
The last row of the table gives RMS va.lue!C, of re!C.pective vnltages and currents.

RESULTS: Provides tol;ll harmonic voltage distortion and current distcrtion at the
bus.
Current Distoriion - Bu·; Current OF =- 4.86%
Voltage Distortion - Bus Potential OF = 2.34%
NOTES: Typically provides information related to:
1. Customer Name
2. Name of Plant
3. Rating of the Drive
4. Case Analyzed

COMMENTS:
1. lconv current is not equal lo lac bridge #1 currer 1t becm,se of the primary to secondary
voltage ratio of bridg•J 11 ;1nsformer.
PRI (Vp) /SEC (Vs) = 4160/360')
=- 1.155
konv = 557 A
lac Bridg!' 1f·t = 643.3 A
IGonv = 643.3/1 .155
= 556.96 A

2. The secondary voltage of ! 'ridge? transformer or drive transformer i~, optimized to provide
better power factor at n''' input with allowable alpha angle margin.
3. The impedance of tile ckve transformer is lyrically selected b(3tween 6S~ to 9%.

HARMONIC ANALYSIS \PPLICATIONS MI\NUAL


----------------------- ------------
24 HOUR SERVICE (713) 467-2523
59

HARMONIC ANALYSIS EXAMPLE


The following examples of harmonic analysis cover different cases to show the effects ol
6 pulse converter, 12 pulse converter and several different harmonic filter arrangernenb.
The criteria for the analysis is to limit the total voltage distortion on the input supply bus
to 5%.
Example 1: Analyses 5-2, 5-3, and 5-4
Input Supply Bus Voltage - 2400 V
Drive Rating - 2UOO HP, 2400 V
Drive Configuration - 6 pulse converter, No input transformer
Input isolation transformer is not used because motor is adequately insulatuJ
for common mode voltage levels.

Case 1 (Figure 5-2) - Drive without any filter


Case 2 (Figure 5-:J) - Drive with input reactor
Case 3 (Figure 5-4) - Drive with input reactor and harmonic filter trap:;

Example 2: Analyses 5-5 and 5-6


Input Supply Bus Voltage - 4160 V
Drive Rating - 4000 HP, 4160 V
Drive Configuration - 6 pulse converter, Input isolation transformer - two
winding

Case 1 (Figure 5-5) - Drive with input iransformer


Case 2 (Figure 5-6) - Drive with input tmnsformer and harmonic filte!' traps

Example 3: An,Jiyses 5-l, 5-8 and 5-9


lnpt 1t Supply Bus Voltage - 4160 V
Drile Rating - 4000 HP, 4160 V
Dril'e Configuration - 12 pulse convertm, Input isolation transformer · three
win. ling

Ca:.;e 1 (Figure 5-7) - Drive with input transformer

Case 2 (Figure 5-8) - Drive with input transformer


Tra11sformer impedance is higher than typical 6% and secondary voltage is
reduced to rJhase up the converter bridfJe.

Case 3 (Figure 5-9) - Drive with input transformer and harmonic filter.
Note that harmonic filter is not required to meet the distortion requirements.
ca~;e included to show effect of harmonic trap addition.
5-10

#930,116A\j~-- ~~~~_P_L~--~- ~~=~- -==-~=-


Source: Rs = .015 !'U Ls
- ==- ----- =
2400 VOLT CIRCUIT ELEMENTS (5000 KV/\ BASE)
= .15 PU ( .01728 n
=~=-=-~-~-==- -~ J _
+ t!58.4 pH )
j

Bus Adder: Ra == 0 PU La == 0 PU ( 0 !2 + 0 pH )
____§~~~[~_!f_1~- _ ---~f_= _9__ f=>U u__~_?__~U_LOE2_+ -~J~~ !_'::_?~_ ~---~2_~2~_1::1e_n~ ________________ _
OPERATING CONDITIONS:
Bridge # 1: 609 ADC ~")99 VDC A = 33.4" U == !:>.75°.' Rc == .0859 (6-Pulse)
--------·-~---~---- ---------· - - - - - - - --~-------·--·

SYSTEM FUNDAMENTAL COMPONENTS:


Input Bus: 2307 VAC @ -2.64' lac == ·175.2 Arnps @ -36.23"
VFD Filter: 2307 VAC @ -2.6'1 lac = •175.2 Amps @ 36.23°
I
Bridge #1: 2307 VAC @ -2.6tl lac == 475.2 rU) -36 ..~'
-------· ------ ~
SYS !EM HARMONIC COMPONENTS I
HARM ____Eb~_s ~J:)e_~·-- ___ 1_~1.!!;_::) !:?_~~---- 1£_0_1"1."__ #1 #2 #4 __ _!t~_- #6 --- -~~~d___ j
1332 -3 475 -36 475 0 0 0 0 0 0
----------- --- ---------- --------------- -·--- ·-·· -------- ------ -------1
5 -92 103 0 0
89 103 -1
---·-··-·-- --· ·-·-0 . 0 0 0
~--- --- ---- ----i_
7 69 -164 57 -74 57
11
-

77
-----------------------------
-129 41 -39
41 . . -00 - 0
-0 -()-
0 0
0 ---0-
0
0 .... ---0- --,
0
---- -----·-- -·--·- -------
------- ---- ---·-·----- -- -- ------ -- ------- -- ------------------- ---------
13 68 159 30 - t 11 30 0 0 u 0 0 0 0 I
17 70 -166 24 -76 24 0 0 I) 0 0 -- - -0- 0 I
--·-·---------------~ ----~----- ---------- -- -------- - - - --- --~---

19 64 121 19 -148 19 0 0 0 0 0 0 0
--- ---------- · - - - - - - - - - - - _j_
23 62 156 16 -113 16 0 0 0--- 0 0 0 0
--------- - ---------- --- ------ ----- ------. ---1
25 57 84 1J 174 13 0 0 0 0 0 0 0
---------·-------- - --- - - ---- --- ---- -------

29 53 119 10 -151 10 0 0 0 0 0 0 0
-- ---------
31 49 47 9 137 9 0 0 0 () 0 0
. I-
35 43 ------------------
82 7 172 7 0 0 0 0 0
- - --~----- -------·-- - ~ --- -----
37 40 ----------- 9 6 99 6 0 0 () 0 0
-- ----- - ~------ - -------- . - -·-- ·---- -- -- --- -~ ------- -------·---·--
41 32 44 5 134 5 0 0 --- 0 0 0 0
--- ----- ----- -- -- -------- --- ---------------
4~3 30 -28 4 62 4 0 0 0 0 0 0 0
47 22 7 3 97 3 0 0 ------ 0 0 0 0 0
- - -------- - ----
41) 20 -66 2 25 2 0 0 0 0 0 0 0
RMS 1351
--------- ------ --- ------- - - - - · - - · - - ----------
494
----- --
494 0 0 0 0 0 0 0
RESULTS: Bus CtmPnt OF::: 28.3% Bus Potential DF= 16.9%
1. 2000 HP 2400 VOLT VARI/\BLE FREQUENCY DRIVE
2. 6 PULSE CONVEfHER
3. CASE 1

_j

J
-------------------- ------------ ~----------.J

Analysis 5-2

HARMONIC ANALYSIS APPLICATIONS MANU/


------------------ --· ----
24 HOUR SERVICE (713) 4{)7-2523
, .. ';.,_,~~~ ... -- . '''''·~·~-

'I

SCR BRIDGE SYSTEM VJAVEFOR~v1S

!NPUT BUS:
...---_..________,__ _____ ,

1899 KVA@ .83 PF


I A . • --4~ : .
PLOT PARAMETERS:
!n 1""•urt. . c! lr'l'~n- +
~t-J Vttl._,,"'
lr
·;r~
\~ ~ ~ . ---··-
-(~\
1J. ~ ~
-n

c
L-L Bus Volts
lr~Aim A
ro
CJ1i
r\,\ MAX SCALE CURRENT: i•
'1
2000 Amperes ~~
:1

h
i·!

I
MAX SCALE POTENTIAL: \,,
5000 Volts ~ 't" 1'

I
)>
:II
s:
0
z +a 2 CYCLES AT 60 HZ +
0
)>

·~
\~
ICJ)
#930416AVB EXAMPLE-1 CASE 1
-----------------~'~
I!
5-12
#930~1-~VB_-__ ~X_A~PL_~_-!_____ ___ _ __ ___ _______ ____________ ______ - 't
2400 VOLT CIRCUIT ELEMENTS (5000 KVA BASE)
Source: As == .015 PU Ls == .15 PU ( .01728 U + 4:,8.4 11H
Bus Adder: Ra == 0 PU La = 0 PU ( 0 l..l. + 0 ~LH )
-~~~-g~-Jt_~: ____ !1_1_=:: ~?O_G_ _PU_ Lf "' ---~- ~~L-00_691_~_u _:':_~11J~!__ !:~~___l L~~ -==-~~ 322_f~e~-
OPERATING CONDITIONS:
Bridge # 1: 609 ADC 2599 VDC A == 26.W U == 17.
-·---------------------~-~---------~---- - - - - - · - - - - - - - - - - ·-~-- ------ ------
r Rc == .0699 (6-Pulse)
---------- - - - - - - - ~-~-- --

SYSTEM FUNDAMENTAL COMPONENTS:


Input Bus: 2308 VAG @ -2.6:\ 0
lac == 473.5 Arnps @ -35.68°

VFD Filter: 2308 VAG @ -~.G!," lac = 473.5 Amps @ -35.68°

Brid9e #1: 2162 VAG @ -8.8U' lac


----------------·
= 473.5 @ -35.7"
----- ~-------
--~------

SY! · fEM HARMONIC COMPONENTS


lconv #1 #2 #3 #4 #5 #6 Load
___E!Ju_~-~-1:)~~---- Ibus , lle~.
-36 474 0 0 0 0 () 0 0
1 ----
1333
---------
-3
---------
474
---·----- ---- ----------
81 -90 94 2 94 0 0 0 0 0 0--- 0
5 ----- -·-- -

-161 46 -70 46 0 (l 0 0 0 0 0
7 56

I
44 -123 23 -32 23 0 () 0 0 0 0 0
11 - -- - -·--- ------------------ · - - - ---
---------- ---------

35 166 15 -104 15 0 0 0 0 0 0 0
~

13 - ------- - - -

17 11 -157 'I----- -67 4 0 0 0 0 0 0


------------- --·-·------------ ----- --
--- ------

19 8 132 2 -138 2 0 0 0 0 0 0
- -- ·------------- ----·---------- - - - - - - - - · - · - -·----·- - -··----·-

11 -11 3 79 3 0 0 0 0 0 0 0
23 -- ----
3 8 3 0 0 0 0 0 0 0
25 11 -82 - ·--· ·---

-45 3 45 3 0 0 0 0 0 0 0
29 17 . -· -·- -. ---- - ·-·- ···-- ·-·-----

31 16 -116 3 -26 3 0 0 0 0 0 0
·-·- - - - · - · - · - ---- -------·-
10 -79 2 11 2 0 0 0 0 0
35 ---------·

37 8 -150 1 -60 1 0 0 0 0 0

41 2 67 0 157 0 0 0·-·----------
0 0 0 0
-- - - - - - - - - - - - - - - - - - -

43 3 -4 0 86 0 0 0 0 -- ---
0 0 0
------· --- ----- - - - - - -----------
0
-·-· ·-.---·- -··-- - - ----
47 9 33 123 0
----- ----
0
0 - - - · -0 ·-- ------ 0
-- --
0
·--------
0
------------- ---

49 9 -38 1 52 - --
0- - - 0
--- ----
--
0 0 ---
()---- 0
---·- - - -
0
-·--- - - - - - - - -

RMS 1338 486 486 0 0 -- 0-·--·- 0 0 0 -.---


0
------------

RESULTS: Bus Current OF== c' \''~ Bus (lotential Dl""" 8.93%
----- -- ----- --
. ·-·---- ·--·-··-- --·· -·--···- -··-···-·· ·--· ---

NOTES: 1. 2000 HP 2400 Vnl_T VAl \1:\BLE FREOUENCY DRIVE


2. 6 PULSE CONVEIITER INPUT REACTOR
3. CASE 2

Analysis 5·3

HARMONIC ANALYSIS
24 HOUR SERVICE (713) 467-2523
\ SCR BRIDGE SYSTEM WAVEFORMS
I
INPUT BUS:
1893 KVA @ .84 PF l .;.
• .;.

_..-{,
- '/L.r-..
PLOT PARAMETERS: [(<r ~( \ ~
\ F
Input Current

i1
((S"
c
L-L Bus Volts vr rn ~i/
!~ ;'\l /l :
ro
(J1
i'
{
w MAX SCALE CURRENT: \ )

~ \'-}
2000 Amperes
.1-

MAX SCALE POTENTIAL:


5000 Volts ·V • .\ ~J ~
~ ~ ~

I
)>
JJ
$::
0
z
+a 2 CYCLES AT 60 HZ +
o
)>
z)>
S( #930416AVB EXAMPLE-1 CASE 2
(/)
IC/5 -~----- ~-----
...-
U1
I

f
-""
5-14
#930416AVB - EXAMPLE-1
2400 VOLT CIRCUIT ELEMENTS (5000 KVA BASE)
Source: Rs = .015 ~>U Ls = .15 PU ( .0172!1 Q + 458.4 pH )
Bus Adder: Ra = 0 PU La = 0 PU ( 0 U + 0 11H )
Bridge #1: Rf = .006 f'U Lf ,- .3 PU ( .006912 n + 916.7 11H ) Ldc = .01322 Hen

-~----~-----~---~~--------------
Xfmr: 10000 KVA
-----
Z = .08- - - -FL
-------
= .008065 NL = .0015 Pri/Sec = 4160 I 3600
- - - - - - · - - · - - - - -------- -------------· - - - - - - - - - - - - - - - - - · -
2770 VOU HARMONIC FILTER COMP0NENTS
Circuit # Capacitance Inductance Resistance Circuit Freq. Harmonic
(KVAR) (pH) (!:2) Q (Hz) #
C1 = 800 II = 1017.64
-·---- -·--. ---------
R1 = .0191
---- - -~~
100 300 5
OPERATING CONDITIONS:
Bridge # 1: 608 ADC 2599 VDC A = 2(J.JD U :- 15.2" f{c = .0171 (6-Pulsn)
- - - - - - - - - - - - - - - - - - - - - - ·---- ------- ------------- -~- --- ·------------~-- ---
svsr:M FUNDAMENTAL COMPONENTS:
Input Bus: 2349 VAC @ -2.7" lac 409.1 Amps ro -20.04°
VFD Filter: 2349 VAC @ -;!.T' lac = 409.1 Amps '11 -20.0 11°
Bridge #1: 2195 VAC @ -BJ3" lac = 474 -37 l"

- - --- - - - - - -·- - - - - ·- --- - - - ------ ·-


(Ln

SYSTEM HARMONIC COMPONENT!;


---~j

-~_A1R~_ -~{~~~s ~o~;· --:~'(is =~o~~:____ lc ~~v-+ ~--· 1~_


4 1
#3
0 0
tfl)

0
Load
--·- - - - -

0
----- ·---- -- --~----------·--- -·-·---- -------- ------~-------- ---- ------ -----~-

5 2 175
------------------------------- ----------
2 -- ----
-94 97
--------------
97
------
0
-----
0 0 ()
------
0
--- -----
7 31 -172 -----
2.5 -81 49 23 0 0 0 --+--
0 0
-·-·---· ----
---·-~- --~-----~-------~- --------- ---~---- ~-·.

11 34 -141 18 -50 28 10 0 0 () 0
-- ------- ---· - - ------·-- ----
28 145 -125 19
--··--- ----
7
------
0 0 0 0 0
16 176 5 -94 8 3 0 0 0 0- 0
----------
- - - - - · - - - - · - - - ---· --·-- ----- ---.- --- .

