GCS Troubleshooting&Applications1v0 (3.23.01)

Centrilift.
A Division of Baker Hughes

Copyright 1998,1999,2000,2001
Version 1.0 Release

March 2001
TABLE OF CONTENTS
FORWARD .......................................................................................................................................6
ELECTROSPEED GCS TROUBLESHOOTING GUIDE ..................................................................7
PCB functionality ...........................................................................................................................7
Diagnostic LEDs............................................................................................................................7
Converter problems ...................................................................................................................7
Inverter/load problems...............................................................................................................7
GENERAL TROUBLESHOOTING PROCEDURE ...........................................................................8
Functionality Test ..........................................................................................................................8
No Load Test.................................................................................................................................9
Shorted Output Test......................................................................................................................9
IGBT Testing .................................................................................................................................9
GENERAL TROUBLESHOOTING FLOW CHARTS......................................................................10
Figure 1: Flow Chart Symbol Definitions .....................................................................................10
Figure 2: Diagnostic Overview Flow Chart ..................................................................................11
Figure 3: Display Problem Flow Chart.........................................................................................12
Figure 4: Converter Problem Flow Chart ....................................................................................13
Figure 5: Starting Problems Flow Chart ......................................................................................14
Figure 6: Inverter Problems Flow Chart ......................................................................................15
FAULT/ACTIVE ALARM CHART....................................................................................................16
OPERATIONAL THRESHOLDS .................................................................................................16
Fault/Active Alarm: Input Over Voltage ...................................................................................16
Fault/Active Alarm: Input Under Voltage .................................................................................16
Fault/Active Alarm: Input Voltage Unbalance ..........................................................................16
Fault/Active Alarm: Low Speed Trip ........................................................................................17
Fault/ Active Alarm: Overload..................................................................................................17
Fault/ Active Alarm: Underload................................................................................................17
ON BOARD I/O ...........................................................................................................................17
Fault/Active Alarm: Analog Input High Threshold....................................................................17
Fault/Active Alarm: Analog Input Low Threshold.....................................................................17
Fault/Active Alarm: Digital Input ..............................................................................................18
EXTERNAL I/O ...........................................................................................................................18
Fault/Active Alarm: External Analog Input High Threshold......................................................18
Fault/Active Alarm: External Analog Input Low Threshold ......................................................18
Fault/Active Alarm: External Digital Input ................................................................................18
SOFTWARE FAULTS.................................................................................................................18
Fault/Active Alarm: CITIBus Communications Error ...............................................................18
Fault/Active Alarm: PCM Converter Fault................................................................................19
Fault/Active Alarm: PCM Inverter Fault ...................................................................................19
Fault/Active Alarm: PCM System Error ...................................................................................19
Fault/Active Alarm: Serial Communications Error ...................................................................19
HARDWARE FAULTS ................................................................................................................19
Fault/Active Alarm: Ambient Temperature Alarm ....................................................................19
Fault/Active Alarm: Auxiliary Temperature Alarm....................................................................20
Fault/Active Alarm: Inductor Temperature Alarm ....................................................................20
Fault/Active Alarm: Heat sink Over Temperature Alarm .........................................................20
Fault/Active Alarm: Inverter IOT (Instantaneous Overcurrent Trip).........................................20
Fault/Active Alarm: PCM Zero Crossing Fault.........................................................................20
Fault/Active Alarm: System Controller Zero Crossing Fault ....................................................21
OTHER FAULTS / ALARMS .......................................................................................................21
Fault/Active Alarm: Central Shutdown.....................................................................................21
Fault/Active Alarm: Drive Stopped Manually ...........................................................................21
Fault/Active Alarm: External HOA in Off..................................................................................21
Fault/Active Alarm: First Start..................................................................................................21
Fault/Active Alarm: Lockout.....................................................................................................21
Fault/Active Alarm: Max Starts ................................................................................................22
Fault/Active Alarm: Motor State Sync Error.............................................................................22
Fault/Active Alarm: PCM Bus Volts .........................................................................................22
Fault/Active Alarm: Real Time Clock Invalid ...........................................................................22
TYPICAL WAVEFORMS ................................................................................................................23
ELECTRIC SUBMERSIBLE PUMP APPLICATIONS.....................................................................25
Introduction .................................................................................................................................25
ESP Basics .................................................................................................................................25
Variable Speed Controller (VSC) Advantages ............................................................................25
VSC effects on centrifugal pumps...............................................................................................26
VSC Effects on Motor..................................................................................................................27
Starting Torque ...........................................................................................................................27
Cable Voltage Drop .....................................................................................................................28
VBOOST SYNC at Start..............................................................................................................28
Matching Motor, Pump & VSC sizes ...........................................................................................28
Pump Shaft Horsepower Limit ....................................................................................................28
Pump Housing Limit ....................................................................................................................29
Vibration and Wear .....................................................................................................................29
BASIC VSC CONFIGURATION .....................................................................................................29
Start-up Work Sheet ...................................................................................................................30
Installation and Service Record ..................................................................................................31
Basic Parameter Setup ...............................................................................................................32
Forming Capacitors.....................................................................................................................34
No-Load Tests.............................................................................................................................35
No Load Test ...........................................................................................................................35
Shorted Output Test ................................................................................................................35
MOTOR START TROUBLESHOOTING ........................................................................................37
Optimization ................................................................................................................................37
Input Power Factor ......................................................................................................................37
Harmonic Distortion of Input Power Line.....................................................................................37
ESP vs PWM Operation..............................................................................................................38
Minimum Motor Current ..............................................................................................................38
I LIMIT Operation for Gassy Wells..............................................................................................38
Restart Time Delays....................................................................................................................38
ESP MOTOR STARTING ...............................................................................................................39
INTRODUCTION ........................................................................................................................40
MOTOR STARTING ...................................................................................................................40
REDUCED VOLTAGE STARTING .............................................................................................41
Series Inductor ........................................................................................................................42
High Impedance Transformer .................................................................................................42
Autotransformer.......................................................................................................................42
Solid-state................................................................................................................................43
VARIABLE FREQUENCY STARTING........................................................................................43
CONCLUSION ............................................................................................................................44
Figure 7: Impedance Model for Direct On Line Start...............................................................46
Figure 8: Maximum Cable Lengths .........................................................................................47
Figure 8: Torque / Speed with Constant Voltage.....................................................................48
Figure 9: Torque / Speed with Voltage Drop ...........................................................................48
Figure 10: Variable Speed Torque / Speed .............................................................................49
FACTS REGARDING THE USE OF PWM DRIVES ON ESP SYSTEMS .....................................50
Figure 11: PWM Spectrum, 3 kHz carrier generating 50 Hz ...................................................52
Figure 12: PWM Spectrum 2.97kHz carrier generating 60 Hz power .....................................53
Figure 13: 3 kHz carrier generating 50 Hz power, Single lumped value model.......................54
Figure 14: 3 kHz Carrier generating 50 Hz power, cable modeled with 15 sections ...............54
Figure 15: 4875 Hz carrier generating 50 Hz power, cable modeled with 15 sections............55
Figure 16: 3675 Hz carrier generating 50 hz power, cable modeled with 15 sections ............55
Figure 17: Six-step generating 50 Hz power, Cable modeled with 15 sections ......................56
VARIABLE SPEED DRIVES: DEFINITIONS, APPLICATIONS & COMPARISONS ......................57
Introduction .................................................................................................................................57
Definitions ...................................................................................................................................57
AC VSD Components..............................................................................................................57
Converters .......................................................................................................................... 57
Input Rectifier (or Converter) .............................................................................................. 57
DC Bus................................................................................................................................ 58
Output Inverter .................................................................................................................... 58
Common AC VSD Topologies.................................................................................................58
Three Phase Full Bridge Rectifiers ..................................................................................... 59
Multi-Pulse Converter Rectifiers ......................................................................................... 59
Current Source Inverters..................................................................................................... 60
Voltage Source Inverters .................................................................................................... 60
Optional Equipment .................................................................................................................61
Input Line Reactors............................................................................................................. 61
Surge Arrestors................................................................................................................... 61
Passive Filters & Power Factor Correction ......................................................................... 62
Active Filters ....................................................................................................................... 62
Applications .................................................................................................................................64
VSD Advantages .....................................................................................................................64
Improved System Efficiency................................................................................................ 64
Maximized Well Production ................................................................................................ 64
Production Matched to Process .......................................................................................... 65
Down Hole Equipment Isolated........................................................................................... 65
Reduced Starting Stresses ................................................................................................. 65
Utility Interface .........................................................................................................................65
Input Power Factor.............................................................................................................. 66
Input Current Distortion....................................................................................................... 66
Input Voltage Distortion....................................................................................................... 67
ESP Interface ..........................................................................................................................68
Motor Heating/Current Distortion ........................................................................................ 68
Mechanical Wear ................................................................................................................ 68
Voltage Stresses................................................................................................................. 68
Torque/Amp ........................................................................................................................ 69
Comparisons ...............................................................................................................................70
Utility Interface .........................................................................................................................70
Six Pulse Full Bridge Rectifiers........................................................................................... 70
Twelve Pulse Rectifiers....................................................................................................... 72
ESP Interface ..........................................................................................................................73
Motor Heating/Current Distortion ........................................................................................ 73
Voltage Stresses................................................................................................................. 75
Torque/Amp ........................................................................................................................ 76
Conclusions.................................................................................................................................77
Glossary ......................................................................................................................................78
References.......................................................................................................................... 78
USE OF THE PC CARD ATA FLASH DISK WITH GCS CONTROLS PRODUCTS .....................80
Introduction .................................................................................................................................80
Inserting the PC Card into the Graphic Display...........................................................................81
Orientation ...............................................................................................................................81
Recognition of PC Card on the Graphic Display .........................................................................81
Accessing PC Card features ...................................................................................................81
Writing Historical Data to the PC Card........................................................................................82
Accessing the “Other PC Card Functions Screen”..................................................................82
Saving the Shutdown History to the PC Card..........................................................................82
Saving Event History to the PC Card.......................................................................................82
Saving Phase B Digital Ampchart to the PC Card...................................................................82
Saving the last Startup Waveforms to the PC Card ................................................................83
Setup and Enable Datalogging....................................................................................................83
Set Up Parameters to be Logged ............................................................................................84
Enable / Disable data logging ..................................................................................................84
Disabling datalogging / removing the PC Card........................................................................85
Using the PC Card in the Windows 95/98 PC.............................................................................85
Working with the PC Card files................................................................................................86
Point ID descriptions for parameters that can be logged in GCS devices:..............................88
Troubleshooting PC Card Problems ...........................................................................................91
Problems using the PC Card with the GCS Display ................................................................91
Problems using the PC Card with a Windows PC...................................................................92
APPENDIX A: CABLE SIZING .......................................................................................................93
APPENDIX B: CABLE VOLTAGE DROP .......................................................................................94
APPENDIX C: VARIABLE TORQUE VSC RATINGS.....................................................................95
APPENDIX D: RECOMMENDED SPARE PARTS.........................................................................96
Forward
This manual contains information regarding the troubleshooting and application of Electrospeed
GCS variable frequency drives (VFD). Although some of the following information is specific to
ESPs (Electrical Submersible Pumps) and the unique characteristics presented by these
applications, much of the information is applicable to all types of electric motors. Any person
responsible for the selection, application and maintenance of variable frequency drives can gain
valuable insight from the information presented herein.
The first section, Electrospeed GCS GENERAL TROUBLESHOOTING, contains trouble shooting
and diagnostic procedures specific to the Electrospeed GCS (Graphic Control System).
Subsequent sections provide insight into several important topics including; ESP BASICS, ESP
Motor Starting, Application of PWM drives to ESPs and Comparisons and Definitions of VFDs.
Also included in this guide is a section describing the use of the Electrospeed's built in datalogging
facility.
The final portion of this guide contains several appendices covering:

Cable Sizing, Cable Voltage Drop, Variable Torque Vsc Ratings and a Recommended Spare
Parts List
Electrospeed GCS TROUBLESHOOTING GUIDE
One of the features of the GCS drive that makes localizing a particular problem easier is that the
hardware is modularized and grouped into logical physical locations. Additionally, the presence of
multiple identical driver boards helps to locate a defective board more rapidly by allowing direct
swapping of boards.
PCB FUNCTIONALITY
The function of all of the boards is straightforward and logical. The Switching Supply PCB
generates all of the internal power used by the drive and it controls the cooling fans. The System
Control PCB is responsible for all of the basic drive functions. In addition, this board is the master
for all communications, both internal and external to the drive. The Graphic Display PCB is only
keypad entry and display. It does not affect the operation of the drive. (the exception is that it does
perform the data logging function) All of the operating parameters are stored in the System
Control PCB and not in the display. The driver boards control each of the power devices, but get
their actual signals from the System Control PCB. The External I/O modules are simply extra
digital and analog inputs.
DIAGNOSTIC LEDS
Most of the Diagnostic LEDs have an obvious function. For instance, all of the power supply LEDs
indicate that there is some nominal power supply voltage present, and the processor activity LEDs
indicate that the processors are at least awake and executing instructions. However, the IOT
LEDs are probably the most misunderstood LEDs in the drive. An IOT LED does not automatically
indicate that the driver board is bad, or that the IGBT is bad or that the System Control PCB is
bad. It could mean any, all, or none of these things, Of course a consistent IOT in one physical
location can indicate a hardware failure. If this is the case, refer to the Fault/Active Alarm Chart for
troubleshooting tips. On the other hand, if more than one IOT LED is coming on at once, it is
important to note the pattern.
Two principals are important. First, since all of the current produced by the drive has to flow out of
one of the output cables and return on another, it makes sense that if there is a problem, it will
show up in at least two phases. Secondly, remember that all of the current that the inverter is
dealing with has to come through the converter. Because of this, when you start to have IOT
problems, the first thing to note is whether the IOTs consistently show up in the same place. If
they do, then the problem is likely in the load or in the inverter hardware. If not, the problem is
more likely in the converter or power system related.
Converter problems
Any disturbance in the converter (whether hardware problems or power system
transients) will cause a change in DC bus voltage. Since the frequency must follow the
voltage, this means that if the DC bus voltage goes up, there will be extra current on the
output as the drive tries to accelerate the motor. Now this can happen at any instant, and
because there is no correlation between which output device is on and the converter
disturbance, any of the IOT circuits can detect a problem. In this situation, check all of the
converter hardware (SCRs, gate leads, Converter Signals Boards, System Control PCB)
and repair as needed. Also, as noted earlier, suspect the power system including all
connections leading to the drive and input transformer.
Inverter/load problems
It would seem obvious that if there is a problem with the load connected between phase A
and phase B on the output of the drive, that an IOT would always appear on these phases
in the drive. Unfortunately, that is not always the case. This is especially true with some
arcing faults. This is because there is an element of time involved as well due to cable
and transformer inductance. Sometimes the actual fault may be delayed in time. Because
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of this, the fault may appear to move from phase to phase. However, if you note the
pattern, it will normally tend to show up in a predominant pattern. (A-B, A-B, A-B, A-C, A-
B, etc) In these cases it can be helpful to rotate the output cables to the drive (A moves to
B, B moves to C, and C moves to A) to see if the problem follows the cables. Remember
that even if the fault is securely between A and B phases, it might show up on either the
positive or the negative cycle. This means that any pair of four LEDs could turn on to
indicate only one problem.
GENERAL TROUBLESHOOTING PROCEDURE

1. Always start with the diagnostic LEDs on the boards. With power applied to the drive there
should be two LEDs visible on the power supply board, one on each of the Inverter Signals PCBs,
two steady LEDs on the System Control PCB, and two blinking. In addition, the display should
have at least one LED on (either steady or blinking) and the main menu screen should be
displayed. If there are I/O modules present, there should be one steady LED visible from the
outside, and a blinking LED visible through the opening. The proper operation of these LEDs
indicates nominal operation of all of the local power supplies, and normal processor activity.
2. Once this level of operation has been achieved, the next step is to perform a Functionality Test.
To do this, disable the converter(s) by moving the converter enable jumpers on the System
Control PCB. Then press the start button and verify normal status display functions, and proper
inverter signal LED activity. If the drive won’t start, view the status screen and take the appropriate
actions concerning any Active Alarms that show up.
3. After stopping the drive, re-enable the converter(s) and perform a no load test. Verify that the
drive will regulate the output voltage correctly (half voltage at half frequency etc) and that it will
reach full voltage without generating a fault. It is important that this test be performed with nothing
tied to the output terminals. Even an unloaded transformer can add to the confusion.
4. If the drive will operate properly no load, the next test to perform is the shorted output test. The
purpose of the shorted output test is to verify that both the inverter and converter sections will
produce rated current. While operating the drive in shorted output, verify that all three output
currents and input currents are approximately balanced and stable. In addition, verify that there is
no significant DC component to the currents. (this is evident by the fact that a clamp on ammeter
will appear to “stick” in the closed position) Any excessive DC would indicate a device not turning
on. Of course, IOTs during this test will normally indicate hardware problems. (see the section on
Diagnostic LEDs above, and the portion of the Fault/Active Alarm Chart dealing with IOTs)
FUNCTIONALITY TEST
1. Power on. Verify that Graphic Display initializes properly and that processor activity LEDs are
normal. Also, verify all power supply LEDs.
2. Disable converter(s) by moving enable jumpers.
3. Setup: Underload-no, Overload & ILimit-Max. Low Speed Trip-No, Inverter Mode-6-Step
4. Press “Start”. Status screen should show “Running xxHz” (where xx should be (Low Speed
Clamp)- 5hz), Run LED should be on, fans should start, and inverter signal LEDs should be
blinking at the operating frequency. (converter LEDs will not be on with converter(s) disabled)
5. Verify output voltage and current display zero
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6. This is a good time to verify that all internal temperature sensors read approximately ambient
temperature.
NO LOAD TEST
1. Disconnect all cables from output of drive. (A test on an unloaded transformer might confuse
the results of the test if the transformer has problems)
2. Enable converters by moving the enable jumpers.
3. Setup: Underload-no, Overload & ILimit-Max, Volts@60hz-480, Vclamp-500, Vboost-0, Set

Frequency 30hz. Low Speed Trip- No, Inverter Mode-6-Step.
4. Press “Start”. Status screen and Run LED should show status as running, all inverter and
converter signal LEDs should be on. Verify that frequency and output voltage ramp smoothly
from minimum to 30hz and 240V. (a sudden jump of voltage and frequency after start
accompanied by a “thump” from the drive could indicate converter problems) Frequency and
voltage should be relatively steady. NOTE: A small amount of “hunting” or oscillation of the
voltage and frequency can occur and is not a problem. It should be a few tenths of a hz to a
hertz max.
5. Adjust Set Frequency to 60hz. Frequency and voltage should ramp to 60hz and 480 volts at
the rate set by the Accel Time parameter. (NOTE: this parameter sets the time from 0-60hz)
6. Press “Stop” and verify that the drive slowly ramps to a stop and shuts off. Since the drive is
completely unloaded, it will take some time for this to happen and is not affected by the Decel
time parameter. (unless Decel is set to an extremely long value)
SHORTED OUTPUT TEST

1. Connect shorting cables to output of drive or secondary of step up transformer.
2. Make sure converter(s) are enabled.
3. Setup: Setup: Underload-no, Overload & ILimit-Max, ILimit Sync-Max, Volts@60hz-480,

Vclamp-500, Vboost-0, Set Frequency 30hz. Low Speed Trip- No, Inverter Mode-6-Step, Sync
Frequency 15hz, Sync Delay-6 sec.
4. Press “Start”. Drive should start and output current should reach ILimit Sync value for the
length of time set by Sync Delay and then fall to the ILimit value. Output currents should be
balanced, stable, and free of DC.
5. If drive trips in IOT during Sync Delay, reduce ILimit Sync by 10%. Under some field
conditions, peak current may be slightly reduced.
6. The drive can either be allowed to run continuously in this mode, or can be cycled by setting
the Underload Setpoint to slightly higher than the ILimit value and setting the restarts to
“Infinite”.
IGBT TESTING
With an ohmmeter, about the most that you can be sure of in testing power devices is that they
are not dead shorted. Be careful about pronouncing devices “bad” because you measure 6
megaohms instead of 10 megaohms. The only sure test in the field is “Does it work in the drive?"
When testing an IGBT, first make all terminals to terminal measurements using the “diode” scale
on the meter. Most of these should read open circuit. The exception is the measurement from
collector to emitter with the positive lead on the emitter. This reading should be the forward drop
of the internal parallel diode or about .3 - .4v. Then change to the ohms scale and check gate to
Page 9
emitter. You will see the effect of the gate capacitance if you look quickly when connecting the
leads. The display should show a rapid change from low to high resistance as it charges the
internal gate capacitance. If you then reverse the leads, you should see the same thing.
General Troubleshooting Flow Charts

The following section provides several troubleshooting flow charts that will assist the user in
diagnosing problems with a GCS drive. The illustration below depicts the symbols used in the
charts and lists their associated functions.
START
Start or End of Flow Chart
Section
Chart or test flow direction

indicator
Check Power
Supply LEDs
On ISBs
Procedure or Function
YES NO
OK? Decision
Check ISBs
& IGBTs or Off Page connector or pointer
GoTo Fault
Chart to another Flow Chart section
FIGURE 1: FLOW CHART SYMBOL DEFINITIONS
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START
YES NO
Display? No Display
NO Active YES Fault / Active

Alarms? Alarm Chart
YES Drive will NO Won't Start

Start?
NO Blows YES Bad

Fuses? Converter
Fault / Active
NO YES
Fault? Alarm Chart or
Bad Inverter
YES Normal NO Setup

Operation? Problems
END
FIGURE 2: DIAGNOSTIC OVERVIEW FLOW CHART
Page 11
NO DISPLAY
24V LED
Replace YES On System NO
or Cable Control
PCB On?
Replace 24V LED

Control PCB YES On Power NO
Power Supply
Wires PCB On?
150V LED Check

Replace YES NO
On Power Fuses Or
Power
Supply 120V
Supply
On? Transformer
FIGURE 3: DISPLAY PROBLEM FLOW CHART
Page 12
Bad
Converter
Check All
YES Fuses NO
SCRs for
OK?
Shorts
NO SCRs YES
OK?
Press
Replace
Replace Start
Bad SCRs
Bad Fuses
and Fuses
Replace
SysCon
Disable NO LEDs YES PCB
Converter(s) On?
Verify proper
Replace Cnv Bus Control
&
Sig. PCB Balanced
Power On Input Current
NO LEDs YES
OK?
Measure
Bus Volts
YES OK? NO
Replace Cnv
Sig. PCB
YES Bus NO
Volts=0?
Enable Recheck
Converter(s) All SCRs
END
FIGURE 4: CONVERTER PROBLEM FLOW CHART
Page 13
Won't Start
Check Activity
LEDs on SysCon
PCB
YES NO
Normal?
Replace SysCon
Replace Display
PCB
END
FIGURE 5: STARTING PROBLEMS FLOW CHART
Page 14
Bad Inverter
Check Power
Supply LEDs
On ISBs
YES NO YES Controls NO

OK? Bad
Bus
Converter
Volts?
Replace Bad
ISBs
Perform Shorted
Output Test
Perform
Functionality
Test NO YES
IOTs?
Signal
YES NO YES Balanced NO NO YES
LEDs Random?
Currents?
OK?
Replace Bad
ISBs
Check ISBs Decrease
& IGBTs ILimit Sync
Perform No
Load Test
END
Check ISBs
Signal
YES NO & IGBTs or
LEDs
GoTo Fault
OK?
Chart
FIGURE 6: INVERTER PROBLEMS FLOW CHART
Page 15
Fault/Active Alarm Chart
An Active Alarm is any condition that can cause the drive to stop other than a manual stop.
(pressing the Stop button) Most alarm conditions can be associated with a timer to delay shut
down for some period of time. When the unit stops, the Active Alarm is considered a Shut Down,
and is stored as such in the Shut Down History. Although the names “Fault” and “Alarm” imply
problems, an Active Alarm may not necessarily mean that something is wrong. Some can be
caused by a normal external process condition that should cause the drive to stop for some period
of time. Others are actual problems detected by the drive itself. While the conditions that cause
any Active Alarm are present, the alarm will be annunciated on the status screen in the area
labeled “Active Alarms”. After a shut down, the area of the status screen marked “Lst Shtdn” will
indicate which Active Alarm caused the last shut down of the drive.
Most Active Alarms have an associated Bypass Delay timer which determines how long an Active
Alarm will be ignored after a Start is initiated, and a Shut Down Delay timer which determines how
long the Active Alarm must be valid before a Shut Down occurs. In addition, most can be
disarmed, or set to cause the drive to “Lockout” or stop permanently as a result of the alarm. A
few of the Alarms, such as Heat Sink temperatures, can only be monitored but not edited as they
affect the operation of the drive.
The Faults/Active Alarms can be loosely grouped into six categories. These are:
Operational Thresholds
On board I/O
External I/O
Software Faults
Hardware Faults
Other
Each group will be discussed in detail in the following sections.
OPERATIONAL THRESHOLDS
Operational Thresholds refer to any number of measured or calculated real-time parameters.
Many of these can be set up to cause a shutdown of the drive if the value of the parameter
crosses a user-defined threshold. Some, such as the input voltage, are monitored because they
can affect the operation of the drive if outside of nominal values. Others, such as output current,
are used to monitor and protect the load.
Fault/Active Alarm: Input Over Voltage

