Vacon Driven NA Case Studies Booklet 2008 - 2015

2
Case Study Product Segment/Industry
Date of
Publication
Volume Page
Energy and Cost-Efficient
Ventilation for Alaskan
Mine
VACON® NXS Mining, Building Automation 2015 Volume 22 3
Vacon Propels Northern
Leader
VACON® NXP Liquid
Cooled (AFE), VACON®
NXP Air Cooled
Marine and Offshore 2013 Volume 19 4
Iconic Moment in Gold
Recovery
VACON® X Series 50X Mining and Metals 2013 Volume 19 5
Compact, Liquid Cooled
Drive for Cementing
Systems
VACON® NXP Liquid
Cooled drive
Cementing Pumps, Oil &
Gas
2012 Volume 18 6
Retrofitting at Wausau
Water Works
VACON® 100 HVAC Water and Waste Water 2012 Volume 18 7
Size Matters to Wichita
Clutch
VACON® Common DC
bus, VACON® NXP
Liquid Cooled
Marine, Oil & Gas 2012 Volume 17 8
Mega Yacht With Innovative
HVAC Solution
VACON® NXP Air
Cooled
Marine, Building
Automation
2012 Volume 15 9
Conveying the Solution VACON® NXS
Conveyors, Building
Automation
2012 Volume 15 10
A Majestic Barge
VACON® NXP Liquid
Cooled, VACON® NXP
Common DC Bus
Innovative Air Compressor
Puts the Squeeze on the
Competition
VACON® X Series
Compressors, Building
Automation
2011 Volume 14 12
Horse Walkers Driven by
VACON® X4
VACON® X Series X4 Special Application 2011 Volume 13 13
Drilling Holes in Canada
VACON® NXP Air
Cooled
Special Application 2011 Volume 13 14
Turbo Blowers Save Energy
in Water Treatment
VACON® NXP Liquid
Cooled, VACON® NXS
Water and Waste Water 2010 Volume 11 15
Retrofitting a Raymond Mill VACON® X Series X5
Minerals, Mill, Special
Application
2010 Volume 10 16
World's First True Hybrid
Tug Sets New Benchmark
VACON® NXP Liquid
Cooled, VACON® NXP
Common DC Bus
Have a Little Wine With
Your VACON® X4
VACON® X Series X4
and X5
Food and Beverage 2009 Volume 9 18
Poultry Drives Industry on
the Eastern Shore
VACON® X Series X Food and Beverage 2008 Volume 8 19
CONTENTS

3
Automation Electric and Controls Inc. is
a value-added distributor and integrator
of AC drive systems based in Mt. Vernon,
WA. Bob Alexander, partner in Automation
Electric and Controls, is well known locally
and in Alaska, where he spends much time
providing variable frequency drive (VFD)
solutions for a variety of applications. Mr
Alexander has been traveling to Alaska
for decades developing relationships and
a solid reputation; he started in the 1990’s
by providing VFD solutions to lumber and
paper mills throughout Alaska. A recent
successful and exciting VFD installation
for Automation Electric and Controls was
at a large underground mine in Alaska.
The mine currently uses 100 hp (75
kW) motors with soft starters for the
ventilation fans and blowers that provide
air to the miles of underground tunnels
and roads that form the mine. Powering
the motors is costly because energy
is very expensive when hydropower is
not available, and this depends on the
annual rainfall. Some years, hydropower
is available for seven months but other
years only for one month. Hydropower is
delivered via dozens of miles of cable and
costs the mine USD 0.16 (EUR 0.12)/kW.
When hydropower is not available, the
mine has to use local power generated
by diesel generators at a cost of USD 0.35
(EUR 0.27) /kW.
Great energy savers with short payback
period and excellent quality
Knowing that variable frequency drives
(VFDs) were great energy savers when
used with fans because of the affinity
laws2, Mr Alexander wanted to bring this
technology to the mine. He discussed with
a key engineer at the mine about providing
100 hp (75 kW) VFDs in NEMA 12 (IP54)
enclosures to replace the soft starts in
the mine.
Years earlier, Mr Alexander had read about
VACON AC drives in a trade magazine and
had requested a catalog. “I remembered
Vacon when this project opportunity came
up and contacted Vacon Inc. in the USA,”
Mr Alexander says. “The proven track
record of the VACON® NXS AC drives
and their easy-to-use interface made
them a contender for this project. The
easy startup and successful testing of the
first 100 hp (75 kW) VACON NXS AC drive
installed in the mine showed the excellent
quality and level of support provided
by Vacon. However, even more exciting
was the short payback period: thanks to
the energy savings, the cost of the drive
was paid back in a matter of months!”
When the first VACON NXS AC drive was
installed on a test fan, this resulted in
energy savings of 33 kW an hour! That
translates into annual savings of USD
100,000 (EUR 77,369)
for generator power or USD 28,000 (EUR
21,663) for hydropower, and that is just for
one fan.
With these favorable results from the
test fan, approval was obtained to install
VACON AC drives on a large number of the
ventilation fans and blowers in the mine.
Once the project has been completed, the
estimated annual energy cost savings to
the mine will be considerable – and could
be enormous, depending on the power
rate they are paying, with the added bonus
of an improved power factor.
Published in 2015 Driven Volume 22.
Written by Lise Houston & Nicki Bowling.
Canary birds are especially sensitive to methane and carbon monoxide and at one time were regularly used in coal
mining as an early warning system: any signs of distress from a bird indicated to the miners that conditions were
unsafe. Today’s mines are ventilated. Using VACON® AC drives to control fans and blowers at a mine in Alaska has
significantly improved the energy-efficiency of the ventilation system.
Energy-
and cost-
efficient
ventilation
for
Alaskan mine
1 Established in 2003, Automation Electric and Controls Inc.
based in Mt. Vernon, Skagit County, Washington, USA is a
licensed ETL 508A panel building shop that has provided
products for companies all over the world, for example in
Canada, the Caribbean, Cayman Islands, Australia, all over the
Continental United States and in Alaska and Hawaii.
www.automationelectric.com
2 The affinity laws for pumps/fans are used in hydraulics and
HVAC to express the relationship between variables involved
in pump or fan performance (such as head, volumetric flow
rate, shaft speed) and power. They apply to pumps, fans, and
hydraulic turbines. In these rotary implements, the affinity
laws apply both to centrifugal and axial flows. The affinity
laws are useful as they allow prediction of the head discharge
characteristic of a pump or fan from a known characteristic
measured at a different speed or impeller diameter. The only
requirement is that the two pumps or fans are dynamically
similar, that is the ratios of the fluid forced are the same.
Source: Wikipedia

