Eaton LED Solutions For Oil Refinery Applications

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Eaton has over 100 years of oil and gas market leadership and servesthe world’s oil companies,original equipment manufacturers and EPCs with electrical, hydraulics and filtration solutions supported by a global network of over 2,500 services professionals. Over the years, Eaton’s innovative portfolio has grown, including solutions from names like Aeroquip-Vickers, B-Line, CEAG, Crouse-Hinds, Cutler-Hammer, Holec, and Synflex among others.

Refineries are commonly faced with the growing challenge of keeping up with uptime, budget and regulatory requirements despite aging equipment. Operating around the clock in harsh environments also demands the utmost in visibility and illumination to support worker safety. Eaton LED solutions for oil refinery applications with todays modern light emitting diode, (LED) technology delivers increased energy efficiency, lowers maintenance costs and improves light quality, lighting upgrades present a great opportunity for refineries to cut costs while bettering work environments.

Application Cases– Eaton LED Solutions For Oil Refinery Applications In USA

When a major U.S. refinery was looking to modernize its lighting systems to provide a better environment for personnel, it sought a solution that could also reduce ongoing maintenance, replacement and energy costs. The increasing costs incurred from the aging high-pressure sodium (HPS) and incandescent lighting technology began to compound, and the refinery knew it needed to collaborate with an industrial lighting expert to develop a solution that would continue to deliver benefits well into the future.

Solution

Following an extensive inspection by lighting experts in Eatons Crouse-Hinds business, the refinery replaced legacy HPS and incandescent fixtures with Champ VMV Series and Vaporgard Series explosion proof LED luminaires. Exceeding the refinerys expectations as a HPS replacement for overall light quality and durability, the Champ VMV Series LED fixtures provided full-spectrum lighting and custom distribution at a fraction of the energy consumption.

Consuming less than 50W, the Champ VMV3L delivers equivalent lighting levels of a traditional 100W lamp, offering a lifetime energy savings upwards of 77 percent compared to traditional HPS luminaires. The robust design provides protection from flammable vapors, gases, corrosive chemicals and liquids to withstand the harshest of environments and has a lifespan more than six times that of typical luminaires. The Vaporgard LED explosion proof luminaires were implemented to provide the refinery with uniform, crisp light in low-mounted applications. An ideal replacement for traditional 100-200W incandescent applications, the luminaires comply with T5 temperature codes in Class 1, Div. 2 locations to provide the safety and performance required in downstream applications. The 22W LED system can also help save up to 85 percent in energy costs, and provides a rated life of up to 50,000 hours for nearly 10 years of maintenance-free lighting.

Results

By implementing the Eaton LED lighting technology, the refinery was able to reduce its annual energy usage by $34,668 while decreasing annual maintenance costs by $766,647. The complete lighting solution is also designed in compliance with applicable industry standards, providing the highest quality, safety and optical performance for hazardous areas.

To learn more about Eaton LED solutions for oil refinery applications, visit the Eaton Website. For Eaton Drive Repair and Replacement quotes, contact Precision Electric.

 

VFD Conveyor Systems

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Automatic conveyors are used to transport and sort materials. Automatic VFD conveyor systems areinstalled as part of a storage or logistics system or may be used between the machining stations of factory plant and equipment. In the case of unit loads, the speeds of individual conveyor sections must be aligned with the flow of material. In comparison, bulk materials are conveyed continuously.

Typical applications include

  • Roller conveyors
  • Chain conveyorstant movement
  • Belt conveyors
  • Screw conveyors

Continuous VFD conveyor systems support constant movement. Their speed depends on the materials being transported and the process conditions. Defined acceleration and braking ramps prevent materials tumbling or slipping during stopping and starting. VFD conveyor systems are used when variable speed is required for industrial conveyor systems.

On conveyor VFD systems, torque is determined on the deformation work and churning work of the belt conveyor. The proportion of potential energy is also taken into account from a need to overcome height differences. Acceleration is not a primary concern, as the drives change speed gradually. In the case of conveyor sections used to transport unit loads (from which individu al units are discharged and sorted), the speed of the material must be varied in accordance with specific requirements. That is why dynamic torque loads also need to be taken into account within this context. As a result, servo drives are often used in such situations.

The sensor signals (from photoelectric barriers or limit switches) that are neces sary for the purpose of monitoring and controlling the volume flow are processed by higher-level controls or directly by the inverter.

 

Lenze VFD Conveyor Systems And Solutions

The driving force behind a conveyor is the geared motor. Fixed speed motors are either controlled via a contactor or a distributed motor starter. To facilitate soft starting, Lenze’s electronic motor starter, starttec, can be used to raise motor voltage gradually by means of a ramp. If variable speeds are required, there will be a need for precise acceleration, braking and positional accuracy when stopping. In this case, VFD conveyor systems using variable frequency drives are the ideal solution. Lenze’s 8200 vector and 8200 motec frequency drives can be connected to field buses. This minimizes wiring and cabling to the controller. The decentralized Lenze 8200 motec frequency drivesshould be installed outside the control cabinet and directly on the machine frame or on the motor in place of the terminal box. This means that the VFD conveyor systems can be tested easily prior to delivery, thereby reducing installation and commissioning times. This results in cost savings, especially when you consider the layout concept, which allows loop-through wiring of the power and control cables.

