Sustainability is an essential part of ABB’s business

Feature story: A new generation oftechnology delivers precise controlof multiple motors via a compactmultidrive design.

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VOLUME 19 SUMMER 2006

the customer magazine of ABBin Australia and New Zealandwww.au.abb.com

ABB Australia Pty Limited(ABN 68 003 337 611)

Level 20, 1 Alfred Street

Sydney NSW 2000 Australia

Tel: +61 2 9255 3999

Fax: +61 2 9255 3988

ABB Limited (New Zealand)Level 1, 83 Grafton Road

Auckland New Zealand

Tel: +64 9 356 2160

Fax: +64 9 357 0098

Diversity and inclusion is an important element of ABB’s competitiveadvantage

We started 2006 at ABB bylaunching our diversity andinclusion statement. Thestatement aims to help ourline managers provideequality of opportunity andbring out the best in allemployees. A major challengefor us is ensuring diversity andinclusion permeates the waywe recruit, manage, rewardrespect and retain talent.

The statement covers diversity, or the differences thatmake each of us unique, and inclusion or the processby which diversity is respected and integrated toachieve ABB objectives.

This is not an initiative with a beginning and an end soin many countries where ABB operates we held aseries of workshops to brainstorm how to turn thestatement into actions that will truly create a diverseand inclusive ABB culture. Our intention is to usefeedback from within the organisation to constantlyhone and improve what we do.

As we approach the end of this year, we recognisethat ABB is actually quite advanced in our diversityactivities, but we want to do more. We will continue tofocus on bringing diversity and inclusion to life in ourorganisation in a real way and not just within policies.We believe it is an important element in ABB’scompetitive advantage and a unique opportunity tostrengthen our organisation.

John GaskellChief Executive ABB Australia & New Zealand

ACTIONVOLUME 19 SUMMER 2006

the customer magazine of ABB in Australia and New Zealand

www.abbaustralia.com.au

Published by Marketing and Corporate Communications

Editor: Diane Leonard Designer: Lu Nan Subscriptions: Leanne Sprlyan

2 action

Australasia news

4 ABB opens new analyser calibration

laboratory

5 Taking charge at the annual turbocharger

Customer Awareness and Information Day

5 ABB people to watch

6 ABB switchgear first choice for

Ergon Energy

7 ABB to supply IndustrialIT DCS to Australia’s

largest pulp and paper facility

8 ABB supplies MV switchgear to one of

Australia’s largest infrastructure projects

8 ABB sharing the load with Western Power

9 ABB receives EEO award from NZ Prime

Minister

Global news

10 ABB drives bring water to

China’s driest regions

11 ABB agreement brings big benefits to TVA

12 ABB drives raising the roof in Phoenix

13 A helping hand for the deaf and blind

Feature

14 Why and when to install multidrives?

Applications

16 Speed controlled Ferris wheel

17 Coil winding solution with motion control

Product news

18 Enhanced motor protection with UMC22

and FieldBusPlug

18 No more ‘secrets’ with low voltage

interactive CD

19 ABB launches air cooled 6kV drive

20 ABB introduces new backwards-bending,

6-axis robot with 3.9 m reach

21 The world’s first “mount it anywhere”

videographic recorder

22 ABB launches a novel indicator of voltage

presence for indoor and outdoor

applications in MV systems

23 System Pro M compact: new motor

operating devices

23 ZVC with integrated PF compensation

Insert: Contact us

List of contents

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4 action ABB

Australasia newsABB has extended its calibration laboratory capabilities with the recentopening of a new analyser calibration laboratory at Moorebank, NSW. Thenew facility is set up to test, repair and re-calibrate process gas measuringequipment.

The laboratory will provide gas calibration services for gasmeasurement equipment that is generally used for themeasurement of a process or to quantify the level of emissionsfrom a process. If these details are known, the process can beimproved which can lead to increased efficiencies andenvironmental outcomes and reduced costs.

Exacting calibration is a crucial element of any analyseroptimisation or maintenance program. Accurate process gasmeasurement enhances plant optimisation and can lead to largesavings in operating costs.

ABB project engineer, Stephen Keays explains, “Imagine whateffect a one percent process efficiency improvement would haveon a power station with fuel costs of $1 million per day –calculate the positive benefits to their bottom line, along with thelower environmental impacts. It really is something to thinkabout!”

“A key benefit of using the services provided by ABB’s calibration laboratoryis we can confirm the Continuous Emission Monitoring Systems (CEMS) andprocess monitoring systems read correctly over the entire operational rangeof equipment”, says Keays. “This will ensure the readings are accurate in theplant’s normal operational range as well as in extreme excursions. Accuratereadings from these instruments allows for tighter and quicker automaticcontrol of the plant or process.”

The Moorebank facility also has the capability to blend gases down to10,000 to 1, with an accuracy of one percent of the selected blended gasusing NATA certified gases (NATA certified calibration gases are alsoavailable from ABB).

Keays explains: “This ability to blend the gases means we can make the gasconcentration to suit most applications. The gas calibrator used in thetesting facility makes it easier to mix gasses by taking into account the “K”factor for multiple gas blends.”

For over half a century, ABB has developed, manufactured, and installedanalysers for the process industries. ABB’s capability embraces one of thelargest laboratory, at-line and process analyser portfolios in the world,performing real-time analysis of the chemical composition and/or physicalproperties of a process sample or stream. The investment in the newlaboratory is a notable addition to ABB’s long history in analyser expertise.

ABB’s Moorebank site is quality accredited to ISO 9001 and ISO 14001envionmental management systems accredited. The site is also home to theNATA accredited flowmeter calibration laboratory which was established byABB in 2004.

ABB opens new analysercalibration laboratory

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ABB analytical installation.

Advanced Cemas NDIR(non dispersive infrared)System.

Stephen Keays explains, “Imaginewhat effect a one percent processefficiency improvement would haveon a power station with fuel costs of $1 million per day – calculate thepositive benefits to their bottom line,along with the lower environmentalimpacts. It really is something tothink about!”

action 5ABB

Customers and ABB staff at the Turbocharger customerawareness day.

Did you know ABB’s ‘Aturb’ database provides a comprehensive list ofevery ABB turbocharger installation in the world? What this means forcustomers with turbochargers is ABB can look-up the turbocharger’sservice history on-line and see the ship/plant specifications, find out whichturbochargers are due for service and also what has been serviced -building a complete service history for each turbocharger.

“This helps keep our customersinformed so they can plan scheduledmaintenance and minimiseequipment downtime”, explainsSteve Douglas, ABB Australia’sturbocharger manager.

The ‘Aturb’ database and otherturbocharger specific initiatives wereon the agenda at the annual CustomerInformation and Awareness Day heldrecently at the ABB turbochargerworkshop in Canningvale, WA. Over25 customers representing theshipping, mining and power generationindustries attended the event whichprovided a mix of hands-on

instruction, as well as informational seminars.

