Control System Retrofits and Upgrades - Enhancing Efficiency and Performance in UAE

Control System Retrofits and Upgradation

Retrofitting refers to the addition of new technology or features to older systems. CoreSystems has the ability to upgrade and retrofit modern technology and equipment to your existing system.


Why is Retrofitting and Upgradation of Control System Necessary?

Retrofitting provides you with the ease of use and reliability of fresh new equipment at little of the expense. Many times, it is very cost effective for the customer to retrofit a machine with new controls rather than buy a new machine. Spare parts are readily available and less expensive than outdated components.

Modern HMI (Human Machine Interface) technology can store machine parameters, saving thousands of dollars in setup and changeover time and can display alarm conditions, making troubleshooting and service easier. Every industrial control panels are completely wired and checked before delivery, thus decreasing start-up time. All retrofit solutions include updated electrical schematics.


Benefits of Retrofitting and Upgrading

  • Your upgraded and retrofitted system will have more capabilities than it did before.
  • Production will overtake your previous benchmarks.
  • The equipment will be more reliable than it ever was.
  • You can revive on labor expense as the automation can handle more duties than when the system was first built.
  • Save energy
  • Reduce downtime due to scheduled maintenance
  • Report operating data and productivity information in real-time
  • Increase reliability
  • Troubleshoot problems quickly with detailed diagnostic information


What is Done During Retrofitting and Upgradation of Control System?

To perform engineering commissioning and work included in an upgrade in a short time, all gears are not upgraded in block; in its place, a phased upgrading is performed. In regards to the phased upgrading, the upgrades of all the equipment are split up and performed in several set inspection periods; consequently, the required capital investment per inspection is reduced. Although doing the upgrade it can suppress the total amount of investment, optimization is achieved according to the ingenuity of the upgrading sequence.

The following three points are evaluated in three separate steps

(1) Level of importance of equipment

The upgrade is planned to start from equipment that is either extremely difficult or impossible to operate the plant in the case that parts in that equipment age and malfunction.

(2) Rebuilt dimensions of gears other than that upgraded

To upgrade existing equipment, temporarily upgrading equipment that is to be upgraded in the next. There are many paths that could be opted for by the end user while deciding on an upgrade. Most of the DCS OEMs have already designed their upgrade paths accordingly. One of the easiest way is to substitute every current DCSs at the same time—along with all human-machine interfaces (HMIs), input/output (I/O) modules, control hardware etc. This path might seem easier to deploy, but it has some factors like longer downtime, reduced efficiency of operational staff as they have to switch to newer systems in one go, and so on inspection period or later is wasteful; therefore, an upgrade sequence that gives rise to a little temporary work as possible is set up.

(3) Completing upgrading work and sufficient testing within the predetermined inspection test period

An upgrading sequence that permits finishing of upgrading work and satisfactory testing in the predetermined inspection test period was exhibited. Because unlike simple upgradation, the phased plan requires proof testing of elements that are newly accepted in widening of the automation scope. There are episodes in which old and new networks survive together. Hence, prevailing pieces of gear and the gateways for conveying their communications should be established as a short-term equipment until the whole upgrading is finished.


How is Retrofitting and Upgradation of Control System Done?

The most commonly used approach is upgrading in steps or phases.

Phase 1: Supervisory layer component upgrade

Supervisory layer components involving HMIs and communication network elements between control systems and HMIs are upgraded in phase 1. This lets the end user to become acquainted with the operations of new system. Having the old HMIs run in parallel with the new HMIs is beneficial because it gives the operators a chance to become familiar with the new system.

Phase 2: Control system upgrade

Phase 2 involves upgrading DCS control hardware. This is a critical phase and has to be planned in more detail as compared to phase 1. It may include downtime depending on upgrade limitations and DCS configuration.

Phase 3: I/O modules upgrade [Optional]

Phase 3 involves upgrading I/O modules and relevant hardware in a DCS. It may also involve downtime based on I/O module configuration and upgrade limitations.


Whatever the reason for replacing a control system, there are 3 major steps that we take to ensure the success of the change out.

Phase 1: Determine how the existing system functions.