4
Vacon propels
Northern Leader
J.M. Martinac Shipbuilding* in Tacoma, WA, United States, has been building ships since 1924. The company started
with fishing vessels, and over the years has built more than 300 vessels of various types. Martinac’s latest project, the
Northern Leader, is the largest longliner ever built in the US and one of the largest in the world. It is also eco-friendly.
*J.M. Martinac Shipbuilding Corporation, now in its third generation of family management, specializes
in the design and construction of vessels up to 250 feet (76 m) long. Over the years they have delivered
more than 300 vessels, including tuna seiners, harbor tugs for commercial and military customers,
oceangoing tugs, factory trawlers, ferries, yachts, U.S. Coast Guard patrol boats and a research sailing
vessel. **Jensen Maritime, part of Crowley Maritime Corporation, Inc., is a full-service naval architecture
firm, providing solutions from concept design all the way through vessel delivery. Jensen was very pleased
to bring its more than 50 years of naval architecture and marine engineering services to the Northern
Leader and the Alaskan Leader Fisheries. ***Techsol Marine, part of the Imtech Marine group, is an
established systems integrator of ‘Whole Ship Solutions’ including propulsion, automation and electrical
distribution equipment for the Workboat Marine marketplace. Based in Quebec City Canada, Techsol has
been an innovator in the field of energy-efficient electric propulsion technology.
The Northern Leader was launched
at high tide on January 26, 2013 and
commissioned sea worthy in Seattle’s
Puget Sound during the spring. The
Northern Leader is one of the largest
longliners and one of the most eco-
friendly commercial fishing vessels ever
constructed, with a length of 184 feet
(56 m) and a total weight of 1,600 tons.
Owned by Alaskan Leader Fisheries, the
Northern Leader will support the longline
fisheries of the North Pacific, Bering Sea
and Aleutian Islands and will sail out of
Kodiak, Alaska.
Diesel-electric propulsion with lower
emissions and higher fuel efficiency
Designed by Seattle-based Jensen
Maritime**, a Crowley company, the vessel
uses equipment that causes minimal
environmental impact on the ocean’s
ecosystem, while maintaining the lightest
possible operational fossil fuel footprint.
Designed to be fully diesel-electric, the
Northern Leader features low emissions
and high fuel efficiency.
The propulsion is powered by propellers
supplied by Schottel, a long-term
customer of Vacon. This is the first
time Z-Drives have been installed on a
longliner. The two Schottel Z-Drive rudder
propellers are each controlled by a 1,000
kW VACON® NXP Liquid Cooled drive, and
one Schottel tunnel thruster is controlled
by a 300 kW VACON NXP Air Cooled drive.
The VACON NXP units are bidirectional
(regenerative) active front-end units,
which are suitable for applications where
low mains harmonics are required. The
diesel generating system consists of four
Caterpillar C32 gensets rated at 715 kW
each, one Caterpillar C18 genset rated
at 425 kW, and one Caterpillar C9 genset
rated at 238 kW.
Joe Martinac, President of J.M. Martinac
Shipbuilding, says: “The VACON NXP
drives with active front-end (AFE)
technology were chosen for their optimal
performance, compact footprint and
ability to minimize harmonic distortion
to vessel systems. Combined with the
Schottel Z-Drives for enhanced control
of the ship, they give the captain virtually
seamless power on tap when needed. The
fluctuating power demand inherent in
longlining is well suited to take advantage
of the efficiencies of a diesel-electric
propulsion system, since the generators
can be tailored on-line to the power
demand at any given time. The Automatic
Power Management System supplied
by Techsol***, Canada, is designed to
optimize efficiency under all operating
conditions.”
Sustainable fishing
Northern Leader has been designed to
reduce waste and maximize the value of
the catch through full utilization of primary
and secondary, less valuable products. The
vessel has the space and capacity to save
components of the catch that previously
would have been discarded.
“The National Marine Fisheries has
determined that the industry may capture
up to 12 percent of the ocean’s available
catch,” says Nick Delaney, Managing
Director, Alaskan Leader Fisheries, in a
press release published on December 6,
2012. “This fishing limit is one of many
ways that the industry ensures sustainable
fishing. Jensen has designed this new
longliner to help meet this limit while
maintaining a responsible, sustainable
catch. The Northern Leader is not only
one of the largest longliners in the world,
but it’s also one of the greenest ever
designed.”
Northern Leader
This state-of-the-art fishing boat was christened in Seattle, WA, USA, on
July 31, 2013. Northern Leader is 184 feet (56 m) long, 42 feet (12.8 m)
wide and has a depth of 18.75 feet (5.7 m). Northern Leader has a crew
of 31 to support fishing and processing, and more than 38,000 cubic feet
(1076 m3) of freezer hold, representing a frozen production capacity of
1,867,000 pounds (almost 847,000 kg), which is one of the largest freezer
hold capacities of any longliner vessel. The maximum freezing capacity is
153,000 pounds (69,400 kg) a day. Longline fishing is a commercial fishing
technique that uses a long line, called the main line, with baited hooks
attached at intervals. The Northern Leader is capable of fishing 76,800
hooks using a Mustad Auto line Super Baiter designed by Mustad Longline
AS in Norway. The length of line may stretch to 45 miles (72 km)!
Written by Rusty Heller.

5
Iconic moment in
gold recovery
In small-scale gold recovery operations, the methods used by miners are often unsafe and hazardous to their health.
For instance, using mercury to recover gold in artisanal mining can cause serious long term problems and even death.
Sepro Mineral Systems Corporation
located in Langley, British Columbia,
Canada recognized the need to improve
the methods of gold recovery. As the result
of years of research and development
they introduced iCON, a family of mineral
processing products specifically designed
to recover fine gold, meeting the needs
of artisanal miners worldwide. The iCON
equipment is now used in more than 30
countries.
UV and water resistant
Sepro Mineral Systems worked with
Vacon Canada to provide an affordable and
efficient mineral recovery solution. Other
drive products were considered but the
VACON® 50X AC drive was selected for
its value and features. The VACON® AC
drive products provide ultimate reliability
in extreme conditions and service
environments worldwide where iCON gold
recovery products and plants are being
used.
“The VACON 50X AC drives were chosen
for their high UV resistance, fully sealed
outdoor wash-down rating, and very
good price for our entry level equipment.
The drives are also very simple, and
easy to program and operate with very
little training or instruction required.
The competitors have similar products
but none of them could match the
requirements concerning UV and wash-
downs as well as the price or ease of use
that the VACON® X Series drive offers,”
says Trevor Elliot, Automation Manager,
Sepro Mineral Systems Corporation.
High centrifugal force
The iCON creates an artificially high
centrifugal g force that sends the heavier
materials to the outer bowl wall. From
this efficient and safe process, gold
rich concentrate is produced from the
separation and collected safely from
the concentrator. The iCON gives people
financial and environmental benefits, and
also benefits their health and safety.
Reliability is paramount in remote areas
Matt St. John, General Manager for iCON
Gold Recovery Corporation, travels all
over the world assessing potential mine
sites and providing sales support for
artisanal and small scale gold miners:
“The iCON i350 concentrator is currently
installed in 19 countries utilizing the
VACON 50X AC drive. Our gold mining
product installations are always in remote
areas with extreme climates, and our end
users generally do not speak English.
The reliability of a VACON AC drive is
paramount to us, since a simple one
hour service or replacement could take
over a week when shipping spare parts
internationally.”
“You also have to consider the logistics
of reaching the remote mine sites of the
world. In the equatorial regions of the
world the temperature can exceed 100 °F
(38 °C) with 99% humidity. Our products
are often installed in high mountains and
northern latitudes where snow and daily
freeze thaw cycles are common. Our
equipment is generally installed outdoors.
The VACON 50X AC drive is easy to operate
for speakers of all languages,” concludes
St. John.
The VACON 50X AC
drives for the iCON
equipment are supplied
and supported by 3 Phase
Power Systems located in
Delta, British Columbia,
Canada. iCon i350
Concentrator developed
by Sepro Mineral Systems
Corporation.
www.seprosystems.com
Written by Nicki Bowling.

6
for cementing systems
Compact, liquid
cooled drive
Zadok Technologies Inc. specializes in the land and marine engineering; manufacturing of power,
electrical and automation systems. Zadok additionally offers field installation and services for electrical
and mechanical systems. Zadok Technologies operates globally, providing support services to leading
national and multinational companies in the oil & gas industries.
On some offshore drilling platforms, the
same drives that are used in the drilling
processes are also used for the cementing
pumps. These drilling drives are usually
located inside the drilling rig, and quite
a distance from the cementing system
on the rig floor. Some customers have
requested separate cementing system
drives near the cementing equipment.
Zadok Technologies of Houston, Texas,
USA, took on this challenge and developed
a liquid-cooled drive cementing system
capable of meeting the small space, harsh
atmosphere and high power requirements.
Zadok Technologies chose VACON® NXP
Liquid Cooled drives for the system.
Every bit of space counts on the deck
of a drilling rig and many systems
are squeezed into areas that require
creative engineering to make them fit.
Zadok’s Principal Engineer James Keig
had the challenge of fitting a 1,120 HP
(835 kW) VACON NXP Liquid Cooled
drive into a stainless steel Nema 4X
(IP65) enclosure just 1.8 metres wide.
What made this a real test was that the
enclosure also contained the incoming
main circuit breaker, an incoming line
reactor, a VACON NXP Liquid Cooled
drive (CH74, 1300 A, 690 V), the output
dv/dt filter, liquid-cooling manifolds and
the associated bussing to the input and
output connections on top of the cabinet.
Zadok also mounted a stainless steel air
conditioner to the top of the drive cabinet
to reduce humidity within the cabinet.
Finally, each drive was matched to its own
dedicated titanium heat exchanger system
so that it could be cooled using the rig’s
seawater circuit. When completed, two
of these systems were mounted back-to-
back on the rig floor, with each running a
1,120 HP (835 kW) cementing pump.
Dedicated drive right beside the
cementing equipment
The cementing system personnel are now
able to perform their tasks − including
the weekly Blowout Preventer (BOP)
testing − more efficiently with a dedicated
drive located alongside the equipment,
meaning no more waiting for the driller
to reassigning one of the drilling system
drives to be a cementing pump drive. The
small size and high power output of the
VACON NXP Liquid Cooled drives allowed
Zadok to provide a lot of power despite
limited space.
Once completed, the cementing system
supplier load tested each drive system
at their shop before installing them
on the drilling rig platform. During
commissioning of the new rig and
cementing system, Tony Campbell, Senior
Application Engineer and Field Service
Manager at Vacon, Inc. had to ride in a
crane basket about 300 feet (91 metres)
to the rig floor. “It was a cool, once-in-a-
lifetime experience,” he says.
Zadok expects their patent-pending
VLX cementing system drive package to
provide years of trouble-free service for
their customers.
Drilling for oil & gas involves many processes and
special components. One crucial step in the drilling
process is to cement the riser and casing pipe. As
drilling depths increase, the size of the electrical
cementing pumps continues to increase.
Power dispite limited space.
Written by Craig Sims.