Lenze VFD conveyor systems and servo drives are designed for high dynamic performance applications. The servo motors can be combined with the complete Lenze range of gearboxes and this means that they can be adapted perfectly to the requirements of any conveyor section. To learn more about Lenze VFD Conveyor Systems, visit the Lenze Website. For Lenze VFD drive repair and replacement quotes, contact Precision Electric.

ABB Frequency Converter

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ABB frequency converter modules are used for electric motor control to reduce energy consumption. ABB frequency converter modules offer plug and play motor control convenience, straight from the box. When you are looking for simplicity and intelligence in a self-contained solution, general purpose ABB frequency converter modules cover your options wisely. Wherever your business needs are, the ABBglobally renowned reliability and service easily matches all aspects of industry requirements.

ABB Frequency Converter Modules For Waste Water Utilities

It is not only water utilities but every major industry thathas a need for water. Water is critical to industry. Water isthe most common heat transfer fluid, cleaning fluid andsolvent – and often forms a significant proportion of thefinal product.Yet water is the most untapped source of financial and energysavings within a plant. The challenge is to use water of theappropriate quality and cost, effectively throughout the wholeproduction process.The responsible and sustainable treatment of water is oneof the most important global issues. The efficient use of water and for the purification ofwaste water, ABB frequency converter modules play a major role in in managing this challenge.

With the help of ABB frequency converter modules, ABB aims to optimizethe water supply, process use and effluent treatment to giveindustry a competitive advantage.ABB frequency converter modulesare used in every phase of water supply andwastewater plants: from the moment water is taken in from thereservoir or river, through the water treatment and pumpingstations, into the distribution system, back into the sewagesystem and, then, as final effluent, returned to the environment.ABB frequency converter modules are used for regulating a variety of pumps, fans andcompressors used for flow and pressure control throughout thewater process. They regulate the processes according to actualdemand, based on inputs from flow meters, pressure transmittersand other sensors. ABBfrequency converter modulesbring many benefits, including large plant efficiency improvements, energy savings and less wear and tear on moving equipment.

ABB Frequency Converter Modules For Food And Beverage Applications

Competitiveness in the food and beverage sector is highlydependent on the efficiency of the entire value chain,with the primary focus being on the performance of theproduction processes. Examples of todays increasingchallenges are high process uptime, permanenttraceability, uncompromising hygiene and unbroken coldchain. Additional requirements include lowering energyconsumption and minimizing maintenance costs. Thisleads to increased demand for ways to boost processcontrol throughout the supply chain.ABB frequency converter modules bring superior process control, savings in energyconsumption as well as in operational and maintenance costs. ABB frequency converter modules can help offset the squeeze on profitscaused by changes in buying behavior and increased qualitydemands, whether in processing, packing, transportation orstorage.Recent years have seen a dramatic increase in the level ofautomation and, in particular, the use of low voltage frequency converters.Automation leads to less errors in production, while optimizingprocesses and making them easier and faster.

For more information about ABB frequency converter modules, visit the ABB Website. For ABB frequency converter repair and replacement quotes, contact Precision Electric.

 

ABB Drives With BACnet For HVAC Applications

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ABB drives with BacNet for HVAC applications were introduced in 2004. Today ABB’s standard drive is the markets leading AC drive with native BACnet as standard. Several thousand of these drives have been installed worldwide since their launch. ABB standard drives for HVAC require no plug-in cards or gateways. The drives operate direct on an MS/TP (master slave/token passing) network, supporting all standard baud rates up to 76.8 k. The ABB standard drives I/O points can be freely used by other devices through the BACnet protocol, such as the building management system (BMS) or direct digital controllers (DDCs). Using ABB standard drives for HVAC with native BACnet saves time, reduces installation costs and makes monitoring and fault finding easier. ABBs new BACnet router, RBIP-01, enables connection from BACnet/IP to drives. The RBIP-01 snap-on module, fitted inside the drive, is fully compatible with all ABB standard drives for HVAC, including older product generations. The module is easy to use and simple to install with built-in Help functionality. Web server functionality enables access and configuration from a standard web browser.

