DISTRIBUTOR Power Drive Systems

engineered by HELMKE

Single source supply and responsibility.

Turn-key project management

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HELMKE Power Drive Systems

 

Power Drive Systems

engineered by HELMKE

Single source supply and responsibility.

Turn-key project management.

2 HELMKE | Power Drive Systems

Power Drive Systems made in Germany

Reliable drives and motors technology.

Power Drive Systems made in Germany

HELMKE | Power Drive Systems 3

Project management. Drive systems. Testing.

The experts

We care for the competitiveness and

completeness of our technical solutions.

For each and every customer.

Low voltage

• Voltage range: 230 V to 690 V

• Power range: 0,55 kW to 2.800 kW

High voltage

• Voltage range: 2,4 kV to 13,8 kV

• Power range: 0,2 MW to 25 MW

We continuously update and expand

our product portfolio, in line to

the increasing market demand for

sophisticated process control and

automation as well as maximum

energy efficiency for power driven

equipment in industrial applications.

In parallel, we evolve our engineering

expertise and know-how through

strategic investments in product

R & D: Our state-of-the art testing

facilities for complete Power Drive

Systems (PDSs) in the full power

range from 315 kW up to 6 MW is

the undisputable proof of our corporate

commitment towards premium

quality services and respective

technical products.

This is what enables HELMKE today

to offer a wide range of various

complete PDSs to Original Equipment

Manufacturers (OEMs) and

end-customers, over a broad range

of application and market sectors

around the globe.

4 HELMKE | Power Drive Systems

HELMKE | Power Drive Systems 5

6 HELMKE | Power Drive Systems

Our product offerings

HELMKE Solutions based on reliable

motor and drive technology.

Distribution and converter transformers

• Oil immersed or dry type with

impregnated or cast resin windings

– ready for converter duty

• 3 phase or multiple phase depending

on the drive topology

3-phase power factor compensation

systems

Starters

• Electronic (SCR controlled) or

liquid type with configurable

starting curve and duration as

well as enhanced thermal capacity

for consecutive motor starts

Complete Drive Modules

Voltage source or current source

(PWM or load commutated)

inverters for:

• 2Q/4Q operation (for bi-directional

drive and regenerative braking)

• Standard 2-level or multi-level

cascaded topologies (for LV/MV

motors)

Standard 6 pulse, multi-pulse or

Active Front End rectifiers for:

• 2Q/4Q operation

• Low Total Harmonic Distortion of

the current (THDi) on the grid side

(improved grid power quality and

utilization)

Modular converter systems, based

on common DC-rail and parallel

inverter (DC-AC) or parallel rectifier-

inverter (AC-DC-AC) module

topology, providing:

• Overload capability according to

the application type and specification

• System redundancy

EMI and harmonic filters on the grid

side for minimum grid disturbance

as well as du/dt filter(s) on the

motor(s) side for maximum longevity

of the motor insulation system

respectively.

Customized user interface and

control functionality based on the

HELMKE comfort control panel

technology. Seamless integration to

existing automation and monitoring

systems through optional fieldbus

communication boards.

Our product offerings

Motors

• LV and MV

• Squirrel cage and slipring induction

motors

• Synchronous or DC motors on

request

For more information on motor

products, please visit our website.

Mechanical power transmission

systems

• Single or multiple stage helical

gearboxes for main/auxiliary

drives

• Clutches

• Rigid or flexible and safetly

couplings

Complete foundation skids

A complete HELMKE Power Drive

System (PDS) may comprise of

different combinations of the

above components, depending on

the application type and customer

specification. HELMKE exclusively

uses power electronic modules of

renowned European manufacturers

for all HELMKE PDS products.

HELMKE | Power Drive Systems 7

3

5

2

4

1

1. High voltage AC Drive, liquid cooled.

Modular and redundant design features

for mission critical applications in the

heavy industry.

2. High voltage squirrel cage motor and

electronic soft starter for a 3 MW, 10 kV

air-compressor drive.

3. Site commissioning of step down transformer.

4. Liquid resistance starter. Typically offered

in combination with HELMKE slipring motors

for high torque demand applications.

