Catalog. MoCon Robust Drives for heavy duty cranes

Transcription

1 Catalog MoCon Robust Drives for heavy duty cranes

2 Content Introduction 4 MoCon Robust FC 5 Drives for induction squirrel cage motors 5 Specification data 6 Line voltage: V, 50/60 Hz 8 Line voltage: V, 50/60 Hz 9 Line voltage: V, 50/60 Hz 10 Line LCL filter 11 Options 12 MoCon Robust PC 14 Drives for induction slip ring motors 14 Specification data 15 Rotor resistance selection 16 Rotor contactor selection 17 Line voltage = V, 50/60 Hz 18 Line voltage = V, 50/60 Hz 19 Mechanical sizes 20 Crane control functions 21 Extra remote I/O 22 Control interface 23 Commissioning and Maintenance Tool 25 How to order 28 MoCon Robust Catalog 3

3 Introduction MoCon Robust FC Drives for induction squirrel cage motors MoCon Robust is a family of crane drives that utilize MoCon Robust FC for frequency control of induction squirrel cage motors and MoCon Robust PC for phase angle control of induction slip ring motors. The drives are designed to fulfill the heavy industry standards, safely and cost effectively. The demanding conditions of the steelmaking environment with temperatures up to 70º C and conductive dust set the general drive requirements. Power modules are air-cooled only; fluids are not desirable in hot-metal handling. MoCon Robust FC The FC is a four-quadrant active front-end, general purpose industrial crane drive, with vector or scalar control mode of operation. The drives internal DC link is a closed-mould system with copper plates and insulation material to reduce exposure to conductive dust. By using a thyristor DC link charging unit, charging time and intervals are reduced. This solution makes the equipment ready for operation in the shortest possible time, typically less than two seconds from power-up to the motor turns. The FC is designed as modular, four-quadrant, active frontend drive (AFE), with either vector or scalar control mode of operation. Single drive units frame sizes FC1, FC2, FC3, FC4 and FC5 are used to cover the full range from 20 A up to 600 A. For currents higher than 600 A, parallel FC5 units are used. The cooling fan arrangement is dependent on the frame size. Frame sizes FC1 and FC2 have single-phase cooling fans powered by the control voltage. FC3 and FC4 drives have three-phase fans. The FC5 drive is equipped with a frequency controlled fan. The drives are designed as single units, utilizing the latest automotive digital signal processors and component technology that guarantee extended safe and reliable service throughout their calculated service lives. The single-unit design approach simplifies engineering solutions in complying with high availability requirements, such as for single-fault tolerance for motions, future upgrades and modernizations, and for crane redundancy policies. MoCon Robust PC The PC is a four-quadrant drive. It is based on phase angle voltage control, phase sequence reversal and selection of the optimal rotor resistance. The PC drive is suitable for modernizations of cranes with existing slip ring motors, and for installations with special requirements such as cabinet installations or when air conditioning systems are not desired. The drives are also cooled during idling. 6.) 1.) 1. A line contactor is used for disconnection and is activated after a successful DC link charging sequence. The line contactor is directly controlled by the drive. 2. The RFI filter is included in the EMC assessment that is a part of CE-marking. The design process for the drives has incorporated specifications from both end-users and crane manufactures to fulfill heavy industry operational requirements. These requirements include reduced downtime, minimum wear of mechanical parts (such as gearboxes and wheels) and maximum safety and support integration in plant information systems. MoCon Robust common drive approach Both drives, FC and PC, are built with common and drivespecific building blocks. Fans, the power supply, I/O and the control board, the panel and computer software tool are the same, while driver boards and power components are different. This means that staff training, parts inventories and routines can be more efficient. Both drives can be connected to an overriding system (PLC or MoCon Robust Motion Controller device) via ProfiBus DP or CAN communications links. Another CAN is used for master-follower communications and external remote I/O. The drives have a rugged MoCon Robust operators panel with keys that are distinctive to the touch. The panel displays faults, history, signals and parameter values. Parameters can only be modified if authorization is correct. All input and output signals are indicated by individual LEDs on the panel. Control Voltage: V AC, 1 ph Special Voltage: V AC, 3 ph 7.) 8.) 2.) 3.) 4.) 3. Electrically, the LCL filter is an integrated part of the frequency converter. For FC1, FC2, FC3 and FC4, the LCL filter is a separate unit with its own ordering code. For FC5, the LCL filter is part of the drive. 4. Electrically, the dv/dt filter is an integrated part of the drive. For FC1, FC2, FC3 and FC4, the dv/dt filter is a separate unit with its own ordering code. For FC5, the dv/dt filter is part of the drive. 5. The motor contactor is used for disconnection in case of emergencies or during maintenance of back-up or branches drives. The motor contactor is directly controlled by the drive. 6. Short-circuit protection for charging unit. 7. Charging contactor used for safe disconnection of charging unit. 8. Thyristor charging unit. Typical charging time is 1 second. 5.) Figure 1: FC drive 4 MoCon Robust Catalog MoCon Robust Catalog 5

