Every AC motor deserves a Vacon drive

Jaykumar & Rohan Sharma, Vacon India

M Jaykumar

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

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

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The Vacon saga

Acquisition of TB Wood's completed.

The saga continues.

2009 2008 2005 2000 1995 1993

Founding charter of the Vacon Group signed on 9 November 1993. First products of the Vacon CX range launched. Factory opening at Runsorintie 5 in Vaasa. The first subsidiaries founded in Germany and Sweden. First products launched of the second product range, Vacon NX. Listing on the Helsinki Exchanges. Production starts in China.

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

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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. 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 20052030. 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. 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

Vacon Plc Production Sales offices

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Finland factory
Capacity: 500,000 units/year
Production area: 17,000 m2 350 persons Products: Production of Mid-, High-End and Mega power range products New product ramp-up

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US factory
Chambersburg, PA, USA
Standard AC drives Manufactures more than 150,000 units

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Italian factory
Naturns, Italy
Electronics design, assembly and testing Custom-made AC drives

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VACON INDIA

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Vacon India Managing Director: Shailendra Salvi

Sr. Manager Commercial (Finance a/cs & logistics) Udesh
HS. Ramesh Asha J. Ramesh Jisha Thilagavathi

Sales Shailendra Salvi

Director Solution Sales & Marketing Syed Nazeer

Director Product Mgmt Rohit

Engg & Order Handling Venkatesh
Swetha Muralee Syamala Rao Ram Kumar

Manager HR & Admin Bavani

HVAC & Water KAM Honeywell & Veolia Jaykumar Marine KAM Metso & L & T Vispute

Sales South Ram

Anil Venugopal Rahul Srivatsav

Divya

Channel Mgmt Jaykumar

Distributor Vacon10 Jaykumar

Sales East Nazeer

Sudip Saha Shakil

Service Service Santhanam

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

Steel &Mining KAM Converteam & KEC Ram

Sales North Jaykumar

Rohan Sharma

Power Nazeer

Sales West Salvi

Mitesh Vispute Jaykumar Sandeep Thakur

Production & Testing Rohit Shah

Sathish Sree Ram Manjunath Praveen Nagappa (Testing)

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Vacon India

Headquartered in Chennai Facilities in Chennai Design & Engineering of Drive Systems Warehouse Training Service Centre Sales & Service Offices in Chenani Delhi, Mumbai, Pune, Ahmedabad, Bhilai, Vizag, Bangalore, Kolkota, Ludhiana, Hyderabad Factory: Bangalore Repair Centre: Chennai, Bangalore Employees:41

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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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Typical industrial segments

Mining Machine building Power stations Marine and offshore

Pulp and paper

Food and beverage

Motor industry

Rubber and plastics

Building industry

Water and waste water

Chemical industry

Oil and gas industry

Renewable energy resources

Cement Industry

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M Jaykumar

Typical Cement Industry Applications

Raw Mill feeding belt conveyors Air separator for Coal Mill & Raw Mill Booster fan for Raw Mill & Coal Mill Coal Mill Bag Filter fan

Screw Feeders

Cement Mill classifier Motor

Cement Mill Booster Fan

Reject Belt conveyor Raw Mill

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

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M Jaykumar

Complete Product Portfolio

MULTI-PURPOSE AC DRIVES
Vacon NXS Vacon NXS standalone Vacon 500X 0.75 200 kW 200 560 kW 4 132 kW

INDUSTRIAL AC DRIVES
Vacon NXP, air-cooled Vacon NXP, liquid-cooled Vacon NXC, enclosed Common DC bus components up to 0.75 3250 kW 5.5 5300 kW 110 3250 kW 5300 kW

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Vacon NXS

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Vacon NXS
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 control
208...240 V (3-phase supply) Power range 0.55/0.75 ... 75/90 kW (230 V) IP21, IP54, Nema 1, Nema 12 H, T 380...500 V 0.75/1.1 ... 355/400 kW (400 V) IP21, IP54, Nema 1, Nema 12 H (wall mounted) L (stand alone), T, C 525...690 V 2.2/3... 500/560 kW (690 V) IP21, IP54, Nema 1, Nema 12 L, T

Protection class EMC class

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M Jaykumar

Vacon NXS Family Overview

IP54 IP21
FR4 230V 400V 500V 690V 3 kW 5.5 kW 7.5 kW FR5 7.5 kW 15 kW 18.5 kW FR6 15 kW 30 kW 37 kW 30 kW FR7 30 kW 55 kW 75 kW 45 kW FR8 55 kW 110 kW 132 kW 110 kW FR9 90 kW 160 kW 200 kW 200 kW FR10 250 kW 355 kW 400 kW FR11 400 kW 500 kW 560 kW

