PIL 149

Product Information Letter

Direct-drive AC Start System

Ty Reed
Solar Turbines Incorporated
PURPOSE
The following describes the application and installation, of direct-drive AC start systems. These
standard configurations use Rockwell Automation PowerFlex Variable Frequency Drives (VFD).
The starting power requirement of the package determines the applicable PowerFlex 750 VFD and
motor combination.
CONTENTS
PURPOSE ........................................................................................................................... 1
CONTENTS........................................................................................................................ 1
LIST OF FIGURES ............................................................................................................ 2
LIST OF TABLES .............................................................................................................. 2
1. Introduction ....................................................................................................... 3
1.1 Basic Description ................................................................................................ 3
1.2 Availability ......................................................................................................... 3
2. PowerFlex 750 Series Variable Frequency Drives ........................................... 4
2.1 PowerFlex 750 Applications ............................................................................... 4
2.2 3-Phase Power Rating ......................................................................................... 5
2.3 Additional Components ...................................................................................... 5
2.4 Cable Ampacity Recommendations & Terminal Sizes ...................................... 8
2.5 VFD Installation.................................................................................................. 9
2.6 VFD Heat Rejection Rates .................................................................................. 9
2.7 Grounding Systems ........................................................................................... 10
2.8 Titan 250 Onshore Ride Thru Solution............................................................. 10
3. Line Harmonics ............................................................................................... 10
4. Description of Operation and Control.............................................................. 11
4.1 Control Description, Including ControlNet and EtherNet/IP ........................... 11
4.2 Protection against Motor Thermal Overload .................................................... 11
5. Conductor Sizing............................................................................................. 12
5.1 Determining Disconnect and Conductor Sizing (Supply to VFD) ................... 13
5.2 Determining Conductor Sizing (VFD to Motor) .............................................. 13
5.3 Voltage Drop Calculation ................................................................................. 14
5.4 Example: How to Calculate Conductor Size .................................................... 14
6. Summary......................................................................................................... 16
7. Source Data Table References....................................................................... 17
8. Appendix ......................................................................................................... 18

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LIST OF FIGURES
Figure 1. NEC Temperature Correction............................................................................ 15
Figure 2. NEC Grouping Derating .................................................................................... 15
Figure 3. Max Power Consumption of Saturn CS&MD ................................................... 18
Figure 4. Max Power Consumption of Saturn GS ............................................................ 18
Figure 5. Max Power Consumption of Centaur 40 -Taurus 60 CS&MD ......................... 19
Figure 6. Max Power Consumption of Mercury 50 .......................................................... 19
Figure 7. Max Power Consumption of Centaur 40, Centaur 50 GS ................................. 20
Figure 8. Max Power Consumption of Centaur 40, Centaur 50 GS ................................. 20
Figure 9. Max Power Consumption of Taurus 60 GS ...................................................... 21
Figure 10. Max Power Consumption of Taurus 65 GS .................................................... 21
Figure 11. Max Power Consumption of Taurus 70 CS&MD ........................................... 22
Figure 12. Max Power Consumption of Taurus 70 GS .................................................... 22
Figure 13. Max Power Consumption of Mars .................................................................. 23
Figure 14. Max Power Consumption of Titan 130 CS&MD ............................................ 23
Figure 15. Max Power Consumption of Titan 130 GS 60 Hz .......................................... 24
Figure 16. Max Power Consumption of Titan 130E GS 60 Hz ........................................ 24
Figure 17. Max Power Consumption of Titan 250 ........................................................... 25

LIST OF TABLES
Table 1: PowerFlex 750 Power Ratings.............................................................................. 4
Table 2. PowerFlex 750 Series Maximum Transformer kVA ............................................ 5
Table 3. PowerFlex750 Series Line Reactor Dimensions and Weights ............................. 6
Table 4. PowerFlex 755 380 - 480 VAC VFD-to-Motor Distances ................................... 7
Table 5. PowerFlex753 380 – 480V Minimum Conductor Ampacity and Terminal Sizes 8
Table 6. Comparison of Motor Nameplate Ratings and Actual Peak Load...................... 12
Table 7. Duty Cycle Service, NEC Code Table 430.22(E) .............................................. 13

