Sparks Electrical News April 2019

MCCS AND MOTOR PROTECTION

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ALUZINC IS A GAME CHANGER FOR MCCS

T he replacement of steel by aluzinc in the manu- facture of Shaw Controls motor control centres (MCCs) is giving a range of benefits to the com- pany’s customers, according to the company’s senior manager operations, Anderson Kohler. “Traditionally, we used only steel for our MCCs, which needs to be powder coated in order to protect it from corrosion,” says Kohler. “This made it necessary to follow quite a long process in completing our products – a process which aluzinc can now simplify and speed up.” The usual process of preparing the MCC panels includes welding, grinding and prewashing before the powder coating painting process can take place. These phases can now be bypassed by using aluzinc which is a material that effectively resists corrosion without a protective coating being applied. Kohler highlights the extended lifespan of aluzinc, which comprises 55% aluminium, 43,5% zinc and 1,5% silicon. Manufacturers of the product guarantee it will last for about 35 years before any major maintenance is required. “The powder coating of steel panels complicates

of aluzinc allow parts to be kept in stock, ready for quick assembly. He notes that this is not possible with mild steel due to corrosion. “By introducing the use of aluzinc in the manufacture of our MCCs, we can reduce the lead time on components by as much as two to three weeks, and this is a time-saving we can pass on to our customers by delivering more quickly,” he says. There are also environmental benefits to using aluzinc as a replacement, says Kohler. No welding means a saving on gas and electricity, for instance, while no pre-washing obviates the need for harsh chemicals. In the painting process, there is invariably waste created through surplus paint that must be carefully disposed of in terms of environmental regulations. Shaw Controls has over 30 years’ experience as a manufacturer of quality MCCs, distribution boards, medium voltage (MV) switchgear, control desks, PLC and instrumentation enclosures, portable and containerised substations, E-Houses and various other electrical enclosures. The company’s Robertsham facility is ISO 9001 accredited.

the earthing requirement on an MCC, as the paint layer insulates the panel and prevents conductivity,” he says. “This means that technicians and installers must take special care to ensure that proper contact is made between the unit and the earth connection.” For instance, the use of star washers must be strictly enforced among installation staff. Alternatively, certain areas of the MCCs are left unpainted to allow for earth connections. Kohler points out that this does raise the concern that it only takes a small oversight and the earthing will not be fully effective. The use of aluzinc eliminates this issue as there is no longer a paint layer between the earth connection and MCC panel. There is also the possibility of painted parts being scratched or damaged during transport and installation. When this occurs, it leads to the time consuming task of being returned to the factory for proper powder-coating, further delaying the installation and commissioning process. Indeed, if there is a need to weld again for any reason, then there is a repeat process of grinding and pre- washing before painting again. Kohler explains that the corrosion-resistant properties

Enquiries: +27 (0)11 723 6000

GEARBOX LUBRICANT HELPS COMBAT WATER INGRESS

SIMPLIFIED, COST-EFFECTIVE SOLUTION FOR DC RETROFIT APPLICATIONS T he new Allen-Bradley PowerFlex dc field controller from Rockwell Auto- mation enables customers to upgrade

F ood and beverage, pharmaceu- tical, and other clean environ- ments require NSF H1-grade lubricants for hygiene and health and safety purposes. ROCOL Rapid Demulse 220 from Bearings Inter- national is ideal for such demanding applications. It is a non-toxic, high-performance gearbox lubricant designed especially for applications where water ingress is an issue. The ROCOL Rapid Demulse 220 splits rapidly from the water, which can be drained from the gearbox periodically, allowing the oil to continue lubricating. Hence service life between oil changes is extended rapidly, as conventional oils tend to emulsify into a creamy, frothy mix that does not lubricate effectively. Such premature oil changes escalate costs and increase downtime. “ROCOL Rapid Demulse allows for rapid water demulsification under

into gearboxes is a problem that many plants and industries have to contend with, and we are able to provide an ideal solution. In terms of the food-and-beverage industry especially, increasingly stringent requirements are focusing on food- safe lubricants with regard to cross- contamination regulations,” ROCOL Product Manager Michael Daley concludes.

