ABB Technical Guides Explain Motor Operation

ABB has produced a range of technical guides that offer concise explanations of the major technologies and technical issues in motor and variable-speed drive operation. The technical guides cover subjects such as the basics of variable-speed drives, dimensioning a drive system, electrical braking, harmonics and AC drives, and bearing currents.

Fully indexed and illustrated with explanatory diagrams, the guides are said to form a library of drive and motor information. Other titles in the series are motion-control drives, EMC-compliant installation of variable-speed drives, EU Council directives on adjustable-speed and electrical-power drive systems, and direct torque control.

There is also a guide on functional safety, with advice on how to meet the latest European directives.

ABB Supplies Integrated Telecommunications System

ABB has been commissioned to supply a integrated telecommunications system including CCTV, security, access control and communications. The facility is being built for E.ON at Holford in Cheshire and will store gas in eight salt caverns deep underground. The processing plant consists of several gas compressors that optimise the pressure of gas stored and withdrawn from the caverns into the National Grid Transmission System.

Designed to hold over 160 million cubic metres of gas, the plant will be controlled by ABB Extended Automation System 800xA and integrated with the telecoms systems, providing a single point of access and control for operational personnel. It includes multiple workstations and two 52in wall-mounted monitors, allowing operators to visualise the entire process. It incorporates CCTV images, along with other plant process and asset-management information, increasing uptime and site security, and reducing operational costs.

The telecoms scope includes: CCTV - perimeter surveillance and plant-asset monitoring, including video recording; site security - access control and intrusion detection for site, including perimeter fence, gates, turnstiles and buildings; communications - fixed telephones and a site-wide mobile radio system; remote operation - from a remote location both production and site security visibility is provided; public address - zoned systems for alarms and broadcast messages; fibre optics - a dedicated fibre-optic network for security voice and data communications.

The System 800xA will also interface to fire and gas monitors around the plant and third-party packages such as the compressor unit controls. The combined solution will provide E.ON with an integrated process-control, safety and security system that, through the use of the System 800xA aspect-object technology, allows operators to call up process and telecoms aspects from relevant graphics.

ABB Cuts Maintenance Costs At Severn Trent

Severn Trent Water (STW) is achieving savings of up to GBP2,400 a week on pump maintenance after upgrading its pump control software, which was supplied by ABB. STW had installed four submersible foul pumps at its sewage treatment works in Worcester, pumping raw sewage from a new foul well. The pumps are driven by four 132kW ABB industrial drives, supplied complete with filters to reduce harmonics caused by the drives.

Following commissioning of the variable speed drives (VSDs), STW experienced a number of blockages in the foul pumps, caused largely by rags sticking to the impeller. As well as downtime, clogging can lead to sewage pollution. A total system failure can lead to effluent leakage, with implications for the environment and health and safety, as well incurring clean-up costs and resulting in possible breaches of legislation.

Clearing these blockages was a time-consuming process. Every time a pump became blocked, it had to be removed from the well, split open and cleaned out, which is an expensive job because a crane has to be hired each time to clean the pump.

To cure this problem, ABB suggested installation of its Anti-Jam software, a module of its Intelligent Pump Control software. The Anti-Jam software performs a number of cleaning cycles every time the pump starts; each cycle consist of a series of rapid ramp ups in both forward and reverse directions.

Taking one to two minutes to complete, the cleaning cycle removes the debris from around the pump volute, preventing it from entering the pump and blocking it when the pump ramps up from zero to its normal operating speed. The cleaning cycle is also started when the VSD detects a drop in pump efficiency. Following installation of the software in February, STW has not experienced a single blockage of the foul pumps. ABB supplied its module completely free of charge to STW.

Schaffler Agrees Uniair Cooperation With ABB

Schaeffler and ABB Turbo Systems AG have signed a cooperation agreement with regard to the Schaeffler valve-control system, Uniair. The collaboration agreement will see ABB contribute its knowledge of efficient, single- and two-stage turbocharger technology, as well as marketing and sales of large, high-performance engines. The cooperation applies to units with a performance of 400kW (544 PS) per cylinder or higher.