The drives can either be equipped with one RBIP-01 module each, or can be daisy-chained into a subnetwork. In this case, one router can manage up to 31 drives. The router is powered by 24 V AC or DC supply. The power for the router can be supplied by the drive itself, or by an external power supply. A range of different network technologies for various performance requirements is supported by BACnet. BACnet can be used to fully integrate the BMS with the HVAC system, fire alarm, intruder protection and other systems in the building, from field level up to management level. Being an open system, and with no cost associated with its use, BACnet gives users the freedom to select the most suitable equipment from a range of manufacturers. All BACnet devices communicate in the same language, without the expense of additional hardware. Equipment using BACnet is integrated without effort and gives more comprehensive information than other communication technologies when in use.

The ABB standard drive for HVAC supports 73 objects (device object, binary inputs, binary outputs, analog inputs, analog outputs, binary values and analog values). The drive can be started and stopped from an external controller. Remote interlock ensures that run commands from the external controller can be disabled with a feedback signal. The built-in energy counter is used to monitor energy consumption. The BMS can store these values for reporting, trending or to produce instant energy consumption reports. The ABB standard drive for HVAC uses MS/TP, which is designed to run over RS-485 twisted pair wiring. MS/TP is cost-effective and can handle up to 31 drives plus a router on the same subnetwork without additional components.

Most BMS and DDCs use BACnet/IP that allows integration to the same network. ABBs new RBIP-01 module provides a simple way to connect the ABB standard drive for HVAC to these BMS and DDCs.

For more information about ABB Drives with Bacnet for HVAC applications, visit the ABB Website.

Preventive Maintenance VFD

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A VFD (variable frequency drive) controls the speed, torque and direction of an induction motor. A VFD takes fixed motor voltage and AC frequency and converts it to a variable voltage and frequency AC output. In very small VFDs, a single power pack unit may contain the converter and inverter modules. Preventive maintenance VFD programs preventmanufacturing downtime while maintaining optimal production performance.

Clean Environment– Preventive Maintenance VFD:

Most VFDs fall into the NEMA 1 category or NEMA 12 category. Drives that fall in the NEMA 1 category are susceptible to dust contamination. Dust on VFD hardware can cause a lack of airflow resulting in diminished performance from heat sink and circulating fans. Dust on an electronic device can cause malfunction or even failure. Dust absorbs moisture, which also contributes to failure. Periodically spraying air through the heat sink fan is a good PM measure. Discharging compressed air into a VFD is a viable option in some environments, but typical plant air contains oil and water. To use compressed air for cooling, you must use air that is oil-free and dry or you are likely to do more harm than good. A non-static generating spray or a reverse-operated ESD vacuum will reduce static build-up. Common plastics are prime generators of static electricity. The material in ESD vacuum cases and fans is a special, non-static generating plastic. These vacuums, and cans of non-static generating compressed air, are available through companies that specialize in static control equipment.

Control boards and other electronic components can be damaged when subjected to periodic moisture or water. Some VFD manufacturers include a type of condensation protection on certain product versions. If you operate a VFD all day every day, the normal radiant heat from the heat sink should prevent condensation. Unless the unit is in continuous operation, use a NEMA 12 enclosure and thermostatically controlled space heater where condensation is likely.

Keep Connections Tight – Preventive Maintenance VFD:

Checking connections is a step many people miss or do incorrectly, and the requirement applies even in clean rooms. Heat cycles and mechanical vibration can lead to sub-standard connections, as can standard PM practices. Reusing torque screws is not a good Idea, and further tightening an already tight connection can ruin the connection.

Bad connections eventually lead to arcing. Arcing at the VFD input could result in nuisance over voltage faults, clearing of input fuses, or damage to protective components. Arcing at the VFD output could result in over-current faults or even damage to the power components.

Loose connections can cause erratic operation. For example, a loose START/STOP signal wire can cause uncontrollable VFD starting and stopping. A loose speed reference wire can cause the drive speed to fluctuate, resulting in scrap, machine damage, or personnel injury.

Additional Considerations – Preventive Maintenance VFD:

  • As part of a mechanical inspection procedure, don’t overlook internal VFD components.
  • Check circulating fans for signs of bearing failure or foreign objects.
  • Store spare VFDs in a clean, dry environment, with no condensation allowed.
  • Power spare VFD’s every 6 months to keep the DC bus capacitors at their peak performance capability.
  • Regularly monitor heat sink temperatures.
  • Inspect DC bus capacitors for bulging and leakage. Either could be a sign of component stress or electrical misuse.

You wouldn’t place alaptop computer on the roof of a building or in direct sunlight, where temperatures could reach 115 degrees Fahrenheit or as low as -10 degrees Fahrenheit. A VFD, which is basically a computer with a power supply, needs the same consideration. Some VFD manufacturers advertise 200,000 hours-almost 23 years-of Mean Time between Failures (MTBF). Such impressive performance is easy to obtain, if you follow these simple procedures.

By integrating a preventive maintenance VFD program, you can ensure your drives provide minimal repair service while maximizing production.Always call certified variable frequency drive integrators or experienced technicians to perform preventive maintenance VFD services to prevent injury or death.

