quadramaticpgei 5329

Document number: PGEI-5329

Page: 1 of 67

Date issued: May 5, 2009 Instruction Manual

GE Energy QuadramaticTM Drive Instruction Manual

Supersedes: New

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 purchasers purposes, the matter should be referred to the nearest office of GE Canada. General Electric Canada 2009. All rights reserved.

GE QuadramaticTM Drive Instruction Manual



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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) 21 6.3 Q-field Supply Check 24 6.4 Q-Current Test 26 6.5 Clutch Test 27 6.6 Calibrate Clutch 28 6.7 Manual Clutch Pulse - Load 1/2 29

7. QUADRAMATIC CONTROL MILL COMMISSIONING.................................32 7.1 Q-field Current Regulator Tuning 33 7.2 Kilowatt Difference Regulator Tuning 36 7.3 Effect of Q-Current on kW Difference (QKW_AMP) 38

8. PREVENTATIVE MAINTENANCE............................................................... 39 8.1 Power-Off Checks 40 8.2 Q-Axis Exciter Maintenance and Troubleshooting 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 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 serious injury.

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 personal safety is not at risk.

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

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 equipment under test presents potential electrical hazards. If the test equipment cannot be grounded to the equipment under test, the test equipments 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.

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

ESP1 -EXCITER

CONTROL FORMOTOR A -

(controls motorDC exciter)

QUADRAMATIC DRIVE- includes Q-PLC

(controls cutch and q-axis power)

VALVECONTROLCABINET -

controlled by Q-PLC (operatesmill air clutch)

D

Q

MOTORA

ESP1 EXCITERCONTROL FOR

MOTOR B -(controls motor

DC exciter)

D

Q

MOTORB

VALVECONTROLCABINET -

controlled by Q-PLC (operates mill

air clutch)

to DCS(to initiate mill start and stop,

send faults, and status)

SWITCHGEAR (BY OTHERS)

MCC SUPPLY (BYOTHERS)

MILL FLOOROPERATOR STATION- motor and mill start/

stop. Sends signaldirect to Q-PLC

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 motors 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



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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 operators control interface.

Figure 3: Quadramatic Drive Control Diagram

KW1TRANSDUCER

KW2TRANSDUCER

KW

KW

KWPID loop

+

+

+ _

_ +

DKW_REF

Q-CURRENTPID loop

QCURREF

GPG

Q_CURR

Q

BRUSHLESS EXCITER

Q

BRUSHLESS EXCITER

RING GEAR

PINION 1

PINION 2

PR2

PRV

AIRSTORAGE

TANK100PSI

PR1

PRV

QTS-1

QTS-2

Q-PLC CLUTCH PULSING

CONTROL

START/STOP MILLMOTOR 1/2 READY

MILL READY

SYSTEM PROTECTION

EXTERNALCONTROLSIGNALS

QUADRAMATIC DRIVE

Q-PLC LOGIC

MV2

MV1

SERIAL OR ETHERNET COMMUNICATION

FIELD SUPPLY

PT2

PT1

D

D

CLUTCH 2 CONTROL CABINET

CLUTCH 1 CONTROL CABINET

EXCITATION PANEL



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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)

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. 2) 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 lift pumps operating. The Mill Floor Station Motor Ready light will be on when all permissives are OK. Other mill run interlocks such as gear lube spray are satisfied through the DCS.

3) 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

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) 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.

6) 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 can be by the plant DCS, local Stop Motor PBs, 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

86TRIP

CIRCUIT

86QUAD

E-STOP ESP1MFS

STOPMOTOR

TS 86

52a

TO QUAD DRIVE

Others

Stopping the Mill 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

60

40

100

90

%I8QCTESTM Q-Current Test -> Required to start the motors

%M15CL_RDY Two motors synchronized. No clutch faults

%I22LSCLILK Mill lube system running from PPLC

%I31MILRDYP Mill ready to start from DCS

%M3CL_PERM Clutch close permissive

%I29MILRUNP Mill run request from DCS

%M58CLSCLRQ Close clutches request

%M60CLOSECL Close clutches command

5 secSound mill horn

Close dump valves (MV1 & 2)%Q4 / Q5QPULS1/2

%M65FULLSPD Mill accelerated up to full speed

~12 sec

%M2Q_PERM Q-field current control permissive

%Q2QXCP Close Q-field contactor (QXCC)

