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  Document number: PGEI-5329
 

Document number:

PGEI-5329

GE Energy Quadramatic TM Drive Instruction Manual

Page:

1 of 67

Date issued:

 

Instruction

May 5, 2009

Manual

 

Supersedes:

New

GE Quadramatic TM Drive Instruction Manual

New GE Quadramatic T M Drive Instruction Manual These instructions do not purport to cover all

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the nearest office of GE Canada.

© General Electric Canada 2009. All rights reserved.

GE Quadramatic T M Drive Instruction Manual Document number: PGEI-5329

GE Quadramatic TM Drive Instruction Manual

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PGEI-5329

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TABLE OF CONTENTS

1. SCOPE

 

5

2. RELATED DOCUMENTS

 

5

3. SAFETY PRECAUTIONS

5

4. QUADRAMATIC CONTROL – THEORY

7

5. DESCRIPTION OF OPERATION

10

6. START-UP AND MAINTENANCE NOTES

20

6.1

Initial Quadramatic Inspection (after Installation) Q-field Supply Check Q-Current Test Clutch Test Calibrate Clutch Manual Clutch Pulse - Load 1/2

 

21

6.3

24

6.4

26

6.5

27

6.6

28

6.7

29

7. QUADRAMATIC CONTROL – MILL COMMISSIONING

 

32

7.1

Q-field Current Regulator Tuning Kilowatt Difference Regulator Tuning Effect of Q-Current on kW Difference (QKW_AMP)

 

33

7.2

36

7.3

38

8. PREVENTATIVE MAINTENANCE

 

39

8.1

Power-Off Checks Q-Axis Exciter Maintenance and Troubleshooting

 

40

8.2

42

APPENDIX A - QUADRAMATIC DRIVE SPECIFICATIONS

50

APPENDIX B – QUAD CONTROL PERMISSIVES – LOGIC DIAGRAM

51

APPENDIX C – MODBUS INTERFACE TO QUADRAMATIC CONTROL PLC

52

APPENDIX D – DESCRIPTION OF SELECTED QUAD VARIABLES

55

APPENDIX E – MILL MARKER INSTRUCTIONS

57

APPENDIX F – SUMMARY OF GE WIRING PRACTICE (PGEI-1343C)

59

APPENDIX G – LIST OF POSSIBLE START-UP PROBLEMS

61

APPENDIX H – RENEWAL PARTS

63

APPENDIX I – GLOSSARY

65

SERVICE

66

INDEX

67

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TABLE OF FIGURES

Figure 1: Quadramatic Drive System

7

Figure 2: Principles of Quadratorque Operation

8

Figure 3: Quadramatic Drive Control Diagram

9

Figure 4: Mill Floor Station (typical)

10

Figure 5: Typical Pre-trip Circuit

12

Figure 6: Mill Start Sequence

13

Figure 7: Quadramatic Drive HMI Home Screen

14

Figure 8: Clutch pulsing “Rough adjustment”

17

Figure 9: Quadramatic Drive Line-up

22

Figure 10: Clutch Valve Cabinet

27

Figure 11: Clutch Calibration Cycle

28

Figure 12: Clutch Test Diagram

31

Figure 13: Q-regulator Tuning

35

Figure 14: Quad PID Regulator Diagram

37

Figure 15: AC1 to AC2 Waveform

43

Figure 16: Terminated Cell SCR Mounting Details

45

Figure 17: 53mm Presspack Cell Assembly

46

Figure 18: Converter Control Timing Waveforms

49

TABLES

Table 1: Communication Protocols

19

Table 2: Q-Field Current Regulator Polarity

34

Table 3: Troubleshooting Checks – Drive Does Not Operate

47

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DANGER indicates an imminently hazardous situation that, if not avoided, may result in death or

DANGER indicates an imminently hazardous situation that, if not avoided, may result in death or serious injury. This signal word is to be limited to the most extreme situations.

WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or

WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or

CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION without the exclamation symbol indicates a situation in which equipment/property damage can occur, but

CAUTION without the exclamation symbol indicates a situation in which equipment/property damage can occur, but personal safety is not at risk.

NOTICE is used for non-safety related items that the author wishes to highlight for importance.

NOTICE is used for non-safety related items that the author wishes to highlight for importance.

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1. SCOPE

This document provides instructions for the installation, commissioning, and operation of the GE Quadramatic Drive System. It is recommended that a person trained in the Quadramatic System perform this commissioning.

2. RELATED DOCUMENTS

PGEI-217---

Motor Instruction Manual

PGEI-1343C

GE Drive Systems Wiring Practices

PGEI-5296

Medium Term Storage of Motor Systems Electronic Equipment

PGEI-5334

Quadramatic Drive Simplified PLC Loading Instructions

GFK-0356Q

Series 90-30 PLC Installation and Hardware Manual

0234B2---

Quadramatic Drive Elementary Drawings

4002B------

Pneumatic schematic for the clutch valve cabinets

3. SAFETY PRECAUTIONS

for the clutch valve cabinets 3. SAFETY PRECAUTIONS Only qualified individuals should install, op erate,

Only qualified individuals should install, operate, troubleshoot, and maintain this drive. Do not touch energized circuits. To avoid electric shock, disconnect all power sources from the equipment before initiating maintenance or troubleshooting procedures. The control power supply may be feed from a separate source then the main power supply. Review the project-specific elementary drawings to ensure that all power sources are de-energized. Follow appropriate lock-out/tag-out procedures. Always wear appropriate personal protection equipment (PPE) for the task at hand. Never run the drive with cabinet doors open. The only exception is the control cabinet, which contains low voltages. Never install the drive where hazardous, explosive, or combustible vapours or dust may be present.

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Isolation of test equipment from the equipm ent under test presents potential electrical hazards. If

Isolation of test equipment from the equipment under test presents potential electrical hazards. If the test equipment cannot be grounded to the equipment under test, the test equipment’s case must be shielded to prevent contact by personnel. Always lift the drive using the removable lifting angles, which have been provided. Always confirm the lifting rating of cranes, hooks, and slings when lifting the drive.

rating of cranes, hooks, and slings when lifting the drive. Always be aware of electrostatic discharge

Always be aware of electrostatic discharge (ESD) when working on or near components inside the drive cabinets. Use the wrist strap provided when handling ESD sensitive components. Before removing any covers from electrical equipment, ensure that no dust or harmful material will enter as the cover is being removed or during the time that it is removed. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques. When transporting the drive line-up, the truck bed must be even and flat. Before unloading, be sure that the concrete pad is level for storage as well as permanent positioning The drive line-up must be transported and stored in the upright position.

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4. QUADRAMATIC CONTROL – Theory

The Quadramatic drive system is comprised of two low-speed, synchronous motors driving through air- clutches to two pinions connected by a common ring gear. To facilitate an initial load sharing, a special clutch pulsing technique has been developed to bring the two motor rotors into near equal load angles. Quadratorque motors then maintain load sharing by continuously, and automatically, adjusting for load differences between the two.

kW load balance between the two motors is controlled by the motor Q-axis fields, which vary the motor load angle, and by motor clutch pulsing for coarse balance control. Quadramatic-controlled motors offer a high performance system to correct for clutch unbalances and mill gear eccentricities while maintaining excellent steady state load sharing.

Figure 1: Quadramatic Drive System

SWITCHGEAR (BY OTHERS)

D D ESP1 - EXCITER CONTROL FOR MOTOR A - (controls motor DC exciter) Q
D
D
ESP1 -
EXCITER
CONTROL FOR
MOTOR A -
(controls motor
DC exciter)
Q
Q
MOTOR
A
QUADRAMATIC DRIVE
- includes Q-PLC
(controls cutch and q-axis power)

VALVE CONTROL CABINET - controlled by Q- PLC (operates mill air clutch)

ESP1 EXCITER CONTROL FOR MOTOR B - (controls motor MOTOR DC exciter) B
ESP1 EXCITER
CONTROL FOR
MOTOR B -
(controls motor
MOTOR
DC exciter)
B
FOR MOTOR B - (controls motor MOTOR DC exciter) B VALVE CONTROL CABINET - controlled by
FOR MOTOR B - (controls motor MOTOR DC exciter) B VALVE CONTROL CABINET - controlled by

VALVE CONTROL

CABINET - controlled by Q- PLC (operates mill

air clutch)

MILL FLOOR OPERATOR STATION - motor and mill start/ stop. Sends signal direct to Q-PLC

MILL FLOOR OPERATOR STATION - motor and mill start/ stop. Sends signal direct to Q-PLC
MCC SUPPLY (BY OTHERS)
MCC SUPPLY (BY
OTHERS)

to DCS (to initiate mill start and stop, send faults, and status)

Dynamic (“fine”) load balance is done by controlling current through the two motors’ quadrature field windings connected in anti-parallel for improved control gain. The controlled quadrature current increases the load angle on the lighter-loaded motor and decreases the load angle on the heavier-loaded motor so

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that the two motor loads are balanced (KW difference 0). The control configuration uses an outer KW

difference regulator and an inner quadrature field current regulator. These regulators act quickly to maintain

a minimal KW difference through such disturbances as mill out-of-round, gear eccentricity, mill load shift, etc. The motor load angle can be controlled to approximately +/- 25% of rated motor power. If the quadrature fields current average over a mill revolution is above a pre-set level, or the motor’s KW difference without quadrature field current control is above a preset level, then the “coarse” load balance strategy of clutch pulsing is initiated.