Before we can begin retrofitting a controller, we must first fully understand how the existing system works. This requires a certain amount of documentation and knowledge, including:

  • drawings such as P&IDs, mechanical, process or electrical
  • an understanding of any hardwired safety circuits
  • identifying the existing I/O on the controller and the function of each device connected to the I/O
  • capturing HMI screens and determining what each active element (such as a pushbutton) does
  • a list of all setpoints and alarms that have been programmed into the existing system
  • an understanding of all data that may be sent to the SCADA system
  • a clear and concise Functional Specification that explains the details of how the system functions and the expected product throughput of the system. If written properly, this document can also be integrated into an Operator’s Manual.
  • a Control Narrative that verbally describes the sequence of operation of the machine or system
  • list of applicable personnel, environmental and machine safety standards that apply

In most cases, all of this information is not readily accessible. That is not the fault of the owner, as he may never have received that information in the first place.

In any event, if any of the items listed above are not available, we will perform an audit of the existing system so that we have the required information.

This serves a dual purpose. If the owner, does not have that information, he is usually very happy to get it. Also, it gives us the information we need to proceed to the next phase.

Sometimes, this first phase is completed in a couple of days. Other times, it may take a few weeks or even months. We have been involved in projects where there was very little documentation, resulting in us interviewing the machine operators to find out how the system worked.

Phase 2: Create new drawings, write the control program and generate the necessary HMI and SCADA screens

Of course, if we are installing a new controller new drawing will be required.

We will sit down with the owner and go over the new drawings, the new program, the screens, alarms, SCADA data collection and safety concerns. We want to capture any issues that may present a problem in the final phase.

During this phase, our primary goal is to make sure that the system operates as defined in the Functional Specification. However, we certainly understand that the owner might want to make enhancements to increase productivity, decrease downtime or otherwise improve performance. We are more than willing to accommodate any changes to the original operation.

Phase 3: Retrofitting and Start-Up

We work with the owner to determine who will actually remove the old controller and install the new one. Perhaps the owner wants his personnel to perform the work, or maybe he would prefer that the work be done by contractors.

As physical situations vary, sometimes a new controller can be installed in an existing enclosure. Other times, a new enclosure is required. In either case, we will provide drawings and define a step-by-step procedure for installing the new controller.

With the owner, we will determine how much downtime is available to replace the existing controller with a new one. We understand that production demands must be met and we will accommodate those demands. This may require making provisions to operate the equipment manually during the controller changeout. In large systems, it probably would be best to divide the systems into sub-systems, so that the entire system is upgraded a section at a time.

We will define the acceptance criteria for the project. Typically, this is as simple as going through the Functional Specification and confirming that the system operates as stated. However, there may be other variables, and we want to make sure the client’s needs are met.

After we have a clear plan for the start-up, we will monitor and assist in the physical retrofit, load the new program and test the system to the defined acceptance criteria.

Written by CoreSystems

Control System Retrofits and Upgradation

Field Service Automation Process - Streamlining Operations

Field Service Automation

Field service automation (FSA) or Field service management (FSM) software is a mature market. While FSA has been around for two decades, the market is changing due to mobile technologies that are altering core capabilities of field services personnel. Field service automation(FSA) is the method of reorganizing all your field service procedures to improve efficiency and productivity. At its core, FSM is simply any system that is designed to keep track of the various components of field operations.  These components typically include inventory management, vehicle tracking, scheduling, customer portals and more.

CoreSystem’s cloud-based field service automation makes it possible to centralize company information from anywhere. With intuitive and configurable features for scheduling, dispatching and invoicing, CoreSystems streamlines your processes for optimal efficiency.


Why is Field Service Automation Necessary?

Field service is often the place where enterprise information systems, labor controls, and productivity tools falter. The opaque nature of the work, far removed from the office or shop floor is the chief cause for blame. The effectiveness of cellphones are limited, even though they offer visibility and connectivity. Technology is, however, changing the situation, transforming field service through new improved paradigms.