Typical Display: OvrVlt
Description: The input voltage to the drive is higher than the Over Voltage Setpoint
Corrective Action: Check the input power or adjust the Over Voltage Setpoint.
Fault/Active Alarm: Input Under Voltage

Typical Display: UndVlt
Description: The input voltage to the drive is lower than the Under Voltage Setpoint.
Corrective Action: Check the input power or adjust the Under Voltage Setpoint. Also, since the
input voltage is monitored through the SCR gate leads, loose gate leads or a damaged CSB could
cause this symptom.
Fault/Active Alarm: Input Voltage Unbalance

Typical Display: Vunbal
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Description: The relative magnitudes (in percent) of the three input voltages has exceeded the
value of the Voltage Unbalance Setpoint
Corrective Action: Check the input power or adjust the Voltage Unbalance Setpoint. As with the
Input Under Voltage, the converter hardware can affect these values.
Fault/Active Alarm: Low Speed Trip

Typical Display: LST Sd Alm
Description: Drive output frequency has fallen below the Low Speed Clamp Setpoint for longer
than the Shutdown Delay time.
Corrective Action: Since the Frequency Setpoint can not be set below the Low Speed Clamp,
and the only thing that can override this is ILimit, this fault will normally indicate that the load on
the drive has increased dramatically. As the load increases, the ILimit function will cause the drive
to slow down in an attempt to control output current. If this affect is severe enough, the output
frequency will fall below the setpoint, generating a Low Speed Trip. Check the motor and load for
problems.
Fault/ Active Alarm: Overload

Typical Display: Ovld
Description: The output current of the drive has exceeded the Overload Setpoint for longer than
the Shutdown Delay time.
Corrective Action: Either decrease the output current by changing the operating frequency, or
increase the Overload Setpoint. If the problem is a transient condition, lengthening the Shutdown
Delay can help.
Fault/ Active Alarm: Underload

Typical Display: Undld
Description: The output current of the drive has fallen below the Underload Setpoint for longer
than the Shutdown Delay time.
Corrective Action: Either increase the output current by changing the operating frequency, or
decrease the Underload Setpoint. If the problem is a transient condition, lengthening the
Shutdown Delay can help.
ON BOARD I/O
The System Control PCB has built in digital and analog I/O that can be used to start, stop, and
control the drive frequency. Each digital input can be programmed to trigger a stop in either state
(active high or active low). Each analog input has an associated upper and lower threshold that
can be armed to trigger a stop.
Fault/Active Alarm: Analog Input High Threshold

Typical Display: AIx Hi (where x will designate the input and be 1 or 2)
Description: The designated analog input has exceeded the value of the High Threshold
Setpoint.
Corrective Action: Determine the cause of the excessive analog signal or adjust High Threshold
parameters. All hardware associated with this input is on the System Control PCB so failures of
this board can cause erroneous readings.
Fault/Active Alarm: Analog Input Low Threshold

Typical Display: Aix Lo (where x will designate the input and be 1 or 2)
Description: The designated analog input has fallen below the value of the Low Threshold
Setpoint.
Page 17
Fault/Active Alarm: Digital Input
Typical Display: Dix (where x will designate the input and be 1, 2 or 3)
Description: The designated digital input state has changed to the value of the Active Alarm
State Setpoint.
Corrective Action: Check the digital input or change the associated set up parameters to correct
the alarm All hardware associated with this input is on the System Control PCB so failures of this
board can cause erroneous readings.
EXTERNAL I/O
Each External I/O Module has digital and analog inputs that are used in a similar manner to the
Onboard I/o. The primary difference is in the way that the Active Alarms are displayed.
Fault/Active Alarm: External Analog Input High Threshold

Typical Display: EXm AIx Hi (where x will designate the input and be 1 or 2, and m will designate
which External I/O Module associated with the input [EX1 to EX3])
Description: The designated analog input has exceeded the value of the High Threshold
Setpoint.
Fault/Active Alarm: External Analog Input Low Threshold

Typical Display: EXm Aix Lo (where x will designate the input and be 1 or 2, and m will designate
Description: The designated analog input has fallen below the value of the Low Threshold
Setpoint.
Fault/Active Alarm: External Digital Input

Typical Display: EXm Dix (where x will designate the input and be 1, 2 or 3, and m will designate
Description: The designated digital input state has changed to the value of the Active Alarm
State Setpoint.
Corrective Action: Check the digital input or change the associated set up parameters to correct
the alarm All hardware associated with this input is on the System Control PCB so failures of this
board can cause erroneous readings.
SOFTWARE FAULTS
The GCS drive can contain as many as 6 microprocessors, which are all in constant
communication and all constantly monitoring and verifying normal operation. Certain internal
errors such as a timing errors or serial communications errors will cause a shut down and an
annunciated Fault/Alarm. Most of these faults will cause an instantaneous shut down and have no
associated set up parameters.
Fault/Active Alarm: CITIBus Communications Error

Typical Display: xxx Com Error (where xxx will be PCM, Display, or Ex I/O)
Description: One of the internal processors has ceased communicating on the internal serial
bus.
Corrective Action: The xxx will indicate which processor has ceased communicating. Since there
are no set up parameters that can affect this, the only action to take is to identify the errant
Page 18
hardware and replace it with a new component. (i.e. new display, External I/O module, System
Control PCB etc)
Fault/Active Alarm: PCM Converter Fault

Typical Display: Cnvtr Flt
Description: The internal watchdog timer for the PCM has determined that the converter software
module has quit operating.
Corrective Action: This “fatal” fault will always cause a shutdown as it implies that the converter
has quit functioning. Although the shutdown routine will attempt a restart of the software module, a
sure way to recover from this fault is to cycle power to the unit. This re-initializes all of the software
and restores normal operation.
Fault/Active Alarm: PCM Inverter Fault

Typical Display: Invtr Flt
Description: The internal watchdog timer for the PCM has determined that the inverter software
module has quit operating.
Corrective Action: Similar to the Converter Fault. If the drive does not recover automatically,
cycle power.
Fault/Active Alarm: PCM System Error

Typical Display: PCM Sys Err
Description: This is a catchall fault related to internal errors in the 68332. Included are things like
divide by zero and data bus failures. This fault implies some type of improper processor operation.
Corrective Action: This fault should only be seen rarely. If it occurs repeatedly the only thing to
do is replace the System Control PCB
Fault/Active Alarm: Serial Communications Error

Typical Display: Serial Com
Description: There has been a unrecoverable error in the RS-232 communications.
Corrective Action: This problem can be caused by either improper setup, or actual hardware
problems. First check the SCADA settings on the “SCADA, Security, and Systems” menu. Make
sure they are the same as those on the host computer trying to communicate. If that does not
correct the problem, try a slower baud rate to see if throughput is the problem. For hardware
problems, first try connecting directly into the System Control PCB on J22, and finally, try a new
System Control PCB.
HARDWARE FAULTS
These classes of faults/alarms generally refer to some dedicated internal piece of hardware that
has detected improper operation, or some measured value that is out of limits. In addition, these
faults are focused on the proper operation and protection of the actual drive hardware rather than
the load or motor that is connected to the drive. With the exception of the Auxiliary Temperature
Alarm, these alarms do not have customer settable parameters.
Fault/Active Alarm: Ambient Temperature Alarm

Typical Display: Amb tmp Alm
Description: The internal ambient temperature has exceeded 85 degrees C.
Corrective Action: This temperature sensor is located on the System Control PCB, therefore it
measures the internal drive temperature. First, check the small fan(s) blowing air through the air-
to-air heat exchanger. If they are inoperative, check the power supply board fuses first and then
check the fans themselves. These fans are switched on and off with a relay on the power supply
board, so a failure of that board could also cause this symptom. Finally, the System Control PCB
itself could give a false reading if the board is damaged.
Page 19
Fault/Active Alarm: Auxiliary Temperature Alarm
Typical Display: Aux tmp Alm
Description: The Auxiliary temperature input has exceeded its set threshold.
Corrective Action: This input is for customer use. Its operating parameters are completely
adjustable by the customer. Because of this, this is not a fault as much as it is an annunciation.
An occurrence of this alarm can be corrected by either changing the condition of the monitored
equipment, or changing the setup parameters for this input
Fault/Active Alarm: Inductor Temperature Alarm

Typical Display: Ind tmp Alm
Description: The Temperature of the link reactor(s) (inductor) has exceeded the allowable
threshold.
Corrective Action: High inductor temperature can be cause by either improper cooling, or
improper drive operation. First, verify that the cooling fans are operational, and that the base of
the drive is not blocked by foreign material. Also, insure that the ambient temperature is not above
that rated for the drive under the present operating conditions. If these conditions are all OK, then
check for possible improper operation. The temperature of the link reactors is (in some operating
modes) directly proportional to difference between input and output voltage of the drive.
Therefore, it is desirable to operate the drive at the highest possible output voltage. This is
especially true if the drive is heavily loaded. If necessary, readjust the Volts@60HZ and operating
frequency setpoints.
Fault/Active Alarm: Heat sink Over Temperature Alarm

Typical Display: HSx Alm (where x designates an individual heat sink HS1-HS4)
Description: The temperature of the designated heat sink has exceeded the preset value.
Corrective Action: Depending on the drive size, there will be from one to four heat sink
temperature sensors. Each sensor approximately monitors the operation of one external cooling
fan due to the physical location of the sensors. If only one sensor indicates an over temperature,
first check the cooling fan associated with that sensor. Also, as with other cooling related
problems, insure that the air path is not obstructed. If the cooling fans appear to be operating
correctly, check the temperature sensor and wiring by temporarily connecting it to a different input.
If necessary, replace the System Control PCB.
Fault/Active Alarm: Inverter IOT (Instantaneous Overcurrent Trip)

Typical Display: Phase X Pos (Neg) IOT (X designates which phase A, B, or C)
Description: An IOT condition has been detected in the designated phase. The Pos or Neg
indicates whether it is the device connected to the positive or negative bus bar.
Corrective Action: The IOT circuit monitors each power semiconductor in the inverter and
watches for improper operation. It is important to understand the actual function of the IOT circuit
to make troubleshooting simpler. Basically, the assumption is that for normal operation, when the
power device is supposed to be on, it will look like a switch, or have a very low voltage drop. If, on
the other hand the device is asked to handle more current than it is capable of, the voltage drop
across it will rise dramatically. The IOT circuit, therefore, monitors the voltage across each power
device. When that voltage exceeds a predetermined threshold, (approximately 8V) the IOT circuit
turns the device off within 1us and sends an inhibit signal to all other power device gate signals as
well as a stop command to the microprocessor. Because of this, within about 10-15us of detecting
a problem on one power device, the entire drive will be shut down. NOTE: the IOT circuit does not
tell you that there has been an over current (although that will be the most common reason for an
IOT) or that the device is bad. It simply tells you that there has been too much voltage drop across
the device during operation. That could be caused by improper gate drive as well. If you determine
that you have a consistent IOT in one location, the first, and easiest thing to do is to change the
Inverter Signals Board. If this does not solve the problem, next check the IGBT and gate
connections. Finally, replace the IGBT if all else fails.
Fault/Active Alarm: PCM Zero Crossing Fault

Typical Display: PCM 0-xing
Page 20
Description: The 68332 has detected a problem with the timing of the zero crossing signal.
Corrective Action: This circuit monitors the period of the A-B voltage to the drive and captures
the time of each zero crossing of the waveform. During normal operation, the period of each cycle
should be nearly constant, and each zero crossing should be approximately one period later than
the last. If you get this fault only once, or infrequently, it could be indications of power system
problems. If a check of all of the connections to the drive and step down transformer reveal
nothing, then a power system transient analyzer might be necessary to identify the problem. For a
frequent or continuous problem, the first thing to check is SCR gate leads. This circuit gets its
connection to the power system through the SCR cathode leads. It then passes through the
Converter Signals Board and on to the System Control PCB. A failure of anyone of these
hardware items can cause a false zero crossing error.
Fault/Active Alarm: System Controller Zero Crossing Fault

Typical Display: 0-xing
Description: The 68HC16 has detected a problem with the zero crossing signal.
Corrective Action: Since the 68HC16 needs a timing signal to reference A/D conversions to, the
C-A voltage is used as a reference. This signal follows the same path as the 68332 signal, so any
of the same pieces of hardware are suspect.
OTHER FAULTS / ALARMS

There are a number of other messages that can appear on the status screen that are not faults or
alarms, as such, (although they do show up in the Active Alarm area of the Status Screen) but
rather are indications of some particular status that might affect the operation of the drive.
Fault/Active Alarm: Central Shutdown

Typical Display: Cent Shtdn
Description: A remote host has requested a lockout of this drive. The drive cannot be restarted
until the host has released this condition.
Corrective Action: None required
Fault/Active Alarm: Drive Stopped Manually

Typical Display: Man Kpad Lk
Description: The drive has been stopped by pressing the stop key. This inhibits all automatic
restarts. The drive sill stay stopped until it receives a start command from the keypad, a digital
input, or a remote host.
Fault/Active Alarm: External HOA in Off

Typical Display: Ext HOA in Off
Description: This indicates that the drive has been told (on the SCADA, Security, and System
menu) that there is an external HOA switch connected, and the drive has detected the switch in
the “Off” or “Stop” position.
Fault/Active Alarm: First Start

Typical Display: First Start
Description: This is simply and indication that the System Control software has been updated
since the last start.
Corrective Action: Although no action is required, this is a reminder to check all of the setup
parameters to insure that they have not been changed during the reprogramming.
Fault/Active Alarm: Lockout

Typical Display: Lockout
Page 21
Description: This is an indication that some alarm has been programmed to cause a permanent
stop if the alarm condition occurs. The drive will not automatically restart.
Corrective Action: To restart the drive it will be necessary to clear whatever condition caused the
alarm, then press the “Stop” button. This will clear the lockout and allow a restart. Because this
will cause a Manual Keypad Lockout, the drive will not automatically restart even if restarts are
enabled. The first start will have to be done manually.
Fault/Active Alarm: Max Starts

Typical Display: Max Starts
Description: When auto restarts are enabled, the “Max Allowed Starts” parameter determines
how many times the drive will be allowed to restart after a fault. When this number of starts has
been reached, the drive will stop with a Max Starts lockout.
Corrective Action: To reset the starts counter and start the process over, it is only necessary to
press the “Stop” button. As with any lockout, it will be necessary to make the first start manually
with the “Start” button, a digital input, or a remote host.
Fault/Active Alarm: Motor State Sync Error

Typical Display: Motor State Sync
Description: The System Controller has determined that the state of the PCM is different than
what has been commanded (i.e. running after a stop command)
Corrective Action: Typically, none is required. This should only be a transient condition as the
System Controller and the PCM communicate with each other. If the condition persists, cycle
power to the drive to reset the software.
Fault/Active Alarm: PCM Bus Volts

Typical Display: PCM Bus Vlts
Description: This is an indication that there is voltage present on the DC bus. During a normal
stop, the bus voltage goes to zero. Certain faults and the e-stop mode can temporarily leave
voltage on the bus. In the 6-step and Hybrid inverter modes, voltage on the bus will inhibit starting.
Therefore, this status indication informs the operator when a start is not possible.
Corrective Action: Normally it is only necessary to wait a minute or two for the bus voltage to
bleed off to zero. However, some types of cathodic protection and certain ground faults can
induce enough voltage on the DC bus to inhibit starts. If this status persists, first disconnect the
output terminals to see if the problem goes away. If so, check the load and associated wiring. If it
does not, turn power off to the drive and check the power circuit for any leakage to ground. Debris
or water in the drive can cause a high resistance path to ground that can cause this symptom. In
addition, problems on the power system can cause this as well. Check the incoming power for
correct and balanced voltages.
Fault/Active Alarm: Real Time Clock Invalid

Typical Display: RTClock Invld
Description: The real time clock has an invalid time.
Corrective Action: Usually this status is seen after a software reload since all of the internal data
is written over to defaults. All that is necessary is to go the SCADA, Security, & System menu and
reset the clock.
Page 22
Typical Waveforms
T
1>
T TT
TT
1>
2>
2>
1) C h 1: 2 V 2 ms 1) C h 1: 2 V 2 ms
2) C h 2: 500 mV 2 ms 2) C h 2: 2 V 2 ms
TP6 & TP7 TP19 & TP20 TP9 & TP7 TP10 & TP20
1> T
1>
TT
2>
1) C h 1: 100 mV 10 ms
2) C h 2: 100 mV 10 ms 1) C h 1: 2 V 10 ms
TP1,2, & 3 PWM/HYBRID TP11 ESP
1> T
1>
TT
2>
1) C h 1: 100 mV 10 ms
2) C h 2: 100 mV 10 ms 1) C h 1: 2 V 10 ms
Tp1,2, & 3 ESP TP11 HYBRID
Page 23
T
T
1> 1>
1) C h 1: 2 V 10 ms 1) C h 1: 50 V 10 ms
TP11 PWM OUTPUT PWM
T T
1> 1>
1) C h 1: 50 V 10 ms 1) C h 1: 50 V 10 ms
OUTPUT HYBRID OUTPUT ESP
Page 24
Electric Submersible Pump Applications
INTRODUCTION
This guide provides specific information
pertaining to the application of the Electrospeed
GCS controller to the control of electrical
submersible pumping systems (ESPs).
Information is also provided to guide the user
through the setup for several control modes of
operation and troubleshooting. However,
unusual applications may require a more in-
depth understanding of the Electrospeed GCS
than can be provided within this guide. In such
cases, Centrilift offers classroom training
courses that thoroughly cover the operation,
maintenance and troubleshooting of the
Electrospeed GCS Variable Speed Controller
(VSC). Whenever possible, the user should take
advantage of Centrilift’s Autograph Pump Sizing
program to calculate and/or verify the selection
of the correct ESP system and parameter setup.
ESP BASICS
The electrical submersible pumping system
(ESP) is considered an effective and economical
means of lifting large volumes of fluids from
great depths under a variety of well conditions.
However, the output of the electrical
submersible pump is inherently inflexible when
run at a fixed speed. In this situation, the unit is
limited to a fixed range of production rates and a
fixed head output per pump stage. To minimize
the restrictions of a fixed speed system, a
variable frequency controller (VSC) can be
successfully used to drive the pump motor. The
basic operation of the VSC is to convert the
incoming 3-phase AC power, typically at 480
volts, to a single DC power supply. Then, using
power semi-conductors, the controller
sequentially inverts this DC supply to regenerate
three AC output phases of pseudo-sine wave
power at controllable voltages and frequencies.
Since the ESP motor is a synchronous induction
motor, varying the frequency of the applied
power changes the motor’s (and the directly
coupled pump’s) rotational speed. By varying the
pump speed, the flow rate, the pump head or
both can be adjusted with no modification of the
downhole unit.
VARIABLE SPEED CONTROLLER

(VSC) ADVANTAGES
Pumping flexibility is usually the main reason for
applying a VSC to an ESP installation, but
Page 25
several other advantages are realized as well. Of greatest interest are those that help to extend
downhole equipment lifespan; soft-start, automatic speed control, line transient suppression and
elimination of surface choke valves.
In the common operating range of frequencies between 30 and 90 Hertz, it is convenient to
consider pump speed as directly proportional to power supply frequency since the errors
introduced are small compared to other system inaccuracies and effects. Given this principle, one
can assume that the speed of the pump and hence its hydraulic output characteristics can be
controlled by simply varying the power supply frequency. This flexibility will not damage the pump
or motor provided that the motor voltage and loading limits are properly observed. As well as the
hydraulic flexibility provided, the VSC also isolates the load from power supply switching and
lightning transients; balances output voltage to reduce motor heating; compensates for brown-
outs (voltage sags), overcomes frequency instability from generator power supplies and minimizes
motor starting stresses. Additionally, depending on the application, the VSC can improve overall
system efficiency, reduce required generator and downhole unit size, obviate the need for a choke
valve and provide intelligent, programmable control functions to maximize production and
minimize equipment stress. Since not all of these benefits can be obtained simultaneously, the
user or designer must select the combination relevant to each application.
VSC EFFECTS ON CENTRIFUGAL PUMPS

The performance of a centrifugal pump is characterized by a curve on a head versus production
rate graph at a specified operating speed. If the speed changes, a new performance curve is
generated; larger if the speed increases, smaller if the speed decreases. For any specific pump,
50 Hz and 60Hz performance curves can be generated and then both plotted on the same graph
to illustrate pump characteristics for the two frequencies.
When the rotational speed of a centrifugal pump is changed, the performance characteristics of
the load change as well. Fortunately, these performance changes are predictable and are
governed by the Centrifugal Pump Affinity Laws. These laws were derived from dimensional
analysis of rotating machines and show that for dynamically similar or relatively common
conditions, certain dimension-less parameters remained constant. These laws, which have proved
to be experimentally correct, state that when the speed is changed, capacity is directly
proportional to the new speed, head is proportional to the square of the speed and horsepower is
proportional to the cube of the speed. Using these laws, curves can be plotted that predict pump
performance at any speed. Remember that these Affinity Laws do not predict actual pump
performance response to speed changes in an actual well, they simply relate common points on
graphs of pump performance curves of different speeds. Therefore, both pump and well
characteristics must be considered together
to analyze or predict the overall system
New Hertz
performance.
60 Hertz Rate
New Rate =
60 Hertz
* Since the head versus rate curve of a pump
is modified by changing the speed, any point
on the standard speed curve can be used to
2 calculate equivalent points on the new speed
New Hertz
New Head =
* 60 Hertz Head curve that have nearly identical hydraulic
60 Hertz conditions, fluid flow pattern, thrust balance
and pumping efficiency. This technique can
3 be used to develop a performance curve for
New Brake = New Hertz 60 Hertz BHP any frequency within useful limits and is
Horsepower 60 Hertz
* based on the derived conversion equations
shown at left.
Using these equations, a set of graphs can be developed for speed ranges of 30 through 90
Hertz, producing a family of curves as seen in the illustration below. The shaded portion of the
performance graph for each pump indicates a rate of production that is within acceptable limits of
loading. Ensure that the ESP system is producing fluid at a rate that falls within those limits to
maximize pump lifespan.
Page 26
VSC EFFECTS ON MOTOR
A motor of any particular frame size operating at a fixed frequency has a specified maximum
output torque, if the required voltage is supplied to its terminals. This same torque can be
achieved at other speeds by varying the voltage in proportion to the frequency. In this way, the
magnetizing current and flux density will remain constant, and so the available torque will also be
constant, at a nominal slip rpm. Consequently, the power output rating will be directly proportional
to speed since the power rating is
obtained by multiplying rated torque
times speed. It is important to realize that
Starting Torque Vs Frequency & re-rating motors in this way increases the
Current
horsepower available to fit any particular
240 size of casing.
Ft*
190
lb
s
450A T STARTING TORQUE
300A T
140 One of the benefits of applying a VSC to
90 an ESP is the ability to “soft start" the
0 20000 40000 60000 80000 motor at a lower frequency. As shown in
I2/F the graph at left, with a constant value for
current, the motor torque increases
linearly with frequency until the output
transformer saturates. After that point,
any additional current circulates in the
Page 27
transformer primary only and does not produce torque in the motor. On an ESP application, the
added impedance of the output transformer and cable become significant when compared to the
locked rotor impedance. Therefore, ensure that the drive is configured to provide sufficient current
and hence torque to start the motor.
CABLE VOLTAGE DROP

As shown on the graph in the appendix section of this guide, as motor current increases, the
amount of voltage drop due to cable losses also increases. Since all induction motors exhibit a
best efficiency point at a specified nameplate terminal voltage, it is important, when configuring a
VSD system, to properly compensate for these losses. Use the graph to calculate the amount of
voltage drop present in the system and then adjust the output transformer taps and VSD volts per
hertz to produce the nameplate voltage on the motor’s terminals at the required operational
frequency.
VBOOST SYNC AT START

In some situations, such as hard starting motors, it can be necessary to provide a higher voltage
at the start frequency than is dictated by the volts per hertz setting. This voltage boost is used to
drive more current to the motor and hence increase the starting torque available. The
Electrospeed GCS drive provides a VBOOST SYNC parameter that controls the amount of
additional voltage produced during the SYNC DELAY period. Take care when adding VBOOST so
as to not cause the output transformer to saturate, since that condition produces additional current
in the transformer primary not to the motor. In general, the user should first try to start the motor
without any VBOOST.
MATCHING MOTOR, PUMP & VSC SIZES

