solutions Overland Conveying Systems Wanted a Rugged and Reliable Reducer for Armstrong Coal Project...

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1 solutions A Publication Featuring Baldor Electric Company Products Number 7 m a g a z i n e Overland Conveying Systems Wanted a Rugged and Reliable Reducer for Armstrong Coal Project......and Found Everything It Needed in the Baldor Dodge MagnaGear XTR Plus Commitment to Innovation Leads Fairchild International to Launch New AC Scoop Powered by Baldor Products Baldor Motors and Drives Are Key to Condominium's Goal to Save Energy and Water

2 Invest in Gold Electric motors consume 63 percent of all electricity used in U.S. industry. Designed and built to meet or exceed NEMA Premium efficiency standards, Baldor Reliance Super-E motors run cooler, last longer and cost less every minute they operate. Fractional to 15,000 Hp, Baldor Reliance Super-E motors reduce your electricity costs with a return on your investment that s as good as gold. baldor.com Energy Efficient Unmatched Quality Superior Reliability Quickest Delivery Available 2011 Baldor Electric Company

3 Cover: PG 16 Contents Number 7 Solutions Magazine Featuring Baldor Reliance & Baldor Dodge Products baldor.com 2 Briefings 4 Commitment to Innovation Leads Fairchild International to Launch New AC Scoop Powered by Baldor Products 10 Illuminating the Line for Highway Safety... Potters Industries, Iowa Plant Standardizes on Motorized Torque-Arm II for More Reliable Glass Bead Production 16 Overland Conveying Systems Wanted a Rugged and Reliable Reducer for Armstrong Coal Project......and Found Everything It Needed in the Baldor Dodge MagnaGear XTR 22 Baldor Motors and Drives Are Key to Condominium, s Goal to Save Energy and Water 28 TurfBreeze Fans Powered with Baldor Products Help Keep Greens More Green Baldor s mission is to be the best (as determined by our customers) marketers, designers and manufacturers of industrial electric motors, mechanical power transmission products, drives and generators. Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company. For more information, please contact smtraylor@baldor.com. baldor.com

4 Briefings The New Baldor Dodge Pre-lubricated GRID-LIGN Coupling Maximizes Productivity, Minimizes Downtime The Baldor Dodge pre-lubricated GRID-LIGN coupling is a maintenancefree, lubed-for-life design that eliminates the time and expense associated with preventive maintenance. Interchangeable with existing grids, hubs and covers, this product is easy to install with no mess, and eliminates unexpected downtime associated with improper coupling lubrication. The unique, environmentally friendly design of the pre-lubricated GRID-LIGN coupling features highperformance synthetic oil impregnated into a polymer shell that encapsulates the grid element. This polymer shell allows for efficient, long-lasting lubrication throughout the life of the coupling. The polymer acts as a reservoir for the oil that prevents contamination during installation and avoids the mess required with greasing a traditional grid design. The coupling not only includes the optimal amount of lubrication for the life of the element, but the synthetic oil used actually improves the lubricating performance of the grid segment during operation. Baldor Dodge pre-lubricated GRID- LIGN coupling components are interchangeable with competitive tapered-style grid couplings. Interchangeability includes use with complete vertically or horizontally split covers and half or full spacers. This new product can be specified via the online Dodge coupling selection program. Go to dodge-pt.com, select online tools and click PT Wizard. Following a login, select product selection and click coupling. The coupling selection program is userfriendly and gives customers the opportunity to customize the coupling selection to their exact application needs. Baldor Reliance Super-E Motors Now Available with AEGIS Shaft Grounding Ring Baldor Reliance Super-E motors with the AEGIS Shaft Grounding Ring are ideal for end users looking for ways to prevent bearing damage caused by adjustable speed drive-induced currents. While most shaft ground applications utilize a shaft ground on the outside of the motor, the Baldor Reliance Super-E has the grounding ring uniquely installed internally on the motor. This internal design minimizes exposure to the outside elements and also keeps the ground from being exposed to external forces that might damage the grounding ring. This new line of motors is stocked from 1-50 HP, 143T through 326T, in TEFC or ODP enclosures. Applications include heating, ventilation and air conditioning blower and fan motors, pump motors and other general purpose applications using an adjustable speed drive. 2 Solutions Magazine Number 7