5. Customer-specific electrical control and

communication panels.

8 HELMKE | Power Drive Systems

Our service offerings

Turn-key implementation of projects:

From Engineering to Planning

and Commissioning (EPC)

• Project planning: From initial

concept, to system commissioning

and up to the end of the product

life cycle.

• Engineering Procurement Commissioning

(EPC) project management:

Execution and monitoring

of project plan – status reporting.

• Engineering of complete PDSs,

including full definition of electromechanical

interfaces to existing

infrastructure and equipment.

• Experimental validation of PDS

performance on the testing field:

Realistic equipment testing under

environmental (thermal/vibration)

and electromechanical conditions

emulating steady-state, transient

or faulty states of the end-application.

• Engineering of containerized systems

for complete drive modules.

Application in severe climatic or

hazardous environments.

• PDS delivery and commissioning

under the sole responsibility of

HELMKE.

Single source supply and responsibility

according to the customer

specification

Either one from our standard series,

or a tailor-made PDS, they all come

under the same EPC project support

as well as HELMKE guarantee.

HELMKE is your single source supplier

for reliable motor and drives

technology, from the tendering

phase up to the successful project

completion.

Our service offerings

Our application engineers have wide

experience in planning and engineering

of tailor made PDSs for industrial

applications.

HELMKE | Power Drive Systems 9

1 2

3

1. Motor and power transmission system

engineered for heavy duty excavators in the

mining industry.

2. Complete solution kits for the cement

industry – kiln and ball mill drives are in the

core of our technical expertise.

3. ATEX certified drives in the petrochemical

industry.

4. Drives for accurate speed and torque control

in the paper industry.

4

10 HELMKE | Power Drive Systems

Comfort control panel

The HELMKE comfort control

panel technology offers an optional

interface between the supervisory

system and the device-specific

controllers of the various PDS

components. It serves as a generic

user-machine interface, enabling

system parameter acquisition,

monitoring and control.

Full PDS control with HELMKE

comfort control panel

• Handling from a single physical

location (touch panel interface)

• Communication via a single data

channel (fieldbus interface to the

automation system)

HELMKE comfort control panel

technology provides a transparent

and configurable interface to the

full PDS, irrespectively from the

type and number of different

controllers and controller vendors,

which may co-exist in a complex

system. HELMKE comfort control

panel technology is the way to

reduce operator training and third

party software costs, when it comes

to management of important and

complex drives.

Key features and benefits

• Enhanced graphical interface:

Full color, high resolution touchscreen

used to display interactive

equipment and process diagrams.

• Customized parameter menus

and user access levels. The touch

panel is pre-configured according

to the customer specification and

application requirements.

• Monitoring of actual process

values with real time fitting and

update of trend curves.

• Automatic evaluation and real

time reporting of system health

based on programmable supervision

criteria.

User-machine interface – functional

simplicity via touch panel

• Start/Stop Local/Remote

(Reference values/Actual values)

• System-/process measures

• System status (ready/operating/

fault)

Complete Drive Module (CDM)

• Low voltage: 230–690 V /

0,55–2800 kW

• High voltage: 2,4–10 kV /

0,2–20 MW

Electrical machines

• Low and high voltage motors:

up to 13,8 kV

• Output range: up to 25 MW

• Type of protection IP23 up to IP67

• Air and water cooling

Complete PDS, engineered and

delivered by HELMKE: Full EPC

project support from a single source

supplier with sole responsibility

throughout the product life-cycle.

Unified communication for seamless

system integration and operation

User-friendly interface via programmable

touch panel.

HELMKE | Power Drive Systems 11

1

3

4a 4b 4c

2

1. Real time monitoring of process critical

parameters acc. to customer specification.

2. Multi-lingual support (any further language

on request).

3. User-friendly, simplified graphical design.

4. (a–c) Further Graphical User Interfaces

(GUIs) and reporting tools on demand.

Any further language

on request

12 HELMKE | Power Drive Systems

1

HELMKE | Power Drive Systems 13

2b

1. Batch delivery of drive systems for the

cement industry. Single source supply and

responsibility, including full logistics support.