0.5 sec Delay for contactor to operate%M27QFCR_EN

%M63FULSPDT

5 secReduce clutch pressure to running

%M197CLCTLAV

5 secClutch pulsing allowed

5

%R1002 = RUNPR = 200% of rated motor

%R1012 = ACCELPR = 250% of rated motor torque%AQ3/4

PRRF1/2AQ15 psi Pressure feedback

(%AI5 / AI6)

15 psi/sec

Clutch calibrate



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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

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 KWs, two clutch pressures, two Q-currents.



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

Q-current control

OFF AUTO Clutch pulse control

OFF AUTO

The Mill can still operate if both controls are selected 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 AUTO: With Q-current control selected AUTO, the Q-PLC compensates for KW difference between the two

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

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 OFF: No current balance operates if Q-current control is selected 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.

Manual Q-curr ref.

Manual clutch pulse



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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 doesnt 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 AUTO: With clutch pulse control selected AUTO, clutch pulses are generated if the average KW difference

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

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 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 OFF: No clutch pulses are generated by the Q-PLC if clutch pulse control is selected OFF (Clutch operate

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



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Figure 8: Clutch pulsing Rough adjustment

Mill markerpulse

MARK_OS%M140

Mill Rotation TimeMROTTIM

%R336

Clutch 2 PulsePressure

CommandPULPR_2

%M83

Clutch 2 PressurereferenceCL2PREF

%R253

Clutch 2 Pulsepressure OKPULPOK2

%M80

Clutch pulse timerCLP_TIM%M141

Clutch 2 PulseCLPULS2

%M94

If the average KWdifference > 1250 kW; then

auto clutch pulse

100 ms 100 to 200 msThe pulse width adjustsaccording the feedback on the

effectiveness of the pulse

Pulse 2 OutputQPULS2

%Q5{MV2 Dump valve

solenoid}

Clutch 2 PressureCL2_PRS

%R206

14.6 mA = 66 PSI= RUNPR (%R1002)

10.2 mA = 39 PSI= NOMPPR (%R1000)

66 PSI

PULSEPR (%R83) = 39 PSI

TRUE if the clutchpressure is lower than

44 PSI

The mill rotation timer isreset by each mill marker

pulse

The mill marker is aproximity switch that counts

the mill revolutions

-12.5 PSI/sec (%R1006)

If the load unbalance is not reduced to less than25%of the unbalance limit (1250 kW) within 5

minutes, the pulsing will time-out

0 PSI

4 mA

1 sec

Clutch pulsing pressure level (PULSEPR) isadjusted depending on the kW unbalance

0V

24V

If the clutch pulsing is successful, load balance willre-start using automatic Q-field current regulation.



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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: Silence Horn (Q-door buzzer), Ack All and Ack (acknowledge all or just the selected faults / alarms display lines will change

colour to Acknowledged), 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 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. 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

RS485 Serial Ethernet

Hardwired

Modbus RTU Slave Modbus TCP/IP Server

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, customers 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.



Page: 22 of 67

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 Power

Q-axis Exciter

Contactor 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 RotorsealTM (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).



Page: 23 of 67

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 (PTs), current transformers (CTs), 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 CTs Stator and bearing RTDs 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 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 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 youre ready to work on the field supply remember that CB4 has a shunt trip.



Page: 24 of 67

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 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 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). 6.3.2 In the incoming cubicle, open the small auxiliary breaker #BA-CB5 before inserting the three 3A

fuses for 240VAC Q-field supply phasing #BA-FU13 to FU15.



Page: 25 of 67

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.



Page: 26 of 67

6.4 Q-Current Test

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 dont 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.



Page: 27 of 67

6.5 Clutch Test 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

PR1 Pressure regulator

Clutch test pushbutton

MV1 Dump

l

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.