7
at Wausau Water Works
Retrofitting
In June 2011, Pat Vanouse, Senior Plant Maintenance Mechanic at Wausau Water Works, was introduced to Vacon
during Vacon North America’s Drive Ahead Road Show Tour. Attending the local event at Vacon distributor Linder
Electric Motors Inc, Wausau, WI, he was very impressed by the vast range of products and the state of the art
technology that VACON® AC drives had to offer.
Wausau Water Works in the city of
Wausau, WI provides a wide range of water
and sewerage services to approximately
16,000 households and maintains over
200 miles of water and sewer mains. The
department treats and ensures superior
water quality for 1.5 billion gallons of
water and handles over two billion gallons
of wastewater annually.
As a loyal customer of Linder Electric
Motors Inc., Pat Vanouse worked with Bob
Rohde, Regional Sales Manager at Linder
Electric Motors Inc. and decided to start
with a small application using a 25 HP
(18.5 kW) VACON® 100 HVAC series drive
at Wausau Water Works.
Four influent pumps with individual
VACON 100 HVAC drives
However, a more important project came
up very suddenly as one of their two
original Stromberg drives failed. These
drives controlled the four 100 HP
(75 kW) vertical shaft influent pumps,
which handle the incoming waste water.
The drives had to be replaced in a matter
of two weeks. With Vacon’s strong
inventory of products, getting the drives
to the plant within a few days was not a
problem. Placing the four new VACON
100 HVAC drives in the existing cabinets
was also not a concern as the footprint
of the VACON drives is very compact.
This situation was a good opportunity to
convert all of the pumps so that each of
the vertical shaft influent pumps had its
own individual VACON 100 HVAC drive.
Tom Schaeffler, Engineering Manager
from Van Ert Electric, which is one of the
largest electrical contractors locally, was
called in to oversee the application plan
and the start up of the installation process
on the new drives. The switch over to the
VACON 100 HVAC drives, followed by a
training course, was completed in a few
days after which the water utility was
back up and running again. The training
course was also attended by three other
customers, who learned about Vacon and
are now using VACON AC drives as well.
Energy savings increased – short payback
time
In pump applications, VACON AC drives
control the speed of the pump according
to actual needs, which gives considerable
energy savings and results in a short
payback time, in some cases less than a
year. At Wausau Water Works, increasing
the number of AC drives from two to four
to run each of the four influent pumps
not only gives energy savings but also
improves process control and operational
reliability.
The VACON 100 HVAC drives are controlled
by central PLC running PID and sending
analog reference signal to the drives to
control the speed. The IP00 configuration
gives additional space saving benefits.
Drives make for silent motors
The newly installed VACON 100 HVAC
drives at the Wausau Water Works make
the 100 HP (75 kW) motors run so quietly
that Pat Vanouse wondered if the pumps
were even running. “The harmonics and
whine of the motors disappeared and you
could not hear a thing,” he says. “It was so
quiet I had to ask my plant superintendent
to come and listen, but he could not hear
anything either. It was unbelievable!” The
use of ear plugs in this pump room has
become a thing of the past.
At Wausau Water Works, VACON 100 HVAC drives run each of the four
influent pumps, which not only gives energy savings but also improves
process control and operational reliability. The VACON 100 HVAC is an AC
drive with a power range of 0.75 to 200 HP (0.55-160 kW), and for supply
voltages of 230 V, 400 V or 480 V. The VACON 100 HVAC can enhance pump,
fan and compressor applications. Easy installation and efficient, trouble-
free operation mean that just about anyone can commission the VACON
100 HVAC, with a speedy return on investment guaranteed.
VACON®
100 HVAC

8
to Wichita Clutch
Size matters
“The Vacon team’s help and expertise played a huge part in helping us get the test stands up and running.
Not only have they allowed us to achieve more, but also our customers can now get their brake solutions
up and running quicker.”
Wichita Clutch’s new dual 1,500 HP (1,118 kW) test stand.
Wichita Clutch is the brake and clutch
division of Altra Industrial Motion and
is based in Wichita Falls, Texas. The
company is an industry leader when it
comes to clutches and brakes, supplying
major players in the Marine & Offshore
and Oil & Gas segments. Clutches and
brakes are key components in marine
applications such as propulsion systems,
anchor handling, mooring and wenches.
Wichita Clutch also supplies brakes
and clutches for a number of Oil & Gas
applications, on drilling rigs, such as mud
pumps and draw works. Over the years,
the company has tested friction materials
in order to provide customers with the
most long-lasting materials available. This
R&D service has been a great success,
and its importance led a sharp increase
in orders. In turn, this led to a backlog of
five man years in testing. When one adds
the ever-increasing demand for larger
clutches and brakes into the equation, it
soon became apparent that the only option
for Wichita Clutch was to double the size
of their test stand.
Double the drives, double the capacity
Before the change, the test stand
consisted of a VACON®
NXP 1500 HP AC
drive and a 1500 HP motor. The stand was
designed to test features such as brake
performance and run static and dynamic
load changes, R&D and many more
customer-specific requirements. The
VACON Engineering upgrade would double
the capacity by retaining the existing
VACON AC drive and OEM motor, while
adding a second VACON NXP 1500 HP AC
drive. Wichita Clutch’s sister company,
Nuttall, were chosen to produce the
combining gearbox. This setup was chosen
due to the versatility it provided – either
each AC drive and motor could run a
single 1500 HP load or the two drives and
motors could combine to work in unison
and manage a single 3000 HP load.
While the plans were relatively
straightforward to devise, there were still
a number of issues that needed expertise
and knowledge to resolve. Perhaps the
greatest issue was accommodating the
extra components without having to
discard parts from the existing system.
This was important so that costs were
kept low and a perfectly good AC drive
was not discarded. Altra Industrial Motion
coordinated with Nuttall to select the
hardware for the gearbox while VACON
Engineering came up with a master-
follower control function.
A lot of things needed to be sorted out
before the test stand could get up and
running. Two key tasks were calculating
the harmonic content of the new additional
drive system and increasing the water-
cooling system for the addition brake
and gearbox. Greg Parker, Service
Engineer for Vacon Inc, was put in charge
of creating a control system that would
work smoothly. “Our service products
really came into their own when we were
engineering the control system,” said
Parker. “It was important to give both test
stands the option of running individually,
or being combined to run at a combined
3000 HP. Vacon software, namely
DriveSynch and Master-Follower, were
instrumental in helping us achieve this.”
Finding the right solution
The test stand was assembled so that the
new VACON NXP drive was controlling
the existing motor while the new motor
was conversely controlled by the older
drive. Meanwhile, the connecting drive
shafts were designed as a floating end
configuration. This was to ensure that
all the components remained perfectly
aligned, and during initial commissioning
it seemed to have worked. However,
it emerged that vibrations became a
problem when increased loads were run
at higher speeds. Ultimately a supporting
bearing was added to the centre of the
shaft to alleviate the vibration. This proved
successful and ensured commissioning
could be completed.
Despite the numerous challenges
regarding vibrations, alignment and the
coexistence of liquid cooled brakes and
gearboxes and air-cooled VACON NXP
drives, the test stand has so far proved
a success and has run six days a week
faultlessly. Wichita Clutch is now the
proud owner of the industry’s largest
test stand for clutches and brakes, and
saves its customers a day of time when
having a large brake burnished before it
arrives offshore – often a saving of around
$500,000.
Demand in the Marine & Offshore industry has grown
exponentially in recent years, and technology has
increased along with it. Adding the latest technology
to existing solutions often requires a careful balancing
act in order to avoid having to completely replace
the old installation – wasting time and valuable
components – and ensuring that the new parts work in
unison with old parts. So when Wichita Clutch decided
to double the throughput and capacity of their existing
1500 HP test stand for brakes, the knowledge and
expertise that comes with VACON® Engineering was
to prove vital.