Principles of Quadratorque Operation

The apparent magnetic position of the rotor poles, with respect to the stator poles, can be changed rapidly in

a Quadratorque motor. This enables the two motors to share load equally within their dynamic range, in spite

of average and transient errors in rotor position due to initial clutch lock-up and instantaneous gear run-out.

Since this system has a very short time constant, it can also be made to act as a system damper.

The main flux produced by the direct-axis field winding is symmetrical about the centre line of the rotor pole.

If a flux is created in the quadrature axis – i.e. symmetrical about the interpolar centre line, it will combine with the main flux to produce a resultant flux, which is offset from the main flux. The degree of offset is determined by the magnitude and direction of the current flowing in the quadrature axis winding. By connecting the quadrature axis winding of the two motors in push-pull (or anti-parallel), a wide dynamic range of adjustment is achieved.

Figure 2: Principles of Quadratorque Operation

(or anti- parallel), a wide dynamic range of adjustment is achieved. Figure 2: Principles of Quadratorque
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The Quadramatic Drive controls the clutches and balances the two motor loads, including compensation for gear run-out between the twin synchronous motors, which are coupled to the mill. The Quad-control is packaged in one line-up and includes both the motors’ quadrature windings excitation power equipment and the operator’s control interface.

Figure 3: Quadramatic Drive Control Diagram

QTS-1

BRUSHLESS EXCITER PINION 1 D Q PT1 QUADRAMATIC DRIVE MV1 PR1 Q-PLC PRV CLUTCH PULSING
BRUSHLESS
EXCITER
PINION 1
D
Q
PT1
QUADRAMATIC DRIVE
MV1
PR1
Q-PLC
PRV
CLUTCH PULSING
CONTROL
CLUTCH 1
CONTROL CABINET
MILL READY
EXTERNAL
MOTOR 1/2 READY
CONTROL
SIGNALS
START/STOP MILL
AIR
SYSTEM PROTECTION
STORAGE
TANK
SERIAL OR ETHERNET
COMMUNICATION
100PSI
FIELD
EXCITATION PANEL
GPG
SUPPLY
RING GEAR
KW
+
_
QCURREF
KW
Q-CURRENT
KW1
PID loop
PID loop
CLUTCH 2
CONTROL CABINET
TRANSDUCER
_
+
PR2
PRV
DKW_REF
Q_CURR
MV2
BRUSHLESS
PT2
EXCITER
Q
D
KW2
+
TRANSDUCER
Q-PLC LOGIC
PINION 2
+
KW
QTS-2
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5. DESCRIPTION OF OPERATION

Once installation, start-up, and commissioning have been completed, the Quad-control is automatic. The Q- current control should be in AUTO, clutch pulse control in AUTO, and start / stop motors and mill from the Mill Floor Station or DCS. It is only when electrical maintenance will be performed that any other selection will be required.

Emergency Stop

All Emergency stop pushbuttons / contacts (such as Mill Floor Station, Quad-control door, exciter control cubicle door, plant DCS, PROCESS PLC, Quad-control PLC = Q-PLC) are normally closed, open for E-stop, and are accumulated into one relay (NESTP1/2) in the Quad-control. Loss of relay power, open circuit, pushing a button or opening a contact will drop out the relay, making this a fail-safe configuration. The Q-PLC logic will open the clutches, disable Q-current, and drop out the Q-current contactors, so that the mill will rock to a standstill and the motors will coast until friction stops them.

Figure 4: Mill Floor Station (typical)

friction stops them. Figure 4: Mill Floor Station (typical) Mill Starting Sequence 1) All control equipment

Mill Starting Sequence

1)

All control equipment and protection must be powered-up and “ready”, including motor direct-axis exciters, Quad-control, DCS, MCCs, switchgear, etc. Motor start permissives from the Quad-control must be healthy to allow a start. These include clutch open, Quad-current control test successful, Quad-shorting contactor closed to short out the Quad- winding current induced during start. Motor start permissives from the DCS include motor high-pressure

2)

   

lift pumps operating. The Mill Floor Station “Motor Ready” light will be on when all permissives are OK.

3)

Other mill run interlocks such as gear lube spray are satisfied through the DCS. Individual motor start/stop (clutch open) is by closing/opening the motor breaker. Control is normally from the Mill Floor Station. Under special circumstances, motor starts and stops can also be done at the associated breaker (local control) or by the DCS. All stops and Emergency Stops are active at all times. To allow the motor to synchronize, the exciter control turns on the motor direct-axis exciter field current a fixed time after the motor breaker closes, then tells the Quad-control that the motor is synchronized and “ready to load” if all remains OK.

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Note: The motor brushless exciter controls are independent, and each operates entirely on its own to apply motor field and protection in a timed sequence after the main motor contactor (or circuit breaker) closes, finishing by telling the Q-PLC that the motor is “ready to load” = synchronized.

4)

With both motors ready to load, all process systems ready, the Quad-control ready, and all motor and

sy stems ready, the Quad-control ready, and all motor and mill auxiliaries ready, the Mill Floor

mill auxiliaries ready, the Mill Floor Station “Mill Ready” light is turned on.

Mill start/stop is by the Quad-control closing/opening the two clutches together, after a 5-second “start”

warning horn. There is a separate control valve cabinet for each clutch. Each cabinet has a dump valve and

a pressure-regulating valve. To engage the clutches, the Q-PLC closes the two dump valves and ramps both

clutch air pressures to typically 2.5 times motor rated torque (should be less than the motor pullout torque) to accelerate the mill, then down to “run” pressure (typically 2 times motor rated torque) to “lock in” the clutches for running.

Note: Mill start/stop control is normally from the Mill Floor Station, but can also be from the DCS. Mill starts are never initiated at the Quad-control HMI display. All stops and Emergency Stops are active at all times. The load balance control is initiated when the mill has stabilized at run speed.

5)

6)

After the mill is stabilized at operating speed, the Quad-control operates contactors to enable motor quadrature field excitation control for “fine” load balance, and then enables clutch pulsing for “coarse” load balance if the Quad-field current is high or selected off. After at least one mill revolution and if the mill is at least 95% of rated speed, the Quad-control will tell the DCS that the mill is running, so that mill feeder conveyors can be started.

Stopping the motors

The two motors are stopped separately by opening their individual contactors (or circuit breakers). This is

their in dividual contactors (or circuit breakers). This is can be by the plant DCS, local

can be by the plant DCS, local “Stop Motor” PB’s, process PLC operator, or even manually at the switchgear. A

permissive from the Q-PLC and MUC PLC (if provided) is directly wired into the contactor, these contacts may also stop the motor.

Normal operation will stop the mill (open the clutches) before stopping a motor, but if the mill is running when

a motor is stopped, then the Q-PLC opens both clutches immediately.

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Note: A pre-trip input should be supplied to in order to prevent possible damage to the field control SCRs when the main motor circuit breaker is tripped. This pre-trip signal will allow the SCRs to be phased off before the main motor circuit breaker opens.

Figure 5: Typical Pre-trip Circuit

MFS QUAD 86 TS ESP1 STOP E-STOP MOTOR TRIP CIRCUIT 86
MFS
QUAD
86
TS
ESP1
STOP
E-STOP
MOTOR
TRIP
CIRCUIT
86

Others

86 TO QUAD DRIVE 52a
86
TO
QUAD
DRIVE
52a
MFS QUAD 86 TS ESP1 STOP E-STOP MOTOR TRIP CIRCUIT 86 Others 86 TO QUAD DRIVE

Stopping the Mill

86 Others 86 TO QUAD DRIVE 52a Stopping the Mill Mill stop is by the plant
86 Others 86 TO QUAD DRIVE 52a Stopping the Mill Mill stop is by the plant

Mill stop is by the plant DCS, the local “Stop Mill” PB on the Mill Floor Station, a “Stop Mill” PB on the

Quadramatic HMI (Human-Machine Interface) screen, or from the PROCESS PLC, all as inputs to the Q-PLC. Both clutches are disengaged simultaneously by opening the two dump valves and calling for zero pressure from the two pressure-regulating valves. The motors will continue to run until their breakers are opened. The mill will not be ready to run again for five minutes. This allows time for the mill to stop.

