Variable Frequency Drives For Mining Equipment

The mining industry is challenging, and ABB operates accordingly to the highest standard of occupational health and safety excellence and remains constantly vigilant in carrying out its duty of care. ABBs combined efforts and commitment allows it to achieve a continuing improvement in its safety record. The machines and equipment used in mining must provide reliable, safe and efficient operation in hot, humid and dusty environments. ABBs low voltage AC drives and high efficiency motors are designed to meet motor-driven application challenges found in the most hostile locations. Together with extensive mining experience and a wideportfolio of life cycle services, ABB is well positioned to tackle the industrys most demanding situations. Recent years have seen a significant increase in the level of automation and, in particular, the use of low voltage AC drives within the mining industry. Automation leads to less man power and increased safety in production, while optimizing the process and making control easier, faster and more efficient.

Replacing traditional control with variable-speed drives Low voltage AC drives are primarily used to adjust the speed and/or torque of standard AC motors. AC drives, together with induction motors, replace DC and slip-ring motors along with their control systems. AC drives also replace the need for starters, cascade drives, hydraulic speed control, mechanical gears, fan inlet vane control, fan damper control and manyother techniques of regulating the speed of electric motors used throughout the mining industry. From surface to underground mining, there are hundreds of motor-driven applications that benefit from the speed and/or torque control offered by ABB drives for mining equipment. The ever stricter targets to improve productivity and reduce energy costs are often the main reasons for selecting drives.The following benefits of ABBdrives for mining equipment can be attained using ABB low voltage AC drives. Constant changing of environmental regulations are forcing mining companies to find more energy-efficient and environmentally friendlier drilling techniques. The varying soil quality also requires a drill motor that is able to adjust its speedcontinuously. Low voltage AC drives help meet these challenges.

The drive controls the drill motor speed, ensuring the correct drilling impact is achieved for the particular soil quality. Because the motor speed is raised or lowered depending on the type of soil, the energy use is considerably reduced compared to that of hydraulic or pneumatic drilling systems. Environmental impact is lower by avoiding hydraulic liquids or compressed-air. Below are the benefits of using variable frequency drives for mining equipment:

  • High uptime
  • Unrivalled energy efficiency
  • Extended machinery lifetime
  • Lower investment, installation, operational and maintenance costs
  • Improved safety and comfortable working environment Whether pumps, fans, conveyors, compressors, drills, crushers or excavators

The mining industry is a big energy user and as such is a major contributor to the emission of greenhouse gases. Replacing fixed speed motors with ABB drives for mining equipment can significantly reduce the energy consumed and the greenhouse gas emissions generated. ABB has the expertise and tools, such as its energy appraisal, to quickly identify which motor-driven applications can benefit. A replacement drive scheme is available for upgrading older, inefficient drives for new, space saving and highly efficient versions. Following an assessment of a plant, ABB helps select a replacement drive with improved efficiency and features relevant to the application.

Expertise – Variable FrequencyDrives For Mining Equipment

ABBvariable frequency drives for mining equipment are designed from a wealth of knowledge and expertise on all aspects of drive systems throughout the mining sector. ABB has dedicated experts who understand motor-drivenmining applications and can offer the quickest route to a profitable solution, without forgetting personnel safety and environmental responsibility.Leading technology in design and production For over 100 years, ABB has consistently invested a large proportion of its turnover in research and development, working closely with some of the worlds leading universities and institutions. The result is the most advanced range of low voltage AC drives in the market, designed to meet the specific needs of various mining applications. This has also led to several patents for leading edge technology within ABB drives. This cooperation contributes to the safety of ABBs products and personal safety of mining equipment users. ABB can exploit the latest component technology when designing its drive products. This results in improved quality of ABB variable frequency drives for mining equipment and in enhanced component quality. ABBs drive manufacturing facilities are equipped with the most modern assembly lines using the latest production techniques and advanced software.

Access to authoritative technical advice ABB constantly monitors all legislation, regulations, directives and standards, not only ensuring that its products comply but by offering sound advice to customers. ABBs expertise extends throughout mining operations and their entire electrical installation. ABBs engineers can advise on the correct selection, dimensioning, installation, operation and maintenance of drives, motors, transformers, relays, switches, contactors through to transducers and meters. Advice is available on long cabling, weak networks, protection functions, harmonics, EMC, power factor correction, mounting options and air flow requirements. Using harmonic filters on ABB variable frequency drives for mining equipment will eliminate the severe plant disruptions caused by harmonic disturbances in electrical equipment. ABB offers proven ways to assess your vulnerability to harmonic problems and your need for filters.Throughout mining, the consumption of inductive reactive power is significant. Reactive power compensation equipment offered by ABB helps minimize the amount of reactive power. In many applications there is a need to interface the drives with external systems. ABB has the expertise in all high performance communication protocols including PROFIBUS DP, Devicenet, CANopen and Modbus fieldbus.