13 101 ~ -169 6 2 0 0 0 0
--- -·---------------·---- -------- - --·------- -- -

0 -48 0 42 ---------
0
·------ -
0
--- --
0 0 ----------0
--
0
25 1 -123 0 -33 0 0 ' 0 0 0 () 0
'--·--- ------------- - - - - - - - - - - -
?9 10 -92
----
2
- -~2-- -- --i- 1 - -1- -
0 0 : 0 I 0 I
--- ----------
0
:Jl 10 -167 2 -76 3 0 0 0 0 0
35
------------ ----
11
--~-·---·
-136
----------- -·----
2 -46 3 0 0 -- -- 0
- -
0--- --
0
-~--·---·

37
----------·----
10 150
---------------- -----------
2 -120 2 0 0 0 0
41 7 -180 I -89
--~--- ----------
1 0 0 0 0 --
0
---------
43 6
------------------------------------
106 1 164 1
-------------
0 0 0 0 0 0
47 0 -43 0 47 0 0 0 0 0 () 0
49 -118 0 -28 0 0 0 0 0 () 0
--------------------------------------- ------- - ----- - -- -- --·--
---- --- ·-- -

RMS 1358
-~------~------------------------
411 -- - --
488
----------
178
----------
0 0 0 0
--------------·---·---· - - - - -
0
-~--
0
RESULTS: Bus Current DF= 8.37% Bus Potential DF=c 4.53%
------------- --------------------- --·------ ---------------·--
NOTES: 1. 2000 HP 2400 VOLT VARIABLE FREQUENCY DRI'/E
2. 6 PULSE C0NVUHER - INPUT REACTOR AND llt\RMONIC TRAP
3. CASE 3

Analysis 5-4

HARMONIC ANALYSIS APPLICATIONS MANUAL


--
24 HOUR SERVICE (713) 467-2523
,-
1 SCR BRIDGE SYSTEM WAVEFORMS

INPUT BUS:
[email protected] ~ + • +

)>
JJ
s:
0
z
~ 2 CYCLES AT 60 HZ -+
(")
)>
z
)>
S( #930416AVB EXAMPLE-1 CASE 3
(!)
Cii ....
\tfl
()1

·~---'
5-16
#9:30416AVB - EXAMPLE-2
4160 VOLT CIRCUIT ELEMENl S ( 10000 KVA BASE)
Source: Rs = .01 PU Ls = .1 PU ( .01731 U + 459 11H )
Bus Adder: Ra = 0 PI J La = 0 PU ( 0 l.l + 0 pH )
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 u + 0 pH ) Ldc = .01972 Hen
Xfmr: 4000 KV/1. Z = .06 FL = .01 NL = .0025 Pri/Sec = 4160 I 4160
---- -----·-- ------- ---- -- ----- ----.--- ------ ---- ---- --~- -------- -----·----------- ----~---

OPERATING CONDITIONS: ·
Bridge # 1: 708 ADC 4473 VDC A = 31.1 o U = 9.71 a fk = .0805 (6-Pulse) ______ !
------ -------------~----------~---- ··---~·-- ---~----------- ------- ------- -· -------·-
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4045 VAC @ -1.7:J" lr-lC = 564.8 Amps @! -37.59"
VFD Filter: 4045 VAC @ -1.Y," lac = 564.8 Amps (<V -37.59"
Bridge #1: 3886 VAC @ -4.5' lac = 552 @ -36° - - - -------j
-- ~------------------

SYSTEM HARMONIC COMrONENTS ---- _ I


#1 #2 113 #4 #5 #6 Load
HARM _ __Ebu_~~l:)~g_._ ___l~ll~ )'2_e~·-- -~~~"- ------------ ----- - - . -----~

2336 -2 565 -38 552 0 0 0 0 0 0 0


----- --~

5 101 -91 117 0 117 0 0 0 0 0 0 0


---------

7 76 -163 63 -72 63 0 0 0 0 0 0 0
---- ---- --- --

11 80 -126 42 -36 42 0 0 0 0 0 0 0
----- -- ··-· --- ---------------- - - - - - ------· ---·

13 69 162 J1 -108 31 0 --
0 0
------------- --
0
~-~-
0 0
------- - - -----·-
0 -~
----------------------- --·· ------·-------- ------------ ---·-·-- -
17 62 -162 21 -72 21 0 .. ()_ - . 0~- ___()__ _9__ _Sl__ 0 ___ ]
19 55 126 17 -143 17 0 __()____ 0 0 0 .. ___q__ .____9_ ----:!
- - ------ -- --------
----,
- -- --- ----------------- ----

23 41 162 10 -107 10 0 0 0 0 0 0 0
----- ----- -- --- ----- ------ -·-- ----

25 37 90 8 -179 8 0 0 0 0 0 0 0
29 21 127 4 -143 4 0 0 0--- 0 0 0 0
----- - -· ----
0 f)
31 18 55 3 145 3 0 0 0 0 0
-- ------ ---- - --------· -----

35 4 91 -179 1 0 0---·- __0 ______ 0 0 0 u


-- -------- - - , - --- --------------
0 0 (\
37 2 19 0 109 0 0 0 0 0
0 0 0 0 0 (J
41 10 -125 1 -35 0 - - -- ___ ____j

43 11 163 -107 0- - --
0
------
0
-----------
u 0 0 ---
0
~-- ------j

47 17 -161 2 -71 2 0 0 0 0 0 0 0

49 17 127 2 -143 2 0 0 0 0 0 0 0
- ----------- ~- ~- ·--· --- ----·· -

RMS 2344 0 0 0 0 583 0 571 0 0


RESULTS: Bus Current DF= 25.9% -·-
Bus f 'otential DF= 8.44%
--·-- -------- ------ ---------
-------··--- . --····--·--------·---
--

NOTES: 1. 4000 HP 4160 VOLT VAniABLE FREOUENCY DRIVE WITf I INPUT TRANSFORMEFI 1
2. 6 PULSE CONVL 11TER
3. CASE 1

Ancllysis ;;.5

HAI~MONIC ANALYSIS _ _ _ _ _ _ _ APPLICATIONS MANUA


24 HOUR SERVICE (713) 467-2523
..

SCR BRIDGE SYSTEM WAVEFORMS

INPUT BUS:
3957 KVA @ .81 PF . ... .;.

..
~fAA~
'

PLOT PARAMETERS:
Input Current (
~~
VOLTAGE

L-L Bus Volts N


I \ I +'
11;
cQ.
C I
J
(i)
'{'
MAX SCALE CURRENT:

\\
CJ1

2000 Amperes l...


... .;.

MAX SCALE POTENTIAL:


10000 Volts
+

.,.
~ .
.,. :vj
I
)>
:IJ
s;:
z
o +- 2 CYCLES AT 60 HZ ~
(")

)>
z)>

\~cr; #930416AVB EXAMPLE-2 CASE i


i'fl
1-"
.....
5-18
------~· ------· -------~---------------

#930416AVB - EXAMPLE-2
----- ------ ----------·------------~---------- -~------·---~

4160 VOLT CIRCUIT ELEMENTS ( 10000 KVA BASE)


Source: Rs = .01 PU Ls = .1 PU ( .01731 .Q + 459 JlH )
Bus Adder: Ra = 0 PU La =0 PU ( 0 .Q + 0 JlH ) r
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 .Q + 0 ~tH ) Ldc = .01972 lien
Xfmr:
---·----
4000 KV/\
-------·-----~----------------------------~----~-'"
Z = .08 FL = .01 NL = .0025 Pri/Sec = 4160 I 3900
- -----· ------------ -------------- ------------------

4800 VOLT HARMONIC FILTER COMPONENTS
-- ·----~-----~------------- - - - - - - - - - - - -------· - - - - - - - - - -~------~

Circuit # Capacitance Inductance Resistance Circuit Freq_ Harmonic


(KVAR) (~tH) (D) Q (Hz) #
-----·- -- ------~------ - - - - - - - - - - - - - - - - ------------- ---~--- - - - - ------
1 C1= 1400 Lh 1746.15 R1= .0.'329 100 300 :;
- - - - -- ------~-------·--- ---------- -----------~-- ----- - -- ------ -- - - - - - ----- - - - - - - - - · -
OPERATING CONDITIONS:
Bridge # 1: 708 ADC 4473 VDC A = 25.8'' U = 11.5° Rc -== .0631 (6-Pulse)
-------------~--~--- -- - - - -
- - - - - - - - - - - -- -------- ----~--- - ---- ~-~-- ---
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4106 VAC @ -1.81° lac = -168.2 Amps @ -17.59°
VFD Filter: 4106 VAG @ -1.81° lac = 'IG8.2 Arnps @ -17.59°
!Jridge #1: 3690 VAC @ -5_fJ 0
lac = £>51.6 @ -31.6°

I HARM

------
1
5
7
2371
-----------·-·-
4 -156
-2

---~-----------------~-------------·-

47
-------------------·--
-132
-·-·-
468

39
SYSTEM HARMONIC COMPONENTS
. -~~b_ll~_=~ Q~~L- __!l:>_us -~ £:>!9___._ -~~~"'-~ _l!_~ _ _ . #2 ____ _!_~--

----------~---
-------------
-65
-41
-18 517
----~-

107
59
·---
150
--·------ ------
107
21
----·-·--··
--0
0

0
-----
0
-----

---~---
0
--··-

0
#4
0
Load

0
0
0

------·-
11 53
----~--------
-78
~--··--·-
28
----------
13 37
---~----- -··--·-
9
- - - ·----
0
-~-
0 0
13 46 -141 21 -51 27 G 0 0 0 0 0
---- ---- --·-- -----
17 38 -87 13 3 17 4 0 0 0 0 0 0
-------·--·-------- -··------ ---- ----------· ------
19 ----- - - -
-1 50
33 -- ----·-------·-· 10 -60 13 3 0 0 0 0 0 0
-------~-- ·--- ---- - - - - ---~-

23 20 -97 5 -7 6 1 0 0 0 0 0 0
- ---·---- - --------- ----- ----···- --------------- -- . -- ---·--
25 16 -160 4 -70 5 1 0 0 0 0 0 0
--------------
29 4 -106 -16 0 0 0 0 0 0 0
31 - -
2
--·------- -- -----
-169
··--·------- ---
0 -79 0 0 0 0 0 0----- ---·-
----
0 0
------
35 ·-- -------
8
·-------
64
-------- ------
1 154
·-- ---- --
2
-·---·--- --- --
0 0 0 0 0 0 0
37 9 1 1 91 2 0 0 0 0 0 0 0
--- ·- --~------- -·---·-------- -- ~----~-- --- ---- -- - - - - ------- - - - - -
41 14 55 2 145 2 1 0 0 0 0
---------
0
---- --
0
43 14 -8 2 82 2 0 0 0 0 0 0 0
47 14 45 2 135 2 0 0 0 0 0 0 0
--------··------------------ --·---- ---- --·------ ------- --·- --- -·- -·

--·-
49
------ ------------
13 -18 · -
---------------
2
---------- ---
72 2 0 0 (l
-
0
-------
0 -·-
0
----
RMS 2373 471 534 186 0 0 0 0 0
RESULTS: Bus Current DF=-·--·
· - ------------ --- -·------·-· -------------·-
11.7% Bus Po!t 11tial OF= 4.47%
------ -----·-- ---- __ --- ---- ---~---------- ---------~----- _, -- -----~--

NOTES: 1. 4000 HP 4160 VOLT VARIABLE FREQUENCY DRIVE WITH INPUT TRANSFORMEn
2. 6 PULSE CONVERTER - WITH HARMONIC TRAP
3. CASE 2

- -----··-------~-----~-------~----· ---------- -----~--------~ ---~----- -----------'


Analysis 5-G

HARMONIC ANALYSIS .
APPLICATIONS MANUAL
24 HOUR SERVICE (713) 467-2523
''.::..;:·,v

r---------------~ -- -~

I
SCR BRIDGE SYSTEM WAVEFORMS

I
>
IJ
s:
0
z
~ 2 CYCLES AT 60 HZ +
0
)>
z)>
~
(/)
#930416AVB EXAMPLE-2 CASE 2 Cf
.... p-:"
i"

~--~-,c,· j
(/) --------- ~

-------.----~- ~
5-20
#930416AVB - EXAMPLE-3- - - - - -
--------~---- ----------~ ------------ ---------------··- -·- ------- - --------- -----~~--~-~--

4160 VOLT CIRCUIT ELEMENTS ( 10000 KVA BASE)


Source: Rs == .0 1 PU Ls == .1 PU ( .01731 n + 459 11H )
Bus Adder: Ra == 0 PU La == 0 PU ( 0 U + 0 pH )
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 U + 0 pH ) Ldc = .0197;. Hen
Xfmr: 4000 KVA Z = .06 FL = .01 NL , .0025 Pri/Sec 0
·' 4160 I 41GO
--- -- --------------------~-- ---------- -------- ----·--------- ------. ----------- ---~-~-- - - · ·---
.. - · - - --~
OPERATING CONDITIO. JS:
Bridge # 1: 708 ADC 4473 VUC A = 31 n U "" 9.93° Rc = .0393 (12-PulsP)
- ---- -------------- - - - - ----- -- ---- - --- - - - - - - -------- - - -------~----- ---------- ----
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4045 VAC @ -1.75° lac == 5Gt1.1 Amps @ -37.57°
VFD Filter: 4045 VAC @ -1.75° lac = 564.'i Amps @ -37.5r
Bridge #1: 3886 VAC @ -tL5° lac = 551 .i @ -:<5.9°
---------- -- - - - - - -------- - - - - - - - - - -------------

SYSTEM HARMONIC COMPONENT~;

HARM__ -~-~':1_~~-l?~-~---
2336 -2
lbu~_~__r:>ejJ._
561
lconv #1
-38
#2
tt~ ------· - - - -
552 0 0
--~4- I #: #6
0
-~--- o~ 1·_-o-•~~
--------------·--- ----------
---- --------
5 10 -91 11 0 11
---------
0 o o
7 8 -162 7 -72 -------
7 0 0 -- ~--- - 0 . -- Q ___(:)__ . ----~~-
11 81 -126 42 -35 42 0 0 () 0 0 0 0
I------ ----------1

13
17
72
--------- --------------
6
162
-161
32
2
-107
-71 -- -
---------

-
32
2
--·---- ----
0
------
0
0
0
~ ~ I ~ - --5-- --{-
-----

19 6 127 2 ·143 2 0 0 0 o I o o o
'2
- -··-------

23 42 163 10 -107 10 0 0 0 0 i 0 0
25 36 91 8 -179 8 0 0 0 0 0 0 0
------------
00 0 0 0
29 2 127 0 -'142 0 0 -0- - - - ----- - - ------- -

31 2 56 146
0 --------·- 0 0 0 0 0 0 0
--. ---------· - ---·- ------- --- ~ ---

35 2 92 0 -178 0 0 0 0 0 0
37 -160 0 -70 0 0 0 0 0 0
------- -

41 -124 0 -34 0 0 0 0
------
0 0
t13 164 0 -106 0 0 0 0 0 0
47 18 -160 2 -69 2 0 0 0 0 0 0
49 --·- -------
19 129 2 -141 2--- -------
0 --
0 0 o 1
_o 0
RMS 2339 567 555 0 0 0 0 0 0
RESULTS: Bus
------------ ----·-------------
Cmrent OF= 10%
-------
Bus PotPntial
----·--···-- ---·------·------
----- -----------~·
OF= 5.37'/o
----------- - - - - - - - - - - - - - - - - - - -
NOTES: 1. 4000 HP 41GO VOLT VARIABLE FREQUENCY DRIVE WITH INPUT TRANSFORMER
2. 12 PULSE CONVERTER
3. CASE 1

-------------- --~·- -· --------------------~-


_________ ___]
Analysis 5-7

HARMONIC ANALYSIS APPLICATIONS MANUAL


·-------·-- ·-
24 HOUR SERVICE (713) 467-2523
I
I
SCR BRIDGE SYSTEM WAVEFORMS
I
INPUT BUS:
3955 KVA @ .81 PF .. .. ..

PLOT PARAMETERS: [;~


' ~ ~-, T CURRENT
:r~
I;/\ t,
Input Current (\ ~
L-L Bus Volts
Ti:
(,0
c
j \
....,
CP

Cf
-....;
r
:'- l\ v '-J
~i ..;nr\A r:: C 'u,f RuC'ur::
Q, vt\,_,_
l\ 1 .... ~"~:""'·
i.
I
!;
,J
2000 Amperes I
.\ 'l.f---1 + +
\,
/
MAX SCALE POTENTIAL: l ... '-,.JY
. ...
- .

10000 Volts ,. 't" T

[
>
,.D
)
7
E- 2 CYCLES AT 60 HZ -+
::;
>
:::
>
<
f)
#930416AVB EXAMPLE-3 CASE 1 !tn
~~..;

·~'·

Ul
' "
.l
5-22
---------- ------ ------------· ---- ----- · - -
#9:J0416AVB - EXAMPLE-3
--------~---~---·------------~---·-- -- --------------- -~-- -- --------· - - - - - - - -----·- -----------
4160 VOLT CIRCUIT ELEMENTS ( 10000 KVA BASE)
Source: Rs = .0 t I'U Ls =- .1 PU ( .01731 U + 459 11H )
Bus Adder: Ra =0 Pl J La =0 PU ( 0 n + 0 11H )
Bridge #1: Rf = 0 PU Lf = 0 PU ( 0 .n + 0 11H ) Ldc = .019n Hen
Xfmr: 4000 KVA Z = .08 FL = .01 NL = .0025 Pri/Sec = 4160 I 3900
- - - - - - - - - - - - - - - - - - - - - - - · - - - - - -------- ---------------- --- -------------------- - - - - - - - - - - - - -------
--------

OPERATING CONDITIONS:
Bridge # 1: 708 ADC '1473 VDC A = 23.9° U = 13o Rc = .0289 (12-Pulse)
-- - -·--- - - - · · · - - - - - - - · - - - - ·------
SYSTEM FUNDAMENTAL COMPONENTS:
Input Bus: 4064 VAC @ -1. 77" lac -, 527. rl Amps @ -32.32°
VFD Filter: 4064 VAC @ -1.77" lac =- 527 9 Amps @ -32.32"
Bridge #1: 3655 VAC @ -5.54" lac ,.,. 551.1 @ -30.5°
- · - - - - - - - - - - - - - - - - - - - - - --------------- --- - - · - - - - - - - - - - --- ------ . ----

- ------ ----- ------------------ - - -- ----------


SYSTEM
---
HARMONIC
---------
COMPONENTS
------· ----- ------ -------- -1 · - - - - -· -
-~~-~fill __Eb~_!;-~E_eg._ - lbus _, D_~g._ lconv #1 _!!3_____ I!~-- __ #~ #5_ m; Lond
2346
---------------
-2 -
528-~----
-32 517
- - - - - - -- -
0
--- -
0
-------- -----
0----·- 0
--~-
0 0 - -- --0
5
---- ------ ~- ~
9
-~~----------~--~-
-63 1 0
·------
28 10
· - - - ---
-
0 0 --
0
-------
0
-----
0 0 (\
l ------- 8
------~-------~--~--
-124 6 -3~\
----~-
6 0 0 0 0 0 u
11 67 -66 35 2~i 35 0 0- - - - - - 0- 0
. ---

13 58 -126 26 -3G 26 0 0 0 0
---------------------- ---- . ---- - - - - - - - - -··---~ ~---- ~-- -

17 4 -68 1 2 ')
L. 1 0 0
·--·-------~.
0··- ---
0
19
------ --·-----

23
------·--
16
3
~------·-
-129
---- --·-
-71
---
1
-------·----
4
-- -
-3!1
·-- --

Hl
1
----------
0 0 0
0
0
0 0
!?.___ -----
0
-l
4 0 0 ------------ -1
25 10 -132 2 -41 2 0 0 0 0 0 0
29 0 -16:3 0 0 0
0 ---1
0
-~------·-

----~
31 0 131) 0 0 0 --------
35--- 17
-----------~---·-----
104 3 -166
-------
3 0
---- -- ---
0
----- --- -- --
0 0 _ _j
37
---~-- -----~-
18 43
------------------------
3
-- -----·-- -
133 3
-------------
0 0 - -- ____o -1
41 2 101 0 -169 0 0 0 0
---·-·----~- -------~ --------- - -I
43------ ----·---2 40
------~-
0 130 0 0 0 ------ --- -------· ------0 -I
47 13 98 2 -171 2 0 0 0 . 0 0 0
49
---·----~-- --·-----
10 ----·------~---
37 128
-------·--
1 0 0
- - - --·- ------
0 I~~--~--_ CI.. -~-~~-() - --l
RMS 2348 530 519 0 0 0 0 0 0 0
RESULTS: Bus Current DF= -8.64%
- - - - - - - - - - - - - - - - - - - - - --··----·-- ----- ----~-
Bus Potential
--------------·---·
OF · ·--------
-------
---
4.09% ------------
NOTES: 1. 4000 HP 4160 VOLT VARIABLE FREQUENCY DRIVE WITH !NPUT TRANSFORMER 1 __
2. 12 PULSE CONVERTER
3. CASE 2 I

-------- - - - - -- --------'
Analysis 5-8

HARMONIC ANALYSIS APPLICATIONS Mt\NUAl


------------ - -
24 HOUR SERVICE (713) 467-2523
) ) ) I ) I )
I
)
~~-------- -----

SCR BRIDGE SYSTE~J! WAVEFORMS

INPUT BUS:
3716 KVA @ .86 PF . ... ...