Page: 28 of 67

Most of the motors 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 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

%R102490psi

70

50

30

1050

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Time

mA

mA

Difference =reference -feedback

psi+20

+15

+10

+5

0

-10

Close thedumpvalve(MV1)

Open thedumpvalve(MV1)

75

Open thedumpvalve(MV1)

Toolow



Page: 29 of 67

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 Description 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 75psi (CLTSTPR = 75.0 on the HMI clutch set-up screen), and adjust the pilot

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

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 (Clutch operate screen), Q-current control 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 didnt 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 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.



Page: 30 of 67

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.

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.

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 Set Factory Values (which affects ALL preset values) or on the clutch operate screen by manually making each equal to CPTBASE %R1020, shown on the clutch set-up screen).



Page: 31 of 67

Figure 12: Clutch Test Diagram

psi1009080706050403020100

mA20

12

40 1 2 3 4 5 6 7 8 9 10 sec.

5

%R999 (MAXPR) = 100 PSI = Maximum clutch pressure

PLC REFERENCE

5

%R252 = CLA PREF = Clutch A pressure reference =%AQ3 (2TBA06(+), 2TBA07(-)

%R253 = CLB PREF = Clutch B pressure reference =%AQ4 (2TBA10(+), 2TBA11(-)

%R1004 = CLACLSR =15 PSI/sec = Clutch Aclosing pressure rate%R1005 = Clutch B

psi1009080706050403020100

V10

5

00 1 2 3 4 5 6 7 8 9 10 sec.

5

%AI9 = Clutch A PR feedbackpressure (2TBA23(+), 2TBA24(-))%AI10 = Clutch B PR feedback

pressure (2TBA27(+), 2TBA28(-))

5

psi1009080706050403020100

mA12

8

40 1 2 3 4 5 6 7 8 9 10 sec.

PLCcounts32000

12

0

counts32000

12

0

%R205 = CLA_PRS = Clutch A pressure feedback =%AI5 (2TBA14(+), 2TBA15(-)

%R206 = CLB_PRS = Clutch B pressure feedback =%AI6 (2TBA19(+), 2TBA20(-)

Close the"dump" valve

Open the"dump" valve

counts32000

12

0

Difference between referenceand actual pressure



Page: 32 of 67

7. QUADRAMATIC CONTROL Mill Commissioning

Perform the following tests when the mill is ready

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

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 and clutch pulse control OFF for early mill starts / stops.

7.3 Once the electrical system is ready, select AUTO 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 theres 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.



Page: 33 of 67

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 OFF from the HMI Q-current set-up screen to verify Q-current or regulator tuning. There are regulator tune-up instructions in the Q_CURR program block comments, which are reproduced here for reference. 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 (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 square wave on the Q-field current reference, sec at the manual reference and 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 MTBs 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 currents 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 from the HMI Q-current set-up screen. 7.1.13 Zero the Q-current manual control reference, then select Q-current control AUTO.



Page: 34 of 67

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

Table 2: Q-Field Current Regulator Polarity

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

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 = POSITIVE

DC(+) BUS = NEGATIVE

DC(+) BUS= NEGATIVE

DC(+) BUS= POSITIVE

MOTOR A REDUCE LOAD INCREASE LOAD REDUCE LOAD INCREASE LOAD

MOTOR B INCREASE LOAD REDUCE LOAD INCREASE LOAD REDUCE LOAD

MOTORS CCWBIT 12 OF PID = 0

MOTOR CWBIT 12 OF PID = 1



Page: 35 of 67

Figure 13: Q-regulator Tuning

QMANCUR%R220

1/2 sec

Q_CURR%R201

3 cases:+300A-300A+25A

3 cases:+250A-350A-25A

50A

FC_KP andFC_KI = Too low

time

FC_KI = Too high

FC_KI = GoodFC_KP = Too low

FC_KP = Too high

Correct



Page: 36 of 67

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 (i.e. from this regulator). Toggle the KW difference regulator tune KWRTUNE %M1008 ON to make the KW difference reference a square wave of +/-300KW. NOTE: tune the Q-current regulator BEFORE the KW difference regulator. Remember that you can turn Q-current OFF from the HMI Q-current set-up screen to verify the Q-current or regulator tuning. Step Description 7.2.1 KWRTUNE toggle is on the HMI Q-current set-up screen. When KWRTUNE is 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 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

