You guys that have problems with non-inverter generators causing appliances to act goofy should try buying a large 2 or 3 inch ferrite coil and looping the power cord from your appliance through it about 4 or 5 times..
I built a track driven "pick and place" robot once in a 3 car garage.. The control systems all ran on 3 phase 480 so I had to build a rotary phase converter and then run it through a 240/480 transformer to boost the voltage.
One of the servo controllers had an attitude problem with that power setup.. I thought it was shielding so we replaced a bunch of control wires with shielded cable... didn't fix squat.. Then I ran the power input to the controllers through ferrite coils.. Each leg got 3 loops through its own coil.. problem fixed.
What you describe is an RFI/EMI filter. The ferrite presents resistance to higher frequency content and converts that energy to heat dissipating it away leaving the lower fundamental frequency 50/60hz
This does not filter out harmonic distortion. To do that you need a load/line reactor. It's basically a large inductor and capacitor combo, but they are very large in size and not practical in the portable generator realm.
How Inverter generators work: They take a spinning permanent magnet rotor driven by the prime mover to excite a 3 phase AC alternator. All these phases are rectified which is then fed to the input stage of the inverter. It's higher than the final voltage (~200-300VDC for 120VAC output) to allow for proper regulation. That rectified charge is dumped into large input capacitors, to which the output stage will use PWM using fast switching IGBTs to approximate a sine wave output at the 60hz/120VAC. There are filtering components to remove enough of the hash, AKA transistor noise from switching on off so quickly in the 20k-100khz range...depending on how advanced the output stage is. The more one/off pulses to approximate the sine wave, the higher the switching frequency and efficiency. Resulting in very little THD, though switching noise is suppressed on the output, many cheap inverters skimp here just to pass FCC15 rules.
The 12VDC to 120VAC inverters add one extra stage, a boost stage. Multiple transformers inside connect their primaries in parallel, and the secondaries in series. Multiple banks of MOSFETs fire each side of the center tapped primary to ground creating an AC Square wave. The secondary windings in series boost the 12V to over 200VAC. Noone needs a ~50khz AC square wave so they rectify it to DC and dump into large input caps. The rest of the inverter stages are the same as described above.
I wrote this portion on my YouTube community page. It not only applies to HVAC but on any switch mode power supply device. Should hopefully be helpful info.
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HVAC Problems on Portable Generators - THD (Total Harmonic Distortion) - Proper Grounding of HVAC Systems On Generator Power.
You find a lot of posts about these two topics. Why doesn't my furnace run on my portable generator? The biggest issue is not always THD, rather improper grounding when using a portable generator. However all these factors play into the main problem of the furnace not working on generator power.
- The #1 issue is surge protection. Most but not all HVAC control boards were NOT designed to have any type of surge protection. You will not find basic components like MOVs that are meant to short any voltage spikes to ground. Here in the USA the National Electric Code standards to voltage/frequency/THD denotes there is no need to add these components because it is "stable enough" by spec. Obviously not the case everywhere but trying to think of logical reasons why. There are aftermarket solutions to protect the 24VAC lines running the controller boards for example, and there are also whole house surge protection devices available.
24VAC Surge Protector:
https://www.supplyhouse.com/Zebra-I...t-Surge-Protector-Plug-In-Surge-and-Spike-Protector-for-24V-Transformer-Systems
Whole House Surge Protector:
GE Whole Home Surge Protection Unit-Panel Mount THQLSURGE - The Home Depot
Portable Generators, either brushed/brushless, are NOT going to have as stable of a voltage/frequency like the utility. A heavy load starts on generator power, the voltage drops as a result, and so does the frequency as the engine slows down momentarily until its engine governor can respond to the load. This momentary drop then quick rebound of voltage/frequency will often overshoot (AKA spike beyond the nominal voltage/frequency for a brief instance) to compensate for that instantaneous load draw. The spinning rotor of a generator is an electro magnet, or known as an "inductor." Inductors by design store energy, and as long as the voltage/frequency is constant, everything is good. When those change, the inductor resists that change, and that causes a voltage spike. It is at these moments where sensitive devices not properly protected for surge can fail.
