Your One-Stop Source WESCO & Magnetek Crane Team Partners for Mittal Steel USA.

Your One-Stop Source

WESCO & MagnetekCrane Team Partners for

Mittal Steel USA


• Who is Electromotive Systems/Magnetek?

• Digital DC Technical Brief

• OmniPulse DDC Physical Specifications

• Digital DC Operation

• Energy Savings

• LOWER Total Cost of Ownership

WESCO & Magnetek


• Incorporated in 1981 as Electromotive Systems

• Became part of Magnetek in 1999

• Acquired Mondel Engineering in 1999

• Acquired Telemotive Industrial Controls in 2002

Magnetek Material Handling – YOUR ONE-STOP SOURCE


• Electromotive Systems: FIRST name in crane drives

• Over 100,000 drives shipped

• 65%+ Market Share

• Dominant competitive position with larger horsepowers

• Superior Technology and Product

• Never-ending innovation

• Excellent Support

• Average monthly production = 250+ control packages



• A Full Range of Digital AC Control Products– IMPULSE AC Drives

• ¼ to 1500 HP, 230,460 & 575 V

– MAC Soft Starters / Contactor Controls

– AC Motors

• ½ to 1000HP: 230, 460 ,575, & 690V

– Collision Avoidance Systems

– Complete Standard and Engineered Control Panels

– Wireless Diagnostic Tools

– Parts and Service



• Full Range of Digital DC Control – OmniPulse DDC Drives

• DC in / DC out

• 60 to 2000 amp

– Omnipulse DSD Drives

• AC in / DC out

• 25 to 1200 amps

– Complete Engineered Control Panels

– Parts and Service



• Full Range of Industrial Braking Products

– 200S General Purpose

– 300M AISE

– 400D Disc

– Braketronic (solid state controller)

– Stand alone Thrusters for a Variety of Applications

– Brake Parts

– Brake Service and Repair



• A Full Range of Power/Control Delivery Systems

– Electrobar® / Electrobar FS

• 90 to 400 Amp

– Electrobar® HX

• 400 to 1500 Amp

– Electrobar® Elite

• Enclosed conductor, 60 to 200 Amp



• A Full Range of (AC/DC) Radio Control Products– MLTX

TM

– SLTXTM

– JLTXTM

– telePilotTM

– telePendantTM

– Parts, Repairs and Service



• Two Lines of Pendant Stations

• SBP & SBP2• A Full Range of Power/Control

Delivery Systems

– Standard to Mill Duty Festoon Hardware

– Plug and Play Festoons



OmniPulse DDCSolid State

Digital DC Crane Control


OmniPulse Digital DC Technology

• 100% IGBT Solid State control

• Utilizes existing power connections (A1, A2, B2)

• Successfully Applied To EOT Cranes Since 1998

• Most energy efficient DC drive available

• Minimal maintenance costs


OmniPulse DDC

• Maintains Series Brake connection(s)

• Maintains Dynamic Braking Safety Circuit (AIST Technical Report 6)

• Maintains Limit Switch connections

• Series Hoist...Shunt Lowering


Control ComparisonContactor Control

• Multiple Electro-Mechanical Contactors & Relays

• Multiple Power Resistors

• Open Loop (no feedback)

• Two Quadrant Motor Operation

DDC Technology

Uses Microprocessor

IGBT Switching

Closed Loop Control

Four Quadrant Operation

Regenerative


DCCP Typical Hoist Control Panel

Single Motor Control Board

Consists of:1 – Main Contactor

4 – Directional Contactors

1 – DB Contactor

3 – Accelerating Contactors

2 – Electro-Mechanical Dashpot

Type Overload Relays

1 – Under Voltage Relay

1 – Limit Switch Back-Out Relay

UV Relay

LSR Relays

Main & Directional Contactors

DB Contactor

Accelerating Contactors

Overload Relays


Power Resistor Assembly

Grid Type“3” Bank Resistor

Assembly

A Typical Hoist Control Will Require Multiple Resistor Banks:

• 65HP = 10 Banks• 100HP = 15 Banks• 200HP = 29 Banks• 265HP = 39 Banks


Disadvantages of DCCP

•Poor reliability & availability

•Maintenance Intensive

• Inconsistency of Operation

•More Power Connections

•Energy Inefficient


Reliability

37 ELECTRO-MECHANICAL COMPONENTS PER CRANE

Crane Board

No. of Contactors

No. of Relays

Typical No. of E/M

Components

Hoist 9 4 13

Trolley 9 3 12

Bridge 9 3 12

37

The number of mechanical components impacts reliability.


