QUANTUM CONTROLS'
TODAY’S ENGINEER
Vol 27 Issue 33: July 2018
The Elisha Otis Story
Until the 1850’s, the Manhattan skyline was mostly flat. Developers would not build a property over 4 floors because
nobody trusted lifts due to safety concerns. That all changed in 1854 at the world’s Fair in New York City.
L ift Designer Elisha Otis built a four story lift
which he displayed at the fair. Every hour,
on the hour, he rode the lift to the top on a
platform then told his assistant to cut the rope
that was holding up the platform. The assistant
cut the rope but the platform only dropped a
few inches - due to the ‘technology’ Otis had
invented. Thousands saw the demonstration,
which was widely reported in the newspaper
and magazines.
After this powerful demonstration, the good
people of New York felt safe riding in a lift and
the skyscraper was born, forever changing New
York’s skyline.
You’ll have to admit, the safety demonstration
was excellent news for the revenues and profits
of the companies that made and installed the
lifts. And I tell you this story to prove the power
of proving your claims.
It’s one thing to say, “All lifts are safe” to a
distrusting public, but it’s quite another when
you give a demonstration as powerful as the
one Otis made. Today you see Otis lifts in
buildings around the world.
We live in an age of mass distrust. Potential
clients or customers are extremely wary.
Their natural instinct is to say, “I don’t believe
this” or “that’s rubbish” when presented with
information from salespeople.
And even more so in the case of energy saving
predictions, made by salesmen whose job it is
to sell the kit they claim will save the client lots
of money in reduced energy bills.
Of course it is the case that huge savings can be
made using high efficiency motors and installing
Variable Speed Drives as the motor control
method, especially on centrifugal pumps and
fans where a 20% reduction in the motor
speed will deliver a staggering 50% reduction
in energy cost. But that’s not the whole story.
Almost all Drive manufacturers provide their
“salesmen” with a basic software tool that will
estimate what saving can be achieved on a
pump or fan application. But just how accurate
are the predications?
Well that would depend upon whether the
salesman is also an engineer who understands
driven motor applications; if so he should have
asked all the relevant questions for your specific
application and entered the correct data into
Quantum Controls, Quantum House, Low Prudhoe Industrial Estate, Prudhoe, Northumberland NE42 6PQ
T: 01661 835 566 F: 01661 833 868 E: sales@quantum-controls.co.uk W: www.quantum-controls.co.uk
Published exclusively for members of Quantum Controls' VIP Inner Circle
the energy saving calculator.
Alas, this generally proves not to be the case.
The salesmen actually don’t understand
the application at all and are often not even
qualified engineers! So the prediction report
you may receive is most probably incorrect,
and who takes the rap when your company
invests sometimes tens of thousands of £’s in
new equipment only to subsequently find the
savings are not what you were told they would
be and the payback period is many years? Yes it
may well be you.
David Green, engineer manager with Alma,
asked Quantum Controls to look at the energy
use of its extruders and recommend options
for cutting the company’s energy consumption.
The extruders were running in a DC drive system
which drew a load whether it was required or
not, because DC motors draw a current even
while producing zero torque. The maintenance
cost of the DC motors was also an issue, as it far
outweighed the AC motor option.
A precise energy save prediction had to be
obtained for converting from DC to AC on
the extruder lines. Alma Products obtained
two ‘estimates’ from other ‘variable speed
drive manufacturers’, one companies ‘sales
representative’ attended site took the motor
details and then faxed a single page report
quoting an annual saving £14k per year. The other
VSD manufacturer representative attended site
was shown the application and subsequently
issued a three page document stating that saving
of £95k would be gained after installation of his
companies drive and motor.
Quantum Deliver the Facts not Fiction
Quantum Controls were approached for advice
and a hire trial was proposed to prove the
savings before committing to a purchase as
it was almost impossible to predict the exact
saving that would be obtained.
One of the DC systems was monitored by
Quantum Controls over a two week period
with a 3 phase energy data logger on the input
supply to the DC system. Quantum Controls
then fitted a temporary ABB 132 kW AC drive
and ABB 132 kW IE3 motor and monitored it for
a further two weeks for comparison.
The test results showed that the AC drive had
saved just over 25
percent of consumed
energy compared to
that of the DC drive
system. This would
give an estimated
total saving of over
£80,000 when all four
main extrusion lines
were converted to AC
drives.
Savings
"GUARANTEED"
So as Elisha Otis did
back in 1854, so do Quantum, we Guarantee
the savings that would be achieved on each
and every application we assess for our clients,
pump, fan, extruder, compressor and whatever
it is we take the risk out of your decision.
We offer a unique non-intrusive temporary
hire service for drives and motors that will
demonstrate to you the exact saving that will
be achieved on each and every application,
leaving you with the opportunity to make a
decision with.
Today companies such as your need to
reduce energy cost to ensure they stay
competitive in their market, with energy
pricing increasing and no hope in the future
of this trend changing.
YOUR FREE HIRE TRIAL
There are 10,000,000 million motors installed
in the UK, 75% of all electricity consumed by
industry is through electric motors, a 4 pole
160kW motor cost in region of £88,000 a year
to run continuous.
So don’t let mistrust and ‘energy salesman
fatigue’ prevent you from maximising the energy
savings that are capable at your company.
Take advantage of our unique service, we
are offering a two week FREE hire trial for
you today.
Matched to your application with before and
after monitoring and a comprehensive report
showing the savings that you can achieve on
an application of your choice.
To register you interest simply e-mail
m.hodgekinson@quantum-controls.co.uk
with your enquiry and we will do the rest.
 Vol
Vol2713Issue 18:July
Issue33: Aug2018
2016| |Engineers’
Engineers’Q&A's
Q&A's2018
2016 Engineers’ Q&A's 2018 | Vol 27 Issue 33: July 2018