9
with innovative HVAC
solution
Mega yacht
Dometic Group’s Marine Division* in Pompano Beach in Florida, USA, has 50 years’ experience in producing seaworthy
HVAC systems. On their compressor system, they needed a solution to minimize harmonic distortions and radio
frequency interference without costly line filters and conditioners. Vacon Inc. in the US and Canada – in cooperation
with their partners – provided a solution: a bypassable variable frequency drive.
* Dometic Group is a customer driven, world-leading provider of leisure products for the caravan, motor
home, automotive, truck and marine markets. Dometic Marine division’s primary offerings include air
conditioning systems, power systems, sanitation systems and kitchen equipment for pleasure boats.
In addition, the division has started to target medium-large commercial vessels, such as tugboats or
coast guard boats. Dometic Group’s marine brands include Marine Air, Cruisair, SeaLand, Condaria and
Dometic.
Key benefits
of Dometic’s
Bypassable
VFD
• Eliminates inrush current at
compressor startup.
• Eliminates power spikes at com
pressor shutdown.
• Bypasses the VFD once
compressor is at peak speed for
no electrical disturbances.
• Eliminates the need for line
reactors and RFI filters.
• One unit can control up to four
compressors.
• Available in sizes from 5 HP (3.6
kW) to 25 HP (18.3 kW) for 208
V/240 V or 380 V/460 V systems.
• Visit http://www.dometic.com/
enus/Americas/USA/
Marine/Marine-Products-
Videos/New-Products-Videos/
Bypassable-Variable-
Frequency-Drives/ to view
the revolutionary bypassable VFD
seamlessly disconnecting itself,
eliminating all harmonic
distortion and RF interference.
The customers of Dometic’s Marine
division are primarily manufacturers of 24
– 240 foot (7.3 – 73 metre) pleasure boats
and yachts. Dometic needed an AC-driven
soft-starter for their air conditioning
compressor that would not cause
problems with harmonic distortion and
radio frequency interference (RFI). Vacon’s
Manufacturing Representative Bob Darby
of Darby & Associates and Vacon, Inc.’s
Product Sales Specialist Jake Roeder
looked at the specification to see if Vacon
could provide a solution. After further
testing and evaluations, Vacon Canada and
its distributor partner GLC Controls were
also asked for help.
Line Synchronization with enhanced soft
stopping
GLC Controls was tasked to modify Vacon’s
standard Line Synchronization application
with an enhanced soft stopping feature
for Dometic. This new and much needed
application for the Vacon NXP AC drives
enabled Dometic to fill a long-term void in
the Marine HVAC business.
“We have used variable frequency drives
(VFDs) as glorified ‘soft starters’ and
‘soft stops’, because we have built our
business around using hermetic scroll
compressors that do not allow a wide
range of speed control,” says Matteo
Giovanetti, Director of Engineering at
the Dometic Group. “Our customers,
especially those in the mega yacht
industry, have continually had problems
with harmonic distortion and RFI caused
by VFDs, regardless of their quality and
despite heavy expenditure on elaborate
filtering schemes. We knew that switching
out the VFD once the compressor was up
to speed was a feasible concept, especially
with the advent of synchronizing inverters.
However, no other VFD manufacturer
was willing to work with us to find a new
solution like Vacon,” states Mr Giovanetti.
Bypassable VFD with unique capabilities
A VFD completely eliminates the large
inrush current, when starting up the
compressor, by ramping up frequency
and voltage in a controlled time period.
This prevents overload when on limited
dockside power or on a generator, without
causing noticeable voltage reductions
throughout the rest of the yacht’s
electrical system. Until now, however, a
VFD also created harmonic distortion and
RFI on the yacht’s electrical and navigation
systems, which required additional line
filters and conditioners.
The bypassable VFD provides the ultimate
solution. It eliminates the starting inrush
of current, then seamlessly disengages
and reconnects the compressor to the
main power once it is running at peak,
thus eliminating all harmonic distortion
and RFI. There is also no need for line
filters and conditioners. In addition, it
reconnects to the compressor just before
compressor shutdown for a smooth stop. It
accomplishes this with completely unique
capabilities that have previously never
been available in a marine HVAC system.
Phase locking is the key
Before bypassing can take place, the VFD
synchronizes the phase of its AC power
sine wave with that of the main power
source, a process called phase locking.
Once phase lock occurs, the bypass is
achieved by opening and closing a series
of electrical switches, timed so precisely
that there is no interruption or overlap of
current.
For smooth compressor shutdown,
the bypassed VFD performs another
phase lock, and then reconnects to the
compressor by reversing the electrical
switching. While in bypass mode, the VFD
is available for connecting to another
compressor for ramp up or ramp down.
Support and protection for up to four
compressors
One bypassable VFD can support up to
four compressors, making it especially
cost effective for chillers with two, three or
four stages. A standard VFD can run only
one compressor.
In addition to its primary functions,
the bypassable VFD also protects the
compressor by monitoring input voltage
and output current, and will shut down the
system if a problem is detected. A display
allows the user to monitor operation
and faults. The bypassable VFD is pre-
programmed from the factory and no
further setup is required. It is designed to
operate in extreme environments, such as
an engine room. However, the enclosure is
ventilated and must be kept dry since any
direct water contact can damage the unit.

10
the solution
Conveying
In 2010, Bunge Grain associates attended the Vacon Drive Ahead Road Show Tour in New Orleans, LA, USA, to learn
more about Vacon. They realized that they had an application at their plant in Destrehan, LA, that could really benefit
from a Vacon AC drive.
Bunge had four 125 HP (92 kW) motors
powering belt conveyors that were
controlled by AC drives equipped with
bypass controls for back-up. These
drives, which were not made by Vacon,
were starting to give Bunge some
problems, so the company was looking for
replacements. Bunge wanted a drive that
was reliable, easy to use, and would give
the company the performance it needed.
To avoid additional costs, Bunge also
wanted a drive that fitted into the existing
cabinet to eliminate the need to retrofit or
replace the cabinet.
Easy and quick replacement process
After the initial meeting with Bunge Grain
associates Lucas DiPuma, Maintenance
Manager, and Monty Real, Maintenance
Supervisor, at the Vacon truck stop in
New Orleans, Vacon Manufacturing Rep
Tim Harrison of Control Reps, and Vacon
Inc.’s Jake Roeder visited the plant in
Destrehan. They collected information and
then gave a quote which Bunge accepted.
Soon after this, Tim Harrison visited the
site to assist with the start up of the drive.
The Vacon NXS drive fit perfectly. A major
benefit was that the input line reactor,
which was required by the old drive,
could be removed because the Vacon
NXS drive has its own built-in AC input
reactor. Bunge personnel involved in the
installation were very impressed by the
ease and speed of the process.
Bunge has been very pleased with the
performance of Vacon’s AC drives and
the professional service provided by
Vacon. As a result, other plants have
inquired about Vacon’s solutions, and two
additional Bunge facilities are now using
Vacon AC drives thanks to the success
at the Destrehan plant. Vacon has won
these orders largely because the North
American Drive Ahead Road Show Tour
stopped in their backyard and introduced
them to all of Vacon’s AC drives products
and solutions.
Benefits of AC drives
Soft start and soft stop: AC drives reduce mechanical wear and tear on
belts, gears and other equipment. Process control: Different products
need to be conveyed at different speeds for a variety of reasons. Being
able to vary the speed gives quick, easy and reliable control of the
processes. Energy savings: Since AC drives eliminate the inrush current
seen in across-the-line applications, using an AC drive allows Bunge to
reduce peak demand charges from the utility company.