Overview of OmniPulse DDC

• 5 – 500 hp (within 2 Frame Sizes)

• 230 – 360 VDC

• Speed Regulation

•5% Closed Loop Sensorless

•.1% Closed Loop with Tach Feedback

• Configurable for Series, Shunt or Compound Wound Motors

• Digital Micro-Processor Based

• Universal Software (Version 3)

• Only DC to DC Drive with Four Quadrant Operation


OmniPulse DDC Platform Design

• Standard NEMA Sizing: 2 - 8L (66A - 2000A)

• Only two frames sizes (Cubes) cover entire HP range

• Size 2 & 3 same chassis


• Size 6 = Size 5 Master + Size 5 Follower

• Size 7 = Size 5 Master + TWO Size 5 Followers



• Master/Follower Conversion

• Less than 10 minute preparation

• Only difference is Control Card & Display

• Master Includes Control Card & Display

• Follower has Control Card & Display removed

• Completely Interchangeable, not motion specific




• Dimensions: 18” H x 8.5” W x 12.5” D

• Weight: 50 lbs




• Dimensions: 30” H x 13” W x 14.5” D

• Weight: 110 lbs


OmniPulse DDC Components

• Display Module

• Control Card

• Driver Board

• Power Section: IGBT’s, Capacitors, & Heat Sink


Modular DesignIntegral LCD Integral LCD Display and Display and

KeypadKeypad

Common Common HardwareHardware

Fully Fully Integrated Integrated PackagingPackaging

Common Common Control Control BoardsBoards

Common Common SoftwareSoftware




• Display Module--SAME all sizes

• Control Card--SAME all sizes

• Driver Board--only TWO sizes

• Power Section--sizes per appropriate NEMA capacity



• REDUCED spare inventory

• SIMPLIFIED spare inventory

• SAME CUBE HOIST & TRAVEL!!!

• Software is UNIVERSAL to all drives sizes

• OmniPulse DDC is the most flexible and powerful design


OmniPulse DDC Display

• Display Module--integrated into drive

• Display Module--will not get lost, dropped

• Handheld NOT an option

• Various interface protocols available--PLC, laptop communication, Radio, Pendant, or Master Switch


OmniPulse DDC Typical Panel

• Main drive unit

• One Main Contactor, One DB Contactor (hoist only)

• Main CB, Control CB

• Interface (IF) Board with control power terminal strip

• L1/L2 Power Studs

• A1/A2/B2 Stack Section


Size 6 Hoist OmniPulse DDC Hoist


Size 6 Hoist OmniPulse DDC Hoist





Advantages with OmniPulse DDC

• Minimal Maintenance

• Full Four Quadrant Control

• Programmable Consistent Speeds and Acceleration Rates

• Wiring From The Motor Control To The Resistor Bank Is Eliminated

• Extremely Energy Efficient


OmniPulse DDC

• 100% Solid State Technology

• NOT a hybrid combination

• NO Directional Contactors

• Speed Resistors Eliminated--Hoist OR Lower

• DB Resistors included per AIST TR-6


Brand X

• Hybrid Technology

• Speed Resistors (Lowering)

• Directional Contactors

• Passive Heat Sink

• Non-Standard NEMA Sizing

• L2 - L3 Lower Delay

• Hoist Drive only, Travel only

• Drive-specific software


OmniPulse DDC

• 100% Solid State Technology

• Four Quadrant Motor Control

• Programmable Consistent Speeds and Acceleration Rates

• Extremely Energy Efficient

• Logical & Functional Panel Design

• Flexible Design


OmniPulse DDC Safety Features

• Pre-charge circuit

• Continuity check

• Capacitor LED status

• Motor Armature & Field Loss Detection

• Current Limit Control


OmniPulse DDC Closed Loop

• DCCP = Two Quadrant Control

• Hybrid DDC = Two Quadrant Control

• OmniPulse DDC = FOUR Quadrant Control

• CEMF feedback = Continuous Communication between Motor and Drive

• Large Regenerative Potential


OmniPulse DDC Four Quadrants

• Q1--Power Hoisting

• Q3--Power Lowering

• Q2--Hoist Braking

• Q4--Dynamic Lowering


OmniPulse DDC

• Closed Loop Control via CEMF feedback

• Armature & Field Voltages & Current controlled via IGBT

• PID Loop fully programmable

• Speed does NOT vary with Load

• Runaway not permitted


OmniPulse DDC Simplified Motor CircuitT1/T2/T3 Referenced to L2-


OmniPulse DDC Operation

• Faster Empty Hook Speeds--either direction (Economy Field)