DEADBAND%R903/904

= 0

PROPORTIONALGAIN - Kp

%R905

INTEGRAL GAIN -Ki

%R907

SLEWLIMIT

%R911= 0

UPPER/LOWERCLAMP

%R909/%R910= +/- 600A

POLARITY%R912

Bit 1

SP%R45

DKW_REF= 0 kW

PV%R257

DIFF_KW

CV%R250

QCURREF

DEADBAND%R943/944

= 0

PROPORTIONALGAIN - Kp

%R945

INTEGRAL GAIN -Ki

%R947

SLEWLIMIT

%R951= 0

UPPER/LOWERCLAMP

%R949/%R950= +/- 75% max

POLARITY%R952

Bit 1

CV%AQ1

QGPGREF

+

-

BIAS%R908

= 0

PV%R199

Q_CURR

SP+

-

BIAS%R948 =+/- 19000

KW PID Regulator

FC PID Regulator



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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 ON, average Q-current and average (leftover) motors KW difference over a full mill revolution.

With Q-current 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 AUTO, clutch pulse control selected MANUAL, you can exercise all the Quadramatic control components by doing several manual clutch pulses on the same motor (e.g. Load 1 = pulse clutch 2). Dont 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 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 AUTO, you will 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.



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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



Page: 40 of 67

8.1 Power-Off Checks

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 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.

2. Using a fine-filtered vacuum cleaner with a non-metallic nozzle, remove dust and dirt from wiring and electrical components.



Page: 41 of 67

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.

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.



Page: 42 of 67

Contactors and Relays

1. If possible, manually trip the device to ensure that it works properly.

2. Inspect contacts on open (as opposed to sealed) contactors and relays. Discoloration and rough contact surfaces are normal.

3. If beads have formed because of severe arcing:

a. Dress the contact faces with a fine file. Do not use emery cloth or sandpaper. Remove any carbon residue.

b. Identify and correct the cause of arcing.

c. Refer to the components publication for detailed instructions on maintenance, repair, and replacement procedures.

8.2 Q-Axis Exciter Maintenance and Troubleshooting

The SCR cells and cooling fins should be kept free from dirt, oil and grease, since an accumulation of dirt may cause overheating. Check for loose power or control connections to the conversion unit.

The fans should be inspected regularly. Check for:

Excessive noise or vibration. Loose mounting. Fan blade striking housing. Motor overheating. Dirty blades.

The airflow switch should also be checked.



Page: 43 of 67

Phase Shift Network Checks

The angles of the phasing signals can be easily checked with a differential oscilloscope by connecting the two probes across the input power lines AC-1 and AC-2 with the top probe on AC-1.

When checking phasing on the AC lines, caution must be exercised to avoid injury. Ensure that only 10X or 100X probes are used. Do not connect or remove the probes when the power is on.

When checking the phasing voltages on the card, ensure that the drive contactor is not energized in case of accidental shorting, which can cause random SCR firing and damage components.

Set the oscilloscope triggering to AC line and adjust the waveform to give one cycle on the scope face as shown in Figure 15.

Figure 15: AC1 to AC2 Waveform

0 180 360

The probes can now be removed and used to check the phasing signal inputs to the card for correct magnitudes, which should be approximately 30 volts peak-to-peak, and for the correct phase relationships as outlined below:

CP205 - Common 0 (i.e. in phase with AC1-AC2) CP204 - Common 180 CP203 - Common 60 (i.e. lags AC1-AC2 by 60) CP202 - Common 240 CP201 - Common 120 CP200 - Common 300



Page: 44 of 67

The phase-shifted signal should have amplitude of approximately 20 volts peak-to-peak and will have phase relationships with AC1 - AC2 as follows:

CP210 - Common 30 (i.e. lags AC1-AC2 by 30) CP211 - Common 210 CP212 - Common 90 CP213 - Common 270 CP214 - Common 150 CP215 - Common 330

Circuit Card Removal and Replacement If it should ever be necessary to replace a circuit card, the following procedure should be used:

