SWITCHGEAR (BY OTHERS)

ESP1 - D D
ESP1 EXCITER
EXCITER
Q Q CONTROL FOR
CONTROL FOR
MOTOR B -
MOTOR A -
MOTOR MOTOR (controls motor
(controls motor
A B DC exciter)
DC exciter)

VALVE VALVE
CONTROL QUADRAMATIC DRIVE CONTROL
CABINET - - includes Q-PLC CABINET -
controlled by Q- (controls cutch and q-axis power) controlled by Q-
PLC (operates PLC (operates mill
mill air clutch) air clutch)

to DCS
(to initiate mill start and stop, MILL FLOOR
send faults, and status) OPERATOR STATION
MCC SUPPLY (BY
- motor and mill start/
OTHERS)
stop. Sends signal
direct to Q-PLC
 QTS-1
BRUSHLESS
EXCITER

PINION 1

PT1
QUADRAMATIC DRIVE
MV1

PR1
Q-PLC
CLUTCH PULSING PRV

CONTROL
CLUTCH 1
CONTROL CABINET
MILL READY
EXTERNAL
MOTOR 1/2 READY
CONTROL
SIGNALS START/STOP MILL
AIR
SYSTEM PROTECTION STORAGE
TANK
SERIAL OR ETHERNET 100PSI
COMMUNICATION

EXCITATION PANEL FIELD

GPG SUPPLY RING GEAR
KW
+ _ KW QCURREF Q-CURRENT
KW1 PID loop PID loop CLUTCH 2
TRANSDUCER _ + CONTROL CABINET

PR2

PRV
DKW_REF Q_CURR

MV2

BRUSHLESS PT2
EXCITER

Q
D
KW2 +
TRANSDUCER
Q-PLC LOGIC
+ PINION 2
KW

QTS-2
 QUAD MFS
86 TS ESP1 STOP Others 86
E-STOP
MOTOR TO
QUAD
DRIVE
TRIP 52a
CIRCUIT 86
 psi
90 %R1012 = ACCELPR = 250% of rated motor torque
%AQ3/4 60 15 psi/sec
PRRF1/2AQ %R1002 = RUNPR = 200% of rated motor
40 15
5 psi Pressure feedback
10 (%AI5 / AI6)
0
Clutch calibrate

%I8
Q-Current Test -> Required to start the motors
QCTESTM

%M15
Two motors synchronized. No clutch faults
CL_RDY

%I22
Mill lube system running from PPLC
LSCLILK

%I31
Mill ready to start from DCS
MILRDYP

%M3
Clutch close permissive
CL_PERM

%I29
Mill run request from DCS
MILRUNP

%M58
Close clutches request
CLSCLRQ
Sound mill horn
%M60 5 sec
Close clutches command
CLOSECL

%Q4 / Q5
Close dump valves (MV1 & 2)
QPULS1/2

%M65 ~12 sec

Mill accelerated up to full speed
FULLSPD

%M2
Q-field current control permissive
Q_PERM

%Q2
Close Q-field contactor (QXCC)
QXCP

%M27 0.5 sec Delay for contactor to operate

QFCR_EN

%M63 5 sec
Reduce clutch pressure to running
FULSPDT

%M197 5 sec
Clutch pulsing allowed
CLCTLAV
Q-current control Clutch pulse control
OFF AUTO OFF AUTO

Manual Q-curr Manual clutch

ref. pulse
 Mill marker The mill marker is a
proximity switch that counts
pulse
the mill revolutions
MARK_OS
%M140

The mill rotation timer is

reset by each mill marker
pulse

Mill Rotation Time

MROTTIM
%R336

1 sec

Clutch pulse timer

CLP_TIM
%M141

Clutch 2 Pulse
Pressure
Command If the average KW
PULPR_2 difference > 1250 kW; then
%M83 auto clutch pulse

14.6 mA = 66 PSI
= RUNPR (%R1002)

-12.5 PSI/sec (%R1006)

10.2 mA = 39 PSI
= NOMPPR (%R1000)
Clutch 2 Pressure
reference
CL2PREF
%R253

4 mA

Clutch 2 Pulse
pressure OK TRUE if the clutch
PULPOK2 pressure is lower than
%M80 44 PSI

100 ms The pulse width adjusts 100 to 200 ms

Clutch 2 Pulse according the feedback on the
CLPULS2 effectiveness of the pulse
%M94

Pulse 2 Output
QPULS2 24V If the load unbalance is not reduced to less than
%Q5 25%of the unbalance limit (1250 kW) within 5
{MV2 Dump valve minutes, the pulsing will time-out
solenoid}
0V
If the clutch pulsing is successful, load balance will
re-start using automatic Q-field current regulation.
66 PSI

Clutch 2 Pressure PULSEPR (%R83) = 39 PSI

CL2_PRS
%R206 Clutch pulsing pressure level (PULSEPR) is
adjusted depending on the kW unbalance