• FULL Access to drive parameters

• Flexible

• Separate Accel & Decel inputs

• Separate Hoist & Lower speeds

• Micro-Speed/Load Positioning



• Typical 125VDC - 390VDC operating range (250VDC Bus)

• FULL Access to drive parameters

• Fully programmable

• Built-in Diagnostics

• 31 “A” Monitoring Parameters

• Fault History with time stamp



• Designed to perform in HOT environments

• Built-in safeties to protect control

• Minimize heat generation


OmniPulse DDC Heat Equation

• Heat Sink Design

• Duty Cycle/IGBT Switching

• Enclosure Sizing

• Ambient Temperature


OmniPulse DDC Heat Sink

• 115˚ Celsius / 239˚ Fahrenheit Trip Level/Maximum Temp

• Aluminum Core

• Multiple Extruded Fins

• Maximum Surface Area

• High Velocity Fan


OmniPulse DDC Heat Sink

• Chassis Design isolates digital components from Heat Sink

• Only IGBT’s produce Heat

• Only IGBT’s contact Heat Sink

• Move Air/Heat up & through

• ACTIVE cooling

• Most Efficient Heat Exchange


OmniPulse DDC Performance

• Higher Cycles equates to higher heat production

• Only IGBT’s produce Heat

• OmniPulse DDC temp rating based on 100% switching

• Most Mill Duty Cycles ~50%



• Large enclosure

• Adequate component spacing

• Braced back plate

• Optional venting

• Optional supplemental cooling--per application



• 50 - 60˚ C Ambient Rating

• 122 - 140˚ F Ambient Rating

• Varies based upon IGBT headroom

• Reduced switching below 100% dramatically reduces Heat Sink Temperature Rise

• 115˚C/239˚F Max Heat Sink Temp


Various OmniPulse DDC Benefits

• Fewer Items To Mount On The Crane

• No Acceleration Resistors To Connect

• Less Power Cable, Lugs and Hardware

• Keep Existing Power Limit, Brake and Motor Connections

• Keep Existing Cross Conductors (rail or festoon)

• Use Existing Operators Controls

• Less Installation Time

• Prolongs Brake and Brake Shoe Life

• Prolongs Motor Brush, Commutator, and Field Insulation Life

• Reduces Shock Loads On Mechanical Power Train


Lower Energy Costs

• No Wasted Energy In Resistor Banks On Travel Motions

• Eliminates Power Losses In Hoist Resistors

• Requires Less Power During Low Speeds and Acceleration

• Regenerates Into The Power Bus When Lowering Loads

• Regenerates Into The Power Bus When Braking Hoist Loads


Potential Energy Savings

AssumptionsAssumptions Hoist motion 8 hour turns 100 lifts per turn 30 foot lift distance 30 FPM lift speed $.054/kWh 21 turns/week

Frame HP Savings

606 33 $8,190

608 45 $11,111

610 65 $15,756

612 100 $23,809

614 135 $31,746

616 200 $46,245


WESCO & OmniPulse DDC

• Large local installed base

• Superior local service support

• Pre-installation inspection

• Commissioning

• Service

• Training


WESCO & OmniPulse DDC

• Training at Burns Harbor Deerfield

• September 2007

• Programming

• Troubleshooting

• Advanced Topics


Lower Total Cost of Ownership

• Increased Reliability

• Competitive Initial Cost

• Universal spares

• Dramatic Energy Cost Savings

• Powertrain-friendly

• Increased Motor Life

• Simplified Maintenance


Q & A?

Feedback?

Thank You!

Date post:	29-Dec-2015
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Your One-Stop Source WESCO & Magnetek Crane Team Partners for Mittal Steel USA.

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