IEEE-IAS 2012.02.18 Presentation - Major Components of Fire Pump Controllers

Major Components of Motor Drive Controllers

- for -

IEEE-IAS - by -

James S. Nasby

Columbia Engineering

C.E. IEEE-IAS 2

Items to be Covered Power Path Components Line Voltage Components Critical Path Items

C.E. IEEE-IAS 3

Model ECA A-T-L(D-O-L)

I/S

C/B

“M” Contactor

Emergency (Manual) Operator

C.E. IEEE-IAS 4

Model MCP Part

Winding

Current Transformers

Surge Arrestor Fuses

Control Unit

Digital Recorder

Balance Beam Dual Actuator

Motor Contactors "M1" & "M2"

C.E. IEEE-IAS 5

Common Power Path Components I/S: Isolating Switch (Means) C/B: Circuit Breaker (Disconnect Means) Contactor(s)

Running Starting

Current Transformers (Rigidly Mounted -vs- Tie Wrapped to Power Wiring)

Internal Wiring NEC® Table 310.16 -vs- 310.17 Single Hole Lugs -Often up to "F" Frame (217 Amps = 250A /

1.15) Two Hole Lugs "J" (400 amp) Frame and up 90°C or 75°C or 90°C Columns?? U.L. 60°C up to 100 amp & 75 °C @ FLA F.M. 90°C @ 1.25 x FLA E.g.: U.L. Greater < 100A and F.M. >100A

Note: Table 310-17 is for Conductors in Free Air, Not Bundled.

C.E. IEEE-IAS 6

Model ECP Part

Winding

C.E. IEEE-IAS 7

Internal Wiring and Contactor Currents Main = 1.00 x FLA Part Winding = 65% (M1) Reduced = 65% of FLA

Primary Reactor (Start) Primary Resistor (Start) Autotransformer (Start) Soft Start/Stop (Start)

Wye (Wye-Delta) = 57.7% of FLA (M1 & M2) Wye-Delta (Closed) Transition Wiring = 33% W- Closed Transition = FLA/(6x1.414)=11.8%* Wye (Autotransformer) = 25% (Includes Xfmr Saturation Current)

Variable Speed Wiring Bypass. R1 & R2 Contactors = 100% of FLA Link Reactor = Calculate (may exceed 100%)

* Proprietary Information

C.E. IEEE-IAS 8

Other Power Path Components

Transfer Switch 115% FLA Starting Reactors: Rating in FLA or Hp

Primary Reactors Neutral Reactors (Above 4800 Vac)

Note: Starting Reactors support numerous 10 Second starting attempts. Starting Resistors Sizing: Rating in Amps and

Watts Note that these have a limited duty cycle. W- Transition Resistors Sizing: (ditto) Autotransformer: Rated in Hp

Three Coil Two Coil

Soft Starter H.P. Rated? Continuous or Intermittent Duty Rated?

C.E. IEEE-IAS 9

Primary Reactor Transfer Swich Unit Combination Unit (285 FLA)

C.E. IEEE-IAS 10

Other Power Path Components

Variable VFD Fuses (Must be Selectively Coordinated with F.P. Breaker)

Medium Voltage Controllers Motor Fuses ("R" Rated) CPT Primary Fuses ("E" Rated)

Optional Terminal Blocks (UL Listed for Required WIC Rating)

C.E. IEEE-IAS 11

VFD Fuses

C.E. IEEE-IAS 12

Model ECHA"R" Rated

Motor Fuses

C.E. IEEE-IAS 13

Model ECHA Aux. CPT Primary "E" Rated Fuses

C.E. IEEE-IAS 14

Running ContactorsMust Be Sized for Either Motor Horsepower, or sized for the Greater of Running (FLA) Amps -or- Starting Amps

One Main (Run) Contactor: Motor Hp A-T-L & Variable Speed (Hp Rated) Primary Reactor, Resistor, Softstart Autotransformer

Part Winding: M1 & M2 M1 = 65% (Starting) M2 = 50% or 65%

Wye-Delta (W-): M1 & M2 M1 & M2 = 58% (1/3½)

Note: All of these are used for Manual Mechanical Starting.

