DRIVES & CONTROLS SERVICES, INC. EXCAVATOR ELECTRICAL ... · accomplished by varying dc current to the generator shunt field windings. control of generators with silicon controlled

DRIVES & CONTROLS SERVICES, INC.

EXCAVATOR ELECTRICAL CONTROL SYSTEMS

SAFETY ENHANCEMENTS OF DIGITAL DRIVE

REGULATOR CONTROLS


VISIT US AT DRIVESANDCONTROLS.COM




HIGH HORSEPOWER AC SYNCHRONOUS MOTORS DRIVING LARGE DC GENERATORS.

MOTOR/ GENERATOR“MG SETS”


MG SETS DRIVE LARGE DC MOTORS FOR HOIST, DRAG/CROWD, SWING AND PROPEL MOTION CONTROL


CONTROL OF THE HOIST, DRAG/CROWD, SWING

AND PROPEL MOTIONS IS PROVIDED BY THE

LARGE DC GENERATORS


CONTROL OF THESE GENERATORS IS

ACCOMPLISHED BY VARYING DC CURRENT TO THE

GENERATOR SHUNT FIELD WINDINGS.

CONTROL OF

GENERATORS

WITH SILICON

CONTROLLED

RECTIFIERS

(SCR) DRIVES





SCR DRIVES PROVIDE

CONTROLLED DC

CURRENT TO THE

GENERATOR FIELDS AS

REQUIRED BY THE

SYSTEM REGULATOR





1 2 3 1 2

1 - 23 - 2 1 - 3 2 - 3 2-1 3 - 1 3 - 2 1 - 2

6F

1F

3F

4F

5F

6F

1F

2F

5F

2F



GENERATOR FIELD EXCITATION VOLTAGE

GENERATOR OUTPUTVOLTAGE

TIME

TIME


GENERATOR FIELD EXCITATION VOLTAGE

GENERATOR OUTPUTVOLTAGE

TIME

TIME


SOME SYSTEMS INCORPORATED THE USE OF TWO

GENERATOR FIELD CIRCUITS – ONE FOR EACH

DIRECTION OF MACHINE MOTION

DUAL FIELD

CONTROL

HOIST – LOWER

DRAG – PAYOUT

CROWD – RETRACT

SWING LEFT - RIGHT


DUAL FIELD CONSTRUCTION

SINGLE FIELD CONSTRUCTION


GShunt Field

SeriesField

CommField

PoleFaceBars


G

Shunt Field

SeriesField

CommField

PoleFaceBars


600 V

0 V

300 V

400 V

500 V

PEAKPOWER POINT

VOLTAGE LIMIT

STATIC LIMIT

DYNAMIC LIMITSTATIC + 25%

58% 72%

595 VOLTS

PEAK POWER LOADS MUST NOT EXCEEDTWO MINUTE DURATION

RMS CURRENT MUS NOT EXCEED RATEDCURRENT OVER ANY FIVE MINUTE PERIOD

100 V

200 V

20 40 60 80 100

PERCENT RATED STALL CURRENT

125

110% STALL SETTINGFOR SCR CONTROLLEDEQUIPMENT

RMS CURRENT ON ANY APPLICATIONMUST NOT EXCEED RATED MOTORCURRENT - RESPONSIBILITY FOR WHICHSHOULD BE RECOGNIZED AND ACCEPTEDBY EXCAVATOR BUILDER

STALLFRAME AMPS RPM 804 200 1420 806 300 1245 808 450 1125 810 660 1075 812 860 1025 814 1250 955 816 1670 930 818 2130 820 820 2700 800 822 3600 740 824 4500 700

175

100

50

25

75

125

150

MO

TO

R O

R G

EN

ER

AT

OR

AR

MA

TU

RE

VO

LT

AG

EP

ER

CE

NT

RA

TE

D M

OT

OR

SP

EE

D

EQUIPMENT MANUFACTURERS SPECIFY THE

ELECTRICAL AND

MECHANICAL LIMITS

FOR THE MOTORS

AND GENERATORS

TYPICAL

ELECTRICAL

AND MECHANICAL

LIMITS


100 V

200 V

300 V

400 V

500 V

600 V

MO

TO

R O

R G

EN

ER

AT

OR

AR

MA

TU

RE

VO

LT

AG

E

VOLTAGE LIMIT

STATIC LIMIT

DYNAMIC LIMIT


20 40 60 80 100 125 %

PEAK POWER POINT

THE SYSTEM INTEGRATOR NEEDS TO DESIGN

AN ELECTRICAL CONTROL SYSTEM TO OPERATE

WITHIN THESE ELECTRICAL AND MECHANICAL

LIMITS.

