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	<title>EMA Inc.</title>
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	<link>http://emainc.net</link>
	<description>The experts in drives and automation.</description>
	<lastBuildDate>Tue, 08 May 2012 18:32:55 +0000</lastBuildDate>
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		<title>EMA team attends Chick Fil A leadercast</title>
		<link>http://emainc.net/newsletter/ema-team-attends-chick-fil-a-leadercast/</link>
		<comments>http://emainc.net/newsletter/ema-team-attends-chick-fil-a-leadercast/#comments</comments>
		<pubDate>Tue, 08 May 2012 18:25:15 +0000</pubDate>
		<dc:creator>Eddie Mayfield</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2194</guid>
		<description><![CDATA[Norcross, GA: May 8, 2012  EMA Drives and Automation had a team of 15 attend the Chick Fil A Leadercast in Atlanta on Friday May 4th. EMA prides themselves on being the undisputed customer service leaders in the electronic motor drives and automation business.  In business for over 22 years, the Norcross based company specializes [...]]]></description>
			<content:encoded><![CDATA[<p>Norcross, GA: May 8, 2012  EMA Drives and Automation had a team of 15 attend the Chick Fil A Leadercast in Atlanta on Friday May 4th.</p>
<p><span id="more-2194"></span><a href="http://emainc.net/wp-content/uploads/2012/05/chik2.jpg"><img class="alignleft size-medium wp-image-2195" style="border: 3px solid black; margin: 10px;" title="chik2" src="http://emainc.net/wp-content/uploads/2012/05/chik2-300x224.jpg" alt="" width="300" height="224" /></a>EMA prides themselves on being the undisputed customer service leaders in the electronic motor drives and automation business.  In business for over 22 years, the Norcross based company specializes in VFD s , DC Drives, PLCs, systems integration, and repair services.</p>
<p>This is EMA&#8217;s third year to attend the Chick Fil A leadercast, and the company is proud to be part of it.  This year&#8217;s speakers included Andy Stanley, John Maxwell, Patrick Lencioni, Tim Tebow, Soledad O&#8217;Brien, Dr. Roland Fryer, Angele Ahrendts, Urban Meyer, and Dr. Sheena Iyengar.</p>
<p>The Master of Ceremonies was <a href="http://www.trippandtyler.tv/" target="_blank">Tripp Crosby</a>, an Atlanta based actor, comedian and producer.  Tripp produced the well received and funny <a href="http://www.youtube.com/watch?v=_V-hPHusTxo" target="_blank">&#8220;Career Day&#8221; video</a> for EMA.</p>
<p>The primary takeaway this year for the EMA team was &#8220;build on your strengths,&#8221; and acknowledge but don&#8217;t focus on your weaknesses.   The company will continue to do that with forays into medium voltage VFDs and services, and touch screen monitor programming and repair.  Andy Stanley said. . &#8220;if you get better, people will demand you get bigger.&#8221;  EMA is taking that to heart.</p>
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		<title>Lowest Priced VFD we&#8217;ve found?</title>
		<link>http://emainc.net/newsletter/lowest-priced-vfd-weve-found/</link>
		<comments>http://emainc.net/newsletter/lowest-priced-vfd-weve-found/#comments</comments>
		<pubDate>Thu, 03 May 2012 21:22:25 +0000</pubDate>
		<dc:creator>Eddie Mayfield</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2185</guid>
		<description><![CDATA[We often get asked to find the lowest priced VFD for our customers.  The least expensive VFD we&#8217;ve found thus far is the EV Drive. The EV drive is a relatively new player in the market.  While it&#8217;s by far the lowest cost VFD we&#8217;ve seen, don&#8217;t think that means low quality. This is a [...]]]></description>
			<content:encoded><![CDATA[<p>We often get asked to find the lowest priced VFD for our customers.  The least expensive VFD we&#8217;ve found thus far is the EV Drive.</p>
<p><span id="more-2185"></span><a href="http://emainc.net/contact-us/" target="_blank"><img class="alignleft size-medium wp-image-2186" style="border: 3px solid black; margin: 10px;" title="evdrive3" src="http://emainc.net/wp-content/uploads/2012/05/evdrive3-300x275.jpg" alt="" width="300" height="275" /></a>The EV drive is a relatively new player in the market.  While it&#8217;s by far the lowest cost VFD we&#8217;ve seen, don&#8217;t think that means low quality. This is a fully featured VFD that&#8217;s suitable not only for HVAC applications, but industrial applications requiring full vector control.</p>
<p>Pricing Examples:  A 20 HP EV Drive will sell for about $1000.00.  A 100 HP EV Drive for about $3000.00.  If you know of a lower priced or less expensive VFD, we&#8217;d like to hear about it.</p>
<p>These are attractive drives in Nema 1 enclosures. They&#8217;re  well made and have user friendly keypads and interfaces.  If you need closed loop vector, you must also install the optional PG card.   Otherwise, you need nothing else.</p>
<p>These low priced VFD s  have a 485 serial communication bus standard. Other communication protocols are available.</p>
<p>These VFDs are available in 230/460/575 volts from 1 to 800 HP.</p>
<p>Call us at 800-848-2504 to discuss,  hit the &#8220;Live Support&#8221; icon, or the <a href="http://emainc.net/contact-us/" target="_blank">contact icon</a> on the top right of this page.</p>
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		<title>VFD for single phase induction motor</title>
		<link>http://emainc.net/newsletter/vfd-for-single-phase-induction-motor/</link>
		<comments>http://emainc.net/newsletter/vfd-for-single-phase-induction-motor/#comments</comments>
		<pubDate>Thu, 12 Apr 2012 18:59:07 +0000</pubDate>
		<dc:creator>Eddie Mayfield</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2171</guid>
		<description><![CDATA[You can run a single phase motor from a VFD.  The motor cannot use a switched starting capacitor;  it must be either a split capacitor or shaded pole single phase motor.  A single phase VFD can be used on these motors.  The other consideration is starting torque. The single phase output VFD  should be used [...]]]></description>
			<content:encoded><![CDATA[<p>You can run a single phase motor from a VFD.  The motor cannot use a switched starting capacitor;  it must be either a split capacitor or shaded pole single phase motor. <span id="more-2171"></span> <a href="http://emainc.net/wp-content/uploads/2012/04/splitcapmotor.jpg"><img class="alignleft size-full wp-image-2173" style="border: 3px solid black; margin: 10px;" title="splitcapmotor" src="http://emainc.net/wp-content/uploads/2012/04/splitcapmotor.jpg" alt="" width="198" height="198" /></a>A single phase VFD can be used on these motors.  The other consideration is starting torque. The single phase output VFD  should be used only on centrifugal loads, such as fans and pumps.</p>