conditions of high load and elevated temperature. It also allows for quick water drainage to reduce downtime, and has good wear-protection properties to boot,” BI Product Manager Richard Lundgren explains. “It can be used in a wide temperature range from -5 °C to 130 °C, and is NSF H1 registered for use where incidental contact with foodstuffs may occur, as well as ISO 21469 certified.” ROCOL Key Accounts Manager Richard Daley comments that Rapid Demulse 220 is anticipated to continue gaining traction in the South African market owing to its capability to enhance production significantly at processing plants. In one of the first large-scale applications of the product locally, it has been slashing downtime on gearboxes at a particular client since July 2017. “The challenge of water ingress

their dc motor application to a modern system, without the need for complex external devices. An up-to-date digital networked control sys- tem helps customers gather and leverage vital information throughout their enterprise. The dc field controller provides three- phase, four-quadrant (reversing) dc motor or generator field control. The field controller can be used on its own or with a PowerFlex dc digital drive. In stand-alone mode, it provides power to a dc motor field with a fixed reference by using fixed I/O. The field controller can also control electromagnets and other non-motor loads. “For dc retrofit applications that require motor reversing, the PowerFlex dc field controller helps eliminate the need for an additional armature bridge or a complex system of external devices, saving customers time and money,” said Nancy Rivard, product manager for Rockwell Automation. “Having a single source for all automation equipment – including ac and dc drives – also simplifies machine start- up, operation and maintenance.” The field controller offers output ratings from 17 A to 575 A and input of 200 V and the customer requirement to reduce operating costs by installing the latest technology. Project management is critical The team liaises closely with its clients to best meet all technical requirements and time constraints. “Project management in this regard is critical, from the time the or- der enters our system, to the point where the product is finally delivered,” says Mar- quez. “Once this stage is reached, other departments become involved.” “We specialise in integrated solutions,” adds Meid. “Many clients tend to regard SEW solely as a gear unit supplier, but we offer a host of ancillary services that can add significant value, reduce risk and downtime, and improve efficiency. This is why the projects department remains in a growth phase, with the bulk of its work being secured in the rest of Africa at present. In this regard, it also works closely

Enquiries: www.bearings.co.za

and 500 V. It enhances the capability of the PowerFlex dc drive family, designed for demanding, standalone and coordinated drive system applications. The PowerFlex dc drive family is well suited for dc motor applications and retrofits up to 6 000 Hp or 4 000 kW. The PowerFlex dc family has core capabilities aligned with the PowerFlex ac family of drives, including seamless integration into a Logix-based environment, flexible feedback and communication options, as well as voltage settings designed to global standards. with the Exports Department, headed by Marcio Sicchiero, to realise additional opportunities on the continent. M-Series industrial gear units In terms of main products, the M-Series industrial gear units (the M indicating modular) are ideal for meeting the high- est demands for quality, reliability, and performance. The product range has been optimised for a range of drive characteris- tics, allowing for simple machine design by easily adding options and mounting parts. A long service life is guaranteed as a result of highly efficient lubrication and sealing, which also cuts down on maintenance requirements. Easy mounting and installation are facilitated by advanced features such as EBD (extended bearing distance) and an axial thrust bearing arrangement on the output shaft. Enquiries: www.rockwellautomation.com

SEW SUPPLIES INDUSTRIAL GEAR UNITS FOR WEST AFRICAN MINE

H aving an in-house projects department to focus on the specific requirements of project houses, OEMs and other tender-related project activity is starting to bear fruit for drive and automation special- ist SEW-Eurodrive South Africa, which has clinched an order for five M-Series industrial gear units for a mining operation in West Africa. The department, headed by Andreas Meid and with Pat Marquez as project sales coordinator and Brett Weinmann in charge of project sales development, oversaw this entire venture from receipt of the initial order to successful installation and commissioning at the mine, in addition to all back-up service and technical assistance required. It is this capability to offer complete solutions, as opposed to standalone products, in addition to the necessary aftermarket support, that has resulted in SEW’s projects division showing consistent growth year- on-year. “We pride ourselves on on-time delivery, which is a clear differentiator for us in a highly competitive market,” comments Meid. “We are committed to supplying high-quality products, in addition to the continuous improvement of our customer service offering.” The department also has a drawing office and a mechanical engineer to compile any calculations that are needed. Its core function is to respond to queries

from either project houses or OEMs for specific project work. It focuses mainly on Greenfield projects related to conveyors, agitators, and mixers in mineral-processing applications. “Based on enquiries received, we work in conjunction with the specific project house or OEM to offer a complete solution for their mining clients,” explains Meid. “In other words, our products essentially allow them to complete their portion of the work in hand.” Such collaboration between suppliers and related companies is a growing trend in response to a tough business environment,

Enquiries: www.sew-eurodrive.co.za

SPARKS ELECTRICAL NEWS

APRIL 2019