SYSTEM REGULATOR

DESIGN CRITERIA


PE

RC

EN

T R

AT

ED

MO

TO

R S

PE

ED 25

50

75

100

125

150

175


20 40 60 80 100

125 %

MOTOR LIMITSFOR WEAK FIELD

MOTORS AND GENERATORS NEED TO BE

PROTECTED FROM EXCESS VOLTAGE,

CURRENT AND SPEED

THE CONTROL PROVIDES

PROTECTION TO THE

MOTORS AND GENERATORS


OPERATIONAL TESTING CONFIRMS

CONTROL SYSTEM FUNCTIONS

VOLTAGE VS. CURRENT

PLOT SHOWING SYSTEM

OPERATING WITHIN THE

PRESCRIBED ELECTRICAL

LIMITS


DCGENERATOR

PLCAllen Bradley

ControlLogix 5000

SIEMENS6RA70SCR

GENERATORFIELD

EXCITER

OPERATORMASTERSWITCH

AC POWER460 VAC 3 PH

MECHANICALLOAD

VOLTAGE FEEDBACK

CURRENT FEEDBACK

ACSYNC

MOTOR

23 KV TRAIL CABLE POWER

7.2 KV 23 / 7.2 KV TRANSFORMER

CONTROL POWER230 VAC



SIEMENS6RA70

SCR MOTORFIELD EXCITER

SIEMENS6RA70 SCR

SYNC MOTORFIELD EXCITER

7.2 KV/480 VAC AUX POWER TRANSFORMERS

480 VACTO MOTOR CONTROLCENTERS

RESISTORDIVIDERCIRCUIT

DATAFORTHISO/AMPLIFIER

METERINGSHUNT


METERINGSHUNT



METERINGSHUNT


METERINGSHUNT

7.2 KV PT

CURRENT TRANSFORMERS

STARTCO -MOTOR PROTECTION RELAY

FUSEDVACUUM

CONTACTOR

SYNC MOTOR FIELD APPLICATION CONTACTOR

8 KV DISCONNECTSWITCH

23 KV DISCONNECTSWITCH

LIGHTING TRANSFORMER

TO LIGHTINGDIST PANELS

333KVA

333KVA

DCMOTOR




G


G

DCSOURCE


VOLTAGE

CURRENT



GShunt Field

SeriesField

CommField

PoleFaceBars


RESISTANCE

TEMPERATURE

T



G


EARLY CONTROL SYSTEMS INCORPORATED LITTLE

PROTECTION TO THE MOTORS AND GENERATORS

NO PROTECTION FOR:

OVER CURRENT

OVER VOLTAGE

MOTOR OVER SPEED

OVER TEMPERATURE

UNBALANCE

GROUND FAULT

COUPLING FAILURE


TYPICAL FOR A SYSTEM OF THIS DESIGN TO BE

PROTECTED BY FUSES TO THE SCR EXCITER DRIVE


G



REGULATOR CONTROL SYSTEMS WERE MADE UP OF

ELECTRONIC COMPONENT BOARDS (CARDS) AS SUB

ASSEMBLIES


MULTIPLE CARDS REQUIRED MEET THE

ELECTRICAL DESIGN REQUIREMENTS

TYPICAL SCR DRIVE COULD

HAVE UP TO 12 ELECTRONIC

COMPONENT BOARDS

REGULATORS COULD HAVE

UP TO 14 BOARDS PER

MOTION


ELECTRONIC BOARDS WERE INTERCONNECTED

BY BACKPLANE WIRING TO BUILD THE SYSTEMS


WIRE WRAP AND TERMI-POINT CONNECTIONS

BETWEEN ELECTRONIC COMPONENT BOARDS


ELECTRICAL ADJUSTMENTS TO REGULATORS

MADE BY POTENTIOMETERS

“ONE TURN” POTS

DIFFICULT TO ADJUST.