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Figure 6: Mill Start Sequence

psi 90 %R1012 = ACCELPR = 250% of rated motor torque %AQ3/4 60 15 psi/sec
psi
90
%R1012 = ACCELPR = 250% of rated motor torque
%AQ3/4
60
15 psi/sec
PRRF1/2AQ
%R1002 = RUNPR = 200% of rated motor
15
40
5
psi
10
Pressure feedback
(%AI5 / AI6)
0
Clutch calibrate
%I8
Q-Current Test -> Required to start the motors
QCTESTM
%M15
Two motors synchronized. No clutch faults
CL_RDY
%I22
Mill lube system running from PPLC
LSCLILK
%I31
Mill ready to start from DCS
MILRDYP
%M3
Clutch close permissive
CL_PERM
%I29
Mill run request from DCS
MILRUNP
%M58
Close clutches request
CLSCLRQ
Sound mill horn
%M60
5 sec
Close clutches command
CLOSECL
%Q4 / Q5
Close dump valves (MV1 & 2)
QPULS1/2
~12 sec
%M65
Mill accelerated up to full speed
FULLSPD
%M2
Q-field current control permissive
Q_PERM
%Q2
Close Q-field contactor (QXCC)
QXCP
%M27
0.5 sec
Delay for contactor to operate
QFCR_EN
5 sec
%M63
Reduce clutch pressure to running
FULSPDT
5 sec
%M197
Clutch pulsing allowed
CLCTLAV
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Parameter Indications (on Quad-control door):

Total Motor KW meter (i.e. both motors, Q-PLC analog output)

Motors KW Difference meter (Q-PLC analog output) (reads zero with Q-current auto, else follows mill gear run-out)

Q-current meter (from shunt, follows mill gear run-out when Q-current is in auto)

HMI – digital displays / trend graphs of KW difference, Q-current, clutch pressures, and also viewing of adjustable set-up parameters, alarms / faults, load balance conditions when a fault occurred, etc.

HMI screens:

Faults / alarms list is included on all screens except “Quad Fault Log”.

Overview – motors load balance general status.

Clutch operate – clutch pulse control mode select, manual clutch pulse initiation, view clutch pressure values + trend graph, view clutch control data, view clutch logic progression.

Q-current operate – Q-current control mode select, manual Q-current reference, view KW difference and Q-current values + trend graph, view Q-current control data, view Q-current logic progression.

Clutch set-up – test / calibrate / find slip for both clutches, view clutch pressure values + trend graph, view / adjust clutch control parameters.

Q-current set-up – toggle regulator reference square waves on / off, initiate Q-current test, view KW difference and Q-current values + trend graph, view / adjust Q-current control parameters.

Process PLC Signals – view logic / values for data to / from Process PLC.

Figure 7: Quadramatic Drive HMI Home Screen

Process PLC. Figure 7: Quadramatic Drive HMI Home Screen • Quad Fault Log – load balance

Quad Fault Log – load balance conditions stored in the Q-PLC when faults occur, including fault number (in PLC program), PLC time stamp, two motor KW’s, two clutch pressures, two Q-currents.

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Load Balance control device hierarchy (devices on the Quad-control HMI):

Q-current control

 

Clutch pulse control

 

OFF

AUTO

OFF

AUTO

 

Manual Q-curr

   

Manual clutch

 

ref.

 

pulse

The Mill can still operate if both controls are selected

The Mill can still operate if both controls are select ed OFF, but the Q-PLC will

OFF, but the Q-PLC will not do any load sharing

adjustments. This is not a recommended mode of operation. Selected load balance controls will operate only after the mill has stabilized at run speed.

Load Balance by motor quadrature field windings current:

The motor loads can be adjusted to be equal within a close range by sending current in opposite directions through the quadrature windings of the two motors (approx. 25% of rated KW can be added or subtracted per motor). This is equivalent to a “fine” adjustment for motors load balance whereas clutch pulsing is a more “coarse” adjustment.

The normal mode of operation for the Q-current control is

With Q-current control selected

AUTO:
AUTO:

AUTO, the Q-PLC compensates for KW difference between the twocontrol is • With Q-current control selected AUTO: motors continuously, so the KW difference meter should

motors continuously, so the KW difference meter should stay near zero (unless the Q-current requirement reaches its limit). This is the normal mode of operation.

If there are any regulation issues while in AUTO mode, manual control can be selected:

With Q-current control selected

MANUAL, the quadrature fields current is per the HMI Q-current manual ure fields current is per the HMI Q-current manual

reference value (“Q-current operate” screen). The manual reference outline will be green when manual reference is operating, red when not. The operator would not try to catch every movement of the KW difference meter, but would try to move the KW difference average to zero. Increasing the reference + (to load motor B) makes Q-current move the KW difference meter average right (showing more motor B load). Conversely, decreasing the reference will add load to motor A. The KW difference average over the past mill revolution is displayed with the immediate (dynamic) value.

During certain commissioning checks of the clutch pulsing, the Q-current control is selected

No current balance operates if Q-current control is selected

OFF:
OFF:
OFF
OFF

(“Q-current operate” screen -- the OFF

button will be green, the other two will be grey). In this case, the Q-field supply has zero output, and the two contactors are dropped out, one blocking Q-field supply current and the other shorting both motor quad-field windings. The clutch pulse load sharing can still operate.

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Load Balance by clutch pulsing (Refer to Figure 6):

By opening the clutch dump valve of the more heavily loaded motor momentarily, the rotor of the more heavily loaded motor is allowed to move ahead with less load while the lighter loaded motor is pulled back slightly. The motor load angles will be better matched after the clutch pulsing, if the pulsing time has been set up correctly. Loading one motor means pulsing the clutch of the other motor.

If the clutch pulse did not improve the average KW difference by a preset amount, then the pulse time is increased (within an upper limit) on the next pulse for improved “effectiveness”. The “effective” pulse time is remembered for the next time this clutch is pulsed.

Before a clutch pulse occurs, the clutch pressure of the heavier-loaded motor is reduced from “run” pressure to “pulse” pressure so that the dump valve doesn’t have to blow off as much air before getting some clutch slip on the heavier loaded motor. This also makes the clutch pulsing more responsive. Once clutch pulsing is completed, the clutch pressure is ramped up to “run” pressure again.

The normal mode of operation for the clutch pulse control is

With clutch pulse control selected

AUTO:
AUTO:

AUTO, clutch pulses are generated if the average KW differencecontrol is • With clutch pulse control selected AUTO: between the motors over one mill revolution

between the motors over one mill revolution goes outside a deadband. The average KW difference is calculated using the Q-current feedback plus the actual KW difference remaining between the motors. Clutch pulses always occur at a preset mill rotation position. The KW difference is averaged over the next complete mill revolution to see if further correction is required. If the clutch pulse did not improve the average KW difference by a preset amount, then the pulse time is increased on the next pulse for improved “effectiveness”. The “effective” pulse time is remembered for the next time this clutch is pulsed. If auto clutch pulses continue for longer than a preset time, then auto clutch pulses are stopped and an alarm is set.

If there are any regulation issues while in AUTO mode, manual control can be selected:

With clutch pulse control selected

MANUAL, clutch pulses are generated by pressing the “Manual pulse” lses are generated by pressing the “Manual pulse”

button (“Clutch operate” screen) -- the button outlines will be green if manual clutch pulses are permitted, red if not. The operator would be watching the Q-current meter (if Q-current is AUTO) or the KW

difference meter (if Q-current is

is AUTO) or the KW difference meter (if Q-current is OFF) to determine that one motor

OFF) to determine that one motor is more heavily loaded than the other.

Pressing a “Manual clutch pulse” button will cause one clutch pulse -- the button colour will be grey normally, but red when a manual clutch pulse is “armed”, waiting for clutch air pressure to reduce to “pulse” pressure and also for the preset mill rotation position where all clutch pulses occur (no less than every second mill revolution). After the clutch pulse, the average reading on the Q-current or KW difference meter will swing towards the motor that is adding load.

During certain commissioning checks of the Q-current control, the clutch pulsing control is selected

No clutch pulses are generated by the Q-PLC if clutch pulse control is selected

OFF:
OFF:
OFF
OFF

(“Clutch operate”

screen -- the

OFF
OFF

button will be red, the other two buttons will be green).

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Figure 8: Clutch pulsing “Rough adjustment”

Mill marker

pulse

MARK_OS

%M140

Mill Rotation Time MROTTIM

%R336

Clutch pulse timer CLP_TIM

%M141

Clutch 2 Pulse Pressure Command

PULPR_2

%M83

Clutch 2 Pressure reference

CL2PREF

%R253

 

4

mA

Clutch 2 Pulse pressure OK

PULPOK2

%M80

Clutch 2 Pulse

CLPULS2

%M94

Pulse 2 Output

QPULS2

24V

%Q5

{MV2 Dump valve solenoid}

0V

Clutch 2 Pressure

CL2_PRS

%R206

0 PSI

The mill marker is a proximity switch that counts the mill revolutions The mill rotation
The mill marker is a
proximity switch that counts
the mill revolutions
The mill rotation timer is
reset by each mill marker
pulse
1 sec
If the average KW
difference > 1250 kW; then
auto clutch pulse
14.6 mA = 66 PSI
= RUNPR (%R1002)
-12.5 PSI/sec (%R1006)
10.2 mA = 39 PSI
= NOMPPR (%R1000)
TRUE if the clutch
pressure is lower than
44 PSI
100 ms
The pulse width adjusts
according the feedback on the
effectiveness of the pulse
100 to 200 ms
If the load unbalance is not reduced to less than
25%of the unbalance limit (1250 kW) within 5
minutes, the pulsing will time-out
If the clutch pulsing is successful, load balance will
re-start using automatic Q-field current regulation.
66 PSI
PULSEPR (%R83) = 39 PSI
Clutch pulsing pressure level (PULSEPR) is
adjusted depending on the kW unbalance
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Other standalone functions:

Faults / alarms are displayed on every HMI screen (except “Quad Fault log”), showing HMI time when the fault / alarm was seen; alarm ID (= Q-PLC mnemonic), descriptive message. The faults / alarms area includes buttons to:

message. The faults / alarms area includes buttons to: colour to “Acknowledged”), “Silence Horn” (Q-door

colour to “Acknowledged”),

“Silence Horn” (Q-door buzzer),

“Ack All” and “Ack” (acknowledge all or just the selected faults / alarms – display lines will change

“Help” (to view an explanation and guidance file for the selected fault / alarm),

“Reset Quad” (open fault seals in the Q-PLC logic, so that you can operate again).

