Transcript DDC. Presentation for End-users - Kor

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OmniPulse DDC
DC to DC Control
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Presentation Overview
• Types of DC Motors
• DCCP (Traditional Electromechanical Crane Controls)
– Overview of the DCCP
– Operation of DCCP
– Disadvantages of Using DCCP
• OmniPulse DDC
– Overview of the OmniPulse DDC
– Benefits of OmniPulse DDC over DCCP
– Marketing and Sales Tools
•
Brochure, FAQ, Application Guide, Competitive Report,
Cost Savings Analysis Software, Etc.
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DC Motor Construction
Brush Rigging even number of
brushes in pairs
(Pos and Neg)
Series Field
Armature
Commutator
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DC Motor Connections
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DC Motors - Summary
•
Series
– Typically on Crane Applications Due to High
Starting Torque
– At Very Light Loads Have the Potential for Runaway
•
Shunt
•
Cumulative Compound
– Typically on Process Lines
– Lower Starting Torque but Better Speed Regulations
– Typically on Outdoor Cranes (Portal, Ore Bridges)
– The effect of the wind on an outdoor crane could
cause a series motor to runaway.
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DC Motor – Speed/Torque Curves
Differential
compound
Shunt
Series
Cumulative
compound
Rated load
current
Armature Current /2(A)
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Four Quadrants of Motor Operation
The motor must
provide the
braking torque to
slow the hoisting
or traveling speed
resulting from the
rotating inertia
reflected at the
motor shaft.
The motor must
provide the
physical torque
to overcome
frictional forces
to lower a light
load.
Braking Hoisting Motion
Power Hoisting
The motor must
provide the physical
torque to raise the
load or move the
trolley or bridge
Power Lowering
Braking Lowering Motion
The motor must
provide the
braking torque to
counter act the
gravity effect
when lowering a
load at a
controlled speed.
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Traditional DC Crane Control
• Traditional Steel Mill Cranes Utilize:
–
–
–
250VDC Power Supply
Series Wound 600 and 800 Mill Frame Motors
DCCP (Contactor and Resistor Control)
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What Is DCCP?
(Direct Current Constant Potential)
•
DCCP Crane Control Consists of:
– Control Panel (Board) – Contactors
– Power Resistor Bank
– Master Controller
•
•
•
Radio
Pendant
Master Switch
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DCCP Typical Hoist Control Panel
Overload
Relays
UV
Relay
LSR
Relays
Main &
Directional
Contactors
Single Motor Control
Board Consists of:
DB
Contactor
Accelerating
Contactors
1 – Main Contactor
4 – Directional Contactors
1 – DB Contactor
3 – Accelerating Contactors
2 – Electro-Mechanical Dashpot
Type Overload Relays
1 – Under Voltage Relay
1 – Limit Switch Back-Out Relay
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Power Resistor Assembly
A Typical Hoist Control
Will Require Multiple
Resistor Banks:
• 65HP = 10 Banks
• 100HP = 15 Banks
• 200HP = 29 Banks
• 265HP = 39 Banks
Grid Type
“3” Bank Resistor Assembly
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DCCP Operation
• Hoisting (Up)
– Series Motor Connection
• Dynamic Lowering (Down)
– Shunt Motor Connection
• Travel and Reverse Plugging
– Series Motor Connection
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Hoisting – Controlling Motor Speed
• Hoisting (Raising) Requires
the Motor in Series
Connection
• High Speeds = Light Loads
• High Torque = Low Speeds
• Effect of Increasing Resistor
– Reduced Torque
– Poorer Speed Regulation
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Lowering – Controlling Motor Speed
•
•
Lowering Connection
Requires Motor in
Shunt Connection
Increasing Resistance
– Reduces Starting Torque
– Reduces Speed Regulation
– Increases Dynamic
Lowering Speed
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Hoist Speed Steps
Speed 1
Speed 2
Speed 3
Speed 4
Speed 5
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Lowering Speed Steps
Speed 3
Speed 1
Speed 4
Speed 2
Speed 5
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Hoist Safety Circuit (DB Off Position)
Retained and Required by AIST Standard TR6 for DDC Technology
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Disadvantages of DCCP
• Reliability
• Maintenance Intensive
• Inconsistency of Operation
• More Power Connections
• Energy Inefficient
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Reliability
The number of mechanical components impacts reliability.
