VFDs

Every AC motordeserves a Vacon drive

Jaykumar & Rohan Sharma, Vacon India

Vacon variable-speed AC drives,a choice of clean technology

AC drives provide stepless control of the rotation speedof electric motors, reducing the load on the electricity network and the mechanical stress on machinery when starting a motor.

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16/04/2010 2

starting a motor.

AC drives make it easy to connect electric motors to automation systems.

AC drives allow considerable energy savings to be achieved, and they can be used to help generate energy from renewable sources. These two benefits also help to reduce carbon dioxide emissions.

2000First products launched of the

2005Production starts in China.

2007Vacon 10,the first product of the third generation product range

Acquisition ofTB Wood's completed.

2008

The saga continues.

2009

The Vacon saga

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1993Founding charter of the Vacon Group signed on9 November 1993.

1995First products of the Vacon CX range launched.

Factory opening at Runsorintie 5 in Vaasa.

The first subsidiaries founded in Germany and

Sweden.

launched of the second product range, Vacon NX.

Listing on the Helsinki Exchanges.

product range launched.

Vacon in brief

Vacon is driven by a passion to design, manufacture and sell only the best AC drives on the planet — and nothing else.

AC drives can be used to control electric motors or to help generate power from renewable sources.

R&D and production units in Finland, the United States, China and Italy, and sales offices in 27 countries.

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In 2009, Vacon had revenues of EUR 293.2 million and globally employed ca 1,200 people.

Vacon's shares (VAC1V) are listed on the Helsinki Stock Exchange.

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Energy-saving technologies

We are more and more dependent on electricity. It is estimated that the energy consumption will increase by 50% between the years 2005–2030. The consumption of electricity is estimated to double at the same time.

65% of the electricity is produced by burning fossil fuels (oil, coal and gas), creating a lot of CO2 emissions.

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All technologies that are capable of reducing the consumption of electricity are needed. AC drives are one of the technologies that brings energy-saving benefits and helps preventing the climate change

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Global with strong local presence

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Vacon Plc

Production

Sales offices

Finland factoryCapacity: 500,000 units/year

Production area: 17,000 m2

350 persons

Products:

Production of Mid-, High-End and Mega power range products

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and Mega power range products

New product ramp-up

US factoryChambersburg, PA, USA

Standard AC drives

Manufactures more than 150,000 units

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Italian factoryNaturns, Italy

Electronics design, assembly and testing

Custom-made AC drives

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VACON INDIA

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HS. Ramesh

Asha

J. Ramesh

Jisha

Thilagavathi

DirectorProduct Mgmt Rohit

Sr. ManagerCommercial (Finance a/cs & logistics)Udesh

Vacon India Managing Director: Shailendra Salvi

HVAC & WaterKAMHoneywell & VeoliaJaykumar

MarineKAM Metso & L & TVispute

Service

Engg & Order HandlingVenkatesh

SalesShailendra Salvi

ManagerHR & AdminBavani

Director Solution Sales & MarketingSyed Nazeer

ServiceSanthanam

DivyaSales SouthRam

Channel Mgmt Jaykumar

SwethaMuraleeSyamala Rao

AnilVenugopalRahul Srivatsav

Ram Kumar

Steel &MiningKAM Converteam & KECRam

DistributorVacon10Jaykumar

Power

Nazeer

ServiceSanthanam

Production & TestingRohit Shah

Sales EastNazeer

Sales NorthJaykumar

Rohan Sharma

MiteshVisputeJaykumarSandeep Thakur

Sales WestSalvi

Sudip SahaShakil

JayaramPrakash (Bangalore)Chandrabhan (Bhilai)Vipul (Ahmedabad)Shafiullah (Bombay)Sridharan (Delhi)Yuvaraj (Kolkatta)Sababathy (Pune)Himachalam Anil Cheriyan

SathishSree RamManjunathPraveenNagappa (Testing)

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• Headquartered in Chennai

Facilities in Chennai

• Design & Engineering of Drive Systems

• Warehouse

• Training

• Service Centre

• Sales & Service Offices in Chenani

Vacon India

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• Sales & Service Offices in Chenani

