V04 - C03 - Andina Ball Mill Op Manual - 3BHS235454 - EN - Rev - Cert

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Gearless Mill Drive Manual 3BHS 235 454

Issued by department: Date: Language: Register No.: Revision: Page:
CHIND / ATBDE 28.07.2009 en Volume 4 - 1/115
ABB Switzerland
Building Material & Mineral Industries
CH-5405 Baden-Dättwil, Switzerland
TITLE: Ball Mill Drive Operation Manual

EQUIPMENT: Cycloconverter for
Gearless Mill Drive
CLIENT: Codelco Chile
CONSULTANT: Bechtel Chile
CERTIFIED
EQUIP. TAG: M1-3340-2110-01 26-Jan-2010
Visum: M. Garnier
PROJECT: ANDINA – Phase 1
ORDER NO.: 1-9501271
Issued: Released: Revision:

Date: 16.10.2003 28.07.2009 Date:
Sign: J.Gonser M.Garnier Sign:
Std name: Std issued: File name: I:\01D\13Proj\GMD\11046221 Andina GMD\02 Design
Documents\040 GMD\Cyclo\Manuals\Andina Ball Mill Op
Manual_3BHS235454_EN_rev-.doc
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TABLE OF CONTENTS
1. INTRODUCTION 6
1.1 Why You Should Read this Manual 6
1.2 How to Read The ‘Operation Manual’ 7

1.2.1 Safety Instructions 7
1.2.2 General Secrecy 8
1.2.3 Edition 8
1.3 ABB GMD Documentation Set 9
2. ABB RING MOTOR TECHNOLOGY 10
2.1 Good reason to go gearless 10
2.2 The Cycloconverter-Fed Synchronous Motor 10
2.3 Design and Operation 12
2.4 Motor 13
2.5 Static Converter 13
2.6 Methods of Controlling the Cycloconverter 14
2.7 Static Flux Model 17
2.8 Dynamic Flux Model 19
2.9 Current Control Circuit 20
2.10 Trapezoidal Mode 21
2.11 Specific System Features 21
2.12 Network Reactions 22

2.12.1 Power Factor 22
2.12.2 Harmonic Currents 22
3. SYSTEM DESIGN 23
3.1 Design datas 23
3.2 System Overview 27

3.2.1 General Description of the Converter Cubicle 28
4. OPERATION 29
4.1 Safety Instructions 29
4.2 Why You Should Read this Chapter 31
ABB Switzerland Ltd. / ATBDE Andina Ball Mill Op Manual_3BHS235454_EN_rev-.doc

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4.3 Operation Instructions 32

4.3.1 Reasonable Use 32
4.3.2 Plant / Converter Interface 33
4.3.3 Converter Local Control Panel 34
4.3.4 Faults and RESET Function 40
4.3.5 Faults Control 54
4.3.6 System Interlocks 55
4.3.6.1 Mill / Drive Interlocks 55
4.3.6.2 Device / Function Group Interlocks: 57
4.3.7 GMD Start Sequence 58
4.3.7.1 Auxiliaries Start-Up sequence 58
4.3.7.2 Close Circuit Breakers Command 58
4.3.7.3 Mill Start Up 59
4.3.8 GMD Stop Sequences: 60
4.3.8.1 Complete system shutdown 60
4.3.8.2 Normal stop sequence 61
4.3.8.3 Abnormal stop sequence 62
4.3.8.4 E-stop / Cycloconverter Faults / Fire Fighting Alarm 62
4.4 Motor Local Control Panel (MLCP) 63

4.4.1 Layout 63
4.4.2 Construction 64
4.4.3 Control display panel AF C094 65
4.4.4 Control Place Selection 65
4.4.5 Key Switch 65
4.4.6 Function Push Buttons 66
4.4.7 Inching Mode (Positioning) 66
4.4.8 Creeping Mode 67
4.4.9 Normal Mode 67
4.4.10 Reduce Mill Rocking 67
4.4.11 Manual Lowering 67
4.4.12 Safe Mode 67
4.4.13 Frozen (locked) charge 67
4.4.14 Horn 68
4.4.15 Control push button station 68
4.4.16 Status, Fault & Alarm Signals 68
4.4.17 Analogue Signals indicated 68
4.5 Ring Motor 69

4.5.1 Airgap Supervision 69
4.5.2 Dust Sealing 70
4.5.3 Knife Switches 71
4.5.4 Motor Winding Temperature Supervision 71
4.5.5 Motor Cooling System 72
4.5.5.1 Cooling Fans and Overpressure Make-Up Fans 72
4.5.5.2 Heat Exchanger 73
4.5.5.3 Motor Space Heater 73
4.5.5.4 Humidity Sensor 74
4.6 Medium Voltage System 75

4.6.1 Main Circuit Breakers (Medium Voltage) 75
4.6.2 Cycloconverter Transformer 75
4.6.3 Excitation Transformer 76
4.7 E-House 77
4.7.1 Air Conditioning 77
4.7.2 Fire Fighting System 77
4.7.3 UPS 78

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4.8 Motor Control Center (MCC) 79

4.8.1 MCC Incoming Breaker +F05 79
4.8.2 MCC 120V Distribution Panel +F06 79
4.8.3 MCC 230V Distribution Panel +F06 79
4.8.4 MCC Motor / Heater Starter Module 79
4.8.5 MCC Single Feeder 81
4.9 Excitation Converter – DCF600 81

4.9.1 Rotor Protection 81
4.9.2 Rotor Overvoltage Arrester 82
4.9.3 Diagnostic Software Tool 84
4.10 PLC 84
4.10.1 Profibus Communication 84
4.10.2 Input /Outputs 84
4.10.3 MCC Link 84
4.10.4 DCS Link 85
4.10.5 Modbus Communication 85
4.10.6 VMS 85
4.11 Seismic Recorder 86

4.11.1 Triaxial Sensor 86
4.11.2 SED Seismic Event Detector (Recorder / Trigger / Evaluation) 87
4.11.3 Function 88
4.11.3.1 Suggested Set points 88
4.12 Lubrication System 89
4.13 Brake System 89
5. REGULATION 90
5.1 Principle of regulation 90
5.2 Overview 90
5.3 Current regulators (INT1 - S16..S18) 92
6. THYRISTOR SUPERVISION 93
6.1 Introduction 93
6.2 The thyristor control system 94

6.2.1 Monitoring PCB (MP) 95
6.2.2 Thyristor Monitoring (TM Li) 95
6.2.3 Indication of a faulty thyristor 97
6.2.4 Fibre optic (FOP) 97
6.2.5 Power supply 97
6.3 Operation 97
6.3.1 Preparational operations 97
6.3.2 Checks before start up 97
7. FROZEN CHARGE PROTECTION 98
7.1 Precalculation and Comparison 99

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7.2 System Description 100
7.3 Advantages 100
7.4 Limits 101
7.5 Implementation of DCP 101
7.6 Frozen charge application software. 102

7.6.1 Angle detection. 102
7.6.2 Frozen charge detection. 103
8. TROUBLE SHOOTING 105
8.1 Safety Instructions 105
8.2 Why You Should Read this Chapter 106
8.3 Dealing with Troubles 107
8.4 Scope 107
8.5 SupportLine 108
8.6 Converter Fault or Malfunction - What to Do 109
8.7 Converter Fault Finding and Trouble Shooting Chart 113
9. TRAINING 114
9.1 General 114
9.2 Basic Training (1 day / compulsory) 114
9.3 Maintenance Training (3 to 5 days / optional) 114
10. SPECIAL TOOLS 115

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1. Introduction
Notice
Read this manual before energizing the converter!

Keep this manual for future reference!
In case of fire
High voltage!
Toxic Gases!
Overheating!
1. Press the emergency off button.

2. Put on a protection mask. Inflammable substances, toxic gases!
3. De-energize the converter.
4. Earth the de-energized converter module.
5. Don’t use water or any other chemical agent to extinguish the fire; use FM200.
1.1 Why You Should Read this Manual
Before beginning the maintenance work read this manual carefully in order to be able to do
maintenance work of the converter in a safe and correct manner.
Note that all parts of the 'Operation Manual' are intended to be the basic documentation for operation,
checking and maintenance tasks. Pay special attention to all safety instructions.

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1.2 How to Read The ‘Operation Manual’
1.2.1 Safety Instructions
The safety instructions always appear at the beginning of each chapter, paragraph and/or sub-
paragraph. The safety instructions are divided into five categories and emphasized by the use of the
following safety signs on the left side of the page:
Danger Herewith an imminent danger, which can lead to life

threatening injuries, is indicated.
! Attention Herewith a possibly dangerous situation, which could lead to

bad or life threatening injuries, is indicated.
! Caution Herewith a dangerous situation, which can lead to

injuries, is indicated.
Notice Herewith is indicated that something can damage the

converter or other equipment.
! Important All important information is emphasized by the use of this

sign and text on the left side of the page.

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1.2.2 General Secrecy
ABB Switzerland Ltd reserves all rights to the information contained in this document. Reproduction,
use or disclosure to third parties without express authority is strictly forbidden.
1.2.3 Edition
The 'Operation Manual' is subject to revision. The ABB update service provides you with the most
recent edition.

