Starters & VFDS: Terry Garletts

Starters & VFDs
Terry Garletts
May 2010
Branch Power
Circuit wiring in
Protection conduit
© 2009 McQuay International

MCQUAY CONFIDENTIAL - DO NOT DISTRIBUTE
Starter Topics
• Terms & Acronyms

• Codes & Approval Agencies
• Functions of a Starter
• Types, Features, and Benefits
• Low Voltage Starters

• Medium Voltage Starters
• VFDs (and Harmonics)
• Information and Resources
• Summary
Motor Terms
• FLA – Full Load Amps: Current draw at design HP of motor
• RLA – Rated Load Amps: Current draw at chiller full load

design
• LRA – Locked Rotor Amps: Current draw at design voltage

with rotor prevented from turning

KAIC and SCCR
• KAIC – acronym for 1000’s(K) of Amps Interrupting Capacity
• Maximum amps that a device can safely interrupt from the power.
• Ratings apply to circuit breakers, and fuses.
• SCCR – acronym for Short Circuit Current Rating
• Maximum amps an electrical assembly can safely pass without

blowing debris out of the enclosure.
• Ratings are applied to starters, and other electrical assemblies.
• SCCR replaced the term short circuit withstand rating.
• DO NOT confuse interrupt ratings with short circuit current ratings.

MCA and MOCP
• Minimum Circuit Ampacity (MCA)
• Used for sizing conductors
• Not the same as current draw
• Maximum Overcurrent Protection (MOCP)
• Used for sizing fuses or circuit breakers

Formulas – Positive Displacement (PDC)
• MCA = (1.25 x largest motor RLA) + (RLA/FLA of

remaining motors)
• MOCP = (2.25 x largest motor RLA) + (RLA/FLA of

remaining motors)

Engineered for flexibility and performance 7 DISTRIBUTE
MCQUAY CONFIDENTIAL - DO NOT
Formulas - Centrifugal
• MCA = (1.25 x RLA) + (3000 / job voltage)
MINIMUM Circuit Ampacity
• MOCP = (1.75 x RLA) + (3000 / job voltage)
MAXIMUM Over-Current Protection

Codes and Approval Agencies
All of the below are certified testing agencies:
UL - Underwriters Laboratories
• generates safety standards through committees
• UL1995 is the safety standard for chillers
• UL508A and UL508C standards for starters
• CSA - Canadian Standards Association
• generates safety standards through committees
• CSA - accepts C-UL, and C-ETL labeling
• ETL - Electrical Testing Laboratories
• cETLu - equivalent of UL and CSA Listed marks

throughout U.S. and Canada

Codes and Approval Agencies
• NFPA - National Fire Protection Association
• Writes numerous safety codes
• “Design to NFPA 70” appears in a majority of

specifications
• NEC 2008 - National Electric Code
• Is publication NFPA 70 of the NFPA
• Updated every 3 years
• AHJ – Authority Having Jurisdiction

NEC Requirements (Key Points)
• NEC Article 440 - A/C and Refrigerating

Equipment (7 sections)
• I. General
• II. Disconnecting Means - optional in starter or

readily accessible (circuit breaker, fused or nonfused disc.
switch, molded case switch)
• III. Branch Circuit Short Circuit and Ground Fault Protection

– optional in starter, based on MOCP (fuse or circuit
breaker)
• IV. Branch Circuit Conductors – sizing based on MCA (MCA

based on RLA for hermetic motors, not FLA)

NEC Requirements (Key Points)
• NEC Article 440 - A/C and Refrigerating

Equipment (7 sections)
• V. Motor Controllers
• VI. Motor Compressor and Branch Circuit Overload

Protection - provided in starter to protect motor-
compressor and conductors from overcurrent
• VII. Room Air Conditioners

Enclosures – NEMA Ratings (IP Ratings)
• NEMA 1 (IP23) – Indoor
• NEMA 1A – Indoor Gasketed
• NEMA 2 (IP30) – Indoor Dripproof
• NEMA 3R (IP32) – Outdoor Raintight
• NEMA 12 (IP65) – Indoor Dusttight, Oiltight
• NEMA 4 (IP66) – Outdoor Dustight, Oiltight
• NEMA 4X (IP66) - NEMA 4 Corrosion Proof
• NEMA 7 & 9 – Hazardous Locations

