Commissioning Report GMD System: ABB Switzerland LTD

Commissioning Report
ABB Switzerland Ltd GMD System

Supplier: ABB Switzerland Ltd Customer:
Dept.: ATBDE
CH-5405 Baden, Switzerland Sociedad Minera Cerro Verde / Perú
ABB-Order-No.: 1-1032937 Project: Primary Sulfide Project
Consultant: Fluor Equipment: BALL MILL 3 / 12 MW
Contract PSP108 TAG Name: C-3320-ML-301M

Number:
P.O. Number: A1WF-65-013-P0
Commissioning/Service Engineer: ............................................…………Dept:………...............

............................................…………Dept:………...............
............................................…………Dept:………...............
Commissioning date/period: …………............................................
GMD System
“Part A”
(Cycloconverter & Drive Controller)
Issued: P. Meier 28.09.04 Change: Off. resp.: ATBDE Doc.- Language Format Page No of
type pages
Check. 1: I. Novotny 15.08.05 A Rec. off.: E A4 1 92
Check. 2: B Der. from:
Released: M. Garnier 16.08.05 C Replaces:
Doc.-Nr.: 3BHS 215357
I:\01D\Drives\Projects\PIBD\11032937 Cerro Verde\03 Final Documents\Vol 16 - GMD System Commissioning
Report\3BHS215357_Commiss Report Cerro Verde GMD_BM3_PartA_rev0.doc
Table of Contents:
1 General .........................................................................................................................5
1.1 Abbreviations ..................................................................................................................... 6
2 Tools, Documentation and Software..........................................................................7
2.1 Commissioning tools list..................................................................................................... 7
2.2 Documentation................................................................................................................... 8
2.3 Commissioning Software.................................................................................................... 8
3 Visual Inspection .........................................................................................................9
3.1 E-House............................................................................................................................. 9
3.2 Main Circuit Breaker of Stator Cycloconverter Transformer................................................ 9
3.3 Main Circuit Breaker of Rotor Excitation Transformer....................................................... 10
3.4 Cycloconverter Transformer............................................................................................. 11
3.4.1 Transformer for cycloconverter +CA ....................................................................................................... 11
3.4.2 Transformer for cycloconverter +CB........................................................................................................ 12
3.4.3 Transformer for cycloconverter +CC........................................................................................................ 13
3.5 Excitation Converter Transformer..................................................................................... 14
3.6 Synchronisation Transformer ........................................................................................... 15
3.7 Cycloconverter ................................................................................................................. 16
3.8 Excitation Converter......................................................................................................... 16
3.9 Stator Isolating (Knife) Switch .......................................................................................... 17
3.10 Rotor Isolating (Knife) Switch ........................................................................................... 17
3.11 Ring Motor ....................................................................................................................... 18
3.12 Protection Relay............................................................................................................... 19
3.12.1 Main Feeder Protection Relay.................................................................................................................. 19
3.12.2 Rotor Transformer Protection Relay........................................................................................................ 19
3.12.3 Cycloconverter Transformer Protection Relay (Protection Panel)........................................................... 20
3.13 Fire Suppression System ................................................................................................. 21
3.14 Air Conditioning System ................................................................................................... 22
3.15 GMD’s Auxiliary ............................................................................................................... 23
4 Wiring Test .................................................................................................................26
4.1 Single line diagram, power cable wiring ........................................................................... 26
4.1.1 High Voltage cables.................................................................................................................................. 26
Power Part................................................................................................................................. 27
4.1.2 Power Cable of Cycloconverter Circuit ................................................................................................... 27
4.1.3 Power Cable of Excitation Converter Circuit .......................................................................................... 29
4.1.4 Power Cable of MCC (Motor Control Centre)......................................................................................... 30
4.1.5 Power supply 110VDC from substation to protection relay panel........................................................... 35
4.1.6 Tightening Torque Bolt of Cycloconverter Circuit.................................................................................. 36
4.1.7 Tightening Torque Bolt of Excitation Converter Circuit ......................................................................... 38
4.1.8 Tightening Torque Bolt of MCC ............................................................................................................. 39
4.2 Control part ...................................................................................................................... 45
4.2.1 Control signals between PSR control panel (+F02) and cycloconverter main circuit breaker................. 45
4.2.2 Control signals between PSR control panel (+F02) and excitation main circuit breaker......................... 45
4.2.3 Control signals between PSR control panel (+F02) and ring motor ........................................................ 46
4.2.4 Control signals between PSR control panel (+F02) and field emergency stops ...................................... 46
4.2.5 Control signals between PSR control panel (+F02) and mill local control panel (+MLCP).................... 46
4.2.6 Control signals between mill local control panel (+MLCP) and radio control, remote module .............. 47
Title Project
Primary Sulfide Project
Commissioning Report GMD System Equipment
“Part A” BALL MILL 3 / 12 MW
Document identity Lang. Rev. ind.
Sheet 2
ABB Switzerland Ltd 3BHS 215357 E 0
No. of
sheets 92
File: 3BHS215357_Commiss Report Cerro Verde GMD_BM3_PartA_rev0.doc
4.2.7 Control signals from cycloconverter transformer protection box ............................................................ 47
5 Energise MCC’s & Low Voltage Distribution...........................................................48
5.1 Energise Incoming MCC Supply Voltage (3 Phase). ........................................................ 48
5.2 Energise Lighting and Power Sockets. ............................................................................. 48
5.3 Internal Auxiliary Power Supply 230/240 Volts. (Single Phase) ........................................ 48
5.4 Internal Auxiliary Power Supply 110/120 Volts. (Single Phase) ........................................ 49
5.5 Start up UPS. ................................................................................................................... 49
5.6 Energise Control Voltage in Panels.................................................................................. 50
6 Signal Test..................................................................................................................51
6.1 Cycloconverter Transformers phase U Protection ............................................................ 51
6.2 Cycloconverter Transformers phase V Protection ............................................................ 51
6.3 Cycloconverter Transformers phase W Protection ........................................................... 52
6.4 Air-gap Measurement....................................................................................................... 53
7 Function Tests ...........................................................................................................54
7.1 Check Rotational of Aux. Motor (Motor Cooling Fan, Lubrication and Brake System) ...... 54
7.2 Cycloconverter Cooling Unit (+F15) ................................................................................. 56
7.3 Cycloconverter transformer over current protection.......................................................... 58
7.4 Emergency stop relay (Control Panel +F02)..................................................................... 59
7.5 ON/OFF Main Circuit Breaker Function Test (Stator and Rotor)....................................... 59
7.5.1 Rotor Main Circuit Breaker Function Test .............................................................................................. 59
7.5.2 Stator Main Circuit Breaker Function Test.............................................................................................. 59
7.6 Earth Fault Protection ...................................................................................................... 60
7.6.1 Rotor Protection....................................................................................................................................... 60
7.6.2 Stator Protection ...................................................................................................................................... 61
7.7 Hardware Protections....................................................................................................... 62
8 PSR2 Drive Protection Settings................................................................................64
8.1 General drive requirements:............................................................................................. 64
8.2 Stator and Thyristor Protection Settings ........................................................................... 64
8.3 Excitation Protection Settings........................................................................................... 65
8.4 Network Protection Settings ............................................................................................. 65
8.5 Ring Motor Air gap Protection Settings............................................................................. 66
8.6 Frozen Charged Protection Settings ................................................................................ 66
8.7 Cycloconverter Cooling Protection Settings...................................................................... 67
8.8 Cycloconverter Current Control Phase R-S-T Settings..................................................... 67
8.9 Cycloconverter Speed Control Settings............................................................................ 67
8.10 Cycloconverter Low Speed Control “Phase Correction” Settings...................................... 68
8.11 Cycloconverter Low Speed Control “Amplitude Correction” Settings ................................ 69
8.12 Delta psi-T and Network Voltage >85%<95% Speed Control Limit Function .................... 69
8.13 Cycloconverter Internal Calculation Settings .................................................................... 70
9 Energizing Power Transformer.................................................................................71
9.1 Energizing Excitation Transformer ................................................................................... 71
9.2 Energizing Cycloconverter Transformer ........................................................................... 72
10 Load Test “Rotor Circuit” .........................................................................................73
10.1 Start up Excitation Converter............................................................................................ 73
10.2 DC Current injection on rotor circuit.................................................................................. 73
10.3 Dis-excitation Function..................................................................................................... 75
11 Synchronisation of Reference Voltage to Power ....................................................77
12 Load Test Stator (without Excitation) .........................................................................80
13 Ring Motor Test..........................................................................................................85
13.1 No Load Test ................................................................................................................... 86
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13.2 Load Test......................................................................................................................... 89
14 Final Work ..................................................................................................................90
15 Attachment logbook. .................................................................................................91
15.1 Hardware Modification log book. ...................................................................................... 91
15.2 Software Modification log book......................................................................................... 92
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1 General
The GMD drive system commissioning report is divided in part A & part B, containing the following test:
GMD Commissioning Report “Part A” (Document No 3BHS215357)

- E-House
- Air condition
- Fire suppression system
- Motor Control Centre. “MCC”
- Main Circuit Breaker Stator
- Main Circuit Breaker Rotor
- Cycloconverter Transformer
- Excitation Transformer
- Cycloconverter
- Excitation Converter
- Ring Motor (air gaps)
GMD Commissioning Report “Part B” (Document No 3BHS215357)
- PLC point to point test

- PLC signal test
- PLC test interlocks
- Mill Brake System function test
- Mill Lubrication System function test
- PLC drive system function test
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1.1 Abbreviations
GMD = Gearless Mill Drive ixR1 = Motor Current Phase R/0°
Cyclo = Cycloconverter ixS1 = Motor Current Phase S/0°
MCB = Main Circuit Breaker ixT1 = Motor Current Phase T/0°
Programmable High Speed
PSR = ixR2 = Motor Current Phase R/30°
Controller
FUPLA = Function Plan Programming ixS2 = Motor Current Phase S/30°
PLC = Programmable Logic Control ixT2 = Motor Current Phase T/30°
VMS = Visual Monitoring System UxMR = Motor Voltage Phase R
MCC = Motor Control Centre UxMS = Motor Voltage Phase S
+MLCP = Mill Local Control Panel UxMT = Motor Voltage Phase T
+F01 = Excitation Control Panel ixe = Excitation Current Actual
+F02 = Cycloconverter Control Panel iwe = Excitation Current Reference