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1.3 ABB GMD Documentation Set
Together with the GMD System, ABB provides a complete documentation set, where you can find all
the technical information related to every sub-system belonging to the GMD System. The ABB
Documentation Set is available in hardcopy as well as in electronic format (pdf files),
Volumes available in the ABB Documentation Set are the following:
Volume Description
0 List of Documents
1 Circuit Diagram GMD System
2 Stator and Excitation Transformers
3 E-House, UPS and Seismic Detector
Cycloconverter, Power Part and Cooling Unit Manuals
4
and Drawings
Cycloconverter, Power Part and Cooling Unit
5
Datasheets
6 PSR Software Listing
7 PSR Datasheets
8 Excitation Converter
9 Transformer Protection Relay
10 Fire Fighting & Air Conditioning
11 MCC - Specification, Manuals and Electrical Drawings
12 PLC and VMS
13 PLC Software Listing
14 Ringmotor Design and Drawings
15 Ringmotor Manuals & Knife Switches
16 GMD System Commissioning Reports

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2. ABB Ring Motor Technology

2.1 Good reason to go gearless
In minerals processing, profit requires throughput. Grinding low-grade ores calls for high volume mills
and round-the-clock reliability. High power, huge capacity, and brute strength are balanced against
critical bottom-line issues like efficiency, control and availability. Today, there is only one motor type
capable of meeting the demands of high-throughput minerals processing.
Our GMD is strong, rigid and round. The tremendous forces involved with todays huge SAG and Ball
mills demand it. Designed and built for maximum stiffness, our GMD’s pit mass and muscle against
torque and heat to retain concentricity and precision control over your grinding process. ABB has
always provided individual alignment of every pole for precise adjustment for concentricity.
GMD’s are synonymous with low maintenance. With a GMD from ABB, all maintenance is scheduled
and performed during planned downtime. Our superior dry sealing design uses no grease and
effectively prevents contamination. The ABB GMD ring motor has only two wearing parts-brushes and
dry seals. And with the resulting low maintenance, your mill is more available.
No other motor achieves the cost efficiencies of an ABB GMD. Calculated on the basis of all
operational electrical losses, ABB efficiency helps you achieve the lowest total production costs per
ton of ground ore. The reasons are simple: more final product where it counts. Optimized electrical
frequency. Lower operating temperatures requiring less cooling power. And ABB gives you the
fastest, most precise control on the market.
ABB meets all your established standards. We assure compatibility with your key systems: PLC,
MCC, HVAC, and fire-fighting, as well as local safety codes. And ABB works with your choice of
consultant and mechanical mill supplier. Connectivity is never a problem with ABB. We provide
solutions for every electrical and motor-related challenge you face.
2.2 The Cycloconverter-Fed Synchronous Motor
Although the principle of the cycloconverter has been known since the thirties, it has only been
possible to employ it for the supply of synchronous machines with variable frequency since the
introduction of semiconductor systems to the fields of power and electronic control engineering.
Moreover, the requirements placed by industry on drive systems could no longer be mastered by
conventional means.
In the mid-sixties ABB respectively BBC undertook to build a drive for the then largest cement
tube mill in the world, with a drive rating of 6400 kW and a speed of 15,5 rev/min. Considerable
thought was given to the question of whether this was possible with conventional gearing and a
high-speed motor. A reliable drive system could only be realized without gearing. For this
application BBC built his synchronous motor direct on the mill shell, i.e. with a speed of 15,5
rev/min. For a 50 Hz supply this speed would require 400 poles, a number for which the motor
could not be designed. This problem was solved by supplying the motor via a cycloconverter with
which the pole number and the motor frequency could be optimized, using 44 poles at a
frequency of 5,5 Hz. Its low frequency also complies with the principle of the cycloconverter,
which is operated preferably at frequencies lying well below the mains frequency.
At the same time, it was possible with the cycloconverter to control the frequency continuously,
beginning at zero. This also solved the start-up problem in that the motor, during frequency start-
up, produced the required high starting torque with the lowest possible power system load. In
addition-although this was no original requirement-the drive system permits the operating speed
to be controlled to the optimum grinding speed.

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Since successfully beginning operation at the end of 1969, this first gearless cement mill drive in
the world operating with a cycloconverter-fed synchronous motor has been followed by no less
than 49 such ABB’s drives confirmation that ABB is on the right path.
To make this established drive system suitable for other applications, particularly for mine
winders and rolling mills, it was necessary to satisfy other requirements not applicable to the tube
mills. These lay in the direction of higher speeds and frequencies (up to 50% of the mains
frequency) and also in the direction of improved control response, thus permitting very high
torque adjustment speeds and additional development required to this end. The result is a
cycloconverter-fed synchronous motor which, with respect to its control response, is at least
equal to the converter-fed DC drive and is not subjected to the power limitations imposed by the
latter’s commutator.

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2.3 Design and Operation
Figure 1 shows the circuit diagram of the power section with the synchronous motor,
cycloconverter for stator supply with variable frequency and the controllable rectifier for the
excitation winding of the rotor.
H
S
T2 T1 T1 T1
n2 n1
i-
A
u+
i+
u-
iS
iR iT
uR uS
uT
ie
SM
H
3
Fig 1 – Basic circuit diagram of the cycloconverter-fed synchronous motor (Power section)
S = Circuit-breaker i+,i-,u+,u- = Output current and

T 1, T 2 = Converter transformer voltage of the cycloconverter
n1 = Cycloconverter ie = Excitation current
n2 = Excitation converter iR, iS, iT = Stator currents
SM = Synchronous machine uR, uS, uT = Stator voltages
A, B = Three-phase bridges f1 = Mains frequency
connected in antiparallel f2 = Frequency of synchronous motor

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2.4 Motor
The motor is usually a conventional three-phase synchronous machine. The motor and cycloconverter
can be adapted to some extent to the operator’s required speed range without great cost by
appropriate selection of the pole number and frequency. Whether or not a damper winding is required
in the rotor depends largely upon the response requirements to be met by the controlled drive. As a
rule, the cycloconverter-fed synchronous motor is used as an individual drive, being operated
exclusively as a self-regulating machine. This means that the synchronous machine sets its own
frequency so that the oscillations produced when operating with a power system with constant voltage
and frequency cannot occur. Consequently, the damper winding necessary to prevent these rotor
oscillations is no longer required. The winding would even be detrimental since it greatly reduces the
synchronous machine reactance responsible for the harmonic currents, and therefore increases the
stator harmonics. Drives whose dynamic response requirements are less strict, such as continuous
tube mill drives, are therefore realized with motors without damper windings.
For drives with a high level of control response for fast torque reversal, such as drives for
reversible rolling mills, the rotor must either have solid poles or, when laminated, be provided with
a damper winding. In this way it is possible to obtain machine reactance and time constants
which are sufficiently low to enable, in connection with a suitable control system, rapid variation
of the stator current component producing the torque.
2.5 Static Converter
In the operating range with constant machine flux, the synchronous motor requires stator
voltages UR, US, UT which rise in proportion to frequency f2. The three-phase cycloconverter
(Fig.1 ) consists of three star-connected, line-commutated reversible static converters without
circulating current, such as are employed in d.c. drive systems. Since the static converters are
line-commutated, normal mains thyristors can be used. Converter transformers are used for the
connection to the mains.
The cycloconverter produces the machine stator voltages direct from the mains voltages by
means of phase angle control. The converter control angle is controlled such that converter
output voltages with a mean sinusoidal characteristic result (Fig. 2). Both the frequency and the
amplitude are adjustable.
The output frequencies f2 are restricted to frequencies lying clearly below the mains frequency (in
the range f2 = 0 to around 50% of the mains frequency), so that the maximum speed attainable
for a drive, referred to the motors frequency, lies at approximately half the synchronous speed.
As shown in Fig.2 the output voltage and output current are in phase, corresponding to a power
factor of cos M2 = 1 for the synchronous machine.
The three-phase bridge A (Fig.1) delivers current I+ for the positive, and the antiparallel bridge B
current I- for the negative half-wave of the stator current. To ensure that the transfer between
bridges A and B entails no circulating current, a short interval without current is introduced at
each polarity change before the antiparallel bridge is released.
The cycloconverter can operate, as can every reversible static converter, in all four quadrants,
i.e. the cycloconverter output voltage and current can assume both polarities independent of
each other. This property is required, for example, for rapid torque reversal. It would also present
no problem to operate the system with any given machine power factor. For cos M2 = 1 during
operation as a motor (or cos M2 = -1 for operation as a generator during braking). The
cycloconverter, however, need only deliver active power to the synchronous machine and could
then be dimensioned for the lowest possible power. The control system compels operation of the
machine with a power factor of cos M2 = r 1.

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For better utilization of the system properties it is useful to control the three reversible converters
indirectly via three phase-current controllers, and thus to operate the cycloconverter as a three-
phase current source in star connection. The control equipment regulates the three stator
currents i R, S, T and the excitation current ie such that the characteristics of the overall system are
optimized both statically and dynamically over the entire frequency range.
2.6 Methods of Controlling the Cycloconverter
Two different modes of operation are used to control the entire speed range (i.e. frequency
range) of the drive:
-Sinusoidal operation
-Trapezoidal operation
In the sinusoidal mode for the lower speed range, the machine voltages, and therefore the
voltages to be generated by the cycloconverter, are low. The converters always operate with
partial firing angles and the output voltages retain their mean sinusoidal characteristic (Fig. 2).
This operating mode is possible as long as the converters do not attain their natural control limits
as the output voltage amplitudes increase (rectifier and inverter in their end position). One
drawback is the relatively high reactive power required for control. At low speeds, this results in a
correspondingly low power factor for the mains.
Fig. 2-Output voltage (u) and current (i) of the cycloconverter operating in sinusoidal mode
A = Three-phase bridge A in rectifier mode
B = Three-phase bridge B in rectifier mode
= Current changeover interval
f2 = Frequency at converter output
1 = Three-phase input voltage with mains frequency
2 = Mean value of output voltage
To improve the mains power factor the trapezoidal mode is employed in the upper speed range,
where the cycloconverter also has to supply higher voltages. This mode also utilizes the static
converters more effectively with respect to the voltage.
In the trapezoidal mode the static converters are operated at their firing limits for as long as
possible in the low-frequency cycle 1/f2, i.e. during operation as a motor with the rectifier in its
end position and during operation as a brake with the inverter in its end position. The control
angle only deviates from this in the area where the polarity of the converter output voltages
changes. As shown in Fig. 3 these have an almost trapezoidal characteristic. Since there is no
star connection between the machine and the cycloconverter, the machine voltages still retain

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their sinusoidal shape. The difference between the star points at a frequency three times the
machine frequency.
Fig. 3 – Output voltage (u) and current (i) of the cycloconverter in trapezoidal
1 = Fundamental oscillation
of the input main voltage
A = Three-phase bridge A in rectifier mode
B = Three-phase bridge B in rectifier mode
= Current changeover interval
f2 = Frequency at converter output
1 = Three-phase input voltage with mains frequency
2 = Mean value of output voltage
The longer the converters are operated with a full firing angle over one cycle of the machine
frequency f2, the better the mains power factor is. The slopes of the trapezoidal characteristic are
then also correspondingly, although the slope gradient does have a certain limit.
If the voltage system of the synchronous machine is to remain controllable, not more than one
converter may ever be operated with the full firing angle at any one time. This condition is
satisfied when each converter is in its end position for no longer than S/3 in a half-cycle of f2.
This makes utilization of the cycloconverter more effective with respect to the voltage. In this
mode the peak value of the machine voltage for the fundamental component is 15% higher than
the maximum instantaneous value of the converter output voltage.
Closed-Loop Control
Rapid torque control is an important aspect of a regulating drive. The drive torque at the motor
shaft should follow the torque value specified by a higher-order control system, for example a
speed controller, with as little delay as possible, as in the case of the converter-fed d. c. drive. In
the case of a d.c. drive, intervention in the torque is via the armature current. The drive torque
corresponds to the desired value as soon as the current controller and the converter are able to
regulate the load current ix to the given reference value iw . The proportionality between the
current and torque is the result or the principle according to which the d.c. motor operates.