5 Briefings Introducing the New Baldor Dodge Type E-Xtra Bearing American Made with the Highest Load Ratings and Most Advanced Sealing System in the Industry Since the first bearing in the Dodge Type E family was introduced in 1938, engineers have continued to design new and better bearings to meet the needs of industrial customers. This legacy of innovation continues with the introduction of the new Baldor Dodge Type E-Xtra bearing, designed with features that ensure premium performance with greater reliability. Manufactured in the USA at Baldor s Dodge roller bearing plant in Marion, N.C., the high-capacity tapered roller bearing insert allows for a combination of radial and thrust loads, yielding the highest load ratings in the industry. Lab tests have proven that the new tapered insert has 13% to 14% ratings increase over the previously purchased insert. The carburized inner ring has also been designed to absorb shock and resist cracking. Bearings are preassembled, prelubricated and are factory adjusted for easy installation. The Type E-Xtra is offered in a variety of configurations for maximum application flexibility. The New cone assembly manufactured at Baldor's Dodge roller bearing plant in Marion, North Carolina offering includes: two- and four-bolt pillow blocks, flanges, piloted flanges, top angle take-ups, and wide-slot takeups. The Type E-Xtra bearing features the exclusive XTS triple-lip seal, an advanced system that protects against contamination in dusty or wet environments. Plus, oversized dual Springlok collars act as flingers for added seal protection. For extreme conditions, customers may also choose the XTS Plus sealing system, which incorporates the Baldor Dodge E-Tect seal kit for extra protection. New XTS Triple-Lip Seal Number 7 Solutions Magazine 3

6 Commitment to Innovation Leads Fairchild International to Launch New AC Scoop Powered by Baldor Products 4 Solutions Magazine Number 5

7 Coal River Energy agreed to field test the first Fairchild AC powered scoop with new Baldor technology at its underground mine in West Virginia. At the end of the test, mine executives, impressed with the scoop's superior performance, bought the unit and placed an order for a second scoop. Number 5 Solutions Magazine 5

8 f eatures Fairchild International chose Baldor to help it move from DC to AC technology. Baldor engineers designed a gearbox (front of photo) with a new gear ratio to meet torque and speed requirements, while adding bearings built strong enough to handle the force of the application. The traction motor developed for the project is based on the Baldor Reliance RPM AC product, with an optimized pole design, a robust sealing system to withstand underground environments and a feedback device for better speed control. The motor is also MSHA-approved explosion proof. Fairchild International, a U.S.-based manufacturer of underground mining equipment, has produced batterypowered DC scoops since the early 1980s. With 17 different models available, Fairchild offers a size to fit into any coal mining operation, making it the leader in the industry. Maintaining that leadership position led Jack Fairchild, Jr., the company s vice president of sales, to the decision that it was time to move from DC technology to AC technology. Making the change would require a major investment for the company, but Fairchild was determined to be the first to launch an AC battery-powered scoop. In this industry, if you want to remain successful, you have to stay ahead of the game, explains Fairchild. We also felt 6 Solutions Magazine Number 7 strongly that AC technology provides so many advantages that making the investment would be worth the risk. This is the technology for the future and is the best way for us to take our product line to the next level. Fairchild believed that the key to the project s success was to build the right team. At the beginning of the project in 2008, Fairchild brought together his employees to discuss who they should partner with. They wanted to work with companies that had engineering and technical knowledge, good communications skills and the willingness to be a member of a team. As a result, Fairchild chose EnerSys for the battery, Magnatec for the drive and Baldor for the motors and gearbox. We chose Baldor because of our long relationship with the company, and the confidence and trust we have in its employees, says Fairchild. There was really no doubt that Baldor was the company I wanted for this project because the people are top-notch and true professionals. Engineering New Products Baldor engineers Nick Marsh, strategic account executive for the mining industry, and John Clark, senior customer order engineer for specialty gearing, led the design team effort for product development. With Baldor s history in the mining industry and experience in moving from DC to AC technology in other projects, both engineers were confident they were up

9 manufacturer to optimize performance. According to Marsh, the traction motor developed for Fairchild is based on the Baldor Reliance RPM AC motor design with a good many enhancements. We optimized the pole design to meet the torque and speed requirements, explains Marsh. This motor is MSHA explosion-proof approved, and we added a robust sealing system so it can more than handle the underground environment. And, as requested by the customer, we also added a feedback device for better speed control. With motor specifications in hand, the gearing team began its design work by starting with an existing gearbox base and then building from there. Engineers created a new gear ratio to meet Fairchild s exact needs for torque and speed, building a box with new gears and bearings strong enough to handle the force. For Clark, the bigger design challenges came from some special requests by Fairchild. The company wanted us to design the gearbox so it could be used on either side of its dual tram scoop, explains Clark. This universal design means they only need to stock one gearbox because it is interchangeable. A box that can be flipped gives them the flexibility they need to manage their inventory. One other feature Fairchild wanted was a self-contained brake directly mounted on the gearbox. In the past, Clark explains, brakes were mounted with brackets hanging off the side of the box and taking up a great deal of space. To accommodate this request, we created new patterns and new castings for the top of the gearbox, says Clark. This was a great idea because now that the brake is a part of the gearbox, it s more secure and provides much better performance. Because this was a new design, the project team attached special instrumentation on the box to capture data, while Fairchild ran the completed unit under test at its facility. Clark says the data was critical for him to understand what the gearbox was doing and how it performed under test. However, Clark was not content with just collecting and studying data. to the technical challenge. However, according to Marsh, the hardest and most critical part of the project comes at the very beginning. It s our job to take the time to ask all the right questions up front so we can get detailed specifications, explains Marsh. In this case, we helped the Fairchild team think through the machine and the application, so we could address all of the possible issues and requirements. It s critical to get a clear understanding of their requirements and expectations, so we can design and build the exact product they need. From a motor perspective, that means detailing the exact torque and speed requirements. And because the motor would be controlled with a variable frequency drive, the Baldor team worked closely with the drive Switching from DC to AC technology meant that Baldor engineers could design a more powerful motor and gearbox, but in a smaller package. In another space-saving design, gearing engineers created new patterns and new castings to accommodate a self-contained brake that the customer wanted mounted directly on the gearbox. Number 7 Solutions Magazine 7

