14. SOURCE FOR MCC PANEL
c
KAHRAMAA SUPPLY MV PANELS MCC PANELS LOADS
15. 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 VFDs
Direct 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.
44. 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.
45. Basic Principle of Operation
A 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.
46. 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.
47. 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.
48. 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.
49. 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.
50. 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.
51. Wide Range of Interactive Assistants
• Start-up
• PID
• Timer functions
• Serial communication
And 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.
52. 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.
53. Interactive start-up assistant
The start-up assistant shows how to use the PID controllers, timers and serial
communications settings.
54. Ease of Access
Interactive 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 Assistant
Should a fault occur, the diagnostic
assistant displays, in plain language,
possible causes and potential solutions.
Fault logger
The 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
PC tools for
• calculating energy savings and
pay-back times
• commissioning (Drive Window
Light 2)
Noise smoothing
Clever software function to smooth
the audible noise.
58. 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
60. All Inside as Standard-Simple Selection
STANDARD
(INSIDE THE DRIVE)
HVAC Macros
N2-FLN-BACnet-Modbus
HVAC Control Panel
Real-Time Clock
Built-in timers
Fieldbus (Lon&others)
3 Relay Outputs
OPTIONS
(INSIDE THE DRIVE)
EMC Filters
Swinging Chokes
Thermal Reliability
61. 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
62. Installing The Drive
NOTE-Before installing the ACH550, ensure the
input power supply to the drive is off.
Preparing the mounting location
1. Use the mounting template to mark the
position 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 allow
room to remove the fan for maintenance).
63. 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.
64. 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.
66. Power wiring
1. Open the appropriate knockouts in the connection box.
2. Install the cable clamps for the input power and motor
cables.
2
1
3. Install the connection box and tighten the cable clamps.
3
4. On the input power cable, strip the sheathing back far
enough 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.
5
4
6. Route both
cables through the
clamps. On the
motor cable,
360º grounding
under the clamp is
recommended to
minimize noise
radiation
67. Control wiring
1. Install the cable clamp(s) for the control cable(s). (Input
power and motor cables are not shown in the figure)
2. Strip the control cable sheathing
3. 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).
1
4
5
3
68. 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.
69. 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 turning
power on.
The ACH550 will start up automatically at power-up
if the external run command is on at I/O.
• Apply input power.
• Green LED is lit.
70. 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
72. 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
73. Start-up by using the Start-up assistant
1 Press MENU to go to the
main menu.
2 Select the PARAMETERS
mode with the UP/DOWN
keys and press ENTER to
go to the Parameters
mode.
3 Select the appropriate
parameter group with the
UP/DOWN keys and press
SEL.
4 Select the appropriate
parameter in a group with
the UP/DOWN keys. Press
EDIT to change the
74. 5 Press the UP/DOWN keys
to change the parameter
value.
6 Press SAVE to store the
modified value or press
CANCEL to leave the set
mode. Any modifications
not saved are cancelled.
75. Start-up by Changing the Parameters Individually
1 Press MENU to go to the
main menu.
2 Select the PARAMETERS
mode with the UP/DOWN
keys and press ENTER to
go to the Parameters
mode.
3 Select the appropriate
parameter group with the
UP/DOWN keys and press
SEL.
4 Select the appropriate
parameter in a group with
the UP/DOWN keys. Press
EDIT to change the
parameter value.
76. 5 Press the UP/DOWN keys
to change the parameter
value.
6 Press SAVE to store the
modified value or press
CANCEL to leave the set
mode. Any modifications
not saved are cancelled.
7 Press EXIT to return to the
listing of parameter groups,
and again to return to the
main menu.
Note: To restore the default factory settings, select the
HVAC default application macro.
78. 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
79. 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).
87. Maintenance Intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB
89. 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.
90. 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
109. Maintenance of DOL & Star-Delta Starters
1. Keep the interior dust
free.
2. Re-tighten terminal
screws from time to time.
3. No maintenance is
required for overload
relay
and switch. Do not open
them.
4. Blackening of silver
coated/alloyed contacts
does
not affect operational
life. If necessary, clean
the
contacts with white
5. If the conductor hums,
clean the pole faces with
soft cloth.
6. Replace contacts of the
contactor if they are
severely pitted or when
only 30% original
139. 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
140. 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.
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.