+F03 = Programmable Logic Control uxe = Excitation Voltage Actual
+F04 = Visual Monitoring System psi-x = Actual Flux Vector in ∝/β coordinate
system
+F05…09 = Motor Control Center Panel psi-alfa = Actual Flux Vector in ∝/β coordinate
system
+F14 = Fire Fighting System Panel U-alfa = Firing Angle Control
+F15 = Cyclo Cooling Unit Panel Nx = Mill Speed Actual
+F17 = Lighting Panel Nw = Mill Speed Reference
+AC01…02 = Air Condition no.1-2 Iw = Torque Reference
+CA = Cycloconverter Power Part (U) psiT = Converter Voltage trapez limit
+CB = Cycloconverter Power Part (V) psi-beta = Actual Flux Vector in ∝/β coordinate
system
+CC = Cycloconverter Power Part (W) +idw = Additional Torque Reference
+UPS = Uninterrupted Power Supply AGC1...9 = Actual Air gap Signal.
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2 Tools, Documentation and Software
2.1 Commissioning tools list
Item Description Quantity Checked Date Sign.
1 Drive Windows for DCF 600 incl. PCMCIA card for laptop 1
…………. …………
2 Control Panel CDP 312 for DCF 600 1 …………. …………
3 P6021 Current Probe, Tektronix TE6021 3
…………. …………
4 Fluke Scope meter 200MHz, 2,5GS/s, 2 channel 1
…………. …………
5 Memo box 800S, SET LEMFLEX 1
…………. …………
6 Insulation Tester Metriso 5000 (Megger) 1
…………. …………
7 Clamp-Ampermeter LEM AC/DC 2
…………. …………
8 Digital Multimeter MetraHit 28S 2
…………. …………
9 Raytek Infrared Thermometer 1
…………. …………
10 Three-phase Sequence Tester 1
…………. …………
11 Fluke Volt/mA Calibrator 2
…………. …………
12 AC Current Probe i-1000s 1
…………. …………
13 Differential Probe SI-9005 6
…………. …………
14 Maxi-Thermipoint Tool incl. wire, clamps 1
…………. …………
15 Set of Hand Tools & diff. small Parts 1
…………. …………
16 Various Special Test Cables, Plugs, Clamps 1
…………. …………
17 Thyristor test device FADEC 90 1
…………. …………
18 Recorder 4 channel: HIOKI 8835-01 incl. Int. printer 1
…………. …………
19 Recorder 8 channel: HIOKI 8855 incl. Int. printer 2
…………. …………
20 Extension print, XB 9599 a 1
…………. …………
21 Interface Converter RS232/RS485 SSV-3E (220Vac) 1
…………. …………
22 Resistor / Capacitor Set 1
…………. …………
23 Calculator 1
…………. …………
…………. …………
…………. …………
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2.2 Documentation
Document Revision
Item Description Checked Date Sign.
Number Used
1 Cycloconverter Test Report.
…………. …………
2 E-House Test Report.
…………. …………
3 GMD Drive System Circuit Diagram.
…………. …………
4 MCC Circuit Diagram.
…………. …………
5 Printout PSR Software.
…………. …………
6 PSR fault and alarm list.
…………. …………
7 Design data sheet cycloconverter
…………. …………
8 P&ID Cooling System.
…………. …………
Software Description of Drive Controller
9
PSR2. …………. …………
Function Block Library of Drive
10
Controller PSR2. …………. …………
DCF 600 User’s Manual, for Excitation
11
Converter. …………. …………
ABB Acceptance report
12
(Doc. Nr. HKM 650 164) …………. …………
13 Contract (Drive Specification)
…………. …………
14 PSR signal list including settings
…………. …………
Log book for temporary or permanent
15
Hardware & Software Changes …………. …………
16 Connections for the Transient Recorder
…………. …………
2.3 Commissioning Software
Software
Item Description Checked Date Sign.
Version
1 FUPLA400 for Cycloconverter
…………. …………
2 Drive Windows for Excitation Converter DCF600
…………. …………
…………. …………
…………. …………
…………. …………
…………. …………
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3 Visual Inspection
Inspecting of existing, condition and mounting of the Main Components.
3.1 E-House
- Erection completed Date:...............Sign.:……
(Abnormal/unusual cases see note below)
Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Protection/IP
………………………… ………………….
Note: ………………………………………………………………………………………………………………….
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3.2 Main Circuit Breaker of Stator Cycloconverter Transformer

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Rated Voltage kV
………………………… ………………….
Isc kA Time Sec.
…………………. ………………….
Frequency Hz Standard
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.3 Main Circuit Breaker of Rotor Excitation Transformer

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Rated Voltage kV
………………………… ………………….
Isc kA Time Sec.
…………………. ………………….
Frequency Hz Standard
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.4 Cycloconverter Transformer
3.4.1 Transformer for cycloconverter +CA

- The tap changer position number: …………. Date:...............Sign.:……
(Put the tap changer to position as it is a nominal input and output voltage)
Tag Name
……………………………………………………………………………….
Manufacturer Year of Manuf.
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Standard Vector Group
…………………………. …………………………...
Cooling Frequency Hz
…………………………. ………………….
Primary Winding
Power kVA Voltage V

…………………. ………………….
Current A Impedance %
…………………. ………………….
Secondary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Tertiary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
No-load loss kW No-load power kVA
…………………. ………………….
Total Weight kg Weight of oil kg
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.4.2 Transformer for cycloconverter +CB

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
…………………………. …………………………...
…………………………. ………………….
Primary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Secondary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Tertiary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
…………………. ………………….
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
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3.4.3 Transformer for cycloconverter +CC

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
…………………………. …………………………...
…………………………. ………………….
Primary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Secondary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Tertiary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
…………………. ………………….
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
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3.5 Excitation Converter Transformer

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
…………………………. …………………………...
…………………………. ………………….
Primary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
Secondary Winding
Power kVA Voltage V

…………………. ………………….
…………………. ………………….
…………………. ………………….
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.6 Synchronisation Transformer

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
…………………………. …………………………...
Power VA Frequency Hz
…………………. ………………….
Primary Winding
Voltage V Current A
…………………. ………………….
Secondary Winding
Voltage V Current A
…………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.7 Cycloconverter
Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Type No.
…………………………. …………………………...
Input Voltage V Output Voltage V
…………………. ………………….
Input Current A Output Current A
…………………. ………………….
Input Power kVA Output Power kVA
…………………. ………………….
Input Freq. Hz Output Freq. Hz
…………………. ………………….
Standard Protection/IP
………………………… …………………………...
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
3.8 Excitation Converter

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No.
…………………………………………………………………….…………
Input Voltage V Output Voltage Vdc
…………………. ………………….
Input Current A Output Current Adc
…………………. ………………….
Input
Hz
Frequency ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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………………………………………………………
3.9 Stator Isolating (Knife) Switch

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Rated Voltage V
………………………… ………………….
Continuous
A Frequency Hz
Rated Current …………………. ………………….
Maximum
A Protection/IP
Current …………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
3.10 Rotor Isolating (Knife) Switch

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Rated Voltage V
………………………… ………………….
Continuous
A Frequency Hz
Rated Current …………………. ………………….
Maximum
A Protection/IP
Current …………………. ………………….
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
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3.11 Ring Motor

Tag Name
……………………………………………………………………………….
Manufacturer Type
…………………………. …………………………...
Serial No. Power kW
…………………………. ………………….
Voltage V Current A
…………………. ………………….
Speed Range rpm Cosine phi
…………………. …………………………...
Freq. Range Hz Ins. Class
…………………. …………………………...
Protection/IP Rotation
………………………… …………………………...
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
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3.12 Protection Relay
3.12.1 Main Feeder Protection Relay

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
3.12.2 Rotor Transformer Protection Relay

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Note: ………………………………………………………………………………………………………………….
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3.12.3 Cycloconverter Transformer Protection Relay (Protection Panel)
3.12.3.1 Transformer protection relay of cycloconverter +CA

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type
………………………………………………………………………………..
Serial no.
……………………………………………………...………………………...
3.12.3.2 Transformer protection relay of cycloconverter +CB

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type
………………………………………………………………………………..
Serial no.
……………………………………………………...………………………...
3.12.3.3 Transformer protection relay of cycloconverter +CC

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type
………………………………………………………………………………..
Serial no.
……………………………………………………...………………………...
Note: ………………………………………………………………………………………………………………….
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3.13 Fire Suppression System

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.14 Air Conditioning System

Tag Name
……………………………………………………………………………….
…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Voltage V Current A
Power kW Frequency Hz
Tag Name
……………………………………………………………………………….

…………………………. …………………………...
Type Serial no.
…………………………. …………………………...
Voltage V Current A
Power kW Frequency Hz
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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3.15 GMD’s Auxiliary
Nameplate Protection
Customer Data
Item Description setting Date Sign.
Tag Name Voltage Current (A)
1 Motor Cooling Fan 1 C-3320-FA-303
………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
5 Motor Overpressure Fan Left C-3320-FA-307

………. ………. ……………... …………... …………....
6 Motor Overpressure Fan Right C-3320-FA-308

………. ………. ……………... …………... …………....
7 Motor Space Heaters 1 C-3320-HE-317

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
11 FTB Lube Tank Heater 1 C-3320-HE-301

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

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………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
19 FXB Lube Tank Heater 1 C-3320-HE-309

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
Title Project
Sheet 23
No. of
sheets 92
Nameplate Protection
Customer Data
Item Description setting Date Sign.
Tag Name Voltage Current (A)
………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
27 Low Pressure Lube Pump A C-3320-PP-306M

………. ………. ……………... …………... …………....
28 Low Pressure Lube Pump B C-3320-PP-307M

………. ………. ……………... …………... …………....
29 FTB High Pressure Lube Pump A C-3320-PP-308M

………. ………. ……………... …………... …………....
30 FTB High Pressure Lube Pump B C-3320-PP-309M

………. ………. ……………... …………... …………....
31 FTB High Pressure Lube Pump C C-3320-PP-310M

………. ………. ……………... …………... …………....
32 FTB High Pressure Lube Pump D C-3320-PP-311M

………. ………. ……………... …………... …………....
33 FXB High Pressure Lube Pump A C-3320-PP-312M

………. ………. ……………... …………... …………....
34 FXB High Pressure Lube Pump B C-3320-PP-313M

………. ………. ……………... …………... …………....
35 FXB High Pressure Lube Pump C C-3320-PP-314M

………. ………. ……………... …………... …………....
36 FXB High Pressure Lube Pump D C-3320-PP-315M

………. ………. ……………... …………... …………....
37 FTB Accumulator Pump A C-3320-PP-316M

………. ………. ……………... …………... …………....
38 FTB Accumulator Pump B C-3320-PP-317M

………. ………. ……………... …………... …………....
39 FXB Accumulator Pump A C-3320-PP-318M

………. ………. ……………... …………... …………....
40 FXB Accumulator Pump B C-3320-PP-319M

………. ………. ……………... …………... …………....
41 Air Conditioning Unit 1 C-3320-AC-301

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
43 KP001 Cooling Pump no. 1 C-3320-PP-324

………. ………. ……………... …………... …………....