Delhi, Mumbai, Pune, Ahmedabad,

Bhilai, Vizag, Bangalore, Kolkota,

Ludhiana, Hyderabad

• Factory: Bangalore

• Repair Centre: Chennai, Bangalore

• Employees:41

12

Vacon India factory at Bangalore

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Key customers

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Driven by Drives

Applications, Products & References

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MiningMachinebuilding

Powerstations

Marine andoffshore

Pulp and paperFood andbeverage

Motorindustry

Rubberand plastics

Typical industrial segments

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Buildingindustry

Water andwaste water

Chemicalindustry

Oil and gasindustry

Renewable energyresources

Cement Industry

Raw Mill feeding belt conveyors

Air separator for Coal Mill & Raw Mill

Booster fan for RawMill & Coal Mill

Coal Mill Bag Filter fan

Typical Cement Industry Applications

Screw FeedersCement Mill classifier

MotorCement Mill Booster

FanReject Belt conveyor

Raw Mill

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Cooler Grate Fans & Cooler ESP fans

Primary air fans Apron Feeders Drag Chain Conveyors

Rotary Kiln Main Drive, 690V Raw Mill Bag House Fan, 690V

Complete Product Portfolio

MULTI-PURPOSE AC DRIVESVacon NXS 0.75 – 200 kW

Vacon NXS

standalone 200 – 560 kW

Vacon 500X 4 – 132 kW

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INDUSTRIAL AC DRIVESVacon NXP, air-cooled 0.75 – 3250 kW

Vacon NXP, liquid-cooled 5.5 – 5300 kW

Vacon NXC, enclosed 110 – 3250 kW

Common DC bus

components up to 5300 kW

Vacon NXS

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Designed for typical heavy industry applications such as conveyors, mixers, pumps and fans

Easy to use ”All in One” software package – minimized amount of parameters for all demands

High performance open loop vector control208...240 V

Vacon NXS

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208...240 V

(3-phase supply)380...500 V 525...690 V

Power range0.55/0.75 ...

75/90 kW (230 V)

0.75/1.1 ...

355/400 kW (400 V)

2.2/3...

500/560 kW (690 V)

Protection classIP21, IP54,

Nema 1, Nema 12

IP21, IP54,

Nema 1, Nema 12

EMC class H, T H (wall mounted)L (stand alone), T, C

L, T

IP21, IP54,

Nema 1, Nema 12

20

Vacon NXS Family Overview

IP54

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FR10

Maximum nominal power in mechanical size at different voltages

230V 3 kW 7.5 kW 15 kW 30 kW 55 kW 90 kW

400V 5.5 kW 15 kW 30 kW 55 kW 110 kW 160 kW

500V 7.5 kW 18.5 kW 37 kW 75 kW 132 kW 200 kW

690V - - 30 kW 45 kW 110 kW 200 kW

FR4 FR5 FR6 FR7 FR8 FR9

IP21

FR11

250 kW

355 kW

400 kW

- -

400 kW

500 kW

560 kW

21

Standalone Vacon NXS drive IP21/(IP54)

A compact drive for the upper power range

Ready to install

Integrated filtering for EMC level L

Integrated aR fuses as standard

Integrated load switch as option

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FR10

IP21/IP54

FR11IP21

400 V 250 kW

355 kW

400 kW

500 V

400 kW

500 kW

690 V 560 kW

Maximum nominal power in mechanical size at different voltages

FR10 IP54

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Temperature controlledcooling fan, easy replacement

Cooling channel isolated from electronics

Robust structure/frame

Removable display panel

Vacon NXS – Everything required for high reliability and flexibility integrated in compact dimensions

All units protected against water drips and mechanical particles (IP21 and IP54)

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structure/frame

Integrated EMC filter as standard for both industrial and public networks

Integrated AC choke as standard

Modular design to fulfill all EMC regulations (Faraday cage)

High voltage separated from control unit

Standard control I/O

Option board slots

Power terminals

Integrated brake chopper availablefor all sizes (standard up to 30kW)

23

Terminal Defaults settings Programmable

21 RO1

22 RO1 RUN Many possibilities

23 RO1

24 RO2

25 RO2 FAULT Many possibilities

26 RO2

+24 V GND

230 VAC

N

Vacon NXS Standard I/O


1 +10V Reference voltage

2 AI1+ Frequency reference 0-10 V -10 - +10 V, 0/4 -20 mA

3 AI1- AI common (GND) Differential

4 AI2+ Frequency reference 4-20 mA 0-20 mA, 0/-10 V – 10 V

5 AI2- AI common (differential) GND

6 +24V Control supply (bidirectional)