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1. Introduction
1.1 Basic Description
The Direct-drive Alternating Current (DAC) start system is a proven configuration for Solar® gas
turbine packages. Since its introduction in 1994, the DAC start system has demonstrated high
reliability, and low maintenance, across all of Solar’s gas turbine product lines.
The system consists of a solid-state, pulse-width-modulated VFD that converts three-phase utility
voltage to a variable voltage, variable frequency supply. This power is applied to a rugged,
intermittent duty, AC induction motor that was designed exclusively for this application. The motor
is coupled directly to the gearbox through an overrunning clutch and shaft.
The system initiates engine rotation, maintains engine purge speed, assists acceleration to self-
sustaining speed, and perpetuates a slow roll speed. Assuming a four-minute purge, the system
is designed to provide three consecutive full-speed start cycles with 10-minute motor rest periods
between attempts. Fewer or more consecutive start attempts may be possible, depending upon
ambient temperature, turbine conditions, purge time, and motor rest time. For an example, see
Service Bulletin 2.3/108A DAC start information for the Mars® gas turbine.
Because the load on the motor at engine purge / wash speed is below its nameplate rating, the
system is capable of extended purge cycles for exhaust Heat Recovery Unit (HRU) applications,
and water wash cycles, without concern of overheating.
Slow roll is required on Taurus™ 70 and larger engines. Slow roll speeds range from 3-12% NGP,
and are required for up to 4 hours. The Titan™ 250 Onshore product is equipped with a ride thru
device that maintains rotor rotation, in the event of an AC power outage. Other products rely on a
constant speed AC or DC motor for slow roll.
The DAC system is certified to the following codes and standards, provided that the VFD is installed
in a Motor Control Center (MCC) room or other suitable ordinary (non-hazardous) location:
• National Electrical Code (NEC)
• Underwriters’ Laboratories (UL)
• Canadian Standards Association (CSA) Class I, Division 1, Group D, T3
• International Electrotechnical Commission (IEC) and Comité Européen de Normalisation
Électrotechnique (CENELEC) Zone 1 Exde IIA T3, ATEX
Additionally, the Centaur® 40, Centaur 50, and Taurus 60 generator set applications are equipped
with DAC start systems suitable for NEC Class 1, Group D, Division 1 locations, when the VFD is
in an MCC or other suitable ordinary (non-hazardous) location.
A user-supplied fused disconnect, or circuit breaker, is required at the VFD input; filters, line
reactors, or transformers may also be necessary.

1.2 Availability
Solar has leveraged more than two decades of experience with Reliance/Allen-Bradley VFDs to
develop the configurations used today in the DAC start system. VFD’s that are ordered through
Solar Turbines are configured specifically for seamless integration with our equipment. While it is
possible to order a PowerFlex VFD from a different source, there may be differences in firmware,
option cards, etc., which may result in substantial work on-site to modify the VFD system to function
successfully in this application.
Once installed, Solar’s proprietary Turbotronic™ system downloads all the configuration
parameters to the VFD for operation in the intended application.
1.2.1 Standard DAC Start System
The standard DAC start system is available on all of Solar’s gas turbine packages. It
requires a three-phase power supply from 380 to 480 VAC, 50 or 60 Hz. A Custom Feature
is required for 600 to 690 VAC supply. This document primarily focusses on the 380-480
VAC systems, but information for 600-690 VAC systems can be provided upon request,
and is provided in the same Rockwell documents that are referenced herein.

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1.2.2 “High Torque” DAC Start System

Centaur 40 and Centaur 50 GS packages, with a generator rotor inertia exceeding 340 kg-
m2 (8000 lb-ft2), employ a motor designed for the higher inertia requirements. Inquire with
Solar Engineering if this “high torque” application motor is needed.

2. PowerFlex 750 Series Variable Frequency Drives

2.1 PowerFlex 750 Applications
Table 1 lists the 400 VAC (400 VAC is the nominal value, provided by Rockwell Automation for
drives designed to operate between 380 – 480 VAC) PowerFlex 750 rating used by engine model.
Throughout the referenced Rockwell Automation manuals, kW Rating is used to identify VFDs.
Some of the referenced tables list duty ratings, and Solar’s drives are considered Normal Duty.

Table 1: PowerFlex 750 Power Ratings

Package Frame Size kW Rating kVA Rating

Saturn CS & MD 4 37 48.8

Saturn GS 5 55 71.3

Centaur 40 & 50 CS & MD 5 55 71.3

Centaur 40&50 GS (Low Torque) 6 90 115.4

Centaur 40&50 GS (High Torque) 6 132 176.5

Mercury 50 6 132 176.5

Taurus 60 CS & MD 5 55 71.3

Taurus 60 GS 6 132 176.5

Taurus 65 GS 7 200 309.5

Taurus 70 CS & MD 6 110 139.1

Mars CS, MD & GS 6 132 176.5

Titan 130-20500 CS & MD 7 160 205

Titan 130 -23500 CS & MD 7 160 205

Taurus 70 GS 8 315 369.3

Titan 130-20500 GS 8 315 369.5

Titan 130-23000 GS 8 400 512

Titan 250 8 400 512

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2.2 3-Phase Power Rating

For rating information, refer to Rockwell Automation Publication: 750-td001, PowerFlex 750-
series AC Drives, Technical Data. The full technical data includes the 3 second, 1 minute, and
continuous current rating for the 750 family of drives.
2.3 Additional Components
In addition to the motor and VFD, the following components may be part of the project scope, if
required as indicated.
2.3.1 Line Reactors (Input)
Line reactors can provide protection to the VFD from imbalance in the distribution system.
Line reactors also increase the load impedance so that current transients, caused by the
VFD, do not cause voltage spikes on the rest of the distribution system.
Line reactors are required for all PowerFlex 750 series applications if any of the following
conditions exist:
• The power system has power factor correction capacitors
• The power source has intermittent voltage spikes exceeding 6000V
• The input lines to the VFD have voltage imbalance greater than 2%
• The transformer kVA rating exceeds the values listed in Table 2.
Refer to Table 3 for dimensional information.
Supplied by: Custom Feature
Installed at: VFD input