ANALOG REGULATOR

SETTINGS “DRIFT”


MOTOR GENERATOR PROTECTION PROVIDED BY

“WALL OF ELECTRO-MECHANICAL RELAYS”


CONTROL RELAYS FOR SYSTEM COORDINATION


GEN

MOTOR

OPERATIONALAMPLIFIERREGULATOR

SCRGENERATOR FIELD EXCITER

MASTERSWITCH


AC POWER 480 VAC

MECHANICAL LOAD

ROTATING MOTORFIELD EXCITER

VOLTAGE FEEDBACK

CURRENT FEEDBACK

AC

DC

GENERATOR FIELDOVERCURRENT RELAY


ADDITIONAL SPEED AND TORQUE CONTROL OF

THE LARGE DC MOTORS PROVIDED BY ROTATING

DC EXCITER GENERATORS

DC EXCITER

GENERATORS

SUBJECT TO HIGH

MAINTENANCE

OUTPUT DRIFTS

WITH TEMPERATURE



GShunt Field

SeriesField

CommField

PoleFaceBars


DAWN OF A NEW DAY (ERA)


COMPONENTS FOR AND INTEGRATED CONTROL SYSTEM

PLC CONTROL

DIGITAL DRIVES

OPERATOR

INTERFACE

OPERATOR

CONSOLE


DIGITAL DRIVE CONTROLS

MINIMIZE COMPONENT

CARDS

DIGITAL REGISTERS

INSTEAD OF

ADJUSTMENT POTS

INTERNAL PROTECTION


PROGRAMMABLE LOGIC CONTROLLER (PLC)

REPLACES ELECTRO-MECHANICAL RELAYS


ALLOWS FOR GREATER PROTECTION OF MOTOR

GENERATOR EQUIPMENT


CENTRALIZED ACCESS FOR TESTING AND

TROUBLE SHOOTING

COMPREHENSIVE SYSTEM

DOCUMENTATION AND

WORK SPACE


OPERATOR CONSOLE CONSOLIDATES CONTROL

FUNCTIONS –

EMPLOYS

“JOYSTICK”

CONTROLLERS


OPERATOR INTERFACE TERMINAL – MACHINE

STATUS – PRODUCTION RECORDING – FASTER

TROUBLE SHOOTING

INTERFACED WITH

PLC – MONITORS

MACHINE STATUS

CAPABLE OF REMOTE

ACCESS VIA RADIO

LINK



MOTOR CONTROL CENTERS

CONSOLIDATES

CONTROL OF

SUPPORT EQUIPMENT

BLOWERS

FANS

COMPRESSORS

DECK WENCHES


INCORPORATION OF AUXILIARY CONTROLS

SUCH AS THE LUBE SYSTEM

COMMUNICATE TO

OPERATOR

SYSTEM STATUS

FAULTED SYSTEMS

RE-SET CYCLE

TIMERS


DAWN OF A NEW DAY (ERA)

RED SKY AT MORNING……


SYSTEM INTEGRATION:

THE PLC AND DIGITAL DRIVE SYSTEM MUST BE

COORDINATED TO REGULATE AND PROTECT THE

MOTORS AND GENERATORS.


SYSTEM INTEGRATION:




PLC CONTROL VS. DIGITAL DRIVE CONTROL


SYSTEM INTEGRATION:




PLC CONTROL VS. DIGITAL DRIVE CONTROL

In September 1999, NASA said the Mars Climate Orbiter

presumably burned up in the Martian atmosphere because

propulsion engineers failed to convert feet and inches into

meters and centimeters.


