DIWAN ANNEX

STARTER PANELS

SOURCE FOR MCC PANEL

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KAHRAMAA SUPPLY MV PANELS MCC PANELS LOADS

Types of Motor Starters The Motor Control Center (MCC) consists of one or more vertical metal cabinets

referred to as “sections.” Each section contains one or more fixed modular units, that are employed to distribute power to discrete loads, such as motors and other loads.

MCC can be specified with a range of options such as separate control transformers, ON/OFF/TRIP lamps, start / stop push button, control terminal blocks, various types of thermal overload protection relays, circuit breakers and VFDs.

MCC Panels have different types of starters i.e DOL, Star delta and VFDsDirect Online starters (DOL): A DOL starter is a type of motor starter which is basically simple and attaches

the motor terminals directly to the power supply. It normally governs the performance of an electric motor by applying the full line voltage to the motor terminals.

Star Delta starters (S/D): Star/Delta starters are probably the most common reduced voltage starters.

They are used in an attempt to reduce the start current applied to the motor during start as a means of reducing the disturbances and interference on the electrical supply.

Variable Frequency Drive (VFD): Variable-frequency drive (VFD) is a type of adjustable speed drive used

in electro -mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage.

System Location

System Location

STARTER PANEL QUANTITY

VFD’S INTEGRATION WITH BMS SYSTEM

RATING OF STARTER PANELS

VFD STARTER PANELS

30KW VFD PANEL DRAWINGS (TYPICAL)

Variable Frequency Drive• The Variable Frequency Drive (VFD) is a type of adjustable

speed drive used in electro -mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage.

• The ABB HVAC drives fulfil IEC/EN 61000-3-12. This European standard sets strict limits for harmonic currents produced by products connected to the electrical network.

• Harmonic currents are forms of pollution on the electrical network. The harmonics can cause several undesired effects - flickering lights, failing computers and overheating of electrical equipment.

• The drive is programmed with several HVAC applications, including supply and return fans, cooling tower fans, booster pumps and condensers. The intelligence within the HVAC control panel means that the user is given direct and understandable instructions in clear text at all times.

Basic Principle of OperationA VFD operates by converting the input sinusoidal AC voltage to DC voltage and then back to AC voltage. This conversion occurs by using either silicon-controlled rectifiers (SCRs) or IGBTs. The DC voltage is switched using IGBTs to create an AC output voltage (called the inverter). The IGBT can switch on and off to create an AC voltage waveform that delivers power to the motor. The IGBTs create an AC waveform by using pulse width-modulated (PWM) switching. The frequency at which the switching occurs, which varies from manufacturer to manufacturer, is called “carrier frequency.”

A typical 6-pulse VFD has six diodes as a front-end bridge rectifier that converts AC to DC. VFDs can also have 12 diodes — two sets per phase (2 × 2 × 3 = 12 pulse) — or 18 diodes — three sets per phase (3 × 2 × 3 = 18 pulse) — and so on. One set of diodes is supplied by a Delta-Y transformer to create a phase shift on the AC side between the two rectifiers to reduce harmonics reflected back to the source.

Main Features of ACH550 Drives Keeps you out of trouble• EMC filters for building sector,

class C2 (1st environment).• Meets mandatory harmonic

current standard EN 61000-3-12.

• Coated electronic boards supporting longer lifetime of the drive.

• Full motor (kW) output at 50 °C

All items carry written manufacturer’s statement of conformity.

Real-time Clock and Calendar

The inbuilt real-time clock and calendar function provides true time and date stamps to drive events. Information is displayed clearly on the control panel.

The clock and calendar function enables the use of timers. Further, daylight saving times are easily selected according to different time zones.

The real-time clock has the following features: Four daily times Four weekly times Timed boost function, e.g. a set constant speed which is on for a certain

pre-programmed time. Activated with a digital input. Timer enable with digital inputs Timed constant speed selection Timed relay activation.

Inbuilt Timers

The External timer circuits are no longer needed. Inbuilt timers - utilizing the real-time clock - allow starting and stopping the drive or changing the speed, according to the time of day or night. Relay outputs can be operated with timers to control any auxiliary equipment on site.