<p>The drive we sell is the Bardac Optidrive.  <a href="http://www.emainc.net/downloads/optidrive.pdf" target="_blank">(download brochure here)</a>.  It&#8217;s for motors 2 horsepower and less.  Call us if you have an application at 800-848-2504  or hit the &#8220;Live Support&#8221; icon on the right during normal hours.  You can also email us by hitting the contact icon on the top right of this page.</p>
<p>Single phase output VFD s are used often for small exhaust fans and so forth in both industrial and commercial facilities and institutions.  The advantages to using a single phase output VFD is energy savings, soft starts, and reduced noise.</p>
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		<title>Electrolytic (DC Bus Capacitors) Capacitors: The Ticking Time Bomb</title>
		<link>http://emainc.net/newsletter/electrolytic-bus-capacitors-capacitors-the-ticking-time-bomb/</link>
		<comments>http://emainc.net/newsletter/electrolytic-bus-capacitors-capacitors-the-ticking-time-bomb/#comments</comments>
		<pubDate>Tue, 10 Apr 2012 15:54:39 +0000</pubDate>
		<dc:creator>Dean Williams</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2156</guid>
		<description><![CDATA[VFD s use Electrolytic Capacitors in the DC Bus section.   This article by Dean Williams is useful information. Electrolytic Capacitors, The Ticking Bomb Author:  Dean Williams Inside most industrial electronic equipment resides a component called an electrolytic capacitor.  (IF you need to purchase DC Bus Capacitors for your VFD, click the contact icon on the [...]]]></description>
			<content:encoded><![CDATA[<p style="text-align: left;" align="center">VFD s use Electrolytic Capacitors in the DC Bus section.   This article by Dean Williams is useful information. <span id="more-2156"></span></p>
<p style="text-align: center;"><strong>Electrolytic Capacitors, The Ticking Bomb</strong><br />
<strong></strong>Author:  Dean Williams</p>
<p>Inside most industrial electronic equipment resides a component called an electrolytic capacitor. <strong><em> (IF you need to purchase DC Bus Capacitors for your VFD, click the contact icon on the top of this page)</em></strong> Typically, the function of this capacitor is to act as a power supply filter.  It’s comprised of two strips of aluminum foil (called plates) separated by a paper insulator.  The foil and paper are rolled into a cylinder and immersed in an electrolyte solution consisting of an ethyl glycol fluid.  All of this is placed inside an aluminum can and sealed up via some sort of rubber safety vent plug.  (image courtesy of <a href="http://learnabout-electronics.org/ac_theory/capacitors01.php" target="_blank">learnabout-electronics.org </a>)</p>
<p style="text-align: center;"><a href="http://emainc.net/wp-content/uploads/2012/04/electrolytic_construction.jpg"><img class="aligncenter size-medium wp-image-2157" style="border: 3px solid black; margin: 10px;" title="electrolytic_construction" src="http://emainc.net/wp-content/uploads/2012/04/electrolytic_construction-300x160.jpg" alt="" width="300" height="160" /></a>The capacitor works by storing a DC charge between the two plates.  One of the plates has an insulating oxide layer that is created &amp; maintained when the capacitor is charged up.  It is this insulating oxide layer (called a dielectric) that is crucial to proper capacitor operation.  If the dielectric was not present, the capacitor would short circuit and draw large amounts of current.  When large amounts of current flow into the capacitor, it causes the electrolyte solution to boil and turn into a gas.  Once turned into a gas, pressure builds rapidly until, hopefully, the safety vent plug releases pressure.</p>
<p>This rupture can be very dramatic and destructive.  Not only is the boiling liquid and gas hot, it is also corrosive and will damage any components covered by the solution.  Under controlled laboratory conditions, measurements have been taken during a violent, large capacitor rupture.  The equivalent explosive force of half a hand grenade has been measured.  For some interesting viewing go to <a href="http://www.youtube.com/">www.youtube.com</a> and type in “capacitor explosion”. You will see perfect examples of violent failures.</p>
<p>The dielectric oxide-insulating layer is created during manufacture.  However, it will deteriorate in the absence of a sufficient rejuvenating voltage, and eventually the capacitor will fail if voltage is not applied.  Maintaining the integrity of the dielectric requires the steady application of power.  When voltage is applied, the oxide layer is rebuilt.  The oxide layer thickness is the crucial factor to determine the voltage rating of the capacitor.  Otherwise, the oxide layer will break down under voltage and cause a spectacular failure.</p>
<p>By applying voltage to the capacitor on a regular basis, the oxide layer is “reformed”, and the integrity of the insulating characteristic is ensured.  In EMA’s experience, the maximum time between power ups should be no longer than 1 year, provided the equipment is kept in a dry location at roughly 70 degrees F.  Large temperature swings require less time between power ups.</p>
<p>The procedure to “reform” the capacitors in electronic equipment is to <strong><span style="text-decoration: underline;">apply rated voltage for a period of at least 1 hour</span></strong>.  Realizing after the unit is de-energized, a chemical reaction is still occurring for up to 24 hours, thereby rebuilding the oxide layer during this “resting” period.  Should more than 12 months pass between power ups, great caution should be exercised.</p>
<p>At EMA, we constantly see equipment that is sent to our repair shops with damage caused by improper “reforming” of the capacitors.  Often, the customer has a spare piece of equipment sitting on a shelf for years with no attention made to reforming the capacitors.  During an emergency breakdown, the spare unit is brought out to the machine, installed and powered up, only to have a dramatic failure occur when the capacitors violently fail.  This can occur in many different pieces of equipment such as monitors, PLC’s, power supplies, and especially variable frequency drives (VFD’s).  VFD’s have a large capacitor bank that is especially prone to becoming “unformed” and failing dramatically upon power up after a long de-energized period.</p>
