Starter & VFD Basics

Date

PROPRIETARY and CONFIDENTIAL

INTRODUCTION

• Overview of 19, 23, and 30 Series “starters”

• Generic Comparison Starter Types – General

• Six (6) types with diagram, description, key items
• Harmonics
• IEEE-519

•19 / 23 Series Specifics

• Product Line matrix of starter/drive combinations

•30 Series Specifics

• Water and Split Air Cooled
• Product Line matrix of starter/drive combinations

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UNIT SERIES & STARTER TYPES
Overview of Types
•19 Series
•30 Series
• Starter Types
19XR • Starter type
• Free Standing
o Starter, Control Panel, Oil Pump Sources • Across the Line (XL)
• Unit Mounted • Wye Delta (WD)
o “Single Source”
• Power Connections
• Type • Single Point
• Starter Constant Speed • Dual Point
• Variable Speed

30RAP
•23 Series 23XRV (100 - 150 Ton)
• Starter Type (352 – 527 kW)
• Unit Mounted
• Type
• Variable Speed
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MOTOR COMPONENTS
Compressor Example
Motor Components - Typical

Stator (motor windings) Rotor (compressor shaft)

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ELECTRICAL DEFINITIONS
19 / 23 Series
Motor Electrics

• Voltage Classes
• Low Voltage (up to 600v)
• Medium Voltage (>600v to 6600v)
• High Voltages (10000 to 13800v)

• Start-up Methods / Inrush Amps

• Full amps Driven by
Motor HP
• Reduced amps

• Full Load Amps at 100% Capacity

• Overload Trip Amps at 108% Capacity 5

STARTER TYPES

• Across-the-Line

• Part-Winding Start

• Wye-Delta

• Solid State

• Autotransformer

• Primary Reactor

• Variable Frequency Drives

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ACROSS THE LINE
Starting Characteristics:

 The motor terminal voltage will be the same

as the line voltage.

• The motor current will equal the line current.

• The motor starting torque will be the same

as the rated starting torque.

Applications:

• This is generally used for smaller general

purpose duty motors, i.e. up to 100 HP
(74.6 kW) in low voltage applications.

• In electrical systems where the system

can withstand the inrush amps without
excessive voltage drop.
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PART WINDING START
Part Winding

• The motor is incrementally started

• Motor windings may be 50% or 66%

• The start winding is only engaged for a

short time, i.e. 2 -3 seconds.

• On the start connection, the motor is not

expected to accelerate. It may not turn.
Starting Characteristics:

• Current (amps) at start-up may be 60-75%

which is dependent on the specific winding connection.

• Torque at start-up is low and shaft may not turn

• Heating in the windings is high on the start connection.

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WYE DELTA
Wye Start Delta Run

• This method is actually reduced voltage

• It is accomplished by changing the motor phase

connections so that a winding that is designed to run
with phase voltage equal to line voltage.

• On delta connection it is wye connected for starting

to put less than line voltage on each phase. (‘Wye-
Delta Start’)

• Wye is also known as ‘star” --- SDCT

Starting Characteristics:

• The starting current will be approximately 30% of

normal.

• The starting torque will be approximately 25-30% of

normal.

Applications:
Where load torque during acceleration is low.
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SOLID STATE
Solid State
• This method is actually reduced voltage

• Uses Silicon Controlled Rectifiers (SCRs)

to vary voltage to motor terminals

• Three parameters of initial current,

maximum current and ramp time

• Ramp is linear and stepless, i.e. SDCT. Typical ramp

time is 0-120 seconds, smooth ramp
Silicon Controlled
Rectifier
• Less stress on the motor winding insulation
Starting Characteristics:
• The motor inrush current with this design is approximately 35-50% of the LRDA
• The starting current is 300-500% of the RLA.

Common Misconception:
Misconception by the customer that it has the same starting characteristics as a
variable speed drive
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AUTOTRANSFORMER
Autotransformer
• This method is actually reduced voltage

• This is a transformer configured with multiple contactors /

taps to allow stepped starting and motor acceleration

• Common taps are 50%, 65%, and 80% of full voltage.

• One of these taps is first step with second step

being full voltage. Open and closed transition types.

 Open transition is first step is disconnected

and then full voltage tap connected.

