AKEP Solutions for Cement Plant

LIQUID STARTERFOR SLIP RING MOTORS

FROM 250kW to 10.000kW

AKA solution

AKA developed a robust and reliable range of liquidstarters suitable for heavy duty applications such asmines, cement plants, shredders or conveyors.Since 1990 AKA focused in improving its starterperformance so it can meet very specificrequirements for special applications. Thanks to R&Deffort, AKA achieved unprecedented starting resistanceratios, up to 150.

The issues

Wound Motors offer the possibility to adapt motorstarting characteristics to the driven load) byadjusting the secondary motor resistor.AKEP Liquid starters with their continuous resistancevariation were designed to progressively start a widerange of large slip ring motors (stepless) compared tomultistep resistor systems specifically designed forone application.Liquid resistance can be easily adapted for a specificneed as motor replacement.

SMOOTH START WITH HIGH TORQUE

AKEP advanced features

Best performances up to 150 ratio

Optimum control over starting current, torque &motor load acceleration

AKAMAS: device which measures the torque &speed in real time (option)

Modular construction

Expertise in liquid starter applications:

AKA will adapt and configure AKEP to specialrequirements and applications

Key benefits

Robust, simple and reliable

Stepless thanks to a continuous variation ofthe resistance

Easy to adapt to different motor

Cost effective: One shorting contactorcompared to multi stage metallic resistors withmultiple contactors for traditional starters

Low maintenance costs (minimizes shocks, andenergy usage)

For applications in which the load presents a high starting torque and/or a low starting current, the wound motor(slip ring motor) provides unique starting characteristics.

Starting is smooth, without anymechanical shocks and startingcurrent can be limited to very lowvalues.

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

Tank

Four tanks to cover the range made out of steel orStainless steel 304 (option).Tank can be custom designed for specific applications.Tank wall thickness: 3mmVolume : 750L, 1500L, 2500L, 4500LTank Protection : IP42

Panel

Three types of panels to suit the shorting contactor:1, 2 and 3 doors panel. Panel protection: IP56

MODULAR CONSTRUCTION FROM 250kW TO 10.000kW

Electrode drive mechanism

It is the heart of the liquid starter. It consists of ageared motor, a screw and nut moving a set of mobileelectrodes.

The drive mechanism is a mechanical assemblyindependent of the tank that can be taken off formaintenance .

Electrodes

Two material for electrodes are available :

Stainless steel for standard applications.

Cast alloy for heavy duty applications

Resistance Ratio: 150 (option)

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

Resistance ratio

It defines the liquid starter : Rmax/Rmin

Standard Ratio: For basic application as cement plants with driven loads as Ball Mills, Raw Mills, Crushers, Fans …

Ratio 150: For high performance applications as mining operations and driven loads as : mining Ball mills, Sag mills, Conveyors, Shredders

The two technology differs mainly by the design andtechnology of the electrodes.

Principles

The secondary liquid resistor is connected to the sliprings of the motor. Resistor is constituted by theelectrodes and the electrolyte in the tank. Theelectrodes’ drive mechanism moves the electrodesmodifying the value of the resistance.During start up the resistance value is reduced fromRmax to Rmin.

Rmax when electrodes are in “Ready to start”, up position.

Rmin when electrodes are lowered and reach down position, “End of start”

SLIP RING MOTOR STARTING

Standard ratio High performance ratio= 150

The announced ratio’s are measured on site in real operations

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

Conveyor Belts

Are characterized by a specific starting process like:Pretension of the belt at 5% FLTAutomatic adjustment of startup unloaded orloaded: 50% to 150% FLT depending on beltmaterial, at optimal starting time.Constant torque startup: at a preset value at120% FLTCreep speed at 15% of belt speed (85% slippage)It may require a heat exchanger.