Display lines will change colour to “Normal” when the fault is cleared in the PLC, but a display line will disappear from the list only after that fault / alarm has been both acknowledged and cleared.

The HMI reads data from the PLC on a 250 ms cycle which is the resolution of its time stamp in the faults / alarms area. The PLC is where faults / alarms are recognized and action taken – the HMI is only the operator

interface / monitor. When the PLC sees a process-related fault, it stores current load balance conditions for that fault at the same time. These include:

Fault number (in the PLC program)

PLC time stamp (resolution is PLC scan time, approx. 10 ms)

Motor A and B KW

Clutch A and B pressure

Motor A and B Q-current

Faults / alarms which have this detail data available will have as part of their descriptive message “Fault xx –

have as part of their descriptive message “Fault xx – “Quad Fault log”. Go to that
have as part of their descriptive message “Fault xx – “Quad Fault log”. Go to that

“Quad Fault log”. Go to that screen, and then find the fault number to see what the Q-PLC saw when the

fault occurred.

General note: the HMI / PLC communication is by Ethernet, so response is quick but not instantaneous. The operator should continue pressing an HMI button until he sees some confirmation e.g. some colour change.

until he sees some confirmation e.g. some colour change. • The HMI “Q-current test” button (“Q-current
until he sees some confirmation e.g. some colour change. • The HMI “Q-current test” button (“Q-current

The HMI “Q-current test” button (“Q-current set-up” screen) will close the Q-contactors and force a preset

low current for a short time. The Q-PLC will measure the voltage and determine whether a short or open circuit exists in the Quadramatic system by checking if the voltage drop across the q-axis field is within a preset range. This manual Q-test is only permitted when the clutches are open, and the motors are stopped or synchronized – never when a motor is starting, because of the Q-current induced back from the motor quadrature winding during motor start. The same Q-test is automatically performed per PROCESS PLC command with the motors at standstill A successful Q-test is required before every motor start.

Stop the mill for “sustained high load unbalance” and for “instantaneous high load unbalance” (preset levels and time delays) not corrected by Q-current or clutch pulses.

There is a “trap” in the Q-PLC logic for when the PROCESS PLC stops the mill -- coil PROCESS PLCSTP %M12. This shows up on the alarms as “Mill stopped by PROCESS PLC”.

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The Quad can communicate to a remote DCS via several protocols (see Table 1). The Modbus signal interface is described in more detail in Appendix B.

Table 1: Communication Protocols

Communication Protocol

Hardwired

RS485 Serial

Modbus RTU Slave

Ethernet

Modbus TCP/IP

Server

Communication Protocol Hardwired RS485 Serial Modbus RTU Slave Ethernet Modbus TCP/IP Server Standard Option 1 Option

Standard

Option 1

Option 2

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6. START-UP AND MAINTENANCE NOTES

PLC Program Support

The PLC CPU contains the Quadramatic Drive application programming and configuration. Since these are special purpose programs, which are used to control and protect the synchronous motor, GE does not encourage users to make changes to program or configuration. Any changes must be restricted to changing parameters and options in the setup portion. The PLC program is password protected. The password is available if there is concurrence between the customer and GE on the validity of proposed changes.

Since the application programming contains proven failure detection, it should not be necessary to monitor operation of the logic for trouble shooting purposes.

The GE Fanuc PLC Series 90/30 CPU may be replaced with one that contains the same program without any configuration effort. Simply remove power, replace the module, and re-apply power. Replacing the module with an unprogrammed CPU requires that the flash EEPROM be reloaded when power is re-applied. This is done using a PC and the software and cable supplied with the equipment. See PGEI-5334 for step-by-step instructions. The procedure will restore the program to the "As Shipped" status, so if any setup parameters are changed in commissioning, the program should be updated. GE will provide this service free for the first commissioning revision. Note that the PLC RAM capacitor is not required to retain the program without power.

Contained on the CD-ROM diskette that is shipped with the Drive is a folder, which contains all the logic in the application program. This folder can be used with the concurrence of GE to modify the program using the programming software.

Receiving

Immediately upon receipt, place all equipment under adequate covers, as unless otherwise noted, the packing cases are not suitable for outdoor storage. To prevent the condensation of moisture on equipment, which has been subjected to low temperatures, covers should remain in place and cartons should remain unopened until the temperature of the contents has risen to the indoor temperature.

Examine each shipment carefully and check the contents against the packing list. Promptly report and shortage or damage incurred in shipping to the carrier and to GE Canada.

Handling

Shipping boxes or skids, and the outline drawing should be checked to determine if special lifting positions have been designated.

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Storage

Storage recommendations are contained in the Instruction PGEI-5296 “Medium Term Storage of Motor Systems Electronic Equipment”.

Periodic energizing of the PLC is not required since the PLC program is stored on the CPU EEPROM during the factory testing. Before the PLC leaves the factory, the battery connection plug is disconnected from the PLC power supply post (PL1) to prevent premature discharge of the battery. Once the plug is re-connected and the PLC is powered up at site, it will be ready to use with the correct program already loaded into it.

The PLC back-up battery should be replaced annually.

6.1 Initial Quadramatic Inspection (after Installation)

Step

Description

6.1.1

Examine the Quadramatic Drive for any damage that occurred during shipping or installation.

6.1.2

Ensure that the Quad line-up has been bolted to the foundation using anchor bolts (by others) as per the outline drawing.

6.1.3

Remove the packing material from the contactors QSC and QXCC.

6.1.4

Remove the Industrial PC from its packing material and install it on the control cubicle back wall on the pre-tapped mounting holes.

6.1.5

Install the AC line filter (#BA-ACF) above the Q-axis excitation cubicle.

6.1.6

Confirm that the main power cables have been adequately sized.

6.1.7

Confirm that the Drive has been grounded as recommended in PGEI-1343 (minimum 1/0 AWG cable, common ground point, at least one ground connection per shipping section).

6.1.8

Confirm that the ambient temperature of the electrical room is within the specification limits for the Drive.

6.1.9

Check the cable interconnections (no power) and prove out signals (with power) between locations – motor breakers, motors, Quad-control, direct-axis exciters, customer’s PROCESS PLC, mill floor station, clutch valve cabinets, etc. All interconnecting cables should be properly tightened, terminated, and free from stress throughout their length.

6.1.10

Ensure that the different signals are separated as per PGEI-1343 “Drive Systems Wiring Practices”. The wiring may have to be re-routed for adequate noise level separation to support a reliable installation.

Note that the Quad-control 120Vac power is distributed to a fuse block. These fuses allow the control power supplies to be individually connected for commissioning or test purposes.

The Quad-control does not need to be commissioned before the mill motors since the motors are normally started individually and unloaded (clutches open / disengaged), with direct-axis field applied per time after motor breaker close. Any interface signals required between the Quad-control and the PROCESS PLC may be overridden in the software during the mill motor commissioning.

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The motors are shipped with a shorting bar across the quad-field windings (to provide a path for the current induced in the quad-fields during motor start, and to prevent overvoltage on the quad-field windings). This bar must be place if the motors are being started without the Quad control. The motor slip rings and brush riggings for external connection to the quad-field windings would not be used yet. Once the control has been commissioned, there is a shorting contactor in the Quad contactor cubicle to perform the same function as the motor-mounted shorting bar.

Figure 9: Quadramatic Drive Line-up

Incoming Q-axis Contactor Power Exciter Cubicle Control Cubicle
Incoming
Q-axis
Contactor
Power
Exciter
Cubicle
Control
Cubicle

6.2 System Verification

To prevent any possibility of a motor moving the mill, the initial motor start should be done before clutch air

is piped to the motor non-drive-end Rotorseal TM (or equivalent). If this approach is not feasible, it may be

possible to open the manual valve in the clutch air feed line on the clutch valve control cabinet to block air to the clutch. All installation safety procedures must be followed.

A separate contract-specific Instruction Book PGEI section EC describes the interface to the self-contained

direct-axis exciter control, with installation, start-up, and trouble-shooting procedures. These exciters allow for the motor VARs to be controlled. However, the initial motor starts should have the exciter set to field

current control mode. The control can be changed over to VAR control once the motor starts are acceptable and the VAR feedback has been proven correct (also required for motor pull-out protection).

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Required brushless exciter control interconnections are detailed in the project-specific elementary (typical sheets are 04FC,FD, FM, GA, 05AA,AB, 06AA,AB):

AC power input;

Switchgear potential transformers (PT’s), current transformers (CT’s), breaker auxiliary contact (52a), breaker trip contact (EXC READY), start block contact (NO START BLOCK);

Motor DC brushless exciter field F1, F2, Rotector power and data;

Interface to the Q-PLC – EXC READY, OK to load, field force contacts, motor KW feedback;

Interface to the PROCESS PLC – motor OK to load contacts, Modbus serial link, and remote VAR reference.

