Wood’s@Work

W i n t e r 2 0 0 3 • V o l u m e 6
Wood’s@Work
®
TB Wood’s —
A Sure Bet in Las Vegas
E-trAC,WFCHT & WF2
Something to Crow About
TBWOODS.COM
Changing to Meet Your Needs
Powering Your Success

Wood’s@Work
®
All In a Day’s Work
Michael Hurt
President
New Products For
More Wood’s @ Work
Success In 2003
In 2002 we introduced new products to
offer more opportunities to put “Wood’s
@ Work”. We added to our product portfolio
a broad line of gearmotor and gear
reducer products, and a new line of E-
traAC ® EF1 Microdrives. These new products
combined with our existing AC drive
products and broad mechanical product
offerings of belted drives and couplings
should offer many more opportunities to
put “Wood’s@Work.”
As we leave 2002 and move into 2003, I think it’s
worth reflecting on the past 12 months. From a
revenue growth perspective, 2002 was a disappointing
year for TB Wood’s. We continued to see
soft demand due to the sluggish industrial economy.
However, we remained committed to our
business strategy consisting of these key elements:
1. Aggressively develop new and differentiated
products and services
2. Serving our selective distribution partners with
excellence
3. Drive for continuous cost reductions and efficiency
improvements
4. Make accretive strategic acquisitions
Continuing our tradition of bringing you new and
differentiated products, we remained committed to
Our drive
churns through
a blizzard of
gizzards
Chickens are peculiar birds. In order to
better digest their food, they eat small pebbles.These
pebbles wind up in the chicken’s
gizzard. Grinding up the pebbles with the
gizzards for use in animal food can dull the
blades of the gizzard harvester, but more
importantly, in the manufacture of humangrade
food, the ground pebbles are not
acceptable by either the food processor or
the FDA.
“TB Wood’s chicken and poultry manufacturing
clients use the NSF Series ® WF2 controller
to sense the load, pause when the
load indicates pebbles, then change direction
so they can be
removed,” explains
Curtis Litten,
applications
manager for TB
Wood’s. “After the
pause to remove the objects, the program
restarts and resets to continue the process.”
The key to the TB Wood’s gizzard harvester
solution is a standard program sequencer
feature in WF2 software.
A Programmable Logic Control (PLC) miniprogram
in the WF2 software allows the
operator to set a sequence of timed operational
steps.
For example, in step one in the gizzard harvester
program, the drive is set at a desired
production speed. If a stone or pebble is
sensed, the drive shifts to the second step in
the sequence and stops.
In the third step, Litten says, the drive is
reversed so the operator can spot the foreign
matter and remove it.
Finally, after pausing the assigned length of
time, the program cycles to the beginning
of the sequence and restarts the production
process.The sequence program runs continuously
throughout the production day.
“Because TB Wood’s builds the sequencing
program right into the drive it doesn’t need
to be added on as an extra piece of equipment.This
is a major difference between the
Wood’s design and competitive products. It
means we can save our clients 15% to 20%
over the cost of competitive systems,”
Litten states.
As the saying goes, that ain’t chicken feed.
Continued on inside back cover.
W i n t e r 2 0 0 3 • V o l u m e 6

Power Tools
Adding to your
sales momentum
At TB Wood’s, we’re doing our part to educate
your customers about our well-engineered
products, worldwide reputation and
well respected brand. Our 2003 advertising
schedule is designed to support your own
advertising efforts in both the electrical and
mechanical markets. Throughout the next
year, we’ll be advertising the TB Wood’s
brand and family of products in a targeted
group of electrical and mechanical engineering
trade publications.
To help customers find you, each ad will
contain our Web site address. On our site,
prospects can locate the TB Wood’s distributor
closest to them.
Look for our ads in these top tier industry
publications: New Equipment Design,
Motion System Design, Food Processing,
Machine Design, and Industrial Distribution.
The TB Wood’s Web site
is being revised and new
features will begin
appearing early in 2003.
TBWOODS.COM changing
to meet your needs
Our 2003 ads will be running in these trade
publications to increase awareness of TB Wood's
products and to direct customers to you.
After extensive review of TBWOODS.COM,
the company’s Web Advisory Committee
(WAC) recommended a major overhaul of
the look, feel and functionality of the Web
site.
“The redesigned TBWOODS.COM will be
a huge improvement over the old site,” said
Tracey Schroder, marketing services manager.
“WAC focused on improving the site for our
distributors. We took our time and carefully
reviewed not only how the site looked, but
how it functioned and, most importantly,
how distributors would use this valuable
tool.”
Many of WAC’s recommendations came
from a focus group that included Wood’s distributors,
outside consultants and representatives
from Wood’s sales, marketing, engineering,
production and information services
departments. They carefully reviewed the
site, screen-by-screen.
Based on what was learned in the focus
group, the site will be redesigned with new
enhancements starting to appear in the first
quarter. Look for the most requested
upgrade – Wood’s@Work ® application stories
that will be archived in a password protected
distributor-only area.
W i n t e r 2 0 0 3 • V o l u m e 6