“The aim of the day is to allow our customers to improve their knowledge ofturbochargers and the science behind them,” says Douglas. “Thesecustomer days are very important for us because we get the opportunity toshow off some of the in-house support tools that we’ve been equippedwith. I’m pleased to say that our customers were extremely impressed withthe attention to detail and the investment ABB has made to this aspect ofour business.

Taking charge at theannual turbochargerCustomer Awareness andInformation Day

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Kel Morrison, sales manager medium voltage indoor switchgear (Qld) hasreceived an Energex ‘Customer Care’ award recognising his excellentwork in making safety improvements to the 11kV Safelink Ring Main Unitused extensively throughout the Energex network.

“The award is signed by Energex CEO Andrew Kremor andacknowledges the value Exergex places on the proactive and responsivecustomer service given by Kel on this and many other occasions”,explains Kevin Nuttall, technical standards manager at Energex.

Delighted with the recognition but quick to point out that it was a teameffort, Kel accepted the award in mid-October 2006.

ABB people to watch

ABB’s Kel Morrison with Energex’s TechnicalStandards Manager, Kevin Nuttall.

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Australasia news

ABB6 action

Australasia newsErgon Energy, which operates one of the largest power distributionnetworks in the world, has made ABB its sole supplier of medium voltageswitchgear. Product reliability, performance and safety were key.

Owned by the Queensland government, Ergon Energydistributes electricity to Australia’s second largest state –across an area that the utility describes as a “truly diverselandscape, ranging from the harshest, most demandingterrains to the most sensitive.”

“To meet these challenges, we are constantly looking forworld-class electricity distribution technologies,” says ErgonEnergy. As part of this process, the company recentlychose a single supplier of medium voltage primaryswitchgear from among international and local suppliers.

Ergon Energy chose ABB.

Previously Ergon Energy had selected suppliers on aproject-by-project basis, but the benefits and savings ofcontracting a single vendor and single switchgear platformwere too compelling to ignore.

ABB will supply Ergon Energy with UniGear ZS1 and ZS3.2medium voltage switchgear for the utility’s 11 kV and 22 kVdistribution systems and 33 kV sub-transmission system.UniGear excelled in Ergon’s requirements for performance,reliability and safety – key factors in a distribution system aslarge and climatically diverse as Queensland.

ABB manufactures UniGear switchgear in ten factories worldwide, includingAustralia. The UniGear platform is designed to meet the switchgearrequirements of all markets and is uniquely certified for withstanding seismicstress and the extreme vibrations of marine applications.

Ergon Energy has also selected ABB to be the company’s sole supplier ofpad-mounted transformers. The utility requires an estimated 5,000 pole-mounted distribution transformers a year for its extensive distributionnetwork, and is seeking to improve reliability and quality as well as reduceexpenditure on one of its largest sources of equipment outlay.

ABB switchgear firstchoice for Ergon Energy

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ZS3.2

UniGear excelled in Ergon’s requirements for performance,reliability and safety – key factors in a distribution system aslarge and climatically diverse as Queensland.

action 7ABB

Australasia newsAustralian Paper, the sole manufacturer of fine papers in Australia, and partof the PaperlinX Group, has awarded ABB a A$5 million contract to supplyan IndustrialIT Distributed Control System (DCS) for their Maryvale milllocated 160 km east of Melbourne in Morwell, Victoria. In addition ABB hassecured a further A$1 million in orders for MV switchgear, LV relays, and

variable speed drive systems.

Australian Paper is making a A$258 millioninvestment in the development of pulpingfacilities at Maryvale mill. The project willinvolve replacing and upgrading parts ofthe existing plant with new world-classfacilities that will manufacture elementallychlorine free pulp.

The DCS from ABB will provide acommon data and process controlnetwork, and is based on the latest ABBIndustrial IT platform using AC800Mcontrollers, S800 I/O and OperateIT, whichwill integrate all pulp mill operations,connecting a new central control room tothe system servers and all of theapplications and process controlsincluding the continuous digester, bleachplant, wood yard, wetlap machine, pulpstore, batch digester and chemical

recovery area. The delivery will also include ABB advanced processmanagement software to monitor and control the batch digester process.

All project engineering,software configuration,testing and factoryacceptance tests will beconducted at ABB’sNotting Hill facility inMelbourne.

Australian Paper andABB have beenpartners for many yearswith ABB delivering acomprehensive rangeof products and

solutions to the Maryvale Mill. Choosing ABB was based on a number offactors including the relationship between the companies, ABB’s reliable,first class products and proven technical solutions as well as the localavailability of engineering and commissioning capabilities.

Today, Maryvale Mill is the largest pulp and paper making complex inAustralia, with three pulp mills, five papermaking machines, and a wastepaper processing plant.

ABB to supply IndustrialIT

DCS to Australia’s largestpulp and paper facility

AC800M

The DCS from ABB is based on latest ABB industrialIT

platform using AC800M controllers, S800 I/O and OperateIT.

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8 action ABB

Australasia newsABB has been awarded a contract to supply some 300 sections of mediumvoltage switchgear to the Dalrymple Bay Coal Terminal (DBCT) upgrade andexpansion project. Under the contract, ABB supplied UniGear ZS1switchgear and UniGear ZVC motor starters as part of a transportablesubstation configuration.

“Among the factors that contributed to the award of the contract was ABB’sswitchgear offering – a compact, well proven product within the industrywhich is designed for optimum safety and reliability”, explains Kevin Napper,ABB’s national sales manager for MV switchgear.

“The switchboards have been designed for installation into transportablesubstations on the Dalrymple Bay site which provides some tremendousadvantages but also required careful selection of switchgear to ensure thesafety of plant and people”, says Napper. “When using MV switchgear athigh fault levels in the confined space of transportable buildings, safety forpeople in the switchroom is dependant on proper fault management.

“The ABB solution provided to DBCT can be relied upon by using type-tested arc ducting to direct hazardous arc products to a safe area outsidethe switchroom, combined with the ability for complete operation of theswitchgear behind closed doors for maximum operator safety”, says Napper.

Connell Hatch is managing the engineering and project management of theupgrade to the terminal which will see an increase in the capacity of theterminal by more than 50 per cent to match increasing production andinternational demand for quality coal.

Located near Mackay in Queensland, the DBCT is a major part of Australia’sexport infrastructure handling more than 50 million tonnes of coal from theBowen Basin.

Today, DBCT is one of the world’s largest coal export facilities, exportingapproximately six per cent of the world’s seaborne coal trade.