4 MoCon Robust FC Specification data General Application: Frequency control of squirrel cage motors in steel mill conditions Protection rating: IP 20 Designed for pollution degree 4 (IEC 60664). Continuous conductivity occurs due to conductive dust. Steel mill cranes are subject to pollution degree 4 with permanent exposure to conductive dust. Reference temperature: +40 C (Reduce capacity with 1% per C above the reference temperature) Maximal installation temperature: +70 C Reference altitude: 1000 meters above sea level Options Motor contactor Brake control circuit Loss calculation: 530 V range: Loss = 3 x motor current x 6 [W]. Losses include filters 690 V range: Loss = 3 x motor current x 8 [W]. Losses include filters Switching frequency: Normally 2-3 khz Field weakening: 1:1.5 power optimization Control voltage: V DC/AC 50/60 Hz Measurement: Current: 2(3) line phases and 3 motor phases Voltage: 3 line phases and the DC-link Electrical environment Requirement of THD: IEC TR2 Stage 3 Power factor: Unity Current [A] 145% 130% Rated Interface Communication links Via terminal board: Panel Overriding control system: ProfiBus DP slave and CAN Master-follower and I/O communications: CAN 17 DI 110 V DC or 24 V DC 10 DO 24 V DC transistor, two processor controlled 2 Incremental encoders, A, B, Z and synch 1 Tachometer 1 AI. Reference, load cell, etc. Supply capacity for remote I/O Presentation of signals, faults, history and I/O status Editing of parameters 80% Figure 2: Permissible motor current Time [sec] Commissioning and maintenance tool (CMT) USB for computer connection (See Commissioning and maintenance tool on page 25) 6 MoCon Robust Catalog MoCon Robust Catalog 7

5 MoCon Robust FC Line voltage: V, 50/60 Hz MoCon Robust FC Line voltage: V, 50/60 Hz Type code Ordering code Rated current [A] Frame size Type code Ordering code Rated current [A] Frame size FC BSE050744G2001 FC BSE050744G2011 FC BSE050744G2021 FC BSE050744G2031 FC BSE050744G2041 FC BSE050744G2051 FC BSE050744G2151 FC BSE050744G2061 FC BSE050744G2071 FC BSE050744G2081 FC BSE050744G2091 FC BSE050744G FC BSE050744G2201 FC BSE050744G2211 FC BSE050744G2221 FC BSE050744G2231 FC BSE050744G2241 FC BSE050744G2251 FC BSE050744G2351 FC BSE050744G2261 FC BSE050744G2271 FC BSE050744G2281 FC BSE050744G2291 FC BSE050744G Options for FC drives are described on page 12. Options for FC drives are described on page MoCon Robust Catalog MoCon Robust Catalog 9