BACnet, N2, FLN and Modbus Embedded Commonly used HVAC fieldbuses are embedded into the memory of the

drive, ensuring that they are always there if you need them. ABB has supplied, to building automation, tens of thousands of drives utilizing serial communications, including thousands BACnet installations.

BACnet is a communications Protocol for building automation and control networks. It is an ASHRAE, ANSI and ISO standard protocol.

Makes Your Life Comfortable

• Multilingual control panel with HELP-button• 14 HVAC application macros are pre-programmed and selectable without programming.• A printed user’s manual is delivered with each drive.• Miniature circuit breakers can be used instead of fuses.

Wide Range of Interactive Assistants• Start-up• PID• Timer functions• Serial communicationAnd many more…The ABB HVAC drive has two independent PID controllers built in. As an example: one PID controller works with the frequency converter to maintain the duct static pressure. Simultaneously, the other PID controller can be used to control a separate external device, e.g. A chilled water valve. All of this can, of course, be monitored and controlled through serial communications.

Tailor-made HVAC software

The ABB HVAC drive delivers a complete solution with a tailor-made configuration that will save you time and money. For example, actual process values like differential pressure signals can be converted inside the frequency converter and displayed in engineering units like bar, l/s and °C.

Interactive start-up assistant

The start-up assistant shows how to use the PID controllers, timers and serial communications settings.

Ease of AccessInteractive Maintenance Assistant

Maintenance scheduling no longer requires guesswork. The ABB HVAC drive alerts you when maintenance is required based on your individual requirements.

Interactive Diagnostic AssistantShould a fault occur, the diagnostic assistant displays, in plain language, possible causes and potential solutions.

Fault loggerThe fault logger of the ABB HVAC drive is especially useful in tracking down drive failures through its use of the real-time clock. In addition to recording both time and date, the fault logger also takes a snapshot of 7 diagnostic values - like motor speed and output current so that you know what happened and when.

PC tools for• calculating energy savings andpay-back times• commissioning (Drive WindowLight 2)

Noise smoothingClever software function to smooththe audible noise.

TECHNICAL SPECIFICATION OF VFDs

TECHNICAL SPECIFICATION OF VFDs

TECHNICAL SPECIFICATION OF VFDs

ACH550 - Drives for HVAC.Control Your comfort With Intelligent Precision 

Your HVAC system demands effortless comfort for everyone.  Our intelligent variable speed drive is dedicated to saving energy, producing quality air, and alleviating environmental concerns.  Reduce costs by controlling your building’s fans, compressors, and pump motors efficiently, for an energy conscious commercial environment. The ACH550 provides proven reliability, flexibility, and every essential HVAC communication protocol. It is pre-programmed for several applications, including: air handling units, cooling towers, chillers, and more

ACH550 - I/O Connections

Option Slot 1:Relay output extension

3 “true” relay outputs

Form C, potential free switching,

250 VAC, 2A RMSOption slot 2:

Plug-in fieldbus

connectionLonWorks,

Profibus-DP,CANopen,

DeviceNet,ControlNet &

Ethernet

6 digital inputs

PNP/NPN

2 analogue inputs

0(2)–10VDC/0(4)-20mA

2 analogue outputs

0(4)-20mA

Panel connection

Embedded FieldbusModbus, BACnet, FLN & N2

FlashDropconnection

All Inside as Standard-Simple Selection STANDARD

(INSIDE THE DRIVE)

HVAC MacrosN2-FLN-BACnet-Modbus

HVAC Control Panel

Real-Time ClockBuilt-in timers

Fieldbus (Lon&others)3 Relay Outputs OPTIONS

(INSIDE THE DRIVE)

EMC Filters

Swinging ChokesThermal Reliability

Tailor-made Control Panel for HVAC Applications

Interactive assistants advise on the use of PID (Incl. air flow calculation), timers, fieldbus and facilitate commissioning

HELP button always available Up- and downloading of parameters from

one frequency converter to another Easily detachable by hand (both IP21 and

IP54) Inbuilt real-time clock 15 languages available in one single

panel, including Russian, Turkish, Czech and Polish

Installing The Drive

NOTE-Before installing the ACH550, ensure the input power supply to the drive is off.Preparing the mounting location1. Use the mounting template to mark theposition of the mounting holes.2. Drill the holes.3. Insert the screws halfway into the holes.Note: Frame sizes R3 and R4 have four holes along the top.Use only two. If possible, use the two outside holes (to allowroom to remove the fan for maintenance).