ENGINEERS' Q & A

Every month we will put your questions to one of our engineers.

Here are the questions for November from Joe Parnaby.

Question
What are the main reasons for the loss in efficiency of rewound motors?
Joe Parnaby, Electrical Maintenance Lead Engineer

Answer...
Approximately 300,000 motors are rewound in the UK every year,
with an average rating of about 12 kW, so the efficiency of rewound
motors is extremely important. The loss in efficiency on rewinding
depends on the techniques, processes and skill used to perform the
rewind, and is usually between 2 – 5%.
The reasons for increased loss are discussed below. If the choice is
between rewinding a standard efficiency motor or purchasing a new
high efficiency motor, the difference in efficiency will be 4 to 5% at
full load in favour of the high efficiency motor, which will also have a
much longer service life.
Generally speaking, there are three factors affecting the efficiency of
rewound motors, and let’s talk about each of them:
1. Increase in Iron Losses
2. Copper Loss
3. Mechanical Considerations
1. INCREASE IN IRON LOSSES
An increase in the iron losses can be caused by:
• Mechanical damage to the core
• Thermal damage to the core
• Electromagnetic changes
Mechanical stress in the core will increase the hysteresis loss,
as might happen if the core is fitted into a new frame with an
undersized bore. The practice of hammering stator teeth back into
place after stripping will result in increased hysteresis locally as a
result of the residual stress.
Eddy current loss will increase if the insulation between adjacent
laminations is damaged, for example by burring together by filing or
by accidental impact.
Steel laminations being
destroyed. The vertical slots
were originally in straight lines,
not broken up as shown. Since
their edges are sharp, they can
easily cut through the stator
winding insulation and short
them together, creating an
electric heating circuit instead of a motor. (photo credit: nlcpr.com)
The stator tooth tips and rotor surface are the most vulnerable,
since both carry high frequency harmonic fluxes. Skimming to
remove damage is rarely acceptable because the air gap is increased
and efficiency reduced.
Thermal damage to the oxide or varnish insulation between the
laminations is normally regarded as the usual cause of increased
iron loss following a rewind. New work in which the increased loss effect on flux density and resistance.
after rewind under carefully controlled conditions for a number of Of load losses, stator copper losses (also referred to as I2R losses)
motors was measured has shown that for conventional steels the are caused by heating from the current flow through the resistance
temperature should not exceed 380°C. Losses increase very rapidly of the stator winding. Techniques for reducing these losses include
at higher temperatures. optimizing the stator slot design. Rotor losses are caused by rotor
The very highest efficiency motors use thin laminations of high currents and iron losses.
quality steel, coated with a microfilm of varnish and these were These losses are reduced for example by increasing the size of the
found to exhibit no increased loss over the test range of 350 – 400°C. conductive bars and end rings to produce lower resistance. Stray load
Most motors are designed to run with flux densities in the stator and losses are the result of leakage fluxes induced by load currents. These
rotor core just over the knee can be decreased by improving slot geometry of rewound motors.
of the magnetisation curve. Full considerations of these losses are very complex, and are beyond
If the winding characteristics the scope of this article. Full details can be found in this reference.
are changed after rewind,
for example if the number of 3. MECHANICAL CONSIDERATIONS
turns are reduced, the flux The concentricity of rotor and stator is very important. It is common
density and hence the loss practice to metal spray shafts or bearing housings which have been
will increase. damaged in service. This is acceptable only if special care is taken
to preserve concentricity – errors which result in a minimum to
2. COPPER LOSS maximum gap ratio greater than 1:1.25 will adversely affect efficiency.
Stator copper loss is the largest loss (at full load) in most induction Replacement bearings (and lubricants) should be to the original
motors. The winding pattern may be changed during rewinding to specification, and repairers should be aware that high efficiency
simplify the process, and in doing so the repairer must consider the motors are beginning to use newer, more sophisticated bearings.

