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ABSTRACT
Accurate estimates of heat lost by power equipmentfacilitate proper sizing of cooling and ventilation equipment
required by buildings and industrial plants. Information on
heat loss is available in papers published in the 1970s and
1980s, but some of the informationprovided in thesepapers is
dated and, in some cases, includes overly conservative
assumptions. The main focus of this paper is to describe an
efJbrt toprovide updated information on heat losses by various
electric power devices. The information was gathered from
equipment manufacturers and relevant standards associated
with this equipment. Laboratory tests or mathematical simulations were done to determine heat loss for equipment with
insuficient information and to verzb published data. A calorimeter was constructed for the testing of equipment. The
construction and calibration of the calorimeter are described.
Testprocedures used in acquiring loss data are described. For
each equipment item in the scope of the project, a description
is provided as to where and how the loss data were obtained.
A summary of areasfor future investigation is discussed.
INTRODUCTION
Chris Cruz
Warren N. White is an associate professor and Chris Cruz is a graduate student in the Mechanical and Nuclear Engineering Department, and
Anil Pahwa is a professor in the Electrical and Computer Engineering Department, Kansas State University, Manhattan, Kans.
02004 ASHRAE.
Equipment Investigated
Equipment
Size Range
Electric motors
5 kV, 7.2 kV, and 13.8 kV with 1200,2000, and 3000 amp breakers
i Transformers
1 Reactors
1 Standard sizes
Inverters
1 DC switchgear
phase
Panelboards
I Battery chargers
1
I
Motor control centers (combination starters, breakers, auxiliary relay Standard NEMA sizes
compartments, bus losses, and space heaters)
25 to 500 hp-three
phase
843
was concluded that transformer and electric motor manufacturers followed the standards cited from statements made on
various manufacturers' Web sites. However, no series reactor
manufacturer was found to follow IEEE C57.16. The fact that
standards covering heat loss measurements are followed by
manufacturers is significant since published loss data are
subject to the uncertainty levels specified by the standards;
thus, the quality of the published information can be easily
inferred. Heat loss information was found for battery chargers
in the standard NEMA PE 5, covering utility type battery
chargers; however, no manufacturer was found that claimed to
follow this relevant standard that specifies how battery charger
efficiency is to be determined.
A side benefit of the standards search provided information regarding the influence of ambient temperature on equipment heat losses. According to the cited standards,
environmental temperature has only a small influence on
transformer, motor, or series reactor heat losses.
In this work, one very important source of information is
equipment manufacturers. Manufacturers of a particular
equipment item were located through a search of the NEMA
Web site. This search provided the starting point for any
contact with equipment manufacturers since postal and e-mail
addresses were available.
Contact through e-mail was made to the companies
included on the manufacturer lists to inquire about dissipated
heat from their products. Since a contact was being made with
equipment manufacturers, information not only relevant to the
classification was sought but also information useful to other
parts of the study. For each type ofpower equipment involved
in the survey, a contact letter was written that explained the
nature of the project and requested information relevant to this
study. The requested information consists of the name and
number of the standards followed in determining the loss
numbers or the procedures used to determine the losses in the
case where no loss determination procedures are specified in
the standards. Also, the manufacturer was requested to supply
loss numbers for its products or to specify the Web pages andl
or public company documents where loss figures are
presented. This step was not done for every piece of equipment
under study, e.g., cables, since it was not expected that power
losses would vary from manufacturer to manufacturer and
excellent mathematical cable loss models are available.
Each of the equipment types was documented regarding
applicable standards, loss measurement methods, availability
of loss data, and results of the manufacturer survey. From the
accumulated data, the equipment was classified into one of
three categories. The first category consisted of those products
for which the standards require specific, well-defined tests for
loss determination and reporting in addition to the availability
of published loss information. The third category includes
equipment for which there was no standard either requiring or
describing any heat loss tests and for which no heat loss data
could be found. The second category included all equipment
satisfying neither of the first nor third category descriptions.
ASHRAE Transactions: Symposia
Items in the second category represent a wide range of different situations or conditions. The best description for this category is that information was available on equipment heat
losses, but the measurement quality was unknown. The first
category included transformers and motors. The devices in the
second category were reactors, medium-voltage switchgear,
circuit breakers, motor control centers, inverters, battery
chargers, adjustable-speed drives, plus cables and cable trays.
The remainder of the power equipment constituted the third
category that includes transfer switches, DC switchgear, and
panelboards.
From the assessment determined in the previous activities,
a test plan was devised to provide as much of the information
as possible for covering the equipment heat losses for the items
listed in Table 1. In the case of the first category equipment, the
information was gathered from manufacturers' Web sites, catalogs, survey information, and personal contacts. For the equipment in the second and third categories, the test plan involved
experimental procedures for building andlor verifying the
information necessary to complete this study. Both the steps of
the test plan and the necessary experimental apparatus will be
described for each of the required equipment items.
Test Plan and Test Facility
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200
400
600
800
1000
1200
1400
1600
Input Watts
Figure 4
temperature environments and were tested both with and without enclosures. The environmental temperature did not play a
significant factor in breaker power losses. The enclosure did
play a significant role where it was seen that the power losses
increased by a factor of almost 1.5 in some of the breaker loss
tests. The factor of 1.5 was chosen since that bracketed all of
the enclosure loss data. The reported loss information from
manufacturers for low-voltage breakers varied over a wide
range. It was not clear if some of the reported data involve
enclosures or not. The assumption was made that the reported
data for those breaker frames not tested did not involve enclosures. Plots of the peak breaker loss as a function of frame size
varied roughly in a linear fashion. These plots were used to
predict the breaker losses for those frames not tested. The largest frame for which heat loss was reported by a manufacturer
was 5000 amp.
Unit Substations. Unit substations can be thought of as
low-voltage switchgear. Information from the low-voltage
breaker tests was used together with manufacturer component
losses for current transformers, power buses, auxiliary
compartments, control power transformers, and space heaters.
In order to predict the unit substation losses, a spreadsheet was
developed. No information on accuracy was available for the
manufacturer reported component losses. Owing to the excessive costs, no unit substations were available for testing in this
investigation. The influence of ambient temperature on the
losses of components not tested could not be determined.
Series Reactors. The series reactor is used for both limiting fault current and in filtering inverter-produced noise on
electric motor power feeds. Loss information from four different manufacturers was found. Reactors of sizes 4, 18,200, and
750 amps were tested. For the 200 and 750 amp sizes, two
reactors from different manufacturers were tested. The test
results compared favorably with the reported loss figures. It
was observed that the absolute winding temperature rise must
be used to scale the losses so that the manufacturer reported
losses would agree with the measured results. According to
standards, the losses are reported as if the reactor conductors
are at room temperature. Although standards exist for measuring reactor power losses, no manufacturer reporting loss information stated that these standards were observed in the testing
of their products. Environmental temperature was not a significant influence on the reactor losses.
Adjustable-Speed Drives. Adjustable-speed drives
(ASD) are also known as variable-frequency drives (VFD).
Drives of 25 and 60 hp sizes were tested in this work. Also,
loss information from several manufacturers was found in this
effort. The published loss information consisted of power loss
as a function of drive rating in horsepower for the standard
supply voltages of 230, 460, and 600 volts. So many loss
values were available that it was possible to plot the loss as a
function of rating for each of the supply voltage levels. A
striking linear trend was apparent even though different
manufacturers' data were on the same graph. The linear trends
allowed curve fitting of the heat loss information as a function