VLT Solutions for Sugar and Alcohol

Transcription

1 1 VLT Solutions for Sugar and Alcohol

2 Energy saving using a VLT drive is achieved even with a modest reduction in speed. Electronic fan control for 50% energy reduction Traditional regulation of air streams employs dampers, with the fans running in on/off operation dimensioned for maximum required flow. As energy consumption rises with the cube of the fan speed, only half of the energy is required to run the fan 20% below maximum speed. 2

3 Leading sugar and distillery companies choose Danfoss Drives Danfoss VLT frequency converters operate in leading sugar plants and distilleries all over the world. VLT a strong brand Danfoss is a strong brand name with sugar consultants and end users. Sugar and alcohol producers choose VLT for to complete engineered panels, prompt pre- and post-support and excellent application knowledge. Rely on Danfoss Danfoss provides reliable solution with uncompromising, well-tested technology you can count on. It is solution that offers customers peace in mind that comes from using products that have demonstrated their ability to operate without hassle over the long term, even in harsh environments. Application knowlegde We have extensive knowlegde of your business and can offer our process expertise in all stages of application, development and implementation. Our experts will work with you to design the optimal application for your needs. Comprehensive product range With our modular product range, we are able to combine relatively few components into a multitude of variations and solutions, passing the economic benefits to you. Stable operation Using our high-quality frequency converters and softstarters, designed for virtually every purpose in the sugar and the alcohol industry, our comprehensive solutions put an end to costly downtime. Customer driven innovation Customers are deeply involved in Danfoss Drives product development and design. Customer requirements for an intuitive user interface have been adopted and have turned the VLT user interface into the most userfriendly interface on the market winner of the if design award. Innovative supply chain The modular technology concept allows for mass production of highly customised drives. The production set-up assembles and tests a customised drive out of thousands of hardware configurations in 24 hours. Test centre Danfoss manufactures and supplies customised solutions with VLT panels for the sugar industry. Solutions range from energy savings to process efficiency improvements across business segments. Danfoss offers a vast repertoire of knowledge of process oriented load testing on drive systems. The new VLT series local control panel (LCP) won the international if design award in The panel was chosen from a total of 1,003 entries from 34 countries in the category interface in communication. Danfoss Drives received the Frost & Sullivan Award for Product Innovation 2006 for the unique VLT AutomationDrive series. 3

4 Intelligent VLT features in the full power range Intelligent cooling solutions We offer intelligent cooling solutions, cold plate solutions, coating solutions, panel through solutions, and smart duct cooling solutions for high power drives. A thermally tested, dedicated kit allows high power drives up to 1,5 MW to be mounted in Rittal cabinets. Using the drive s main fan. 85% of excess heat is dissipated without contact to the electronics. Installation savings 10 drives providing 6.3 MW (at 690 V) produce 126 kw of process heat. Leading the heatsink cooling air through the outside wall, only 19 kw must be removed from the room, reducing investment in cooling capacity and operational significantly. IP 55 for harsh environments IP 66 for wash down areas All VLT AutomationDrive versions have Manganese Phosphorus rear bodies. The back of IP 66 is dipcoated with epoxy or polyester spray finish ( μm). The cover is powder coated ( μm). The IP 66 enclosed drives are suited for installation in outdoor and in wash-down areas. The silicone gasket is tested with different detergents, so the drives withstand the harsh cleaning agents in the food & beverage industry. Coated control boards are available for harsh environments. Danfoss provides a broad range of IP 66/NEMA 4 enclosed drives suited for mounting in production areas, exposed to humidity, dust and frequent washdowns. 4

5 Coated control boards are available for harsh environments. VLT flexibility through the whole power range Easy upgrade With the VLT plug-and-play flexibility in adding option cards in the drive, it is child s play to expand the standard drive. Minimum time and no extra space is required. Same hardware up to 1,2 MW The same VLT hardware is used for the entire power range up to 1,2 MW. Up to 300 metres between the drive and the motor The basic design of VLT drives allows for up to 150 metres of screened motor cable or 300 metres screened cable without disturbing other electronic equipment. This allows the VLT to be installed in a central control room far away from some of the most remote variable speed conveyors and machines in a modern bottling plant. Highly efficient components and innovative designs make Danfoss VLT drives extremely compact as well as easy to commission and operate. Overall : Easy to install Lower cost of installation Efficiency Serviceability Integrated options Size Danfoss gives you: Drives dedication Innovation Reliability Overall VLT features VVC+ control algorithm Flying Start Multi Setup Built-in PID controllers Load dependent cooling fans Screened motor cables up to 150 m Unscreened motor cables up to 300 m Built in DC coils Hot pluggable clear lettered control panel Automatic Motor Adaptation (AMA) Close to 100% power output No derating of motor No torque ripples Drive catches spinning motor without tripping, with SW selection You can program up to four set-ups for the motor Optimised processes Energy saving, less noise Need no extra motor coils Saves space and costs Reduced AC line harmonics Protects external eqipment Easy setup Optimum torque performance Smooth coasting/trip by maintaining DC Kinetic backup voltage when power failure occurs Energy meter Savings 50 C ambient temperature Reliable operation Reduced EMC Long motor cables (150/300 m) 5