C.E. IEEE-IAS 15

Starting ContactorsMust Be Sized for the Greater of Running Amps -or- Starting Amps

A-T-L & Variable Speed (Hp Rated) Part Winding (See Running) Resistor/Reactor/Soft Start = 65% W-

Wye = 33% FLA & LRC Tansition = FLA/(6x1.414)=11.8%*

A.T. Wye = 25% (Includes Xfmr Saturation Current)

* Proprietary Information

C.E. IEEE-IAS 16

Line Voltage Components All Power Path Components Control Power Transformers (CPT's)

Critical Path (Two or Three) Auxiliary Stepdown Transformers

• Cabinet Heaters, Aux. Power, Etc. Surge Arresters Sensors or Modules (Phase Rotation, etc.) Shunt Trip Circuitry & Coil** Note: Not all controllers protect against failures of any of

the three phases. Some provide no motor or controller or conductor protection if either L1 or L2 are lost, particularly with Manual Operator or welded contactor.

C.E. IEEE-IAS 17

Surge Arresters Most are NOT fused (coordination needed along

with higher voltage withstand ability). Many Still Connected on Service Terminals (I/S

Line Side Terminals) Special Option needed for:

Corner Grounded Delta Corner Grounded Wye Ungrounded Systems (Common in process plants to

permit first ground fault without shutting down the process - resulting in a Corner Ground System.)

Only one Mfr. Has UL/FM Option

C.E. IEEE-IAS 18

EC-LC Line Voltage Chassis,S/A Fuse Cover, Shop Current Test Cables

C.E. IEEE-IAS 19

Controllers Rated in Excess of 600 VAlso Called "High" Voltage and "Medium" Voltage*

Isolating Switch Interlocked w/ Contactor -or- Load Break Rated (per UL-347)

Vacuum Contactor Low Chop Motor Type -or- High Chop C/B Type (Suppression Needed)

Fuse Size Rules Door Interlocking Stress Cone Space

"High" Voltage = Old NFPA-20 Designation

"Medium" = Enclosed Switchgear above Low Voltage (600 Vac )

C.E. IEEE-IAS 20

Model ECHAIncoming Bus Bars (Tin Plated)

Shown w/ Shop Current Test Connections

Isolating Switch Stabs

C.E. IEEE-IAS 21

Model ECHAIncoming Bus Bars Cover in Place

C.E. IEEE-IAS 22

Model ECHASwing-outBay PartiallyClosed

C.E. IEEE-IAS 23

Model ECHA Motor Contactor -and- "R" Rated Silver/Sand Motor Fuses

C.E. IEEE-IAS 24

Model ECHA Interlocking

C.E. IEEE-IAS 25

Model ECHAEmergencyMechanicalManualOperator

Quick Make - Quick Break mechanism matches normal electrical operating speeds.

C.E. IEEE-IAS 26

Model ECHA Motor Terminals

C.E. IEEE-IAS 27

Model ECHAIsolatingSwitch

QMB Quick-Make Quick-Break Isolating Switch Mechanism

Includes Four Way Door, Contactor and Handle Interlocking

C.E. IEEE-IAS 28

Fully CoordinatedNote: Contactor is a "Low Chop" type vacuum contactor specifically designed for Motor Applications.

No special cable studies, capacitors or surge arresters required.

Note all Front Top or Bottom Access. Some Mfr's require Rear Access.

C.E. IEEE-IAS 29

Critical Path Items Anything Needed for Automatic Operation Controls

Processor Hardware & Programing Other Electronic Components Relays, Wiring, Connectors, etc.

Timers Lockouts (When Not Wanted) Sensors (False C/B Trip or False Single Phase

Start Protection Circuitry or Phase Reversal Circuitry

Anything that Can Prevent Starting

C.E. IEEE-IAS 30

Door Interlocks

Door Hooks

Interlock Bars

C.E. IEEE-IAS 31

Questions?