Decanter Basic Core controller VFD Panel Recommendations

61244585

Original Manual. Version: 00

Decanters Basic Core Controller VFD Panel

Recommendations
61244585

Revision 00 released on June 15, 2011. Updates are as follows:

- Document created,

Version:

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Decanters Basic Core Controller VFD Panel

Recommendations
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Contents
WARNING ...............................................................................................................................................................3
VFD Panel General Requirements ..........................................................................................................................4
Common DC bus system .........................................................................................................................................5
Other components in the VFD panel .......................................................................................................................5
Panel components layout example .......................................................................................................................... 7

WARNING
To avoid communication problems the following rules
are to be observed:

Version:

00

The cables used for Ethernet and Ethernet PowerLink networks are to be
S/FTP type (foil-shielded twisted pairs surrounded by an overall braided
shield) with shielded RJ45 jacks on both ends. Cable external diameter is
4.5 - 8 mm. The diameter of the core insulation must not exceed 1.6 mm.

Both attached to the HMI cover grounding wires are to be connected.

2
2
The 4 mm wire connects to the screw on HMI chassis and the 2.5 mm
wire to the HMI panel 24VDC power plug terminal.

Use the screened cable with twisted wires to bring 24VDC power to the
HMI.

Network cables parallel runs with power cables are not allowed.

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VFD Panel General Requirements

The current VFD panel design recommendations are not the substitute for the local rules and standards in a
country where the panel is built and/or where its going to be used. Any special or safety requirements that may
deviate from or not covered by this document shall take precedence over the general requirements below.
Variable Frequency Drives (VFD) panel does not represent a part of Alfa Laval Decanter BCC Controls and could
be build for the end customer either by Alfa Laval approved panel shop on behalf of Alfa Laval or by the customer.
Alfa Laval Standard Modules Group accepts orders for building standard design panels for various motor sizes
combinations made to CE standard.
Customer provides the VFD panel with the source of power supply 400-690 VAC, 3 ph, 50/60 Hz.
Standard VFD panels are built for the supply voltage range 400-500 VAC, 3 ph, 50/60 Hz.
Feed for the motor loads, including Main Drive (MD), Back Drive (BD), optional lube or grease pump motors, slide
gate motor, application panel is protected with the fusible disconnect switch sized to match the load demand.
Recommended type: ABB Powerline compact, heavy duty fusible disconnect switches, range 30-800A.
The VFD's to be used are ABB ACS800 industrial drives for three phase supply voltage range up to 690V, motors
power up to 160kW. Standard degree of protection for frame sizes R2-R6 is IP20.
The MD, BD VFD's front ends are protected with individual fuses.
The Safe Torque Off function +Q967 is used for drives shutdown in E-stop mode as well as in case of the
overspeed. The function disables the control voltage to of the power semiconductors, thus preventing the inverter
from generating the AC voltage required to rotate the motor. Safe Torque Off function +Q967 is according to
standards EN 61800-5-2:2007; EN ISO 13849-1:2008, IEC 61508 and EN 62061:2005. The function
also corresponds to an uncontrolled stop in accordance with category 0 of EN 60204-1
and prevention of unexpected start-up of EN 1037.
The following additional components are to be ordered and used with ACS800 :
- Ethernet PowerLink Adapter Module REPL-02 used for drive connection to the Basic Core Controls
communication network
- +Q967 ASTO-11C kit for Safe Torque Off and reliable shutdown in Emergency stop mode.
The need for du/dt filtering depends on the motor insulation, distance between the motor and the VFD.
(See ABB VFD manual for details)

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Common DC bus system

On traditional planetary gearboxes (not Direct Drive) the BD motor in most cases need to brake, and to facilitate
that, the BD VFD should be connected to the MD VFD via a common DC bus.
If the BD motor is also required to be driven in the opposite direction to the bowl (running very high Dn) the MD
VFD has to be sized to handle with its front end both full loads of the MD and BD motors simultaneously. Its also
advised to check on MD VFD charging circuit capacity against the total charging energy needed to make sure that
the charging resistor on the MD VFD frame can stand the whole charging energy as described in ABB application
guide publication 3AFE64786555 RevE.
The same application guide also advise on obligatory DC link fuse sizing. ABB recommends semiconductor
ultrarapid aR fuses rated 690VAC for 230-500V converters and 1250VAC rated fuses for 690V converters.

Other components in the VFD panel

Other components located inside VFD panel may include the following:
- POWER ON pilot light,
- panel thermostat and fan or air conditioner,
- E-stop pushbutton and E-stop safety relay,
- controls for HI and LO RPM flush valves,
- dV/dT output filters when needed,
Optional equipment are selectable by customers and may include:
- AC powered starters and protection for conveyors, feed and polymer pumps, grinders and macerators,
- monitoring equipment for pumps dry run protection,
- Power Factor correction capacitors banks,
- equipment for sludge and/or polymer tanks level monitoring,
- conveyors motion failure alarms and flush valves,
- diverter controls and flush valves,
- internal panel light,
Depending on volume and nomenclature, the customer specified equipment can be either fit inside the VFD panel
or be mounted in the separate enclosure.

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Panel components layout example

Wall mount VFD panel is to be used when MD VFD frame does not exceed size R5, or size R4 in case du/dt output
filters are employed.
Free standing VFD panel is to be used either with MD VFD frame size R6 or smaller VFD frame sizes when volume
of project specific additional components fit into VFD panel is significant.
Layout drawings below shows example of enclosure, size HxWxD 1400x1000x400 mm (55x39x16 in) for VFD
frame size R3 and R5 for BD and MD VFD's (7.5 kW and 37 kW motor size).
Fusible disconnect is located directly below the MD VFD to streamline the power cables connections.
See also 61244586 Generic BCC panel drawing example.

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