6 Features designed to ease production of sugar and alcohol Wherever wheels turn, VLT drives will provide the optimal control, by controlling the power supply to the motor according to the actual power demand, speed, torque, pressure, flow etc. Change of recipe requires merely shifting between several fixed set-ups. VLT benefits are: Less energy consumption Less waste and material Better, consistent product quality Improved pump control VLT drives have several pump dedicated features that optimise production and protect the drive, the motor and the equipment. Flow compensation Flow resistance is dependent on flow speed. The drive will reduce the pressure when low flow is sufficient to save energy. Motor alternation Built-in logic can control alternation between two pumps in duty/standby applications. Motion of the standby pump prevents the pump from sticking. Comparison of energy consumption Energy savings using a VLT drive are achieved even with a modest reduction in speed. Energy optimisation VLT drives have Automatic Energy Optimisation, assuring optimal magnetisation in the motor. Bus control Automation means less waste and better process control. VLT drives handle the most common bus protocols in the industry and integrate seamlessly into the overall control system. For centrifugal pumps, power consumed is directly proportional to the cube of the speed: %P = (%rpm) 3 Therefore a small reduction in pump speed results in a large reduction in energy consumption. Even a 20% reduction in pump speed results in almost 50% reduction in energy consumption. Easy commissioning and service The VLT drives can be commissioned from the drive display or using MCT10 PC software in its free-of-charge down load version. The MCT10 configuration tool makes setup of the drive para meters child s play. The application status can be followed in the drive display during operation. System performance is easily tracked. Sugar production in Usina Coruripe s Iturama plant in Brazil using Danfoss drives. Improved ROI in co-generation plants The by-products of sugarcane after the sugar production is used as fuel in cogeneration of power and heat. The produced power is purchased by the Government electricity boards. Leading sugar companies choose VLT drives In these power plants. VLT drives operate fans, boiler feed water pumps and increase manufacturer s ROI (return on investments). 6

7 Precise and configurable speed synchronisation Fewer encoders New VLT drives provide open-loop positioning with high accuracy and minimum installation cost, so that encoders and encoder cables can often be omitted. Less downtime Adjustable ramps ensure that bottles on conveyors don t fall over during starts and stops. Positioning functions ensure that bottles are placed correctly in an inspection situation regardless of production speed. Less noise less waste Syncronisation features adjust conveyor speeds according to the overall production to prevent congestion, broken bottles, noise, and energy waste. Fieldbuses available Profibus DeviceNet CanOpen Ethernet IP Powerlink Swift and easy service VLT drives are designed for real side-by-side mounting and easy access to all vital parts from the front. The overall VLT quality ensures maximum uptime, even when the drive meets extra ordinary challenges and a part is damaged. A repair can be made with minimum downtime. 1.2 MW Eliminate harmonic distortions Central compensation Active filters Danfoss active filters identify harmonic distortion from non-linear loads and inject counter phased harmonic and reactive currents to reestablish optimal sinusoidal power. Danfoss active filters can compensate individual VLT drives as a compact integrated solution or be installed as a compact stand alone solution at a common point of coupling compensating several loads simultaneously. Grid M 3- M 3- Individual compensation M 3- Group compensation M 3- M 3-7

