drives & controls services, inc. excavator electrical ... · accomplished by varying dc current...
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DRIVES & CONTROLS SERVICES, INC.
EXCAVATOR ELECTRICAL CONTROL SYSTEMS
SAFETY ENHANCEMENTS OF DIGITAL DRIVE
REGULATOR CONTROLS
DRIVES & CONTROLS SERVICES, INC.
VISIT US AT DRIVESANDCONTROLS.COM
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
HIGH HORSEPOWER AC SYNCHRONOUS MOTORS DRIVING LARGE DC GENERATORS.
MOTOR/ GENERATOR“MG SETS”
DRIVES & CONTROLS SERVICES, INC.
MG SETS DRIVE LARGE DC MOTORS FOR HOIST, DRAG/CROWD, SWING AND PROPEL MOTION CONTROL
DRIVES & CONTROLS SERVICES, INC.
CONTROL OF THE HOIST, DRAG/CROWD, SWING
AND PROPEL MOTIONS IS PROVIDED BY THE
LARGE DC GENERATORS
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
CONTROL OF THESE GENERATORS IS
ACCOMPLISHED BY VARYING DC CURRENT TO THE
GENERATOR SHUNT FIELD WINDINGS.
SCR DRIVES PROVIDE
CONTROLLED DC
CURRENT TO THE
GENERATOR FIELDS AS
REQUIRED BY THE
SYSTEM REGULATOR
DRIVES & CONTROLS SERVICES, INC.
CONTROL OF THESE GENERATORS IS
ACCOMPLISHED BY VARYING DC CURRENT TO THE
GENERATOR SHUNT FIELD WINDINGS.
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
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
GENERATOR FIELD EXCITATION VOLTAGE
GENERATOR OUTPUTVOLTAGE
TIME
TIME
DRIVES & CONTROLS SERVICES, INC.
GENERATOR FIELD EXCITATION VOLTAGE
GENERATOR OUTPUTVOLTAGE
TIME
TIME
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
DUAL FIELD CONSTRUCTION
SINGLE FIELD CONSTRUCTION
DRIVES & CONTROLS SERVICES, INC.
GShunt Field
SeriesField
CommField
PoleFaceBars
DRIVES & CONTROLS SERVICES, INC.
G
Shunt Field
SeriesField
CommField
PoleFaceBars
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
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
PERCENT RATED STALL CURRENT
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
DRIVES & CONTROLS SERVICES, INC.
PE
RC
EN
T R
AT
ED
MO
TO
R S
PE
ED 25
50
75
100
125
150
175
PERCENT RATED STALL CURRENT
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
DRIVES & CONTROLS SERVICES, INC.
OPERATIONAL TESTING CONFIRMS
CONTROL SYSTEM FUNCTIONS
VOLTAGE VS. CURRENT
PLOT SHOWING SYSTEM
OPERATING WITHIN THE
PRESCRIBED ELECTRICAL
LIMITS
DRIVES & CONTROLS SERVICES, INC.
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
AC POWER460 VAC 3 PH
AC POWER230 VAC 3 PH
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
DATAFORTHISO/AMPLIFIER
METERINGSHUNT
DATAFORTHISO/AMPLIFIER
DATAFORTHISO/AMPLIFIER
METERINGSHUNT
DATAFORTHISO/AMPLIFIER
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
CONTROL POWER230 VAC
CONTROL POWER230 VAC
DRIVES & CONTROLS SERVICES, INC.
G
DRIVES & CONTROLS SERVICES, INC.
G
DCSOURCE
DRIVES & CONTROLS SERVICES, INC.
VOLTAGE
CURRENT
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
GShunt Field
SeriesField
CommField
PoleFaceBars
DRIVES & CONTROLS SERVICES, INC.
RESISTANCE
TEMPERATURE
T
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
G
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
TYPICAL FOR A SYSTEM OF THIS DESIGN TO BE
PROTECTED BY FUSES TO THE SCR EXCITER DRIVE
DRIVES & CONTROLS SERVICES, INC.
