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Drive Centre Vicenza
Welcomes You All Welcomes You All
Control Techniques Control Techniques IndiaIndia
Drive Centre Vicenza
Founded in 1973 Founded in 1973 CT is a world leader CT is a world leader
in the in the Design,
Manufacture, Marketing and Application of….
AC & DC Drives, Servo Drives
Systems
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Every Electric Motor is Every Electric Motor is a Potential a Potential
Application for Control Application for Control Techniques productsTechniques products
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Control TechniquesControl Techniques -- a history of Firsts & Successa history of Firsts & Success
1986 Launches Mentor - world’s first digital DC drive
1989 Launches first closed loop Flux Vector drive
1995 Introduces the world’s first universal AC drive
1988 Launches world’s first IGBT-based digital AC Drive
We set the Benchmark for Drives We set the Benchmark for Drives We set the Benchmark for Drives We set the Benchmark for Drives
2002 Introduces world’s first “Solutions Platform” AC drive
2005 Introduces world’s first “knowledge” AC drive in small rating (Commander SK)
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Control Techniques IndiaControl Techniques India
CT India started in 1993CT India started in 1993
CT India is a fully owned subsidiary of CT India is a fully owned subsidiary of CT-Worldwide (CT - UK)CT-Worldwide (CT - UK)
CT-Worldwide is a fully owned CT-Worldwide is a fully owned company of the US Electrical company of the US Electrical conglomerate Emerson Electricconglomerate Emerson Electric
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• $20 Billion Fortune 500 $20 Billion Fortune 500 CompanyCompany
• Global product/market Global product/market leadershipleadership
• Recognized for outstanding Recognized for outstanding management practicesmanagement practices
• Strong International Strong International presencepresence
• Solid financial positionSolid financial position
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Sales by Business GroupSales by Business Group$20 Billion Total$20 Billion Total
Appliance & Tools23%
Electronics & Telecommunications
15%
Process Control21%
HVAC17%
Industrial Automation24%
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Expectations from Customers Today…For Plant Expectations from Customers Today…For Plant AutomationAutomation
Motors / Alternators
& Power Products
Single Point Source
Floor LevelFloor Level
Drives & Automation
Floor LevelFloor Level
Distributed Control
Plant LevelPlant Level
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Distributed Control
Motors / Alternators
Products
Drives & Automation
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United KingdomUnited KingdomNewtown, WalesNewtown, Wales
London
Headquarters R&D
Manufacturing Plant
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Situated in Newtown, Mid Wales country, UKSituated in Newtown, Mid Wales country, UK
The most advanced facility of its kindThe most advanced facility of its kind
Robotic Assembly of Drive modulesRobotic Assembly of Drive modules
800 Drives per day800 Drives per day
Control TechniquesControl Techniques
World Class Drive World Class Drive Manufacturing FacilitiesManufacturing Facilities
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Product PortfolioProduct Portfolio
General Purpose AC DrivesDC Drives
Cabinet Free AC Drives
Energy Saving Drive
High Performance AC Drives Motion Motion
ControllerController
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Product PortfolioProduct Portfolio
Networking And SoftwareProducts
Soft StartersSoft Starters Servo MotorsServo Motors
CTIU 200
OPERATOR INTERFACE
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Digital DC / AC Digital DC / AC DrivesDrives
MentorMentor : Digital DC : Digital DC 7.5 Kw to 750 7.5 Kw to 750 KwKw
Commander SK : Simple ,Knowledge 0.25 Kw to Commander SK : Simple ,Knowledge 0.25 Kw to 110Kw 110Kw
Unidrive SP : Solution Platform 0.75 Kw to Unidrive SP : Solution Platform 0.75 Kw to 1.0 MW1.0 MW
PV /EV - Fans & Pumps 5.5 Kw to PV /EV - Fans & Pumps 5.5 Kw to 280 Kw280 Kw
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Other ProductsOther Products
MC 204/216 - Motion Controller 4 to 16Axes MC 204/216 - Motion Controller 4 to 16Axes
CT START - Soft Starters 4 to 800 CT START - Soft Starters 4 to 800 Kw Kw
Unimotor - AC ServoUnimotor - AC Servo 1 to 70 1 to 70 NmNm
LSMVLSMV - Inverter Grade - Inverter Grade AC MotorsAC Motors 0.75 to 0.75 to
132 Kw132 Kw
SincrovertSincrovert - - AC Spindle Motors 0.75 to 110 AC Spindle Motors 0.75 to 110 Kw Kw
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Worldwide Operations
EUROPEEUROPE
ASIA PACIFICASIA PACIFIC
AMERICASAMERICAS
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Drive Centres in North AmericaDrive Centres in North America
Chicago
Toronto
Providence
Charlotte
Cleveland
Distributors S.America
Minneapolis (Head Office)
Dallas
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Drive Centres in Asia PacificDrive Centres in Asia Pacific
SouthAfrica
Australia
Thailand
India
S. Korea
China
Indonesia (distributor)
Malaysia
Singapore
Hong Kong
Taiwan
Vietnam (distributor)
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New Delhi Application CenterNew Delhi Application Center
Kolkata Application Center
Kolkata Application Center
Drive/Application Centers Drive/Application Centers
Indian OperationsIndian Operations
AhmedabadSales Office
AhmedabadSales Office
Pune Application CenterPune Application CenterChennai Drive CenterChennai Drive Center
Nagpur Sales OfficeNagpur Sales Office
Hyderabad Sales OfficeHyderabad Sales Office
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Control Techniques IndiaControl Techniques IndiaManufacturing & Support FacilitiesManufacturing & Support Facilities
Facilities / ExpertiseFacilities / ExpertiseTesting FacilitiesTesting Facilities
12,000 Sq. ft. Purpose built 12,000 Sq. ft. Purpose built factoryfactory
45 People ( of which 20 are 45 People ( of which 20 are Engineers) at ChennaiEngineers) at Chennai
15 People (of which 10 are 15 People (of which 10 are Engineers) in Branch OfficesEngineers) in Branch Offices
Extensive Systems CapabilityExtensive Systems Capability
Over 150 Domestic Projects Over 150 Domestic Projects
Over 50 Export Projects Over 50 Export Projects
Complete Manufacturing facilities Complete Manufacturing facilities with Test Set Upwith Test Set Up
Test Jigs for PCB’s (PC Based)Test Jigs for PCB’s (PC Based)
PROM ProgrammerPROM Programmer
DC Motors , AC Motors Test BedsDC Motors , AC Motors Test Beds
High Current Low Voltage Source High Current Low Voltage Source for Load Testfor Load Test
Insulation Tester, High Voltage Insulation Tester, High Voltage Break Down TesterBreak Down Tester
Training / RepairTraining / Repair
CT Approved Training CentreCT Approved Training Centre
CT Approved Repair CentreCT Approved Repair Centre
Component Level Repair FacilityComponent Level Repair Facility
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HIGHHIGH
PERFORMANCEPERFORMANCE
INTELLIGENT DRIVESINTELLIGENT DRIVES
FORFOR
SYSTEMSSYSTEMS
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Digital DC DrivesDigital DC DrivesMentor II - Mentor II - Flexible Systems Drive - Flexible Systems Drive - 25 to 1850A25 to 1850A
Single & Four QuadrantSingle & Four Quadrant6-pulse Fully Digital6-pulse Fully Digital
7.5 -75kW100-300kW
300 – 750kW
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Mentor Family RangeMentor Family Range
0.75-75KW
H-370 mmW-250 mmD-195mm
300-750KW
H-1355 mm W-450 mm D-510 mm
100-300KW
H-423 mm W-450 mm D- 280 mm
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VoltageVoltage
220-480 V +/- 10%220-480 V +/- 10%
Suitable for Global Power Suitable for Global Power SuppliesSupplies
NO Tap SelectionsNO Tap Selections
MENTOR INPUT SPECSMENTOR INPUT SPECS
VoltageVoltage
525 V and 660 V525 V and 660 V(Optional)(Optional)
FrequencyFrequency
47-62 Hz.47-62 Hz.
Wide tracking Range for PLLWide tracking Range for PLL
TemperatureTemperature
40 Deg C for Power40 Deg C for PowerDerating upto 55 Deg CDerating upto 55 Deg C
Electronics upo 55 Deg CElectronics upo 55 Deg C
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Phase SequencePhase Sequence
Insensitive to Supply Phase Insensitive to Supply Phase SequenceSequence
MENTOR featuresMENTOR features
Field ControlField Control
Controlled FieldControlled Field
Field weakening Inbuilt Field weakening Inbuilt and Programmableand Programmable
Field ControlField Control
Inbuilt (8 A) upto 210 AInbuilt (8 A) upto 210 A20 A External20 A External
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Analog InputsAnalog Inputs6 Nos.6 Nos.
4 No. Programmable (Volt)4 No. Programmable (Volt)1 No. Dedicated 1 No. Dedicated
(Volt/Current Selectable) (Volt/Current Selectable) 1 No. Dedicated for Motor 1 No. Dedicated for Motor
ThermistorThermistor
MENTOR I/OMENTOR I/O
Analog OutputsAnalog Outputs4 Nos.4 Nos.
3 No. Programmable (0-10 Volt)3 No. Programmable (0-10 Volt)1 No. Dedicated 1 No. Dedicated
(10Volt=200%Current ) (10Volt=200%Current )
Digital InputsDigital Inputs10 Nos10 Nos
2 Dedicated 2 Dedicated
8 Programmable 8 Programmable
Digital OutputsDigital Outputs7 Nos7 Nos
1 Dedicated Relay1 Dedicated Relay1 Programmable Relay1 Programmable Relay
5 Programmable 5 Programmable (Open Collector Type)(Open Collector Type)
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The most versatile DC systems drive in the world
More than 3000 drives in India
More than 125,000 drives in use world-wide
Drive Centre Vicenza
The most versatile DC systems drive in the world
Control Techniques alsoControl Techniques also
Brand LabelsBrand Labels Digital DC Drives for..Digital DC Drives for..
