New DC-EXX Shared Bus IGBT MG Control

Western Mining Electrical Association – Fall 2007

New IGBT Exciter-

Based MG Set
Excavator Drive

ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

MG Set DC Drives - A History

2007 Shared Bus

IGBT Control
1995
1987
Full Digital Control
Hybrid PLC/Analog
1967
Static Analog
1960
Amplistat
1950’s
Amplidyne
1940’s Three Field Control

Slide 2 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

DC EXX
• DC is part of a
wide product
family from
TMEIC-GE
• Robust DC
Conversion for
armature supply
to 20,000 HP
• New complete
drives and DFE BUT, high performance, single field
retrofit Thyristor [SCR] based MG set control
not part of development plan
Slide 3 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Excavator MG Set DC-EXX

IGBT System Block Diagram

MVAC
Input AC
Motor DC DC
One per motion Gen Motor
Generator Field
IGBT Sync Fld
Regul. & IGBT PWM
Supply Exciter Regulator
Diode rectifiers One per motion
Profibus
Motor Field
Ref & control
IGBT PWM
Exciter Regulator

Slide 4 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Gen Field Control Design Goals

• Maximize reliability and safety.
• Protect the motor and gen fields from
overvoltage insulation damage.
• Protect mechanical equipment.
• Use high response regulators and flexible
control to maximize machine productivity.
• Minimize maintenance.
• Use unique advantages of IGBT
technology over thyristor system.

Slide 5 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Comparison Thyristor vs IGBT

Thyristor Family of Devices Transistor Family of Devices
Easy current-controlled turn-on. Easy voltage-controlled turn-on.
Difficult, uncontrolled turn off. Easy voltage-controlled turn off.

DC From Source

[-] VDC

Thyristor Reversing Exciter IGBT Reversing Exciter

3-ph AC in, DC Out DC in, Chopped DC Out

Slide 6 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007
DC-EXX Comparison with GE DC2000 or other Thyristor
Exciter
Quick Comparison of Structure & Function
Thyristor
DC-EXX
Such as DC2000 / Simoreg / AVTRON
+ Thyristor Based + IGBT Based
+ Individual Motion Transformers + Common group transformer(s)
+ Fully integrated drive individualized by
+ Standard drive with PLC individualization
motion
+ Integrated Isolators for most feedbacks + External Isolators for Feedbacks
+ Low Variation of cards Drive/Drive + No Variation of cards Drive/Drive
+ Low Spares requirement + Very Low Spares Requirement
+ Individual AC feeders & Drive Transformers + Maximum two Common Transformers
+ Function blocks within drive + Standard drive pattern & PLC master
+ Windows Control System Toolbox + Windows Toolbox

Slide 7 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Simplified DC-EXX One-Line

Slide 8 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007
Overall Typical System One-line [Dragline]

Common Gen Exciter

DC Bus
Common Motor
Exciter DC Bus

Slide 9 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

One Motion & Loop Detail

24 vdc fail-
safe PLC
trigger

24 vdc fail-
safe PLC
trigger
Slide 10 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Gen Field Supply DC Shared Bus Chopper vs SCR

Generator Converters and Exciters
Generator Data [from published designs] KVA Equiv SCR Xfmr
Bus DC
Individual Field Watts watts Practical
Motion Qty kW Data Sheet 36H.. IRMS Ea Calc kVA
Exciter RMS per Gen watts x qty Selection
gens
Hoist 6 1254 926224RA-SH2 18.9 113.4 2244.7 13467.9 70.5 75

Drag 1 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0 35.3 50

Drag 2 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0 35.3 50

Swing 6 836 925638RA-SH6 16.8 100.8 3663 21978.0 62.7 100

total bus Total kva
48913.8 203.7 275
watts = 4 transf.
Min DC Bus Volts = 550 exciter effic = 95%
total Bus DC Amps = 93.6 Net total converter load kW 51488
Converter PF 0.95 savings!
Converter eff. 0.98
Transformer kVA = kW/(pf*eff) 54.2 Use 60
Primary Supply Volts = 440
AC Feeder Amps 71.1

