Pool Main Pump Motor - Revision history

Matt Parnell: /* VFD Unit */

2022-03-20T11:34:58Z

VFD Unit

@@ Line 97: / Line 97: @@
 === VFD Unit ===
-==== Overview ====
+This section has been updated to alter its context from research to implementation.  A majority of the data for "other" VFD units has been removed.
-Cost is a major driver in the VFD selection process.  As noted, up to $900 will be reimbursed by DTE.  Longevity is an issue, too, as failure becomes a MAJOR issue for pool operation.
+Yaskawa GA50U2042ABA:
 * The 2042 model sized for "normal duty" (ND) 15 HP which is appropriate for variable torque (VT) applications (i.e. centrifugal pumps).
 * Internal PCBs are conformally coated (IEC 60721-3-3, Class 3C2 for chemical gasses).  <b>This is a huge plus!</b>
@@ Line 125: / Line 111: @@
 * 391 W total loss @ 2 kHz, 42 A output.
-==== Automation Direct GS23-2015 ====
+{| class="wikitable"
+!colspan="2"|Drive Catalog Code
-The alternative (and past front-runner).
+!Description
+!Comment
-==== Automation Direct GS4-2015 ====
+|-
+!Product Series
-Not presently being considered.
+|GA50
-* Substantially larger: 12.60" L x 7.48" W x 7.48" D (versus 8.15" L x 4.29" W x 6.06" D for the GS3).
+==== Prior Considerations ====
-==== ABB ACS310-03U-50A8-2+J400 ====
+VFDs from various manufacturers were considered during the evaluation process.  In particular, the following other drives were evaluated:
-Not presently being considered.
+* ABB ACS310-03U-50A8-2+J400
 === Line Reactor ===

Matt Parnell: /* Starting and Stopping */

2022-02-19T10:59:31Z

Starting and Stopping

← Older revision		Revision as of 10:59, 19 February 2022
Line 9:		Line 9:
	=== Starting and Stopping ===		=== Starting and Stopping ===

	Prior to spring of 2022, this was performed via pushbuttons on the motor starter.		Prior to the spring of 2022, this was performed via pushbuttons on the motor starter.

	Further details will be posted once the VFD is brought up.		Further details will be posted once the VFD is brought up.

Matt Parnell: /* Flow Adjustment */

2022-02-19T10:59:16Z

Flow Adjustment

← Older revision		Revision as of 10:59, 19 February 2022
Line 15:		Line 15:
	=== Flow Adjustment ===		=== Flow Adjustment ===

	~~The~~ pump flow is adjusted via the butterfly valve on the output side of the pump~~. The flow rate must be periodically adjusted via this valve as debris in the strainer basket and sand filters provides additional resistance~~.		Prior to the spring of 2022, pump flow was manually adjusted via the butterfly valve on the output side of the pump.

	In the ~~future, a~~ VFD ~~may be used~~ to ~~reduce the motor speed, eliminating the need for manual adjustment via a valve~~.		Flow adjustment will be automatic with the VFD (details to follow).

	== Maintenance ==		== Maintenance ==

Matt Parnell: /* Starting and Stopping */

2022-02-19T10:58:14Z

Starting and Stopping

← Older revision		Revision as of 10:58, 19 February 2022
Line 9:		Line 9:
	=== Starting and Stopping ===		=== Starting and Stopping ===

	~~This is~~ performed via the motor starter. Further details ~~on hold, pending replacement with a~~ VFD.		Prior to spring of 2022, this was performed via pushbuttons on the motor starter.

			Further details will be posted once the VFD is brought up.

	=== Flow Adjustment ===		=== Flow Adjustment ===

Matt Parnell: /* Variable Frequency Drive */

2022-02-19T10:51:05Z

Variable Frequency Drive

← Older revision		Revision as of 10:51, 19 February 2022
Line 35:		Line 35:
	== Variable Frequency Drive ==		== Variable Frequency Drive ==

	~~<b>IMPORTANT:</b> At this time, this section is for investigation purposes only. It has not been determined when/if a VFD will be implemented.~~		=== Background ===

	~~=== Justification ===~~		Prior to the spring of 2022, the main pump motor was controlled by a Square D 8536 latching motor starter (relay). Start and stop operations were manually performed by pushbuttons. Adjustment of the flow rate was only possible by positioning the butterfly valve on the output side of the pump.