When you send a human resource out to the field, you deal with so many variables, like their attendance, what kind of transportation they use, what route they use with the transportation, their mobile connectivity, data requirements, etc. that it becomes nearly impossible to keep track of by someone sitting in-house on their own. What further complicates things is that all these variable costs add-up in ways that ultimately cripple your bottom-line and customer satisfaction.

Automation is the slogan to decrease cost and increase efficiency at the same time. This is true for almost all facets of work, and more so for field services, which has a historical reputation for delays, inefficiencies, and high costs.

The savings resulting from such automation is often underestimated. Even a conservative estimate of 20 service technicians who can complete an average of five work orders each day, and customers raising a dispute on just 5% of service invoices results in needing to investigate and resolve 1,300 inquiries per year


Benefits of Field Service Automation?

  • Efficient scheduling and dispatching (including redirecting technicians to customers based on expertise, location, and availability).
  • Providing a singular window of visibility into all resources (including integration with backend systems like CRM, accounting, and inventory management).
  • Comprehensive data analytics that provide insights into customer behavior and the ability to make better predictions.
  • Technician location tracking with real-time job updates and vehicle tracking with GPS route optimization.
  • Customer portals that facilitate real-time communication with technicians via messaging.
  • Integrated payment processing and invoice generation.
  • Regulatory compliance at every stage.


What is Done During Field Service Automation?

Field service automation is a scheme for organizing field operations through a mobile or similar system. At a basic level, this entails scheduling service orders, dispatching agents, and tracking vehicle locations and job status. A proper software solution will assist automate these chores and offer mobile access through a cloud-based platform. FSM is prevalent in numerous industries, but particularly those that employ mobile agents or contractors, such as waste management, utilities, telecommunications, public sector transportation, and even in-home healthcare.

FSA solutions can differ widely based on industry and intention of usage, varying from best applications for order scheduling to all other product suites for enterprises. In general, you can expect to see some or all of the following capabilities in a standard platform:

  • Scheduling and order management
  • Vehicle/technician location tracking
  • Job status updates
  • Route optimization and GPS navigation
  • Time tracking and driver logs
  • Knowledge and asset repositories
  • Parts and inventory management
  • Integrated invoicing/payment processing
  • Customer portals
  • Regulatory compliance measures

Field service management(FSM) allows operations manager and business to stay in safer control of the situation. The following are some processes that happen after Field service automation is done:

  • Automated scheduling of service calls, deploying the right technician at the right site, within the shortest time.
  • Real-time tracking of field service technicians, to give an accurate picture of the expected arrival time of the technician at the field site, reducing uncertainty and ambiguity, and sparing the need for clients to make follow up calls and clarifications.
  • Ability for supervisors and other stakeholders to monitor movement of technicians in real time, to resolve any bottleneck, slack, or other glitches in real time, pre-empting disruption of work
  • Enabling field service technicians to connect with the command and control office in real-time for better insights on the nature of the job, any required assistance with experts, and for follow-up, sparing the need to make duplicate visits, and also for doing a more accurate job
  • Increased accuracy and precision, as forms are populated automatically wherever possible, and delivered to all stakeholders and regulatory agencies at the correct time, in the correct format, automatically.
  • Self-initiation of appropriate reminders and alerts, whenever manual interference is necessary.
  • Automatic replenishment orders for spares and other stock, avoiding stock-out situations which may delay field service.

Such interventions eliminate wastage, paving the way for lean operations, with reduced operations cost and maximum returns on investment.


How is Field Service Automation Done?

There are 3 different ways we can perform field service automation:

  • Mobile: Field service is mobile by nature. In most cases, an agent has to be physically on site to complete a work order or asset pick-up. The technology that best supports field service workflows is usually the technology that’s built to travel. As an alternative to entering data at the office again, numerous field agents now work from smartphones and tablets, renew job statuses while they do the work, obtain digital customer signatures on their mobile devices or print invoices and forms on a mobile printer.
  • Software-as-a-Service: In current years, the preface of software-as-a-service pricing models has caused FSM to become an achievable chase for even tiny service companies, which provides them an option to contend against bigger corporations. Examples might include window cleaners, landscapers, or plumbing and HVAC technicians. As an alternative to paying for a costly upfront license and even costlier IT infrastructure, businesses can give a monthly subscription fee to access cloud-hosted FSA software. SaaS deployment also enables greater mobility, since the system is accessible from any device with a web connection, rather than an allotted physical network.
  • Integration with back-end systems: Especially for teams who work directly with customers, field service doesn’t exist in a vacuum. Their task is to hand-deliver a solution—whether that be equipment repair, installation, or regular maintenance—in a way that is helpful and convenient for customers. Your agents can only do part of the job, if they don’t have access to the right information, accounts, and back-end systems, which leaves customers incompletely satisfied. That’s why many companies are now adopting solutions with built-in access to other core systems like customer relationship management (CRM), inventory, and accounting. With better integration, field agents can deliver true end-to-end service.

Main challenges faced by field service automation are:

Making the System Responsive:

Another major challenge in field staff management is providing a responsive system for leaders and employees to use. One of the selling points of some field service management (FSM) systems is that companies can get rid of phone calls from field service employees by simply requiring everyone to use a common communication interface. That’s based on the idea that phone calls are an obsolete bother to modern business.

Keeping Things Moving:

Another commonly reported problem with field staff management is actually customer-facing. It’s making sure that deal contact points and business processes happen in a timely manner. Some companies using field staff management platforms may see problems with invoices getting processed. They also may see problems with customers getting responses from individual employees.

Assuring Ease of Use:

A field staff management platform is really not that helpful for businesses if the interface is not intuitive. Poorly designed interfaces lead to massive frustration on the part of individual workers. It’s important to get a certain amount of ‘social buy-in’ when implementing a field staff management tool in the first place — otherwise, the company risks some form of rebellion when mandating the use of that tool for communications. That can be a problem for a manager or someone with a supervisor role.

As customers grow savvier and more selective about the products and services they pay for, field service will become an increasingly competitive industry. An establishment’s skill to deliver fast and effective results through a mobile workforce may be the factor between leading or trailing their competitors. Field service management software is no longer a secret weapon wielded by enterprises; it’s a necessary tool for survival, and one of the best gifts you can give your agents.

Written by CoreSystems

Field Service Automation

PLC and HMI Programming Process - Enhancing Industrial Automation

Current control systems employ a PLC or Programmable Logic Controller as a way to control motors, valves and many other gears used in a procedure. Computer based Human Machine Interface(HMI) products offer the measures by which process personnel interact with the PLC control system. A well-designed combination of PLC’s and HMI’s can be a solid foundation for you’re process automation needs. 


Why chose PLC and HMI Programming?

Programmable Logic Controllers propose businesses the chance to rally modify their mechanical processes. Serving as the “brain” of the control system, PLC delivers automated solutions by initiating operation based on a system of inputs and outputs. Other common programming languages used include: 

  • Structured Text
  • Sequential Flow Chartor SFC, very similar to a traditional flowchart 
  • Instruction List
  • Function Block Diagram

PLC programming is extremely valuable. Advantages or benefits of PLC are: 

  • Minimize the monotony of simplistic work tasks
  • Simplify wiring and reduce material costs
  • Create dynamic, complex routines dat outdated methods such as mechanical relay-based control simply cannot handle
  • Offercost effective solutions to even the minor and major manufacturers looking for solutions to process control, complex assembly, manufacturing and testing  

HMI is the best choice coz of its user-friendliness of the graphical interface. The graphical interface contains color coding dat allows for easy identification. Advantage or benefits of HMI are: 

  • Alarms/Warnings
  • Reliable Messaging
  • Easier Overall Management of Plant
  • Accurate Testing with Simulation
  • Cost Reduction
  • Improved Communications


CoreSystems blends the right components with customized design to build quality automation solutions.  Our goal is to provide efficient, well documented programs dat blend well with existing system logic and maintenance personnel expertise.  Our widespread system control knowledge of current development platforms and our history permits us to offer proven technologies dat can progress you’re process efficiencies. 


What is Done During PLC and HMI Programming?

PLC or Programmable Logic Controller from the I / O signals is responsible for the control of the entire machine or equipment. Its programming, in addition to meeting production requirements, must also be structured and accessible to provide fault diagnostics quickly and accurately. 