Bottom Line: One GF AC MCC Feed vs 4

One Transformer vs 4
Slide 11 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

DC Chopper “Kilowatt Source” Concept

Generator Data
Bus DC
Individual Field
watts
Motion Qty kW Data Sheet 36H. IRMS Ea Exciter W atts per
watts x qty
RMS Gen
gens
PWM Chopper
Hoist 6 1254 926224RA-SH2 18.9 113.4 2244.7 13467.9
Output varies
average voltage Drag 1 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0
to control current
kW in = Total Drag 2 3 1254 926224RA-SH2 18.9 56.7 2244.7 6734.0
Field kW Swing 6 836
925638RA-
16.8 100.8 3663 21978.0
SH6
Amps = kw/volts total bus
"SUM" = 327.6 48913.8
watts =
Min DC Bus Volts = 550 exciter effic = 95%
total Bus DC Amps = 93.6 otal converter load kW 51488

1. Power In = total power of load

/ efficiency
2. DC amps = bus kw / buss volts
3. DC Amps NOT = total of DC
load amps
Field kW 4. Transformer load = kw at 0.95
= I2 x Rhot PF, 0.98 efficiency

Slide 12 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007
Motor Field Supply DC Shared Bus Chopper vs SCR
Motor Field Converter [no diversity included except propel at 40% when digging]
Series Per Motor
Motor Model Connected IRMS
Individual
Field watts Total Field
kVA Contrib
Qty [start with ' & single ckt, 6
Exciter DC RMS
[propel at Watts
to SCR Type
enter as text] Amps Exciter
fields 40%]

Case 1. Hoist 6 826 25.0 150 5270.3 31622 48.5

Drag 6 826 25.0 150 5270.3 31622 48.5
Swing 6 822 20.0 120 4287.9 25727 38.8
Only Motion Motor Propel 2 824 33.0 66 3485.3 6971 21.3 No Effect

Exciters on Bus 157.2

IGBT Fed Sync motor field Contribution From Below 175
USE IGBT Sync Exc?
{Check Box at left if IGBT Exciter is used]
Not Applic Use
kVA
Sync Motor IGBT = FALSE total bus watts = 95941 Comparison Total DC
Motor Field Exciter
separately fed exciter effic = 95%
Transformer kVA for SCR
System

Min DC Bus Volts 550

total Motor Source Bus DC Amps for converter rating = 183.6
Net total converter load kW 100991
Converter PF 0.95 savings!
Converter eff. 0.98
Required Transformer Transformer kVA = kW/(pf*eff) 106.31 Use 125
Primary Supply Volts = 440 kVA
Converter AC line Amps 139.5

Bottom Line: 28% Smaller Field Transformer

Slide 13 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

New Choice: IGBT vs Thyristor Sync Motor Excitation

Sync Mot Sync Mot

DC-EXX DC-EXX
E E
dv/dt dv/dt
Filter Filter

Thyrite Thyrite
Typical Typical

IGBT Sync Motor

Excitation System
[2 motors shown]

IGBT SYNC EXCITATION

TRADITIONAL THYRISTOR
FED FROM MOTION MOTOR
SYNC EXCITATION
FIELD DC BUS

Slide 14 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

IGBT vs Thyristor System

Thyristor Sync Motor Field Exciters with one exciter for all sync motor fields
Fed from separate sync Converter & Transformer
SYNC Field Transf Sec Transformer
Sync Motor SYNC Field Single Exciter DC AC Line Sec
SYNC HP Watts at 120 vdc Volts 3-ph Bus KVA Size for SCR
Qty IRMS Ea RMS Amps Amps
Typical Hot Drop Volts System
Motor 1 3 4000 185 22200 555 452.88 240 188.3 Use