To learn more about ABBvariable frequency drives for mining equipment, or for ABB drive repair and ABB drive replacement quotes, contact Precision Electric, Inc.

Replacing Constant Speed With Variable Speed

In the past, applications operating at less than 300rpm, and rated from 500 kW to 5000 kW, have been controlledusing a medium-voltage constant speed synchronous motors. Commonapplications include crushers and various mills used inmetals, cement or mining.Replacing a constant speed with variable speed drive control brings substantial operating and maintenanceimprovements. Variable-speed drives provide soft starting, precise speed andtorque control and low stress on the electrical network.Soft starting lets the motor get up to speed gradually, therebyavoiding high inrush currents that can prevail when direct-onlinestarting is used. As such, the stress on the motor and allcomponents in the transmission train are much reduced. Thisavoids failure of key components while reducing maintenancecosts and prolonging motor and transmission life time.

ABB industrial drives feature the motor control platform, and direct torque control (DTC). DTC provides the highly accuratespeed and torque control often needed in slow speedapplications.With a power factor approaching unity, the variable-speeddrive has low reactive power consumption; thereby loweringvoltage variations on the supply network. The variable speed drive and motorcan be connected to weaker supply networks without theneed for power factor correction equipment. An advantage of using new synchronous motors with ABB industrial drives is that, for most cases, the existingfoundations can be re-used.A key benefit of variable-speed control is that the new motorhas fewer pole pairs and a smaller shaft height. This is becausea constant speed synchronous motor needs to be designed forits maximum speed. So a 2500 kW motor requiring 150 rpmhas 40 poles and typically a shaft height of 2000 mm. However,using variable-speed drive, the motor has between 8 to 24poles and a typical shaft height between 1250 to 1600 mm.This substantially lowers the motor costs and even when thedrive and transformer are considered, the investment will beless expensive than a 40-pole motor.

Benefits Of Replacing Constant Speed With Variable Speed:

  • Soft starting capability reduces stress on motor andtransmission train
  • Optimum speed according to process requirements
  • Lower maintenance costs and prolonged motor life
  • Low stress on the electrical network through unity powerfactor and low reactive power consumption
  • Choice of smaller traditional synchronous motor
  • No need to alter foundations thereby avoiding any loss ofproduction and costly civil works
  • Typically lower total cost than a new constant speedsynchronous motor

To learn more about replacing constant speed with variable speed, or forvariable speed drive repair and replacement quotes, contact Precision Electric, Inc.



VFD Machine Safety

Today, VFD machine safety technology is making the previously-complicated job of implementing a machine safety system much easier. Recent technical advances make safer operation less complex, while at the same time offering new potential for productivity. New developments in drive-based functional safety contribute to greater overall protection of people, machines and ecosystems. The aim is to help make VFD machine safety, and especially drive-based functional safety, easier for machine safety professionals.

In any industrial process it is critically important that when something goes wrong, the machinery is quickly and safely brought to a safe state, which usually means stopped. Once stopped it must not start unexpectedly. Depending on the application and its work cycles, machines may also need to operate at reduced speed during specific times. Any malfunction in machine control can result in hazardous situations leading to serious injury, or even death, with disastrous effects for the company, its people and its image. Ultimately, machine builders and system integrators have the responsibility for ensuring that any product or machine they supply is safe. It must be designed by following safety principles and must comply with relevant directives, standards and national laws. The machines end user has responsibility extending through the entire lifecycle of an industrial system. It is thus vitally important that safety planning is included from the very start of any machine design process. This way safety becomes a natural, functional part of the machinery and not an afterthought.

Drive-Based / VFD Machine Safety

VFD Machine SafetyDrive-based functional safety simplifies the task because drive safety functions are certified and integrated into the drive system. Safety is important in industrial applications involving motors, drives and programmable logic controllers. VFD machine safety is achieved by identifying and reducing risks to an acceptable level. Risk reduction is done by an inherently safe design and by applying risk-reducing protection measures.When done correctly, these measures can be flexible, reliable and easy-to-use. They also bring solid economic benefits such as increased productivity and uptime, without generating additional risks. The job of implementing a VFD machine safety system is today easier thanks to three main factors:

First, modern electronics enable safety functions to be directly integrated into a drives safety logic, so functional safety is a standard feature of the drive. Second, legislation has kept pace with these advancements, with new
standards that define the requirements and provides guidelines for implementing machinery safety. Third, engineering companies such as ABB have developed a wide range of safety devices and solutions that are easy to integrate in industrial applications for improved safety, uptime and functionality.