Crane
Board
No. of
Contactors
No. of
Relays
Typical
No. of E/M
Components
Hoist
9
4
13
Trolley
9
3
12
Bridge
9
3
12
37
37 ELECTRO-MECHANICAL
COMPONENTS PER CRANE
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Maintenance Intensive
• Contactors Require Frequent Tip, Arc Chute
and Bushing Replacement
• The DCCP System Does Not Provide Smooth
Acceleration and Deceleration Rates
–
–
Mechanical Gear Life is Reduced
Brake Lining Life Reduced
• Power Resistors Require Periodic Inspections
and Replacement
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Inconsistency in Operation
• Speeds and acceleration
rates will vary based on load
and temperature.
• Adjustments require manually
changing a step resistance value.
• Plugging torque varies based on
the setting of the plugging relay
and resistor temperature.
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More Power Connections
• Multiple Acceleration Resistor Steps
– Require More Power Wiring between the Resistor Banks
and the Control Board
• Labor Intensive Installation - $$
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Energy Inefficient
• DCCP systems consume additional line
power during hoisting and travel acceleration.
• DCCP systems waste power
during a lowering operation.
– Energy generated by the motor
is dissipated in the power
resistor bank.
– Generated heat accumulation
inside buildings requires
additional ventilation.
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Overcome Disadvantages
of DCCP Control
with the
OmniPulse DDC
Advantage
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History of DC-DC Technology
• Basic Technology Developed during the 80’s
– To Control Series Motors for the
Mining Industry
• Evolution of IGBT Technology
– Made the DC-DC Drive A Practical Solution
• Successfully Applied on Steel Mill Overhead
Cranes Since 1998
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Technology Comparison
DCCP Technology
DDC Technology
• Multiple Electro-Mechanical • Uses Microprocessor Control
Contactors and Relays
• IGBT Switching
• Multiple Power Resistors
• Closed Loop Sensorless
Control
• Open Loop
• Four Quadrant Motor
• Two Quadrant Motor
Operation
Operation
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Overview of OmniPulse DDC
• 5 – 500 hp (within 2 Frame Sizes)
• 230 – 360 VDC (std.)
• Speed Regulation
–
–
5% Closed Loop Sensorless
.1% Closed Loop with Tach Feedback
• Configurable for Series, Shunt or
Compound Wound Motors
• Digital Micro-Processor Based
• Universal Software (Version 3 Includes
MB RTU)
• Only DC to DC Drive with Four
Quadrant Operation
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Overview of OmniPulse DDC(cont.)
• Diagnostics
– Monitor 32 Items (amps, volts, rpm, hours, etc.)
– Status LED's
– Fault History (15 Most Recent)
• Continuity Check at Start (Hoist Mode)
• Fail-Safe Pre-Charge Circuit
• Compact, Modular Design
Integral LCD
Display and
Keypad
Fully
Integrated
Packaging
Common
Control Boards
Common
Hardware
Common
Software
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Keypad Operation in Display Mode
• Right Key
–
Selects the Parameter Group/Menu
to be Displayed
• Down Key
–
Selects the Parameter within the
Selected Menu/Group
• Up Key
–
Selects the Parameter within the
Selected Menu/Group
• Left Key
–
Switches from Display to Adjust Mode
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Keypad Operation in Adjust Mode
• Right Key
–
Positions the Flashing Cursor to
Select the Digit to be Adjusted
• Down Key
–
Used to Decrease the Selected Digit
–
Used to Increase the Selected Digit
–
Switches from Display to Adjust Mode
• Up Key
• Left Key
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Status LED’s
58-7614
L1
+
L2COM+
SB 230VDC Output
230 VDC
Conn.