Table 2. PowerFlex 750 Series Maximum Transformer kVA

Package Max. Transformer kVA

Saturn CS & MD 1000

Saturn GS 1000
Centaur 40 & 50 CS & MD 1000
Centaur 40&50 GS (Low Torque) 1500
Centaur 40&50 GS (High Torque) 2500
Mercury 50 2500
Taurus 60 CS & MD 1000
Taurus 60 GS 2500
Taurus 65 GS 3000
Taurus 70 CS & MD 2000
Mars CS, MD & GS 2500
Titan 130-20500 CS & MD 2500
Titan 130 -23500 CS & MD 3000
Taurus 70 GS 4000
Titan 130-20500 GS 4000
Titan 130-23000 GS 4500
Titan 250 4500

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Table 3. PowerFlex750 Series Line Reactor Dimensions and Weights

Width Height Depth Weight

Package
Mm in. mm in. mm in. kg lb

Saturn CS & MD 331 13 331 13 331 13 26 58

Saturn GS 331 13 331 13 331 13 37 82

Centaur CS & MD 331 13 331 13 331 13 37 82

Centaur GS
331 13 331 13 331 13 37 81
(Low Torque)
Centaur GS
331 13 331 13 331 13 68 151
(High Torque)
Mercury 50 GS 331 13 331 13 331 13 68 151

Taurus 60 CS & MD 331 13 331 13 331 13 37 82

Taurus 60 GS 331 13 331 13 331 13 68 151

Taurus 65 GS 432 17 610 24 470 18.5 77 170

Taurus 70 CS & MD 331 13 331 13 331 13 44 98

Mars CS, MD & GS 331 13 331 13 331 13 68 151

Titan 130-20500 CS &

432 17 610 24 470 18.5 77 170
MD

Titan 130-23500 432 17 610 24 470 18.5 91 200

Taurus 70 GS 686 27 1195 47 635 25 119 262

Titan 130-20500 GS 686 27 1195 47 635 25 119 262

Titan 130-23000 GS 686 27 1195 47 635 25 132 292

Titan 250 686 27 1195 47 635 25 132 292

2.3.2 Line Reactors (Output)

Line reactors provide inductive reactance to counteract the interconnect capacitive
reactance between the VFD and motor. This reduces impedance and increases the voltage
at the motor. PowerFlex 753 VFDs may use motor cables up to 1200 ft. in length with or
without line reactors. PowerFlex 755 drives require output line reactors when the distance
between the VFD and motor exceeds a specified value. Refer to Table 4 for the maximum
distance requirements of the PowerFlex 755 drives.
Supplied by: Custom Feature
Installed at: VFD output

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Table 4. PowerFlex 755 380 - 480 VAC VFD-to-Motor Distances

No Reactor Reactor
Package
m (ft) m (ft)

Taurus 70 GS 259.1 (850) 365.8 (1200)

Titan 130-20500 GS 259.1 (850) 365.8 (1200)

Titan 130-23000 GS 259.1(850) 365.8 (1200)

Titan 250 213.4 (700) 365.8 (1200)

2.3.3 Sine Wave Filters

Sine wave filters can be used on the output of the VFD to reduce the noise, and EMI, that
is inherent to pulse width modulation. Neither Solar nor Rockwell Automation require the
use of sine wave filters for the DAC start system application. If sine wave filters are desired,
then Solar Engineering must be consulted. Specific VFD parameters must be configured
when sine wave filters are used with PowerFlex 750 series VFDs. Reference Rockwell
Automation Publication: pflex-at002B, Parameter Settings for PowerFlex Drives Using
Sine Wave Filters, dv/dt Filters, and Adjustable Voltage, for more information on this
topic.
Supplied by: User
Installed at: VFD output

2.3.4 Isolation Transformer

When Total Harmonic Distortion (THD) exceeds 5%, the impact of multiple VFD’s on the
system should be reviewed. Isolation transformers may reduce THD, due to the added
impedance, however, alone they are not necessarily more effective than line reactors at
harmonic reduction. Isolation transformers are commonly used to isolate the VFD
grounding system, especially when multiple drives are on a circuit. They are also used
when ground fault detection schemes are employed, such as in marine applications. If
more aggressive harmonic content reduction is required, input filters should be considered.
Supplied by: User
Installed at: VFD input

2.3.5 Fuse and Circuit Breaker Requirements

Input fuses are required to protect the cabling to the VFD and other devices on the system.
A circuit disconnect is required for VFD servicing. Fuses between the VFD and motor are
not required. The VFD is designed to protect the motor, and motor interconnect. Input fuse
and/or circuit breaker ratings must not be larger than specified in Rockwell Automation
Publication: 750-td001, PowerFlex 750-series AC Drives, Technical Data. To avoid
nuisance tripping, Solar recommends that circuit breakers be rated at least 115% of the
input current rating of the VFD.