………. ………. ……………... …………... …………....
45 FTB Filter Pump A C-3320-PP-320M

………. ………. ……………... …………... …………....
46 FTB Filter Pump B C-3320-PP-321M

………. ………. ……………... …………... …………....
47 FXB Filter Pump A C-3320-PP-322M

………. ………. ……………... …………... …………....
48 FXB Filter Pump B C-3320-PP-323M

………. ………. ……………... …………... …………....
49 Hydraulic Brake Pump A C-3320-PP-326M

………. ………. ……………... …………... …………....
50 Hydraulic Brake Pump B C-3320-PP-327M

………. ………. ……………... …………... …………....
Title Project
Sheet 24
No. of
sheets 92
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
Title Project
Sheet 25
No. of
sheets 92
4 Wiring Test
4.1 Single line diagram, power cable wiring
4.1.1 High Voltage cables
Title Project
Sheet 26
No. of
sheets 92
Power Part
ABB requests following test protocols:
• Hi-Pot test for all HV power cables
• Megger test for all power cable
• Point to point test for all power cable
• Tightening torque bolt
The above-mentioned tests will not be carried out by ABB!
4.1.2 Power Cable of Cycloconverter Circuit

Referring to single line diagram see chapter 4.1.1
Point
Megger Hi-Pot Date &
Description to
Test test Sign.
Point
Cables between MCB and cycloconverter transformer
……………….
no.1
See cable section 1.
……………….
Remark:
Cables between cycloconverter transformer no.1 and

……………….
cycloconverter transformer no.2.
……………….
Remark:
Cables between Cycloconverter transformer no.2 and

……………….
Cycloconverter transformer no.3.
……………….
Remark:
Cables between cycloconverter transformer no.1 (0°)

……………….
and cycloconverter input +CA (0°)
……………….
Remark:

……………….
and cycloconverter input +CA (30°)
……………….
Remark:

……………….
and cycloconverter input +CB (0°)
……………….
Remark:
Title Project
Sheet 27
No. of
sheets 92
Point
Megger Hi-Pot Date &
Description to
Test test Sign.
Point
……………….
and cycloconverter input +CB (30°)
……………….
Remark:

……………….
and cycloconverter input +CC (0°)
……………….
Remark:

……………….
and cycloconverter input +CC (30°)
……………….
Remark:
Cables between cycloconverter +CA (output) and stator

……………….
isolator switch.
……………….
Remark:
Cables between cycloconverter +CB (output) and stator

……………….
isolator switch.
……………….
Remark:
Cables between cycloconverter +CC (output) and stator

……………….
isolator switch.
……………….
Remark:
Cable between star point fuse of cycloconverter and

……………….
stator isolator switch.
……………….
Remark:
Title Project
Sheet 28
No. of
sheets 92
4.1.3 Power Cable of Excitation Converter Circuit

Megger Hi-Pot Point to Date &

Description
Test test Point Sign.
Cables between MCB and excitation converter

……………….
transformer.
……………….
Remark:
Cables between excitation converter transformer and

……………….
excitation converter.
……………….
Remark:
Cables between excitation converter ( ⊕ Bus) and rotor

……………….
isolator switch ( ⊕ Bus).
See cable section 16. ……………….
Remark:
Cables between excitation converter ( Bus) and rotor

……………….
isolator switch ( Bus).
……………….
Remark:
Cables between rotor isolator switch ( ⊕ Bus) and slip

……………….
ring rotor ( ⊕ Bus).
See cable section 19. ……………….
Remark:
Cables between rotor isolator switch ( Bus) and slip

……………….
ring rotor ( Bus).
……………….
Remark:
Title Project
Sheet 29
No. of
sheets 92
4.1.4 Power Cable of MCC (Motor Control Centre)
Megger Point to Date &

Description
Test Point Sign.
……………….
Cables between LV power and MCC (Incomer)
……………….
Remark:
Cables between MCC (+F09/BA01) and Air Condition ……………….

Unit 1 (C-3320-AC-301)
……………….
Remark:
Cables between MCC (+F09/BA03) and Air Condition ……………….

Unit 2 (C-3320-AC-302)
……………….
Remark:
Cables between MCC (+F07/DA01) and Cyclo- ……………….

converter Cooling Unit Pump 1 (C-3320-PP-324)
……………….
Remark:
Cables between MCC (+F07/DA03) and Cyclo- ……………….

converter Cooling Unit Pump 2 (C-3320-PP-325)
……………….
Remark:
Cables between MCC (+F07/FA01) Ring Motor Cooling ……………….

Fan 1 (C-3320-FA-303)
……………….
Remark:
Cables between MCC (+F07/FA03) Ring Motor Cooling ……………….

Fan 2 (C-3320-FA-304)
……………….
Remark:
Cables between MCC (+F07/HA01) Ring Motor Cooling ……………….

Fan 3 (C-3320-FA-305)
……………….
Remark:
Title Project
Sheet 30
No. of
sheets 92

Description
Test Point Sign.
Cables between MCC (+F07/HA03) Ring Motor Cooling ……………….

Fan 4 (C-3320-FA-306)
……………….
Remark:
Cables between MCC (+F07/BA01) and Ring Motor ……………….

Over Pressure Fan Left (C-3320-FA-307)
……………….
Remark:
Cables between MCC (+F07/BA03) and Ring Motor ……………….

Over Pressure Fan Right (C-3320-FA-308)
……………….
Remark:
Cables between MCC (+F08/FA01) and Ring Motor ……………….

Space Heaters 1 - 4 (C-3320-HE-317…320)
……………….
Remark:
Cables between MCC (+F08/MA01) and FTB High ……………….

Pressure Pump A (C-3320-PP-308M)
……………….
Remark:
Cables between MCC (+F08/PA01) and FTB High ……………….

Pressure Pump B (C-3320-PP-309M)
……………….
Remark:
Cables between MCC (+F08/RA01) and FTB High ……………….

Pressure Pump C (C-3320-PP-310M)
……………….
Remark:
Cables between MCC (+F08/TA01) and FTB High ……………….

Pressure Pump D (C-3320-PP-311M)
……………….
Remark:
Title Project
Sheet 31
No. of
sheets 92

Description
Test Point Sign.
Cables between MCC (+F07/RA01) and FTB ……………….

Accumulator Pump A (C-3320-PP-316M)
……………….
Remark:
Cables between MCC (+F07/RA03) and FTB ……………….

Accumulator Pump B (C-3320-PP-317M)
……………….
Remark:
Cables between MCC (+F07/MA01) and FTB Filter ……………….

Pump A (C-3320-PP-320M)
……………….
Remark:
Cables between MCC (+F07/MA03) and FTB Filter ……………….

Pump B (C-3320-PP-321M)
……………….
Remark:
Cables between MCC (+F08/DA01) and FTB Tank ……………….

Heaters (C-3320-HE-301…308)
……………….
Remark:
Cables between MCC (+F09/MA01) and FXB High ……………….

……………….
Remark:
Cables between MCC (+F09/PA01) and FXB High ……………….

……………….
Remark:
Cables between MCC (+F09/RA01) and FXB High ……………….

Pressure Pump C (C-3320-PP-314M)
……………….
Remark:
Title Project
Sheet 32
No. of
sheets 92

Description
Test Point Sign.
Cables between MCC (+F09/TA01) and FXB High ……………….

Pressure Pump D (C-3320-PP-315M)
……………….
Remark:
Cables between MCC (+F07/TA01) and FXB ……………….

Accumulator Pump A (C-3320-PP-318M)
……………….
Remark:
Cables between MCC (+F07/TA03) and FXB ……………….

Accumulator Pump B (C-3320-PP-319M)
……………….
Remark:
Cables between MCC (+F07/PA01) and FXB Filter ……………….

Pump A (C-3320-PP-322M)
……………….
Remark:
Cables between MCC (+F07/PA03) and FXB Filter ……………….

Pump B (C-3320-PP-323M)
……………….
Remark:
Cables between MCC (+F08/BA01) and FXB Low ……………….

……………….
Remark:
Cables between MCC (+F08/BA03) and FXB Low ……………….

……………….
Remark:
Cables between MCC (+F08/DA03) and FXB Tank ……………….

Heaters (C-3320-HE-309…316)
……………….
Remark:
Title Project
Sheet 33
No. of
sheets 92

Description
Test Point Sign.
Cables between MCC (+F07/KA01) and Hydraulic ……………….

Brake Pump A (C-3320-PP-326)
……………….
Remark:
Cables between MCC (+F07/KA03) and Hydraulic ……………….

Brake Pump B (C-3320-PP-327)
……………….
Remark:
Cables between MCC (+F06/-F41) and Cyclo

……………….
Transformers Heater + Light. 230V AC (C-3320-XF-
301…303)
……………….
Remark:
Cables between MCC (+F06/-F44) and E-house Light & ……………….

Socket 230V AC (+F17)
……………….
Remark:
Cables between MCC (+F06/-F48) and Brake Reservoir ……………….

Immersion Heater 230V AC
……………….
Remark:
Cables between MCC (+F06/-F51) and Control Panel ……………….

+F01, 02, 03 Light & Socket 230V AC (+F01)
……………….
Remark:
Cables between MCC (+F06/-F53) and Excitation ……………….

Converter 230V AC (+F01)
……………….
Remark:
Cables between MCC (+F06/-F54) and PLC Panel ……………….

230V AC (+F03)
……………….
Remark:
Title Project
Sheet 34
No. of
sheets 92

Description
Test Point Sign.
Cables between MCC (+F06/-F56) and Cyclo Cooling ……………….

Unit 230V AC (+F15)
……………….
Remark:
Cables between MCC (+F06/-F61) and UPS Panel ……………….

120V AC (+UPS)
……………….
Remark:
Cables between MCC (+F06/-F67) and Fire Fighting ……………….

Panel 120V AC (+F14)
……………….
Remark:
Cables between MCC (+F06/-F73) and PSR Control ……………….