PLOT PARAMETERS:
Input Current
rI~ ~~\ :
) ~\
r"'-\ - , """
L-L Bus Volts
11
I'
)
tCi" . .I \ \\
c
a; I
'
.r
Cf
CP, MAX SCALE CURRENT:
2000 Amperes
.,
~~~ \ \\t1
MAX SCALE POTENTIAL: ... v ... ...
~/
10000 Volts 't
.,. 't

)>
::0
~
0
z ~ 2 CYCLES AT 60 HZ ~
R
)>
z)>
!:<
(/) #930416AVB EXAMPLE-3 CASE 2 I~
~
(j)
k------------------------------------------------------------------------------------------------------- ~

--------------·-·-··· -·---
.·A-
5-24
#930416AVB - EXAMPLE-3
----------- ~ --------~-------- - -----------
4160 VOLT GIHCUIT ELEMENTS ( WOOO KV/\ [lASE) L

Source: Rs = .01 PU Ls = .1 PU ( .01731 •,2 + 459 pll )


Bus Adder: Ra =0 PU La =0 PU ( 0 U + 0 !tH } L
Bridge #1: Rf =0 PU Lf c' 0 PU ( 0 U + 0 1·H) Ldc = .01972 lien L
Xfmr:
---------------------------------------
4000 KVA Z = .08
--
FL = .0 I
-- ----- ----------· ---
NL "' .0025 Pri/Sec
----- --~---- --------------
= 4160 I 3DOO
- - - - · --

4800 VOLT HARMONIC FILTER COMPONENTS L


Circuit # Capacitance lnuuctance Resistancr' Circuit Freq. Harmonic L
(KVAR) (pH) (U) Q (Hz) #
C1= 200 L1' · 12223.W R1= .23(1:1 100 300 5
2 C2= 200 L 1 ~' 6236.27 R1= .164', 100 420 7
660 11 L
3 C3= 600 L1, 841.81 R1= .034" 100
------------------------------------· ------ ------ --------·--·- ---···-- ----
OPERATING CONDITIONS:
l
______ f3r~d_g~ #_1_:__7_0~~[)_~-- '14~3 yo_c __~__== _?~_.6" u .!}_:_1° n_~ =_ .~30~_(1?-~~lseL ______ _
SYST! .M FUNDAMENTAL COI\WONEN rs: 1
Input Bus: 4094 VAC @ -1.G lac o-o 482.il Amps @ -22.3~1" l
VFD Filter: 4094 VAC @ -1.UO lac = 482.:1 Amps @ -22.35° .l
Bridge #1: 3680 VAC @ -5')2° lac =- 551.1 @ -31 1° l

1
SYSTEM HARMONIC COMPONENT~;

HAnM~~-=2~~~~s~?:~~-- :-~~~:; ~Q_t~f- J~~~~ --~~- J J{--~ ~f~ _#04~:~--~~~ ff.'


(
Lund
0
l

~
11
-~-=~~~i-= - - -
1 -161
:.1 -1-~i- -- ~
-7 I
1

38
1
~
0
~
0 l8
~~ ~ci_l ~t
0 ! -----
0
(}
0
0
. J

·- ------. ·- ----·-cd.
0
--- --- - -- . - - - - ·----j
1:3 21 -136 9 -46 29 0 1 18 0 0 0
- --- -·--·-- ·--- -----··- --------- -------·- -----
11 3 -80 1 10 2 0 0 1 0 0 () 0 .L
-··---- --··---- ----------- - --·--·------ -- --------- -~- -·

19 2 -142 -52 1 0 0 1 0 0 (\ 0
- -·--- ----

23 17 -87 4 4 8 0 0 3 0 0 u--- 0
--·--·- ---
1
2G 14 -149 3 -59 6 0 0 2 0 _o__ _ o__ o -~
29 1 -93 0 -3 0 0 0 0 0 0 0 0 --1
31 0 -156 0 -66 0 0 0 0 0 0 0
- ---·-- - -·- . -:J
35 4 80 170 1 0 0 0 () 0 0 0
0 --.l
37 6 17 - - - ---- --- -
108 2 0 0 1 0 0 - -
0
---·

41---- 1- - - - - - ----------
73 0 163 0 0 0 0 () 0 0 0 J
----- -·----- -- ---

43 11 0 101 0 0 0 0 0 0 0 0 .l
--- -- -·------·------·----- -------
47 11 66 1'16 2 0 0 0 0 0
49----- ---------
11 - - ---- --
4 l4 2 0 0 0 0 -----0 --- --·---.
-·-- 0 -.J
RMS 2364 4B3 519 24 22 75 0 0 0 0
RESULTS: Bus Current DF= 2.37% Bus Pc tential DF"' 1.48%
NOTES: 1. 4000 HP 4160 VOLT VARIABLE f-=HEOUENCY DRIVE WITH INPUT TriANSFo'RMEPJ.
2. 12 PULSE CONVERT! .R - WITH IIARMONIC TRA!'S .J
3. CASE 3
~'
- - - - - - -------- -----'
Analysis 5-9

HARMONIC ANALYSIS t\PPLICATIONS MANU/


. - - - - .. - - - - - - - ---- -------
24 HOUR SERVICE (713) 4G7 -2523
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SCR BRIDGE SYSTEf\11 VVAVEFORrV\S
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3424 KVA @ .94 PF


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PLOT PARAMETERS:
Input Cu:-rent
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~. ., CURRENT l \ .
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L -L Bus Volts I \\\\
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MAX SCALE CURRENT:
2000 Arr-iperes
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MAX SCALE POTENTIAL:
10000 Volts .,. 't
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5-26

INFORMATION TO BE SUPPLIED BY THE U~~ER FOR HARMONIC ANALYSIS


r• NAME OF COMPANY: ___ --~ ---~-- -~------- ---
"'~ ADDRESS: ------~--- ______________ ----~ _ _ _ _ _ __
t CITY: ______ --------~-~ _____ STATE: __ ~------~~---- ZIP:
'
I CONTACT NAME: --- -~~-~-------~--------- --
I
i
PHONE NO.: _ __ ____ FAX NO.:
ANALYSIS INFORMATION:
PLANT OR STATION: --- ---~-~-- ---- - -- ---
APPLICATION: _ _ __ - ~--------~--~ ---- ~---

NO. OF UNITS: ----- - - - - - - - - -------


POINT OF COMMON COUI 'LINC 1:
• NOMINAL VOLTAGE AND TOt I flANGE: KV

• NOMINAL FREQUENCY: H~
• SOURCE IMPEDANCE Al FU JDAMENTAL FHEQUENCY
AND ASSOCIATED X/Fl l \fl! ·, IF KNOWN.
a) SHOFl CIHCUIT MVA
b) --~---+j , , ;1_ UASE MVA IN PFR UNIT
OR PERCENT OR 01--'lv'l' ··
• PROVIDE SYSTEM ONE 1 .lr\1' (PREFERRED) WITH IMPEDAf\lCE INFORMATION. -
• MAXIMUM DEMAND LOA J C. IRHENT AT POINT OF COMMON COUPLING
COMPLIANCE TO STANDAI D: ~------------
TOTAL HARMONIC DISTOr\! 10 J LIMITS: VOLTAGE ______
CURRE.NT _ _ _ _ _ __
NO. OF VFD DRIVES OPC !Al·NG AT A GIVEN TIME
(FOR WORST CASE ANAL 'SI; ·): _ __
OPERATING POINTS AT \J\il~IU-1 THE HAHMONIC ANALYSIS IS REQUIRED
(SPEED AND OUTPUT HO· !Sl POWER):--~-~ ~-----~-

-----~---~-----

--------- -- ----------

------- ~--- --- ------------ ----~-- --------

ADDITIONAL INFORMATIOf J: _ _ ---~------~-- ________ ---------~


----------~------- ---

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HARMONIC ANALYSIS ·------~~- -----~~ ---~~---


APPLIC/1TIONS f.MNUAL
----
24 tiC·JR SERVICE (713) 467-2523
POWER CONVERSION
EQUIPMENT
I This side of the page 1s intentionally left blank.
G-1

POWER CONVERSION EQUIPMENT

The heart of any variable frequency drive • The Peak Inverse Voltage rating of t11e
is made up of the components which convert SCR's is 200% with one devico failed
AC power to DC and then from DC to AC in a bridge leg.
power in order to operate /\C ind1rction or
• The bridges are designed such that the
synchronous motors. The power
thyristor junctions operate at a cool 95''C
conversion sections of a Ross Hill Controls
temperature at a 5oac ambient
variable frequency drive sy~>tem nre made
temperature.
up of identical rectifier and inverter ~;ections.
For induction motor drives, <'t divertHr bridge • Fluid cooling with a remote heat
section and output filter arn adele• t; these exchanger produces low heat loss in H1e
features will be discussed later. equipment room for clean, quiut
operation.
Whether the drive provided is an induction
• Filtering of the output current and voltaue
motor drive or an LCI synchronous motor
waveforms produce near sinusoidal
drive matters little with Ross Hill Controls.
The rectifier and inverter bridges for the two waveforms in RHCC induction motur
systems are the same within a volta! 1e class. drives; thus, allowing retrofit to a11y
A Ross Hill induction motor drive may be existing induction motor without deratit iSJ
thought of as an "LCI" for induction motors. of the motor.

A quick overview of the power conversion


IDENTICAL POWER
features offered by Ross Hill is in order at
this point. BRIDGES
• Identical bridges are used for both the
The rectifier and inverter thyristor bridges
rectifier and inverier bridges ro ;ulting in
are identical in construction. The bridgus
fewer parts.
are designed as electrical mirror images with
• The power thyristors are gr (1uped in tho rectifier converting AC power to DC and
convenient slide out phase c. dis. the invnrter converting DC power back to
• Slide out construction allows qtlick, easy AC. The power handling device utilized in
access to all components. both bridges is the same power thyristor.
• Fiber optic firing of thyristors provides All the principles of operation are identical.
the optimum voltage isolation ; 1 i 1d noise The only difference between the two untls
immunity. is the manner in which the firing signals
are derived. The use of identical bridge
• Fiber optic feedback from e;ich SCR
construction reduces the parts count in the
continuously verifies proper <•peration.
drive, thus increasing reliability and
• Each phase cell is providud with simplifying maintenance.
redundant thyristors to allow t1 "~ system
to operate even if one thyrist< li in each
bridge leg fails.
6-2

REDUNDANT THYRISTOR The nlost cornmon causes of SCI~ failures


lie in the areas of encapsulation flawf; or
DESIGN intental contamin<lills. The failure
mechanism can be either chemical or
A key feature of Ross Hill medium voltage electrC~chemical in nature, thus resulting in
drive~; is the N-1 thyristor. In simple terms, a variable f~1ilure rate. The failure rate
N-1 is the addition of one extra bridge further deperrds upon the electrical stress
thyristor in each phase leg than is necessary and junction tempemture applied to the
to mE!et the voltage margin of the drive. The devb'. Then~fore, Ollf' key to enhance the
failuro of a thyristor typically results in a reliability is dmating of 1he SCR device. The
shorting condition, i.e. the device always deratir1g rest !Its in lowrH failure rates and
shorts in the closed condition allowing increased MTBF (mean time betheen
conduction of electrical current. This is tile failure).
reason that the N-1 feature is al 1le to work
Extensive te~;ting has shown tl1at thyri -tors
in a string of devices whose put pose is to
operated at loss than 1! tO% of the max in 1um
turn on and off repeatedly.
voltage ratinq show si1 :nificant ir 1crease.s in
A bridge containing the N-1 foature will the lifo of a SCR. It is on this basis that
continue to operate with one device failed RHCC power bridge::> are designed 'Nith
in any or all bridge legs. Tl ,is bilure is thyristors connected in series to share the
alarmed to the operator, whrJ C<J n then voltage stresses.
choose a time to bring the system down
Bridqe assumblies are desiuned Nith
for maintenance. It is only with the failure
devices which will provide a n linimur' 2:1
of two devices in a single bridge leg that
ratio between the devk;e rating nnd the .1eak
the drive will actually shutdown.
working voltage. With the addition o: the
N-1 feature, lhe voltagrJ margin is incre;tsed
RELIABILITY to a rnini111um of 2.5:1 . This d(·sign
approach rdlows th£' drive to con!:nue
Variable frequency drive system reliability operation with a single failed device in f'ach
is best maximized by increasing the reliability bridge leg without decreasing the voltage
of each of its major components, including margin below the minimum 2:1 ratio.
the frequency conversion components.
There are several factors in design, rating, EASE OF MAINTENANCE
control, and applications that effectivnly
determine the reliability of a semiconductor,
The bridge cubicle; are arrunged for
such as the thyristor (SCR).
simplicity and ease · 1f maintenance. All
Thyristor manufacturers conduct operating, power thyristors are gruuped into phase cells
storage, and environmental tests to and placed in convenient pull out trays. This
deter mine the integrity and reliability of pull out feature means that there am no
SCR's. Various conditioning and testing heavy lifts or awkward positions need,!d to
procedures have been developed by the;;e remove SCR's from the bridge loqs.
manufacturers to simulate the most obvious Replacing a single SCn device requires only
causes of failures in an attempt to prevent the loosenin~J of tension bolts in the phase .t
'
and/or weed out devices which may l>e cell; lifting r'ut the faulty thyristor; adding
subject to infant mortality i.e., failure in the a new tllyri·,tor; re-tightening the tension
first week or two of operation. bolts.

POWER CONVERSION EQUIPME_-N_T____.. _-=~---,---:--:: _ _A_PPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
G<l

DIVERTER CIRCUIT AND LCI drives produce a square wave output,


which is unacceptable for the operation <JI
OUTPUT FILTER standard squirrel cage induction motort,.
RHCC adds an output filter assnmbl'/
The RHCC induction motor cL~sign could be carefully selected for the application tu

I described as a Load Commt ttated Inverter


(LCI) for induction motors. However, this
drive differs from a conventional LCI drive
in three ways:
produce a near sinusoidal waveform to tit<!
motor. The filter is sized to provide motor
excitation over a wide frequency rango plu~;
limit total harmonic distortion (THO) of tltt!
motor current to less than 5% at full loa, l,
1. The motor will operatCJ any new or
60 Hertz operation. An output isolatittq
existing standard squirrel cage, or
device is provided to disconned tit•:
wound rotor, induction motor. capacitors in the filter from the m(,tor lt 1
prevent overexciting the motor in the eVL;Ilt
2. A diverter circuit is a1lded to force
that input power to the drive is lo~;t.
commutate (switch off) the inverter at
low frequencies. Charactoristics of the resulting filtered .)utr,ut
are:
3. An output filtnr is addecl to smooth the
1. The voltage and current wave~;llapt)~;
output waveforms and provide
are nearly sinusoidal, typically
excitation for the indu1 :tion rnotor.
containing less than 5% harmontc
As with conventional LCI !.ridges, normal distortion at rated output, 60 Hertz. tlu
operation has the rectifier commutated by motor derating is required.
line voltage and the inveriH comrnutated
2. Low current distortion results in lvw
by the load. Unlike the LCI, thu RHCC
indttction drive incorporates <1 divertur circuit output torque harmonics. No couplit IU
on !he DC link to commuttle the inverter or torsional problems.
bridge during low frequency operation. The
en tit e inverter is commutatecl by the diverter, 3. At all frequencies the output voltaqu
then appropriate SCR's are qated (~;witched and current waveshapes are t;moolh
on) to produce the three phase output. and contain no excessive dv/dt. Tlti:;
Depending upon the motor load, above eliminates high turn to turn volta~Je
about 60% of rated frequency, the diverter stress.
circuit turns off and the irtverter is load
commutated by the combined effects of the 4. The drive can be applied with eitltur
output filter and the back EMF of the standard or high efficiency induction
induction motor itself. motors, either individually or in multiple
motor groups.
I

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CONTROL ELECTRONICS
7-2

VFD DIGITAL CONTROL Primary functions of the control module are:


MODULE • Rospond to operator commands in a
prr::)scribed and stable manner
The control module is desi~met I lo b(~ the • Pr' JVide IIi oper signals for thyristor g; 1ting
focal point for the control and luuic sy3tern in respor1se to command and feedi.Jack
which operates current source typ£' AC ~;itJnals
motor drives. The microproce~;~;or b;1sed • Pr uvide- proper responses to unusual
control module is a self-contained pacLage
of p;::1ge construction using a sinqle b•)ard
per page with a common hinged ~ide. The
system conditions
• Di.tgnoslic and m' ·nitoring interfaces I
1
number of pages can vary depen' ling 11pon
the specific application. Tit•· module Seco11dary I• rnctions of the control module
incorporates state of the art components and are:
manufacturing techniques and includes the
following features: • C<>ntinu:1lly monitor the system for
ur 1desiralJie conditi· ms which may cause
• MIL Spec Industrial Grade components an "alann" or "trip" signal to be issued
for critical functions • Permit "on-line" changes in the operaiing
• lr 1dustry standard processor~ parameters to be implemented
• Microprocessor based logic for drive • Display system stat'IS in the local and/or -
control and diagnostics remote locations
• Multiprocessor control
• Tightly coupled processors
Environmental Conditions:
• Self test diagnostics
• Page module construction Temperature Range
• Non-volatile memory fqJ r'rogram Sto1 age: -40° to l0°C
settings Operating: oo to -t-!)5°C
• rv1ultiple information screens
Humi•lity R. 'nge
• On screen metering with usur selectable
rneters Stotage: 0 to 99% relative
• Customer permitted "on linn" ; )arameter Operating 0 to 99'/o relative
changes within the factOP' sd internal
limits
• Key protection to prevent unauthorized
use
• Black box repairability
• PLC style programmability
• Industry standard Digital comr nunication
capability

CONTROL ELECTRONICS - - - -P.PPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
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1·11
TliE FRONT PANEL (Cont'd.) REMOTE ACCESS PORT
This port is used to provide remote cont.
PRINTER INTERFACE
opqration through several industry/prodt '
The front panel provides an interface to any st<,ndard serial interfaces. Presenl 1' '
printer with CENTRONICS interface tar Jeted are MODI CON and ANSALD()
capability. The printer is used to log various pr•ltocols. The interface consists of d
operations of the drive system: standard serial communications port usi. J
the RS-,122/485 or RS-232 electric l
POWER-ON START-UP MESSAGES definitior,. Remote control via this pC'¥t
• Date and Time permits normal STAI1T, STOP, HOT SYNC,
COLD SYNC, and SPEED COMMAND vi
• RHCC name and Software version the drive system. This port is also capal .)
• Customer Name of 1eporting status of the drive system su ~:
• Communication Connection as alarm, trip, and metering informatior
• Power-on Self Test Status

FRONT PANEL COMMUNICATIONS


STATUS MESSAGES
• Communications Loss with Date and
Time
• Communication Connect with Date and
Time

MODULE STATUS MESSAGES


• Abnormal (with Reason) with Date and
Time
• Lockout (with Reason) with Date and
Time

ALARM/TRIP STATUS MESSAGES


• Initial Message with Date and Time
• Ringback Message with Date and Time
• Meter Values at Trip with Date and Time

DRIVE STATUS MESSAGES


·'
• LOCAL/REMOTE Status Change with
Date and Time
• START/STOP Status Change with Date
and Time
• BYPASS/DRIVE Transfer with Date and
Time

CONTROL ELECTRONICS -~-----


APPLICATIONS MANUr.L
--
24 HOUR SERVICE (713) 467-2523
7-1

CONTROL ELECTRONICS
..J ___ -
-
·-----
----
---

VFD ]fl DIGITAL MODULE


0 ll

0
POWER
SUPPLY ON

u
PROCESSOR
()

OK

50

FREQUENCY CONTRCJL

I•
• .~
VARIABLE FREQUENCY
,- MOTOR CONTflOL
_.-,

,-

,-

~ [B.OSS HILL CONTRQL:§) OFF


~ RO:JS HILL CONTROLS CORPOHATION
~
·,( )l
I tiJ(J V.Jeal Sctm Houtston Parkway tJorth. Houston, L ... d.b 17043 ON

I ,.....
IRl I FINMECCANICA I ANSALDO
CHANGE
ENABLE

" II
" I
,.....
7-6
TRIP DISPLAY SCREEN
Selecting this ::creen allov s tl iO use -
to display the status of t:1e rnoduiP
and system tt ips. All ai munr:iuteu_
shutdowns arn highlighted. Tht-
number precedi·1g the highligllied tri 1
conc:Jition indic0tes the srJquence c~
trip events.

DISPLAY o~.:VICES SCREEr-


Seleding tl-i--; screen displays tht;t
relati\·e location and conditiun of oac ..
SCR (thyristor) and diode in th -~
system. All ( 1 • r · :ctive SC Rs an . .
diodes are hi~ >lighted.

SETPOINT ~;HANGE
SCREEN
The user cu 1 change sever~.
setpoints US( I by the module .-
control the vat 1ble frequency < lriv,...
The "RAISE V \LUE" push button .-.
used to updatf the selected setpoi~•
value. Pushin! the "RAISE VALUF:-"
button cycle: the change value::;
within the pre~~"t range. The chan!:J..J
operation is inl Jrlocked with the frc ~-:
panel change r.;nable key.

CONTROL ELECTRONICS
--·- ------·---·-~-·--~--------- ---~----~---~----- --------- '\PPLICATIONS MANU -
24 HOUR SERVICE (713) 467-2523
7-/
DATE AND TIME UPDATE
SCREEN
The: user can reset the time and datl;
display using the Date and Tirnu
Update Screen.
The Raise and Lower push button:,
are used to change the value of the:
selected item. When set, the clock
waits until the start of the next secon~ l
to reset.

CONTROL ELECTfiONICS
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r

ROSS HILL CONTROLS


CORPORATION
COOLING SYSTEM OPTIONS
- r
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ROSS HILL CONTROLS CORPORATION
t
·~ COOLING SYSTEM OPTIONS
1

I t
OVERVIEW

• Forced ve11tilated or closed loop liquid cooled systems available


• Conservative design provides safe power device junction temperatures
• Redundancy provided for critical components

FORCED VENTILATED CClOLING SYSTEM


• Standard supply for DC and low voltage AC drive systems
• Designed for reliable operation

CLOSED LOOP LIQUID COOLING SYSTEM

• Standard supply for medium voltage AC drive systems


• Quiet, clean and efficient operation
• Designed to facilitate ease of service

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8-2

COOLING SYSTEM OPTIONS losses are di~~char~ ed to the outside


environment, the lar· Je air conditioning
system and forr;ed ai' fans necessary for
OVERVIEW an air cooled systen are not required.
Ross Hill Controls Corporation provides Elimination of filis air handling equipment
either forced ventilated or closed loop liquid signifi( :antly reduces t ·re noise associated
cooled variable speed drive systems. with tl1e VFD.
Whether forced air or liquid cooled the
conservative design of the RHCC cooling