A PLC program is usually written on a computer and then is downloaded to the controller Most PLC programming software offers programming in Ladder Logic. Ladder Logic is the traditional programming language. Due to its visual nature Ladder Logic is simpler to employ TEMPthan many other programming languages. Some PLC manufacturers supply control programming software. 

When users don’t have easy access to a laptop nor PC nearby the installation or the machine, is difficult to face the task of making some modification or backups by downloading/uploading the PLC program. For this reason, their’s a method to upload/download the PLC program directly from or to a USB through the Human Machine Interface. This is how PLC and HMI interface. 

The programming of HMI as its name says, is responsible for the provision of interface with the machine. Thus, from network communication with the CLP, Programming of HMI provides a series of information to operators and other users of the system, such as: fault diagnosis; Production reports; Status of equipment; Manual controls etc. An HMI Programming application need an intuitive and friendly function and its resources must be rightly employed according to the customer needs. 

Choosing an HMI:

An HMI is a considerable purchase thus it is vital to know correctly what is needed of it. An HMI is used for three primary roles: 

  • The pushbutton replacer takes the place of LEDs, On/ Off buttons, switches or any mechanical device dat performs a control function. The elimination of these mechanical devices is possible coz the HMI can provide a visual representation of all these devices on its LCD screen, while performing all the same functions.
  • The Data Handler is utilisedfor applications dat need monitoring and stable feedback. Most of the times these Data Handlers come arranged with large capacity memories.  
  • The last of the HMI three types is referred to as the overseer.These are centralized systems dat watch and regulate whole sites or complexes of large systems expanded over vast areas 


How is HMI PLC Programming Done?

PLC programming is done mostly with the halp of ladder language. Procedure for PLC programming using ladder language is given below: 

  • Analyze and Get the Idea of Control Application: The primary step to program the PLC is to get the idea for which you are going to develop an application-based program.
  • List All the Conditions and Get the Design using Flowchart
  • Open and Configure the PLC Programming Software: Open the programming software installed in the PC dat comes with PLC hardware. Select the hardware model of the PLC in the software and configure it with appropriate input and output modules. From the listingof the programming languages, chose ladder language and provide a name for the program after selecting the hardware processor. 
  • Add the Required Rungs and Address Them: Add the required rungs based on the control application logic and give the address to the each and every input and outputs.
  • Verify if their are anyErrors and Simulate It: Locate the Online section in the menu bar and select Online. Check for the errors and make necessary changes after selecting Offline.  
  • Download the Program to PLC CPU Memory: After the successful simulation of the program, download the program to CPU by selecting the Download option through a network or communication cable.


HMI-PLC Programming

Given here are the steps through which a PLC and HMI interface or communicate: 

  • Copy the PLC program into an USB memory stick
  • Insert the memory stick into the USB port of the HMI
  • Enter the system menu of the HMI
  • Enter the “Up/Download” sub menu
  • Select “HMI <->PLC” transfer mode by navigating through the “LEFT” and “RIGHT” buttons at the bottom
  • PressUSB on left side of the screen and chose the PLC program file you need to download 
  • On the right part of the screen, select the port dat is connected to the PLC
  • After selecting the port, HMI will search PLC automatically
  • After the PLC is detected by the HMI user can now download the program by clicking Download button
PLC-HMI Integration - Industrial Automation Interface

Streamlining Operations: PLC-HMI Integration

The requirements for data exchanges between a PLC and an HMI station are basically: 

  • This first part of basic requirements is the components for data exchange.
  • A physical link dat is obtainableto PLC as well as HMI like an Ethernet cable or a RS-485 connection with the adequate ports on both. 
  • A common protocol dat can exist on the selected physical connection.
  • Protocol drivers dat will bind the communication interface to the protocol.
  • The part two is what is switched between the HMI and the PLC. 
Written by CoreSystems

PLC and HMI Programming

VFD Panel Installation and Commissioning Process - Ensuring Operational Efficiency

Starting and stopping a motor can be done with three common methods: a motor starter, soft start or variable frequency drive (VFD). As of late, the use of a VFD is becoming more popular than ever due to its claimed efficiency benefits but be sure it is needed. And, once specified, it must be properly installed to ensure reliable operation.