10 Above: Designing a new AC motor for the scoop project meant Baldor engineers worked hard to get detailed specifications from Fairchild International at the front end of the project. From a motor perspective, that meant detailing the exact torque and speed requirements. And because the motor would be controlled with a variable frequency drive, the Baldor team worked closely with the drive manufacturer to optimize performance. I visited Fairchild after the test was finished and tore the gearbox down so I could examine and evaluate it myself, says Clark. I looked at the gear patterns to make sure there were no issues, and I did the same thing with the bearings making sure there was no unusual wear. What I found was that everything looked great. Achieving Results While the AC powered scoop performed beyond expectations at the Fairchild location, Ken Mosley, Fairchild s vice president of customer service, was eager to get some running time on the scoop A commitment to craftsmanship and quality has made Fairchild International a leading manufacturer of underground mining equipment. 8 Solutions Magazine Number 7

11 at an actual mine site. Coal River Energy agreed to take a unit and use it at one of its coal mines and provide feedback on what it thought of the new technology. I was fairly confident that it would run successfully at the mine, but then again you never know what might happen, says Mosley. It turned out to be a manufacturer s dream because they started running the scoop, and it never quit. After three months of testing, we met with them to get their feedback, and to our surprise, they asked to purchase the unit. It was even more exciting when they quickly ordered a second unit, plus put in an order for one of their DC scoops to be converted to AC. We couldn t have scripted a better introduction of a new product. Mosley says the reason why Coal River Energy was so quick to adopt the new technology comes down to performance, durability and longevity. He describes the new AC scoop as a workhorse, ideally suited for slope-graded mines with machine torque greater than any We chose Baldor because of our long relationship with the company, and the confidence and trust we have in its employees. Jack Fairchild, Jr., vice president of sales, Fairchild International other scoop on the market. He says that everything he wanted this scoop to do, it does. This new scoop goes faster and maintains a constant speed even going uphill, explains Mosley. This AC unit runs cooler, and less heat means all of the other equipment lasts longer and reduces the amount of maintenance required. But most importantly, the battery life in our new unit is now twice the life of DC units. Fairchild achieved his goal of being the first to introduce AC technology to battery-powered scoops. He says he never doubted the team could pull it off because he involved all the right people. So, what comes next? This is the technology of the future, claims Fairchild. Right now, we are ahead of the game, and that s exactly where I want to stay. We will continue to improve the technology, perfecting it for our complete line of equipment. Who knows what the future will bring. Fairchild s AC powered scoops are ideally suited for sloped mines with machine torque greater than any other scoop on the market. The new scoop goes faster and maintains a constant speed, even going uphill. Plus, the battery life of the new unit is now twice the life of DC units. Number 7 Solutions Magazine 9

12 Illuminating the Line for Highway Safety Solutions Magazine Number 5

13 Potters Industries Iowa Plant Standardizes on Motorized Torque-Arm II for More Reliable Glass Bead Production Potters Industries Inc., an affiliate of PQ Corporation, is a leading producer of engineered glass materials used for metal finishing, a reinforcing additive for plastics and conductive particles. However, the majority of the company s glass bead production is used for highway safety, providing the light-reflective lane markings found on highways around the world. Number 5 Solutions Magazine 11

14 At the front end of the glass bead-making process, bucket elevators move raw materials through the initial stages of grinding and pulverizing. The abrasive nature of the glass grain dust damaged the rubber belts, sheaves and sprockets used on traditional style gearing, causing unplanned downtime and increased maintenance costs. When the plant was renovated in 2007, and new bucket elevators were installed, Potters engineers standardized on the Baldor Dodge Motorized Torque- Arm II (MTA), a totally enclosed, shaft-mounted speed reducer. 12 Solutions Magazine Number 7