The cubicies are co )led by convection
coolinq, rather than fo 1 ced air. This means
t
f

system will assure safe operating airbome contarninant: , such as dust and
temperature margins for power devices. dirt, are not blown into the system.
The thyristors used in RHCC drive syst<?rn~; TherPfore, "fOil are tssured of cleaner
are rated for operating junction temperatures opernting oquipmet t without requiring
of 125°C. The RHCC cooling system, air filtered ambient air or lhe cle8nliness of an
or liquid, is designed to provide device air cunditionocl envi11 nment.
junction temperature, at full lo<~d, of 95°C Sinco large uir conditi ners ure not required
or less. Since the life of a thvristor is directly for tho liquid cooled ~ {stem, overall system
related to the operating junction efficif:ncy is much be 1er. Typically, a 5000
temperature, the conservative 1' ~rnpemlure HP drive will requ!e three 15 ton air
marqins designed into the HHCC systems conditioning unils (h •J operating, one for
<1ssure you, the customer, the highest level redundancy). C )mpare the power
of reliability. consumed by litis ai• conditioning load to
FORCED VENTILATED the two horsopow r pump and two
horsepower l1eat exct· mger fan used by the
COOLING SYSTEM liquid cooled system
Forced air cooling is stand;ud ·:;upply with Drives featuriny the : ~HCC liquid cooling
the flHCC low voltage (480V or GOOV) drive system feature bett• r reliability than air
systems. Designed to allo··.N the safe cooled units of com ·arable horsepower.
temperature margins previously discussed, With the liquid c:oolin1 system, operation is
the forced ventilated cooling ';yst0m will no Iunger tied to 1 1eration of the air
assure long term reliability with the low conditioning svste1 Since the active
voltage drive systems. compunents of :he liq •cl co~) ling system are
CLOSED LOOP LIQUID isolatod fro111 high v· ilage compartments,
and I 00% rC'dw tdanc of the cooling system
COOLING SYSTEM components is provicf, I, maintenance of the
Closed loop liquid cooling is stan lard supply cooli119 systern can · : performed without
for the RHCC medium voltage drive shutduwn of tl 1e VF system.
systems. The typically higher power rt1tings The combination of q' 1et, clean and efficient
of rnodium voltage systems have higher heat operation makrJs li• :Jid cooling the only
loss than their low voltage counterparts. sensible methu•l of c oling medium voltage
Liquid cooling provides a more quiet, clean drive systems. Cour 'e these benefits with
and efficient means of cooling tl mse higher the reliability built intt our closed loop liquid
power drives. cooling system :md y u can clearly see why
The liquid cooled system uses n deionized Ross Hill Conl1 liS Cc poration continues to
water/ethylene glycol mix to carry heat from be the leader iJ 1 variai e frequency AC motor
the VFD power components (SCRs) to the drive systerns.
outside atmosphere. Since most of the heat

COOLif'-lG SYSTEMS
------- Ar' LIGATIONS MANUAL
------ ------
.... ----------
24 HOUR SERVICE (713) 467-2523
-· '"~~ """_.,.,.,-~~"·-~"'"'~ .
,--n-~:- ~,., ''';"""'"'"""'~·.

VFD LIQUID COOLING SYSTEM I


Cii'-IAlt\ ._:Nt:. .;:, .; ;- ;:.I

-y~
30 GAL
~ 60GPM

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SHUTTLE ·:;....·------., - ' 'INt::
VALVE ~=£ALARM ""BLEED" -
PRESSURE lQ: -·=
---:::::_
1TRIP
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PRESSURE -----....
'i1
10' GAUGE
c
Ci) TEMPERATURE
'P RTD
_.

DEIONIZER
PHASE
=:;C;=
RESISTIVITY
PROBE
RESISTIVITY \ CELLS
LAMP
SHUTOFF VALVE
10% BYPASS QUICK
~ DISCONNECT.___-.-J ......,__---l
HEAT
EXCHANGER
c:: =t= ::::.
12 HP I
('")
0
0
c
z AIR BLEED LINE

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(/)
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5: IC?O
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' ""~ '0 '·M~·r l" "&' ·k:):§yrr-p;;mil%i§'-~i!!lo/ilt1~'£"~-;~·"'
.,. ........ '
This side of the page IS intentionally lei t blank.
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.:I Vt\RIABLE FREQUENCY
}~

I;;·.;IOTOR DRIVE GUIDE


1
SPECIFICATION
.I (1\flEDIUM VOLTAGE)

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This side of the page 1s inte11tionally le t blank.
9-1

VAPIABLE FREQUENCY MOTOR DRIVE


GUIDF SPECIFICATION (MEDIUM VOLTAGE)

1.0 GENERJ\ ;_ 2.0 MANUFACTURER


RESPONSIBILITY
This specification c. ,vers the requirements
_ for a variable freq~ 1ency drive (VFD) to
Manufacturer shall have responsibility for
control the speed ,f a standard or high
design, procurement, production, quality
efficiency, three ,d1ase squirrel-cage
control, testing, and documentation, as
- induction, or a syr: :llronous motor. The
necessary to furnish a completed system
VFD shall consist of 1 thyristor (SCR) based
conforming to the requirements of thb
rectifier. bridge to .:onvert AC power to
specification. The manufacturer's systen 1
variable voltagr: DC power, DC link
shall be compatible with the main AC power
smoothing reacto1 . and an SCR based
system, with the electric motor and with thu
- current source invet, }r bridge to convert the
driven equipment.
DC power to a Vet! 1:lble voltage, variable
frequency, current i :gulated output power. All material furnished by the manufacturur
The VFD shall soft ·,tart the motor limiting shall be new, of recent manufacture, an,J
the starting current, : ,tpically to no more than of proven design. Previously used,
motor full load curr. 11t, accelerate the load refurbished, or remanufactured rarb,
and control its spee., proportional to the 4-20 components, or assemblies shall not b.:
mA automatic proc, ·ss signal. Tho driven furnished in conjunction with the specified
load will have a (v·riablt:/constant) torque equipment. Components and assemblio~~
vs. speed profile o· .-:r a speed ranqe from in like service shall be directly
_ _ _ _ % to _____ % spend. interchangeable.
This specification • , intended to describe The manufacturer shall be capable uf
an industrial gracl: curl'ent source VFD providing any technical assistancu
which will provi<!.: thn reliability this necessary during the installation and
application require~ . Tho system E;hall be start-up of the system.
per the attached el. drical one-line diagram

I - and include the f1. !owin~J:


• Input isolatiO!i transformer (when

I required)
• SCR bridge ct •. icle
• Control cabinel
• Pump cabinet
• DC link reacto: cabinet
• Output filter c1 :: d~le (induction drive)
• Field supply C<1: ,jnet (LCI 'synchronous
drive)
• Switchgear cui •!de(s)
• Heat exchang11 cubicle (outdoor)
• Squirrel cage i1 1duction or
synchronous n i ltor (optional)
9-2

3.0 QUOTATION 3.8 Pmvide a preli: :inary computer


analysis t stim ting harmonic
REQUIREMENTS di~.:;tortion on the ncoming AC line.
(Source imped, ·1ce and systeh1
Response to this request shall re~~i1 e operation del 1ils 1 ust be provided in
i_
submittal of a technical proposal of ~;uff1c1ent thr: specification.)
detail to fully define the variable f1 uquency
drive offered. 3.9 Spare pnrts qual· per Section 4.0.
As a minimum, the technical propo::;al shall
include the following: 4.0 SPABE PAl iTS LIST
3.1 1\ detailed proposal compl·!te with
The manufacturer ·;hall list in his proposal
1~rochures and an installatiun list.
the recornmen< led r ritic; d spare parts for the
3.2 /\ completely filled out quotation data drive and include the :ost of each part ..
sheet (if required). A sam1 'le dol a If requested by th< Purchaser, the
~~heet is attached. manufacturer .•;hall als<' list recommended
spare parts lor two \2) years of drive
3.3 Estimated dimensions and wuights of operation and incli!de :ost of each part.
llll equipment.
5.0 DRA\IVIf'!G~;
3.4 Uuaranteed overall efficienr ., of the
<mtire system at 50 poi 1 • ~nt, 75
1>ercent, and 100 percent ~ ,>eed or Formal "approval" Jraw 'lgs shall inclu_de a
power one-line dr: ,winp outline draw~ngs,
<1t other specified load poit li '>. -,he
~;ystem efficiency shall include loss0s
and power and cc·: ttrol nterface_ draw1~g~.
/\JJproval drawing~; '_;hall >e submitted w1th1n
lrom the variable frequency drivns,
isolation transformers, input l1armonic
e weeks after roc !ipt ' f written purchase
order. One set of I /pica! ·nanuals, drawings
filters, and motor, if applic;-1ble.
and data nece~;sar·.t for fi Jld installation shall
be included wi!h sl,ipmc 1t. Three (3) prints
3.5 /\n outline schedule for a mairil.emmce
and one (1) rep rod• rciblr · •Jf all final drawings
training class on the unit quotod
~-;hall bE: provided to tl' ' Purchaser. ~he
including tuition. costs at construction
lllunufadurer shCJ.Ii pro rle SiX (6) COpieS
site and the manufacturer's facility. of operation and 1nainl !nRnce instruction
manuals. The in ;trur iion manuals shall
3.6 1\ list of all deviations and exceptions
includo (but not be limited to) device
to this specification shall bn cleat ly
ir1·;truction books, 1::con ''nended spare parts
identified in the bid with reference to
ld schnmatics ar :u bh ;k diagrams. The
paragraph numbers. If the1 o aro no firte:~l dmwings and instn ;tion manuals shall
specific exceptions enum01 ;1ted then bn provided no l;·ter 11 ·n four (4) weeks
it will be assumed that manufactumr's <.1fter start up.
design is in complete colllpliance to
the specification. All drawings an J daiJ shall show the
equipment nutnb(~', location, projoct narne,
3.7 Man days and cost for rnwtufaclurer and Purchase Ot Jer f 'umber.
to provide installation iw;pedion, final
check-out and start-up service of the
drive system. Installation will be dono
by others.

V;\RIADLE FREQUENCY DRIVE SPECIFICA[IONS______ ~------ ___ __ _ Af 'b_!yATIONS MANUAL


24 HOUR SERVICE (713) 467-2!1~3
------- ___________.....
r
'
9-:3
supplied with the bid, indicating equipment
6.0 WARRANTY description, application, and location ot
installation.
The variable frequH 1cy AC drive shall be
warranted for no li :s than one year after 8.0 REFERENCE CODES
installation and sta11 up or 18 montlts after
shipment, whichevc. period expires first. A AND STANDARDS
qualified field sen. ice nngineer sllall be
provided, if require• I, for warranty repairs All work performed and equipment provided
on site at no char~~~~ (tmvel and pnr diem shall conform to the latest editions of the
charges may be bili<:d at applicable rates). following standards, where applicabln.
IEEE Standard 519
7.0 EXPERII NCE NEMA Standard Publications
UL Standards for components
- The drive manui.tcturer shall l1ave a National Electrical Code
minimum of 10 varial)le speed drive ANSI and CSA Standards
installations of ll1is tvpe and voltage
operating for at least 3 ye:ars. These drives
shall be shown 011 an installation list,

I /I\ n l " 01 c cr:u:nlll=f\.Jr.V nRIVF SPECIFICATIONS


9-4

9.0 SERVICE CONDITIONS

9.1 Input Main Power:

Rated System Supply Voltage _______ V 1-/- ___ /o


0

Steady State, 3 Phase, 60 Hz +1- ___ %.


Maximum Phase unbalance %
9.2 Auxiliary Control Power:

a. Rated Supply Voltago __ _ V, +1- ___ %


Steady State, 3 Pha~;e, 60 Hz +1- ______ '!o
b. UPS (Uninterrupted Power Supply) with complete dc'(lils, available
for use in the variable frequency drive system.
9.3 Ambient Conditions:

Ambient Temperature - Minirnurn ___ _


Maximum ____ _
Relative Humidity _ _ _
Altitude
Environmental Conditions (list)
9.4 Installation:

Indoor/Outdoor
9.5 Driven Equipment

Motor nameplate data (for exi:.ling motor only)


Performance Curves
Speed - Torque Curve
Inertia WK 2
9.6 Drive Input Power

Volts AC lin(~ to line nominal at GO Hz. inr)i 1t 3 hase


9.7 Drive Output Power

Volts AC line to line nominal at GO Hz. ouluut ~1 Phase


Constant volts per Hertz
Normal operating speecJ range ___ to ____ .

VARIABLE FREQUENCY DRIVE- SI'L.:CIFIC/\TIONS


----· -··----- ---------- !JPL!CATIONS MANUAL
24 HOUR SERVICE (713) 467-- '523
9-5

10.0 EFFICIEN(_;y Purchaser shall provide following


information to enable the manufacturer to
perform the preliminary harmonic analysis.
·The variable frequen. y drive shall have a
minimum guarantee(\ effici,3ncy of 9!:i% at • One line drawings which include
.ull load, full speed. 1 lle elficiency of major transformer data and system short circuit
_;omponents (e.g. trar, :formnrs, motor, VFD, current available on the purchaser's bus.
1tc.) can be den1onstrated at the • Source impedance or supply impedance
manufacturer's facility. The cost of this in ohms or percent or per unit values.
efficiency test shall be quotud a~> a separate Also indicate MVA rating on which the
line item. The drive uuarnnteed efficiency impedance values are based.
Nill be evaluated at J,OOO $/I<W.
• If more than one drive is involved,
purchaser shall state operatinu
11.0 HARMONIC STUDY requirements of the system.
• Point ol common coupling and maximun 1
The manufacturer o: the drive equipment
demand load current at point of common
_shall perform a bus ,_,nlta~Je and/or current
coupling as specified by IEEE-519.
distortion calculati· .n fot each bu~3 that
supplies a drive. Th · hart11onic study shall
be performed to dt:'.>rmine tl1e harmonic 12.0 TORSIONAL ANALYSIS
content expected on :1 te Pttrchaser's .';upply
bus due to the ad,iilion of the variable The drive manufacturer shall conduct a
frequency drive a1 d to determine the torsional c:malysis covering the motor, shaft
harmonic filter req' ;~rem,mts. Thn total coupling and driven equipment combination
harmonic distortion .· hall not exceed THO to identify torsional resonance and vibration
values as recomm( :tded by IEEE 519, problems in the system speed range. Th(c:
1992 under normal .'Vorsl case opr:rating torsional analysis shall be performed for all
conditions. The re. , )mm(mclud harmonic operatinf) conditions, all continuous
filter shall be su 1 .plied by the drive operating conditions (constant load), all
manufacturer. dynamic (accelerating and decelerating)
operating conditions and worst cast:
A preliminary har1:!onic study shall be
electrical fault conditions.
included in the prot ')sal <tnd shall include
the following: The Purchaser shall provide all necessary
available data for the torsional analysis
a. Expected ha1:nonic components
requested by the drive manufacturer withir1
through 49th L trmotlic.
30 days after issuing the drive system
purchase order. The torsional analysis
b. RMS value of t. tal hilrmonic distortion
results shall be submitted to the purchaser
of current ancl volta')e expectud.
within 8 weeks after receipt of all the
c. Recommend( d harmonic filter to information requested for the study.
AppropriatG shaft coupling recommendations
maintain total l1art110nic distortion
shall be made by the drive manufacturer to
specified abov. ·.
the Purchaser.
d. Proposed hart, :~mic distortion (items
"a" & "b") with d1e installation uf filter.
9-6

13.0 INPUT LINE ISOLATION internal 1•atur; i draft air circulation


(no exter· 1al r 1s shall be used).
An isolation transformer is recommended 14.3 PCB con~ lruct' :n shall be rigid and
for all medium voltage application!:; in which robust. Cor :ponents shall be
the motor insulation level is less than twice wave soh iered lo the PCBs. Each
the line-to-ground voltage ratirrg. The componcilt or the board must be
isolation transformer shall be eitht)r dry type clearly idcntifie• by means of etching
or mineral oil filled or silicone filled or (specify or high hmp< rature curing ink in
type). The transformer shall be designed, accordar,ce v ith manufacturer's
manufactured and tested in acco• lqnce with circuit s· .herr :J.tics. Each PCB
latest revisions of applicable Ni :.MA and module r· rust lso be identified by
ANSI standards and shall be suitable for type/revi: ion 1 1mber.
indoor/outdoor installation on n conc;rete
foundation. 14.4 All printc u cir uit boards shall be
hard wire I. N edge connectors or
The transformer shall be consl111 :ted such plug/soci\et ( mnectors shall be
that the audible noise level at full load shall
allowod.
not exceed the maximum allowable by
NEMA TR-1 Table 0-1. The t~<msformer 1'1.5 The unit · hall be designed to permit
shall have a 1 per unit KVA rating, be ready a• ·:es~ to power switching
designed for "Rectifier Duly", include an SCR cel:s, ( ..Jntrol modules and
electrostatic shield, and includn standard printed cin~uit boards. The
accessories required per ANSI/NEMA placom1 'lt oi COit1ponents, test
standards. The transformer primary winding points, md !ernlinals shall be
shall be provided with two 2 1/2 percont such tha 1 thr 1 are accessible for
taps above and below nominal voltage. The circuit • heel inq, adjustment,
transformer must be a coordinated part of troubles! ·ootir J, and maintenance
the drive system suitable for a converter from the front of enclosure without
application. The transformer slr811 allow full removal of ar y adjacent module,
voltage starting (if requirud for VFD printed t ;rcuil board or assembly.
k>y-pass). The transformer slwll limit the
The we ght -hall be kept to a-
available fault current to a value which is
minimu n to allow removal of
safe for the converter thyristors.
assernbli· !S by ·me man without the
aid of li!:ing , •wices.
14.0 CONSTRUCTION
14.6 The pov, · )r bt ; shall be tin plated -
·14.1 The drive shall be copslructed for copper n td C( rservatively rated for
ease of maintenance to minimize maxirnur•; cur mt rating per NEMA
downtime. The corn11onents sh;lll standarr 's. .' .art circuit bracing
be grouped by function and proviue shall be de~; 1ned for available
interchangeability between any symrnetr ·~~al r ult current.
assemblies which have the same 14.7 The grot nd I· s shall be provided
function. in the c.tbin•Jts of the VFD and
14.2 All printed circuit board (PCB) contacto; s rur ning the full length of
components shall be high quality, all of thr · cal:inets. The minimum
industrial grade type, d(~signed to size sh<tl! be /4" x 1" and be rated
operate within modules using only for shorl circuit current.

VARIABLE FREQUENCY DRIVE SPECIFICATIONS


--~---
\PPLICATICNS MANUAL
24 HOUR SERVICE (713) 467-2523
9··/

14.0 CONSTnUCTION 15.0 WIRING AND EXTERNAL


(Cont'd) CONNECTIONS

14.8 NEMA cl :.trances shall be 15.1 All internal wiring shall be colcJI
maintaine< i in all cubicles. The coded or tagged with permane11t
cubicles sh. :1 be holtt)d tognther to labels at each termination, junctio11
form a C• :llint,ou~; switchgear box, and device. Wire label
assembly. (Jesignations and/or color coding
shall correspond to the schr:matic
14.9 Power and • . ~ntrol ter1ninations shall
and wiring diagrams furnished witlt
be easily a1 :essil 1le for cable entry
the unit. All control wiring shall bt3
in the cubic: : top nr l1ottom. Power
stranded copper conductors, hi~Jil
termination· ~;hall tJe ~:uitablu for bolt
tnmperature, abrasion resi:;tald,
on lugs. C. 1lrol rerlllinatiOJlS shall
r::xane wiring.
be screw i. pe I· :rminal blocks.
15.2 All control wiring shall be isolakd
14.10 The powe1 .~onvnrsi.,n eqt~ipment
from power wiring and all AC
shall be h. qsed in free-standing,
voltages shall be isolated frnm cdl
ventilated I . : :'MA 1, 14 gaw.Je steel
DC voltages via separation 11r u~;e
enclosure witl1 12 gaurJO steel
of shielded cables.
bolted fran. worl·. l loors ·;hall be
lockable .tnd hinged. The 15.3 Insulated compression (crit npod)
enclosure ~ . 1all btJ ck:e1ned. primed, ring tongue type lugs shall I.Je
and finishi . 1 with elc:ctro~.tatically provided for all wiring terminating un
applied pol; :ste1 paint to a 111inimum terminal blocks. Soldered termin<tls
dry film th! lme~;,; of 3 mils. The are not acceptable for conrtection
color shall :le J\i~SI b1 li~Jht gray. to terminal blocks.
14.11 Audible n .ise uenlHated by the ·15.4 All external wiring including input,
controller ir, .ide :t building under any output, grounding, controls, .:ontrol
condition . , f opora lion shall not signal, and alarms shall be wirod
exceed a uund prnssure level of to functionally identified screw type
80 dBA m(. lSUrc:d five (5) f,;et from terminals within the enclosure. All
any surfa, of the enclo~:ure. interconnection terminal blocl<s sl1dll
include 20% spares. A maximum
of two wires per point should l>e
permitted.
;)
15.5 All line and load power connections

I shall be compression bolted type


lugs for reliability. The connections
shall include lock washers and
anti-galvanic corrosion protection to
assure long term integrity.
9-13

16.0 POWER BRIDGES wavefot 'n to approximately 5% c*


60 Hz·.
16.1 The drive manufacturer shall offer 16.2. ~ 12 Ful: '3 In 1erter Bridge
the optimum rectifier bridge
configuration, in conjunction with The po ver 1ridge shall utilize at.
