Wednesday, December 10, 2014
Offering a highly versatile and powerful package, the Smart Motor delivers maximum standardization-drastically reducing (by up to 70 percent) the number of different motor variations customers might otherwise need. Equipped with control intelligence in the terminal box, the Smart Motor provides design flexibility for speeds from 500 to 2,600 rpm, while maintaining constant torque. The easy-to-install motor enables mains and starter applications to be handled with greater ease than with conventional motors.
The Smart Motor complies with IES2 the top efficiency class for drive systems, while maintaining a small footprint. Among its standard functions, the Smart Motor enables speed switchovers and the ability to set individual start-stop ramps. Integrated ramps ensure smooth acceleration and deceleration to protect the system mechanics and product being handled. The Smart Motor features full motor protection, eco mode for energy savings, and digital outputs for speed selection, direction and status messages.
The new g500 gearboxes minimize losses, so the motor can generate less energy, which improves the bottom-line efficiency of the entire system. The lower level of generated heat increases the overall service life. The g500 gearboxes are designed for total integration with the Lenze Smart Motor. A single, efficient motor for many applications, the Smart Motor offers numerous integrated functions for material handling applications, including higher starting torque and freely adjustable speeds between 500 and 2,600 RPM, which reduces the required number of drive versions by up to 70 percent. The compact Smart Motor meets the highest requirements in energy efficiency and can be conveniently operated using an NFC-capable smart phone.
The helical, helical-bevel and shaft-mounted helical g500 gearboxes are now available in sizes of 45 to 600 Nm constructed in aluminum housings. In 2014, Lenze plans to release g500 gearboxes with up to 13,000 Nm ratings produced in cast iron. The g500 gearboxes can be combined with the Lenze Smart Motor, in addition to IE2 MH three-phase AC motors, the inverter-optimized MF motors, and the MCA and MCS servo motors.
The first is motor temperature. Temperature rise is described thoroughly in last month’s issue. The relationship between motor heating and current is a square function, and motor current draw is generally proportional to load. Heating is a function of current2 x resistance x time. This is usually referred to as current2 x time, or I2t. At SF loading, if current is 1.15 x rated, the heating effect will be 1.152 = 1.32 x normal. This roughly means that if the temperature rise at full load is 80°C (‘B’ rise) the temperature rise at 1.15 SF loading will be in the order of (1.15)2 x 80°C = 105.8°C (‘F’ rise). This is why most manufacturers design a motor to have a B rise or less at full load for a 1.15 SF motor.
[ASIDE: This clearly shows how a motor designed with a ‘B’ rise @ 1.15 SF, which is 90°C, is better than a motor with a ‘B’ rise @ 1.0 SF, because this motor with a ‘B’ rise @ 1.0 SF, loaded to 1.15 SF will have a temperature rise of 105.8°C.]
In general, Toshiba motors use an insulation system that is Class F (155°C) rated and has B rise or less @ 1.0 SF (80°C), and in the case of the EQP Global® series, all motors 445T frame and smaller have a B rise or less @ 1.15 SF. This means that the insulation will be well below design temperature of the insulation system even when operated at continuous overload up to 115% of nameplate. The smaller the motor frame, the larger the thermal margin, and the greater the overload a motor can handle. This is why you’ll often see motor manufacturers advertise as a 1.25 SF rating on the smaller frames. Furthermore, in the case of TEAO (Totally Enclosed Air Over) motors used in ventilation fans for the mining industry, the increased air flow from being mounted in the center of the fan (3000 ft./min.) often allows for 1.35 SF as standard.
The second issue is mechanical capability. Bearings are an important part of the mechanical capability and life of a motor. For every 15°C hotter that a bearing runs, the grease life is cut in half. Open-style bearings run cooler than sealed or even shielded bearings. When a motor is run into its SF, it runs hotter and consequently, so does the bearings. As a result, grease life, or re-greasing intervals, is reduced.
Shaft strength is another consideration when designing a motor with a SF capability. A 1.15 SF motor has a strong enough shaft to handle the additional continuous shaft load. Although this is not usually an issue with smaller HP motors, it becomes a real consideration on larger machines. Just because a motor is specified with a B rise at full load doesn’t necessarily mean that it is suitable to be rated as a 1.15 SF motor.