During normal equipment sizing calculations, a pump is selected to deliver a certain hydraulic
output at a particular speed. A motor frame is then chosen whose capacity matches the pump
requirements when operating at the chosen speed. Above that speed, the motor will be
overloaded and conversely, underloaded when operating below that speed due to the cubic
relationship between horsepower and
Horsepower frequency. This is reflected by the current
200 drawn by the motor since nameplate amps will
be drawn only at the rated speed.
150 Motor HP Capability
The graph at left illustrates the linear
Match Point
characteristic of the motor HP capability
100
@ Maximum Speed intersecting the cubic pump HP characteristic
at the designed maximum frequency
Pump BHP
50
In calculating the capacity required and
selecting a VSC, the surface KVA
30 60 90 requirements are calculated in the normal
Frequency way, including the resistive loss of the power
Motor HP vs Pump BHP cable, but the calculation is performed at the
maximum operating frequency. Since this
maximum frequency represents the peak power requirement of the system, a VSC model should
be selected whose KVA capacity matches or exceeds this peak value.
The above principles illustrate the theoretical considerations, but in practice, several additional
details must also be considered when designing or applying a full VSC system.
PUMP SHAFT HORSEPOWER LIMIT

Since the HP capacity of the shaft is proportional to speed and the HP required by the pump is a
cubic function of speed; for any pump there will be a speed above which the shaft’s rating will be
exceeded. Manufacturers normally state the shaft limit as a HP capability at 60 Hertz. This rating
Page 28
should then be checked at maximum operating frequency to ensure sufficient pump shaft
capacity.
PUMP HOUSING LIMIT

Housing strength is normally stated as the limiting or maximum differential pressure for the
housing threads at the discharge of the pump. If operated above this limit, the threads could burst.
When operating at high frequencies, the shut-in or no-flow pressure generated by the pump could
exceed this limit. Therefore, it is prudent to take precautions to avoid this situation and since the
normal underload detection is too slow, a properly sized, surface over-pressure shutdown switch
should be utilized.
VIBRATION AND WEAR

Higher than normal speed operation increases the radial vibration due to unbalance in the rotating
assembly. This is not normally a significant factor in determining pump life span as is
demonstrated by the fact that manufacturers only take the first step of dynamically balancing
impellers when building large diameter pumps. However, if abrasives are present in the pumped
fluid, equipment wear due to abrasive grinding and erosion at high speeds can be serious. In
these situations, a VSC can be used to operate the pump at lower speeds to reduce wear. This
usually means that to maintain a required flow rate, a larger sized pump and motor will required.
Basic VSC Configuration

This section will guide the user through the steps required for initial configuration and start-up of
the ESP system. If the VSC is being installed and commissioned for the first time, all of the
following steps should be completed in order. If the unit is being re-configured and the reader is
experienced with VSC applications, only the pertinent steps need to be followed.
Before any configuration is performed, the user should review the installation of the equipment
and ensure that all safety guidelines are understood
and adhered to. For further information, read the
section entitled SAFETY & INSTALLATION in the
operator’s manual supplied with this Electrospeed
GCS controller.
The first step in configuring an Electrospeed GCS

controller requires the calculation of some important
data. The start-up worksheet on the next page
provides the user with a template that can be used to
calculate and record this information.
Page 29
START-UP WORK SHEET
Customer : Date:
Well Number: Drive S/N:
1: Motor Voltage: Amps: Cable Size: Length:
2: Desired Operating Frequency Minimum: Maximum:
3: Maximum Volts Available (Input)
4: Secondary Voltage @ Maximum Hertz: =
Motor Voltage X Max. Hz. + Cable Drop =

60 Hz.
5: Secondary Voltage Taps Selected:
6: Transformer Ratio: = Secondary Voltage Taps Selected =

Transformer Primary (480)
7: Secondary Voltage @ 60 Hertz:=

(from line 4) Secondary Voltage @ Max. Hertz X 60 =
Maximum Hertz
8: Drive Volts @ 60 Hertz: =
(from line 7) Secondary Voltage @ 60 Hertz =

Transformer Ratio
9: Required KVA @ Max. Hertz: =
Surface Voltage X Motor Nameplate Amps X 1.73 =

1000
10: Controller sizing: = Motor Nameplate Amps X Transformer Ratio =

(Select a drive Model with a continuous current rating => than this calculation)
(Refer to Appendix A: Specification and Sizes)
11: V-Clamp: = (from line 8) Drive Volts @ 60 Hertz X Max Hz =

60
Page 30
INSTALLATION AND SERVICE RECORD
Area ________________ District _______________

Startup____ Service____ Restart____ Report
Custom er ___________________ County / Province ________________ State / Country

Facility /Field ______________ Unit / Lease ______________ No____________ City
VSC S/N: _____________ Model _____________ Am ps ________ KVA Software Rev.:
SYSCON______
Motor Mfg__________ Volts __________ Am ps_________ Hp________ Service
DISPLAY______
Cable Size_________ Ft__________ Volts/Ft________ Tem p Factor__________ Cable
Pum p Mfg__________ Model__________ Series__________ Stages________
Intake (Rotary, Rev-Flow, Std) Min Hz_______ BPD_______ Max Hz_______ BPD_______
Check Valve_________ Jap Setting ___Ft Bottom Hole Tem p_____
______F. deg
Xfrm S/N_________________ Voltage_________ Ratio__________ Taps 1______ 2______ Delta W YE
Drive Input Volts Unloaded Drive Input Am ps

a/b________ a/c________b/c_______ @ Hz_____ a)______ b)______
@ Hz_____ a)______ b)______
Drive Input Volts to Ground Drive Output Am ps
a________ b________ c________ @ Hz_____ a)______ b)______
@ Hz_____ a)______ b)______
Drive Input Volts Loaded Down Hole M otor Am ps
a/b________ a/c________b/c________ @ Hz_____ a)______ b)______
@ Hz_____ a)______ b)______
Drive Output Volts
@ Hz_____ a/b______ a/c______ M otor & Cable Ohm s Phase to Ground
@ Hz_____ a/b______ a/c______ a_________ b_________c__________
Surface Voltage Phase to Ground M otor & Cable Ohm s Phase to Phase
a)______ b)______ c)_____ a/b________ a/c________ b/c________
Setup or Operating Param eters

______Overload Am ps ______Volts @60Hz ______Sync Delay ______Low Speed Clam p
______Overload Tim e ______Start Frequency ______Hi Speed Clam p_ _____VBoost
______I Lim it ______V Boost Sync ______Accel Tim e ______Reg.Gain%
______I Lim it Sync ______V Clam p ______Decel Tim e ______Slip Com p%
______Fault Restarts ______Underload Am ps ______Control Setpoint______Aux. Restart
______Restart Delay ______Jog Frequency ______PHD Zero ______ PHD Span
______Fault Reset ______Underload Restarts ______Frequency Avoid
______Set Speed(Hz) ______UL Trip Delay ______Output Rotation
______Run Speed(Hz) ______Mode ______Control Signal ______Analog 1 or 2
______Bypass LSTrip Delay ______LSTrip Delay ______LSTrip Enable ______LSTrip Lockout
______UL Bypass Delay ______UL Delay ______UL Enable ______UL Lockout
______DI1 Bypass Delay ______DI1 Delay ______DI1 Enable ______DI1 Lockout
______DI2 Bypass Delay ______DI2 Delay ______DI2 Enable ______DI2 Lockout
______OL Bypass Delay ______OL Delay ______OL Enable ______ OL Lockout
______W ait for Restart Delay
Com m ents / Observations_____________________________________________________________________

:
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Job Started: Job Com pleted:
Page 31
BASIC PARAMETER SETUP
The following procedure will set the majority of the
GCS SETUP 1 parameters required for actual start-up of the GCS
MORE MORE controller in normal submersible pump operating
Set Frequency 60.0 hz conditions. Perform the “FORMING CAPACITORS”
High Speed Clamp 120.0 hz steps only if the unit has not been operating for 6
Low Speed Clamp 10.0 hz months or more. Please ensure safety precautions are
Run ILimit 100 amps observed.
Sync ILimit 100 amps
Voltage at 60 H 230 Vlts 1. Turn on the Main Input Power Switch, then press
VClamp 480 Vlts the STOP key on the Keypad.
VBoost 0 Vlts 2. Set Frequency to 60 Hz.
VBoost Sync 0 Vlts 3. Set High Speed Clamp to hertz required for
Sync Frequency 10.0 hz application.
Sync Delay 2 sec 4. Set Low Speed Clamp to hertz required for
application.
5. Set Run ILimit to motor nameplate amps X
transformer ratio X 105%.
6. Set Sync ILimit to motor nameplate amps X
transformer ratio X 125%.
7. Set Voltage at 60H to the value calculated in the
START-UP worksheet.
8. Set VClamp to value of incoming voltage, but no
greater than 480 volts.
9. Set VBoost to zero
10. Set VBoost Sync to zero.
11. Set Sync Frequency to 10 Hz.
12. Set Sync Delay to 2 seconds.
13. Set Accel Time to 10 seconds.
14. Set Decel Time to 10 seconds.
15. Set Inverter Rotation to FORWARD or “FWD”.
16. Set Regulator Gain to 70 %.
17. Set Slip Comp to zero.
GCS SETUP 2 18. Set FREQUENCY AVOIDANCE to OFF
MORE MORE
19. Set Mode Select to KEYPAD FREQUENCY
Accel Time 10 sec 20. Set Max Alowd Strts to 5.
Decel Time 10 sec
Inverter Mode 21. Set Strts Cntr Rst delay to 30 minutes.
6-Step
Inverter Rot FWD 22. Set Rstrt Dly to 30 minutes.
Converter Mode 6 PLS 23. Set OVERLOAD setpoint to motor nameplate
Regulator Gain 70 % amps X transformer ratio X 120%.
Slip Comp 0 24. Set OVERLOAD SHUTDOWN DELAY to 5
Jog Freq 0 hz seconds
Restart Delay 30 min 25. Set UNDERLOAD Setpoint to ZERO.
Password 0 26. Set UNDERLOAD Shutdown Delay to 30
Scty Jmp Status yes seconds.
Drive Mdl Num 1060 27. Check and/or set CLOCK to current time and
Torque Rating CT date.
28. If required, perform the steps in the following
section to FORM CAPACITORS or proceed to
NO-LOAD SETUP.
Page 32
FOR INITIAL START-UP OR TROUBLESHOOTING IT IS RECOMMENDED, WHERE
PRACTICAL, THAT THE LOAD BE DISCONNECTED, AND THE VSC OPERATED NO-LOAD
TO VERIFY CORRECT OPERATION.
Page 33
FORMING CAPACITORS
STARTS Perform these steps only if the unit has not been
MORE MORE
operating within 6 months.
Int Auto Rstrt no
1. Perform the preceding steps for BASIC
Strts Cntr 0 PARAMETER SETUP.
Ttl Strts 0 2. Disconnect load from output terminals of the
Max Alowd Strts 5 VSC.
Strts Cntr Rst 30 min 3. Set Run I LIMIT to the maximum value.
Prog Rstrt Tm 0 min 4. Set SYNC I LIMIT to the maximum value.
Rstrt Dly 30 min 5. Set VOLTS AT 60HZ to 230 volts.
Tm Til Rstrt 00:00 min 6. Set OVERLOAD SETPOINT to maximum rating
Wait Fr Rstrt T no of controller
Rstrt On Ovld no 7. Press the START button and confirm the
controller ramps up to 60 Hz.
8. Monitor output volts, at 60 Hertz drive should
Internal Automatic Restart Enable have 230 volts out.
9. Increase VOLTS AT 60 HZ. in 50 volt
increments with five minute pauses between each
increase until maximum output voltage is
reached.
10. Press STOP to shutdown controller.
Page 34
NO-LOAD TESTS
If the GCS controller has not been started or used in this application before, the steps in BASIC
PARAMETER SETUP should be performed before these NO-LOAD or SHORTED OUTPUT
steps are attempted.
GCS SETUP 1 No Load Test

MORE MORE
Set Frequency 60.0 hz 1. Set Voltage at 60H as per start-up worksheet.

High Speed Clamp 120.0 hz 2. Ensure that OVERLOAD setpoint equals motor
Low Speed Clamp 10.0 hz nameplate amps X transformer ratio X 120%.
Run ILimit 100 amps 3. Ensure that Run ILimit equals motor nameplate
Sync ILimit 100 amps amps X transformer ratio X 105%.
Voltage at 60 H 230 Vlts 4. Ensure that Sync ILimit equals motor nameplate
VClamp 480 Vlts amps X transformer ratio X 125%.
VBoost 0 Vlts
5. Turn off the Main Input Power Switch and disconnect
VBoost Sync 0 Vlts
Sync Frequency 10.0 hz load from output terminals of VSC.
Sync Delay 2 sec 6. Connect a phase sequence meter to output of the
controller to the point nearest the well head to confirm
proper phase rotation.
7. Turn on the Main Input Power Switch.
8. Press START button and confirm correct phase
sequence, then stop the controller.
9. Turn off the Main Input Power Switch and disconnect
phase sequence meter
Shorted Output Test
1. Set Sync Frequency to 15 Hz..

2. Ensure that OVERLOAD setpoint equals motor nameplate amps X transformer ratio X 120%.
3. Ensure that Run ILimit equals motor nameplate amps X transformer ratio X 105%.
4. Ensure that Sync ILimit equals motor nameplate amps X transformer ratio X 125%.
5. Turn off the Main Input Power Switch and disconnect load from output terminals of VSC.
6. Connect shorting cables between all three output terminals.
7. Press START button to start drive.
8. Ensure that the STATUS screen displays the three output currents and that they are of the
correct magnitude for the model size of the drive.
9. Press STOP and allow the drive to decelerate and shutdown.
10. Disconnect shorting cables and reconnect the load to the output terminals.
Page 35
MOTOR START-UP
The following steps will cause the Electrospeed GCS to start the motor / pump connected to its
output terminals. Following these steps is a section called Troubleshooting that should be read
and used to identify and correct any problems if they appear at start up time.
RUN 60.0 Hz 1. Connect the load to the output terminals of

the VSC.
Rot : FWD Mode : 1
2. From MAIN MENU, select and display
Current : IA IB IC STATUS screen.
(Amps) 51 52 49 3. Press START button and confirm that output
frequency ramps up to set speed or 60 Hz.
Volts Out: 480 11:47
4. Confirm correct Voltage at 60H-output
Analog Input #1 1634 PSI voltage of controller on STATUS screen.
Analog Input #2 947 BPD 5. Set FREQUENCY to maximum desired
frequency per start-up worksheet.
Lst Shtdn Active Alarms 6. Measure and calibrate output amps and
1998 Feb 15
23:17:12 voltage of controller as shown on STATUS
Underload screen using True RMS meters. Record input,
output and downhole amps and volts on start-
up sheet.
7. Set FREQUENCY to minimum speed per
start-up worksheet.
8. Set UNDERLOAD setpoint to 10% less than
lowest output phase current while running at
minimum hertz. Record on start-up sheet.
9. Set FREQUENCY to desired operating speed.
NOTE: OVERLOAD PARAMETER & UNDERLOAD PARAMETERS may need to be reset

after well has stabilized.
Page 36
Motor Start Troubleshooting
After all necessary parameters have been set, press the START button. The controller will ramp
quickly to the START FREQUENCY. The controller will remain at the START FREQUENCY
through the SYNC DELAY period. After SYNC DELAY, the controller will accelerate the motor at
the rate established by the ACCEL TIME if the controller can provide sufficient current. If the
controller cannot provide sufficient current, the motor will accelerate at a lower rate determined by
the load inertia and the current available.
NOTE: The Electrospeed controller If the controller is unable to start the motor, check the
load current during an attempted start. If it is equal to
will not restart if voltage is present
I LIMIT SYNC, increase I LIMIT SYNC and try again.
on the DC bus. There will be a delay
Continue the process of increasing I LIMIT SYNC
of 30 to 60 seconds between starts
and start attempts until the motor starts, or the load
to allow the bus to discharge.
current is not limited by I LIMIT SYNC. If the motor
still does not start, increase V BOOST SYNC in 5-volt
increments up to 33% of starting voltage. If the output current becomes equal to I LIMIT or I
LIMIT SYNC, further increases of V BOOST will be ineffective. If the motor still does not start, set
V BOOST SYNC to 0 and increase START FREQUENCY. Be careful in increasing V BOOST
SYNC. If the start voltage is too high for the start frequency, the motor or output transformer, if
used, may saturate. This causes the excitation current to dramatically increase. In this situation, I
LIMIT SYNC current may be reached, but a large portion of the current may be excitation current
for the transformer or motor. For this reason it is generally best to initially attempt starting with no
V-BOOST SYNC, and then increase only as necessary.
The problem of transformer saturation is particularly evident in submersible pump applications
where output step-up transformers are used. Submersible applications typically include long
lengths of cable between the step-up transformer and motor. Cable voltage drop is typically high,
and may require some V BOOST SYNC for motor starting. Output transformers for submersibles
are typically designed to allow for intermittent over-voltages of about 33% without significant
increases in excitation currents. Even with the capability of boosting output voltage by 33%,
problems can still be encountered with transformer saturation. In some cases, though rare, it may
be necessary to increase START FREQUENCY to obtain maximum available current without
saturating the transformer. Since the voltage/frequency ratio will remain constant, neglecting V
BOOST SYNC, the output voltage will be higher at the increased START FREQUENCY. The load
reactance will also increase, but the load resistance will remain constant making the increase in
overall load impedance less than the increase in voltage. This will allow for more starting current
without saturating the transformer. In some situations, well conditions deposit foreign material in
the pump that can cause it to jam. If this is suspected, try starting the motor in the backward
rotation first to free it up, then try a forward start again.
OPTIMIZATION
After the ESP has been successfully started, several operating parameters should be checked
and, if necessary, adjusted to ensure optimal operation of the system.
INPUT POWER FACTOR

To ensure the best possible input power factor, fine-tune the VSD volts per hertz and transformer
taps to allow the converter section’s SCRs to operate fully phased on. Configure the VSD to
produce the maximum volts per hertz at the desired operating frequency and select the correct
output transformer taps to produce the required voltage at the motor terminals.
HARMONIC DISTORTION OF INPUT POWER LINE

When the size of the ESP system’s load on the utility power supply becomes a significant
percentage of its capacity, a VSD can reflect large amounts of distortion back into the power
Page 37
system. When this situation becomes a problem, the Electrospeed GCS can be configured to
operate in twelve pulse-input mode. For this configuration, the user must add three additional
o
converter control cards into the slots provided on the main circuit board. An additional 30 phase
shifting transformer is connected to the input power line and its output connected to the drive. The
drive’s personality module must also be changed out to inform the GCS operating system of the
new mode of operation. Using this type of configuration can yield significant reductions in total
input harmonic distortion. Contact Centrilift’s Control Technology technical support group for
further information.
ESP VS PWM OPERATION

The Electrospeed GCS drive is capable of operating in both PWM mode (pulse width modulated)
and ESP mode (variable voltage, six-step pseudo-sine wave). Although PWM operation can lower
the total harmonic currents conducted by the motor, the user must be aware of some potentially
damaging effects due to this mode. (See “Facts Regarding the Use of PWM Drives on ESP
Systems” on page 51.) Since PWM typically switches the full output bus voltage to the motor at a
high carrier frequency, the ESP system, complete with output transformer and long power cable
can exhibit significant under-damped voltage ringing. This ringing of the output voltage will
produce voltage spikes higher than twice the normal operating voltage. These high voltage
transient spikes can seriously degrade the insulation of both the cable and motor, and lead to
premature equipment failure. If PWM operation must be utilized on an ESP system, the user
should install a properly sized and configured filter circuit on the drive output. A correctly sized
filter will minimize the damaging voltage transients delivered to the ESP system, but at a cost of
higher total electrical power consumption and heat generation. Whenever possible, Centrilift
recommends that the GCS drive is run in the ESP (six-step) mode to minimize equipment
damage and increase run life. PWM mode can safely be used in surface motor applications where
there is no output transformer and short motor power leads are used. Contact Centrilift’s Control
Technology technical support group for further information.
MINIMUM MOTOR CURRENT

While the pump is running at the desired frequency, adjust the Volts/per/Hertz parameter to
produce the minimum value of load current. Do this by increasing or decreasing the
Volts/per/Hertz parameter a few volts at time and checking the value of motor current. If the
change causes the motor current to decrease, repeat the value change until motor current starts
to increase. At this point, change the volts per hertz back to the previous setting that produced the
lowest load current. The motor will now run at its most efficient and hence most economical state.
I LIMIT OPERATION FOR GASSY WELLS

When operating in wells producing significant amounts of gas the I LIMIT parameter can be used
to help compensate. In this type of situation, set the FREQUENCY LIMIT to the highest allowable
operational speed. Set the I LIMIT parameter to cause the output frequency to be limited to the
desired optimal value. Then, when gas is present in the pump, the motor load will decrease and
the output frequency will rise until the I LIMIT or Frequency LIMIT parameters are reached. The
slight increase in frequency will further compress the gas and help to move it out of the pump.
RESTART TIME DELAYS