Starter Functions
• Start and Stop the Chiller
• Protect the Motor from Abnormal Operating Conditions overcurrent,

overheating
• over/under voltage, phase unbalance/loss/reversal
• Additional Functionality
• unit disconnect switch
• short circuit protection
• provide control circuit power
• provide a percent motor load signal to unit controller
• metering options
• other safeties

HVAC Voltage Ranges
• Low Voltage – 600 volts or less

• Ex.: 220-3-50; 380-3-50; 460-3-60; 575-3-60
• Medium Voltage – 7200 volts or less

• Ex.: 3300-3-50; 4160-3-60; 6600-3-60
• High Voltage – greater than 7200 volts

• Ex.: 10kv-3-50; 11kv-3-50; 13.2kv-3-60

McQuay Starter Manufacturers
• BENSHAW
• Low Voltage (unit mounted and free standing)
• Wye-Delta
• Solid State
• Medium Voltage (free standing only)
• Across the Line
• Solid State
• CUTLER-HAMMER (Eaton Electric)
• Medium Voltage (free standing only)
• Primary Reactor
• Auto-transformer
Standard Features (All Types)
• NEMA 1A Enclosure
• Power Terminal Blocks
• 3kVA, 120 volt, Control Circuit Transformer
• Solid State Motor Overcurrent Protection
• Phase Unbalance, Failure/Rev./Loss Protection
• Undervoltage and Overvoltage Protection
• Jam (stall) Protection

MV (only) Additional Standard Components
MV Standard Components Also Include:

• Current limiting power fuses
• Self indicating blown fuse
• Isolating safety switch
• Benshaw - load break switch as standard
Across the line, and solid state
• Cutler-Hammer - non-load break switch as standard
Primary reactor, and auto-transformer

Options (SelectTOOLS checks for compatibility)
• Disconnects and Breakers

• Non-fused disconnect switch (molded case switch)
• Fused disconnect switch (fuses by others)
• Circuit Breaker (low voltage)
• Select interrupt rating if specified
• Unit Mounting, or Freestanding (use SelectTools for
choices)
• Meters
• Ammeters/ voltmeters with 3-ph selector switch
• Full Metering Display on MT II : 3-ph amps,
3-ph volts, KW, KWH, power factor,
(Benshaw-only)

Options (Selection Program checks for compatibility)
• Aux. Control Relay ( 2 - N.O. and 2 - N.C.)
• Lightening Arrestors
• Pilot lights (green-chiller on; red-chiller off)
• Power Factor Correction Capacitors
• Miscellaneous: Enclosure Modifications, Other

NEMA ratings, medium voltage multiple Line-Ups

OITS Screen (standard display - percent of unit RLA shown)

OITS Screen (with full metering display option)

PFCC Concept

Option - P.F. Correction Capacitors
• Improving Power Factor DOES NOT INCREASE CHILLER

EFFICIENCY
• Power factor is shown on the SelectTOOLS rating output
• Power factor correction is allowed to a maximum of .95
• Enter in SelectTOOLS input screen if minimum power factor is specified
• SelectTOOLS will correct with a standard size PFCC as close

as possible to meet the minimum specified without
exceeding .95
• Selecting power factor correction capacitors will prohibit unit mounting
of starter

Starter Selection Requirements
• Voltage
• Hertz
• Starter Type
• Mounting Configuration
• Options (May affect mounting configuration)
• SelectTOOLS will pick starter size to satisfy above

requirements as well as meet the following:
• Rated Load Amps (RLA) of Selection
• Locked Rotor Amps (LRA) of Motor

Starter Selection Requirements
• Low Voltage: Solid state is the most

competitive up to 963 RLA.
(Use wye-delta above 963 RLA)
• Medium Voltage: Across-the-line is most
competitive.
• If a customer wishes to provide their own
starter, go on to McQuayBIZ for the latest
copy of the starter specification,
359A999.
• VFD must be provided by McQuay only