15 Recycled glass, typically architectural glass, is delivered by rail or truck to the Potters facility. This raw material is ground, dried, pulverized and heated to create 23 different sizes of perfectly round glass beads. Starting with recycled glass, the Potters facility in Muscatine, Iowa, produces 23 different sizes of glass beads that are then mixed per customer specification. The end product is a truly round glass sphere that optimizes reflectivity. Potters Highway Safety Marking Spheres are applied, or dropped on, when marking lines are applied to a roadway. The motorized version of the world-leading Baldor Dodge Torque-Arm II speed reducer, the Motorized Torque-Arm II, is a right-angled, shaft-mounted speed reducer with a three-piece coupled NEMA C-face motor input. Plant officials say the MTAs have been running trouble free since 2008, which they call an ideal situation. The MTAs have been running since January 2008 with absolutely no issues. This product has met all my expectations. Glenn Amundson, plant manager, Potters Industries Iowa plant One 50 HP and one 30 HP Baldor Reliance motor powers the dust collector fans in the grinding area. Number 7 Solutions Magazine 13

16 In late 2007, part of the plant was renovated, adding all new bucket elevators at the front end of the beadmaking process. Company engineers say the new construction gave them a unique opportunity to select and standardize on a product they believed would solve existing maintenance problems and help the plant improve its productivity. They installed the totally enclosed, shaft-mounted speed reducer, the Baldor Dodge Motorized Torque- Arm II, a product that has delivered the reliability the engineers were looking for. In the past, belted shaft-mount reducers were used on bucket elevators moving glass through the initial stages of the process, which includes grinding and pulverizing. In this environment, the glass grain dust, even in minimal amounts, is abrasive to rubber belts, sheaves and sprockets. Bob Schult, plant production manager, says the belts would wear quickly and then begin to slip, creating a constant maintenance issue. Belts would have to be re-tensioned on a regular basis, but even with the extra time spent to keep the product running, he says they would go through a set of belts on each unit about every three to six months. It s not just the expense of the belts, it s the expense of shutting down to allow our maintenance staff to make the change, explains Schult. We tried to monitor belts through a structured preventive maintenance program, but I would say there was a good 30% of the time we would have belt issues that would cause us unplanned downtime. Dealing with the problem was costly and time consuming. At the end of the bead-making process, the plant continues to use the traditional belted Baldor Dodge Torque-Arm II shaft-mounted speed reducers. Here, the reducers are used in this stacked configuration, moving the finished product perfectly round glass beads to the packaging area. The issues of uptime and reliability are critical to the plant, according to Muscatine Plant Manager Glenn Amundson. He explains that the plant operates 24/7, 360 days a year, to meet the demand for its product, and unplanned downtime disrupts the beadmaking process. 14 Solutions Magazine Number 7

17 Once the raw material comes into the plant and we start the process of making glass beads, there is limited storage capacity in any of the process areas along the way, explains Amundson. So any time the belts failed and we had unexpected downtime, it took away from what we were doing downstream. This issue had a tremendous impact on our ability to get our product out the door. Both Amundson and Schult were intrigued when they learned that company engineers were specifying the Baldor Dodge Motorized Torque-Arm for the project. While neither of them knew all the product details, Schult says the concept of an enclosed gear reducer made sense for this application, and he was certain it would work because the Baldor Dodge brand of gearing is well known for quality. Amundson says based on what he knew about direct drive products, he was confident that this gear reducer would provide the reliability he needed to keep the plant up and running. This product has met all my expectations, says Amundson. The MTAs have been running since January 2008 with absolutely no issues. All we have done is the regular maintenance, but other than that, we have not had to Potters Highway Safety Marking Spheres, a truly round glass sphere that optimizes reflectivity, are applied when marking lines are applied to a roadway. The issue of uptime and reliability is critical at the Muscatine plant because it operates 24/7, 360 days a year to meet the demand for its product. do anything. They run trouble-free, which is an ideal situation for us. It s clear the product has had a major impact on increasing uptime at the plant, but Amundson says making the switch has helped save time and money in other ways as well. For example, the plant did not generally staff maintenance personnel on weekends or off hours. Instead, operators had to take time away from their regular duties to be trained to handle some of the maintenance issues, including changing belts. Now, all that has changed. Today, we don t have to spend the time to train operators to work on replacing belts and sheaves, explains Amundson. Our operators can focus on their job, which is to make quality product. In addition, our maintenance staff is no longer tied up with constantly inspecting, tensioning or replacing belts. Instead, they can spend their time on other critical areas in the plant, helping us become even more productive. After more than three years of reliable performance, Amundson says he s grateful to the company engineers who made the decision to standardize on the MTA. He says he still doesn t know all the engineering details of why the reducer works so well. But then again, he doesn t need to. He just knows that the MTAs work without fail, and that makes him a very happy plant manager. Number 7 Solutions Magazine 15