CGEE ALSTOM CGEE ALSTOM
(FRANCE)(FRANCE)
CGEE ALSTOM CGEE ALSTOM
(FRANCE)(FRANCE)
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UnidriveUnidrive
Unified AC Drive with Solution PlatformUnified AC Drive with Solution Platform
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Application Type of Control What you get…
Fan/Pump / Conveyors V/f Open Loop
No Speed Loop
No Current Loop
Constant Torque Load Mostly O/L Vector Full Torque to 1 Hz
No Speed Loop
Good Current Loop
Cranes / Hoists
Process Lines
Sectional Drives
Closed Loop Flux Vector Full Torque upto Standstill
Excellent Speed & Current Loop
Very good Dynamic responses
Servo Applications Servo Full Torque upto Standstill
Excellent Speed, Current & Position Loop
Very good Dynamic responses
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UniSP – The Universal Drive With Solution UniSP – The Universal Drive With Solution PlatformPlatform
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The The UniSP UniSP Advantage Advantage
Single Drive from Simple to Complex Single Drive from Simple to Complex applicationsapplications
Can be adapted to any mode of operation by Can be adapted to any mode of operation by simple parameterisationsimple parameterisation
Single Learning Curve for End-userSingle Learning Curve for End-user
Single Control module for all sizesSingle Control module for all sizes
Minimum InventoryMinimum Inventory
Integral Braking module for all sizesIntegral Braking module for all sizes
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• 200/240V 3ph, 50/60Hz
• 380/480V 3ph, 50/60Hz
• 500/600V 3ph, 50/60Hz
• 500/690V 3ph, 50/60Hz -
Global power suppliesGlobal power supplies
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6 (//)54321 7(//)
575V
400V
220V
15
11
22114.0
5.52.2 22
LV 48 / 96Vdc
45 75 132 160
37 55 90 132
45 75
- Servo, Closed loop-Open loop, V/F-- Open loop, V/F,Servo, Regen
110 160690V
110%
150%
175%
KW
O/L
Volts
*8
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Input VoltageInput Voltage
380-480 V +/- 10%380-480 V +/- 10%
NO Tap SelectionsNO Tap Selections
UNISP SPECSUNISP SPECS
Output FrequencyOutput Frequency
0-3000 Hz0-3000 Hz
Suitable for Suitable for High Frequency SpindleHigh Frequency Spindle
Input FrequencyInput Frequency
47-62 Hz.47-62 Hz.
Switching FrequencySwitching Frequency
3/4/6/8/12/16 KHz3/4/6/8/12/16 KHz
Quiter OperationQuiter Operation
Reduced HarmonicsReduced Harmonics
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Ambient Ambient
40 Deg C 40 Deg C
1 % per Deg C deration for 1 % per Deg C deration for 40- 50 Deg C 40- 50 Deg C
Environmental Specs Environmental Specs
Module IP ratingModule IP rating
IP 20IP 20
Nema 1Nema 1
Special Cooling FansSpecial Cooling Fans
Suitable for IP54 Suitable for IP54
Extended IP ratingExtended IP rating
IP54 IP54
Nema 12Nema 12
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48V DC supply input48V DC supply input
Ideally suitable for
Emergency battery operation for lift rescue
Limited speed set up for Machine Tool robot cells
Jog Operation in Extruders in case Of Power failure
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24V DC Auxiliary Power 24V DC Auxiliary Power
• External 24V / 2A input for control backup
• Encoder position retained
• Fieldbus stays live
• Safe programming of drive
• Additional means of Maintaining control
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Intelligent Options for AC Drives…Intelligent Options for AC Drives…
– Palm-sized Second ProcessorPalm-sized Second Processor
– Intel i960 32-bit RISC Intel i960 32-bit RISC processorprocessor
– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity
– Programming in Ladder / Programming in Ladder / Function Blocks or ScriptFunction Blocks or Script
– Connects to Remote I/O BlocksConnects to Remote I/O Blocks
– Distributes Real Time ControlDistributes Real Time Control
Zero Zero Space Space PLCPLC
Plugs into Plugs into Drive Drive modulemodule
CalculatCalculatee
LogicLogic
ConnectConnect
SystemsSystems
Connect Connect I/OI/O
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SM-I/O Plus
SM- PROFIBUS-DP
SM-Applications
SM-Universal Encoder Plus
SM-CANopen
SM- DeviceNet
SM-INTERBUS
SM-Applications Lite
SM-ResolverSM- Encoder Plus
SM-CAN
SM-Ethernet
SM-SLM
SM-SERCOS
• Customisation at point of uses• 3 options,X million number of combinations
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Unidrive SP with all front cover removed
Option module docking bays
Universal encoder connector(will accept 12 different types of encoder)
Control Terminals with safety disable function as standard
AC input power and motor connections
Relay connections
Cable support bracket
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Option Module AssemblyOption Module Assembly
• Application Module (incl CTNet)
• Profibus DP• Devicenet • Interbus S• CANopen • Ethernet • SERCOS • Extra I/O
• 2nd Encoder• Resolver• SLM• “Easy Motion”
PowerTools
Designed to Empower
ApplicationsEngineers
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UniDrive SP Field Bus GatewayUniDrive SP Field Bus GatewaySmart Card Facility - As standardSmart Card Facility - As standard
• Hot pluggableHot pluggable
• Auto backup of parametersAuto backup of parameters
• Fast low cost cloningFast low cost cloning
• Fast Network Start-Up’sFast Network Start-Up’s
• Up to 4 full parameter sets Up to 4 full parameter sets
• Supplied as standard with Supplied as standard with UniDrive SPUniDrive SP
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Field Bus ConnectivityField Bus Connectivity
Modules are available for
Modbus RTU ProfibusDeviceNetCANopenInterbus SSercos EthernetCTNet,
RS485 PortModbus (RTU or ASCII)
Johnson Controls (Metasys)CSI
Drive Centre Vicenza
Level – 1Addl. Hardware – NilMemory - 4k ExeProg. Software – SyPT Lite
PLC FUNCTIONALITY IN UNISPPLC FUNCTIONALITY IN UNISP
Level – 2Addl. Hardware – SM Appln Lite (Option)Memory - 10 k ExeProg. Software – SyPT Lite
Level – 4Addl. Hardware – SM Appln+ CT Net (Option)Memory – 384k Exe, 80k RAMProg. Software –
SyPT Pro (Option)
Level – 3Addl. Hardware – SM Appln Lite (Option)Memory - 100k Exe, 20k RAMProg. Software –
SyPT Pro (Option)
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DRIVE PROGRAMMINGDRIVE PROGRAMMING
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Application ProgrammingApplication Programming
SyPT PROSyPT PRO
• Industrial NetworkingIndustrial Networking
• Realtime MultitaskingRealtime Multitasking
• Confirms to IEC 61131-3Confirms to IEC 61131-3
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Programming ToolProgramming Tool
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SYPT OverviewSYPT Overview
• Main Areas– ConfigurationConfiguration– ProgrammingProgramming– DPL EditorDPL Editor– Function Block EditorFunction Block Editor– Quick Ladder EditorQuick Ladder Editor– Watch WindowWatch Window– Function BlocksFunction Blocks
• Standard Library
• User Define
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Configuration Configuration EditorEditor
• Project Oriented.
• Configuration of:-– Distributed CTNet SystemsDistributed CTNet Systems
OPC Server availableOPC Server available..
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DPL EditorDPL Editor
• Drive Prog Language(Quick Basic)
• Standard constructs like IF, THEN,ELSE as well as Loops
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Quick Ladder EditorQuick Ladder Editor
• Compliant to -61131
• Quick development of boolean and function block ladder diagrams.
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Function Block EditorFunction Block Editor
• Compliant to -61131
• Library of more than 256 Function Blocks.
• Can create additional Function Blocks
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Function BlocksFunction Blocks
• Standard Library– Floating Point & Integer Floating Point & Integer
Types.Types.– DPL commands, std DPL commands, std PLC PLC
functionsfunctions, Motion & , Motion & communication types.communication types.
– Maintained by SSPD.Maintained by SSPD.– Powerful:-Powerful:-
• Development.
• Modular
• Easy to Understand
• Common standard block
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Allows you to Allows you to Monitor the Drives Monitor the Drives Parameters and Parameters and
Program Variables.Program Variables.
Immediate Window Allows Immediate Window Allows you to Set the Drive you to Set the Drive
Parameters or Program Parameters or Program Variables and Monitor Variables and Monitor
status.status.
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Help filesHelp files
SyPTPro Includes a SyPTPro Includes a comprehensive help file comprehensive help file and the manuals for all and the manuals for all
related products.related products.