any necessary input harmonic filter SCil cr nfigL• ation to provide a 1 L

system which may be required, to pulse wav form to minimiz


minimize harmonics reflected into ha.rrnorw~s. H !uce torque pulsation,.
the supply bus. The rectifier bridge and to '1Xtert . the operating speerl
may be either of the following: range 1 r the motor. For induction
motors ;m r •· ttput filter system wi ..
16.1.1 6 Pulse Rectifier Bridne be inc'•Jde· to provide a nea
sinuso: lal v C\Veform and to limi
The power bridge shall utilize an
curren! han ·onics in the outpu~
SCR configuration to provide a 6
wavefor:n. .n output transformer
pulse wave. The power l>ridgo shall
with du d prit ary windings shall be
be fed by a transformer with a single
includ1 d, il required, with thi::,_
secondary winding.
configw ttion
16. 1.2 12 Pulse Converter Bridge
16.3 The in1 · rt tu he power converter::,
The power bridge shall utilize an shall b' pro· cted against voltagL
sur~JeE: on ! e incoming line b~
SCR configuration to pruvide a 12
pulse waveform to minimize clarnpir g sr ;es with high powe·
harmonics on the m'lit 1 AC power MOV s trge rrestors.
line. The power bridge shall be fed 16.4 Fen ite (salt able) core reactor:
by a transformer with dun! secondary shall cl:so t::; included for dv/d*
windings phase shifted 30° suppre: ;ion
electrically.
16.5 The lh) 'istot . shall be rnounted ir
16.2 The drive manufacturer shall offer modula; gro• 1ps. Each module or
the optimum invertor bridge pha~;e < ~II ~;! 1all contain associated
configuration, in conjunction with an snubb• r :1nd gate isolation
output harmonic filtf'r system comp01 · 'Ills. The SCR phase cell~
(induction drive only), tc• minimize shall b1 fror ' accessible and fran -
harmonics introduced into the output rernova 1 >le. -ach phase cell shal'
waveform. The inverter l •ridgu may contain 1 per .rtive and nngative ler'
be either of the followir q: of snrir ·; C(l mected SCR's. The
16.2.1 6 Pulse Inverter Bridge SCFl's ;hall · Je standard, proven,
readily .tvail ·ble, conw;rter gradE.
The power bridge shall utili/:e an SCR's.
SCR configuration to provido a 6 16.6 The po'.ter '3CR's for tl1e rectifier
pulse waveform. For ;ttduction and in erkr sections shall bE.
motors an output filter · ystern will identic: t an· I interchangeable fo· --
be included to provide a near simplic:'y c:u·d to minimize spare
sinusoidal waveform a11d to limit parts r• 'Juirt nents.
current harmonics in the output

YAF~IABLE F_REQUENCY DRIVE SPI CIFIQf\.:fiONS _---· ---~ ___ ___ 1PPLICATIOf\jS MANUAL
24 HOUi~ SERVICE (713) 467-/523
-------------------------------
r
!

16.0 POWER BRIDGES 17.0 DRIVE COOLING


(Cant' d) SYSTEM

16.7 SCR's sl1 ,!1 ho of a mature 17.1 The power bridges shall utilize .1

I manufactu1
allow repla•
•19 todmcJiogy which will
. :menl of individual failed
closed loop liquid cooling systnm lur
optimum efficiency, increased

I
: -
devices wit:
to replace
,)ut rt:sorting to I he need
dl d(;vicos in a bridge
reliability and to minimize tho si.::tJ
of and dependence on <.:tir
! leg. conditioning units. Bridge coolittU
shall be accomplished using d
16.8 The syste: ; sh; dl bo desiuned to
mixture of deionized water ar.d
continuous: - provide rated power in
ethylene glycol which shall have dll
a 50°C an. ~ient at 7500 ft. altitude
ambient operating range from -30'\_:
with a m1 imttin ~;cR jttnction
to +50°C.
temperatt ,o c,f D5°C without

I 16.9
derating tl, sy~.tem.

All high vc.: tge :.hall be isolated at


17.2 The major components of u,~:
cooling system shall consist of 1oou;)

II
redundant close coupled centrituwd
tho phase ell L )r uperatot" safety
pumps, a liquid to air (or liquid tu
in the regu: -!or c. ;mpartment. Gate
water) heat exchanger and a mix(:d
pulses shcc1o be 1: ansmitted utilizing
bed resin filter to maintain the punt y
fiber optic '"chniquos to rninimizo
of the deionized water/ethyle11u
noise probl- ms. The regulator shall
qlycol solution.
monitor inc 1 tidu;d SCR's to insuro
they receiv, their gate sign; 11 at the 17.3 Either pump shall be capable tJt
proper tin., and that each SCFl running as the primary. Tho
conducts '' , I bl( •cks at the; proper back-up pump shall automatically
times. Sh( dd either the g<tle firinu start if the primary pump shuts dow11.
or SCR co1 -lucti, ill be impt oper an The cooling system shall bo
alarm in die :ion <tnd <mnunciation of designed with a separate low volta~JLl
the individt d failed device ~;hall be cubicle to allow resin bed filtur
provided. replacement or pump servicinq With
the drive completely operati,mal
16.10 Each leg c: ihe flOWer bridqe shall
contain se;: :s SCR's which have a 17.4 All hoses shall be comprised of
minimum p. · 1k inverso voltaqe (PIV) hi-dielectric, flexible material
rating of ; ·10% with all devices pressure rated to a minimum of 150
operatin~J Tho failure of one PSIG. The hose shall have an
device, in : ty 0118 k:g or ; ill legs, operating range of -40 degrHes F
shall not c. -1se :~ shutdown. With to 250 degrees F. The hose shall
one device :lwrJ,:d, the PIV rating t >e Hi Pot tested to 50KV.
of the po• .:r bridge sh;:tll be a
minimum o: 195°,. All SCR's in the
VrO shall : , ; te~iled to inSlll"e they
have simil;., char:lcteristics so they
will share L;.; power reliably durin~J
turn-on, 01. ratio11 and turr1-off.
9-10

18.0 DC LINK REACTORS 19.0 INSTRUM .:.NTATION


(DCLR) AND .-;Qi ~TROLS

18. I Two DCLR's shall be provided. One 19.1 The in: trui 1entation shall be
for the positive and one rot the designe1: for ·r1se of operation and -
negative DC side of the power mainten; nee I the equipment and
bridges to properly control current shcill as a n· ·1imum include:
flow during normal operation and
Output :. oqu· ncy meter
any fault condition.
Output ·oltn 1 Jer
·t8.2 The reactor shall be desinned to limit
Output •rnm '11r
the peak to peak DC ripple to
approximately 15%. "Local- · ~em1 e" selector switch
Local s1•eed 10tentiometer
18.3 The reactor shall !Je dry type,
air-core convection cooled w1th Motor "'·tart op" control
Class H insulation not to m ceed Cooli1 g I' mp and blowe-
Class B temperature ri:::;o Tlte "Hand-Cff-Al' •" switch
reactor enclosure sholl be NlMA 1 Red mol· q· ou 1ut contactor "Closed"
indoor or NEMA 3R outdoor with light (in lucli· 1 drive)
screened or louvere<J C1lJGninqs.
Greon :not· r output contactor
18.4 The enclosure shall be provided with "Open" 1ighl induction drive)
a ground bus. Grenn ' l"riv- OK" light
Green ·· t\lan > OK" light
Logic p •wer illl
Motor 'Driv· Off-Bypass" contro 1
(option< d)(ind .;lion drive)
Red in1 >~Jt c' ·tactor "Closed" lighL
(optionnl)
Green i tput ')ntactor "Open" lighl
(option;.!)
Red by! ass -lased" light (optiona,,
(inductic 111 ell ·e)
Greon I ;pa~. "Open" light (optiona.,
(inducti· ·n d! o) -

Vl\f~IABLE FREQUENCY DRIVE: SPECIFICATIONS APPLICATIONS MANUh ...


-- ---~------ ----- -~----- -~~-

24 HOUR SERVICE (713) 467-25? .


9-11
- 19.0 INSTRUIV:ENTATION AND 19.3 A trip annunciator shall be provided
and as a minimum include
CONTROLS (Cont'd) identification of:

19.2 An alarm i!ilnunciator shall be Power supply


provided ani: as a minimum include Output over frequency
identification of: 011tput over current
Input power Output over voltage
Motor staiiE:· i Input over current
Loss of spt .:d c()mmand Field supply (LCI synchronous driVt;)
Heat excha ;qer blower shtttdown Capacitor failure (induction drive)
Low coolin~. fluid lev1:l Coolant Condition
Coolant put iJer bilur1~ Cooling fluid over temperature
High coolin:. fluid ternperat: 1re Cooling fluid low level
Output grot" id f<u1lt Loss of cooling fluid pressure
High ambiE.·: :l air temperatme System over temperature
Loss of thr, cooling water pump Manual emergency shutdown
Series SCFl failuro (with indication Door interlock
of actual cl. vice) Two series SCR failures (indicatio1 1
of actual devices)
19.4 Meters shall be either represented
on the control module display or
individually mounted shock resistant
NEMA switchboard grade with <1270
degree scale. Each meter and
operator interface shall have an
appropriate descriptive nameplate.
19.5 All nameplates shall be firmly
attached by the use of hanlward
such as corrosive resistant sell
tapping screws or approved nqual.
In no case will adhesivos be
l
accepted as an approved rnethod
for attaching nameplates.
f
H

~ ..
9-12

20.0 INPUT AND OUTPUT 21.0 MICROaR( CESSOR


INTERFACES DIAGNQSl .C SYSTEM

20.1 Each output shall be an isulnted 21.1 The contr, dan' regulation functions -
contact rated 10 amps at 600 Vf\C. shall be S( pam ·1 from the protection .
The following minimum VfD status and anrl,rnci. ion functions to _
indication shall be provided: enswre l11at U '} integrity of one
function i~ ma i tained in the event
• Alarms OK
of a faillJ· e of !he other.
• Trips OK
21.2 rhe rwr~ro: ocessor based
• Local Control
diagnnsti< sy.:.l m shall monitor all -
• Remote Control trip and <Y<~rm ; :nctions and display
• Output Contactor Opon (induction them 0n ; ' fror, l panel for indication
drive) by mean:·. of ei 11er LED light display _
• Output Contactor Closed or a con '!)Ute; display.
(induction drive) 21 .3 A RS23~' or I )422 port shall be_
• Spare provided :ur cc · 1munication with the
• Spare User's n·onil ring system. Tht-
syster n sl all b· · capable of remote I) -
20.2 The following 4-20 mA UC output
transmith1g ;1 um conditions, trir
signals shall be provided:
condition: , di~r al signals and analog-
• Output Voltage signals ':sin~ modbus protocol.
• Output Current This c a 1-" 1b iIi : ; s h a II inc I u de t h G
voltage <':ld ( urrent waveforms o.
• Output Frequency
the molt r, tl 1~ input voltage anc'
20.3 The variable frequency drive shnll current l< · the; -irive, and regulator
be configured to accept following analog f1 •!Jctit· s.
user provided inputs as a tninimum:
21.4 The regui.ttor lmll be designed tr-
• Input speed reference S;Jnal (~~-20 operate n·mTI; :y with input controL
mA frequency command) voltage frot: 75% to 125% oL
• Remote Start - dry contact nominal.
• Remote Stop - dry cor1tact :.->1.5 The foil< ·winu Diagnostic Option~­
• Input Breaker Open-dry contact (If may be · lros' 1 (select one option
furnished by User) only):
• User Alarm - dry conlact a. Tho d1 ;ve : .111 be supplied with
• User Trip - dry contact an evt r1t w !Hder and printer to_
record the !entity of the drive,
date <'' 1d ti 1e of occurrence 01
any t1 :. ' or Iarm. The recorde1
shall I"~ in' died at the drive o,
at a re•, 1ote .mtral control station.

VARIABLE FREQUENCY DRIVE SPECIFICATIONS


--·------ ------- - - - - · ----- - - -
F>PLICATIONS MANUA
24 tiOUR SERVICE (713) 467-~'523
r -------- ··------~-
2£ Q#.tlflp'·
'. f-~' ;. '-

Ii
,·.,

9-13

21.0 MICROPROCESSOR mask to prevent solder tracking.


The PCB shall then be oversprayod
DIAGNOSTIC SYSTEM with a clear insulating varnish to
(Cont'ri) protect the PCB from corrosion.

2-1.5 (Cont'd) 23.0 OUTPUT FILTER


(INDUCTION DRIVE)
b. The di;.:Jnostic system shall be
design. d to cor,Jmunkate with 23.1 The VFD output shall l1av~: a
any ·· d3M PC" compatible capacitor filter to allow retrofittinu an
comptt•.or usin~J a modem to existing motor without derating u1 to
monito1 the openttion o1 the drive. allow use of a standard irtducttun
motor.
22.0 PRINTr 0 CIRCUIT 23.2 The output filter shall providu a
BOAR;.'S nearly sinusoidal wavel,"m
containing a maximum of !-i% t•.tal
current harmonic distortion at bO
21.1 The print d cir~~uit board:; (PCB's)
shall utilt ~~ S(;lid ~jtate ouvices. Hertz.
23.3 The drive output shall r,owur a
~1 2.2 Semicon' ·, rctor cornponertts of full
standard induction motor of tire
military tt, 11per;dure range (-55°C to
same horsepower without derating
125°C) L, tt h:tve passed JAN-TX
or operation in the servicu factor.
burn-in ; ~ 11d tE:stin~J reqtlirements
shall be ;~sec! for critic;tl control 23.4 Output filter capacitors used in the
functions system shall be manufacturGd in
accordance with the latest slancbi ds
22.3 All cc)'''poitents sltall be
and shall be designed to reduct.1 the
conserve · ;vely rated such that they
voltage, after the power is switd 1ed
will alw. ys oper<tte below their
off, to 50 volts or less in five rninutt::s.
maximu1,, ratings even while the
I system i~ -)per; ttinu at its worst case 23.5 The manufacturer shall strpply an
1- con d it i 1. :1. I\ II ~,em icon duct or output contactor per Paragri!ph
l- devices , trd rr:!ays shall he sealed. 25.3.

,
l- 22.4 After ali .:ompon<:nts have been

I
mounteti and wave soldered, the
L PCB sh;.IJ be ~;outed willl a solder
t
L
l
J
l
l
l
l
l
.l • , ... .......... r""\1 r- , . . - . - , , " ' ...... r-,, ll.ni\Jc cocr--lr·lr/\.Tinf\IC!
9-14

24.0 MOTOR FIELD EXCITATION 25.2 By-Pass (induction drive)


(LCI synchronous drive) 25.2.1 The system shall include a drawout
fused contactor or a fused fixed
24.1 The motor field excitation control contactor with isolation switches in
and protection system shall be line and motor side, to by-pass the
housed in a NEMA 1 enclosure and drive during VFD outage for
shall be furnished as an integral part maintenance or to operate the motor
of the variable speed drive. at full speed. The contactor shall
24.2 The excitation system shall be include a Multilin 269 motor
suitable for connection to a protection relay or equal for overload
volt, 3 phase, 60 i-iz. auxiliary power protection of the motor. A drawout
supply. The system shall provide or isolable input contactor shall be
the appropriate level of excitation to provided to allow complete isolation

I satisfy all required operating torques


in the desired speed range. The
exciter control and protection
module design shall be coordinated
of the VFD during bypass.
25.2.2 Synchronous Transfer (induction
drive)
25.2.2.1 T h e bypass system s h a II be
with that of the motor exciter.
designed to provide a smooth,
24.3 The field power unit shall be a closed transition synchronous auto
thyristor (SCR) controlled AC to AC transfer of the induction motor from
unit to regulate the amount of AC the drive to the main AC line and
power delivered to the windings of from the main AC line back to the
the exciter. drive. Transition shall be
accomplished without stopping or
25.0 SWITCHGEAR slowing down the motor and without
any significant transients on the line.
25. 1 Input Disconnect Device CAUTION In some specific
applications, e.g. pump drives, low
An input circuit breaker, contactor, inertia systems, the synchronous .·
or disconnect switch (fused or auto transfer is more difficult to
non-fused) shall be provided with the accomplish. Purchaser should
Variable Frequency Drive. This consult manufacturer for specific
disconnect device shall have a trip application requirements.
device capable of interfacing with
the VFD trip signals. The 25.3 Output Contactor
disconnect device shall be able to
be locked in the open position, and 25.3.1 The system shall include a drawout,
rated Amps, KV electrically operated contactor or a .
voltage Class, 60 Hertz, _ _ __ fixed, electrically opemted contactor
MVA class interrupting. with an isolation switch on the motor~
side to allow complete isolation of ·
the VFD from the motor.

VARIABLE FREQUENCY DRIVE SPECIFICATIONS APPLICATIONS MANUAl:.


24 HOUR SERVICE (713) 467-2523
9-15

26.0 TESTING After installation, the required drive


testing listed in 26.4 shall be
performed. The drives shall not be
26.1 The drive shall be completely and
dissembled after ·testing for
thoroughly tested at the
shipment to the job site.
manufacturing facility to identify any
components which may be subject
to ''infant mortality" failures. 27.0 START-UP SERVICE
26.2 The equipment components shall
AND TRAINING
meet the requirements of all
standard factory production tests. 27.1 Provide installation check-out and
Each drive system shall be factory start-up service, as required, for
tested at rated voltage and rated proper operation of installed variable
current (these conditions do not frequency AC drive system.
have to be met simultaneously). Installation will be done by others.
A minimum of days of start-up
26.3 All standard routine factory tests shall be included per drive system.
including quality control tests shall Travel and living expenses shall be
be made on each drive system. included.
Thyristors shall have the following
critical parameters tested - gating, 27.2 Ross Hill Controls Corp. offers
turn-on, turn-off, forward blocking comprehensive training courses for
and reverse blocking. All printed Variable Speed Drive systems.
circuit boards shall be burned-in These courses are designed to
continuously for 168 hours at 65°C increase your engineers, instrument
to stabilize the components and technicians and maintenance
detect premature failure early electricians' understanding of the
warning signs. The PCB's shall be VFD's operation, circuit functions
tested after burn-in to insure stability and troubleshooting. A focus of the
of calibration and proper functioning. maintenance course is to develop
All the assembled phase cells shall awareness of things that prevent
be tested at rated voltage, maximum downtime of the drive system. The
current, maximum dv/dt and Ross Hill courses are taught by
maximum di/dt. professional instructors skilled in
drive technology and troubleshooting.
26.4 Continuity tests, protective circuitry Variable Speed drive training can
test and system operational tests be conducted in the customer's
shall be conducted. The completely training facilities or at Ross Hill's
assembled drive shall be burned-in training facilities located in the
at rated full load current for a Houston plant. Please direct your
minimum period of 4 hours. training questions to the Ross Hill
26.5 Whenever drives are specified with Training Department or to your
a control house, the drives shall first regional sales manager.
be installed in the control house.
9-16

28.0 CONTROL HOUSE of the spacer channels shall be 3".


Spacer channels shall be placed
28.1 The control building shall be designed between the runners and stringers
to contain one/two variable at each seam in the floorplate or
frequency drives as specified every 4 feet, whichever is less.
above. 28.4.5 Floorplate shall be 3/16" A36 steel.
28.2 The drive equipment shall be
28.5 Walls shall be constructed in the
mounted, wired and tested in a
following manner.
totally enclosed, weatherproof,
walk-in, 100% seam welded steel 28.5.1 Corner members shall be TS3X3.
control house.
28.5.2 Normal framing members shall be -
28.3 The control house skid shall be of S3X5. 7 with a maximum spacing
heavy duty construction to assure between members of 48".
a solid foundation for the
surrounding structure. 28.5.3 Door opening and access panel
framing members shall be C3X5.
28.4.1 The load bearing members are
primary members which transfer 28.5.4 Exterior wall panels shall be 12 -
load to the foundation. Members gauge A36 Steel.
are MC12X50 welded as a 28.5.5 All walls shall be insulated with 2. 75"
rectangular frame under the exterior thick polystyrene. The insulation
wall of the building, flanges facing panels shall be cut to fit between _
outward. wall framing members.
28.4.2 Floor stringers, load members which 28.5.6 Interior walls shall be covered with
transfer their load to the bearing 1/4" plyboard, aluminum veneered
members, are to be W4X 13. They (Weyerhauser or equal brand). The
span the building width and have plyboard shall be bolted to the walls --
a maximum spacing of 24". and panel framing members. -
28.4.3 Runners, auxiliary support members Seams in the plyboard shall be _
which support the building during covered by seam channels provided _
transport, are W6X 15. They shall by the plyboard manufacturer for
span the building length and attach that purpose.
flush with the bottom of bearing 28.6 Roof construction shall be suitable
members. Their maximum spacing for the normal wind and snow
shall be 94" to allow transport on conditions associated with the -
an 8' wide trailer. jobsite.
28.4.4 Spacer channels, auxiliary support 28.6.1 Roof girders shall be used to transfer -
members which distribute some the roof load to the side walls. The -
loading on the runners to the side girders shall be TS3X3 members
bearing members during transport, resting on top of the wall members.
shall be formed 3/16" steel channel. All girders shall be capped at the
The flange length shall be end with 12 gauge end caps, seam
determined by the spacing between welded.
the bottom of the W4X13 stringer
and the W6X 15 runner. The web

VARIABLE FREQUENCY DRIVE SPECIFICATIONS APPLICATIONS MANUAL