To learn more about preventive maintenance VFD programs or for VFD repair and replacement quotes, contact Precision Electric.

Drives Save Labor And Reduce Energy Costs

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Variable frequency drives save labor and reduce energy costs while extending the lifespan of equipment for industrial applications. In the following ABB case study, afarm owner began looking toralternatives to an old irrigation system, which worked by running the water pumps at constantspeed, with control than being done bymanual opening and closing of valves In the pipelines. The system still worked, but it wascertainly not energy efficient.In addition, the need tor manual opening and closing of valves during startup combined withfrequent power outages and voltage dips from the electrical utility, made the whole process varylabor-intensive. To start one of the six pumping stations could take one person up to an hour andwith sometimes as many as three power outages a day, start ups became almost a full-time job.

The young owner of this farm was not previously a customer of ABB, but upon meetingwith ABB energy efficiency engineers, he decided to test variable frequency drives (VFD)on the water pumps at one of Its six pumping stations. ABB recommended a VFDand working witha system integrator, assisted in thedesign, installation and commissioning of five variable frequency drives running irrigation pumps with 45 to 75 kWmotors, and the sixth variable frequency drive used on the water transfer pump.The results were quite dramatic. With the new VFD installed, Riecor saw a significant drop inelectric energy. Demand from the irrigation system went from 291 kW, 308 kVA down to only 175kW, 186 k:VA. This amounted to 116 kW; an impressive 40 percent reduction in electric consumptionfor just one pumping station.

In financial terms, based on the local crop factor tor this region that Indicates the irrigationpumps would operate at 2,970 hours per year means an annual savings of $19,700 U.S.D. in electricitycosts. The payback time amounted to a short 7 months. The farm quickly made a repeat order and hasinstalled similar drives on a second pumping station

MajorBenefits
In addition to the financial savings on the electricity bill, the farm also had further operationalsavings in both labor hours and troubleshooting the initial start up process. Operators now only need to flicka switch to start, and in the eventof power interruptions the system wouldstart back up automatically at pre-set times.The variable frequency drivesgive a long ramp-up timethat allows for a very smooth pipe filling process, so the previous mechanical stresses on the pumpcouplings during start up were completely eliminated, together with fewer friction losses in thepipes. Additionally water hammering following switching off disappeared and fewer losses on theimpeller were seen due to these extended ramp-up and ramp-down times.

The ABB Energy Efficiency engineers who worked most closelyon the project, says that the Riecor Farming installation is a good example of how energyefficiency projects can also give additional benefits on the operational side.

Cost efficient retrofit

  • 40 percent reduction in energy consumption gave rapid seven- month payback of investment
  • Reduced labor costs, manpower needed for startup process is dramatically reduced
  • Smoother operation and pipe filling, power drops handled easier, water hammer and system shockseliminated

To learn more about applications where drives save labor and reduce energy costs, or for additional information about ABB Drives, visit the ABB Website. For ABB variable frequency drive repair or replacement, contact Precision Electric, Inc.

How To Control How A Motor Starts And Stops

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Nearly any three phase motor can be started and stopped with a variable frequency drive.

These motors can easily have different start and stop control methods performed by a variable frequency drive.

If you’re not familiar with the motor and drive industry, controlling a motor can be intimidating. Technology offers us many solutions when controlling motors and electronics, but not all of those solutions are equal. There are a number of different ways you can control how a motor starts and stops, and it all begins with a variable frequency drive.

Variable frequency drives give you complete control over your motor. You can control the start method, stop method, speed, direction and much more. They also offer several layers of protection to make sure your motor doesn’t get damaged in the process.

We would like to help you get exactly what you’re looking for. As a distributor of many variable frequency drives through our online store, we’re here to help you find the exact solution you need. In this instance, we will help you start and stop the motor in different ways.

How To Control How A Motor Starts

We begin with our personal favorite, the SMVector Series variable frequency drive. This drive is extremely versatile and cost effective. Once you’ve commissioned the drive, you can easily control how your motor starts and stops. Here’s how you do it:

  1. Press the menu button.
  2. If prompted for the password, use the arrow keys to select 0224 and press themenu button again.
  3. Scroll to parameter P110 and press the menu button again.
  4. Choose from one of the following start methods:
    • 00 – Normal – Drive starts when you press the start button. Start command must be applied at least 2 seconds after power-up; F_UF fault will occur if start command is applied too soon.
    • 01 – Start on Power-up – Drive attempts to start as soon as the unit is powered up. For automatic start / restart, the start source must be the terminal strip and the start command must be present.
    • 02 – Start with DC Brake – When start command is applied, drive will apply DC braking according to P174 and P175 prior to starting the motor.Start command must be applied at least 2 seconds after power-up;F_UFfault will occur if start command is applied too soon. If P175 = 999.99, DC braking will be applied for 15 s.
    • 03 – Auto Restart – Drive will automatically restart after faults, or when power is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present. Drive will attempt 5 restarts; if all restart attempts fail, drive displays LC (Fault lockout) and requires a manual reset.
    • 04 – Auto Restart with DC Brake – Combines Start on Power-up with Start with DC Brake.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.
  5. Once you’ve made a selection, press the menu button.

