The Motor Pump Group Distribution Panel

The Motor Pump Group Distribution Panel setup you provided includes various subsystems, such as an electric compressor, diesel engine heater, water circulator, and diesel control panel, along with auxiliary circuits. Here's a breakdown of the elements:

1. Panel Specifications: Distribution panel: Enclosure rating IP65 or higher, transparent front. Terminals: Located on a DIN rail at the lower side. Power supply: 400Vac/3Ph+N+PE/50Hz with 16 mm2 cables.
2. Main Components: Disconnector with auxiliary contact. Phase presence monitoring with fuses.
3. Startup Items and Their Components: Electric Compressor (ECP001): Power: 400V/3Ph+N+PE/50Hz/9kW. Protection: Magnetothermic automatic switch with differential, with auxiliary contacts (AUX1). Contactor K1, operated by logic (diagram reference). Diesel Engine Heater (SCA001): Power: 400V/3Ph+PE/50Hz/6kW. Protection: Magnetothermic switch with differential, auxiliary contacts (AUX2). Contactor K2, operated by logic. Water Circulator (CIR001): Power: 230Vac/1Ph+N/50Hz/30W. Protection: Magnetothermic switch with differential, auxiliary contacts (AUX3). Contactor K3, operated by logic. Diesel Control Panel (DCP001): Power: 230Vac/1Ph+N/50Hz/3kW. Protection: Magnetothermic switch, auxiliary contact (AUX4). Cabin Lights (LIGHTS): Power: 230Vac/1Ph+N/50Hz/0.3kW. Protection: Magnetothermic switch with differential, auxiliary contacts (AUX5).
4. Auxiliary Circuits (24V): Input Signals: Output Signals: Motor Run (NC). Solenoid +/-. Temperature Switch (NO). Pressure Switch (NO).

In terms of logic and contactors, the provided diagram in the uploaded file seems to refer to the connections between components like K1, K2, K3 contactors, and signals like KA NO/NC, motor run signals, and temperature/pressure switches.

This overall structure ensures coordinated control and protection for each component, using the auxiliary signals for proper operation feedback.

Here’s a breakdown of the key details of the above system:

• Panel Name: Motor Pump Distribution Panel (Quadro Elettrico Distribuzione Motopompa).
• Project: 2005454 - Raff. GELA (Raffineria GELA project).
• Client: Audioli & Bertola.
• Main Contractor: Elettroquadri S.r.l.
• Panel Size: 700x1095x205 mm.
• Protection Rating: IP65 (suitable for environments requiring dust-tight and water-resistant enclosures).
• Power Specifications:

• Operating Voltage: 400/230V AC, 50Hz.
• Nominal Current: 63A.
• Auxiliary Voltage: 24V AC for control circuits.

Components:

1. Main Switch:

• Type: Automatic power disconnector (ABB SD204/63).
• Capacity: 63A.
• Protection: Magnetothermic switch (combined overcurrent and differential protection).

2. Individual Start-Up Circuits:

• Electric Compressor (ITEM ECP001):9kW, 400V/3Ph. Controlled via ABB AF09-30 contactor and S204 switch.
• Diesel Heater (ITEM SCA001): 6kW, 400V/3Ph. Controlled via ABB AF26-40 contactor.
• Water Circulator (ITEM CIR001):30W, 230V/1Ph.Controlled via ABB AF09-30 contactor.Diesel Engine Control Panel (ITEM DCP001):3kW, 230V/1Ph.Similar protections as the above units.

3. Auxiliary Circuits (24V AC):

• This section powers the control logic and signaling devices using a 24V AC auxiliary power supply (ABB TMS100VA24).
• Protection with 6A circuit breakers (ABB S202 C6).
• Auxiliary devices include solenoids, relays, temperature and pressure switches, and motor run signals.

4. Symbols and Legend:

• KM: Power contactor.
• KA: Auxiliary relay.
• QF: Automatic power switch.
• K1, K2, K3: Contactors associated with different devices like compressors and heaters.
• HL: Indicator lamp.
• M: Three-phase motor.

Safety and Control Features:

• The document specifies emergency push buttons, manual push buttons, and inductive sensors for monitoring and controlling system safety and operations.
• Additional protection for overloads, short circuits, and differential currents is provided through magnetothermic switches.

Additional Notes:

• The system is designed per CEI EN 61439-1 and CEI EN 61439-2 standards for electrical panels.
• Identification Plate: Includes information like the rated current (63A), short-time withstand current (6kA), and voltage ratings (400/230V).

To provide further details, We can expand on key areas of the Motor Pump Distribution Panel as described in the above , covering the components, their functions, and the overall system operation.

To provide further details, I'll expand on key areas of the Motor Pump Distribution Panel as described in the above document, covering the components, their functions, and the overall system operation.

1. Power Supply and Protection Overview:

• The panel operates at a primary voltage of 400/230V AC and uses three-phase power (3Ph+N+PE) for its main components, such as the motor pump, electric compressor, and diesel engine heater.
• The main switch (ABB SD204/63) is a 63A automatic power disconnector with built-in overload and short-circuit protection. It ensures that the system can be safely shut down in case of faults.
• The system provides IP65 protection, making it resistant to dust and water, ideal for industrial environments like refineries or outdoor installations.

2. Detailed Description of Components:

Main Circuit Breakers and Switches:

• QF (Main Switch): Protects the entire system from overcurrent and short circuits. The ABB SD204/63 (63A) serves as the main input breaker for the system.
• Differential Switches: Used in each subsystem (like ECP001, SCA001, CIR001) to detect leakage currents and prevent electrical hazards. These switches also offer overload protection.

