4100C BOSS AC
Shovel Drive
System Overview
WMEA Edmonton - June 2008
Overview
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Drives Partnership with ABB
Deck Plan / One-Line Schematic
ISU (IGBT Supply Unit)
Shovel Motion Inverters
Cabling / Grounding
Centurion System Control / Hardware
AC Motor Development
4100C BOSS Performance
Current 4100C BOSS AC Shovel Orders
Final Thoughts
P&H and ABB Drive
Technology
• ABB is a world leader in AC & DC drives
systems
• ABB continues to invest in R&D for AC and
DC drive technology
– Upcoming DCS800 development
• ABB has thousands of ACS800 drive
installations world-wide
• Partnership with P&H to increase
performance of our mining equipment
• History with P&H
4100C BOSS Deck Plan
Inverter Lineup on Shovel
Base Frame for Inverter Lineup
One-Line / Main Xfmr. To ISU
DC Bus and Motion Inverters
IGBT Supply Unit Functionality
• Individual block consists of Inverter
Modules (2), a line filter (LCL Filter Module),
and AC & DC Fuses
• The IGBT Supply Unit rectifies three-phase
AC current to Direct Current for the
intermediate DC link, which further supplies
the inverters that run the motors.
• The line filter suppresses the AC voltage
distortion and current harmonics.
ISU Control Functionality
• The ISU controls the Charging Circuit and
Main Circuit Breaker of the drive system.
• The charging contactor closes, connecting
the intermediate DC link capacitors to the
AC supply via the charging resistors.
– DC link voltage rises
– When the DC voltage is high enough, the Main
Circuit Breaker is closed and the Charging
Contactor is opened.
– Line-side converter synchronizes itself to the supply
network and begins modulation.
– Motion Inverters are then ready for operation.
ISU Control - Continued
• DC Voltage Control
– DC Voltage Reference = 930VDC
– Controller Parameters are tuned by default, no
need to reset them
• Reactive Power Control
– Q Power Reference of 1.0 (unity) for normal
operation
– Power Factor control adjustments for Motivator
Mode Operation
• Only two setpoints required
• Full regenerative operation
Main Circuit Breaker Cubicle
ISU Inverter Section View
Shovel Motion Inverter Units
• ABB Multidrive system with parallel
operation for all motions. Each module is a
complete three-phase inverter.
– Hoist1 and Hoist2 = 4 parallel inverters (each)
– Crowd, Swing1, Swing2, Propel1, Propel2 each have
2 parallel inverters
• All inverter modules have a rating of 580kVA
– This coupled with reduced-run operation allows for
higher availability and machine run time.
• 4100C BOSS AC Drive system designed with
4100XPC AC Drive system in mind.
– Propel 1&2 = +1 module, add Swing3 cubicle
Motion Inverter Section
Motion Enhancements
• Higher speeds for Hoist and Crowd
• Higher peak horsepower
• Dedicated Propel drive system / No
Transfer Switch
• Optimal performance with ABB DTC
(Direct Torque Control)
DTC – Direct Torque Control
• Field orientation achieved using ABB
adaptive motor model to calculate motor
torque directly and without using a PWM
modulator
– Self-Identification / Auto-tuning completed using the Drive
ID Run which identifies specific motor parameters (stator
resistance, mutual inductance, saturation coefficients, etc.)
– Motor Torque and Stator Flux used as primary control
variables
– Quick Torque response
– Accurate Torque control at low frequencies
– Torque repeatability
– No predetermined switching frequency of power devices
reduces mechanical resonances and stress in gearboxes
DTC - Control Diagram
System Cabling / Grounding
• Symmetrical multicore cables are used
– Symmetrical arrangement of three phase leads and three earth
conductors
– Continuous outer shield provides low impedance path for common
mode current to return to the inverter
• 360 degree termination at both ends using Roxtec
modules
– A conductive, low impedance foil is wrapped around the cable
shield and entire Roxtec module
• High frequency bonding connections using braided
straps and EMI shielding gaskets at motor frames
– Flat conductors provide a lower inductance path than round wires
System Cabling - Continued
Roxtec Connections
High Frequency Bonding
Inverter Connections
Centurion Control System
• Consistency with proven DC Centurion
System
– Drive communication between AC800 and drives are
identical
– Re-use of existing code between both systems with
use of shared libraries
• New Control Cabinet with AC Drive Controller
panels
• New I/O Assemblies
– Converter, RPC, and Transfer Cabinet I/O removed
– ISU I/O Station, Rear Machinery House I/O Station
added
Control Cabinet / Drives
Drive Controllers
Parallel Drive Branching Unit
AC Shovel GUI
• Same look and feel as current DC System
– Consistency of symbols and images so operator’s experience
between shovels is similar
• DriveWindow tool for loading / saving drive parameters
and making recordings of drive signals
• Drive Datalogger update / save function
– Each drive has two dataloggers enabled
– Once triggered by a fault, the GUI will upload & save the data, then
re-start the datalogger for next event
• ShoveLink II as an available option
– Built-in expanded help files and information
– Schematic viewer with inventory links to Parts Book
– Flowcharts that simplify logic and troubleshooting
AC Motor Development
• Two motor frame sizes
– P&H HAF8412 1600HP/1194 kW, used for both hoist motors
– P&H HAF7510 730 HP/545 kW, used for Crowd, Swing, and Propel
• Heavy duty mechanical design
• Proven bearing designs
• Replaceable non destructive INPRO type brass
bearing seals for improved contaminate protection
• Lower inertia for improved system performance
• Premium insulation system ( class H or better )
• Insulated bearing and a shaft grounding feature
• Improved reliability
– No brushes, commutator, or exposed uninsulated conductors
– Single set of coils ( Stator coils as compared to armature coils,
interpole coils, compensating coils, field coils)
Stator Winding Assembly
HAF8412 Hoist Core Assembly
Cooling Scheme
AC Shovel Motor Rotor Assembly
Cooling Scheme
4100C BOSS AC Shovel
Performance
• Availability of the three operating 4100C
BOSS AC shovels exceeding initial design
criteria
• Preliminary production numbers show
significant increase
– Faster motion operation, increased horsepower
– Instant propel feature allows operator to position
shovel closer to the bank more often, which results in
ideal shovel positioning for increased fill factors.
AC Shovel Systems – Order
Status
• Three (3) 4100C BOSS AC machines are
currently operating at Suncor Energy in
Fort McMurray
– Two more machines currently on order
• Two (2) 4100C BOSS AC machines
ordered for U.S. market
– Lignite & Phosphate operations
Final Thoughts
• P&H is committed to strengthening our DC
shovel offering with R&D and continuous
improvements focusing on the entire shovel
system.
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DC Motor Design (brush / commutator life)
Performance / Productivity
Power Quality
Reliability
• DC Centurion Control will continue to be
offered in all shovel models.
• Common Centurion platform allows for ease
of implementation of product enhancements
for AC and DC shovels.
THANK YOU!