Why is VFD Panel Installation Necessary?

A Variable Frequency Drive or VFD or Variable Speed Drive is a kind of alterable speed drive utilized in electro- mechanical drive systems to regulate AC motor torque and speed by changing motor input voltage and frequency.

The VFD, often called an ac drive or inverter, takes a single- or three-phase signal and varies the speed of a three-phase ac induction motor. This is its main benefit. Running a motor more slowly can save significant energy, and speed changes may be useful to the application. Another big benefit is adjustable acceleration and deceleration. A smaller amount of acceleration can unstiffen the mechanical forces at starting /of the motor and reduce inrush current. The VFD also has built-in overload protection and motor start/stop control functions.

Variable frequency Drive, better known as VFD Control panel is a complete enclosure that helps to protect numerous electronic components and also VFD in the first place. Exposing VFD dust and windy environment can affect the drive to a great extent and that is why it is important to get VFD Panels installed.

One of the main reasons why VFD control panels have become so important is because they help to keep all electric components in one single place. In fact, it is treated as a comprehensive control solution for harmonic filtering, bypass and various other electric solutions. Over the years, control panels for VFD have gone under the scanner for improving the efficiency, but the ones that are used now are completely safe and highly functional.


Benefits of VFD

  • Controlled Starting Current
  • Reduced Power Line Disturbances
  • Lower Power Demand on Start
  • Controlled Acceleration
  • Adjustable Operating Speed
  • Adjustable Torque Limit
  • Controlled Stopping
  • Energy Savings
  • Reverse Operation
  • Elimination of Mechanical Drive Components


What is Done During VFD Panel Installation and Commissioning?

There are both physical and electrical installation basics to be aware of when using a VFD. When mounting the VFD on a back panel, be sure to check the specifications. It is common for multiple devices to be installed in one location, but all VFDs need proper air flow, so check the installation instructions carefully when laying out a control panel. Mount the drives vertically.

  • Electrically, proper run/stop control of the VFD is important. Many manufacturers do not recommend using contactors or disconnect switches on the line or load side of a VFD for run/stop control of the ac drive and motor, except for emergency situations. Opening a contactor at the line or load side of a VFD while the motor is running can cause failures in the inverter section of the drive or reduce its life.
  • With any motor control circuit, proper overcurrent and ground-fault protection is required at the input of the device. A normal VFD takes single-phase voltage, but it isn’t planned for usage with single-phase motors. Although a standard three-phase induction motor works with a VFD, a three-phase inverter duty motor should be used.
  • There are many more factors, features and functions to consider when using a VFD, so study the catalogs and manuals and then get with your vendors. With constant-speed or constant-torque applications, like compressors, conveyors or mixers, there might be easier possibilities. However, whether replacing a dc motor or varying the speed and acceleration of your conveyor, fan, blower or pump, go with the VFD option. It’s often the best choice, if installed properly.
  • Cooling: VFD control units must be placed in positions where the highest ambient temperature doesn’t surpass 40˚C. This is a common temperature rating for most units. If higher ambient are expected, derating of the variable frequency drive may be required.
  • Supply line power quality: The supply to the VFD input mustn’t change minus or plus ten percent as most VFDs will trip through a protective error. This voltage steadiness must be taken into consideration while operating conductors to the VFD and voltage drops must be found out for long runs.
  • Electrical connections: The installation and sizing of VFD load and line conductors must obey the NEC or similar appropriate local codes.
  • Grounding: For dependable and safe functioning, all VFDs should be correctly grounded. This usually demands for a grounding conductor to be taken back to a single point grounding position, generally chosen to be at the service. Along with that, a grounding conductor should also be carried back from the motor to the VFD’s inner grounding terminal.
  • Fault protection: Numerous VFD have short-circuited shield, in the form of fuses, previously fit by the manufacturer. This is usually the case on larger hp units. Minor units need external fuse shielding. In any of these case, the sixing and choice of these fuses is vital for shielding a semiconductor in the event of an error.
  • Motor protection: All motors require overload protection. The utmost customary practice is the utilization of a motor overcurrent relay system that would shield all 3 phases and shield in contradiction of single-phasing.
  • Humidity and moisture: in both electrical and electronic equipment, large corrosive atmospheres and humidity are worrisome. VFD units must be mounted in a non-corrosive position at any time, with ambient humidity ranging between zero to ninety five percent noncondensing.