11
*HMI = Human Machine Interface ** BOP (blowout preventer) is the safety device that shears the drilling
pipe (sealing the well) in the event of a blowout of oil or gas.
1
The International Convention for the Safety of Life at Sea (SOLAS) is an international maritime safety
treaty.
2
International Labour Organization
IDS founders, David L. Huntington and
Norman S. Myers, have been industry
leaders and innovators in the drives and
controls business since the early 1970s.
IDS also needed a trustworthy and capable
partner who understood their needs and
could meet the requirements for this
rare opportunity. Because of previous
experience of working together, Vacon was
chosen as exclusive supplier of the AC
drives used to power the drive system on
the drilling barge called the Majestic.
With only just over 30 bottom-founded
barges in the world and the Majestic as
the only new-build globally, these units
have distinctive operating features. Barges
do not change location very often and tend
to focus on specific shallow-water areas of
the world, particularly swamp areas. They
also employ crews that remain on board
for long periods while they are working.
This unique lifestyle places certain
requirements on the rig to accommodate
the needs of the workers and enable them
to carry out their work as effectively as
possible.
Mud pumps driven by Vacon common DC
bus inverter modules
The power for the Majestic comes from
three diesel generators each rated at
2,100 kW. The entire AC drilling system
has four 1,200 HP (895 kW) motors for
driving two 2,200 HP (1,640 kW) mud
pumps (two motors are needed for each
pump). Each mud pump motor is driven by
a Vacon common DC bus (FI13-1180Amp)
inverter module. The two 1,800 HP (1,343
kW) drawworks motors are each driven by
a Vacon common DC bus (FI14-2250Amp)
module. The top drive and rotary table,
through a contactor arrangement, each
use the same Vacon common DC bus
(FI13-1180Amp) rated for 1,200 HP (895
kW). In addition, the system includes three
large rectifiers for the DC bus supply,
three generator control cubicles to control
the large engine-generator sets, dynamic
braking modules and resistor grids for
braking, a PLC-based rig operation control
system with touch screen HMIs* and auto
drill capability, and a motor control center
system to control the large number of
fixed speed motors.
Meeting all current environmental, safety
and construction regulations
Robert P. Dunn is an industry veteran
with a career of 40 years and is owner
of MegaDrill. He describes the Majestic,
which is being assembled in Singapore,
as the best of the best. It is 232 feet
(70 m) long, has a beam of 70 feet (21
m), hull depth of 14 feet (4.3 m) and a
posted deck of 14 feet (4.3 m). The rig is
self-sufficient, with accommodation for
more than 120 workers, including a fully
equipped hospital, recreation room, gym
and helicopter waiting room.
Because of the size of the barge, the
accommodation on board and the
numerous safety systems, the American
Bureau of Shipping (ABS) classified the
barge itself, as a rig, and its machinery.
The rig meets all current environmental,
safety and construction regulations laid
down by ABS, SOLAS1
and ILO2
and by the
International Maritime Organization on
pollution prevention. The drilling mast has
an impressive safe hook load: it can lift
2,000,000 lbs (1,000 short tons) of drilling
pipe and drill down to 30,000 feet (9,144
m). The rig is also fitted with a 15,000 PSI
(1,000 bar) working pressure for the BOP
(blowout preventer**) and control system.
The safety systems include a water mist
system for the engine compartments,
a CO2
system for the electrics, and gas
detection throughout the barge with
smoke and thermal protection.
Much interest has been generated for
the Majestic to work in West Africa,
particularly in Nigeria, which is the
probable destination upon completion.
The rig should be commissioned during
the fourth quarter of 2011 and mobilized
before year-end.
< The drive system that
will power the Majestic
shown here is being
built by IDS in their
Houston, TX based
shop. AC drives (VFDs)
are now recognized as
the preferred method
of control for offshore
and land rig equipment.
AC drives provide
many benefits over old
technologies including
better control, faster
block speeds, lower fuel
consumption, enhanced
drilling and tripping
operations, and lower
maintenance costs.
A majestic barge
When MegaDrill Services Limited, based in Houston, TX, USA,
decided to design and build the most technologically advanced
drilling barge in the world, they had many challenges ahead of
them. The decision to partner with Integrated Drive Systems
(IDS), Inc. in Houston, TX, to build the power, control and drilling
systems was an easy choice, however.

12
puts the squeeze on
the competition
Innovative air
compressor
Located in Barrie, Ontario, Canada, one hour north of Toronto, DV Systems Inc. has been manufacturing high-quality
air compressors for over 50 years. In 2009, DV Systems started the process of developing more advanced compressor
technology: a low-cost rotary screw compressor with a low amp start and high performance, designed for commercial
applications.
Small commercial customers typically do
not have access to a three-phase power
supply, and this limits their choice of
compressor to conventional fixed speed,
single-phase, 7.5 HP (5.6 kW) piston
compressors. However these are not
designed to operate continuously, are less
efficient and much noisier than screw
compressors, and they have a shorter life
expectancy due to the large number of
moving parts. DV Systems
came to the conclusion that a screw
compressor with a variable speed drive
would give optimum performance, and
they found what they needed in the Vacon
X Series of AC drives.
Compressor package with modular
enclosure for harsh environments
Vacon, Inc. in Chambersburg,
Pennsylvania, USA, had already developed
a version of their rugged Vacon X Series
drive specifically for use on single-phase
supplies, with motor ratings up to 30
amps. The NEMA 4 (IP66) enclosure
rating of the drive gave Iraj Filsoofi,
DV Systems Engineer Manager, and
his team maximum flexibility, since
they could incorporate the drive inside
the compressor enclosure, creating
a clean finished compressor package
with modular enclosure. Enclosure was
required to maintain a stable operating
temperature, and it also reduces audible
noise and enhances the appearance of the
unit. The NEMA 4 inverter enables the unit
to operate in harsh environments without
the risk of damaging the drive and its
related components.
Easy to set-up and operate
Further cost reduction was achieved by
integrating the compressor controller
directly into the Vacon X Series memory
rather than using an additional control
module. Todd Snider from the Vacon
R&D team, located at the factory in
Chambersburg, was instrumental in
developing this solution, which required
a re-map of the Vacon X Series user
display to allow set-points and displays
in compressor verbiage. Pressure and
temperature sensors are terminated
in the variable speed drive, and the
required intake valve and cooling
system commands are also integrated.
This makes it very easy to set-up and
operate the compressor, ensuring it
receives a good reception on the market.
The software even includes ‘service
reminders’, based on hours of operation,
and a provision for automatic starting of
the compressor, using the ‘real time clock’
built in the drive, as well as customized
fault indicators for easy diagnosis. Simple
navigation on the controller allows the
end user to make basic changes to the
pressure and speed to optimize the
performance and to match the required
application.
Sales rising steadily
“This product has been very successful
since it was launched in the spring of
2010,” says Mr Filsoofi of DV Systems.
“It has been very well received by our
customers because of the unique design
for a single-phase screw compressor
application, its great performance and
reliability, which set us apart from our
competition. Vacon engineers were a
tremendous help in developing software
that meets our requirements for
compressor operation.”
Sales of this innovative compressor
design are increasing steadily and the
close cooperation between Vacon and DV
Systems has led to Vacon NX products
being adopted for DV Systems larger
models of rotary screw compressors.
< DV Systems (formerly Devair) industrial piston compressors and
rotary screw air compressors are manufactured in Barrie, Ontario,
Canada. Shown here is the B10 HP “Huron” rotary screw compressor.
Written by Vacon Canada and Nicki Bowling.

13
driven by Vacon X4
Horse walkers
J P Livestock Co in Marana, Arizona, USA, has over 80 quarter* horses. It would take many cowboys to perform daily
exercise routines for this many horses, but J P Livestock has a Trojan horse walker. Trojan manufactures state of the
art horse walking machines with automated exercise programmes to accommodate almost any need from exercise to
rehabilitation.
* Quarter horse – a small, powerful breed of horse developed in the USA. The name comes from it being
formerly trained for races of up to a quarter of a mile.
Horses are very intelligent animals. Like
humans, their basic needs are healthy
diets, exercise and mental stimulation. If a
horse lives in the wild, is kept in a pasture
or ridden often, getting enough exercise is
rarely a problem as they can instinctively
move about. However, many of our long
legged friends are kept in barns or stalls
and more often they have inadequate
physical stimulation.
Automated exercise programmes for
different needs
Horse walkers are used to automate
the exercise programmes for horses
with many different needs. These needs
range from standard daily workouts
for healthy animals to less rigorous
programmes for younger horses and those
that need rehabilitation. Trojan Horse
Walkers provide all of these variations
automatically in regard to speed, direction
and time with a simple to use Vacon X4
drive.
Trojan Horse Walkers in Iowa Park,
Texas, is the oldest manufacturer of
horse walkers in the US. They sold their
first walker in 1961. Present owner Dan
Kingcade and his family purchased the
business 20 years ago and have supplied
thousands of horse walking machines to
seven countries. These machines walk
anything from four to eight horses at a
time. This significantly cuts down on the
number of personnel it takes to keep
horses in good physical condition.
Trojan Horse Walkers change with time
The original Trojan horse walkers used
3-speed auto transmissions. The second
generation used mechanical variable
speed belt drives. Five years ago, Trojan
Horse Walkers moved into the third
generation using AC variable frequency
drives.
Vacon came into the picture several years
ago, when Trojan had a major design
problem: The 3 HP 230 volt variable speed
and control requirements were met with
a large Nema 4 enclosure that housed
a PLC, AC drive, fused disconnect and
terminal blocks, all hard wired. A dynamic
brake resistor was also required for faster
deceleration, which generated heat and
required upsizing of the enclosure.
The outside of the box had push buttons
for control of speed and direction. The
problem was the complexity of meeting
different speed, direction and time
requirements for specific needs. The PLC
that controlled the time, direction and
speed functions could not be modified
unless it was returned for service or a call
was made to the customer.
Vacon X drives solve the design issues
The Vacon X4** was the solution to all
of the design issues. The Vacon X4 has
a built-in nine event PLC that allows
sequencing control of acceleration
time, direction, speed and run time.
Programming to fit custom needs
was easy. The customer could do this
with a few key strokes themselves or,
since the Vacon X4 has wireless PDA
programming***, Trojan Horse Walkers
could modify the sequencer files in the
PDA and send it to the customer who
simply points the PDA at the drive and
installs the new program. The standard
drive is already housed in a Nema 4/
IP66 indoor/outdoor enclosure. Dynamic
braking is standard in the Vacon X4, so no
external resistors were required.
One step up from the Vacon X4 is the Vacon
X5** model, which has a USB flash drive
port that will allow Trojan to send a flash
drive ready to go with an infinite number
of programs to fit any horse walking,
exercise or rehabilitation needs. Simply
connect the USB and download the desired
program with a few key strokes.
Cost-effective and user-friendly
Dan Kingcade, owner of Trojan Horse
Walkers, is very pleased with his choice of
drive supplier and says: “We went through
six different manufacturers of variable
speed drives and Vacon was the only one
that was cost-effective and user-friendly.”
One of Trojan’s many satisfied customers
is Joseph Parsons of J P Livestock,
Marana, Arizona. “We did a lot of research
before the purchase and found that Trojan
was the most rugged and easy to operate
horse walker on the market,” he says.
Joseph Parsons and his USD 150,000 horse Big Iron won second place
in the PRCA (Professional Rodeo Cowboys Association) Tie-Down
Roping horse of the year in 2010.