SYSTEM PROTECTION:

MOTOR/GENERATOR OVER VOLTAGE

MOTOR/GENERATOR OVER CURRENT

MOTOR OVER SPEED

MOTOR/GENERATOR LOAD UNBALANCE

GROUND FAULT PROTECTION

OVER TEMPERATURE PROTECTION

MECHANICAL COUPLING/GEARING FAILURE


ELECTRICAL START UP AND TESTING

FEEDBACK TOUCH TEST

ISOLATED FEEDBACK SIGNALS

ENCAPSULATED SCR CELLS

NO COMPUTER NEEDED TO TROUBLE

SHOOT DIGITAL DRIVES



GEN

MOTOR

OPERATIONALAMPLIFIERREGULATOR

SCRGENERATOR FIELD EXCITER

MASTERSWITCH


AC POWER 480 VAC

MECHANICAL LOAD

ROTATING MOTORFIELD EXCITER

VOLTAGE FEEDBACK

CURRENT FEEDBACK

AC

DC

GENERATOR FIELDOVERCURRENT RELAY


ELECTRICAL START UP AND TESTING

DIGITAL DRIVES – INTERNAL DIAGNOSTICS

MULTIPLE FEEDBACK – HIGHEST TAKEOVER

PLC VOLTAGE AND CURRENT MONITOR

ONE DIGITAL DRIVE TYPE, SOFTWARE CHANGES


OTHER CONSIDERATIONS:

DUAL GENERATOR FIELD APPLICATIONS

WIRE HARNESS TO DOORS

CIRCULATING CURRENT IN MOTORS/GENERATORS

SINGLE REGULATOR/SCR BRIDGE UNIT


MOTOR FIELD CONTROL:

ROTATING DC GENERATORS FOR MOTOR

FIELD EXCITATION REPLACED BY

DIGITAL DRIVE APPLICATION.

INCREASED PRODUCTION

DECREASE MAINTENANCE


CENTRALIZED ACCESS FOR TESTING AND

TROUBLE SHOOTING

COMPREHENSIVE SYSTEM

DOCUMENTATION AND

WORK SPACE




COMPLIANCE ENGINEERING - The CE marking (also known as CE mark) is a mandatory conformity mark on many products placed on the single market in the European Economic Area(EEA). The CE marking certifies that a product has met EU consumer safety, health or environmental requirements.

http://en.wikipedia.org/w/index.php?title=Conformity_mark&action=edit&redlink=1

http://en.wikipedia.org/wiki/European_Economic_Area












[8H39A] [8H31A]

VOLTAGE FEEDBACK TO DOM IIVOLTAGE TO TEST PANEL

CURRENT FEEDBACKAND TEST PANEL

D1R2

D1R1

[8H25C]

[8H23B]

(DM2A1)

CCW

DM2

(DM2A2)

DG1 DG1C1+

CCW(DG1A2)

(DM1A2)

DM1CW

(DM1A1)

(DG2A2)

DG2+

CCW(DG2A1)

TP

PM1CW

(PM1A1)

(DG1A1)

(PM1A2)

1PCA [8Q]

1DCA [8Q]












1 2 3 1 2

1 - 23 - 2 1 - 3 2 - 3 2-1 3 - 1 3 - 2 1 - 2

6F

1F

3F

4F

5F

6F

1F

2F

5F

2F



DUAL FIELD CONSTRUCTION

SINGLE FIELD CONSTRUCTION








1 2 3 1 2

1 - 23 - 2 1 - 3 2 - 3 2-1 3 - 1 3 - 2 1 - 2

6F

1F

3F

4F

5F

6F

1F

2F

5F

2F




100 VOLTS 100 AMPS

OHM’ LAW I = E / R

R = E / I

R= 1 OHM


100 VOLTS 100 AMPS

OHM’ LAW I = E / R

R = E / I

R= 1 OHM

120 VAC / 1 OHM = 120 AMPS


IMPEDANCE Z = 2 pf L


IMPEDANCE Z = 2 pf L

I = 120 V / 540 OHM = .222 AMP










VISIT US AT DRIVESANDCONTROLS.COM

THANK YOU FOR THIS OPPORTUNITY TO BE

HERE TODAY –

ANY QUESTIONS?

Documents

DRIVES & CONTROLS SERVICES, INC. EXCAVATOR ELECTRICAL ... · accomplished by varying dc current to the generator shunt field windings. control of generators with silicon controlled