18 Overland Conveying Systems Wanted a Rugged and Reliable Reducer for Armstrong Coal Project Solutions Magazine Number 5

19 ...and Found Everything It Needed in the Baldor Dodge MagnaGear XTR Number 5 Solutions Magazine 17

20 Overland Conveying Systems used a total of 10 Baldor Dodge MagnaGear XTR reducers throughout the Armstrong Coal project. The OEM chose the heavyduty reducer because of its reliable, compact, power-dense design. Each reducer is connected to a Baldor Reliance Mining Industry motor with a Baldor Dodge GRID-LIGN coupling (located behind the yellow safety cover). verland Conveying Systems, based in Madisonville, Kentucky, has been in business a little over 10 years, designing and building conveyor systems primarily for the coal industry. One of its key customers is Armstrong Coal, a company that controls approximately 415 million tons of proven coal reserves in Western Kentucky, and a leading producer of steam coal in the Illinois Basin. In late 2008, Overland Conveying Systems won the business to do the conveyor work for Armstrong s newest mine site, the Equality Boot Mine, located approximately eight miles from the company s prep plant. Trucking coal over county roads was not an option, and when Armstrong learned it could not convey the coal overland, its only option was to transport the coal by barge on Kentucky s Green River. The project involved thousands of feet of conveyors down to the river for load-out, plus a new system to off-load the coal from the Armstrong dock up to the prep plant. At the mine site, David Daniel, Overland Conveying Systems chief engineer, had the challenge of building a nearly 4,000-foot-long conveyor high enough off the ground to evade the annual river flood. The only way 18 Solutions Magazine Number 7

21 The universal housing with the reversible mounting design of the MagnaGear reducer is another reason why Overland Conveying Systems chose the Baldor Dodge product. This design provides the option of right- hand or left-hand mounting, offering the customer flexibility and minimizing spares. The OEM says other products don t offer this same kind of flexibility. to reach key equipment during a flood would be to walk a narrow catwalk 20 feet off the ground all the way from the mine to barge load-out. What Daniel wanted for this project was a reliable gearbox that wouldn t require a lot of attention, small enough to fit in a confined space, but powerful enough to do the job. As luck would have it, about the time Daniel started the project, Baldor introduced the full line of MagnaGear XTR high horsepower speed reducers; a compact, power-dense design in a heavy-duty package. Based on his experience with other Baldor Dodge gearboxes, Daniel says he was eager to see the new gear reducer and get more details. I have used the company's Torque- Arm reducer for years on many projects with a lot of success, says Daniel. This product sets the standard in our industry because they do the job, they are user-friendly, and they last a long, long time. With a reputation like that, it was not a stretch for us to take a serious look at a new gearing product because we naturally expected it to be just as good. Convinced that the MagnaGear was the right product, Daniel says he worked out all the designs and product specifications to present to company officials at Armstrong Coal for final approval. His plan included a total of 10 Baldor Dodge MagnaGear reducers, coupled to Baldor Reliance Mining Industry motors. Despite the newness of the product, Daniel says Armstrong Number 7 Solutions Magazine 19

22 up at our shop in a complete package, my shop manager doesn t have to worry about it either. MagnaGear Does Not Disappoint Daniel says the reducers have delivered everything he expected from a Baldor Dodge brand gearbox, from installation to performance. And he points to several design elements that he believes make this reducer an ideal choice for high torque applications, including the power-dense design. Overland Conveying Systems chose the MagnaGear XTR reducer because it offers more torque out of a smaller package. The compact design of the reducer has been a plus on the Armstrong project because many of the units are located along a catwalk or in other confined spaces. The way engineers designed this product means we get more torque out of a smaller reducer, explains Daniel. This makes the MagnaGear very appealing because you get more torque for the money compared to others in the market. It s a very cost-effective package. gave its OK to the plan based on the reputation of Baldor Dodge gearing. Like me, they knew that the gearing is well respected in the marketplace, says Daniel. Your company is not new to this industry, and you have been cutting gears for a long time. We didn t hesitate because we trusted that this gearbox would be a good product and that we would get good support. Some of that support came from Baldor s System-1 group, a team that facilitates the design, quotation and order processing of multiple power transmission and electrical products into a complete packaged solution. While Daniel performed all his own calculations and made his own motor and reducer selection, he did appreciate the System-1 team confirming his selections, plus the help they provided on other products required for the job. I don t have the same level of knowledge on couplings, sheaves and guards, says Daniel. I simply let the System-1 team handle all of those details, and when the equipment shows A 210K MagnaGear XTR was selected to operate this 1,197-foot-long conveyor, with an 86-foot lift. This conveyor moves coal from the river barge to Armstrong s prep plant. 20 Solutions Magazine Number 7