……………….
Remark:
Cables between MCC (+F06/-F75) and PLC Control ……………….

……………….
Remark:
4.1.5 Power supply 110VDC from substation to protection relay panel (Not applicable for Cerro
Verde Project).

Description
Test Point Sign.
Cables between substation (110V DC) and relays in

……………….
panel +F02 (-112K1…3)
……………….
Title Project
Sheet 35
No. of
sheets 92
4.1.6 Tightening Torque Bolt of Cycloconverter Circuit
Note: tightening torque is given in document: User’s Manual for Cycloconverter (document No. 3BHS130738
page 17)
Description Received Checked Date Sign.
Tightening torque bolt group at output of cycloconverter

……………… ……………….
main circuit breaker.
See section point 1a.
……………… ……………….
Tightening torque bolt group at input of cycloconverter

……………… ……………….
transformer phase no.1.
See section point 1b.
……………… ……………….

……………… ……………….
……………… ……………….

……………… ……………….
……………… ……………….

……………… ……………….
……………… ……………….
Tightening torque bolt group at input of Cycloconverter

……………… ……………….
……………… ……………….

……………… ……………….
transformer phase no.1 (0°).
……………… ……………….

……………… ……………….
+CA (0°).
……………… ……………….

……………… ……………….
transformer no.1 (30°).
……………… ……………….

……………… ……………….
+CA (30°).
……………… ……………….

……………… ……………….
……………… ……………….
Title Project
Sheet 36
No. of
sheets 92

……………… ……………….
+CB (0°).
……………… ……………….

……………… ……………….
……………… ……………….

……………… ……………….
+CB (30°).
……………… ……………….

……………… ……………….
……………… ……………….

……………… ……………….
+CC (0°).
……………… ……………….

……………… ……………….
……………… ……………….

……………… ……………….
+CC (30°).
……………… ……………….

……………… ……………….
+CA.
……………… ……………….
Tightening torque bolt group at input of isolator switch.

……………… ……………….
(Phase R)
……………… ……………….

……………… ……………….
+CB.
……………… ……………….

……………… ……………….
(Phase S)
……………… ……………….

……………… ……………….
+CC.
……………… ……………….

……………… ……………….
(Phase T)
……………… ……………….
Title Project
Sheet 37
No. of
sheets 92

……………… ……………….
star point fuse.
……………… ……………….

……………… ……………….
(Star connector, Neutral)
……………… ……………….
4.1.7 Tightening Torque Bolt of Excitation Converter Circuit

Tightening torque bolt group at output of excitation main

……………… ……………….
circuit breaker.
……………… ……………….
Tightening torque bolt group at input of excitation

……………… ……………….
transformer.
……………… ……………….
Tightening torque bolt group at output of excitation

……………… ……………….
transformer.
……………… ……………….
Tightening torque bolt group at input of excitation

……………… ……………….
converter.
……………… ……………….
……………… ……………….
converter ( ⊕ Bus).
……………… ……………….
Tightening torque bolt group at input of isolator switch

……………… ……………….
( ⊕ Bus).
……………… ……………….

……………… ……………….
converter ( Bus).
……………… ……………….
Tightening torque bolt group at input of isolator switch

……………… ……………….
( Bus).
……………… ……………….
Tightening torque bolt group at output of isolator switch

……………… ……………….
( ⊕ Bus).
……………… ……………….
Title Project
Sheet 38
No. of
sheets 92
Tightening torque bolt group at input of slip ring rotor

……………… ……………….
( ⊕ Bus).
……………… ……………….
Tightening torque bolt group at output of isolator switch

……………… ……………….
( Bus).
……………… ……………….
Tightening torque bolt group at input of slip ring rotor

……………… ……………….
( Bus).
……………… ……………….
4.1.8 Tightening Torque Bolt of MCC

Tightening torque bolt group at output of power supply ……………… ……………….

3x480VAC for MCC.
……………… ……………….
Tightening torque bolt group at input of incomer for ……………… ……………….

MCC (+F05).
……………… ……………….
Tightening torque bolt group at output of MCC for Air ……………… ……………….
Conditioning Unit no.1 (+F09/BA01).
……………… ……………….
Tightening torque bolt group at input of Air Conditioning ……………… ……………….

Unit no.1 (C-3320-AC-301)
……………… ……………….
Tightening torque bolt group at output of MCC for Air ……………… ……………….
Conditioning Unit no.2 (+F09/BA03).
……………… ……………….
Tightening torque bolt group at input of Air Conditioning ……………… ……………….

Unit no.2 (C-3320-AC-302)
……………… ……………….
Tightening torque bolt group at output of MCC for Cyclo ……………… ……………….
Cooling Unit Pump 1 (+F07/DA01).
……………… ……………….
Tightening torque bolt group at input of Cyclo Cooling ……………… ……………….

Unit Pump 1 (C-3320-PP-324)
……………… ……………….
Title Project
Sheet 39
No. of
sheets 92
Tightening torque bolt group at output of MCC for Cyclo ……………… ……………….
Cooling Unit Pump 2 (+F07/DA03).
……………… ……………….
Tightening torque bolt group at input of Cyclo Cooling ……………… ……………….

Unit Pump 2 (C-3320-PP-325)
……………… ……………….
Tightening torque bolt group at output of MCC for Ring ……………… ……………….
motor Cooling Fan 1 (+F07/FA01).
……………… ……………….
Tightening torque bolt group at input of Ring motor ……………… ……………….

Cooling Fan 1 (C-3320-FA-303)
……………… ……………….
motor Cooling Fan 2 (+F07/FA03).
……………… ……………….

……………… ……………….
motor Cooling Fan 3 (+F07/HA01).
……………… ……………….

……………… ……………….
motor Cooling Fan 4 (+F07/HA03)
……………… ……………….

……………… ……………….
Tightening torque bolt group at output of MCC for ……………… ……………….

Overpressure Fan Left (+F07/BA01)
……………… ……………….
Tightening torque bolt group at input of Overpressure ……………… ……………….

Fan Left (C-3320-FA-307)
……………… ……………….

Overpressure Fan Right (+F07/BA03)
……………… ……………….
Title Project
Sheet 40
No. of
sheets 92
Tightening torque bolt group at input of Overpressure ……………… ……………….

Fan Right (C-3320-FA-308)
……………… ……………….
motor Space heaters 1 – 4 (+F08/FA01).
……………… ……………….

Space heater 1(C-3320-HE-317)
……………… ……………….

……………… ……………….

……………… ……………….

……………… ……………….
Tightening torque bolt group at output of MCC for FTB ……………… ……………….
High Pressure Pump A (+F08/MA01)
……………… ……………….
Tightening torque bolt group at input of FTB High ……………… ……………….

Pressure Pump A (C-3320-PP-308)
……………… ……………….
High Pressure Pump B (+F08/PA01)
……………… ……………….

Pressure Pump B (C-3320-PP-309)
……………… ……………….
High Pressure Pump C (+F08/RA01)
……………… ……………….

Pressure Pump C (C-3320-PP-310)
……………… ……………….
High Pressure Pump D (+F08/TA01)
……………… ……………….
Title Project
Sheet 41
No. of
sheets 92

Pressure Pump D (C-3320-PP-311)
……………… ……………….
Accumulator Pump A (+F07/RA01)
……………… ……………….
Tightening torque bolt group at input of FTB ……………… ……………….

Accumulator Pump A (C-3320-PP-316)
……………… ……………….
Accumulator Pump B (+F07/RA03)
……………… ……………….
Tightening torque bolt group at input of FTB ……………… ……………….

Accumulator Pump B (C-3320-PP-317)
……………… ……………….
Filter Pump A (+F07/MA01)
……………… ……………….
Tightening torque bolt group at input of FTB Filter Pump ……………… ……………….
A (C-3320-PP-320)
……………… ……………….
Filter Pump B (+F07/MA03)
……………… ……………….
Tightening torque bolt group at input of FTB Filter Pump ……………… ……………….
B (C-3320-PP-321)
……………… ……………….
Tank Heater (+F08/DA01)
……………… ……………….
Tightening torque bolt group at input of FTB Tank ……………… ……………….

Heater (C-3320-HE-301…308)
……………… ……………….
Tightening torque bolt group at output of MCC for FXB ……………… ……………….
High Pressure Pump A (+F09/MA01)
……………… ……………….
Tightening torque bolt group at input of FXB High ……………… ……………….

……………… ……………….
Title Project
Sheet 42
No. of
sheets 92
High Pressure Pump B (+F09/PA01)
……………… ……………….

……………… ……………….
High Pressure Pump C (+F09/RA01)
……………… ……………….

Pressure Pump C (C-3320-PP-314)
……………… ……………….
High Pressure Pump D (+F09/TA01)
……………… ……………….

Pressure Pump D (C-3320-PP-315)
……………… ……………….
Accumulator Pump A (+F07/TA01)
……………… ……………….
Tightening torque bolt group at input of FXB ……………… ……………….

Accumulator Pump A (C-3320-PP-318)
……………… ……………….
Accumulator Pump B (+F07/TA03)
……………… ……………….
Tightening torque bolt group at input of FXB ……………… ……………….

Accumulator Pump B (C-3320-PP-319)
……………… ……………….
Filter Pump A (+F07/PA01)
……………… ……………….
Tightening torque bolt group at input of FXB Filter Pump ……………… ……………….
A (C-3320-PP-322)
……………… ……………….
Filter Pump B (+F07/PA03)
……………… ……………….
Title Project
Sheet 43
No. of
sheets 92
Tightening torque bolt group at input of FXB Filter Pump ……………… ……………….
B (C-3320-PP-323)
……………… ……………….
Tank Heater (+F08/DA03)
……………… ……………….
Tightening torque bolt group at input of FXB Tank ……………… ……………….

Heater (C-3320-HE-309…316)
……………… ……………….
Low Pressure Pump A (+F08/BA01)
……………… ……………….
Tightening torque bolt group at input of FXB Low ……………… ……………….

……………… ……………….
Low Pressure Pump B (+F08/BA03)
……………… ……………….
Tightening torque bolt group at input of FXB Low ……………… ……………….

……………… ……………….

Hydraulic Brake Pump A (+F07/KA01)
……………… ……………….
Tightening torque bolt group at input of Hydraulic Brake ……………… ……………….

Pump A (C-3320-PP-326)
……………… ……………….

Hydraulic Brake Pump B (+F07/KA03)
……………… ……………….
Tightening torque bolt group at input of FXB Hydraulic ……………… ……………….