14
in Canada
Drilling holes
High-performance Vacon NXP forms heart of unique single
spindle, 3-axis beam drilling system by Edge Automation
Located in London in Ontario, Canada,
Edge Automation provides engineering,
machining, millwrighting, fabricating,
PLC/electrical controls and on-site
services. Edge Automation serves many
large companies in the automotive,
food and beverage, and miscellaneous
manufacturing industries.
When Edge Automation was challenged
to build a single spindle, 3-axis beam
drilling system for a customer in Quebec,
President Gerard Regier decided
immediately that this should be a unique
design with as much Canadian content as
possible. One of his first calls, however,
was to Vacon with a sales office in
Stratford, Ontario.
Vacon had proved to be a valuable partner
in previous projects and it was decided
early on that the Vacon NXP product
platform would drive the heart of the
machine, the spindle.
Spindle and motor with broad speed and
torque range
Working with a local tooling expert, the
optimum RPM, torque and thrust for the
spindle were calculated for the full range
of hole sizes, using parameters for the
latest tooling technology for structural
steel drilling. The machine needed to drill
hole sizes ranging from 6 to 50 millimetres
without a mechanical speed change and
still provide the required horsepower for
all sizes at the optimum speed.
Edge Automation rejected numerous
drive concepts and motors from many
manufacturers before finding a suitable
off-the-shelf motor and synchronous
system that could handle the broad speed
range and deliver the required power. The
motor was paired with a high-performance
Vacon NXP drive. This combination also
proved that it had the accuracy to enable
the Rhino Beam Drill System to thread
holes!
The motor, synchronous drive and
custom precision spindle were all
manufactured and assembled as a unit
based on Edge’s requirements by Colonial
Tool – a precision spindle manufacturer
in Windsor, Ontario, with over 80 years
of spindle expertise. Edge Automation
integrated the spindle with the Vacon NXP
drive.
The drill head assembly weighs in excess
of 4 tons and travels at speeds above 50
centimetres (20 inches) per second. This
mass helps absorb drill vibration, making
this the quietest drill on the market
yet still keeping it agile and quick. This
design produces the highest precision, the
highest speeds and broadest power range
of any drill machine in its class.
Air compressor and other systems
Vacon also suggested other local
component manufacturers that use
Vacon AC drives for their systems. DV-
Systems in Barrie, Ontario supplied the air
compressor that allowed Edge Automation
to have an on-board compressed air
supply to other systems on the machine,
so the customer does not need a
compressed air line for the machine.
Other local companies were involved in
providing all the other necessary on board
systems. Everything from the coolant
systems to the wireless communication
system for the CNC control pendants
and wireless computer networking was
selected with an eye toward cutting edge
design, aiming to leap ahead of all other
available systems while using as many
standard parts as possible for future
serviceability.
Vacon, the drive partner in all future
projects
Edge Automation is already designing a
multi-spindle machine for 3-axis drilling,
with an integrated saw to cut the I-beams
precisely to the desired length. Because
of the valuable expertise it has already
provided, Vacon will be the drive partner in
all future projects.
“None of our competitors have adequate
power and full speed range to drill this
range of hole sizes using the latest
structural steel drill technology. By
working with Vacon, we succeeded in
achieving this. Add this to the excellent
support we get from the local Vacon
office in Stratford and it’s a winning
combination,” says Gerard Regier,
President of Edge Automation.
High speed, robust construction, and precise operation combined to
make the perfect cut.
Written by Vacon Canada and Nicki Bowling.

15
save energy in
water treatment
Turbo blowers
Aeration blowers have an important task in wastewater treatment, but their handicap is high energy consumption.
Houston, Texas based company, HSI*, introduced in early 2008 the air bearing HT series blower, which can reduce
energy costs by 20-40 %. Vacon AC drives are used for speed control.
*HSI is an ISO 9001-2008 certified manufacturer of high speed turbo blowers, centrifugal blowers,
exhausters and control systems with representatives worldwide. HSI offers blower equipment
performance ranges up to 25 PSI (1.7 bar) pressure or 18 inHg (457 mmHg) vacuum and flows from 100
CFM (3 m^3/hr) to 40,000 CFM (1130 m^3/hr). All engineering, manufacturing and testing is located in
Houston, Texas, USA.
Sewage, or domestic wastewater, treatment
is the process of removing contaminants from
wastewater and household sewage, including
surface runoff water. It includes physical,
chemical and biological processes to remove
these contaminants. Its primary goal is to
produce a waste stream of liquid and solid waste
(sludge) that is suitable for discharge back into
the environment.
One of the most important parts of the process is
aeration. HSI Multistage blowers and High Speed
Turbo blowers are used to shake up the sewage
and expose it to the air. This causes some of the
dissolved gases, such as hydrogen sulfide with
its foul taste and smell, to be released from the
water. The wastewater then enters a series of
long, parallel concrete tanks that are divided into
two sections. In the first section, air is pumped
through the water. As organic matter decays, it
uses up oxygen, and aeration replenishes the
oxygen. Bubbling oxygen through the water
also keeps the organic material suspended,
while it forces grit such as coffee grounds, sand
and other small dense particles to settle at the
bottom of the tank, from where it is removed and
taken to landfills.
Matching the blower speed to the aeration
requirement
In the light of the current economic situation
across the globe, municipalities are exploring all
avenues to minimize operating costs and make
their facilities more energy efficient. One of the
largest consumers of energy at the plant is the
aeration blowers. These blowers are typically
variable torque applications that benefit from
‘affinity laws’, which state that ‘power varies
with the cube of the speed’. In laymen’s terms,
slowing the speed down 20 % will reduce power
by 50 %. So the objective is to match the blower
speed to the actual aeration requirement, and
this is also true with any centrifugal pump
application throughout the plant.
HSI has been able to help municipalities in this
quest to be more “green”, introducing the air
bearing HT series blower to replace the old
positive displacement or centrifugal blowers
used for their aeration systems.
The City of Louisville, Colorado is one of many
such municipalities that have joined the “green”
technology movement and purchased HSI
High Speed Turbo blowers for its wastewater
treatment facility. The decision to purchase the
High Speed Turbo from HSI was based on quality
and the annual energy savings.
“The wastewater treatment facility is saving
25-30 % in energy and that will pay off the
equipment within 5-6 years,” says Paul Bremser,
Wastewater Facility Superintendent. “HSI was
not the lowest in price amongst the competitors
but I knew they stood behind their equipment.
When I visited the operation in Houston, TX, I
saw their Quality Center and that put my worries
to rest.”
Energy costs reduced by 20-40 %
Using a HT series blower can result in a 20-40
% reduction in energy costs. Additional benefits
include lower maintenance costs, since there are
no belts, gears or couplings and no lubrication,
with the only scheduled maintenance being
routine inlet filter changes. The HT series is
quiet, less than 80 dB(A) and complying with
OSHA standards. In addition, the HSI HT series
can operate in parallel with other types of
blowers with a smaller footprint than traditional
blowers.
The HSI HT series are shipped as a pre-
engineered working system with integrated
controls, Vacon variable frequency drive,
filter inlet, and electrical disconnect to keep
installation costs to a minimum.
Further energy savings are possible when
utilizing the HT blowers’ “plug and play” control
system. This can be connected directly to a
dissolved oxygen probe via a 4-20 mA connection
or via Ethernet to a plant SCADA for remote
monitoring and operation, or HSI can add
process control panels to automate the existing
basin control valves, maintaining effluent quality
while minimizing the total energy consumption
of the blowers.
Vacon liquid-cooled and air-cooled drives
preferred choices of HSI
HSI has chosen the Vacon NXP liquid-cooled
drive to vary the speed on their High Speed
Turbo blower. There are many reasons for
selecting the liquid-cooled Vacon NXP drive.
It has the capability to control the speed on a
special permanent magnet 2 pole motor that
can exceed speeds of 520 Hz or more than
30,000 RPM in this application. These PM motors
can sometimes run in open loop but may also
require encoders and/or resolvers that are used
to close the loop for more precise speed control.
Another major benefit from specifying the
Vacon liquid-cooled drive is the small footprint,
typically 33 % that of an air-cooled drive. This
allows the drive to be installed in the blower
enclosure, maintaining the compact size and low
noise features of the High Speed Turbo blower.
HSI is also a leading manufacturer of Multistage
blowers that use a standard induction motor.
HSI’s choice of drive is the air-cooled Vacon NXS
drive. One item that separates Vacon from other
drive companies is their built-in AC line choke in
the air-cooled Vacon NXS drives. There are many
ways to reduce the negative effects of harmonics
generated back to the line, and the standard
AC choke on the air-cooled Vacon NXS drive
automatically reduces harmonics by an average
40 %. It also helps with high voltage spikes or
disturbances on the line and protects the drive
from possible damage.
“HSI offers a closed loop liquid cooling system or
can use the discharge effluent if available; this
makes a perfect marriage between the HSI High
Speed Turbo blower and the liquid-cooled Vacon
NXP drive,” says Jim Pearsall, Vice President,
HSI. “For our Multistage blowers, the air-cooled
Vacon NXS drive is the preferred choice.”
“Two key advantages with the Vacon drive are
continuity between the programming for the
liquid-cooled and the air-cooled NXS drives
and the possibility to use 10 kHz output carrier
frequency that results in reduced audible noise,”
says Andrew Balberg, Vice President, Sales and
Marketing, HSI.
HSI High Speed Turbo blower HT-300 unit with the liquid-
cooled Vacon NXP drive. The liquid-cooled drive has only
minimal power losses to the air, which reduces the
need for drive cabinet ventilation.