2. Fast accessible locations in the heart

of Europe. Benefit from major land,

sea and air transportation nodes nearby:

(a) Headquarters in Sarstedt near Hanover,

Germany and (b) main branch in Pulversheim,

France.

2a

14 HELMKE | Power Drive Systems

Geared Power Drive Systems

Geared PDSs are a cost effective

and reliable technology for applications

featuring speeds of the driven

equipment outside the standard

motor speed envelope. In the heavy

industry in particular the requirements

are for multi-MW power at

either very low speed (mill applications)

or high speed (pump applications)

and push the direct drive

technology to its limits.

Just in the case of unsuitable planning

a disproportionate increase

of equipment cost or substantial

reduction of system reliability is

to be expected. HELMKE experience

has shown that for a technocommercially

optimized design

and utilization of those systems,

a holistic approach on system design

and management is required. As the

sophistication level of production

processes and equipment increases,

HELMKE tackles the challenge by

both deepening and expanding the

experience and know-how from

different application areas. We are

in position to mobilize engineering

and project management resources

and specific expertise, in order to

provide holistic management and

respective technical solutions to

key OEMs and end-customers:

Planning and engineering of geared

PDSs, from the electrical power

supply to the driven equipment

point of coupling.

Equipment procurement and

manufacturing, including:

• Controlled drive motors

• Gearboxes

• Safety clutches and transmission

couplings

Test, certification, equipment packaging:

System delivery in turn-key

configuration and according to the

technical specification.

Equipment commissioning and lifetime

service: We remain your single

source supplier well after the system

is put into service.

Single source supplier

for Geared Power Drive Systems

Supplying the complete mechanical

transmission chain, from the motor

up to the driven machine shaft.

Custom engineered foundation skid for

application in a geared power train.

HELMKE | Power Drive Systems 15

Industrial market

Oil and gas

• PDSs with speed-up gearboxes,

driving pump and compressor

applications

Cement, sugar, steel, mines and

minerals, paper, rubber, plastic,

solvent extraction as well as power

generation

• PDSs with helical speed-down

gearboxes, driving agitators,

conveyors, crushers, cranes,

mixers, aerators, roller presses

and ball mills

• PDSs with bevel helical gearboxes,

driving conveyors, bucket elevators,

toasters, mixers, cooling

towers and vertical mills

At the high end of power range,

the below system diagram offers

an insight to our particular product

offerings for the cement industry:

Expanding the application envelope

though step-up and step-down gear boxes

Our offerings for the industrial market

are sorted based on the gearbox type.

To girth gear

8. Pinion shaft coupling

All steel coupling,

supporting:

1. 1000 mm shaft

distance between

the gear box and

the pinion shaft

2. Large diameter of

the pinion shaft

4. Motor coupling

Flexible pin coupling

7. Overrunning clutch

Operated by lever

5. Main gearbox

Single stage helical

gearbox for main mill

girth gear

Output speed

= 200 rpm

6. Auxiliary gearbox

Helical gearbox

Output speed

= 9,2 rpm

3. Auxiliary motor

HELMKE Plus

3-phase squirrel cage

induction motor

22 kW, 400 V, 50 Hz, 4-pole

Auxiliary Power Drive System

Main Power Drive System

1. Main motor

HELMKE Pro

3-phase slipring motor

2.250 kW, 11 kV, 50 Hz, 994 rpm

IC611 cooling

2. Liquid rotor starter

3-phase liquid starter

16 HELMKE | Power Drive Systems

Solutions. Tested.

Performance tests are an integral

part of quality assurance in the

development and production process

of electrical machines and

drive systems.

To meet the ever increasing demand

of the market and our customers,

the HELMKE Group is operating

three testing fields for full load

testing up to the power of 6 MW.

Site Pulversheim

(France, near Mulhouse)

Two load testing fields for low/high

voltage machines and drives:

• Power of max. 6 MW and max.

1,5 MW respectively

• Max. torque of 120 kNm for speeds

up to 500 rpm

• AC voltage for equipment under

test up to 33 kV

• Supply frequency – standard value

50 / 60 Hz (other frequency values

on request)

• Maximum speed 4.000 rpm

• Self-contained water cooling

circuits for machines and converters

under test having a re-cooling

power of 330 kW.