	As of ~~Fall 2021~~, the pump is controlled by a Square D 8536 latching motor starter (relay). ~~The pump is manually operated via start~~ and stop pushbuttons. ~~The~~ flow rate ~~is adjusted via~~ the butterfly valve on the output side of the pump~~. Removal of the motor starter and replacement with a Variable Frequency Drive (VFD) has been proposed. This system would ideally be implemented prior to the 2022 swim season~~.

	Benefits to changing to the VFD include:		Benefits to changing to the VFD include:

	* ~~Main~~ pump motor speed can be automatically adjusted (via the [[Pool Systems Automation\|automation system]]) to compensate for changes in flow rate due to the state of the strainer basket and [[Pool Filter Tanks\|sand filters]]. A constant ~~and~~ flow rate can be assured until the strainer basket or filters become too clogged. The automation system is NOT required to operate the drive. In the event that the automation system is not operational (or remote VFD control is disabled), the VFD can be operated with start and stop pushbuttons in a manner very similar to that of the motor starter.		* The main pump motor speed can be automatically adjusted (via the [[Pool Systems Automation\|automation system]]) to compensate for changes in flow rate due to the state of the strainer basket and [[Pool Filter Tanks\|sand filters]]. A constant flow rate can be assured until the strainer basket or filters become too clogged. The automation system is NOT required to operate the drive. In the event that the automation system is not operational (or remote VFD control is disabled), the VFD can be operated with start and stop pushbuttons in a manner very similar to that of the motor starter.
	* No need for the operator (~~managers~~ or B&G personnel) to regularly adjust the flow rate due to changing conditions. An improper flow rate:		* No need for the operator (the pool manager or B&G personnel) to regularly adjust the flow rate due to changing conditions. An improper flow rate:
	** Violates best practices and/or health department requirements if too low (minimum number of complete water turn-over cycles per 24 hour period).		** Violates best practices and/or health department requirements if it is too low (there is a required minimum number of complete water turn-over cycles per 24 hour period).
	** Causes channeling in the sand filters due if too high. This can lead to incomplete filtration (cloudy water) and requires opening and manually stirring tank sand to resolve.		** Causes channeling in the sand filters due if it is too high. This can lead to incomplete filtration (cloudy water) and requires opening and manually stirring tank sand to resolve.
	* Utility incentives will pay for a significant portion of the material cost. As of ~~2022~~, DTE ~~will reimburse~~ up to $900 for a 15 HP VFD.		* Utility incentives will pay for a significant portion of the material cost. At the time of the project, DTE reimbursed up to $900 for a 15 HP VFD.
	* Enhanced safety with the addition of two emergency stop buttons, including one at the gallery level (near the pump).		* Enhanced safety with the addition of two emergency stop buttons, including one at the gallery level (near the pump).
	* Reduced stress on the mechanical system during startup as the motor speed can be ramped up rather than instant-on. This prevents "hammering" that can occur from an abrupt start.		* Reduced stress on the mechanical system during startup as the motor speed can be ramped up rather than instant-on. This prevents "hammering" that can occur from an abrupt start.
Line 55:		Line 53:
	There are some downsides, too:		There are some downsides, too:

	* ~~Material~~ cost (see the [[#Bill of Materials\|bill of materials]]).		* The material cost (see the [[#Bill of Materials\|bill of materials]]). This is managed by creative purchasing - utilizing refurbished and surplus materials where possible.
	* ~~Added~~ complexity.		* Some added complexity.
	* Added failure points - including the addition of sensitive electronics in a harsh environment.		* Added failure points - including the addition of sensitive electronics in a harsh environment (corrosive vapors and dust).