<p>EMA has the capability to reform these older capacitor banks by using special power supplies that allow for controlled voltage increase, and limited current supply.  In some worst case situations it has taken 8 hours to safely bring a capacitor bank to full voltage.</p>
<p>In conclusion, look through your shelves to see if you have any electronic equipment that has not been powered up in the last 12 months.  If the answer is yes, you should seriously consider sending it to EMA for an operational checkout under power.  If you find that a large amount of items need capacitor reforming, EMA can travel to your site and perform the service at your facility.</p>
<p>To locate your nearest EMA facility, see the listings at the bottom of this page, or click the contact icon at the top right.</p>
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		<title>Service Call on Toshiba HX7 Plus Pak VFD on Carrier Chiller</title>
		<link>http://emainc.net/newsletter/service-call-on-toshiba-hx7-plus-pak-vfd-on-carrier-chiller/</link>
		<comments>http://emainc.net/newsletter/service-call-on-toshiba-hx7-plus-pak-vfd-on-carrier-chiller/#comments</comments>
		<pubDate>Thu, 05 Apr 2012 17:51:45 +0000</pubDate>
		<dc:creator>Jon Blakeslee</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2145</guid>
		<description><![CDATA[The Holiday Inn in downtown Binghamton, NY was hit severely by the 2011 flood. Their whole basement mechanical room was completely underwater, including their VFD s.  One of the casualties was a Toshiba G3+ 350 HP VFD. The drive runs their Carrier 350 ton Chiller for all of the air conditioning in the building. The [...]]]></description>
			<content:encoded><![CDATA[<p>The Holiday Inn in downtown Binghamton, NY was hit severely by the 2011 flood. Their whole basement mechanical room was completely underwater, including their VFD s.  <span id="more-2145"></span> <a href="http://emainc.net/wp-content/uploads/2012/04/binghamptonflood.jpg"><img class="alignright size-medium wp-image-2149" style="border: 3px solid black; margin: 10px;" title="binghamptonflood" src="http://emainc.net/wp-content/uploads/2012/04/binghamptonflood-300x225.jpg" alt="" width="300" height="225" /></a>One of the casualties was a Toshiba G3+ 350 HP VFD. The drive runs their Carrier 350 ton Chiller for all of the air conditioning in the building. The drive was replaced with a new Toshiba HX7 Plus Pack VFD, the motor checked out, and new wires run to the motor.</p>
<p>&nbsp;</p>
<p>EMA was called in to perform factory startup on the Toshiba HX7 Plus Pack VFD. The &#8220;startup&#8221; quickly turned to more of a troubleshooting call once the VFD was powered on.  Attempting to run the VFD resulted in an &#8220;Earth Fault&#8221;. The motor/wires were re-meggered on 1000V scale to ground = 2200 Mohm, the VFD ran ok and had a balanced output voltage waveform with no motor attached. When Carrier specifies a VFD for their chillers they also require this &#8220;GFD&#8221; module be included. On further inspection of the GFD module the following was found.</p>
<p>&nbsp;</p>
<p><a href="http://emainc.net/wp-content/uploads/2012/04/toshibaholidayinn.jpg"><img class="alignleft size-medium wp-image-2153" style="border: 3px solid black; margin: 10px;" title="toshibaholidayinn" src="http://emainc.net/wp-content/uploads/2012/04/toshibaholidayinn-300x225.jpg" alt="" width="300" height="225" /></a>The input to the GFD module is taken off center tap of the DC bus via four ten to twenty watt resistors in reference to ground. The output is a set of contacts off a small relay on the GFD circuit board.</p>
<p>&nbsp;</p>
<p>I took oscilloscope measurements of the input to the GFD board and had a meter on the relay contacts off the board. I ran the VFD, which  immediately tripped on Earth Fault again even though the input to the board stayed at zero volts and the relay contact never closed.</p>
<p>&nbsp;</p>
<p>To verify the trip was coming from the GFD module the relay contact could be jumpered and the VFD would show an Earth Fault. The 24VDC from the logic board feeding to the relay contacts on the GFD board was disconnected. Ran the VFD; still had an Earth Fault trip. Traced the wires back to the Master Gate Drive board from the relay output on the GFD board, and disconnected the wires at the Master Gate Drive board.</p>
<p>&nbsp;</p>
<p>I then ran the VFD, which ran well without trips. Upon further inspection,  those wires from the GFD circuit to the Master Gate Driver board were zip tied along fan power wires. Once the drive is called to run the eight cooling fans in the VFD would kick on, induce noise into the wires to the Master Gate Drive board,  and cause the nuisance trip. The wires were re-routed, connectors reseated and the VFD ran well.</p>
<p>We find this situation occasionally, and it&#8217;s a reminder to exercise good engineering practices in wiring and cable runs.  EMA services nearly all brands of VFDs, and performs service on everything from standalone VFD s to coordinated drive systems.   Contact your nearest EMA facility as listed at the bottom of this page, or hit the contact icon on the top right.</p>
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		<title>Load Sharing using the WEG VFD</title>
		<link>http://emainc.net/newsletter/load-sharing-using-the-weg-vfd/</link>
		<comments>http://emainc.net/newsletter/load-sharing-using-the-weg-vfd/#comments</comments>
		<pubDate>Thu, 05 Apr 2012 15:51:48 +0000</pubDate>
		<dc:creator>Abdou Barrow</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2137</guid>
		<description><![CDATA[Load Sharing using  hard coupled VFD s requires special tuning and setup.  Here&#8217;s a brief overview.  All most all newer VFDs come with an auto-tune function these days. Auto tune automatically adjusts the tuning parameters of  the VFD to the motor. All that is required from a technician or engineer is to input the motor [...]]]></description>
			<content:encoded><![CDATA[<p>Load Sharing using  hard coupled VFD s requires special tuning and setup.  Here&#8217;s a brief overview.  <span id="more-2137"></span><a href="http://emainc.net/wp-content/uploads/2012/04/cfw-11_softkey_ing.jpg"><img class="alignleft size-full wp-image-2138" style="border: 3px solid black; margin: 10px;" title="cfw-11_softkey_ing" src="http://emainc.net/wp-content/uploads/2012/04/cfw-11_softkey_ing.jpg" alt="" width="170" height="244" /></a></p>