 Closed transition type does not disconnect the motor

from the voltage supply when transitioning to full
voltage.
Application:
• More use in past before industry development of SDCT, VFD, and SS technologies
• May be seen in replacement applications, i.e. 1500 ton (5275 kW) at 208/230v
and at some larger medium voltage (4160v) applications 11
PRIMARY REACTOR
Primary Reactor
• Mostly used in medium voltage applications, i.e. 4160v

• Similar to autotransformer in that it reduces inrush

current by reducing voltage applied to the motor.

• A resistor is used to reduce the voltage to the motor.

• Utilizes 1M and 2M contactors

• By its design using resistors, technically it is not the

most efficient starting method.

• Allows the changing of incoming line voltage taps to set

the level of inrush voltage and current.
Application:
• Primarily medium voltage applications.

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VARIABLE SPEED DRIVES
Operation Variable Speed Drives (VSD)

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STARTER TYPES & INRUSH CURRENT
Starting Current Comparison
Affected by Type of Chiller Starter Used
Motor Starting Current as a % of
Starting Method OR
Full Load
Locked Rotor Current Current/Amps or RLA
Across-the-Line 100 600 - 800
Auto Transformer & Primary Reactor
80% 80 480
65% 65 390
50% 50 300

Wye-Delta 33 200 -275

VFD 16.6 100
Solid-State 45 320

Locked Rotor Current - Motor is in stop position ready for start

Full Load Current – Motor full load amps running at design
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VFD DESCRIPTIONS/DEFINITIONS
Std Tier & Freestanding VFD LF2
Fixed Front End Active Converter

M M

Input Current Waveform

Carrier Confidential 15
HARMONICS
•Harmonics are distortions in currents or voltages with
frequencies that are integer multiples of the Standard Electrical AC
fundamental power frequency being 50 or 60Hz. 1.5 Sinewave
1
Example, if the fundamental power frequency is 60 Hz, 0.5
then the 2nd harmonic is 120 Hz, the 3rd is 180 Hz, etc.

Voltage
0
-0.5
•Harmonics are caused by and are the by-product -1
of modern electronic equipment. This includes: -1.5
Angle
Personal or notebook computers Laser printers
Fax machines Telephone systems
Stereos Radios Sinewave Distortions
TVs Battery Chargers from a specific type of drive
UPS Adjustable speed drives
Variable frequency drives Variable Speed Dive
Solid State Starters (at start-up 6.5% to 9.5% THD, at full speed
SCRs are bypassed so filtering is not req’d)
Any other equipment powered by switched-mode power supply
(SMPS) equipment.

•Harmonics may lead to

Interference with Communication Equipment
Overheating of Transformers and other Branch equipment
Overheating of Motors connected on the same power line

Carrier Confidential 16
IEEE-519 COMPLIANCE

Institute of Electrical and Electronics Engineers

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IEEE-519 COMPLIANCE
Point of Common Coupling
The place where Harmonic Distortion is measured.
Where drives are electrically connected with other loads.

Distortion Levels
According to IEEE Std 519-1992 Recommended
Practices and Requirements for Harmonic Control in
Electrical Power Systems, the voltage harmonics
distortion limits are as follow: Utility Source

Per Table 10.2 from IEEE 519-1992: Voltage

Distortion Levels
3% for Special Applications
Sensitive equipment tied directly to M otors
VFD feeder circuit Loads Loads Loads

5% for General Systems

Most common in commercial buildings

10% for Dedicated Systems

VFD dedicated power distribution feeds
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HARMONICS
Drive Type Comparisons – Current Total Demand Distortion (iTDD)

LF2 w/ Active Recti-

fier 5 IEEE 519
Freestanding VFD w/ % iTDD
Harmonic Filter 5 IEEE 519
Rockwell Std Tier
Optional 5% Line 30
Reactor
Eaton Std Tier Op-
tional 5% Line Reac- 30
tor
Eaton Std Tier Std
3% Line Reactor 32
Rockwell Std Tier 35

Basic VFD 110

1 10 100 1000

5% Line Reactor is not 5% Harmonics Distortion

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IEEE-519 COMPLIANCE
Utility Source

Carrier LF2 VFD

• IEEE 519 Compliant M otors
Loads Loads Loads

Voltage Total Harmonic Distortion (vTHD) shall not

exceed 3% and Harmonic Current Total Demand
Distortion (iTDD) shall not exceed 5% as
calculated per IEEE-519 using the VFD circuit
breaker input terminals as the point of common
coupling (PCC).
Know your point of common coupling definition and reference
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CABINETS, ENCLOSURES, PANELS
NEMA Classifications – Commonly Seen
Non Hazardous Locations
NEMA 1 Enclosures constructed for indoor use to provide a degree of protection to Personnel against
incidental contact with the enclosed equipment and to provide a degree of protection against falling dirt.