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RemoteI/O
CTNet @ 5Mbps
Ethernet
CT-Net System: CT Digital DrivesSCADA - CT32CTIU user interfacefor Local Monitoring CTNet I/ORepeaters/Hubs
Hub
R
Repeater
RemoteI/O
SCADAMMI - CT32
ProgrammingDiag. Tools PC Gateway
CT Net Distributed Control SystemCT Net Distributed Control System
CTIU CTIUCTIU
CTIU
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Cranes
Fans & Pumps
Food and Drink
Material Handling
Metals & Metal FormingPaper
Printing
Rubber & Tyre
Stage Scenery
Textiles Wire Drawing
Industrial Sector Industrial Sector FocusFocus
Plastic
Oil & Gas
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Control Techniques are Control Techniques are the preferred Suppliers the preferred Suppliers
to…to…
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Control Techniques India is Preferred Control Techniques India is Preferred Supplier toSupplier to
TISCOTISCO TELCOTELCO TUBE PRODUCTSTUBE PRODUCTS STEELCO GUJRATSTEELCO GUJRAT ESSARESSAR
FLAT PRODUCTSFLAT PRODUCTS MULTIFORMMULTIFORM
NESTLENESTLE BALKRISHNA TYRESBALKRISHNA TYRES
BALLARPUR INDUSTRIESBALLARPUR INDUSTRIES SHESASAYEE PAPER AND BOARDS SHESASAYEE PAPER AND BOARDS
LUCAS TVSLUCAS TVS BRAKES INDIABRAKES INDIA
KOHLI INDUSTRIESKOHLI INDUSTRIES
and ………..so onand ………..so on
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CT India Sample ReferencesCT India Sample ReferencesAutomation Solutions for Metal IndustryAutomation Solutions for Metal Industry
• Over 40 Customers Served till dateOver 40 Customers Served till date• Major Repeat References include:Major Repeat References include:
– TISCO (Over 35 projects till date)– Salem Steel– Flat Products Equipment (Process Line OEM) – Over 20 Export Projects– Multiform Machinery (Process Line OEM) – Over 10 Projects– Visakhapatnam Steel Plant– Metastrips– ITW Signode– PHP Steel - Bangladesh– Karnafully Steel - Bangladesh– Tube Product of India– Pennar Steel– Ispat Industries– SteelCo Gujarat– Shree Pre-Coated Steels
• Applications Expertise in:Applications Expertise in:
– Rolling MillsRolling Mills– Skin Pass RollingSkin Pass Rolling– Continuous Galvanizing LineContinuous Galvanizing Line– Cut-To-Length LineCut-To-Length Line– Pickling & Slitting LinesPickling & Slitting Lines– Rewinding & Electro-Cleaning LineRewinding & Electro-Cleaning Line– Color Coating LineColor Coating Line– Partial Line Upgrades + RetrofitsPartial Line Upgrades + Retrofits– Fan & PumpsFan & Pumps– Flying ShearsFlying Shears
• Supplies include Drive Systems + SCADA + PLC Automation + Motors + MCC’sSupplies include Drive Systems + SCADA + PLC Automation + Motors + MCC’s
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Galvanising Lines Galvanising Lines
• Karnafully Steel - Bangladesh (Thru, MAS )
• Rajesh Metals - Nepal (Thru, MAS )
• PHP Steel, Bangladesh
• PT Essar Indonesia
• Kandil Steels,Egypt
• Yung Kong Steel , Malaysia
(PCC+MCC+Drives( AC ) + LINE PLC + FURNACE PLC + SCADA +UPS)
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Galvanising Lines Galvanising Lines
• Cheman Ispat, Bangladesh (Thru’ Multiform)
• PHP Steel, Bangladesh
• YESU STEEL, ETHIOPIA
• VARDHAMAN STEELS, AMBALA(DC )
• Kandil Steels, Egypt
• Midgal, Nigeria
• Doo Won Steel, Korea
PCC+MCC+Drives( DC ) + LINE PLC + FURNACE PLC PCC+MCC+Drives( DC ) + LINE PLC + FURNACE PLC
+ SCADA +UPS + SCADA +UPS
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Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills
• Tube Products of India( 4 Hi)
• Shamon Ispat Ltd( 4 Hi)
• Meta Strips(4 Hi)
• Kandil Steels, Egypt( 4 Hi)
• Karnafully, Bangladesh(4 Hi and 20 Hi)
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Steel IndustrySteel IndustrySkin Pass MillSkin Pass Mill
• Essar Steel, Indonesia
• Kandil Steels, Egypt
• KYCR Steel, Bangladesh
• SPSL, Pune
• Balco(Slab)
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Steel IndustrySteel IndustrySlitting LineSlitting Line
• Raymonds Ltd (3 Lines)• Meta Strips• Pennar Steel• SPSL,Pune• TATA SSL,Navsari-C.R.Slitter (thro. Metpro)• TATA SSL,Navsari-H.R.Slitter (thro. Hollow
Block)• Tube Products Of India
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Steel IndustrySteel IndustryCCUT TO LENGTH LINEUT TO LENGTH LINE
• Tube Products of India-3 Lines• TATA SSL• Dass Nagar (A/c.Galsheet , Kenya)• Flat Products (A/c. Uttam Steel revamping)• Flat Products (A/c.PHP Steels)• Flat Products (A/c.Apollo Steels) • Flat Products (A/c.R.M. Steels)• T.K.Steels
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Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line
• Jai Corp
• Meta Strips
• S Alam , Bangladesh
• Lloyds Steel
• Essar, Hazira
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Steel IndustrySteel IndustryPickling Line / Cleaning LinePickling Line / Cleaning Line
• Flat ProductsKandil Steel Steel,Egypt.R.M.Steel BangladeshYung kong Steels, MalaysiaYesu Steel, EthiopiaMobati Steel,Kenya
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Steel Industry Steel Industry Rewinding Line Rewinding Line
Flat Products:
R.M. Steels,Bangladesh
Yesu Steel, Ethiopia
PHP Steel,Bangladesh
Apollo Steels, Bangladesh
Jindal Steel, Kolkata
Uttam Steel, Khopoli
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Steel Industry Steel Industry Rewinding Line Rewinding Line
PT Essar, Indonesia
SPSL,Pune
S ALAM, Bangladesh(Thru’ Multiform)
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Steel Industry Steel Industry TLL TLL
PT Essar, Indonesia
SPSL,Pune
Jai Corp, Nanded
Mobati Steels, Kenya
Multiform(at Malaysia)
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TISCO TISCO
• ROLLER TABLE DRIVE SYSTEM – 315 KW * 8 SETS (Getting upgraded to 480 Kw)
• GAS BOOSTER FANS – 450 KW – 5 NOS
• THYRISTOR CONVERTERS FOR HSM- 16 SETS
• VARIOUS UPGRADES
• MORE THAN 500 Modules of Various Ratings
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Wire Rod Mills Wire Rod Mills • TAMILNADU STEEL, ARAKONAM
• NATIONAL ENGG, CHENNAI
• SUMANGALA STEEL, BHUVANGIRI
• INDO BAZHA , INDONESIA ETC
DC Drives (Stand ,Coilers) + PLC + AUTOMATIONDC Drives (Stand ,Coilers) + PLC + AUTOMATION
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CRANES CRANES
• SALEM STEEL PLANT
• TATA STEEL
• TATA MOTORS , PUNE
• RANK CRANES, HYDERABAD ETC
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Additionally Additionally
• Wagon Tippler Drives in VSP
• Static Excitation for Generators
• Double Column Planing Machine Controls Retrofit for BHEL ,with Active Front end
• 12 Pulse Converters for Banbury Mixers
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Steel IndustrySteel IndustryCold Rolling MillsCold Rolling Mills
• Tube Products of India
• Shamon Ispat Ltd
• Meta Strips
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 1993 /1994• Uncoiler : 2 x 75 HP / 250 V DC• Main Mill : 300 HP• Coiler : 2 x 75 HP / 250 V DC• PLC : S 135• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 2005
• Uncoiler : L&T Stack with Mentor Electronics
• Main Mill : 375 Kw/ 575 V(New)
• Coiler : L&T Stack with Mentor Electronics
• PLC : S-7/400
• MMI : Win CC
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Steel Industry- Tube Mills for China Steel Industry- Tube Mills for China Tube Products of India HighlightsTube Products of India Highlights
• Supplied & Commissioned in 2006
• Forming/Fin Pass/ Sizing: 150 Kw DC
• Accumulator: 55 Kw AC
• Pinch Rool:30 Kw AC
• Shear: 55 Kw AC
• Carriage : 60 Nm Servo
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Shamon Ispat Ltd – Haldia HighlightsShamon Ispat Ltd – Haldia Highlights
• Supplied & Commissioned in 1998 / 1999 • Uncoiler : 500 HP / 600V• Main Mill :1500 HP /600V• Exit Coiler : 500 HP / 600V• Screw Down : 50 HP / 250V each near /far
• PLC : GE Fanuc • MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi Shamon Ispat Ltd A/c. Karnafully Steels- 4 Hi MillsMills
• Supplied in 1999 & Commissioning under progress• Payoff : 60 HP / 250V• Entry Coiler : 500 HP / 600V• Mill Drive: 1500 HP / 600V• Exit Coiler : 500 HP / 600V• Screw down : 50 HP /250V each far/near• PLC : GE Fanuc• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling Mills Karnafully Steels- 20 Hi MillsKarnafully Steels- 20 Hi Mills
• Supplied in 2003 & Commissioned in 2004• Payoff : 100 HP / 400V• Entry Coiler : 2*950 HP/350V(Series)• Mill Drive: 2*1800 HP/ 750V(Tandem)• Exit Coiler : 2*950 HP/350V(Series)• Screw down : 50 HP /250V each far/near• PLC : GE Fanuc• MMI : Intellution
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Steel Industry- Steel Industry- Cold Rolling MillsCold Rolling MillsMeta Strips HighlightsMeta Strips Highlights
• Supplied & Commissioned in 1999/ 2000
• Pay Off : 50 Kw
• Uncoiler : 230 Kw
• Main Mill : 600 Kw
• Coiler : 230 Kw
• PLC : S7 300
• MMI : PCIM
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Steel Industry Hot Mills Steel Industry Hot Mills Sumangala Steel Sumangala Steel
• Supplied & Commissioned in 1995 /1996
• Main stand : 6 x 200 Kw
• Coiler : 2 x 15 Kw
• Pinch Roll : 2 x 15 KW
• PLC : S 135
• MMI : Intellution
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Steel Industry Hot MillsSteel Industry Hot MillsIndo Baja - Indonesia Indo Baja - Indonesia
• Supplied & Commissioned in 1997 /1998
• Main stand : 3 x 400 Kw
• PLC : S 135
• MMI : Intellution
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How have we been sustaining this Success How have we been sustaining this Success ––
Year after Year?Year after Year?
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The Driving Force behind our The Driving Force behind our success….success….
Application Specific Engineered Systems – We have Application Specific Engineered Systems – We have the Experience!the Experience!