The preceding issues are concerned with sinusoidal operation. When an ASD is utilized, the motor sees additional heating over and above the I2t heating effect. This is due to the harmonic content of the drive’s output waveform. This additional heating can range from 5% extra heating for a good quality PWM drive with an adequately high carrier frequency to up to 30% additional heating for a square wave variable voltage inverter (VVI) drive. When using an ASD on a 1.15 SF motor, as a rule of thumb, you should now treat your motor as being a 1.0 SF motor, as a result of the heating from the ASD.
A 1.15 SF motor installed “across the line” can be operated at 1.15 SF. However, you will theoretically get a varying insulation life depending on the operational temperature of a motor on a specific application. For a fixed set of conditions on an application, the motor manufacturer with the largest thermal margin (difference between actual design temperature rise v. insulation class) will give you a longer insulation life span overall.
The g700 can be used in conjunction with Lenze’s synchronous and asynchronous servo motors, as well as a single gearbox with a servo motor. Designed specifically for servo application, the one-, two- and three-stage planetary gearboxes are available in five sizes and cover torques ranging from 177 in-lbs to 7080 in-lbs.
The special handling of the toothing edge, which includes grinding and honing, and the precise, balanced clamping system for the motor, help to minimize the noise generation. As a result, a noise of ≤58 dB(A) is achievable which corresponds to a quiet conversation.
The g700 is a gearbox with lowest life-cycle costs. The gearbox is robust and reliable and achieves a service life of 30,000h. It does not need lubricant change or top up and is completely maintenance-free.
“Our growing solutions portfolio is scalable and precisely tailored to the requirements of servo applications,” said Robert Gradischnig, electro-mechanical business development manager, Lenze.
“This new g700 planetary gearbox is another step forward in our ‘easy engineering’ philosophy. Whether they need products for relatively simple machine tasks or highly complex ones, our customers can easily find the right solution for their application.”
Friday, October 24, 2014
Most parameters in the real world are measured using sensors with analogue outputs sensors and Brainboxes ED-549 takes these real world signals and turns them into data on your network. As well as the popular 0-10V and 4-20mA input devices, there is now a Programmable Gain Amplifier (PGA) allowing full scale 12 bit readings from signals as small as ±75mV.Each of the 8 channels is individually configurable for voltage or current input with its own programmable gain.
The product particularly targets use in industrial process control environments such as water utilities, petrochemical, transportation and food and drink manufacturing, which require the constant remote monitoring of analogue signals such as temperature, weight, pressure and power supply. The device is also highly suited to locations where equipment is not easily accessible.
While some competitive analogue-input products are hard wired to handle either differential voltage or current inputs, the ED-549 offers enhanced flexibility by allowing both voltage and current measurements via user-selectable jumper-enabled resistors. Users can configure the inputs independently on each of the eight channels allowing any mixture of measurement channels, such as three voltage and five current inputs for example. While competitive products will often only allow a ±10V or ±5V measurement range, the ED-549 integrates a Programmable Gain Amplifier (PGA) that enables the device to offer measurement voltages as low as ±75mV full scale, With the built-in jumper enabled resistors for current measurement, the input ranges are ±20mA, 0 to 20mA or 4 to 20mA.
The ED-549 has a power input range from +5V to +30V DC, accommodating both the 24VDC factory floor supply as well as being able to be powered from any PC or laptop USB port. Dual power supply inputs allow a redundany connection which prevents downtime in the event of failure of either power supply There are three isolation domains: the analogue inputs; the power circuitry and the Ethernet port providing 1500V protection.
The ED-549 can be configured, monitored and controlledby a Windows computer via its very easy-to-use software interface allowing users to be up and running quickly without requiring any extensive programming or networking knowledge. Users can also monitor the factory floor from a smartphone or tablet via the product’s web-based user interface and the solution is also compatible with legacy software via a Windows COM port and industry-standard applications such as LabView, MATLAB and Agilent VEE.
Other features of the ED-549 include a compact 22.6mm-wide footprint, ideal when DIN rail space is at a premium; removable colour-coded and numbered terminal blocks that mean easy and simple installation; and a –30 to +80°C operating temperature range, which makes it suitable for deployment in harsh environments. The device arrives with its own calibration certificate where each voltage range has been individually factory calibrated by precision equipment whose calibration is directly traceable back to National Standards.
