ABB

General description Automation Technologies

Gearless Mill Drive
Training Course
© ABB Industries - 1 -
 Agenda
„ System overview
„ General description of individual components
„ MV switches
„ Converter transformer
„ Cyclo-converter and excitation
„ Ringmotor
„ Auxiliaries and E-house
„ Controller (drive control and system control)
„ Harmonic filter and power factor compensation
„ Function description of main system components
„ MV Switches and converter transformer
„ Cyclo-converter and excitation
„ Ringmotor
„ Drive control
„ System control (PLC) and auxiliaries
„ Operation & maintenance aspects
© ABB Industries - 2
 General description of individual components
MV switches Converter transformer
Harmonic filter & power
factor compensation

M

S

T2 T1 T1 T1

E-house & Auxiliaries

n2 n1
Cycloconverter & excitation
B

i-
A

u+
i+
u-

iS
iR iT Superior Control System Bus

1 Communication

Controller
Processor

uR uS B448 Bus

uT
ie
Ringmotor (drive control,

Interface
Analog

Analog
and Digital PSR2 Gate Control
SM Unit

M
 Input/Output
iSBX

3 ARCnet

ARCnet® Bus system control)

© ABB Industries - 3

Digital I/O Converter Converter Digital I/O Operation

Overvolt. Protection Excitat. int. Electronics Electronics Customer Alarms
CROWBAR

.....

........
1
..... Superior

........
1 Control System
T93_0070.DRW
 GMD block diagram
23kV / 50Hz / 3ph -15/+5%
3.3 kV / 3ph / 50Hz

380 V / 3ph / 50Hz 4

1
24
380 V / 3ph+N / 50Hz 22
2 Power Legend
Lighting Circuit Main Circuit VAR
Breaker Breaker Stator Synchronisation Volt
DCS VMS
Rotor Transformer
Amp Distributed Tower 1. MCC LV Power Supply
4
Control System (not ABB Scope) Telephone
2. Synchronisation Transformer HV Supply
1pc for 3 mills 4. HV Power Supply stator
5 5. Excitation Transformer Power Supply
6 7 8 Others 6. Stator Transformer 1 Power Supply
7. Stator Transformer 2 Power Supply
8. Stator Transformer 3 Power Supply
38 39a
Stator Stator Stator 9. Synchronisation Voltage
Excitation Transformer 1 Transformer 2 Transformer 3 ABB 10. Excitation Converter Power Supply
Transformer
Switzerland 11. Stator Phase (R) Power Supply
12. Stator Phase (S) Power Supply
13. Stator Phase (T) Power Supply
14. Motor Excitation Power Supply
44 9 43 15. Motor Phase U,V,W Power Supply &
23 Motor Starpoint
Circuit 16. Converter Auxiliary LV Power Supply
17. Space Heater, Motor Fans Power Supply
Breaker 25 26 27 18. Mill Brake Power Supply
19. Cycloconverter Recooling System
23a Auxiliary Power Supply
10 11 12 13
20. Mill Lubrication System
Auxiliary Power Supply
Differential 120VAC / 50Hz/ 1ph MCC-supplied Fire Fighting 21. MCC Control and Supervision
Air condition
Protect. Relay 22. Excitation Breaker Control and Supervision
redundant
UPS 40 System
+F16 23. Excitation Transformer Supervision
39 +F14 23a. Excitation Circuit Breaker Supervision
40
MCC +CA +CB +CC 24. Main Breaker Control and Supervision
25. Stator Transformer 1 Supervision
+F05...+F20 30 PSR +F02 PLC Video Monitoring 26. Stator Transformer 2 Supervision
Control & Regulation +F03 System +F04 27. Stator Transformer 3 Supervision
28. Serial Interface PSR to PLC (RS 232 / DH+)
29. Motor Winding temperature Supervision
Cyclo-Converter 12-Pulse Water inlet / outlet temp. supervision by PT100
16 Excitation 30. Cycloconverter control & supervision
+F01 Cycloconv.Recooling Unit 31. Cycloconverter Recooling System
Supervision
19 Cooling pumps redundant 31 28
32. Mill Lubrication system Supervision
+F15 VMS Tower Data Logger 33. Excitation converter control
33 34. Air Gap Supervision