1) Ensure that power to the drive is removed and locked out. 2) Attach the anti-static wristband. 3) Remove the cover from the circuit card by depressing the retaining latch of each of the supporting

standoffs and pulling the card cover until free. 4) Carefully pull off all wires going to the stab connectors on the circuit card. 5) Loosen the screws on the circuit card connector terminal board (1TB) approximately two turns. 6) Loosen the top of the circuit card from the conversion unit by depressing the retaining latch of each

of the supporting stand-offs and carefully pull the card forward until free. 7) Remove the circuit card, taking care not to bend the 1TB connectors. Replace the card cover on the

card assembly to ensure that it does not get damaged. 8) Install the new circuit card by using the reverse of the above procedures. All wires terminating on

stab connectors on the card have sleeve markers to indicate the correct position. Ensure that the circuit card sits squarely on 1TB before tightening the 1TB screws.

9) When the replacement card has been installed, recheck all wire numbers on the stab connectors and set the potentiometers shown on the new card to match those on the old card. Wiper positions of the potentiometers on the old card can be determined by using a small screwdriver to turn the pot setting to either end stop and noting the amount of turning required.

10) The circuit card should now be ready to run. Ensure that no tools or loose hardware have been left in the control enclosure before reapplying ac power.

11) When the power is reapplied, check that the phase rotation light is on and then run the drive.



Page: 45 of 67

SCR Removal and Replacement Terminated Cell

1) For the removal of a terminated cell SCR, it is suggested that the aluminium heat sink be unbolted from its insulated standoffs so that the SCR retaining nut (3/4 - 16) can be easily removed. Note the routing of the SCR gating leads before removing them from the stab connectors of the SCR Disconnect Cards.

2) Ensure that the gating leads of the replacement SCR are cut to the same length as those on the SCR being removed. Transfer all insulating and marking sleeves from the removed SCR to the replacement and crimp the new stab connectors securely.

3) Referring to Figure 16, ensure that the surface noted has sufficient silicone grease (GE No. 623, Dow Corning DC3 / DC4, or equivalent) to completely cover it. Insufficient grease will impair heat transfer from the cell to the heat sink and may damage the SCR.

4) The correct position of the Belleville washer is concave towards the aluminium heat sink 5) Before tightening the SCR to the heat sink, rotate the cell in the hole so that its terminal lug end can

be connected without strain on the cell. 6) Torque the - 16 retaining nut to approximately 28Nm (250 inch-pounds). 7) Wipe excess grease from around the base of the cell to prevent excessive accumulation of dust. 8) Ensure that all gating and snubber leads are routed exactly as they were before the SCR change.

Figure 16: Terminated Cell SCR Mounting Details



Page: 46 of 67

Press pack Cell Since the press pack cell assemblies are tested after assembly into the heat sinks, the cells are not individually replaceable by the customer and must be returned to the factory for repair. Note the routing of control wires, which make connections to the press pack cell assembly to be removed before removing it. The identical routing should be maintained after the replacement is made. All bolts used to make connections to the press pack heat sinks can be tightened to normal torques for the particular bolt size and type used. Ensure that when a cell is replaced, it is oriented in the same direction as the original. For reference, a copy of the cell orientation will be found on the rear of the conversion unit door.

Figure 17: 53mm Press pack Cell Assembly



Page: 47 of 67

Table 3: Troubleshooting Checks Drive Does Not Operate Step Check Point Action

1 Control Card Lights If all lights on the control card are extinguished, this may indicate that two or more phases of input ac power are not present on the converter. This same condition may also be indicated by all of the cell monitor lights being extinguished. If any lights are illuminated, go to Step 2.

If all lights are out, check the line-to-line voltages between the top terminals of FU4, FU5, and FU6 which should be within 10% of the ac input voltage as shown on the elementary diagram.

2 Phase Loss Light

(L181)

If the Phase Loss Light (L181) is illuminated, press and release PB100. If the light extinguishes, try to operate the drive. If the light remains illuminated, this

quadramaticpgei 5329

Documents

appendix e

quadramatic drive system

quadramatic control

quadramatic control

qcurrent test

appendix g list of possible

qfield current regulator

effect of q