Motor control system with integrated solid-state contactor and relays and method of operation thereof

A controller-implemented method of operating a motor switching assembly for controlling power delivery from a power source to a load, the method comprising:

• controlling the motor switching assembly to operate in one of a power conditioning mode or a bypass mode;
• wherein controlling the motor switching assembly to operate in the power conditioning mode comprises:
• operating a solid-state switching unit of the motor switching assembly in a conducting mode;
• operating an input relay of the motor switching assembly in a closed position;
• and
• operating a bypass relay of the motor switching assembly in an open position such that power from the power source is routed through the power converter;
• wherein the solid-state switching unit is positioned upstream from the power converter and upstream from a node to which the input relay and the bypass relay are parallelly connected;
• and
• wherein controlling the motor switching assembly to operate in the bypass mode comprises:
• operating the solid-state switching unit in a conducting mode;
• operating the input relay in an open position;
• and
• operating the bypass relay in a closed position such that power from the power source bypasses the power converter.

A board-level motor switching assembly for controlling power from a power source to a load, the board-level motor switching assembly comprising:

• a printed circuit board (PCB) structure;
• and
• a plurality of protection and control components integrated onto the PCB structure, the plurality of protection and control components comprising:
• a multi-functional solid-state contactor comprising a plurality of solid-state switches that are selectively switchable to control and condition power flow through the multi-functional solid-state contactor;
• a variable frequency drive (VFD) unit downstream from the multi-functional solid-state contactor and operable to provide a controlled output power to the load;
• an input relay positioned between the multi-functional solid-state contactor and the VFD unit and being switchable to control power flow into the VFD unit;
• and
• a bypass relay positioned between the multi-functional solid-state contactor and the VFD unit and connected to the input relay, the bypass relay being switchable to control power flow onto a bypass path that routes power flow around the VFD unit.