The applications of these large engines are typically in marine, machinery and stationary operation. The advantages of the VVT system in conjunction with high-pressure turbocharging are in the fields of emission- and fuel-consumption reduction and in the improvement of the start, part load and acceleration behaviour. The Uniair fully variable, hydraulic valve-control system is behind the VVT system and enables the variation of valve timing and lift.

The Alfa Mito 1.4 Multiair is the first vehicle to utilise this technology, which is branded 'Multiair' by Fiat. The fully variable valve-control system reduces fuel consumption and CO2 emissions - in conjunction with downsizing - by up to 25 per cent. Uniair also improves the performance and driving characteristics of these optimised engines by increasing performance, torque and optimising the response of the engine.

ABB Drives Reduce Swimming Pool Energy Bills

ABB drives have helped a UK holiday park operator save GBP77,000 a year on energy bills for its swimming pools. Bourne Leisure, which owns brands such as Haven, Butlins and Warner Leisure hotels, has swimming pools at a number of its properties. ABB Drives Alliance partner APDS was asked to investigate the energy-saving potential for the swimming pools and a trial was conducted on two of the three filtration pumps at Bourne Leisure's Devon Cliffs site.

The pump was monitored for a period before a variable speed drive (VSD) was installed. Monitoring with a temporary VSD fitted demonstrated that considerable energy savings could be made. The direct-on-line pumps were working at 50Hz drawing an average of 30A. When the drive was introduced, this figure was reduced to 23A during the day and 15A at night, with no effect on water quality. APDS and ABB recommended fitting VSDs to the pumps feeding the pool filters.

The pump filters operate by trapping dirt and debris in the sand filter and returning clean water back to the swimming pool. Pumping the water at a reduced flow rate improves the filtration process and removes more contaminants. The traditional method achieved this by increasing the diameter of the feed pipes and introducing a control valve to limit the flow. This was obviously wasteful as the pump was still running at maximum speed.

Doug Pitt of APDS said: 'The trial showed the predicted savings for each 18.5kW pump at Devon Cliffs was GBP4,899 per annum, giving a payback period of less than six months. 'The actual savings exceeded those predicted in the energy report as the motor speed could be accurately mapped to pool utilisation,' he added. ABB drives ranging from 3.3kW to 30kW were eventually installed in 36 Bourne Leisure owned pools around the country, including two Butlins parks, making savings of up to GBP11,000 depending on size of pool and number of drives. In total, the company is saving nearly GBP77,000 per annum on running its pools, with a total payback time for the entire project of just over a year.

'The conversion only takes a day, with most of the rewiring done at night, so there has been very little disruption for our guests,' said Craig Valentine, health and safety manager for Bourne Leisure. Other features of the ABB drives include the real-time clock that allows the pumps to be started and stopped according to a schedule of use. The drives also have a boost button that can immediately take the pumps up to full speed for the backwash cycle.

Reduced bearing wear of the pumps has also been another benefit of the drives, due to extended ramp times. ABB is working with a specialist pool company on phase two of the project, which will see the drives receiving signals from a dosing machine. This will ensure the drives run at a speed more accurately matched to how the pool is used to ensure the correct dosing of additives such as bromine to maintain the optimum conditions in the pool.

ABB's MSP Brochure Outlines Motor-Service Offering

ABB's Motor Service Partners (MSP) has released the 2009 edition of its motor service brochure, outlining services and products available to its customers. ABB Motor Service Partners is a network of independent motor-service companies, working together and with ABB to provide full lifecycle care of industrial motors and stocking a largest range of electrical motors to suit virtually all applications.

Many of the products are available at short notice. The ABB MSP network can advise on the best purchase for individual needs, help install, maintain and repair motors, and dispose/recycle them once their useful life is spent. The ABB MSP network exists to provide end users with a supply network of high quality products backed up by comprehensive support.

The network comprises of 12 independent motor specialists, located throughout the UK, who have collaborated to offer customers a full range of services related to low-voltage motors, including sales, application engineering and modifications, overhauls and repairs of standard as well as explosion-proof motors, energy efficiency programmes and stock management.