Motor 2 0 NA 0 0 0 240 0.0 200

AC Supply Volts = 440 Total KVA for SCR Exciter Transformer = 188.3 kVA

Primary AC Amps = 247.0

IGBT Sync Motor Field Exciters with exciter one per sync motor field
Fed from Motion Motor DC Converter & Transformer
Total SYNC Added kVA to
SYNC Field Peak Exciter amps SYNC Field Field source feed
Sync Motor
Qty
SYNC HP I RMS for at 1.6 P.U. peak Watts at 120 vdc Watts on DC transformer at
Each Field Exciter field Typical Hot Drop Motor Exciter typical pf and
Bus effic
Motor 1 3 4000 185 296 22200 66600 71.5 savings!
Motor 2 0 NA 0 0 0 0 0.0
Total Sync Motor DC Watts [Contributes to Motor Source Bus Load Above] 66600 71.5

Slide 15 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Motor Field Supply DC Shared Bus Chopper vs SCR

Motor Field Converter [no diversity included except propel at 40% when digging]
Series Per Motor
Motor Model Connected IRMS
Individual
Field watts Total Field
kVA Contrib
Qty [start with ' & single ckt, 6
Exciter DC RMS
[propel at Watts
to SCR Type
enter as text] Amps Exciter
fields 40%]
Case 2. Hoist 6 826 25.0 150 5270.3 31622 48.5
Drag 6 826 25.0 150 5270.3 31622 48.5

Sync Motors AND Swing 6 822 20.0 120 4287.9 25727 38.8
Propel 2 824 33.0 66 3485.3 6971 21.3 No Effect

Motion Motor 157.2

Exciters on Same USE IGBT Sync Exc?
IGBT Fed Sync motor field Contribution From Below
66600 Use
175
{Check Box at left if IGBT Exciter is used] kVA
Bus IGBT = TRUE total bus watts = 162541 Comparison Total DC
Motor Field Exciter
Transformer kVA for SCR
exciter effic = 95% System

Min DC Bus Volts 550

total Motor Source Bus DC Amps for converter rating = 311.1
Net total converter load kW 171096
Converter PF 0.95 savings!
Converter eff. 0.98
Required Transformer Transformer kVA = kW/(pf*eff) 180.10 Use 200
Primary Supply Volts = 440 kVA
Converter AC line Amps 236.3

Bottom Line: One AC MCC Feed vs 2

One Transformer vs 2, total kva 200 vs 400 kva

Slide 16 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Common Bus MG Set Exciters

Making of a “Green” System
• Fewer Exciter EXAMPLE LARGE DRAGLINE
transformers [2 vs 6] & 6 H, 6 D, 6 SW

Kva total load reduced KVA load for SCR Transformers

KVA load for DC-EXX Transformers
549.1
-234.3
to 42% Difference KVA load DC-EXX vs Thyristor 314.8

• Aux transformer load Power Factor of kVA Load Difference

KW load for difference
0.70
220.4
and losses reduced Transformer efficiency 0.985
Exc Transf Kw saved 3.31
• Cleaner harmonics – Aux transformer kW saved 3.31
dual transformers form Total kW saved
Cost of electricity
6.61
$0.065
delta-wye with partial Cost / Hour $0.430
cancellation Hours per year
Saved per year
8000
$3,438

Slide 17 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Three Stop Modes

1. Master switch to Neutral – normal stop
2. Motion LE stop – DC-EXX operates to
bring motion to stop under full control,
then LE opens
3. “Emergency” – lost power, lost fuse, or
ESTOP – LE opens, Static Crowbar
9 connects DBR to gen fields for fast decay
9 shorts motor fields for slow decay.