6 MoCon Robust FC Line voltage: V, 50/60 Hz MoCon Robust FC Line LCL filter Type code Ordering code Rated current [A] Frame size Electrically, the LCL filter is an integrated part of the drive, and must be ordered together with the FC drive to attain a complete functioning drive system. FC A 3 3BSE050744G2401 FC A 3 3BSE050744G2411 FC A 3 3BSE050744G2421 FC A 3 3BSE050744G2431 FC A 3 3BSE050744G2441 FC A 4 3BSE050744G2451 FC A 4 3BSE050744G2461 FC A 5 3BSE050744G2471 FC A 5 3BSE050744G2481 FC BSE050744G A 5 Options for FC drives are described on page 12. MoCon Robust FC Line voltage: V, 50/60 Hz Type code Ordering code LCL BSE050744G4001 LCL BSE050744G4021 LCL BSE050744G4041 LCL BSE050744G4151 LCL BSE050744G4071 Current Suitable for 20 A FC FC BSE050744G2001 3BSE050744G A FC FC BSE050744G2011 3BSE050744G2211 FC FC BSE050744G2021 3BSE050744G A FC FC BSE050744G2031 3BSE050744G2231 FC FC BSE050744G2041 3BSE050744G A FC FC BSE050744G2051 3BSE050744G2251 FC FC BSE050744G2151 3BSE050744G A FC FC BSE050744G2061 3BSE050744G2261 FC FC BSE050744G2071 3BSE050744G2271 MoCon Robust FC Line voltage: V, 50/60 Hz Type code Ordering code LCL BSE050744G4501 LCL BSE050744G4521 LCL BSE050744G4541 LCL BSE050744G4561 Current Suitable for 15 A FC BSE050744G A FC BSE050744G2411 FC BSE050744G A FC BSE050744G2431 FC BSE050744G A FC BSE050744G2451 FC BSE050744G2461 Options for FC drives are described on page MoCon Robust Catalog MoCon Robust Catalog 11

7 MoCon Robust FC Options Options for FC drive as follows: Frame size Option code Option Example FC1-5 +IT For isolated networks FC C230+IT FC1-5 +C For control voltage FC C230+C FC5 +RFI With this filter, the converter fulfils the EU EMC-directive FC C220+RFI for second environment (industrial network). +DVT Filter to reduce voltage stress on motor windings FC C220+DVT FC C220+RFI+DVT +OC Motor contactor (line contactor always included) FC C220+RFI+DVT+OC +BR High capacity MCB and two contactors with serially FC C220+RFI+DVT+OC+BR connected main circuits and supervision. Terminals for brake connection +X2 The converter is divided in two parts after factory FC C220+RFI+DVT+OC+BR+X2 testing, and shipped with the filter compartment as a separate unit. +FAI The converter can be installed without any mounting FC C220+RFI+DVT+OC+BR+X2+FAI frame. Cooling air inlet is executed as a front mesh close to the floor. Filter for +RFI With this filter, the converter fulfils the EU EMC-directive LCL C220+RFI FC1-4 for second environment (industrial network). +DVT Filter to reduce voltage stress on the motor windings LCL C220+DVT LCL C220+RFI+DVT Also refer to Frequency control of induction motors on page MoCon Robust Catalog MoCon Robust Catalog 13

8 MoCon Robust PC Drives for induction slip ring motors MoCon Robust PC Specification data The PC is a four-quadrant drive. It is based on the phase angle voltage control principle, phase sequence reversal and selection of optimal rotor resistance. Travel motions in most cases use a simple rotor circuit, with one fixed resistor per motor and no contactor is used. Hoist motions use two, three or four contactors. 1.) Fuse selection Fuses for the PC drive should be selected to reduce the short-circuit energy to the specified i2t recommendation. General Application: Voltage and rotor control of slip ring motors in steel mill condition Protection rating: IP 20 Designed for pollution degree 4 (IEC 60664). Continuous conductivity occurs due to conductive dust. Reference temperature: +40 C (Reduce the capacity with 1% per C above the reference temperature.) Maximal installation temperature: +70 C Reference altitude: 1000 meters above sea level. Acceleration and retardation current is 200% of rated current with short-time peaks 300% of drive rated current. Loss calculation: 530 V range: Loss = 3 x motor current x 1,1 [W] 690 V range: Loss = 3 x motor current x 1,2 [W] Control voltage: V AC 50/60 Hz Measurement: Current, three phases Voltage, three phases Interface Communications links Overriding control system: ProfiBus DP slave, CAN 2.) Via terminal board: Master-follower and I/O communications: CAN 17 DI 110 V DC or 24 V DC Control Voltage: V AC, 1 ph Special Voltage: V AC, 3 ph M 3 1. Fuse 2. Thyristor voltage controller 3. External rotor resistors 4. Rotor contactors Panel 10 DO 24 V DC solid switch, two processor controlled 2 Incremental encoders, A, B, Z and synch Either tachometer or incremental encoder must be used 1 Tachometer for speed control. 1 AI. Reference, load cell, etc. Supply capacity for remote I/O Presentation of signals, faults, history and I/O status Editing of parameters 4.) 3.) Figure 3: PC drive Commissioning and maintenance tool (CMT): USB for computer connection (See Commissioning and maintenance tool on page 25) 14 MoCon Robust Catalog MoCon Robust Catalog 15