ABB supplies MV switchgearto one of Australia’s largestinfrastructure projects

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ABB recently issued a cheque for more than $480,000 to Western Powerunder a strategic commercial arrangement negotiated by the two businesses12 months ago aimed at delivering win/win results.

Under the agreement, ABB and Western Power take a cooperative, ‘openbook’ approach to planning and working together to identify ways to reducecosts and increase efficiencies. This enables both organisations to ‘gainshare’ so if ABB exceeds a certain level of profit from the contract withWestern Power, both organisations retain a share of the extra profit.

ABB supplies Western Power with transformers and substation equipmentand will play a vital role in helping to ensure Western Power is summer readyby providing additional distribution transformers and substation equipmentduring the critical summer months.

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ABB sharing the load with Western Power

action 9ABB

Australasia newsAt the 2006 Equal Employment Opportunities (EEO) Trust Work & LifeAwards, ABB New Zealand won the prestigious First Steps Award inrecognition of ABB’s work with the Kinleith Pulp and Paper Mill.

Presented by Prime Minister Rt. Hon. Helen Clark, the awards offer achance to publicly recognise the achievements of New Zealand organisationswhich have created workplaces offering a balance between the responsibilitiesand interests of employees at work and in their personal lives.

An early initiative gave every employee an opportunity to attend “ForestCamp” to help with team building, goal setting and identifying individual andteam values. Following the Forest Camps, staff developed the vision, missionstatement, values and goals for the ABB team at Kinleith. The “Pathfinders”group was then formed to focus on workplace initiatives and site communication.

ABB’s work-life initiatives at Kinleith include flexible shift work patterns, with twostructured rosters - four 10-hour days and five 8-hour days. Staff can changefrom one roster to another, and can vary start and finish times to accommodateoperational and personal needs. The 10-hour roster has business KPI’sattached to it, which need to be maintained for the roster to stay available.

Staff are also offered free annual medical check-ups, an on-site gym andcanteen, community volunteer days, medical insurance for staff and families,a company super scheme, and contributions to study fees.

ABB management at Kinleith believe that the work-life initiatives havesignificantly increased employee ownership of ABB’s goals and vision,resulting in increased productivity and lower maintenance costs.

Over the last three years the total output of the Kinleith mill has increased bymore than 17 percent and the mill is outstripping its production goals in keyareas, with 19 production records broken in 2005. Sick leave hasdecreased from 11 percent in 2002 to 3.7 percent in 2005.

ABB receives EEO awardfrom NZ Prime Minister

Juergen Link of ABB New Zealand accepts the EEO TrustWork & Life award from Prime Minister Rt. Hon. Helen Clark.

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10 action ABB

Global newsEight sets of ABB drive packages at theHuinanzhuang pump station near Beijingwill pump water up a 60 metre slope at 60cubic metres per second and bring safe,stable and sanitary supplies to the capitalof Beijing and the surrounding region.

ABB will deliver eight sets of 7.3 megawattACS6000 drives packages, includingtransformers, frequency converters andmachines to power the stations’centrifugal water pumps and machinery.

About one-third of China is very dry or adesert. The most arid regions are in thenorth and northwest, while each yearChina’s south is plagued by torrentialrains and floods. In recent years, massiveeconomic growth has compelled the country to launch new steps to manage,preserve and redistribute its precious water resources.

This includes the multi-billion dollar south-to-north water diversion projects,the largest scheme of its kind in the world. This ambitious undertaking willsend billions of cubic meters of water from the south to satisfy spiralingdemand for water in the country’s dry, resource-rich north, where boomingpopulations in Beijing and Tianjin, massive construction and an arid climatehave conspired to create chronic water shortages.

The south-to-north projects consists of three, thousand-kilometre-long waterdiversion routes in the eastern, middle and western parts of China that will useexisting or new rivers, channels, reservoirs and canals to transport water fromthe south to the north.

These three routes will eventually link the country's four major rivers - theYangtze River, Yellow River, Huaihe River and the Haihe River, and create ahuge, controllable water net system that can allocate and regulate China’swater resources.

The 1,267-kilometre-long middle route will bringwater from the Yangtze River up to the capitalof Beijing by 2010. And because the route isnot always flat, water must be pumped overobstacles. Huinanzhuang is the only majorpump station to be built in the main channel ofthe middle diversion route.

Planning of the south-to-north diversionprojects began in the 1950s, and the entirescheme is expected to take about 50 years tocomplete. The Chinese government expects tobe able to divert 44.8 billion cubic metres ofwater annually by 2050.

ABB drives bring water toChina’s driest regions

ABB drive packages will power the heart ofa key pumping station in the middle routeof China’s enormous south-to-north waterdiversion project.

The south-to-north projects consists of three, thousand-kilometre-long water diversion routes in the eastern, middleand western parts of China that will use existing or newrivers, channels, reservoirs and canals to transport waterfrom the south to the north.

About one-third of China is very dry ora desert, and the most arid regionsare in the north and northwest.

Planning of the south-to-northdiversion projects began in the1950s, and the entire scheme isexpected to take about 50 years to complete.

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action 11ABB

Global newsABB and TVA have been working closely for many decades, a collaborationthat led to an agreement in 1997 by which ABB undertook to manageTVA’s transformers of up to 230 kilovolts (kV) as well as circuit breakers andother high voltage equipment.

The results achieved were so impressive that a second agreement wassigned in 2002 for extra high voltage transformers of up to 735 kV. Thiscontract alone saved TVA $78 million in costs in the first three years and isprojected to result in savings of $120 million over the five-year duration.

With savings of this magnitude and a transmission system that is operatingat 99.999 percent reliability for the sixth consecutive year, it is perhaps notsurprising that TVA recently renewed the first agreement for a further five years.

TVA operates a fleet of almost 1200 transformers, many of which are morethan 25 years old and some, 40 or more. ABB’s job is to prevent this stockof aging transformers – made by a number of different manufacturers – fromfailing and ensure that TVA maintains its outstanding reliability track record.

How does ABB do that?ABB has supplied more power transformers to customers in the UnitedStates than any other company. It has direct access to more than 12,000transformer designs and owns the property rights to more than 75 percentof TVA’s installed base – a unique position that gives ABB unrivalledexpertise on transformer technology and transformer fleets. ABB uses this expertise to conduct life cycle assessments of TVAtransformers and critical components to identify which units are in mostneed of refurbishment or replacement. ABB reserves production slots at its dedicated power transformermanufacturing centers worldwide to ensure TVA receives new units 50percent faster than current standard delivery times. ABB operates a full-scale service center in the heart of TVA territory(Nashville, Tennessee) to ensure TVA has immediate access to technicalexpertise and field support for vital equipment like power transformers;high voltage circuit breakers; medium and low voltage switchgear, circuitbreakers and motor control centers; distribution protection and control;and general service and maintenance.