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The force acting on the armature conductors can be calculated from a machine vector product of
the resultant armature flux linkage and armature current, illustrated in the diagram by the area
between the vectors of the linear current density of the armature flux linkage \ (Fig. 4a). The
torque is a maximum when these two vectors are perpendicular to each other. We then have:
MG \ x I (1)
\ comprises the flux linkage \e in the direction of the exciter pole, which is produced from the
field current and active in the armature, and the flux linkage \a in the brush shaft, which results
from the armature current. Due to this load-dependent reaction of the armature, the vector \ of
the resultant armature flow linkage would rotate from its optimum position perpendicular to the
current if there were no compensating winding on the brush shaft. The armature current also
flows through this winding and produces a compensating flux linkage \k of the same magnitude
in opposition to \a, with the result that \ is determined by the current in the excitation winding
alone. The arrangement of the windings in the d.c. machine automatically provide for decoupling
of the resultant armature flux linkage \ and loading. \ is set, for maximum utilization of the
magnetic circuit, by the excitation current ie or is controlled in the field-weakening range to the
maximum armature voltage uaw.
The object of the machine control system is to determine and generate the reference values for
all currents with the aim of obtaining the same operating conditions as with the d.c. machine:
-The reference excitation current value iew ensures that the machine flux is independent of the
load.
-The reference stator currents iRw, iSw, iTw form a three-phase system, the amplitude of which is
given by the speed controller for setting the drive torque direct.
In the synchronous machine too, the torque is the vectorial product of the stator current and the
resultant stator flux linkage. To obtain a torque which is proportional to the amplitude of the three
–phase system, the phase position and frequency of the reference values must be calculated
such that, at that moment in the machine, the vector of the linear current density of the stator I
with the reference length iw is perpendicular to the rotating vector of the resultant stator flux
linkage \ (or “machine flux”).
Correct calculation of the reference current values presupposes that, for \, the length of the
vector and its relative position (angle) to the stator winding are known. The possibility of direct
measurement of the air-gap flux can be eliminated, since this would require changes to the
machine design. Indirect methods such as integration of the stator terminal voltages can also be
disregarded. These methods cannot be used since they are subject to error at low speeds and
standstill.
ABB use a model of the machine flux \ as the heart of their machine control system.

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2.7 Static Flux Model
The electro-magnetic behaviour of the synchronous motor in operation becomes particularly clear
when considered in relation to the rotor. The excitation flux points always in the direction of the
rotor or d axis, irrespective of whether the motor is at standstill or rotating. If the stator current
vector I rotates at the same speed Z as the rotor, the vectors of the currents and fluxes present a
stationary picture with fixed angles. This is the vector diagram of the synchronous machine in
rotor coordinates (Fig. 4b).
Fig. 4 – Circuit and vector diagrams

a: DC machine b: Synchronous machine
La = Inductance of armature winding c = Winding axis of stator phase R
Le = Inductance of excitation winding LS = Synchronous inductance
Lk = Inductance of compensating winding
a = Exciter axis
b = Brush axis
Explanation of indices:
w = Reference value q = Quantity in the quadrature axis
x = Actual value
d = Quantity in the direct axis

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Since there is no compensating winding in the synchronous machine, that machine flux \ is load-
dependent due to the stator reaction “Ls x I” . If the stator current vector “I” with length I is
perpendicular to the machine flux \ , load angle - is produced as the result of angle rotation
between the rotor axis and \.
Ls x I
- arctan
\
(2)
To obtain the total angle D between the stator current vector I and the fixed winding axis of the
stator, the angle H of the mechanical rotor position need only be added to the angles of the vector
diagram.
The reference stator current values are determined electronically by means of two matrices, each
circuit formed by multipliers and adders. An initial rotation of - + S/2 is controlled by a
characteristic, taking equation (2) into account, while a second rotation is controlled by a
transmitter which measures the angle H using opto-electronics or flux calculation to determine the
rotor position.
The basic structures of the three block diagrams indicate agreement. The only difference lies in
the functional unit for machine control, which determines the reference current values and
transmits them to the current controllers for excitation and to the armature or stator.
The formation of a load angle between the machine flux \ and the excitation flux \e cannot be
avoided in the synchronous machine. However, if the reference value for the excitation current is
given in advance with the aid of the geometric relationship
iew a <e where :
\e \ 2 Ls 2 I 2
(3)
the point of the machine flux vector \ moves in a circle. Except for operating ranges with
selected field weakening the machine flux therefore remains constant in magnitude.
With this type of machine control the synchronous motor exhibits a new operating behaviour
which can no longer be compared with operation on an infinite bus. The controlled cycloconverter
acts as a commutator, the linear current density of the stator is linked direct to the position of the
rotor and oscillations can no longer occur. When the linear current density and machine flux
vectors are perpendicular to each other, the currents and terminal voltages are in phase and the
synchronous machine runs with a power factor of cosM2 = 1. As with the armature converter of
the d.c. machine, the cycloconverter needs only to be dimensioned for the active power of the
drive. The synchronous motor draws reactive power via the excitation system alone.
The model of the synchronous machine, which is based on the described machine control, is
restricted to steady-state operating points. The machine condition is calculated in advance from
the reference load iw. Good control results can only be achieved when the speed control circuit
requires slow changes in load. This is the case for continuously operated, heavy machines such
as those red in tube mills.
The static model, however, is inadequate for highly dynamic drives requiring, for example,
sudden torque reversal, During transient conditions, simulation of the machine flux is poor. At

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higher converter frequencies, the current control circuits are no longer able to make the machine
carry the currents with the required accuracy without support from the model.
2.8 Dynamic Flux Model
The model arrangement is based on the flux-linkage equations for the direct axis and quadrature
axis of the synchronous machine.
When the machine data are known the actual state of the flux linkages \d and \q can be
determined direct from the reactance and the measured currents.
The actual value of the excitation current iex is transmitted direct to the flux model. The stator
current vector is obtained in rotor coordinates using the same method - a means already used
calculate the reference value. A matrix controlled by a rotor position transmitter enables the
three-phase system of the stator iRx, iSx, iTx, to be broken down into its components id (in the
direction of the rotor poles) and iq ( at right angles to this).
The damper winding currents still missing cannot be measured on a normal motor. For each axis
the flux model solves a differential equation, which simulates the currents of the damper winding
in the direct axis and quadrature axis from the remaining quantities. The flux model therefore
requires no additional points for measurement.
All information required for correct calculation of the reference current values is available at the
model outputs. When sudden load jumps occur, the stator current vector remains perpendicular
to the momentary vector of the resultant stator flux linkage. It is only when the compensating
currents in the damper windings are decaying that the load angle changes and guides the stator
current vector to the new steady-state angular position.
The excitation current can only be used to influence the flux linkage \d of the direct axis. \d
must always be added vectorially to the momentary flux linkage \q in the quadrature axis to
obtain a constant resultant stator flux linkage \ = \w.
\d \ w 2 \ q 2
Taking into account the instantaneous stator reaction, the reference excitation current iew is
calculated such that the flux of the direct axis attains the required value \dw.
Machine control with the dynamic flux model has the advantage that the control objectives are
achieved and adhered to already during transient machine conditions. From the very beginning
the torque area has the form of a right-angle when load surges occur and the excitation current
suppresses the effect of stator reaction on the resultant stator flux linkage with optimum speed,
without initiating any form of compensation itself.

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2.9 Current Control Circuit
The control objectives defined by the machine control system can only be adhered to when the
stator and excitation currents attain their reference values rapidly and without error.
I\I = Resultant stator flux linkage

MG = Air-gap torque
iR, iS, iT = Stator current
uT = Frequency converter phase voltage
Index w = Reference value
Index x = Actual value
When the dynamic flux model is used for control, the excitation current controller considers the
excitation winding as being more or less as passive load. A conventional solution with a PI-
controlled three-phase bridge on therefore be used for the exciter supply.
The current controllers of the cycloconverter phases operate under adverse conditions with the
currents having to follow an alternating signal. In addition, alternating voltages are induced in the
stator which act on the control system as dynamic disturbance quantities already during steady-
state operation.
Selective control interventions in the converter are required to relieve the controller. The
switching logic guarantees short intervals without current when changeover takes place between
the bridges with negative and positive current direction, and an adapter ensures smooth current
build-up after pulse release.
The effect of the induced machine voltages on the control result is suppressed by connecting an
additional voltage. The machine control system with the dynamic flux model calculates from the
vector of the resultant stator flux linkage and the machine speed nx the rotationally induced
voltages of the stator uhR, uhS, uhT. The three-phase bridges are controlled such that the
converter and machine voltages are balanced in the steady state. The controller only needs to
intervene to correct faults caused by an inaccurate additional voltage and to vary the state of the
machine’s magnetization when the load changes.