“Ideal for many different industrial applications that operate in harsh environments, the new Brainboxes ED-549 is a highly flexible, easy-to-use and configure industrial Ethernet device that delivers high-precision remote monitoring of independent voltage and current inputs,” said Eamonn Walsh, Managing Director of Brainboxes. “If you want to get industrial data live into your networked applications this is the product for you."
Monday, September 29, 2014
Ras az Zawr is a purpose built industrial city/zone on the Arabian/Persian Gulf coast in a region that is one of the richest natural and mineral resources areas in the world. One of the key activities within the Ras az Zawr zone is processing of phosphates for use in fertilisers. This involves phosphate concentrate being processed in a fertiliser production facility, consisting of a phosphoric acid plant, a sulphuric acid production facility, an ammonia plant, a DAP granulation plant and co-generation and desalination plants.
Outotec was successful in winning the contact for the sulphuric acid (SA) segment of the project, the largest production facility of its type in one phase in the World. The total investment in the production facility, which includes three SA plants, is approximately $240M. When complete, the three plants will have a total production capacity of 13,500 tonnes of sulphuric acid per day.
Due to the remoteness of Ras Az Zawr, and the possibilities for issues with multiple suppliers should problems occur, Outotec insisted on single suppliers for each element of the Sulphuric Acid project.
“We didn’t have a previous track record with Outotec in Germany, but we had already done business with the company – successfully - inugh there was no specific reference to this type of plant,” commented WEG General Manager Energy Business, Andreas Schulte M Brazil and Australia, althoesum. “However, our project management single contact, allied with single supplier argument was definitely the key to our winning the bid.”
The project started in 2006, and is only today nearing completion. To-date WEG Germany has supplied 21 Medium Voltage motors: 6 x MAW710 5200kW 4p 13,8kV 60Hz, 6 xMGW450 1400kW 2ph 4,16kV 60Hz, and 9 x HGF400 620kW 6p 4,16kV 60Hz. These motors are used extensively in mining, marine and oil and gas applications; they provide the high levels of efficiency, reliability and long life demanded in the challenging conditions encountered in the Arabian Gulf.
The MGWs and HGF type motors are used in the boiler feed water and circulation pumps of the sulphuric acid plant. The higher power (5,200kW) MAW units are slip ring motors that drive the main blowers in the plant. WEG decided to use slip ring motors controlled by liquid rheostat starters for this application as the blower inertia was large and starting current was an issue. The benefit of starting the main blowers in this way is that the customer can easily control the starting current of the blowers, at the same time handling the very high torques involved.
In addition to the motors and starters, a total of 24 WEG transformers are used to supply and condition electricity to all types of equipment across the whole SA plant, including the WEG MV motors. In common with the MV motors the WEG transformers are designed for use in some of the most demanding operating conditions worldwide in hydro electric plants, desalination systems, oil and gas installations, mining, marine and many more. As evidence of this, WEG recently manufactured and supplied 200-ton transformers – the largest step-up power transformers ever made by the company - for the World’s largest hydroelectric plant, Itaipu Binacional, on the Brazil/Paraguay border.
In terms of project support, WEG was active during the project management stage at Ras Az Zawr, managing three different suppliers, and also co-ordinated with Outotec to ensure that several technical modifications required by the main contractor were actioned promptly and with the required level of customer support. Now that the project is in its start- up phase, WEG is, once again, heavily involved, its co-ordination expertise and technical support being much in demand.
“Once again in a major Global flagship project, WEG has demonstrated its ability to provide a package of key products and the project expertise to integrate them at the highest level,” said Andreas Schulte Mesum, WEG’s General Manager Energy Business. “As a result of this, and other similar successes, no one can deny our credentials as a premier global supplier of integrated supply, control and automation solutions to key commodity markets across the World.”