How To Control How A Motor Stops

Now that you’ve set how you want your SMVector series drive to start, you can select how you want it to react when it is configured to stop. Here’s how you do it:

  1. Press the menu button
  2. If prompted for the password, use the arrow keys to select 0224 and press the menu button again.
  3. Scroll to parameter P111 and press the menu button again.
  4. Choose from one of the following stop methods:
    • 00 – Coast – Drive’s output will shut off immediately upon a stop command, allowing the motor to coast to a stop.
    • 01 – Coast with DC Brake – The drive’s output will shut off and then the DC Brake will activate (refer to P174, P175)
    • 02 – Ramp – The drive will ramp the motor to a stop according to P105 or P126.
    • 03 – Ramp with DC Brake – The drive will ramp the motor to 0 Hz and then the DC Brake will activate (refer to P174, P175)
  5. Once you’ve made a selection, press the menu button

The Alternative Flying Start / Restart Method

The SMVector series also has the option to perform different types of flying starts and restarts. A “flying” start is a start that occurs while the motor is in motion. If you have an application that requires the motor stop and restart without completely stopping the motor, this option may be for you.Here are some things you need to consider.

Warning! Automatic starting / restarting may cause damage to equipment and / or injury to personnel! Automatic starting / restarting should only be used on equipment that is inaccessible to personnel.

  1. Press the menu button.
  2. If prompted for the password, use the arrow keys to select 0224 and press themenu button again.
  3. Scroll to parameter P110 and press the menu button again.
  4. Choose from one of the following start methods:
    • 05 – Flying Start / Restart – Type 1–Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at max frequency (P103). If P110 = 0, a flying start is performed when a start command is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset. If drive cannot catch the spinning motor, drive will trip into F_rF fault. If drive trips into F_OF fault, try P110 = to 07 or 08.
    • 06 – Flying Start / Restart – Type 1–Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at the last output frequency prior to faulting or power loss. If P110 = 0, a flying start is performed when a start command is applied.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip into F_rF fault. If drive trips intoF_OFfault, try P110 = to 07 or 08.
    • 07 – Flying Start / Restart – Type 2– For 2-pole motors requiring a flying restart.Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting at max frequency (P103). Type 2 utilizes P280 and P281 to set Max Current Level and Decel Time for restart.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip intoF_rFfault.
    • 08 – Flying Start / Restart – Type 2– For 2-pole motors requiring a flying restart.Drive will automatically restart after faults or when power is applied. After 3 failed attempts, drive will Auto Restart with DC brake. This option performs a speed search, starting atthe last output frequency prior to faulting or power loss. If P110 = 0, a flying start is performed when a start command is applied.Type 2 utilizes P280 and P281 to set Max Current Level and Decel Time for restart.For automatic start / restart, the start source must be the terminal strip and the start command must be present.If P175 = 999.99, DC braking will be applied for 15 s.Drive will attempt 5 restarts; if all restart attempts fail, drive displaysLC(Fault lockout) and requires a manual reset.If drive cannot catch the spinning motor, drive will trip intoF_rFfault.
  5. Once you’ve made a selection, press the menu button.

The Best Variable Frequency Drive For The Money

The SMVector Series drive is one of the most cost effective and versatile choices for controlling your motors start and stop method.

If you want complete control over every aspect of your motor, we recommend the SMVector Series variable frequency drive.

We offer a wide range of variable frequency drives that will fit your needs at our online store. Don’t hesitate to contact us if you have any questions or concerns when looking to purchase a variable frequency drive. We will get you taken care of.

You’ll likely have the most success, and save the most money, by purchasing an SMVector Series variable frequency drive. The SMVector drives areMade In America, include a 2 Year Manufacturer Warranty and the Price Includes Engineering & Application Support.

The performance and flexibility make the SMVector an attractive solution for a broad range of AC Motor applications and with several communications protocols available, networking drives and components into a system solution can be done now or in the future.

The SMVector NEMA 1 (IP31) is the most common and cost effective drive enclosure for a wide range of applications including packaging, material handling / conveying, positive displacement pumping, and HVAC systems.

The SMVector Series can be used with 3-phase AC induction motors and is available in NEMA 1 (IP31) , NEMA 4X (IP65) and NEMA 4X (IP65) with an integral disconnect switch. Filtered input versions of the SMV are available in NEMA 4X (IP65) models for compliance with the CE EMC directive.

Programmable digital and analog I/O allow the drive to be configured for many application specific tasks such as multiple preset speeds, electronic braking and motor jogging to name a few. Like all Lenze AC Tech sub-micro drives, the SMVector uses EPM memory technology for fast and efficient programming.