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2.10 Trapezoidal Mode
In the trapezoidal mode, one three-phase bridge is always operated at the full firing angle.
Reserve control potential is therefore available in the two remaining cycloconverter phases. A
balancing network between the control voltages ensures that intervention by the controllers and
additional voltages in the three-phase voltage system of the cycloconverter is still retained even
in this mode. Since there is no star-point connection between the cycloconverter and the
machine, the unrestricted three-phase bridges can combine the voltages between the phases to
form a sinusoidal system.
The machine voltages may exceed the available converter voltage by 15% without losing control
over the stator currents.
In the field-weakening range, the machine voltage is held exactly at this value. However, the
excitation current controller does not, as in the case of a d.c. motor, follow a voltage regulation
system, but receives via a “trapezoidal controller”, a reference correction value such that at least
one converter is operating at its full firing angle. However, excitation decreases as long as more
than one converter phase is in its end position. The trapezoidal shape and reliable control of the
current are retained irrespective of the supply voltage.
2.11 Specific System Features
The cycloconverter –fed synchronous machine corresponds, similar to the d.c. drive fed by a
reversible converter, to a genuine four-quadrant drive. As does the armature of the d.c. machine,
the stator of the synchronous motor receives only active power, so that the machine power factor
is equal to unity at all operating points. The possible frequency range spans 0 to approx. 50% of
the mains frequency. The required maximum speed is obtained from the maximum frequency
which can be set within this range can also be accommodated to optimize matching of the drive
to the load.
Even very low speeds down to n ~ 0 can be controlled without any problem, since the
cycloconverter-fed synchronous motor generates no torque pulsations of any consequence. No
additional equipment is therefore necessary for operation at the crawling speed and for
positioning.
The synchronous machine is not, as in the case of the d.c. machine, subject to the restrictions
imposed by a commutator. At standstill it is therefore possible to attain and hold very high
torques. High breakaway torques can be overcome. When running up to the operating speed, the
frequency of the synchronous machine is set by its own control system. The machine is therefore
synchronized during run-up, requiring from the mains a current which corresponds to the load
and acceleration torque only and not, as in the case of an asynchronous run-up, a multiple of the
rated current.
Since the machine controls itself, torque overloads do not cause the synchronous machine to fall
out of step. As with the d.c. drive, only the speed decreases when the load torque is too high.
The machine, however, remains synchronized.

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2.12 Network Reactions
2.12.1 Power Factor
Since the cycloconverter is line-commutated, it receives its reactive power for both control and
commutation from the three-phase power system. In respect of the network power factor, its
behaviour is similar to that of the converter-fed d.c. drive. When running up from standstill the
power factor is very low. The mean power factor cos, at the mains end depends not only upon
the firing angle of the cycloconverter but also upon the actual machine power factor cos2. The
maximum values are obtained in the trapezoidal mode with the synchronous machine controlled
to cos2 = 1. General these values apply at rated frequency and voltage and are therefore also
in the field-weakening range of cos1 = 0.72-0.84.
2.12.2 Harmonic Currents
The cycloconverter-fed synchronous motor causes harmonic currents in the mains in the same
way as with the converter-fed d.c. motor. Since the static converters of the three-phase
cycloconverter also operate in steady-state mode with a firing angle which varies continuously,
not only the known mains harmonic currents applying to the classical converter system occur, but
also the side-bands resulting from the output frequency f2 of the cycloconverter. The ideal three-
phase cycloconverter generates mains harmonic currents with the following ordinal numbers:
f2
v kp r 1 r 6 n
f1
where:
v = Ordinal number of the harmonic
k = 1, 2, 3, etc.
p = Pulse number of the static converter circuit
n = 0, 1, 2, 3, etc.
f1 = Mains frequency
f2 = Output frequency of the cycloconverter
The magnitude of the individual harmonic currents depends largely upon the firing angle of the
cycloconverter, and different values are obtained for operation in sinusoidal mode in the start-up
range and in trapezoidal mode at high speeds. Nevertheless, the amplitudes attained are never
as high as those with a converter-fed D.C. motor of comparable rating, irrespective of the
operating conditions.

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3. System Design
3.1 Design datas
Overview Diagram
UL(e) UL, duL, fL, SCL
ST(e) ST ST ST
exT(e) exT exT exT
Uv0(e) Uv0 Uv0 Uv0

Iv(e) Iv Iv Iv
UM, IM, fM PM
n
Uf, If
MAIN DATA
SUPPLY
line voltage UL [V] 33’000
line-voltage variation 'uL [%] ± 10
line frequency fL [Hz] 50
line- frequency variation 'fL [Hz] ±3
min. short-circuit power SCmin [MVA] 387
max. short-circuit power SCmax [MVA] 856
CONVERTER TRANSFORMER (3 x three-winding transformer) cont.

(5 x 30 s/h) operation
rated power (acc. to IEC 61378-1) SR [kVA] 7374 / 2 x 3687
rated transformer input voltage UL [V] 33’000
rated converter no-load voltage Uv0 [V] 2 x 1155
rated transformer output current (fund.) I1S [ARMS] 2371 1843
short-circuit impedance ex [%] 13
vector group D d0 y1

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CONVERTER (5 x 30 s/h) rating

converter input current (incl. harmonics) Iv [ARMS] 2483 1930
type of converter 12-pulse VERITHYR WX M for MEGADRIVE-CYCLO
type of thyristor 72 x 3BHB010085 (4" / 5200 V)
series connection of thyristors ns 1
cooling water-cooled type
max. raw-water intake temperature Tin [°C] 15
max. ambient temperature Ta [°C] (e-room) 40
Remark: the Andina site is situated on 3200 m a.s.l.
MOTOR
Stator rating max. values rating
(uL = 90 %)
output power PM1 [kW] 13’050 13’050
voltage UM1 [V] 3384 3760
current (fund.) IM1 [A] 2363 2127
frequency fM1 [Hz] 5.56 5.56
rated speed / max. speed n1 / nmax [rpm] 11.92 / 12.3 11.92 / 12.3
creeping speed nc [rpm] 0.3
inching speed ni [rpm] 1.0
Overload
motor starting current (1.43 p.u.) IM,start [Arms] (5 x 30 s per hour) 3041
STATIC EXCITATION
EXCITATION TRANSFORMER (5 x 30 s per hour) rating
rated power (acc. to IEC 61378-1) SR(e) [kVA] 370
excitation transformer input voltage UL(e) [V] 4160 (±10)
rated transformer no-load voltage Uv0(e) [V] 575
rated transformer output current (fund.) I1S(e) [Arms] 413 372
short-circuit impedance exT(e) [%] 4
EXCITATION RECTIFIER (5 x 30 s per hour) rating

output voltage rating Uout [VDC] 777
output current rating Iout [ADC] 530 415
MOTOR EXCITATION max. values rating

excitation voltage Uf [VDC] 490 385
excitation current If [ADC] 530 415

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Motor Voltage and Current

as a Function of Line-Voltage Variations
4000 3000
3800 duL > +0% 2900

3760 V
3600 2800
duL = -10%
3400 3384 V 2700
motor
voltage
motor voltage [V]
3200 2600
motor current [A]

3000 2500
2800 2400
duL = -10%
2363 A
2600 2300
2400 motor 2200

current duL > +0%
2127 A
2200 2100
constant torque constant power
n < 11.92 rpm 11.92 rpm < n < 12.3 rpm
2000 2000
8 9 10 11 12 13
motor speed [rpm]
Note:
motor starting current (1.43 p.u.) IM,start [Arms] (5 x 30 s per hour) 3041

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Maximum Inverter Firing Angle versus Load Current
160
154.4 deg
150
140
firing angle [deg]
130
120
110
100
97.2 deg
90
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Current [p.u] (Note: 1 p.u. refers to 100% rated current)
PROTECTIVE SETTINGS
Converter input current

converter input current limit Iv,peak [Apeak] 4850
converter overcurrent setting Ipeak,max [Apeak] 5700
I*t Protection
current limit Ilimit [Apeak] 3100
duration of the delayed

overcurrent release W [s] 10

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3.2 System Overview

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3.2.1 General Description of the Converter Cubicle
The converter-cubicle described in these instructions consists of two parts:
- the converter
- the mechanical part which includes the cooling unit, all auxiliary and protection accessories
Sub-Cubicles and components, which are labeled with ‘+F…’ and which are built-into the container
are listed in the table below (refer also to the cabinet overview layout 3BHS235452 page 29)
+F Cubicle No. Designation

+F01 Control Excitation Cubicle
+F02 Cycloconverter Control Cubicle (PSR Controller)
+F03 Process Control (ABB PLC)
+F04 Video Monitoring System
+F05 … +F09 Motor Control Center Panels
+ UPS UPS*
+ MLCP Motor Local Control Panel
+F14 Fire fighting system*
+F15 Cycloconverter Recooling system
+F16 Transformer Protection Panel
+F17 Lighting panel
+AC1 Air Conditioner 1*
+AC2 Air Conditioner 2*
+CA, +CB, +CC Cycloconverter Power Part
*Note: The constructional design as well as the function and operation of fields marked ()* are shown
in separate operating instructions.
The complete container (E-House) is an accessible enclosure which has the converter and all
accessories built-in to it.
The converter power section is water-cooled.
The container is air-conditioned.
For fire-fighting purpose an automatic fixed extinguishing system (HFC-227ea heptafluoropropane) is

installed. Additional the portable fire extinguishers are located closed to the main doors.
See Block diagram 3BHS 235451

See Single line Power part 3BHS235450 page 21
See MCC-Single Line / Low voltage distribution 1TCH110006 page 22
All ringmotor and mill auxiliary drives are controlled by the ABB PLC.

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4. OPERATION
4.1 Safety Instructions
!
Heart Pacemaker
The converter can influence the working of heart pacemakers. Be sure you have installed the safety
sign (part of the delivery) at a minimum distance of 6000 mm / 20 feet!
High Voltage
Danger
Always close the doors at normal operation!
1. High voltage in the incoming cubicle (+CA, +CB, +CC)!

2. Never remove the protecting shields.
3. Before you attempt any converter maintenance task:
- switch off the converter
- disconnect the converter from the main power supply
- take steps against unintentional energizing
- check that HV has disappeared
- be sure the converter is disconnected from all machine side power supplies.
4. Be sure there is no high voltage at the incoming bars of +CA,+CB,+CC (line side) and at the
outgoing bars of +CA, +CB, +CC (machine side) before you attempt any earth connection.
5. Connect the incoming bars of +CA,+CB,+CC (line side) to earth according the User’s Manual
3BHS246003 instructions.
6. Connect the outgoing bars of +CA,+CB,+CC (machine side U,V,W) to earth according the
User’s Manual instructions (mentioned above).

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Low Voltage
Danger
Always low voltage (380 VAC, 230 VAC and 120 VAC) applied, if you disconnect the converter from
the main power supply.
Observe all local safety rules and regulations!
!
High temperature
Danger of burning
Always high temperature at bars, reactors and heaters.