2 3
 Vol 27 Issue 33: July 2018 | Engineer of the Month Engineer of the Month | Vol 27 Issue 33: July 2018

ENGINEER OF THE MONTH

"Being involved
with Rental means
This month we're talking to: that the diversity
of the engineering
Mark Hodgkinson, Rental schemes I have
Manager at Quantum Controls been involved
with is great with
each bringing
its different
challenges."

Let’s start by telling us your
background and when you
started at Quantum Controls.
A It’s been 2 and a half years
since I joined Quantum after
spending the past 30 Years of my
remained with me throughout my
working life
What would you consider
to be your greatest success
in using your skills to solve
an engineering problem?
received has been invaluable, with
each day bringing more knowledge "... the Variable
and awareness of the potential for
Speed Drive &
market growth 
Motor application
What do you get out of Quantum Unique Weatherproof Hire Drive Range
engineering that you
and product

working life in and around the
Rental Business.
What do you enjoy most/
A
Engineers are only as good couldn’t get from any other the expectancy that changes What personal
training I have
as the teams and tools they kind of work? sometimes have to be made characteristics do you received has been
use, so having the opportunity

A
least about engineering? to be involved with the people, As previously mentioned the must always be at the forefront feel are necessary to be a invaluable."
of any project, with the proviso successful engineer?

A
diversity of the day to day

Being involved with Rental
means that the diversity
of the engineering schemes I
have been involved with is great
with each bringing its different
challenges.
The least enjoyable thing seems
to be the fact that some schemes
always seem to raise their heads
out of hours so the ability to
keep focus 24/7 is always a major
challenge, but my family have
products and services Quantum
Controls have to offer our
customers, makes the solving of
engineering problems that much
easier, working as a team and
using the wealth of knowledge
held at Quantum Controls places
us ahead of our competitors.
What new engineering
specialty skills have you
developed during the past
year?
challenges, makes my role
interesting and never mundane,
I could never see myself in a 9 til
5 office environment doing the
same tasks every day, each to his
own I suppose!
On your last project
assignment, what problems
did you identify that
had been previously
overlooked?
A
that the final solution is the
Vision - The ability to
best most cost effective solution
research, define and
for our customer, as at the end
design a project from the onset. "... the ability to
of the day they pay the bills
Flexibility - Schemes/Customer be flexible with
What do you need from requirements invariable change
during its lifespan. your approach
a supplier?
along with the
A
Knowledge - The delivery
Good supplier relations
team’s knowledge of the expectancy
are key to delivering all
scheme and the reasons behind
projects and I would
the design. that changes
demand the same attributes
that my customers demand from Conviction - Confidence in the sometimes have