36. Interconnection MLCB to PLC

14 15
21 E-House 37 Arcnet Interface MLCB to PSR
38. Interface PLC to DCS
39. Serial Interace VMS to PLC
42 39a.Serial Interace VMS to Monitor in DCS
40. UPS Power Supply (PSR,PLC, VMS)
Knife switches
34 41. Mill Brake Control & Supervision
37
42. Knife switch (rotor/stator) Control & Supervision
17 V
36 43. Line current, line power, line VAR signals to PLC
Ringmotor
2 x Make up Fan

W
MLCB
water leakage

U
dust sealing
© ABB Industries - 4

44. Transformer Differential Protection

PT100

Y
9x Probe
PT100
* x Motor Fans

2x heat Motor Local Control

water flow

air temp.

exchanger
Box
Excitation

M
Heater

air gap

29

35
32
20
Mill Lubrication System
41
(scope of mill supplier) Mill Brake
System
(scope of mill supplier)

18
 Switchgear / main circuit breaker
„ GMD switchgear installation
„ Rectifier respectively converter application
„ MV-Circuit breaker for switching ON/OFF the isolating cycloconverter &
excitation transformers,controlled by drive controller (PSR).

„ Knife switches for isolating

stator & rotor of the ringmotor
„ Supervised and controlled by the
overall PLC.
© ABB Industries - 5
 Cycloconverter transformer
„ adapts and isolates the medium network voltage to the converter
supply voltage, and restricts short-circuit currents to the converter.
„ general 3 or 4 winding transformers are used for GMD drive
systems, to achieve multi-pulse systems with substantial harmonic
reduction.
„ shield between HV & LV windings reduces transferred radio
interference from the drive to the network.
„ impedance acts as a commutating reactor and reduces harmonics.

Active part of 3-winding cycloconverter transformer

Rated power: 8504 / 2*4252 kVA
Voltage ratio: 33000 / 2*1262 V
© ABB Industries - 6

Active part of 7-winding cycloconverter transformer

Rated power: 9720/6*1620 kVA
Voltage ratio: 33000/6*1000 V
 Cycloconverter drive systems: 6p-basic circuit
Basic circuit diagram of 6p-cycloconverter-fed Power supply side,
synchronous motor (Power Section)
net cos phi max 0.84 without
S = Circuit-Breaker F&C
T1, T2= Converter Transformer
n1= Cycloconverter M

n2= Excitation Converter S
SM = Synchronous Machine
A, B = Three-phase Bridges

„ Base component is a 6-pulse anti-parallel bridge T2 T1 T1 T1

„ Frequency converter without energy storage

„ Input frequency (f1) 50…60 Hz
„ Output voltage controllable n2 n1

„ Output frequency controllable (f2 = 0....20Hz) B

„ Variable speed = f2 / p

i-
A

u+
i+
u-

iS
iR iT
© ABB Industries - 7

uR uS
uT
ie
SM
M

3
© ABB Industries - 8 Cycloconverter basics – power part
 Cycloconverter including cooling system

Thyristor cooling system

Thyristor stack
© ABB Industries - 9
 Excitation converter for rotor supply

„ Excitation cubicle consists of:

„ Compact 6-pulse DC
Converter incl. digital control
„ Overvoltage suppressors
netside & motorside
„ Thermal protection
„ Cooling Fan
„ Rotor ground fault detection
© ABB Industries - 10
 Ringmotor
„ Synchronous motor
„ Salient pole rotor design
„ Typically used for lower speeds
„ Larger number of poles
„ Single poles feasible due to lower centrifugal
forces
„ Large diameter, short axial length
„ Motor poles can be individually adjusted
„ Laminated poles, without damper winding or
damper cage
„ DC current supply to rotor windings via
sliprings and brushes
© ABB Industries - 11
 Ringmotor mounting method