8 Optimised for sugar and alcohol Grinder/mill features High torque capability Variability of speed Easy change of setup Robustness to overload Robustness to uneven substances Flexibility of grinder Saves time Flexibility Pump features Pump Cascade Controller Automatic Energy Optimisation Dry Pump Detection End of Curve Flow compensation Minimises wear and tear Saves energy Protects the pump Save energy Protects the pump Reduces energy consumption Saves energy ID/FD fan features I/O points are available as remote I/O s Resonance Monitoring Cascaded P-PI for temperature control Multi-zone pressure control Flow balancing AEO using Cos phi algorithm Flying start Precise flow control Extends the system s capacity Noise reduction Maintenance free Problem free operation in harsh environments No external cooling or oversizing necessary Upto extra 10% savings Can control free-wheeling fan in both directions Clean combustion in boilers Evaporator features Auto tune PID controller I/O points are available as remote I/O s Resonance Monitoring Cascaded P-PI for temperature control Multi-zone pressure control Flow balancing AEO using Cos phi algorithm Flying start Improved Floating Head pressure SW algorithm to detect abnormal overall input power VLT Pre-heat function Less maintenance Extend the systems capacity Noise reduction Maintenance free Problem free operation in harsh environments No external cooling or oversizing necessary Up to extra 10% savings Can control free-wheeling fan in both directions Reduced power consumption Eliminates need for multi motor klixon Eliminates anti-condensation heater 8

9 Compressor features Over capacity Reduced current limit Running at current limit Minimum starts and stops Setpoint in temperature Monitor running hours Electronic control Cascade control Quick start up No need for larger compressor/drive Ensures functionality of cooling system Protects the application Extends the system s capacity Protects compressor Reduces energy consumption Easy commissioning Schedule maintenance Less maintenance Stable pressure Protects compressor Reduces energy consumption Cooling tower fan features Smart Logic Controller Auto tune PID controller I/O points are available as remote I/O s Resonance Monitoring AEO using Cos phi algorithm Improved Floating Head pressure SW algorithm to detect abnormal overall input power VLT Pre-heat function Lower installation cost Valuable data points are saved Less maintenance Extends the system s capacity Noise reduction Up to extra 10% savings Reduced power consumption Eliminates need for multi motor klixon Eliminates anti-condensation heater Centrifuge features High starting torque Constant torque mode Multi set-up AC brake Flux High enclosure classes Flying start Controlled ramp up and -down Common DC-bus Saves time Process control Flexibility Saves time Robust against load shifts Suited for washdown areas Saves time Saves time Energy can be regenerated 9

10 MAKING MODERN LIVING POSSIBLE VLT Motion Control Tools Release Danfoss A/S All trademarks in this material are property of the respective companies. All rights reserved. Product overview VLT AutomationDrive An extremely flexible and costeffective drive suitable for all industry applications from simple speed control to dynamic servo applications kw at V ,000 kw at V 37 1,200 kw at V VLT HVAC Drive Extremely flexible and cost-effective drives suitable for all air handling applications kw at V ,000 kw at V 37 1,200 kw at V Built-in DC coils and RFI filter (optional) Enclosure ratings from IP 00 to IP 66 Integrated Smart Logic Controller, (USB and RS485) as standard Integrated optional communication options (Profibus DP/V1, DeviceNet, CanOpen and more) Built-in DC coils and RFI filter (optional) Enclosure ratings from IP 00 to IP 66 Integrated Smart Logic Controller, (USB and RS485) as standard Integrated optional additional I/O (digital I/O's, NAMUR, Thermistor) Integrated PLC option according to IEC Integrated optional communication options (Profibus DP/V1, DeviceNet, CanOpen and more) Integrated optional additional I/O (digital I/O's, NAMUR, Thermistor) Integrated PLC option according to IEC VLT Soft Starter MCD 3000 The MCD 3000 is a total motor starting solution providing all the best in soft starter functionality. It offers high end functionality whatever it is for starting, stopping or protection of motor or application. Sine-wave and du/dt Filters Sine-wave filters reduce motor insulation stress (du/dt & peak voltage) and noise from the motor. Bearing currents are also reduced. A perfect solution for: Applications with older motors Installation of motors in Ex areas Applications with frequent braking VLT Harmonic Filter AHF 005/010 Easily & Effective Harmonic distortion reduction by connecting the AHF 005/010 harmonic filter in front of a Danfoss frequency converter kw, versions for VAC Current limit soft start with initial current ramp up Four different auto-adjustable ramp down profiles du/dt filters also reduce the motor insulation stress reduce by reducing du/dt values across the motor terminal phase-to-phase voltage. The du/dt filter is smaller A perfect solution for: Applications with motors where du/ dt need to be reduced. AHF 005 reduces total harmonic current distortion to 5% AHF 010 reduces total harmonic current distortion to 10% Small compact housing that fits into a panel Numerous motor protection features Manual or remote control and password protection of parameters Range 3 x V 3 x V The filters come in IP 00 and IP 20 enclosures Easy to use in retrofit applications User-friendly start-up no adjustment necessary No routine maintenance required VLT Active Filter MCC 108 Danfoss active filters are a flexible solution for both harmonics mitigation and power factor correction. Built on our drive platform and extensive knowledge in controls, the active filter offers a reliable and user friendly solution. Range: A@400V A@690V higher by paralleling The perfect solution for Restoring weak networks Increasing network capacity Increasing generator power Meeting compact retrofit demands Securing sensitive environments Utilising energy savings VLT Software VLT Set-up Software VLT Set-up Software VLT Motion Control Tools Release VLT Motion Control Tool MCT10 ideal for commissioning and servicing the drive including guided programming of cascade controller, real time clock, Smart Logic Controller and preventive maintenance. VLT Energy Box comprehensive energy analysis tool; shows the drive payback time MCT 31 Harmonics calculations tool easy selection of harmonic filters easy and quick calculation of harmonics condition 10