7 GND I/O Ground

8 DIN1 Start forward Many possibilities

9 DIN2 Start reverse Many possibilities

10 DIN3 External fault input Many possibilities

11 CMA Common for DIN1 – DIN3 (GND) Floating

OPT-A1

1...10 kΩ

OPT-A2

OPT-A3

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11 CMA Common for DIN1 – DIN3 (GND) Floating

12 +24V Control supply (bidirectional)

13 GND I/O Ground

14 DIN4 Multi-step speed select 1 Many possibilities

15 DIN5 Multi-step speed select 2 Many possibilities

16 DIN6 Fault reset Many possibilities

17 CMB Common fot DIN4 – DIN6 (GND) Floating

18 AO1+ Output frequency (0-24 mA) Many possibilities

19 AO1- AO common (GND) 4-20 mA, 0-10 V

20 DO1 READY, I ≤ 50 mA, U ≤ 48 VDC Many possibilities

mA


21 RO1

22 RO1 RUN Many possibilities

23 RO1

25 RO2

FAULT Many possibilities

26 RO2

28 TI1+ Thermistor Warning,

29 TI1- input fault no response

+24 V GND

230 VAC

N

PTC

24

Vacon NXS Modularity

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• 5 option board slots (A, B, C, D, E)

• Slots and boards are hardware coded

• 2 slots occupied by standard I/O

25

26

Card typecode Card slot I/O signal

A B C D E DI DO DI

DO

AI

mA

±V

AI

mA

isol

AO

mA

V

AOmAisol

RO

NO

NC

RO

NO

+10V

ref

Therm

+24

EXT

+24V

Pt100

42-240

VAC

input

NOTE

Basic I/O cards (OPT-A)

OPT-A1 6 1 2 1 1 2

OPT-A2 2

OPT-A3 1 1 1

OPT-A8 6 1 2 1 1 2 1)

OPT-A9 6 1 2 1 1 2 2,5 mm2

terminals

I/O expander cards (OPT-B)

OPT-B1 6 1 Selectable DI/DO

OPT-B2 1 1 1

Vacon NXS Option Boards

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OPT-B2 1 1 1

OPT-B4 1 2 1 2)

OPT-B5 3

OPT-B8 1 3

OPT-B9 1 5

Fieldbus cards (OPT-C)

OPT-C2 RS-485 (Multiprotocol) Modbus, N2

OPT-C3 Profibus DP

OPT-C4 LonWorks

OPT-C5 Profibus DP (D9 type connector)

OPT-C6 CANopen (slave)

OPT-C7 DeviceNet

OPT-C8 RS-485 (Multiprotocol, D9 type connector) Modbus, N2

OPT-CI Modbus/TCP (Ethernet)

OPT-CJ BacNet (RS-485)

NOTES: Allowed slots for the board are marked in blue.1) analogue signals galvanically isolated as a group, 2) analogue signals galvanically isolated separately.

Software ModularityWater Solutions Applications

• MultiMaster PFC

• Level Control

• MultiFollower PFC

Special Applications

• Fire mode PID

• High speed 1900 Hz

• Etc.

Local / Remote

Multi-step Speed

PID Control

Standard

(Start-up Wizard)

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All-in-One Applications

Multi-purpose

Pump and Fan Control

Basic

Minimized amount of parameter settings for all demands

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Vacon NXS Keypads

Alphanumeric LCD display panel with clear text display as standard.

Full graphic LCD display with support for Cyrillic and Chinese letters as option.

Features: Start-up Wizard, Multi-Monitoring, Default page, Copy Function, Back-up Function, RS-232 communication

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NX G_PANNX A_PAN

Start-Up Wizard

Common Settings Application Specific Settings

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Common Settings Application Specific Settings

Ready !!

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Vacon NXP IP00 Drive Modules

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High Power NXP IP00 Converters

Designed for easy cabinet installation:

– Control, power electronics and cooling integrated in one compact unit

– Low weight of power module as AC chokes are external

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EMC versions N and T

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FR10-FR12

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Robust IP00 module design

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Feature:

Complete drive modules + AC chokes

380-500V/525-690V 50-60Hz networks

Integrated brake chopper (option)

Segregated cooling air channel

Varnished boards

Robust connections (bus-bar type)

Integrated or external control part

Advantage:

Easy cabinet design, chokes can be elsewhere

No settings needed, ideal for global OEM

Space saving, cost efficient

Reliabilty: humidity, aggressive gases

Reliabilty: humidity, aggressive gases

Connections are not limiting cable selections

Flexibility in cabinet design

FR10 FR11 FR12

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FR13-FR14

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FR13 / FR 14 IP00 Units

2xFI9 3xFI93xFI9FI13 FI13

FI14

Max. 1180A 6p/12p Max. 1450A 6p

Max. 1450A 12p

1500A/690V 6p

Max. 2250A 6p/12p

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4xFI9 3xFI9FI13 FI14

FR13 FR14

380-500V 1450A 2150A

525-690V 1180A 2250A

The FR13/14 construction is based on rectifier units and inverter units,the number of rectifier units depends on current rating and 6 pulse or 12pulse

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Inverter unit FI13IP00 module

DC-pulse supply

External control part

Types used in FR13:

– NXI1150 5 - 630kW

– NXI1300 5 - 710kW

– NXI1450 5 - 800kW

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– NXI0920 6 - 900kW

– NXI1030 6 - 1000kW

– NXI1180 6 - 1150kW

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Inverter unit FI142xFI13 IP00 modules

DC-pulse supply

External control part

Types used in FR13:

– NXI1770 5 - 1000kW

– NXI2150 5 - 1200kW

– NXI1500 6 - 1500kW

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– NXI1900 6 - 1800kW

– NXI2250 6 - 2000kW

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Other Components

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Input Chokes

3 5 0

3 0

1 5

1 5 0

2 7 5

1 1 1

3 3 3

2 2 2

2 3 83 9

1 4 0

2 6 2

1 2 0 1 2 0

15

30

150

275

1 1 1

2 2 2

3 3 3

206

39

230

108

min. 19mm

120 120

354

460A261A

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497

40

20

1 1 1

3 3 3

2 2 2

200

165 165

204

43

0145

244

520A

Note !Tappings

Heat Loss:261A 460W400A 570W520A 810W650A 890W

650A

39

Cabinet Mounting

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FR13 / FR14 Cabinets

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Vacon NXP Common DC bus Products

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Common DC Bus – High configurability

43

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Typical common DC Bus drive system Supply unit(s) depending on system total power requirement

Motor inverters depending on load of specific motors (process requirements)

=FRONT

COMMON DC BUS

INVERTER INVERTER INVERTER

BRAKE CHOPPER

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~ =~

M

=~

M

=~

M

=~R R

FRONT END *

AC SUPPLY

*) Front end can

be either AFE

or NFE

Where to use Common DC bus systems?Production linesin various Process industries

Braking needed often- Winding machines- Cranes

- Winches- Roller tables

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- Roller tables- Sugar centrifuges

Braking needed rarely- Small production lines- Small paper machines

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Complete range C’n DC productsAir Cooled units, 3-2250A, ~1-2000 kW

465-800 VDC640-1100 VDC

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46

FR4 FR6 FR7 FR8 FI9 FI10 FI12 FI13 FI14

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Front Ends – Technical Comparison

47

Front Ends → AFE

Features ↓ Active Front End

Technology IGBT

Type Regenerative

Switching frequency 1,5-3,6 kHz

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DC Voltage 1,35x1,1xUs

THDi < 5%

Line filter LCL

Charging External

Paralleling Yes

AFE - Basic

Regenerative low harmonic rectifier module

Based on IGBT technology

AFE module HW = INU module HW

– switching frequency = 3,6 kHz

LCL-filter on line side is necessary

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LCL-filter on line side is necessary

No additional line voltage measurement needed

AFE-modules can be connected in parallel in order to increase the power

– each AFE are working independently, the load sharing is determined by drooping

– no additional measurement or connection between modules needed

– redundacy

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NFE*

3

FFE*

3

AFE*

* alternative2 2 2

AFE+INUs

• Regenerative operation is required

• Low THD level is required

• Paralleling possibility

• Redundancy

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2

3

INU

2

3

INU

2

3

INU

2

2

BCU

Common DC bus

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AFE – Redundancy

Better redundancy can be acheaved if AFE units are connected parallel. A module can be stopped or started in any time.

– No additional measurements are needed

– No communication between modules is needed

– Different power sizes can be connected parallel

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50

Typical AFE unit connection

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AFE - Modules 380-500V and 525-690V

1. Single Modules 380-500V

– Fi9 220kW

– Fi10 388kW

– Fi13 1095kW


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– Fi9 198kW

– Fi10 378kW

– Fi13 1199kW

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AFE – CURRENT RATINGSSupply voltage 380-500VAC

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Supply voltage 525-690VAC

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VACON NXP The Compact and Flexible Hot Standby Configration

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Redundancy of the system

The units working in parallel with Vacon DriveSynch have high level of redundancy. The system could be made to continue its operation even if any of the follower unit is non-functional.