- The #2 issue not often talked about is proper grounding and polarity of the generator wiring. I've read and seen too often the failure of an HVAC system is due to faulty grounding/wiring. Modern furnaces use a method called "flame rectification." A flame can actually be used as a rectifier (converts AC to DC) to sense if the burner is ignited or not. The neutral/earth ground in your main panel is the 0VAC reference point the HVAC controller needs to see for this process to work correctly. If your ground connections at your generator are not properly configured based on how you hook it up to your panel, whether it be an interlock, 2 pole transfer switch, or 3 pole T-switch, this can cause problems.
A. Two pole interlock breaker or Two Pole Transfer Switch to an L14-30 Inlet box at a main panel with its Neutral/Earth Ground bonded needs to have a "floating neutral generator." One N/G bond in the system that is utilized by the generator, called a "Non Separately Derived System." A Ground Rod at the generator is not required unless certain criteria in the NEC 250.52 (A) are not met.
**These are the most common LEGAL methods of connecting a portable generator to a house.
According to 250.53(A)(3), if multiple rod, pipe, or plate electrodes are installed to meet the requirements of 250.53(A)(2), they must be at least 6 feet apart.
www.electricallicenserenewal.com
B. The 3 Pole Transfer switch will change over the two hot X&Y leads AND the neutral wires. The Earth grounding lead is left solid connected between the generator and panel. This is known as a "Separately Derived System." In this configuration, a "bonded neutral generator" with its own ground rod MUST be used. This is because the transfer switch breaks the neutral ground bond at your main panel and thus needs to have it bonded at the generator. This maintains a single bond within whichever system is powering the house circuits.
***This is the least common configuration used in the USA.
Please refer to a licensed electrician that knows what they are doing and understands the NEC. I learn from research and listen to others more qualified than me!!!!!
- The #3 issue is High THD: What is THD in its simplest explanation without getting too technical? Its voltage/current at another frequency than at the 50/60hz commonly found in households. If I have 120/240VAC at 60hz, but I also have say 12VAC at 120hz, or 8VAC at 240hz etc, now my 120/240VAC is contaminated with voltages/currents that my devices are unable to utilize. This is commonly known as "DIRTY POWER." Most residential HVAC controllers run off of stepped down mains voltage. This would be 120VAC down to 24VAC. If the THD is high on the mains, the stepped down 24VAC voltage IS JUST AS DISTORTED.
**The effects of High THD:
1. Can cause the microcontrollers to lock up. Microcontrollers usually run on 5VDC, and stray voltage spikes at the higher harmonics will bleed through the rectification process and stop the processor from operating, malfunction which cascades to its external peripherals, or simply fail completely.
2. Excessive heat buildup can occur in the PCB components. This is because that voltage at the higher harmonics cannot be utilized by the devices, and that energy is wasted in the form of heat, shortening the life of the component. This is also true of the electric motors in your HVAC system.
i. A permanent split capacitor (PSC Motor) is an inductive motor, operates at a single speed. Due to their energy inefficiency (~45%) These are commonly found in older systems. High THD will create a "reverse torque" in the motor windings, opposite of the spinning direction. This leads to overheating of the motor and premature failure.
ii. An Electronically Commutated (ECM Motor) is a variable speed motor commonly found in newer HVAC Systems. Like the PSC, the same problems occur. High THD can also interrupt the PWM signals the controller board running the variable speed causing malfunction/failure. Voltage surge/spikes is the most common failure as it will destroy the MOV(s) located on the speed controller of the motor itself.
Hopefully this post will educate you on some of the issues to watch out for. The reality with modern HVAC systems is that conventional portable generators are simply not adequate to handle their power needs. However, there are measures you can do such as employing a proper certified electrician to install your generator hookup, add the proper surge protection to your house and its devices, and consider purchasing a proper sized inverter generator. They are the best generators IMO for home backup power as they pose far less issues than what is discussed here.