When the drive has shutdown due to a non-lockout condition, the GCS operating system begins
to decrement the restart delay timer. If the associated alarm / shutdown is still active at the end of
the restart delay, the GCS drive will wait in the off condition until the alarm is cleared. At this time,
if no further alarms are active and the drive is configured for automatic restarts, the drive will
attempt to start the motor.
Page 38
ESP MOTOR STARTING
Centrilift
A Baker Hughes Company
Presented at:
1996 ESP Workshop
SPE Gulf Coast Section
May 2, 1996
Page 39
INTRODUCTION
As we continue pushing the limits of ESP’s to higher and higher power ratings, and operating on
longer and longer power cables, the need to understand starting requirements increases. In many
cases the operator, the utility, and the ESP manufacturer must work together, to insure that all
starting requirements are met for reliable operation of the ESP. Several papers have been written
on the starting characteristics of the submersible motor, yet we continue to see the same
mistakes repeated over and over. Every few years, it seems, we need to review the basics of
starting the ESP.
The length and size of cable has the most dramatic impact on the starting characteristics of the
submersible motor. Submersible motors are operated with cable lengths varying from virtually
zero to over 20,000 ft. Short cable length results in higher starting torque, and in extreme cases
shaft failure is possible. Long cable lengths, on the other hand, may prevent the motor from
developing sufficient torque for reliable starting. Proper selection of the motor, power cable, and
starting method can insure the ESP will start reliably without damage.
MOTOR STARTING
Most submersibles are started by applying the full available voltage at the surface. The starter
used is referred to as a “full voltage” starter, and the method of starting is referred to as “across
the line” or “direct on line” (DOL). The term “full voltage” is a bit misleading for ESP’s in that most
ESP systems have significant voltage drop on the power cable, and, in effect, provide a reduced
voltage start. DOL starting is by far the most common method used for induction motors including
the submersible motor. It is the least expensive, and the most reliable, and therefore, should be
considered first. There should be good reasons for considering other methods.
To understand whether DOL starting is viable for a particular application, a per phase electrical
model is used. A typical model of this type is shown in figure "7". The power system is modeled
as an idea voltage source with a series impedance. The step down transformer, power cable, and
down-hole motor are each modeled with a series inductance and resistance. The goals are to
insure that the starting torque developed by the motor is sufficient to adequately start the ESP
over the acceptable life of the installation on one extreme, and to insure that the starting torque
developed will not damage the ESP on the other extreme. Motor starting current can be used as
an indicator of motor starting torque. The relationship between current and torque is established
by test, and each type of machine will have its own unique characteristics, making generalization
dangerous.
The motor starting current can be calculated using the per phase model shown in figure "7". The
motor locked rotor reactance (Xm) is a function of the available motor terminal voltage under
locked rotor conditions. Unfortunately, Xm is needed to calculate the motor terminal voltage from
the model. An iterative method can be used to determine the motor terminal voltage. To
accomplish this, a motor terminal voltage is assumed. A value for Xm can then be determined
from locked rotor test data for that particular motor. The starting current and resulting motor
terminal voltage can then be calculated. If the calculated motor terminal voltage does not agree
with the assumed value, either increment or decrement the assumed value and repeat the
process until the assumed and calculated values converge. This method can be quite time
consuming if undertaken manually, but can be easily adapted to spreadsheet software or a
programmable calculator.
Calculating the motor starting current is good way to understand the starting requirements of a
given installation, but the process requires data that is often not easily obtained. Using “rules of
thumb” is easy, but similarities to the actual installation may be pure coincidence. Some
manufacturers publish data indicating the maximum recommended cable lengths based on motor
series, motor voltage, and cable size. Figure "8" is an example. This data is typically
Page 40
conservative and is intended to keep the user out of trouble. An indication that the system will not
start should be used as a warning indicating further analysis is needed.
The relationship between shaft torque and speed for induction motors is traditionally displayed as
a plot of the torque (y-axis) versus motor speed (x-axis) and is referred to as the torque-speed
curve. The top curve in figure “9” is a typical motor torque-speed relationship. The torque values,
at all speeds, are at 100% motor nameplate voltage. This might make sense for a surface motor
where the terminal voltage will remain relatively constant during starting, however, with the
submersible and associated length of cable, the motor terminal voltage during start will drop
significantly. The motor torque-speed relationship continually changes with voltage, and a lower
motor terminal voltage will yield a lower torque. Figure “9” shows the effect of reduced voltage on
the torque-speed relationship. Figure “9”, however, does not adequately describe the overall
relationship between torque and speed for the submersible motor and cable.
When voltage is first applied, the motor impedance will be at its lowest, the resulting starting
current and cable voltage drop will be at their maximum. When the motor begins to turn, its
impedance will increase, reducing both the current and cable voltage drop, increasing the motor
terminal voltage. When running at full speed, the motor is at its maximum impedance and lowest
current. Assuming we have correctly compensated for the full load running cable drop, the motor
should be running at nameplate voltage. Figure “10” more closely represents the torque-speed
relationship with cable. The top curve in figure “10” is the full voltage torque-speed curve. As the
voltage drop due to system and cable impedance increases, the torque at the low speeds drops
dramatically, but recovers due to the increase in motor impedance and associate drop in current
as the motor increases in speed.
The motor load, a centrifugal pump, has a torque requirement that varies approximately as the
square of the speed. A portion of the pump load is friction that will be the highest when the pump
is stopped. Once the motor breaks the pump loose, this part of the load will drop. Figure “10” has
a curve representing the pump torque requirement. The curve is a bit exaggerated, but this is to
illustrate how the available torque from the motor can dip below that required for the pump. When
this happens, the motor will “hang up”, to the left of the “pullout torque” point as indicated in figure
“10”, and will not accelerate to full speed. The pump will be running, but at a low speed. The
Operation in this manner is unstable, and can severely damage the submersible equipment due to
torsional oscillations. An ESP that initially started may eventually exhibit this problem due to
increasing starting torque requirements for the pump.
When an ESP fails to start, the overload trip time is often increased to give the ESP more time to
start. The longer the ESP start cycle, the greater the chance for damage. It is not uncommon to
break a pump, motor, or seal shaft in attempting to get a “hard to start” unit going. This is often
thought to be simply a case of too much starting torque applied to the shaft, however, in many
cases the shaft failure is the result of allowing the ESP to operate to the left of the pullout torque
point for too long. For this reason, the overload trip time should be kept a short as possible, and
typically no higher than one second for overload currents above 200% nameplate.
REDUCED VOLTAGE STARTING
Reduced voltage starting, often called soft starting, refers to any of several methods employed to
reduce the applied motor terminal voltage during starting. Several years ago, there was
significant interest in reduced voltage starting as a means of extending the life of ESP’s. The idea
of fewer starts relating to longer run times is somewhat universally accepted. Reduced voltage
starting was considered as a means of reducing the impact of starting, extending ESP run times.
Of the various problems that can be associated with starting, only shaft failure due to excessive
starting torque is addressed by reduced voltage starting. This the most common application for
reduced voltage starting of ESP’s, and is typically on installations with short cable lengths where
pump and/or seal shafting is operated near its maximum rating.
Page 41
A second reason to consider reduced voltage starting is to reduce the impact of motor starting on
the power system. It is not uncommon for electrical utilities to require the use of reduced voltage
starting to prevent one customer from interfering with others. Utilities are generally more familiar
with surface motors, which may require several seconds to reach full speed, dependent on the
load. ESP’s, on the other hand, start much quicker, 0.1 to 0.2 seconds. The effects of starting an
ESP are therefore much less, and traditional guidelines for the requirement of reduced voltage
starting by utilities are not totally applicable. In many cases, the utility will waive this requirement
once they understand the ESP and its starting characteristics.
If a reduced voltage starter is used, it is important to understand the starter, and why it is being
used, to insure it is properly set up. Reducing the starting voltage can have similar effects to
those discussed above in relation to Figure “10”. Reducing surface voltage has the same effect
as increasing the voltage drop at the motor terminals. If not properly applied and properly set up,
reduced voltage starting can cause severe damage to the ESP. The idea that, if a little is good,
then a lot must be better, does not apply to reduced voltage starting. Starting torque is
proportional to the square of the motor terminal voltage. A small reduction in voltage will have a
much more significant impact on the starting torque. If the voltage is reduced too much, the motor
will not start. To better understand the effects of reduced voltage starters, some of the different
types used with ESP’s are discussed below.
Series Inductor
A series inductor is placed in each of the three phases to drop voltage. The voltage drop will be
proportional to the current flow through the inductor. During starting, the current through the
inductor will be high causing a proportionally high voltage drop. Once the motor has started, the
current will drop to the normal running current reducing the inductor voltage drop. The inductor
can be left in the circuit, or it can be bypassed with a contactor. If left in the circuit the system
voltage must compensate for the voltage drop during running, and the inductor must be capable
of operating continuously at the running current. If bypassed, the inductor is required to support
current for the short starting cycle, and can therefore be physically much smaller and less costly.
The inductors can be provided with taps to select the proper inductance for the application. The
main disadvantage of the inductor starter is that the starting current must be known to determine
the voltage drop across the inductor.
A variation of the inductor starter employs a saturable core inductor that self regulates the voltage
drop. Once the motor is started, the inductor is bypassed with a contactor. The primary
advantage of this arrangement is that the voltage drop remains the same regardless of the
current. It is, therefore, not necessary to know the starting current to determine the voltage drop.
High Impedance Transformer
A special high impedance transformer is substituted for the standard step down transformer. The
higher impedance will act very much like the inductor starter discussed above, and will cause a
significant voltage drop during starting. The proper voltage tap must be selected to compensate
for the transformer voltage drop during running. As with the inductor, the starting current must be
known to determine the voltage drop. A maximum of about 10-12% impedance is possible.
Autotransformer
A step down autotransformer is employed to provide the lower voltage for starting. In effect, this
provides two, or more, separate voltage sources for the motor. Contactors can switch the lower
voltage for starting, and then switch over to full voltage once the start is complete. The
autotransformer can have taps for selecting the proper starting voltage, and can be quite small
due to the short duty cycle. The starting voltage will be reasonably constant during starting due to
Page 42
the low impedance of the autotransformer, therefore, it is not necessary to know the starting
current to get a reasonable estimate of the voltage drop.
Solid-state
The solid-state reduced voltage starter utilizes SCRs to control the output voltage. This is
accomplished by allowing the SCRs to conduct during only a portion of the voltage cycle; the
lower the conduction time, the lower the voltage. This type of starter is the most elegant of the
reduced voltage starters, and provides continuos control of the output voltage from virtually zero to
full voltage. Continuous voltage control allows considerable flexibility and has resulted in several
different starting techniques used with ESP’s. Some of these are:
1. Voltage Ramp
The voltage is a linear ramp with respect to time from zero to full voltage. The ramp time is
adjustable. At some point during the start cycle, the motor terminal voltage will be high
enough for the motor to start. This method does not provide much control, and the start cycle
must be long.
2. Constant Current
The starter regulates the output current to a preset value that is known to be sufficient to start
the motor. This system works well in that the starter ramps quickly to the voltage that can
supply the set current. This minimizes the time with voltages too low for starting, however, if
the set current is too low, or if conditions change, the motor may not be able to start.
3. Current Ramp
The current ramp operates much like the constant current in that the starting current is
regulated to a preset value. The difference is that the current ramp has two current set-
points. During the start cycle, the starter will quickly ramp to the voltage that will support the
first preset current and then ramp at an adjustable rate to the second preset current. This
approach also minimizes the time with voltages that are too low for starting, and provides
additional protection against possible changes in starting conditions. Proper setup would be
to set the first current set-point to a value that should start the motor, and the second to a
value much higher, but not high enough to break a shaft. The ramp time should be very short,
no more than 1.5 seconds.
VARIABLE FREQUENCY STARTING
The use of variable frequency controllers (VFC) to operate ESP’s has brought another dimension
to starting. Not only are we able to vary the starting voltage, we are also able to vary the starting
frequency. Minimum starting current is commonly used as the criteria for starting an ESP, and the
following relationship can be used to determine the current required for equivalent torque at other
starting frequencies.
Torque ∝ I2/f
By setting the starting torque at 60 Hz. equal to the starting torque at frequency “f”, we get:
I602/60 Hz. = If2/f
Or
_____
Page 43
If = I60√ f/60
For example:
Determine the starting current required to start a motor at 10 Hz., which requires 300% nameplate
current at 60 Hz.
_____
I10 = (300%)(√10/60) = 122%
A down-hole starting current of 122% of the motor nameplate at 10 Hz. would provide
approximately the same starting torque as 300% motor nameplate at 60 Hz.
The VSCs typically used with ESPs are low voltage (380V, 415V, and 480V), and a step-up
transformer is used to match the controller to the required surface voltage. To operate at
frequencies other than 60 Hz. the motor terminal voltage must be adjusted proportionally. This is
true of starting as well. A 10 Hz. start would require 1/6 of the 60 Hz. voltage. At low frequencies,
however, the cable resistance is far more significant when compared to the motor reactance, and
it may be necessary to increase or “boost” the output voltage to establish the required starting
current. During the start cycle, the VSC ramps quickly to the start frequency. The frequency is
held constant for a period of time called “SYNC DELAY”. During this time, the output current is
limited to an adjustable value called “I-LIMIT SYNC”. The motor will start and run at
approximately the synchronous speed for the starting frequency (10Hz.= 600 RPM). At the end of
“SYNC DELAY”, the VSC will ramp at an adjustable rate to the set operating frequency. Fig. “11”
indicates the effect of lower frequency starting on the torque-speed curve. The curve shifts to the
left. Starting is accomplished at low frequencies which minimizes the impact of the pump load,
and the load is accelerated to the operating frequency with the motor operating to the right of the
breakdown torque point on the torque-speed curve.
Though generally not justifiable for starting alone, the variable speed start is the “best” method
available for starting an ESP. The problems discussed above with the motor “hanging up” due to
a large voltage drop at the motor terminals do not exist with the variable speed start. The VSC
isolates the ESP from the electrical power system, and compensates for downhole cable drop
allowing the variable speed start to be the same under virtually all conditions.
The selection of the VSC and transformer can significantly impact the available starting torque.
How much starting torque is enough? You never know for sure until you can’t start, and then you
know you don’t have enough. The VSC should have a high peak current rating since torque is
proportional to the square of the current. The VSC and transformer must be capable of providing
adequate boost capability to get the maximum starting current. The ability to boost the output
voltage beyond the base voltage for the start frequency allows the variable speed submersible
motor to develop higher starting torques than DOL starting on systems with long lengths of cable.
The amount of boost can be limited by either the VSC or step-up transformer. If designed
properly, the VSC can provide adequate boost for virtually any condition with no impact on cost.
However, the transformer’s boost capability has a significant impact on cost, as boost is, in effect,
an overvoltage for the transformer at the start frequency. The transformer must be able to
support the overvoltage without a significant increase in excitation current. For starting, the VSC
selection should be based on peak starting current capability and the associated step-up
transformer on boost capability. Proper selection of the VSC and step-up transformer will insure
reliable starts for the life of the pump.
CONCLUSION
Starting is a critical element in the application of an ESP. The starting characteristics of a

submersible pump are impacted by a myriad of parameters relating to the power system, well
environment, surface control equipment, starting method, downhole cable, pump, and motor. The
Page 44
electrical designs of submersible motors continue to change making previously old “rules of
thumb” inaccurate. Do not generalize. Motor characteristics vary with manufacturer and series.
Rely on information provided by the manufacturer of the motor to make decisions on starting. DOL
starting should be used when practical. Reduced voltage starting should be considered for
applications where shafts are loaded close to maximum ratings, and cable lengths are short.
Make sure the motor is provided adequate voltage for starting to prevent failure. Again, do not
generalize. Rely on the manufacturer to provide specific guidelines for the applications in
question. Variable speed controllers provide the safest starting for the ESP, because it totally
controls the electrical environment for the motor. The starting power requirements, with a VSC
are typically lower than the full load running requirements making the VSC ideal for operation from
small generators. The savings on the generator will often more than offset the additional cost of
the VSC.
Page 45
SYSTEM VOLTAGE
MODEL FOR Xs
DIRECT SYSTEM
ON LINE IMPEDANCE
START Rs
Xt
TRANSFORMER
IMPEDANCE
Rt
IS
START
CURRENT
Xc
CABLE
IMPEDANCE
Rc
Xm
MOTOR
IMPEDANCE
Rm
Figure 7: Impedance Model for Direct On Line Start
Page 46
Figure 8: Maximum Cable Lengths
Page 47
350
300
250 TORQUE-
SPEED
Torque (%Full Load) CONSTANT
WITH
200 O G
100% VOLTAGE
150
90%
80%
100
70%
60%
50 50%
0
0 20 40 60 80 100
% SYNCHRONOUS
Figure 8: Torque / Speed with Constant Voltage
3 50
P U LLO U T
TORQUE
T O R Q U E -S P E E D
3 00 W IT H
V O LT A G E D R O P
2 50
TO R Q U E (% FU LL LO A D )
2 00
0% V O LT A G E D R O P
15 0
10%
20%
1 00
30% PUM P TORQUE
40%
50
50%
0 20 40 60 80 1 00
% SYNCHRO NO US SPEED
Figure 9: Torque / Speed with Voltage Drop
Page 48
350
300
V A R IA B L E F R E Q U E N C Y
T O R Q U E -S P E E D
250
T O R Q U E (% F U L L L O A D )
200
3 0 H z. 4 0 H z. 5 0 H z. 6 0 H z.
150
100
50
0 20 40 60 80 100
% SYNCHRONOUS SPEED
Figure 10: Variable Speed Torque / Speed
Page 49
FACTS REGARDING THE USE OF PWM DRIVES
ON ESP SYSTEMS
1. Phase to phase peak negative to peak positive transitions will occur if the carrier
frequency is not right for the power frequency.
A first consideration that must be given to a PWM 3-phase source is the relationship that should
exist between the fundamental power frequency to be generated and the carrier frequency.
Each phase is generated with a carrier frequency that is pulse width modulated in accordance with
a sine wave at the power frequency. Since a motor operates on the phase to phase voltage it is
important to consider what happens from phase to phase. Specifically, the pulses on each phase
need to be appropriately timed to prevent phase to phase output transitions that switch from the
negative peak to the positive peak. If this happens the voltage transition that enters the cable is
twice the amplitude of that produced on any one phase, which immediately doubles problems due
to impedance mismatch between the cable and the motor at the pump. This mismatch is severe
and practically doubles fast rise time voltage transitions at the end of the cable.
The rule to follow that will prevent this is actually quite simple, only use carrier frequencies that are
multiples of 1.5 times the power frequency being generated. This yields phase to phase voltages
that always transition between zero and the minus peak or zero and the positive peak and is the
smallest allowable carrier frequency resolution that will avoid the problem.
Careful examination shows the carrier frequency is removed from phase to phase voltages when
this rule is followed.
2. The carrier frequency cannot be tuned to prevent high motor voltage peaks with
“Reflection cancellation”.
A very brief calculation shows that this would require switching frequencies beyond that practical
with current technology even if it could be accomplished. In fact any time a fast rise time pulse
enters the cable it will be nearly doubled at the impedance mismatch point between the cable and
motor.
Consider a piece of cable with the motor end open as an example, (the motor inductance causes
the motor end to appear open to fast rise time steps). If a voltage step is introduced at the source
end then, (allowing that the cable slows the propagation to .4 c, where c is the speed of light), the
step will traverse a 10000 ft cable down and be reflected back in 5.1 usec. This means that the
source must be ready to switch in the opposite direction in 5.1 usec, which would correspond to a
half cycle, hence the carrier period would be 10.2 usec corresponding to a 9821 Hz carrier. This of
course does not solve the problem any way, in fact it makes the problem worse. The pulse
doubled in amplitude when it hit the motor end of the cable and was reflected back. If at the
instant it gets back the source switches to the opposite level to attempt to cancel the reflection
another wave propagates down the cable. The motor end of the cable was left at double
amplitude and the new level coming down the cable is zero, so, when it arrives a double amplitude
step is impressed at the open end which is then doubled. The open-end voltage now goes to
quadruple amplitude in the opposite direction (twice the new step). The process would continue to
increase in voltage if the cable were lossless until the insulation finally broke down. Cable losses
cause the end step to not quite double hence a limit is eventually reached. The actual open-ended
Page 50
cable resonant frequency is lowered below 9821 Hz by the cable losses even for an open-ended
cable.
The question now is, can some other frequency cancel the reflections? No, however, we can
select frequencies that will lessen the effect. If we choose a frequency that corresponds to the
travel time down one length of the cable (twice the above frequency) the behavior is as follows. At
the time the first step reaches the end of the cable the source switches back setting up a wave
that steps down to zero moving into the cable. At the same time, a double amplitude wave begins
traveling back from the open end. These obviously meet in the center and tend to cancel one
another. The result is 2*step - step = step. Therefore, the center of the cable goes to amplitude
1*step which propagates to each end. At the instant the new amplitude reaches the source the
source will be ready to switch back to exactly that level, no current flows and the voltage is stable.
At the same time, the new level reaches the open end which is at 2*step and attempts to move it
back to 1*step. The voltage step is of course doubled which moves the open end to zero. This
zero begins propagating back to the source and arrives at exactly the time that the source
switches back to zero. Again, no current flows and we are back to the state we started with, both
ends at zero. Seems great, but remember the source end is pulsing at one times the step
amplitude while the open end is pulsing at two times the step amplitude. Of course the frequency
required to do this is 19642 Hz for 10000 ft of cable. If the cable is shorter, the required frequency
increases.
Other frequencies will alternately miss and match the propagation energy to add to or subtract
from it and cause the voltage at the open end to increase and decrease with some beat
frequency. The peak amplitude will depend upon how many reflections constructively add before
destructive phasing occurs, which will vary with the carrier frequency.
The above is true for constant duty cycle square waves at the carrier frequency. In actual power
generation, the duty cycle is constantly changing to produce the imbedded sinusoidal power
frequency. Consequently, there is no frequency that can always provide even the optimum
behavior of only double voltage at the open end.
Another approach to this whole argument is to use a PWM frequency low enough to allow the
reflections to propagate back and forth until they die out, before another pulse enters. This of
course introduces power frequency harmonics due to the low number of pulses per cycle of the
power frequency. In fact if this approach is used a stepped waveform makes more sense since it
never makes a full amplitude step.
3. High motor peak voltages cannot be avoided by tuning the carrier frequency to avoid
“system resonance”.
In actual practice the reflection phenomena is overshadowed by system resonance, (although the
former never goes away). The system will behave as a resonant system at a frequency lower than
the cable reflection resonance. The actual frequency is primarily controlled by the cable total
inductance and capacitance and the %Z of the transformer. In fact, if all the cable capacity is
lumped as one capacitor and an equivalent series inductance is calculated from all system
inductors, the resonant frequency can be calculated. It is indeed imperative that the system not be
driven with any energy near resonance because the resonant system is a high Q system. A
resonant circuit will have a voltage gain approximately equal to the Q at the resonant frequency,
hence, with a Q of 20 and an excitation voltage of 1 kV, 20 kV at the motor would not be unusual.
To avoid this one must understand what frequencies are generated by a PWM waveform.
A three-phase PWM waveform produces frequency groups that are centered around the carrier
frequency and each harmonic of it. These frequencies are the sum and difference frequencies
between the carrier and the power frequency being generated. For example, if the carrier is 1000
Hz and 50 Hz power is being generated, there will exist frequencies at 950 Hz and 1050 Hz, 900
Hz and 1100 Hz and so on. The third multiple of 50 will be absent as will other triples and the
Page 51
strongest will be the second (unless the aforementioned rule is not followed which will cause the
carrier to appear and be strongest). In the first group, the amplitude of each will decrease until
th
they are insignificant by about the 12 . The frequencies surrounding 2 times the carrier will all be
of lower amplitude but they will not decrease in amplitude as quickly giving a wider envelope. With
each harmonic of the carrier, the envelope will get smaller but broader until finally they overlap the
previous envelope. Before the envelopes overlap, there are regions of frequencies in between the
carrier harmonics where no energy is generated.
In order to avoid system resonance excitation the carrier must be chosen such that the system
resonant frequency is in between the harmonics of the carrier.
This means that