Maximum nominal power in mechanical size at different voltages

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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

FR10 IP21/IP54 400 V 500 V 690 V

250 kW 355 kW 400 kW

FR11 IP21
400 kW 500 kW 560 kW

Maximum nominal power in mechanical size at different voltages

FR10 IP54

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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) Temperature controlled cooling fan, easy replacement Cooling channel isolated from electronics Robust structure/frame Standard control I/O Option board slots Power terminals High voltage separated from control unit Integrated brake chopper available for all sizes (standard up to 30kW) 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)

Removable display panel

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OPT-A1 Defaults settings

Reference voltage Frequency reference 0-10 V AI common (GND) -10 - +10 V, 0/4 -20 mA

Terminal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 mA 18 19 20 +10V AI1+ AI1-

Programmable
+24 V GND

OPT-A2 Terminal
21 RO1 22 RO1 23 RO1 24 RO2 230 VAC 25 RO2 26 RO2 FAULT Many possibilities RUN Many possibilities

Defaults settings

Programmable

1...10 k

Vacon NXS Standard I/O

Differential AI2+ AI2+24V GND DIN1 DIN2 DIN3 CMA +24V GND DIN4 DIN5 DIN6 CMB AO1+ AO1DO1 Frequency reference 4-20 mA AI common (differential) Control supply (bidirectional) I/O Ground Start forward Start reverse External fault input Common for DIN1 DIN3 (GND) Control supply (bidirectional) Many possibilities Many possibilities Many possibilities 0-20 mA, 0/-10 V 10 V GND

OPT-A3
Floating +24 V GND

Terminal
21 RO1

Defaults settings

Programmable

I/O Ground Multi-step speed select 1 Multi-step speed select 2 Fault reset Common fot DIN4 DIN6 (GND) Output frequency (0-24 mA) AO common (GND) READY, I 50 mA, U 48 VDC Many possibilities Many possibilities Many possibilities 230 VAC Floating N Many possibilities 4-20 mA, 0-10 V Many possibilities PTC 29 TI1input fault no response 26 RO2 28 TI1+ Thermistor Warning, 25 RO2 22 RO1 23 RO1 FAULT Many possibilities RUN Many possibilities

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M Jaykumar

Vacon NXS Modularity

5 option board slots (A, B, C, D, E) Slots and boards are hardware coded 2 slots occupied by standard I/O

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Card typecode
26

Card slot
A B C D E DI DO DI DO AI mA V AI mA isol AO mA V AO mA isol

I/O signal
RO NO NC RO NO +10 V ref The rm +24 EXT +24 V Pt1 00 42240 VAC inpu t NOTE

Basic I/O cards (OPT-A)

OPT-A1 OPT-A2 OPT-A3 OPT-A8 OPT-A9

Vacon NXS Option Boards

6 1 6 6 1 1

1 2 1 1

1 1 1 2 2 1) 2,5 mm2 terminals

2 2

1 1

I/O expander cards (OPT-B)

OPT-B1 6 1 Selectable DI/DO

OPT-B2 OPT-B4 OPT-B5 OPT-B8 OPT-B9 1 2

1 1 2)

3 1 1 3 5

Fieldbus cards (OPT-C)

OPT-C2 OPT-C3 OPT-C4 OPT-C5 OPT-C6 OPT-C7 OPT-C8 OPT-CI OPT-CJ RS-485 (Multiprotocol) Profibus DP LonWorks Profibus DP (D9 type connector) CANopen (slave) DeviceNet RS-485 (Multiprotocol, D9 type connector) Modbus/TCP (Ethernet) BacNet (RS-485) 16/04/2010 NOTES: Allowed slots for the board are marked in blue. 1) analogue signals galvanically isolated as a group, 2) analogue signals galvanically isolated separately. Modbus, N2 Modbus, N2

Software Modularity
M Jaykumar

Water Solutions Applications MultiMaster PFC

Local / Remote Multi-step Speed Level Control MultiFollower PFC

Special Applications Fire mode PID

High speed 1900 Hz Etc.

Standard

PID Control (Start-up Wizard)

Basic

Multipurpose Pump and Fan Control

All-in-One Applications
Minimized amount of parameter settings for all demands

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M Jaykumar

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

NX A_PAN

NX G_PAN

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M Jaykumar

Start-Up Wizard

Common Settings

Application Specific Settings

Ready !!

