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BMG’S VACON 100 AC DRIVES ENSURE ENERGY SAVINGS, HIGH PRODUCTIVITY AND EFFICIENT PROCESS CONTROL

BMG’s VACON® 100 AC drives have been designed to save energy, optimise process control and improve productivity in many sectors, including processing, mining and minerals, industrial HVAC, marine and water, as well as chemical, oil and gas industries.

VACON 100 INDUSTRIAL and VACON 100 FLOW drives are suitable for a wide range of variable torque and constant power/torque applications, such as pumps, fans, compressors and conveyors.

bmg-vacon-100-ac-drives-ensure-energy-savings-high-productivity-and-efficient-process-control
VACON 100 AC drives for energy savings high productivity and efficient process control

“Through VACON 100’s economical solutions – energy savings, optimised process control and improved productivity – BMG is able to ensure a quick return on project investments for our customers,” says Mick Baugh, Electronics Manager, Electromechanical division, BMG. “VACON 100 AC drives, available from 0,55 kW to 800 kW, allow our customers to use the most efficient motor for each application, with the ability to run new motor technologies – including permanent magnet and synchronous reluctance motors – for improved efficiency.

“All VACON 100 AC drives are equipped with integrated Ethernet, which means there is no need for additional interface cards to communicate with process automation. Integrated Ethernet also provides access for commissioning and maintenance through the VACON® Live configuration tool and makes local or remote monitoring, configuring and troubleshooting possible.

“VACON 100 AC drives use electrolyte-free DC link technology that extends the life of the system. Because there is no need to replace electrolytic capacitors – which wear over time – interruptions and maintenance costs are minimised. This energy-efficient system works in harmony with the environment and conforms with stringent global environmental standards for reduced emissions.”

Although VACON 100 INDUSTRIAL looks like a traditional AC drive, this single drive has integrated smart features and is dedicated for a wide range of constant power/torque applications. This user-friendly system is easy to integrate into all major control systems and is quickly adaptable to different plant automation requirements and retrofit situations.

VACON 100 INDUSTRIAL has standard features, such as built-in input/output (I/O’s) with three option slots, integrated RS485 and Ethernet-based fieldbus support and varnished boards.

Easy-to-use motor control features improve reliability and efficiency of all AC motors types, including induction motors, permanent magnet motors and synchronous reluctance motors.

VACON 100 FLOW is an AC drive with dedicated functionality for improving flow control and enhancing energy-savings in pumping and ventilation applications.

This system combines the core functionality of VACON 100 INDUSTRIAL with specific flow-control functions that optimise pump and fan performance, at the same time protecting pipes and equipment, to ensure reliable operation and extended service life.

A standard Proportional Integral Derivative (PID) controller eliminates the need for an external controller, by using a sensor to control pump speed. This is particularly useful when reacting to fluctuations in demand for flow and pressure during operation.

There are three multi-pump control solutions in the VACON 100 FLOW range to suit exact demand for water or ventilation that fluctuates throughout the day. For example, cooling water demand in a plant may peak during the day as the plant runs at full capacity, but requirements for water may be lower at night when the plant runs at reduced capacity. Multi-pump control is a single drive solution in which one AC drive controls the leading pump. If the demand exceeds the capability of the pump, additional fixed-speed pumps can be connected online directly, or with a soft starter. Users can choose between fixed set-ups and solutions in which the leading and auxiliary pumps alternate in roles, to equalise wear and tear.

All VACON 100 AC drives have a user-friendly keypad that allows for fast set-up and installation, easy commissioning and trouble-free operation, VACON Programming software tools enable OEMs to achieve a high level of machine performance.

Safety features of this system include the Safe Torque Off (STO) facility that prevents the AC drive from generating torque on the motor shaft and prevents unintentional start-ups. Safe Stop 1(SS1) initiates motor deceleration and starts the STO function after an application-specific time delay.

The optional integrated STO and SS1 safety options have several advantages over standard safety technology using electromechanical switchgears. For example, with this system, separate components and laborious wiring are no longer necessary and there is no compromise on safety.

An ATEX-certified integrated thermistor input in an option that has been designed for temperature control of motors used in areas where potentially explosive gas, vapour, mist or air-mixtures are present, or where there is combustible dust. If over-heating is detected, the drive immediately stops feeding energy to the motor. As no external components are necessary, cabling is minimised, improving reliability, reducing space requirements and optimising costs.

Another notable feature is VACON Save – a savings calculator for pump, fan and compressor applications, which is used to estimate costs and energy savings. An energy counter and real-time clock enable easy monitoring of energy savings and optimised control of the cooling fan. They also reduce the noise levels of the system.

VACON 100 compact wall-mounted drives have all necessary components integrated in a single drive and are available in IP21/UL Type 1 or IP54/UL Type 12, available at 230 V, 500 V and 690 V. Integrated features include a DC choke, EMC filters and a brake chopper standard in frames MR4 to MR6. Benefits include reduced installation space, cost-efficiency and greater reliability in harsh environments.

VACON 100 IP00 drive modules are designed for installation into any enclosure. These modules offer improved reliability by separating the main cooling air flow from the rest of the drive electronics. Other features include integrated components and a wide power range, using only four frames. Compact VACON 100 enclosed drives are available from 75 to 630 kW at 380 – 500 V and 75 to 800 kW at 525 – 690 V and can be installed in pumps or conveyors used in the most demanding conditions. The air-cooling channel provides dependable thermal handling of the enclosure, also extending service life of the drive. Approved EMC solutions ensure reliable operation of the drive, without disturbing other electrical equipment.

VACON 100 enclosed drives are configurable with power, control and enclosure options to meet the specific needs of every application. Output filter options, input disconnect and brake choppers are integrated into the cabinet solution, eliminating the need for additional equipment outside of the enclosure. Power options, such as output filters are integrated into the air-cooling solution and provide a thermally approved cabinet design.

Other notable features of enclosed drives include a system that is configured to exact requirements, a door-mounted control compartment separate from the main drive and a dedicated area for signal lights and control switches. For user convenience, all components are accessible from the front of the enclosure. Benefits include quick installation, faster commissioning and easy serviceability, as well as safe accessibility to controls.

BMG’s distribution and engineering facilities at BMG WORLD in Johannesburg, comprise electronic workshops and a technical resources centre for the repair, maintenance and commissioning of the Danfoss and VACON product ranges.

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