The master drive unit and the fast drive to drive optical communication has to be functional for the Vacon DriveSynch functionality. The auxiliary power (+24V) must be continuously provided for the all the control units including the non functional drive units in Vacon drive synch system by UPS.

It is also common practice to use (n+1) units, where n is the number of required units for full functionality of the system. In this case, 100% redundancy is possible even if any one of the follower is non functional. Maximum number of units in Vacon Drive Synch configuration is

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follower is non functional. Maximum number of units in Vacon Drive Synch configuration is however four.

In the event of one unit non- functional , the system will continue to deliver without interrupting 3x 460A= 1380A, In case if the load is more than 1380A then drive will séance the over load and drive will try and match the load by reducing RPM automatically to the max 1380A. And the system will continue to be in operation.

In Case of Hot redundant The DC BUS will not be shorted, Only in the case of Multi motor Motoring and Generating and Braking in combination .

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Patented Drive Sync technology for Hot Standby

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HOT STANDBY

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HOT STANDBY

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Typical scheme

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Vacon NXP - Topology and Enclosures example

1.6 MW

Motor current = 1637A

NXP04606A0N0SSAA1A2 460 X 4 = 1840A

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NXP04606A0N0SSAA1A2 460 X 4 = 1840A

All four units conected on Hot standby with UPS control supply.

0.65 MW

Motor current = 726A

NXP03856A0N0SSAA1A2 385 X 2 = 770A

Both units conected on Hot standby with UPS control supply.

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Vacon NXP - Topology and Enclosures example

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NXP03856A0N0SSAA1A2

DoubleOutput

385 X 2 = 770A

M

NXP04606A0N0SSAA1A2

DoubleOutput

460 X 4 = 1840A

M

X 4 = 1840A Plus input Braker

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VACON INDIA REFERNCES

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VACON India References in Cement IndustryCLIENT PLACE APPLICATION RATING QTY

L&T C&A - A/c. ACC Wadi-Plant III

Mumbai Kiln 650kw/690V 2

L&T C&A - A/c. FLSmidth-Orient Cement

Mumbai Kiln 1500kw/690V 1

ACC Limited – Wadi Wadi Fan 355kW 4

ACC Limited - Wadi Wadi Pump 7.5kW 1

ACC Limited - Wadi Wadi Grate Cooler 7.5kW 1

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ACC Limited – Jamul Jamul ID Fan 75kW 1

ACC Limited -Madukkarai

Madukkarai Slurry Pump 22kW 1

ACC Limited - Mancherial Mancherial Kiln132kW (using existing

Slip Ring Motor)2

ACC Limited - Tiakaria Tikaria Fan 110kW 1

ACC Limited - Chaibasa Chaibasa Conveyor 37kW 1

ACC Limited - Kymore Kymore Various 200kW 10

ACC Limited - Sindri Sindri ID Fan 45kW 1

VACON India References in Cement Industry

ACC Limited - Gagal Works

Gagal

Cooler Fan 75kw 7

Cooler Fan 110kw 1

Cooler Fan 160kw 2

Toshali Cements (Bayyavaram Unit)

Hyderabad Ball Mill 355kw 1

Kakatiya Cements A.P Fan 45kW 2

Kakatiya Cements A.P Boiler Feed Pump 315kW 3

My Home Cements A.P Pump 75kW 3

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My Home Cements A.P Pump 75kW 3

My Home Cements A.P Pump, Fans110kW250kW

13

Mysore Cements Mysore 55kW 2

Penna Cements – Export Order (Pioneer Cement)

Dubai Fans 360kW 2

Priyadarshini Cements A.P ESP Fan, Apron Feeder 55kW, 7.5 kW 2

Madras Cements Ariyallur Fans 110kW till 425kW 15

VACON India References in Cement Industry

CLIENT PLACE APPLICATION RATING QTY

Vasavadatta Cements Fans 160 kW & 30 KW 2

Saurashtra Cements Gujarat Coal Feeder & Fan 11 kW & 132 kW 2

Sidhigram Cements Gujarat Fan 90 kW 3

Manikgarh Cements Chandrapur Compressor, Feeder 160kW & 30 kW 2

Malabar Cements Kerala Fan 75kW 1

Gujarat Sidhee Cements Gujarat Fan 75kW 5

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Gujarat Sidhee Cements Gujarat Fan 75kW 5