<p>All most all newer VFDs come with an auto-tune function these days. Auto tune automatically adjusts the tuning parameters of  the VFD to the motor. All that is required from a technician or engineer is to input the motor data from the motor name plate and run auto-tune to achieve optimum performance in a single VFD application. However it can get complicated when you have to set up two or more VFDs to perform rigid (motors coupled to the same shaft) load sharing applications.</p>
<p>&nbsp;</p>
<p>The WEG CFW11 and CFW09 VFDs have six modes of control. Saturated mode/Torque control is available only in sensorless vector mode or vector with encoder feedback/full flux vector.</p>
<p>&nbsp;</p>
<p>Basic understanding of the physics or mechanics of the application is very helpful in setting up load sharing. Typically, on a WEG VFD,   we set the master drive in speed mode and the followers in saturated mode (Torque mode). The CFW11 and CFW09 follower VFD has to have its speed loop kept saturated. Both speed reference and torque reference to the follower VFD will be required.</p>
<p>&nbsp;</p>
<p>One of the analogue outputs of the master is programmed for speed reference output and the second output is <a href="http://emainc.net/wp-content/uploads/2012/04/conveyorchain.jpg"><img class="alignright size-medium wp-image-2139" style="border: 3px solid black; margin: 10px;" title="conveyorchain" src="http://emainc.net/wp-content/uploads/2012/04/conveyorchain-151x300.jpg" alt="" width="151" height="300" /></a>programmed for torque reference output. Since the follower VFD is set in saturated mode an increase in the master torque will result in increase in torque on the follower. You can also scale the torque reference input on the follower accordingly to allow it to pull more torque than the master or vice-visa.</p>
<p>&nbsp;</p>
<p>The tuning parameters are very important to achieve critical dampened responses in all the VFD in the system.</p>
<p>&nbsp;</p>
<p>Speed regulator gains: These are calculated by auto-tune but may need to be readjusted to meet the speed dynamic response for the system. The proportional gain stabilizes sudden changes in speed reference while the integral gain corrects the error between speed reference and actual speed. Lowering  the gains too much will usually result in the VFD not attaining set speed and gains set too high will result in oscillation. The mechanical time constant which is available in both CFW11 and CFW09 can provide further speed stability adjustments in the WEG CFW09 and CFW11.</p>
<p>&nbsp;</p>
<p>The auto tune also takes care of the flux regulator gains. However,  in a load sharing application,  this setting may not be able to achieve optimum performance. So adjusting the gains may also  be required just like in the speed loop gains.</p>
<p>&nbsp;</p>
<p>The key  thing to keep in mind when tuning any system is to start with lower gains and gradually increase the gains until critically dampened response is achieved. EMA provides start ups on coordinated VFD systems.  Contact your nearest EMA facility as listed below, or click the contact icon at the top right of this page.</p>
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		<title>Leadership:  The Power of a Story</title>
		<link>http://emainc.net/newsletter/leadership-the-power-of-a-story/</link>
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		<pubDate>Thu, 22 Mar 2012 01:52:01 +0000</pubDate>
		<dc:creator>Eddie Mayfield</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2092</guid>
		<description><![CDATA[The Power of a Story Tell me your stories, I&#8217;ll teach you my songs and we&#8217;ll have one more Isn&#8217;t that what friends are for? Isn&#8217;t that what friends are for? Those lyrics from a 1972 Paul Williams song seem to capture what many business leaders have learned over the years.  Stories and illustrations have [...]]]></description>
			<content:encoded><![CDATA[<h2 class="MsoTitle" style="text-align: center;" align="center"><span style="font-family: Verdana; font-style: italic; font-weight: bold;">The Power of a Story<span id="more-2092"></span></span></h2>
<p class="MsoTitle" style="text-align: center;" align="center"><span style="font-family: Verdana; font-style: italic; font-weight: bold;"><br />
</span></p>
<p class="MsoTitle" align="center"><span style="font-family: Verdana; font-style: italic; font-weight: bold;"><br />
</span><em><strong><img class="alignleft" style="border: 3px solid black; margin: 10px;" title="TELLINGASTORY" src="http://www.emainc.net/images/tellingastory.jpg" alt="" width="280" height="347" />Tell me your stories, I&#8217;ll teach you my</strong></em><br />
<em><strong> songs and we&#8217;ll have one more</strong></em></p>
<p style="text-align: center;"><em><strong>Isn&#8217;t that what friends are for?</strong></em></p>
<div style="text-align: center;" align="center"><em><strong>Isn&#8217;t that what friends are for?</strong></em></div>
<div style="text-align: center;" align="center"></div>
<p class="MsoNormal" align="left"><span style="color: #000000;"><em><strong>Those lyrics from a </strong></em>1972 Paul Williams song seem to capture what many business leaders have learned over the years.  Stories and illustrations have sticking power, and provide insight into personalities, hopes, and dreams like nothing else. </span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;">They’re great vehicles for imparting vision, teaching procedures, and coaching performance.   One of my mentors very often started an impromptu coaching lesson by saying: “let me tell you a story.”  Out of all the principles he taught me, the ones taught with a story have stuck the longest.</span></p>
<p class="MsoNormal" align="left"><strong><span style="color: #000000;">This isn’t a new concept.  </span></strong></p>
