Portfolio of Completed Projects

Drive Clean – Overheating Issue

Protec Controls Ltd attended a UK water industry pumping station to carry out inspection, fault investigation, and refurbishment works on a large ABB ACS800 variable speed drive system controlling a critical pumping application. The project involved the removal and cleaning of multiple inverter and line converter modules, including cooling fans, heatsinks, and internal airflow paths heavily contaminated with dust and debris. All IGBT power sections were electrically tested and confirmed healthy before the units were reassembled and recommissioned. During testing, a persistent main circuit breaker fault remained present, requiring further specialist breaker investigation. The works significantly improved the condition of the drive system and identified the environmental factors contributing to repeated overheating issues, with recommendations provided for improved filtration and environmental cleanliness to improve long-term reliability.

Smoke Extract System Inspection and Report

Protec Controls carried out a detailed inspection and fault assessment of multiple smoke and extract ventilation control panels within a major UK commercial retail environment. The works included functional testing of extractor fan control systems, verification of PLC and BMS interfaces, inspection of soft starters, phase monitoring circuits, 24 VDC control supplies, indication lamps, relays, and associated field wiring. Engineers identified a range of operational, environmental, and corrosion-related defects across several MCP panels, with all findings documented through a full photographic asset record and condition report to support future remedial and upgrade planning.

Soft Start Replacement

A soft starter replacement and commissioning project was successfully completed at a UK water treatment facility, involving the upgrade of a high lift pump control system to a modern digital soft starter (AuCom EMX4i). The scope included isolation and removal of legacy equipment, re-termination of existing power and control cabling, and integration of a unit with an internal bypass function, removing the operational requirement for the external bypass contactor while retaining it for structural support. Motor nameplate data was configured to ensure correct starting profiles, protection limits, and operational stability. Insulation resistance testing and full verification of wiring were carried out in accordance with manufacturer specifications. Additional improvements included installation of a door-mounted isolator and bespoke Perspex shrouding to provide compliant touch protection to exposed conductive components. Following operational clearance, the system was energised, functionally tested, and commissioned, delivering reliable pump performance with controlled acceleration and reduced electrical and mechanical stress during start-up.

Temporary Hire Drive

Protec Controls provided a temporary ABB ACS800 variable speed drive solution for a borehole pump at a UK water utility site, supporting additional operational capacity with minimal disruption to the existing infrastructure. The drive was externally mounted to the rear of the control cabinet, with existing motor cabling reused via underground cable channels and the incoming three-phase supply taken from the existing pump contactor. The drive was configured for a 115 kW asynchronous motor with appropriate operating limits, ramp settings, and speed reference control. Following completion of the control wiring, the system was fully commissioned, tested under control reference, and successfully run at full speed, confirming reliable operation for the temporary installation.