9 MoCon Robust PC Rotor resistance selection MoCon Robust PC Rotor contactor selection The rotor resistor s service life can be extended if certain conditions are fulfilled: Stainless steel grid resistor with good welding properties Manufacturing insulation test for one minute: 6 kv 50/60 Hz. The resistor must allow continuous operation with at least 110% rated rotor current. R mot R cable r 1 Drives directly operate the rotor contactors. Contactors with short opening times are required. Our recommendation tables are based on a Y connection of the contactors. For a Δ connection, current capacity values should be multiplied by factor 1.5 or A Δ connection increases voltage stress. r 2 Recommendations for ABB contactors Highest recommended rotor current for contactors: Figure 4: Rotor resistor control r 3 r 4 ABB contactor type A A A A A A A A A A A A AF AF AF AF Duty % % Opening time, ms 20 Closing time, ms Pull-in power², VA Electronic control Max 3-phase rotor rated voltage when starting and with reverse current braking Ur (550)³ 600 (690) 730 (690) 1000 Selection table for resistor values ² At 60 Hz, which is worst case ³ Values in parenthesis are for -connection 100% rotor resistance lets the motor develop a rated torque, at rated voltage, with locked rotor: Movement R1 R2 R3 R4 Hoist 8% 18% 38% 60 to 65% Hoist (small motor) 12% 40% 60 to 65% Travel 30% R1 = r1 + R mot + R cable R2 = r2 + R1 R3 = r3 + R2 R4 = r4 + R3 16 MoCon Robust Catalog MoCon Robust Catalog 17

10 MoCon Robust PC Line voltage = V, 50/60 Hz MoCon Robust PC Line voltage = V, 50/60 Hz Type code Ordering code PC BSE050744G0991 PC BSE050744G1001 PC BSE050744G1011 PC BSE050744G1021 PC BSE050744G1031 PC BSE050744G1041 PC BSE050744G1051 PC BSE050744G codes: +Cvvv for control voltage 1 x vvv volt. Size [A] Rated current Frame size i2t for fusing [A2s] A A A A A A A A Type code Order code Size Rated current Frame size Ii 2 t for fusing [A2s] PC A BSE050744G1091 PC A BSE050744G1101 PC A BSE050744G1111 PC A BSE050744G1121 PC A BSE050744G1131 PC A BSE050744G1141 PC A BSE050744G codes: +Cvvv for control voltage 1 x vvv Volt. Example: PC C110 for control voltage 110 V Example: PC C110 for control voltage 110 V 18 MoCon Robust Catalog MoCon Robust Catalog 19