<p class="MsoNormal" align="left"><span style="color: #000000;">Jesus’ favorite method of teaching his followers was to tell them stories.  You may be completely ignorant of the Bible, but no one is ignorant of the principles taught in the story of the Good Samaritan, or the Prodigal Son.  Aesop&#8217;s fables have been used for centuries to make moral points.  Most of us remember the folk stories of the little boy that cried wolf, and the exaggerated warnings from an overly excited chicken little. Those stories put flesh on truths and concepts, and add practical value to our lives. </span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;">When I first began doing field service on motor drives, I went into a plant with a huge burn mark on the wall behind an obviously newly replaced 2000 amp disconnect.  “What happened here?” I asked.  “Let me tell you about that” was the opening reply, and then the maintenance supervisor told me the story about one of his men getting killed on that spot while  attempting to open the previous disconnect with the motor grounded, and fault current flowing.  The resulting explosion killed him. </span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;"><strong> I understood electrical physics, but that story drove home a safety point that I never forgot</strong>.  I’ve been in similar situations where a piece of equipment faulted a high energy circuit to ground, and never have I been tempted to try opening the circuit.  I just stay out of the way and let the fuses open.  The story that gentleman told me went deep into my psyche, and has served me well for decades. </span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;">Shortly after getting my pilot’s license, I went to the airport one day and noticed a blurb about a crash involving a plane that I’d flown several times.  I asked what happened and was told the story of a pilot that decided to do a touch and go over an unknown airstrip.  Unfortunately, the strip was long enough for landing and take offs but not for touch and goes.  He hit the trees, destroying the plane, and seriously injuring himself and his passengers.    </span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;">Every time I’ve been tempted to make an unplanned, non-emergency landing at an unfamiliar small strip, I thought of that story and continued on my way.  It isn’t that I didn’t already know better, in fact that’s part of pilot training, but the story drove home the point in ways that reading a safety procedure never could. That’s the power of a story.</span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;"><strong>What about you, how do you teach and coach your coworkers or family?  </strong>If you’re in leadership, how do you flesh out your vision for the organization or department in ways that everyone can understand and grasp?</span></p>
<p class="MsoNormal" align="left"><span style="color: #000000;"><strong>Maybe you need some stories.</strong> Your stories can be about your own experiences, those of  others, or stories, illustrations or jokes that you’ve heard or read. Here are a few ideas that may help:</span></p>
<ol>
<li>
<p class="MsoNormal" align="left"><span style="color: #000000;"> <strong>Keep them</strong></span><span style="color: #000000;"><img class="alignleft" style="border: 3px solid black; margin: 10px;" src="http://www.emainc.net/images/manwomantalk.jpg" alt="" width="274" height="184" align="left" border="0" /></span><br />
<span style="color: #000000;"><strong> short.</strong>    Just about the worst sin you can commit is taking too long to tell the story.  The story of the Good Samaritan takes about 90 seconds to read.  Think about that..  90 seconds to read probably one of the best known and most  influential stories known to mankind.  Get the picture?  Keep it short.</span></p>
</li>
<li>
<p align="left"><span style="color: #000000; font-family: Verdana;"><strong>Don’t talk down to your listener.</strong>  People do not appreciate being treated as inferiors.  Let’s face it, you don’t know everything, and the people you work with are already aware of this.  So drop the pretense.   Self d</span><span style="color: #000000; font-family: Verdana;">epreciating stories about your own embarrassing incidents and mistakes make great stories. Use them.<br />
Try not to us</span><span style="color: #000000; font-family: Verdana;">e stories where you are the hero; people will miss the point of your story wondering how such an <em>arrogant jackass</em> managed to get the position you hold!<br />
</span></p>
</li>
<li>
<p align="left"><span style="color: #000000; font-family: Verdana;"><strong> </strong><strong>Give credit where credit is due.</strong>  If you heard a great one liner on Seinfeld that illustrates a point, then tell them where it came from.  Never claim anything as yours that you borrowed from someone else. People love hearing popular culture being used to illustrate truths, values, or business principles.<br />
</span></p>
</li>
<li><span style="color: #000000; font-family: Verdana;"><span style="color: #000000; font-family: Verdana;"><strong>Be interesting! </strong><br />
</span></span></p>
<p align="left"><span style="color: #000000; font-family: Verdana;"> Read or listen to great storytellers and match their style to your own.  You don’t have to pretend to be something you aren’t; rather just be humble and yourself. But, be interesting!  Honesty, competence and interesting are not mutually exclusive terms. </span></p>
</li>
<li>
<p align="left"><span style="color: #000000; font-family: Verdana;"><strong>Encourage others to tell you their stories</strong>  If the person you’re coaching is able to tell you their story that drives your point home, you’ve done well!</span></p>
</li>
</ol>
<p><span style="color: #000000;"> <strong><em>Finally,</em></strong> let me give you a little example.   I don’t teach many of our troubleshooting classes any longer, but I’ve used this illustration to drive home a simple point.   There’s a <em>Far-Side </em>cartoon that shows this poor sap sitting wide-eyed in an electric chair with his arms and legs strapped down, and an electrode shaped like a beanie on his head. It’s obviously an execution.   Two big guards are standing next to him looking down at a large wall mounted disconnect switch.  One of the guards is rubbing his chin saying, “<strong><em>I dunno, just click it up and down a few times, maybe the contacts are dirty.</em></strong>”</span></p>
<p class="MsoNormal" align="left"><span style="color: #000000; font-family: Verdana;"><strong> </strong><span style="color: #000000; font-family: Verdana;"><strong> </strong>After they quit chuckling, I’ll just say, “The majority of electrical and electronic problems, no matter how complex they may appear, are due to dirty contacts and loose connections. Don’t let yourself get suckered into anything else until you eliminate that” It’s just a way to drive home a point in a way that’s more likely to be remembered. </span></span></p>
<p class="MsoNormal" align="left"><span style="color: #000000; font-family: Verdana;"><strong> </strong>Rather than preaching about the dangers of disconnecting the motor field on an unloaded DC motor, I just tell my guys about the time I had to dive to the floor behind a control cabinet while a DC motor self destructed as it tried to spin up to infinity, throwing shrapnel all over the plant. The stories (especially ones that involve you nearly getting killed) are great ways to drive home important points! </span></p>
