SWF DV/DT Solutions Sinewave Filters. N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI P. (262) F. (262)

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1 SWF DV/DT Solutions Sinewave Filters N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI P. (262) F. (262)

2 Does your application use variable frequency drives for improved motor control? Have you experienced premature motor failure? Maximize your motors life with an SWF Solution from APQ LLC. Protect the heart of your application today! Eliminate premature insulation breakdown Return the voltage to a near sine wave Meet Nema MG-1 standards Limit peak voltage and increase voltage rise time Reduce motor noise and vibration Attenuate the PWM inverter switching frequency Protect submersible pumps Eliminate voltage reflection points Maximize application power Utilize a low voltage drive, step up transformer, and medium voltage motor Increase cable distances Centrally locate VFDs, regardless of motor location Improve system uptime Reduce application downtime Decrease Equipment Replacement Costs Increase equipment life spans with efficient power usage The information provided within this product catalog is subject to change without notice. For complete product details, please contact APQ, LLC. 2 SWF DV/DT Solutions Sinewave Filters

3 THE CHALLENGE: PROTECT MOTOR INSULATION IN LONG LEAD AND SUBMERSIBLE APPLICATIONS Engineered Power Quality Variable Frequency Drives, commonly referred to as VFDs, allow for the more efficient use of energy in a myriad of applications. The technology utilizes PWM, or pulse width modulation, to simulate an AC sine wave with numerous fast rising pulses. The ability to vary both frequency and voltage allows for more precise control of motor speed. However, these pulses can lead to voltage peaks that exceed the insulation rating of the motor windings. The excessive peak voltage typically impacts the first few turns of the motor windings, causing damage and premature failure. The SWF DV/TV Solutions PWM to Sine Wave Conversion The SWF DV/DT Solution output is nearly a sine wave, eliminating the threat of excessive peak voltages. This allows for the use of either an inverter duty or non-inverter duty motor within any given VFD application. Through the use of PWM rated reactors and rugged harmonic rated capacitors, the PWM switching frequency is attenuated. When properly adjusted for voltage drop, lead lengths can extend beyond 15,000 feet. Optimized for Industry APQ SWF DV/DT Solutions are intended for motor protection, especially in applications with long motor cable lengths. These high performance filters virtually eliminate the harmful effects of voltage reflection by establishing a near sine wave for the motor. Many industrial applications do not run at full load at all times, including fans and pumps. These variable torque applications have motor speeds that are often in the range of 50% to 70% speed, resulting in extended operation at lower load current. As such, the SWF DV/DT Solutions are optimized for real world conditions, with typical 5% voltage drop at 70% rated load current. Designs for Any Carrier Frequency The standard designs for the SWF DV/DT Solutions focus on 2.5 khz output carrier frequency and 5 khz output carrier frequency. APQ can design a solution for any PWM frequency desired. The 5 khz Design Type offers the most economical solution based upon cost, size, and power losses. This model is suitable for all PWM frequencies from 5 khz to 20 khz. Contact APQ for assistance with your particular application. Meet MG-1 Requirements In order to protect motors from premature insulation failure, NEMA MG-1 guidelines were developed to limit both peak voltage and voltage rise time. MG-1 Part 30 sets a limit of 1000 volts peak and a rise time of 2µ seconds for non-inverter rated motors. MG-1 Part 31 sets a limit of voltage peaks less than or equal to 3.1 times the rated voltage and a rise time of 0.1µ seconds for inverter rated motors The APQ SWF DV/DT Solutions achieve these performance levels for all VFDs and motors rated up to 690 volts. Submersible Applications Applications that require the motor cable to become submerged are especially susceptible to motor insulation degradation due to reflective voltage. The dielectric constant for water is approximately 80 times greater than the dielectric constant of air. As reflected voltage is caused by the difference in impedance between the output terminals of the VFD and the input terminals of the motor, the point where the cable enters water becomes another point of reflection. The overall impact will be voltage reflection issues that are significantly more pronounced. By applying an SWF DV/DT Solution to the output of the VFD, the reflected voltage is minimized. Various Sizes and Options SWF DV/DT Solutions can be deployed at any voltage level between 208 V and 690 V. The selection charts provided are only a portion of the available product offerings. From high frequency application designs to integrated performance monitoring systems, APQ can design the right solution for your application. Contact us today to learn how we can help you solve your voltage reflection issues. SWF DV/DT Solutions Sinewave Filters 3