NEMA 12 Enclosures constructed (without knockouts) for indoor use to provide a degree of protection
to personnel against incidental contact with the enclosed equipment; to provide a degree of protection
against falling dirt; against circulating dust, lint, fibers, and flyings; and against dripping and light
splashing of liquids.

NEMA 4 Enclosures constructed for indoor use to provide a degree of protection to personnel against
incidental contact with the enclosed equipment and to provide a degree of protection against falling dirt.
rain, sleet, snow, wind blown dust, splashing water, and hose-directed water; and that will be
undamaged
by the external formation of ice on the enclosure.

NEMA 3R Enclosures constructed for either indoor or outdoor use to provide a degree of protection to
personnel against incidental contact with the enclosed equipment; to provide a degree of protection
against falling dirt, rain, sleet, and snow; and that will be undamaged by the external formation of ice on
the enclosure. From NEMA 250-1997
Other Variations in Enclosure and Construction Classes NEMA Guide
located in
 Indoor or Outdoor
Chiller Builder
 Hazardous and Non-Hazardous
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UNIT SERIES AND STARTER TYPES

Applied Chillers

19 / 23 Series

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STARTERS, VFDS, AND CONTROLS MATRIX
Applied Chillers – 19 / 23 Series
TYPE VFD / STARTER MANUFACTURER PIC II PIC III PIC 5
Control** Control Control*
Low Voltage (600V and less)
Unit Mtd. Std. Tier (445 Amps & Below) VFD Rockwell Automation X
Unit Mtd. Std. Tier (446 Amps & Above) VFD Eaton X
Unit Mtd. (LF2) VFD Rockwell Automation X
575V Unit Mtd. (LF2) VFD Rockwell Automation X
Freestanding VFD Toshiba X
Unit Mounted Wye-Delta STARTER Benshaw X
Unit Mounted Solid State STARTER Benshaw X
Freestanding Wye-Delta STARTER Benshaw X
Freestanding Solid State STARTER Benshaw X

Medium Voltage (> 600V up to 6900V)

Freestanding VFD Rockwell Automation X X
Freestanding Solid State STARTER Benshaw X X
Freestanding Across the Line (XL) STARTER Eaton X X
Freestanding Autotransformer STARTER Eaton X X
Freestanding Primary Reactor STARTER General Electric X

High Voltage (> 6900V)

Freestanding Solid State STARTER Benshaw X X
Freestanding Across the Line (XL) STARTER Eaton X X
Freestanding Autotransformer STARTER Eaton X X

** PIC II & III Controls available for XR2-XR5 & XRE

* PIC 5 Controls used on XR6 and XR7 only

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UNIT SERIES AND STARTER TYPES
Field Wiring Comparisons
480-3-60

•19 Series Centrifugal with Unit Mounted Starter/Drive

• One (1) 480v connection

o Starter/Drive
o Compressor Motor
o Unit Controls
o Oil Pump
o Oil Heater
Field Wiring 24
UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES

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UNIT SERIES AND STARTER TYPES
Benshaw LV PIC II Starters for Frames 2-5 & E Compressors
Customer Supplied LV
Customer Supplied LV (208-575v / 3) to Oil Pump
Interconnecting LV (115v) to Oil Heater and Control Power
Interconnecting LV Wiring to Motor Terminals
Interconnecting Communication Wiring Between Power Panel and Starter

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UNIT SERIES AND STARTER TYPES
Toshiba LV VFD, PIC II for Frames 2-5 & E Compressors
Customer Supplied LV
Interconnecting LV (208-575v / 3) to Oil Pump
Interconnecting LV (115v) to Oil Heater and Control Power
Interconnecting LV Wiring to Motor Terminals
Interconnecting Communication Wiring Between Power Panel and Starter