POWER
SOLUTIONS
GoodNews
Patience, Professionalism
Lead to The Big Sale
by Arnie Colbert
To make a big sale, I believe you have to
know the customer’s product and
process as well as you know your own
product. You have to look at how they’re
doing things now and figure out how
Wood’s products can make business
easier and better for them. You need
to be able to offer a Wood’s solution to
their problems and to their customers’
problems.
That’s how we landed the Goulds Pump
account in Seneca Falls, NY. We worked
with them for five years, calling on them
about every two weeks before I finally
sold the account. Closing that sale
helped me win the TB Wood’s Electronic
Charge Award in 2002. That honor goes
to the person who has done the most
each year to promote the electronics
portion of Wood’s business. I’m really
proud to have received it this year.
I’m proof, I guess, that some really worthwhile
sales in this industry can take time.
I’ve been with Wood’s for seven years,
working as an automation sales engineer
until I moved to the OEM division as an
account manager. During my sales
career, I’ve learned good customer relationships
are built on simple but important
things: being on time, being professional,
being responsive to customer
needs and problems, and listening to customers
to learn what they need. If you
do that, and persistently call on them,
you can learn enough to offer valuable
solutions to them. Then you’ll be there
with the answer when the contract
comes up.
Arnie Colbert is OAM for TB Wood’s North Central and
Northeast sales regions.
It’s a sure bet: Wood’s
solution adds bottom
line energy savings
Air handlers in Las Vegas casinos never get a
day off. “This city runs on gambling,” says
Larry Carruthers, sales rep for Aztec
Industrial Bearing and Supply, a TB Wood’s
distributor. “If you have a high roller playing
blackjack and the air conditioning shuts
down, a casino can lose untold dollars.These
systems have to work 24/7, year after year.”
Last summer Aztec got the chance to
redesign and replace 80 primary air handlers
at the Rio All-Suite Hotel and Casino and
the Rio was the big winner.The TB Wood’s
E-Flow adjustable speed drive packages lowered
the casino’s energy costs with a
dependable, better engineered approach.
This playground known as Las Vegas, Nevada
The TB Wood’s E-Flow
System lowered the
casino’s energy costs with
a dependable,
better engineered
new approach.
is the fastest growing city in the United
States. Along with this growth has come a
substantial increase in electrical energy useage.
The hotel and casino industry has been
under the gun to find creative ways to save
energy. Air handlers are the primary consumers
of electrical energy in any hotel and
casino. Aztec Industrial Bearing, saw an
opportunity to help with this cause.
The TB Woods’ solution began with Larry
Carruthers. He understood the Rio’s needs
and knew the new air handler design had
to be:
Reliable: Each component had to be well-
engineered and durable enough to stand up
to unrelenting use.
Energy efficient: The desert environment
is extreme with summer temperatures that
can hover over 100 degrees for days. Since
the cost per kilowatt-hour in Las Vegas is
high, each handler needs to provide the maximum
cooling for the least amount of energy.
Low maintenance: Wear and tear on individual
components in the system needed to
be minimized.The need to continually replace
parts or components could eat up any energy
savings.
Air flow before TB Wood’s
“The Rio air handlers were using discharge
dampers to control the air flow,” Rusty
Heller,TB Wood’s Western Regional Manager,
remembers.The old handler used a 40HP
1750-RPM motor with a V-belt to drive a
centrifugal fan.That energy-eating fan ran at a
constant speed 24-hours a day. When more
airflow was needed, a signal from the transducer
opened the discharge dampers allowing
additional air flow.
“This was a very inefficient system,” Heller
explains. “The fan
was a constant
energy drain and
maintaining the
fan and the discharge
dampers
was a maintenance
headache.”
Rusty Heller
The TB Wood’s solution
Aztec solved the Rio’s problem by installing a
TB Wood’s E-Flow adjustable speed drive
package that matched the speed of the fan
W i n t e r 2 0 0 3 • V o l u m e 6