~~~~~~~24~H~O~U~R~S~E~R~V~IC~E~~(7~1~3~)~4~67~-~2~52~3~---
9-17

28.0 CONTROL HOUSE (Cont'd) sheeting shall be seam welded on


the outside and stitch welded with
a 2" bead on 12" centers inside.
28.6.2 Members between trusses (purlins)
shall be provided for support of roof 28.7.3 Roof framing shall be welded all
panels and/or roof-mounted around each connection. Roof
equipment. Purlins shall be formed sheeting is seam welded on top and
of 10 gauge channel, with 2" flanges, stitch welded with a 2" bead on 12"
and a 6" web. They shall be centers below.
mounted at the peak of the root with
28.7.4 All external seam welds shall be
the web bent to conform to the
1 00% crack penetration tested
changing slope of the roof at the
before painting to ensure weld
peak.
strength integrity and absence of
28.6.3 All roof panels shall be 12 gauge leaks. Welding procedures shall
steel. conform to codes and practices
currently written by the American
28.6.4 All interior roof areas shall be
Welding Society.
insulated with 2.75" polystyrene
having a .06" aluminum covering. 28.8 Electrical connections within the
This aluminum covering shall be control house shall be per applicable
bolted to the bottoms of the roof NEG standards and be of sound
trusses. Seams shall align with the engineering practice.
truss flange centers. The insulation
28.8.1 All low voltage and signal wiring
panels shall be cut to fit between
exiting from the electrical equipment
the roof framing members.
cubicles supplying loads in other
28.6.5 A drop ceiling shall be provided in parts of the building, i.e.
the interior of the building. The drop transformers, distribution panels,
ceiling shall be supported by 2" x light fixtures, and switches, etc. shall
2" aluminum angles mounted on be run in conduit.
walls at 90" above floor height and
28.8.2 Conduits run in the ceiling above
tops of electrical equipment
the drop ceiling shall be liquidtight
cubicles. The angles shall also be
flexible metal conduits, supported by
mounted as framing for flush-mount
unistrut conduit clamps attached to
fluorescent light fixtures. This
unistrut members, which are bolted
ceiling shall be made of 1/4"
to truss flanges through the
plyboard with aluminum veneer.
aluminum roof insulation cover. All
28.7 The building shall be of welded installations of liquidtight flexible
construction. Lapped and screwed metal conduit are to be in
siding and roofs shall not be allowed. accordance with National Electrical
Code (NEG) Article 351.
28.7.1 The skid framing shall be welded
all around each connection. 28.8.3 Conduits which penetrate the drop
Flooring steel is seam welded on ceiling shall be electrical metallic
top and stitch welded with a 2'; bead tubing. All installations of electrical
on 12" centers below. metallic tubing shall be in
accordance with NEG Article 348.
28.7.2 Wall framing shall bE? welded all
around each connection. Wall
9-18