Able to obtain the latest technology in Automation – Able to obtain the latest technology in Automation – No CompromisesNo Compromises
Product Leadership positionProduct Leadership position
Getting the most-up-to-date engineering design – Getting the most-up-to-date engineering design – Due to our Shared Resource NetworkDue to our Shared Resource Network
All our Drive products carry a Product Warranty for 2 All our Drive products carry a Product Warranty for 2 Years & your nearest Support Centre will honour all Years & your nearest Support Centre will honour all Warranty Commitments for supplies made to youWarranty Commitments for supplies made to you
Excellent and prompt after sales service support Excellent and prompt after sales service support
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INTELLIGENCE INTELLIGENCE
IN IN
DRIVESDRIVES
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Intelligence in DrivesIntelligence in Drives
Modern System RequirementsModern System Requirements
High Resolution Speed Ref(Master High Resolution Speed Ref(Master Speed)Speed)
Draw Calculations(Section Draws)Draw Calculations(Section Draws)
Diameter Calculations and Diameter Calculations and TensionReference Generation(Uncoilers)TensionReference Generation(Uncoilers)
Length ComputationsLength Computations
Logical Decision MakingsLogical Decision Makings
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INTELLIGENCE IN DrivesINTELLIGENCE IN Drives
All these require quite a good amount of All these require quite a good amount of Computing Power and hence need of Computing Power and hence need of Additional Processor.Additional Processor.
While selecting the control system,other While selecting the control system,other parameters also need considerationparameters also need consideration
• Updates need to be periodic & Updates need to be periodic & deterministicdeterministic (Data must arrive at regular (Data must arrive at regular guaranteed time intervals)guaranteed time intervals)
• The period or cycle of updates The period or cycle of updates should be should be synchronizedsynchronized with the digital control loops with the digital control loops in the drive / controller to eliminate any in the drive / controller to eliminate any undesirable “beating” effectsundesirable “beating” effects
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVES
• In addition to these critical parameters, In addition to these critical parameters, Non-Time critical access to network should Non-Time critical access to network should also be supportedalso be supported (e.g. Operator (e.g. Operator interaction / Drive set-up / Downloading interaction / Drive set-up / Downloading application software / Diagnostics / Data application software / Diagnostics / Data logging)logging)
• Implementation can be by Centralized Implementation can be by Centralized Intelligence or Distributed Intelligence Intelligence or Distributed Intelligence approachapproach
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Configuration PossibilitiesConfiguration PossibilitiesCentral IntelligenceCentral Intelligence
• All System Control Functions can be All System Control Functions can be located in the Central Controller & transfer located in the Central Controller & transfer Demands + Feedbacks cyclically over the Demands + Feedbacks cyclically over the network. This is a typical network. This is a typical Centralized Centralized Intelligence systemIntelligence system
Most PLC manufacturers prefer this Most PLC manufacturers prefer this approach even for Drive digital control for approach even for Drive digital control for obvious reasons!!obvious reasons!!
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVESC.T. ApproachC.T. Approach
• C.T.uses Distributed Control and pioneered C.T.uses Distributed Control and pioneered use of an additional Microcomputer Board use of an additional Microcomputer Board fitted on the Drive.fitted on the Drive.
• This function board is called MD29 and This function board is called MD29 and uses a 32 bit 2uses a 32 bit 2ndnd Processor for onboard Processor for onboard maths and logicsmaths and logics
• All Drive related functions and calculations All Drive related functions and calculations reside as preprogrammed Macros and the reside as preprogrammed Macros and the user has just to enter certain system datauser has just to enter certain system data
• The 2The 2ndnd Processor will communicate with Processor will communicate with the processor in the Drive and execute the the processor in the Drive and execute the additional functions with timings additional functions with timings synchronised with Drive Processorsynchronised with Drive Processor
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Distributed Architecture BenefitsDistributed Architecture Benefits
• With Distributed architecture, With Distributed architecture, the the load on the networkload on the network is reduced to a is reduced to a large extentlarge extent
• Peer-To-Peer communications is Peer-To-Peer communications is possible. This allows data to be possible. This allows data to be shared easily between the nodes shared easily between the nodes without reducing network speedswithout reducing network speeds..
• The The dynamic performance dynamic performance of the of the system is better handled by system is better handled by distributed systems.distributed systems.
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INTELLIGENCE IN DRIVESINTELLIGENCE IN DRIVESC.T. ApproachC.T. Approach
Add-On Co-Processor Add-On Co-Processor Card for Mentor IICard for Mentor II
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Intelligent Options for AC Drives…Intelligent Options for AC Drives…
– Palm-sized Second ProcessorPalm-sized Second Processor
– Intel i960 32-bit RISC Intel i960 32-bit RISC processorprocessor
– With High-speed Fieldbus With High-speed Fieldbus ConnectivityConnectivity
– Programming in Ladder / Programming in Ladder / Function Blocks or ScriptFunction Blocks or Script
– Connects to Remote I/O BlocksConnects to Remote I/O Blocks
– Distributes Real Time ControlDistributes Real Time Control
Zero Zero Space Space PLCPLC
Plugs into Plugs into Drive Drive modulemodule
CalculatCalculatee
LogicLogic
ConnectConnect
SystemsSystems
Connect Connect I/OI/O
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The 1986 Industrial Revolution.The 1986 Industrial Revolution.
• In 1986 Control Techniques launches MD21.– The birth of the intelligent drive.The birth of the intelligent drive.
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From revolution to evolutionFrom revolution to evolution
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Hardware EvolutionHardware Evolution
MD21
MD29
UD70
MD29AN
UD75SM-Applications
1st Generation 2nd Generation 3rd Generation
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Software EvolutionSoftware Evolution
Terminal Window DPL Toolkit
SyPT V1
1st Generation 2nd Generation 4th Generation3rd Generation
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Functionality Functionality EvolutionEvolution
Intel Basic with Parameter
Access
Winder, Digital Lock, Spindle Orientation, kWh
Software, PID
Advanced Position
Controller added
Winder, Flying Shear and Duty Assist Solutions
PLCOpen Function Blocks
Windows Software, Multi-Tasking Environment, Drive Programming
Language (DPL)
Function Block and Ladder Support, CTNet support.
Constant Function Block Development
Constant Fieldbus Development
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MD21 MD29 UD70 SM-Apps
Program Memory
32Kb 96Kb 256Kb 384Kb
Variable Memory
8Kb 44Kb 80Kb
Execution Speed
<1% 90% 90% 100%
Processor Intel Basic Interpreter
I960 (16kHz) I960 (16kHz) Hitachi SH2 (28kHz)
Multi-Tasking
No Yes Yes Yes
Functionality Evolution
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Example Line Configuration Example Line Configuration
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ENTRY SECTION
PROCESS SECTION
GENERAL LAYOUT OF CONTINUOUS PICKLING LINE
EXIT SECTION
PROCESS SECTION
PROCESS SECTION
UNCOILER PR. CUM FLATT. EDGE TRIMMER PINCH ROLL
FOR LENGTHCOUNTING
PINCH ROLL RECOILER
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Master Reference GenerationMaster Reference Generation
• A Basic Programme is written in MD29AN card simulating up-A Basic Programme is written in MD29AN card simulating up-down counter operationdown counter operation
• Accuracy is 1 in 64000Accuracy is 1 in 64000• Increase and Decrease in adjustable steps (Ramp adjustable)Increase and Decrease in adjustable steps (Ramp adjustable)• Reference is transmitted in Digital form to other sections Reference is transmitted in Digital form to other sections
along CT Net busalong CT Net bus
Please note PLC is not used for Master ref Please note PLC is not used for Master ref generationgeneration
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Tension Control for UncoilerTension Control for Uncoiler
• MD 29AN is provided with Centre wind SoftwareMD 29AN is provided with Centre wind Software• Dia is calculated in MD29ANDia is calculated in MD29AN• Inertia compensation, Friction compensation etc. are inbuilt Inertia compensation, Friction compensation etc. are inbuilt
in MD29in MD29• Taper tension, Stall tension, dia hold, strip breakage Taper tension, Stall tension, dia hold, strip breakage
protection etc. are standard inbuilt facilities in MD29ANprotection etc. are standard inbuilt facilities in MD29AN
• Please note PLC is not used for Tension ControlPlease note PLC is not used for Tension Control
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Line Automation FeaturesLine Automation FeaturesFeatureFeature
• Loop Pit Control Loop Pit Control
• 2 No. Encoders will be mounted, (one on delivery side 2 No. Encoders will be mounted, (one on delivery side and another on entry side) for each loopand another on entry side) for each loop
• MD29AN is used for Counting and comparing the pulses MD29AN is used for Counting and comparing the pulses from both Encoders and the differential is a measure of from both Encoders and the differential is a measure of Loop.Loop.
• Depending upon required Loop,the speed of the Depending upon required Loop,the speed of the concerned DC Pinch Roll Units are modified such that concerned DC Pinch Roll Units are modified such that Process speed remains constant.Process speed remains constant.
Please note PLC is not used for Loop ControlPlease note PLC is not used for Loop Control
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Line Automation FeaturesLine Automation FeaturesFeatureFeature
• Squeeze Roll ControlSqueeze Roll Control
• The Encoder mounted on the delivery side of Loop Pit (in The Encoder mounted on the delivery side of Loop Pit (in the Process Section ) is used to measure the length of strip the Process Section ) is used to measure the length of strip (initiated after Head indexing)(initiated after Head indexing)
• Length counting is done in MD29 AN and passed to PLC on Length counting is done in MD29 AN and passed to PLC on BUS.BUS.
• PLC will initiate commands to squeeze rolls to lift whenever PLC will initiate commands to squeeze rolls to lift whenever welding is passing and after certain time, rolls would be welding is passing and after certain time, rolls would be lowered.lowered.
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Acid Dozing ControlAcid Dozing Control
• The length calculated is used on different scaleThe length calculated is used on different scale
• Acid pumps can be switched ON/OFF Acid pumps can be switched ON/OFF automatically after certain length of material is automatically after certain length of material is passed thru’ Process Section.passed thru’ Process Section.