The combination of these and other measures has enabled TVA to maintain an enviable reliability record and avoid a number of costly andimage-bruising crises.

For instance, the hot-spot temperature of an old transformer at a TVApower plant was showing signs of increasing instability. The problembecame critical over the July 4 holiday. ABB immediately sent a team ofexperts to monitor the transformer and perform modeling until the source ofthe problem – a bus connection that was impacting the transformer - wasidentified. If ABB had not pinpointed the problem TVA would have had toshut down the generators at a cost of $1 million a day.

Similarly, when TVA increased the capacity of a generator, ABB avoidedhaving to procure three new power transformers by refurbishing three 20-year-old transformers at an underutilised substation and moving them to the upgraded generating unit – saving TVA millions of dollars inprocurement, transportation and commissioning costs.

ABB agreement bringsbig benefits to TVA

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ABB is helping Tennessee Valley Authority(TVA), the largest public power company inthe United States, manage its vast fleet ofpower transformers – a service that savesTVA hundreds of millions of dollars andhelps it deliver power with 99.999 percentreliability.

The Apalachia dam (above) is part of the power generatingnetwork of the Tennessee Valley Authority (TVA), whichsupplies electricity to 8.6 million people and 650,000 businessesin seven states in the USA. TVA maintains about 1,200 powertransformers, many of them more than 25 years old.

12 action ABB

The 25-acre stadium in Phoenix, Arizona, home to National Football Leagueteam Arizona Cardinals, is the first in the USA to be equipped with both aretractable roof (that opens and closes to admit or shut out the sun or rain)and a retractable playing field built into a giant steel tray holding more thantwo acres of natural grass that will move in and out of the stadium on rails -the first of its kind in North America.

The $450-million stadium is widely considered an engineering marvel andhas already been featured on the Discovery Channel series “ExtremeEngineering” which highlights projects that extend the frontiers ofengineering capability.

Designed by U.S. engineering company Uni-Systems, the dome-shapedroof is unlike any other previously constructed in that its two retractable roofpanels move along a sloping trajectory. If the brakes holding the panels inplace were released and the motors that power retraction failed to start, thepanels would collapse and fall to the ground.

“An important factor in choosing the ABB drives was to combat the inherent risks associated with running a roof on a sloped track,” saysLennart Nielsen, Uni-Systems’ senior electrical designer.

Nielsen explains that they wanted a variable speed drive that would enablethem to test the drive torque before opening the motor brakes to ensurethat each drive was operational and capable of a 100-percent torque output.

“We wanted to have this capability all the way down to a motor speed of 0 Hz, and none of the manufacturers – except ABB – could guarantee that,”says Nielsen.

The retractable roof consists oftwo movable panels divided intoeight sections. Each section ispowered by 16 motors andeight ABB ACS800 variablespeed drives that aremaintenance-free and mountedin air-conditioned enclosures onthe roof carriers.

The drives solution has been sosuccessful that Uni-Systems hasselected ABB to provide drivestechnology for two otherretractable roof stadiums thatthe company is currentlyworking on: the RCA Dome inIndianapolis and the DallasCowboys’ stadium in Texas.

ABB drives raising the roofin Phoenix

Global news

The retractable roof consists of two moveable panelssuspended between two parallel tracks.

The dome-shaped roof of Cardinal stadium is unique, becauseits two retractable panels move in a sloping trajectory. ABBdrives were chosen to combat the inherent risks associatedwith operating a sliding roof on a sloping track.

ABB variable speed drives are controlling theretractable roof at a new first-of-its-kindstadium in the United States. “We wanted tohave a capability that none of themanufacturers – except ABB – couldguarantee,” says the designer.

3/11 on reply cardEach roof quadrant is powered by 16 motors,which are controlled by eight ABB ACS800drives.

action 13ABB

Global news

The electronic Malossi keyboard (top) haspressure points which correspond to theletters of the Malossi hand alphabet (above),a touch spelling system in which differentparts of the hand correspond to the lettersof the alphabet.

Designed by ABB Sace in collaborationwith students of Cesare Pesentitechnical-professional high school inBergamo, Italy, the hand shaped pad isequipped with special sensors andsoftware to serve as a keyboard.

A person with severe sensory deficits likeblindness can place a hand on thekeyboard and use a familiar style ofblind/deaf communication known as theMalossi alphabet, a hand-to-handmethod in which people press and pinchspecific areas of the fingers and palmcorresponding to letters.

The new technology converts their pinchingand pressing motions into electronicimpulses that can be relayed to a monitorand read by a sighted person.

With Malossi, different parts of a person’shand correspond to different letters. Bygently touching (black letters) andpinching (blue letters) in these areas, thehand becomes a kind of typewriter for theperson sending the message.

In the upcoming school year, the projectswings into its final phase, in which theelectronic hand pad will be designed toactually pinch and touch the fingers andpalm of a deaf-blind user in order to relaya Malossi message that comes indigitally, by computer email for example.

The method will allow communicationwith the deaf and blind over a distanceand in a style with which many arealready comfortable.

The development is part of an ongoingABB program to involve local students inthe business of research and development.

Last year, researchers with ABB Saceand students from a local school votedon a pet project and then nominated ahalf-dozen young people to help see itthrough over a period of several weeks.

The original idea for the Malossi tool camefrom Ezio Manzoni, an electronics engineerwith ABB Sace who has been making asecond career of charity work since 1982.In this case he and colleague AlbertoSannino, also an electronics engineer,turned to a nonprofit organisation devotedto people with multisensory deficits.

A doctor working with the organization,known as Lega del Filo d’Oro, alertedthem to a problem facing the deaf andblind, who often rely on Malossi but needto communicate with others who do notknow it. Manzoni pitched this idea to thestudents, who voted on several proposalsand chose his.

Sannino and Manzoni say the opportunityto help increased the appeal of a goodbusiness idea.

ABB Sace taught a week-long course atthe school on how to research and developa prototype like this one. Six studentsauthored product specifications and otherdesign documents. “They spent weeks atABB and, in 240 hours, they designedthis project with us,” said Sannino.

Since human hands are unique in fingerlength and general size, Sanninoenvisions several prototypes to cover themajority of users.

“The software could be adapted to managedifferent languages and help more people,”he added. “It was a fantastic thing, agreat experience for us because we getto interact with the students. They learnfrom us, and we learn from them.”

Manzoni hopes that everyone involved inthe project gained a better understandingof the difficulties faced by deaf and blindpeople.

“I am really grateful that ABB allows me todevote some work hours to socialcauses,” he said.

“The collaboration with schools andstakeholders – along with its technical,business and social benefits – is a missionfor ABB Italy and for me. We believe thatour contribution can really improvewelfare for business and society as well.”

“And the annual collaboration helps toteach young people about a scientific and business approach to invention –which is, after all, ABB’s bread andbutter”, he added.