motor to the demand for the air flow.The
discharge dampers are left wide open all the
time, saving wear and tear on these mechanical
devices. Using the TB Wood’s E-Flow
design, a transducer that measures pressure
in the air ducts, converts this variable to a
0 – 10V reference signal.This reference signal
is fed to the E-Flow variable frequency drive
which matches the speed of the motor to
the required air flow.
The TB Wood’s designed system also included
synchronous-belted drives in place of the
old V-belt drives.The synchronous belt transfers
power more efficiently saving additional
energy, making a maintenance-free solution
that runs at 98% efficiency all the time. A
typical V-belt drive runs at 93% at best and
this is rarely the case.
Pay out
“How much energy savings the casino will
realize from the new air handling system
depends, of course, on a lot of factors,”
Carruthers cautions. “It’s affected by the outside
temperature, the humidity and how
many people are in the building, for instance.”
Still, he conservatively estimates that modifying
80 of the 123 air handlers with TB
Wood’s products could easily cut the Rio’s
air handling energy cost by 25% the first year.
(The remaining handlers are fractional HP
units and were not part of the redesigned
system.)
The TB Wood’s difference
The experts at TB Wood’s worked in partnership
with Aztec and Carruthers to engineer
and customize the air handler systems
to the Rio’s specific needs.
“Rusty Heller (TB Wood’s western regional
manager) was very helpful in designing the
electronics for each air handler,” Carruthers
says. Using TB Wood’s computer programs,
Carruthers was able to choose the appropriate
synchronous drive for each handler.
Heller also directed the TB Wood’s factory
to pack all the components for each Rio air
handler as a unit. Instead of 400 individual
parts arriving at the Rio to be sorted out,
the components for each air handler arrived
in one box. Installation went very smoothly,
Carruthers says.
“TB Wood’s was our first choice for this job.
Their equipment is durable, dependable and
lasts a long time,” says Carruthers, summing
up his satisfaction with the job.“They gave
us great personal service. We’ve had a
profitable relationship with TB Wood’s for
over 30 years.They’ve earned our trust and
our business.”
WFC HT & E-Flow controls one of the 80 primary
air handlers at the Rio.
Typical Energy Consumption of a
Centrifugal Fan System
Using Selected Speed Control Techniques *
Synchronous drives are 98% efficient and are
maintenance free.
Energy savings based on
laws of physics
The Affinity Law of Physics says:
Horsepower varies with
the cube of the speed.
Eddy Current Drive Hi SH
Eddy Current Drive OSH
Discharge Damper
Variable Frequency Drive
Variable Inlet Vanes
*Electric Power Research Institute's (EPRI) ASD Demonstration Office
It works like this.
If the TB Wood’s design and equipment could slow
down the average speed of the centrifugal fan by
20%, theoretically, the energy needed to run the
fan would be cut in half. That’s saving 50¢ of every
energy dollar.
If the average speed of the fan could be slowed
down by 50%, theoretically, only 1/8th as much
energy would be needed to operate the fan.
That’s saving 78 1 /2¢ of every energy dollar.
W i n t e r 2 0 0 3 • V o l u m e 6