Pedestal mounted motor

© ABB Industries - 12

Floor mounted motor

 E-house and auxiliaries
„ The E-House container is constructed to be suitable for
transportation on road by flat cars or skeletal chassis, secured by
twistlocks or equivalent at the bottom corner fittings. All materials
used in the construction can withstand extremes of temperature
range from – 30° to + 60° C without effects on strength of the basic
structure and water tightness.
„ E-House is housing the following equipments:
„ Cycloconverter power part incl. cooling & control
„ MCC for the complete drive system (Motor & Mill auxiliaries)
„ PLC panel
„ VMS system
„ Transformer differential protection panel
„ UPS incl. bypass switch
„ Fire fighting system
© ABB Industries - 13

„ Lighting panel
„ Air condition
© ABB Industries - 14 E-House - layout
 E-House - layout

„ External dimensions
„ Length: 12.270 mm
„ Width: 3.658 mm
„ Height: 3.500 mm
© ABB Industries - 15
© ABB Industries - 16 E-House - layout
© ABB Industries - 17 E-House general view
© ABB Industries - 18 E-House – connection side, cooling unit
© ABB Industries - 19 E-House - MCC
© ABB Industries - 20 Drive control and system control
 Drive controller (PSR)
„ The cycloconverter drive controller named PSR2 is an ABB developed high speed controller used for:
„ Motor current and flux control
„ Speed control
„ Pulse firing control
„ Control & supervision of the cycloconverter & cooling unit

„ Drive specific control & supervisions:

„ main circuit breaker control
„ mill brake control logic
„ frozen charge protection
„ air gap monitoring & supervision
„ mill creeping (low speed operation)
„ positioning of the mill etc. …)
© ABB Industries - 21
 Overall control system (PLC)
„ PLC is responsible for the overall system control and
supervision of the following tasks:
„ Communication with client’s DCS system
„ Communication to the VMS system
„ Communication with the PSR2 drive controller
„ Cycloconverter transformers supervision
„ Excitation transformer supervision
„ Ringmotor auxiliary system (control & supervision)
„ Mill lube system (control & supervision)
„ Brake system (supervision)
„ MCCs
„ Air condition
„ Fire fighting system
„ Alarm/ Fault handling of auxiliary drives/ devices
© ABB Industries - 22
 Drive men-machine interface (VMS)
„ The VMS system (Video Monitoring System), is a men-machine interface, based on the ABB
Industrial IT 800xA System, designed for Gearless Mill Drive (GMD) applications.

„ The VMS consists of about 8 main displays covering the most important aspects of a GMD Drive.
„ It is installed inside the E-House and is designed for maintenance and troubleshooting use.
„ In the VMS is possible to:
„ - View trends of the ABB PLC variables;
„ - Check alarm and events;
„ - View active interlocks;
„ - Monitor the cycloconverter cooling unit;
„ - Monitor the ringmotor;
„ - Monitor the stator and rotor medium voltage system;
„ - Monitor the lubrication system;
„ - Monitor the brake system;
„ - Monitor the E-House equipments like: fire-fighting, UPS, air conditioners;
„ - Supervise all drive controller faults, warnings and status messages.
© ABB Industries - 23
© ABB Industries - 24 Drive men-machine interface (VMS)
 Harmonic filter and power factor compensation
„ More adjustable speed drives and bigger plant capacity requests for
properly designed Power Factor Correction (PFC) system.
„ Improvement of the power factor:
„ Avoidance of penalties due to higher electrical quality standards (IEEE 519)
„ Reduction of harmonic distortions:
„ Avoidance of harmonic related problems
© ABB Industries - 25
 Harmonic flow in networks
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© ABB Industries - 26

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