WEG W22 High Efficiency Motors Chosen for Driving Pumps & Blowers in New Prestigious €21.5M Water Treatment Plant
The €21.5 million project to build the new EDAR Arroyo Quiñones sewage treatment facility was begun in November 2009 and is now nearing completion. The plant is ultra-modern; has a capacity of 45,705.60 m3/day, and serves 172,500 inhabitants in San Sebastian de los Reyes, a municipality in the community of Madrid.
Among the total of 100 W22 motors supplied by WEG Spain for the EDAR Arroyo Quiñones project are four 160kW machines for the blowers. These blowers were supplied by Aerzen – which add air to the biological and other processes: another three 15kW motors, also for blowers; four sludge recirculation pump motors of 15kW which were supplied by Sterling Fluid; and smaller denominations of motors for driving different processes right across the plant. The operation of these motors is mainly constant, but at different speeds, as determined by process requirements.
“We are obviously delighted that our high efficiency motors have been chosen for such a prestigious project,” said Javier de la Morena from WEG Spain. “The W22 motors have been supplied as part of OEM packages involving both pumps and blowers. They are used as standard fitment, because of their ability not only to deliver high levels of energy saving, but also reliability in what is a critical continuous process environment.”
The W22 motors deliver a highly efficient solution for addressing the 90% of total operational costs attributed to energy expenditure over the lifetime of typical motors used in pumping applications.
They deliver efficiencies above the minimum values specified in IEC 60034-30, the new harmonised IE (International Efficiency) grading standard for three-phase cage induction motors. A key factor in this improvement in energy use is the W22’s new and aerodynamic frame, which increases airflow and reduces operational temperatures.
“Today, electric motors account for as much as 65% of industry’s energy usage,” said Javier de la Morena. “Yet a huge amount of this energy is wasted, as organisations use solutions that are poorly designed, or inappropriate for their applications. By reducing this wastage with high efficiency motors such as the W22 line, companies not only meet their environment responsibilities, but also cut their costs and improve their profitability.”
As well as delivering high efficiency and reliable operation, the W22 motors are robust and built to last – highly important factors in the demanding conditions of sewage treatment plants. The motor housings, endshields, terminal boxes and fan covers are produced in WEG’s own foundries using high quality cast iron, ensuring maximum durability and high performance in aggressive environmental conditions. The fan cover is a new design that provides greater resistance against impacts, while the endshields have been designed to improve bearing heat dissipation.
Summing up, Javier de la Morena said that: “This one of the latest in a long line of major projects where OEM pump suppliers, have specified WEG W22 motors. Today, the same motors are used in some of the most prestigious pumping projects in the world: desalination plants, hydro electric facilities, irrigation systems, water and waste treatment plants, cavity pumping applications, oil extraction and major testing facilities - to name but a few.”
WEG is an ISO 14001 certified manufacturer, and has a truly global presence with representatives on every continent, in over 60 countries; and a network of 1100 service centres worldwide.
The WEG CFW100 Mini Drive has power ranges of 1/4HP, 1/3HP, 3/4HP and 1HP at 230 VAC with single-phase in and 1.5A, 2.6A and 4.2A three-phase output current. Its simplicity and flexibility are unsurpassed with design features such as built-in HMI, DIN rail mounting, detachable fan for easy maintenance and plug-in modules for communication and I/O options. All this in a size no larger than a typical panel contactor.
Programing is easy with the built in keypad that monitors two different parameters at the same time along with operation status, alarms and faults. A remote keypad CFW100-HMIR connected through a USB cable or remote serial connection for longer distances is also available. The CFW100 works with WEG’s Superdrive G2 programing control software, available free from WEG website.
A full complement of plug-in communication and I/O modules are available to meet most machine designer’s application requirements. A flash memory module is available to upload and transfer the drive parameters and PLC program to other CFW100 drives. Powered by internal batteries, the flash memory module has the capacity for over 5000 operations and can be used without applying power to the VFD. The module saves drive parameters and the PLC code directly from the Soft PLC feature. The CFW100 can interface using a USB connection, Bluetooth® or infrared wireless.
The built-in PLC enables the VFD to do much more than just turn a motor. Programing flexibility combined with network and I/O options make the CFW100 the most powerful drive of its size available. This built-in PLC often eliminates the need for an external PLC which reduces cost and optimizes space.