How is VFD Panel Installation and Commissioning Performed?

The process of setting up the parameters of the drive adds additional time for commissioning and installation, and is most easily completed by copy/paste tools which have many positive functions such as:

  • The ability to copy the parameter set from one drive to the next
  • Able to store parameters to maintain the parameter set for a different application configuration
  • Can be used to easily replace downed or failed drives

These tools can easily decrease how complex the processes of installation, commissioning, and troubleshooting may become.

  • VFDs are installed at Fan Pump motors.
  • Fan pump motor responsible for providing stock to the Head Box
  • Head Box requires a control of either head or level
  • Control of a level or pressure in Head Box is done by VFITD
    A reference signal is fed to the VFD and using a comparator, an error signal is generated based on the deviation of current value from the reference value. The controller in the VFD, then, increases/ decreases the speed based on the signals generated

Input AC Power

  • Circuit breakers feeding the VFDs are recommended to be thermal-magnetic and fast acting.
  • They should be sized as 1.5 times the input amperage of the drive. Refer to the table below.
  • Each VFD should be fed by its own breaker. If numerous drives are to be united on the same breaker, every drive must have its own protection measure from the breaker.
  • Input AC line wires should be run in conduit from the breaker panel to the drives. Using a single conduit, AC input power to several VFDs can be driven, if necessary.
  • The VFD should be grounded on the terminal marked PE.

Output Power

  • Motor wires from each VFD to its respective motor MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring to avoid noise and crosstalk between drives.
  • If the gap among the VFD and the motor exceeds two hundred and fifty feet, an output reactor must be utilised amid the VFD and the motor. The output reactor should be sized accordingly.
  • If the distance between the VFD and the motor is between 500 and 1000 FT, a dV/dT filter should be used.
  • No contactor must be fit amid the motor and the drive. Operating such a device while the drive is running can potentially cause damage to the power components of the drive.
  • When a detach switch is fit amid the motor and the drive, it must only be activated when the drive is in a STOP stage.


An example of programing is given below:

The Drive should be programmed for the proper motor voltage.

  • The Drive should be programmed for the proper motor overload value
  • To enter the PROGRAM mode to access the parameters:
  • Press the Mode (M) button. This will activate the password prompt (PASS).
  • Use the Up and Down buttons to scroll to the password value and press the Mode (M) button. After entering the right password, the display will show that the PROGRAM mode has been opened or assessed at the starting of the parameter menu.
  • Use the Up and Down buttons to scroll to the desired parameter number.
  • After the wanted parameter is located, press the Mode (M) button to exhibit the current parameter adjustments. The parameter value will begin blinking, indicating that the present parameter setting is being displayed. The value of the parameter can be changed by using the Up and Down buttons.
  • Pressing the Mode (M) button will store the new setting and also exit the PROGRAM mode. To alter a different parameter, press the Mode (M) button once more to enter the PROGRAM mode again. If the Mode button is pressed within 1 minute of exiting the PROGRAM mode, the password is not required to access the parameters. After one minute, the password must be re-entered in order to access the parameters again.
Written by CoreSystems

Vfd Panel Installation and Commissioning

Control Panel Installation and Maintenance Process - Ensuring System Reliability

You are bankrolling a new control panel installation, upgrading your company to the era of automation. The designs and the parts are ready, all that is left is to install your system correctly. This is the stage where CoreSystems comes into play.

Why CoreSystem is the Best Choice in Control Panel Installation?

Our Team

CoreSystem team is rich with skilled professionals who have numerous experiences to be able to give you proper advice. All our instructors are approved by a number of accrediting bodies. Making sure they are up to date with relevant regulations and industry best practices.

