Binay OVERHEAD CRANE BUSBAR POWER INDICATOR (DSL/CRS) UTILISING LIGHT EMITTING DIODES (LEDs)

The Binay LED Crane Power Indicator is a vibration-resistant, solid-state unit which provides a MAINTENANCE-FREE 'fit-and-forget' solution for busbar power indication in overhead cranes

In overhead cranes, it is mandatory to indicate the ener-gised status of the supply on the adjacent busbar. To en-able visibility at a distance this is normally done by means of 100-watt filament bulbs.

The obligatory safety requirement in plants of Russian ori-gin (such as Bokaro, Bhilai, and Vishakhapatnam) calls for such 3-phase indication to be provided at distances of every 10 to 20 metres throughout the length of the shed. However, the fragile filament of the conventional incandes-cent bulb is unable to withstand the extreme shock and vibration which is present due to the movement of these cranes, and consequently these bulbs fail very frequently. This is extremely hazardous, as the fused and unlit bulb can give an incorrect indication, causing confusion and creating a potentially dangerous and unsafe condition for personnel. Moreover, the changing of these bulbs at the extreme heights of the busbars is a cumbersome and hazardous procedure.

BINAY has developed unique long-life, maintenance-free, shock-proof and vibration-resistant crane Indica-tor units (DSL/CRS) using LEDs. LEDs being solid-state devices are impervious to vibration; they also offer the fol-lowing additional advantages:
  • A long life of 1,00,000 hours (11 years on a continu-ous burning basis, thus requiring no further re-placement once fitted; BINAY guarantee for three years against manufacturing defect failure)
  • Low power consumption (as a result of our patented circuitry), greatly reducing energy costs
  • Ability to withstand an input voltage variation of up to 25 percent (which normally occurs on the starting and stopping of crane motors)
  • Solid-state reliability
  • A short payback period
These units are available in two models:

Omni Type: This provides all-round visibility and greater clarity at a distance, as high intensity LEDs are mounted in a circular configuration (see figure 1). These LED arrays are affixed in circular black oxidised or chrome-plated brass modules, with polycarbonate fire-retardant lenses in different colours (such as RYB or RYG) for AC phase identification. Normally, three such units are vertically mounted on a rust-proof frame, which can be fixed on a suitable support in front of the running busbar at appropri-ate distances. Visibility is assured to be within 30 meters at the sides, when the unit is mounted at a height 10 to 15 meters above ground level.

Approximate dimensions for the Omni Type are: 63cm (Height) x 9cm (Width) x 12cm (Depth at the maximum point).

Ordering specification: "BINAY DSL/CRS Unit with three metal body fire-retardant circular modules consisting of LED arrays (visibility 30 meters), in chrome-plated brass body mounted on rust-proof vertically mountable base plate. Wattage with LEDs in two equally spaced parallel circuits is 1 watt max. Available in red, green or yellow. Life: 11 years. "

N.B. While the conventional colour coding of 3-phase indications is red, yellow and blue (RYB), at present, blue LEDs are extremely ex-pensive; as such, many users prefer green in place of blue. How-ever, if required, we can supply blue units to comply with the RYB standard.

Panel Type: This model is a simpler version, and has lim-ited visibility on the sides while providing greater axial visi-bility (see figure 2). It consists of three DIN-sized LED Ma-trix Annunciator windows (each of size 96mm x 96mm) in different colours (such as RYB or RYG) as light sources. The life of such units is 11 years continuous burning.

Approximate dimensions for the Panel Type are: 69cm (Height) x 14cm (Width) x 36cm (Depth at the maximum point).

For both the Omni and the Panel Type, power connec-tions are made to four input terminals (one common neu-tral, and three phase lines) mounted at the base of the unit (If desired, three MCB units can also be provided in-stead). These units can be supplied in 110V, 240V or 415 volts AC; or 220V or 440V 3-wire DC. A Low Voltage Glow Protection (LVGP) circuit can also be incorporated, if de-sired, to prevent the LEDs from giving a false indication at leakage input voltages.

These LED DSL/CRS units are extremely economical if the following facts are considered:
  • Saving in electricity, as low-wattage LED modules re-place 3 x 100-watt bulbs. This can result in a saving of nearly Rs. 15,000.00 per annum in electricity charges alone
  • Saving in the cost of physical replacement of the failed filament bulb
  • Safety and reliability, resulting from elimination of random bulb failure
  • Saving in the cost of replacing more than 24 bulbs over a 12-month period - this can amount to as much as Rs. 250.00 per annum (normal life of a filament bulb is 1000 hours in an ideal, vibration-free condition, burning 24 hours a day).
  • Safety and reliability, resulting from the elimination of random bulb failure
THE BINAY LED DSL/CRS DESIGN IS PATENTED (PENDING), AND AS SUCH IS A PROPRIETARY PRODUCT