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Vacon NXP IP00 Drive Modules

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M Jaykumar

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

EMC versions N and T

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M Jaykumar

FR10-FR12

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M Jaykumar

Robust IP00 module design

FR10 Feature:

FR11 Advantage:

FR12 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

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

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M Jaykumar

FR13-FR14

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M Jaykumar

FR13 / FR 14 IP00 Units

Max. 1180A 6p/12p Max. 1450A 6p 1500A/690V 6p

2xFI9

FI13 3xFI9 Max. 1450A 12p

FI13

3xFI9 Max. 2250A 6p/12p

FI14

FI14 3xFI9 4xFI9 FI13 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
FR13 380-500V 525-690V FR14

1450A 1180A

2150A 2250A

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M Jaykumar

Inverter unit FI13

IP00 module DC-pulse supply External control part Types used in FR13:
NXI1150 NXI1300 NXI1450 NXI0920 NXI1030 NXI1180 5 5 5 6 6 6 630kW 710kW 800kW 900kW 1000kW 1150kW

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M Jaykumar

Inverter unit FI14

2xFI13 IP00 modules DC-pulse supply External control part Types used in FR13:
NXI1770 NXI2150 NXI1500 NXI1900 NXI2250 5 5 6 6 6 1000kW 1200kW 1500kW 1800kW 2000kW

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Other Components

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M Jaykumar

Input Chokes
206 39
1 1 1

261A
350
1 1 1

460A
238 39

30 15
3 3 3

30 15
3 3 3

150 275

min. 19mm 108 230

150 275

140 262

120 354

120

120

120

Note ! Tappings Heat 261A 400A 520A 650A Loss: 460W 570W 810W 890W
40 20

497

204 43

3 2

3 2 200

3 2 145 244 0

520A

165

165

650A

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M Jaykumar

Cabinet Mounting

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M Jaykumar

FR13 / FR14 Cabinets

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Vacon NXP Common DC bus Products

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43

Common DC Bus High configurability

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M Jaykumar

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)
COMMON DC BUS

=
FRONT END *
*)

INVERTER

INVERTER

INVERTER

BRAKE CHOPPER

= ~

= ~

= ~
R

= ~
R

Front end can

be either AFE or NFE AC SUPPLY

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Where to use Common DC bus systems?

Production lines in various Process industries Braking needed often - Winding machines - Cranes - Winches - Roller tables - Sugar centrifuges Braking needed rarely - Small production lines - Small paper machines

45

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Complete range Cn DC products

Air Cooled units, 3-2250A, ~1-2000 kW 465-800 VDC 640-1100 VDC

FR4

FR6

FR7

FR8

FI9

FI10

FI12

FI13

FI14

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47 M Jaykumar

Front Ends Technical Comparison

Front Ends Features
Technology Type Switching frequency DC Voltage THDi Line filter Charging Paralleling

AFE
Active Front End
IGBT Regenerative 1,5-3,6 kHz 1,35x1,1xUs < 5% LCL External Yes

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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 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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AFE+INUs
NFE* operation FFE* Regenerative is required 3 3 Low THD level is required Paralleling possibility Redundancy
2 2

AFE*

* alternative

Common DC bus

INU

INU

INU

BCU

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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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Typical AFE unit connection

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

1. Single Modules 380-500V
Fi9
220kW 388kW 1095kW

Fi10 Fi13

2. Single Modules 525-690V

Fi9
198kW 378kW 1199kW

Fi10 Fi13

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AFE CURRENT RATINGS

Supply voltage 380-500VAC

Supply voltage 525-690VAC

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VACON NXP The Compact and Flexible Hot Standby Configration

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M Jaykumar

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 nonfunctional. 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 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 sance 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

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

X 4 = 1840A Plus input Braker

NXP04606A0N0SSAA1A2 NXP03856A0N0SSAA1A2

Double Output

Double Output

460 X 4 = 1840A

385 X 2 = 770A

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VACON INDIA REFERNCES

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VACON India References in Cement Industry

CLIENT L&T C&A - A/c. ACC Wadi-Plant III L&T C&A - A/c. FLSmidth-Orient Cement ACC Limited Wadi ACC Limited - Wadi ACC Limited - Wadi ACC Limited Jamul ACC Limited Madukkarai ACC Limited - Mancherial ACC Limited - Tiakaria ACC Limited - Chaibasa ACC Limited - Kymore ACC Limited - Sindri PLACE Mumbai APPLICATION Kiln RATING 650kw/690V QTY 2

Mumbai Wadi Wadi Wadi Jamul Madukkarai Mancherial Tikaria Chaibasa Kymore Sindri

Kiln Fan Pump Grate Cooler ID Fan Slurry Pump Kiln Fan Conveyor Various ID Fan

1500kw/690V 355kW 7.5kW 7.5kW 75kW 22kW 132kW (using existing Slip Ring Motor) 110kW 37kW 200kW 45kW