Gujarat Sidhee Cements GujaratID Fan, Fuel Feeder, Centrifugal Fan, Coal & Fuel Feeder

160kw, 132kw, 90kw, 75kw, 37kw, 11kw, 3kw

7

Dhar Cements Indore Apron feeder, Pump 4kW, 110kW 2

Chettinad Cement thru Holtec

Karikali Various applications3.7kW till 1300kW

90

Madras Cements Ltd Ariyallur Fans 110kW – 425kW 15

Vacon India High Power References

Customer Total VFD

ACC Wadi Power plant – ID FD SA PA - 75kW to 355kW – 32drives 2.5MW

Chamundeswari Sugars – ID FD SA PA and BFWP 5.5kW and 75 to 560kW – 31nos 3MW

Department of Atomic Energy – FD 250kw – 4nos ( 12 Puls trafo & motor) 1MW

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Doodganga Sugars – ID FD SA & PA 75kW & 250nos – 6nos 1MW

Himatsinga – ID FD SA PA and BFWP ,fuel feeder 5.5kW to 380kW – 31nos 2.5MW

Hindalco – ID and FD 120kW & 160kW – 2 no. each 0.5MW

Ind Bharat – ID FD SA PA and BFWP 410kW to 710kW – 21drives (all 12 puls 690V) 14MW

Kakatiya – ID FD SA PA and BFWP,V 3.7 and 45kW to 315kW – 35nos 2MW

66


Customer Total VFD

Utkal Alumina (Aditya Birla Group) – ID FD SA PA and BFWP 550kW – 15drives (all 12 pulse 690V) 9MW

Nandi Sugars – ID FD SA PA 75kW & 160kW – 5nos 1MW

NBVL, Paloncha, Orissa, Dharmavarm – ID ,FD & BFWP 55kW to 355kW – 55nos 3MW

RR Ispat - – ID ,FD & BFWP 55kW to 900kW – 55nos 6 MW

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Saradamibka – ID and fuel feeder 5.5kW & 250kW – 12drives 1MW

Sri Metalic - – ID ,FD & BFWP 55kW to 900kW – 45nos 3 MW

The Madras Alunimum Co. Ltd., (Vedanta) CT 160kW – 6nos 1MW

The Madras Alunimum Co. Ltd., (Vedanta) ID and FD 132kW & 160kW – 9+9 nos 2MW

TNPL Power Plant - ID FD SA PA and BFWP fuel feeder 2.2kw and 37 kw to 580kw ( 12 puls and 6 puls with Trafo) 3MW

Ugar Sugars Limited., ID FD SA and BFWP – 75kW to 250kW – 15nos 2.5MW

67


Customer Total VFD

ACC Wadi Power plant – ID FD SA PA - 75kW to 355kW – 32drives 2.5MW

Chamundeswari Sugars – ID FD SA PA and BFWP 5.5kW and 75 to 560kW – 31nos 3MW

Department of Atomic Energy – FD 250kw – 4nos ( 12 Puls trafo & motor) 1MW

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Doodganga Sugars – ID FD SA & PA 75kW & 250nos – 6nos 1MW

Himatsinga – ID FD SA PA and BFWP ,fuel feeder 5.5kW to 380kW – 31nos 2.5MW

Hindalco – ID and FD 120kW & 160kW – 2 no. each 0.5MW

Ind Bharat – ID FD SA PA and BFWP 410kW to 710kW – 21drives (all 12 puls 690V) 14MW

Kakatiya – ID FD SA PA and BFWP,V 3.7 and 45kW to 315kW – 35nos 2MW

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Kirloskar Electric – A/c. DGNP

A.P MG Set 1350 kW, 690 V 2

Kirloskar Electric – A/c. CPRI

Karnataka MG Set 2000 kW, 690 V 1

FLSmidth – A/c. Penna Cements

A.P 4.1 km Long Conveyor 400 kW, 690 V 3

Marine Electricals – A/c. ABG Shipyard

Maharashtra Bow Thruster 1000 kW, 415 V 12

Marine Electricals – A/c. ABG Shipyard

Maharashtra Azimuth Thruster 560 kW, 415 V 2

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ABG ShipyardMaharashtra Azimuth Thruster 560 kW, 415 V 2