TECH
Corner
Calendar
of Events
Something to Crow About
By Curtis Litten
The Thanksgiving holiday has just passed
and the last thing most of us were thinking
about was the processing of the large
stuffed bird on our table. It was something
we took for granted. However, for us at TB
Wood’s, poultry processing is an industry
we never take lightly. For many years,
Wood’s drives have been the drive of
choice by many poultry processing facilities.
With simple programming and a robust
enclosure, we had the right stuff to pluck
the competition out of the market.
The E-trAC‚ WFCHT and WF2 series of
drives have specific features that allow
them to excel in the food processing industry.
Looking at specific applications such as
the conveying system, the kill line, and the
automated plucking machines, the E-trAC
series of AC drives has proven time and
again to be the right choice. As illustrated
in the story about the Rio Casino in this
issue of Wood’s@Work ® , the standard features
of our drives allow them to do more
with less energy.
For example, in a typical conveying system
the “birds” are hung from shackles suspended
from a chain conveyor.The application
basics are not difficult, although care in the
sizing and positioning of motors can be a
bit unique from installation to installation in
multi-motor drive systems.The advantage
of variable speed becomes evident when
the process changes in either quantity or
size of birds.This advantage is shared by all
manufacturers of drives in the market.
However, the Wood’s advantage goes way
beyond this. First, with our robust NEMA
4/IP66 enclosure, we can mount the drives
right on the process line and not back in
the control room. Since our enclosure
Continued on next page.
AHR Expo, January 27 - 29, McCormick Place, Chicago, IL.
January 22 - 24, 2003
International Poultry Exposition
Atlanta, GA
The International Poultry Exposition is one
trade show you shouldn’t miss! Every segment
of the poultry and egg industry is represented:
feed milling, live production, hatchery,
processing, further processing, packaging,
commercial egg, marketing, and all.
January 27 - 29, 2003
AHR EXPO
McCormick Place, Chicago, IL
Since 1930, the International Air
Conditioning, Heating, Refrigerating
Exposition has been the leading source for
new HVAC&R equipment, products, components,
systems and services.
W i n t e r 2 0 0 3 • V o l u m e 6
March 17 - 20, 2003
19th International Pump Users
Symposium
Texas A&M University, College Station,Texas
The Pump User Symposium is dedicated
strictly to users of pumping systems.The
technical lectures, short courses, discussion
groups, and user case studies make this the
most valuable trade show in the industry.
May 5 - 9, 2003
TB Wood’s Product Clinic
TB Wood’s Corporate Headquarters
Chambersburg, PA
This is a full week of mechanical and electronic
training.

TECH
Corner
D I D Y O U K N O W . . .
Continued from previous page.
meets the National Sanitation Foundation (NSF)
standards, we have raised the bar in environmental
protection. Our WF2 NSF drive can
handle worse conditions and higher washdown
pressures than any other drive. Few, if any, competitive
drives can handle this difficult environment
and live to tell about it.
Another advantage we provide is single control
source operation. Rather than adding all kinds of
peripheral devices, we let the drive handle the
application alone. Unfortunately, chain conveyors
can bind. One of those little cluckers getting
loose can shut a line down for extended time if
the mechanical shear pin on the chain drive
breaks. With our electronic shear pin function,
resetting the drive is only a button press away.
Downtime is cut considerably. And with the
WF2 series, there is no need to worry about
difficult starting loads tripping the drive.This
fault can be generated if the starting load on
the chain is high. The WF2 has the capability to
delay the sensing circuit for the trip until the
drive is up to speed to allow for the distinction
between starting and binding.
Customizable display functions also have been a
favorite in the industry. Our customers are not
processing “Frequency” or “RPMs.” By allowing
the display to be changed to a unit such as BPM
(Birds Per Minute), the operator can run the
process to his criteria, not ours. Simple ratio
programming can be accomplished to allow the
drive to suit each application need.
Just think, we didn’t even discuss the pluckers or
slicers. Both machines are perfect for variable
speed. Varying the speed of the plucking
machine helps with both quality and quantity.
The starting and stopping duty cycle of the
slicers screams for an AC drive. Packaging and
freezing systems also use quite a few variable
speed drives. The opportunities are endless, but
the solution is one place…TB Wood’s E-trAC
AC drives.
Curtis R. Litten is Application Manager for TB Wood’s Incorporated.
Do you know what it takes to design a modern AC Drive like the
WF2 Sensorless Vector Drive?
• 1 to 2 years design time is needed from specification to production
• 6 or more unique technologies are needed to produce the custom
parts inside the drive
• 6 different processes are
needed to build the drive
• 1200 parts are used in each
drive
• 3 levels of testing are done on
the subassemblies and final drive
Continued from inside front cover.
New Products For More Wood’s @ Work Success In 2003
funding product development. Operationally, we focused on efficiently running our business with “tight fisted”
cost controls, while making sure that we met the demands of our customers. To ensure cost competitiveness
in the future we began producing selective mechanical products in our new plant at San Luis
Potosi, Mexico. In late 2002, we installed Goldmine software and upgraded our field sales engineers’ laptop
computers to give them enhanced tools to better service our distributor partners and OE customers.
We’re excited about our business as we enter 2003. We’ve strengthened our balance sheet and maintained
our profitability throughout the recession while continuing to invest in our business.
So in 2003, we are ready to put “Wood’s@Work” for you— with more new products.
Michael L. Hurt, President

Powering Your Success
Wood’s@Work is a publication
from TB Wood’s Incorporated.
Comments and subscription
requests should be directed to
Marketing Communications at:
TB Wood’s Incorporated
Chambersburg, PA 17201
Call: 888-TBWOODS
Fax: 717-264-6420
www.tbwoods.com
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