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4.2 Why You Should Read this Chapter
For your own safety read this chapter carefully before starting the converter.
In this chapter you will learn about the converter module's features and its control. You will find useful
information on how to locate and operate its features and controls. Knowing what the converter
signals and pushbuttons indicate will help you to correct little problems before they become big
problems.
Do not hesitate to call your local ABB service organisation if any question arises. Pay special
attention to all safety instructions

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4.3 Operation Instructions
4.3.1 Reasonable Use
The converter is intended to drive a Ball Mill grinding machine, it is designed for continuous operation
and shall not be combined with other drives.
Expected lifetime: 10 years

Operation cycle: continuous
Note: The expected lifetime of the Variable Speed Drive System (VSDS) is defined as the time during
which the VSDS will remain suitable for the application for which it was made, provided that it is used,
regularly inspected and serviced in accordance with the manufacturer’s instructions, and provided
that lubricants and parts, which are subject to mechanical wear, are replaced regularly.
The converter shall be installed in a protected environment intended for medium voltage equipment.
Access shall only be allowed to authorized personnel.
Be sure that all converter doors are accessible. Never install anything inside or outside to the
converter block. Never cover it for protection grids. Opening the doors to the cubicles +CA, +CB,
+CC, or F01 (Excitation Converter) will cause a trip to the external main circuit breakers.
Pay attention to always fulfill the following environmental conditions for properly operating the
converter:
Air temperature: +5°C... +40°C

Cooling air quality: free of particles (e.g. coal, iron, sand ...)
Relative air humidity: 5 ... 85 % (without condensation)
Raw water temperature and quality: min >= 5 °C, max. 30 °C, drinking water, ph-neutral
The minimum requirements for stationary use are defined on the basis of IEC 721-3-3 'Classification
of environmental conditions; Part 3: Classification of groups of environmental parameters and their
severities; stationary use at weather protected locations'.
Classification: 3K3 / 3Z2 / 3B1 / 3C1R / 3S1 / 3M1

Microclimatic class: X2 / Y1

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4.3.2 Plant / Converter Interface
The converter operates as an integral part of the plant. The converter is normally remotely controlled
in normal operation by the central control room. The local control of the converter by the use of the
converter control system is possible for maintenance, tests and commissioning. The main control
system initiates the start-up process of the converter.
Local control of the drive is only possible, if the DCS gives the local release.
(please check chapter 4.4 Motor Local Control Panel”).
The converter supplies the synchronous machine with voltage and current of variable frequency
causing it to accelerate from standstill to the preselected speed.
DCS
see I/O Signal List
VMS
OperatelT Modbus
serial communication
Modbus
PLC PSR
Ethernet see PLC-PSR Signal List
OPC
Profibus
I/O
see I/O Signal List
The standard interface signals with the remote control system are transferred via serial data link (e.g.
Profibus, Modbus) from the ABB PLC (inside cubicle +F03) to the DCS, see DCS signal list (inside
the I/O Signal List).

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4.3.3 Converter Local Control Panel
The control panel indicates different operating conditions, the information displayed can be used for
controlling and testing the converter. The control panel is connected to the ABB Drive Controller.
Control Panel – (Location +F02.K01 – Tier1)
ABB
.
01 Speed Setpoint
20 . 40 . 60 80 . 100%
... RPM
02 Actual Speed ... RPM

. 20 . 40 . 60 80 . 100%
04 Excitation Current ... A

. 20 . 40 . 60 80 . 100%
05 Motor Voltage ... V

. 20 . 40 . 60 80 . 100%
123 #
SELECC
AUXILIAR. INTERRU. PARTIDA MAS PRUEBA
ADELANTE METER CENTRAL
ON MV - ON MOLINO RAPIDO LUCES
INDICAT.
SELECC
AUXILIAR. INTERRU. DETENC. MAS PANEL SALA
REVERSA PRUEBA
OFF MV - OFF MOLINO LENTO LOCAL E-HOUSE
PROGRAM.
1. Control Panel
The control panel consists of the following display, signal and control elements (for detailed
description see below point 2 and 3) :
a) display with 8 lines and 40 characters per line to indicate:

- 8 (of max. 152) fault messages with error number and description; the first failure always
appears in the first line (plain-language fault message mode)
- 8 (of max. 64) analog values with channel number, signal name, value and physical unit
(analog display mode)
- 4 (of max. 64) analog values with channel number, signal name, value, physical unit and an
analog bar display of 0-120% (bar mode)
b) 6 control pushbuttons and 4 combined feed-back and control pushbuttons (each equipped with a
LED) for controlling the operation mode and the functions of the display
c) 16 feed-back and control pushbuttons (each equipped with a LED) for specific converter
functions

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2. Feed-back and Control Pushbuttons for the Display Control
The following feedback and control pushbuttons serve to control the operation mode and the
functions of the display:
123
Analog Display Button
Press this button to indicate numerical values in physical units of 8 plant parameters
(analog variables) together with the channel numbers and signal name in plain language.
Select following values by the scroll button. The yellow LED is on.
Bar Display Button

Press this button to indicate 4 plant parameters as above, each with an additional bar
display having a scale 0 ... 120%. Select following values by the scroll button. The yellow
LED is on.
Trip/Alarm Button
By pressing this button or when a fault occurs the display changes automatically to the
fault message mode indicating 8 plain-language fault messages (intermittent red light at
the LED). The first fault appears on the first line and any evolving fault(s) on the following
lines. Press the scroll button to indicate additional fault messages. The messages remain
in the memory (even if the supply fails) until they are deleted by pressing the reset button
(see below).
Reset Button
Touch slightly the button for less than 1 second to reset alarms.
Press this button for more than 1 second to reset trips and first faults.
The red LED at the trip/alarm button will be off.
Note: The red LED at the trip/alarm button changes from blinking to continuous light if
you press the reset button before the fault has been removed.
Printer Key (Option)

Note: Ask your local ABB service organisation if you would like to connect a printer to the
control panel.
Printer installed: By pressing the printer key the analog signals of lines 1...8 are sent to
the optional printer via the serial interface RS-232. If error messages are present they are
also sent to the printer. The yellow LED is only active during data transfer and printer
ready mode. It starts blinking if the printer buffer is full.

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The following control pushbuttons serve to move within the display information:
# Cursor Button
The line to be edited is selected using the cursor button. The button is only active when
displaying analog variables with or without the bar display.
Scroll Buttons
The function of the scroll buttons depends on the display mode.
In the analog and bar display mode the selected line jumps to the next or the preceding
analog variable (line by line scrolling).
In the faults display mode lines 2 to 8 are all shifted up respectively down one position.
The first line does not change and always indicates the first fault.
Page Buttons
The page buttons are similar to the scroll buttons (see above) with the exception that they
scroll 10 lines at a time.

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3. Feed-back and Control Pushbuttons for the Converter Control
The converter is controlled remotely from the control room. Local control is only possible if the drive is
preselected to “LOCAL” operation mode (see chapter “MOTOR LOCAL CONTROL PANEL). The
following control functions are available:
‘Auxiliaries On’ Feedback Signal and Button

Auxiliaries Press this button to start the auxiliaries.
ON LED Off: the auxiliaries are off
LED blinking: the auxiliaries are in the ON sequence
LED On: the auxiliaries are on
‘Auxiliaries Off’’ Feedback Signal and Button

Auxiliaries Press this button to stop the auxiliaries.
OFF LED Off: the auxiliaries are on
LED blinking: the auxiliaries are in the OFF sequence
LED On: the auxiliaries are off
MAIN ‘Main Breaker ON’ Feedback Signal and Button
BREAKER Press this button to switch on the stator and rotor main circuit breakers
ON
LED Off: Main breakers off
LED On: Main breakers stator and rotor on
LED blinking: Main breakers stator on
‘Main Breaker OFF’ Feedback Signal and Button
MAIN
BREAKER Press this button to switch off the stator and rotor main circuit breaker
OFF LED Off: Main breakers stator and rotor on
LED On: Main breakers off
MILL ‘Mill Start’ Feedback Signal and Button

START Press this button to start the mill, the mill will turn with the preselected
minimum speed (Thyristor pulse release).
LED Off: Mill stop
LED On: Mill start / running
MILL
‘Mill Stop’ Feedback Signal and Button
STOP Press this button to stop the mill, the mill will stop with an activated
electrical break, end of the elec.break sequence pulse blocking.
LED Off: Mill running
LED blinking: the mill electrical break acting
LED On: Mill stopped, thyristor pulse blocking
‘Faster’ Feedback Signal and Button

FASTER Press this button to increase the speed of the mill.
LED Off: command not activated
LED On: speed increase
‘Slower’ Feedback Signal and Button

SLOWER Press this button to decrease the speed of the mill.
LED On: speed decrease

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‘Forward’ Feedback Signal and Button

FORWARD Press this button to select the direction of rotation of the mill, selection
only possible if the drive is not running.
LED On: forward selected
‘Reverse’ Feedback Signal and Button

REVERSE Press this button to select the direction of rotation of the mill, selection
only possible if the drive is not running.
LED On: reverse selected
SELECT
‘Select Meter Indication’ Button
METER Press this button to select different analog signals at the meter 340P7.
INDICAT. The analog signals are internal regulation signals, only for service and
commissioning purpose.
‘Select Testprogram’ Button

SELECT Note: Press this button to select between different test modes (total 6 test
TESTPRO. modes are available, caution only for service and commissioning
engineers). The button is only active if the drive is in ‘Local’ & ‘Service’
mode The selected mode Nr. will be indicated at the display screen.
‘Lamp Test’ Feedback Signal and Button

LAMP Press this button to check all LEDs at the converter control panel. While
TEST
pressing the button the LED will light continuously.
‘Motor Local Control Box’ Feedback Signal

MLCP LED Off: other control mode
LED On: the drive will be controlled from the MLCP
‘Central Process Control System’ Feedback Signal

DSC LED Off: other control mode
CENTRAL
LED On: the drive will be controlled from the DCS
‘E-House’ Feedback Signal

E-HOUSE LED Off: other control mode
LED On: the drive will be controlled from the E-House

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4. Emergency Off
The emergency off pushbutton inside the E-House and on the MLCP are specially designed for
emergency situations. If you press this button
a) The converter (*and the auxiliaries) are switched off;

b) The main circuit breakers (stator and rotor) open immediately.
c) Brakes are applied
* depending on the plant control philosophy

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4.3.4 Faults and RESET Function
Different alarm and trip signals indicate faults or malfunctions of the converter and the system
components. These faults are classified as follows (detailed description see below):
1. General faults
2. Hardware protection faults
3. Excitation controller faults
4. Thyristor monitoring faults
! Important: Write down in form 1 (see paragraph 8.6 of this manual) what has happened
and which fault is indicated before you press the reset button and before you
start any repair work.
! Important: Any repair work has to be done only by specially trained personnel.
1. General Faults
These faults are indicated at the converter control panel (+F02) by
a) the common alarm or trip LED on the trip/alarm button is blinking

b) one or several fault message(s) on the panel display describes the fault by indicating the fault
number, the trip (F) or alarm (W) sign and the message text.
To reset the trip or alarm status press the reset button on the converter control panel as
follows:
- Briefly press (less than 1 second) the reset button to reset all alarms. Note: The first fault remains
on the converter control display.
- Press (for more than 1 second) the reset button to reset all trips and the first fault.
The converter control display indicates 8 fault messages at the same time (first message = first fault).
Press or for scrolling to show additional faults.
2. Hardware Protection Faults
The supervision for following equipment is realized in the ABB PLC:

- cycloconverter transformers
- excitation transformer
- ringmotor auxiliaries
- knife switches
- MCC
- lube & brake
- air condition
- fire fighting system
- UPS
All cycloconverter supervisions are detected and supervised by the PSR-system. In addition to this
supervision there is a hardware electronics provided with two prints (CS A463, CS A465). Hereby a
safe and controlled switching-off sequence is ensured even in case of failing of the PSR Drive
Controller, or any periphery device.