ABB Robot Achieves Improved Path Performance

ABB has launched its most compact multipurpose robot offering high accuracy even at high speeds. Weighing 400kg, the fourth-generation IRB 4600 features ABB's Quickmove and Truemove path technology as standard. This technology enables the IRB 4600 to achieve improved path performance of up to 50 per cent while typically reducing cycle times by as much as 30 per cent. The use of ABB's Truemove and Quickmove technology allows the robot to offer consistent path accuracy even at high speeds.

Truemove checks path accuracy by constantly comparing actual and programmed path positions. Quickmove minimises cycle time by automatically optimising acceleration to match the process conditions. The consistency ensured by the technology also eliminates the need for trimming or fixing to maintain a set path, making the IRB 4600 suitable for applications demanding high accuracy such as gluing or sealing. Truemove and Quickmove also eliminate the need for 'path tuning' to cope with changes in speed.

This is particularly beneficial for cutting and dispensing applications, when speeds and orientations often have to be fine tuned at the start of production in order to achieve the optimum quality process. The IRB 4600 has been designed to offer a compact and lightweight robot suitable for installation in the widest possible range of locations. Weight-saving features include an aluminium upper arm and the removal of the robot's parallel rod. Together, these features make the IRB 4600 suitable for use in confined areas or as part of multi-robot manufacturing cells, with installation possible in inverted, floor mounted, tilted or shelf-mounted configurations.

The removal of the parallel rod also allows the IRB 4600 to bend backwards, opening up a range of operating possibilities. The IRB 4600 is available in four versions. Two short-arm versions provide a reach of 2.05m for 45-60kg payloads, while two long-arm versions provide a reach of either 2.5m or 2.55m for payloads of 40kg or 20kg. The IRB 4600's suitability for manufacturing applications has been widely tested, including under harsh foundry conditions.

To maximise the IRB 4600's utility, ABB will be working with its partners to create dress packs for material handling, machine tending and arc welding. The IRB 4600 is the first in ABB's fourth-generation multipurpose robot range.

Terminal Blocks - Entrelec By ABB Low Voltage

For over 50 years, Entrelec® By ABB Low Voltage has been one of the leading manufacturers of terminal blocks, with products in use all over the world. All terminal blocks are manufactured using only the highest quality materials and carry UL, CSA, VDE, IEC and other worldwide approvals. Entrelec® by ABB offers space savings, industry standard DIN rail mountable terminal blocks and a variety of colors, functions and connection technologies that customers demand.

Product Offering

• Accessories
• Mini Terminal Blocks
• AMS 500 Marking Systems
• PCB Connection Devices
• ATEX Terminal Blocks
• PLC Wiring System
• Blocks for 5.08mm Connections
• Power Terminal Blocks
• Cable Management System
• Screw Clamp Terminal Blocks
• Distribution Terminal Blocks
• Specific Terminal Blocks
• IDC (ADO) Terminal Blocks
• Spring Clamp Terminal Blocks
• Test Connectors

The industry’s most identifiable termination technologies are:

• Screw Clamp technology remains the most popular in connection devices.
• Spring Clamp technology is a fast growing standard in screw-less connection.
• IDC (insulation displacement connection) technology is the newest, fastest, and most innovative of screw-less connections.

In addition to general purpose terminal blocks, Entrelec® by ABB offers definite purpose products such as Distribution, 5.08mm connection, Power, Mini, ATEX , and Railway terminal blocks to satisfy the specialty needs of their customers. Terminal Blocks entrelec® by ABB's dedication to its customers is proven by offering FREE software to assist in rail design and operating a 24 hour hotline for orders.

Markets and applications include:

• Process Control
• Large and small panel building
• Machine Tool
• Energy/Utility
• Railway/Transport
• Chemical/Petrochemical
• HVAC
• Ship Building
• Building Automation
• Instrumentation
• Utilities
• Automobile

ABB For Cost-Effective Wiring Solutions

ABB has launched its Concept BS range of switches and switch accessories, ideal for achieving a high specification look in new builds, at a lower cost. The new range offers an extensive choice of competitively priced wiring accessories, encompassing switches and socket outlets through to electronic products such as dimmers and motion detectors. Like ABB's popular high-end Alpha BS range, ABB's Concept BS range adheres to all British electrical standards and offers consumers a flexible range of products catering for a full spectrum of building and design needs in homes, offices and hotels.