Technical documentation for the SMVector Series Drive, and all AC Tech brand drives, is available in our Technical Library.

 

Industrial Packaging Systems Using Variable Frequency Drives

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D&D Engineering (Hull) Ltd is a manufacturer ofconveyors and product handling equipment. Eighty percent ofits customers are in the food industry, mainly in the preparedproduce sector, with some involved in the production ofchilled products and bakery goods.One of D&D Engineerings recent customers is John BaardaLtd, a company specializing in the growing of tomatoes.John Baarda Ltd needed to replace its current tomatohandling conveyor system, which used inefficient chainsand sprockets, with a solution that would allow it to packtomatoes more quickly and accurately while allowing qualityinspection of the tomatoes.The company was experiencing difficulties with themechanically interfaced conveyors, as their coordinatingseries of chains and sprockets are subject to wear andstretch. This causes maintenance problems, with any timingadjustments having to be made mechanically, leading toproduction interruptions and reduced output.Gavin Walker, Engineering Sales Manager of D&D Engineering(Hull) Ltd explains: The speed of the conveyor must becoordinated with the speed and timing of the wrapper toensure that the tomatoes are delivered to the flow-wrapperat exactly the right time.

Quick And Accurate Industrial Packaging Systems Using Variable Frequency Drives

Integrating their industrial packaging systems using variable frequency drives was the goal for this application. The conveyor systemthat uses ABB servo motors and ABB high performancemachinery drives to control the speed of the tomato handlingconveyors, matching the speed of the packing machineand ensuring that the tomatoes are packed quickly andaccurately. An ABB component drive runs rollers on theconveyors, allowing the tomatoes to be turned automaticallyand inspected for quality.The two feeder conveyors are each driven by an ABB highperformance machinery drive in master-slave configuration,with the master receiving an encoder signal from the wrapper.This ensures that the drive knows where the wrapper is in itscycle and can control the speed of the conveyor precisely toensure the tomatoes arrive at the wrapper at the correcttime. If the speed of the wrapper changes, the drive canalter the speed of the conveyor accordingly to maintain thecorrect timing.

Challenges:

  • Accurate co-ordination of tomato handling conveyor withwrapping machine to allow quicker packing of tomatoeswhile providing quality inspections

Solution:

  • ABB servo motors controlled by ABB high performancemachinery drives match the speed of the tomato handlingconveyors to the speed of the packing machine
  • ABB component drive controls rollers on the conveyors,allowing the tomatoes to be turned for inspection

Benefits:

  • Tomatoes are packed quickly and accurately
  • Packing rate has doubled from 40 packs per minuteto up to 80 packs per minute
  • The drives programmed product menus allow different
  • products to be run on the conveyor with quick changeovers
  • Easier to build thanthe previous mechanical interfaced systems
  • Operation and maintenance costs reduced

Doubling The Packing Rate

Tim Howarth, Business Development Manager with JohnBaarda says: With mechanical systems, we can achievea maximum rate of around 60 packs per minute. Withstoppages, this averages around 40 packs per minute.The ABB machinery drive based electronic control systemgives us an average of 70 to 80 packs per minute.The ABB high performance machinery drives can be used withboth synchronous and induction motors and their modulardesign and flexible software make them suitable for use in arange of machinery applications, including those of the foodand beverage industry, material handling and packaging.

To learn more about ABB Low Voltage Drives or for ABB Repair and Replacement Quotes, contact Precision Electric, Inc.

Information References:

www.abb.com/drives
www.abb.com/drivespartners

ABB Energy Management Systems

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Today industry and commerce are facing an energy challenge. Pressures to reduce energy consumption, lower carbon dioxide emissions and provide secure power supplies are coming from governments, consumers, legislators and shareholders alike. All of these pressures are against a background of ever-rising energy prices and the dramatic effects climate change ishaving on the environment. As a result, industry and their consumers are demanding ever more energy-efficient products.

The worlds demand for energy is rising steadily. Under current policies, energy demand is set to rise 47 percent between 2008 and 2035, according to the International Energy Agency (IEA), reflecting global economic growth and rising living standards. Electricity demand is expected to grow almost twice as fast, with most of the increase occurring in emerging markets.Helping industries and utilities improve energy efficiency Industry consumes about 42 percent of all electricity generated, according to the IEA. The most energy-intensive industries are cement, chemical, iron and steel.

The energy saving potential in industries and utilities is enormous just in electric motor-driven applications alone: hundreds of millions of electric motors driving machines, compressors, fans, pumps or conveyors in virtually every sector account for about 70 percent of all the electricity that industry uses.More than 90 percent of industrial motors either cannot adjust their power consumption or use very crude methods to do so. Many of these electric motors always run at full speed, regardless of the actual output needed. In many applications, energy use can be cut to one- eighth just by reducing the motor speed by half.