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In this safety unit the following signals are supervised:

- stator currents ixR, ixS, ixT (card CSA463)
- PSR processor boards and peripherical devices (card CSA465)
These faults deriving from the protection PCB's CS A463 and CS A465 (placed in the standard
control rack Tier 6) are indicated at the converter control panel (+F02.K01) and at the PCB by :

b) the fault message no. 49 (“49 F: Hardware Overcurrent I>>,CSA463”) or message no.93 (“93 F:
PSR Print boards failure, CSA465”) appears on the panel display
c) the fault indicated by a LED on the PCB
To reset the trip status press the reset button on the PCB CS A463 and/or CS A465 in addition to the
reset button at the converter control panel (see above point 1).
3. Excitation Controller Faults
These faults deriving from the excitation controller (+F01) are indicated at the converter control panel
and at the controller component as follows:

b) the fault message no. 58 (‘58 F: Excitation Converter DCF600 ’) appears on the panel display
c) the fault number (e.g. ‘F07’) of the first fault is blinking at the excitation controller display; to
indicate any further or resulting fault press the UP pushbutton at the excitation converter panel.
4. Thyristor monitoring faults
These faults deriving from the thyristor monitoring unit (+F02.K01, Tier 8) are indicated at the
converter module control panel and at the monitoring unit as follows:

b) the fault message no. 47 (‘47 F: Thyristor Failure’) appears on the panel display
c) the location of the faulty thyristor is indicated on the thyristor monitoring print boards (see chapter
6 Thyristor Supervision)
To reset the trip status press the RESET button at the thyristor monitoring display in addition to the
acknowledge button at the converter module control panel (see above point 1).

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5. List of Fault Messages

(monitored at the Drive Control panel)
! Important: 1. The converter faults and malfunctions and the result (F = trip / W = alarm)
are indicated at the converter control display (+F02.K01) and Local Control
panel MLCP.
Note: The first fault always appears on the first line and any evolving faults
on the following lines.
2. If the display has no light check the low voltage supply. If there are no
messages on the display the control panel has a defect. Replace the panel,
if necessary.
Fault Function / Text on display Fault Possible Cause Action & Remarks
No.
01 "F: Overcurrent detection Cycloc. Overcurrent in a) broken thyristor -Check thyristors phase R –(+CA)
Bridge RA" phase RA b) motor overloaded -Check load level
c) short circuit stator - megger stator power cables
d) network power failure
02 "F: Overcurrent detection Cycloc. Overcurrent in Check thyristors phase R (+CA)
dto..
Bridge RB" phase RB
03 “F: Overcurrent detection Cycloc. Overcurrent in Check thyristors phase S (+CB)
dto..
Bridge SA” phase SA
04 “F: Overcurrent detection Cycloc. Overcurrent in Check thyristors phase S (+CB)
dto..
Bridge SB” phase SB
05 “F: Overcurrent detection Cycloc. Overcurrent in Check thyristors phase T (+CC)
dto..
Bridge TA” phase TA
06 “F: Overcurrent detection Cycloc. Overcurrent in Check thyristors phase T (+CC)
dto..
Bridge TB” phase TB
07 “F: Thermal overload (I*t) Thermal overload of a) speed too low Check mill load respectively decrease load
Phase R” Motor phase R b) motor overloaded
c) motor blocked
d) too low starting torque
08 “F: Thermal overload (I*t) Thermal overload of
dto..
Phase S” Motor phase S
09 “F: Thermal overload (I*t) Thermal overload of
dto..
Phase T” Motor phase T
10 “F: Excitation overcurrent” Overcurrent in the rotor a) broken thyristor DCF600 check excitation converter
circuit of the ringmotor b) short circuit of the rotor megger motor power cables
power cables check brushes of motor
c) motor overloaded or check load level
blocked Notice
Run test program only if you have passed the
ABB additional training.
In all other cases contact your local ABB
service organisation.

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11 “F: Excitation undercurrent“ Current too low in the a) cable broken - Check cable
rotor circuit of the b) excitation converter not - Check release signal from PSR
ringmotor released - Check DCF600
c) Failure in the excitation Notice
supply circuit Run test program only if you have passed the
ABB additional training.
In all other cases contact your local ABB
service organisation.
12 “F: 22.9kV Line overvoltage” Line voltage too high a) voltage dip Check network
(>110%for 50ms) b) lightning or voltage
increase beyond the
allowed level in the
external power network
13 “F: 22.9kV Line undervoltage Line voltage too low a) main circuit breaker not Check network
“ (<85% for 20ms) closed or tripped
b) network voltage drop
14 “F: 22.9 kV Breaker No feedback signal from a) circuit breaker did not Check circuit breaker and cabling
Feedback missing” the 22.9kV main circuit close after the ON
breaker command
15 “F: 22.9 kV Stator Circuit 22.9kV main circuit a) line overcurrent check motor load
Breaker Trip” breaker tripped b) motor overload check relay settings
c) short circuit
16 “F: Rotor Circuit Breaker rotor circuit breaker a) line overcurrent check relay settings
Trip” tripped b) motor overload
c) short circuit
17 “F: Pulse Amplifier-R1A Pulse amplifier fault a) Print board hardware Change print board
(LT8978) +21” fault
18 “F: Pulse Amplifier-R1B dto. dto. dto.
(LT8978) +25”
19 “F: Pulse Amplifier-R2A dto. dto. dto.
(LT8978) +45”
20 “F: Pulse Amplifier-R2B dto. dto. dto.
(LT8978) +49”
21 “F: Pulse Amplifier-S1A dto. dto. dto.
(LT8978) +29”
22 “F: Pulse Amplifier-S1B dto. dto. dto.
(LT8978) +33”
23 “F: Pulse Amplifier-S2A dto. dto. dto.
(LT8978) +53”
24 “F: Pulse Amplifier-S2B dto. dto. dto.
(LT8978) +57”
25 “F: Pulse Amplifier-T1A dto. dto. dto.
(LT8978) +37”
26 “F: Pulse Amplifier-T1B dto. dto. dto.
(LT8978) +41”
27 “F: Pulse Amplifier-T2A dto. dto. dto.
(LT8978) +61”
28 “F: Pulse Amplifier-T2B dto. dto. dto.
(LT8978) +65”
29 “F: 24 VDC Power Supply 24 Vdc power supply 304 a) 24VDC power supply - Check power supply replace if necessary
(-304U2)” U2 for PSR Control with fault - Check auxiliary voltage
no voltage output b) AC circuit breaker off For replacement switch off auxil. supply voltage

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30 "F: Power Supply 48VDC (- 48VDC power supply (- a) 48VDC power supply - Check power supply (-304U6) replace if
304U6) " 304V6) for pulse fault necessary
amplifiers tripped b) Failure in the output - Check cabling relay
Relay Power supply - Check auxiliary voltage
c) AC circuit breaker off For replacement switch off auxil. supply voltage
31 "F: Arcnet Communication Communication disturbed a) ArcNet node Check ArcNet connections and restart ArcNet
Error" between PSR, converter disconnected devices by switching DC supply off and on
control panel and field b) fault on device at ArcNet Notice
bus coupler a) power supply for ArcNet If the fault remains after 2 to 3 restarts contact
node not sufficient your local ABB service organisation.
d) communication time-out
e) software fault
32 "F: Error MB-Coupler Fault at the print board a) Hardware error at the -Replace print board
PMA324 (+F02)" PMA324 (Tier 4) or print board ir converter -Check Connections
converter 232/485 232/485 For replacement switch off auxil. supply voltage
33 “F: Line Overvoltage Input network a) Surge voltage in the - Check the network.
arresters R” overvoltage. network. - Check the fuses cycloconverter at phase
b) Lightning. R (F121,F122,F123, F221,F222,F223 )
c) Voltage dip.
d) On/Off switchgear for
capacitor bank.
34 "F: Auxiliaries stop when mill Auxiliaries fault while mill a) Problem with lubrication - Check in the VMS for some abnormal situation
is running" was running pumps. with the auxiliaries: lubrication system, brake
b) E-Stop pressed. system or ringmotor cooling fans.
c) Brake System Fault.
35 “F: Cycloconverter Auxiliary Short circuit at basic load a) Short circuit to earth for - Check the fuse F301, F302 at phase R.
Fuses R” of phase R. capacitor C301. - Check the basic load.
36 “F: Motor Overvoltage Output motor voltage too a) Network lost - Check thyristors of overvoltage arrester in
arrester phase U” high. b) Result of motor phase U.
overcurrent
37 “F: Motor star point fuse” Overcurrent at star point. a) Unbalanced current. - Check ring motor.
- Check the fuse at F303.
arresters S” overvoltage. network. - Check the fuse at phase S (F121,F122,F123,
b) Lightning. F221,F222,F223)
c) Voltage dip.
capacitor bank.
39 “no message stored”
40 “F: Cycloconverter Auxiliary Short circuit at basic load a) Short circuit to earth for - Check the fuse F301, F302 at phase S.
Fuses S” of phase S. capacitor C301. - Check the basic load.
arrester phase V” high. b) Result of motor phase V.
overcurrent
arresters T” overvoltage. network. - Check the fuse at phase T (F121,F122,F123,
b) Lightning. F221,F222,F223)
c) Voltage dip.
capacitor bank.
44 “F: Cycloconverter Auxiliary Short circuit at basic load a) Short circuit to earth for - Check the fuse F301, F302 at phase T.
Fuses T” of phase T. capacitor C301. - Check the basic load.

