Sparks Electrical News April 2018

MCCS AND MOTOR PROTECTION

18

LOW VOLTAGE MOTOR CONTROL CENTRES MARKET SET FOR GROWTH T he low voltage motor control centres market is projected to reach USD 4.03 billion by 2022, at a compound an- nual growth rate (CAGR) of 5.62% from 2017 to 2022. Increasing industrial automation, increased use of low voltage electric motors in key industries, and increased industrial plant uptime have boosted demand for low voltage motor control cen- tres. In addition, the booming power sector and increasing elec- tricity demand globally will further aid the growth of this market. The stagnancy in the oil and gas industry and a decrease in min- ing activities in Asia-Pacific, Latin America, and Africa will act as a restraint for the low voltage motor control centres market. The intelligent motor control centres segment is estimated to be the fastest growing low voltage motor control centres market, by type, from 2017 to 2022. The growth of this segment can be attributed to the increasing levels of industrial automation in Asia-Pacific and the Middle East & Africa regions. While the ini- tial costs of intelligent motor control centres are high, they offer advantages of reduced installation time, less wiring, increased reliability, greater speed and precision in defect identification, re- duced maintenance time, and remote monitoring and control. Further, intelligent motor control centres are more compact when compared to conventional motor control centres. All these factors are expected to drive the low voltage motor control cen- tres market during the forecast period. The industrial segment is estimated to be the largest mar- ket for low voltage motor control centres in 2017. Motor control centres are extensively used by industries to control the speed, frequency, voltage, and torque of motors, among other functions. Moreover, this segment is expected to grow at the highest CAGR from 2017 to 2022. The increasing demand for low voltage elec- tric motors from various industries, such as oil and gas, chemi- cals, water and wastewater, mining and metals, and paper and pulp, is expected to drive the low voltage motor control centres market in the industrial segment. Asia-Pacific is estimated to be the largest market for low volt- age motor control centres in 2017, followed by North America and Europe. The market in Asia-Pacific is driven by rising indus- trialisation automation, rising electricity demand, and growth of the power sector in the region. It is projected to grow at the fast- est rate during the forecast period. China and India are estimated to be the largest markets for low voltage motor control centres in the region. In addition, the low voltage motor control centres market is growing at a steady pace in countries such as Japan, Malaysia, Australia, and South Korea. These factors are expected to boost the growth of the low voltage motor control centres market in Asia Pacific.

MODERN MOTOR MANAGEMENT: EASY, COMPACT AND SAFE

A utomation technology is character- ised by the type of movement that electric motors can provide. The mo- tors are responsible for every translatory or rotary movement. This means that in terms of devices they are the central element of all automated systems. Contactron hybrid technology supports the easy, space-saving, and long-term switching, protection, and net- working of electric motors. Some drives that act as the central unit, require high precision. Servos or frequency- controlled electric motors are used for this. These types of drives are the main components of many applications but, on average, they represent a small proportion of the total number of drives installed. This means that most electric motors are still not controlled. They are often installed in the periphery of the central drive unit and they drive conveyor belts, pumps, grinding and cutting machinery, chip shredders, as well as numerous other applications. The vast majority of these components comprise three-phase asynchronous motors, which cover a power range of less than 3 kW. Each of the motors must be switched on, turned, and switched off again as required based on a control signal. In addition, the motor should be protected against overload, which can occur in the event of a blockage, for example. Furthermore, some safety-related applications which pose a danger to the operator and machine under certain circumstances, e.g., when an emergency switch-off button is pressed or a photoelectric barrier is crossed, need to be shut down safely. More space and wiring effort required than before The application requirements described present a significant challenge for the circuit technology of a motor starter combination. The selection of components needs to be well thought out. Two contactors are usually required for one reversing starter. One device implements forward running, the other reverse running, whereby two phases are switched for the reverse running contactor compared to the forward running contactor. When it comes to motor protection, a motor protection relay, usually based on bimetal technology, is used. The bimetal is heated thermally due to the flowing current. It opens in the event of an overcurrent, and sends a signal to shut down. In order to satisfy the highest requirements for emergency switching off in accordance with DIN EN ISO 13849-1, a redundantly designed emergency shutdown is required which is implemented via two emergency stop contactors connected in series. The installation of this type of reversing contactor combination requires consider- able space and wiring effort. If the effort involved in control and interlocking wiring is also taken into consideration, this addition- ally results in the danger of wiring errors that will be difficult to find and remove later, and this should not be underestimated. The com- mon practice of using blue coloured wires throughout for the control wiring further im- pedes troubleshooting. Users in machine building, and systems manufacturing in particular, require switch combinations that are compact and easy to install. With this in mind, Phoenix Contact developed Contactron hybrid technology, which provides an ideal solution for drives up to 3 kW. This is because Contactron Circuit technology with low power dissipation

