4100C BOSS AC 4100C BOSS AC Shovel Drive Shovel Drive

System OverviewSystem Overview

WMEA Edmonton WMEA Edmonton -- June 2008June 2008

OverviewOverview• Drives Partnership with ABB• Deck Plan / One-Line Schematic• ISU (IGBT Supply Unit)• Shovel Motion Inverters• Cabling / Grounding• Centurion System Control / Hardware• AC Motor Development• 4100C BOSS Performance• Current 4100C BOSS AC Shovel Orders• Final Thoughts

P&H and ABB Drive P&H and ABB Drive TechnologyTechnology

• ABB is a world leader in AC & DC drives systems

• ABB continues to invest in R&D for AC and DC drive technology– Upcoming DCS800 development

• ABB has thousands of ACS800 drive installations world-wide

• Partnership with P&H to increase performance of our mining equipment

• History with P&H

4100C BOSS Deck Plan4100C BOSS Deck Plan

Inverter Lineup on ShovelInverter Lineup on Shovel

Base Frame for Inverter LineupBase Frame for Inverter Lineup

OneOne--Line / Main Xfmr. To ISULine / Main Xfmr. To ISU

DC Bus and Motion InvertersDC Bus and Motion Inverters

IGBT Supply Unit FunctionalityIGBT Supply Unit Functionality• Individual block consists of Inverter

Modules (2), a line filter (LCL Filter Module), and AC & DC Fuses

• The IGBT Supply Unit rectifies three-phase AC current to Direct Current for the intermediate DC link, which further supplies the inverters that run the motors.

• The line filter suppresses the AC voltage distortion and current harmonics.

ISU Control FunctionalityISU Control Functionality• The ISU controls the Charging Circuit and

Main Circuit Breaker of the drive system.• The charging contactor closes, connecting

the intermediate DC link capacitors to the AC supply via the charging resistors.– DC link voltage rises– When the DC voltage is high enough, the Main

Circuit Breaker is closed and the Charging Contactor is opened.

– Line-side converter synchronizes itself to the supply network and begins modulation.

– Motion Inverters are then ready for operation.

ISU Control ISU Control -- ContinuedContinued• DC Voltage Control

– DC Voltage Reference = 930VDC– Controller Parameters are tuned by default, no

need to reset them• Reactive Power Control

– Q Power Reference of 1.0 (unity) for normal operation

– Power Factor control adjustments for Motivator Mode Operation

• Only two setpoints required• Full regenerative operation

Main Circuit Breaker CubicleMain Circuit Breaker Cubicle

ISU Inverter Section ViewISU Inverter Section View

Shovel Motion Inverter UnitsShovel Motion Inverter Units• ABB Multidrive system with parallel

operation for all motions. Each module is a complete three-phase inverter.– Hoist1 and Hoist2 = 4 parallel inverters (each)– Crowd, Swing1, Swing2, Propel1, Propel2 each have

2 parallel inverters• All inverter modules have a rating of 580kVA

– This coupled with reduced-run operation allows for higher availability and machine run time.

• 4100C BOSS AC Drive system designed with 4100XPC AC Drive system in mind.– Propel 1&2 = +1 module, add Swing3 cubicle

Motion Inverter SectionMotion Inverter Section

Motion EnhancementsMotion Enhancements• Higher speeds for Hoist and Crowd

• Higher peak horsepower

• Dedicated Propel drive system / No Transfer Switch

• Optimal performance with ABB DTC (Direct Torque Control)

DTC DTC –– Direct Torque ControlDirect Torque Control• Field orientation achieved using ABB

adaptive motor model to calculate motor torque directly and without using a PWM modulator– Self-Identification / Auto-tuning completed using the Drive

ID Run which identifies specific motor parameters (stator resistance, mutual inductance, saturation coefficients, etc.)