Slide 18 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Crowbar Connected Gen Field DB Resistor

•No contactors = No
Maintenance
24 vdc fail-
safe PLC
trigger

•Crowbar trip set at level

high enough to avoid false
trips.
•Takes full advantage of new
exciter capabilities –
controlled DB first, crowbar
is emergency backup

Slide 19 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Field Circuit & Dynamic Brake Designs

No Contactors – Dual Mode Trigger Crowbar DBR
Open
Feeder for
LE Stop,
E-Stop or
Fault

1. For regular LE Stop, LE Opens, DC-EXX control

Crowbar connected DBR with NO quickly brings drive to stop within VA Limits
LE or DB contactors but with 2. Under true E-stop, lost fuse, or exciter fault, field
good DB performance decay & braking set by crowbar & DBR only..

Slide 20 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Controlled Braking During LE Stop

??

UNCONTROLLED
DBR - LE STOP

DC-EXX DC-EXX USES STORED

CONTROLLED FIELD ENERGY
LE STOP TO MAINTAIN EXCITATION WITH AC
POWER REMOVED

Slide 21 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Drive PLC Functionality - General

• High speed regulation functions in drive exciter
• Outer loop and excavator functionality in PLC like…
9Speed and torque limits
9Loaded bucket control
9Swing gearing quadrant transition
• Basic Settings done with simple windows tool
• Drive PLC communicates with DL supervisory PLC
over HS Profibus

Slide 22 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Exciter System Drive PLC Role

• Drive PLC & Software is included O-HMI
Supervisory

in system for mode selections,

PLC
DRIVE M-HMI
PLC

tapered current limits, loop Gen Field

DC Bus

unbalance, etc. LE
H S D1 D2

T1
• Excavator supervisory PLC
[OEM or supplied as part of
upgrade] Mot Field

9Sends references, start-stop and DC Bus

hard contact control signals to drives

T2
9Receives feedbacks over Profibus H S D P

9Has access to global data buffer for

offboard monitoring or onboard
reporting

Slide 23 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Drive PLC Example Functionality - Details

Showing Drive PLC & Supervisory PLC Split

EXAMPLE PAGE
1 OF
APPROXIMATELY
FOUR

Slide 24 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Exciter Configuration
• Digitally Configurable
• Windows-based
simplified PC tool
• Few basic parameters
• Outer current and upper
voltage limits
• Protective limits for
fields
• All other dynamic
performance set by
DRIVE PLC

Slide 25 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Exciter Performance Testing

• Instantly shows
effects of settings on
operation
• Digitally
Configurable on PC
tool for display on
PC screen
• Any parameters can
be displayed,
scaled.
• Simple controls

Slide 26 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

PLC Driven HMI Maintenance / Setup Screens

Range from Simple to Elaborate

Slide 27 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Communication
• Drive PLC to exciters and to Supervisory
PLC via HS Profibus
• Gen exciter field commands to motor
exciters via CAN protocol bus.
• Supervisory PLC sends commands &
reads data plus drive status in real time to
mapped data area.
• Data configuration is flexible
Slide 28 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Circuit & Component Details

Slide 29 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

DC Converters
• Three-phase, up to 600
VAC in
• Up to 600 volts DC out
• Two Basic Frames 120,
350 amp frames for
excavator applications
• “Soft-on” for charging
DC bus capacitors
• Ruggedized for
excavator use.
• Built in Absorption
chopper feeds remote
resistors for field
protection during power
loss.
Slide 30 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Chopper Exciters

DC From Source
• Two Basic Frames: 150 & 300
amps
• 300 or 600 volt DC bus feed
[-] VDC

• Included dv/dt filter produces

insulation-friendly output for
motor and generator fields.
• Basic Current limits, gains, lead-
lags, high speed protections, & 6W x
parameter scalings all included 20 H
X 12 D
within exciter.
• Capacitors are film-foil type, not
electrolytic type.
150 A
9Not sensitive to temperature
extremes
9No “wearout” & timed
replacement or failures

Slide 31 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Compact Modules

9Hx6W
x6D

150 A 300 A 350 A Crow

Exciter Exciter Converter bar

Slide 32 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Output dv/dt Filter

Simple dv/dt filter limits peak Field
voltage output to motor and Coil [s]
generator fields to equal or less
than thyristor legacy systems.