A helping hand forthe deaf and blind

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ABB technology has helpedItalian students develop aunique, hand-shaped keyboardthat lets deaf and blind peoplesend electronic messages thatcan be read on a computerdisplay. Within a year, thekeyboard will be equipped toaccept and display returnmessages as well.

14 action ABB

Extremely compact multidrive series from ABB – the ACS800 – offers anarray of benefits to integrators, OEMs, panel builders and end users whoare optimising energy usage through precise control of motors. Since drivesare available both in multidrive and single drive configurations, it is useful todefine the difference – and profile the benefits that the next generation ofmultidrives now provides to users.

A single ABB industrial drive

Variable Speed Drives (VSD) are used in any application in which there ismechanical equipment powered by motors; the drives provide extremelyprecise electrical motor control, so that motor speeds can be ramped upand down, and maintained, at speeds required; doing so utilises only theenergy required, rather than having a motor run at constant (fixed) speedand utilising an excess of energy.

Since motors consume a majority of the energy produced, the control ofmotors, based on demands of loads, increases in importance, as energysupplies become ever more strained. Additionally, end users of motors canrealise 25-70 percent energy savings via the use of motor controllers(despite these benefits, the majority of motors continue to be operatedwithout drives).

Single ABB industrial drives are highly flexible AC drives that can becustomised to meet the precise needs of a single-motor application. These

units convert AC power to DC, and then invert the DCback to an AC output to a motor. These drives cover awide, full range of powers and voltages. Single industrialdrives also feature a wide range of built-in options asstandard equipment. They can be installed for mostapplications right out of the box; and they also can beordered and manufactured as a customised unit for aparticular application.

What is an ABB multidrive?

A multidrive is built from industrial drive modules that areconnected to a common DC bus bar. The common busbar is used to supply the drive modules with DC power,and each module then converts the DC to AC andpowers an individual motor. The DC power is derivedfrom a single supply unit (rectifier) that is built into thefront end of the same multidrive configuration.

This construction simplifies the total installation andresults in many benefits: savings in cabling; reduced linecurrents and simpler braking arrangements; energy

distribution over the common DC bus bar, which can be used for motor-to-motor braking without the need for a braking chopper or a regenerativesupply unit; reduced component counts; increased reliability; and spacesavings; and there is no need for a separate Motor Control Centre (MCC).

Where can multidrives be used?

In general terms, the ABB multidrives can be used whenever severaldrives/motors form part of a single or integrated mechanical process. Thecommon supply of the multidrive enables the implementation of overallsafety and control functions, and permits the close coordination of individualdrive motors. For example, a paper machine has many motors that must beindividually controlled as a complete system. The ABB multidrives offer fastcommunication of torque and speed signals between the drives, to controlthe tension in the paper web. Multidrives also can be used where the shaftsof the individual drive motors are not tightly coupled; for example, inprocesses where each drive module can be programmed with a speedprofile so that the overall use of energy is minimised. These two examples

Why andwhen to installmultidrives?

Feature

A new generation of technologydelivers precise control of multiplemotors via a compact multidrivedesign.

Since drives are available both inmultidrive and single driveconfigurations, it is useful to definethe difference – and profile thebenefits that the next generation ofmultidrives now provides to users.

action 15ABB

merely demonstrate therange of applicationswhere ABB multidrivesoffer substantial benefitsover other types of driveconstructions.

ABB multidrivepromises

Modular configuration ofmultidrives providescontrol of multiplemotors across a 1.5 to5600 kW power range,from 380 to 600 (690)VAC. A single rectifierunit can be combinedwith a host of inverterunits that are connectedin parallel, to provideoutput current requiredby any given application.

Additional major benefits include:

Encoderless motor operation – superiordynamic-response performance of ABB’spatented Direct Torque Control (DTC)motor control algorithm. Many applicationscan be run without encoder feedback.

Flexibility – There arefive different types ofdiode rectifiers (supplyunits) that can be usedto invert AC three-phaseinput power to thecommon DC bus baracross the entire ACS800power range-regenerative(low harmonic) IGBT, 6pulse diode supply, 6pulse regenerative (TSU),12 pulse diode supplyand 12 pulse regenerativethyristor supply (130 to3431.6 kW). Invertermodules (drives) areavailable in seven sizes

(R2i – R8i frame sizes) and cover the 1.5 to5600 kW range; single R8i units, or R8iunits in parallel, supply the motors.

Compact design – Improvements intechnology and power components havereduced the total footprint of thesemultidrives by up to fifty percent, comparedto the generation of multidrives precedingthe ACS800 line! This frees up significantwall-panel and floor-space.

Wide range of options – I/O extensions,field buses and a pulse encoder module allfit inside the inverters.

Adaptive programming – This programextends the freely programmable I/O andextensive parameter selections built into themultidrives and accessed via the Start-upassistant. The adaptive programmingaccesses extensive parameter selectionsfor complete flexibility in precise control ofall individual motors; like a mini PLC built in.

Reduced installation costs – Since themodular configuration utilises a commonDC bus, the cabling input power required isa single three-phase AC connection.Further, the cabling is wired to the rectifiermodule through a unique plug-in connector,which then powers the entire common DCline-up. And the plug-in connectors for theinverters (132 KW and up) are wired to themotor terminals. Both the rectifiers and theinverters are rolled in on their wheels andseated into the connectors.

Redundancy – Common spare parts andthe ability to keep running at reduced load,if module is disabled.

Overview of the construction

An ABB multidrive is built from severaldifferent sections (see figure 1). The keyunits within these multidrive systems include:

Drive units – inverters have built-incapacitors for smoothing the voltage of DC bus bars.

Diode Supply Units (DSU) – these unitsautomatically adapt to 6- or 12-pulseoperation and, during start-up, they deploya built-in control system that automaticallycharge the inverters’ capacitor banks.

IGBT Supply Units (ISU) – used inregenerative drive systems and applicationsrequiring low harmonics, to convert three-phase AC voltage to DC voltage.

Thyristor Supply Units (TSU) – in aregenerative drive, can regenerate powerback to the mains.

Dynamic braking units – in resistorbraking, whenever the DC bus voltage of afrequency converter exceeds a certain limit,a braking chopper connects the circuit to abraking resistor.

Control units (optional) – are equippedwith communication interfaces, powersupplies, etc. for automation equipment.

Bridge in oil tanker, DAT oil tanker M/T Masterais fitted with electric cargo and ballast pumpscontrolled by AC drives. ABB supplied water-cooled multidrive frequency convertersfrom its industrial drives range.

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Figure 1

16 action ABB

ApplicationsLinnanmäki, an amusement park in the heart of Helsinki, has been providingrides and amusement for the inhabitants of Helsinki for the past 57 years.