Removing Front Cover

1. Remove the control panel, if attached.2. Loosen the captive screw at the top.3. Push side clamps in.4. Pull up to lift the cover.

Mounting The Drive

1. Position the ACH550 onto the mounting screws or bolts and securely tighten in all four corners.2. Warning stickers in different languages are supplied with the instruction manual. Attach a warning sticker in the appropriate language on the inside plastic shell.

Overview of Wiring Installation

Power wiring1. Open the appropriate knockouts in the connection box.2. Install the cable clamps for the input power and motorcables.

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13. Install the connection box and tighten the cable clamps.

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4. On the input power cable, strip the sheathing back farenough to route individual wires.5. On the motor cable, strip the sheathing back far enough to expose the copper wire screen so that the screen can be twisted into a pigtail. Keep the pigtail short to minimize noiseradiation.

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6. Route both cables through the clamps. On the motor cable,360º grounding under the clamp is recommended tominimize noise radiation

Control wiring1. Install the cable clamp(s) for the control cable(s). (Inputpower and motor cables are not shown in the figure)

2. Strip the control cable sheathing3. Route the control cable(s) through the clamp(s) and tighten the clamp(s).4. Connect the ground screen for digital and analog I/O cables at X1:1.5. Strip and connect the individual control wires to the drive terminals.6. Install the connection box cover (one screw).

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Check Installation The installation preparations have been

completed according to the installation checklist.

The drive is mounted securely The space around the drive meets the

drive’s specifications for cooling The motor and driven equipment are

ready for start. The drive is properly grounded. The input power (mains) voltage matches

the drive’s nominal input voltage.

The input power (mains) connections at U1, V1 and W1 are connected and tightened as specified.

The input power (mains) fuses and mains switch are installed.

The motor connections at U2, V2 and W2 are connected and tightened as specified.

The motor cable is routed away from other cables.

NO power factor compensation capacitors are in the motor cable.

Note- Make sure that:-1.NO tools or foreign objects (such as drill shavings)are inside the drive.NO alternate power source for the motor (such as a bypass connection) is connected - no voltage is applied to the output of the drive.

Re-install Cover

1. Align the cover and slide it on.2. Tighten the captive screw.3. Re-install the control panel

Always re-install the front cover before turningpower on.The ACH550 will start up automatically at power-upif the external run command is on at I/O.

• Apply input power.• Green LED is lit.

Note

Before increasing motor speed, check that the motor is running in the desired direction

If you want to generate a fault to check the I/O, select HAND mode and remove the control panel

START UP & CONTROL OF VFD

Start-Up

Start-up can be performed in two ways:1. By using the Start-up assistant.2. By changing the parameters individually.At the first start, the drive activates the Start-up assistant. You can restart it and its individual tasks in the Start-up assistant mode

Start-up by using the Start-up assistant1 Press MENU to go to the

main menu.

2 Select the PARAMETERSmode with the UP/DOWNkeys and press ENTER togo to the Parametersmode.

3 Select the appropriateparameter group with theUP/DOWN keys and pressSEL.

4 Select the appropriateparameter in a group withthe UP/DOWN keys. PressEDIT to change theparameter value.

5 Press the UP/DOWN keysto change the parametervalue.

6 Press SAVE to store themodified value or pressCANCEL to leave the setmode. Any modificationsnot saved are cancelled.

Start-up by Changing the Parameters Individually

1 Press MENU to go to themain menu.

2 Select the PARAMETERSmode with the UP/DOWNkeys and press ENTER togo to the Parametersmode.

3 Select the appropriateparameter group with theUP/DOWN keys and pressSEL.

4 Select the appropriateparameter in a group withthe UP/DOWN keys. PressEDIT to change theparameter value.

5 Press the UP/DOWN keysto change the parametervalue.

6 Press SAVE to store themodified value or pressCANCEL to leave the setmode. Any modificationsnot saved are cancelled.

7 Press EXIT to return to thelisting of parameter groups,and again to return to themain menu.

Note: To restore the default factory settings, select the HVAC default application macro.

