F.2-2
WindPACT Drive Train Report – Appendix F
1.5 MW PM SCR/SCR Drive - Rev. 5.0
3
1.5 MW PM SCR/SCR Drive
3-Phase SCR Line/Gen Side Matrix
A
B
C
* Note - Heatsink not shown
6
7
* Note - Cooling Fan not shown
1
Gate Drive Board
4
To Control Board
Fiber Optic Harness
Snubber Typical
6 Required
5
3
2
1.5 MW PM SCR/SCR Drive - Rev. 5.0
4
1.5 MW PM SCR/SCR Drive
3-Phase SCR Line Side Matrix
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
6
SCR, 2500 A, 2400 V, C781
$240.00
$1,440.00
2
6
Resistor, Snubber, 33 Ohm
$2.50
$15.00
3
6
Capacitor, Snubber, .5 uF
$11.00
$66.00
4
1
Gate Drive Board
$404.00
$404.00
5
1
Gate Wire Harness
$112.00
$112.00
6
1
Heatsink, Clamps, Terminations
$700.00
$700.00
7
1
Cooling Fan & Sw itch Gear
$372.00
$372.00
Total
$3,109.00
F.2-3
WindPACT Drive Train Report – Appendix F
1.5 MW PM SCR/SCR Drive - Rev. 5.0
5
1.5 MW PM SCR/SCR Drive
3-Phase Line Side Inductor, PF Caps, & DC Reactor
3
Enclosure
2
A
B
C
A
B
C
1
15
14
13
12
8
4
5
6
7
9
10
11
1.5 MW PM SCR/SCR Drive - Rev. 5.0
6
1.5 MW PM SCR/SCR Drive
3-Phase Line Side Inductor & DC Reactor
BOM
Item #
Qty
Description
Unit
Cost
Extended
Cost
1
1
Inductor, Line, 150 uH, 3-Phase
$2,212.00
$2,212.00
2
1
Inductor, DC, 2.5 mH, 1500 A
$2,025.00
$2,025.00
3
1
Enclosure
$1,876.00
$1,876.00
4,5
6
Fuse & Fuse Holder, 50 Amps, 690 Volts
$33.00
$198.00
6
3
Fuse & Fuse Holder, 100 Amps, 690 Volts
$33.00
$99.00
7
3
Fuse & Fuse Holder, 200 Amps, 690 Volts
$33.00
$99.00
8,9
2
Contactor, 50 Amps, 690 Volts, 3-Pole
$111.00
$222.00
10
1
Contactor, 100 Amps, 690 Volts, 3-Pole
$212.00
$212.00
11
1
Contactor, 200 Amps, 690 Volts, 3-Pole
$334.00
$334.00
12,13
2
Capacitor, 50 kVAR, 690 Volts, 3-Phase
$200.00
$400.00
14
1
Capacitor, 100 kVAR, 690 Volts, 3-Phase
$400.00
$400.00
15
1
Capacitor, 200 kVAR, 690 Volts, 3-Phase
$800.00
$800.00
Total
$8,877.00
F.2-4
WindPACT Drive Train Report – Appendix F
1.5 MW PM SCR/SCR Drive - Rev. 5.0
7
1.5 MW PM SCR/SCR Drive
Sub-Panel
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
1
Fab, Panel, Pow er Dist
$127.00
$127.00
2
1
Sw itch, Disconnect, 80 A, 1000V
$36.00
$36.00
3
2
Circuit Breaker, 30A, 1000V
$152.00
$304.00
4
3
Fuse, 30A, 1000V
$12.00
$36.00
5
3
Fuseblock, 100A, 1000V
$21.00
$63.00
6
2
Res, 40 OHM, 250 W
$57.00
$114.00
7
2
Cap, Electrolytic, 3300 uF,
$23.00
$46.00
8
1
Assy, Harness, Main
$282.00
$282.00
9
1
Circuit Breaker, 20A, 1000V
$152.00
$152.00
10
1
Circuit Breaker, 2A, 1000V
$100.00
$100.00
11
4
SSR, 12A, 400 VDC, MOSFET OUT
$23.00
$92.00
12
1
Transformer, Control
$100.00
$100.00
Total
$1,452.00
1.5 MW PM SCR/SCR Drive - Rev. 5.0
8
1.5 MW PM SCR/SCR Drive Pricing Estimates
Direct Variable Materials
(1)
26,154
$
26,154
$
26,154
$
Direct Variable Labor
(2)
1,560
$
1,560
$
1,560
$
Direct Fixed Costs
(3)
4,157
$
4,157
$
4,157
$
Total Direct Costs
31,871
$
31,871
$
31,871
$
Gross Margin
(4)
30%
40%
50%
Purchase Price
45,530
$
53,119
$
63,742
$
(1)
Includes 3% freight in.