For a small compact package, the CFW100 is extremely robust allowing it to accept an overload of 150% for one minute, every 6 minutes in a 50°C ambient. This capability eliminates the need for the machine designer to oversize the VFD.
Along with all these features you also receive WEG quality advantages. Each CFW100 is tested under load at the factory, has protection against ground fault, short circuit and over temperature and all are manufactured with conformal coated circuit boards classified as 3C2 per IEC specification 60721-3-3.
WEG Electric is releasing its newest line of open three phase induction motors, available with standard frame sizes from NEMA 254T to L6808/09. Key features of these newly designed motors are their competitive cost, highly efficient cooling and lightweight and compact construction. In most applications a least one frame size smaller can be specified over a TEFC motor. In addition, for applications where the elements are a factor the W40 can be specified with WPI or WPII levels of environmental protection depending on the frame size.
This new motor design can be used in compressors, blowers, oil well and fire pumps and industrial refrigeration applications. All models meet or exceed NEMA standards as well international efficiency requirements.
The W40 motor line comes with standard features such as a rated output of 60Hz at 15 to 2,250 HP, either 2 or 4 pole models in NEMA frame sizes from 254T – L6808/09. Input voltage can be from 208 to 4,160V available with ODP (IP23) protection for frames 256T to L5810 and WPI (IP24) protection for frame L6808/09. As an option, models are also available with 5,000 – 6,000V, 6 or 8 pole, and WPI and WPII protection for frame sizes 5010 and up.
The ODP version of this new motor is an effective option for applications which do not need a high level of protection from the elements. Due to its open enclosure and new motor design it can achieve higher output levels when compared with TEFC motors. The result is a cost effective solution for driven equipment.
Also, new IEC 365, 400 and 450K/J as well as L5010 and L6808/09 frame sizes are available in the W40 motor line with both 50 and 60 Hz versions available with ratings from 600 – 2,250 HP. This represents a significant increase in output power with lower noise levels, improved mechanical stiffness and excellent heat dissipation. This new design enables WEG to now offer the W40 in both medium and high voltage versions, up to 6.6kV.
W40 motors come standard with ball bearings, grease nipples, Class F insulation and are suitable for inverter operation up to 460V. Optional features include, roller bearings (sleeve bearings above L5810), space heaters, an accessories terminal box, thermal protections, Class H insulation and are suitable for inverter operation above 575V. To further enhance its cool running and maintenance free operation, lubrication options are available such as an automatic lubrication system and external AEGIS SGR Ring.
Wednesday, September 24, 2014
LED light fixture is designed to provide interior lighting for an enclosure. Can be mounted to light channels in the top of an enclosure or on the front flange of most enclosures. Door activated adjustable switch, switch can be removed and relocated. Terminal block on each end of fixture, making it easy to wire and daisy chain multiple lights continuously. LED bulb with PVC frosted white protective light diffuser included. Housing made from steel and powder coated white. Units with convenience receptacle outlet are 120 VAC with ground 50/60 HZ. Without convenience receptacle outlet 100 to 277 VAC 50/60 HZ.
Monday, September 22, 2014
The Mini Bulk Fastening Power Block (mini BFPB) is available in multiple configurations to suit individual requirements. This product is ideal for power distribution options when terminating flexible stranded wire with crimp lugs or flexible bus bar. It accommodates din rail spacing, is available in 750 and 1500 amp models, and the modular construction allows for assembly of one or more terminal positions.
The Mini BFPB is suited for use across multiple industries including industrial controls, commercial HVAC, solar and oil & gas. This product offers SCCR 25kA rating with no over current protection device. Hinged covers are also available for added safety.
Friday, September 19, 2014
The new V200 Micro PLC CPU (pictured right) features one Modbus TCP/IP Ethernet port, two serial com ports for peripheral connections and one USB port for programming. As a server, the module can be programmed simply as intelligent I/O to a high level controller – only performing network control in the event of a network interruption. Client features of the port include master controller capability for small independent Ethernet networks. The V200 Series also includes native protocol for Toshiba’s Adjustable Speed Drives.
The V200 Series is used for machine-control, process skid-control and in any island of automation. The controllers also are UL rated for Class 1 Div. 2 hazardous locations. The advanced communications and instruction capabilities allow the V200 Series to be an ideal replacement for larger and more expensive programmable controllers.