ABB Energy Management Systems Solutions

The most immediate, cost-effective and practical way to address the energy challenge is to grasp the opportunities for energy reduction that come from using energy more efficiently with available and proven technology.ABBenergy management systems include variable frequency drives, motors and other technologies tohelp lower energy use, either by reducing power consumption and losses, improving productivity or through better management of equipment.

With ABB energy management systems there is great potential to save energy and costs in industry. Nearly 70 percent of all electrical energy consumed by industry is used by the millions of electrical motors installed worldwide. Every year, several more million motors are added. These motors are the workhorses of industry, driving machines, compressors, fans, pumps and conveyors in virtually all industrial sectors. Not only are pumps andfans numerous, they also have the greatest energy saving potential. Therefore, targeting pump and fan applications is a great way to begin with ABB energy management systems.

ABB supplies virtually every industry with a broad range of electric motors and variable frequency drives to reduce energy consumption, increase productivity and safeguard quality. Among the industries served are cement, minerals, metals, oil and gas, chemicals, pharmaceuticals, pulp and paper, water, and marine.

During the 40 years since the first variable frequency drives appeared, ABB has delivered millions of units across the globe to every type of application in all industries. During this time, vast experience has been gained of how industry can save energy in the most effective ways. The installed base of ABB drives saved 310 million megawatt-hours (MWh) in 2011, equivalent to the yearly consumption of about 75 million EU households. In terms of CO2 reduction, these savings equate to 260 million tons, more than the yearly emissions of over65 million cars.

ABB energy management systems use variable frequency drives to reduce the output of an application, such as a pump or a fan, by controlling the speed of the motor, ensuring it runs no faster than it needs. Many motors are oversized to cope with a maximum demand that rarely or never occurs. The drive brings the motor speed down to match the actual demand needed by the application.This often cuts energy consumption by 50 percent and in extreme cases by as much as 90 percent.

When other control methods are used, such as dampers, vanes or valves, the motor runs at full speed and the flow of the output is mechanically restricted. For instance, the flow through a pipeline may be reduced by a valve. This is wasteful, because the motor keeps running at its nominal speed regardless of the demand. The pump delivers maximum output and the excess is reduced at the valve, where the surplus energy is wasted through friction.The relationship between a pump or fans speed and its energy need is known as the cube law, because the demand for power increases with the cube of the speed. This means that a small increase in speed requires a lot more power,but also that a modest speed reduction can give significant energy savings. A pump or a fan running at half speed consumes only one-eighth of the power compared to one running at full speed.

In addition to the energy savings, the variable frequency drive delivers accurate control and less mechanical wear, reducing maintenance and extending the life expectancy of the system. ABB energy management systems products range from 0.18 kW to 72 MW, is the widest available from any manufacturer, offering drives for every need.Many of ABBs drives have built-in energy calculators to monitor energy consumption and savings in kilowatt hours, local currencies and carbon dioxide reductions. The drives built-in energy calculators show actual results that can be used as a basis for future energy saving projects.

To learn more about ABB energy management systems, or for ABB repair, retrofit, and replacement quotes, contact Precision Electric, Inc.

 

AC Electric Motors

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AC electric motors operate by applying alternating current (AC) power to the electric motor. The main parts of AC electric motors are the stator and rotor. The AC electric motors’ stator consists of coils that are supplied with alternating current power and produce a rotating magnetic field. AC electric motors rotor will rotate inside the electric motor coils and the output shaft produces torque via the rotating magnetic field.

There are two different types of AC electric motors and each of them uses a different type of rotor. The first type of AC motor is called an induction motor. Induction motors use a magnetic field on the rotor of an induction motor that’s created by an induced current. The other type of AC motor is called a synchronous motor and rotates precisely at the supply frequency or on a sub-multiple of the supply frequency. Synchronous motors are able to operate with precision supply frequency because it doesn’t reply on an induced current. The magnetic field on a synchronous motor is generated by current delivered through slip rings or a permanent magnet. Synchronous motors run faster than induction motors because the speed is reduced by the slip of asynchronous motors.

AC Electric Motors With Variable FrequencyDrives

Over the past decade, AC electric motors have been paired with variable frequency drives as a cost efficient way to reduce power costs and increase system production efficiency. Approximately one third of the world’s electrical energy is supplied by electric motors in fixed-speed centrifugal pump, fan, and air compressor applications. These fixed-speed applications don’t always require the full load speed (RPM) of the electric motor in which they’re operating. By installing a variable frequencydrive to these AC electric motor applications, the motor speed is reduced, and power costs can be reduced by 50% or more.This energy savings is often significant enough to cover the cost of a variable frequency drive within a few months.