23 Daniel says the compact design of the reducer has also been a plus on the Armstrong project, especially when you consider many of the units are located along a catwalk or in other confined spaces. Not only are the units compact, I also like the way the reducer is coupled to the motor, says Daniel. The coupling housing is only 20 inches long; others in the marketplace are up to 3 feet long, which causes a lot of problems. The engineers who designed the MagnaGear must understand the industry because they built us a product that we needed. The engineers who designed the MagnaGear must understand the industry because they built us a product that we needed. David Daniel, chief engineer, Overland Conveying Systems The versatility of the reducer is also appreciated by Daniel. MagnaGear reducers are available in parallel shaft or right-angle configurations with solid or hollow output shafts. They also come in several mounting configurations, including tunnel housings. For Daniel, the reducer s universal housing design also means the customer doesn t need to keep multiple spares on-site. The reducer is set up to work on either side, so I have the option of right-hand or left-hand mounting, explains Daniel. Now, I only need one spare that can work anywhere on the project. Other products out there do not offer this same kind of flexibility. Reliable Proven Performance The first coal from the Equity Boot mine was loaded and unloaded in September Since then Daniel says the reducers have done the job everyone expected them to do, moving coal with no issues. Both Overland Conveying Systems and Armstrong Coal are so pleased with the performance of the product that Daniel has purchased seven MagnaGears on a new Armstrong Coal project. All I can say is that if the MagnaGear product didn t work, or if we had any problems, I would not be using them again, says Daniel. But it s a good product, and I had a good experience working with Baldor on the Boot project, and that s why I m back. This 285K MagnaGear XTR reducer and 350 HP Mining Industry motor powers the 3,950-foot-long conveyor that carries coal from the mine site to the river barge. Coal is transported 45 minutes up the Green River to the Armstrong Coal dock at its prep plant. Number 7 Solutions Magazine 21

24 Baldor Motors and Drives Are Key to Condominium s Goal to Save Energy and Water By replacing fixed speed pump motors with variable speed drives and motors from Baldor, Villa Magna has a more reliable system that is saving electricity and water. These changes, along with the installation of solar panels, heat pumps, energy-efficient lighting and appliances, has earned Villa Magna a great deal of recognition, including the 2010 Florida Communities of Excellence Award for Energy and Water Conservation.

25 he Villa Magna, a 92-unit luxury condominium in Highland Beach, Florida, sits between the Atlantic Ocean and the Intracoastal Waterway. When it was time for a major maintenance program to be carried out at the 30-year-old highrise, the Villa Magna condominium association approached repairs as a unique opportunity to improve the efficiency of systems in order to conserve water and energy. The results of their efforts have not only benefited their budget, but also the environment.

26 10 HP variable speed Baldor motors controlled by Baldor VS1PF drives were selected for the system to maintain constant water pressure under different flow rates. 24 Solutions Magazine Number 7

27 Bresnak Services Inc., a company that specializes in pumping systems for boosting water pressure in highrise buildings, did the work on a new domestic water supply system and an air conditioning condensation collection system at the condo. Gary Bresnak, managing director for Bresnak Services, says after investigating the existing water supply and air conditioning systems, he concluded that the primary problem with both was in their lack of controllability. The system for boosting the pressure of the domestic water supply, which is a common feature in high-rise buildings, used two 25 HP pump motors running we are saving approximately $2,000 a month on our water bill, and over the last 12 months, we have saved about $24,000 on electricity. Frank Strachan, building manager, Villa Magna The drives V/Hz control mode enables motor speed to be controlled by feedback from a pressure sensor, to maintain constant water pressure under different flow rates, explains Bresnak. A time switch sets the duty cycle of each pump to 12 hours, to maximize reliability. Each motor consumes just 5.8 amps, which is less than a third of the energy demanded by the previous system. The condominium s air conditioning system was equally inefficient. Water is pumped through heat exchangers in each of the building s apartments, and then fed via a roof-mounted cooling tower before being fed back into the system. Bresnak found that the existing pump system used two 40 HP motors running at full speed from the 60 Hz supply, which consumed 80 amps. He also discovered that the flow rate was far too high, resulting in a temperature drop of only a few degrees in the cooling tower. By retrofitting the condenser pumps with Baldor motors and VS1PF bypass pump drives, we can now run the pumps at full speed for 24 hours a day. The motors consumed 19 amps continuously, regardless of water demand. Pressure was controlled by mechanical regulators, an inefficient system that required regular and expensive maintenance. Since modern domestic appliances are considerably more water efficient, Bresnak also judged the existing system to be far too large for what was required. For a more efficient and reliable solution, Bresnak replaced the fixed-speed 25 HP motors with 10 HP variable speed Baldor motors, controlled by Baldor drives. By utilizing Baldor drives to control the domestic water system in the high-rise building, residents now have constant water pressure despite usage. Number 7 Solutions Magazine 25