Supplied by: User

Installed at: VFD input

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2.4 Cable Ampacity Recommendations & Terminal Sizes

Table 5 lists conductor minimum ampacity recommendations, and terminal sizes, for the
corresponding VFD and motor. Refer to Section 5 for an example of how these ampacity values
were determined. VFD terminal sizes for PF 753 drives are listed in the Rockwell Automation
Publication: 750-in001, PowerFlex 750-Series AC Drives, Installation Instructions. The PF
755 power connections terminate on the VFD bus bars using customer-supplied lugs.

Table 5. PowerFlex753 380 – 480V Minimum Conductor Ampacity and Terminal Sizes

Minimum Conductor Terminal Sizes

Ampacity
Package ATEX Motor
Terminals NEC Motor
VFD Motor
Conduit Entry
(Amps)3 (Amps)4 (Quantity 6) Size (Inches)
Size (mm2)
Saturn CS, MD & GS 129 24 16 1

Centaur 40&50, Taurus 60 CS

129 144 95 2
& MD
Centaur 40 & 50 GS (Low) 208 144 95 2

Centaur 40 & 50,

318 208 150 4
Taurus 60 GS (High) 1

Mercury 501 318 128 N/A 2

Taurus 60 GS1 318 208 150 4

Taurus 65 GS1 449 263 150 4

Taurus 70 CS & MD1 251 144 95 2

Mars CS, MD & GS1 318 202 150 4

Titan 130-20500 CS & MD1 370 202 150 4

Titan 130-23500 CS & MD1 558 271 150 4

Taurus 70 GS2 666 263 150 4

Titan 130-20500 GS2 666 438 150 4

Titan 130-23000 GS2 924 523 150 4

Titan 2502 924 548 9 x 240 4

Notes:
1. Frames 6 and 7 have barrel lugs, maximum lug width shown.
2. PowerFlex 755 has barrel lug terminals, using M12 bolts.
3. Calculated by NEC code, VFD Ampacity = Input current x 1.25.
4. Calculated by NEC code, Motor Ampacity = Rated Motor Amps x 1.2 (refer to Section 5 for
assumptions made for conductor sizing).

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2.5 VFD Installation

The standard VFDs supplied by Solar are rated IP20 and must be installed in a non-hazardous
environment, where adequate ventilation is available, and the drive is protected from dust and
moisture. This level of protection enclosure provides little defense against circulating dust, and no
protection against water ingress. VFDs are vulnerable to corrosion caused by exposure to
environmental conditions that are beyond the rating of the drive enclosure. Moreover, intrusion by
foreign debris, can cause internal short circuit or arc-flash events that lead to VFD failure. Care
should be taken to protect the VFD during installation and commissioning.
It is critical that location and environmental conditions are considered prior to drive procurement to
avoid early failures and loss of package availability. Higher protection enclosures can be provided
for drives that are not installed in a suitably controlled environment. Rockwell publication, DRIVES-
AT003B, Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives,
elaborates on the ingress protection options and requirements.
The operating ambient range of the VFD is 0° to +40°C (32° to 104°F), and 5 to 95% relative
humidity. Continuous VFD operation above 1000m (3300ft) elevation requires de-rating of the VFD
power output, due to reduced ambient cooling capacity. Typical DAC start applications operate in
a non-continuous mode and de-rating is not required. Inquire with Solar Engineering if installation
conditions are not within these parameters.
VFDs should be positioned such that input wiring from the feeder breaker is as short as possible.
MCC manufacturers may not be familiar with the requirements for installing a VFD. Solar
recommends that a copy of this document be provided to the MCC manufacturer. PowerFlex 750
series VFDs cannot be installed with a motor interconnect cable length greater than 366 m (1200
ft).
System operation is verified during turbine package test at Solar, so the VFD will not be available
for site installation until these procedures are completed. The construction / manufacturing cycle of
the MCC should accommodate VFD availability for installation.
2.5.1 PowerFlex 753 Specifics
Solar recommends that VFD installations adhere to Rockwell Automation Publication: 750-
in001, PowerFlex 750-Series AC Drives, Installation Instructions including the
following:
1. If VFDs are installed in a panel-like cabinet, the cabinet should be “empty” (no bus bars),
ventilated (louvers at top and bottom), and should have a back panel suitable for mounting
of the VFD. All PowerFlex 753 VFDs are designed to be wall mounted.
2. Cooling requires that ventilation and access minimum clearances are 76.2 mm (3.0 in)
at the top and bottom of the drive. Bottom clearance should be increased, as needed, to
accommodate cable bend radius requirements.
3. A minimum 600-mm (24-in.) wide cabinet is recommended.
2.5.2 PowerFlex 755 Specifics
Minimum ventilation and access clearances for each VFD are 182 mm (7.2 in.), at the top,
and 860 mm (33.9 in.) at the door swing. Clearances should be increased, as required, to
accommodate cable bend radius requirements.
The standard PowerFlex 755 VFDs are 600mm deep. Power cables enter the PowerFlex
755 from the top, but a custom feature is available for 800mm deep PowerFlex 755 VFDs,
which allow for either top or bottom cable entry. The Titan 250 Onshore VFD, with ride thru
capability, is a double wide cabinet.