Pairing AC electric motors with variable frequency drives is common in many applications such as swimming pool pumps, air compressors, conveyor belts, lathes, mills, food processing, plastic extrusion, waste water treatment pumps, HVAC fans and blowers, and many more. AC electric motors and variable frequencydrivesare used on machinery to increase or decrease the acceleration and deceleration times on alternating current (AC) motors.

Adjusting the acceleration and deceleration time of AC electric motors can extend the motor’s lifespan, and can also improve efficiency on production demands. Variable frequency drives on AC electric motorscan also provide the ability to control the frequency of starting and stopping an AC motor.This ability provides a means by which AC electric motors are only operating when needed for the equipment they’rerotating. AC electric motors have a longer lifespan if they’re not continuously operating when they don’t need to be.

To learn more about AC Electric Motors, Variable Frequency Drives, or for Repair and Replacement Quotes, Contact Precision Electric, Inc.

 

 

 

 

 

 

 

 

 

 

Pump VFD

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The BEP (Best Efficiency Point) of a centrifugal pump is dened as the operating point of highest efficiency, but also the point where velocity, and therefore pressure, is equal around the impeller and volute. The corresponding BEP for variable speed follows the Affinity laws.

Centrifugal pumps should be selected and normally operated at or near the manufacturers design specific speed for the rated conditions of head and flow best efficiency point.In a xed speed pumping application, BEP is xed. When ow modulation is required, throttling or bypassing is used. This is not the most efcient way to operate, both in energy use and mechanical stress (reliability) of the pump vfd system.

When fixed speed pumping motors are operated at reduced capacity, ie, at a flow significantly less than BEP and at a higher head, the fixed vane angles will cause eddy flowswithin the impeller, casing, and between the wear rings. The radial thrust on the rotor will increase, causing higher shaft stresses, increased shaft deflection, and potential bearing and mechanical seal problems while radial vibration and shaft axial movement will also increase. Any pump operated at excess capacity, ie, at a flow significantly greater than BEP and at a lower head, will surge and vibrate, creating potential bearing and shaft seal problems as well as requiring excessive power. Additionally, it may also infringe net positive suction head (NPSH) leading to cavitation and erosion of the impeller.

Many pump vfd systems require variable ow to meet changing process demands. The most common methods for controlling a variable ow system is a control valve, bypass line or a variable speed drive. Valve control Controlling the pump with a valve forces the pump back on the curve away from the pumps BEP, resulting in wasted energy across the valve and at the pump. In addition the pumps reliability is reduced.Bypassing the excess fluid allows the pump to operate at or near BEP, however the energy used to move the excess fluid is wasted.

Control Of Pump VFD Systems

Variable frequency drives are the most efficient method for controlling pump flow. Because the drive controls the speed of the motor directly based on actual demand, a more efficient match to the actual system requirements is more easily achieved, increased energy savings are possible, and stress on the pumping system as a whole is reduced. Variable speed operation also changes the thinking about BEP, introducing instead the pumping systems best efficiency, where the specific energy can be kept at the minimum possible value.

BEA And Pump VFD Drives

A pump vfd system’s BEA (Best Efficiency Area) considers variable speed operation and optimization of the pumping system as a whole. BEA helps to understand the benefits ofrunning pumps at variable speeds. This is achieved by using variable frequency drives to control the speed of the pumping systems motors. BEA takes hydraulic losses of the system into account, and is based on the specific energy use of the total pump vfdsystem. BEA shows the advantages of operating the pump at lower rotational speeds.

These advantages include:

  • Lower total pump system mechanical stress
  • Less stress on pump bearings, shaft and sealing system
  • Longer pump life span
  • Reduced cavitation
  • Reduced risk of pump failure
  • Good specific energy for a wide operational flow range with either single or multiple pumps

Water Hammer And Pump VFD Applications

The term water hammer comes from the pressure surges hammering effect on a system. Water hammer is also known as liquid hammer since the phenomenon can occur in other liquids. This phenomenon is the result of a rapid increase in pressure (typically in a closed loop system) when the liquid velocity is suddenly changed.

The effect of water hammer occurs due to a force applied to move and add pressure to a liquid (which is virtually incompressible) thereby creating dynamic energy that is transmitted instantly across the system. When liquid moves, stops, or changes velocity abruptly, the dynamic energy amplifies the normal system pressure creating a sudden pressure surge, or spike. When the pressure surge accelerates and approaches the speed of sound, the surge becomes an acoustic resonance with a sound wave. The pressure surge is amplified many times greater than the normal system pressure. This pressure surge can be extremely destructive to the pump, piping and valves.

In order to provide the gradual deceleration of the pump, sufcient motor torque needs to be available.Gradual deceleration of the pump speed is obtained by using a variable frequency drive with the pump vfd system.

To learn more about pump vfd systems or for pump vfd repair and replacement quotes, contact Precision Electric, Inc.

 

Information References:

http://www.abb.us/drives

Variable Frequency Drives For Mining Equipment

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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.