ESSCO Project Spotlight: Custom NEMA 4 1,000HP VFD Package
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. By controlling the design and assembly process in its own shop, ESSCO reduced field unknowns and delivered a dependable long-term solution.
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 provided 700HP and 1,000HP configurations by sourcing internal VFD components from ABB and integrating them into an ESSCO-designed NEMA 4 enclosure complete with all required controls and cooling systems.
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.