28.0 CONTROL HOUSE (Cont'd) the building size, maximum and


minimum outdoor expected ambient
28.8.4 Junction boxes shall be used above temperatures, and the indoor
the drop ceiling as a transition equipment losses.
between liquidtight flexible conduit 28.11.1 The HVAC shall, as a minimum,
and electrical metallic tubing. consist of either two 100% units or
28.8.5 All wires shall be suitable for the three 50% units completely -
voltage and current in the circuits independent and self-contained.
where they are used. Standard wire 28.11.2 The air conditioners will be
used shall be Exane 90 degrees C, incorporated into an air handling
600V insulation wire. The gauge system that adequately ducts all hot
shall be determined by the circuit air back to the air conditioner return
full load current. All wiring shall be 2
inlet and the air conditioning outlet
protected. blows cold air into the house center
28.8.6 Power cables for medium voltage aisle.
power routings shall be run 28.11.3 The air conditioning units shall be
separately in approved cable ways. manufactured by Bard (wall-mount
The cable ways shall be supported units), Trane (roof-mount units), or
by the roof trusses. Standard Carrier (floor-mount units). All air _
medium voltage cable shall be conditioning units shall be UL listed.
ethylene propylene rubber insulated, Roof-mount HVAC units shall have
5KV or 15KV voltage rated, 90 local disconnects mounted at each
degrees C temperature rated. The unit.
wire gauge shall be determined by
28.11.4 Exterior to the building, roof-mount -
the circuit full load current.
HVAC units are to be drained via
28.9 The complete House and skid shall minimum 3/4" diameter, Schedule -
be sandblasted to near white. All 40 PVC pipe routed down the
exterior surfaces of the house will building side.
have a minimum 3 mil dry film
28.11.5 Wall-mount HVAC units shall drain
thickness of inorganic zinc primer,
down from the units themselves.
3-5 mil dry film thickness of epoxy
intermediate coat and 2 mil dry film 28.11.6 Site drainage shall be determined
thickness of polyurethane top coat. by the Building Owner.
The underside of the skid shall have
28.12 Optional accessories may bP
a coating of 3-5 mil dry film thickness
provided with the house, and are_
of inorganic zinc primer.
listed below:
28.10 Interior fluorescent lighting shall be
28.12.1 Exterior lights, one over each
provided. Two exit doors with panic
personnel door, photo-cell activateo,
bars shall be provided.
75 W High Pressure Sodium.
28.11 The heating, ventilation and air
conditioning shall be sized based on

I!
;
j
1

~~,.! VARIABLE FREQUENCY DRIVE SPECIFICATIONS APPLICATIONS MANUAl


'I

1 24 HOUR SERVICE (713) 467-2523


9-19
~ 28.0 CONTROL HOUSE (Cont'd) Frequency
Speed (Number of Poles)
~· 28.12.2 Emergency exit lights, activated Service factor
upon power failure, installed within Enclosure
the control building over each
personnel door. Lights shall include Insulation. class/Temperature Rise
necessary battery packs. Noise level

28.12.3 Two (2) modular telephone jacks for Bearings type


standard telephone sets. Jacks Mounting arrangement (Horizontal/
wired to common terminal strip for Vertical)
connection to Customer's plant Type and characteristics of driven
telephone system. machine
28.12.4 Fire/smoke detection system with Typical Accessories
alarm horn and manual pull station Space heater
at each personnel door. System Bearing RTD's
shall be capable of being connected
to the Customer's plant fire detection Stator winding RTD's
system. Sealed VPI insulation
Shaft encoder
29.0 MOTOR (LCI Synchronous)

The motor shall be of squirrel cage induction Thrust Requirements (for vertical
or LCI synchronous (as required by the drive motors only)
- type) design suitable for variable speed
- operation. If bypass is specified, the motor shall
~ Following shall be specified for motor bid: be designed suitable for across the
line start.
Dual Winding (LCI synchronous)
Output Power
Voltage (specify per winding for LCI
dual winding machine)

Ross Hill Controls Corporation continues to make improvements in the quality,


engineering, and manufacturing techniques used in our drive systems. As a result,
~ the specifications listed above are subject to change, and should be used as a general
guide only. Prior to using the above for firm specifications in a particular application,
contact Ross Hill Controls Corporation for a review of your requirements and the
- latest update to specifications.
9-20

This side of the page 1s intentionally left blank.

VARIABLE FREQUENCY DRIVE SPECIFICATIONS APPLICATIONS MANUAL -


24 HOUR SERVICE (713) 467-2523
9-21

ADJUSTABLE FREQUENCY MOTOR DRIVE SYSTEM


EVALUATION SHEET

Manufacturer shall provide data applicable to each type drive system proposed. Write N/A
in spaces not applicable to a particular drive system type. Estimated quantities shall be
given and indicated as such when actual requested quantities are not known.

GUARANTEED OVERALL EFFICIENCY DATA


(INCLUDING DRIVE, FILTER AND TRANSFORMER)
... At Rated Output ·
( 100% Rated Speed)

... And at Additional Load Points


as specified by end user.
(Specify HP outputs and corresponding speeds.)

VARIABLE FREQUENCY DRIVE


Drive Manufacturer
Model Number
Drive Type
Maximum Continuous Horsepower Rating
Rated Voltage
Amount of heat generated
by Drive (KW) (Drive and filter)
Type of Cooling
Guaranteed Drive Efficiency
at rated load and 60 Hz.
(Drive and Filter)
9-22
~
ADJUSTABLE FREQUENCY MOTOR DRIVE SYSTEM
EVALUATION SHEET (Cont'd)

THYRISTORS
Manufacturer
Model No. or Type
Rated Current
Peak Inverse Voltage Rating
No. of thyristors per 3 phase bridge
Converter
Inverter
Peak Inverse Voltage Design Margin
Peak Inverse Voltage Design Margin
with one failed thyristor
Operating Design Junction Temperature
at 40°C ambient

DC LINK REACTOR
Manufacturer
Model No. or Type
Rated Current
Rated Voltage
Reactance Value

ENCLOSURE TYPE
Indoor Equipment
Outdoor Equipment
;:
r

VARIABLE FREQUENCY DRIVE SPECIFICATIONS APPLICATIONS MANU .._.:


24 HOUR SERVICE (713) 467:-2523
.:
9-23

ADJUSTABLE FREQUENCY MOTOR DRIVE SYSTEM


EVALUATION SHEET (Cont'd)

ESTIMATED DIMENSIONS
Indoor Line-up
DC Reactor Enclosure

ESTIMATED WEIGHTS
Indoor Line-up
DC Reactor Enclosure

ISOLATION TRANSFORMER (WHEN REQUIRED)


Manufacturer
Model No. and Type
KVA Rating
Temperature Rise
Cooling Class
Impedance
Primary Voltage
Secondary Voltage
Primary BIL Level
Secondary 8 IL Level
Sound Level
Vector Relationship
No Load Loss
Load Loss
Guaranteed Efficiency at Rated KVA
Estimated Dimensions
Estimated Weight

\IAf"'\IAnl r- r-l"""'or-,...llr-t.l-.~>1 .-.........,.,,,_ ----·-·-·-·-··-


9-24

ADJUSTABLE FREQUENCY MOTOR DRIVE SYSTEM i.

EVALUATION SHEET (Cont'd)

OUTPUT TRANSFORMER (WHEN REQUIRED)


Manufacturer
Model No. and Type
KVA Rating
Temperature Rise
Cooling Class
Impedance
Primary Voltage
Secondary Voltage
Primary BIL Level
Secondary BIL Level
Sound Level
Vector Relationship
No Load Loss
Load Loss
Guaranteed Efficiency at Rated KVA
Estimated Dimensions
Estimated Weight

.,.

VARIABLE FREQUENCY DRIVE SPECIFICATIONS


- - - - - APPL:CATIONS
--- MANUAL
24 HOUR SERVICE \ . 13) 467-2523
9-25

ADJUSTABLE FREQUENCY MOTOR DRIVE SYSTEM


EVALUATION SHEET (Cont'd)

MOTOR (IF SUPPLIED WITH DRIVE)


Manufacturer
Type
Ref. Standards
Rated power
Rated voltage/frequency
Rated current
Insulation class/Temperature rise
Ambient temperature/Altitude
Enclosure
Number of poles/Speed
Guaranteed Efficiency at 4/4-3/4-2/4 load
Power factor at 4/4-3/4-2/4 load
Locked rotor torque/Minimum torque
Break-Down torque
Locked rotor current
Service factor
Weight
Bearing type/Lubrication
Rotor Type
Accessories
This side of the page 1s intentionally left blank.
GUIDELINES FOR
SPECIFYING MOTORS FOR
USE WITH ADJUSTABLE
SPEED DRIVES
!I'
,,

This side of the page 1s intentionally left blank .


10-1

GUIDELINES FOR SPECIFYING MOTORS FOR USE


WITH ADJUSTABLE SPEED DRIVES

THE ELECTRIC MOTOR - flow control contributes significa~tly to


increased system efficiency, thereby
RELIABLE WORKHORSE reducing operating cost and environmental
impact.
Since 1889, alternating current electric
motors have proven to be reliable and The use of adjustable frequency controls,
efficient power conversion devices. Their however, impacts the design, performance
operation and maintenance is routine and and reliability of AC motors. Many of the
uncomplicated. Electric motor dependability effects are positive. Decreased speeds
and adaptability is such that approximately mean reduced cycles (thereby diminished
70% of worldwide electric power generation fatigue) of bearings, fans, and other rotating
is consumed by AC electric motors. e I em en t s . " S oft-start i n g " of a m o tor
Furthermore, the utilization and importance eliminates the high starting stresses on
of AC electric motors stands to increase stator coils and rotor bars that are customary
as we enter the 21st century. when starting motors "across-the-line."
Adjustable frequency drives can positively
GROWTH OF DRIVE USAGE - influence motor life, when properly applied.
NEED FOR SPECIFICATION However, there are a few important issues
which must be addressed when using
GUIDANCE
motors with drives. These concerns are
For many years, AC motors had been used well-defined and manageable, as explained
strictly for constant speed applications. in this paper. The likelihood of experiencing
Traditionally, with pumps, fans and problems with a drive installation can be
compressors, flow control has also been significantly reduced by properly addressing
handled by mechanical means such as these issues in the technical specifications.
throttles, valves and dampers. When
adjustable speed was required, DC motors,
.. LARGE .. DRIVES AND MOTORS
along with mechanical drivers such as Industry has long recognized the importance
turbines and engines, were the drivers of of electric motors in their operations. In
choice. recent years, electric motors have received
The advent of reliable, cost effective increasing attention within efforts to improve
adjustable speed drives is rapidly changing performance and reliability (and thereby
this model. These drives, which regulate process reliability). Toward this end, many
motor speed by controlling input power industries and individual customers have
(voltage and frequency), have vastly created detailed motor specifications to
enlarged the envelope of AC motor ensure quality and reliability. Vast amounts
applications and capabilities. This can be of time and engineering effort went into the
done without adding gears, clutches or other development of these standards and work
equipment to the drivetrain. Of course, AC continues on revisions and updates. Yet
motors have lower cost, lower maintenance these specification rarely address the
and less sparking incidence than DC motors. special requirements of adjustable speed
Also, AC motors have lower cost and applications.
maintenance than combustion drivers without
any local emissions. The elimination or
bypass of high-loss mechanical means of
10-2

ADJUSTABLE-SPEED FIGURE 10-1A

~-·
MOTOR SPECIFICATION
CONCERNS
r~ l
I V Neutral
c

Variable speed applications possess most


of the same concerns as constant speed FIGURE 10-lB
motor applications such as specific load
B~
R
requirements, insulation integrity, vibration,
quality of materials and construction, etc. " M2 A
1
Most specifications address these topics in R c
a thorough and reasonable fashion.
However, there are five additional areas of VoHape DC Mid-Point To Neutru.l
e
3 PHASE BRIOOE
ON...Y W.O PHASES CONDUCT
concern that need attention when specifying ~--:..._-------1 e
AT A TIME.
1'W) VECTORS 00 NOT 1£10
10 ZERO.
motors for adjustable-speed applications: 1) e TI-'E OC UNK CENTER (M)

common mode voltage, 2) harmonics, 3)


switching frequencies and standing waves,
[lC
In
c .......,
O~und

DC· I I I
1flJlJ1Jlfl e
MOVES Mt-M:? MJ ANO
OENF.rlA IES n 11n0 I!NlMONIC
WJl TS TO NEUTAAL..
THE OC+ & DC- BUSES
JOV\ HA't{: A ()QMMON UCO:
loOt.TAGE.
4) speed range, and 5) starting considerations. 30 deogrees
- -·----
eo degntes 90 dngreee
Every Cycle of Input Ff'&quency - ---
e THE MAGNITUDE OF lHE
COMMON MOO(: CHANGES
V't'm-i rnE BRIDGE RAING
NIIGLE.

COMMON MODE VOLTAGE FIGURE 10-1C

When operated across-the-line (without a


drive), the motor is fed directly by the
incoming three-phase line. In such a VOlTAGE smess ON MOTOR PHASES WITHOUT ORNE IS VL-N
VOLTAGE SffiESS Wlrn DRIVE SYSTEM IS
standard three-phase supply, all of the phase VL-N • 0.5 VL-N INPUT + 0.!5 VL-N OUll'UT = 2 VL-N

vectors ·sum to zero, the neutral point is FIGURE 10-lD


stationary and is usually held at ground USE AN INPUT OR OUTPUT TFVINSFORMER OR INCREASE MOTOR WINDING INSUt.AllON

·-1
(Figure 10-1a).Figure 10-1b illustrates a --]l~~c----{)f-mn_~
- cotAM0N MODE VOLTAGE 1
ACROSS INPUT TRANSFORMER .
three-phase bridge which is the motor power
source of an adjustable frequency drive. In
operation, only two phases conduct at any
time, hence, the vectors do not sum to zero. Figure 10-1
The DC link center moves and has positive
and negative voltage values (the so-called Such motors may be expensive since the
"common mode" voltage) relative to ground, higher voltage requires additional insulation
the magnitudes of which vary with the bridge thickness, meaning larger stator slots,
firing angle. The magnitude of the common ultimately translating into larger, more costly
mode voltage in each bridge can be equal motor frames, especially on motors rated
to half the rated line-to-neutral voltage. 4kV and greater. Another solution is to use
Thus, the total voltage stress on motor an input or output transformer and connect
phases with an ac-ac converter (with input the neutral of the motor to ground (Figure _
and output bridges) can be Vl-n + 0.5 V1-n 10-1 d). A transformer can be insulated for
+ 0.5 Vl-h, or two times rated line-to-neutral higher voltage levels without significant
voltage (Figure 10-1c). performance compromise or cost penalty.
This is a concern since motors are not With an output transformer between the
normally designed to operate at twice-rated drive and motor, the common mode voltage
voltage. One approach to solving this is isolated from the motor and placed on
problem is to specify motors with sufficient the drive-side transformer winding. -
insulation to handle twice the rated voltage. Applying an input transformer and

GUIDELINES FOR SPECIFYING MOTORS ... APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
10-3
connecting the motor neutral to ground also common mode voltage responsibility would
forces the common mode voltage onto the lie with the drive manufacturer who, as
transformer. Additionally, this arrangement purchaser (typically) of both motor and
(Figure 10-1 d) has the benefit of isolating transformer, is in the best position to direct
the drive from the line and reducing the the common mode voltage solution.
harmonics on the bus. Since the input
transformer is frequently required to reduce HARMONICS
the harmonic contribution to the bus, this Harmonic effects of the drive on the power
is commonly the least cost solution. line were mentioned briefly in the preceding
For applications where drives are retrofit to discussion of common mode voltage.
existing motors, the transformer solutions Beyond this, drive harmonics can affect
are the only choices. New installations motor operation, life and performance. The
allow the choice of any of the above effects of drive harmonics on motors can
solutions. The primary concern in writing be broken down into three categories,
the specifications for such an application heating effects, insulation effects and
is to specifically assign system responsibility mechanical effects.
for dealing with this issue. Because the Figure 10-2 illustrates some sample voltage
drive is usually the most expensive element and current waveforms that may be supplied
in the drive system, the drive vendor is to a motor from an adjustable frequency
usually assigned this responsibility. Hence, drive.
VOLTAGE SOURCE TYPE
------

--3~
~-~--L.___fJ
>1- 'il- )1.
t VOLTS
---
-
·----~---

f------

lr -
-- ALTER f----

Q

--- r£=-\=;
Q
AMPS

CURRENT SOURCE TYPE


------- ------

_::VOLTS~
r

1TS
--j(---- - - - -
-- ,_ ALTER
~~--- ~-
---
- - ---------- - - - - -
-

lr r AMPS~
--------- --------
- ---.---- __ , ________ ---- ------------

PULSE WIDTH MODULATED TYPE

-
It VOLTS~-
ALTER -- 1- t-r--r--
1"'\J
1- ~

1~--...:L
1 AMPS
- - - - '-------- '--
--

ALTERED CURRENT SOURCE


CONVERTER INVERTER
-------
- c--· ,.-

-
r-- FILTER - I-- FILTER
r---l/1\\ f& I

~v WJ \x
f-

1-
v
-- ~-

Figure 10-2
10-4
HARMONICS (Cont'd.) OUTPUT WAVEFORMS I-
The value of voltage and current harmonics AT VARIOUS SPEEDS I-
varies tremendously with different drive
configurations. Many of the large
horsepower, medium voltage induction drive
systems (such as those offered by Ross
Hill Controls) are of a type which has low
harmonic currents at rated load and speed.
While the harmonics almost always increase
dramatically at reduced frequencies/speeds,
the typical pump/fan/compressor application
has such a significant reduction in load at 100% TORQUE AT RATED SPEED
reduced speed that the total current
(fundamental plus harmonics) will be well
below the motor's rated value and within T

-\-
the motor's self-cooling capability.
Harmonic currents are additive to the
fundamental current and thus generate
additional heat in the motor windings. If
har:-nonics are negligible, there will be v
negligible additional heating in the motor.
Even a value of thirty percent current 100% TORQUE AT 75% RATED SPEED
distortion in a motor is unlikely to generate ,-·------
more than about 8% additional heating.
However, since the type of drive and the
allowable harmonics will be specified in a
separate specification, the motor
specification must consider the entire range
of possible drives that may provide motor
power. It is necessary for the drive supplier
v \/ o_/

to furnish the motor vendor with sufficient


. \/ /
harmonic information to allow the motor to
be designed with an adequate amount 100% TORQUE AT 50% RATED SPEED
of heat dissipation/absorption to KEY:
counterbalance any extra losses/heating. A T = MOTOR TORQUE
variable speed motor operating with a drive
should be required to meet the same V = MOTOR VOLTS

temperature rise limits as a motor purchased I = MOTOR AMPS


for operation on sine wave power. Figure 10-3
Furthermore, for critk;al application
machines, test results (or test data from With motors, almost every electrical
similar motor/drive combinations) should design concern has a parallel and more
demonstrate that the motor temperature rise mischievous mechanical concern. Such is
during operation with the drive will not the case with harmonics.
exceed the specified value.