now come to accept that this is
the norm.
The satisfaction gained when our
customers issues are resolved is
always my main driver and has
A
Although I have only been
with Quantum Controls for
2 and a half years, the Variable
Speed Drive & Motor application
and product training I have
A No one particular me. I feel that Key Performance schemes design to be made must
Self-Motivation -
problem but generally as Indicators and regular face to
Taking ownership always be at the
engineering projects evolve face review meetings always lay
during the design and installation the foundations for continuous of the project and forefront of any
seeing it through
phases the ability to be flexible improvement, which is something
to completion.
project."
with your approach along with we must all strive to achieve

4 5
 Vol 27 Issue 33: July 2018 | News ENGINEER MASTERY Drive Jogging Function | Vol 27 Issue 33: July 2018

TRAINING & DEVELOPMENT ENGINEER MASTERY

Are you getting the most out of What is PID loop control?
your Variable Speed Drives? Lots of things need to be controlled - if your car speeds up or slows down you
need to correct it so that it comes back to the speed you want. Many of today’s
Have you, as an engineer had the relevant training if any at all? machines are controlled not by people but automatic systems that keep them
Quantum has had 267 engineers attend our certified VSD Drives training courses in 2017. doing what they should do to achieve the right result.

B
Here is what some of the attendees thought of the course:- ut it still all goes back to people. In 1922, an engineer indeed any quantity provided the drive can be given a feedback
called Nicolas Minorksy designed automatic steering signal from a suitable transducer.
‘Just a note to thanks John and Quantum for an excellent ‘A very well presented day the systems for the US Navy. He noticed that helmsmen So when you are looking to improve the performance of your
course, we now understand exactly what can be done information was at the right level for controlled the ship based not only on the current error, but also process, consider controlling the quantity that is critical to the
with our Variable Speed Drives’ Judith Singleton myself and colleagues' Stewart Smith past error as well as the current rate of change. application with a PID loop and a variable-speed drive.
Minorsky came up with the mathematics that describe these
‘John delivered an excellent course with the right level of presentation and hands on programming’ actions and laid the foundation for today’s PID controllers.
John Lightfoot But what does PID mean?
P stands for Proportional gain, I for integral time and D for
We have been inundated with requests for our certified courses this year and we are fully booked Derivative gain. How do they work?
now until September. Imagine driving your car along a flat straight road. Trying
Upon completion of our day courses attendees will be able to install, commission and fault find on to maintain 30 miles per hour, you alternately depress and
release the accelerator pedal according to the speed on the
Variable Speed Drives. The venue can be our Head Office near Newcastle or on your site if getting your
speedometer. Here you are acting as the PID controller, using a
engineers off site is difficult.
feedback loop to correct the speed. Simple pedal depressions
use proportional control to maintain your desired speed. You
Quantum Controls are official drive service partner for Schneider, Danfoss, Vacon, Nidec (Control
press the pedal proportional to the error you perceive.
Technique), Mitsubishi and have 20 years experience as The UK`s largest ABB AVP Drives partner. What if the car suddenly starts climbing a steep hill? The speed
This means our courses can be tailored to your preferred drive manufacturer type and needs. rapidly drops off, so we need to apply a lot of accelerator
quickly to counteract this sudden drop in speed. The faster
ABB VARIABLE SPEED DRIVES TRAINING - MODULE TW0 the speed is dropping the more acceleration we apply. This is
Installation and Commissioning Derivative control.
So, if we have a large difference in target and actual speed, we
0900 - 1015 Introduction to VSD’s and the process improvements they can deliver use a proportional control to apply a correction. If we have a
1015 - 1100 Correct Installation of VSD’s sudden change in speed the derivative control is used.
1100 - 1200 Basic Fault Finding However, if we only have a small fixed error between target
1200 - 1245 Lunch speed and actual speed, the proportional element is too
1245 - 1600 Hands on Programming small to be effective and because there is no change in speed,
the derivative contribution is zero. So this small error stays
Module Two is aimed at electrical engineers/technicians. This course will instruct the delegates how to install VSD’s to correct
uncorrected. What we need is something that comes more into
recommendations, program the units for standard applications such as pumps, fans and conveyors. The course also covers how
play the longer the error exists, however small it is. The integral
to interrogate the drives under fault conditions and utilise the drives protection features.
controller integrates away the standing error over a set time,
The course cost £495 per delegate with a maximum of 12 / minimum of 4 delegates per course.
ensuring the target speed and the actual speed are the same.
Each attendee will be issued with a delegate pack, Certificate of Competence, and be provided with lunch and refreshments.
All major drive types contain PID loops that can be used to
Courses are held at out training facility near Newcastle, but can be held at your site. Travel and accommodations costs will apply
control the level of water in a tank, the pressure of a fluid in a
for on- site training
pipe, or the accurate speed of a moving or extruded product;