Other motor connections must be made as per the motor accessories connection drawing. These include:

Stator power

Differential CT’s

Stator and bearing RTD’s

High-pressure lift pump switches and motors

Space heaters

The first motor starts may require the high-pressure lift pumps to be operated manually, on for at least 30 seconds before motor start and left on until the motor is synchronized. This process is normally controlled by the DCS, which can be proven later.

Do not touch energized circuits. To avoid electric shock, disconnect all power sources from the

Do not touch energized circuits. To avoid electric shock, disconnect all power sources from the machine and accessories before initiating maintenance procedures.

Follow appropriate lock-out/tag-out procedures and wear appropriate PPE.

The function and method of operation of th e circuit must be clearly understood. The

The function and method of operation of the circuit must be clearly understood. The slightest doubt must be cleared up before attempting to energize.

With the incoming power is available to the Quad-control line-up:

Step

Description

6.2.1

With all breakers open (elem #BA-QSCB and #BA-CB5 in the incoming cubicle door, #BA-CB4 in the Q-field supply door):

Verify correct 3-phase line-to-line voltage on the incoming external connection bus stubs.

Check that the phase rotation is 1-2-3 (required for Q-field supply operation).

6.2.2

Close the incoming breaker #BA-QSCB, then:

Verify correct 125VAC voltages on the 125KVA transformer secondary

Confirm that all three lights are lit on the roof-mounted AC-line filter

Leave the Q-field supply power breaker #BA-CB4 open until you’re ready to work on the field supply – remember that CB4 has a shunt trip.

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6.2.3 With all fuses #BA-FU13 to FU18 and #BB-FU1, 2,3 (on the exciter fan assembly) on the load side of the 3KVA transformer #BA-T5 opened, close the small auxiliary breaker #BA-CB5, then verify correct 240VAC voltages on the 3KVA transformer secondary.

6.2.4 Open all load isolation fuses on the 120VAC 750VA transformer #DA-T6 secondary. There are two (2) on the contactors diode exciter #DM-FU1, 2, and 12 TB fuse holders (elem #DA) in the Quad-control cubicle.

6.2.5 Open the small auxiliary breaker #BA-CB5 in the incoming cubicle again so you can safely insert the three 10A fuses #BA-FU16 to FU18 feeding the 750VA transformer. Close the small auxiliary breaker (CB5) and then verify correct 120VAC voltages on the 750VA transformer secondary.

6.2.6 Close fuse #DA-FU21 in the control cubicle to power on the PLC.

6.2.7 Close fuse #DA-FU34 in the control cubicle to power on the Industrial PC. Turn on the PC.

6.2.8 Close the other fuses used only within the Quadramatic line-up:

#DA-FU11 for Quad-line-up contacts.

#DA-FU13 for control relays (elem #FL).

#DA-FU31 for the Q-field supply breaker shunt trip coil.

#DA-FU33 for the +/-15V power supply, for Q-current control transducers / isolators.

6.2.9 Enter factory preset Quadramatic control parameters by pressing the HMI “Set Factory Values”

paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc
paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc
paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc
paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc
paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc
paramet ers by pressing the HMI “Set Factory Values” button (“Clutch set-up” or “Q-current set-up” sc

button (“Clutch set-up” or “Q-current set-up” screens). Press the HMI “Reset Quad” button (any

screen except “Quad Fault log”) to clear any Q-PLC fault seals except those caused by signals not commissioned yet.

Perform the following tests after the motor Quad-field connections are made, before the mill is

Perform the following tests after the motor Quad-field connections are made, before the mill is ready

Once the motor quad-field Q1 and Q2 slip ring connections are wired back to the Q-contactors cubicle, there is a shorting contactor to provide the path for quad-fields induced current. The motor-mounted shorting bar must be opened to permit Quad-control load balance current in the motor quadrature fields winding.

Note that the two motors Q1 and Q2 must be separately connected to the Quad-control bus in the contactor cubicle (4 cables), in order to achieve effective load balancing.

Check that the two motor quad-fields are connected in anti-parallel i.e. motor 1 Q1 and motor 2 Q2 to one bus in the Quad-control contactor cubicle, motor 1 Q2 and motor 2 Q1 to the other bus.

6.3 Q-field Supply Check

The motor must be at standstill during these checks.

Step

Description

6.3.1

The two fuses in the diode rectifier for contactor coil power should be pulled out, so that no Q- current can flow (elem #DM).

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6.3.3 Insert 120VAC fuses on the Q-field supply fans (elem #BB), and then close the small auxiliary breaker again. The Q-field supply should pick up relays #BD-UV1 and PL, and the three fan relays. #BB-FANxOK should pick up with cooling air through the self-heated airflow sensors.

6.3.4 Disconnect the Q-PLC analog output supplying the Q-field supply GPG reference 1TB29 (elem #BD) and connect an adjustable +/-10VDC test power supply to the GPG reference – leave the power supply turned off or set to 0V to start. There is still no power to the Q-field supply SCRs because the Q-field supply breaker is still open.

6.3.5 Connect oscilloscope 10X probes in differential DC mode to the Q-field supply output DC bus bars.

6.3.6 Close the Q-field supply breaker. Nothing should happen – no voltage, no current, and no contactor operation.

6.3.7 Verify that the Q-field supply breaker shunt trip works, either by closing the PLC output contact (#FL-QXBTRIP) or by overriding it ON through PLC logic. Restore the PLC contact and leave the breaker closed.

6.3.8 Turn up the test power supply voltage to around 5V to get an open-circuit voltage output from the Q-field supply. Use the oscilloscope to verify that the bus voltage DC waveform is uniform i.e. that all field supply SCRs are firing and blocking correctly. Repeat for the opposite voltage polarity from the power supply. Verify the operation of the voltage feedback transducer #CA-VT1 and the corresponding Q-PLC analog input (elem #GD) with this open-circuit voltage.

6.3.9 Turn the test power supply to 0-V.

6.3.10 The next test is to control some small (25A) current through the motor Quad-fields. Pick up the Q-field contactors, by overriding ON Q-PLC output #FL-QXCP %Q2 to pick up the #FL-QXCP relay.

6.3.11 With the power off, replace the fuses in the diode rectifier (elem #DM) contactor coil power. Restore power, this will close the N.O. bus contactor (elem #DM-QXCC) and open the N.C. bus shorting contactor (elem #DM-QSC) to permit current to the motors quad-windings. CAUTION – the QSC coil is only short-time rated – if the holding resistor is not inserted by PLC logic output QSCX %Q3 picking up relay #FL-QSCX within a short time, the contactor coil may be damaged –> drop out QXCP or open the rectifier fuses if this happens.

6.3.12 Move the oscilloscope leads to the shunt (elem #CA-SH) or even better (isolated and higher voltage ~3.7VDC instead of ~30mV) across one of the current feedback isolator outputs (elem #CA-MTBC16 to 06, MTBC 17 to 05).

6.3.13 Turn up the power supply voltage carefully until there is a little current (25A) flowing, and verify that the current waveforms are uniform i.e. that all field supply SCRs are firing and blocking correctly.

6.3.14 Repeat for the opposite current polarity. CAUTION: Do not apply current for more than 30 seconds on the motor slip rings at standstill in order to avoid local overheating and damage. Check that equal current flows to the two quad-field windings, connected in anti-parallel but with no other current-sharing mechanism.

6.3.15 Turn the test power supply to 0-V, open the Q-field supply breaker, and remove any Q-PLC override on QXCP %Q2 so that the contactors drop out.

6.3.16 Replace the wire from the Q-PLC analog output to the Q-field supply GPG reference 1TB29.

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6.4 Q-Current Test

Perform the following tests after the clutch valve cabinets are connected and verified (air &

Perform the following tests after the clutch valve cabinets are connected and verified (air & electrical) but before the mill is ready. The clutch air supply system should have already been purged to ensure that it is free of debris.

Step

Description

6.4.1

Perform a controlled Q-current test per the HMI “Q-current test” button (“Q-current set-up”

   

screen) with the two motors either both stopped (stator breakers open) or synchronized (unloaded). This test will request 100 Amps for 2 seconds to the two motors quadrature fields windings (50 Amps per motor), which is low enough and short enough to not damage the motor slip-ring connections at standstill. Note that the Q-current regulator has not been tuned yet, and initial regulator performance is deliberately slow (Kp = 10, Ki = 1000) to allow the regulators to turn on, even if they don’t perform satisfactorily yet. The Q-Drive may not produce precisely 100 Amps in the Q-current test with such low regulator gains. The Q-current test may fail because the winding volts are less than expected. Ignore that fault for now just reset it if needed. The response of the Q-current regulator is different when the motors are powered but uncoupled, when the motors are coasting, or when the motors are running clutched to the mill. The Q-current regulator should be tuned once the mill is ready (Section 7.1).

