The Zest WEG Group has successfully manufactured, delivered, installed and commissioned its first locally manufactured new generation modular variable speed drive (VSD). The CF11-M VSD – 750 kW, 1600 A normal duty, 380 V – was supplied to Weir Minerals Africa, together with three motors – 750 kW, 400 kW and 110 kW – for use in its state-of-the-art pump test facility at Isando.
Modular VSDs were previously assembled into enclosures by Zest WEG Group’s holding company, WEG, in Brazil and imported to the African market as a complete product. However Zest WEG Group company, Shaw Controls has developed an enclosure to suit the South African market and is able to assemble modular VSDs into locally manufactured enclosures. This makes it possible for the steelwork to be fabricated to local requirements.
Although the VSD technology came from WEG Brazil, the contract was executed locally by Zest WEG Group’s drives and automation specialists, who performed the custom design, testing and commissioning. Shaw Controls manufactured the enclosure and assembled the modular VSD, while EnI Electrical, another Zest WEG Group company, performed the site installation and cabling of the modular VSD to the Weir Minerals supply and pump test rig.
The system was developed based on plug-and-play philosophy, allowing simple and fast installation of the VSD and its accessories. The keypad has a navigation and programming system similar to mobile phones, with soft-key buttons.
It comprises complete cubicle modules and switchgear assembled in a robust steel enclosure. The main design components are the control unit, rectifier module and power modules (inverter). The modular VSD features the new generation of WEG CFW11 frequency inverters for ratings ranging from 370 to 2000 kW, with line voltages from 380 to 690 V. The compact power modules can be configured to achieve the required motor power ratings using a combination of up to five power modules.
Full-featured monitoring and protection functions in the VSD help prevent heat build-up, resulting in longer motor life and safer, more reliable performance. The IGBT overload protection feature monitors junction temperature via thermal imaging and has built-in protections and alarms. For example, the heat sink fans have an automatic on/off control to ensure added protection.
“This VSD has benefited Weir Minerals Africa in terms of a lower cost, custom design and a manufacturing period reduced from twelve to six weeks,” concludes Johan van Niekerk, Zest WEG Group manager for automation.
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