5 Amp
Fuses
DB 230VDC Output
M 230VDC Output
Stop
Enable
Lower
Hoist
2nd Speed
3rd Speed
4th Speed
5th Speed
Prog Input
Output Status
Ind.
Reset
Input Status
Ind.
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Overview Parameter Groups
• Group A - Monitoring
• Group B - Access
• Group C - Controller Setup
• Group D - Protection
• Group E - Drive Control Setup
• Group F - Speed and Torque Settings
• Group G - I/O Configuration
• Group H - Fault History
• Main Menu Screen
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Parameter Groups
• Group A – Monitoring
–
–
–
–
–
–
–
4 Parameters for Motor Current and Voltage
5 Parameters for Motor Speed and Torque
4 Parameters for Power, Energy and Operation Cycles
2 Parameters for Analog Input Status
5 Parameters for Current and Speed /Adv.Tools
2 Parameters for Logic I/O Status
9 Parameters for Controller Status / Adv. Tools
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Parameter Groups (cont.)
• Group B – 6 Parameters for Access
• Group C – 8 Parameters for Controller Rating Setup
• Group D – 16 Parameters for Protection
• Group E – 23 Parameters for Drive Setup
• Group F – 23 Parameters for Speed and Torque Settings
• Group G – 21 Parameters for I/O Configuration
• Group H – 15 Parameters for Fault History
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DDC Sizing Based Upon
DCCP NEMA Ratings
NEMA
Contactor Size
Crane Rating
DC Amps
Max Crane
HP
2
67
15
3
133
35
4
200
55
5
400
110
6
800
255
7
1200
325
8
1800
500
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Modular Design = Minimal Spares
133Amp DDC Drive
NEMA Size 3
*Standard
Interface
Display
board
Driver
board 133A
Control
board
133A Stack
200 Amp DDC Drive
NEMA Size 4
*Standard
Interface
Display
board
Control
board
Driver
board
200A Stack
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Modular Design = Minimal Spares
400 Amp DDC Drive
NEMA Size 5
*Standard
Interface
Display
board
Control
board
Driver
board
400A Stack
800 Amp DDC Drive
NEMA Size 6
*Standard
Interface
Display
board
Control
board
Driver
board
400A Stack
97-3620
400A Follower
Available up to 1200, 1600 and 2000 Amps
through paralleling of stacks
Driver
board
400A Stack
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Typical DDC NEMA Size 6 Hoist Panel
CCB
Follower
MASTER
M
L2-
DB
L1+
MCB
IFB
A2
A1
S2
SB
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Before and After Retrofit
DDC
Crane
DCCP
Crane
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Retrofit DDC Control
Hoist Panel &
DB Resistor
Hoist Panel &
DB Resistor
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Retrofit DDC Control
Trolley
Panel
Bridge
Panel
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Benefits Of OmniPulse DDC
• Improved Performance
• Minimized Downtime and
Improved Serviceability
• Improved Safety
• Reduced Maintenance
and Energy Costs
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Improved Performance –
Motor Speed And Torque Control
• Digital Micro-Processor Control
– Repeatable Precision
– Programmable Performance Characteristics
• Flexibility in Customer Setup
– Separate Acceleration and Deceleration Inputs
– Separate Hoisting and Lowering Speeds
• Micro-Speed (Load Positioning)
• High Hook Speeds (with No-Load) in Both Directions
• Enhanced Plugging with 5-step Plugging Capability
• Four-Quadrant Motor Operation
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Minimized Downtime And
Improved Serviceability
• Easy-to-Use Programming to
Meet Changing Production Needs
• Solid State Design
• Built-in Diagnostics (31 Monitor
Parameters and 16 LEDs)
• DDC Can Apply Stopping Torque
to Improve Brake Life
• Drop-In Design to Utilize Existing
Power and Control Connections
– Facilitates Quick Upgrades
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Use of Existing Connections
Respondor DDC
Original Power
Connections Retained
Motor Circuit
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Improved Safety
• Motor Armature Continuity
Check at Start (in Hoist Mode)
• Motor Series and Field
Loss Detection
• Current Limit Control
• Emergency Shut-Down with
DC Supply Power Loss
• Fail-Safe Pre-Charge
Circuit Design
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Reduced Maintenance Costs
• Less Contactors Used – (Reduces
Scheduled Maintenance to Replace
Tips, Aux. Contacts, Etc.)