	An improvement in energy efficiency may be possible. However, it is not confirmed. Restricting the output flow on a centrifugal pump reduces the amount of work (pushing a lower volume weight of water). Data in the appendix below confirms this to a point.		An improvement in energy efficiency may be possible. However, it is not confirmed. Restricting the output flow on a centrifugal pump reduces the amount of work (pushing a lower volume weight of water). Data in the appendix below confirms this to a point.

	~~=== Requirements ===~~

	* Must withstand an ambient operating range in the 40 °C to 50 °C (122 °F) range. For the GS23-2015 at 75% load, 50 °C, no de-rating is necessary up to a 4 kHz carrier frequency (SVPWM mode).
	* Must be compatible with 240 VAC high-leg delta.
	* A two-channel safety relay will be used.

	=== Theory of Operation ===		=== Theory of Operation ===

	The sections ~~below~~ are ~~theoretical at this point, describing possible operation for the VFD controls~~.		NOTE: The sections that follow are still under development.

	==== Reset ====		==== Reset ====

Matt Parnell: /* Line Reactor */

2022-02-11T01:27:31Z

Line Reactor

← Older revision		Revision as of 01:27, 11 February 2022
Line 158:		Line 158:
	A 3% impedance reactor absorbs transients and prevents nuisance tripping of drives in most applications and is typical for the line side. A 5% impedance reactor can be used if the harmonic content is severe or if IEEE519 recommendations should be met. The reactor impedance magnitude is said to be equal to the voltage drop.		A 3% impedance reactor absorbs transients and prevents nuisance tripping of drives in most applications and is typical for the line side. A 5% impedance reactor can be used if the harmonic content is severe or if IEEE519 recommendations should be met. The reactor impedance magnitude is said to be equal to the voltage drop.

	For 37 FLA (motor rating). Assume the VFD has about 97% efficiency (given loss is 391 W @		For 37 FLA (motor rating). Assume the VFD has about 97% efficiency (given loss is 391 W @ 42 A).

	{\| class="wikitable"		{\| class="wikitable"

Matt Parnell: /* Variable Frequency Drive */

2022-02-11T01:27:05Z

Variable Frequency Drive

← Older revision		Revision as of 01:27, 11 February 2022
Line 39:		Line 39:
	=== Justification ===		=== Justification ===

	As of Fall 2021, the pump is controlled by a Square D 8536 latching motor starter (relay). The pump is manually operated via start and stop pushbuttons. The flow rate is adjusted via the butterfly valve on the output side of the pump.		As of Fall 2021, the pump is controlled by a Square D 8536 latching motor starter (relay). The pump is manually operated via start and stop pushbuttons. The flow rate is adjusted via the butterfly valve on the output side of the pump. Removal of the motor starter and replacement with a Variable Frequency Drive (VFD) has been proposed. This system would ideally be implemented prior to the 2022 swim season.

	Removal of the motor starter and replacement with a VFD has been proposed. This system would be implemented prior to the 2022 swim season.

	Benefits to changing to the VFD include:		Benefits to changing to the VFD include:

	* ~~Motor~~ speed can be automatically adjusted (via the [[Pool Systems Automation\|automation system]]) to compensate for changes in flow rate due to the state of the strainer basket and sand filters. A constant and flow rate can be assured until the strainer basket or filters become too clogged. The automation system is NOT required to operate the drive. In the event that the automation system is not operational (or remote VFD control is disabled), the VFD can be operated with start and stop pushbuttons in a manner very similar to that of the motor starter.		* Main pump motor speed can be automatically adjusted (via the [[Pool Systems Automation\|automation system]]) to compensate for changes in flow rate due to the state of the strainer basket and [[Pool Filter Tanks\|sand filters]]. A constant and flow rate can be assured until the strainer basket or filters become too clogged. The automation system is NOT required to operate the drive. In the event that the automation system is not operational (or remote VFD control is disabled), the VFD can be operated with start and stop pushbuttons in a manner very similar to that of the motor starter.
	* No need for the operator (managers or B&G personnel) to regularly adjust the flow rate due to changing conditions. An improper flow rate:		* No need for the operator (managers or B&G personnel) to regularly adjust the flow rate due to changing conditions. An improper flow rate:
	** Violates best practices and/or health department requirements if too low (minimum number of complete water turn-over cycles per 24 hour period).		** Violates best practices and/or health department requirements if too low (minimum number of complete water turn-over cycles per 24 hour period).

