Case Study: VSD Upgrade and Rewiring

Customer: Anglian Water
Site details/Job: Botesdale temporary aerator 7.5kW VSD install
Date: 13/10/25

Project Overview:
The project involved upgrading an existing Variable Speed Drive (VSD) system to a new ABB ACQ580 unit. The work required complete isolation of the existing control panel, careful disconnection of all cables and components, and installation of a fully rewired control solution to improve reliability and functionality.

Scope of Work:

1. Panel Isolation and Preparation:

   • Fully isolate the existing panel.

   • Document all connections and take note of component locations.

   • Disconnect and remove all existing cables and components.

   • Remove the existing door.

2. Door and Backplate Upgrade:

   • Fit a new label incorporating an amp meter, indicator lamps, switch, emergency stop, and reset button.

   • Install trunking and DIN rail on the backplate to accommodate new contactors, fuses, and relays.

   • Install new terminals for control cables from the VSD.

   • Rewire the door and backplate to suit the new VSD configuration.

3. VSD Installation:

   • Mount the new ABB ACQ580 VSD on the wall.

   • Run cable tray and wiring back to the MCC and make all necessary connections.

   • Install a screened SWA cable from the control section to connect the DO probe.

4. Programming and Commissioning:

   • Program the ACQ580 to meet operational requirements.

   • Commission the system to ensure correct functionality and integration with the MCC.

Outcome:
The installation of the new ACQ580 VSD and the rewiring of the control panel provided improved operational control, enhanced safety through updated indicators and emergency stop mechanisms, and ensured reliable, long-term performance of the system.