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Line Automation FeaturesLine Automation Features
FeatureFeature
• Coil weight MeasurementCoil weight Measurement
• The existing weighing control system will The existing weighing control system will be connected to PLC System on the Bus.be connected to PLC System on the Bus.
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Line AutomationLine Automation
Drives (Network #1) Drives (Network #1)
• All Drives connected on Hi-speed CT NetAll Drives connected on Hi-speed CT Net
• Data Transfer at 5MB/S (Large amount of data Transmitted Data Transfer at 5MB/S (Large amount of data Transmitted quickly)quickly)
• Peer to Peer System and no Master PLC Controller requiredPeer to Peer System and no Master PLC Controller required
• Each node takes control of network on its turn to Each node takes control of network on its turn to communicate directly with other Network nodes.communicate directly with other Network nodes.
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Line AutomationLine Automation
Drives (Network #1) ……Drives (Network #1) ……
• Each Drive fitted with MD 29 AN Application cum Each Drive fitted with MD 29 AN Application cum Fieldbus Module with CT Net connectivityFieldbus Module with CT Net connectivity
• All Line specific controls like Tension control, Loop All Line specific controls like Tension control, Loop Control etc.are set up in Application Module,located Control etc.are set up in Application Module,located within drive module itself. This frees PLC from doing within drive module itself. This frees PLC from doing Maths functions related to Drive systems.Maths functions related to Drive systems.
• Fast real time control of equipment is achieved.Fast real time control of equipment is achieved.
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Line AutomationLine Automation
PLC’s in MCC/Main/Remote Racks PLC’s in MCC/Main/Remote Racks
(Network #2)(Network #2)
• All I/O’s are connected on fast Profi-bus NetworkAll I/O’s are connected on fast Profi-bus Network
• Remote stations are located to minimize cablingRemote stations are located to minimize cabling
• PC in ECR Room is loaded with PLC programme and PC in ECR Room is loaded with PLC programme and SyptSypt
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Line AutomationLine Automation
Interfacing between Two Bus Systems Interfacing between Two Bus Systems
• An UniSP Drive is usedAn UniSP Drive is used
• One Addon Slot is fitted with CTNet ModuleOne Addon Slot is fitted with CTNet Module
• Relevant FieldBus (Profibus/ Modbus / DeviceNet) Module Relevant FieldBus (Profibus/ Modbus / DeviceNet) Module from UniSP family is put in the 2from UniSP family is put in the 2ndnd Slot Slot
• Application Programme for Register to Register Transfer Application Programme for Register to Register Transfer is written by SyPTis written by SyPT
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Control Techniques IndiaControl Techniques India
Scope of Supply:
Drives, PLC & Scada system
Mill Specification:
Max. Speed: 300 MPM
Material Thickness: 0.2mm to 2.00mm
Material Width: 600mm to 1320mm
Maximum Roll Force: 3500 kN
Process Line : 4 Hi Non Reversible Skin Pass MillCustomer : Flat products Limited, IndiaEnd User : PT Essar Dhananjaya, IndonesiaContract value : US $ 180,000Project Team : Ganesh + Satish
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M 700 R M 420 R M 420 R M 420 R
ENT . BR IDLET O P 100 K W
ENT . BR IDLEBO T . 70 KW
EXIT . BR IDLET O P 100 K W
EXIT . BR IDLEBO T . 70 KW
REC O ILER 300 KW
ENT RY D EFLECT O R RO LL EXIT DEFLECT O R RO LL
L IN E C O N F IG U R A T IO N
LINE ENCO DER1024 PPR
LINE ENCO DER1024 PPR
PO R150 KW
M ILL200 KW
M 1200 RM 420 R M 825 R
1024 PPR 2500 PPR 1024 PPR 2500 PPR1024 PPR
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LINE DRIVES (7 Nos.)
DC CO NVERT ERS ANDDC M O T O RS
(7 Nos.)
M CC ANDFIXED SPEED AC
M O T O RS
M CC
ACB2500 A(F IXED)
M CCB630 A
DC M O T O RS T O BESUPPLIED BY O T HERS
FPE
C T INDIA
FPE
C T INDIA
INCOMER , - 2500 APOR - 150 KWENTRY BRIDLE BOTTOM - 70 KWENTRY BRIDLE TOP - 100 KWMILL STAND - 200 KWEXIT BRIDLE TOP - 100 KWEXIT BRIDLE BOTTOM - 70 KWRECOILER - 300 KW
FIXED SPEED AC M O T O RS T OBE SUPPLIED B Y O T HERS
P O W E R SU P P L Y D IST R IB U T IO N
350 A
C UST OM E R
ACB(EDO )
V.S.S
KWH
PV1
PA1A
V
FU
A.S.S
FU
433 V,2000KVA
ACB3200 A(EDO )
P D B
C UST OM E R
2100 A
3 Ø
, 4
Wir
e, 4
15 V
, 50
Hz
3 Ø
, 4
Wir
e, 4
15 V
, 50
Hz
POW ER SUPPLY DISTRIBUTION (SINGLE LINE DIAGRAM)
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DPM M I
F IE L D R IO (R S - 4 )
M A IN P L C
SPM C D (R S - 2 )
PLC S7-300
PO R C D (R S - 1 )
R E C O IL E R C D(R S - 3)
POR ENT. BRIDLETOP
M ILL EXIT. BRIDLEBOT.
EXIT.BRIDLE TOP
RECOILERENT. BRIDLEBOT.
UNI SP
GATEW AY
M PIA
HUB
CP5611 PCI20CP5611
E NGINE E R ING PC
H AR DWAR E :-C P5611 (DP/ M PI)PC I 20 (DR IVE S)
SOF T WAR E :-ST E P 7 (PL C )SYPT (DR IVE S APPL IC AT IO N)C T -NE T BR O WSE R (DR IVE PAR AM E T E R )
H M I F OR L INE
H AR DWAR E :-C P5611 (DP/ M PI)
SOF T WAR E :-WIN C C DE VE L O PM E NT(SC ADA1024 T AG
SYSTEM CONFIGURATION
DR IVE S & M C C (M AINPL C )
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SYSTEM CONFIGURATION FOR 4-HI SPM (Project GE)
MCC PANEL
MMI
5611
FIELD RI/O
DRIVE PANELS
HMI
INCOMER , - 3200 A
POR - 150 KW
ENTRY BRIDLE BOTTOM - 70 KWENTRY BRIDLE TOP - 100 KW
MILL STAND - 200 KW
EXIT BRIDLE TOP - 100 KWEXIT BRIDLE BOTTOM - 70 KW
RECOILER - 300 KW
ENGINEERING PC ( DRIVES & PLC)
POR CD
PCI 20
MMI PC
RS - 4
PLC S7- 300DP
DP
UNI SPGATW AY
HUB
MAIN PLC
POR ENT. BRIDLE BOT.
5611
ENT. BRIDLE TOP MILL EXIT. BRIDLE BOT. EXIT. BRIDLE TOP RECOILER INCOMER
COILER CD
PC TABLE
PC TABLE
SPM CD
RS - 1
0 0
RS - 3 RS - 2
CONTROL CABLE
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Control Techniques IndiaControl Techniques India
Application Motor Rating Drive Rating
Uncoiler 225kw M 1850R
Entry Bridle Roll – M1
90kw M550R
Entry Bridle Roll – M2
140kw M550R
Mill Stand 250kw M1850R
Exit Bridle Roll – M1
140kw M550R
Exit Bridle Roll – M2
90kw M550R
Recoiler 325kw M1850R
Application Module : MD29ANPLC : Siemens, S7 - 400Gateway Module : UniSP + SM Application + SM ProfibusScada System : WinCC V 5.1
Process Line : 4 Hi Non Reversible Skin Pass Mill
End User : PT Essar Dhananjaya, Indonesia
Project Team : Ganesh + Satish
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Control Techniques IndiaControl Techniques India
• Time taken for commissioning
I/O Checking 5 Mandays
No Load motor Test 2 Mandays
Operation from CD with interlock
3 Mandays
Drive Software Simulation Test 1 Manday
Interaction withAEC Panel Check
1 Manday
SCADA Modification 2 mandays
Commissioning 3 Mandays
Post Commissioning Observation/Tuning
5 Mandays
Process Line : 4 Hi Non Reversible Skin Pass Mill
End User : PT Essar Dhananjaya, Indonesia
Project Manager: B. Ganesh + Satish
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Drive Centre Vicenza
• End-Customer: M/s PT.Essar, Indonesia
• Application: Continuous Galvanizing Line(Non-OX Furnace)
• OEM: M/s Flat Products Equipment (I) LtdMumbai, India
• Contract Date: 26th August 2003
• Contract Value: US $ 652,000
• Scope of Supply: Drives, PLC & SCADA Systems
• Commissioned on: October 2004
Project Details
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Line Specifications
• Max Machine Speed: – Entry Section: 190 MPMEntry Section: 190 MPM– Process Section: 150 MPMProcess Section: 150 MPM– Exit Section: 190 MPMExit Section: 190 MPM
• Material Thickness Range: – Min: 0.16 mm Min: 0.16 mm – Max: 2.00 mm Max: 2.00 mm
• Material Width Range:– Min: 600 mm Min: 600 mm – Max: 1320 mm Max: 1320 mm
• Max Furnace Capacity:– 25 Tons / Hour25 Tons / Hour
• Other Specialties:– Online 4-Hi Skin Pass MillOnline 4-Hi Skin Pass Mill– Online Tension Leveling LineOnline Tension Leveling Line– Online Chemical CoaterOnline Chemical Coater
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Drive System Details• There are 33 Nos. of Unidrive Classic and the Range of the Motors from 5.5 KW to 400
KW.
• All the Line Drives are connected on COMMON DC BUS.
• One no. of 2000 Amps Uncontrolled Diode bridge is there to provide the DC Supply.