TERMINAL DETAILS FOR VFDS

Serial Communications of ACH550

The drive can be connected to an external control system by a fieldbus controller, either:

via a plug-in fieldbus adapter (EXT FBA) module mounted inexpansion slot 2 of the drive

OR via the standard RS485 interface at

terminals X1:28.32 on the control board of the drive

When using serial communication, the ACH550 can either:. Receive all of its control information from the fieldbus, or. Be controlled from some combination of fieldbus control and other available control locations, such as digital or analog inputs, and the control panel (operator keypad).

The Figure Below Shows The Mounting of The Fieldbus Module.

Maintenance & Fault Analysis of VFD’s

Maintenance & Fault Analysis of VFD’s

Maintenance & Fault Analysis of VFD’s

Maintenance & Fault Analysis of VFD’s

Maintenance & Fault Analysis of VFD’s

Maintenance & Fault Analysis of VFD’s

Maintenance IntervalsIf installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB

FVNR (DOL) STARTER PANELS

DOL & Star-Delta Starters

The simplest form of motor starter for the induction motor is the Direct On Line starter. The Direct On Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an overload relay for protection. Electromagnetic contactor which can be opened by the thermal overload relay under fault conditions.

Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is electrically latched closed while the motor is operating.

Most induction motors are started directly on line, but when very large motors are started that way, they cause a disturbance of voltage on the supply lines due to large starting current surges. To limit the starting current surge, large induction motors are started at reduced voltage and then have full supply voltage reconnected when they run up to near rotated speed.

Traditionally in many supply regions, there has been a requirement to fit a reduced voltage starter on all motors greater than 5HP (4KW). The Star/Delta (or Wye/Delta) starter is one of the lowest cost electromechanical reduced voltage starters that can be applied

TYPICAL DRAWING FOR FVNR PANELS (3-PHASE STARTER)

TYPICAL DRAWING FOR FVNR PANELS (1-PHASE STARTER)

TYPICAL DRAWING FOR STAR/DELTA STARTER PANELS

Maintenance of DOL & Star-Delta Starters1. Keep the interior dust free.

2. Re-tighten terminal screws from time to time.

3. No maintenance is required for overload relayand switch. Do not open them.4. Blackening of silver coated/alloyed contacts doesnot affect operational life. If necessary, clean thecontacts with white petrol, carbon tetrachlorideor perchloroethylene, Globules may be removedwith a scrapper but do not dress the contacts.

5. If the conductor hums, clean the pole faces withsoft cloth.6. Replace contacts of the contactor if they areseverely pitted or when only 30% originalcontact tip remains. For details of contactormaintenance refer to ‘our Guide to ContactorInstallation & Maintenance’.

TYPICAL DRAWING FOR SCR -HEATER CONTROL PANELS

Safety Instructions The ACH550 should ONLY be installed by a qualified technician Even when the motor is stopped, dangerous voltage is present at

the power circuit terminals U1, V1, W1 and U2, V2, W2, and, depending on the frame size, UDC+/BRK+ and UDC-/BRK-

Dangerous voltage is present when input power is connected. After disconnecting the supply, wait at least 5 minutes before removing the cover. To check, measure for zero voltage at the DC terminals, which are, depending on the frame size, UDC+/BRK+ and UDC-/BRK-

Even when the power is switched off, there may be dangerous voltage (from external sources) on the terminals of the relay outputs R01.R03

EXTRAS

When the control terminals of two or more drive units are connected in parallel, the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply.

The ACH550 is not a field repairable unit. Never attempt to repair a malfunctioning unit; contact the factory or your local Authorized Service Center for replacement.

The ACH550 will start up automatically after an input voltage interruption if the external run command is on.

WARNING! Do not control the motor with an AC contactor or disconnecting device (disconnecting means); use instead the control panel start and stop keys or external commands (I/O or fieldbus). The maximum allowed number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is three in five minutes.

THANK YOU

Sheikh Imran(Sales Engineer) Qatar SwitchgearMH-Al Muftah Est