<p class="MsoNormal" align="left"><strong><span style="color: #000000; font-family: Verdana;"><strong> </strong>Use stories…  They’re a powerful tool of leadership.</span></strong></p>
<p class="MsoNormal" align="left"><span>(one guy says to another,&#8221;did I tell you about my grandson?&#8221;  The other guy says, &#8220;no, and I&#8217;ve always appreciated it.&#8221;)  </span></p>
<p class="MsoNormal" align="left"><span><strong>Eddie Mayfield</strong><br />
<strong></strong></span></p>
<p><span style="color: #0000ff;"><a class="MsoNormal" style="font-size: x-small;" href="http://www.emainc.net">www.emainc.net</a>  </span></p>
<p><span style="color: #0000ff;">Call us at 800-848-2504</span><br />
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		<title>Electric Motor Drives:  Market Overview</title>
		<link>http://emainc.net/newsletter/electric-motor-drives-market-overview/</link>
		<comments>http://emainc.net/newsletter/electric-motor-drives-market-overview/#comments</comments>
		<pubDate>Tue, 20 Mar 2012 17:01:23 +0000</pubDate>
		<dc:creator>Eddie Mayfield</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2083</guid>
		<description><![CDATA[This blog is an overview of the Electric Motor Drive Market.  By Eddie Mayfield, President, EMA Inc. (to download this in PDF form, Click Here) Despite a persistently sluggish U.S. economy, most electric motor drive manufacturers reported good sales in 2011, and are optimistic about 2012. &#160; Here at EMA, we experienced a very good [...]]]></description>
			<content:encoded><![CDATA[<p style="text-align: center;">This blog is an overview of the Electric Motor Drive Market.  <span id="more-2083"></span><!--more--></p>
<p style="text-align: center;">By Eddie Mayfield, President, EMA Inc.</p>
<p style="text-align: center;">(to download this in PDF form, Click <a href="http://www.emainc.net/downloads/electricmotordrivemarket.pdf" target="_blank">Here</a>)</p>
<p>Despite a persistently sluggish U.S. economy, most electric motor drive manufacturers reported good sales in 2011, and are optimistic about 2012.</p>
<p>&nbsp;</p>
<p>Here at EMA, we experienced a very good 2011, even with a slower 4<sup>th</sup> quarter than normal, and are experiencing an excellent 1<sup>st</sup> quarter in 2012.</p>
<p>&nbsp;</p>
<p>A variety of sources predict sales of lower horsepower AC drives, which includes fractional horsepower drives,  to grow by almost 8% , while high horsepower drives are expected to grow by over 9%.</p>
<p>&nbsp;</p>
<p>DC Drive sales continue to be a factor, but there’s no question that the primary interest is in AC drives.  DC drives are likely to sustain revenues however, primarily as customers buy newer drives to replace old DC drives.  Almost all of our DC drive sales at EMA fit within this model.  In fact, I can’t recall the last time we sold a DC drive on a new application.  We continue to get requests for DC drive service, but many of these have been in operation for years.</p>
<p>&nbsp;</p>
<p>Here at EMA, we think the AC drive growth rates are understated, especially the high horsepower predictions.  For one thing, the oil and gas market continues to expand the use of electronic drives, and for many, if not most, drive suppliers, this market segment accounts for a significant portion of their sales.  While the world-wide demand for oil is actually down due to slowing economies, concerns about supply have driven continued growth.   Even if it slows, this is an industry that has embraced the efficiencies that motor drives bring to their processes, and a slowing market could actually fuel even higher interest in motor drives as cutting process costs become more important.</p>
<p>&nbsp;</p>
<p><strong>Much of the AC Drive market is driven by energy savings</strong>. This has been evident to even the most casual observer for years, especially in the HVAC marketplace. In addition, we are seeing increased interest in a much wider range of industries, and getting more and more inquiries on energy saving applications using higher horsepower drives.  Since a significant portion of industrial drives are constant torque applications such as conveyors, energy savings, even on their variable torque loads, were not always considered.  There,  drives have been purchased, and continue to be purchased,  for process control factors.  But now, plants are increasingly looking at energy savings, by  placing drives on all their centrifugal loads.  Since many of these are high horsepower applications, the energy savings potentials can be substantial.</p>
<p>&nbsp;</p>
<p>I have seen nothing to indicate lower electricity costs in the near future, and therefore nothing that will dampen the interest in energy savings.   Along with the interest in drives, we’re seeing more inquiries on power quality issues.  These can range from harmonic assessment and mitigation techniques, to preventing motor damage from VFD switching transients.</p>
<p>&nbsp;</p>
<p>So the electric drive market looks to continue expansion, driven primarily by energy savings, and at least in dollar terms, heavily influenced by high horsepower and medium voltage applications.</p>
<p>&nbsp;</p>
<p>Despite marketing claims to the contrary, we’ve seen little in the way of technology advancement in the last 12 months.  Several manufacturers have new VFD models out.  These have packaging innovations, added features, and improved software, but little in the way of the real advances.  Motor drive quality has been consistently high for a number of years, and there are no significant technical failings to address.  Drive manufacturers are working on making drives more linear in terms of loading, in order to combat power quality issues created by non-linear drive loads.  That will likely be the next significant advance in motor drives.</p>
<p>&nbsp;</p>
<p>Baldor was recently purchased by ABB, and that’s just another step in what has been for many years the migration of electronic motor drives manufacturing to either offshore or multi-national corporations.   There are very few U.S. owned manufacturers of electronic drives remaining, and those are small players.</p>
<p>&nbsp;</p>
<p>Mergers and strategic partnerships are widespread within the industry. It’s more common than ever to purchase a VFD from one drive manufacturer, that is actually designed and built by a different manufacturer.  Even, if those two companies have historically been competitors.</p>
<p>&nbsp;</p>