16
a Raymond mill
Retrofitting
Gypsum is an ancient, versatile material that was once used as plaster in the Egyptian pyramids. Today it is most
commonly used in gypsum board in homes and commercial buildings. Smooth grinding of the gypsum rock into fine
powder is essential for guaranteeing the quality of the end product. After a retrofitting project at National Gypsum
Company’s Portsmouth site, a ball mill manufactured by Raymond is now fitted with Vacon X5 variable speed AC drives.
AC drive control improves the process significantly.
Headquartered in Charlotte, North
Carolina in the USA, National Gypsum
Company is a building products
manufacturer and one of the leading
gypsum board producers in the world.
At its Portsmouth site in New Hampshire,
Vacon X range AC drives were recently
installed to improve process control of
the Raymond mill — a powerful roller-
style mill that takes raw gypsum rock
and converts it into a fine powder. The
mill was originally not fitted with variable
speed, which caused problems and wasted
energy.
Smooth ramp up with Vacon X5
The Raymond mill uses rotating weights
that spin from a central fixture inside a
circular drum. Centripetal force pushes
these weights towards the sides of the
drum where they crush and roll the rock
against the outer wall. This mill uses
several motors; the two most important
ones are the 200 HP motor that spins the
weights and the 200 HP motor operating
the blower that helps suspend the rock in
the mill during processing.
Because the mill could not operate at
variable speed, the primary means for
adjusting the amount of air blowing into
the mill was a manually operated damper
system. The main motor spinning the
weights simply ran at full speed. If an
operator did not begin feeding the raw
material into the mill quickly after startup,
the weights hit the outer walls of the
drum, which was very noisy and caused
excess wear. Conversely, if an operator
dumped too much raw material into the
mill, the weights became bogged down
and it was necessary to empty the mill by
hand, which was a long and dirty process.
Vacon’s solution was to apply 200 HP
Vacon X5 drives to both the main motor
and the blower motor. By introducing a
ramp-up period and using the program
sequencer, it was possible to get the mill
up and running with fewer problems. In
addition to the gradual startup, National
Gypsum can fine-tune the blower and
rotor speeds to optimize the product
output and also maximize energy savings.
AC drives reduce energy usage and stress
National Gypsum Company has invested
millions in capital improvements to
reduce energy usage. Using an AC drive to
control the motor to operate according to
actual need is an effective way to achieve
considerable energy savings. The use of
AC drives also improves adjustability, and
reduces the load on the electric network
and mechanical stress on machinery.
In some installations, the payback time
for the investment can be as short as six
months.
In addition to the Raymond mill at the
Portsmouth site, National Gypsum
Company also uses Vacon X range AC
drives in other harsh duty applications,
such as conveying raw materials and
moving finished products.
Gypsum board begins with gypsum (calcium sulfate). The mineral is
crushed and calcined (baked). Water is added and the liquid slurry is
sandwiched between two pieces of paper. After drying, the gypsum
board is ready for delivery. Gypsum board is a rigid, light-weight
building product, valued for its fire-resistant properties.
Written by Jordan Engel.

17
sets new benchmark
World’s first
true hybrid
tug
The world’s first true hybrid tug was unveiled in January 2009 in southern California, United States. Named the ‘Carolyn
Dorothy’, the tug is powerful, green and quiet. She is likely to have many followers, as hybrid tugs are expected to be a
significant trend in the marine industry. Vacon AC drives technology is used as part of the hybrid propulsion system.
*Aspin Kemp & Associates (“AKA”) is a systems integration company specializing in developing, applying,
managing, supporting and maintaining engineering solutions primarily in the marine and offshore oil and
gas industries. In 2007, AKA teamed up with XeroPoint Energy, a renewable energy development company,
to design, build, and install a hybrid power generation and control system for Foss Maritime.
A typical harbour tug has highly variable duty
requirements but a very inflexible power
plant. This results in inefficiency, higher
costs and a negative environmental impact.
Seattle-based Foss Maritime, founded in
1889 and specializing in worldwide marine
transportation and logistics, decided to solve
this problem and concluded that the answer
lies in hybrid technology.
Foss partnered with Canada-based Aspin
Kemp & Associates (AKA)* and their affiliate
XeroPoint to develop a unique hybrid
energy conversion and power management
system that would be environmentally
responsible without sacrificing horse
power or manoeuvrability. With an efficient
combination of batteries, generators
and main engines, the hybrid tug offers
improved vessel performance and lower
fuel consumption, maintenance costs and
emissions. It is also quieter than its Dolphin
sister tugs, when operating on batteries that
can be recharged using shore power or the
vessel’s own electrical generating sources.
Foss anticipates that there will be a growing
market for their ‘green’ tugs in the years to
come.
Named ‘Carolyn Dorothy’ after the wife of a
Foss shareholder, the first hybrid tug joins
a fleet of standard tugboats that service
the needs of the ports of Los Angeles and
Long Beach, the number one and number
two container ports in the USA. The 5000-hp
‘Carolyn Dorothy’ will be used primarily for
harbour assist services — moving vessels
such as tankers and container ships in and
out of the harbour and into their berths.
The hybrid tug is part of the San Pedro Bay
Ports Clean Air Action Plan, which aims to
significantly reduce the health risks posed
by air pollution from port-related ships,
trains, trucks, terminal equipment and
harbour craft. The hybrid tug design was
awarded the Clean Air Excellence Award for
Clean Air Technology in 2008, given by the
US Environmental Protection Agency (EPA).
This was the first time a maritime operating
company has ever received the federal
government’s prestigious award.
California leaders praise the hybrid tug. In
a letter to Foss Maritime on the day of the
unveiling ceremony, Arnold Schwarzenegger,
Governor of California, says: “My deepest
gratitude goes to all those who make this
project possible. You deserve a big hand for
your hard work, and I thank you for helping to
keep our state green.”
“Green” technology suitable for conversions
Tugs at Los Angeles and Long Beach spend
up to 50 %
of their time idling, with the main engines
running and ready to respond, but with no
power actually being used for propulsion.
With the Foss’ hybrid tug, energy when idling
and transitting the harbor is provided by
batteries or smaller diesel generators, so the
main engines no longer need to idle.
The hybrid tug provides the same high power
and bollard pull as a conventional Dolphin
tug, but uses a power management system
that keeps the main engines running at or
near their design points when needed, and
shuts them down when they are not required.
To support these requirements, the boat
uses a combination of smaller main diesel
engines and larger diesel-generator sets
than on a conventional Dolphin tug, main
shaft-driven motor/generators, state of the
art power conversion and control technology,
and storage batteries. The boat can operate
in direct-diesel, diesel-electric, diesel plus
electric, and electric configurations.
The design of the Foss hybrid tug makes it
suitable for converting existing harbour tugs
of all types to hybrid vessels. The flexible
design of the tug means it can also take
advantage of emerging technologies such as
improved fuels, for example biodiesel and
ethanol. The tug can also utilize cleaner,
less expensive shore power to charge the
batteries. The fuel efficiency of the main
engines or the diesel generators is improved
by recharging the batteries as required.
AC drives technology form part of the hybrid
propulsion system
Vacon AC drives technology is used as part of
the hybrid propulsion system of the ‘Carolyn
Dorothy’. Vacon’s involvement in the project
has its origins in the company’s long-term
partnership with Eaton Corporation, a US
customer and global leader in industrial
control. Eaton serves the North American
marine market and supplied the AC
drives to Aspin Kemp & Associates. Eaton
offers a broad range of energy-efficient
and environmentally friendly electrical
solutions, and has an exceptional array of
services to reduce energy consumption.
With a commitment to energy efficiency and
innovation, Eaton’s application expertise
paved the way for the inclusion of the Vacon
technology.
The Eaton drives, manufactured by Vacon,
used in the hybrid propulsion system include
two 750-kW liquid-cooled LCX9000 drives
(Vacon’s NXP line - 525-690 V) that control
the motors/generators on the main drive
lines, and two 325-kW Active Front-End (AFE)
units (525-690 V) that supply power to the
inverters and the batteries from the auxiliary
diesels. The AFE unit is a bidirectional
(regenerative) power converter for supplying
a common DC bus drive line-up. The INU
(inverter unit) is a bidirectional DC-fed power
inverter for the supply and control of AC
motors, and it is supplied from a common DC
bus drive line-up.
The Active Front-End (AFE) is a highly
advanced drive supply solution comprizing
a regenerative supply bridge and a passive
LCL filter. Its advantages in shipboard use
are twofold: it presents very low harmonic
distortion to the generators, which means
that the voltage is not distorted and can
be used by hotel loads, and it can feed
surplus energy back into the grid — feeding
hotel loads and others from the main or
auxiliary diesels. The AFEs easily meet all
requirements for harmonic distortion and
power factor in respect of the generators and
other loads. The power factor is higher than
0.99 and the harmonic current distortion is
less than 5%.
Owned and operated by Foss Maritime, this revolutionary
vessel represents a significant step forward in the
“greening” of the tugboat industry. Foss President and COO
Gary Faber, left, and Port of Long Beach Executive Director
Richard Steinke at the unveiling ceremony.
Written by Vacon.