This year the park opened its gates with a new attraction - a 34 metre Ferriswheel driven by ABB industrial drives replacing the old Helsinki Wheel thathad been in operation for 40 years.

After a naming competition, the newride was named “Rinkeli” (whichloosely translates into a bagel!).

The Ferris wheel was manufacturedby Technical Park, an Italianamusement ride manufacturer locatedin Melara, Italy.

Here’s how it works

A rubber tyre attached to a motorrotates the steel frame of the wheel.Two 37 kW ACS800-01-0040-3drives with master/follower controldrive the motors. Each drive controlstwo motors. Altogether, four motorswith a combined power of 57 kW areused to rotate the Ferris wheel.

There are 24 gondolas suspendedalong the circumference of the wheel,and 144 people can be carried at atime. Only two motors are used todrive the wheel if fewer than half of

the gondolas are in use. When filling the gondolas, the operator ensuresthat the load is evenly distributed across the wheel.

The height of the wheel is 34 metre andit weighs 74 tonnes (about the weight of 7 buses). Fully loaded it has a weight of 85 tonnes. The peripheral speed is 4.3metres per second, giving the gondolas amaximum speed of 15.5 kph.

The three-minute ride providesenjoyment and wonderful viewsoverlooking the city and its vicinity.Afterwards, thanks to ACS800 drivesthe riders are brought smoothly back on the ground to continue the fun in the park.

Speed controlled Ferriswheel

Two 37 kW ACS800-01-0040-3drives with master/follower controldrive the motors.

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action 17ABB

Applications

ABB Automation Products, NewZealand decided to use ACS800-01drives with motion control softwareand an operator interface to get acost effective solution using standardmotors and gearboxes.

The ABB Automation Products division in New Zealand was asked by theABB Transformers group to do a local control upgrade of a low voltage andhigh voltage transformer winding machine (up to 5MVA and up to 25 mmthick wire) using an existing machine frame.

ABB Transformers have traditionally bought their HV and LV winders fromoverseas, and these have included high speed servos and CNC type controlsystems.

The LV and HV winding machines take winding wire from a drum and wind itonto a mandrel that forms the part of the HV and LV phase windings. Theprocess involves a high degree of accuracy as any gaps in the winding arenot acceptable for a quality finish. Ideally the operator would simply like toenter the number of turns per layer of winding, number of layers and thenumber of taps in the winding.

New Zealand ABB Automation Products decided to use ACS800-01 driveswith motion control software and an operator interface to get a cost effectivesolution using standard motors and gearboxes. The winding algorithm andprogramming was done by ABB Automation Products, New Zealand.

As it was paramount that the finished product was layered evenly withoutgaps in the coils, the bobbin and the traverse had to be synchronised. Thiswas achieved with the motion control software using its synchronous CAMdisk function. The bobbin (master) running at constant speed and thetraverse (follower) was synchronized with the bobbin through amaster/follower optical link.

The CAM disk function has two tablesprogrammed for the follower to run insynchro with the master, i.e. thefollower is always in the correctposition relative to the master. The firsttable forces a run in exactsynchronisation with the master, thesecond does the same but in theopposite direction.

The elimination of the PLC broughtsavings in cost, space and installation.In addition, the production has goneup by almost 80 percent, from about15 coils to 25 coils in one day on thelarger coils, as a result of not havingany intermittent stoppages.

Coil winding solution withmotion control

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ACS800-01 drive

18 action ABB

Product news

UMC22

The UMC22, ABB’s motor protection and control relay suitable for OEMs,end users and switchboard builders, has now been enhanced withadditional features. Along with phase failure, locked rotor and overloadprotection with trip classes 5, 10, 20 & 30, the device now includesthermistor and optional earth fault functions.

The 6 digital (24VDC) inputs and 3 relay outputs, allow for various motorcontrol setups with pre-programmed modes for; DOL, reversing, star delta,valve & actuator drives for motors from 0.24 to 63 Amp, and extendable upto 3200 Amps with external CTs.

The UMC22 is suitable for 415 and 690V installations, with Type 2 co-ordination protection systems with ABB fuse gear up to 80kA, andcircuit breakers up to 100kA.

The UMC22s optional control panel allows for direct local control as well asspecific function programming and status monitoring.

Utilising ABB FieldBusPlugs the UMC22 can be fully controlled and monitoredby PLC & DCS systems, and is fully integrated into the ABB 800XA system.

The FieldBusPlug lies at the heart of the ABB low voltage product family’scommunications. By selecting different FieldBusPlugs, Profibus-DP V0 & V1,DeviceNet, and Modbus methods of communication are accommodated.

ABB now offers the PDQ22-FBP and through it, the possibility to connectup to four ABB FieldBusPlug devices to PROFIBUS DP. The PDQ22-FBP iscapable of offering low-cost solutions especially for devices that are in closevicinity, and is in addition to the tried and tested PROFIBUS DP connectorPDP22-FBP.

As with all the other FieldBusPlug components, PDQ22-FBP offers easydiagnostic functions. This enables users to quickly detect and correctproblems, thus maintenance down times are reduced to a minimum.

The FieldBusPlug system generates significant benefits with respect toinstallation expenditure, e.g. the installation of motor controllers in plug-in ordrawout technology. As the underlying concept provides a separation offieldbus nodes and devices, PROFIBUS nodes remain in the cablecompartment, whereas the motor controller is installed in the module.

Enhanced motorprotection with UMC22and FieldBusPlug

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The FieldBusPlug lies at the heart ofthe ABB low voltage product family’scommunications. By selectingdifferent FieldBusPlugs, Profibus-DPV0 & V1, DeviceNet, and Modbusmethods of communication areaccommodated.

With its massive product range, it’s sometimes difficult forcustomers to keep up with exactly what’s available fromABB’s low voltage products group. The fact is ABB probablysupplies just about every type of low voltage electrical equipmentimaginable, but we just probably haven’t told you about it.

This CD should help solve that! It contains a complete rangeof technical catalogues in which, you will find ourcomprehensive range of building and automation products

and accessories, suited to the Australian market. Thesecatalogues cover everything from part numbers and technicalspecifications to dimensional drawings and cut-outs, ideal forOEMs and end users.

This is one of the most comprehensive low voltage productranges available from any manufacturer. Including everythingfrom standard components through to the latest controltechnology, ABB’s product portfolio can meet your needswhether you want a stand-alone product or a completelymatched system.

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No more ‘secrets’ with lowvoltage interactive CD

action 19ABB

Product newsABB has launched the air-cooled version of its ACS 5000 range of mediumvoltage AC drives, adding to its water cooled series. The new drive isavailable from 2 to 7 MW at voltages up to 6.9 kV. By creating a partialoverlap in the power range already covered by the water cooled series, ABBoffers customers the widest choice in cooling for medium voltage AC drives.