<p>Pricing has remained relatively stable, but customers should be careful to compare apples to apples when looking to purchase.  Buying a less expensive and less featured drive, can actually cost more if you have to purchase ancillary control equipment. In those cases, it can actually be less expensive to purchase a more featured drive which has the ancillary functions included.</p>
<p>&nbsp;</p>
<p>Most drive manufacturers do a good job at providing a stand alone drive unit.  Our experience is that performance suffers when they’re asked to provide engineered or modified equipment.  This is understandable;  their primary focus is providing consistently high quality, and low cost units.  Companies like EMA benefit because we are able to do integration and equipment modifications in a timely and cost effective manner. I expect that trend to continue and accelerate.</p>
<p>&nbsp;</p>
<p>Medium voltage VFDs are one of the fastest growing segments of the industry, and every drive manufacturer is moving to capitalize.  Until recently, there were a very limited number of players providing this equipment.  Compared to the low voltage drive market, the number of participants is still relatively few, but it’s growing quickly.</p>
<p>&nbsp;</p>
<p>EMA decided to begin performing service work on medium voltage VFD s a few years ago, and has been successful in penetrating this market.  The demand is high.   For one thing, the manufacturers, due to a lack of competition, got very lax in this area, and the resulting customer frustration opened a window of opportunity for EMA and a few other companies. (If you Google “Medium Voltage VFD repair” you’ll find us listed several times on the first page)</p>
<p>&nbsp;</p>
<p>We begin selling medium voltage drives as well, and for a small company, are operating at the front of this curve.  We are fully aware of the fact that this is a moving window, and other companies will evolve to fill the growing demand.</p>
<p>&nbsp;</p>
<p>We mistakenly thought a few years ago, that the service side of the electronic motor drive market would decline. We observed the computer repair market, where as equipment  pricing declined, people began to replace failed equipment rather than repair.  This was of considerable concern to us, since EMA began as a service company, and depended on it for the majority of our revenues.  While the market has certainly changed, our service business remains as strong as ever.</p>
<p>&nbsp;</p>
<p>We trace this to a number of factors, some of them related to business decisions and practices by us, and some to external factors.  There’s no question that low horsepower drives on simple applications are more likely than ever to be replaced rather than repaired.  Our service business in those situations has declined.</p>
<p>&nbsp;</p>
<p>We have seen however, a dramatic increase in service on both higher horsepower drives and complex applications.  For one thing, the number of companies that can perform that level of service is considerably less than those that were doing the more simple service.  We’ve been fortunate at EMA to retain and train service engineers skilled at this, and to have built a culture and reputation that is oriented toward this more difficult service.</p>
<p>&nbsp;</p>
<p>It is one thing to have a service engineer look at a small drive on an air-handler, and another thing altogether to have a service engineer tune a complex coordinated drive system, or confidently work on a 3000 HP drive.</p>
<p>&nbsp;</p>
<p>While we still perform for and value our HVAC service customers, we recognize the need for us in those routine services is less than it was years ago.  That has been offset a bit by the growing need to have HVAC drives communicate via various protocols, and that complexity has been a niche where we’ve enjoyed growth.  We began doing turnkey installations as well, and this has served us well. Removing an older drive, and installing a new one that will not only integrate with the existing control system, but has the capability to communicate with an upgraded control system has proven to be a valuable service to our customers.</p>
<p>For EMA, we see continued expansion, despite the uncertainty of both the U.S. and international economies.  Historically, we’ve actually grown during  down economies.  Cost cutting by many companies can involve personnel reductions.   As maintenance and engineering staffs are reduced, a portion of those functions are often outsourced to companies like EMA.</p>
<p>&nbsp;</p>
<p>In the same way, even during times of growth,  we see companies being reticent to add employees, choosing instead to rely on companies like EMA to help them service and apply motor drives.</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>Eddie Mayfield</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p><em>EMA is a privately held corporation, founded in 1990, and headquartered in Norcross, Georgia.   EMA has facilities in Cortland, NY and Hazleton, PA.  EMA both sells and services electronic motor drives, provides training, and power quality assessments all over the United States and into several other countries.   EMA has the highest measured customer satisfaction rating in the industry, with in excess of 98.5% of customers reporting they were “very satisfied” with their last EMA experience.</em></p>
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		<title>New York State NYSERDA: VFD and Motor Energy Saving Rebate Programs</title>
		<link>http://emainc.net/newsletter/new-york-state-nyserda-vfd-and-motor-energy-saving-rebate-programs/</link>
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		<pubDate>Tue, 28 Feb 2012 13:27:46 +0000</pubDate>
		<dc:creator>Rebecca Zeeuw</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2067</guid>
		<description><![CDATA[Currently NYSERDA has over $50 million available for distribution to New York State businesses and institutions for VFD and Motor energy saving applications through December 31, 2015, or until the funds are exhausted. There are specific requirements to take advantage of this program.  EMA offers services at no charge to help you take advantage of [...]]]></description>
			<content:encoded><![CDATA[<p><strong>Currently NYSERDA has over $50 million</strong> available for distribution to New York State businesses and institutions for VFD and Motor energy saving applications through December 31, 2015, or until the funds are exhausted. There are specific requirements to take advantage of this program.  EMA offers services at no charge to help you take advantage of this program. <span id="more-2067"></span></p>