These three factors have enabled VFD machine safety solutions that can be more effective in preventing accidents, less costly to implement, easier to adapt and more reliable than previous hardwired electromechanical systems. Electromechanical safety systems are the result and can now be replaced with electronic safety functions. Built directly into the drives safety logic, the safety functions work seamlessly, side-by-side with the drives normal control functions.

VFD Machine SafetyDrives control movements such as motor speed and torque in industrial applications like conveyors and cranes. As levels, complexity and modularity of industrial automation increase, drive-based functional safety isfast becoming an important part of overall safety design for industrial processes. When sensing a hazardous situation a drive-based functional safety system can react in several ways. It might, for example, initiate an emergency stop based on user input. Or if it detects an out of control situation such as system overspeed, it can stop a process in a controlled and orderly way.

In larger systems with several drives, control of the overall safety system can be done using a safety PLC, which activates drive-based safety functions when required in the whole system. Functional safety can be easily achieved with safety devices that are, themselves, already certified to the most relevant functional safety standards. ABB drives include many certified safety functions either as standard, or are offered as options.ABB has put great emphasis on building safety functionality into its drives. ABB offers cost-efficient safety solutions with their drives, PLCs, and a full range of safety relays and contactors, emergency stop switches and othersafety devices. Depending on the needed machinery safety, ABB VFD machine safety solutions can range from one drive to an entire system of drives.Compared to the traditional safety solution, integrated drive-based functional safety includes the same functionality but it is simply built into the drive. The most basic functionality level is the STO circuit inside the drive whichcan safely disable the drives power stage, thus eliminating any need for a motor contactor.

ABBs offering of low voltage AC drives with STO as a standard feature are included on the following ABB products: ACS880, ACS580, ACS850, ACS355, ACQ810, ACSM1 and MicroFlex e150. The ACS800 drives have ABB STO (safe torque option) built-in as an optional feature.

Summary – VFD Machine Safety

The industrial environment is full of moving machine parts which can cause hazardous situations and lead to severe and often permanent injuries. The role of functional VFD machine safety is to protect people, property and ecosystems from often preventable accidents. It is therefore the ultimate responsibility of device suppliers, machine builders and system integrators to ensure that the products they deliver are safe.Safety for machines is achieved by complying with relevant safety directives and standards. In the EU, the EHSR which machine builders must comply with are defined in the Machinery Directive 2006/42/EC and the harmonized standards under this directive. For machine builders outside of EU the IEC/ISO versions of the EUs harmonized standards provide the necessary requirements and guidance.

Drives have been used for decades in many industrial applications. Where safety in automation systems once required many external add-on devices, the ever-increasing levels of automation employed in industry combined with the electronic technical capability of many modern drives and safety PLCs, mean drive systems now contribute greatly to the overall safety of a system. Today, new and improved safety solutions and standards enable VFD machine safety to become an integrated part of drive functionality. Drive-based functional safety means providing drive-based motion control that protects people, property and ecosystems. ABB drives offer many features that can help the safety designers achieve the required level of safety, in a cost-effective way.

For ABB VFD Repair or Replacement Quotes, Contact Precision Electric, Inc. To learn more about VFD machine safety or for more information about ABB drives, please visit the ABB Website.





Eaton Drive Repair

Variable speed drives have over the past decade allowed to become a cost efficient way to reduce power costs and increase system efficiency. Today manufacturers around the globe within a wide range of industries are finding more ways to apply drives to their rotating equipment.From past experience, smaller horsepower drives typically fail in eight years and are more often replaced rather than repaired.Larger horsepower drives last longer by virtue of repairs that often require replacement of circuit boards and other electrical components. After bearing the cost of two or three replacement boards in any one VFD drive, the user often realizes that the drive should have been junked sooner.

Eaton drive repair is common for Sullair service centers and manufacturers who use Eaton drives. Eaton drive repair is preferred by Sullair service centersand other Eaton drive usersbecause replacement is more expensive than repair.Most industrial manufacturing repair centers do not have the capabilities to offer Eaton drive repair, and that creates few alternativesfor Eaton drive users who are broke down.Eaton offers repair services for their drives with extensive lead times and most Eaton drive users cannot afford downtimewith extensive lead times.

Precision Electric saves Eaton drive users thousands of dollars by repairing failed Eaton drives. Precision Electric has also saved Eaton drive users in downtime by repairing Eaton drives in less time than it would have taken Eaton to replace a non-stock drive. Eaton drive repair is an asset to Sullair service centers and manufacturers who use Eaton drives.Precision Electric uses the most advanced testing equipment for all Eaton drive repair, and PrecisionElectric repair technicians have hundreds of years combined experience in testing and replacing Eaton drive components.

To learn more about Eaton drive repair or for Eaton drive repair and replacement quotes, contact Precision Electric.