Matt Parnell: /* Variable Frequency Drive */

2022-02-09T01:19:43Z

Variable Frequency Drive

← Older revision		Revision as of 01:19, 9 February 2022
Line 359:		Line 359:

	* SAB Cable 08610804 8/4 THHN VFD Cable (eBay option).		* SAB Cable 08610804 8/4 THHN VFD Cable (eBay option).

			=== Thermal Considerations ===

			According to the datasheet, the Yaskawa GA50U2042ABA dissipates 391 W @ 42 A. Assuming operation at 37 A, and an approximately linear decrease is power dissipation, up to 344 W of power dissipation is expected. The drive is specified to operate (without de-rating) at up to 50 °C (122 °F). Assuming that the pump house may reach temperatures exceeding 90 °F, thermal rise must be kept to a minimum. Assume that no more than 10 °F of temperature rise is allowed (112 °F ambient).

			Using the formula: CFM = (3.17 * P) / dT (where dT is in °F), CFM = 3.17 * 344 W / 10 °F; 109 CFM.

			The line reactor dissipates considerably less. Exact dissipation is TBD; conservatively assume 67 W (KDRD24L value @ 48 A = 85 W; 85 W * 38 A / 48 A = 67 W). CFM = 3.17 * 67 W / 10 °F; 21 CFM.

	=== Bypass ===		=== Bypass ===

Matt Parnell: /* Line Reactor */

2022-02-08T23:51:29Z

Line Reactor

@@ Line 159: / Line 159: @@
 A 3% impedance reactor absorbs transients and prevents nuisance tripping of drives in most applications and is typical for the line side.  A 5% impedance reactor can be used if the harmonic content is severe or if IEEE519 recommendations should be met.  The reactor impedance magnitude is said to be equal to the voltage drop.
 {| class="wikitable"
@@ Line 175: / Line 177: @@
 |208/240 V
 |46.2 A
-|0.22 mH
+|0.22 mH<br>(rated)
 |$179
 |Recommended for the LR-2015.
@@ Line 184: / Line 186: @@
+|
 |45 A
-|0.300 mH
+|0.300 mH<br>(rated)
 |$289.31 (Galco)
 |-
 |TCI
@@ Line 192: / Line 195: @@
+|
 |40 A
+|
 |}
 * MTE RLW-004601 (42 A, 3.68" H x 6.00" W x 5.76" D).  Not readily available.
 * TCI KDRD24L (208/240 VAC 48 A 15 HP, 3-phase, 3% - Low Z, 3.82" H x 6.95" W x 5.57" D).  $195.94 on Galco (eBay TBD).

Matt Parnell: /* Line Reactor */

2022-02-08T01:34:39Z

Line Reactor

← Older revision		Revision as of 01:34, 8 February 2022
Line 155:		Line 155:

	=== Line Reactor ===		=== Line Reactor ===

			<b><i>This section is currently being revised.</i></b>

	A 3% impedance reactor absorbs transients and prevents nuisance tripping of drives in most applications and is typical for the line side. A 5% impedance reactor can be used if the harmonic content is severe or if IEEE519 recommendations should be met. The reactor impedance magnitude is said to be equal to the voltage drop.		A 3% impedance reactor absorbs transients and prevents nuisance tripping of drives in most applications and is typical for the line side. A 5% impedance reactor can be used if the harmonic content is severe or if IEEE519 recommendations should be met. The reactor impedance magnitude is said to be equal to the voltage drop.