1	"Cooling Tower Drives" Cooling Tower Drives January, 2010 Motorreductores y Controles SA de CV www.mcweb.com.mx
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3	Cooling Tower Designs
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8	"Matched Performance VS1CTD drive and..." Matched Performance VS1CTD drive and RPM-AC Motor Baldor VS1CTD drive designed for variable speed operation High Torque Direct Drive Motor: Laminated Frame IPM (Permanent Magnet) Motor is designed as a drop in replacement for existing gearbox packages; matching bolt holt patterns (may require a mounting plate) Water tight motor uses fan air stream for optimal cooling Improved efficiency over standard gearbox and motor Fan couples directly to the motor shaft
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12	"Industry requires improved motor power..." Industry requires improved motor power density and increased efficiency Permanent Magnet Motors meet these needs Due to dramatic improvements in PM materials, these types of motors are now viable alternatives to standard induction motors Laminated RPM-AC frame allows more room for active material creating a power dense package Frame construction improves thermal transfer and heat dissipation capability of the motor Efficiency of PM motors is a band level higher than induction cast iron frame motors
13	"Laminated Frame Interior Permanent Magnet..." Laminated Frame Interior Permanent Magnet rotor technology Motor is compact enough to direct drive cooling tower fans Finned Laminated frame in fan air stream is optimum construction for application VPI electrical insulation system for extreme environmental conditions
14	"Sealed insulation system" Sealed insulation system: Same insulation system used in off shore oil drilling motor applications Provides ultra reliable motor life in hostile north sea environment Drive end sealing utilizes a slinger and an Inpro seal for superior bearing protection.
15	Baldor VS1CTD Drive Designed for the cooling tower industry Focus is on ease of startup, minimal maintenance and efficiency of operation Matched Performance drive and motor RPM-AC motor models are stored in the VS1CTD drive software Precise control capability Simplified Cooling Tower Startups Eliminates the need for users to input data Basic software parameter set designed exclusively for the cooling tower industry Designed around proven H2-Technology Unique Sensorless Vector Software Smooth, low speed operation Optimized motor control increases efficiency
16	Optimized Efficiency Optimized motor speed Traditional cooling towers are designed for the “Worst Case” (highest air flow) scenario Running the fan at reduced speed saves energy and cost of operating the tower Allows for optimized cooling of return water; increasing the efficiency of compressor operation and this components life
17	Partial Load Power Factor Cooling Tower Loading Typical cooling fans run the majority of their time lightly loaded Traditional AC motor power factor is negatively impacted by light loading
18	VS1CTD Trickle Current Heating Trickle Current Heating is used to keep the temperature of the motor above the dew point during times when not in use. Set by a single parameter (units of amps) Limited to 50% FLA of motor (0 amps disables) Wattage calculation based upon amperage and motor stator resistance Enabled automatically once motor stops and after a 300 second delay Digital input provided for customers that want control via hardware input for CTD operating modes Modbus coil provided for building automation control systems Additional benefit of providing anti-windmilling torque
19	VS1CTD Accessories and Options Communication Networks: System automation and control can be a requirement for cooling tower operations The VS1CTD communicates with multiple networks: Dynamic Braking Input / Output Reactors Keypad Extension Cables High Resolution Analog I/O Expansion Board Ethernet Browser Board
20	Application Example On the campus of Clemson University in Clemson, SC
21	"Cooling Tower Information" Cooling Tower Information Built in 1986 Ceramic Cooling Tower Job # CT-1206 2 Fan Units
22	"Existing Motor Nameplate Information" Existing Motor Nameplate Information Both Units were Reliance Motors Motor 1 S/O: 1MOF26353-G1-WM Motor 2 S/O: 1MOF26353-G2-WM Frame Size: 326T Rating: 50HP @ 1765 RPM / 12.5 HP @ 885 RPM 480 V / 3 Phase / 60 Hz
23	"Amarillo Gear Box Information" Amarillo Gear Box Information 2 Units Model: 155 (single reduction) Gear Ratio: 8.5 to 1 Pinion: 8 Teeth Ring Gear: 68 Teeth
24	"Fan Information (Both Units" Fan Information (Both Units) Manufacturer: Hudson Fans (80% of all towers use these fans) Model: APT-18B-5 Diameter: 18’ - 0”
25	"New motor is 93.6" New motor is 93.6% efficient (existing motor is 22 years old) Gearbox manufacturer states gearbox efficiency at 96% Test data indicates mechanical system (gearbox, couplings, driveshaft) is 90.2% Data verified by Clear Air Engineering on site at Clemson University * Published Data
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27	"Laminated Frame Interior PM motor..." Laminated Frame Interior PM motor technology enables direct drive gearless system Gearbox low speed lubrication issues are eliminated No drive shaft No couplings No guards No alignment Minimizes blade load fluctuation Motor can be configured to be drop in replacement for gearbox Clemson University Beta site was a drop in Conversion at Clemson took under six hours Improved Reliability and Maintainability Simplified System Increased overall system efficiency Elimination of gearbox provides biggest improvement in overall fan drive system efficiency Direct motor reduces noise level of cooling tower Although a Baldor V*S drive is required, the majority of cooling towers are being retrofitted with VFDs for overall cooling tower system efficiency improvement
28	"Simplified installation and reduced maintenance..." Simplified installation and reduced maintenance are the major selling points No gear, line shaft, couplings guards, etc Biggest gains in energy savings when system takes advantage of airflow Reduces the overall Motor HP requirements for the fan 50-60% energy savings are typical Applying drives on NEMA induction motors saves a similar amount of energy as with the Baldor PM direct drive motor solution Old retrofits can show significant energy savings Both PM or Induction motor upgrades if the original gear and motors are lower efficiency 10-15% energy savings are possible Minimal energy savings if variable speed is not required Efficiency difference between Baldor IPM motor and newer efficient installation is minimal 2% Plus or minus energy savings is the expectation The primary reason is that the efficiency of the PM motors at the very low speeds of the fan is not very high, drive losses also have to be considered
29	VS1CTD Smooth Control
30	VS1CTD Calc Motor Model Calc Motor Model Requirements Enter motor design number for existing motor If non-existent, prompted to use custom motor block For new motor, enter data from motor electrical design into custom motor parameter block Execute Calc Motor Model Drive will not run until successful (fault occurs indicating this problem)
31	RFQ Data Sheet Please have data sheets filled out when sending in Quote requests Fan Shaft Hp required Presently assuming a required min air flow over motor of 500 fpm for 250 frame & 750 fpm for larger frames. This is one of the inputs required. We will run an evaluation of the application.
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