<p><a href="http://emainc.net/wp-content/uploads/2012/02/nyserda2.jpg"><img class="alignleft size-medium wp-image-2070" style="border: 3px solid black; margin: 10px;" title="nyserda" src="http://emainc.net/wp-content/uploads/2012/02/nyserda2-300x230.jpg" alt="" width="300" height="230" /></a>It has long been established that Variable Frequency Drives (VFD) and high efficiency motors save energy.  (See <a href="http://emainc.net/newsletter/energy-savings-with-variable-frequency-drives/" target="_blank">Energy Savings with Variable Frequency Drives </a>).</p>
<p>The <strong id="yui_3_3_0_1_1330434661015238">New York State Energy Research and Development Authority</strong> (NYSERDA) has money available for qualified VFD and Motor energy saving projects in New York.</p>
<p><strong>EMA can help  determine if you qualify, and if you do, walk you through the application process.</strong></p>
<p>EMA has been working with numerous customers over the years utilizing the NYSERDA VFD and Motor Rebate Programs. Our understanding of the program requirements and the application process is the key to assisting our customers. Having the capabilities to answer questions, assist with choosing the correct equipment for your precise needs, and completing the lengthy applications are all services we offer that benefit YOU.</p>
<p>(want to see a real life example?  <a href="http://www.yaskawa.com/site/dmdrive.nsf/link2/NKOE-8DJQH8/$file/PR.HPAC.03.pdf" target="_blank">Click Here to read an article about a boiler fan project at the University of Rochester)</a></p>
<p>&nbsp;</p>
<p>Understanding the NYSERDA program has become our focus. In the past five years we have worked with several energy consulting firms to verify the program,  its processes and eligibility requirements. We have participated in  Energy Trade Shows,  including NYSERDA and National Grid where we were a featured speaker on VFD and Motor Energy Savings.  We shared examples of completed projects,  verifying the energy savings,  and the NYSEDRA monies awarded. We also hold Energy Saving Seminars on our own and in conjunction with educational institutions in Central New York.</p>
<p>NYSERDA&#8217;s Existing Facilities Program (EFP) offers two programs <strong>Pre-Qualified</strong> and <strong>Performance Based</strong> where incentives for a variety of energy efficiency retrofit projects for commercial, institutional and industrial buildings could lead to additional money for your business.</p>
<p>The most common is  <strong>Pre-Qualified Projects</strong>. These involve the installation of energy-saving equipment that NYSERDA has pre-approved to be included in this program on a dollar-per-unit basis. <strong>Variable Frequency Drives (VFD)  and NEMA Premium Efficiency Motors are two such items where EMA can assist</strong>.</p>
<p>The <strong>Performance-Based Projects</strong> involve assessing current energy usage, and submitting plans for energy savings from the installation of energy-saving products like VFDs and Premium Efficiency Motors. Monies are awarded upon completion.  The final evaluation is based on kWh Savings. These projects tend to be larger in scale than Pre-Qualified Projects. They often include VFDs rated at over 200 HP. This program also has a different application process than the Pre-Qualified since the incentive amounts are typically higher.</p>
<p><strong>EMA can provide Energy Savings Analysis Reports for your next VFD Project</strong>. This report utilizes your information including what you pay per kWh, peak demand charges; estimated run time of the equipment, new equipment costs, options for EMA installation, and NYSERDA estimated rebates you could possibly obtain. <strong>We will calculate Carbon Dioxide Emissions CO2, Simple Payback, Duty Cycle, Power Required, Annual Energy Usage, and Predicted Annual Energy Savings.</strong></p>
<p><strong>These are services we offer at no charge</strong>. So,  if you have a Pump or Fan application where you want to see an Estimated Energy Savings Analysis Report and determine if you potentially meet the NYSERDA VFD and/or Motor Program requirements,  please contact our office at 607-756-0424 or click the &#8220;Live Support&#8221; button on the right of this page, or complete the email form.</p>
<p>To download a white paper on this (PDF), click <a href="http://www.emainc.net/downloads/energysavings%20and%20nyserda.pdf" target="_blank">HERE. </a></p>
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		<title>Danfoss VLT 3000 Repair  and Interface Board Repair 175L3216</title>
		<link>http://emainc.net/newsletter/danfoss-vlt-3075-interface-board-repair-175l3216/</link>
		<comments>http://emainc.net/newsletter/danfoss-vlt-3075-interface-board-repair-175l3216/#comments</comments>
		<pubDate>Fri, 24 Feb 2012 19:07:15 +0000</pubDate>
		<dc:creator>Jon Blakeslee</dc:creator>
				<category><![CDATA[Newsletter]]></category>

		<guid isPermaLink="false">http://emainc.net/?p=2057</guid>
		<description><![CDATA[EMA&#8217;s New York facility regularly repairs the old Danfoss VLT 3075 controls and in particular, the interface Board 1753216. EMA  can repair the Danfoss Interface Board 175L3216 as as a stand alone unit, or as part of the entire Danfoss VLT 3075 VFD.   EMA New York has a complete test stand to repair either. [...]]]></description>
			<content:encoded><![CDATA[<p>EMA&#8217;s New York facility regularly repairs the old Danfoss VLT 3075 controls and in particular, the interface Board 1753216.<span id="more-2057"></span></p>
<p><a href="http://emainc.net/wp-content/uploads/2012/02/danfossboard.jpg"><img class="alignleft size-medium wp-image-2058" style="border: 3px solid black; margin: 10px;" title="danfossboard" src="http://emainc.net/wp-content/uploads/2012/02/danfossboard-169x300.jpg" alt="" width="169" height="300" /></a>EMA  can repair the Danfoss Interface Board 175L3216 as as a stand alone unit, or as part of the entire Danfoss VLT 3075 VFD.   EMA New York has a complete test stand to repair either.</p>
<p>Since these Danfoss VLT 3075 VFD s  are fairly large in size (ranging from  a small to standard refrigerator) it&#8217;s sometimes easier to just send the Danfoss interface Board.</p>
<p>If you&#8217;re going to do this, be certain that there are not other problems with the Danfoss VLT 3075 VFD.   Typically on the Danfoss 1753216  board there are overheated resistors, leaking capacitors, and other heat related issues.</p>
<p>You can contact EMA New York at 607-756-0424, or by clicking the &#8220;Live Support&#8221; button or contact form on the right.  Visit our Shop Repair page.  EMA also performs Field Service on the Danfoss VLT 3075 VFDs.</p>
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