 Our Aim

We believe in delivering a quality, honest, straight forward and professional service. Our customers need straight forward and honest advice when it comes to their training and rely on ourselves to separate fact from fiction and cut through the jargon that can surround the Health & Safety industry.

Our Work

A cabinet installed with quality workmanship should have neatly organised wires run in gutters or channels, laid-out with only smooth bends to the wire radii, no sharp bends or kinks.


All wires, components and terminals should be clearly labelled. We cannot stress the importance of a sound labeling strategy upon installation, when maintenance and troubleshooting is necessary it will save time in testing for errors, saving money therein and ultimately saving you the stress.

Hard working

Our team will work tirelessly to get the training you require, when you require it. Although we cannot always work miracles, our team will do everything we can to get you what you need.

What is Done During Control Panel Installation?

The installation must be in accordance with the all applicable national (NEC, IEC, EN, etc.) and local electrical codes and ordinances. 

  • An ignoredmatter with bigger control panels is the necessity to power test appliances and equipment, for instance vacuums utilised for maintenance. Working with the electrical distributor to see what standard offerings are closest to what you need can produce significant savings in cost and delivery.
  • After the panel is designed, next step is tofigure out where to place it. Determine the outside dimensions and the swing requirements of cabinet doors. To reduce maintenance inefficiencies and other hidden costs during operation, it is ideal to allow enough room for a test cart to roll across the area with those doors open.
  • Control panels often are near the process area. Anelevated ambient temperature might need a air conditioning or ventilation fan on the cabinet, both of which will have filters that need Other circumstances may dictate adding a heater or dehumidifier.
  • Findthe air exhaust and intakes vents for simple filter spare and make sure there is no process meddling; having a cabinet vent suck in air off an aluminum melting pot is generally not helpful.
  • Figuring out the ampacity for the supply conductors can be confusing unless you break down the requirements intodiscrete steps
  • You can either put a single main overcurrent protective device (OCPD) in the panelor put overcurrent protection ahead of the panel.
  • The NEC requires marking every panel with its short circuit current rating (SCCR)
  • Look for the grounding measures.

How is Control Panel Installation Performed?

  • The Control Panel should bemounted on the position decided by the General Contractor according to the Interconnect Drawings.
  • The Control Panel is indicated by a ( )on the Interconnect Drawing. If there are several Control Panels for the installation, they will be marked with their selected location and labeled to match with the Interconnect Drawings.
  • Before mounting the Control Panel to the wall, be sure enough clearance is provided to install the Trunk Line and Power Insert cables as required.
  • Firmlyplace the Control Panel onto the wall according to industry standard mounting routines.
  • Open the front panel to reveal the inside of the Control Panel. Configure the AC Power wiring as shown on the silver panel.
  • Once the AC Power is installed, turn the Control Panel on.
  • Confirmthe green light is lit on the front of the Control Panel and then turn the Control Panel off.

Regular Maintenance of Control Panel

There is no standardised protocol for the maintenance of control panels, however we tend to live by the old adage prevention rather than the cure.

  • Pest control:This may consist of a rodent trap in one corner. Whatever method, ensure it is inspected periodically.
  • Dust control: Vacuum the accumulated dust off the cabinet floors. If conditions require vacuuming anything else, remember it’s an energized cabinet — follow the applicable procedures.
  • Connection control: Retightening terminal screws leads to loose connections. Instead of inadvertently over-tightening terminal screws (consequently diminishing their clamping power), use an infrared gun to see which terminals high resistance are. Disassemble, clean, and reassemble.
  • Insulation: An insulation resistance testing program is the best way to prevent wiring failures.

You have to remember that cutting corners really impacts on the future reliability of all that investment, financially and hourly. Imagine redecorating your entire house without first fixing the hole in the roof and the creeping threat of rising damp. It won’t take long for all your fresh walls to be completely ruined. Well, the same premise can be applied to control panels, in a cabinet installed with shoddy workmanship it will not take long before errors start piling up until servicing will be rendered useless, leaving repair or replacement as the only option. Which will obviously impact reliability, impacting on time and ultimately cost to you.

Written by CoreSystems

Control Panel Installation and Maintenance