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ELECTRICAL DEFINITIONS – 19 / 23 SERIES

Three Electrical Areas:

• Compressor Motor

• Starter/Electrical Control Panel

• Total Unit

Actual “control panel” on 19/23

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ELECTRICAL DEFINITIONS – 19 / 23 SERIES
1. Motor Input KW: Chiller compressor
motor KW draw at full load

2. Motor Rated Load Amps (RLA):

Amperage being drawn by the
compressor motor for specific application.
Typically this will be quite a bit less than
the FLA.

3. Motor Overload Trip Amps (OLTA):

1.08 X RLA reference point for control
settings

4. Motor Locked Rotor Wye (LRYA) 4. Chiller Inrush Amps – VFD

Amps (wye delta only): Peak inrush
OR chillers – unit mounted or free-
amps for YD starting configuration. standing.

5. Motor Locked Rotor Delta (LRDA)

Amps: Inrush current as in across the line
start.
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ELECTRICAL DEFINITIONS – 19 / 23 SERIES
6. Chiller Rated Load Amps (RLA): Amperage
being drawn by the entire chiller (includes starter
amps, oil pump, and any control circuit amp draw).
This value is used to size harmonic filters and line
reactors.

7. Maximum Fuse/Circuit Breaker Amps*: Largest

value usable for sizing the field supplied and installed
branch line protection.

8. Minimum Circuit Ampacity*: Amperage value

used by the electrical engineer for sizing the field
supplied and installed three phase wiring from the
mechanical room to the chiller starter. This value is
1.25 X chiller RLA.

9. Ampere Interrupting Capacity (AIC) = rating of

electrical current flow that a protective device (fuse,
breaker, etc.) can interrupt to protect a circuit

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ELECTRICAL DEFINITIONS – 19 / 23 SERIES
10. Short Circuit Current Rating (SCCR)
– is a calculated value that represents the
maximum short circuit current that the
control panel can withstand under fault
conditions.

SCCR accounts for all components

contained within the control panel:

Motor Controllers
Circuit Boards
Contacts
Control Power Transformers

Units have standard ratings and optional

higher rating.

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SCCR – 19XR(V) & 23XRV (LOW VOLTAGE)
Standard
Series High SCCR Option
Rating
19XRV LF2 & Std. Tier 100 kAIC
65 kAIC
(Up to 445 Amps) Standard Option
19XRV Std. Tier
65 kAIC 100 kAIC
(446 Amps and Above)*
23XRV 100 kAIC
VFD 65 kAIC
(LF2 & Std. Tier) Standard Option
575v Std Tier 35 kAIC -

19XR
65 kAIC 100 kAIC
(Free Standing)

19XR (Unit Mounted & Free Standing) 30 kAIC 65 kAIC

CS
19XR Solid State 30 kAIC 65 kAIC

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SCCR – 19XR (MEDIUM VOLTAGE)
Standard
Series High SCCR Option
Rating

Free Standing Solid State

50 kAIC N/A
(Benshaw)

Start Free Standing Across-the-Line 50 kAIC

N/A
ers (Eaton)

Free Standing Auto-Transformer

50 kAIC N/A
(Eaton)

N/A
VFD Rockwell 25 kAIC

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FUSE SIZING

VFD Type Fuse Sizing Rule of Thumb

VFD (Std Tier) 1.35 x Chiller RLA
VFD (LF2) 1.35 x Chiller RLA
Freestanding VFD 1.35 x Chiller RLA

• Fuse sizes should be no less than the RLA

and no more than the MOCP.

• It is still highly recommended to consult a

Certified Electrician regarding fuse sizing

Carrier Confidential 41
STARTER TYPES
Summary Comparison - Chiller Electrical Information
Constant Speed Variable Speed

Let’s review the same chiller with

different starter /drive options …
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ELECTRICAL 19 / 23 SERIES
Documents and References Chiller Builder Program
• Use Document Library

• Use ‘Find and Select’ icon for ‘keyword’ to find information to questions or
inquiries
• Sometime an owner requests to supply their own starter/drive or reuse an
existing starter/drive.
 They can be provided the starter/drive specification, i.e. Z-415 from the document
library.