3 5 7
fr = fc, fc, fc,...
2 2 2
or solving for fc,

2 2 2
fc = fr, fr, fr,...
3 5 7
Where fc = carrier frequency
fr = System resonant frequency.
In actual practice, the midpoint is not the ideal point since each envelope broadens, rather than
1 1 1
2/3, 2/5, 2/7 the best position is , , ,...
2 1+ 2 2 + 2
An example of all this is,
100
carrier fresonant
10
F
k . 1
100
maxf
0.1
0.01
4 4 4 4 4 4
0 2000 4000 6000 8000 1 10 1.2 10 1.4 10 1.6 10 1.8 10 2 10
k
N .dt
Figure 11: PWM Spectrum, 3 kHz carrier generating 50 Hz
Figure 12 is the spectrum of a PWM drive generating 50 Hz with a carrier frequency of 3 kHz. This
is the nearest multiple of 75 to 41.4% of the system resonant frequency (7358 Hz). The system is
a 180 hp 1580 volt motor with a 6.5% 500 KVA transformer and 5000 ft of #1 cable. The cable is
140 uH and .075 uf per kft.
Assuming the system resonant frequency is accurately determined, an optimum carrier frequency
can be selected. Remember that the carrier frequency must move in increments of 1.5 times the
Page 52
power frequency or double amplitude transitions will emanate from the drive, therefore the
optimum frequency cannot always be precisely generated.
In the above example, the target value was 3012.68 Hz, however, since the valley between the
second and third envelope is fairly broad the slight shift is insignificant. If a higher power
frequency is generated the position becomes more critical as can be seen from figure 13 which is
the same system with 60 Hz being generated. The frequency step is now 90 hz making it more
difficult optimize the carrier position.
100
100
carrier fresonant
10
F
k .
100 1
maxf
0.1
.01 0.01
4 4 4 4 4 4
0 2000 4000 6000 8000 1 10 1.2 10 1.4 10 1.6 10 1.8 10 2 10
0 k endplot
N .dt
Figure 12: PWM Spectrum 2.97kHz carrier generating 60 Hz power
Note in figure 13 that the width of the no energy region about the system resonant frequency,
(valley between carrier harmonics 2 and 3), has narrowed. As the generated frequency goes
higher the energy from the second and third envelopes will overlap and the system resonance will
be excited. In many cases shorter cable length or a lower transformer impedance will be used,
both of which result in a higher resonant frequency. When the resonant frequency reaches a
certain point, the resonant frequency must be positioned between the third and fourth envelope
because a high enough carrier to keep it between the second and third is not practical due to
switching losses. The low energy region between envelope three and four is very narrow and
unfortunately, overlaps, in many applications, hence no good operating point can be achieved.
It should be noted that the voltage peaks at the motor will always be higher than at the output of
the transformer. This is due to reflections at the motor terminals because of impedance
mismatch, (as stated before, reflections never go away completely) and is essentially independent
of the voltage drop on the cable at the power frequency. As the transformer impedance is
lowered, the transformer output voltage peaks decrease, but the motor voltage peaks tend to
increase. Even when an optimum carrier frequency is used, the motor peak voltage is always
higher than the transformer output peak voltage.
Care must be taken in modeling these systems, single lumped circuit analysis will show a
difference between transformer end and motor end voltages but it will always be below the actual.
To properly analyze the system, cable characteristics must be analyzed with at least 10 lumped
value sections, the more sections the more accurate the result. An example of lumping all cable
parameters into a single LRC ‘T’ section is shown in figure 14.
Page 53
sclo 5000
stdev ( vto ) = 1919 max( vto ) = 4522 stdev ( vm ) = 2021 max( vm ) = 5044
Transformer Output Voltage Motor Voltage
5000 5000
4500 4500
4000 4000
3500 3500
3000 3000
2500 2500
2000 2000
1500 1500
vto 1000 vm 1000
j 500 j 500
0 0
500 500
1000 1000
1500 1500
2000 2000
2500 2500
3000 3000
3500 3500
4000 4000
4500 4500
5000 5000
0 0.01 0.02 0.03 0.04 0 0.01 0.02 0.03 0.04
j .T j .T
Figure 13: 3 kHz carrier generating 50 Hz power, Single lumped value model
If a cable model is used with the cable divided into 15 sections the result is,
o 5000 stdev ( vtopp ) = 1939 max( vtopp ) = 4745 stdev ( vmpp ) = 2098 max( vmpp ) = 5507
Xfmr ouput voltage (Phase to Phase) Load Voltage (Phase to Phase)
5000 5000
4500
3750 4000
3500
3000
2500 2500
2000
1500
1250 vmpp 1000
vtopp k
k 500
0 ntd 0
500
1000
1250 1500
2000
2500 2500
3000
3750 3500
4000
4500
5000 5000
0 0.01 0.02 0.03 0 0.01 0.02 0.03
k .T k .T
Figure 14: 3 kHz Carrier generating 50 Hz power, cable modeled with 15 sections
Note that the 15-section cable model shows a higher motor voltage, by nearly 500 volts.
Page 54
If the resonant frequency is placed between the first and second envelope (and moved about to
find the minimum voltage point), the best operating point is a carrier of 4875 Hz,
sclo 5000 stdev ( vtopp ) = 1839 max( vtopp ) = 4587 stdev ( vmpp ) = 1966 max( vmpp ) = 5187
5000 5000
4500
3750 4000
3500
3000
2500 2500
2000
1250 1500
vmpp 1000
vtopp k
k 500
0 ntd 0
500
1000
1250 1500
2000
2500 2500
3000
3750 3500
4000
4500
5000 5000
0 0.01 0.02 0.03 0 0.01 0.02 0.03
k .T k .T
Figure 15: 4875 Hz carrier generating 50 Hz power, cable modeled with 15 sections
In all of the above, 1315 volts RMS at 50 Hz is generated and utilized by the motor. Figure 15
represents the best that can be achieved with a carrier around 3 kHz. Figure 16 is the best that
can be accomplished positioning the resonant frequency between the first and second envelope.
As can be seen only a few hundred volts lower motor voltage is achieved.
For a drive without a transformer the situation actually gets worse due to higher rise times into the
cable (no transformer impedance to slow it), which increases the reflection problem and raises the
resonant frequency to very close to the cable self resonance.
If the carrier is ¼, ½, or ¾ of the resonant frequency a harmonic of the carrier will be centered at
the resonant frequency with disastrous results. Here is an example of a carrier frequency at ½ of
the resonant frequency, (the scale is left the same to illustrate the magnitude change).
5000 5000
4500
3750 4000
3500
3000
2500 2500
2000
1250 1500
vmpp 1000
vtopp k
k 500
0 ntd 0
500
1000
1250 1500
2000
2500 2500
3000
3750 3500
4000
4500
5000 5000
0 0.01 0.02 0.03 0 0.01 0.02 0.03
k .T k .T
Figure 16: 3675 Hz carrier generating 50 hz power, cable modeled with 15 sections
Page 55
In summary, a filter should always be used when PWM power generation is employed. Even the
best positioning of the carrier frequency will result in motor voltages that over stress insulation and
eventually cause a failure. This study was performed for the generation of 1315 volts RMS phase
to phase at 50 Hz. Many applications must use higher voltages than this and will produce voltages
that far exceed insulation ratings even for the best carrier frequency positioning. Poor carrier
frequency selection will produce voltages that rapidly destroy equipment.
As a point of reference, the same system driven by a six-step wave yields,
5000 5000
4500
3750 4000
3500
3000
2500 2500
2000
1250 1500
vmpp 1000
vtopp k
k 500
0 ntd 0
500
1000
1250 1500
2000
2500 2500
3000
3750 3500
4000
4500
5000 5000
0 0.01 0.02 0.03 0 0.01 0.02 0.03
k .T k .T
Figure 17: Six-step generating 50 Hz power, Cable modeled with 15 sections
Note the much lower peak voltages.
Page 56
Variable Speed Drives: Definitions, Applications &
Comparisons
INTRODUCTION
Over the past twenty years, the electrical submersible pump (ESP) industry has seen a marked
increase in the application of variable speed drives (VSDs). Over that same period, the complexity
and diversity of VSD products has increased as well. To properly apply VSDs in this demanding
environment, users need a greater understanding of the available options.
In many cases, engineers involved in the equipment selection for ESP installations may have little
knowledge of VSD topologies and their associated benefits and difficulties. This paper will
describe the basic VSD block functions, how these blocks can be combined to create different
VSD topologies, and when the different topologies would be beneficial. We begin with definitions
of the various building blocks.
DEFINITIONS
AC VSD Components
In order to understand the various considerations that arise when applying VSDs to ESPs, it is first
desirable to have knowledge of the fundamental building blocks of the technology. In this paper,
focus will be on AC VSDs used to control AC induction motors. While many different types of
converters have been developed, our discussion will be limited to currently available and applied
technologies. We will discuss each of the basic building blocks of a VSD in the sections that
follow.
Converters
Any electrical equipment that changes electrical energy from one form to another is called a
converter. A converter may change the voltage and current magnitudes, change from AC to DC or
DC to AC, and/or alter the frequency. An AC VSD is therefore an AC to AC converter. For
example, a typical VSD will convert the 480 volts at 60 hertz applied at the input, to 0 to 500 volts
at 0 to 120 hertz on the output terminals.
VSDs typically use two internal converters to accomplish their overall functionality: an input
rectifier and an output inverter. Often the term converter is used specifically to refer to the input
rectifier section of a VSD. Connecting the two converters is the DC bus. The input rectifier
(converter), the DC bus, and the output inverter will be discussed in the following sections.
Input Rectifier (or Converter)
At the input of a VSD is its rectifier. The rectifier converts bi-

directional or AC current and voltage into unidirectional or DC
current and voltage. At this point, the DC current and voltage will
still be time varying, but the current will only flow in one direction
and the voltage will never change polarity. These fluctuations are
minimized in the DC bus discussed below. The simple
representation for a three-phase converter is shown in Figure 19.
This type of representation emphasizes the VSD basic building

blocks, rather than the interconnection of multiple solid state
components. In practice, the input converter rectifier of any VSD
Figure 18: Converter
would likely contain many SCRs or diodes or both. Rectifiers may
be controlled or uncontrolled. A diode bridge is an example of an uncontrolled rectifier. Its output
voltage is strictly dependent on the applied input voltage. A silicon controlled rectifier (SCR) bridge
is an example of a controlled rectifier. A controlled rectifier can convert any portion of the
Page 57
incoming AC voltage to DC voltage thereby enabling selection of voltage levels from zero to that
approaching the peak line to line values.
DC Bus
The DC bus of the VSD is composed of passive, non-controlled devices. Typical elements include
inductors, capacitors, and resistors. These devices form a damped low-pass filter to smooth the
DC current and voltage provided by the rectifier. Depending on the
VSD topology, the DC bus provides a smooth DC voltage or current
source to the inverter. The simplified block is shown in Figure 20.
Again, the emphasis here is on general topology, not specific

component-level connection. Most often in medium horsepower VSD
units, the DC bus will be made up of multiple inductors, capacitors,
and/or resistors to achieve the necessary voltage and current ratings.
Some topologies will include only inductors, or only capacitors and

resistors, while others will require all three. Sizing of bus
components, along with whether all three elements are present can Figure 20: DC Bus
affect the VSD's input current distortion, along with overall drive
performance.
Output Inverter
At the final stage of a VSD is the inverter. The inverter converts the DC source provided by the
DC bus of the drive back into a variable frequency AC source for the induction motor. While an
inverter could be fixed frequency, for purposes of this paper, we will be concerned with variable
frequency inverters. Some inverters control both voltage or
current levels and frequency, while others control frequency
alone. More will be said about this in the VSD Topologies
section.
As mentioned in the previous section, the inverter could be

either a current or voltage source inverter. (In a voltage source
inverter, the output voltage waveform is controlled, and the
output current waveform is determined by the load applied. A
current source inverter is just the opposite in that the output
current waveform is controlled and the output voltage
waveform is determined by the load applied.) Most ESP
installations employ voltage source inverters. This means that
the DC bus will include a large bank of capacitors to provide a Figure 21: Inverter
voltage source to the inverter. In Figure 21, the simplified block
for an inverter is shown using a transistor switch. Many
different semiconductor devices are used in VSD inverters, from SCRs to insulated gate bi-polar
transistors (IGBTs) to gate turn-off thyristors (GTOs).
Common AC VSD Topologies
Now that the basic building blocks of VSDs have been discussed, let's take a closer look at the
details of these systems. When attempting to understand the performance of any particular VSD,
one must realize that different converter types can be combined to make many different VSD
topologies.
Due to this diversity, some confusion has developed recently. Engineers have specified a
particular VSD to gain reduced harmonic current levels, only to find that the reduction in current
harmonics was not on the utility side where the concern arose. In the following sections, each of
Page 58
the basic building blocks will be described. Remember that any drive must contain three blocks:
input rectifier, DC bus and output inverter. These individual blocks may be varied somewhat
independently.
Three Phase Full Bridge Rectifiers

The most common rectifier in high power electronic devices is the three phase full bridge rectifier.
It uses six devices, most commonly diodes or SCRs, to form the bridge. Two devices are
connected to each of the three incoming phases. One device from each phase connects to the
positive DC bus, the other to the negative bus. Each of these six devices conducts during either
the positive or the negative half cycle of its respective phase. This means we get two pulses on
each incoming phase thus in total we have a six pulse converter.
The six pulse converter has characteristics that are somewhat invariant, depending on the
manner in which it is applied. Input current distortion levels of 25% to 35% are typical. However,
through misapplication or improper DC bus component sizing, the level can be much higher. Six
pulse converters should not be confused with the six-step or variable voltage inverter. These are
two different converters, and neither or both may be present in any given VSD.
Multi-Pulse Converter Rectifiers

Multi-pulse converter rectifiers are used to reduce input current harmonics in power electronic
equipment. Most multi-pulse systems used today are multiple three phase bridge rectifiers
connected in parallel via phase or time-
shifted power supplies. In multi-pulse
systems, two pulses per phase are still
achieved, thus the pulse number is always
twice its input phase number.
A phase-shifted power supply is

accomplished by using a phase shifting
transformer. The transformer is connected
to a standard three phase supply and
through vector combination of those three
phases develops the required number of
output phases. This transformer may or
may not be included as a part of the VSD Figure 22: 12P Converter System
hardware. Care must be used to understand
whether or not a multi-pulse VSD system
requires a special or standard power supply.
The most common multi-pulse system is the

twelve pulse bridge, which uses two six pulse
converters phase shifted by 30 degrees. In
Figure 22, two six pulse converters are
connected to a dual wound delta/wye
secondary which provides the necessary 30
degree phase shift.
Generally, a twelve-pulse converter can

reduce input current total harmonic distortion
(THD) from the six-pulse average of around
30% to about 8%. This is a significant
reduction in THD. In cases where the short
circuit system capacity is more than twenty
times greater than the VSD load current, the Figure 23: 18P Converter System
twelve pulse converter will allow full
compliance with the IEEE Std 519-1992,
Page 59
IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power
1
Systems. More will be said about this standard in the Applications section.
Higher pulse number converters will further reduce the input current distortion levels. For instance,
an eighteen pulse converter will operate at less than 3% THD quite readily. In Figure 23, three six-
pulse converters are fed by an auto phase-shift transformer to provide eighteen-pulse operation.
Again, care must be taken to understand whether or not the phase shifting transformer is included
in the VSD or must be supplied separately. Twenty-four and higher pulse numbers can be
implemented cost effectively in higher horsepower systems.
Multi-pulse converters can be paired with the appropriate DC bus components and combined with
any of the following inverters to make a fully functional VSD.
Current Source Inverters

As stated earlier, the DC bus in a VSD provides either a current or voltage source to an inverter.
In a current source inverter, large inductors are used to supply a current source to the inverter.
The current supplied to the inverter is normally controlled by an SCR. This is an example of the
output inverter type of the VSD influencing the choice of the input rectifier type.
The current source inverter controls only the output frequency of the drive, while the current and
voltage are controlled by the input converter. The inverter may operate in either six-step or PWM,
both to be discussed in the following section. Current source technology is typically the preferred
method in extremely high horsepower systems, say 5,000 HP+, due to the availability of the
necessary power semiconductor devices at those voltage and current ratings.
Voltage Source Inverters

In a voltage source inverter, large banks of capacitors act as a low impedance DC voltage source
for the inverter. The inverter then changes this DC voltage into AC voltage by one of various
switching methods. These methods generally fall into two categories: variable voltage inverters
(VVIs) or constant voltage inverters (CVIs). VVIs usually employ a controlled rectifier, mentioned
earlier, to control the DC bus voltage and thereby the output voltage of the inverter. In a CVI, the
output voltage is controlled by the method of switching.
Variable Voltage Inverters

VVI drives are most generally six-step inverters. The unit consists of six switches, each
one turning on and off one time during every output cycle. The name comes from the fact
that each cycle is divided into six 60-degree periods. During each period, there is a
unique combination of power devices activated. This results in a phase to phase voltage
waveform that has six identifiable "steps" to approximate a sine wave. This is also
referred to as a "quasi-sine-wave" inverter. The inverter controls only the output
frequency, and is a relatively simple and rugged topology. Because of the unique
characteristics of the six-step waveform, the electrical stresses on the power devices are
significantly reduced over other topologies.
Pulse Width Modulated Inverters

Pulse width modulated (PWM) inverters also consist of six switches, but they switch many
times per output cycle to control both output voltage and frequency. For this reason, they
are typically fed by an uncontrolled diode bridge rectifier. In a PWM inverter, the voltage
waveform is divided into many small time periods. (The number of periods can range from
a few hundred to several thousand.) During each period, the instantaneous output voltage
is approximated by a square wave at some duty cycle. A 100% duty cycle would represent
full voltage, and a 0% duty cycle would represent zero voltage.
To generate a sine wave, these "pulses" would start at zero width and build, sinusoidally,
to 100% duty cycle at the 90 degree point of the waveform. Then they would decrease in
width sinusoidally to zero again at the 180 degree point of the waveform. The connections
to the motor would then be reversed, and the process would repeat to finish the
Page 60
waveform. The output voltage level is the integral of these pulse widths of DC bus voltage
height over any given cycle. This integration is performed by the inductance of the motor,
and the resultant current waveform becomes increasingly sinusoidal as more pulses are
used. To vary the average voltage, each pulse width is multiplied by a scale factor. (To
get half the output voltage, each pulse would be one half of its original width.)
The electrical stresses on the power devices of a PWM inverter are significantly higher
than on a six-step inverter. Each switching transition causes high losses in the power
devices, occurring hundreds or thousands of times per cycle. Because of this, greater
care must be taken to ensure that the losses and the resulting voltage stresses are
managed properly. This can add to the complexity and cost of this type of inverter.
PWM inverters are also used in some current source topologies. In this configuration, the
PWM inverter may be combined with an SCR to regulate the current source.
The Load
In any discussion of inverters, it is necessary to consider the load. In most industrial drive
applications, the motor usually sits relatively close to the drive, and its electrical
characteristics dominate the load that the inverter "sees". With the submersible motor and
pump, this is not the case. The motor can be thousands of feet away from the drive.
There will almost always be a step-up transformer in between it and the drive to obtain the
desired terminal voltage. The parasitic elements in all of this equipment can be a
significant portion of the electrical load to the drive, and transmission line effects begin to
appear. In the worst cases, the down hole system can become an underdamped tuned
circuit. These effects will be discussed in more detail later.
Optional Equipment
Input Line Reactors
Input line reactors are inductors placed in series with the VSD input (Figure 24). These inductors
most typically have been applied in cases where a VSD with a very small DC bus inductance
needed the additional inductance to reduce peak
input current levels. In this case, the input line
reactors are seen to reduce the input current
harmonics of the VSD. If a VSD has an
adequately sized DC bus inductance, the addition
of input line reactors will not greatly improve
harmonic current levels.
Surge Arrestors
Surge arrestors are applied to the input of a VSD
to provide protection against line transients.
While the simplest arrestor is the spark gap, most Figure 24: Input Line Reactors
VSD surge suppressors are metal oxide varistors
(MOVs). An MOV is simply a resistor whose resistance falls dramatically with rising voltage. When
a dangerously high voltage is present, the MOV provides a shunt path to dissipate the surge
energy. Some units will combine the MOV with a resistor capacitor snubber for higher frequency,
lower energy transient suppression.
Once again, some confusion has been present recently due to concerns regarding harmonics.
While surge arrestors can react to and clamp transient including harmonics, they should not be
regarded as steady state harmonic eliminators. The easiest way to understand this is in terms of
power dissipation. If a VSD produces current with 30% THD, then a filter to reduce that distortion
would need to be capable of handling a large portion of 30% of the input RMS current level in the
steady state. Clearly, the size of surge suppressors makes this level of steady state energy
dissipation impossible.
Page 61
Passive Filters & Power Factor Correction
Filters can be applied to either the input or the output of a VSD. Most filter topologies include
some combination of the same components used in the DC bus section of the VSD: inductors,
capacitors and resistors.
Filters change the harmonic characteristics

of a voltage or current waveform by blocking
harmonic currents or by providing an
alternate path in which the harmonic currents
are allowed to flow. High pass filters, low
pass filters, and tuned filters are examples of
the various filter types.
In Figure 25, an input converter is being fed

from the utility with a shunt power factor
correction capacitor (PFCC) and a series line
reactor. There is little distinction between Figure 25: Series Reactor Shunt Capacitor
input harmonic filters and power factor
correction in VSDs. Again noting Figure 25, the PFCC certainly improves the power factor, but in
concert with the series reactor, the two components behave as a low pass filter.
Input harmonic filters are the most common, and are applied to reduce current harmonics injected
by the VSD into the utility system. Most often, tuned filters are placed in parallel (shunt filter) with
the drive input to provide a path for the VSD's characteristic
harmonic components. A tuned filter is shown connected in
parallel to the VSD input in Figure 26. More will be said about
converter characteristic harmonics in the Comparisons section.
Any time capacitors are introduced into a power system, the

possibility of unwanted system interaction exists. This
interaction can take many forms. One example would be the
absorption of harmonic currents generated by other loads
connected to the power system. When this occurs, the
capacitors may experience higher current than the design called
for, leading to premature failure. Further, the capacitors can
create a system resonance resulting in high circulating
harmonic currents. These currents then produce high harmonic
voltages elsewhere in the system. Any time capacitors are Figure 26: Input Harmonic
introduced to the power system, a study of the interaction of Filter
those capacitors with the system would be advisable.
Passive filters are also being applied on the output side of VSDs to lower the amount of THD
being introduced to the ESP. This becomes essential in the application of high frequency PWM
drives, since the fast switching times tend to excite transformer, cable and motor system
resonance. The interaction of the drive switching frequency with the tuned circuit of the down hole
system can cause dangerously high over voltages at the motor terminals. Left unchecked, these
voltage stresses will damage the motor winding insulation leading to premature failure.
Active Filters
Active filters are relatively new and, due to cost and complexity, are seen only in small numbers.
Essentially active filters are specialized converters, which monitor a current, identify the existing
harmonic components and inject harmonic currents, which are out of phase with the existing
harmonic components in order to cancel them.
Page 62
Active filters are also combined with passive filters in order to reduce the amount of power
handling capacity required by the active device. In this way, custom wave shaping can be
accomplished without requiring large auxiliary converters.
Page 63
APPLICATIONS
The application of VSDs to ESP systems is, in itself, a science. While many of the same concerns
in applying VSDs to other systems arise, so do unique considerations. The characteristics of the
submersible motor alone are quite different than those of a typical surface motor. Also unique to
ESP applications is the need for a step up transformer and long lengths of cable. These three
components create a complex, fine-tuned circuit.
Today, most surface equipment VSD manufacturers are designing VSDs with a minimal cable
distance requirement between the VSD and motor. While this greatly simplifies the application, it
is obviously not an option for ESPs.
VSD Advantages
The reasons for applying VSDs to ESPs are numerous and well documented. They will be shown
here in the interest of completeness, and to emphasize the fact that VSD technology is used to
gain specific advantages over fixed speed operation. Decisions relating to specific VSD topology
selection will be left to the Comparisons section.
Improved System Efficiency

Well productivity indexes
contain uncertainties.
Combining this fact with finite
flow rate steps in pump bowl
designs, the process of
matching a particular pump at a
predetermined speed to a given
well is at best difficult. In
practice, it is often impossible.
When well productivity

fluctuates below the design
point after completion, the
optimum pumping rate also
decreases. In fixed speed
application, the only way to
control excessive flow rate is
through the application of
Figure 27: VSD Tornado Pump Curve
valves (equipment can be
cycled on and off but increased
losses and wear are introduced with that scenario as well). Any time a valve is introduced, the
pressure drop across the valve is proportional to the energy dissipated in that valve. This results in
decreased system efficiency.
With a VSD, flow can be optimized for a given pump and a given well productivity index so as to
maximize the efficiency of the overall system. Note in Figure 27 how a pump's flow rate capability
varies from roughly 5,000 barrels a day to more than 13,000 over the 50-70 Hz speed range
without leaving the pump's designed operating range.
Maximized Well Production

On the other hand, if the productivity index is higher than expected, the producer must opt for
changing the size of the ESP string in order to increase production. With a VSD, the speed can be
increased up to the maximum available horsepower of the motor in order to maximize production
while maintaining system efficiency. Again, note in Figure 27 how the pump speed could be
increased above 60 Hz to gain additional thousands of barrels a day. The speed can be increased
to the point at which the horsepower ratings of the VSD or the motor are reached.
Page 64
As a pump experiences normal wear during the course of operation, its head-flow properties
change resulting in decreased production. When a VSD is used, the speed can be increased as
the pump wears to maintain maximum production over a longer pump life.
Production Matched to Process

As available pump input fluid affects the required pumping rate, so too can the output process
capability. In practice, many ESP systems may feed one tank, or one pipeline. As the productivity
of the various wells fluctuates, so would the total production of all of the ESP units seen as one
system.
In some cases, fluctuating production rates over many wells need to be combined to create a
relatively constant production system. With VSDs, this is accomplished easily. Each VSD monitors
its own well productivity and is fed a demand by the system controller. As one ESP well declines
in productivity and must slow down, another with a higher productivity can increase speed to
maintain a constant overall system production level. When this is achieved, pipeline stresses are
well behaved and process controls do not have to cope with fluctuating input levels.
Down Hole Equipment Isolated

In any ESP installation, one of the primary concerns is long equipment life due to the cost of
pulling and re-running a system, not to mention the loss in production or cost of the equipment
itself. For these reasons, measures to ensure the longest possible ESP system life are in order.
Power system disturbances are one of the leading causes of premature ESP motor failure in fixed
speed applications. This results from the fact that the motor is connected via the contactor directly
to the utility line with transformer and cable impedances being the only isolation. Large voltage
transients can thus travel through the transformer and down the cable to damage the motor
insulation.
When a VSD is connected in the stream, automatic isolation occurs. The input converter and the
output inverter of the VSD are effectively decoupled by the low pass filtration in the DC bus.
Further, high energy transients will open fuses or even destroy solid state semiconductor devices
while never leaving the cabinet of the VSD. While the latter results in a VSD failure, typically these
failures can be repaired in a fraction of the time and at a fraction of the cost when compared to an
ESP string failure.
Reduced Starting Stresses

Across the line starting for ESP motors is both electrically and mechanically stressful. Depending
on the combination of input system and down hole cable impedances, inrush currents can be
seven to ten times the full load input current rating of the motor. With the motor torque being
directly proportional to the current, the instantaneous torque values can be very high. This results
in mechanical fatigue, possibly leading to shaft failure. Also occurring as a result of the high inrush
current is extra heating during start up. This is particularly troublesome if repeated start attempts
are required due to hard starting conditions. Finally, large inrush currents during start up can
create utility system voltage "sags" or "dips". These fluctuations in system voltage can cause
problems with other users.
With a VSD, the maximum current levels can be controlled during start up. In this fashion, the
minimum required starting torque can be developed. The reduced current level in start up means
less residual heat after the start. Improved system life can be expected from both of these
reductions.
Utility Interface
When specifying a VSD, it is desirable not to introduce problems to the utility system which could
interact with the rest of the users on the system. Undesirable interactions are mainly poor input
power factor and high input current distortion. Poor power factor leads to unnecessarily high input
current levels thereby reducing the overall system capacity to serve other loads. Input current
Page 65
distortion which is injected into the power system can reduce the life of other equipment
connected to the system or cause electronic devices to malfunction.
Input Power Factor

The input power factor of any electrical installation is by definition the ratio of real power delivered
measured in kilowatts (kW) to apparent power delivered measured in kilo-volt-amps (KVA). This
is referred to as the total power factor (TPF).
In the case of traditional motor loads, this boils down to the displacement in time or the phase
angle between the voltage and current waveforms. The cosine of the displacement angle is then
the displacement power factor (DPF). If no
harmonics are present, the DPF multiplied
by the apparent power in KVA yields real
Displacement
power in kW. When harmonics are present, KVAR
the issue of power factor becomes slightly
more complex, and is comprised of three
factors. In addition to the real power
component and the displacement reactive
Total KVA
component, measured in kilo-volt-amps-
reactive (KVAR), harmonics add the
distortion component also measured in KW
KVAR. In other words, we now have three
power factor components: total power factor, Distortion KVAR
displacement power factor & harmonic
power factor (HPF). In Figure 28, a three
dimensional diagram shows the relationship
between these three components and the
total apparent power in KVA.2 Figure 28: 3D Power Factor Diagram
Utility companies are concerned with total power factor. This number describes the relationship
between the current they must deliver and the part they can actually charge you for in terms of
energy consumption. If the DPF, HPF or a combination of both cause the TPF to be low, utility
system capacity is consumed by reactive current that does not deliver power. To compensate, the
utility will sometimes charge a power factor correction charge, and install PFCCs near the load
with a poor power factor.
Input Current Distortion