• Also, there are 19 Nos. of Auxiliary Drives (5 Nos. Unidrive Classic for higher rating and Commander SE Drives for the remaining).
• Further,there are some emergency Drives, which are related to the furnace system
• 3 Nos. of Siliconics Soft Starters used for Heater Controls.
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Single Line Diagram (Line Drives)
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
L C 1
560V D C B U S
A
C T Q SP A
H LR Y B P H A SE O N
P VQ S
A.S .S
V .S .SF U
V~
~E~
QF(ACB)2000 A
(MF)
V O L T A G E : 415 V ± 10 % , F R E Q U E N C Y : 50 H z ± 3 %3Ø , 3 W IR E SY ST E M
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
F U
K M 1 K M 2
L C 1
E N C O D E R
M
M O T O R
E N.
L C 2
Q S
C h argin gresisto r
F U
K M 1 K M 2
L C 1
BR2000 A
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Drive Details (Line Drives)
Sr.No DescriptionMotorRatin
g
DriveRating
Apps.Module
1 Payoff # 1 110.0 UNI 4404 UD75
2 Payoff # 2 110.0 UNI 4402 UD75
3 Bridle # 1A 15.0 UNI 3401 ~
4 Bridle # 1B 15.0 UNI 3401 UD75
5 Bridle # 1C 18.5 UNI 3403 ~
6 Bridle # 1D 18.5 UNI 3403 UD75
7 Entry Accumulator 45.0 UNI 4401 UD75
Entry Section Drives
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Drive Details (Line Drives)
Process Section Drives (1 of 2)
Sr.No DescriptionMotor Rating
Drive Rating
Apps. Module
8 Bridle # 2A 30.0 UNI 3404 UD75
9 Bridle # 2B 30.0 UNI 3404 ~
10 Furnace Bridle A 5.5 UNI 2402 ~
11 Furnace Bridle B 18.5 UNI 3403 ~
12 Furnace Bridle C 30.0 UNI 3404 UD75
13 Bridle # 3A 37.0 UNI 3405 UD75
14 Bridle # 3B 37.0 UNI 3405 ~
15 Bridle # 4A 45.0 UNI 4401 UD75
16 Bridle # 4B 55.0 UNI 4402 ~
17 Backup Roll-Bot 160.0 UNI 5401 UD75
18 Backup Roll-Top 160.0 UNI 5401 ~
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Drive Details (Line Drives)
Sr.No DescriptionMotorRating
Drive Rating
Apps.Module
19 Bridle # 5A 75.0 UNI 4403 UD75
20 Bridle # 5B 132.0 UNI 5401 ~
21 Bridle # 5C 90.0 UNI 4404 UD75
22 Bridle # 6A 200.0 UNI 5401 UD75
23 Bridle # 6B 132.0 UNI 5402 ~
24 Chromate Coater#1 18.5 KW UNI 3402 UD75
25 Chromate Coater#2 18.5 KW UNI 3402 ~
26 Chromate Coater#3 18.5 KW UNI 3402 UD75
27 Chromate Coater#4 18.5 KW UNI 3402 ~
28 Bridle # 7A 75.0 UNI 4403 UD75
29 Bridle # 7B 55.0 UNI 4402 ~
Process Section Drives (2 of 2)
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Drive Details (Line Drives)
Sr.No DescriptionMotorRating
Drive Rating
Apps.Module
30 Exit Accumulator 55.0 UNI 4402 UD75
31 Bridle # 8A 37.0 UNI 3405 ~
32 Bridle # 8B 55.0 UNI 4402 UD75
33 Recoiler 400.0 UNI 5403 UD75
Exit Section Drives
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Single Line Diagram (Aux. Drives)
V O L T A G E : 415 V ± 10 % , F R E Q U E N C Y : 50 H z ± 3 %3P H A SE , 3 W IR E SY ST E M
AC TQ S
P A
H LR Y B P H A SE O N
P VQ S
A .S .S
V .S .SF U
V~
~E~
Q F 1600 A(ACB)
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
X
Q F
M
M O T O R
L C 2
F U
K M 1
L C 1
Drive Centre Vicenza
Drive Details (Aux. Drives)1 Jet Cool Fan # 1 22 KW 37 KW - SE
2 Jet Cool Fan # 2 22 KW 37 KW - SE
3 Jet Cool Fan # 3 22 KW 37 KW - SE
4 NOF flue Exhaust Blower 37 KW 37 KW - SE
5 Cooling Tower Blower # 1 90 KW UNI 4404
6 Cooling Tower Blower # 2 55 KW UNI 4403
7 Cooling Tower Blower # 3 55 KW UNI 4404
8 Air Knife Blower # 1 110 KW UNI 5402
9 Air Knife Blower # 2 110 KW UNI 5402
10 Jet Act Up/ Down # 1 2.2 KW 4 KW - SE
11 Jet Act Up/ Down # 2 2.2 KW 4 KW - SE
12 Jet Act In/ Out # 1 0.83 HP 1.1 KW - SE
13 Jet Act In/ Out # 2 0.83 HP 1.1 KW - SE
14 Jet Act In/ Out # 3 0.83 HP 1.1 KW - SE
15 Jet Act In/ Out # 4 0.83 HP 1.1 KW - SE
16 Boot Roll 5.5 KW 7.5 KW - SE
17 Entry Seal Roll 5.5 KW 11 KW - SE
18 Hearth Roll Drive # 1 7 x 2.2 KW 18.5 KW - SE
19 Hearth Roll Drive # 2 7 x 2.2 KW 18.5 KW - SE
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Automation Details• All the Line Drives are connected through CT-Net.
• The Auxiliary Drives & Soft starters are hard-wired to PLC.
• Automation (PLC) Part is segregated into two parts. One is Line controls & other is Furnace Controls.
• Siemens Step-7 PLC is used.
• S7 – 400 for Line Operations & S7 – 300 for Furnace Operations.
• There are 14 Nos. of Remote I/O Stations and all are connected through Profibus- DP.
• S7-400 & S7-300 Data exchange is done by Global Data Communication.
• Unidrive SP + SM-Apps + SM-Profibus are used as the communication gateway between drive system & PLC system
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Line SpecificationsCommunication Schematic
WinCC
scada1
Line PLC
(S7-400)
CTNet
Entry Section Drives
Remote I/O
Operator Interface Units
Process Section Drives Exit Section Drives
Profibus UniSP
As
Comm.
Gateway
UniSP
As
Comm.
Gateway
UniSP
As
Comm.
Gateway
Furnace PLC (S7-300)
Remote I/O
WinCC
scada2
Prog. Station
Drive Centre Vicenza
Profibus Routing
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY CDESA
PROFIBUSADDRESS : 51
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY CDRS # 7
PROFIBUSADDRESS : 22
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY FIELDRS # 12 (1/1)
PROFIBUSADDRESS : 21
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY FIELDRS # 12 (0/1)
PROFIBUSADDRESS : 20
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY M CCRS # 4
PROFIBUSADDRESS : 18
PROFIBUSCONNECTOR
A1 B1 S B2A2
PROCESS M CCRS # 5
PROFIBUSADDRESS : 19
PROFIBUSCONNECTOR
A1 B1 S B2A2
FURNACE PLCRACK # 4/4
PROFIBUSADDRESS : 17
PROFIBUSCONNECTOR
A1 B1 S B2A2
FURNACE PLCRACK # 3/4
PROFIBUSADDRESS : 16
PROFIBUSCONNECTOR
A1 B1 S B2A2
FURNACE PLCRACK # 2/4
PROFIBUSADDRESS : 15
PROFIBUSCONNECTOR
A1 B1 S B2A2
FURNACE PLCRACK # 1/4
PROFIBUSADDRESS : 14
PROFIBUSCONNECTOR
A1 B1 S B2A2
FURNACE PLC (CPU S7-300)RACK # 0/4
PROFIBUSADDRESS : 5
PROFIBUSCONNECTOR
A1 B1 S B2A2
M PIADDRESS : 5
PROFIBUSCONNECTOR
A1 B1 S B2A2
LINE PLC (CPU S7-400)RACK - UR2
PROFIBUSADDRESS : 2
PROFIBUSCONNECTOR
A1 B1 S B2A2
M PI ADDRESS : 2
PROFIBUSCONNECTOR
A1 B1 S B2A2
ENTRY DRIVESRS # 1
PROFIBUSADDRESS : 10
PROFIBUSCONNECTOR
A1 B1 S B2A2
AUX DRIVESRS # 3 (0 / 2)
PROFIBUSADDRESS : 11
PROFIBUSCONNECTOR
A1 B1 S B2A2
AUX DRIVESRS # 3 (1 / 2)
PROFIBUSADDRESS : 12
PROFIBUSCONNECTOR
A1 B1 S B2A2
AUX DRIVESRS # 3 (2 / 2)
PROFIBUSADDRESS : 13
PROFIBUSCONNECTOR
A1 B1 S B2A2
PULPIT CDRS # 8
PROFIBUSADDRESS : 25
PROFIBUSCONNECTOR
A1 B1 S B2A2
PROCESS FIELDRS # 13 (0 / 1)
PROFIBUSADDRESS : 23
PROFIBUSCONNECTOR
A1 B1 S B2A2
PROCESS FIELDRS # 13 (1 / 1)
PROFIBUSADDRESS : 24
MMI PC-1PROFIBUS
CONNECTOR
A1 B1 S B2A2
MMI PC-1PROFIBUS
CONNECTOR
A1 B1 S B2A2
REPEATER
PROG PC-1
PROFIBUSCONNECTOR
A1 B1 S B2A2
SPM CDRS # 9
PROFIBUSADDRESS : 26
PROFIBUSCONNECTOR
A1 B1 S B2A2
SPM CD - ESA
PROFIBUSADDRESS : 61
PROFIBUSCONNECTOR
A1 B1 S B2A2
TLL CDRS # 10
PROFIBUSADDRESS : 27
PROFIBUSCONNECTOR
A1 B1 S B2A2
TLL CD - ESA
PROFIBUSADDRESS : 71
PROFIBUSCONNECTOR
A1 B1 S B2A2
EXIT M CCRS # 6
PROFIBUSADDRESS : 28
PROFIBUSCONNECTOR
A1 B1 S B2A2
EXIT DRIVESRS # 2
PROFIBUSADDRESS : 29
PROFIBUSCONNECTOR
A1 B1 S B2A2
GATEW AY(EXIT)
PROFIBUSADDRESS : 103
PROFIBUSCONNECTOR
A1 B1 S B2A2
GATEW AY(PROCESS)
PROFIBUSADDRESS : 102
PROFIBUSCONNECTOR
A1 B1 S B2A2
GATEW AY(ENTRY)
PROFIBUSADDRESS : 101
PROFIBUSCONNECTOR
A1 B1 S B2A2
EXIT FIELDRS # 14
PROFIBUSADDRESS : 41
PROFIBUSCONNECTOR
A1 B1 S B2A2
EXIT CDRS # 11
PROFIBUSADDRESS : 40
PROFIBUSCONNECTOR
A1 B1 S B2A2
EXIT CD - ESA
PROFIBUSADDRESS : 81
GL
OB
AL
DA
TA
NE
TW
OR
K
PRO FIBUSADD : 0
PR OJ E C T - J WPR OF IBUS NE T WOR K DE T AILS
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CT-Net Routing
UD75
1 2 3
PAYOFF # 1PAYOFF # 2
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
PAYOFF # 2BRIDLE # 1ABRIDLE # 1DENT ACCUMBRIDLE # 2A
UD75
1 2 3
H.BR # C
UD75
1 2 3
BRIDLE # 4APAYOFF # 2
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
BRIDLE # 5ABUR - BOTBRIDLE # 3ABRIDLE # 5CGATW AYENTRY
UD75
1 2 3
GATW AYPROCESS
UD75
1 2 3
GATW AYEXIT
UD75
1 2 3
RECOILERPAYOFF # 2
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
UD75
1 2 3
BRIDLE # 8BEXIT ACCUMBRIDLE # 7AORG COAT-3
UD75
1 2 3
BRIDLE # 6A ORG COAT-1
ADD: 11ADD: 12ADD: 14ADD: 13ADD: 15ADD: 16ADD: 17
ADD: 03 ADD: 02 ADD: 01 ADD: 31 ADD: 18 ADD: 19ADD: 20 ADD: 21
