Hydraulic Mining Excavators

CAMP/ SIL Electric System CAT-6040FS AC

Drive Controller Operation Manual

Sebastian Fillinger - 2014

Location of the Drive Control System

Service Training

-3A3

Drive Controller

Service Training

The following pages describe the interconnection inside the servo controller via software.
It is represented in so called functional modules:

And module:
The output is high if input 1 is high and input 2 is high
Input 1
Input 2

&

Output

Or module:
The output is high if input 1 is high or input 2 is high
Input 1
Input 2

OR

Output

Drive Controller

Service Training

Time delay module (turn on time delayed):

The output is high if input 1 is high for at least 15s
15s
Delay

Output

Input 1

Time delay module (turn off time delayed):

The output is high when input 1 is high and turns off after 15s time delay
15s
Delay

Input 1

Output

Drive Controller

Service Training

Negation module:
The incoming signal will be swapped from high to low or from low to high
The output is high if input 1 is low/ The output is low if input 1 is high

Input 1

Output

Main motor start

Service Training

Start interlock

See page 8

1S115 Ignition

Power supply controller outputs

X3/ 98 Emergency chain ok

3S401 Maintenance switch
3B531 Shut off valve 1
3B532 Shut off valve 2
3B533 Shut off valve 3

&

3B534 Shut off valve 4

X3/ 103 Motor protection relay ok

Main motor start

X3/ 102 High voltage ok

X3/ 101 Phase sequence ok
X3/ 100 Power factor correction ok
5S7 Motor start button

CAN Bus

Auxiliary Controller

Main motor stop

1S115 Ignition

Service Training

Power supply controller outputs

1

X3/ 98 Emergency chain ok

1

3S401 Maintenance switch

1

3B531 Shut off valve 1

1

3B532 Shut off valve 2

1

3B533 Shut off valve 3

1

3B534 Shut off valve 4

1

OR

Main motor stop

X3/ 103 Motor protection relay ok

1

X3/ 102 High voltage ok

1

X3/ 101 Phase sequence ok

1

X3/ 100 Power factor correction ok

1

5S8 Motor stop button

CAN Bus

Auxiliary Controller

Start interlock

Service Training

The system allows 2 motor starts per hour. Two starts can be done one after the other. You can start the
motor the third time when the time between first and third start is greater than 1 hour.
Example:

1. Start

1. Start

30 min

10 min

2. Start

2. Start
40 min
30 min

3. Start

1. Start

40 min

3. Start

40 min
1h /
10 min

55 min

2. Start
15 min

3. Start

Overview Pump Control

Service Training

Motor winding temperature via MOD Bus

Hydraulic oil temperature
Voltage
Motor load (active power)
Acceleration
0 - 100%
Pump Requirements
from Servo Controller
via Can-Bus

Signal via CAN-safety-Bus

Joysticks and
Foot pedals

Drive Controller

Servo Controller
PMS Current 200 700mA
(150mA Standby Current)

Angle Main Pumps 0

15

50bar Pressure

8 - 43bar to Main Pumps

Reducing PMS Current / Pressure

Service Training

Hydraulic Oil Temperature exceeds 80C

Motor winding temperature exceeds 120C
Voltage (from grid) is lower than the nominal voltage

OR

Acceleration
0 - 100%

Derated output
current

Pump Requirements
from Servo Controller
via Can-Bus

Signal via CAN-safety-Bus

Joysticks and
Foot pedals

Servo Controller

Drive Controller

10

PMS Reducing PMS current/ pressure

Service Training

If the nominal voltage of the motor drops down, the motor output power will
be reduced (see formula down below).
The min. factor of motor power derating in case of voltage drop down is 60% of the nominal motor output power!

Uact
Derated _ Motor _ Output _ Power =
Unom

Example:
Nominal voltage:
Actual voltage:
Nominal output motor:

2
2

)* P

nom

7200V
6700V
1400KW

2
6700V
Uact 2
Derated _ Motor _ Output _ Power =
* Pnom =
*1400 KW = 1212 KW
2
Unom 2
7200V

Explanation:

In the upper example the Motor can deliver max. 1212KW power to the hydraulic system.

11

PMS Reducing PMS current/ pressure

Service Training

If the winding temperature exceeds 120

C, the motor output power will be
reduced (see Graph down below).
The min. factor of motor power derating in case of winding overheating is 80% of the nominal motor output power!
Motor Output Derating

Motor Output in % of nominal Output Power

120

100

80

60

40

20

0
0

20

40

60

80

100

120

140

160

180

200

Winding Temperature in C

Example:
Nominal motor power:

1400KW

Actual winding temperature:

135
C

Output motor:

1260KW (90%)

Explanation:
In the upper example the motor can deliver max. 1260KW power to the hydraulic system.
12

PMS Reducing PMS current/ pressure

Service Training

In case of voltage drop down and exceeded winding temperature both

factors will be multiplied
Example:

Motor Output Derating

7200V

Actual voltage:

6700V

Actual winding temperature:

135
C

Nominal output power:

1400KW

Motor Output in % of nominal Output Power

120

Nominal voltage:

100

80

60

40

20

0
0

20

40

60

80

100

120

140

160

180

200

Winding Temperature in C

Derating factor under voltage:

0,86 (see formula)
Derating factor winding temperature: 0,9 (see graph)

2
6700V
Uact 2
Derating _ Factor _ Under _ Voltage =
* Pnom =
= 0,86
2
Unom 2
7200V

Derating factor under voltage

0,86

* Derating factor winding temperature

* 0,9

= Total derating factor

= 0,774

Total derating factor

0,774

* Nominal output motor

* 1400KW

= Actual output motor

= 1083KW

13

Overview Hydraulic Oil cooling

Service Training

Hydraulic Oil Temperature

-50C - +150C
4 20mA

150 650mA

Drive Controller

Angle Oil cooling Pump

0 15
Low Speed level Fan
(50C)

Fan Oil cooling

Module

High Speed level Fan

(60C)

14

Questions?

Service Training

Questions are free of charge!!!

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