28 Instead of losing air conditioning condensation down the drain, it is now collected in this 400-gallon tank and recycled back to the cooling tower to further aid cooling. The Baldor motor and bypass pump drive are used on a multistage pump to slowly add water to the cooling tower as needed without overflowing the tower and wasting water. Baldor treats me as its partner and understands that I can t have any problems out in the field. Whenever I call for help, I get it, and that s why I continue to choose Baldor products. Gary Bresnak, managing director, Bresnak Services at 50 Hz, explains Bresnak. The result is that the current consumption has been dropped from 80 amps to 53 amps. Plus, we have been able to lower the flow rate to the point where there is now as much as 10 degrees heat loss in the cooling tower, rendering the entire building s air conditioning system much more efficient. Another part of the project involved an air conditioning condensation collection system to help conserve water, a particularly valuable commodity in 26 Solutions Magazine Number 7

29 Florida. Instead of losing condensation down the drain, it s now collected in a 400-gallon tank and then recycled back into the tower to further aid cooling. Bresnak says the goal is to introduce the cold water into the cooling tower at a slow rate. Again, my solution was to use another Baldor VS1PF bypass pump drive for the multistage pump, says Bresnak. By providing this very slow speed control, we can match the usage rate with the collection rate. This kind of control, allows us to slowly add the water as the cooling tower needs it without overflowing the tower and wasting any water. Results Show Up on the Bottom Line Frank Strachan, Villa Magna s building manager, couldn t be more pleased with the results. The work carried out by Bresnak Services is saving us approximately $2,000 a month on our water bill, says Strachan. Over the last 12 months, we have also saved about $24,000 on electricity. These figures are considerably better than those achieved by some energy-saving schemes in other areas and says much for Bresnak s ability to apply Baldor variable speed technology so knowledgeably. Strachan says the savings achieved so far have more than paid for the motors and drives. Now, with the investment paid for, he says he is looking forward to years and years of more savings. Saving energy and water is the right thing to do, and being green makes you feel good, says Strachan. But it also feels good to save money. This has been a win-win because we are conserving our water resources and using less electricity. These are just the kind of comments that Gary Bresnak wants to hear. He says his business relies on word of mouth, which means he strives to make the project as perfect as possible. For a more energy-efficient and reliable water pumping system, Bresnak Services replaced original 25 HP fixed speed motors with two 10 HP Baldor variable speed motors, controlled by Baldor drives. Bresnak has used Baldor products for years, and with his reputation on the line, he says these are the products he ll stick with. I have a good relationship with Baldor drives engineers, claims Bresnak. Baldor treats me as its partner and understands that I can t have any problems out in the field. Whenever I call to talk through issues and need help, I get it, and that s why I continue to choose Baldor products. Number 7 Solutions Magazine 27

30 TurfBreeze Fans Powered with Baldor Products 20 Solutions Magazine Number 4

31 Help Keep Greens More Green Golfers, both professionals and amateurs alike, understand how important putting is to the game. And with a focus on putting, there is a great deal of attention paid to the putting green. Golf course superintendents will tell you that battling the stress and disease caused by heat and humidity are among their biggest challenges, often requiring frequent spraying. But golf courses around the world have found a more earth-friendly solution to their dilemma: an energy-efficient, maintenancefree TurfBreeze Fan. Number 4 Solutions Magazine 21

32 The Baldor Dodge D-Lok bearing was selected because of the superior DualGuard sealing system, designed with two patented features unique to this bearing. The first is a land-riding, single-lip seal made of nitrile rubber that assures uniform lip contact to keep contaminants out and seal in lubricant. The second is a molded rubberized flinger, which provides additional protection against contaminants entering the bearing. The baffled design of the rubber on the external surface of the flinger helps remove liquid during rotation and creates turbulent airflow around the seal to help protect against airborne contaminants. Solar heat can have a devastating effect on turf grass. When a green s subsoil temperature reaches high levels, roots begin to shrink, diminishing the quality of the putting surface. Creating improved air circulation on a green alleviates heat stress by cooling the grass leaf, removing the humidity that causes disease and allowing the grass to breathe. Developed to provide maximum airflow on the surface of golf 30 Solutions Magazine Number 7 course greens, TurfBreeze is the most respected name in surface aeration. Andy Redd, director of sales for TurfBreeze, says his company is the market leader because of the quality of its product. We know that 90% of golf superintendents in the Southeast start running our fans Memorial Day weekend and keep them running 24/7 until around the first week of October, explains Redd. We know this is an investment for the golf course, so we build them to perform and to last. We have units that have been out in the field for more than 15 years, and today we are building them even better. Instead of aluminum, the fans are made of steel, with a strong powdered coating to withstand the elements. Inside you ll find what Redd describes as premium