(2)
Assumes 30% fringe benefits and 70% utilization, includes final assembly, board test, and final test.
(3)
This number can vary significantly, 15% is used here.
(4)
Gross Margin = (Sales Price - Direct Cost)/Sales Price
1.5 MW Permanent Magnet Drive
F.3-1
WindPACT Drive Train Report – Appendix F
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
1
1.5 MW Diode-IGBT Drive Topology
6
7
8
Enclosure
#
Included Component
#
Excluded Component
10
* Note - 4 Line Side Current Transducers Not Shown
3 Phase
Line
Filter
Control Board
&
Communication
To Turbine Com
9
5
Line Side
A
B
2
1
2
3
4
B
Sub-Panel
Pad Mount
Transformer
575V or 690V
secondary
1
Gate Drive
Board
3 Phase
Line
Filter
A
M
1.5 MW
PM
Generator
3
A
B
-
+
-
+
Gate Drive
Board
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
2
1.5 MW Diode-IGBT Drive
Bill of Materials (BOM)
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
2
Contactor, 800 A, 1000 VAC, 3-pole, Line
1,240.00
2,480.00
2
2
Line Filter, 3-Phase
7,238.00
14,476.00
3
2
Assy, Matrix, 3-Phase, Line
8,045.00
16,090.00
4
2
Assy, Diode Matrix, 3-Phase, Rotor
1,692.00
3,384.00
5
1
Control Board
1,400.00
1,400.00
6
2
Fuse, 900 A, 1000 VAC, 3-pole
281.00
562.00
7
2
Contactor, 800 A, 1000 VAC, 3-pole, Gen
1,240.00
2,480.00
8
1
Enclosure
2,916.00
2,916.00
9
1
Sub-Panel
1,300.00
1,300.00
10
4
Current transducers, 4 Line
268.00
1,072.00
Total
46,160.00
F.3-2
WindPACT Drive Train Report – Appendix F
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
3
1.5 MW Diode-IGBT Drive
3-Phase IGBT Line Side Matrix
IGBT
IGBT
IGBT
IGBT
IGBT
IGBT
A
B
C
CL
CL
CL
Rb
Rb
Rb
3
2
1
8 parallel paths
Gate Drive Board
4
* Note - Heatsink not shown
5
Typical
6
7
* Note - Cooling Fan not shown
8
To Control Board
Fiber Optic Harness
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
4
1.5 MW PM Diode-IGBT Drive
3-Phase IGBT Line Side Matrix
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
3
Resistor, Balance
$1.66
$5.00
2
24
Capacitor, 6500 uF, 450 Volt
$40.40
$969.00
3
6
IGBT, 2400 A, 1700 Volt
$554.00
$3,324.00
4
1
Gate Drive Board, Hex
$404.00
$404.00
5
1
Assy, Laminated Bus
$1,232.00
$1,232.00
6
1
Heatsink
$1,372.00
$1,372.00
7
1
Cooling Fan
$514.00
$514.00
8
1
Fiber Optic Harness
$225.00
$225.00
Total
$8,045.00
F.3-3
WindPACT Drive Train Report – Appendix F
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
5
1.5 MW Diode-IGBT Drive
3-Phase Diode Bridge
A
B
C
* Note - Heatsink not shown
2
3
* Note - Cooling Fan not shown
1
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
6
1.5 MW Diode-IGBT Drive
3-Phase Diode Bridge
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
6
Diode, 1200 A, 2400 V, Fast Recovery
$120.00
$720.00
2
1
Heatsink, Clamps, Terminations
$600.00
$600.00
3
1
Cooling Fan & Sw itch Gear
$372.00
$372.00
Total
$1,692.00
F.3-4
WindPACT Drive Train Report – Appendix F
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
7
1.5 MW Diode-IGBT Drive
3-Phase Line Side Filter