GUIDELINES FOR SPECIFYING MOTORS... APPLICATIONS MANUAL


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24 HOUR SERVICE (713) 467-2523
10-5
Harmonic currents in a motor can give rise in a worst case scenario, axial movement
to higher audible noise emissions. Motors or oscillation of the shaft can occur, to the
must be shown to meet the specified sound detriment of bearings and seals. For this
level limits of the application when powered reason, skewed rotor design? should not
by the drive. be applied.
Moreover, harmonics also contribute "torque SWITCHING FREQUENCIES
ripple," as illustrated in Figure 10-3 AND STANDING WAVES
(opposite). Torque ripple causes torsional
excitations that can have destructive In addition to the possibility of added heating,
consequences if not properly addressed. In drive waveforms can have other direct
severe cases, the magnitude of the ripple effects on a motor's insulation system. All
is large enough to produce negative torque drives use power electronic devices in their
values. Low load inertia applications, inverter section that switch on and off. This
such as direct driven centrifugal pumps, switching action may produce spikes and
usually have little danger. However, fan transients of varying severity and character
applications and high speed centrifugal into the motor insulation. Some inverter
compressors with high inertia gearboxes system designs have very frequent, but
have high risk potential. These dangers small spikes, while others have spikes of
can be analyzed and safely avoided. greater magnitude and lower frequency,
while yet others almost completely eliminate
A torsional analysis is normally performed
the spikes seen by the motor through filtering
on all major drivetrains. With an adjustable
(Figure 10-2). Spikes, or high dV/dt, will
speed drive additional steps must be added
have an impact on the life span of the motor
to the analysis. The torsional excitation due
windings. The frequency, amplitude and
to drive harmonics, so called "torque ripple",
severity of the surges all impact the
must be included as one of the inputs. insulation life and the probable mode of
Torsional resonant frequencies can be
failure. This factor is most pronounced in
identified by the torsional analysis. drives which use IGBT (Insulated Gate
Response magnitudes and resulting Bi-polar Transistors) and, to a lesser extent,
stresses can then be calculated. When a
GTO (Gate Turn Off) switching devices. The
problem is identified, coupling selection can
high dv/dt of such devices and the high
frequently be used to adjust the stiffness frequencies involved can rapidly age some
and/or damping of the train. In other cases, motor insulation systems. Moreover, the
modified shaft diameters and stress high frequency switching can generate
concentration factors may be required to
voltage standing waves in the cable runs
l- avoid fatigue failures of drive-train elements. to the motor. On voltage source PWM
Torque ripple may also lead to problems drives such standing waves can impose as
with skewed rotor designs. Because much as 400% rated motor voltage at the
skewed rotors (which are uncommon on motor terminals. Hence, it is essential that
large motors) have rotor bars that are not cable lengths be considered when use of
parallel to the rotor shaft, they will have a Voltage Source PWM type drive is
both radial torque and axial force contemplated.
components. While the axial component
is but a fraction of the radial component,
10-6

SWITCHING FREQUENCIES From every reasonable point-of-view, the


AND STANDING WAVES actual load data should be provided for all
(Cont'd.) rnnlnr Jllllt:hnnnn Ill "''~:urn lhnl lhn 111t1lt11
h; t:llflllhlo Ill nlnrlhl!J 111111 llt:c:fliPIIllhl\1 tho -
Once again, the type of drive will be specified load and functioniny within the specilied __
elsewhere and it is the drafter of the drive temperature limits under all operating
specification that must decide which conditions. For large variable speed
technologies are acceptable/preferable for applications, this load data should be
any installation. This is the one issue that demanded. Not only does this impact
is difficult to resolve while writing a motor acceleration calculations, but motor steady
specification. A conservative and fair state operation and possibly drive stability
recommendation would be to require the considerations. It is unlikely that a drive
drive manufacturer in the drive specification would be purchased without a duty cycle
to specify to the motor supplier any special and economic analysis which also requires
insulation requirements (such as additional this load data.
tape on the end turns or additional turn
In most adjustable speed applications, the
insulation) and to provide the user with data
maximum operating speed is at or near the
demonstrating long-term operation (five motor's standard direct-on-line rpm. NEMA -
years minimum) of any proposed drive MG 1-20.44 states that motors must be -
design at the specified power and voltage constructed to withstand, in an emergency,
class. Where necessary, estimated cable overspeeds above synchronous rpm of at
lengths must be provided by the user to least 20% (25% for motors with synchronous
the drive supplier. speeds of 1800 rpm or less). Hence,
SPEED RANGE overspeeds of a few percent above
synchronous should not pose a problem for
The design of motors operating over a wide motor mechanical integrity. Always use
speed range entails additional concerns caution in making this assumption ~
beyond that of constant speed motors. This concerning driven equipment, especially -
discussion of speed range considerations fans. Nonetheless, there are growing
for motors will be broken down into four numbers of applications that call for motors
parts: load requirements, high speed to operate significantly above their standard
concerns, low speed concerns and critical synchronous speed. In such cases the -
speeds/frequencies. specifications or data sheets should clearly -
identify the maximum operating speed and
The elementary consideration is the load
specify that the motor(s) should have
and how it varies with speed. The actual
sufficient mechanical integrity to withstand
load characteristics must be accurately
"emergency" operation at an overspeed of -
described to both the motor and drive
at least 20%. [Note: This is a safety factor.
suppliers. While inertia is not a motor
Such operation is never actually envisioned.] _
concern for soft starting, this remains
It should be apparent that bearing, lubrication
a concern for the drive. Centrifugal
and cooling systems must be suitable for the
applications require that the motor and drive
maximum speed condition.
designs are sized based upon maximum
operating speed conditions. Reciprocating Low speed operations do not share thE
loads (or other constant torque loads, such mechnnicRI integrity concmns of hioh srP.Rr1 ~
as some blower/compressor types, operation, but certainly share bearing.-
extruders, etc.) must have their size and lubrication and cooling system concerns._
the cooling system design based upon the The minimum operating speed must bt.
minimum speed operating requirements. specified in the specification or data sheets

GUIDELINES FOR SP ECl FY lNG MOTORS .. :._·--::--:c---::-:-:~---::-::-::~-=-=~A-"-P~P-=L:._:IC::...:..A-'-'T-'--10=-N_S=--M_;_A_N_U_A_l


24 HOUR SERVICE (713) 467-2523
··~-
-- - .~ -~-·-.... ' ..

.D5BIBilT..~ ·n:amm., . •-:- us-"'"' :!.llg~.:;.tr.J


ll:> tO tspbCtly ''lifJ c;(lllt,l;tl !Jt,qUt:;lll,lt:;t;. '1'/1111111
the ope ruting bpulJd r u r~uu." Alluw \It~
motor vendors to propose alternate designs
if necessary or reasonable. A motor
w coastdown test and/or an unbalanced
:::>
a
a:
response test' should be specified to verify
f2 10
HERTZ
20 30 40 50
HERTZ
the specified separation margins.
STARTING CONSIDERATIONS
SPEED
A positive aspect of operating motors with
Figure 10-4 adjustable frequency drives is soft starting.
Typical drive installations are configured to
The bearings, lubrication system and cooling limit motor current to 100% of rated amps,
system must also be suitable for operation thereby eliminating motor insulation starting
at minimum speed followed by coastdown stresses.
to rest.
Most drive applications are designed to
Operation at a lateral critical speed may maintain a constant voltage/frequency ratio
result in high vibration levels that may to maintain uniform flux. Hence, at low
eventually lead to fatigue failure of drive-train frequencies the voltage will be low.
components. To avoid this risk, specify a Through each start the drive controls the
machine that does not have any critical voltage and frequency to allow the motor
frequencies within the operating speed to operate near rated slip and rated flux,
range. This means that the rotor as well avoiding any transition through breakdown
as components such as cooling fans, torque. Hence, the motor will be operating
bearing housings and air shrouds must be in the steady state design portion of the
designed such that they will not be excited motor's speed-torque curve. As the speed
by any frequency (or harmonic thereof) is ramped up, the motor operation remains
within the operating range. The advantages in this portion of the curve as it accelerates
of such a design are minimal vibration and through a family of such curves (Figure
operational flexibility. Some users will 10-4). Thus, for most applications, and
prefer the first critical speed (as defined in certainly for centrifugal loads such as most
the standard) to be above the operating fans, pumps and compressors, the starting
range ("stiff" shaft design), to simplify currents are very low, acceleration is smooth
balancing and troubleshooting among other and controlled and, because slip is minimal,
reasons. For most four-pole and slower rotor cage heating is insignificant. Figure
motors and for most applications (50%- 10-5 (next page) shows speed-torque
100% speed range), such designs are characteristics of a typical centrifugal load,
normal. However, higher speed motors or a motor starting on a drive with that load
wider speed ranges may open up a whole and the torque envelope available with a
spectrum of opportunities for problems. On typical drive. [Note: Drives can be modified
larger, higher speed motors such designs to handle other types of loads and special
may be costly or unavailable. Use of motors torque requirements.]
that have critical frequencies in the operating
range is possible, if they have a well-damped
response. Alternatively, the system
controls can be configured to "block out"
- - · · - ...................... ~ 1..41\1\lll/\1
GUIDELINES FOR SPECIFYING MOTORS ...
10-8

STARTING CONSIDERATIONS Starting SpeedfTorque Characteristics


{Cont'd.) Typical Centrifugal Pump Application

250% l
This "soft starting" is very beneficial to all - Molor Cap. - - - Dnve Cap.

elements of the drive-train, as well as the 200% ····Pump Load n Aclual Oulpul
:!?.
motor. Because an adjustable speed drive 0

provides smooth, controlled acceleration w 150%


:;)
I
there is less stress on the mechanical 0
a:
0100%
drive-train components. Current limited, I-
"soft" starting allows motors to be started 50%
repetitively and safely without the stresses
of high inrush and high slip that occur during 0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
across-the-line starts. This can significantly
SPEED, %
improve the life expectancy of both stator
insulation and rotor cage. Figure 10-5

Hence, starting is easier on a motor if a if the motor is NOT required to start the
drive is used. The decision is whether to load across-the-line, the motor should be
specify starting only with the drive. A motor braced for full voltage starting to allow future
that is always soft-started can be optimized shifting of the motor to an alternate
for efficiency and steady-state operating application.
characteristics. When across-the-line
starting is required and the specified load
has high inertia (typical of fans and some CONCLUSIONS
compressor/gear trains), this will require
compromises in other performance areas Despite the fact that motors have been with
and greater expense. There are two us for more than a century, they serve the -
important negatives in specifying soft-start needs of a new world that values cleanliness
only: ( 1) it may not be possible to start the and efficiency. AC motors are simple in
motor across-the-line (bypass the drive) in operation, reliable, efficient and clean.
the event of a drive failure and (2) the motor Making use of the added flexibility and energy
may not be capable of being shifted to savings that are possible with adjustable
another use without a soft-start control. The frequency drives is easy when four basic
benefits of specifying "soft-start only" are issues are addressed at the specification
optimized motor design and elimination of stage: (1) common mode voltage, (2)
mechanical flow control methods. Hence, harmonics effects, (3) switching frequencies
better efficiency, reduced initial cost, less and standing waves, (4) speed range
maintenance and fewer mechanical flow concerns and (5) starting considerations.
losses. The decision must be based on By supplementing existing motor
the type of drive purchased (reliability/ specifications to address these topics, one
confidence level, redundancy, fault tolerance, can be confident that a specified motor will
etc.) and the nature of the application perform reliably, meet the requirements of
(is this a critical service machine?). This the application and give the user long
decision should be a "bullet" item, requiring operating life.
purchaser input, on the data sheet. Even

GUIDELINES FOR SPECIFYING MOTORS ... APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523
TECHNICAL PAPERS/ NOTES

"

.. -
This side of the page 1s intentionally left blank.
11-1

TECHNICAL PAPERS

Ross Hill Controls has compiled the following 3. Variable Frequency Drive Retrofits on
reading material from various magazines F-D Fans at Texas Utilities Lake
and IEEE technical papers that discuss case Hubbard and Valley Station Power
stu?ies and relative concerns with applying Plants
vanable frequency drives today. Copies are By Jack H. Smith and Steve Stewart ,
available at the Houston plant and can be Utility Engineering Corp. (Utility
sent out upon request. Engineering, Amarillo, TX).
1. Benefits of Variable Speed Drives
Emphasized at Very Low Loads SUMMARY: Two (2) 6900 HP VFD's
By Larry Randel, San Diego Gas & were placed in service at Texas
Electric Co. (Power, June 92). Utilities's Lake Hubbard Plant and One
(1) 5750 HP VFD at the Valley Station.
SUMMARY: Case study retrofitting This article discusses the design,
two 4000 HP starters using inlet guide benefits, considerations, and careful
vanes for control with two (2) variable planning needed when adding VFD's.
frequency drives controlling forced- Reasons for retrofit consist of:
draft fans. Inlet guide vanes were improved unit heat rates, soft start
opened and the efficiency was reduction in motor starting stresses,
increased substantially. Results show energy savings, and an increase in
more than a $1-million/yr savings and spinning reserve capability.
a payback period of just over two (2)
years. Reasons for retrofit consist of: 4. Application of a 5500 RPM, High
efficiency was dropping below 50% at Speed Induction Motor and Drive in a
tow loads, and cracks in the rotor bars 7000 HP Natural Gas Compressor
of the motor were caused because the Installation.
motors were started repeatedly with no By Stephen C. LaGrone, Miles C.
"soft-start" capability. Griggs, and Maurizio Bressani (IEEE
Paper No. PCIC-92-42).
2. Payback Enormous for Variable
Frequency Motor Drives SUMMARY: This paper describes the
reasons for choosing, and some of the
By 0. C. Smith, City Utilities of
considerations in implementing, high
Springfield, Edited by Steven Collins
(Power, February 93). speed induction motors and variable
frequency drives for the Princeton
SUMMARY: The City Utilities of compressor Station in Lawrenceville,
Springfield, Missouri added 4500 HP NJ which is comprised of two 7000
variable frequency drives to both the HP, 5500 RPM compressors. The
induced-draft (i-d) and forced-draft (f-d) selection options relevant to the
fans at their 200-MW plant. The facility application reviewed are: gas turbine
reports a $800,000 savings per year. vs motor driver, high speed motor vs
Reasons for retrofit consist of: conventional motor, induction vs
reducing parasitic load, improving synchronous. Design features of the
combustion control, obtain better major system components discussed
efficiency, and increasing overall plant are: power system, compressor
reliability. motor, and variable frequency drive.
11-2
5. The Steps to Select a High Horsepower 6. Avoid Pitfalls in Economics of Boiler
Variable Frequency Fan Drive System Feed Pump Variable Speed
By W. H. Beck, J. L. Ascher! (IEEE By Eugene Kempers (Power, March
Paper No. PCIC-88-21). 1984).

SUMMARY: The steps to evaluate an SUMMARY: This article illustrates the


application for a high horsepower steps necessary in a feasibility study
variable frequency fan drive include for variable frequency drives on Boiler-
selection of the flow control method, Feed Pumps. Discusses Affinity-law
simulation of the fan and system load differences, pump evaluation, specific
line, definition of the fan shaft power, gravity, efficiency, and maintenance
component selection, a harmonic and concerns.
torsional analysis, and an economic
evaluation. These steps are illustrated
for a pair of 5000 Hp blowers at the
BASF plant in South Kerney, NJ.

TECHNICAL PAPERS APPLICATIONS MANUAL


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11-3

NOTES

~----·····

---------
.~ 1

'

~
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,,
11-4

NOTES

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L

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L.

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111

NOTES APPLICATIONS MANUAL


24 HOUR SERVICE (713) 467-2523

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