Dual Starters

For large applications it is quite usual to find two orthree motors driving a common load. The conditionsfor proper operation are the following:

Common resistorResistance variation strictly identical: electrodesposition synchronized by chain.Common short circuit contactorAKAMAS monitoring measure in real time rotorcurrents of both motors and activate pre-alarm ifthe differential current value is greater than thatpreset.

Dual drives are designed either with 2 tanks or with 1single tank containing 2 sets of electrodes.

SPECIFIC APPLICATIONS

Slip recovery system

AKA Liquid Resistance Starters is designed to workwith Slip Energy Recovery systems.

Heat exchangers

This option is available for any application thatrequires frequent starts that generates substantialheat in the tank.

Shredder drives

A dynamic torque adjustment is necessary to preventHV motor stall. The optional AKAMAS is thencommonly used to control the AKEP liquid starter,adjusting the rotor resistance based on the torqueand slippage it calculates.

Torque and Speed real time measurement

AKA developed this powerful digital system able to measure with great precisionrotor currents whatever the frequency (50Hz or 60Hz to 0.1Hz during startup) aswell as motor speed. It computes motor slippage and frequency too. The AKAMASis an unparalleled device which shows exactly what is happening in the motorduring start up. It interfaces with the AKEP. The starting torque or current canthereby be adjusted to safely meet the requirements.

AKAMAS

Starting simulation tool

A simulation tool running on PC is available to validate and evaluate theperformance of the system before its implementation.

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

Single drive

AKEP RANGE

Starting CharacteristicsAmbient

TemperatureAK10 EP AK15EP AK25EP AK45EP-P

Starting Torque= 120%Starting Time = 20sec

40°C 2.000W 3.000kW 5.000kW 10.000kW

Starting Torque= 120%Starting Time = 30sec

40°C 1.500kW 2.700kW 4.500kW 8.000kW

Starting Torque= 120%Starting Time = 20sec

50°C 1.500kW 2.700kW 4.500kW 8.000kW

Starting Torque= 120%Starting Time = 30sec

50°C 1.000kW 2.000kW 3.200kW 6.200kW

Volume 1000 L 1500 L 2500 L 4500 L

Dual drive

Starting CharacteristicsAmbient

TemperatureAK25 EP

DUALAK45EP

DUAL2 X AK45EP

DUAL

Starting Torque= 120%Starting Time = 20sec

40°C 2 X 3.000kW 2 X 5.000kW 2 X 10.000kW

Starting Torque= 120%Starting Time = 30sec

40°C 2 X 2.700kW 2 X 4.750kW 2 X 8.000kW

Starting Torque= 120%Starting Time = 20sec

50°C 2 X 2.700kW 2 X 4.125kW 2 X 8.000kW

Starting Torque= 120%Starting Time = 30sec

50°C2 X 2.000kW 2 X 3.125kW 2 X 6.200kW

Volume 2500 L 4500 L 9000 L

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

3 starts from cold and 2 starts from hot

www.aka.fr

AKEP DIMENSIONS

Dimensions D L L* H H*

AK10 EP 1 200 mm 925 mm 1 949 mm 2 037 mm

AK15 EP 1 637 mm 1 460 mm 1 964 mm 2 052 mm

AK25 EP 1 837 mm 2 110 mm 2 304 mm 1 964 mm 2 049 mm

AK45 EP 2 037 mm 2 861 mm 3 055 mm 1 964 mm 2 051 mm

L* Dimension with pump system

H* Dimension with “sun roof” option

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27

Since its creation in 1988 AKAcontinuously innovated in order tostrengthen its position as a significantEuropean manufacturer of powerelectronics and motor control. Byfocusing on Research and Development,AKA has built up know-how in thecontrol of electric motors. Thedeveloped products are competitive onnational and international markets andexports account for more than 85 % ofturnover.

More than 800 AKEP are in operation worldwide in Cement and Mine plants

THEY TRUST US

AKA AutomatismesZAC du bois Chaland15 rue des Pyrénées, 91090 LISSES+33(0)1 60 76 15 55+33(0)1 64 97 84 27