Mounting Configurations (Use SelectTools)
Models Low Voltage

WSC/WDC 063, 079, and
Unit mounted or freestanding
087
Freestanding or unit mounted in
field (*Unit mounting request will
WSC 100*, 113, and 126 select bracket and cable kit for field
mounting on WSC100 unit only, if
available.)
WDC 100, 113, and 126 Freestanding only.
All MEDIUM VOLTAGE TYPES - Freestanding only

Low Voltage - Wye-Delta Starters

Starting Configuration Running Configuration

Winding voltage = Line voltage / √3 Winding Voltage = Line Voltage
• Used with a three winding, 6-lead motor designed to run

at full voltage in the delta3configuration
• Both ends of each winding are brought out of the
compressor for connection to the starter

Starting Conditions
% Motor % Inrush
Starter Type % Torque
Voltage Current
Wye-Delta 58 33 LRA 33
As Gradual
Solid State 250 to 300 RLA
needed Increase
Auto-
65 45 LRA 42
Transformer
Primary
65 65 LRA 42
Reactor
Across The
100 100 LRA 100
Line
Ramps @
Gradual
VFD Constant Starts < RLA
Increase
Volts/Hz
Benefits of Applying VFD’s
• Utilizes both Inlet Guide vanes and Speed
• Compressor motor slows when:
• load decreases (with corresponding drop in CEWT)
• and/or as head decreases
• Slower speeds yields excellent kW/Ton values
• As compressor unloads sound improves
• Soft starting and stop of compressor yields longer life for components

McQuay VFDs
• RELIANCE and ALLEN-BRADLEY (both divisions

of Rockwell Automation)
• 380 volt to 480 volt, 50 or 60 hz
• 575 volt, 60 hz
• 4160 volt, 60 hz $$$$$

• Greater Power Factor - 0.95 or better
• Standard DC Bus inductor on the Liquiflo 1 drives for reduced line

harmonics
• Ability to match varying loads and with superior performance.
• Ability to change the lift conditions of the unit without the need for
changing gears

• VFD Chillers to larger capacities than competitors – 2000 tons

(think WDC chillers)
• (2) drives are often more cost effective than one large drive

Applying VFD’s
• Best Applications: Think lots of part load operating hours with reduced
entering condenser water temperature.
• VFD’s give better part load performance
• Key possible installations
• Schools
• Large % run hours at part load
• Large % run hours at reduce ECWT
• Hospitals
• Large % run hours at part load maybe multiple chillers
• Large % run hours at reduce ECWT
• Possible chilled water reset - VFD’s benefit
• Office Buildings

VFD - Harmonics
• Harmonic analysis
• Identify any harmonic’s issues Harmonics Calculator and Analysis
•
for Centrifugal Chillers with VFDs
Harmonics come from

HarmLess OEM v. 2.0M Version 2.0 June 2001.
Project Name:
Company:
System Designation:
feedback into the electrical

Project Notes:
Transformer Rating in KVA 0
system “noise” Transformer Impedance %

Transformer Secondary Voltage in volts
0
0
Drives without any harmonics mitigation devices (HP) 0
•
Drives with 3% Line Reactors (HP) 0
Drives with 5% Line Reactors (HP) 0
Sensitive applications such Drives on 12-Pulse Transformer (HP)

Chiller (LiquiFlo) with no mitigation devices (Load Amps)
Chiller (LiquiFlo) with 3% Line Reactors (Load Amps)
0
0
0
as Hospitals, Data
Chiller (LiquiFlo) with 5% Line Reactors (Load Amps) 0
Chiller (LiquiFlo) on 12-Pulse Transformer (Load Amps) 0
Linear Load (Motor Loads in HP) 0
Linear Load (Resistive Loads in KW) 0
Centers… may require RESULTS:

#DIV/0!
additional filtering Total Voltage Harmonic Distortion % (THD)

Total Current Harmonic Distortion % (TDD)
NOTE: According to IEEE Std 519-1992 Recommended Practices and Requirements for
#DIV/0!
#DIV/0!
Harmonic Control in Electrical Power Systems, the voltage harmonics distortion limits are
•
as follows:
Per Table 10.2 from IEEE 519-1992: Voltage Distortion Levels
Harmonics issues can be