G
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
REGULATOR CONTROL SYSTEMS WERE MADE UP OF
ELECTRONIC COMPONENT BOARDS (CARDS) AS SUB
ASSEMBLIES
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
ELECTRONIC BOARDS WERE INTERCONNECTED
BY BACKPLANE WIRING TO BUILD THE SYSTEMS
DRIVES & CONTROLS SERVICES, INC.
WIRE WRAP AND TERMI-POINT CONNECTIONS
BETWEEN ELECTRONIC COMPONENT BOARDS
DRIVES & CONTROLS SERVICES, INC.
ELECTRICAL ADJUSTMENTS TO REGULATORS
MADE BY POTENTIOMETERS
“ONE TURN” POTS
DIFFICULT TO ADJUST.
ANALOG REGULATOR
SETTINGS “DRIFT”
DRIVES & CONTROLS SERVICES, INC.
MOTOR GENERATOR PROTECTION PROVIDED BY
“WALL OF ELECTRO-MECHANICAL RELAYS”
DRIVES & CONTROLS SERVICES, INC.
CONTROL RELAYS FOR SYSTEM COORDINATION
DRIVES & CONTROLS SERVICES, INC.
GEN
MOTOR
OPERATIONALAMPLIFIERREGULATOR
SCRGENERATOR FIELD EXCITER
MASTERSWITCH
CONTROL POWER120 VAC
AC POWER 480 VAC
MECHANICAL LOAD
ROTATING MOTORFIELD EXCITER
VOLTAGE FEEDBACK
CURRENT FEEDBACK
AC
DC
GENERATOR FIELDOVERCURRENT RELAY
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
GShunt Field
SeriesField
CommField
PoleFaceBars
DRIVES & CONTROLS SERVICES, INC.
DAWN OF A NEW DAY (ERA)
DRIVES & CONTROLS SERVICES, INC.
COMPONENTS FOR AND INTEGRATED CONTROL SYSTEM
PLC CONTROL
DIGITAL DRIVES
OPERATOR
INTERFACE
OPERATOR
CONSOLE
DRIVES & CONTROLS SERVICES, INC.
DIGITAL DRIVE CONTROLS
MINIMIZE COMPONENT
CARDS
DIGITAL REGISTERS
INSTEAD OF
ADJUSTMENT POTS
INTERNAL PROTECTION
DRIVES & CONTROLS SERVICES, INC.
PROGRAMMABLE LOGIC CONTROLLER (PLC)
REPLACES ELECTRO-MECHANICAL RELAYS
DRIVES & CONTROLS SERVICES, INC.
ALLOWS FOR GREATER PROTECTION OF MOTOR
GENERATOR EQUIPMENT
DRIVES & CONTROLS SERVICES, INC.
CENTRALIZED ACCESS FOR TESTING AND
TROUBLE SHOOTING
COMPREHENSIVE SYSTEM
DOCUMENTATION AND
WORK SPACE
DRIVES & CONTROLS SERVICES, INC.
OPERATOR CONSOLE CONSOLIDATES CONTROL
FUNCTIONS –
EMPLOYS
“JOYSTICK”
CONTROLLERS
DRIVES & CONTROLS SERVICES, INC.
OPERATOR INTERFACE TERMINAL – MACHINE
STATUS – PRODUCTION RECORDING – FASTER
TROUBLE SHOOTING
INTERFACED WITH
PLC – MONITORS
MACHINE STATUS
CAPABLE OF REMOTE
ACCESS VIA RADIO
LINK
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
MOTOR CONTROL CENTERS
CONSOLIDATES
CONTROL OF
SUPPORT EQUIPMENT
BLOWERS
FANS
COMPRESSORS
DECK WENCHES
DRIVES & CONTROLS SERVICES, INC.
INCORPORATION OF AUXILIARY CONTROLS
SUCH AS THE LUBE SYSTEM
COMMUNICATE TO
OPERATOR
SYSTEM STATUS
FAULTED SYSTEMS
RE-SET CYCLE
TIMERS
DRIVES & CONTROLS SERVICES, INC.
DAWN OF A NEW DAY (ERA)
RED SKY AT MORNING……
DRIVES & CONTROLS SERVICES, INC.