Flexible and easy to install. The Concept BS range's modular design enables the fixtures to be placed onto a grid structure and simply clicked into place to help cut the time and cost of installation. This flexible design enables contractors to 'mix and match' a series of different switch types to form two, three or four gang combinations and one or two way switch options, providing greater freedom when wiring a room. Providing space where it's needed.

The range offers a slim switch profile, at only 1.2 cms, providing more space inside the wallbox for wiring connections. With silver-nickel alloy contacts offering low resistance and increased conductivity, the switches benefit from increased electrical conductance and performance over a long life span.

Easy maintenance and repair. The Concept BS range has been designed with convenience in mind, offering products that are easily tested without requiring any major upheaval or removal of the product or its components. The switches can be tested without the front cover being attached and as the front panel requires no unsightly screws to hold it in place, the switch becomes more aesthetically pleasing. The new range can handle both small and large capacity loads in a range of locations.

This can be easily controlled with ABB's assortment of Busch-Jaeger multi-channel dimmers. The dimmers can be installed on a DIN rail, an enclosure or simply flush-mounted to provide a comfortable atmosphere as well as helping to save energy over the life of the installation. By dimming the lights by just 50%, up to 40% can be saved in energy costs. Buildings in general are increasingly making use of smart building technology in order to control the atmosphere within a building.

The BS range can easily be combined with, ABB's EIB/KNX technology, giving property owners or operators improved control over lighting, heating and security whilst helping to deliver energy and cost savings. All products in ABB's new Concept BS range are made from a high quality material, giving the switches a robust quality that is also resistant to high temperatures. The range is available in a choice of white or silver switch frames, for either single, dual, three or four gang designs.

ABB Drives Reduce Energy Used By Fridges

ABB Group's Variable Speed Drives have won an award for cutting energy usage and extending the life of refrigerators. The Food and Drink Innovation Network Clegg Food Projects Award for New Process and Environmental Awareness was presented to ABB at a gala dinner at the National Space Centre, Leicester. More than 60 per cent of industrial electrical energy is used to power electric motors, the majority of which are used on fans, pumps and compressors.

These devices are used in refrigeration equipment. The motors driving these applications usually run at a constant speed, even though the load is varying. Using variable speed drives (VSDs), the speed of the motor can be slowed down, thereby reducing the amount of energy consumed. A VSD can be retrofitted to most existing systems.

The mechanical controls are simply locked fully open and the VSD directly controls the speed of the electric motor. Since cold storages and fridge plants typically run for 24 hours, most refrigeration drive applications are potential VSD candidates. Any refrigeration system with a wide variation in operating hours or with a heat load that is less than the peak load can benefit from a VSD. ABB applied existing technology to the food industry by developing bolt on variable speed drive motors for refrigerators.

These keep units running at regular speeds and prevent peaks of energy use when something is put inside a fridge, reducing energy use and costs and cutting carbon footprints. This increases the life of the equipment. Instead of continually running at full speed, the lower speed reduces stresses, increases the equipment life and extends service intervals, cutting maintenance costs.

ABB Installation Contactors

ABB Low Voltage Installation Contactors are designed according to international standards (IEC), European standards (EN) and French standards (NF CUTE, DIN-VDE, BS).

We consider 2 types of "Installation Contactors" for different applications : "Normal " Installation and "Day-Night" Installation. They are essentially used in automated building equipment, industry and offices for terminal circuit controlling less than 40 kW AC-1 (incandescent lamps, fluorescent lamps, convectors heating, batteries, regulation systems, ovens, drying systems), small motors controlling less than 15 kW AC-3 (ventilation, air conditioning, pumping, watering, automatic systems) and unbalasting systems in energy management (possibly enslavement from clocks, unballasting relays, telebreakers, thermostats).