– Motor Torque and Stator Flux used as primary control variables

– Quick Torque response– Accurate Torque control at low frequencies– Torque repeatability– No predetermined switching frequency of power devices

reduces mechanical resonances and stress in gearboxes

DTC DTC -- Control DiagramControl Diagram

System Cabling / GroundingSystem Cabling / Grounding• Symmetrical multicore cables are used

– Symmetrical arrangement of three phase leads and three earth conductors

– Continuous outer shield provides low impedance path for common mode current to return to the inverter

• 360 degree termination at both ends using Roxtec modules– A conductive, low impedance foil is wrapped around the cable

shield and entire Roxtec module

• High frequency bonding connections using braided straps and EMI shielding gaskets at motor frames– Flat conductors provide a lower inductance path than round wires

System Cabling System Cabling -- ContinuedContinued

Roxtec ConnectionsRoxtec Connections

High Frequency BondingHigh Frequency Bonding

Inverter ConnectionsInverter Connections

Centurion Control SystemCenturion Control System• Consistency with proven DC Centurion

System– Drive communication between AC800 and drives are

identical– Re-use of existing code between both systems with

use of shared libraries• New Control Cabinet with AC Drive Controller

panels• New I/O Assemblies

– Converter, RPC, and Transfer Cabinet I/O removed– ISU I/O Station, Rear Machinery House I/O Station

added

Control Cabinet / DrivesControl Cabinet / Drives

Drive ControllersDrive Controllers

Parallel Drive Branching UnitParallel Drive Branching Unit

AC Shovel GUIAC Shovel GUI• Same look and feel as current DC System

– Consistency of symbols and images so operator’s experience between shovels is similar

• DriveWindow tool for loading / saving drive parameters and making recordings of drive signals

• Drive Datalogger update / save function– Each drive has two dataloggers enabled– Once triggered by a fault, the GUI will upload & save the data, then

re-start the datalogger for next event

• ShoveLink II as an available option– Built-in expanded help files and information– Schematic viewer with inventory links to Parts Book– Flowcharts that simplify logic and troubleshooting

AC Motor DevelopmentAC Motor Development• Two motor frame sizes

– P&H HAF8412 1600HP/1194 kW, used for both hoist motors– P&H HAF7510 730 HP/545 kW, used for Crowd, Swing, and Propel

• Heavy duty mechanical design• Proven bearing designs• Replaceable non destructive INPRO type brass

bearing seals for improved contaminate protection• Lower inertia for improved system performance• Premium insulation system ( class H or better )• Insulated bearing and a shaft grounding feature• Improved reliability

– No brushes, commutator, or exposed uninsulated conductors– Single set of coils ( Stator coils as compared to armature coils,

interpole coils, compensating coils, field coils)

Stator Winding AssemblyStator Winding Assembly

HAF8412 Hoist Core Assembly HAF8412 Hoist Core Assembly Cooling SchemeCooling Scheme

AC Shovel Motor Rotor AssemblyAC Shovel Motor Rotor Assembly Cooling SchemeCooling Scheme

4100C BOSS AC Shovel 4100C BOSS AC Shovel PerformancePerformance

• Availability of the three operating 4100C BOSS AC shovels exceeding initial design criteria

• Preliminary production numbers show significant increase– Faster motion operation, increased horsepower– Instant propel feature allows operator to position

shovel closer to the bank more often, which results in ideal shovel positioning for increased fill factors.

AC Shovel Systems AC Shovel Systems –– Order Order StatusStatus

• Three (3) 4100C BOSS AC machines are currently operating at Suncor Energy in Fort McMurray– Two more machines currently on order

• Two (2) 4100C BOSS AC machines ordered for U.S. market– Lignite & Phosphate operations

Final ThoughtsFinal Thoughts• P&H is committed to strengthening our DC

shovel offering with R&D and continuous improvements focusing on the entire shovel system.– DC Motor Design (brush / commutator life)– Performance / Productivity– Power Quality– Reliability

• DC Centurion Control will continue to be offered in all shovel models.

• Common Centurion platform allows for ease of implementation of product enhancements for AC and DC shovels.

THANK YOU!THANK YOU!