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Article from TMEIC GE e-news (http://www.tmge.com/upload/library_docs/english/Multi-Motor_App_Article_1142532580.htm)

June 24, 2004

Soft-Start Multiple Dura-Bilt5i MV® Drive Motors

by Bill Horvath

The Dura-Bilt5i MV
Drive Synchronize to
Utility Line Option
allows one medium
voltage (MV) drive to
smoothly start and
connect one or more
motors to the utility
line. It also allows any
of the running motors
to be smoothly
reconnected to the
drive output.

General

The Dura-Bilt5i MV
drive control can
accelerate a connected
motor to full
synchronous RPM, and
connect this motor
with a Medium Voltage
bypass contactor to the
utility source. The
Dura-Bilt5i MV can do
this smoothly and with
minimum current or torque disturbance. This "bumpless" transfer also works in the opposite
direction. The drive control can match the inverter output to the utility frequency and "capture"
the running motor by smoothly reconnecting it to the inverter output. This ability offers a user
many important operational benefits, such as:

· A single drive can accelerate multiple motors to synchronous line speed, minimizing drive
investment.

· A drive can be used to start and accelerate motors larger than its own rating and then stand-by
at idle.

· Severe duty imposed on the motors by full-voltage starts is eliminated, extending motor life.
Very high inertia loads such as fans can be started and synchronized this way.

· A single drive can be shared by a group of motors. Any of the motors can run on the adjustable
speed drive (ASD) while the other motors are running at fixed speed. This allows energy
utilization to be maximized and process control to be optimized. The motors can all be of the same
rating or of two different ratings.

· When the process requires full-speed operation, a connected motor can be returned directly to
the utility, maximizing energy efficiency by eliminating any losses introduced by drive operation.

· Multiple motors can be "soft started" sequentially, minimizing power line surges and impact.

Circuit Diagrams

Figure 1 shows a Dura-Bilt5i MV drive configured to allow synchronous transfer of the connected
motor to and from the utility line.

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Figure 1. Single Motor Sync-Desync Bypass

Synchronizing a Drive-controlled Motor to the Utility line:

1. The drive is made operational by the proper startup sequence, and contactors M1 and M1A are
closed.

2. The drive is accelerated to speed by the user process input.

3. A contact closure requesting synchronous transfer to line is received.

4. Under drive control, the Dura-Bilt5i MV accelerates the motor on a predetermined ramp to a
voltage and frequency equal to the line voltage and frequency.

5. Using the potential transformers on the utility and output sides of the drive shown as PT in
Figure 1, the drive control continuously monitor's the voltage, frequency, and phase of the drive
input and output.

6. When the drive input and output is matched in voltage level, frequency, and phase, the drive
control activates a digital output on the drive I/O, closing a control relay that initiates closure of
the bypass contactor MBPA. This is shown as point A in the voltage and current chart of figure 2.

7. During the process, a solid-state synchronizing-check relay, designated as 25 in Figure 1,

verifies that the drive control synchronizing decision is correct. The 25 relay is not used to
synchronize the drive and motor, but serves as a permissive in series with the drive control output
relay to ensure accurate operation.

8. Output inductor L-1 is included to eliminate instantaneous inverter overcurrents and output
difficulties during the instant of the closed transition between the inverter and the power line. The
size of the inductor is selected dependent upon the total impedance of the utility source in
comparison to the connected motor load.

9. The drive control monitors current flowing into the motor through the newly established bypass
utility power feed through contactor MBPA.

10. When the drive control determines that proper levels of utility line current are flowing into the
connected motor by current feedback from CTO, the synchronizing process is considered complete,
and the output contactor MO is opened. This is shown at point B.

11. The inverter power switch gating circuits are blocked, and the inverter output stops.

12. If multiple motors are to be started, the process is repeated. Each motor has its own bypass
contactor, and feedback current transformer (CT). A dedicated output contactor is supplied for
each motor. A second drive may be incorporated for redundant control of the group of motors.

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Figure 2. Synchronizing Motor to Utility with DB5i Drive

Note that the bottom trace of Figure 2 shows the motor amps are smooth throughout the whole
process. No noticeable torque or current disturbances are produced

Capturing a Utility-fed Motor and Reconnecting it to the Drive

Once a motor is connected to the line by the drive and is powered entirely by utility power, it can
be "captured" bumplessly by the drive and brought back into variable speed operation or to a
smooth stop. Here is the sequence of operation for this "de-synchronizing" process:

1. Again referring to Figure 1, consider that the motor is connected to the utility line through
contactor MBPA, and is turning its connected load at a speed equivalent to its nameplate RPM. Also
see Figure 3 for traces of the de-sync process.

2. A CAPTURE command contact is received from the user requesting that the drive capture the
motor from the line [de-synchronize].

3. The drive control prepares the inverter by gating the output switches to produce a voltage of
the correct magnitude, phase, and frequency, refer to point A in Figure 3.

4. The output contactor MO is closed.

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5. When the drive current is flowing from the drive to the motor, bypass contactor MBPA is
opened. Operation of the motor is now completely under the control of the drive, refer to Point B
in Figure 3.

Figure 3. Capturing Motor from Utility with DB5i Drive

Synchronizing Multiple Motors

Figure 4 below describes a typical system in which multiple motors and drives are configured for
synchronizing operation. In this system, any motor can be connected to any drive, or to the utility
source. The logic for selecting which motor and which drive are to be connected is determined and
set up in a PLC included with the drive and output switchgear.
Operation of the synchronizing and de-synchronizing is identical to the single motor description
above. The proper utility-to-motor CT is selected by relay logic according to which motor is being
synchronized from the VFD to the power line or captured from the power line to the VFD.

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Figure 4. Dura-Bilt5i MV system with Five Motors and Two Drives.

Special Configurations

Figure 5 below describes a configuration similar to the single motor configuration of Figure 1,
except that a backup mode of operation by means of a full voltage [non-synchronous] bypass start
is possible using a solid-state medium voltage starter. The standard full voltage bypass contactor
can be controlled in a bumpless manner identically to the contactor in Figure 1.

Figure 5. Dura-Bilt5i MV system with Solid-Sate Starter Backup.

The Synchronize to Utility Line option described here provides great flexibility in system design. It
allows savings on initial drive costs and on energy consumption costs. In addition, by eliminating
full-voltage starts, motor life is extended and power line surges minimized. If you have questions
or need more information, please call us.

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Bill Horvath is a Senior Application Engineer with TM GE Automation Systems

Dura-Bilt5i MV is a registered trademark of TM GE Automation Systems LLC

The above article is provided free of charge and without obligation to the reader or to TM GE
Automation Systems LLC. By utilizing this article the reader expressly understands that TM GE
Automation Systems LLC does not accept, nor imply, the acceptance of any of liability with regard
to the use of the information provided. TM GE Automation Systems LLC provides the information
included herein AS IS AND WITHOUT WARRANTY OF ANY KIND, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED STATUTORY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE. The information is provided as a general reference to the
potential benefits that may be attributable to the technology discussed. The reader is encouraged
to perform independent analysis of the technical and commercial benefits described here in. If you
have any questions regarding your project requirements please contact the TM GE Application
Center at 540-387-8070

Published by TMEIC GE Automation Systems LLC

Copyright © 2011 TMEIC GE Automation Systems LLC. All rights reserved.
TM GE Automation Systems LLC, 1325 Electric Road, Roanoke, VA 24018 USA
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