Traditional Thyristor Exciter IGBT Exciter IGBT Exciter

460 volts 3 ph AC In 460 volts 3 ph AC In 460 volts 3 ph AC In
No dv/dt filter With dv/dt filter

Slide 33 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Dual Trigger Mode Crowbar Modules

• Discharges energy
safely from generator
or motor fields
• Bi-directional – for use
with motor or generator
exciters
• Fires either on cell
voltage [>900 v] or by
drop out of fail-safe
relay.

Slide 34 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Current and Voltage Isolators

• 24 – 260 volts AC / DC
powered
• 1200 volts input for loop
voltage feedback
• 100 Millivolt for shunt
feedback.
• DIN rail mounted
• Rugged – used in rail service
• Worldwide distribution

Slide 35 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

DC-EXX System Testing – 3 Stages

• Initial testing – 2 Quadrant MG set

10 – 20 HP -
• Follow-up dynamic testing – PLC
controlled, Full 4 Quadrant MG set
20 – 30 HP
• High power testing on dynamic load
with full control system May 2007

Slide 36 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

High Power Setup Data

• Gen field
940 henries, time constant >2.0 seconds
9Field [cold] drop of ~300 volts DC.
• Motor field
935.1 henries, time constant >2.0 sec
seconds
9Field [cold] drop of ~300 volts DC.
• Both fields excited from 600 volt DC
exciter bus.

Slide 37 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Test Setup – Test Floor Equipment

G
F
PATCH H
PANEL

E
D

B C

Slide 38 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Test Setup – Test Interconnections

460 v DC-EXX PANEL A
3-ph
RECTIF GFEX

CFB 1200 A
MFEX

VFB
Load D
grid
E G H
shunt

2000 HP
752 load eddy MOTOR
F motor curr 450 hp
dyno 230 v

exc exc AC
Gen
Motor
C B

Slide 39 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Test Equipment
AC
AC MG
MG
Drive DC
DC Driven
Driven
Drive
Motor Motor
Motor
Motor

Eddy
Eddy Current
Current
Load
Load Dyno
Dyno
DC
DC Main
Main
Generator Traction
Generator Traction Motor
Motor
DC Load
DC Load
Machine
Machine

DC
DC Driven
Driven
Motor
Motor

Slide 40 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

DC-EXX Test Equipment

MG SET WITH DC GEN AND AC DRIVE MOTOR

EXCITERS AND DRIVE PLC

DC DRIVE MOTOR, EDDY CURRENT DYNO
& DC LOAD MACHINE

Slide 41 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Detailed Test Results

Slide 42 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Armature Tapered Volt-Amp Limits

VOLTS
AMPS

4 Quadrant Volt Amp Limits Regulator step..

Slide 43 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Armature Tapered Speed-Amp Limits

SPEED
AMPS

4 Quadrant Speed Amp Limits Regulator step..

Slide 44 ONE COMPANY. A WORLD OF SOLUTIONS
TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Test: 0 to +/-100% Reference Step (250V)

High inertia load

Arm Volts

Arm Amps

Slide 45 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Test: CEMF Running – 2.5s linear S-curve

ramp, +250V to -248V

Arm Volts

Arm Amps

Field Amps

RPM

Slide 46 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Speed Amp Trace & Volt Amp

Test: Traction motor torque steps – Traces shown for reference
Into Current limit with large load
NO OVERSHOOT!

SPEED
AMP
VOLTS

AMPS

VOLT
AMP

Slide 47 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Speed Amp Trace & Volt Amp

Test: Traction motor torque steps – Start at Traces shown for reference
150A at weak field & slam into current limit
STILL NO OVERSHOOT!