One of the most talked about issues in the application of VSDs today is the input current
distortion, and compliance with harmonic specifications. Of these specifications, none is quoted
more frequently than IEEE519-1992. The 519 standard gives definitions, suggested practices, and
examples. The philosophy of the standard is straightforward: each individual utility consumer must
control their current distortion, and the utility will then be able to supply voltage adequately free of
distortion to all of its users. In order to accomplish this goal, the standard recommends current
distortion levels for each user based on the relative size of the load to the system capacity.
These current distortion values are detailed in the most quoted table from the standard shown
here in Figure 29. On the left hand side of the table is the system short circuit to load current ratio.
This determines the relative size of the system to the load. On the right hand side of the table are
the respective allowable total demand distortion (TDD) values. In between are the individual
harmonic order limits. It is easy to see from the table that the larger the load becomes with
respect to the system, the more stringent the requirements become.
The TDD differs from the THD in the following manner: THD refers to an instantaneous value with
harmonic magnitudes compared to the present fundamental current value. TDD refers to
harmonic values as compared to the demand current value. This is helpful in meeting the
Page 66
standard, since infrequent operation at low speed higher harmonic-generating levels will be offset
by operation at high speed, lower harmonic-generating levels.
Also noteworthy is the fact that the individual harmonic limits quoted are for characteristic
harmonic currents. Non-characteristic harmonic current limits are more stringent. A converter's
characteristic harmonics are those with harmonic orders defined by the converter pulse number
multiplied by any integer, with one then being added to or subtracted from it. That is h = kq ± 1
where h is the harmonic order, k is any integer, and q is the converter pulse number. From this
equation, the characteristic harmonics of a six pulse converter are then the fifth, seventh,
eleventh, the thirteenth and so on.
Current Distortion Limits for General Distribution Systems

(120 V Through 69 000 V)
Maximum Harmonic Current Distortion
in Percent of IL
Individual Harmonic Order (Odd Harmonics)
Isc/IL <11 11 ≤ h < 17 17 ≤ h < 23 23 ≤ h < 35 35≤ h TDD

<20* 4.0 2.0 1.5 0.6 0.3 5.0
20<50 7.0 3.5 2.5 1.0 0.5 8.0
50<100 10.0 4.5 4.0 1.5 0.7 12.0
100<1000 12.0 5.5 5.0 2.0 1.0 15.0
>1000 15.0 7.0 6.0 2.5 1.4 20.0
Figure 29: IEEE519-1992 Table 10.3
The standard also encourages the use of multi-pulse converters by making the limits more lenient
for their characteristic harmonic currents. The values in Figure 29 are multiplied by the square
root of the converter pulse number divided by six or ((q/6). In the case of a twelve-pulse converter,
the allowable limits for the characteristic harmonic currents are then raised by the factor of 1.414.
The TDD limits remain the same. In this way, customers are less likely to have to struggle with
compliance issues based on individual harmonic levels.
Input Voltage Distortion

Input voltage distortion in VSD applications is a function of three factors: the pre-existent voltage
harmonic levels, the impedance of the power system at the point of common coupling (PCC), and
the harmonic current profile being generated by the drive.
The current harmonic profile injected by the VSD is a function of the converter topology and its
loading conditions. The current harmonics injected by the VSD produce a voltage distortion based
on the system impedance through which they pass. Any pre-existent voltage harmonics will be
added by vector addition to the voltage distortion created by the VSD's current harmonics.
In short, if the utility supplies a clean voltage source initially, and the VSD complies with the
current distortion limits shown in Figure 29, voltage distortion levels will be in compliance by
design of the standard.
Page 67
ESP Interface
The primary concern of VSD application to an ESP is accomplishing the advantages in operation
stated earlier. At the same time, unwanted side effects must be minimized in order to realize an
overall gain in performance. Excessive motor heating, increased voltage stresses, additional
mechanical wear, and maximization of torque performance are key areas to consider.
Motor Heating/Current Distortion

Excessive motor heating can certainly reduce ESP life. The additional heating in a motor when
applied with a VSD comes from two main factors: increased winding losses due to higher current
values and increased core losses due to high frequency components.
Since every VSD employs an inverter to convert the DC bus voltage back into an AC waveform,
the resulting waveform is never a perfect sine wave, but rather an approximation. This means that
other frequency components are present, or in other words, the wave presented to the motor is
distorted. Consequently, the total current values when operating a motor with a VSD are higher
than corresponding across the line values. This increased current level produces higher resistive
losses in the motor windings.
Research on surface motors applied with VSDs has shown that after de-rating a motor torque by
five to six percent, increased motor heating is still present. An increase of motor temperature rise
of 7.8% has been noted with PWM inverters, while an increase of 9.4% was recorded using a six-
3
step inverter. ESP motor oil temperature rise test results in using the two inverter types will be
discussed in the Comparisons section.
Increased core losses also result in higher motor operating temperatures. As the motor core
experiences changes in the applied terminal voltage, the magnetic dipoles must re-align to the
new magnetic field present. When VSDs switch to change states, the resulting changes in motor
terminal voltage can be sudden and high in magnitude. The core of the motor will try to respond
by re-aligning its magnetic dipoles. Every time this happens, the friction of motion of the dipoles
releases heat. For this reason, it is important to minimize the sub-cycle voltage fluctuations at the
motor terminals.
Mechanical Wear
Decreased motor bearing life has been noted in units being operated from inverter supplies. This
is a result of increased bearing wear due to a process known as electric discharge machining
(EDM). Induced shaft to stator voltages create currents which remove bearing material as they
flow. The effect is more pronounced in long axial machines. The phenomenon is also noted in
motors fed from a utility source. However, PWM inverter fed surface motors have been shown to
produce fifteen times the voltage potential which produces these bearing currents than a motor
4
operated across the line.
Voltage Stresses
The combined demands of high voltage and limited space in submersible equipment raises the
issue of voltage-related failures to a significant concern. As stated earlier, a VSD can act as a
buffer between the power system and the down hole equipment and isolate it from random
system transients. However, all power inverters, when applied to a submersible system have the
potential to generate higher peak voltages than when the system is operated from a sinusoidal
voltage source. This is due to the fact that inverters are inherently digital in nature rather than
analog. (The output can only change in discrete voltage steps and the transition from step to step
happens quite rapidly.) When these "square" waveforms are applied to the complex impedance of
the down hole system, the natural response is a damped sine wave. The peak value, resonant
frequency, and decay rate of this sine wave is determined by the complex impedance of all of the
equipment connected to the output of the VSD.
Even though this "ringing" is a normal response of the down hole equipment to the VSD output
waveform, it can become a problem under certain conditions. On a six-step drive, the ringing has
Page 68
time to decay to zero between each vertical edge of the waveform. However, on a PWM
waveform the vertical edge of the VSD output waveform can occur at just the right instant to add
to the ringing from the previous vertical edge. Under the worst conditions, this effect can produce
peak voltages in excess of two times the applied peak voltage and can occur many times per
cycle. The two main considerations are the magnitude of the voltage stresses and the frequency
of repetition. The rise time of the over voltage stress greatly impacts the potential for ringing. In
fact, "it is the repetitions, along with the rise time, that have the most potential for insulation
5
damage."
This problem arose in the industrial market a number of years ago where problems were
documented with as little as 100ft of cable between the drive and motor. Manufacturers have
since developed a number of methods to deal with the ringing. When applying these methods, it is
important to understand their limitations and drawbacks. The simplest method is to add series
inductance between the VSD and the load. This can slow the rise time of the voltage waveform
applied to the down hole equipment, but unless very large inductors are used, the overall effect
may be minimal due to the relative impedance of the inductor to the overall system impedance.
Most other methods involve some type of filter applied to the high voltage side of the step up
transformer. These filters can consist of L-C, R-C, or R-L-C combinations or just capacitance. Of
course a large enough R-L-C filter could completely smooth out the waveform into a perfect
sinusoid. However, within the cost constraints of most applications, the filter will only be large
enough to reduce the ringing effects by some percentage.
Torque/Amp
While it is not in the scope of this paper to discuss VSD control algorithms, it is beneficial to
understand how the various control schemes affect the overall system performance. Most of the
VSDs have control methods that can be loosely grouped into one of three classifications: 1)
Voltage control 2) Current control, and 3) Flux or Vector control. There is typically an "outer"
control loop that determines if the motor is operating at the correct RPM and one or more "inner"
loops with the innermost being Type 1, 2, or 3 as listed above. In methods 1 and 2, the process is
just as the name implies. The desired motor terminal voltage (or current) and frequency is
determined by the outer loop(s) and then regulated to some tolerance by monitoring the actual
motor currents and/or voltages. The response time of these two methods is somewhat limited by
the topology. For instance, in a variable voltage inverter, the maximum rate of change of the
output voltage is affected by the choice of DC link components and in a PWM inverter, the
response time is limited by the choice of switching frequency. However, in both cases, the
ultimate limit to the response time is the motor itself. An induction motor is by nature very
oscillatory in its response to step changes in terminal voltage or loading. Because of this, the time
required to stabilize after a change in load can be quite long (particularly for large diameter
surface motors with high inertia).
This response time of the motor itself was one of the reasons for the development of Flux control.
With this method, the control system contains a model of the motor and attempts to compensate
for the motor characteristics dynamically. When applied properly, this control scheme can achieve
nearly instantaneous torque response to changes in the load or the commanded torque.
Unfortunately, to work properly it is necessary to have accurate motor parameters, and any
change in these parameters (for instance change due to heating) that is not accounted for
properly will degrade the system performance. Also detrimental to correct operation would be any
complex impedance between the VSD and the motor as is the case in a submersible installation.
Flux control is sometimes referred to as torque control. In reality, all three control schemes control
torque by controlling current. The difference is that Flux control is capable of slightly more precise
torque control.
Of course, the application is what determines the need or lack of need, for rapid response. In any
application of a VSD, the desired end is to control the RPM of the motor shaft under the various
load conditions that might exist for that application. Typical "high performance" (rapid response
time) would be used on servo systems where the motor is being used for precise positioning or
Page 69
control of an industrial process such as the pulp and paper industry. Pump and fan applications
are at the other end of the spectrum because precise speed or positioning control is not
necessary and the load changes only gradually. Under
steady state conditions, any of the three systems can
achieve the same operating performance from the motor
when set up properly.
In evaluating a VSD and its ability to start a hard starting

motor, we need to examine the torque/current
characteristics. In Figure 30, a typical induction motor's
6
speed torque characteristic is shown. As can be seen in
the figure, the motor has the ability to deliver a large
percentage of its full torque capability over a wide speed
range. It is important therefore to examine the VSD's Figure 30: Constant V/Hz Torque
capability to deliver the necessary current to achieve Speed Curves
those torque levels over a motor's speed range.
COMPARISONS
To better understand the complexities of VSD application to ESPs, testing has been performed to
determine the performance advantages and disadvantages of the various converter and inverter
topologies. All test data was gathered from tests performed inside a controlled test facility. Input
converter topologies tested included six and twelve pulse controlled and uncontrolled rectifiers.
Since most ESPs are applied with voltage source inverters, only six-step variable voltage and
PWM inverters were tested.
Utility Interface
Four converter topologies were tested to determine input power factor and input current distortion
characteristics. Recall from the Applications section that the input voltage distortion is really a
function of the input current distortion as far as the VSD is concerned. Six pulse controlled and
uncontrolled rectifiers are examined in the first section, with twelve pulse controlled and
uncontrolled rectifiers following.
Six Pulse Full Bridge Rectifiers

Six pulse full bridge rectifiers dominate the marketplace due to their low cost and simplicity.
However, those benefits come with increased harmonic distortion levels. In comparing the
controlled and uncontrolled rectifier
types, the first point to address is the Six Pulse Controlled and Uncontrolled
most obvious: DPF.
Converter Input Power Factor
Since a controlled rectifier regulates
1
the DC output voltage by varying the
Power Factor
turn-on time of its input devices, the 0.8

current waveform is displaced in 0.6 Controlled
time from the voltage waveform. 0.4 Uncontrolled
Remember that the DPF is defined 0.2
as the cosine of the angle of
0
displacement between the
25 45 65
fundamental current and voltage
waveforms. As a result, the DPF of a VSD Output Frequency
controlled rectifier decays somewhat w/ESP at Full Load at 60 Hz
linearly with decreased output
voltage, while the DPF of an
uncontrolled rectifier remains near Figure 31: Power Factor Comparison
unity under all operating conditions.
Page 70
Of interest however is the system TPF, which actually determines the total reactive current
demand. As stated earlier, the DPF and the HPF combine through vector addition to yield the
TPF. Both controlled and uncontrolled converters experience an increase in current harmonic
distortion when their output voltages
are decreased. As a result, the TPF of Six Pulse Controlled & Uncontrolled
an uncontrolled rectifier experiences Rectifier Input Current Distortion
some reduction. In Figure 31, the 80%
power factor of the controlled rectifier 70%
drops linearly with speed, while that of 60%
the uncontrolled unit drops to about 50%
80% at half speed. A controlled 40% Uncontrolled
rectifier will operate at power factors 30%
Controlled
comparable to the uncontrolled 20%
rectifier with proper set up. The units 10%
tested were operating the pump with 0%
characteristics shown (Figure 27), and 25 35 45 55 65
at each frequency were operating the VSD Output Frequency w/ESP
pump at its best efficiency point
(BEP). Figure 32: THD-f Comparison of Controlled and
Uncontrolled Six-Pulse Rectifiers
All six pulse rectifiers have the same
characteristic harmonics, and within good
design limitations quite predictable 500
harmonic characteristics. When the
controlled rectifier delays the conduction
period of its current, a higher turn on 250
voltage is experienced resulting in higher Amps

input current distortion. An uncontrolled
0
rectifier experiences an increase in input . 4.17 8.34 12.51
current harmonics due only to increased 2.08 6.25 10.42 14.59
ripple in the DC bus under reduced
-250
loading condition. In general, neither
converter offers exceptional input current
harmonic performance even at full load. mSec
-500
As shown in Figure 32, the best case
harmonic current distortion for either
Figure 33: Fully Loaded Six Pulse Controlled
converter is about 30% with respect to the
Converter Current Waveform
fundamental current(THD-f).
For the sake of reference, a fully loaded 300
controlled six pulse converter waveform is

250
shown in Figure 33 (really either waveform
could be used here, as the profiles are so 200
similar). Note the waveform has significant Amps

periods of time when the value is zero, followed 150
by steep rising or falling edges. This leads to 100

the high harmonic content of the waveform.
50
Finally, the current harmonic spectrum for the

0 1 5 7 11 13 17 19 23 25 29 31
six pulse waveform is shown in Figure 34. Note
the characteristic harmonic orders present Harmonic
follow the criteria discussed earlier.
A few points should be stressed here. First, the Figure 34: Harmonic Spectrum of Figure 33
six pulse converter will never comply with
IEEE519 when considered as a stand-alone system. That is to say, regardless of the system size
it is being connected to, the six pulse converter harmonic levels can never meet the limits stated
Page 71
in the standard without filtration (see Figure 29). However, in instances where a VSD may be
installed as a portion of a large load, the whole installation could meet the harmonic standard. In
these cases, a six-pulse rectifier is still the most cost effective solution.
Twelve Pulse Rectifiers

In cases where low input current harmonics are a requirement, the solution of choice in ESP
systems has been the twelve-pulse converter. The twelve-pulse system can deliver good
harmonic performance at a reasonable cost, while maintaining a high durability and reasonable
simplicity.
When comparing the harmonic performance of the controlled and uncontrolled twelve pulse
rectifier types, it is necessary to understand the basic principle of harmonic reduction through
phase multiplication. Essentially, when two six pulse converters are connected with a 30( phase
shift, the complex current waveforms of each converter are then shifted by 30( of the
fundamental. In a 60 hertz system this equates to 1.38 mSec in terms of time. As the two currents
are injected back through the phase shifting transformer, the fundamental along with the twelve
pulse characteristic harmonic currents combine additively. However, when the characteristic
harmonic currents of the six pulse converter that are not characteristic to the twelve pulse pass
through the transformer, they are 180( out of phase and are eliminated. Let us examine the fifth
harmonic as an example.
The fifth harmonic of one converter is phase shifted by 30( of fundamental, or 5 X 30( = 150( of its
own time base. Being a negative sequence harmonic and going in the reverse direction through
the phase shift transformer, it then is shifted an additional 30(. This results in a net 180( phase
shift with respect to the fifth harmonic current from the opposite converter. Complete cancellation
of the fifth harmonic would then occur in the phase shifting transformer if both converters
produced equal magnitudes of the fifth harmonic current.
This leads us to the crux of the issue in comparing the controlled and uncontrolled twelve pulse
converter topologies: the controlled converter has the ability to match the two input current levels.
The uncontrolled converter must depend on balanced input impedance, DC bus path impedance
and so on to achieve good input current sharing between the two converters. If no other schemes
are employed to balance the two converters' input currents, while the THD of the uncontrolled
twelve pulse converter may be reasonably low, its non-
1000
characteristic harmonic current levels may be above
the limits specified in IEEE519.
500
In general, the behavior of the twelve pulse converter
differs from the six pulse in that its current harmonic Amps
levels do not increase sharply with decreased loading. 0
. 4.17 8.34 12.51
This is good for the system designer, as allowances do
2.08 6.25 10.42 14.59
not have to be made for high harmonic levels during
times of light loading. In general, input current -500
distortion levels are seen in the seven to twelve mSec
percent range over the vast majority of a typical
operating range. Further, harmonic levels typically -1000
decrease with reduced loading.
In Figure 35, the input current waveform for a fully

Figure 35: Fully Loaded Twelve Pulse
loaded twelve pulse controlled converter is shown.
Controlled Converter Current
Again, the differences between the controlled and
uncontrolled types are minimal. The displayed wave contains 9.5% THD. The complete harmonic
spectrum of the wave is shown in Figure 36. Note how the characteristic harmonic currents of the
six pulse converter, which are not characteristic harmonics of the twelve pulse converter, are
nearly eliminated. This is a result of good input impedance balance and proper sharing of current
by the two converters in the twelve pulse system.
Page 72
The uncontrolled twelve pulse converter was 400
operated under the same balanced input impedance
condition as the controlled converter. However, due
to its inability to ensure current sharing between the 300
converters, its THD was a bit higher at 10.78%. This Amps

is not as troubling, however, as the specific reasons 200
for the higher input current distortion. The
characteristic harmonic levels of the two converters
were almost exactly the same. However, some of 100
the non-characteristic harmonic currents of the

uncontrolled converter were nearly double the 0
values of the controlled converter. For instance, the 1 5 7 11 13 17 19 23 25 29 31
fifth harmonic current was 2.3% in the controlled Harmonic

converter, while the uncontrolled converter was
generating a fifth component of 4.2%. This could be
Figure 36: Harmonic Spectrum of 35
a cause for concern in very stringent application of
the IEEE519 standard, as the allowable limits for the
non-characteristic harmonic components are set at
one quarter of the table values (see Figure 29).
If we assume that a twelve pulse converter system is

being considered for an application where the short
circuit to load current ratio is between fifty and one
hundred, the limit for the fifth harmonic component is
then set to 10/4 = 2.5%. While both the controlled and
uncontrolled twelve pulse converters would be in
compliance with the TDD limit of 12%, only the
controlled converter would meet the individual fifth Tcouple 1
harmonic current limit. If the standard were being
strictly enforced, additional filtration would have to be Tcouple Entry
added to the uncontrolled converter in order to bring it Fill & Drain Plug
into compliance.
ESP Interface
Motor Heating/Current Distortion

Much has been written on the effects of various
inverter topologies on surface motors (see references
in the Applications section). Little documentation
exists, however, on their effects on ESP motors.
Tcouple 2
Tcouple 3
In order to demystify this topic, a test was set up using
a 562 series motor, 513 series seal and a 675 series
pump. These series numbers merely define the unit's
outside diameter. The system was sized to operate at
230 horsepower (HP) at 60 hertz. In this way, each
inverter topology's motor heating effect could be
compared to utility system operation.
Three thermocouples were routed through the motor

head fill and drain plug. One was terminated in the oil
return path from the thrust bearing. The second was
located just above the stator laminations near the lead
exit from the stator. The third thermocouple was Figure 37: Thermocouple Location for
positioned in between the motor stator and shaft near Temperature Rise Test
Page 73
the top of the stator. Thermocouple positioning inside the motor is shown in Figure 37.
A fair comparison of the inverter topologies to the across the line values necessitated ensuring the
ESP was operating at the same speed in rotations per minute (RPM), as well as the same position
on its pump curve. The across-the-line test was performed first with the RPM measured and
recorded. A flow control valve was adjusted at the pump output to set the pump operation at its
BEP. With both inverter topologies (six-step and PWM), the output frequency of the inverters was
set to 60 hertz. Next the output voltage was adjusted to establish the motor slip and therefore
RPM to within 1% of the across the line value.
Across the Line, Six Step & PWM Motor Oil Temperature
Rise Comparison
42.00
37.00
°C Rise
32.00 Line
Filtered PWM
27.00 Six Step
22.00
17.00
12.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00
Minutes After Start
Figure 38: Motor Temperature Rise
All three thermocouples deployed tracked each other in each of the three tests with less than one
quarter of a degree of variation between them. This would indicate good oil circulation, and lend
confidence to the temperature reading. All three thermocouple readings were averaged together
to smooth any ripple in the temperature feedback.
Each unit was operated for two hours, even

though temperature stability was achieved
much sooner. Surprisingly, the temperature
rise of the motor was very similar in all three
cases (Figure 38). Since only one degree of
variation is noted in any of the three tests,
one must conclude that the current 6>
waveform to the motor does not greatly

impact its overall efficiency.
The current waveforms of the two inverters

certainly are different and contain different
harmonic characteristics. The PWM inverter
offers a lower harmonic distortion waveform.
The wave shown in Figure 39 contains Figure 39: Filtered PWM Inverter Motor Lead
14.39% THD. Current
Page 74
The six-step inverter current waveform is
shown in Figure 40. The THD in that wave is
25.11%. The increased harmonic distortion of
the six-step inverter did not result in higher
motor temperature as shown in Figure 20.
Heating concerns also arise as a result of the
voltage waveform applied to the motor. While 4>
the THD of the six-step inverter voltage is

higher, the PWM waveform has more high
frequency content which can lead to higher
core losses. Comparisons of the voltage
waveforms are discussed in the next section.
Voltage Stresses
The ringing caused by a VSD waveform is Figure 40: Six-step Motor Lead Current
initiated by each vertical edge of the
waveform. As was noted earlier, you can
see from the waveform of a six-step VSD
(Figure 41), that even when the ringing is
severe, it has decayed to zero by the time
the next vertical edge occurs. Because of
this, the peak voltage impressed on the ESP
motor is very predictable and repeatable. In
this case, the peak value is a very consistent 7>
4.2 KV. However, in the PWM waveform you

can see that the peak voltage often exceeds
6KV (Figure 42). This effect is a function of
cable length, the PWM switching frequency,
and circuit parameters as stated earlier.
Output filters were added to evaluate their

effectiveness on the unwanted ringing. Figure 41: Six-step HV Waveform 2000V/div
Three different combinations were tested. 2mS/div
First was an inductor (L) added between the
VSD output and the step up transformer.
Second was a resistor-capacitor (RC) network
on the high voltage side of the transformer.
Third was a combination of both the inductor
and the RC network. In Figure 43, the resulting
waveforms of these three configurations are
shown respectively (going from top to bottom 3>
in the figure). The inductor alone had minimal

effect. The ringing is significantly reduced
using only the RC network. Of course, the
most improved waveform is the result of using
both the inductor and the RC network.
However, of the two, the RC network had the
largest effect.
Similarly, the PWM output voltage waveform is Figure 42: PWM HV Output Voltage Waveform
shown using the output inductor and the high 2000V/div 2mS/div
voltage RC network (Figure 44). Notice that
even though ringing is reduced, the high peak voltages are still present.
Page 75
Of course, any type of filter or output device
on the VSD adds cost to the system and
because of the increased complexity,
represents an increased potential for failure. 5>
Since they become a critical component of

the system, monitoring for correct operation is
important. Also, the losses in the resistive 11 >
components of the filter can add up to a

significant portion of the overall system losses
and so represent increased operating
1>
expenses. In this test, the RC network was
dissipating 3 KW when operating at 60hz.
Torque/Amp
No attempt was made to study the dynamic
response of either inverter topology since the Figure 43: Output Inductor & RC Filter Effects
loading of a submersible changes relatively on the Six-step Inverter Voltage WaveForm
slowly and steady state response becomes
the primary concern. What was tested, was
the starting torque and the ratio of torque to
current for both the six-step and the PWM
VSD.
In theory, the starting torque of an induction

motor is proportional to the current squared
divided by the applied frequency. This 7>
relationship can be seen in the constant

current graphs of Figure 45 showing the
change in torque due to frequency for the six-
step VSD. The torque increases linearly with
frequency until the step up transformer
saturates. On a submersible application, the
added impedance of the cable and
transformer become significant compared to
the locked rotor impedance. This requires that Figure 44: Filtered PWM Inverter Output
a lot of extra voltage be applied at the surface Voltage WaveForm using L & RC
to deliver the necessary starting current to the
motor. If the voltage is increased far enough, at some point the transformer's maximum volts per
hertz ratio is exceeded and saturation
occurs. Any additional current from the
VSD is then just circulated in the Starting Torque Vs Frequency &
transformer primary and does not produce Current
torque in the motor. This limits the lower
end of the starting frequency and affects 240
the torque per amp ratio at starting. For
Ft*lbs
the motor tested, with a down hole cable 190