– Contactors That Are Used Are Opened
without Load
• Reduced Maintenance on Brakes
– Brake Linings Last Longer
– Less Frequent Adjustments Required
• Prolonged Motor Brush, Commutator
and Insulation Life
• Reduced Shock Loads on Mechanical
Power Train
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Reduced Energy Costs
• Less Power Demand
– Eliminates Power Losses in Hoist and Travel Resistors
– Requires Less Power during Low Speeds and Acceleration
• Regenerative Capability
– Into Receptive Power Bus When Lowering Loads
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Line Amps (Lowering At Half Load)
550
1L
2L
500
DDC
450
DCCP
400
3L
350
300
4L
Line Amps
250
200
5L
Savings Opportunity
150
100
50
0
-50
1L
2L
-100
3L
4L
-150
5L
-200
0
20
40
60
80
100
120
140
160
180
Time (0.1 sec)
200
220
240
260
280
300
320
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Line Amps (Lowering At Full Load)
550
1L
500
2L
DDC
DCCP
450
400
350
3L
300
Line Amps
250
200
4L
150
Savings Opportunity
100
50
5L
0
-50
1L
-100
-150
2L
-200
3L
-250
4L
5L
-300
0
10
20
30
40
50
60
70
80
90 100 110 120 130 140 150 160 170 180
Time (0.1 sec)
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Line Amps (Lifting At Half Load)
425
400
1H
375
DDC
DCCP
350
325
300
Line Amps
275
2H
3H
4H
5H
250
225
200
5H
Savings Opportunity
175
150
4H
125
100
3H
75
2H
50
25
1H
0
-25 0
20
40
60
80
100
120
140
160
180
Time (0.1 sec)
200
220
240
260
280
300
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Line Amps
Line Amps (Lifting At Full Load)
500
475
450
425
400
375
350
325
300
275
250
225
200
175
150
125
100
75
50
25
0
1H
2H
3H
4H
DDC
DCCP
5H
5H
Savings Opportunity
4H
3H
2H
1H
0
20
40
60
80
100
120
140
160
Time (0.1 sec)
180
200
220
240
260
280
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Sales And Marketing Tools
• New Marketing Launch Packets
– OmniPulse DDC Brochure
– Installation / Reference List
– Application Questionnaire
– Savings Analysis Software
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Some of the Current Users Of DDC
Algoma Steel
Pechiney Aluminum
California Steel
SMI
Corus Steel UK
Timken
Dofasco
US Steel – Great Lakes
General Electric
US Steel – Mon Valley
Mittal – Indiana Harbor
US Steel - Irvin
Mittal – Sparrows Point
Wheeling Pitt
Mittal – Burns Harbor
Nucor – Kent Washington
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Application Questionnaire
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Application Questionnaire Addresses
Regeneration And Ripple Issues
• If Regen Compatibility Is Not Addressed:
– Lights Get Brighter
– Drive Trips on Over-Voltage
– Other Equipment Could be Damaged from Increased Voltage
• Compatibility Issues May Exist If:
– Regen Package on the Rectifier – Too Slow (Could Require
Braking Chopper/RPM and Resistor)
– Type of DC Supply (Could Require DC Line Choke)
•
•
Regulated SCR – Voltage Regulator is Too Slow
Diode Rectified – Could See Ripple Issues
– AC Ripple Current and Voltage – Capacitor Passes AC
Current Through
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Questions ?