SYSTEM INTEGRATION:
THE PLC AND DIGITAL DRIVE SYSTEM MUST BE
COORDINATED TO REGULATE AND PROTECT THE
MOTORS AND GENERATORS.
DRIVES & CONTROLS SERVICES, INC.
SYSTEM INTEGRATION:
THE PLC AND DIGITAL DRIVE SYSTEM MUST BE
COORDINATED TO REGULATE AND PROTECT THE
MOTORS AND GENERATORS.
PLC CONTROL VS. DIGITAL DRIVE CONTROL
DRIVES & CONTROLS SERVICES, INC.
SYSTEM INTEGRATION:
THE PLC AND DIGITAL DRIVE SYSTEM MUST BE
COORDINATED TO REGULATE AND PROTECT THE
MOTORS AND GENERATORS.
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.
DRIVES & CONTROLS SERVICES, INC.
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
DRIVES & CONTROLS SERVICES, INC.
ELECTRICAL START UP AND TESTING
FEEDBACK TOUCH TEST
ISOLATED FEEDBACK SIGNALS
ENCAPSULATED SCR CELLS
NO COMPUTER NEEDED TO TROUBLE
SHOOT DIGITAL DRIVES
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
GEN
MOTOR
OPERATIONALAMPLIFIERREGULATOR
SCRGENERATOR FIELD EXCITER
MASTERSWITCH
CONTROL POWER120 VAC
AC POWER 480 VAC
MECHANICAL LOAD
ROTATING MOTORFIELD EXCITER
VOLTAGE FEEDBACK
CURRENT FEEDBACK
AC
DC
GENERATOR FIELDOVERCURRENT RELAY
DRIVES & CONTROLS SERVICES, INC.
ELECTRICAL START UP AND TESTING
DIGITAL DRIVES – INTERNAL DIAGNOSTICS
MULTIPLE FEEDBACK – HIGHEST TAKEOVER
PLC VOLTAGE AND CURRENT MONITOR
ONE DIGITAL DRIVE TYPE, SOFTWARE CHANGES
DRIVES & CONTROLS SERVICES, INC.
OTHER CONSIDERATIONS:
DUAL GENERATOR FIELD APPLICATIONS
WIRE HARNESS TO DOORS
CIRCULATING CURRENT IN MOTORS/GENERATORS
SINGLE REGULATOR/SCR BRIDGE UNIT
DRIVES & CONTROLS SERVICES, INC.
MOTOR FIELD CONTROL:
ROTATING DC GENERATORS FOR MOTOR
FIELD EXCITATION REPLACED BY
DIGITAL DRIVE APPLICATION.
INCREASED PRODUCTION
DECREASE MAINTENANCE
DRIVES & CONTROLS SERVICES, INC.
CENTRALIZED ACCESS FOR TESTING AND
TROUBLE SHOOTING
COMPREHENSIVE SYSTEM
DOCUMENTATION AND
WORK SPACE
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
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.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
[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]
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
CONTROL OF THESE GENERATORS IS
ACCOMPLISHED BY VARYING DC CURRENT TO THE
GENERATOR SHUNT FIELD WINDINGS.
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
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DUAL FIELD CONSTRUCTION
SINGLE FIELD CONSTRUCTION
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
CONTROL OF THESE GENERATORS IS
ACCOMPLISHED BY VARYING DC CURRENT TO THE
GENERATOR SHUNT FIELD WINDINGS.
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
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
100 VOLTS 100 AMPS
OHM’ LAW I = E / R
R = E / I
R= 1 OHM
DRIVES & CONTROLS SERVICES, INC.
100 VOLTS 100 AMPS
OHM’ LAW I = E / R
R = E / I
R= 1 OHM
120 VAC / 1 OHM = 120 AMPS
DRIVES & CONTROLS SERVICES, INC.
IMPEDANCE Z = 2 pf L
DRIVES & CONTROLS SERVICES, INC.
IMPEDANCE Z = 2 pf L
I = 120 V / 540 OHM = .222 AMP
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
DRIVES & CONTROLS SERVICES, INC.
VISIT US AT DRIVESANDCONTROLS.COM
THANK YOU FOR THIS OPPORTUNITY TO BE
HERE TODAY –
ANY QUESTIONS?