C
B
A
4
1
3
6
Enclosure
2
5
A
B
C
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
8
1.5 MW Diode-IGBT Drive
3-Phase Line Side Filter
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
1
Inductor, Reactor, Line, 1000uH, 3-phase
$2,509.00
$2,509.00
2
1
Inductor, Reactor, PWM, 500uH, 3-phase
$1,374.00
$1,374.00
3
3
Resistor, Stainless, 3-phase, .1 OHM/phase
$76.00
$228.00
4
2
Capacitor, 20.8 KVAR, 3-phase, 690 Volt
$172.00
$344.00
5
1
Inductor, 500uH, 800 A
$2,025.00
$907.00
6
1
Enclosure
$1,876.00
$1,876.00
Total
$7,238.00
F.3-5
WindPACT Drive Train Report – Appendix F
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
9
1.5 MW Diode-IGBT Drive
Sub-Panel
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
1
Fab, Panel, Pow er Dist
$127.00
$127.00
2
1
Sw itch, Disconnect, 80 A, 1000V
$36.00
$36.00
3
2
Circuit Breaker, 30A, 1000V
$152.00
$152.00
4
3
Fuse, 30A, 1000V
$12.00
$36.00
5
3
Fuseblock, 100A, 1000V
$21.00
$63.00
6
2
Res, 40 OHM, 250 W
$57.00
$114.00
7
2
Cap, Electrolytic, 3300 uF,
$23.00
$46.00
8
1
Assy, Harness, Main
$282.00
$282.00
9
1
Circuit Breaker, 20A, 1000V
$152.00
$152.00
10
1
Circuit Breaker, 2A, 1000V
$100.00
$100.00
11
4
SSR, 12A, 400 VDC, MOSFET OUT
$23.00
$92.00
12
1
Transformer, Control
$100.00
$100.00
Total
$1,300.00
1.5 MW PM Diode-IGBT Drive - Rev. 4.01
10
1.5 MW Diode-IGBT Drive Pricing Estimates
Direct Variable Materials
(1)
46,160
$
46,160
$
46,160
$
Direct Variable Labor
(2)
1,560
$
1,560
$
1,560
$
Direct Fixed Costs
(3)
7,158
$
7,158
$
7,158
$
Total Direct Costs
54,878
$
54,878
$
54,878
$
Gross Margin
(4)
30%
40%
50%
Purchase Price
78,397
$
91,463
$
109,756
$
(1)
Includes 3% freight in.
(2)
Assumes 30% fringe benefits and 70% utilization, includes final assembly, board test, and final test.
(3)
This number can vary signif icantly, 15% is used here.
(4)
Gross Margin = (Sales Price - Direct Cost)/Sales Price
1.5 MW Permanent Magnet (2X) Drive
F.4-1
WindPACT Drive Train Report – Appendix F
1.5 MW IGBT-IGBT - Rev. 4.0
1
1.5 MW IGBT-IGBT Drive Topology
Pad Mount
Transformer
575V or 690V
secondary
1
Gate Drive
Board
Gate Drive
Board
3 Phase
Inductor
3 Phase
Line
Filter
Control Board
&
Communication
To Turbine Com
8
5
Generator Side
Line Side
A
B
A
B
2
2
1
2
3
4
6
3
7
Enclosure
B
B
Gate Drive
Board
Gate Drive
Board
3 Phase
Inductor
3 Phase
Line
Filter
A
A
T
5
4
1.5 MW
PM
Generator
#
Included Component
#
Excluded Component
9
* Note - 8 Current Transducers, 4 Line & 4 Gen, Not Shown
M
A
B
Sub-Panel
1.5 MW IGBT-IGBT - Rev. 4.0
2
1.5 MW IGBT-IGBT Drive
Bill of Materials (BOM)
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
2
Contactor, 810 A, 600 VAC, 3-pole, Line
$1,240.00
$2,480.00
2
2
Line Filter, 3-Phase
$9,770.00
$19,540.00
3
2
Assy, Matrix, 3-Phase, Line
$6,783.00
$13,566.00
4
2
Assy, Matrix, 3-Phase, Rotor
$6,783.00
$13,566.00
5
1
Generator Control Board
$1,992.00
$1,992.00
6
2
Contactor, 810 A, 600 VAC, 3-pole, Line
$1,240.00
$2,480.00
