Why ZERO GROUND System Solution?

The ZERO GROUND System Solution is a tested, proven and patented method to reduce high frequency ground currents (electrical noise) to zero. These ground currents can and will affect sensitive devices (listed below) causing costly unplanned downtime in VFD/ASD applications. Typically, customers take a trial and error approach to these issues, trying line input/output, emi filters etc, which take time, cost money and are not assured effective. The patented ZERO GROUND System Solution “components” will provide all benefits listed when installed per the patented ZERO GROUND System Solution “method”.

SENSITIVE DEVICES WHICH ARE AFFECTED BY HIGH FREQUENCY GROUND CURRENTS:

Customers using VFD’s who are experiencing sporadic or consistent problems with any of the sensitive devices listed below are likely candidates for the ZERO GROUND System Solution, which will reduce high frequency ground currents (electrical noise) to zero.

• Metal Detectors
• Card Readers
• SERVO Amplifiers
• Proximity Sensors
• Communication Hubs
• Robotic Controls
• Wireless Communications
• Low Voltage Control wiring (0-1mA, 4-20mA, 0-10Vdc, etc.)
• Machine Control Protocols (Devicenet, Profibus, Modbus etc.)
• Video/Security Systems
• Machine Vision Systems
• Flow Sensors

Listed below are additional reasons to consider using the ZERO GROUND System Solution:

1) ALL VFD’s ARE NOT CREATED THE SAME – It is a fact that all VFD’s are not created equal. There is as much difference in the manufacture and quality of VFD’s as there is in Home Stereo Equipment. Not all design theories will be able to regulate their output to the motor as well as others. In any industry today, manufacturers must constantly evaluate component costs in an effort to remain competitive. The prices of VFD’s in the marketplace today are down from where they were. Reducing costs is a required method to maintain and/or gain market share. Cost reductions can affect VFD performance. Today's technology utilizing switching power supplies do not discriminate. Transient phenomenon, both capacitively and inductively coupled, leak indiscriminately into the system and grounds. In applications where several VFD’s are located together in the same environment, these problems can be multiplied accordingly. Variable Frequency Drive controllers produce a wave shape to the motor that is manufactured by the VFD which is known as a Pulse Width Modulated (PWM) Wave. This wave is different than those produced by your local supplier of power (your local Utility). The main difference is that the Utility supplied power is a smooth wavy line with minimal disturbance being generated along its' path and the PWM wave has multiple square edges. It’s the making of these multiple square edges that create the problems. There are manufacturers who have spent many millions of dollars to study the effects of these PWM wave shapes – and learned to reduce their disturbance(s) phenomenon. These problems can be reduced, but not eliminated. The bottom line however is that ALL VFDs create a disturbance along the wave path, therefore a need for ZERO GROUND System Solution.

2) REDUCING MOTOR BEARING CURRENTS (EXTENDING MOTOR LIFE) – ZERO GROUND is conducting joint testing at Baldor Drives & Motors (Ft. Smith, Arkansas) to verify the ZERO GROUND System Solution will reduce and/or eliminate motor bearing currents, thus extending motor life*. The theory behind ZERO GROUNDs’ ability to significantly reduce motor bearing currents was recognized early on, however, was never tested for, due to equipment testing up-front costs. Also, it is possible to run a motor on Utility supplied power for years without incident. It is possible to run a VFD for significant energy savings, and motor without incident also. But take this same application with another VFD in the circuit without taking proper precautions (i.e. installing ZERO GROUND) and the motor bearing could fail in a matter of a couple of months. Bearing Fluting is caused when an electrical discharge occurs between the bearing inner or outer races and the rotating balls.

*For Baldor/ZERO GROUND preliminary test report, please click here.

3) INDUSTRIAL ELECTRICAL DEFFICIENCIES – Today, most manufacturing/business facilities have deficiencies in their Plant Electrical Distribution, and are not aware problems exist. Many plants have older (over ten years old)/outdated electrical systems that need to be upgraded. A once effective electrical system, ten years later, is typically affected by changes over time to the in-house electrical grid. These problems are caused by the addition of new machinery, the installation of switching power supplies, sensitive equipment, changes in electrical service, utility power spikes, surges etc. The chances of a Plants Electrical System having a problem are greater than if it would not.

4) INEFFECTIVE GROUNDS – Meeting all requirements of National Electric Code Sec. 250 is not difficult. Many systems which were initially grounded correctly, no longer meet technical code. Examples include the fact that many cities have replaced aged metallic water supply meter mains with PVC. These metallic mains, which were once effective in providing grounding, no longer can, since PVC is not a conductor. Cities have already moved to correct this. Bonds, where two different types of metal join, corrode. Aged grounds can and will corrode over time.

5) CERTAIN APPLICATIONS NEED PROTECTION MORE THAN OTHERS – It was recognized early on that certain applications need protection more than others. ZERO GROUND does not resolve all issues associated with drives /motors installations and is not recommended for every drive application. However, ZERO GROUND can be successfully used in any application where three phase motors and single phase are utilized, and anywhere EMI/RFI problems are a concern. Recommended candidates for ZERO GROUND systems include, galvanic detectors sensing nuisance alarms, and situations utilizing ultrasonic transducers detecting inaccurate information from liquid flow in piping systems. Currently, installed applications include dairy farms, clean rooms/HVAC, hospitals (i.e.: surgery, intensive care), marinas and where damaging leakage currents are unacceptable. For new or retrofit installations, some recommended applications include: Mining, Water Filtration / Waste Water Treatment, Farms (animal/crop), Pulp and Paper Mills, Glass, Electro-plating, Clean Room Applications, Industrial Applications for Automation/Robotics where AC Servos are being utilized*, continual operation with an ASD where speed and frequency remain fixed for extended periods of time, in addition, Surface / Sub-surface vessels [with onboard switching power supply(s) applications]. Certainly, there are numerous additional applications for this wiring system.

*Sensors determine where servos will be positioned. Noise gives erroneous feedback to the sensors.

The way and time to find out if there is a problem, is NOT when your motor/drive system fails. They will utilize ZERO GROUND System Solution and tell others. Our Beta Sites, successfully operating for over four years, are proof of this and accessible to those considering ZERO GROUND System Solution installations.