The new drive has the option of an integrated or separate input transformerand is available with a built-in monitoring tool that gives remote real-timeaccess to the drive. “Since we launched the water-cooled version of theworld’s first multilevel-fuseless medium voltage drive in 2005, the demandhas been extremely strong”, explains Fuad Mehmedovic, product managerfor medium voltage drives . “Such is the demand that we believe the air-cooledversion will compliment the range well and be equally sought after.”

The success for both drive types is attributed to the re-use of leading edgeand well proven technology including ABB’s motor control platform, DirectTorque Control (DTC) and IGCT power semiconductors. This brings high levelsof efficiency, reliability, performance and size reduction to medium voltage drives.

In addition, the air cooling equipment is available with redundant fans to allowmaintenance during operating hours, thereby minimising downtime. The driveis available with a built-in monitoring tool that gives real-time access to drivediagnostic data. Called DriveMonitor, the tool enables ABB service engineersto monitor the performance of the drive without having to be on site.

The tool consists of a hardware module inside the drive, as well as a softwarelayer that automatically collects and analyses selected drive signals andparameters. Monitoring functions deliver information over time on equipmentstatus, tasks needed and possible performance improvements. Diagnosticprocedures and trend data can cover, not only the drive itself, but other partsof the shaft train as well. It is also possible to connect other ABB drive installations.

The drive has the option of an integrated or separate transformer. Theintegrated input transformer gives simple installation and commissioning,while the separate transformer permits a flexible transformer configuration.The transformer can be placed either inside or outside the electrical room. Ifthe transformer is placed outdoors, it will not add to the cooling andventilation needs of the electrical room.

The multilevel-fuseless voltage source inverter design allows efficient andsmooth switching operations, free from torque pulsations, over the entirespeed range. DTC motor control platform gives fast and accurate processcontrol with low energy consumption, along with the highest torque andspeed performance. IGCT power semiconductors combine fast switchingwith reliability and low losses. The drives do not use medium voltage powerfuses, known to be unreliable, costly and subject to aging. Instead IGCTs areused to provide much faster and more reliable protection of power components.

The drive is intended for 6 kV applications in industries such as cement,mining, metals, chemical, oil and gas, water and waste water and powergeneration. Typical applications include conveyors, compressors, mills, fans,pumps and blowers.

ABB launches air cooled6kV drive

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ABB offers customers the widest choice in cooling formedium voltage AC drives.

20 action ABB

ABB introduces the flexible IRB 6650S-90/3.9 m – a shelf-mounted, six-axisrobot with an enhanced working envelope over previous models.

With a reach of 3.9 metres, the IRB 6650S is capable of full vertical andhorizontal stroke motion – as well as providing increased reach forward and

down. With virtually no footprint, the shelf-mounted robotprovides ample space to handle large parts – allowing forshorter cycle times.

The IRB 6650S is an attractive alternative to a linear, 3-axis robot, conventionallyused in injection moulding applications. Based on 6-axis technology, therobot is superior in versatility, reach and precision – qualities that combine tominimise cycle times and optimise product quality. The IRB 6650S is an idealsolution for large injection moulding machines requiring over 1,000 tonne ofclamping force. The flexibility of the six-axis robot means no idle time betweenshoots, facilitating post-process applications like flaming, sprue cutting, tapedispensing and assembly operations. This allows plant designers to reducethe number of downstream stations and decrease plant throughput times.

“What takes two or more downstream processes with a linear robot, can allbe done in parallel at the injection-moulding station using the IRB 6650S,”says Olivier Coquerel, robotics sales manager (manufacturing industries).

In contrast to a conventional robot, a shelf robot has its principal workingenvelope below the foot. The arm and wrist design of the IRB 6650S facilitateseasy entry into the injection-moulding machine for part extraction, while thecombined ability to reach 2624 mm below its base adds to the robot’s flexibility.This flexibility makes it possible to mount the robot over the injection-mouldingmachine – an important factor, along with the backwards-bending ability, insaving valuable space. To increase productivity even more, the IRB 6650Scan work between two injection-moulding machines from its shelf-mountedposition. The IRB 6650S is a backwards-bending, steam-washable robot,with optional IP 67 classification available in three versions – with a reach of3.9 m 3.5 m or 3.0 m and payload capacity of 90, 125 or 200 kg.

The IRB 6650S comes with a number of safety features. In particular, collisiondetection – which reduces collision force substantially – is especially usefulfor robots handling high payloads. Used for injection moulding, collisiondetection provides extra protection against the damage of moulds and tools.

ABB’s IRC5 robot controller offers flexibility in programming and operatingrobots. RobotWare Plastics Mould is a user-friendly graphical interfacedesigned specifically for the plastics industry. Injection moulders, using six-axis robots and this software, are already reaping major benefits. RobotWarePlastics Mould offers greater efficiency in terms of installation, set-up andproduction. A new program can be installed and operational within thirtyminutes, reducing standard programming by a day or more.

Euromap / SPI is the best signal interface between a robot and an injection-moulding machine – speeding up the installation process. The ABBEuromap kit connects robots to injection-moulding machines and is used forall hand-shaking signals between the two. This is a true “plug and playsolution” based on international standards and safety regulations. Fast andeasy set-up is key to high productivity. For the plastics industry the IRB6650S comes complete with Euromap 12, 67 or SPI interface.

ABB introduces newbackwards-bending, 6-axisrobot with 3.9 m reach

Product news

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The flexibility of the six-axis robotmeans no idle time between shoots,facilitating post-process applicationslike flaming, sprue cutting, tapedispensing and assemblyoperations. This allows plantdesigners to reduce the number ofdownstream stations and decreaseplant throughput times.

IRB 6650S stretched on shelf, 3.9 m

action 21ABB

Product news

What strikes customers the most, isthe compact user-friendliness of thepalm-size data recorder and the factthat it can be mounted anywhere –on a pipe, wall or panel – and in anytype of environment.

The SM500F, the world’s first field-mountable videographic data recorder, is taking the market by storm as customers all over the world recognise thebenefits of on-the-spot access to critical process data in hostileenvironments.

“Customer response to the SM500F has been extraordinary,” says AnilBhatia, product manager for ABB’s award-winning ScreenMaster series ofvideographic data recorders.

“Within just a few weeks of launch, ABB received massive interest fromcompanies all over the world. Customers recognise that this is a genuinelyunique innovation in data recording technology and the benefits comparedto existing options are immense.”

What strikes customers the most, according to Bhatia, is the compact user-friendliness of the palm-size data recorder and the fact that it can bemounted anywhere – on a pipe, wall or panel – and in any type ofenvironment. The device is often demonstrated with water running over it.

