ESSCO Customer Success Story | Project ESS240071
ESSCO completed one of its most advanced custom builds—a NEMA 4 1,000HP Variable Frequency Drive (VFD) package engineered for a demanding industrial application.
The customer needed retrofit and replacement options for multiple aging VFDs, including 700HP and 1,000HP units. While high-horsepower applications like these are often handled with pre-engineered factory cabinets, this project required a greater degree of protection against water and dust than standard offerings could provide.
To meet that need, ESSCO designed and built a custom NEMA 4 assembly in-house using ABB internal VFD equipment and packaging it into a complete solution tailored for the application. Building the package in ESSCO’s own shop gave the team control over assembly and helped limit the unknowns associated with a field retrofit.
The Challenge
This opportunity required a large, high-horsepower VFD package with a higher level of environmental protection than factory-built options typically offer at this size. Instead of relying on third parties or attempting a complex field retrofit, ESSCO developed a fully integrated system designed specifically for the application.
The Solution
ESSCO quoted both 700HP and 1,000HP packages for a customer evaluating replacement options for two aging drives of each size. The customer selected one 1,000HP package as an initial trial. ESSCO sourced the internal VFD equipment from ABB and integrated it into an ESSCO-designed NEMA 4 assembly with a main disconnect, cooling systems, and application-specific controls.
ABB engineered the parallel-drive power design. ESSCO’s role was to integrate the equipment into a complete package, designed for the customer to connect incoming power and a single 1,000HP motor.
The completed package included:
- NEMA 4 enclosure
- 460V configuration
- 1,000HP heavy-duty drive package
- 1,610A current rating
- (2) complete 805A VFDs connected in parallel
- Shared control board powering a single 1,000HP motor
- Main disconnect
- (2) dVdT output filters
- (2) air-to-water heat exchangers
The Result
This project provided valuable experience for the ESSCO team and established a strong blueprint for future high-horsepower VFD packages. It highlights ESSCO’s ability to solve complex application challenges with custom-built systems designed for performance, protection, and long-term reliability.
When standard options are not enough, ESSCO delivers engineered solutions tailored to the application.