Hemarus Andhra Pumps,fan,feed water 5.5kw-650KW 56

L&T Export – A/c. Saudi Arabia Paper Project

Saudi Arabia Various 75kw-200KW 56

L&T Export – A/c. Khazakistan Paper Project

Khazakistan Various 22kw-250KW 230

TNPL (Tamilnadu Newsprint & Papers Ltd)

KarurLime kiln, Pumps, Fans

5.5kw-800KW 49

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VACON INDIA PANEL PHOTOGRAPHS

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Application: Co-generation power plant panelEnd Customer: HimatsingkaConsultant: Avant GardeLocation: Vacon Bangalore during inspection

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7116.4.2010

Application: Co-generation power plant panelEnd Customer: HimatsingkaConsultant: Avant GardeLocation: Himatsingka , Hassan

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7216.4.2010

Application: Co-generation power plant panelACB panels with Areva Relays

End Customer: Himatsingka Consultant: Avant GardeLocation: Himatsingka , Hassan Relays

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7316.4.2010

Application: 210MW Co-generation power plant panelEnd Customer: M/S Ind BharatCustomer: M/S Green soleLocation: M/S Ind Bharat , Tuticorin

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7416.4.2010

Application: Marine ShipCustomer: AMS

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Application: Marine ShipCustomer: AMS

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7616.4.2010

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Application: CraneEnd Customer: M/S IISCO ,BuhranpurCustomer: M/s Mukund Ltd, MumbaiConsultant: MeconLocation: VACON Bangalore

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7716.4.2010

Application: CraneEnd Customer: M/S ISCO ,BuhranpurCustomer: M/s Mukund Ltd, MumbaiConsultant: MaconLocation: VACON Bangalore

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7816.4.2010

Application: Motor Generator set 2MWEnd Customer: M/S CPRI, BangaloreCustomer: M/s KEC, BangaloreLocation: VACON Bangalore

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7916.4.2010

Application: Motor Generator set 2MW End Customer: M/S Naval dockyard, VizagCustomer: M/s KEC, BangaloreLocation: VACON Bangalore

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8016.4.2010

Application: Motor Generator set 2MW End Customer: M/S Naval dockyard, VizagCustomer: M/s KEC, BangaloreLocation: VACON Bangalore

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8116.4.2010

Application: Chain Drive conveyor 250KWCustomer: M/S Vaizag Steel PlantLocation: VACON Bangalore

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8216.4.2010

Application: Sugar Plant Fan Control Customer: M/S HamerousConsultant: M/s Avant Garde

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Application: Roller Table Customer: M/S BSPLocation: Vacon Bangalore

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8616.4.2010

Application: Roller Table Customer: M/S BSPLocation: Vacon, Bangalore

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8716.4.2010

Application: Roller Table Customer: M/S Vizag Steel PlantLocation: Vacon, Bangalore

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8816.4.2010

Application: Roller Table Customer: M/S BSPLocation: Vacon, Bangalore

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8916.4.2010

Application: Wagon TipplerCustomer: M/S BSPLocation: Vacon, Bangalore Wagon tippler Application

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Vacon after-market service offering

Safe and reliable commissioning and start-up.

Proactive maintenance secures the availability of the AC drive during its entire life-cycle and increases its lifetime.

Comprehensive selection of training courses.

71 Vacon Service Centers in 44 countries.

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71 Vacon Service Centers in 44 countries.

All brands are locally supported through the worldwide Vacon service network.

Vacon Technical Assistance offers on-call technical support 24 hoursa day, seven days a week.

CASE STORIES

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LONG DISTANCE PIPE CONVEYORCUSTOMER END USER

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Why Vacon???

Flexible configuration of modules

Use of NC engineering

Input AC Chokes

Strong reference in Cement industry mainly Kiln drives

Good global reference of long conveyor

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Good global reference of long conveyor

Committed ON TIME delivery of 8 weeks

Packaged solution-AC drives, Invertor Transformer & PLC

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System Configuration

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PANEL PICTUREM Jaykumar

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System Info…

Motors:

3x400kW/690V

2 Nos. at Head END

1 No at Tail END

Conveyors:

Distance between Head and Tail End- 4.05kM

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Distance between Head and Tail End- 4.05kM

Speed of conveyor:3.5m/sec

Material: Gypsum

Drives:

Vacon Hardware NXP0650 6- 12 Pulse – 3 Nos.

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Vacon’s Scope of Supply

6.6kV/690V 1200kVA Dual Secondary 12 pulse transformer (at Head end) - 1 No.