1 4 1 1 1 1 2 1 1 10 1

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VACON India References in Cement Industry

Cooler Fan ACC Limited - Gagal Works Toshali Cements (Bayyavaram Unit) Kakatiya Cements Kakatiya Cements My Home Cements My Home Cements Mysore Cements Penna Cements Export Order (Pioneer Cement) Priyadarshini Cements Madras Cements Gagal Cooler Fan Cooler Fan Hyderabad A.P A.P A.P A.P Mysore Dubai A.P Ariyallur Fans ESP Fan, Apron Feeder Fans Ball Mill Fan Boiler Feed Pump Pump Pump, Fans 75kw 110kw 160kw 355kw 45kW 315kW 75kW 110kW 250kW 55kW 360kW 55kW, 7.5 kW 110kW till 425kW 7 1 2 1 2 3 3 1 3 2 2 2 15

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VACON India References in Cement Industry

CLIENT Vasavadatta Cements Saurashtra Cements Sidhigram Cements Manikgarh Cements Malabar Cements Gujarat Sidhee Cements Gujarat Sidhee Cements Gujarat Gujarat Chandrapur Kerala Gujarat Gujarat PLACE Fans Coal Feeder & Fan Fan Compressor, Feeder Fan Fan ID Fan, Fuel Feeder, Centrifugal Fan, Coal & Fuel Feeder Apron feeder, Pump Various applications Fans APPLICATION RATING 160 kW & 30 KW 11 kW & 132 kW 90 kW 160kW & 30 kW 75kW 75kW 160kw, 132kw, 90kw, 75kw, 37kw, 11kw, 3kw 4kW, 110kW 3.7kW till 1300kW 110kW 425kW QTY 2 2 3 2 1 5 7

Dhar Cements Chettinad Cement thru Holtec Madras Cements Ltd

Indore Karikali Ariyallur

2 90 15

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Vacon India High Power References

Customer ACC Wadi Power plant ID FD SA PA - 75kW to 355kW 32drives Chamundeswari Sugars ID FD SA PA and BFWP 5.5kW and 75 to 560kW 31nos Department of Atomic Energy FD 250kw 4nos ( 12 Puls trafo & motor) Doodganga Sugars ID FD SA & PA 75kW & 250nos 6nos Himatsinga ID FD SA PA and BFWP ,fuel feeder 5.5kW to 380kW 31nos Hindalco ID and FD 120kW & 160kW 2 no. each Ind Bharat ID FD SA PA and BFWP 410kW to 710kW 21drives (all 12 puls 690V) Kakatiya ID FD SA PA and BFWP,V 3.7 and 45kW to 315kW 35nos

Total VFD
2.5MW 3MW 1MW 1MW 2.5MW 0.5MW 14MW 2MW

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Vacon India High Power References

Customer Utkal Alumina (Aditya Birla Group) ID FD SA PA and BFWP 550kW 15drives (all 12 pulse 690V) Nandi Sugars ID FD SA PA 75kW & 160kW 5nos NBVL, Paloncha, Orissa, Dharmavarm ID ,FD & BFWP 55kW to 355kW 55nos RR Ispat - ID ,FD & BFWP 55kW to 900kW 55nos Saradamibka ID and fuel feeder 5.5kW & 250kW 12drives Sri Metalic - ID ,FD & BFWP 55kW to 900kW 45nos The Madras Alunimum Co. Ltd., (Vedanta) CT 160kW 6nos Total VFD
9MW 1MW 3MW 6 MW 1MW 3 MW 1MW 2MW 3MW 2.5MW

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

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

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Vacon India High Power References

Customer ACC Wadi Power plant ID FD SA PA - 75kW to 355kW 32drives Chamundeswari Sugars ID FD SA PA and BFWP 5.5kW and 75 to 560kW 31nos Department of Atomic Energy FD 250kw 4nos ( 12 Puls trafo & motor) Doodganga Sugars ID FD SA & PA 75kW & 250nos 6nos Himatsinga ID FD SA PA and BFWP ,fuel feeder 5.5kW to 380kW 31nos Hindalco ID and FD 120kW & 160kW 2 no. each Ind Bharat ID FD SA PA and BFWP 410kW to 710kW 21drives (all 12 puls 690V) Kakatiya ID FD SA PA and BFWP,V 3.7 and 45kW to 315kW 35nos Total VFD
2.5MW 3MW 1MW 1MW 2.5MW 0.5MW 14MW 2MW