4 THE SFW DV/DT Solution Systems LONG LIFE CAPACITORS Rugged Reliability REACTORS Precision Design OPTIONS Engineered Solutions TRANSFORMER Voltage Flexibility Systems are designed with three phase capacitors (single phase also available) Designed for rigorous and harmonic rich applications Self-healing design with segmented film technology Internal pressure switch protects each capacitor Fast connecting terminals for secure wiring for the life of the capacitor Industry leading reactor design ensures continuous high performance Balanced phase to phase inductance in all three coils PolyGap Core construction minimizes losses, audible noise, and stray magnetic fields Integrated temperature switches available upon request 2 khz - 20 khz OEM kits Open panel Enclosed NEMA Types 1, 3R, 4, 4X, 12 Reactor thermal Switch Custom designs Step-up transformers available for medium voltage motors Low voltage controls with medium voltage power Various taps for precise voltage control Voltage at the output of the VFD Voltage at the output of the SWF 2.5 khz SWF Design 5 khz SWF Design Variable Frequency Drive Transformer (Optional) Motor Variable Frequency Drive Transformer (Optional) Motor 4 SWF DV/DT Solutions Sinewave Filters

5 SWF DV/DT Solutions Product Specifications Electrical Specifications: System Voltage: Voltage Tolerance: ± 5% Frequency: PWM Frequency: Fundamental Frequency: Phases: Input Current Ratings: Input Power Ratings: THD-V: Voltage Drop: Efficiency: Dielectric Strength: Capacitance & Inductance: Overload Capability: Damping: Life Expectancy: 200, , , 480, 600, and 690 Volts 60 Hz / 50 Hz 2.5kHz 4 khz 5 khz 5 Hz to 90 Hz standard, others available upon request 3-phase 3 to 3000 amps 1.5 HP to 3000 HP 5% THD-V (4 khz and 5 khz Design Types) Typical 10% THD-V (2.5 khz Design Types) Typical Optimized for 5% voltage drop at 70% load Full Load Drop 7%(for 2.5 khz and 5 khz Design Types) Full Load Drop 9%(for 4 khz Design Types) 99% or higher at rated load Reactors: 3000 volts (1 minute) Capacitors: 2 x rated volts (1 minute) Capacitance is minimized (and inductance maximized) for lowest capacitor current and lowest dv/dt 1.5x rated current (1 minute, 1 time per hour) Self damping reactors (no power resistors required) >480,000 hours at 50 C, rated power Environmental: Motor Cable Length: Ventilation: Enclosures Available: Ambient Temperature: Relative Humidity: Altitude: Unrestricted by Waveform Natural convection up to 300 HP, Forced air at 300 HP and above Indoor, Industrial, Outdoor, Open Panel, Kit -30 C to 50 C <99% non-condensing <1000 meters (3280 feet) Applicable Standards: UL: Assemblies are UL 508 / UL 508A approved Kits are UL 508 IEC / EN: CE (Low Voltage Directive): LVD certificate available NEMA Standards: MG-1 Part 30, MG-1 Part 31 Complies with EN60289, EN SWF DV/DT Solutions Sinewave Filters 5

6 SWF DV/DT Solutions Reflected Wave PWM voltage consists of numerous fast rising (high dv/dt) pulses. Motors with a long cable length between the output terminals of the VFD and motor, or submersible applications, will experience a phenomenon known as voltage reflection or reflected wave. In these instances, peak voltage at the motor terminals can be as high as 1,300 volts, twice the DC bus voltage of the VFD. The excessive voltage will typically cause damage within the first few turns of the motor windings, leading to premature motor failure and expensive application down time. In applications where the motor cable is exposed to water, or other materials with a dielectric constant significantly greater than air, the peak voltages caused by reflected wave can be more pronounced. In fact, since reflected wave is a product of the impedance variance between the drive and the motor, the impedance of the cable changes at the point where it enters the water. This will cause reflection at both the water entry location and the motor terminals. Typical waveform measured at the VFD Output Typical Waveform measured at the motor terminals with no protective filter Typical Waveform measured at the motor terminals with 5 khz SWF DV/DT Solution Mitigating Reflected Wave The introduction of an SWF DV/DT Solution will eliminate excessive peak voltages and increase system uptime. Motor noise, vibration, and heating are significantly reduced by attenuating the PWM inverter switching frequency at the applied filter. The application of an SWF Solution will also reduce common mode current and motor bearing current. As these solutions meet both Part 30 and Part 31 of the MG-1 standards, either inverter or non-inverter rated motors can be used within any given application and experience an extended operating life. Typical Critical Motor Cable Length (for applications without SWF) PWM Pulse Rise Time Critical Cable Length 50 nano-sec. 3 Meters (10 ft) 0.1 µ sec. 6 Meters (20 ft) 0.5 µ sec. 31 Meters (100 ft) 1 µ sec. 62 Meters (200 ft) 2 µ sec. 125 Meters (400 ft) 6 SWF DV/DT Solutions Sinewave Filters

7 APPLICATIONS SWF DV/DT Solutions are designed to withstand the most rigorous applications. The right product design and configuration is available for your application. Products are offered as enclosed, open panel, or even component kits, giving you the greatest amount of flexibility for your harmonic mitigation needs. Oil & Gas HVAC High Rises Submersible Pumping Commercial Facilities Warehouses Breweries Automotive Water / Wastewater Distribution Facilities Pulp & Paper Metal Fabrication SWF DV/DT Solutions Sinewave Filters 7