Site Sarstedt

(near Hannover)

No-load testing field for low/high

voltage machines and drives:

• Up to 2 MW motor nominal power

• Supply voltage 0–100 % free

setting – output steps 690 V /

2 kV / 7 kV / 12 kV

• Supply voltage 0–60 Hz, free

setting

Load testing field for low voltage

machines and drives:

• Nominal power 315 kW

• Supply voltages up to 400 / 550 /

690 V, 50 Hz

• Max. speed 3.000 rpm

• Max. torque 2 kNm

Testing fields of the HELMKE group up to 6 MW

For complete Power Drive Systems.

HELMKE | Power Drive Systems 17

1

4

1. 315 kW load testing field in Germany

Sarstedt. Norm motor under load test for

the purpose of calibrating its load performance

curves.

2. 6 MW load testing field in Pulversheim,

France. VFD and motor system under full

load string test prior to end-customer

delivery.

3. No load testing field for electrical machines

and power electronic converters in

Sarstedt, Germany.

4. Control room of the 6 MW load testing field.

Superordinate control system designed

with adaptability and functional safety

in focus.

2

3

18 HELMKE | Power Drive Systems

Solutions. Tested.

In addition to the realization of

tests for own development-needs

and customer orders, HELMKE

allocates its testing fields to third

parties. HELMKE is a worldwide

known and established authority

for testing services, especially in

the field of drive systems in the

oil and gas industry.

For more information on testing

services, please visit our website.

HELMKE testing services

• Type and routine tests of electrical

machines and PDSs acc. to national

and international standards

• Acceptance tests in the presence

of the customer acc. to common

standards and customer-specific

quality specification

• Prototype and pre-series tests

of single components or complete

PDSs (integration of customer

specific measurement systems

if required)

• R & D testing and experimental

validation for full PDSs: Vibration

and sound pressure level measurement,

testing under emulated

operational transients and faults

Both testing field sites incorporate

state-of-the-art, Fieldbus based,

modular and programmable test

equipment for the measurement

of electrical and mechanical parameters.

Dedicated support for your testing projects

We are your partner for product development,

testing, certification and modification

of the test objects. We take over logistics

and project management.

HELMKE | Power Drive Systems 19

20 HELMKE | Power Drive Systems

References

HELMKE has extensive experience

and know-how on EPC projects for

complete drive systems in the heavy

industry. Reliable Motor and Drives

technology, engineered by HELMKE,

is today established as a premium

professional solution among key

OEMs and end-customers when it

comes to the strategic expansion

or modernization of their products

and equipment.

Today, HELMKE leads the successful

business development of industries

around the globe, providing

full responsibility and EPC project

support within large scale constructional

projects for a broad range

of market sectors:

• Cement

• Petrochemicals

• Mining

• Power generation

• Air separation

• Pulp and paper

• Metal

• Glass

• Water treatment

• Sugar

Our references of successful PDS

deliveries cover all main applications

(types of driven equipment) for

those industries, respectively a variety

of technical products.

HELMKE experience and know-how

Project management. Drive Systems. Testing.

Turn-key project delivered to end-customer:

Site installation of fully containerized drive

system for the air separation industry.

HELMKE | Power Drive Systems 21

Raw mill (ball mill) drive for the cement industry / end-customer in Sri Lanka

HV slipring induction motor

• 1.000 kW, 8-pole

• Stator: 3,3 kV, 50 Hz, 212 A

• Rotor: 1.180 V, 520 A

• Engineered with second shaft-end

for auxiliary drive

• Engineered with redundant

vibration sensors and Shock Pulse

Method (SPM) nipples at DE/NDE

sides

Integrated auxiliary drive:

Pony motor and gearbox

• 45 kW

• Speed, Motor side: 1.478 rpm /

Output side: 29 rpm

• Integrated to the main drive motor,

both installed on custom-built

base frame

• Elastic pin and tooth couplings

Liquid resistor starter

• Engineered for 4 consecutive

motor starts at full load

• Engineered with inverter-supplied

motorized-contacts drive for the

free parameterization of the main

motor starting characteristics

Power factor compensation

capacitors bank

• 300 kVAr / 3 × 3,3 kV, 50 Hz,

delivering 0,95 power factor at the

motor terminals

• Integrated 1 × 3-phase air core

inrush reactor

• Integrated 3 × 7,2 kV fuses with

release signalling

• Rated lightning impulse withstand

voltage 1,2 / 50 μs: 40 kV

22 HELMKE | Power Drive Systems

Ventilator drive / German OEM

Kiln filter drive / end-customer in Ukraine

Kiln drive – 270 kW / German OEM

Dry type cast-resin step-down

power transformer for converter

operation

• 1.000 kVA

• 6 kV / 2 × 710 V

Voltage source frequency converter

• 690 V, 850 A

• 2 × 3-phase / 12-pulse on the

mains side

• 3-phase on the motor side

• Harmonic reactor filter and

EMV-filter for Cat. C3-environment

acc. to EN 61800-3

Dry type cast-resin step-down

transformer for converter operation

• 1.600 kVA

• 6 kV / 2 × 720 V

Dry type cast-resin step-down

transformer

• 500 kVA

• 6 kV / 710 V

Squirrel cage induction motor ready

for converter duty

• 720 kW, 690 V, 50 Hz, 950 rpm

Voltage source frequency converter

• 720 V, 1.208 A

• 2 × 3-phase / 12-pulse on the

mains side

• 3-phase on the motor side

• Installed on modified cabinet for

duct cooling air supply

Voltage source frequency converter

• 690 V, 700 A

• Earth leakage protection

• Motorized circuit breaker with

under-voltage release

• du/dt filter for the reduction of

the winding insulation stress

• Common mode filter

Squirrel cage induction motor ready

for converter duty

• 973 kW, 660 V, 50 Hz, 990 rpm

Squirrel cage induction motor ready

for converter duty

• 270 kW, 690 V, 50 Hz, 1.488 rpm

References

HELMKE | Power Drive Systems 23

Kiln drive – 600 kW / German OEM

Roller press – single motor drive / German OEM

Roller press – dual motor drive / German OEM

Oil immersed step-down transformer

• 1.600 kVA

• 6 kV / 2 × 710 V

Voltage source frequency converter

• 690 V, 1.258 A

• 2 × 3-phase / 12-pulse on the

mains side

• 3-phase on the motor side

• Harmonic reactor filter and

EMV-filter for Cat. C3-environment

acc. to EN 61800-3

Current source inverter drive

• 4.160 V, 60 Hz, 215 A

• 6,5 kV Symmetrical Gate Commutated

Thyristor (SGCT) power

semiconductors for low components

count and high reliability

• Sensorless vector control with

inherent regenerative braking

capability

Oil immersed step down transformer

• 3.000 kVA

• 6,3 kV / 2 × 710 V

Squirrel cage induction motor ready

for converter duty

• 600 kW, 690 V, 50 Hz, 1.492 rpm

HV squirrel cage induction motor

ready for converter duty

• 1.150 kW, 4 kV, 60 Hz, 1.790 rpm

Voltage source frequency converter

• Driving 2 motors (dual drive)