Contactor Control (K1, K2, K3):

• The system relies on contactors to control the high-power loads like the electric compressor, diesel engine heater, and water circulator:K1: Controls the electric compressor (ECP001).K2: Controls the diesel heater (SCA001).K3: Controls the water circulator (CIR001).
• These contactors are operated by logic, meaning they are triggered based on certain conditions, such as temperature or pressure signals, through the system’s control logic.

Auxiliary Relays (KA):

• KA (Auxiliary Relays) are used to transmit control signals throughout the system. These are involved in switching between different operational states, ensuring safe and coordinated operation of the motor pump and other systems.
• Relays handle the 24V control circuit operations and manage feedback signals, such as motor run status and fault conditions.

3. Subsystems and Their Functions:

Electric Compressor (ECP001):

• Power Rating: 9kW, 400V AC, three-phase.
• Protection: Automatic magnetothermic switch (for both overcurrent and earth leakage protection).
• Contactor: Operated by K1, allowing remote and automatic control.
• This component is crucial for the pressurization and compression systems in the pump group.
• To provide further details, I'll expand on key areas of the Motor Pump Distribution Panel as described in the "653-P-24" document, covering the components, their functions, and the overall system operation.

1. Power Supply and Protection Overview:

• The panel operates at a primary voltage of 400/230V AC and uses three-phase power (3Ph+N+PE) for its main components, such as the motor pump, electric compressor, and diesel engine heater.
• The main switch (ABB SD204/63) is a 63A automatic power disconnector with built-in overload and short-circuit protection. It ensures that the system can be safely shut down in case of faults.
• The system provides IP65 protection, making it resistant to dust and water, ideal for industrial environments like refineries or outdoor installations.

2. Detailed Description of Components:

Main Circuit Breakers and Switches:

• QF (Main Switch): Protects the entire system from overcurrent and short circuits. The ABB SD204/63 (63A) serves as the main input breaker for the system.
• Differential Switches: Used in each subsystem (like ECP001, SCA001, CIR001) to detect leakage currents and prevent electrical hazards. These switches also offer overload protection.

Contactor Control (K1, K2, K3):

• The system relies on contactors to control the high-power loads like the electric compressor, diesel engine heater, and water circulator:K1: Controls the electric compressor (ECP001).K2: Controls the diesel heater (SCA001).K3: Controls the water circulator (CIR001).
• These contactors are operated by logic, meaning they are triggered based on certain conditions, such as temperature or pressure signals, through the system’s control logic.

Auxiliary Relays (KA):

• KA (Auxiliary Relays) are used to transmit control signals throughout the system. These are involved in switching between different operational states, ensuring safe and coordinated operation of the motor pump and other systems.
• Relays handle the 24V control circuit operations and manage feedback signals, such as motor run status and fault conditions.

3. Subsystems and Their Functions:

Electric Compressor (ECP001):

• Power Rating: 9kW, 400V AC, three-phase.
• Protection: Automatic magnetothermic switch (for both overcurrent and earth leakage protection).
• Contactor: Operated by K1, allowing remote and automatic control.
• This component is crucial for the pressurization and compression systems in the pump group.

Diesel Engine Heater (SCA001):

• Power Rating: 6kW, 400V AC, three-phase.
• Protection: Similar to the electric compressor, using a magnetothermic switch with differential protection.
• Contactor: Operated by K2.
• The heater keeps the diesel engine at optimal operating temperatures, especially important in colder environments.

Water Circulator (CIR001):

• Power Rating: 30W, 230V AC, single-phase.
• Protection: Fitted with a lower-rated switch due to its smaller power requirement.
• Contactor: Operated by K3.
• This small motor-driven pump circulates coolant or water through the system, essential for temperature regulation.

Diesel Engine Control Panel (DCP001):

• Power Rating: 3kW, 230V AC, single-phase.
• Protection: Magnetothermic switch without differential.
• This component provides control for the diesel engine, including starting and monitoring its operational parameters.

Cabin Lights (LIGHTS):

• Power Rating: 0.3kW, 230V AC, single-phase.
• Contactor: Controls lighting circuits, ensuring the operator’s cabin is properly lit when needed.

4. Control Circuit (Auxiliary Circuits – 24V AC):

• A key part of the panel, the 24V auxiliary circuits handle low-voltage control signals for monitoring and automation.
• Solenoids, temperature switches (NO), and pressure switches (NO) feed into the control logic to start or stop various parts of the system automatically based on operating conditions.
• KA relays operate based on feedback from these auxiliary circuits to ensure coordinated start-up and shutdown of major components like the compressor or diesel heater.

5. Safety Features:

Emergency and Manual Control:

• The panel includes emergency push buttons (SB) that allow for the immediate shutdown of the system.
• Manual push buttons (S) provide local control of system elements, such as starting the water circulator or heater manually when automatic functions are not required.

Inductive Sensors (SQ):

• These sensors are used to detect the position of mechanical components and ensure proper alignment or operation of devices like valves or motors.

6. Monitoring and Feedback:

• The system is equipped with indicators (HL) that provide status signals (such as voltage presence) and other operational feedback. These indicators help operators monitor the system's health and safety.
• Temperature and pressure feedback from the sensors control auxiliary relays, which in turn trigger the respective contactors to start or stop pumps, heaters, or compressors.

7. Standards and Compliance:

• The panel is designed to meet the CEI EN 61439-1 and CEI EN 61439-2 standards for low-voltage switchgear and control gear assemblies. This ensures it complies with European regulations on electrical safety and performance.

8. Wiring and Connections:

• The panel features a terminal block (X1) for power distribution and control signals.
• Wiring is carried out with appropriate cross-sections for the current levels, ensuring safe and reliable operation. For example, 6 mm2 cables are used for high-power connections, while 1.5 mm2 cables are used for control circuits.