8 SWF DV/DT Solutions Part Number System SWF K 01 xxxx Product Designation Current Rating 3000 Max Amps Nominal Voltage & Freq Hz = Volts@ 60 Hz = Hz = Hz = Hz = Hz = 690 Carrier Frequency KHz = 2K 4.0 KHz = 4K 5.0 KHz = 5K Custom = *K Enclosure Type Type 1 = 01 Type 3R = 3R Open Panel = OP Component Kit = CK Options Leg Stand Kit = LS Reactor Thermal Switch = TH Custom Design = * SWF DV/DT Solutions Selection Requirements 1. SWF DV/DT Solutions are designed for use with one 6-pulse type variable frequency drive (VFD). This product offering is not designed to be applied with linear loads such as across-the-line started motors. 2. Solution Current Rating SWF DV/DT Solutions are current rated devices. Select the SWF with the rated current that is equal to or greater than the full load amp rating of the motor. 3. SWF DV/DT Solution Installation Refer to the Installation, Operation, and Maintenance Manual for specific information regarding the suitability of the product for a specific application in a given location. 4. SWF DV/DT Solution Installation Do not test the SWF DV/DT Solution without a connected motor load. Product damage may result. 8 SWF DV/DT Solutions Sinewave Filters

9 SWF DV/DT Solutions Selection Chart 240 V 5 khz Design Type 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF K Wall SWF K CK 28 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 45 SWF K Wall SWF K CK 50 SWF K Wall SWF K CK 64 SWF K Wall SWF K CK 83 SWF K Wall SWF K CK 107 SWF K Wall SWF K CK 107 SWF K Wall SWF K CK 122 SWF K Wall SWF K CK 218 SWF K Wall SWF K CK 217 SWF K Floor SWF K CK 251 SWF K Floor SWF K CK 320 SWF K Floor SWF K CK 297 SWF K Floor SWF K CK 379 SWF K Floor SWF K CK 562 SWF K Floor SWF K CK 521 Motor Submersible Pumps Suggested Motor Filter Application Chart 230 V motors 4-5% Reactor 400 V motors 4-5% Reactor 460 V motors 4-5% Reactor Motor Cable Length 100 ft 300 ft 500 ft 1,000 ft 15,000 ft SWF SWF SWF SWF SWF 4-5% Reactor SWF SWF n/a SWF SWF SWF SWF SWF SWF SWF SWF 575 V motors MPF SWF SWF SWF SWF 690 V motors MPF SWF SWF SWF SWF SWF DV/DT Solutions Sinewave Filters 9

10 SWF DV/DT Solutions Selection Chart 480 V 5 khz Series 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF K Wall SWF K CK 29 SWF K Wall SWF K CK 28 SWF K Wall SWF K CK 27 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 37 SWF K Wall SWF K CK 45 SWF K Wall SWF K CK 50 SWF K Wall SWF K CK 64 SWF K Wall SWF K CK 69 SWF K Wall SWF K CK 83 SWF K Wall SWF K CK 93 SWF K Wall SWF K CK 107 SWF K Wall SWF K CK 121 SWF K Wall SWF K CK 168 SWF K Floor SWF K CK 218 SWF K Floor SWF K CK 251 SWF K Floor SWF K CK 320 SWF K Floor SWF K CK 297 SWF K Floor SWF K CK 377 SWF K Floor SWF K CK 446 SWF K Floor SWF K CK 562 SWF K Floor SWF K CK 569 SWF K Floor SWF K CK 485 SWF K Floor SWF K CK 521 SWF K Floor SWF K CK 610 SWF K Floor SWF K CK 744 SWF K Floor SWF K CK 747 SWF K Floor SWF K CK SWF DV/DT Solutions Sinewave Filters

11 SWF DV/DT Solutions Selection Chart 600 V 5 khz Series 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 30 SWF K Wall SWF K CK 32 SWF K Wall SWF K CK 47 SWF K Wall SWF K CK 47 SWF K Wall SWF K CK 47 SWF K Wall SWF K CK 56 SWF K Wall SWF K CK 67 SWF K Wall SWF K CK 85 SWF K Wall SWF K CK 94 SWF K Wall SWF K CK 94 SWF K Wall SWF K CK 125 SWF K Wall SWF K CK 137 SWF K Wall SWF K CK 141 SWF K Floor SWF K CK 227 SWF K Floor SWF K CK 313 SWF K Floor SWF K CK 327 SWF K Floor SWF K CK 391 SWF K Floor SWF K CK 381 SWF K Floor SWF K CK 395 SWF K Floor SWF K CK 468 SWF K Floor SWF K CK 588 SWF K Floor SWF K CK 621 SWF K Floor SWF K CK 623 SWF K Floor SWF K CK 788 SWF K Floor SWF K CK 935 SWF DV/DT Solutions Sinewave Filters 11

12 N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI P. (262) F. (262)