• Automatic load balancing of the

driven machines

• 690 V, 2 × 1.650 A

2 × squirrel cage induction motor

ready for converter duty

• 1.250 kW, 660 V, 50 Hz, 995 rpm

24 HELMKE | Power Drive Systems

Crusher Drive / German OEM

Vertical mill drive for the cement industry / German OEM

Raw mill (ball mill) drive for the cement industry / German OEM

Squirrel cage induction motor

• 110 KW, 380 V, 50 Hz, 988 rpm

• Engineered for extended ambient

temperature range, down to

–40°C

• Engineered with reinforced

bearing system

HV slipring induction motor

• 1.000 kW

• Stator: 6 KV, 50 Hz, 123 A

• Rotor: 720 V, 840 A

HV slipring induction motor

• 5.600 kW

• Stator: 6,3 kV, 50 Hz, 605 A

• Rotor: 2.107 V, 1587 A

• Engineered with redundant

winding and vibration monitoring

sensors, acc. to the OEM specification

• Safety coupling

Liquid starter

• Engineered for configurable

starting time through inverter

driven, motorized moving contacts

• Engineered for higher number of

consecutive starts

Liquid resistor starter

• Electrolyte temperature monitoring

and automatic trip

• Designed for up to 3 consecutive

starts

References

HELMKE | Power Drive Systems 25

Three-phase slipring motor for a coal mill drive

Separator drive / German OEM

Dryer drive for the paper and pulp industry / end-customer in Germany

ATEX certified squirrel cage induction

motor

• HELMKE motor type

SDSKK630-06

• Ex-Protection Ex II 3D Ex tc III

BT150 °C IP55 (Zone/Area 22)

Oil immersed step down transformer

• 500 kVA

• 6 kV / 710 V

Voltage source frequency converter

• 2 × 690 V, 1.774 A

• 2 × 3-phase / 12-pulse on the

mains side

• 6-pulse / 3-phase on the motor

side

• 1.400 kW

• 11.000 V; ± 10 %; 50 Hz; ± 2 %

• 993 rpm, (6-poles)

• IM B3, IP 55, IC 611

Voltage source frequency converter

• 690 V, 430 A

• Engineered for controlled motor

braking through braking chopper

and braking resistor installed in

additional IP20 cabinet

• User interface / LCD-panel

parameterization for multiple user

access

• du/dt filter for the reduction of

the winding insulation stress

• DTC, Vector and Scalar control

modes preconfigured for on-site

use

Squirrel cage induction motor ready

for converter duty

• 316 kW, 690 V, 50 Hz, 1.488 rpm

Squirrel cage induction motor ready

for converter duty

• 1.278 kW, 690 V, 50 Hz, 990 rpm

26 HELMKE | Power Drive Systems

Fan drive for the paper and pulp industry / end-customer in Germany

Mill drive for the sugar industry / end-customer in Senegal

Constant torque pump drive for hazardous environments / German OEM

Voltage source frequency converter

• 690 V, 2.865 A

• 4Q-regenerative drive execution

• Engineered with aux. temperature

controlled output for the supply of

motor auxiliaries

MV voltage source frequency

converter

• 18 pulse input diode rectifier

• 3,3 kV, 315 A Multilevel-IGBT-drive

• Modular cabinet design, integrated

input transformer, cell inverter

modules and control section

Voltage source frequency converter

• 380 V, 602 A

Squirrel cage induction motor ready

for converter duty

• 2.700 kW, 690 V, 50 Hz, 996 rpm

• Built-in surge arrestors on the

PT100 temperature sensor

terminals

HV squirrel cage induction motor

ready for converter duty

• 850 kW, 3.300 V, 50 Hz, 187 A

Squirrel cage induction motor

• ATEX certified Ex de IIB T4

• Ready for converter duty

References

HELMKE | Power Drive Systems 27

Pump drive with active front end / German OEM

Fully containerized screw compressor drive / end-customer in Germany

Switchgear cabinet for the incoming

field

• 3 automatic circuit breakers 400 V,

5.000 A

• Supervision and protection devices:

• Earth fault

• Over-temperature

• Emergency off button

• Measurement devices: Current,

voltage and power measures

Dry type cast-resin step-down

transformer

• 2.000 kVA

• 6.000 V / 700 V

• Fully containerized transformer

station made of armed concrete

Dry type cast-resin LV transformer

• 3.150 kVA

• 400 V / 690 V

Voltage source frequency converter

• 690 V, 2.770 A

• Active front end offering unlimited

4Q operation and close to unity

power factor

Voltage source frequency converter

• 690 V / 1.774 A

Squirrel cage induction motor ready

for converter duty

• 2.500 kW, 660 V, 60 Hz, 1.194 rpm

Squirrel cage induction motor ready

for converter duty

• 1.700 kW, 690 V, 120 Hz, 3.600 rpm

• Optimized water cooling for

minimum noise emissions

• Supplied along with rigid mounting

frame with anti-vibration

fittings