Brake Pump B (C-3320-PP-327)
……………… ……………….
Title Project
Sheet 44
No. of
sheets 92
4.2 Control part
Check the wiring between PSR Control panel (+F02) and all relevant equipment. Checks are without the
equipment energized.
4.2.1 Control signals between PSR control panel (+F02) and cycloconverter main circuit breaker
Description Checked Date Sign.
MVD1 On Command signal. “Relay –112K1”

……………… ……………….
MVD1 Off Command signal. “Relay –112K2”

……………… ……………….
MVD1 Trip Command signal. “Relay –112K3”

……………… ……………….
MVD1 Feedback signal of circuit breaker closed. “Relay –112K4”

……………… ……………….
MVD1 Feedback signal of circuit breaker open. “Relay –112K5”

……………… ……………….
MVD1 Feedback signal of circuit breaker available “Relay –
112K6” ……………… ……………….
MVD1 Feedback signal of circuit breaker trip. “Relay –112K7”

……………… ……………….
Synchronisation supply voltage 110 Volts (3 phase)

……………… ……………….
4.2.2 Control signals between PSR control panel (+F02) and excitation main circuit breaker
MVD2 On Command signal. “Relay –113K1”

……………… ……………….
MVD2 Off Command signal. “Relay –113K2”

……………… ……………….
MVD2 Trip Command signal. “Relay –113K3”

……………… ……………….
MVD2 Feedback signal of circuit breaker closed. “Relay –113K4”

……………… ……………….
MVD2 Feedback signal of circuit breaker open. “Relay –113K5”

……………… ……………….
MVD2 Feedback signal of circuit breaker available “Relay –
113K6” ……………… ……………….
MVD2 Feedback signal of circuit breaker trip. “Relay –113K7”

……………… ……………….
Title Project
Sheet 45
No. of
sheets 92
4.2.3 Control signals between PSR control panel (+F02) and ring motor

Air gap signal probe no.1 / 21: Control signal between the signal
conditioner box and i/u converter. ……………… ……………….
4.2.4 Control signals between PSR control panel (+F02) and field emergency stops
Emergency stop number 1

……………… ……………….

……………… ……………….

……………… ……………….

……………… ……………….
4.2.5 Control signals between PSR control panel (+F02) and mill local control panel (+MLCP)
Coaxial cable for ARC net communication.

……………… ……………….
Supply voltage for MLCP +24V DC

……………… ……………….
Supply voltage for external horn 120 V AC.

……………… ……………….
Emergency stop signal.

……………… ……………….
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4.2.6 Control signals between mill local control panel (+MLCP) and radio control, remote module
Start command signal.

……………… ……………….
Stop command signal.

……………… ……………….
Emergency stop signal.

……………… ……………….
4.2.7 Control signals from cycloconverter transformer protection box
Cycloconverter transformer phase U, Buchholz trip signal.

……………… ……………….
Cycloconverter transformer phase U, Overpressure relief valve
trip signal. ……………… ……………….
Cycloconverter transformer phase U, CT’s wiring primary side.

……………… ……………….
Cycloconverter transformer phase V, Buchholz trip signal.

……………… ……………….
Cycloconverter transformer phase V, Overpressure relief valve
trip signal. ……………… ……………….
Cycloconverter transformer phase V, CT’s wiring primary side.

……………… ……………….
Cycloconverter transformer phase W, Buchholz trip signal.

……………… ……………….
Cycloconverter transformer phase W, Overpressure relief valve
trip signal. ……………… ……………….
Cycloconverter transformer phase W, CT’s wiring primary side.

……………… ……………….
……………… ……………….
……………… ……………….
……………… ……………….
……………… ……………….
……………… ……………….
……………… ……………….
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5 Energise MCC’s & Low Voltage Distribution
Energizing shall only occur once the LV power and control wiring is checked as detailed in section 4.
Make sure that all circuit breakers on the distribution panel are switched off for each motor starter. Tag and
pad lock all circuit breakers.
- All MCC Modules in off position Date:...............Sign.:……
- Insulation test of the bus bar (500 V) Date:...............Sign.:……
5.1 Energise Incoming MCC Supply Voltage (3 Phase).

Switch on the voltage incoming power supply (3-phase 480V / 60Hz) and measuring the voltage at
incoming breaker.
Date Sign.
Voltage R-S V
…………………….. …………………... …………………..
Voltage S-T V
…………………….. …………………... …………………..
Voltage T-R V
…………………….. …………………... …………………..
Frequency Hz
…………………….. …………………... …………………..
Phase Sequence -
…………………….. …………………... …………………..
Note: ………………………………………………………………………………………………………
………………………………………………………………………………………………………
5.2 Energise Lighting and Power Sockets.

Energise the power for E-house Sockets 230 V AC and Lighting (+F06/ –F44)
Date Sign.
Voltage .......................... V
…………………... …………………..
Frequency .......................... Hz
…………………... …………………..
Note: ………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………
5.3 Internal Auxiliary Power Supply 230/240 Volts. (Single Phase)

Energise the Control panel (+F01, 02, 03) Light and sockets 230 V AC (+F06/ –F51)
Date Sign.
Voltage .......................... V
…………………... …………………..
Frequency .......................... Hz
…………………... …………………..
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Note: ………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………
5.4 Internal Auxiliary Power Supply 110/120 Volts. (Single Phase)

Energise the power for PSR Control panel 120 V AC (+F06/ –F73)
Date Sign.
Voltage .......................... V
…………………... …………………..
Frequency .......................... Hz
…………………... …………………..
Note: ………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………
5.5 Start up UPS.

Energise UPS (+F06/ –F61) and check output voltage/current during no load and full load.
- All circuit breaker are off position Date:...............Sign.:……
Date Sign.
Voltage Input .......................... V

…………………... …………………..
Current Input .......................... A

…………………... …………………..
Frequency .......................... Hz
…………………... …………………..
No Load Measurement
…………………... …………………..
Voltage Output .......................... V

…………………... …………………..
Current Output .......................... A

…………………... …………………..
Full Load Measurement

…………………... …………………..
Voltage Output .......................... V

…………………... …………………..
Current Output .......................... A

…………………... …………………..
Note: ………………………………………………………………………………………………………
………………………………………………………
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5.6 Energise Control Voltage in Panels
- Energise supply voltage 230 V AC (+F06/ –F53) to Excitation

Control Panel (+F01).
Actual voltage measurement: …………….. Volts. Date:...............Sign.:…………
- Energise supply voltage 230 V AC (+F06/ –F54) to PLC
interconnection (+F3).
- Actual voltage measurement: …………….. Volts Date:...............Sign.:…………
- Energise supply voltage 230 V AC (+F06/ -F56) to Cyclo
Cooling Unit panel (+F15).
- Energise supply voltage 120 V AC (+F06/ -F67) to Fire
Fighting System panel (+F14).
- Energise supply voltage 120 V AC (+F06/ -F75) to PLC
Control panel (+F03).
- Actual voltage measurement: …………….. Volts Date:...............Sign.:…………
- Energise supply voltage 120 V AC (+F02/ –303F3) to 24 V
dc power supply of air gap signal conditioner.
- Energise supply voltage 120 V (+F02/ –303F1) to 24 V dc
power supply of PSR control panel (+F02).
- Energise supply voltage 120 V (+F02/ –303F2) to 48 V dc
power supply of PSR control panel (+F02).
- Measuring the control voltage of drive controller.
Uout +24VDC:..............V dc
Uout +15VDC:..............V dc
Uout-15VDC :..............V dc
Uout 5VDC :..............V dc
Uout +48VDC:..............V dc Date:...............Sign.:…………
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6 Signal Test.
- Energise control circuit of all signals to PLC Date:...............Sign.:……

- Energise control circuit of all signals to PSR Date:...............Sign.:……
- Energise control circuit of all signals to Cyclo Cooling Unit Date:...............Sign.:……
- Energise control circuit of all signals to Transf. Protection Panel Date:...............Sign.:……
- Energise control circuit of all signals to Main Substation Date:...............Sign.:……
- Energise control circuit of all signals to Lubrication System Date:...............Sign.:……
- Energise control circuit of all signals to Brake System Date:...............Sign.:……
- Energise control circuit of all signals to Mill Local Control Panel Date:...............Sign.:……
Note: All signals that relate to PLC please see at “part B”
6.1 Cycloconverter Transformers phase U Protection

Hardware protection/interlock to open main circuit breaker
Descriptions Tested Date Name
Buchholz Trip …………………….. ……………………..
Overpressure Relief Valve …………………….. ……………………..
Note: ……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
………………………………………………………
6.2 Cycloconverter Transformers phase V Protection

Buchholz Trip …………………….. ……………………..
Note: ……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
………………………………………………………
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6.3 Cycloconverter Transformers phase W Protection

Buchholz Trip …………………….. ……………………..
Note: ……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
………………………………………………………
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6.4 Air-gap Measurement.

PSR Input
Feeler Gage
Current of Signal PSR PSR
(mm)
Air gap Conditioner (V) Reading PSR Control
Fluor “Mechanica
Probe (mA) “Analogue (%) Offset Panel
Tag Number l
No. “u/i converter input on I/O “Software (%) (+F02)
measureme
module” board Reading” (mm)
nt”
UAC326”
Air gap probe 33-ZE-8011A
no.1
Air gap probe 33-ZE-8011B
no.2
Air gap probe 33-ZE-8011C
no.3
Air gap probe 33-ZE-8011D
no.4
Air gap probe 33-ZE-8011E
no.5
Air gap probe 33-ZE-8011F
no.6
Air gap probe 33-ZE-8011G
no.7
Air gap probe 33-ZE-8011H
no.8
Air gap probe 33-ZE-8011J
no.9
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
Probe no.7 Probe no.6
27 26
Probe no.5
25
28
24
VIEW FROM
FEED SIDE
29 23 Probe no.3
Probe no.9
21 22
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7 Function Tests
7.1 Check Rotational of Aux. Motor (Motor Cooling Fan, Lubrication and Brake System)
Item Description Tag Name CW CCW Date Sign.

……………... …………....

……………... …………....

……………... …………....