450A T
length of 8000 feet, the maximum starting 140 300A T
torque produced was seventy percent of
its full load operating torque when the 90
motor current was at 150% of rated value. 0 20000 40000 60000 80000
This was achieved with the six-step drive I2/F
set to achieve the peak torque point on the
2
I /F curve.
Figure 45: Locked Rotor Torque
The PWM inverter tested was of the vector
control type, and the torque produced by it was about one half of that produced by the six-step
Page 76
drive at the same current. Since starting torque is predominantly a function of current delivered
and frequency, the limitation on this drive was the inability to defeat vector control and directly
control starting conditions. However, when the VSD parameters were varied to indicate much
higher than rated motor terminal voltage, starting torque was increased to comparable values to
the six-step inverter. Unfortunately this would indicate the necessity of a special set up for hard
starting conditions, and then a return to normal settings after the motor was started. A non vector
controlled PWM inverter would be expected to develop approximately the same torque as the six-
step at the same current and frequency levels.
Under normal operating conditions, the torque developed by both drives was approximately the
same. Of course proper setup is important in either case to achieve optimum performance. This
was a little more difficult to accomplish with the vector controlled drive because of the interaction
with the step up transformer and cable.
CONCLUSIONS
In applying VSDs to ESPs, many considerations arise. Some are the same as applications
involving surface motors, while many are unique. In the evaluation of the various topologies, care
must be taken to ensure that the topology chosen achieves the benefits of variable speed
operation while minimizing unwanted side effects.
From the utility interface standpoint, power factor and input current distortion concerns must be
addressed. If a high input power factor must be obtained under all operating conditions, power
factor correction may be required, especially in the application of a controlled converter. This can
be accomplished quite economically in most situations. When strict harmonic guidelines must be
followed, a six pulse converter whether controlled or uncontrolled may be inadequate. A twelve
pulse converter will reduce input current harmonics to an acceptable level in most situations.
Higher pulse numbers can be employed to further reduce harmonic levels. In comparing the
controlled and uncontrolled converter types, special attention may be required regarding the non-
characteristic harmonic levels in an uncontrolled converter. When applying any multi-pulse
converter, the applications engineer must determine if the phase shifting transformer will be
integral to the VSD, or must be supplied separately. If necessary, harmonic filtration can be
introduced to further reduce THD and/or individual harmonic orders. Following the input current
harmonic limits specified in IEEE519 will almost guarantee compliance with the corresponding
voltage harmonic limits.
Any time optional components are introduced to a VSD installation special concerns arise. When
input harmonic filters are introduced, an evaluation of the possible interaction of these filters with
the utility system should be performed. Input inductors will only result in a significant reduction of
current harmonics if the VSD has a small DC bus inductor. While surge arrestors are
recommended for most VSD applications, users should not expect these devices to act as
harmonic filters. If output filters are used on a VSD to reduce voltage stresses, the effectiveness
of these devices should be proven. Further, if the safe operation of the system requires proper
operation of these filters, the filter system should be monitored so that the ESP is protected from
high voltage stresses in the event of filter failure.
When evaluating the performance of different inverter topologies on an ESP, surface motor test
results should not be accepted. The different inverter waveforms presented to the motor do not
significantly change the ESP motor's efficiency. However, these waveforms can differ in the
amount of voltage stress placed on the motor's winding insulation. Voltage stress limits, as
defined by the manufacturer of the motor, should be followed in order to ensure maximum life
expectancy. Any VSD applied to an ESP should be capable of delivering full nameplate torque to
the motor under locked rotor condition. This will ensure the VSD is able to start the motor under
hard starting conditions. Correct set up and application is required regardless of the inverter
topology employed for the highest torque per amp operation. Some control algorithms require
more care in set up than others. Proper application of a flux vector control inverter requires
Page 77
knowledge of motor parameters such as leakage inductance, slip frequency, stator resistance,
etc.
Any VSD is a sophisticated piece of electronic equipment. Through proper selection, application,
and set up, they can deliver many benefits over fixed speed operation. Users should always
compare the advantages of VSD application with its cost and complexity. The most simple and
cost effective VSD for any given application will always achieve the best results.
GLOSSARY
BEP: best efficiency point of a centrifugal pump
Converter: any electrical equipment that changes electrical energy from one form to another;
also referred to as an input rectifier
CVI: constant voltage inverters
DC bus: this unit is comprised of passive, non-controlled devices. Typical elements of the
DC bus include inductors, capacitors, and resistors.
DPF: displacement power factor
EDM: electric discharge machining
ESP: electrical submersible pump
GTO: gate turn-off thyristors, similar to an SCR, but can be turned off by controlling the
gate
HPF: harmonic power factor - that portion of power factor derived from the presence of
harmonics
IGBT: insulated gate BI-polar transistors
Input Power
Factor: ratio of real power delivered measured in kilowatts (kW) to apparent power
delivered measured in kilo-volt-amps (KVA).
KVA: kilo-volt-amps. A measure of apparent electric power.
KVAR: kilo-volt-amps-reactive. A measure of reactive electric power.
kW: kilowatts. A measure of real electric power.
MOV: metal oxide varistor; a resistor whose resistance falls dramatically with rising
voltage
PCC: point of common coupling
PFCC: power factor correction capacitor
PWM: pulse width modulated
SCR: silicon-controlled rectifier - similar to diode, but with a gate to control turn on time
TDD: total demand distortion
THD: total harmonic distortion
TPF: total power factor. This refers to the input power factor or the ratio of real power
delivered measured in kilowatts (kW) to apparent power delivered measured in
kilo-volt-amps (KVA).
VSD: variable speed drive. Any VSD must contain three blocks: the input rectifier
(converter), the DC bus and the output inverter
VVI: variable voltage inverters
References
1
IEEE Std. 519 - 1992, “IEEE Recommended Practices and Requirements for Harmonic Control
in Electrical Power Systems,” April 1993
2
R. Waggoner, “How Harmonics Affect Power Factor-Part 2,” EC&M, February 1997
3
A. Boglietti, P. Ferraris, M. Lazzari, “Power Derating for Inverter Fed Induction Motors,” IEEE
Transactions on Industry Applications
4
J. Erdman, R. Kerkman, D. Schlegel, & G. Skibinski, “Effect of PWM Inverters on AC Motor
Bearing Currents and Shaft Voltages,” IEEE Transactions on Industry Applications, Vol. 32 No. 2,
March/April 1996
Page 78
5
A. Bonnet, “Analysis of the Impact of Pulse-Width Modulated Inverter Voltage Waveforms on AC
Induction Motors,” IEEE Transactions on Industry Applications, Vol. 32 No. 2, March/April 1996
6
S. Chapman, Electric Machinery Fundamentals
Page 79
Use of the PC Card ATA Flash disk with GCS Controls
Products
INTRODUCTION
The Graphic Control System (GCS) line of Centrilift Controls products provides advanced historical
data logging capabilities to the user. This historical information will help to diagnose equipment
problems, extend run life, and analyze production information. Several types of historical information
are available:
An Event history log stores all system events such as power up, parameter changes and alarms.
These events are date and time stamped, with a record of ‘before’ and ‘after’ parameter values.
A Historical Shutdown log stores the cause and date stamp of the last 99 shutdowns.
An on board digital ampchart, that samples ampchart Phase B every 100 ms and stores the
minimum, maximum and average every 4 minutes, replaces the standard paper ampchart and
ensures that the last 7 days of data is always available for viewing.
On the Centrilift Electrostart switchboard running a GCS Vortex motor protection & control unit, a
startup waveform that details the 3 phase Voltage and Current waveforms during a cross the line
start. The first two seconds of the last startup are sampled at 600 samples per second,
producing an informative set of waveforms for analysis and troubleshooting.
Built in datalogging functionality allows up to 12 system parameters (volts, amps, I/O, frequency)
to be logged as fast as once per second with the use of external PC Card ATA flash disks.
To facilitate the transfer and logging of this historical information, the GCS products incorporate a
PCMCIA card slot. The PCMCIA slot accepts type I or II PC Card ATA Flash cards. Currently 8
Megabyte ATA PC Cards from two different vendors have been approved for used, and other sizes
and manufacturers cards are being tested for compatibility and reliability.
The Centrilift part number for the approved 8MB PC Card ATA flash card, with industrial
specifications (-40 to +85 operating) is: 900608. These cards are stocked at Centrilift's head offices
in Claremore, Oklahoma.
The remainder of this document will explain the operation and application of the PC Card with GCS
Controls Products.
Page 80
INSERTING THE PC CARD INTO THE GRAPHIC DISPLAY
Orientation
The PC Card slot is located on the top right

side of the GCS Graphic Display. (See
below)
The initial production of Graphic display

boards had a slot that required the PC Card
to be inserted ‘upside down’
relative to the front of the
display. Most production
models of this version will
have a label below the PC
Card slot that indicates this.
The latest production version

of Graphic Display units require the PC Card to be inserted ‘right side up’ in a more natural
orientation.
In either case, the PC Card slot is keyed, such that if the card is inserted incorrectly, it will only
slide in about ¾ of the way into the slot. In the proper orientation, the card will slide in all the way
into the slot and require only a small amount of force to complete the electrical insertion.
NOTE: The PC Card COULD be pushed into the slot incorrectly if excessive force is used.
The general rule is that if the card slides more than ¾ of the way into the slot without any major
obstruction, it is oriented correctly.
RECOGNITION OF PC CARD ON THE GRAPHIC DISPLAY

Once the PC Card is inserted into the Graphic Display, a dialog box will appear indicating that
the PC Card insertion was noted, and the software will test the card for compatibility and
functionality.
If the PC Card tests OK, the dialog will be closed. At this point, the PC Card is ready for use, as
described in following sections of this guide. If the user had previously ‘Enabled’ the
Datalogging feature, a second dialog indicating that Datalogging was starting would be
displayed. This dialog would also close automatically.
If any problems exist with the card, an error message will be displayed. Consult the section
labeled “Troubleshooting” for error message explanations.
Accessing PC Card features
The PC Card features are accessed from the GCS Operating system via the PC Card Status
screen. The steps to access this screen are as follows:
1. Start at the Main Menu – If the main menu is not displayed, simply press the “MENU” key
several times until the group of 9 main menu options is visible.
2. Using the arrow keys, move the cursor to the ‘Datalog & History’ option, and press the
“ENTER” key.
3. The screen display could be one of many, but will normally be the “Shutdown History”
screen.
Page 81
4. Press the Left arrow key 2 times. This will display
STATUS
the PC Card STATUS screen, which details similar PC Valid ATA PC Card
CARD
information to that shown in the dialog that was Mnfct: SunDisk
OS: FAT 12
displayed when the PC Card was first inserted. (If Label: Logger1
S/N: 40441905
you did not originally see the ‘Shutdown History” SIZE
menu, keep pressing the ‘Left’ arrow key until the PC 7.6 MB, 7.41 MB free
Log file size: 189K bytes
Card STATUS screen is displayed.)
Logging: Enabled
Disable Datalogging
Setup Datalogging
Other PC Card Functions
MORE MORE
WRITING HISTORICAL DATA TO THE PC CARD

All the major historical databases can be stored as files on the PC Card for analysis on a laptop or
desktop computer. The information is stored as a Comma Separated Variable (CSV) file. This is
simply an ASCII file formatted with comma’s between the data fields of a record. This method of
storage was chosen to avoid any proprietary file structures that would need a special driver or
software interpolation program to read. Additionally, the CSV files are recognized by most
spreadsheet programs (Lotus, Excel, Quattro etc.) and are automatically converted to table data
when loaded.
NOTE: The Datalogging function of the GCS Display must be disabled to perform the following
tasks.
Accessing the “Other PC Card Functions Screen” PC Card Functions
Save Data to PC Card:

To save the historical databases to files on the PC Card, the Shutdown History
user must use the “Other PC Card Functions” screen. From Event History
PCCA
RD
the PC Card STATUS screen (see II- C above) use the arrow Phase B Ampchart
Startup Trend
keys to highlight and select the option “Other PC Card
Functions”
Saving the Shutdown History to the PC Card
The causes of the last 99 shutdowns with date and time

stamping can be written to the PC Card by selecting the Shutdown History option on the Other
PC Card Functions screen. This will create a CSV file named ‘SDHIST.CSV’ on the PC Card.
Saving Event History to the PC Card
The list of 255 recent system events, including data and time stamping can be written to the PC
Card by selecting the Event History option on the Other PC Card Functions screen. This will
create a CSV file named EVENTS.CSV on the PC Card.
Saving Phase B Digital Ampchart to the PC Card
The digital ampchart data representing the Phase B amperage recorded for the last week of
runtime, including data and time stamping can be written to the PC Card by selecting the Phase
B Ampchart option on the Other PC Card Functions screen. This will create a CSV file named
AMPCHART.CSV on the PC Card. This is a large file and may take up to 1 minute to complete
the save to disk.
Page 82
Saving the last Startup Waveforms to the PC Card
For GCS Vortex equipped switchboards, the option Startup Trend will appear on the Other PC
Card Functions screen. Selecting this option will cause 1200 records of data for the 3 phase
Voltage and 3 Phase Amperage recorded at the last startup to be saved to the PC Card. The
name of this file will be STARTUP.CSV. It may take 30 seconds or more to create this file.
In all of the cases above, a window opens when the write process begins, indicating the progress of
the file write operation. When this dialog window closes, the file on the disk has been closed and it
is safe to remove the PC Card from the slot.
SETUP AND ENABLE DATALOGGING

The datalogging capabilities of the GCS products are designed to allow long term historical trending
of operational data. A total of 12 system parameters can be logged at a variable sample rate. The
maximum sample rate is 1 sample per second. The data is stored to the PC Card ATA flash disk
using the GCS display. The number of samples available is limited only by disk space.
How long can the PC Card log data before it is full?

The PC Card we have set up in inventory is 8 megabytes (MB) in size. A typical 8 MB card has
7,956,480 bytes (a.k.a. characters) available for use after the disk is formatted. We are testing
with cards up to 32 MB but have not released them for use yet. Each sample taken uses 33
bytes (characters) of space. As the time between samples decreases, the data cards will fill up
faster. Typical sample times are expected to be in the range from 1 minute to 1 hour.
Some sample calculations of memory space usage might be as follows:
Example #1 - 12 parameters sampling once each hour:

Each hour we would use 33 bytes x 12 samples = 396 bytes
Each day we would use 396 * 24 = 9504
We could sample at this rate for 7956480 / 9504 = 837 days.
Example #2 - 6 parameters sampling once each minute:

Each hour we would use 60 * 33 * 6 = 11880 bytes.
Each day we would use 11880 * 24 = 285120
We could sample at this rate for 7956480 / 276480 = 28 days.
Example #3 - 3 parameters sampling 1 sample per second:

Each second we would have 33 * 3 bytes used = 99 bytes.
Each hour would consume 99 * 3600 = 356400
We could sample at this rate for 7956480 / 345600 = 22 hours.
Page 83
Set Up Parameters to be Logged
The setup of parameters to be logged and the interval between samples is handled on the
Datalog Setup screen. This screen is accessed by selecting the Setup Datalogging option from
PC Card Status menu.
NOTE: The Setup Datalogging screen cannot be accessed while datalogging is in progress.
Datalog Setup Datalog Setup
Description Strt Strt Itvl Enable
1 IA Scld 1
2 VCA Scld 2
3 AI1 Prsnt Val 3
4 AI2 Prsnt Val 4
5 5
6 6
7 7
8 8
9 9
Current A Scaled Current A Scaled
Ensure datalogging is disabled before attempting
to access this screen.
The Setup Datalogging screen is arranged in 4 columns:
Description – This is where the system parameter to be logged is selected and the
description of the system parameter will be located here. To select a desired parameter,
position the cursor in the Description column at the desired row and press the ENTER key.
If no parameter was previously listed, the description for the first available parameter will be
displayed. Using the up and down cursor keys, scroll through the list of parameters
available until the desired parameter is found. Then press the ENTER key again to save the
parameter for logging.
Start Time – This column is reserved for future development.
Interval Time – This column is where the time (in seconds) between samples is entered.
Once the desired parameter has been chosen as above, position the cursor in the Interval
Time column for the row the selected parameter is in. Then press the ENTER key to edit
the time. Initially the lower portion of the screen will indicate ‘Not Configured’. The time is
entered in seconds from 0 to 9999. Once the desired seconds are entered using the arrow
keys, press ENTER to save the value. Notice that the interval time, in hours, minutes,
seconds is displayed at the bottom of the screen.
Enable – This column indicates whether the selected system parameter is currently enabled
for logging or not. Once a parameter has been selected in column 1 and a desired sampling
interval has been entered in column 3, the parameter must be enabled for datalogging. This
is accomplished by positioning the cursor over the Enable column for the desired row and
pressing the ENTER key to edit the log status of the parameter. Using the arrow keys, set
the parameter to be enabled (!) or disabled ("). Then press the ENTER key to accept the
change.
Enable / Disable data logging
Once the system parameters to be logged are setup, the user need only insert a valid ATA
PC Card into the PC Card slot and select the Enable Datalogging parameter from the PC
Card Status menu.
If the PC Card is valid and the parameter setup is correct, a dialog box indicating that
datalogging is starting is displayed.
Page 84
The PC Card datalogging features are designed to restart automatically if a power fail
situation should occur. Once the datalogging is enabled, datalogging should continue until
the user disables the logging, or the PC Card fills up, in which case the datalogging will be
automatically disabled.
Disabling datalogging / removing the PC Card
To remove the PC Card the user MUST disable the datalogging feature in the PC Card Status menu.
If the PC Card is removed without disabling datalogging, a warning dialog will pop up indicating that
information loss or file corruption may occur if the card is not re-inserted.
USING THE PC CARD IN THE WINDOWS 95/98 PC

The PC Card ATA Flash disk is supported automatically by standard Windows 95 & 98 installations.
When the PC Card is inserted into a PC with PCMCIA slots, the system recognizes the Flash disk as
another system hard disk of size 8 Mb. This format of PC Card was chosen to allow the most widely
installed base of computer systems to work seamlessly with the data from the GCS Products.
Insert the PC Card in a laptop PCMCIA slot.
When the PC Card is inserted into the PCMCIA slot on the computer for the first time, Windows
will automatically detect the card and load the appropriate driver for use with the flash disk.
Depending on the manufacturer of the PC Card, a screen similar to the screens depicted below
will be displayed as windows prepares the card for system use.
Follow the instructions as indicated by Windows to complete the installation of the PC Card IDE
driver. (This may require the computer to be restarted). Once the driver loading process is
finished, the PC Card Flash disk should appear in the list of devices in the My Computer
explorer window. (See next)
Page 85
Open an Explorer window to view PC Card Contents
In most Windows computers there will be a My Computer icon in the upper left hand corner of
the desktop. This icon will allow the display of the data storage devices that are available on the
computer system. Selecting this icon (normally with a double-click action) will open a window
that appears similar to the one below. In the list of Local Disks, there should be a new drive of
size 7.57 MB (an 8 MB hard drive formatted).
Working with the PC Card files
The new PC Card drive (in this case drive d:) can be accessed just like any hard drive or floppy
drive. Files can be copied to or from the drive, or opened right from the drive. If the user was to
open the drive in a new explorer window by double-clicking on the new drive, a window that lists the
files saved to the disk from the GCS Device will be displayed. The four files which may appear are:
1. log.csv – the datalog output file