6.6kV/690V 600kVA Dual Secondary 12 pulse transformer (at Tail end) -1 No.

Fiber Optic Cable- 4500 Meters

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HUBNER Hollow Shaft Encoders- 3 Nos.

NXP0650 6, 12 pulse drives- 3 Nos.

ABB PLC Hardware – 2 Nos.

Local Control Station- 2 Nos.

Maintenance Jig for Vacon drive hardware-1No.

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System Description Pipe conveyor is being installed for transportation of raw materials (Gypsum)

from Crusher House (Tail End) to Discharge bins/Silo at Head End

The VFD system is for controlling the speed of pipe conveyors having 3 x 400kW Motors (2 nos. at head and 1 no. at tail end, 4.5km away from head end)

Head End VFD’s shall be on Master / Follower configuration connected with each other through ‘Vacon System Bus network’.

Data’s between PLC and Head end drives (1&2) are being exchanged thru Profibus network.

VFD’s in group mode shall receive command and reference thru Field bus

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VFD’s in group mode shall receive command and reference thru Field bus (Profibus).

Ethernet module of PLC transfers speed reference and run commands (with all interlocks) to and from Tail End thru Ethernet/OFC converter.

Digital I/O module of PLC ensures Group/Individual mode operation and other safety interlocks.

Crusher PLC at Tail End sends RUN command and speed reference to Tail End VFD. Tail END PLC receives those from VFD thru Profibus and in turn shares command and reference to Head End VFD’s thru Ethernet.

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System Description, contd…

Different Modes of operation:

Mode selection provided in Head End Master PLC.

Group Mode-1 : All the 3 motors (M1, M2 & M3) will be in operation.

Group Mode-2 :HE Motor M1 & TE Motor M3 will be in operation.

Group Mode-3 :HE Motor M2 & TE Motor M3 will be in operation.

Individual Mode: This is basically test mode where respective drive and motor can be run individually without load sharing.

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be run individually without load sharing.

Fault Conditions:

Under any fault condition, (Transformer, Field devices, Pull cord, Zero Speed and Belt sway switches, Winding/Bearing temp of motors), audible alarms are generated at both ends (Head and Tail) and total system is stopped thus safety is ensured.

ALL DRIVES ARE CONFIGURED IN DROOP MODE,WHICH IS AN OVER RIDING CONTROL INCASE PLC FAILS

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AC Drive for cement kilnCUSTOMER END USER

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Brief of cement plant….

Orient Cement, a Division of Orient Paper & Industries Limited and

a part of the C.K.Birla Group of Companies.

Located at Devapur in Adilabad District at Andhra Pradesh.

Plant capacity : 3.4 million tones of cement per annum.

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PANEL PICTUREM Jaykumar

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System Info…

Motors:

BHEL make induction Motor 705Kw, 743A, 990rpm, 690V, 50Hz

with inbuilt thermistors provided for each winding.

Motor is equipped with external liquid cooling system

Kiln:

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Kiln:

The kiln is 64 meter length, 4.15 meter dia with maximum

Max Speed of Kiln:5 RPM

5rpm

Capacity: 4200 TPD (Tones per Day Production)

Inlet and outlet temperature respectively 900°C and 1400°C.

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System Info…

Drive Details: 12 pulse NFE + INUs + BCU

NFE:520*4

INU:1030*2

BCU:NXB105

Transformer:VOLTAMP Make

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Transformer:VOLTAMP Make

6.6kV/690V/1500KVA (Star & Delta).

3~/50 Hz transformer having Impedance Voltage

HV1– LV1: 6.18%

HV1– LV2: 6.18%

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System Info…

Gear Box:

The gear box and motor is 25:1 ratio. Here the gear box power is

571kw and the rpm details are following.

Primary N1: 816 – 1360 Secondary N2 : 1.58 - 52.63

Motor rpm: 272

Gear Box output: 10.8rpm

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Gear Box output: 10.8rpm

Kiln RPM: 1

Max Kiln RPM with 990RPM motor:3.6RPM

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Why Vacon???

Flexible configuration of modules

Reliable & robust

Use of NC engineering

Input AC Chokes


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16.4.2010


Supplied by L&T, experts in cement solutions

Supplied by L&T under their brand name “LNTAC690”

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Every AC motor

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Every AC motordeserves a Vacon drive

VFDs

Documents

Transcript of VFDs