……………... …………....
5 Motor Overpressure Fan Left C-3320-FA-307

……………... …………....
6 Motor Overpressure Fan Right C-3320-FA-308

……………... …………....
FXB Low Pressure Lube Pump
7 C-3320-PP-306M
A ……………... …………....
FXB Low Pressure Lube Pump
8 C-3320-PP-307M
B ……………... …………....
FTB High Pressure Lube
9 C-3320-PP-308M
Pump A ……………... …………....
10 C-3320-PP-309M
Pump B ……………... …………....
11 C-3320-PP-310M
Pump C ……………... …………....
12 C-3320-PP-311M
Pump D ……………... …………....
FXB High Pressure Lube
13 C-3320-PP-312M
Pump A ……………... …………....
14 C-3320-PP-313M
Pump B ……………... …………....
15 C-3320-PP-314M
Pump C ……………... …………....
16 C-3320-PP-315M
Pump D ……………... …………....
17 FTB Accumulator Pump A C-3320-PP-316M

……………... …………....
18 FTB Accumulator Pump B C-3320-PP-317M

……………... …………....
19 FXB Accumulator Pump A C-3320-PP-318M

……………... …………....
20 FXB Accumulator Pump B C-3320-PP-319M

……………... …………....
21 FTB Filter Pump A C-3320-PP-320M

……………... …………....
22 FTB Filter Pump B C-3320-PP-321M

……………... …………....
23 FXB Filter Pump A C-3320-PP-322M

……………... …………....
24 FXB Filter Pump B C-3320-PP-323M

……………... …………....
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Item Description Tag Name CW CCW Date Sign.

……………... …………....

……………... …………....
27 Hydraulic Brake Pump A C-3320-PP-326M

……………... …………....
28 Hydraulic Brake Pump B C-3320-PP-327M

……………... …………....

……………... …………....

……………... …………....
31
……………... …………....
32
……………... …………....
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………….
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7.2 Cycloconverter Cooling Unit (+F15)
Deionised water of a conductivity less than 20 S/cm must be available for the converter internal
closed water circuit (about 320 litres for each converter)
For flushing and cleaning the system (first water filling), additional 320 litres deionised water
(<20 S/cm) must be available.
Cooling unit has to be commissioned following the procedures mentioned in the Cycloconverter User’s
manual (Document No. 3BHS130198) Date:...............Sign.:……
Check DIP switch of the ARC net communication board UAC096 Date:...............Sign.:……
(Settings according GMD circuit diagram)
Chosen GA :............ x=open DIP - Switch : 0 1 2 3 4 5 6 -
Check control supply voltage Ucontr:.................VDC Date:...............Sign.:……

Check supply voltage for the pumps Uin: 3 x ..............VAC Date:...............Sign.:……
Check adjustment of all sensors itself Date:...............Sign.:……
Running pump 1 / 2 and check rotation Date:...............Sign.:……
Check analogue signals going to the PSR control panel AFC094 Date:...............Sign.:……
Check leakage detection CL011 Date:...............Sign.:……
Sensor Hardware Measured Meter Indication Reading of Fupla

adjustment Value at Input Indication Display Software
board Cooling unit AFC094 (%)
(mA) Panel
CF001 (flow) 4-20mA l/min l/min
for............….. l/min
to ..........……..l/min
CD001 (Conductivity) 4-20mA S/cm S/cm
for.............… S/cm
to..........….... S/cm
CT001 (Internal 4-20mA C°
Cooling Temperature) for...........…... C°.
to...........….….C°
CT002 (Internal 4-20mA C°
Cooling Temperature) for................. C°
to.............…...C°
CT004 (External 4-20mA C°
to.............…....C°
CT005 (External 4-20mA C°
to.............…...C°
CP001 (pressure) 4-20mA bar
for................. bar
to............…....bar
CL001 (water level) 4-20mA %
for................ 100%
to.........……..100%
CL011 (leakage) Logic “0” or “1”
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Notes/Comments
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
..............................................................................................................................................
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7.3 Cycloconverter transformer over current protection

Transformer Protection Relay Type SPAJ 140 C - DA Date:...............Sign.:……
Remarks Page
Relay 1 number
Relay 2 number
Relay 3 number
Visual check for transport damage
Visual check of external wiring
Check of relay grounding
Check of supply voltage (DC/AC)
Check of settings (calculated by....)
Check of C.T. circuits
Secondary injection with test set type ...
Check of input signals
Check of signalisation/alarms
Check of tripping
Final check
Transformer data
Manufacturer ............................................... Type of cooling ....................

Type ............................................... (ONAN, ONAF etc.)
Rated power SN .............../.............../............... MVA Vector group ....................
Primary side HV Secondary side LV Tertiary side TV

Rated voltage .................... kV ± .................... kV .................... kV .................... kV
Rated current .................... A .................... A .................... A
Positive-sequence HV-LV .................... % at .................... MVA

Impedance LV-TV .................... % at .................... MVA
HV-TV .................... % at .................... MVA
Main C.T./P.T. ratio Settings

Analogue inputs 1 - 2 ...................../................... A/A According to separate print out
Analogue inputs 4 - 5 ...................../................... A/A Software version of the relay ..........
Analogue inputs 7 - 8 ...................../................... ...../.....
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7.4 Emergency stop relay (Control Panel +F02)
Test of the emergency stop relay
Test relay time delay in case of an E-stop (time delay set point 500ms) Date:...............Sign.:……
Test that E-stop signal is received by the PSRI/O board Date:...............Sign.:……
Test that E-stop signal is received by the PLCI/O board Date:...............Sign.:……
Test E-stop (-……………) of the field (close to the mill) Date:...............Sign.:……
Test E-stop (-……………) of the motor local control panel (MLCP) Date:...............Sign.:……
Test E-stop (-……………) of the control panel (+F01) Date:...............Sign.:……
Test E-stop of ............................... Date:...............Sign.:……
Test E-stop of ............................... Date:...............Sign.:……
7.5 ON/OFF Main Circuit Breaker Function Test (Stator and Rotor)
7.5.1 Rotor Main Circuit Breaker Function Test

- ON/OFF Command Date:...............Sign.:……
- Hardware Over current Protection OFF-Command Date:...............Sign.:……
- Software Over current Protection OFF-Command Date:...............Sign.:……
- Emergency Stop OFF-Command Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
7.5.2 Stator Main Circuit Breaker Function Test

- ON/OFF Command Date:...............Sign.:……
- Hardware Over current Protection OFF-Command Date:...............Sign.:……
- Software Over current Protection OFF-Command Date:...............Sign.:……
- Emergency Stop OFF-Command Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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7.6 Earth Fault Protection
7.6.1 Rotor Protection
7.6.1.1 Rotor Earth Fault Supervision

Set the alarm and trip threshold values of the protection relay “IRDH 275-435” (use operating manual)
- Alarm 1 reference set point 100 kΩ Actual setting kΩ Date:…........ Sign.:……

…………...

…………...
- Simulate an earth fault and check signal to PSR Date:…........ Sign.:……
Note: Simulation test by connecting the output converter “⊕ Bus” or “ Bus” to ground by a temporary.
2
Test cable (2.5 mm )……………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
7.6.1.2 Rotor Thermal Overload

Set the trip value of the overload relay
Current transformer ratio : 800A/1A.
Overload relay range : 0.4A – 0.63A.
Excitation current 425Adc or 347Aac. (Conversion factor is 0.817)
Recommended setting value : 130% nominal of excitation current.
130% × 347 Aac × 1A

Overload setting = = 0.56 A
800 Aac
- Adjusted value:.......................... Date:...............Sign.:……

- Simulate a thermal overload fault. Date:...............Sign.:……
Note: Simulation test by pressing the test button on overload relay………………..………..……………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
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7.6.2 Stator Protection
7.6.2.1 Stator Earth Fault Supervision

Set the alarm and trip threshold values of the Stator protection relay “IRDH 275-435” (use operating manual)

…………...

…………...
- AGH to 204AK160 Actual setting Date:…........ Sign.:……

…………...
- Language to English Actual setting Date:…........ Sign.:……

…………...
- Simulate an earth fault and check signal to PSR Date:…........ Sign.:……
Note: Simulation test by connecting the output converter to ground by a temporary.

2
Test cable (2.5 mm )……………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
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7.7 Hardware Protections

Stator over current protection
CS A463 Analogue Signal Supervision Unit (+A 09 / Tier: 06)
Check threshold voltage for stator over current detection Date:...............Sign.:

Set point for over current protection check cycloconverter design data
Î>>: Set point:.....................................6 400 A peak value

Îg: Rated Current................................3 164 A peak value
ΙHWLimit 6 x6400
U Th=6V× = =12.1380V
Îg 2x 2237
Analog Input U threshold [V] I>> [A] R2[k ] R3 [k ] Remarks

CSA463 Peak value
1 12.138 6400 300 15
2 12.138 6400 300 15
3 12.138 6400 300 15
4 12.138 6400 300 15
5 12.138 6400 300 15
6 12.138 6400 300 15
U2 =10V
10 kohm
Uk +
R3 -
R2 680 kohm
U Th
U1 =15.3 V 22 kohm
U k= =6.0690
2
1
k= = 0.020408 1
48 R2 // R3 = =14274.975
1+ 1 15.3V 1
Uk ⋅ −1 −
1+ 22kΩ U k (1−k ) 680kΩ
680 kΩ
Calibration of Time delay until fault detection Date:...............Sign.:

The time delay is set to t= 0.56 ms and is generated with a R-C circuit.
(RC- connection with a constant capacitor; C= 0.1µF)
t 0.56 ms
t =R⋅C R= = =5.6 kΩ
C 0.1µF
R = R 228; R 230; R 272; R 274; R 316; R 318 = 5.6 k
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The time delay for circuit breaker is set to t= 700 ms and is generated with a R-C circuit.
(RC- connection with a constant capacitor; C= 1 µF)
t 700ms
t = R ⋅C R= = = 700kΩ
C 1000nF
Cv = C171 = 1 µF Ω
Rv=R353 = 680 kΩ
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8 PSR2 Drive Protection Settings

8.1 General drive requirements:
Net voltage variations:

Nominal line voltage:..................V
Max line voltage:........................V
Min line voltage:.........................V
Nominal line frequency:.............Hz
Max line frequency:....................Hz
Min line frequency:.....................Hz
Ring motor requirements:

Minimum speed:.................... rpm
Maximum speed:....................rpm
Inching speed:........................rpm
Creeping speed:................... .rpm
Starting torque:................................IA / IN
Starting torque duration:..................s...............times per hour
Overload:.........................................%
Overload duration:...........................s
Frozen charge:
- Minimum speed for observing that material is cascading...................................rpm
- Ramping time to start the mill to that min speed.............….................................s
- Min. time to stay at this min speed after material was cascading….....................s
- Maximal angle where the material must cascade................................................°
Remarks:
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
..........................................................................................................................................................................
8.2 Stator and Thyristor Protection Settings
Physical
PSR Setting Time Delay Confirmed
No Description INT Segm Parameter Value
Value Unit Value Unit Value Unit Date Sign
Stator over current fault
1 of ixR1, ixR2, ixS1, 1 S04 ix>-Limit
ixS2, ixT1, ixT2
Thermal overload of
2 thyristor for phase R – 1 S05 Constant
S–T
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8.3 Excitation Protection Settings
Physical
Excitation over current Exci-Limit-
1 1 S06
fault Fault
Excitation under current
2 1 S06 Ie<-limit
fault
Excitation current iwe-
3 2 S27
reference limit max.lim
8.4 Network Protection Settings
Physical
Analogue input network
voltage Unet-R-
1 0 S07
Network under voltage Lowlimit
fault of phase R – S – T
voltage.
Unet-Low-
2 Network voltage <95% 0 S07
delay6
for 60 seconds fault of
phase R – S – T
voltage /UN/-Low-
3 0 S07
Network voltage <95% Limit
speed control limit.
Reading of GDB Card
4 Network over voltage 1 S06 Constant
>110%
Reading of GDB Card
5 Network under voltage 1 S06 Constant
<85%
Reading of GDB Card
6 Network voltage <95% 1 S06 Constant
for 60 seconds
Reading of GDB Card Frequency
7 0 S07
Over frequency fault -Hi-lim
Reading of GDB Card Frequency
8 0 S07
Under frequency fault -Lo-lim
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8.5 Ring Motor Air gap Protection Settings
Physical
Alarm: Air gap no. 1
AGC-
1 and 2, Bottom side from 2 S29 % - - mm
Warn1
feed end view
Alarm: Air gap no. 3 – 4
AGC-
2 and 5, Right side from 2 S29 % - - mm
Warn1
feed end view
Alarm: Air gap no.6 and mm
AGC-
3 7, Top side from feed 2 S30 % - -
Warn1
end view
Alarm: Air gap no. 8 mm
AGC-
4 and 9, Left side from 2 S30 % - -
Warn1
feed end view
Fault: Air gap no. 1 and mm
5 2, Bottom side from 2 S29 AGC-Trip1 % - -
feed end view
Fault: Air gap no. 3 – 4 mm
6 and 5, Right side from 2 S29 AGC-Trip1 % - -
feed end view
Fault: Air gap no.6 and mm
7 7, Top side from feed 2 S30 AGC-Trip1 % - -
end view
Fault: Air gap no. 8 and mm
8 9, Left side from feed 2 S30 AGC-Trip1 % - -
end view
8.6 Frozen Charged Protection Settings
Physical
Maximum Torque Limit
Iw-DCP-
1 (Pickup value of 2 S34
Limit
protection)
Maximum Angle Limit
POLE-
2 (corresponding to 2 S34
NUMBER1
machine supplier)
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8.7 Cycloconverter Cooling Protection Settings
Physical
CT002, Internal cooling
cool-tmp-
1 temperature outlet B S04
cvout-A
“Alarm”
CT002, Internal cooling
cool-tmp-
2 temperature outlet B S04
cvout-T
“Fault”
CF001, Internal water cool-flow-
3 B S04
low flow “Fault” conv-T
CF001, Internal water cool-press-
4 B S04
low pressure “Fault” conv-A
CD001, Internal water cool-cond-
5 B S04
conductivity low “Alarm” A
CD001, Internal water cool-cond-
6 B S04
conductivity low “Fault” T
CL001, Internal water cool-level-
7 B S04
level low “Alarm” A
CL001, Internal water cool-level-
8 B S04
level low “Fault” T
8.8 Cycloconverter Current Control Phase R-S-T Settings
Physical
1 Rectifier limit 1 S16 GR-limit
I-
P-Gain, Proportional
2 1 S16 CONTROL
gain
-R:kp
I-CONT-
3 I-Gain, Integration time 1 S16
R:T0/TN
I-
4 Multiplication factor KN 1 S16 CONTROL
-R:KN
I-
5 Multiplication factor K% 1 S16 CONTROL
-R:K%
8.9 Cycloconverter Speed Control Settings
Physical
Iw-Max-
1 Torque limit during start 2 S14
Start-Lim
Torque limit during Iw-Max-
2 2 S14
running Run-Lim
P-Gain, Proportional CONT-
3 2 S14
gain during start N:kp-start
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Physical
P-Gain, Proportional CONT-
4 2 S14
gain during run N:kp-runn
CONT-
5 I-Gain, Integration time 2 S18
N:integ
6 Multiplication factor KN 2 S17 Constant
7 Multiplication factor K% 2 S17 Constant
Over speed forward Overspeed
8 2 S14
limit -forwar
Over speed reverse Overspeed
9 2 S14
limit -revers
Over speed
Overspeed
10 forward/reverse limit in 2 S14
-incCre
inching/creeping mode
Nx-
Speed actual
11 2 S13 manipulati
manipulation
on
Speed reference limit 1
Nw-
12 in Normal mode 2 S14
Anfahren
“Anfahren”
Anfahren-
13 in Inching mode 2 S14
Inching
“Anfahren”
Anfahren-
14 in Creeping mode 2 S14
Creep
“Anfahren”
15 2 S14 Nw-min
in Normal mode
16 2 S14 Nw-inching
in Inching mode
Speed reference limit 2 Nw-
17 2 S14
in Creeping mode creeping
8.10 Cycloconverter Low Speed Control “Phase Correction” Settings
Physical
1 Speed Actual: 0% 1 S12 Constant
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8.11 Cycloconverter Low Speed Control “Amplitude Correction” Settings
Physical
1 Speed Actual: 0% 2 S05
8.12 Delta psi-T and Network Voltage >85%<95% Speed Control Limit Function
Physical
Speed limit at +Delta-psi-
1 2 S15
Del psi-T: 16% or -25% Lim5
2 2 S15
Del psi-T: 14% or –20% Lim4
3 2 S15
Del psi-T: 12% or –15% Lim3
4 2 S15
Del psi-T:10% or -14% Lim2
5 2 S15
Del psi-T: 0% Lim1
Speed limit at Unet-Limit-
6 2 S15
Network voltage 85% 85%
7 2 S15
8 2 S15
Speed limit at
9 2 S15 Constant
Network voltage 110%
Delta-psi-
10 Counter to limit speed 2 S15
count
Set point to unlock Speed-
11 2 S15
speed limit Reset
Iw-
12 Torque overload limit 2 S15
OverLoad
Converter output
TRAPEZ:
13 voltage high limit 1 S24
UPLIM
“Fault”
Converter output TRAPEZ:
14 1 S24
voltage low limit “Alarm” LOLIM
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8.13 Cycloconverter Internal Calculation Settings
Physical
PHASSHI
1 Phase shift 1 1 S12
FT:dt1
2 Phase shift 2 1 S13 Delta-T2
Phase shift 1 for low
3 1 S13 Delta-T3
speed control
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9 Energizing Power Transformer
9.1 Energizing Excitation Transformer

The main circuit breaker of excitation transformer can be operated by command of PSR2 test program
no.1 at the control panel.
- Line voltage & MVD2 tested and available. Date:...............Sign.:……
- Protection & Supervision of the transformer must be tested and activated. Date:...............Sign.:……
- 24 hours energizing and check the temperature. Date:...............Sign.:……
Energizing Winding Oil Energizing Winding Oil

Time Temperature Temperature Time Temperature Temperature
at at at at
Hour Thermometer Thermometer Hour Thermometer Thermometer
Date Time on on Date Time on on
Transformer Transformer Transformer Transforemer
°C °C °C °C
1 13
2 14
3 15
4 16
5 17
6 18
7 19
8 20
9 21
10 22
11 23
12 24
Note: ………………………………………………………………………………………..………..……………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………
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9.2 Energizing Cycloconverter Transformer

The main circuit breaker of cycloconverter transformer can be operated by command of PSR2 test
program no.3 at the control panel.
- Line voltage & MVD1 tested and available. Date:...............Sign.:……
- Protection & Supervision of the transformer must be tested and activated. Date:...............Sign.:……
- 24 hours energizing and check the temperature. Date:...............Sign.:……
Energizing Winding Oil Energizing Winding Oil

Time Temperature Temperature Time Temperature Temperature
at at at at
Hour Thermometer Thermometer Hour Thermometer Thermometer
Date Time on on Date Time on on
Transformer Transformer Transformer Transformer
°C °C °C °C
1 13
2 14
3 15
4 16
5 17
6 18
7 19
8 20
9 21
10 22
11 23
12 24
Note: ………………………………………………………………………………………..………..……………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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10 Load Test “Rotor Circuit”
10.1 Start up Excitation Converter

- Download the relevant parameter settings. Date:...............Sign.:……
- Checked interface signal, Analogue input/output Date:...............Sign.:……
- Checked interface signal, Digital input/output Date:...............Sign.:……
Note: The current set point between PSR2 “Drive Controller System” and DCF500/600 “Excitation
Converter” is 0 – 10V = 0 – 900 A dc.
10.2 DC Current injection on rotor circuit.
For Testing the rotor circuit use PSR-FUPLA: “Drive Controller Software (PSR2)” Test program
No.: 1. The Set point for the Field can be adjusted with the Control Panel Board, with the keys
“Faster” and “Slower”. Adjust the current limit before switching on the Excitation Converter, which
is corresponding to the table below.
Adjust the current controller and make step responses, the step response can be done via DCF
Software. (More detail please sees at User’s Manual of Excitation Converter).
- Excitation Current Injection Tested. Date:...............Sign.:……
Current Current Calculated Measurement Measurement Analogue Digital

Limit in Limit in (A Set point DCF current clamp With Recorder meter Display
(%) dc) iwe ixe ixe ixe (AFC094)
of nominal of nominal “Analogue input (A) “Analogue input (A) ixe
Rotor Rotor on I/O board on I/O board (A)
current current UAC 326” UAC 326”
“PSR2 “Calculation” (V) (A)
Setting”
20%
40%
60%
80%
100%
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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- Record of Excitation DC Current Injection. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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10.3 Dis-excitation Function
Creating a dis-excitation pulse and checking the pulse length and pulse shape at the excitation over voltage
arrester by Hioki Recorder, check also the de-excitation current by a clamp-ampere meter and Hioki
Recorder. The pulse can be created by:
- “Main Circuit Breaker” OFF Command