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arrester phase W” high. b) Result of motor phase W.
overcurrent
46 “F: Rotor Feedback missing” No feedback signal from a) Circuit breaker did not - Check circuit breaker of rotor and cable.
circuit breaker of rotor. close after ON - Check feedback interface relay
command.
47 “F: Thyristor Supervision Trip Thyristor short circuit a) Broken thyristor. - Check the thyristor and the circuit board XV
(Tier 8)” fault. b) Broken fibre optic link. C513A (Tier8)
48 “F: Emergency stop button Emergency stop button a) Emergency stop. - Check the emergency stop button around ring
pressed” pressed. motor.
49 “F: Hardware Overcurrent Supervision of hardwired a) Cycloc.Overcurrent at - Check the red leds on CSA 463 circuit board,
I>>, CSA 463” analog signals e.g. motor phase R1,R2,S1,S2,T1 and make a note in the logbook.
currents. or T2.
50 “F: Circuit Breaker Control Circuit breaker OFF in a) Short circuit at the - Check the miniature circuit breakers, cable
Part +F01, +F02” one of the control panels synchronisation voltage and synchronisation voltage transformer.
+F01, +F02. transformer. - Check control circuits
b) Miniature circuit breaker
off, due to overlolad,
short circuit or miss
operation.
51 “F: Thermal Overload Overload of excitation a) Excitation current too - Check the excitation converter.
Excitation” circuit. high for long time. - Check rotor excitation.
b) Motor running for long - Check thermal overload protection and cable.
time in low speed - Check operation of the motor, maybe running
operation. too long in low speed.
c) Thermal overload miss - Check setting of the thermal relay
operation.
52 “F: Fire fighting activated” Fire detection system a) Smoke detected in E- - Check fire fighting panel
+F14 activated. house - Check fire alarm push-bottom located close to
b) Fire push-bottom the E-house doors.
pressed
53 “F: Earth Fault Rotor” Earth fault at rotor part. a) Short circuit to earth of Check earth fault protection module, rotor
rotor power part, cable cable, DCF600, slipring rotor and knife switch.
or rotor winding. Check the rotor covers of the ringmotor for any
b) High humidity inside ring material spillage
motor or knife switch.
54 “F: Earth Fault Stator” Earth fault at stator part. a) Short circuit to earth of - Check earth fault protection module.
power part, power cable - Check motor cable, stator winding and stator
or stator winding. knife switch.
b) High humidity inside ring
motor or knife switch.
55 “F: Overvoltage Arrester Rotor excitation a) Network lost - Check the network voltage.
Excitation” overvoltage. b) Result of motor - Check overvoltage arrester in excitation unit.
overcurrent
56 “F: Undervoltage Excitation Excitation Line voltage a) Network lost - Check the excitation network voltage.
Input” too low b) Rotor breaker open - Check the state of the rotor breaker
57 “F: Motor Unbalance Current” Stator current unbalance
58 “F: Excitation converter Excitation Converter a) DCF Converter tripped. - Check fault indication at DCF Converter and
DCF600” Fault. identify the fault with fault list (DCF Manual)
59 “F: Mill Blocked” Mill is not able to turn a) The mill is not rotating - Check the brake system and mechanical part
after mill start command within 5 sec after of the mill.
cycloconverter release. - Check the load of mill.
60 “F: Mill motor over speed” Mill over speed fault. a) If an actual speed of the - Check the mill speed compare with actual
mill > 116% speed.
- Mill speed uncontrollable due to empty mill,
PSR software must be adapted for this
condition.

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61 “F: Stator Transformer Fault” Stator transformer fault. a) Over pressure trip. Check cycloconverter transformer supervisions.
b) Bucholz relay trip.
c) Thermal oil relay trip.
d) Min/Max oil level trip.
62 “F: Excitation Transformer Excitation transformer a) Bucholz relay trip. Check excitation transformer supervisions.
Fault” fault. b) Thermal oil relay trip.
c) Min/Max oil level trip.
63 “F: delta psi-T <” Converter Voltage trapez a) Synchronisation voltage Check synchronisation voltage transformer.
limit < lost. retuning of trapez controller necessary.
b) Line voltage problem.
c) Trapez control is not
working properly
64 “F: delta psi-T >” Converter Voltage trapez a) Synchronisation voltage Check synchronisation voltage transformer.
limit > lost.. retuning of trapez controller necessary.
b) Line voltage problem.
c) Trapez control is not
working properly
65 “F: Air gap too small Ringmotor airgap fault. a) Ring motor airgap too - Check airgap with feeler gauge.
(Probe1)” Airgap < trip limit small. - Check airgap sensor and power supply.
b) Airgap sensor damaged.
c) Power supply of sensor
lost.
lost.
lost.
lost.
lost.
lost.
lost.
lost.

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lost.
74 “F: Air gap too small Ringmotor airgap fault. d) Ring motor airgap too - Check airgap with feeler gauge.
e) Airgap sensor damaged.
f) Power supply of sensor
lost.
75 “F: 22.9 kV line undervolt. Netvoltage phase R, a) Network lost. - Check network voltage.
Phase R” voltage below trip limit b) Reference voltage - Check reference voltage transformer and
(<85%). transformer damaged. cable.
76 “F: 22.9 kV line undervolt. Netvoltage phase S, a) Network lost. - Check network voltage.
Phase S ” voltage below trip limit b) Reference voltage - Check reference voltage transformer and
77 “F: 22.9 kV line undervolt. Netvoltage phase T, a) Network lost. - Check network voltage.
Phase T ” voltage below trip limit b) Reference voltage - Check reference voltage transformer and
78 “F: 22.9 kV network Over or Under Frequency a) Network lost. - Check network frequency.
over/under Frequency” fault. b) Reference voltage - Check reference voltage transformer and
transformer damaged. cable.
79 “F: Mill Charge is Frozen” Frozen charge protection a) The material inside the Check the material inside the mill.
fault. mill does not cascading.
80 "F: Brakes do not release at Check the brake system
start"
81 “F: Mill Moving during Start” Mill in movement when a) Mill was not in balance Balance the mill before starting. Use brake
trying to start release
82 “F: Cool.Unit Sensor Sensor fault of cyclo a) Sensor damaged. -Check all sensor and cabling of cyclo recooling
disturbance” cooling unit (+F15) b) Wiring open circuit. unit (control panel +F15).
c) Analogue input card - check the analogue input card UAC096
failure (control panel +F15)
83 “F: Cool.Unit Overtemp. Water Inlet temperature a) Water cooling high Check water cooling system, Temp. sensor and
Conv.Inlet” Fault. temp.(Primary side) cable.
b) Sensor failure. If the temperature > 44 °C
84 “F: Cool.Unit Water flow low” Water flow low low. a) Water leakage. -Check water cooling system, Water flow
b) Valve closed. sensor and cabling.
c) Circulation pumps - Check operation of circulating pump.
damaged or not running. - Check water level at expansion tank.
d) Sensor failure. - Check if all valves are open and flow is higher
than specified limit
85 “F: Cool.Unit Water level low” Water level low low. a) Expansion tank water Check water cooling system, Level sensor and
missing. cabling.
b) Sensor failure. If the level < 50 %
86 “F: Cool.Unit Water Pressure Water pressure low low. a) Valve closed. - Check water cooling system, Pressure sensor
low” b) Motor pump damaged. and cabling.
c) Sensor failure. - Check circulation pumps.
If the pressure < 1.98 bar within 5 sec.
87 “F: Cool.Unit Overtemp. Water temperature high a) Water cooling high - Check raw water temperature and flow.
Conv.Outlet” high. temp.(Secondary side) - Check water cooling system, Temp. sensor
b) Sensor failure. and cable.
If the temperature > 49 °C
88 “F: Cool.Unit Conductivity Internal cooling water a) Deionizing filter (bottle) -Change deionizing bottle.
high” conductivity high high. old & dirty. If the conductivity >= 2 uS within 10 sec.

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89 “F: Cooling water leakage Internal cooling water a) Sealing problem. - Check water cooling system, Water leakage
(+F15)” leakage fault. b) Connector of pipeline sensor and cabling.
broken. - Check sealing of cyclo recooling system
(+F15)
90 “F: Critical interlock/Status”Only status indication. No a) Critical interlock signal Check error message on DCS or VMS screen.
alarm or trip to PSR from ABB PLC
91 "F: Brake System Fault" Brake group critical a) Problem on brake Check error message on DCS or VMS screen.
interlock signal from ABB system
PLC.
92 “F: UnderFrequency Load Frequency Load a) Network underfrequency - Check the network conditions
Shedding ” Shedding coming from b) 22.9 kV feeder - Check the main feeder protection relay
main sub-station protection relays fault
93 “F: PSR Print boards failure, Digital hardwired a) Digital/Analog fault at - Check the red led on CSA 465 circuit board.
CS A465 ” supervision of digital print circuit board of the - Replace the print circuit board which is
signals. PSR system. indicated on CSA 465 board.
For replacement switch off auxl.supply voltage.
94 “F: Air gap too small Ringmotor airgap fault. g) Ring motor airgap too - Check airgap with feeler gauge.
h) Airgap sensor damaged.
i) Power supply of sensor
lost.
95 “F: Air gap too small Ringmotor airgap fault. j) Ring motor airgap too - Check airgap with feeler gauge.
k) Airgap sensor damaged.
l) Power supply of sensor
lost.
96 “F: Knife switch open during Stator or rotor knif a) Knife switches open due - Check if the stator knife switch is closed.
operation” switches open during mill to some service. - Check if the rotor knife switch is closed.
operation b) Sensor or feedback - Check sensor and cabling
signal failure.
97 “W: Airgap low (Probe 1) ” Ringmotor airgap below a) rotor not in the centre -measure ring motor airgap with feeler gauge
alarm limit. b) stator movement -check air gap sensors & measuring circuit.
c) long standstill of the
motor without turning
98 “W: Airgap low (Probe 2) Ringmotor airgap below dto. dto.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.
alarm limit.