11 Mechanical sizes Crane control functions The motor controller drives are executed as modular systems in various frame sizes. Frame size 1 can be mounted in 400 mm deep normal industrial cabinets. Frame sizes 2, 3 and 4 can be mounted in 500 mm deep normal industrial cabinets. Frame size 5 is executed as a cabinet with hinged doors. Mechanical size table FC Frame size Width, mm Height, mm Depth, mm Weight, 1) kg , Filter (20A) 50 (60A) 2, Filter , Filter , Filter Mechanical size table PC Frame size Width, mm Height, mm Depth, mm Weight, 1) kg ) Does not include options MoCon Robust FC and PC drives offer an assortment of user-selectable basic or advanced functions. Most of the functions are common for slip ring and squirrel cage motors. Some functions can be used for one type of drive only, due to physical consideration. Function Phase control Frequency control Description Ambient temperature measurement X X Integrated into the controller. Brake handler X X The brake handler function controls the mechanical brake. It also handles two different brake contactors and can monitor up to four individual limit switches. The brake handler provides a delayed brake setting for travel motion, enables electrical holding and provides control of the DC brake hold current. It also waits for the controller release for slow brake opening and tests that the motor develops torque before brake activation. Control logic X X The drive control logic allows release of the controller when all start conditions are met, and operates the contactors for the frequency controllers. DC bus charging X Fast DC bus charging (up to 1 second for all unit sizes). No limits on the number of operations per minute. Fault handler X X Classification of faults/events into five classes: 0. Electrical disconnect and stop by mechanical braking. Watchdog relay opens. 1. Electrical disconnect and stop by mechanical braking 2. Electrical stop by fast ramp 3. Electrical stop by normal ramp 4. No action, only warning and logging About 100 different faults and warnings are recorded. Presentation of all faults with time stamps in the commissioning and maintenance tool (CMT) Field weakening X Control of the motor in field weakening range, 1:1.5. Limit switch handler X X Slow-down and stop limit switches Mechanical load functions X X Stops hoisting upon overload Warning level for analog load cell Motor monitor X X Thermal model to prevent overloads on motor or cables Monitoring of up to four motors: Thermistors, warning, trip and overcurrent relays Monitoring of earth fault Power stack temperature monitor X X Protection for avoiding high temperatures in the power stack Reactive power compensation X The drive can operate with a unity power factor, or with inductive/ capacitive load. Rotor contactor handler X Switching of maximum four rotor contactors in zero current state Signal selector X X Assigns signals to I/O-terminals, remote I/O terminals Slack rope X X Stop or slow-down when landing with slack ropes Snatch rope protection X X Restricts the hoisting speed until the ropes are tightened Speed feedback selection X X Selects the speed feedback source: Pulse encoder 1, Pulse encoder 2, Tachometer, Model- based. Speed monitor X X Speed deviation and overspeed Speed reference handler X X Step, continuous or remote speed reference generation Speed regulator X X PID-based controller Statistics X X Recording in power-safe flash memory of current position, of contactor operations, number of lifts and hour counters 20 MoCon Robust Catalog MoCon Robust Catalog 21

12 Extra remote I/O Control interface MoCon Robust remote I/O DI supply and detection voltage distribution 24 V DC power supply DI for 24 V DC or 110 V DC. AI for 0-10V, 0(4)-20 ma, PTC DO with solid switch output, 2 A 24 V DC AO for -10V +10V Pollution degree 4 (IEC 60664). Continuous conductivity occurs due to conductive dust. Max temperature: +70 C Data transfer: CAN bus Protection rating: Frame size I/O 20 has IP 20 protection Dimensions W x H x D: 145 x 90 x 50 mm Ordering code DI 24 V DI 110 V PTC AI DO AO RIO BSE050744G3001 RIO BSE050744G3011 Accessories Power supply Ordering code Data Suitable for 3BSE050744G5501 Input voltage: V DC/AC I/O Output voltage: 110 VDC/25 VA + 24 VDC/120 VA CAN bus termination device Ordering code Data Suitable for 3BSE051923G0661 CAN Last unit in a CAN bus. Add as extension to bus cable. Drive has a number of configurable internal and external connections. FC drive Step control PC drive Digital Inputs (DI) Digital Inputs (DI) A1 Run_Condition_1 Master switch, direction A A2 Run_Condition_2 Master switch, direction B A3 Start command Master switch, step 2 A4 LS stop dir. A Master switch, step 3 A5 LS slow-down, dir. A Master switch, full speed A6 LS slow-down, dir. B LS stop dir. A A7 LS stop dir. B LS slow down dir. A A8 Master switch in neutral position LS slow down dir. B A9 Macro select control bit 1 LS stop dir. B A10 Macro select control bit 2 Thermal O/C-relay A11 Brake contactor 1 open Brake lifter LS A12 Brake contactor 2 open Mechanical overload B1 Line contactor on B2 Brake contactor 1 B3 Brake contactor 2 B4 Master switch in neutral position B5 Macro select bit 1 RIO1 Master switch, direction A Brake lifter 1 LS RIO2 Master switch, direction B Brake lifter 2 LS RIO3 Master switch step 2 Brake lifter 3 LS RIO4 Master switch step 3 Brake lifter 4 LS RIO5 Master switch full speed O/C relay, motor 1 RIO6 O/C Relay Motor 1 O/C relay, motor 2 RIO7 O/C Relay Motor 2 O/C relay, motor 3 RIO8 O/C Relay Motor 3 O/C relay, motor 4 RIO9 O/C Relay Motor 4 Start interlock RIO10 Brake lifter 1 LS RIO11 Brake lifter 2 LS RIO12 Brake lifter 3 LS RIO13 Brake lifter 4 LS RIO14 RIO15 RIO16 A few suggestions for how it can be used Ax Local DI/O Bx System DI/O RIOx Remote DI/O 22 MoCon Robust Catalog MoCon Robust Catalog 23