ADD: 22 ADD: 23 ADD: 24 ADD: 25 ADD: 26 ADD: 27 ADD: 28
A
S
B
A
S
B
A
S
B
A
S
B
A
S
B
A
S
B
75 O
HM
S75
OH
MS
75 O
HM
S
TERM INATINGRESISTO R
TERM INATINGRESISTO R
TERM INATINGRESISTO R
PROG PC
PCI - 20
1 2 3
SYPTW ORKBENCH
CT-NET HUB(RS # 1)
CT-NET HUB(RS # 2)
PROJECT - JWCT-NET COMMUNICATION SCHEMATIC
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SCADA – Overview
• There are 2 sets of 1024 Power tags SCADA Stations, One for Line Operations and other is dedicated for Furnace Operations.
• Siemens WinCC SCADA Package is used.
• SCADA is connected to PLC System through Profibus-DP.
• In addition, there are 4 Nos. of Operator Interface units (OP170B), which are fitted on the Control Desks.
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SCADA – Line Overview
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SCADA – Entry Section
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SCADA – Process Section
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SCADA – Exit Section
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SCADA – Furnace Section
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SCADA – PHF Burner Controls
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SCADA – PHF PID Settings
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SCADA – Pot Furnace
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Textile IndustryTextile IndustryCustomersCustomers
• TEXMACO, CALCUTTA
• SUSSEN ASIA, PUNE
• RAJASTHAN TEXTILE, BILWARA
• MOTEX ENGG. AHMEDABAD
• SANMARCO TEXMAC, COIMBATORE
• OSWAL CHEMICALS
• DRIVES UNIDRIVE & GP DRIVES DIGITAX DRIVES,UNIMOTORS
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Material Handling IndustryMaterial Handling IndustryCustomersCustomers
• CONVEYORS Salem Steel PlantWebb India
TISCO, Jamshedpur
• HOIST & CRANES Salem Steel Plant TISCO, Jamshedpur Telco, Pune
Rain Calcining, Vizag DRDL
• DRIVES UNIDRIVES
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Food & Beverages IndustryCustomers
•COCA COLA
•PEPSICO
•PARLE INDUSTRIES
•MOHAN MEAKINS
•CADBURY INDIA
•NESTLE
•INDIAN DAIRY (AMUL)
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Fiber IndustryFiber IndustryCustomersCustomers
• Application PFY & PSF Plants
• Customers Terene Fibres Ltd Reliance Industries
Indian Acrylics IPCL
Orissa SyntheticsShreeram Fibre
Grasim Industries Indian Organic Chemicals
• Drives Digital DC / AC Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer BALKRISHNA TYRES,AURANGABAD
• Applications 6’’ EXTRUDER LINE(8 DRIVES)
8’’ EXTRUDER LINE(8 DRIVES)
CALENDER LINE (9 DRIVES)
TYRE BUILDING M/C DRIVES
• Drives Digital DC / AC Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer GOVIND RUBBER, DELHI
• Applications 6’’ EXTRUDER LINE(8 DRIVES)
8’’ EXTRUDER LINE(8 DRIVES)
MIXER-170 LITRES
MIXER-210 LITRE
» BIAS CUTTERS
• Drives Digital DC / Servo Drives Systems
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Tyre IndustryTyre IndustryCustomersCustomers
• Customer CORNELL INTERNATIONAL,MUMBAI
• Applications 210 LITRE MIXER FOR
ELASTOMERIC ,SRILANKA
• Drives Digital DC / Servo Drives Systems
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Crane Reference ListIndustry Application Description Customer CT System Supplied
Cranes Gantry Cranes Atelier du Loir - Belgium Vector with IN32 ( 11 - 30kW )Cranes Gantry Cranes Tai York Cranes - Taiwan 59 x Vector (22kW)Cranes 50 Ton Harbour Jib Tonsberg Harbour - Norway Vector (2 x 75kw plus Regen) Unidrive (90,45,37kw)Cranes Container Cranes E.C.T - Rotterdams - Netherlands 1x Mentor DC M350R + system : 150kWCranes Container Cranes Dockwise - Rotterdam - Netherlands 6 x Flux Vector inverters V2200.: 22kWCranes Container Cranes Tonsberg Haavnevesen(Tongsberg Hoist:2x 75kW Vector in parallel.
Boom: 75kW Unidrive in closed loop vector.Slewing: 30kW Unidrive in open loop vectorTraverse: 45kW Unidrive in open loop vector
Cranes EOT Gresse Kranbau Wittenberg - Mentor II Vector & CDECranes EOT Krupp Industreitechnik GmbH - VectorCranes EOT Liebherr GmbH - Germany Mentor II & Vector (x10)Cranes Rubber Tyred Gantry Electruck - Sydney, Australia Vector (5 x 150kW) CDE(x10) with MD29Cranes Aluminium Mill Anode Pechiney - Netherlands CD & V2200: 22kWCranes Freighter Winch Drives Canal Marine - USA Mentor II (x 2) with MD21Cranes Barge Handling Winches DeMar Engineering - USA 75kW VectorCranes Hoist, Long Travel, Cross BHP, Kamataka - Wollongong, Unidrive (200kW 4x30kw 2x15kw)Cranes Ocean Cable Laying Dowty Aerospace - Wolverhampton, Mentor II (3 x 100hp)Cranes Container Cranes Australian Electrical Services - Perth, Mentor II &CDECranes Rubber Tyred Gantry Australian Stevedores - NSW, Mentor IICranes Rubber Tyred Gantry Australian Winch & Haulage - NSW, Mentor IICranes Parrachute Drop Australias Wonderland - NSW, Mentor II & VectorCranes Rubber Tyred Gantry CTAL (National Terminals) - NSW, Mentor IICranes Container Cranes Favell Favco - NSW, Australia 30 - 75kW VectorCranes Gantry Cranes Lloyds British - NSW, Australia Mentor IICranes Automated Warehousing Mannesmann Demag - NSW, Mentor IICranes Container Cranes Perini, Scott and Masterman - NSW, Mentor IICranes Special Hoisting Powerlec - NSW, Australia 75kW Vector Cranes Gantry Cranes W & B Engineering - NSW, Australia 30 - 75kW VectorCranes Gantry Cranes W & D Engineering - Victoria, Australia 75kW VectorCranes Hoist and Long Travel The Steel Authority Of India - India Unidrive (2 x 75kW (H) + 1 x 75kW (LT) + 1 x 15kW (CT)Cranes Auto Crane Warehouse Cadbury - Victoria, Australia (via Mentor II with MD21Cranes Auto Crane Warehouse United Distillers - Sydney, Australia Mentor I with MD21Cranes Smelter Lance Controls Elsag Bailey - Burlington - Ontario, 75kW x 2, 150kW x 1 Cranes Mine Hoists Hepburn Engineering Inc. - Ontario, Mentor II with MD29Cranes Container Cranes Zhenhua Port Machinery Co - China Unidrive 5 (3 x Parallel) with UD70 - 400kW * 2 SetsCranes Container Cranes Zhenhua Port Machinery Co - China Unidrive 5 (5 x Parallel) with UD70 with Regen. - 530kW * 9 Sets
Closed Loop Flux Vector
Above List does not include Material Handling , Pick & Place Automation & Automobile Sectors
Proven Flux Vector Technology
Sample CT Sample CT ReferencesReferences
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CT India References High Performance Crane / MH Drive systems – Sample ListCT India References High Performance Crane / MH Drive systems – Sample List
• Salem Steel Plant – Outdoor Gantry Crane Salem Steel Plant – Outdoor Gantry Crane – - Hoist - 75kW with Regen + LT – 75kW + CT – 15kW + Radio Remote- Hoist - 75kW with Regen + LT – 75kW + CT – 15kW + Radio Remote
• Rain Calcining, Vizag – Outdoor Gantry Crane Rain Calcining, Vizag – Outdoor Gantry Crane – - Hoist 30kW + Aux. Hoist – 15kW + LT – 7.5kW + CT – 4kW + Radio Remote- Hoist 30kW + Aux. Hoist – 15kW + LT – 7.5kW + CT – 4kW + Radio Remote
• L&T-ECCL&T-ECC Highway Construction CranesHighway Construction Cranes
• Neyveli Lignite – Rotary Kiln applicationNeyveli Lignite – Rotary Kiln application– 37kW Drive + Inv. Grade Motors37kW Drive + Inv. Grade Motors
• Chennai Port Trust – Wagon Tippler, Feeder & Conveyor Drives Chennai Port Trust – Wagon Tippler, Feeder & Conveyor Drives » Upto 200kW regenUpto 200kW regen
• TISCOTISCO - EOT Cranes- EOT Cranes
• Mahindra – Synchronized Hoists for Scorpio Manufacturing Line Mahindra – Synchronized Hoists for Scorpio Manufacturing Line » – – 32 Nos. UNiDrive SP with Position Control Loop32 Nos. UNiDrive SP with Position Control Loop
• TELCO – Synchronized Hoists for Indica Manufacturing Line TELCO – Synchronized Hoists for Indica Manufacturing Line » – – 32 Nos. UNiDrives with Position Control Loop32 Nos. UNiDrives with Position Control Loop
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CT India Sample References High Performance Drive SystemsCT India Sample References High Performance Drive Systems
• BHEL Trichy – 3-Axis Servo system for Double Column Planing machineBHEL Trichy – 3-Axis Servo system for Double Column Planing machine
• BHEL Bhopal – 4-Axes FNC Controller for Milling Machine RetrofitBHEL Bhopal – 4-Axes FNC Controller for Milling Machine Retrofit