3% for Special Applications (Sensitve equipment tied directly to VFD feeder circuit)
5% for General Systems (Most common in commercial buildings)
10% for Dedicated Systems (VFD dedicated power distribution feeds)
overcome w/ line reactors /

Per Table 10.3 from IEEE 519-1992: Current Distortion Levels
Isc/IL TDD Limit
<20 5
20<50 8
suppression devices
50<100 12
100<1000 15
>1000 20
DISCLAIMER: This spreadsheet is intended to be used as an estimating tool only. It is not a
•
replacement for an on-site harmonic survey, or modeling services that would consider
detailed drive and distribution system information.
Use harmonics calculator

No warranty including those of merchantability or fitness for a particular purpose is given or implied
© This spreadsheet is copyright of Rockwell Automation, Reliance Electric 2001.
estimating tool

HARMONIC OPTIONS
• Line Reactors - passive device

• SelectTOOLS will advise if provided in a separate NEMA 1
enclosure
IMPORTANT NOTE ABOUT LINE REACTORS - Standard
option is 3% impedance with special quotes for 5%
impedance. The 3% and 5% numbers DO NOT MEAN
percentages of current total harmonic distortion (THD).
• Liquiflo 2 Drives – active front end technology for strict

compliance with IEEE-519

VFD Takeaways
• VFD’s can and will save money in most

applications
• Use the tools to select the proper VFD
• Harmonics are not always a problem !
• Energy Analyzer will give paybacks

analysis for customers
• Utilize dual compressors in the 1500 -

2200 ton range to lock out competition

Solid State StarterFigure
w/1, Solid
Circuit Breaker/Disconnect
State Starter with Circuit Breaker/ Disconnect
Models RVSS47 – RVSS82, RVST47 – RVST82
Removable
Cable Entrance
Panel
Terminal Strip
Grounding Lug
Line Side Lugs
Access for
factory wiring
to motor
Disconnect Switch
Motor Lugs
Remote Switch
Operator (to Door)
SCRs
(3) Current
Transformers
Bypass Contactor
Primary Transformer
Fuses
Motor Control
Relays (MCR)
Secondary
Transformer Fuses
Control
Transformer

Wye-Delta Starter, Closed Transition Grounding Lug
TB4 Terminal
Board
Incoming Power
Connection
Opening to Motor
Terminal Box for
Disconnect Switch
Factory-Wiring
(3) Current
Transformers
(6) Motor Leads (CTs)
Disconnect Handle
Primary Control
Power Fuses
Start & Run
Contactors
Control Module with
Digital Readout (Front)
Y-Connection
Starting Contactor Motor Control Relays
(Behind)
Resistor Contactor for

Closed Transition
Control Transformer
Transition
Resistors

Variable Frequency Drive
Optional Meter
Transformers (2)
Motor Terminals
Terminal Board
Fuses
Disconnect Switch
Drive Unit
Motor Control
Relays (MCR)
Keyboard/Display
Control
Transformer Cooling Water
w/ Fuses Lines

Field Wiring Diagrams and IOMMs - McQuayTOOLS

Diagrams and Enclosures
• Refer to product manual CAT Starter-

6 for additional info.
• enclosure dimensions, and lug
sizes
• Field wiring diagrams can be
downloaded from McQuayBiz
• WSCWDC-MTII-WIRE-2
• Freestanding starter drawings
available on McQuayBiz
• Unit mounted, or direct terminal
mounted starters, are shown
mounted on the unit certified
drawings

Starter & VFD Resources
• Available on McQuay Biz:

• Cat Starter-6
• Starters & VFD’s for Centrifugal, Templifier,
and Heat Recovery
• IOMM VFD-2
• Engineering Newsletter (July2006)
• Saving Energy with a Centrifugal Chiller and
a VFD

Starter & VFD Resources
• Available on McQuay Biz:

• Sales & Engineering Data
• ED 8015 – Successfully Applying a VFD on
an Existing McQuay Water-Cooled
Centrifugal Chiller
• ED 9047 – Reduced Harmonics Technology
• Brochure
• 13F-2315 – Reduce Your Chiller’s Energy
Usage Up to 30% by Adding a VFD