6.4.2

Look at the clutch valve cabinet pneumatic schematic and Quadramatic elementary sheets #MA, MB for electrical interface. In the Quad-control cubicle, with no power, close in fuses:

#DA-FU32 for the 24VDC power supply for both clutch valve cabinets’ regulator and dump valves, pressure transducer.

#DA-FU12 for valve cabinet system pressure switches and test pushbuttons (elem #FE).

CAUTION – FU12 also powers the mill marker proximity switch and lube system clutch interlock. Remove external wires from 3TBA54, 55,66,67 if that wiring has not been verified.

6.4.3

Both manual valves MEV1 and MEV2 should be fully open. The mill air systems should be supplying 100psi to the two clutch valve cabinets. The air supplies should be equal / symmetrical, and comply with GE recommendations (as per the pneumatic schematic for the clutch valve cabinets). The clutch control requires that the regulating valves are working within the spec tolerances. If the regulating valve malfunctions, it will have to be recalibrated, repaired, or replaced. The installation of the clutch valve cabinets by the customer pneumatic instrument technicians should reviewed by the GE commissioning technician.

6.4.4

Verify that the incoming air pressure switch System Pressure OK (SPOK) picks up at 85 psi (increasing) for 100-psi air supply to Q-PLC inputs CL1SPOK %I18 and CL2SPOK %I19.

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6.5 Clutch Test

number: PGEI-5329 Page: 27 of 67 6.5 Clutch Test There is a clutch “test” pushbutton on

There is a clutch “test” pushbutton on each clutch valve cabinet, meant for clutch pressure tests at start-up /

maintenance when the mill and this motor are stopped (motor breaker open). There is also a pair of clutch test buttons on the HMI (“Clutch set-up” screen), outlined in green when clutch test is permitted, in red when not. Pressing a clutch test button closes its dump valve and ramps the clutch pressure up to a preset level as long as the button is pressed. Releasing the clutch test button vents clutch air through the dump valve.

Figure 10: Clutch Valve Cabinet

air through the dump valve. Figure 10: Clutch Valve Cabinet PR1 – Pressure regulator Clutch test

PR1 – Pressure regulator

Clutch test pushbutton
Clutch test
pushbutton
MV1 – Dump
MV1 –
Dump

Step

Description

6.5.1

With mill and motor stopped, press and hold the clutch test button at least three (3) times to prove that the clutch operates correctly.

6.5.2

Verify that the pressure-regulating valve (PR1) receives 4-20mA from the PLC to make 0-100psi.

6.5.3

Verify that the pressure transducer makes 4-20mA = 0-200psi (12mA = 100psi, 20mA = 200psi). Do not try to adjust transducer zero / span outside a pneumatic instrument lab. The factory settings should be good. Do not touch the pilot-regulating valve zero / span pots either, because there is a Q-PLC “calibrate” sequence that is discussed below.

6.5.4

When clutch air pressure is at maximum, close both manual valves, release the clutch test button, and monitor clutch air pressure – drop should be less than 5 psi in 10 minutes, to prove that there are no leaks in the clutch, motor shaft, rotorseal, or valve cabinet.

6.5.5

Repeat the above three steps for the other clutch.

Note that the clutch test pushbutton can also be used to slow / stop a coasting (unpowered) motor against

mill inertia. With the motor breakers open, and mill still rocking, PULSE the clutch “test” pushbuttons when the

mill is rocking in the opposite direction to motor rotation.

rocking, PULSE the clutch “test” pushbuttons when the mill is rocking in the opposite direction to
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Most of the motor’s rotational energy will then appear as insignificant clutch heating. In this way, the motor coasting times of approximately 20 minutes can be reduced to about 45 seconds.

6.6 Calibrate Clutch

can be reduced to about 45 seconds. 6.6 Calibrate Clutch Calibrate both clutches per the HMI

Calibrate both clutches per the HMI “Calibrate Clutch” buttons (“Clutch set-up” screen). The PLC steps clutch

air pressure to 75psi and back to 15psi (3 times), adjusting the PLC analog output span for feedback error at 75psi, adjusting PLC analog output zero for feedback error at 15psi.

Figure 11: Clutch Calibration Cycle

CLTSTPR

%R1024

90

psi

70

50

30

10

5

0

Difference =

reference -

feedback

psi

+20

+15

+10

+5

0

-10

Step 1 Step 3 Step 5 mA mA Step 2 Step 4 Step 6 Time
Step 1
Step 3
Step 5
mA
mA
Step 2
Step 4
Step 6
Time
75
Open the
dump
valve
(MV1)
Open the
dump
valve
(MV1)
Too
low
Close the
dump
valve
(MV1)
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The feedback should match the reference pressure very closely. Do not adjust the factory-set zero and span pots on the clutch pressure transducer outside a pressure instrument lab, and only adjust the pilot regulating valve zero / span pots if you get an HMI alarm message that says the Q-PLC calibration sequence wanted a reference outside of control range “Clutch x calibrate fault – high / low reference”. In that case, you will need to do a “rough” calibration of the regulating valves, as follows:

Step

6.6.1 Reset the Q-PLC analog output zero / span to 0 / 32000 at AQxZERO / AQxSPAN on the HMI “clutch set-up” screen (AQ3 for clutch 1, AQ4 for clutch 2).

6.6.2 “Test” the clutch at 6.6.2 75psi (CLTSTPR = 75.0 on the HMI “clutch set-up” screen), and adjust the pilot 75psi (CLTSTPR = 75.0 on the HMI “clutch set-up” screen), and adjust the pilot

Description

regulating valve span to give 75psi output pressure on the valve cabinet gauge or in the Q-PLC (variable CL1_PRS %R205 or CL2_PRS %R206).

6.6.3

regulating valve zero to give 15psi actual pressure on the valve cabinet gauge or in the Q-PLC.

6.6.4 Repeat steps 2 and 3 until no further zero / span pot adjustment is required (maybe 2 repeats).

6.6.5 Repeat the Q-PLC “fine” calibrate sequence to gain more precise pressure control by adjusting AQxZERO / AQxSPAN. This time, the sequence should finish without any fault message.

time, the sequence should finish without any fault message. “Test” the clutch at 15psi (CLTSTPR =

“Test” the clutch at 15psi (CLTSTPR = 15.0 on the HMI “clutch set-up” screen), and adjust the pilot

6.7 Manual Clutch Pulse - Load 1/2

With all required checks completed and all required permits in place, you can close the clutches and make manual clutch pulses with the mill and motors at standstill i.e. simulate clutch operation as if the mill were running. Alternatively, you would have to wait for the mill to be running, and coordinate with mechanical / production requirements for any changes in clutch control.

Step

Description

6.7.1

On the HMI, select clutch pulse control

MANUAL
MANUAL

(“Clutch operate” screen), Q-current control

OFF
OFF

(“Q-current operate” screen).

 

6.7.2

To enable clutch functions, override the Q-PLC program logic as follows:

 

At the clutch permissive coil CL_PERM %M3 in the CLUTCH block, override ON what you need to get the coil picked up e.g. MILRDYP, BKR1_CL, BKR2_CL, RDY1_LD, and RDY2_LD.

At the test marker coil TSTMRKR %M2000 in the CLUTCH block, change the ALW_OFF contact to ALW_ON. If you didn’t do this, then CL_PERM would drop out per mill speed not up SPDNUP %M78.

6.7.3

Monitor clutch pressures on either HMI clutch screen.

 

6.7.4

Pick up the clutches close request coil CLSCLRQ %M58 in the CLUTCH block by overriding the logic contacts as necessary (toggle the PROCESS PLC mill start contact to seal CLSCLRQ, so you

can use the HMI or Mill Floor Station “Stop Mill” button to stop) – this

can use the HMI or Mill Floor Station “Stop Mill” button to stop) – this will close the two clutches

by ramping the pressures to ACCELPR %R1012, then to “run” pressure RUNPR %R1002 as preset

in the Q-PLC program SYSSU block. The outline of the HMI “Manual pulse Load 1 / 2” buttons

   

(“Clutch operate” screen) will change from red to green when that action is permitted.

 

6.7.5

 

Press the HMI “Manual pulse Load 1” button. The button will blink amber to say that a clutch

pulse is “armed” i.e. waiting for the right conditions to activate. The clutch 2 pressure will go down to NOMPPR / 3, a minimum for standstill testing (in the CLUTCH block 3 rungs above the coil for PULPOK1 %M79), and the clutch 2 dump valve will pulse.

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Document number: PGEI-5329 Page: 30 of 67 6.7.6 The HMI “Clutch Pulse 2” light should flash

6.7.6 The HMI “Clutch Pulse 2” light should flash (“Clutch operate” screen), and/or you can watch for

the Q-PLC output card (rack 0, slot 6) status light for QPULS2 %Q5 to flash, and/or you can hear the QPULS2 relay operate (elem #FL), and/or you can hear the air blast from the clutch valve cabinet as the dump valve opens and re-closes.

clutch valve cabinet as the dump valve opens and re-closes. 6.7.7 If you press the HMI

6.7.7 If you press the HMI “Manual pulse Load 1” button more times, the clutch pulse will be longer

each time by one Q-PLC scan time – you should be able to hear the difference in the QPULS2 relay and the valve cabinet air blast after several pulses.

relay and the valve cabinet air blast after several pulses. 6.7.8 Repeat for “Manual pulse Load

6.7.8 Repeat for “Manual pulse Load 2” and clutch 1.

6.7.9 After these tests, remove the PLC program overrides at CL_PERM %M3 coil and CLSCLRQ %M58 coil; change ALW_ON back to ALW_OFF at TSTMRKR %M2000 coil.