SPEED
AMP
VOLTS

AMPS

VOLT
AMP

Slide 48 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

High-Power DC-EXX Test Goals & Results

Test Goal Result
Results approved for application to standard
1 Check dv/dt filter
fields
Step Motor field current regulator for 30 Achieved 45 plus and could have pushed
2
– 40 Radians more
Step armature current regulator for 100
3 Achieved 110, with use of derivative function
radians
Step Calculated speed regulator for 5 Achieved 6, and accurate enough to
4
rad [no tach] eliminate need for tach
Step voltage regulator for 10 rad without
5 Achieved 13 rad without tach.
tach

6 Current limit function in drive Works as specified.

7 Test current limit function from PLC Worked well.

Achieved 16 rad & could have been more

8 Step CEMF regulator for 10 rad
[added PID function to achieve this]
Check generator field over current
9 “Actual test” proved function works.
protection

10 Check motor field over current protection Proven.

Test Rx3i PLC communications and Tested functionality of TMGE blockware, &
11
outer loop functions Profibus outer loop control

Bottom line: High confidence in moving to actual excavator installation

Slide 49 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Ruggedizing – Excavator Vibration

• Excavator vibration data gathered
from mining shovels in hardrock
mining were used as benchmark
levels
• Modules attached to test
platforms, shaken to find natural
resonances.
• Endurance tests used to sort out
areas needing attention. DC-EXX 300 A Exciter

• Design changes made to modules

On Vibration Stand

and tests repeated for verification

Slide 50 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Let’s Review

ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

IGBT Common-Bus System Features-Benefits - 1

FEATURE BENEFIT
Common Bus – allows field power Smaller feed transformers & lower cost.
1
sharing between motions .
Complete regulation & control during Faster motion stop while protecting
2
LE [Excitation] stop motors and generators
Less space, simpler, lower cost MCC
3 Fewer Excitation Transformers
and AC feeds
Low Harmonics and high power factor Less heating & possible interference,
4
of diode vs thyristor converters. smaller aux transf.
Faster response, no cell state sensors,
5 IGBT Power Switches vs Thyristors
fewer devices
Drive-level PLC sets excavator limits,
Simplified Supervisory PLC system and
6 formats communication, selects
fast real-time monitoring .
operating modes.
Smooth integration with machine
Improved operating, maintenance and
7 supervisory controls and monitor
troubleshooting.
systems.

Slide 52 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

IGBT Common-Bus System Features-Benefits - 2

FEATURE BENEFIT
Replace DC contactors used in field More reliable operation with same field
8
circuits with Thyristor circuit protection & braking.

9 Lower total system cost Better value.

Common Electronics Card set between

10 Fewer, common spares..
all drives
Smaller footprint of Base Drive on Better & smaller panel layout &
11
amp/amp basis maintenance

12 Simpler drive internal controls Easier troubleshooting & setup.

PLC master carries most motion Visible functionality for easier monitoring
13
protection and drive settings and maintenance

14 Current but proven technology Long product life

Bottom Line: IGBT field supplies offer unique

advantages in MG set & exciter application.

Slide 53 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Present Activity

• Two upgrades being installed –

March – May Startup
• New GE MG set draglines
worldwide will use DC-EXX
• Many upgrade inquiries in hand

Slide 54 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Summary – DC-EXX
Excavator MG Control System
• Proven technology with real
advantages for MG control
• Cost, energy, maintenance, and
space effective.
• Easily integrated into a variety of
onboard configurations.

Slide 55 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems
New DC-EXX Shared Bus IGBT MG Control
Western Mining Electrical Association – Fall 2007

Thanks!

Office Location:

TM GE Automation Systems, LLC

1501 Roanoke Blvd. [Office]
2060 Cook Drive [Mailing]
Salem VA, 24153 USA
TEL: +1-540-387-5741; FAX: +1-540-387-7060
www.tmeicge.com

Slide 56 ONE COMPANY. A WORLD OF SOLUTIONS

TM GE Automations Systems