Power Master VFD - 575 V

The Power Master VFD starts, stops, and adjusts speed of the ventilation fan. Additionally, the Power Master protects the duct system against implosion collapse, starts the dust collector on-demand via free START contact (NO) and stops the dust collector via free STOP contact (NC). 

This VFD is a commercial product (i.e. not custom made on a project to project basis), installed with the same settings & software in hundreds of locations. This means that the software is fully tested and requires no last-minute parameter changes or commissioning delays. The Power Master VFDs are avialable for 3-phase 230, 460, and 575 V AC. Three phase disconnect and fuses are built-in to simplify installation. The Power Master is UL Listed out of factory. Easy to follow installation and setup guide is provided.

Equipped with two high-end pressure transmitters (one for FAN pressure, second for FILTER pressure). Automatic, Stop, and Manual mode selector is installed in the front door for quick, easy access as well as the Enabled, Running, and Error door indicators. 

The Power Master is available from 10 to 200 HP as a wall mounted NEMA 12 (dust-proof) enclosure, and as standalone enclosure (NEMA 12 dust-proof) from 250 to 420 HP. The Power Master uses the high-end ABB ACS880 VFD model and is backed by ABB. 

The Power Master VFD is designed to be fully automatic, so users can just use their workstations.

After running the Ecogate "Setup Assistant" the VFD is guaranteed to be properly setup in a couple of minutes!

The Power Master VFD is controlled by the greenBOX control unit via a simple Modbus RS485 connection using the Ecogate Master Cable (all greenBOX models supported). The Power Master “Enable” Input is used to confirm to the Power Master that the dust collector is operating normally (i.e. no error). If there is any dust collector error (for example airlock is not working, cleaning is not working, etc.) the dust collector PLC should open the Enable input of the Power Master. The Power Master will stop the main fan to protect the dust collector. Four customer safety inputs are provided (for example; spark detection, fire alarm etc).

Follow Ecogate Power Master VFD User Guide and ABB instructions for VFD installation. 

The main 3-phase disconnect and fuses are built-in. The 3-phase power input cable, and 3-phase power output cable to the ventilation fan motor must be installed in metallic, grounded conduits (never combine the input and output wires in one conduit and never combine wires from several VFDs in one conduit). Proper grounding of the VFD cabinet, conduits, fan motor must be provided. 

Click here to download the full user and installation guide.

Enclosure Rating
The Power Master VFD is comprised of the ACS880 VFD model by ABB in a NEMA 12 rated enclosure (dust proof, for installation inside the bulding); Power Master is UL rated.

Fan Motor Voltage and Size Rating
Avialable from 10 HP up to 420 HP, for 460, 575, and 230V 3-phase AC; see table below for detailed rating; also see ACS880 detailed specifications here.

3-phase disconnect and fuses
Included

Fan and Filter Pressure Transmitters
Two pressure transmitters are built in (25" w.c. up to 200 HP fan motors, 50" w.c. for 250 HP fan motors and up; 10" w.c. for filter pressure). The Fan transmitter should be connected to read the Fan Total Pressure. The pressure transmitter hoses should be connected per the Power Master VFD User Guide as follows: to the fan inlet and the fan outlet; the hoses should be connected to the top of horizontal ducts (or to a vertical duct) to avoid interference with dust particles. In cold climates, Ecogate recommends to use larger hose diameter outside the building to avoid water freezing inside the hoses during winter months. The hoses should be connected using a “flush adapter” so that the adapter does not create an obstacle inside the duct. The fan pressure is monitored by the VFD, and if pressure is over preset value the VFD will stop to protect the duct system. The second pressure transmitter is used to read the Filter differential pressure. Use same the rules as for Fan pressure transmitter hoses. 

Dust Collector Automatic Start and Stop on Demand
Saves electricity and dust collector wear & tear. The Power Master VFD dry contacts “START” and “STOP” can be used to automatically start and automatically stop the dust collector via dust collector PLC (control system).  The ENABLE output of the dust collector PLC must be connected to one of the Enable inputs on the Power Master VFD. 

Ventilation System Enable/Disable, Safety Stop
Three enable inputs are available on the Power Master. The first Enable input is connected to the dust collector PLC. Other inputs can be used to enable/disable the dust collection system using the building automation system or to connect a fire alarm, spark detection system etc. If a safety stop is required, it can be connected to the ACS880 VFD STO inputs (Safe Torque Off, see ABB ACS880 manual).

Connection to Control System greenBOX
The Power Master VFDs is connected to the greenBOX by Modbus RTU over RS485. By using Ecogate Master cable, 24V DC power is also connected from greenBOX to serve as backup power for the VFD processor: this allows the greenBOX to communicate for troubleshooting with the VFD even if the main 3-phase power fails. Multiple VFDs can be connected to the greenBOX Master control unit in a Modbus loop. At the last VFD in the loop the ACS880 Terminating Resistor DIP switch must be set to ON (the resistor itself is built-in) for trouble-free Modbus communication.

Power Master VFD Setup
During the VFD setup, the Ecogate Startup Assistant (wizard) is used to configure all VFD parameters. All VFD parameters can be read and written from the greenBOX (for remote fine tuning & troubleshooting). Startup logic based on ABB’s Adaptive Programming is used to allow a “grace period” during system start (the dust collector will be directed to start and during the “grace period” the VFD enable input is ignored until the dust collector’s PLC ENABLE signal is confirmed or the grace period expires).

Addtional Features
All VFD parameters, operating mode selector status, inputs status, motor voltage, amperage, power, frequency, fan, and filter pressure are transfered to control unit greenBOX via single Modbus cable. All warning and errors are collected by control unit greenBOX and transffered to Ecogate cloud server for reference and analysis; customer can access these informations on greenBOX and via web user inteface (requires service agreement). greenBOX is monitoring temperature and remaing life of critical components; precise 3-phase power measurement by the VFD is transfered to the greenBOX and cloud server and used for evaluation of electricity savings; control unit greenBOX can read & write all VFD paramters: this allows remote (over internet) troubleshooting ans fine-tuning, it saves time. 

Dimensions and Weight 
Enclosure #1

• Wall-mounted; 10 to 40 HP at 460V AC, 10 to 50 HP at 230V AC, 10 to 40 HP at 575 V AC
• 27” wide, 43” high, 23” deep; wall mounted (min. distance from ceiling: 8”, min. distance from floor 12” for proper cooling); weight 213 to 260 Lb, shipping weight 268 to 336 Lb.

Enclosure #2

• Wall-mounted; 50 HP to 200 HP at 460V AC and 50 to 150 HP 575V AC
• 35” wide, 48” high, 23” deep; wall mounted (min. distance from ceiling: 8”, min. distance from floor 12” for proper cooling), weight 271 to 392 Lb, shipping weight 340 to 461 Lb.

Enclosure #3 

• Standalone; 250 HP to 400 HP at 460V AC
• 33” wide, 92” high, 26” deep; free standing (min. distance from ceiling: 12.5”, min. distance for door opening 32”), shipping weight 938 to 1,274 Lb.

3-Phase 575 V AC

*Two models with different rated output currently are available