6.7.10 Reduce the remembered clutch pulse times C1PTBAS %R1018 and C2PTBAS %R1019 to original

values (on the HMI “clutch set-up” screen by “

values) or on the “clutch operate” screen by manually making each equal to CPTBASE %R1020, shown on the “clutch set-up” screen).

each equal to CPTBASE %R1020, shown on the “clutch set-up” screen). Set Factory Values” (which affects

Set Factory Values” (which affects ALL preset

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PLC

counts

mA

psi

32000

20

100

 

90

80

70

60

12

12

50

 

40

30

20

10

0

4

0

counts

V

psi

32000

10

100

 

90

80

70

60

12

5

50

 

40

30

20

10

0

0

0

counts

mA

psi

32000

12

100

 

90

80

70

60

12

8

50

 

40

30

20

10

0

4

0

Figure 12: Clutch Test Diagram

%R999 (MAXPR) = 100 PSI = Maximum clutch pressure PLC REFERENCE %R252 = CLA PREF
%R999 (MAXPR) = 100 PSI = Maximum clutch pressure
PLC REFERENCE
%R252 = CLA PREF = Clutch A pressure reference =
%AQ3 (2TBA06(+), 2TBA07(-)
%R1004 = CLACLSR =
15 PSI/sec = Clutch A
%R253 = CLB PREF = Clutch B pressure reference =
%AQ4 (2TBA10(+), 2TBA11(-)
closing pressure rate
%R1005 = Clutch B
5
5
0
1
2
3
4
5
6
7
8
9 10 sec.
%AI9 = Clutch A PR feedback
pressure (2TBA23(+), 2TBA24(-))
%AI10 = Clutch B PR feedback
pressure (2TBA27(+), 2TBA28(-))
5
5
0
1
2
3
4
5
6
7
8
9 10 sec.
%R205 = CLA_PRS = Clutch A pressure feedback =
%AI5 (2TBA14(+), 2TBA15(-)
%R206 = CLB_PRS = Clutch B pressure feedback =
%AI6 (2TBA19(+), 2TBA20(-)
Difference between reference
and actual pressure
0 1
2
3
4
5
6
7
8
9 10 sec.
Open the
"dump" valve
Close the

"dump" valve

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7. QUADRAMATIC CONTROL – Mill Commissioning

Perform the following tests when the mill is ready

Perform the following tests when the mill is ready

Step

7.1 Before the mill can run, the following must be verified:

Description

Emergency stop devices and wiring (elem #DP) so that you can close in fuse #DA-FU22 for that circuit.

Exciter control inputs (elem #FC & FD) so that you can close in fuse #DA-FU11 for that circuit.

Mill/Clutch cabinet inputs and wiring (elem #FE & FF) so that you can close in fuse #DA- FU12) for that circuit.

Mill Locked Charge contacts wiring (elem #FJ) so that you can close in fuse #DA-FU14 for that circuit.

Switchgear inputs (elem #FF) so that you can close in fuse #DA-FU15 for that circuit.

Now all external connections should be verified, and all #DA fuse holders should be closed.

7.2 Early mill starts / stops will be mainly for the mechanical verification.

Select Q-current control

OFF
OFF

and clutch pulse control

AUTO
AUTO
OFF
OFF

for early mill starts / stops.

7.3 Once the electrical system is ready, select

for both Q-current control and clutch pulse

control, to let the Quadramatic control system operate with full effectiveness in all modes.

7.4 During the preliminary mill starts, the Q-PLC has been adjusting the mill start ramp rate of clutch 2 air pressure relative to clutch 1 so that the motors are at the same KW (within 5%) after the mill start. Check the HMI “Clutch set-up” screen to see if there’s any difference between the two clutch close rates. This background function can be turned off in the Q-PLC logic by changing ALW_ON to ALW_OFF in the rung for coil SAVAVDK %M1621 or by overriding OFF SAVAVDK, then reset by making clutch 2 ramp rate the same as clutch 1 on the HMI “Clutch set-up” screen. Further, if you change the behaviour of one clutch vs. the other, then clutch 2-ramp rate should be pre- biased manually to compensate for the anticipated new difference between the two clutches.

Remaining steps to be taken include:

Tune Q-current regulator.

Tune KW difference regulator.

Determine the effect of Q-current on KW difference QKW_AMP.

All those functions can be done with an empty mill, but should be checked (and repeated if required) when the mill has significant load and when the results will be more reliable and accurate.

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7.1 Q-field Current Regulator Tuning

With both motors and the mill running, tune the Q-current inner regulator first, and then the KW difference

outer regulator. Remember that you can turn Q-current

Q-current or regulator tuning. There are regulator tune-up instructions in the Q_CURR program block comments, which are reproduced here for reference.

OFF
OFF

from the HMI “Q-current set-up” screen to verify

Step

Description

7.1.1

When the mill is running and Q-current control is on, tune the Q-field current regulator with the

Q-current reference selected

MANUAL
MANUAL

(i.e. from the HMI manual reference) so that it is steady.

7.1.2

Toggle field current regulator tune FCRTUNE %M1007 ON to turn on a test step for Q-field current regulator response. FCRTUNE also blocks a fault QCURFLT %M43 for current feedback not following reference within a preset tolerance for a preset time.

7.1.3

FCRTUNE toggle is on the HMI “Q-current set-up” screen. When FCRTUNE is

ON, it enables a

ON, it enables a

square wave on the Q-field current reference, ½ sec at the manual reference and ½ sec. at (man.ref – 50A).

7.1.4

Set up a >= 2-channel chart recorder, one channel on a Q-current feedback (control cubicle left wall MTB’s on the R-C filter output, elem sht #GA) and the other channel on Q-current reference (put QCREF+S %R251 through the CHART block to a Q-PLC analog output on 1TB, elem sht #GC).

7.1.5

View FC_KP and FC_KI on the HMI “Q-current set-up” screen, or in the PLC using PME at the register table, at the program instruction MOVEing constants into them, by zooming on the FC PID instruction. With the manual reference turned enough that all Q-current is one polarity, increase FC_KI until you get feedback jumps during the flat part of the reference square wave, then reduce FC_KI just enough that the jumps are gone. Previous projects have ended up with FC_KI around 8000.

7.1.6

Increase FC_KP to sharpen the current’s step transition edge without overshoot. Previous projects have ended up with FC_KP around 100.

7.1.7

Store the final values as constants at the PLC program instruction MOVE constants into FC_KP and FC_KI.

7.1.8

Re-check that equal current flows to the two quad-field windings, connected in anti-parallel but with no other current-sharing mechanism.

7.1.9

Check for same performance with the manual reference turned so that all Q-current is the opposite polarity.

7.1.10

Check for same performance with the manual reference turned so that Q-current is back-and- forth through zero. To get the current stepping OK through zero (the field supply deadband), factory tests have led to setting the current regulator bias FC_BIAS at +/-19000 per the sign of the reference.

7.1.11

Record the response charts for future comparison.

 

7.1.12

Toggle FCRTUNE

OFF
OFF

from the HMI “Q-current set-up” screen.

7.1.13

Zero the Q-current manual control reference, then select Q-current control

AUTO.
AUTO.
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Table 2: Q-Field Current Regulator Polarity

%R912 = 16 : BIT 12 OF PID = 0 = POSITIVE = MOTORS CCW / MILL CW (looking at the ring gear facing the motor ODE)

%R912 = 18 : BIT 12 OF PID = 1 = NEGATIVE = MOTORS CW / MILL CCW (looking at the ring gear facing the motor ODE

 

MOTORS CCW BIT 12 OF PID = 0

MOTOR CW BIT 12 OF PID = 1

kW Difference = NEGATIVE {Motor A load = high}

kW Difference = POSITIVE {Motor B load = high}

kW Difference = NEGATIVE {Motor A load = high}

kW Difference = POSITIVE {Motor B load = high}

DC(+) BUS

DC(+) BUS

DC(+) BUS

DC(+) BUS

= POSITIVE

= NEGATIVE

= NEGATIVE

= POSITIVE

MOTOR A

REDUCE LOAD

INCREASE LOAD

REDUCE LOAD

INCREASE LOAD

MOTOR B

INCREASE LOAD

REDUCE LOAD

INCREASE LOAD

REDUCE LOAD

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Figure 13: Q-regulator Tuning

3 cases:

+300A -300A +25A QMANCUR %R220 50A 3 cases: time 1/2 sec +250A -350A -25A Q_CURR
+300A
-300A
+25A
QMANCUR
%R220
50A
3 cases:
time
1/2 sec
+250A
-350A
-25A
Q_CURR
%R201

FC_KP and FC_KI = Too low

FC_KI = Too high

FC_KI = Good FC_KP = Too low

FC_KP = Too high

Correct

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7.2 Kilowatt Difference Regulator Tuning

Kilowatt Difference Regulator With both motors clutched to the mill, tune the KW difference regulator with the Q-current reference selected

AUTO
AUTO

(i.e. from this regulator). Toggle the KW difference regulator tune KWRTUNE %M1008

KW difference reference a square wave of +/-300KW.