11 Service you can rely on 24/7 around the world Sales and Service Contacts worldwide Helping to optimise your productivity, improve your maintenance, and control your finances. 24/7 availability Local hotlines, local language and local stock The Danfoss service organisation is present in more than 100 countries ready to respond whenever and wherever you need, around the clock, 7 days a week. Find your local expert team on Pick your dedicated solution from the VLT service menu: Keep you running Current drives update Commissioning and regular adjustments Preventive maintenance Service features 24/7 availability Hotline Onsite-repair Certified repair with warranty Start-up and commissioning Application experts Training Harmonic survey Preventive inspection Optimisation and retrofit Installed base evaluation Stock maintenance and consignment Extended warranty Agreed response time Fixed repair and maintenance cost Drives Upgrade Program Keep you fit Training Stock maintenance & consignment Harmonic Survey Environmental Disposal The base for efficient use of your resources and Danfoss Drives assets Quick response time Reduced impact on production More reliable production Improved maintenance Increased performance with on-time failure free operation Optimise performance Reduced lifecycle cost Trained resources for optimal design and maintenance Prevent failure Optimise performance Reduce downtime Lower maintenance cost Life-cycle optimisation Reduced capital and space bindings Optimised availability Optimised availability with effective finance planning Predictable budget for repair cost Minimising downtime Effective finance planning for maintenance Long-term finance planning for technology upgrade of drives Fix your costs Fixed Price Post warranty agreement Transport insurance Response time 11

12 What VLT is all about Danfoss Drives is the world leader among dedicated drives providers and still gaining market share. Protects environment VLT products are manufactured with respect for environment, safety and well-being. All activities are planned and performed taking into account the individual employee, the work environment and the external environment. Production takes place with a minimum of noise, smoke or other pollution and environmentally safe disposal of the products is assured. UN Global Compact Danfoss has signed the UN Global Compact on social and environmental responsibility and our companies act responsibly towards local societies. EU Directives All factories are certified according to ISO standard. All products fulfil the EU Directives for General Product Safety and the Machinery directive. Danfoss Drives is implementing in all product series the EU Directive concerning Hazardous Substances in Electrical and Electrical Equipment (RoHS) and is designing all new product series according to the EU Directive on Waste Electrical and Electronic Equipment (WEEE). Products impact One year s production of VLT drives will save energy equivalent to the energy production of a power plant. Better process control at the same time improves product quality and reduces waste and wear on equipment. Dedicated to drives Dedication has been a key word since 1968, when Danfoss introduced the world s first mass produced variable speed drive for AC motors and named it VLT. Two thousand employees develop, manufacture, sell and service drives and softstarters in more than one hundred countries, focused only on drives and softstarters. Intelligent and innovative Developers at Danfoss Drives have fully adopted modular principles in development as well as design, production and configuration. Tomorrow s features are developed in parallel using dedicated technology platforms. This reduces time to market and ensures that customers always enjoy the benefits of the latest features. Rely on the experts We take responsibility for every element in our products. The fact that we develop and produce our own features, hardware, software, power modules, printed circuit boards, and accessories is your guarantee for reliable products. Local backup globally VLT motor controllers are operating in applications all over the world and Danfoss Drives experts located in more than 100 countries are ready to support our customers with application advice and service wherever they may be. Danfoss Drives experts don t stop until the customer s drive challenges are solved. DKDD.PB.34.B1.02 VLT is a trademark of Danfoss A/S Produced by KKM