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SIEMENS VISIT

19 to 21 February 2008
Prepared by: A.ElSweesy
1st Day 19-2-2008 Events:
1- Discussing the problem of broken AFE circuit breakers & explained that this happens because
the CUSA board is enabled before the charging process of circuit breaker motor is finished. In this
case, electric pulses are generated to IGBTs which produces high harmonics to the charging motor
causing it to continue rotating even after the stop point of spring has been reached. Mr. Rudolf
(Siemens specialist) advised to add a hardware on-delay timer to delay enabling the CUSA board
until the charging process is completed.
Attached wiring modification is shown below:

AFE Diagram =10 +E13A7A Page 9

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AFE Diagram =10 +E13A8 Page 14

2- Discussing the problem of damaged power clean filter capacitors & also K7 which passes power
to them. Mr. Rudolf explained that this happens because of possibility of switching ON AFE circuit
breaker immediately after it has been switched OFF & repeating this. In this case, Capacitors are
not completely discharged after switching ON immediately which causes high current through
capacitors & consequently damaging them. He advised to add a hardware off-delay timer to prevent
switching ON immediately before certain time.

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Attached wiring modification is shown below:

AFE Diagram =10 +E13A7A Page 9

AFE Diagram =10 +E13A6 Page 8

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3- Discussing the problem of MASTERGUARD UPS and the recommendation is to charge the
batteries while they are outside the UPS because it must be some charge in batteries to be in a good
performance in the UPS but we replied that all batteries in the store are fully charged and we
replaced many but the problem still exists.
2nd Day 20-2-2008 Events:
1- Regarding the problem of MASTERGUARD UPS, Mr. Rudolf advised to check in other cranes if
the input neutral to the UPS is earthed since it must not be earthed. We checked other UPSs which
is working well and found the neutral is earthed. He will reply to us with corrective action!!!.
2- Regarding the problem of RRU2 auto-transformer overheating in CQ03, Mr. Rudolf advised to
disable regeneration function as long as the crane is OFF and resuming when there is any command.
3- We measured the current to power clean filter capacitors of AFEs in CQ06 and found it around 1
amp. In all AFEs which have defected capacitors in power filter but the normal current is 73 amp.
according to the datasheet. In power filters which have good capacitors the measured current is
around 40 amp. and in some cranes around 70, 90 and 100 amp.. Mr. Rudolf said that the
corresponding capacitors are not OK and may need to be changed but he will reply to us with
corrective action.
4- Mr. Rudolf advised that UPS must be OK to maintain voltage stable and protect contactors from
repeated switching ON and OFF and consequently damage power filter capacitors.
3rd Day 21-2-2008 Events:
1- Gathering data by NETWORK ANALYZER to view harmonics and variations in voltage and
currents in AFEs of CQ06 and CQ11. Mr. Rudolf will reply to us with analysis results from factory
of AFE.
Attached graphs shown below:

AFE current variations in CQ06

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AFE voltage variations in CQ06

Harmonics in CQ06

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Currents Variations in CQ11

Voltages variations in CQ11

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Harmonics in CQ11

2- Reviewing Isometer setting of AFE1 in CQ06 and CQ11. Mr. Rudolf showed that its desired
function is disabled. In our ZPMC cranes the main power neutral is not connected to ground (this
system is called "IT system") as a safety from any short circuit will happen if any line voltage is
grounded.
3- Collecting S/N of all ZPMC CQs AFEs and drives.
Conclusion:
1- Adding hardware on-delay timer to delay enabling the CUSA board until the charging
process is completed to prevent AFE main CB damage, Siemens Advised.
2- Adding hardware off-delay timer to prevent switching ON immediately before certain time,
preventing capacitors damage in AFEs, Siemens Advised.
3- CQ06 flashing UPS batteries indication lights problem still open (Waiting Siemens reply).
4- In Noell cranes, RRU regeneration function should be disabled when crane is off to protect
feedback transformer from heating as siemens advised.
5- Defective capacitors in AFEs should be changed but waiting for Siemens Reply.
6- ZPMC should be inquired about the AFE isometer which is disabled should it be enabled?

Ahmed El-Sweesy
Electrical Engineer -Cranes Team
Suez Canal Container Terminal
22-02-2008 15:00

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