Hydraulic Mining Excavators

CAMP/ SIL – Electric System CAT-6060FS AC

Drive Controller – Operation Manual

Sebastian Fillinger - 2014

Location of the Drive Control System Service Training

-3A3

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Drive Controller Service Training

The following pages describe the interconnection inside the servo controller via software.
It is represented in so called functional modules:

And module:
The output is “high” if input 1 is “high” and input 2 is “high”

Input 1
Output
Input 2 &

Or module:
The output is “high” if input 1 is “high” or input 2 is “high”

Input 1
OR Output
Input 2

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Drive Controller Service Training

Time delay module (turn on time delayed):

The output is “high” if input 1 is “high” for at least 15s

15s
Delay
Input 1 Output

Time delay module (turn off time delayed):

The output is “high” when input 1 is “high” and turns off after 15s time delay

15s
Delay
Input 1 Output

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Drive Controller Service Training

Negation module:
The incoming signal will be swapped from “high” to “low” or from “low” to “high”
The output is “high” if input 1 is “low”/ The output is “low” if input 1 is “high”

Input 1 1 Output

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Main motor start Service Training

Start interlock See page 7

1S115 Ignition Power supply controller outputs

X3/ 98 Emergency chain ok

3S401 Maintenance switch

3B531 Shut off valve 1

3B532 Shut off valve 2

X3/ 103 Motor protection relay ok

X3/ 102 High voltage ok

& Main motor start

X3/ 101 Phase sequence ok

X3/ 100 Power factor correction ok

5S7 Motor start button CAN Bus

Auxiliary Controller
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Main motor stop Service Training

1S115 Ignition Power supply controller outputs

1
X3/ 98 Emergency chain ok
1
3S401 Maintenance switch
1
3B531 Shut off valve 1
1
3B532 Shut off valve 2
1

OR Main motor stop

X3/ 103 Motor protection relay ok
1
X3/ 102 High voltage ok
1
X3/ 101 Phase sequence ok
1

X3/ 100 Power factor correction ok

1
5S8 Motor stop button CAN Bus

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Auxiliary Controller
Start interlock Service Training

The system allows 3 motor starts per hour. Two starts can be done one after the other. You can start the
motor the third time when the time between first and third start is greater than 1 hour.

Example:

1. Start 1. Start 1. Start

10 min 30 min 40 min

2. Start 2. Start
1h / 55 min
40 min
10 min 2. Start
30 min 40 min 15 min

3. Start 3. Start 3. Start

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Overview Pump Control Service Training

Motor winding temperature via MOD Bus

Hydraulic oil temperature

Voltage

Motor load (active power)

Acceleration
0 - 100%

Pump Requirements
from Servo Controller
Signal via CAN-safety-Bus via Can-Bus

Joysticks and
Drive Controller
Foot pedals Servo Controller
PMS Current 250 – 850mA
(150mA Standby Current)

Angle Main Pumps 0 –

15°

50bar Pressure

8 - 43bar to Main Pumps

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Reducing PMS Current / Pressure Service Training

Hydraulic Oil Temperature exceeds 80°´C

Motor winding temperature exceeds 120°C

Voltage (from grid) is lower than the nominal voltage

OR

Acceleration
0 - 100%

Pump Requirements Derated output

from Servo Controller current
Signal via CAN-safety-Bus via Can-Bus

Joysticks and
Drive Controller
Foot pedals Servo Controller

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PMS – Reducing PMS current/ pressure Service Training

If the nominal voltage of the motor drops down, the motor output power will
be reduced (see formula down below).
The min. factor of motor power derating in case of voltage drop down is 60% of the nominal motor output power!

Uact 2
Derated _ Motor _ Output _ Power  (
Unom 2
)
* Pnom

Example:
Nominal voltage: 7200V
Actual voltage: 6700V
Nominal output motor: 1800KW

2
Uact 2 6700V
Derated _ Motor _ Output _ Power  * Pnom  *1800 KW  1558KW
Unom 2 2
7200V

Explanation: In the upper example the Motor can deliver max. 1558KW power to the hydraulic system.

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 PMS – Reducing PMS current/ pressure Service Training

If the winding temperature exceeds 120°C, the motor output power will be
reduced (see Graph down below).
The min. factor of motor power derating in case of winding overheating is 80% of the nominal motor output power!

Motor Output Derating

120
Motor Output in % of nominal Output Power

100

80

60

40

20

0
0 20 40 60 80 100 120 140 160 180 200
Winding Temperature in °C

Example:
Nominal motor power: 1800KW
Actual winding temperature: 135°C
Output motor: 1620KW (90%)

Explanation:
In the upper example the motor can deliver max. 1620KW power to the hydraulic system.

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 PMS – Reducing PMS current/ pressure Service Training

In case of voltage drop down and exceeded winding temperature both

factors will be multiplied
Example: Motor Output Derating

120

Nominal voltage: 7200V

Motor Output in % of nominal Output Power

100

Actual voltage: 6700V 80

Actual winding temperature: 135°C 60

40
Nominal output power: 1800KW
20

0
0 20 40 60 80 100 120 140 160 180 200
Winding Temperature in °C

Derating factor under voltage: 0,86 (see formula) 2

Uact 2 6700V
Derating factor winding temperature: 0,9 (see graph) Derating _ Factor _ Under _ Voltage  * Pnom   0,86
Unom 2 2
7200V

Derating factor under voltage * Derating factor winding temperature = Total derating factor
0,86 * 0,9 = 0,774

Total derating factor * Nominal output motor = Actual output motor

0,774 * 1800KW = 1393KW

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Questions? Service Training

Questions are free of charge!!!

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