Easy integration in bus systems The hybrid motor starters from the ELR range from Phoenix Contact combine the illustrated functions in the same 22.5 mm wide housing. The devices are available in three performance classes for nominal cur- rents up to 0.6 A, 2.4 A, and 6.5 A motor load. Using these devices reduces instal- lation time and offers space savings of up to 75% compared to conventional switch- ing and wiring technology. The motor pro- tection function satisfies the requirements of the ATEX directive and can therefore be used to control motors that are installed in potentially explosive areas. Furthermore, the hybrid motor starters can be integrat- ed into fieldbus systems such as Profibus, Profinet, CANopen®, EtherNet/IP™ or Mod- bus/TCP using SmartWire-DT™ technology. SmartWire-DT™ can be used to control and monitor up to 99 devices on one bus ad- dress. By Dr. rer. nat. Guido Mertens, member of the Business Unit Interface Components, Phoe- nix Contact Electronics GmbH, Bad Pyrmont, Germany.

not only combines wear-free semiconduc- tor switching technology with proven relay technology, it also features a compact de- sign that is just 22.5 mm wide, thereby sav- ing space in the control cabinet. The circuit comprises several redundantly designed elements for each phase. In the initial state, the mains and motor are electrically iso- lated. Switch-on is performed in three steps. First, relays K1 and K2 are closed. As semiconductors V1 and V2 have not yet been switched, no current is flowing in phases L1, L2, and L3 yet. In the second step, semiconductors V1 and V2 are switched on. Now current is flowing in all three phases and the motor starts up. The semiconductors transfer the starting current, which for a moment may be a multiple of the nominal current of the motor. During this time, the semiconductors produce power dissipation, which must be dissipated in the form of heat. In order to stop this power dissipation and the heat generated as a result, bypass relay K3 is closed and the semiconductors are switched off. The current now only flows via relays, which carry the current with a low contact resistance. When switched off, this process, which is controlled and monitored by a microcontroller, is performed in reverse order. Up to ten times longer service life One of the big advantages of the switching sequence described is that the relays close or open with the power switched off. There are therefore no electric arcs that can result in contact erosion or, at worst, fused contacts. In addition, the semiconductor switching el- ements are not subjected to any mechani- cal wear and are virtually unaffected by the very brief load. This is why the service life of the hybrid motor starters in the Contac- tron product range is up to ten times longer than that of purely mechanical switching ele- ments like a contactor. Because of the redundant circuit design, certified emergency switching-off is possi- ble if required. Sophisticated self-diagnostics and continuous measurement of the motor current round off the system’s performance capabilities. These devices therefore satisfy all the requirements for a high-quality revers- ing contactor combination with emergency switching off, in accordance with DIN EN ISO 13849-1 with the highest performance level (PL e) and motor protection. Feedback via an integrated floating PDT relay and an LED status indicator enable fast analysis in the event of an error or incorrect operation, thereby contributing to the high availability of the application.

Enquiries: www.marketsandmarkets.com

Enquiries: kevinp@phoenixcontact.co.za

CUMMINS introduced the C450 D5, as part of its QSG12 series diesel gensets for the commercial and in- dustrial markets, at Middle East Electricity (MEE) 2018 in Dubai from 6 to 8 March at the Dubai World Trade Centre. This latest product offers more power for less space by delivering a much higher power density and a more reliable power solution. The series is available from 400 kVA to 450 kVA, powered by a Cummins four-cycle, inline, six-cylinder dual-speed diesel engine offering more robust performance using less fuel. Additional features include ex- tended service intervals of 500 hours, a lower fuel consumption, and unaided cold-start capability at 12 °C. Also on display was the C1540 N5CC, the newest addition to the QSK60 gas-engine portfolio. This offers customer options that make it a perfect fit for independent power producers and combined heat and power applications. Supplying electrical efficiency of up to 43.8%, the upgraded model reduces total cost of owner- ship for its customers, and delivers world-class power efficiency. The 9.5 litre G-Drive Coolpac series was also showcased in the newly-released Cummins black colour. The 6LTAA9.5-G1 G-Drive Coolpac model, available at 350 kVA, offers higher efficiency and dependability. With a 24-valve and a larger-flow injector design, this model delivers one of the highest power-to-weight ratio in its class. Cummins also displayed its Digital Master Control 8000, a fully-automatic, distributed logic controller for remote applications, making it easier for users to integrate and adapt their varying power needs. The system can control diverse power sources such as solar, genset, and wind. With available remote access and monitoring, users can access the control system securely, and view up to 90 days of data logging anytime, anywhere. Cummins also launched a virtual reality experience at MEE 2018, which allowed users to step inside a generator plant room and connect a complete power system. Alok Joshi, Cummins Power Generation, Di- rector, Africa and Middle East, said that the exhibition was an ideal platform for Cummins to debut its latest innovations for the power-generation sector. CUMMINS LAUNCHES NEW PRODUCTS AT MEE 2018

Enquiries: www.cummins.com

SPARKS ELECTRICAL NEWS

APRIL 2018