2.6 VFD Heat Rejection Rates

Refer to Rockwell Automation Publication: 750-td001, PowerFlex 750-series AC Drives,
Technical Data for heat rejection rates for the VFD.
Use this information to determine cooling requirements for the installation, when referring to the
previous section for VFD mounting recommendations. Except for Waste Heat Recovery Unit
(WHRU) applications, the VFD is operating for short intermittent periods. When the gas turbine is

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used in a continuous duty application, the VFD produces heat for a fraction of the operating life of
the package.
2.7 Grounding Systems
The VFDs are designed to operate using a symmetrical three-phase supply. To comply with IEEE
C62.41, the VFD is equipped with Metal Oxide Varistors (MOV) to provide phase-to-phase and
phase-to-ground voltage surge protection. The MOV circuit is designed for transient surge
protection and not for continuous operation. In ungrounded distribution systems, the phase-to-
ground MOV connection can become a continuous current path to ground. Exceeding the published
phase-to-phase voltage, phase-to-ground voltage, or energy ratings can damage the MOV.
Suitable isolation is required for the VFD when there is potential for high phase-to-ground voltages
(exceeding 125% of nominal line-to-line voltage), or when the supply ground is connected to
another system or equipment that could cause the ground potential to vary. Solar recommends an
isolation transformer when any of these conditions exist.
The VFD contains common mode noise suppression capacitors that are referenced to ground. In
installations with ungrounded or high resistance ground systems, the capacitors can capture high
frequency common mode or ground fault currents. This can cause bus overvoltage conditions that
lead to VFD faults or damage. Systems that are ungrounded, high resistance grounded, or have
one phase grounded apply higher than normal voltage stresses directly to the capacitors and can
lead to shortened drive life or damage.
When installing a PowerFlex 750 series drive in an ungrounded, high-resistance, or B-phase
grounded distribution system, disconnect the phase-to-ground MOV circuit and the common mode
capacitors from ground. Refer to Rockwell Automation Publication:
Drives-in001, Wiring and Grounding for Pulse Width Modulated (PWM) AC Drives,
Installation Instructions.

2.8 Titan 250 Onshore Ride Thru Solution

The Titan 250 Onshore product replaces the DC backup turning gear with a Ride-Thru unit. This
DC-DC converter enables the DAC start system to continue to slow roll, in the event of an AC
power outage, and is supplied by 120V DC power from the package batteries. Battery voltage is
converted to 540 VDC, and powers the DC Bus in the VFD. Additionally, a PowerFlex 753 VFD is
included in the cabinet to operate the AC cooling fans. This VFD derives power from the primary
PowerFlex 755 drive or from the RTU when on battery power. The customer need only connect AC
input power to the primary PowerFlex 755 VFD and DC input power from the package batteries to
the RTU.

3. Line Harmonics
VFDs introduce current and voltage harmonics into the electrical supply system. The VFD is a
nonlinear load that draws current from the supply for very short periods of time. Line harmonics
result because the voltage of the input power is sinusoidal, but the current draw is not.
Even-order harmonics (such as the 2nd and 4th) are not a problem: although the load is nonlinear,
it is symmetric about the x-axis. Harmonics, divisible by three (such as the 3rd and 9th), are very
small when the supply is a balanced three-phase system. With each higher order, the magnitude
of the distortion is smaller and usually insignificant beyond the 13th harmonic. The harmonics of
concern are the 5th, 7th, 11th, and 13th. The Institute of Electrical and Electronics Engineers (IEEE)
standard 519 states that in general, system voltage distortion should be limited to 5% Total
Harmonic Distortion (THD). THD is a ratio of harmonic and total voltage or current: at low loads
(low current flow), very high harmonic current will be measured. THD measurement should be
conducted with the VFD as close to rated current as practicable.
The voltage THD introduced by the drive itself should not exceed 5%. THD examples provided by
Rockwell Automation for a PowerFlex 753 100 hp drive are 1.18% (Vrms) and 36.85% (Irms), and
for a PowerFlex 755 600 hp drive 4.93% (Vrms) and 32.72% (Irms).

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If a large percentage of the plant load includes VFDs, Solar highly recommends that a power
system analysis, with an emphasis on harmonics, be conducted. Rockwell Automation provides
harmonic simulation tools, available online, as an aid to model a power system and estimate
harmonic distortion.
There are several methods to mitigate THD; these vary in cost and effectiveness. Line reactors
are a simple and common method. If a more aggressive method of attenuation is required,
transformers, filters or 12/18 pulse input rectifiers are available. See Rockwell Automation
Publication: DRIVES-WP011C: Straight Talk about PWM AC Drive Harmonic Problems and
Solutions. for more information.