• BHEL Hyderabad - 4-Axes FNC Controller for Milling Machine RetrofitBHEL Hyderabad - 4-Axes FNC Controller for Milling Machine Retrofit
• BHEL Hardwar – Vertical Lathe Servo upgradeBHEL Hardwar – Vertical Lathe Servo upgrade
• HAL Koraput– HAL Koraput– 528kW AC Drive – Motor system 528kW AC Drive – Motor system for Sukhoi Engine Test Jigfor Sukhoi Engine Test Jig
• HAL Engine Division – 5-Axis Controller for Sunstrand machineHAL Engine Division – 5-Axis Controller for Sunstrand machine
• HAL Helicopter Division – 4 Axes Controller for Spiramatic Jig MillHAL Helicopter Division – 4 Axes Controller for Spiramatic Jig Mill
• NAL – NAL – 120kW 120kW Low Speed Wind Tunnel for Boeing components (4 nos.)Low Speed Wind Tunnel for Boeing components (4 nos.)
• Triveni Engineering – Triveni Engineering – 750kW DC Drive System 750kW DC Drive System for High Speed Gear Box Testingfor High Speed Gear Box Testing
• Cornell Industries, Sri Lanka - Cornell Industries, Sri Lanka - 750kW, 12 pulse 750kW, 12 pulse for Rubber Mixer Automationfor Rubber Mixer Automation
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CT India Retrofit BusinessCT India Retrofit Business
• Binjirajka Steel, Hyderabad – 13 Section Rolling Mill Mentor Retrofit (Upto Binjirajka Steel, Hyderabad – 13 Section Rolling Mill Mentor Retrofit (Upto 1200kW)1200kW)
• Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Ballarpur Industries – Yamunanagar – 21-section L&T Sectional Drive System Retrofit with Hi-Speed CT NetRetrofit with Hi-Speed CT Net
• Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29Servall Board Project – 21 Section Asea Retrofit with Mentor II & MD-29
• SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg SPB, Erode – Rewinder-cum-Unwinder Brake Generator Retrofit of Stromberg DC System with AutomationDC System with Automation
• Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length Pennar Industries, Hyderabad: Over 8 projects (Slitter / Mill / Cut-To-Length with Automation)with Automation)
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150kW Coiler Analog Drive Power+Controls
(2 Panels + Winder Control thru PLC)
150kW Coiler Digital Drive Power+Controls + Winder
Software Loop within Drive
(1 Panel + less components+ less wiring)
DC Drive Retrofit ExampleDC Drive Retrofit Example
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CT India Sample ReferencesCT India Sample ReferencesHigh Performance Drive systemsHigh Performance Drive systems
• Sugar IndustrySugar Industry• 160kW Centrifuge Systems (160kW Centrifuge Systems (350 nos. supplied/commissioned in India350 nos. supplied/commissioned in India))
• AutomotivesAutomotives• MICO High Performance Testing MICO High Performance Testing – Over 500 Nos. AC Drives – Over 500 Nos. AC Drives • Lucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’sLucas TVS– over 50 High Performance AC Drive – Motor systems for SPM’s• Ford IndiaFord India• Hyundai Motor IndustriesHyundai Motor Industries• MahindraMahindra• TELCOTELCO• EscortsEscorts• GoetzeGoetze• Delphi TVSDelphi TVS• VisteonVisteon
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Box Wagon - Fine
0
60
0
60
06
00
60
0
35
0
35
0
60
0
60
00 0
-65
0
-65
0
-35
0-3
50
-65
0
-65
0
-35
0-3
50
00 9 18
18 5
0 63 70 83
15
01
50
15
0
14
3
70
54
50
45
20
4 00
-700
-500
-300
-100
100
300
500
700
0 10 20 30 40 50 60
Time
An
gle
/ S
peed
Speed Angle
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Understanding the Understanding the Common DC Bus Common DC Bus
ConceptConceptFor AC Drive SystemsFor AC Drive Systems
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Drive System Drive System ConfigurationConfiguration
Colour Coating AC Drives and MotorsColour Coating AC Drives and Motors
COMMON DC-BUS 560V
RRR R
Brake
ChopperResistorResistor
2000A
CT-NetCT-Net
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Rectifier Unit
6-Pulse Full wave Rectifier
Low Input Harmonics
Power Factor > 0.95
12-pulse configuration can be offered as optional
2000A
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Common DC Bus
Connected to the UniDrive this configuration gives best performance in terms of sharing of Energy between the AC Drives
Regenerated / Braking Energy from one drive is re-used by another motoring drive
Motoring Drive draws less power from Mains.
Drive Centre Vicenza
Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Charging Circuit
Allows re-connection of any inverter to the already running system
This pre-charging is a must. The charging resistor comes into the picture initially, allows the DC Link capacitors within the inverters to reach required potential before the pulses are allowed to fire the IGBTs.
It gets disconnected, once this procedure is safely completed.
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
UniDrive
Fully Digital
IGBT Controlled
Micro-processor based
On-Board 2nd processor for Real Time processing of application programs
High Speed Communication
Field-Bus Connectivity
All Real Time calculations like Diameter Computation, Tension Regulation, Accumulator Position control etc in 2nd processor
Master Line Speed generation within the Drive System
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR
DC Bus ConfigurationDC Bus Configuration
R
Brake
ChopperResistorResistor
Brake Chopper
During the Braking phase, AC Motors give energy to DC Bus.
If DC Bus Voltage exceeds 560V, IGBT-based Chopper gets automatically energized & the DC Bus voltage is kept around 600V
The Brake Chopper has an in-built PI controller, allowing for controlled & smooth braking
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR R
Regenerative Drive
Trafo Elevatore 400V/660V
Alternative DC Bus Alternative DC Bus ConfigurationConfiguration
Using Mentor II Converter
When the DC Bus Voltage increases beyond 600V, the regenerative Mentor II converter is energized.
This returns the regenerated energy to the Mains thru a Step-up Transformer back to Mains.
This configuration will also keep the DC Bus around 600V
Advantages:
No wastage of regenerative energy in the resistor
Disadvantage:
High Cost
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Colour Coating AC Drives and Colour Coating AC Drives and MotorsMotors
COMMON DC-BUS 560V
RRR R
Alternative DC Bus Alternative DC Bus ConfigurationConfiguration
Using 12-Pulse Configuration
Features Double Secondary Transformer, Phase Shifted at Input to Rectifier
Advantages:
Power Factor is near Unity for all load conditions
Very low Harmonics
YY
IPTIPT
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Major Approvals Major Approvals
• MECON
• HEC, RANCHI
• TATA STEEL (TISCO, JAMSHEDPUR)
• NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LTD.
• ERCOM ENGINEERS PRIVATE LIMITED NEW DELHI.
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SummarySummary• We have TechnologyWe have Technology
• We have ProductsWe have Products
• We have Financial StrengthWe have Financial Strength
• We have ExperienceWe have Experience
• We have Application ExpertiseWe have Application Expertise
• We can deliver large Systems in stipulated time We can deliver large Systems in stipulated time limitslimits
• We can commission Systems very fast We can commission Systems very fast
• It will be a privilege for Control Techniques India It will be a privilege for Control Techniques India to have continued association with TATAto have continued association with TATA
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PULPITROOM
HEAD
FURNACEELOGATION
MACHINE
M EN TO R I IELECTR O N I CS
CONVEYOR
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDER
RED HOT CYLINDERMANDREL
RED HOT CYLINDER
PUSH BENCH
MOTOR
ENCODER
CAM
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PUSH SPEED
THREAD SPEED
THREAD END
FAST ACCELERATION
HOME
SPEED PROFILE FOR PUSH BENCH DRIVE
HOME
RETURN POINT
6 Meters / Sec
30 Meters
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Thank You for your Thank You for your Kind AttentionKind Attention
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