ON
ON

to make the

NOTE: tune the Q-current regulator BEFORE the KW difference regulator.

Remember that you can turn Q-current regulator tuning.

OFF
OFF

from the HMI “Q-current set-up” screen to verify the Q-current or

Step

Description

7.2.1

KWRTUNE toggle is on the HMI “Q-current set-up” screen. When KWRTUNE is

ON, it enables a

ON, it enables a

square wave on the KW difference reference, 5 sec at +300KW and 5 sec at -300KW.

7.2.2

Set up a >= 2-channel chart recorder, one channel on actual KW difference (back of the Q-door meter) and the other channel on KW difference reference (put DKW_REF %R45 through the CHART block to a Q-PLC analog output on 1TB, elem sht #GC).

7.2.3

View KW_KP and KW_KI on the HMI “Q-current set-up” screen, or in the PLC using PME at the register table, at the program instruction MOVEing constants into them, by zooming on the KW PID instruction.

7.2.4

Increase KW_KI until you get feedback jumps during the flat part of the reference square wave, then reduce KW_KI just enough that the jumps are gone. Previous projects have ended up with KW_KI around 7000.

7.2.5

Increase KW_KP to sharpen the KW difference step transition edge without overshoot. Previous projects have ended up with KW_KP around 200.

7.2.6

Record the final values as constants at the PLC program instruction MOVEing constants into KW_KP and KW_KI.

7.2.7

Toggle KWRTUNE

OFF
OFF

from the HMI “Q-current set-up”. The Q-door KW difference should stay

on zero, while the Q-current meter will correct for any motors KW unbalance.

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Figure 14: Quad PID Regulator Diagram

KW PID Regulator

BIAS %R908 = 0 SP SLEW UPPER/LOWER DEADBAND POLARITY CV + %R45 LIMIT CLAMP %R903/904
BIAS
%R908
= 0
SP
SLEW
UPPER/LOWER
DEADBAND
POLARITY
CV
+
%R45
LIMIT
CLAMP
%R903/904
PROPORTIONAL
GAIN - Kp
%R912
%R250
DKW_REF
= 0 kW
%R911
%R909/%R910
-
= 0
%R905
Bit 1
QCURREF
= 0
= +/- 600A
PV
%R257
INTEGRAL GAIN -
DIFF_KW
Ki
%R907
FC PID Regulator
BIAS
%R948 =
+/- 19000
SP
SLEW
UPPER/LOWER
+
PV
DEADBAND
PROPORTIONAL
POLARITY
CV
LIMIT
CLAMP
%R199
%R943/944
GAIN - Kp
%R952
%AQ1
-
%R951
%R949/%R950
Q_CURR
= 0
%R945
Bit 1
QGPGREF
= 0
= +/- 75% max
INTEGRAL GAIN -
Ki
%R947
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7.3 Effect of Q-Current on kW Difference (QKW_AMP)

The last parameter to tune is the effect of Q-current on KW difference QKW_AMP. This determines what the motors KW difference would be if Q-current were OFF. If the KW difference is too large, the clutch is pulsed as the “coarse” adjustment to restore load balance.

Step

Description

7.3.1

With the mill running with at least 1/4 load, press the HMI “Determine QKW/AMP” button (“Clutch

   

set-up” screen).

7.3.2

The automatic procedure collects:

With Q-current

• With Q-current ON, average Q-current and aver age (leftover) motors KW difference over

ON, average Q-current and average (leftover) motors KW difference over

a full mill revolution.

With Q-current

• With Q-current OFF, average motors KW difference over a full mill revolution.

OFF, average motors KW difference over a full mill revolution.

7.3.3

The overall KW difference is the same, so the scale factor QKW_AMP on Q-current to make equivalent motors KW difference is calculated. The value can be seen on the HMI “Clutch set- up” screen.

With the mill running, Q-current control selected

exercise all the Quadramatic control components by doing several manual clutch pulses on the same motor (e.g. “Load 1” = pulse clutch 2). Don’t do so many manual clutch pulses that you cause a “sustained load unbalance” fault and mill stop; just enough to go over the preset to initiate AUTO clutch pulses when you

select

the preset to init iate AUTO clutch pulses when you select AU TO, clutch pulse control

AUTO, clutch pulse control selected

pulses when you select AU TO, clutch pulse control selected MANUAL, you can AUTO. The manual

MANUAL, you can

AUTO.
AUTO.

The manual clutch pulses will cause a large motor KW difference, which can be seen by the increase in Q-

current – the KW difference meter will still read zero. If you then turn clutch pulse control to

get clutch pulses on the other motor (e.g. clutch 1) to reduce the overall motors KW difference, which you can see by the decrease in Q-current – the KW difference meter will still read zero. When the auto clutch pulses stop, you could repeat the test by several manual clutch pulses on the other motor (e.g. “Load 2” = pulse clutch 1) and verify Quadramatic control operation for KW difference from that direction too.

= pulse clutch 1) and verify Quadramatic control operat ion for KW difference from that direction

AUTO, you will

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8. PREVENTATIVE MAINTENANCE

Periodic preventive maintenance extends equipment-operating life and minimizes downtime. For maximum benefit, preventive maintenance needs to be performed at scheduled intervals by a qualified technician. The required frequency for each procedure depends on:

How much the equipment is used

Ambient environmental conditions

In addition, an inspection of wiring and components should be completed before re-applying power after an overcurrent trip.

Maintenance Record

GE recommends that the customer keep a detailed record of maintenance for every drive. This record is intended for two purposes:

To verify that all equipment is routinely checked

To provide a history of equipment maintenance and problems that will be useful for both preventing and troubleshooting equipment failure

For example, the record should include the time and date of the maintenance checks, detail any equipment defects found, and specify repairs or corrective action.

Tools/Materials Needed

The tools and materials listed below may be needed when performing preventive maintenance on the drive:

High quality tools, including screwdrivers and pliers, designed specifically for working with electrical wiring systems

Socket set

Wrench set

Feeler gauge

Electrical tape

Fine file

Clean dry cloth

Soft-bristled brush (such as a paintbrush)

Insulation resistance tester

Vacuum cleaner with non-metallic nozzle and finely woven, high efficiency filter

Replacement components, if required, including fuses, wiring, and cabling

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8.1 Power-Off Checks

Power must be de-energized before perf orming any adjustments, servicing, or other act requiring physical

Power must be de-energized before performing any adjustments, servicing, or other act requiring physical contact with the electrical components or wiring.

Power-off checks involve cleaning the equipment and checking for wear and damage through visual inspection and functional tests.

Before starting, the equipment must be prepared as follows:

1. De-energized

2. Tagged and locked out

3. Tested for zero voltage (using a tester approved for the voltage level being measured)

4. Safety grounded

Do not deviate from these conditions. If safety requirements cannot be met completely, or if you do not understand them, do not work on the equipment.

Cleaning the Equipment

• Build up of dust on electrical components and wiring can damage components and may

Build up of dust on electrical components and wiring can damage components and may cause malfunctions.

The electrostatic wristband that is provided in the control cubicle should be used when working around any of the control cards.

Dust Removal

Build-up of dust on components can increase operating temperature, reducing their normal “life”. On standoff insulators, it can collect enough moisture to produce a current path from bus bars to chassis ground.

Dust on wire surfaces can cause “tracking” between connector pins. Tracking is usually capacitive in nature and involves a build-up of electrical charge along the wire surface. This can cause intermittent problems that are hard to find.

Check for and remove accumulated dust as follows:

1. Clean bus bars and standoff insulators with a clean dry cloth – do not use any solvents.

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Note:

Make sure that the air source is directed so that dust and foreign matter is removed rather than relocated

Do not use high-pressure compressed air, which may damage components.

Do not use high-pressure compressed air, which may damage components.

Printed Circuit Boards

If boards in a module are dirty:

1. Vacuum to remove dust from around the board slots/connections (before unplugging). A soft- bristled brush may be used to loosen dirt.

2. Vacuum the boards, using a soft brush, if necessary, to help loosen dust.

Loose Connections

Vibration during equipment operation can loosen mechanical and electrical connections, causing intermittent equipment failure. Additionally, dust and moisture can accumulate in loose connections. This can cause loss of low-level signals at terminal boards and also thermal runaway at bus connections.

1. Check all hardware and electrical connections, and tighten if needed.

2. Tighten or replace any loosened crimp-style lugs.

3. Tighten or replace all loose or missing hardware.

4. Inspect printed wiring boards for correct seating, and check that any plugs, wiring, and bus connectors are tight.

To prevent component damage caused by static electricity, treat all boards with static sensitive handling techniques. Use a grounding strap when handling boards or components.

Damaged Insulation

Wires and cables with damaged insulation are dangerous when carrying electricity. They can also intermittently short, causing equipment and functional failure.

1. Check all wires and cables for fraying, chipping, nicks, wear, or rodent damage.

2. Check all wires and cables for signs of overheating or carbonization.

3. Replace any damaged cables or wires.