Mounting

• Mounting on rail DIN 35 mm (EN 50022) for switchboard.
• Mounting depth: 58 mm
• Width included from 1 to 3 modules (1 module = 17.5 mm)
• The magnetic circuit design ensures a completely silent operation, the coil is supplied by AC (type ESB 20) or by an integrated diode rectifier (type ESB 24, ESB 40, ESB 63)
• Terminals are delivered in open position
• Protection against accidental direct touch
• Extensions 2, 3,or 4 poles depending on the ratings, without built-in auxiliary contacts

Accessories

• 2-pole auxiliary contacts for type ESB 24, ESB 40, ESB63 (addition of one 2-pole block type EH 04 .. for module).
• Sealing cover
• Distance piece

New ABB Industrial Drives Make World Debut

The new multidrives, extension of ABB Low Voltage Industrial Drives, based on a modular configuration of dramatically smaller inverter modules, were introduced on exhibit at the Hannover Messe 2004. Following the debut of the multidrives there, it has been a successful roll out to a wide range of applications and industries around the world. The modular configuration of the multidrive provides control of multiple motors across a 1.5 - 5,600 kW power range, from 380 V up to 690 V. A single rectifier unit can be combined with a host of inverter units that are connected in parallel, to provide output current required by any given application. The multidrive offers a state of art solution for offshore and drilling applications - ultra compact and modular design ensures high availability and service.

ABB's multidrive is built from industrial drive modules that are connected to a common DC bus bar. The common bus bar is used to supply the drive modules with DC power, and each module then inverts the DC to AC and powers an individual motor. The DC power is derived from a single supply unit (rectifier) that is built into the front of the same multidrive configuration. The standard DC bus arrangement enables single power entry and common braking resources for several drives. "Common braking includes regenerative braking and motor-to-motor braking depending on the demands and modes of the various motor loads in a process or on an original equipment machine," according to Tuomo Tarula, market manager for Marine and Offshore, ABB Drives, Helsinki.

Modular construction simplifies the total installation and results in many benefits: savings in cabling, installation and maintenance costs; reduced line currents and simpler braking arrangements; energy distribution over the common DC bus bar, which can be used for motor-to-motor braking without the need for a braking chopper or a regenerative supply unit; reduced component counts; increased reliability; and space savings.

ABB Drives Promote Green Paper Making

Paper manufacturer UPM's plant at Shotton has achieved its goal of producing all its paper from recovered waste paper, rather than virgin wood, with the help of ABB variable speed drives. Known as the '100% Shotton' project, it has involved the building of a new recycled fibre plant, a sludge plant and modifications to Paper Machine 1 and Paper Machine 2. ABB General Purpose Drives are used mainly on pumps in the process, using variable speed to match pump speed to the production rate.

They are also used on chemical dosing pumps to accurately add chemicals to the pulp. Some conveyors on the process also use ABB variable speed drives. The drives help control the process better, adjusting the inputs to the plant to maintain the correct pressure and temperature conditions. The drives also make it easier to control the production rate. Additionally, they contribute to energy savings by reducing the power drawn.

Ray von der Fecht, Project Automation Manager on the 100% Shotton project, says: 'We chose ABB variable speed drives because ABB is a respected name, well known in the paper industry. Also, we know the products and the people. Overall, ABB offered a very good solution along with the best price. So well did the implementation phase go, that start-up of the system went according to plan, with the drives and automation system being switched on at the exact planned minute in the schedule'. 'It was like switching on a light', says von der Fecht.

One of the UPM's major criteria for the drives was maintainability. The drives had to be capable of being changed out quickly in the event of failure and also had to be easy to move. Interchangeable cards were also considered an advantage, allowing the company to keep dives running by simply changing some of the critical components. Compact size was also part of the demand, to save on space, improve efficiency and heat loss and cut cooling costs. The ABB drives scored on all the points. Another useful feature was their ability to communicate over Profibus, the industry standard for communication in paper production. The drives also feature input line chokes to reduce harmonics fed to the network and output filters to reduce the electrical stresses on the motor windings. High reliability was the most important criterion. Says von der Fecht: 'We have had good experience with the ABB drives'.