18
with your Vacon X4
Have a little wine
Rodney Strong Vineyards is dedicated to crafting world-class wines with complexity and expression that capture the
essence of Sonoma County in Northern California, United States. Rodney Strong Vineyards grows and produces wines
exclusively from four of Sonoma County’s finest appellations; Alexander Valley, Russian River Valley, Chalk Hill and
Sonoma Coast. The winery’s twelve unique estate vineyards represent the perfect marriage of varietal selection and
soil composition.
The winery was founded in 1959 by
Sonoma County wine pioneer Rodney
D. Strong as the 13th bonded winery in
the county. Today, the winery is privately
owned by the Klein family, a fourth
generation California agricultural family.
It all starts with the grapes - the
Appellations
At Chalk Hill, ocean fogs and chalky soils
work in combination to produce unique
chardonnays that exhibit crisp citrus and
mineral notes along with lush floral and
tropical character.
In Alexander Valley, Bordeaux varieties
thrive in shallow, hill-side soils, with
warm afternoon temperatures and the
moderating influence of the Russian
River. Cabernet sauvignon and Merlot
grown here are rich with plum and cherry
flavours and soft, chocolatey tannins.
Sauvignon blanc from Alexander Valley
is touched with characteristics of melon,
pear and lime.
Russian River Valley is one of the few
growing regions that can claim the
distinctive flavours it stamps on pinot
noir. Hints of cherry and spice and soft,
luscious textures create sensuous,
memorable wines.
The wine making team at Rodney Strong
Vineyards — Rick Sayre, Gary Patzwald
and Doug Mcllroy — craft fine Sauvignon
Blanc, Chardonnay, Cabernet Sauvignon,
Merlot, Zinfandel, Pinot Noir, and a
Meritage wine, Symmetry.
Rodney Strong’s Meritage wine,
Symmetry, is crafted to be a “high-end”
wine from their winery within a winery,
where all the reserves and single vineyard
wines are made. ”Meritage,” by definition,
must be a winery’s top offering and it has
to be a blend of certain grapes — Cabernet
Sauvignon, Cabernet Franc, Merlot, Petit
Verdot and Malbec.
Wine transfer carts driven by drives
Wine transfer carts are used in many
areas of a winery. These portable
centrifugal pumps are used to transfer
wine from tanks to barrels, from barrels to
tanks, and from trucks to tanks. “Crush” is
the season when the wine maker decides
the sugar content of the grape is right and
ready for harvest. This is usually August
to October. This is the busiest time of the
year and these pumps and the AC drives
that run them are critical to the process.
Vacon X4 and Vacon X5 AC drives are some
of the very few drives in the industry where
the standard enclosure is rated Nema 4/
IP66 and that also have UL indoor/outdoor
approval. This is extremely important as
the Vacon X4 is exposed to everything from
wine to wash down, not to mention the
elements of weather.
Rodney Strong Vineyards produces an
average of 800,000 cases of wine a year.
When it is time to move wine in the
process, these pumps must work. “The
reliability of the Vacon X4 and the ease
of operation make this possible,” says
Larry Solomon, Maintenance Manager.
“Many drive manufacturers operate in this
industry, but the simplicity, reliability and
ruggedness of the Vacon X4 make this the
premier choice for Rodney Strong.”
Derrick Montanye, Maintenance Mechanic, and Larry
Solomon, Maintenance Manager at Rodney Strong Vineyards,
with a wine transfer cart, i.e. a portable centrifugal pump that
is run by a Vacon X4 AC drive. These pumps and the AC drives
that run them are critical to the wine making process.

19
Poultry
drives
industry
Nestled in among the absolute beauty and serenity of the Eastern Shore of Delaware, Maryland and Virginia, many
large, well-known companies provide most of the poultry products across the United States. Only the most rugged
equipment survives in this harsh industrial environment, where high production rates require reliable machinery and
service.
One motor service company with a strong
foothold in the food processing and poultry
industry is Hill’s Electric Motor Service,
Inc. — Vacon’s local distributor-partner,
located in Linkwood, Maryland. Founded
in 1962 by Larry Hill, who is now assisted
by his three sons David, Steve and Mark,
the company has grown to become the
largest motor repair company on the
Delmarva Peninsula. Today they specialize
in all types of motors, motor controls
and pumps, and provide mechanical and
electrical services to support their primary
customer base, which is food processing
and the poultry industry.
The applications found in most facilities
that Hill’s service operate in what is
considered the harshest of the harsh
environments, and this is what brought
Hill’s Electric Motor Service and Vacon
together. According to Mark Hill, V.P.,
“Vacon and the Vacon X series of AC drives
have brought a new degree of reliability
through improved technology that we
badly needed here on the shore.”
Rugged enclosures
The ruggedness of the standard IP66
enclosures on the Vacon X4 and X5 drives
are put to a high-pressure wash-down
test every day. The Vacon X5 now offers
standard conformal coated circuit boards
that offer protection against the air-born
gases often found in wastewater plants. In
grain plants, where fine particle grain dust
has caused havoc with other drives, the
standard IP66 enclosure of the Vacon X5
exceeds their needs.
The Vacon X4 has also served well for
numerous basic stand-alone drive needs
in many plants. For example, the drive
can be mounted directly on the overhead
conveyor frames and utilize the custom
display feature to read in “BPM” or Birds
Per Minute, information required by the
operators.
Extensive economic effects
The Delmarva Poultry Industry, Inc.
states that “Each job in the poultry
processing industry creates 7.2 jobs
elsewhere.” The economic importance of
the poultry industry on the Eastern Shore
is significant; most of the local crops are
sold within the industry, and most of the
jobs are with the poultry growers, grain
farmers and poultry companies.
Poultry truly does drive industry on the
Eastern Shore, and will continue to play an
important part in the way of life there. And
companies such as Hill’s Electric Motor
Service also have an important role, as
they promote new technologies like AC
drives and high-efficiency motors that help
save energy. Encouraging environmental
responsibility and energy conservation will
help support future economic stability.
on the
Eastern Shore
The Vacon X product line
is designed for harsh
environments, enduring
dirt, dust, humidity and
liquids. In addition to
the food and beverage
industry, the Vacon X
series is targeted at
material handling and
water and waste water
treatment, but is ideally
suited for all tough
industrial applications.
Written by Rick Neff.

Vacon Driven NA Case Studies Booklet 2008 - 2015

Vacon Driven NA Case Studies Booklet 2008 - 2015

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