 The detailed engineering work required to verify existing starter/drive capability

is not provided by Carrier Chiller Product Group.

Engineering work for use of existing starter/drive may be provided by owner

engineering staff if available, outside electrical engineering firm, or perhaps Carrier
Service if available.

Generally speaking, reuse of existing starter/drive is not cost effective once all
engineering, verifications, coordination, modifications, and warranty
considerations are accounted for.
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Packaged Chillers

30 Series

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METHODS OF STARTING
Packaged Chillers – 30 Series
30MPW 30HXC 30XW 30RAP 30RB 30XA 30HXA 30MPA

Package Air Cooled Split Air Cooled

Water Cooled Chillers
Chillers Chillers
Unit Mounted
Wye-Delta 208/230 STD STD OPT STD
Wye-Delta 460, 575 OPT OPT OPT OPT
STD
Across-the-Line for
STD STD STD STD
208/230 080 –
102
Across-the-Line 460 STD STD STD STD STD STD STD STD
OPT
Dual Point Connection 325 – OPT
400 T

Low Voltage (208,230,460,575)

STD or OPT applies to all unit sizes unless otherwise indicated

30XA Basis Standard Condenser Motors

Without Hydronic Package
Standard Ambient Condenser Motors

Carrier Confidential 45
ELECTRICAL DEFINITIONS – 30 SERIES

Two Electrical Areas:

• Compressor Motor
30HXC

• Total Unit

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ELECTRICAL DEFINITIONS – 30 SERIES
Specific Electrical Items
30MPA, 30HXC,
MPW HXA 30XW 30RA 30RB 30XA
Maximum instantaneous current flow
during starting.(the point in the starting
sequence where the sum of the LRA
ICF — for X X X X X X
the start-up compressor, plus the total
RLA for all running compressors is at a
maximum)
kcmil — Thousand circular mils X
LRA — Locked rotor amps. X X X
Minimum circuit amps (for wire sizing).
MCA — Complies with NEC, Section 430-24. X X X X X X
MOCP — Maximum Overcurrent Protection X X X X X X
Recommended dual element fuse
Rec
— amps (150% of compressor RLA). Size
Fuse
up to the next standard fuse size. X X
RLA — Rated Load Amp X X X
WD Wye-Delta Start X X X
XL Across-the-Line Start X X X X X
Full Load Amps - Condenser Fan
FLA Motors X

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Key electrical questions commonly encountered.
ELECTRICAL DEFINITIONS – 30 SERIES
Starting Types Comparison 30HXC
• Some 30 Series units have two types
of compressor motor starting available
o Wye-Delta (WD)
o Across-the-Line (XL)

 MCA and MOCP are the same

 ICF is greatly different

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ELECTRICAL DEFINITIONS – 30 SERIES
10. Short Circuit Current Rating (SCCR)
– is a calculated value that represents
the maximum short circuit current that
the control panel can safely withstand
under fault conditions.

SCCR accounts for all components

contained within the control panel:

Motor Controllers
Circuit Boards
Contacts
Control Power Transformers
(30HXC Shown)

Units have standard ratings and

optional higher rating.

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SCCR – 30 SERIES
Series Standard Rating High SCCR Option
30XW (575V) 5 kAIC 25 kAIC = ETO
30XW (All other voltages) 5 kAIC 65 kAIC
25 kAIC Standard Option – 575V
30RB 5 kAIC 65 kAIC Standard Option – 460V
65kAIC ( 208/230 Volts) = ETO
30HX 5 kAIC 65 kAIC = ETO
25kAIC140-350T (575V)
65kAIC140-350T (460V)
65kAIC 80-120T (460-575V) = ETO
30XA 5 kAIC
All 400-500T = ETO
All 208/230 V = ETO
All 380 V = ETO
30XA Greenspeed 10 kAIC 65 kAIC = ETO
30RAP/38AP/38AH/
5 kAIC 65 kAIC Standard Option
09DP
30MP (575V) 5 kAIC 25 kAIC

30MP (All other voltages) 5 kAIC 65 kAIC

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Starter & VFD Basics
July 23, 2015

Charlie Putz
Product Manager

Thank You ………..

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