Competing videographic recorders do not have this versatility. They requirea separate control panel in a non-hostile location which doubles the cost ofthe installation. By eliminating this cost factor the SM500F enablescustomers to migrate from paper chart recorders, which requireconsumables like paper, ink and pens, to a state-of-the-art videographicrecorder at comparatively low expense.

The user-friendly display and front-mounted pushbuttons give easy andrapid access to critical process data in a choice of display formats andintuitive Windows environment.

The SM500F is equipped with an IP66 and NEMA 4X enclosure, whichmakes it ideal for hosedown and dirty environments.

Typical applications for which the SM500F is uniquely suited include coldstorage, temperature and humidity monitoring, effluent monitoring, boreholeabstraction and swimming pool monitoring.

The world’s first “mount itanywhere” videographicrecorder

The SM500F was demonstrated at Automation World 2006,in Texas. Here it is shown working despite moisture anddust.

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22 action ABB

VisiVolt™ is a novel indicator of voltage presence offered by ABB which canbe mounted directly on bare and insulated current bars and conductors of amedium voltage (MV) system. The indicator can be installed both indoorsand outdoors, which is a unique feature among indicators of that type. Thepresence of AC voltage is indicated by appearance of a large and clearlightning arrow sign on the display of the indicator.

The novel technology of the liquid crystal display (LCD) applied in VisiVolt™has been developed by ABB Corporate Research. The prototypes and pilotproducts of the device have been presented earlier under the names “PVI”and “PassVI”. The design of the internal structure of the LCD gives it anunprecedentedly high sensitivity to the electric field making the LCD itselfthe only sensitive element of the indicator. This means that, unlike any otherproduct of that type, VisiVolt™ does not use any electronic circuit, whichmakes the device extremely robust and durable.

Its enclosure is made of a state-of-the-art silicone elastomer for electricapplications which gives it a high resistance to difficult outdoor conditions,while its fluorescent orange color provides excellent visibility among otherelements of the system.

VisiVolt™ indicators are designed for nominal voltage of the system of 3 kV – 36 kV, can operate in temperatures between –40°C and + 85°C andare fully resistant to fault currents and overvoltages. VisiVolt™ indicates thepresence of voltage when it is higher than 45 percent of its nominal value in three-phase systems – as required by the IEC standards related tovoltage indicators.

A number of test installations have been arranged using the pilot version ofthe product. Some of them, as the one installed at a distribution station ofENION S.A. utility in Poland or another one at an ABB sea-side test stationat west coast of Sweden have been operating already for more than oneyear. The outdoor performance of the indicators confirms the results of theextensive laboratory testing conducted during the prototyping and productdevelopment stage.

When installed, VisiVolt™ indicators provide opportunity of reading the stateof voltage presence on distribution systems at a glance of the eye withoutusing any additional equipment.

VisiVolt™ indicators contribute also to a higher safety standard of operationof the system. The additional and independent information about presenceof dangerous voltage provided by VisiVolt™ actively warns the personneland can prevent accidents. Unlike the obligatory installed “high voltage”warning plates, VisiVolt™ informs about the true actual state of voltagepresence and can discourage service people from breaking the safety rules,e.g. working unprotected too close to the live system.

“The greatest challenge in developing the technology was achieving therequired sensitivity of the indicator while in the same time providing it withthe outdoor compatibility, broad temperature range and tens of years ofservice-free operation”, says Jan Czyzewski of ABB Corporate ResearchCenter in Krakow.

ABB launches a novelindicator of voltagepresence for indoor andoutdoor applications inMV systems

Product news

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Testing of VisiVoltTM indicators

Out door use

In door use

Position On Position Off

action 23ABB

Product newsWith the new range of motor operating devices S2C-CM and F2C-CM, it isnow possible to remotely control the opening and closing of the System Pro Mcompact miniature circuit breakers of S200 series up to 63A and all residualcurrent circuit breakers of F200 series up to 100A.

This application is especially useful in centralised, large-scale plants or plantswith difficult access and where many operations per day are required forpowering and switching off lines, for example: power lines of unmanned stations,security systems (detectors and alarms), central lighting commands, etc.

For System Pro M compact residual current circuit breakers, the auto-reclosingunit F2C-ARI is also available. It enables automatic reclosing of the circuitbreaker in case of nuisance tripping, for example due to overvoltagesgenerated by lightnings.

The F2C-ARI auto-reclosing unit is particularly suitable for use in electricitystations located in areas that are difficult to access and unmanned stations,where a high level of service availability is required (mobile phone andtelevision repeater stations, traffic and signalling control, pumping andirrigation stations, refrigeration and cool rooms, public lighting, etc.).

System Pro M compact:new motor operating devices

A new configuration for the ZVC motor control centre has been designed anddeveloped by ABB Australia’s medium voltage R&D and engineering group.

This unique solution used the standard Unigear type ZVC compact panel asa basis for the design and was initially implemented at the Dalrymple BayCoal Terminal (see story on page 8) who required a cost and space savingalternative to PFC (power factor correction) of individual motors.

A 3.3kV three phase capacitor and associated reactors were installed in thepanel which not only contained the MV fused contactor truck V7/ZVC butalso provided access for the power cables.

One major advantage with this solution is that the capacitor is beingautomatically switched in and out, in step with the motor load.

Other benefits of such a configuration include:The line contactor for the motor to be compensated is also utilised forswitching and protection of the capacitorsAll switchgear operations are behind closed doors securing the outmostprotection and safety to the Operatorsinternal arc fault containment is integrated for up to one secondcompact construction of the switchgear allowing substantial capitalexpenditure savings in switch room sizing.The cost of ownership of the switchgear is low with minimummaintenance, high quality, reliability and flexibility

The Unigear type ZVC motor control centre is designed and manufactured atABB Australia’s Global Focused Feeder Factory at Moorebank, NSW. A Global Focused Feeder Factory is one nominated as the principle factoryto supply product and provide technical support to all other ABB factoriesaround the world where secondary components are fitted thus allowing thesupply of complete MCCs.

ZVC with integrated PFcompensation

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One major advantage with this solution is that thecapacitor is being automatically switched in and out, in step with the motor load.

This application is especially useful incentralised, large-scale plants orplants with difficult access and wheremany operations per day are requiredfor powering and switching off lines.

ABB robots provide the following advantages

Applications

Robotic solutions for every application!

For further information contact ABB Australia Pty Limited on 1800 222 435,email info@au.abb.com, or visit our website www.abb.com/robotics.

Power and productivity for a better worldTM© Copyright 2006 ABB.

Competitive solutions24/7 personalised service and support Australia wide

Friendly user interfaceGlobal partner networkTrue Off-line Programming(RobotStudio)

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ABB Robotics - From a single robot to a complete turnkey solution. Wecan help you to increase productivity,quality and profitability.