The V200 Series features small-type micro controllers suitable for both simple relay replacement and complex control applications. The instruction set ranges from simple ladder logic to double length math, for-next loops, logic operations, comparisons and other advanced program control operations.
Red, green, blue, or any combination of the three display colors is possible, and screen colors can be determined by the status of the connected devices. The OIS42 PLUS features an RS485 port compatible with industrial devices. Built-in protocols allow for simple connection to Toshiba industrial products, including Toshiba’s adjustable speed drive (ASD) protocol.
The new OIS42 PLUS also features a built-in ladder logic editor which shares a tag database with the screens for creating interlocks and permissives. Language selection capability is also available for description of cryptic trip and alarm codes from ASDs and other industrial devices. Attached I/O includes 8 DI, 8 DO, 2 AI, and 1 AO. Options include four configurable 100 kHz HS inputs and two configurable 100 kHz HS outputs.
Toshiba OIS products are renowned for reliability and versatility. The range of Toshiba OIS options are easily integrated into most common systems, while offering intuitive display options navigated by keypad or touch screen. Operators depend on Toshiba OIS products to monitor current system conditions via text- or graphics-based displays and initiate changes as necessary.
ENERGY STAR is a federal initiative created by the EPA and the U.S. Department of Energy to help consumers to identify quality products that meet strict energy-saving guidelines, as well as to protect the environment through energy-efficient products and practices. The entire G9000 Series product line was recognized as meeting the stringent standards set by the EPA for ENERGY STAR compliance.
The Toshiba G9000 UPS is purpose-built from the ground up to allow for flexible, custom installations for data centers, co-locations, call centers, and financial institutions. Using Toshiba IGBT technology in the
rectifier/converter, DC/DC chopper, and inverter sections, G9000’s double-conversion topology provides an AC/DC/AC efficiency of up to 97% at loads from 50% to 100%. Even at 20% loading, the efficiency remains greater than 95%. This industry-leading performance makes the G9000 the perfect solution for redundant parallel systems where loads are typically 25 to 40%. This energy-efficient design of the G9000 significantly lowers operational expenses to operate a UPS, in comparison to traditional requirements. The efficiency testing involved rating the 1000 kVA G9000 Series not only by its maximum achievable efficiency, but by a weighted average of its efficiency across its entire load range.
“The Toshiba G9000 UPS has become the industry benchmark for efficiency and reliability among data center uninterruptible power systems,” said Erik Monisera, G9000 Series product manager. “We were certain that the 1000 kVA unit would satisfy Energy Star’s stringent efficiency requirements given the proven performance of the existing models, which it in fact exceeded by 1.9% over the required 94%.”
The all-IGBT design of the G9000 Series also eliminates the need for a front-end harmonic filter and produces less than 3% input current total harmonic distortion. The exceptional dynamic response of its inverter eliminates the need for an output transformer, improving efficiency and reducing weight, noise, and total footprint. They feature an input power factor greater than 0.99, a wide input voltage range of 15% to -20%, and an output power factor rated at .9 (100-225 kVA) or unity (300-1000 kVA). The G9000 supports 100% unbalanced loads and 100% step-load changes without battery discharge, and is equipped to support monitoring adapters utilizing SNMP, MODBUS, and other protocols. These large capacity units also come with Toshiba's industry-leading three-year onsite warranty.
Wednesday, September 17, 2014
The RK46C-VarOS object sensor is a retro-reflective photoelectric sensor which, unlike normal sensors that detect selectively, detects objects over a 50 mm band area. In packaging systems and intralogistics, the object sensor detects objects in the light-band with various sizes and shapes as well as surfaces with openings. In the past, multiple sensors and considerable work was necessary for this purpose.
Adjustable sensitivity levels and automatic sensitivity readjustment (ALC) support high system availability in the event of soiling and changing environmental conditions – even stretch-wrapped or shrink-wrapped objects are reliably detected. The special lens enables reliable detection over the entire light-band width in two adjustable sensitivity levels (8 and 12 mm). Common parts from standard sensor technology and compatibility with established mounting systems considerably simplify mounting of the variable object sensor and bring a noticeable price advantage.