0 PSI
 CLTSTPR
%R1024
90
psi
Step 1 Step 3 Step 5

70 mA

50

30

mA

10 Step 2 Step 4 Step 6

5
0
Time
Difference =
reference -
feedback 75
psi Open the
dump
+20
valve
(MV1) Open the
+15 dump
valve
+10 (MV1)

Too
+5 low

0 Close the
dump
valve
(MV1)

-10
 PLC
counts mA psi %R999 (MAXPR) = 100 PSI = Maximum clutch pressure
32000 20 100
90 PLC REFERENCE
80 %R252 = CLA PREF = Clutch A pressure reference =
70 %AQ3 (2TBA06(+), 2TBA07(-)
60 %R1004 = CLACLSR =
15 PSI/sec = Clutch A %R253 = CLB PREF = Clutch B pressure reference =
12 12 50 closing pressure rate %AQ4 (2TBA10(+), 2TBA11(-)
40 %R1005 = Clutch B
30
20
10 5 5
0 4 0
0 1 2 3 4 5 6 7 8 9 10 sec.

%AI9 = Clutch A PR feedback

counts V psi pressure (2TBA23(+), 2TBA24(-))
%AI10 = Clutch B PR feedback
32000 10 100 pressure (2TBA27(+), 2TBA28(-))
90
80
70
60
12 5 50
40
30
20
10 5 5
0 0 0
0 1 2 3 4 5 6 7 8 9 10 sec.

counts mA psi
32000 12 100 %R205 = CLA_PRS = Clutch A pressure feedback =
90 %AI5 (2TBA14(+), 2TBA15(-)
80 %R206 = CLB_PRS = Clutch B pressure feedback =
70 %AI6 (2TBA19(+), 2TBA20(-)
60
12 8 50
40
30 Difference between reference
and actual pressure
20
10
0 4 0
0 1 2 3 4 5 6 7 8 9 10 sec. Open the
"dump" valve
Close the
"dump" valve
%R912 = 16 : BIT 12 OF PID = 0 = POSITIVE = MOTORS CCW / MILL CW (looking at the ring gear facing the motor ODE)
%R912 = 18 : BIT 12 OF PID = 1 = NEGATIVE = MOTORS CW / MILL CCW (looking at the ring gear facing the motor ODE

MOTORS CCW MOTOR CW

BIT 12 OF PID = 0 BIT 12 OF PID = 1

kW Difference = kW Difference = kW Difference = kW Difference =

NEGATIVE POSITIVE NEGATIVE POSITIVE
{Motor A load = high} {Motor B load = high} {Motor A load = high} {Motor B load = high}

DC(+) BUS DC(+) BUS DC(+) BUS DC(+) BUS

= POSITIVE = NEGATIVE = NEGATIVE = POSITIVE

MOTOR A REDUCE LOAD INCREASE LOAD REDUCE LOAD INCREASE LOAD

MOTOR B INCREASE LOAD REDUCE LOAD INCREASE LOAD REDUCE LOAD

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

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

Q_CURR FC_KP and

%R201 FC_KI = Too low

FC_KI = Too high

FC_KI = Good
FC_KP = Too low

FC_KP = Too high

Correct
 KW PID Regulator
BIAS
%R908
=0
SP SLEW UPPER/LOWER
+ DEADBAND PROPORTIONAL POLARITY CV
%R45 LIMIT CLAMP
%R903/904 GAIN - Kp %R912 %R250
DKW_REF %R911 %R909/%R910
- =0 %R905 Bit 1 QCURREF
= 0 kW =0 = +/- 600A

PV
%R257 INTEGRAL GAIN -
DIFF_KW Ki
%R907

FC PID Regulator
BIAS
%R948 =
+/- 19000
SP
+ SLEW UPPER/LOWER
PV DEADBAND PROPORTIONAL POLARITY CV
LIMIT CLAMP
%R199 %R943/944 GAIN - Kp %R952 %AQ1
- %R951 %R949/%R950
Q_CURR =0 %R945 Bit 1 QGPGREF
=0 = +/- 75% max

INTEGRAL GAIN -
Ki
%R947
 L1-L2
L2-L3
L3-L1
L2-L1
L3-L2
L1-L3

a=0 a = 180 (for SCR P1)

0 60 120 180 240 300 0 60 120 180 240 300 0 60 deg.

L1-N
L2-N
L3-N

0 60 120 180 240 300 0 60 120 180 240 300 0 60

P3 P1 P1 P2 P2 P3 P3 P1 P1 P2 P2 P3
RECTIFYING
N2 N2 N3 N3 N1 N1 N2 N2 N3 N3 N1 N1
P2 P2 P3 P3 P1 P1 P2 P2 P3 P3 P1 P1
INVERTING
N3 N1 N1 N2 N2 N3 N3 N1 N1 N2 N2 N3

P1
N1 POSSIBLE SCR
P2 CONDUCTION
N2 RANGE
P3 (MAX CI=120 deg)
N3