4. Description of Operation and Control

4.1 Control Description, Including ControlNet and EtherNet/IP
VFDs are configured, controlled, and monitored from the Turbotronic control system using a
communications link. The link can be either ControlNet or Ethernet/IP.
The control processor configures the VFD through the communication link by first commanding a
reset to default state, and then issuing a series of messages that configure parameters specific to
the application. The configuration process is executed automatically upon control system power
up, and can be manually initiated from the Human Machine Interface computer.
The control system starts, stops, and controls the VFD speed through the link. VFD status,
parameter monitoring, and fault monitoring is also performed using the communication link. The
communication link status is continually monitored.
To support legacy control systems with no communications link, a hard-wired interface to the VFD
from the control system can be provided.
The motor dual thermostats (or thermistor circuit) are wired to the control terminals of the VFD. In
the event of motor thermal overload, the VFD interrupts operation and communicates this
information to the control processor.
The VFD provides control for the DAC start motor anti-condensation heater. Global motors are
configured to provide connections suitable for 50 and 60 Hz applications. It is critical the applicable
leads are used and heater voltage limitations are followed.
A lube oil pressure switch is hardwired to the start VFD. This switch interlocks the drive with the
lube oil pressure. If lube oil pressure requirements are not met, the VFD is inhibited.

4.2 Protection against Motor Thermal Overload

The DAC start motor is intentionally operated above the motor nameplate rating. Table 6 depicts
the approximate overload by application. The motors used are designed to meet the high current,
high torque, short-term demands for starting Solar gas turbines. The motors are certified to UL,
CSA, CENELEC and/or ATEX standards as required. These motors have been proven, in all parts
of the world, under a wide variety of conditions.
The motor thermostats provide a step-change resistance from near zero to near infinite when the
motor windings reach a temperature of 160°C (320°F). This is slightly higher than a T4 temperature
code of 135°C (275°F).
In the event of a motor thermal overload, the start sequence is aborted; a shutdown is annunciated,
and the motor ramps to a stop. The control processor locks out subsequent start attempts for a
period of 30 minutes.

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Table 6. Comparison of Motor Nameplate Ratings and Actual Peak Load

Motor NP
Current VFD Continuous
Package
Current (Amps)
(Amps)
Saturn CS & MD 20 72
Saturn GS 20 104
Centaur CS & MD 106 104
Centaur GS (Low Torque) 106 170
Centaur GS (High Torque) 173 260
Mercury 50 GS 106 260
Taurus 60 CS & MD 106 104
Taurus 60 GS 173 260
Taurus 65 GS 219 367
Taurus 70 CS & MD 106 205
Taurus 70 GS 209 540
Mars CS, MD & GS 168 260
Titan 130-20500 CS & MD 168 302
Titan 130-23500 CS & MD 226 302
Titan 130-20500 GS* 362 540
Titan 130-23000 GS* 436 750
Titan 250 CS, MD & GS 456 750
*Titan 130-20500 GS and Titan 130-23000 GS include 2 motors. Divide values by 2 for each motor’s rating.

5. Conductor Sizing
ATTENTION: The following example is merely a guide for proper installation.
Solar Turbines cannot assume responsibility for the compliance or the
noncompliance to any code, national, local or otherwise for the proper
installation of this drive or associated equipment. A hazard of personal injury
and/or equipment damage exists if codes are ignored during installation.
These guidelines are for use by licensed, professional engineers and
electricians. The customer’s electrical designers are responsible for
compliance to all applicable codes. It is strongly recommended that the
customer, electrical engineer, and contractor read the VFD manufacturer’s
documentation referenced in Section 6.

Due to the unusual duty cycle of the DAC system, Solar provides an EXAMPLE of how to select
conductor size between the VFD and motor. These sample recommendations are based upon
NFPA70 Articles 310 & 430 of the United States National Electrical Code (NEC), 2017 edition, and
the VFD and motor supplier. The same general approach can be taken to size conductors
according to the International Electrotechnical Commission (IEC).
Inappropriate wiring can cause start-up difficulties, as well as unwanted interaction with other
systems. It is recommended that the VFD use copper conductors with an insulation composed of
XLPE Type RHW-2, or XHHW-2. Shielding is required for the conductors connecting the VFD to
the start motor. Shielded cabling is also strongly recommended at the input to the VFD. Using
unshielded cabling on the input can result in disruption of sensitive control components, such as
the overspeed monitor.

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The VFD conductors should be rated based on supply voltage, NEC Type TC, AC or MC. At least
one ground wire must connect the VFD to the start motor. Ground wire(s) should be spaced
equidistant to the power wires (such as in the center of a triangular arrangement of power wires).
A cable with three symmetrical ground conductors should be used for drives larger than 200 hp
(150kW).

5.1 Determining Disconnect and Conductor Sizing (Supply to VFD)

The 2017 edition of NFPA 70 Article 430 specifies the disconnect and conductor sizing
requirements for VFDs and motors. Solar recommends that each VFD be protected by a fused
disconnect, or circuit breaker, rated not less than 115% of the VFD rated input current.
Input power cable to the VFD can be sized by referencing NFPA 70 Article 430.122, which
specifies an ampacity of 125% of the input current rating of the drive. Refer to 750-in001,
PowerFlex 750-Series AC Drives, Installation Instructions for VFD terminal size ranges.
5.2 Determining Conductor Sizing (VFD to Motor)
The DAC start system is classified as “Varying duty” Referring to NFPA 70 Article 430.22 (E) Other
than Continuous Duty:
“Conductors for a motor used in a short-time, intermittent, periodic, or varying duty application
shall have an ampacity of not less than the percentage of the motor nameplate current rating
shown in Table 430.22(E), unless the authority having jurisdiction grants special permission
for conductors of lower ampacity.”