7
1
Enclosure
$3,451.00
$3,451.00
8
1
Sub-Panel
$1,300.00
$1,300.00
9
8
Current transducers, 4 Line , 4 Gen
$268.00
$2,144.00
Total
$60,519.00
F.4-2
WindPACT Drive Train Report – Appendix F
1.5 MW IGBT-IGBT - Rev. 4.0
3
1.5 MW IGBT-IGBT Drive
3-Phase IGBT Line/Gen Side Matrix
IGBT
IGBT
IGBT
IGBT
IGBT
IGBT
A
B
C
CL
CL
CL
Rb
Rb
Rb
3
2
1
8 parallel paths
Gate Drive Board
4
* Note - Heatsink not shown
5
Typical
6
7
* Note - Cooling Fan not shown
8
To Control Board
Fiber Optic Harness
1.5 MW IGBT-IGBT - Rev. 4.0
4
1.5 MW IGBT-IGBT Drive
3-Phase IGBT Line/Gen Side Matrix
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
3
Resistor, Balance
$1.66
$5.00
2
24
Capacitor, 6500 uF, 450 Volt
$40.40
$969.00
3
6
IGBT, 2400 A, 1700 Volt
$496.00
$2,976.00
4
1
Gate Drive Board, Hex
$404.00
$404.00
5
1
Assy, Laminated Bus
$900.00
$900.00
6
1
Heatsink
$790.00
$790.00
7
1
Cooling Fan
$514.00
$514.00
8
1
Fiber Optic Harness
$225.00
$225.00
Total
$6,783.00
F.4-3
WindPACT Drive Train Report – Appendix F
1.5 MW IGBT-IGBT - Rev. 4.0
5
1.5 MW IGBT-IGBT Drive
3-Phase Line Side Filter
C
B
A
4
1
3
6
Enclosure
2
5
A
B
C
A
B
C
A
B
C
1.5 MW IGBT-IGBT - Rev. 4.0
6
1.5 MW IGBT-IGBT Drive
3-Phase Line Side Filter
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
1
Inductor, Reactor, Line, 250uH, 3-phase
$2,402.00
$2,402.00
2
1
Inductor, Reactor, PWM, 250uH, 3-phase
$2,916.00
$2,916.00
3
3
Resistor, Stainless, 3-phase, .1 OHM/phase
$76.00
$228.00
4
1
Capacitor, 20.8 KVAR, 3-phase, 690 Volt
$172.00
$172.00
5
1
Inductor, Reactor, Line, 250uH, 3-phase
$2,402.00
$2,402.00
6
1
Enclosure
$1,650.00
$1,650.00
Total
$9,770.00
F.4-4
WindPACT Drive Train Report – Appendix F
1.5 MW IGBT-IGBT - Rev. 4.0
7
1.5 MW IGBT-IGBT Drive
Sub-Panel
BOM
Item
#
Qty
Description
Unit
Cost
Extended
Cost
1
1
Fab, Panel, Pow er Dist
$127.00
$127.00
2
1
Sw itch, Disconnect, 80 A, 1000V
$36.00
$36.00
3
2
Circuit Breaker, 30A, 1000V
$152.00
$152.00
4
3
Fuse, 30A, 1000V
$12.00
$36.00
5
3
Fuseblock, 100A, 1000V
$21.00
$63.00
6
2
Res, 40 OHM, 250 W
$57.00
$114.00
7
2
Cap, Electrolytic, 3300 uF,
$23.00
$46.00
8
1
Assy, Harness, Main
$282.00
$282.00
9
1
Circuit Breaker, 20A, 1000V
$152.00
$152.00
10
1
Circuit Breaker, 2A, 1000V
$100.00
$100.00
11
4
SSR, 12A, 400 VDC, MOSFET OUT
$23.00
$92.00
12
1
Transformer, Control
$100.00
$100.00
Total
$1,300.00
1.5 MW IGBT-IGBT - Rev. 4.0
8
1.5 MW IGBT-IGBT Drive Pricing Estimates
Direct Variable Materials
(1)
60,519
$
60,519
$
60,519
$
Direct Variable Labor
(2)
1,560
$
1,560
$
1,560
$
Direct Fixed Costs
(3)
9,312
$
9,312
$
9,312
$
Total Direct Costs
71,391
$
71,391
$
71,391
$
Gross Margin
(4)
30%
40%
50%
Purchase Price
101,987
$
118,985
$
142,782
$
(1)
Includes 3% freight in.
(2)
Assumes 30% fringe benefits and 70% utilization, includes final assembly, board test, and final test.
(3)
This number can vary significantly, 15% is used here.
(4)
Gross Margin = (Sales Price - Direct Cost)/Sales Price
1.5 MW IGBT-IGBT Drive