6 7
 Vol 27 Issue 33: July 2018 | Case Study

CASE STUDY with Dan Fitzsimons, Quantum's Business Development Director

How to Avoid Purchasing

The WRONG Drive.
The first thing to establish is that all Variable Speed Drives (VSDs) are rated by Current,
the power rating should only ever be used as an initial guideline, yet almost daily we have
people coming to us because they have bought VSDs based on a given KW rating.
The current rating of a VSD is essentially based upon
the drives capacity at a given ambient temperature and
atmospheric pressure, however manufacturers will often
quote duty ratings with terms such as; heavy or light duty
rating, or constant and variable duty. It can therefore be
difficult to know whether what you have been sold is
correct, as is the case in this month’s case study.
We were asked to investigate three 132kw VSD’s, that
kept failing every 10-12 months on over temperature
fault, the manufacturer had been replacing these however
declining the warranty, and doing so on the basis that the
environment was too damp for the IP rating of the panel
they were in.
When I got to site I noted that the drives were not damp,
the room was well ventilated, and as ABB VSDs are
available in IP54 wall mounted up to 250kw it wasn't going
to be an issue, so we continued to investigate.
I asked to see the application details, the VSD was labelled
as 132kw light duty, 260 Amps, the application was a glue
paddle stirrer, with a 6 pole 132kw, 262 amp flc.
We know that this is a constant torque application, as the
torque required to turn the paddle is going to be identical
throughout the speed range of the application.
I used our ABB sizing software that we use when looking at
any application, and confirmed that even allowing for ABBs
patented Direct Torque Control the application required a
minimum of 160kw 278amp, to deliver to required torque
throughout the speed range, and that this allowed a 14%
margin on the thermal rating of the IGBTs.
I inputted the existing drives details and established that
it had -8% margin on the thermal rating of the IGBTs and
could not constantly deliver the current required, which
explained why they were regularly failing on internal over
temperature.
So on the face of it when the client was supplied 132kw
VSDs, to go with their 132kw motor, nothing looked
untoward, but as stated above when we are looking at VSD
applications we need to be thinking current not power.
To ensure our clients know exactly what they have, and
what they are buying in the future, we offer a series of
training courses to suit every skill level, spaces are always
limited due to their popularity, but for more information
on what course would best suit you and your team, and
details of when we next have enough space to fit your
team in, contact our customer support team on 01661
835566 or email: enquiries@quantum-controls.co.uk
VSD Training Courses for You
VSD Selection, Installation &
Basic Programming Course
VSD Installation, Programming
and Commissioning
VSD Advanced Programming
Commissioning and Fault Finding
VSD Fault Finding and Repair
Contact our Customer Support Team on
01661 835566
or e mail us at training@quantum-controls.co.uk