33 products: a Baldor Reliance motor and Baldor Dodge mounted ball bearings and synchronous belt drive. According to Redd, TurfBreeze chose these products to make its units not only outperform and last longer than competitive units, but also to be maintenance free. During the summer months, a golf course superintendent has plenty to do without worrying about keeping a fan TurfBreeze chose Baldor products to make our fans not only outperform and last longer than competitive units, but also to be maintenance free. Andy Redd, director of sales, TurfBreeze Switching from V-belts to the Baldor Dodge synchronized drive system means there is no maintenance required after installation. The synchronized sprockets are coated with black oxide to prevent rust. This synchronized system is also more energy efficient and has allowed TurfBreeze to optimize fan performance. running, explains Redd. They just don t have time to shut the units down to grease the bearings or to tighten belts. They need this fan to start up and run through the season with no issues. The bearing of choice is the Baldor Dodge D-Lok pillow block ball bearing with a DualGuard seal design, which includes a patented rubberized flinger. This highly engineered bearing keeps contaminants out, while keeping lubricant in, increasing the life and performance of the bearing. Better yet, the bearing comes fully lubricated and does not need overly frequent regreasing when properly selected, sized and installed. Having the time to keep the bearings maintained is one issue, but another is knowing how to keep them maintained, says Redd. In the past, we found that guys were actually overgreasing and blowing out the seals, damaging the bearing. However, today no one has to worry about bearings at all. Number 7 Solutions Magazine 31

34 Dropping down 3 amps may not sound like a big deal, but remember that less amps means a smaller conductor size, and if you are pulling power from over 2,000 feet away, it adds up to be a huge difference. Not only is Redd pleased with all of the products, he also appreciates the support his company received from Baldor engineers. From design, product selection and product sizing to spending time at the TurfBreeze facility to help explain proper installation techniques, Redd says Baldor engineers worked with them to find the right solution. According to Redd, it s this kind of customer service that sets both TurfBreeze and Baldor apart from the competition. TurfBreeze fans are made of steel, with a strong powdered coating to withstand the elements. Inside you ll find what TurfBreeze officials describe as premium products: a Baldor Reliance motor and Baldor Dodge mounted ball bearings and synchronous belt drive. Both companies stand behind their product because we both understand that it s our reputation that carries us to the top, say Redd. TurfBreeze has an outstanding reputation in the market because if there are ever any issues, we address them, and we take care of our customers. We absolutely get that same level of customer service from Baldor. Another major change to the TurfBreeze product was switching from V-belts to a synchronous product. The issue, according to Redd, was the continuing maintenance challenge of keeping the V-belts tensioned properly. With the Baldor Dodge synchronized drive system, once the tolerances are set at the plant, there is no maintenance required in the field. A synchronized system is also more energy efficient, plus, Redd says, making the switch also allowed them to optimize the fan s performance. Switching to the synchronous drive has allowed us to decrease the size of the pulley in the unit, explains Redd. Because of the smaller, more compressed package, there is more room for air flow, which is very important. Between eliminating maintenance and improving our performance, this is a great product. Like many other businesses, Redd says golf courses are also becoming more interested in cutting electrical costs by choosing energy-efficient products. That s why TurfBreeze offers customers what the company calls its green option, a model that produces maximum cooling with minimal power use. This fan is powered by Baldor s Super-E premium efficient motor. He says most customers understand that using fewer kilowatts per hour, they will save a bit of money on the electric bill. However, Redd says, the significant savings delivered to a golf course come because the Super-E pulls less amperage than standard motors, and the lower the amp draw, the smaller the conductor size. If you look at full load amperage, a 5 HP premium efficient motor pulls 19.1 amps versus the standard motor that pulls 23 amps, explains Redd. TurfBreeze offers customers what the company calls its green option, a model that produces maximum cooling with minimal power use. This fan is powered by Baldor s Super-E premium efficient motor. 32 Solutions Magazine Number 7

35 The First Name in Power Transmission Baldor Dodge power transmission products offer reliable service and low maintenance to help reduce your total cost of ownership. Our innovative bearings, gearing and power transmission products have solved the toughest applications for over 125 years. Our technical sales team can help you with the most challenging applications, and our worldwide distributor network ensures immediate delivery. When it comes to PT solutions, Baldor Dodge is the first name in power transmission. dodge-pt.com baldor.com Unmatched Quality Superior Reliability Improved Uptime Quick Delivery 2011 Baldor Electric Company

36 PRSRT STD US POSTAGE PAID Little Rock, AR Permit No. 175 P.O. Box 2400, Fort Smith, AR U.S.A., Ph: (1) , Fax: (1) , International Fax: (1) baldor.com 2011 Baldor Electric Company All Rights Reserved. Printed in USA. Solutions /11-AG-13M