2. sdhist.csv – the shutdown history output file
3. ampchart.csv – the digital ampchart output file
4. events.csv – the event history output file.
5. Trends.csv – the high speed startup trending output file (GCS Vortex only).
A more detailed description of these file contents was discussed in a previous section.
The CSV format as explained earlier is very versatile and as a result, if the computer has a
spreadsheet program installed (Excel, Lotus, Quatro etc.) the user need only select one of the files
and the tabular information will be imported into a spreadsheet form. These files are simple ascii
text files which can be read and edited with most text editor utilities.
The Datalog output file (log.csv) will appear similar to the captured output below. Note that since the
datalog file can be appended in multiple logging sessions, no header information is recorded, only
the data records:
Page 86
The fields descriptions for each record are: (left to right)
Parameter ID, Value, Date, Time, Status field
The Parameter ID field is a number representing the parameter that was logged. The use of a
number ID saves disk space over continually recording a long filename to disk. The Parameter
description can be decoded using the table on the following page.
The Status field mainly contains a single character ‘S’ to indicate that datalogging was ‘STARTED’ at
this sample.
Note that when multiple parameters are selected, the samples will be mixed together one after
another. Sorting the file on the first column will allow each set of data for the specific parameter to
be isolated and graphed.
Page 87
Point ID descriptions for parameters that can be logged in GCS devices:
5 Electrospeed Output Frequency 728 Expansion I/O Module #2 - Analog Input #2 Slow Average
6 Electrospeed Output Current Phase A 730 Expansion I/O Module #2 - Analog Input #2 Maximum
7 Electrospeed Output Current Phase B 731 Expansion I/O Module #2 - Analog Input #2 Minimum
8 Electrospeed Output Current Phase C 732 Expansion I/O Module #2 - Analog Input #2 RMS
9 Electrospeed OutputVolts 735 Expansion I/O Module #3 - Digital Input #1 Status
42 Analog Input # 1 Present Value 738 Expansion I/O Module #3 - Digital Input #1 Pulse Accumulator
67 Analog Input # 2 Present Value 739 Expansion I/O Module #3 - Digital Input #2 Status
97 Digital Input # 1 Present Status 742 Expansion I/O Module #3 - Digital Input #2 PulseAcc
109 Digital Input # 2 Present Status 743 Expansion I/O Module #3 - Digital Input #3 Status
125 Accumulated Gigawatt Hours 746 Expansion I/O Module #3 - Digital Input #3 Pulse Accumulator
130 Vortex GCS / Input Current Phase A 756 Expansion I/O Module #3 - Analog Input #1 Fast Average
132 Vortex GCS Input Volts CA Frequency 757 Expansion I/O Module #3 - Analog Input #1 Slow Average
135 Vortex GCS / Input Current Phase B 759 Expansion I/O Module #3 - Analog Input #1 Maximum
139 Vortex GCS / Input Current Phase C 760 Expansion I/O Module #3 - Analog Input #1 Minimum
141 Present Amount of Current Unbalance 761 Expansion I/O Module #3 - Analog Input #1 RMS
156 Accumulated Kilowatt Hours 762 Expansion I/O Module #3 - Analog Input #2 Fast Average
157 Instantaneous Kilowatts 763 Expansion I/O Module #3 - Analog Input #2 Slow Average
162 Accumulated Megawatt Hours 765 Expansion I/O Module #3 - Analog Input #2 Maximum
166 Highest Input Amperage Phase (Overload) 766 Expansion I/O Module #3 - Analog Input #2 Minimum
209 Measured Power Factor 767 Expansion I/O Module #3 - Analog Input #2 RMS
259 Average 3 Phase Amperage (Underload) 770 Tracker Channel 1
271 Lowest Voltage Phase Reading (Undervolt) 771 Track Channel 2
285 Vortex GCS Voltage AB 772 Track Channel 3
289 Vortex GCS Voltage BC 773 Track Channel 4
294 Vortex GCS / Input Voltage Voltage CA 774 Track Channel 5
297 Present Amount of Voltage Unbalance 775 Track Channel 6
387 Electrospeed Heatsink 1 Temp 842 Track Channel 7
399 Electrospeed Heatsink 2 Temp 843 Track Channel 8
411 Electrospeed Heatsink 3 Temp 844 Tracker Channel 1 Raw
423 Electrospeed Heatsink 4 Temp 845 Tracker Channel 2 Raw
435 Electrospeed Inductor Temp 846 Tracker Channel 3 Raw
447 Electrospeed Ambient Temp 847 Tracker Channel 4 Raw
461 Electrospeed Aux Temp 848 Tracker Channel 5 Raw
566 Electrospeed Digital Input 3 Status 849 Tracker Channel 6 Raw
611 PCM (Electrospeed) DCLink Amps 850 Tracker Channel 7 Raw
612 Electrospeed Output Voltage AB Average 851 Tracker Channel 8 Raw
613 Electrospeed Output Voltage CA Average 1192 Expansion I/O Module #1 - Analog Output # 1
614 Electrospeed Output IB Average 1196 Expansion I/O Module #1 - Analog Output # 2
628 Serial Communication Status 1200 Expansion I/O Module #2 - Analog Output # 1
665 Expansion I/O Module #1 - Digital Input #1 Status 1204 Expansion I/O Module #2 - Analog Output # 2
668 Expansion I/O Module #1 - Digital Input #1 Pulse Accumulator 1208 Expansion I/O Module #3 - Analog Output # 1
669 Expansion I/O Module #1 - Digital Input #2 Status 1212 Expansion I/O Module #3 - Analog Output # 2
672 Expansion I/O Module #1 - Digital Input #2 PulseAcc
673 Expansion I/O Module #1 - Digital Input #3 Status
676 Expansion I/O Module #1 - Digital Input #3 Pulse Accumulator
686 Expansion I/O Module #1 - Analog Input #1 Fast Average
687 Expansion I/O Module #1 - Analog Input #1 Slow Average
689 Expansion I/O Module #1 - Analog Input #1 Maximum
690 Expansion I/O Module #1 - Analog Input #1 Minimum
691 Expansion I/O Module #1 - Analog Input #1 RMS
707 Expansion I/O Module #2 - Digital Input #2 PulseAcc
Page 88
An example of the shutdown history file that was loaded into Excel is shown here:
Note that a column heading indicates the type of data in each column.
A second example is an event log file from this disk, when loaded into Excel the data appears as
follows:
Page 89
Finally, an example of the startup trending history, which was loaded and then graphed using the
chart wizard features of Excel is shown here:
Page 90
TROUBLESHOOTING PC CARD PROBLEMS
The following question & answer guide should be used as a first step in solving PC Card problems
with the GCS Display.
Problems using the PC Card with the GCS Display
I insert the PC Card into the GCS Display and get a message that says: “Disk Error” or “File
Access Error”:
The GCS PC Card software is designed to operate through power loss situations. There is,
however a small chance that data file corruption could occur while data is being written to the PC
Card. Should a power fluctuation or loss occur at precisely the same time as a write occurs, the
data file size information could be corrupted. In most cases only the last few samples of actual
data may be lost. To correct this problem, simply insert the PC Card into the Windows 95/98
computer and run the SCANDISK utility (found in Start -> Programs -> Accessories -> System
Tools). This utility will likely indicate some file size errors. Allowing windows to fix the errors will
most times fix the corrupted files.
If the previous steps do not fix the problem, the user may attempt to FORMAT the flash disk from
Windows. This is accomplished by selecting the 8MB disk from the My Computer explorer
window and then selecting the FORMAT command from the FILE menu.
IMPORTANT: Ensure the disk selected for formatting is the 8MB flash disk, not any other
disk in the system – if the incorrect drive is selected, the computers primary hard drive
could be deleted.
I insert the PC Card into the GCS Display and get a message that says: “Invalid Card” or
“Disk Error”:
The GCS PC Card slot is designed and programmed following the PC Card ATA standard and as
a result should be compatible with all ATA style PC Card’s. Incompatibilities may, however, still
exist with some manufacturer’s cards. We are actively testing PC Cards from several
manufacturers for compatibility and reliability. If the PC Card in use is shows these types of
errors, there may be a compatibility error. Please report the Manufacturer, Type, Part Number
and Size to Centrilift Control Technologies for investigation.
Alternately, the PC Card in question could be damaged or require re-formatting. See the answer
above for steps to try reformatting the card.
Page 91
Problems using the PC Card with a Windows PC.
When I insert my PC Card Flash Disk into the PC Card slot, no new drive appears in the My
Computer explorer window, why not?
Many new computer systems have almost all of the Interrupt Request Lines (IRQ’s) used with
various hardware such as sound cards, CD –Rom drives, Serial ports Parallel ports, USB ports
etc. When the PC Card ATA Flash disk is inserted, it requires a free IRQ to perform data
transfers to the computers processor. There are only a limited number of IRQ’s available in a
computer system, and if they are all used when the PC Card is inserted, windows will not be able
to add the new drive to the system. On many laptops with multiple PC Cards, this can be
alleviated by removing any other PC Cards which are plugged in, such as modems or LAN
adapters. Consult your local Information Services personnel for other ways to free up system
IRQ’s.
When I try to open the “log.csv” file, my spreadsheet software prompts me with a dialog box which
indicates that all of the file was not loaded. What does this mean?
Most spreadsheet packages have limits on the maximum number of rows a file can have. When
the spreadsheet software opens the CSV log file, this file may contain as many as 250000 rows or
more. In this case the spreadsheet software will load as many rows of data from the file as will fit
within it’s own limitations, and then may present some pop-up dialog indicating that not all of the
rows in the file could be loaded. Microsoft Excel 95 has a limit of 16383 rows, and Excel 97 has a
limit of 65535 rows.
In cases where the log file has too many rows to be loaded, it is necessary to use a text editor
such as Wordpad (part of the Windows 95/98 accessories) to copy only the lines of the text file
which are desired for viewing to the spreadsheet program.
When I try to open one of the CSV files on the PC Card, I get an error which indicates the
file could not be opened because of a “read only” condition.
This error was found to occur in some initial shipments of PC Cards from AVED Memory
Products. This cause was an invalid DOS format on the cards resulting in a corrupted File
Allocation Table (FAT). The solution is to reformat the PC Card in Windows 95/98 which corrects
the file structure and boot record. This is accomplished by selecting the 8MB disk from the My
Computer explorer window and then selecting the FORMAT command from the FILE menu.
IMPORTANT: Ensure the disk selected for formatting is the 8MB flash disk, not any other
disk in the system – if the incorrect drive is selected, the computers primary hard drive
could be deleted.
NOTE: Formatting the PC Card will result in the loss of all data that was logged to the card. If
there is critical data on the card, it can be retrieved with special disk utilities. Please use the
information found below to contact one of our support personnel.
If these steps do not provide a solution, please contact the Centrilift Control Technologies Group
and have the following information ready to facilitate problem resolution:
1. The software versions loaded in the GCS Devices (located in the System, Scada &
Security menu in the Software Rev Num sub-menu.
2. The Manufacturers name and type of PC Card, along with a Part Number and a size.
3. A list of symptoms or error messages displayed on the display.
Page 92
APPENDIX A: CABLE SIZING
Fuse Size Cable Sizes Lug Size per Phase Lug Size per Phase
(Amps) Per Phase Input Output
100 # 2 AWG 1ea. 14-1/0 1ea. 6-250 MCM
200 # 3/0 AWG 1ea. 4-300 MCM 1ea. 6-250 MCM
300 2-2/0 AWG 1ea. 4-250 MCM & 1ea. 2/0-500 MCM 2ea. 6-250 MCM
400 2-4/0 AWG 1ea. 4-250 MCM & 1ea. 2/0-500 MCM 2ea. 6-250 MCM
500 2-300 MCM 3ea. 250-500 MCM 3ea. 3/0-400 MCM
600 2-400 MCM 3ea. 250-500 MCM 3ea. 3/0-400 MCM
700 3-350 MCM 3ea. 250-500 MCM 3ea. 3/0-400 MCM
800 3-400 MCM 3ea. 250-500 MCM 3ea. 3/0-400 MCM
2 - 500 4-300 MCM 6ea. 250-600 MCM 6ea. 250-600 MCM
2 - 600 4-400 MCM 6ea. 250-600 MCM 6ea. 250-600 MCM
2 - 700 6-350 MCM 6ea. 250-600 MCM 6ea. 250-600 MCM
2 - 800 6-400 MCM 6ea. 250-600 MCM 6ea. 250-600 MCM
Recommended Power Cable Sizes
Aluminum or
Input Fuse per Copper Copper Clad Aluminum
Phase (Amps) Wire Size No. Wire Size No.
100 # 8 AWG # 6 AWG
200 # 6 AWG # 4 AWG
300 # 4 AWG # 2 AWG
400 # 3 AWG # 1 AWG
500 # 2 AWG # 1/0 AWG
600 # 1 AWG # 2/0 AWG
700 # 1/0 AWG # 3/0 AWG
800 # 1/0 AWG # 3/0 AWG
2 - 500 # 2/0 AWG # 4/0 AWG
2 - 600 # 3/0 AWG # 250 kcmil
2 - 700 # 4/0 AWG # 300 kcmil
2 - 800 # 4/0 AWG # 350 kcmil
Minimum Size Equipment Grounding Conductors for Grounding Raceway and Equipment as recommended
by the USA National Electric Code. Must meet local and other applicable codes for actual sizes.
Recommended Grounding Cable Sizes
Page 93
APPENDIX B: CABLE VOLTAGE DROP
Page 94
APPENDIX C: VARIABLE TORQUE VSC RATINGS
Output Ratings @ 480VAC Input Ratings

Amps @ 460 VAC
Continuos Overload Start
Current Current Current Fuse Input
Model KVA RMS Amps 60 Sec. 7 Sec. Rating Current
1060 or 2060-VT 66 79 95 119 100 83
1075 or 2075-VT 83 100 120 150 200 105
1100 or 2100-VT 111 133 160 200 200 140
1125 or 2125-VT 130 156 187 234 200 164
2150-VT 163 196 235 294 300 206
2200-VT 200 241 289 362 300 253
2250-VT 260 313 376 470 400 329
4300-VT 325 391 469 587 500 411
4350-VT 390 469 563 704 600 492
4400-VT 454 546 655 819 700 573
4500-VT 519 624 749 936 800 655
8600-VT 624 750 900 1125 500 788
8700-VT 748 900 1080 1350 600 945
8800-VT 873 1050 1260 1575 700 1103
8900-VT 1000 1203 1444 1805 800 1263
NOTE: When applying variable speed controllers to constant torque loads, the continuous
output current and output KVA are de-rated by 20%. The Overload and Start currents remain the
same. The model numbers listed here do not include the enclosure identifier. (i.e. 2200-1VT or
2200-3VT
Page 95
APPENDIX D: RECOMMENDED SPARE PARTS
PART NO. QTY CODE DESCRIPTION VSC SERIES ICS

BASE/MO/YR PART
*For calculating quantities, see instructions at end of list.
SEMICONDUCTORS
900545 B4/ M.2/ Y.4 IGBT 600A 2250/ 4400/ 4500
900546 B4/ M.2/ Y.4 IGBT 400A 2075/ 2100/ 2125/ 2150/ 2200/
4300/ 4350
900547 B1/ M.1/ Y.2 IGBT 200A 2060
900111 B1/ M.1/ Y.2 IGBT 150A dual 1060
900635 B1/ M.1/ Y.2 IGBT 300A dual 1125
B1/ M.1/ Y.2
88465 B1/ M.1/ Y.2 SCR, 250A 1125/ 2000/ 4000/ 8000 X
51617 B1/ M.1/ Y.2 SCR, 92A 1000/ 2000 X
89052 B1/ M.1/ Y.2 DIODE,95A 1000/ 2000 X
88523 B1/ M.1/ Y.2 DIODE,260A 4000/ 8000 X
CIRCUIT BOARDS
900532 B3/ M.3/ Y.6 (CSB) CONV. SIG PCB 1000/ 2000/ 4000
900533 B6/ M.4/ Y.8 (ISB) INVERTER SIGNAL PCB 1000/ 2000/ 4000/ 8000
900531 B1/ M.1/ Y.2 (SCB) SYSTEM CONTROL PCB 1000/ 2000/ 4000/ 8000
901046 B1/ M.1/ Y.2 (SSB) SWITCHING SUPPLY PCB 1000/ 2000/ 4000/ 8000
900535 B6/ M.4/ Y.8 (DCSB) DUAL CONVERTER SIGNALS PCB 8000
57983 B2/ M.1/ Y.2 (TSB) TEMPERATURE SENSING PCB 1000/ 2000/ 4000/ 8000
900534 B1/ M.1/ Y.2 1060 SNUBBER PCB 1060/ 1125 12P
58161 B3/ M.1/ Y.1 SNUBBER PCB 1125/ 2000/ 4000/ 8000
900033 B1/ M.1/ Y.2 GRAPHICS DISPLAY 1000/ 2000/ 4000/ 8000
MAGNETICS
900154 B1/ M.05/ Y.05 INDUCTOR, 50A, 4.5mH 1060 12P/ 2060 12P/ 4300 12P
Page 96
900414 B1/ M.05/ Y.05 INDUCTOR, 100A, 1.6mH 1060 6P/ 2060 6P/ 2150 6P/
2200 6P/ 4300 6P/ 4400 6P/
1125 12P/ 2075 12P/ 2100 12P
2125 12P/ 4350 12P
900527 B1/ M.05/ Y.05 INDUCTOR 200A 1125 6P/ 2075 6P/ 2100 6P/
2125 6P/ 2150 6P/ 2200 6P/
2250 6P/ 2150 12P/ 2200 12P/
2250 12P/ 4000
CAPACITORS
58904 B1/ M.1/ Y.2 BUS CAPACITOR MODULE 1000/ 2000/ 4000/ 8000
900798 CAPACITOR, 1500MFD, 1000/ 2000/ 4000/ 8000
REPAIR FOR MODULE 58904
900022 B1/ M.1/ Y.1 CAPACITOR, 5MFD, DC BUS 2000/ 4000/ 8000
900112 B1/ M.1/ Y.1 CAPACITOR, 1MFD, DC BUS 1060/ 1125
47556 B1/ M.1/ Y.1 CAPACITOR, 7.5MFD 2000/ 4000/ 8000 X
CABLE ASSEMBLIES
900225 B1/ M0/ Y0 CABLE, CITIBUS, 5'10" 1000
900345 B1/ M0/ Y0 CABLE, CITIBUS, 6'3" 2000
900626 B1/ M0/ Y0 CABLE, CITIBUS, 8'-9" 4000
900627 B1/ M0/ Y0 CABLE, RS-232, 8'-9" 4000
900343 B1/ M0/ Y0 CABLE, RS-232, 6'3" 2000
900342 B1/ M0/ Y0 CABLE, RS-232, 5' 10" 1000
901210 B1/ M0/ Y0 CABLE, CITIBUS, 10' 8000
901211 B1/ M0/ Y0 CABLE, RS-232, 10' 8000
TRANSFORMERS
Page 97
900024 B1/ M0/ Y0 CURRENT XFORMER 250:1 1060/ 1125/ 2060/ 2075/ 2100/
2125/ 2150/ 2200
900549 B1/ M0/ Y0 CURRENT XFORMER 500:1 2250/ 4300/ 4350/ 4400
58946 B1/ M0/ Y0 CURRENT XFORMER 1000:1 4500
901261 B1/ M0/ Y0 CURRENT XFORMER 2000:1 8000
900968 B1/ M.05/ Y.05 XFMR CONTROL POWER 350 VA 1000/ 2000/ 4000/ 8000
55533 B1/ M.05/ Y.05 XFMR 240/480-120, 50/60 HZ 115V OPTION
DISCONNECT SWITCHES
58529 B1/ M0/ Y0 SWITCH, 100A 1060/ 2060 X
900987 B1/ M0/ Y0 SWITCH, 100A W/ TRIP COIL 1060/ 2060 CE CONFIG
58528 B1/ M0/ Y0 SWITCH, 250A 1125/ 2075/ 2100/ 2125 X
900988 B1/ M0/ Y0 SWITCH, 250A W/ TRIP COIL 1125/ 2075/ 2100/ 2125 CE
58527 B1/ M0/ Y0 SWITCH, 400A 2150/ 2200/ 2250 X
900985 B1/ M0/ Y0 TRIPCOIL FOR 400A SWITCH 2150/ 2200/ 2250 CE CONFIG
58526 B1/ M0/ Y0 SWITCH, 600A 4300/ 4350 X
58525 B1/ M0/ Y0 SWITCH, 800A 4400/ 4500/ 8000 X
900984 B1/ M0/ Y0 TRIPCOIL FOR 600/800A SWITCH 4000/ 8000 CE CONFIG
FANS/MOTORS
47420 B1/ M.05/ Y.1 FAN MTR NEMA 3 2000/ 4000/ 8000 NEMA 3 ONLY X
51566 B1/ M0/ Y0 FAN HEAT EXCHANGER 1000/ 2000/ 4000/ 8000 X
88424 B1/ M0/ Y0 FAN MUFFIN 1000/ 2000/4000/ 8000 X
FUSES
INPUT POWER
900754 B3/ M.5/ Y2 FUSE, 50A 1060 12P/ 2060 12P
85572 B3/ M.5/ Y2 FUSE, 100A 1060 6P/ 2060 6P/ 1125 12P/ X
2075 12P/ 2100 12P/ 2125 12P
96804 B3/ M.5/ Y2 FUSE, 150A 2150 12P/ 2200 12P
88895 B3/ M.5/ Y2 FUSE, 200A 1125 6P/ 2075 6P/ 2100 6P/ X
2125 6P/ 2250 12P
86805 B3/ M.5/ Y2 FUSE, 250A 4300 12P
88896 B3/ M.5/ Y2 FUSE, 300A 2150 6P/ 2200 6P/ 4350 12P X
Page 98
900865 B3/ M.5/ Y2 FUSE, 350A 4400 12P
88897 B3/ M.5/ Y2 FUSE, 400A 2250 6P/ 4500 12P X
88898 B3/ M.5/ Y2 FUSE, 500A 4300 6P/ 8600 X
86808 B3/ M.5/ Y2 FUSE, 600A 4350 6P/ 8700 X
88899 B3/ M.5/ Y2 FUSE, 700A 4400 6P/ 8800 X
86809 B3/ M.5/ Y2 FUSE, 800A 4500 6P/ 8900 X
SWITCHING SUPPLY PCB

48106 B2/ M.4/ Y1 FUSE, 5A, 500V (SSB F1, F2) 1000/ 2000/ 4000/ 8000 X
901263 B2/ M.4/ Y1 FUSE, 1A, 500V (SSB F3) 1000/ 2000/ 4000/ 8000
901264 B2/ M.4/ Y1 FUSE, 1A, 250V, 5x20mm, SLO-BLO (SSB F4, F7) 1000/ 2000/ 4000/ 8000
901265 B2/ M.4/ Y1 FUSE, 2A, 250V, 5x20mm, FAST ACTING (SSB F5) 1000/ 2000/ 4000/ 8000
901266 B2/ M.4/ Y1 FUSE, 3.15A, 250V, 5x20mm, SLO-BLO (SSB F8, F9) 1000/ 2000/ 4000/ 8000
115 VOLT OPTION
55534 B2/ M.4/ Y1 FUSE, TIME DELAY, 3.0 A, 600 V 1000/ 2000/ 4000/ 8000
55535 B2/ M.4/ Y1 FUSE, TIME DELAY, 4.0 A, 250 V 1000/ 2000/ 4000/ 8000
CONTROL POWER XFMR
900967 B2/ M.4/ Y1 FUSE 2A 250 V TIME DELAY 1000/ 2000/ 4000/ 8000
PLANAR BUS BARS

901250 B1/ M0/ Y0 PLANAR BUS BAR, 2000 SERIES 2000
901271 B1/ M0/ Y0 PLANAR BUS BAR, 4000/8000 SERIES 4000/ 8000
HARDWARE
900862 B2/ M0/ Y0 STDF, M-F, M8X1.25, M4X.7-6H, HEX 2250/ 4400/ 4500/ 8800/ 8900
900557 B2/ M0/ Y0 STDF, SNBR BD, M-F, 8MM HEX, LONG 2000/ 4000/ 8000
900556 B2/ M0/ Y0 STDF, SNBR BD, M-F, 8MM HEX, SHORT 2000/ 4000/ 8000
900113 B2/ M0/ Y0 STDF, HEX, M-F, M5X0.8X25MM, ZINC 1060/ 1125
900861 B2/ M0/ Y0 STDF, M-F, M6X1.25, M4X.7-6H, HEX 2060/ 2075/ 2100/ 2125/ 2150/
2200/ 4300/ 4350/ 8600/ 8700
Page 99
OTHER
54162 B2/ M.1/ Y.4 BULB, LAMP, TYPE 120MB OPTIONAL ON 1000/ 2000/
4000/ 8000
900608 B2/ M.1/ Y.4 MEMORY CARD, 8 MEG OPTIONAL ON 1000/ 2000/
4000/ 8000
900717 B1/ M.05/ Y.05 VCI-142 COMMUNICATIONS INTERFACE OPTIONAL ON 1000/ 2000/
4000/ 8000
900899 B1/ M.05/ Y.05 GCS EXPANSION I/O MODULE OPTIONAL ON 1000/ 2000/
4000/ 8000
The recommended quantity of spare parts for each of the above part numbers listed above should be calculated using the quantity code and the
VSC series listed for each part. The minimum quantity for each part is equal to the quantity after the B (Base) in the quantity code.
For instance, the number B4 indicates that the minimum quantity for this part is 4. The quantity recommended for monthly re-supply is the minimum
quantity plus the number after the M in the quantity code times the total number of drives requiring this part.
The quantity recommended for yearly re-supply is the minimum quantity, plus the number after the Y in the quantity code times the total number of
drives requiring this part.
Example:
20 Ea. 4500 series
15 Ea. 2250 series
For spare part number 900531, System control Board

Base quantity (B) =1
Monthly reorder level to maintain = 1+(.1X35) = 4.5 (round up to 5)
Yearly reorder level to maintain = 1+(.2X35) = 8
For spare part number 88897, 400A Fuse

Base quantity (B) =3
Monthly reorder level to maintain = 3+(.5X15) = 10.5 (round up to 11)
Yearly reorder level to maintain = 3+(2X15) = 33
Page 100

GCS Troubleshooting&Applications1v0 (3.23.01)

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GCS Troubleshooting&Applications1v0 (3.23.01)

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Centrilift.

A Division of Baker Hughes

Version 1.0 Release

The final portion of this guide contains several appendices covering:

GENERAL TROUBLESHOOTING PROCEDURE

2. Disable converter(s) by moving enable jumpers.

5. Verify output voltage and current display zero

2. Enable converters by moving the enable jumpers.

3. Setup: Underload-no, Overload & ILimit-Max, Volts@60hz-480, Vclamp-500, Vboost-0, Set

SHORTED OUTPUT TEST

2. Make sure converter(s) are enabled.

3. Setup: Setup: Underload-no, Overload & ILimit-Max, ILimit Sync-Max, Volts@60hz-480,

General Troubleshooting Flow Charts

Chart or test flow direction

FIGURE 1: FLOW CHART SYMBOL DEFINITIONS

NO Active YES Fault / Active

YES Drive will NO Won't Start

NO Blows YES Bad

YES Normal NO Setup

FIGURE 2: DIAGNOSTIC OVERVIEW FLOW CHART

Replace 24V LED

150V LED Check

FIGURE 3: DISPLAY PROBLEM FLOW CHART

FIGURE 4: CONVERTER PROBLEM FLOW CHART

FIGURE 5: STARTING PROBLEMS FLOW CHART

YES NO YES Controls NO

FIGURE 6: INVERTER PROBLEMS FLOW CHART

Each group will be discussed in detail in the following sections.

Fault/Active Alarm: Input Over Voltage

Fault/Active Alarm: Input Under Voltage

Fault/Active Alarm: Input Voltage Unbalance

Fault/Active Alarm: Low Speed Trip

Fault/ Active Alarm: Overload

Fault/ Active Alarm: Underload

Fault/Active Alarm: Analog Input High Threshold

Fault/Active Alarm: Analog Input Low Threshold

Fault/Active Alarm: External Analog Input High Threshold

Fault/Active Alarm: External Analog Input Low Threshold

Fault/Active Alarm: External Digital Input

Fault/Active Alarm: CITIBus Communications Error

Fault/Active Alarm: PCM Converter Fault

Fault/Active Alarm: PCM Inverter Fault

Fault/Active Alarm: PCM System Error

Fault/Active Alarm: Serial Communications Error

Fault/Active Alarm: Ambient Temperature Alarm

Fault/Active Alarm: Inductor Temperature Alarm

Fault/Active Alarm: Heat sink Over Temperature Alarm

Fault/Active Alarm: Inverter IOT (Instantaneous Overcurrent Trip)

Fault/Active Alarm: PCM Zero Crossing Fault

Fault/Active Alarm: System Controller Zero Crossing Fault

OTHER FAULTS / ALARMS

Fault/Active Alarm: Central Shutdown

Fault/Active Alarm: Drive Stopped Manually

Fault/Active Alarm: External HOA in Off

Fault/Active Alarm: First Start

Fault/Active Alarm: Lockout

Fault/Active Alarm: Max Starts

Fault/Active Alarm: Motor State Sync Error

Fault/Active Alarm: PCM Bus Volts

Fault/Active Alarm: Real Time Clock Invalid

TP11 PWM OUTPUT PWM

OUTPUT HYBRID OUTPUT ESP

VARIABLE SPEED CONTROLLER

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