- “Trip” Signal
T T = 200 - 1000 µs
48 V
- 18 V
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- Record of de-excitation DC Current Injection. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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11 Synchronisation of Reference Voltage to Power
Connect the Reference voltage (Uref) via differential input to the hioki recorder.
Connect the cycloconverter input voltage via differential input to the hioki recorder.
Check the phase shifting between Uref at the GDB “Gate Control Units” input and Ucyclo, for all phases (R-S,
S-T, T-R), due to the vector group Dyn1 of the voltage detection device UUA 358, the cycloconverter input
voltage (transformer delta connection) should be 30° ahead the reference voltage. The cycloconverter input
voltage of the transformer star connection must be in phase.
If the 30° are not reachable, adjust the angle by the angle shifter FM9925a-E with its analogue input signal.
Adjustable with the PSR2 software parameter: ParamGrp_Angle-shifting
Phase Shifting: Ucyclo 0° is leading Uref for 30° …………………….. ……………………..
Phase Shifting: Ucyclo 30° is in phase Uref 0° …………………….. ……………………..
ParamGrp_Angle-shifting:
“At INT:BACKGROUND\S10” ………………………… Degrees. …………………….. ……………………..
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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………………………………………………………………………………………………………………….
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- Record of Phase Shifting Ucyclo 0° is leading Uref by 30° Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
……………………………………………………………….
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- Record of Phase Shifting: Ucyclo 30° is in phase Uref 0° Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
……………………………………………………………….
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12 Load Test Stator (without Excitation)
Sinusoidal current test:
For this current load test use test program No.: 3.
The PSR Software “Service Function” gives the different current reference values with the panel
display keys. The current reference can be limited with a PSR parameter setting for the amplitude of
iw (ParamGrp_SB: AMPL-UPLIM).
-Change test program to No.: 3
-Release the service box function by pressing F8 and F16 for 5sec
-Switch on the auxiliaries (F1)
-Switch on the main breakers (F2)
-Switch on the function “Iaw Man on” (F5)
-Select “amplitude” (F14)
-Push value> to adjust the amplitude set point (F4)
-Select “frequency”(F6)
-Push “Is-on” to release the pulses (F3)
-Push “value>“ to set the frequency of the current
-To block the pulses push “Is-off” (F11)
Load test of Sinusoidal Stator current (0 - 12 V): 6V ~ Îg (Îg =..............) Date:...............Sign.:……
Motor Current Current Bridge Current Measured Voltage of The Current Actual Signal Actual Actual
Phase set Limit Ref. Current Current
point (A (%) Value Current of 0° Current of 30° Clamp Analog.
peak) IwR** [max] Meter
[peak] At Meas. Calcu. At Meas. Calcu. (A) [rms]
(V)) (Input) (V peak) (A peak) (Input) (V peak) (A peak) (A)
RA
200 A
RB
RA
400 A
Phase RB
AI:…….. AI:……..
R RA
600 A
RB
RA
800 A
RB
SA
200 A
SB
SA
400 A
Phase SB
AI:…….. AI:……..
S SA
600 A
SB
SA
800 A
SB
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Motor Current Current Bridge Current Measured Voltage of The Current Actual Signal Actual Actual
Phase set Limit Ref. Current Current
point (%) Value Current of 0° Current of 30° Clamp Analog.
(Apeak) IwR** [max] Meter
[peak] At Meas. Calcu. At Meas. Calcu. (A) [rms]
(V) (Input) (Vpeak) (Apeak) (Input) (Vpeak) (Apeak) (A)
TA
200 A
TB
TA
400 A
Phase TB
AI:…….. AI:……..
T TA
600 A
TB
TA
800 A
TB
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
……………………………………………………………….
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- Record of Sinusoidal Current Injection 400 Amps. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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- Record of Sinusoidal Current Injection 800 Amps. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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- Record of the zero current during the bridge changing. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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13 Ring Motor Test

Put the drive Mode to E-House and activate Test program 0,
That is the PSR-Software under normal operation, (No Test Program) Date:...............Sign.:……
All Interlocks between PSR and PLC must be tested and healthy Date:...............Sign.:……
Connect Recorder to the relevant analogue signals, connect an ext. trigger signal e.g. (Sum. Fault Signal)
Start the Mill at the E-House Control Panel with minimum speed and take readings
Recommended measuring signals during starting:
Description Measuring Point

Nx, Actual speed “+A37” UA C326 Card / Analogue output 1
IxR1, Actual motor current phase R/0° “+A37” UA C326 Card / Analogue input 1
UxMR, Actual motor voltage phase R “+A37” UA C326 Card / Analogue input 7
Iex, Actual excitation current “+A37” UA C326 Card / Analogue input B
AGP6, Actual Air gap no. 6 “+A41” UA C326 Card / Analogue input 6
psi-x, Actual flux vector “+A41” UA C326 Card / Analogue output 6
psi ∝, Actual Flux Vector in ∝/β coordinate system “+A41” UA C326 Card / Analogue output 7
psi β, Actual Flux Vector in ∝/β coordinate system “+A41” UA C326 Card / Analogue output 8
Recommended measuring signals during running:
Description Measuring Point

Nx, Actual speed “+A37” UA C326 Card / Analogue output 1
IxR1, Actual motor current phase R/0° “+A37” UA C326 Card / Analogue input 1
UxMR, Actual motor voltage phase R “+A37” UA C326 Card / Analogue input 7
Iex, Actual excitation current “+A37” UA C326 Card / Analogue input B
U∝, Firing angle control phase R/0° “+A57” GD B021 Card / U∝ output
psi-x, Actual flux vector “+A41” UA C326 Card / Analogue output 6
psi ∝, Actual Flux Vector in ∝/β coordinate system “+A41” UA C326 Card / Analogue output 7
psi β, Actual Flux Vector in ∝/β coordinate system “+A41” UA C326 Card / Analogue output 8
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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13.1 No Load Test
- Record of mill starting with no-load. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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- Record of mill running with no-load. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
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- Record of mill starting with a heavy load. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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13.2 Load Test

- Record of mill running with a heavy load. Date:...............Sign.:……
Note: ………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
…………………………………………………………………….
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14 Final Work
Change all Software - modifications made for testing back to original Date:...............Sign:
Change all Hardware - modifications made for testing back to original Date:...............Sign:
Remove jumpers and toggle switches Date:...............Sign:
Check schematic diagram (red-blue) modifications complete Date:...............Sign:
Disconnect all test cables Date:...............Sign:
Clean all the Panels / E-House Date:...............Sign:
PSR-Software Back-up / Path:.......................................................Date:................. Date:...............Sign:
DCF-Software Back-up / Path:.......................................................Date:................. Date:...............Sign:
PLC-Software Back-up / Path:.......................................................Date:.............…. Date:...............Sign:
VMS-Software Back-up / Path:......................................................Date:................. Date:...............Sign:
Photos / Path:…………………………………………………………………………….. Date:...............Sign:
Loading all Software Back-up to the network

Path:........................................................................................................................ Date:...............Sign:
................................................................................................................................. Date:...............Sign:
................................................................................................................................. Date:...............Sign:
................................................................................................................................. Date:...............Sign:
................................................................................................................................ Date:...............Sign:
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15 Attachment logbook.
15.1 Hardware Modification log book.
Reference Removed
Temporary
Permanent
Change
Change
No. Description Drawing no. Page Date Sign Date Sign.
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15.2 Software Modification log book.
Reference Removed
Temporary
Permanent
Change
Change
No. Description INT Segment Date Sign Date Sign.
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Commissioning Report GMD System: ABB Switzerland LTD

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Commissioning Report GMD System: ABB Switzerland LTD

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Commissioning Report

ABB Switzerland Ltd GMD System

Contract PSP108 TAG Name: C-3320-ML-301M

Commissioning/Service Engineer: ............................................…………Dept:………...............

Commissioning date/period: …………............................................

GMD Commissioning Report “Part A” (Document No 3BHS215357)

GMD Commissioning Report “Part B” (Document No 3BHS215357)

- PLC point to point test

+F02 = Cycloconverter Control Panel iwe = Excitation Current Reference

2.1 Commissioning tools list

Item Description Quantity Checked Date Sign.

2.3 Commissioning Software

Inspecting of existing, condition and mounting of the Main Components.

3.2 Main Circuit Breaker of Stator Cycloconverter Transformer

3.3 Main Circuit Breaker of Rotor Excitation Transformer

3.4 Cycloconverter Transformer

3.4.1 Transformer for cycloconverter +CA

Power kVA Voltage V

Power kVA Voltage V

Power kVA Voltage V

3.4.2 Transformer for cycloconverter +CB

Power kVA Voltage V

Power kVA Voltage V

Power kVA Voltage V

3.4.3 Transformer for cycloconverter +CC

Power kVA Voltage V

Power kVA Voltage V

Power kVA Voltage V

3.5 Excitation Converter Transformer

Power kVA Voltage V

Power kVA Voltage V

3.6 Synchronisation Transformer

3.8 Excitation Converter

3.9 Stator Isolating (Knife) Switch

3.10 Rotor Isolating (Knife) Switch

3.11 Ring Motor

3.12 Protection Relay

3.12.1 Main Feeder Protection Relay

3.12.2 Rotor Transformer Protection Relay

3.12.3 Cycloconverter Transformer Protection Relay (Protection Panel)

3.12.3.1 Transformer protection relay of cycloconverter +CA

- Erection completed Date:...............Sign.:……

3.12.3.2 Transformer protection relay of cycloconverter +CB

- Erection completed Date:...............Sign.:……

3.12.3.3 Transformer protection relay of cycloconverter +CC

- Erection completed Date:...............Sign.:……

3.13 Fire Suppression System

3.14 Air Conditioning System

Manufacturer Year of Manuf.

3.15 GMD’s Auxiliary

2 Motor Cooling Fan 2 C-3320-FA-304

3 Motor Cooling Fan 3 C-3320-FA-305

4 Motor Cooling Fan 4 C-3320-FA-306

5 Motor Overpressure Fan Left C-3320-FA-307

6 Motor Overpressure Fan Right C-3320-FA-308

7 Motor Space Heaters 1 C-3320-HE-317

8 Motor Space Heaters 2 C-3320-HE-318

9 Motor Space Heaters 3 C-3320-HE-319

10 Motor Space Heaters 4 C-3320-HE-320

11 FTB Lube Tank Heater 1 C-3320-HE-301

12 FTB Lube Tank Heater 2 C-3320-HE-302

13 FTB Lube Tank Heater 3 C-3320-HE-303