13 Commissioning and Maintenance Tool FC drive PC drive Step control Digital Outputs (DO) Digital Outputs (DO) A1 Brake contactors Brake contactors A2 Brake control DC economy Brake control DC economy A3 Rail cleaning blower Rail cleaning blower A4 No fatal fault. 0=Fatal fault No fatal fault. 0=Fatal fault A5 Any fault. 1=Fault Any fault. 1=Fault A6 B1 Line contactor off Rotor contactor K1 B2 Charge contactor off Rotor contactor K1 B3 Motor contactor off Rotor contactor K1 B4 Monitor chain 1 Fan B5 Monitor chain 2 MoCon Robust drives are configured using the Commissioning and Maintenance Tool (CMT). The CMT software package is available for download on the Internet. The tool automatically recognizes the connected drive and selects configuration files accordingly. The tool offer a convenient way of editing parameters, monitoring signals and plotting graphs using live data from drives. The USB standard is used to connect the drive. Pulse encoder Pulse encoder 1 For speed control For speed control 2 For speed supervision rope drum For speed supervision rope drum Figure 5: CMT Tool 24 MoCon Robust Catalog MoCon Robust Catalog 25

14 Figure 6: Parameter Tool Figure 7: Signal Tool Parameters are defined in four different user selectable groups/macros. Two DI are used for macro selection. The Signal Tool, similar in layout to the Parameters Tool, allows continuous monitoring of the signals defined in the drive. Figure 8: Monitor Tool Parameter editing is possible either in offline or online mode and parameters can be stored as project files. The Monitor Tool allows graphical representation of 16 realtime signals. The graphs can be recorded and saved on a computer as XML files for later analysis. Parameters and signals are sorted in different views according to specific tasks. Printing is supported for monitor graphs, signals and parameters and they can be saved as PDF files. 26 MoCon Robust Catalog MoCon Robust Catalog 27

15 How to order Notes Ordering codes For all products, the type code (including option specification) and the ordering code must be given. The desired options must be specified according to the following information. For all sizes and types of products The type code for all products must be complemented with the control voltages in the following format: +Cvvv for control voltage 1 x vvv Volt Example 1 PC C110 for phase controller with control voltage 110 V Example 2 LCL C220 for filter unit with control voltage 220 V For FC, frame sizes 1 4 If desired, add the following option: +IT for isolated networks Example FC C240+IT for control voltage 240 V for isolated network. For FC, frame size 5 only If desired, add the following options: Example +OC for output contactor +RFI for EMC filter, second environment +DVT for dv/dt filter + BR for 10 A magnetic short-circuit protection, feeding two series-connected brake contactors including terminals +IT for isolated networks +FAI for grid fitted for front air inlet. For installation directly on the floor when air inlet from below cannot be provided +X2 means that the drive is delivered in two parts one lower part with filters, one upper part with the drive unit. FC C240+OC+RFI for control voltage 240 V with installed output contactor and EMC filters Note that the line filter must be ordered with a separate type code, apart from the FC type code. For the line filter, the following options are available: +IT for isolated networks +RFI for EMC filter, second environment +DVT for dv/dt filter Example LCL C230+IT+RFI+DVT for filter, control voltage 230 V, configured for isolated networks. EMC filter and DV/dT filter 28 MoCon Robust Catalog MoCon Robust Catalog 29

16 Notes Notes 30 MoCon Robust Catalog MoCon Robust Catalog 31

17 Contact us For more information please contact: ABB Crane Systems SE Västerås, Sweden Phone: Fax: Note: We reserve the right to make technical changes or modify the contents of this document without prior notice. ABB Crane Systems does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained herein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in part is forbidden without prior written consent of ABB Crane Systems. 3AST003458D0107 Rav- Copyright 2011 ABB. All rights reserved.