Table 7. Duty Cycle Service, NEC Code Table 430.22(E)

Nameplate Current Rating Percentages

Classification of Service 5 Minute 15 Minute 30 & 60 Continuous
Rated Rated Minute Rated
Motor Motor Rated Motor Motor
Short-time duty operating valves, raising
110 120 150 -
or lowering rolls, etc.
Intermittent duty freight or passenger
elevators, tool heads, pumps, 85 85 90 140
drawbridges, turntables, etc.
Periodic duty rolls, ore- and core handling
85 90 95 140
machines, etc.

Varying duty 110 120 150 200

Solar DAC start motors are designed for 15-minute inverter duty, and the required power during
slow roll is significantly less than the start motor nameplate rating. The ampacity rating of
conductors can be sized to 120% or greater than motor nameplate current rating.
Conservative sizing of conductors, such as using the continuous output current rating of the VFD,
is unnecessary and the increased cable diameter can pose significant challenges to cable
termination at the motor. A few products use a motor that has a nameplate current rating that is
greater than the VFD continuous rating (for example, T60 CS/MD). In this case, the VFD
continuous current rating should be used as the baseline amperage, prior to derating, for conductor
sizing. This is because the VFD will not allow the motor to continuously draw more current than
this limit, even under high load conditions. Refer to Table 6 for a comparison of motor nameplate
and VFD continuous current ratings.
Refer to NEC Table 310.15(B)(16) to size conductors based on ampacity. Conductors rated to 90ºC
with XHHW-2 insulation are recommended for NEC Solar Packages. Table 310.15(B)(16) uses
the following assumptions:

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• Total Voltage Drop is Less Than 5%

• Ambient Temperature of 30ºC (86ºF)
• Not More Than Three Current-Carrying Conductors in Raceway, Cable, Earth
Correction factors for voltage drop, ambient temperature, and cable routing must be considered
and are referred to by NEC Article 215.2(A), Table 310.15(B)(2)(A), and Table 310.15(B)(3)(a),
respectively.

5.3 Voltage Drop Calculation

Solar recommends the total voltage drop (both feeder and branch circuits) not exceed 5%. The
branch circuit includes conductors from the supply circuit breaker to the VFD and from the VFD to
the motor (NEC Exhibit 430.11). The data listed in Table 6 considers a system designed for a 380
VAC. Assuming a negligible voltage drop for the supply to VFD cable, a maximum voltage drop of
11.4 VAC is allowed between drive and motor. (the VFD converts incoming voltage to 380 VAC
output for 380-480 VAC system voltages).
Refer to Table 6 for the maximum current (VFD rated ampacity) and general industry conductor
information (for example, NEC Publication 430) for typical conductor resistances to calculate
voltage drop.
While the distance between the VFD and motor can be up to 1200 feet, the limitation is typically
the size of conduit / cable entry into the motor terminal box. A larger conductor could be used if a
customer furnished marshaling box near the package is employed. Smaller conductors may then
be used to connect from the marshalling box to the motor, provided that ampacity requirements
are still met. Consult Solar Engineering if this is a consideration.

5.4 Example: How to Calculate Conductor Size

The following provides an example of conductor sizing for a Mercury 50 a start system. To calculate
conductor size, the following quantities are necessary (the values used for this example are listed
in parenthesis):
• Motor Voltage – 380 or 575 (380V)
• Distance between the VFD and motor (220 ft.)
• Motor nameplate amperage rating (106A)
• VFD continuous current rating (260A)
• Ambient temperature (50 C° (122F°))
• Number of conductors in enclosed raceway (6)
With these values known, the minimum cable diameter can be determined by multiplying the motor
nameplate amperage rating by 1.2 (per NEC table 430.22(E)).
1.2 × 106 = 127.2 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴
Table 310.15(B)(16) is used to size conductors based on ampacity. It assumes not more than 3
conductors in a raceway and an ambient temperature of 30 C°, so it is necessary to use Table
310.15(B)(2)(a) to add a temperature correction. An ambient temperature of 50 C° correlates to a
derating factor of 0.82 for the Solar recommended cable type.

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Figure 1. NEC Temperature Correction

127.2 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴
= 155.1 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴
0.82
For this example, we assume that 6 conductors are being used in parallel (i.e. that conductors from
another system are run together with the start cables), and derating for 6 conductors using Table
310.15(B)(3)(a) leads to:

Figure 2. NEC Grouping Derating

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155.1 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴
= 193.9 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴
.8
In this example, the derating factors account for an increased current of 66 amps. Prior to final
selection of the conductor size, it is necessary to consider the voltage drop. The following equation
is used to calculate voltage drop:

11.4
D=
Ω
1.732 × × I max
d
where:
D = Distance between the VFD and motor, m (ft)
11.4 = Maximum voltage drop (3% of 380 VAC)
1.732 = Decimal representation of the square root of 3
Ω/d = Conductor resistance per m (ft)
Imax = VFD continuous current rating

Independent of voltage drop, the conductor size needs to be 2/0 according to 310.15(B)(16). Most
cable manufacturers provide a voltage per amp per distance loss, which simplifies the voltage drop
calculation. Solar’s preferred cable supplier provides this information, and 2/0 cable has a 0.193
Volts/Amp/1000 ft drop. To determine voltage drop, multiply the continuous amperage rating of the
VFD by the voltage drop by the distance divided by 1000.

𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉
260 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 × 0.193 × 200 𝑓𝑓𝑓𝑓
𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 ∗ 1000 𝑓𝑓𝑓𝑓
This results in a value of 10 volts, which is less than a 3% voltage drop. Hence, the 2/0 AWG
conductor is the appropriate selection for this example. If the distance between VFD and motor is
increased beyond 227 ft, larger conductors would be needed.

6. Summary
The DAC start system is a proven configuration for Solar gas turbine compressor sets, mechanical-
drive packages, and generator sets. Since introduction, it has demonstrated high reliability and low
maintenance on Solar’s packages across all products.
Despite the simplicity, it requires consideration for the environment, conductor selection, grounding,
inter-connections, and the effects the VFD might have on other electrical components. It is
important that electrical engineers, familiar with site conditions and requirements, be engaged in
the system design, selection of supporting components, and installation requirements, to ensure
success. The modern technology of the VFD provides many advantages for the DAC start system,
when compared to other gas turbine start systems.

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7. Source Data Table References

1. Allen-Bradley. (October 2017). PowerFlex 750-Series AC Drives: Technical Data. 750-
TD001K.
2. Allen-Bradley. (October 2017). PowerFlex 750-Series AC Drives: Installation Instructions.
750-IN001Q.
3. Allen-Bradley. (August 2014). Parameter Settings for PowerFlex Drives Using Sine Wave
Filters, dv/dt Filters, and Adjustable Voltage. PFLEX-at002B.
4. Allen-Bradley. (September 2017). Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives. DRIVES-IN001P.
5. Rockwell Automation, (October 2006), Straight Talk about PWM AC Drive Harmonic
Problems and Solutions. DRIVES-WP011C.
6. Allen-Bradley, (June 2017), Industry Installation Guidelines for Pulse Width Modulated
(PWM) AC Drives, DRIVES-AT003B.
7. Allen-Bradley. (August 2017). PowerFlex Low Voltage Drives Selection Guide. PFLEX-
SG002L.
8. Source Control Drawing 1308818 (revision A)
9. Source Control Drawing 1322844 (revision B)
10. Source Control Drawing 1039135, (revision G)
11. Source Control Drawing 1012991 (revision AR)
12. Source Control Drawing 1558822 (revision N/C)
13. Hydro Composite, CPD 600

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8. Appendix

Figures 3 thru 17 depict the maximum power consumption for the start system for each product.
Load profiles for each product are approximate. Constant acceleration rates and a four-minute
purge at 20% NGP are assumed.

Figure 3. Max Power Consumption of Saturn CS&MD

Figure 4. Max Power Consumption of Saturn GS

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Note: This curve is different than the others due to the unique starting
characteristics of these products

Figure 5. Max Power Consumption of Centaur 40 -Taurus 60 CS&MD

Figure 6. Max Power Consumption of Mercury 50

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Figure 7. Max Power Consumption of Centaur 40, Centaur 50 GS

(Low Torque)

Figure 8. Max Power Consumption of Centaur 40, Centaur 50 GS

(High Torque)

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Figure 9. Max Power Consumption of Taurus 60 GS

Figure 10. Max Power Consumption of Taurus 65 GS

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Figure 11. Max Power Consumption of Taurus 70 CS&MD

Figure 12. Max Power Consumption of Taurus 70 GS

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Figure 13. Max Power Consumption of Mars

Figure 14. Max Power Consumption of Titan 130 CS&MD

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Figure 15. Max Power Consumption of Titan 130 GS 60 Hz

500

450

400

350

300
Power (kVA)

250 Power
%NGP
200
Slow Roll
150

100

50

0
0 50 100 150 200 250 300 350 400 450
Time (s)

Figure 16. Max Power Consumption of Titan 130E GS 60 Hz

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Figure 17. Max Power Consumption of Titan 250

Solar Turbines Incorporated

9330 Sky Park Court
San Diego, CA 92123-5398

This information is intended as a general overview and is not intended to be, and should not be used as, a substitute for obtaining
advice in any specific situation. This document is accurate as of the publication date and any discussion of a particular issue may
become outdated
Cat and Caterpillar are registered trademarks of Caterpillar Inc. Solar, Saturn, Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx,
Turbotronic, InSight System, and InSight Connect, are trademarks of Solar Turbines Incorporated. All other trademarks are the
intellectual property of their respective companies.
© 2019 Solar Turbines Incorporated. All rights reserved. Specifications are subject to change without notice.

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