VFD – 6 Pulse Configuration

VFD – 6 Pulse Current Waveform





VFD – 6 Pulse vs. Active Front End (AFE)

6-Pulse Drive with DC Bus Inductor

Current Harmonics and Drive Output
(PWM: pulse-width-modulation)

VFD Current Harmonics
McQuay % THD
VFD Type
Model Current
6-Pulse -no none 75
reactor/choke
WMC,
6-Pulse - with WME &
35
reactor PF700H
6-Pulse with Liquiflo

32
bus inductor and PF755
12-Pulse WME 14
(6-phase)
18-Pulse 5 to 7
None
24 - Pulse 3 to 5
Active Front
Liquiflo 2 3 to 5
End
Starting Conditions
% Motor % Inrush
Starter Type % Torque
Voltage Current
Wye-Delta 58 33 LRA 33
As Gradual
Solid State 250 to 300 RLA
needed Increase
Auto-
65 45 LRA 42
Transformer
Primary
65 65 LRA 42
Reactor
Across The
100 100 LRA 100
Line
Ramps @
Gradual
VFD Constant Starts < RLA
Increase
Volts/Hz
Do Not Lose an Order Because of a Starter
Specification......Contact the Factory!!!!
We’re here to help you!

Questions ???


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Starters & VFDs

© 2009 McQuay International

• Terms & Acronyms

• Low Voltage Starters

• FLA – Full Load Amps: Current draw at design HP of motor

• RLA – Rated Load Amps: Current draw at chiller full load

• LRA – Locked Rotor Amps: Current draw at design voltage

© 2009 McQuay International

• Ratings apply to circuit breakers, and fuses.

• SCCR – acronym for Short Circuit Current Rating

• Maximum amps an electrical assembly can safely pass without

• Ratings are applied to starters, and other electrical assemblies.

• SCCR replaced the term short circuit withstand rating.

• DO NOT confuse interrupt ratings with short circuit current ratings.

© 2009 McQuay International

• Minimum Circuit Ampacity (MCA)

• Used for sizing conductors

• Not the same as current draw

• Maximum Overcurrent Protection (MOCP)

• Used for sizing fuses or circuit breakers

© 2009 McQuay International

• MCA = (1.25 x largest motor RLA) + (RLA/FLA of

• MOCP = (2.25 x largest motor RLA) + (RLA/FLA of

© 2009 McQuay International

• MCA = (1.25 x RLA) + (3000 / job voltage)

MINIMUM Circuit Ampacity

• MOCP = (1.75 x RLA) + (3000 / job voltage)

MAXIMUM Over-Current Protection

© 2009 McQuay International

• generates safety standards through committees

• UL1995 is the safety standard for chillers

• UL508A and UL508C standards for starters

• CSA - Canadian Standards Association

• generates safety standards through committees

• CSA - accepts C-UL, and C-ETL labeling

• ETL - Electrical Testing Laboratories

• cETLu - equivalent of UL and CSA Listed marks

© 2009 McQuay International

• NFPA - National Fire Protection Association

• Writes numerous safety codes

• “Design to NFPA 70” appears in a majority of

• NEC 2008 - National Electric Code

• Is publication NFPA 70 of the NFPA

• Updated every 3 years

• AHJ – Authority Having Jurisdiction

© 2009 McQuay International

• NEC Article 440 - A/C and Refrigerating

• II. Disconnecting Means - optional in starter or

• III. Branch Circuit Short Circuit and Ground Fault Protection

• IV. Branch Circuit Conductors – sizing based on MCA (MCA

© 2009 McQuay International

• NEC Article 440 - A/C and Refrigerating

• VI. Motor Compressor and Branch Circuit Overload

• VII. Room Air Conditioners

© 2009 McQuay International

• NEMA 1 (IP23) – Indoor

• NEMA 1A – Indoor Gasketed

• NEMA 2 (IP30) – Indoor Dripproof

• NEMA 3R (IP32) – Outdoor Raintight

• NEMA 12 (IP65) – Indoor Dusttight, Oiltight

• NEMA 4 (IP66) – Outdoor Dustight, Oiltight

• NEMA 4X (IP66) - NEMA 4 Corrosion Proof

• NEMA 7 & 9 – Hazardous Locations