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Vacon India High Power References

Kirloskar Electric A/c. DGNP Kirloskar Electric A/c. CPRI FLSmidth A/c. Penna Cements Marine Electricals A/c. ABG Shipyard Marine Electricals A/c. ABG Shipyard Hemarus L&T Export A/c. Saudi Arabia Paper Project L&T Export A/c. Khazakistan Paper Project TNPL (Tamilnadu Newsprint & Papers Ltd) A.P Karnataka A.P Maharashtra Maharashtra Andhra Saudi Arabia MG Set MG Set 4.1 km Long Conveyor Bow Thruster Azimuth Thruster Pumps,fan,feed water Various 1350 kW, 690 V 2000 kW, 690 V 400 kW, 690 V 1000 kW, 415 V 560 kW, 415 V 5.5kw-650KW 75kw-200KW 2 1 3 12 2 56 56

Khazakistan

Various

22kw-250KW

230

Karur

Lime kiln, Pumps, Fans

5.5kw-800KW

49

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VACON INDIA PANEL PHOTOGRAPHS

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Application: Co-generation power plant panel End Customer: Himatsingka Consultant: Avant Garde Location: Vacon Bangalore during inspection

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Application: Co-generation power plant panel End Customer: Himatsingka Consultant: Avant Garde Location: Himatsingka , Hassan

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Application:

Co-generation power plant panel ACB panels with Areva Relays End Customer: Himatsingka Consultant: Avant Garde Location: Himatsingka , Hassan Relays

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Application: 210MW Co-generation power plant panel End Customer: M/S Ind Bharat Customer: M/S Green sole Location: M/S Ind Bharat , Tuticorin

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Application: Customer:

Marine Ship AMS

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Application: Customer:

Marine Ship AMS

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Application: Crane End Customer: M/S IISCO ,Buhranpur Customer: M/s Mukund Ltd, Mumbai Consultant: Mecon Location: VACON Bangalore

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Application: Crane End Customer: M/S ISCO ,Buhranpur Customer: M/s Mukund Ltd, Mumbai Consultant: Macon Location: VACON Bangalore

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Application: Motor Generator set 2MW End Customer: M/S CPRI, Bangalore Customer: M/s KEC, Bangalore Location: VACON Bangalore

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

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

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Application: Customer: Location:

Chain Drive conveyor 250KW M/S Vaizag Steel Plant VACON Bangalore

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Application: Customer: Consultant:

Sugar Plant Fan Control M/S Hamerous M/s Avant Garde

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Application: Customer: Consultant:

Sugar Plant Fan Control M/S Hamerous M/s Avant Garde

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Application: Customer: Consultant:

Sugar Plant Fan Control M/S Hamerous M/s Avant Garde

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Application: Customer: Location:

Roller Table M/S BSP Vacon Bangalore

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Application: Customer: Location:

Roller Table M/S BSP Vacon, Bangalore

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Application: Customer: Location:

Roller Table M/S Vizag Steel Plant Vacon, Bangalore

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Application: Customer: Location:

Roller Table M/S BSP Vacon, Bangalore

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Application: Customer: Location:

Wagon Tippler M/S BSP 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. All brands are locally supported through the worldwide Vacon service network. Vacon Technical Assistance offers on-call technical support 24 hours a day, seven days a week.

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CASE STORIES

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LONG DISTANCE PIPE CONVEYOR

CUSTOMER 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 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 PICTURE

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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 Speed of conveyor:3.5m/sec Material: Gypsum Drives: Vacon Hardware NXP0650 6- 12 Pulse 3 Nos.

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Vacons 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 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 VFDs shall be on Master / Follower configuration connected with each other through Vacon System Bus network. Datas between PLC and Head end drives (1&2) are being exchanged thru Profibus network. VFDs 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 VFDs 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.

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 kiln

CUSTOMER 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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System Configuration

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System Configuration

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PANEL PICTURE

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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: 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 900C and 1400C.

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System Info
Drive Details: 12 pulse NFE + INUs + BCU NFE:520*4 INU:1030*2 BCU:NXB105 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 Motor rpm: 272 Gear Box output: 10.8rpm Kiln RPM: 1 Max Kiln RPM with 990RPM motor:3.6RPM Secondary N2 : 1.58 - 52.63

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Why Vacon???
Flexible configuration of modules Reliable & robust Use of NC engineering Input AC Chokes Strong reference in Cement industry mainly Kiln drives Supplied by L&T, experts in cement solutions Supplied by L&T under their brand name LNTAC690

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Every AC motor deserves a Vacon drive