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109 “W: Thyristor Supervis. Not Thyristor Supervision a) Broken thyristor. Check the thyristor and print circuit board XV
ready” Warning. b) Broken fibre optic link. C515A (Tier 7)
111 “W: Stator Knife Switch Stator Knife Switch Open a) Problems with auxiliary - Check auxiliary contacts and voltage
Open” contacts or PLC input - Check input in the PLC
channel
112 “W: Rotor Knife Switch Open” Rotor Knife Switch Open b) Problems with auxiliary - Check auxiliary contacts and voltage
contacts or PLC input - Check input in the PLC
channel
120 “W: Cool.Unit Sensor Sensor warning. a) open circuit or loose Check sensor and cabling.
disturbance” connection. signal should not be less than < 4 mA.
b) Sensor or feedback
signal failure.
121 “W: Cool.Unit Overtemp. Water Inlet temperature a) Water cooling high Check water cooling system, Temp. sensor and
Conv.Inlet” warning. temp.(Primary side) cable.
122 “W: Cool.Unit Water level Water low level warning. a) Water leakage. Check water cooling system, level sensor and
low” b) Sensor failure. cable.
If the level < 75 %
123 “W: Cool.Unit Water Internal cooling water a) Cooling pump not Check water cooling system, pressure sensor
Pressure low” pressure low warning. running and cable.
b) Valves closed If the pressure < 1.98 bar within 1 sec.
c) Sensor failure -check MCC starter module
d) MCC failure
124 “W: Cool.Unit Overtemp. Water temperature high a) Water cooling high Check water cooling system, temp. sensor and
Conv.Outlet” warning. temp.(Secondary side) cable.
125 “W: Cool.Unit Conductivity Water conductivity high a) Deionizing filter dirty. Change deionizing filter.
high” warning. If the conductivity >= 1 uS.
126 “W: Cooling Pumps not ready Cooling pumps are not a) E-Stop pressed. Check E-Stop button.
to start” ready to start. b) Jog mode selected from Check pump control location from DCS
DCS. (local/remote)
c) Motor tripped Check motor protection relay status

129 “W: No Local Release Control Room is not in a) Control Room is in Change the mode from the Control Room
Control Room” local mode remote mode.

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130 “W: Auxiliaries are not ready” Auxiliaries not ready. a) Cycl.Cooling system not -Check auxiliary drives status, use VMS
ready. -check MCC starter modules
b) Mill brake system not
ready.
c) Mill lubrication system
not ready.
131 “no message stored” c)

132 “W: Excitation converter not Excitation converter a) There might be some - check DCF600 and cable.
ready” DCF600 (+F01) not alarm/fault on the - check control voltage supply (panel +F01)
ready. DCF600 converter.
b) aux. power supply
missing.
133 “W: Brake not ready to Brake system not in a) Check brake pump. - Check message on DCS or HMI screen.
operate” condition to start b) Proximity switches faulty
134 “W: 22.9kV Stator Circuit Main breaker not ready. a) Main breaker in test -Check main circuit breaker
Breaker not available” position, racked out ect. -check feedback signal to interface relay.
b) Breaker failure.
135 “W: Rotor Circuit Breaker not Rotor breaker not ready. a) Main breaker in test -Check main circuit breaker
available” position. -check feedback signal to interface relay.
b) Breaker failure.
136 “W: Stator Transformers Stator transformer fault. a) Over pressure trip. Check stator transformer.
Alarm” b) Bucholz relay trip.
c) Thermal oil relay trip.
d) Min/Max oil level trip.
137 “W: Excitation Transformer Excitation transformer a) Bucholz relay trip. Check excitation transformer.
Alarm” fault. b) Thermal oil relay trip.
c) Min/Max oil level trip.
138 “Non Critical Interlock/Status” Non critical interlock Check error message on DCS or HMI screen.
signal from ABB PLC
139 “W: Speed lowering delta psi- Maximum speed limit 8.0 a) Control voltage trapez -Check network voltage
T>” rpm high - reduce mill speed
140 “W: Speed lowering delta psi- Maximum speed limit 8.0 a) Control voltage trapez -Check network voltage
T<” rpm low - reduce mill speed
142 “W: Torque limit 110% of Load torque >110% for a) Too high load applied to -contact operator and check with DCS.
Nominal” longer than 60 seconds. the mill drive system. - reduce mill speed and load
143 “Start Interlock” Start interlock signal from a) Check operation mode - Check active alarms
ABB PLC with operators, no - Check VMS
permission from PLC.
b) Service or maintenance.
144 “HW-Error UAC326-3(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.
+45)” circuit board(Tier4/+A45) For replacement switch off auxl.Supply voltage.
+37)” circuit board(Tier4/+A37) For replacement switch off auxl.Supply voltage.
+A41)” circuit board(Tier4/+A41) For replacement switch off auxl.Supply voltage.
147 “HW-Error GDB021-R1(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.
148 “HW-Error GDB021-R2(Tier4 Print circuit board fault. b) Hardware error at print Replace print board.

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149 “HW-Error GDB021-S1(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.
150 “HW-Error GDB021-S2(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.
151 “HW-Error GDB021-T1(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.
152 “HW-Error GDB021-T2(Tier4 Print circuit board fault. a) Hardware error at print Replace print board.

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CHIND / ATBDE 27.05.2008 en Volume 4 B 52/115
6. List of Analog Values on the DRIVE CONTROLLER Control Panel
Channel No. Signal name Scaling
01 Speed Reference 100 % = 13.38 rpm

02 Speed Actual 100 % = 13.38 rpm
03 Line Voltage 100 % = 33000 V
04 Excitation current 100 % = 900 Adc
05 Motor voltage 100 % = 3760 Vac
06 Motor Power 100 % = 13050 kW
07 Test Program No.: = 1..7
08 Inching angle 100% 0..360°
09 Temp Conv Inlet CT001 100 % = 100 °C
10 Temp Conv Outlet CT002 100 % = 100 °C
11 Flow Conv Cooling CF001 100 % = 400 l/min
12 Water Level CL001 100 % = 100 %
13 Water Pressure CP001 100 % = 6.0 bar
14 Water Conductivity CD001 100 % = 4.0 PS/cm
15 Service Box Indication 100 % = 10.0 V
16 Temp Ext Inlet CT004 100 % = 100 °C
17 Temp Ext Outlet CT005 100 % = 100 °C
18 Motor Current Phase R 100 % = 2127 A
19 Motor Current Phase S 100 % = 2127 A
20 Motor Current Phase T 100 % = 2127 A
21 Air gap sensor 1 100% = 30.0 mm
For the actual cooling unit setpoint value, please refer to the ”Cooling System General data &
settings” drawing 3BHS235296.

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7. Analogue meter signal indication (Tier 2)
Following signals are indicated with analogue meters (Control Panel +F02/K01)
-actual ringmotor speed (0...14rpm)
-excitation current (0...800A)
-motor current IxR (0...4000A)
-motor current IxS (0...4000A)
-motor current IxT (0...4000A)
-selective indication (only for service purpose)
8. Settings
The circulating- overcurrent detection is stored and signalled with the safety unit:
Measurement on the CS A463 PCB.
The actual current is taken from the current burden and lead to the PCB input.
With the special modifications on the print board (acc. to the schematic diagram),
the trip level is set.
a) analog signals (CSA 463)
Signal Calibration/fault level

Signalisation
(Peak Value)
IXR1,2 5700 A = 11.37 V i ҄ R1 / i ҄ R2
IXS1,2 5700 A = 11.37 V i ҄ S1 / i ҄ S2
IXT1,2 5700 A = 11.37 V i ҄ T1 / i ҄ T2

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4.3.5 Faults Control
Different binary output trip and alarm signals indicate faults and malfunctions of the converter, the
circuit breaker and of external system components as described in paragraph 4.3.4 Be sure you have
integrated these signals in the power plant control system and in the main control panel for properly
controlling the converter .
! Important: Write down in form 1 (see paragraph 8.6 of this manual) what has happened
and which fault is indicated before you press the reset button and before you
start any repair work.
! Important: Any repair work has to be done only by specially trained personnel.
1. 'COMMON-TRIP ' Signal
This signal indicates a converter fault or malfunction. Remove the trip cause and reset the trip status
in order to get the 'READY' signal for restarting the converter.
For your information: A trip initiated during the drive operation will cause the converter to stop
delivering power to the motor. For severe trips the circuit breaker will open to de-energize the
converter. The drive operation is interrupted and cannot be repeated unless the cause is removed.
2. 'COMMON-ALARM' Signal
This signal indicates a converter fault or malfunction. Remove the alarm cause and reset the alarm
status in order to get the 'READY'-signal for restarting the converter.
For your information: An alarm initiated during the drive operation does not influence the ongoing
process. A converter restart, however, is not possible without removing the common alarm cause
(except air gap alarms).

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4.3.6 System Interlocks
The GMD control system counts with different kinds of interlocks, depending on how critical the fault
is, different actions are taken. The interlocks can be divided in two types: Mill/Drive interlocks and
device/function group specific interlocks.
Mill/Drive interlocks will stop the mill, but not the auxiliaries, while device/function group interlocks are
specific and will only stop the involved devices. However, in most of the cases a device/function
group interlock will generate also a Mill/Drive Interlock.
4.3.6.1 Mill / Drive Interlocks
The mill / drive interlocks are handled by the Drive Controller, however for some interlocks, signals
are provided by the ABB PLC.
1. Critical Interlocks
This type of interlock prevents the mill from running or being started. Critical interlocks involves
imminent damage to the equipment or personal injury, therefore, they require stop the mill as fast as
possible. When mechanical brakes are available they will be applied in case of critical interlock. Most
of electrical faults represent critical interlocks. Depending on the nature of the fault, MV Circuit
Breakers can be open or not.
Example of Critical Interlocks are: Too low airgap, thyristor failure, ringmotor faults, overcurrent,
Lubrication System Fault (depending on the mill control philosophy), etc.
2. Non Critical Interlocks
This type of interlock prevents the mill from running or being started. Non critical interlocks are faults
that do not require immediate action and can wait a few seconds for a safe normal stop without
damaging the equipment or causing personal injuries.
Examples of Non Critical Interlocks are: Winding Temperature High, Air Condition Unit Fault, UPS
Failure, etc.
3. Process Interlock
A process interlock prevents the mill from running or being started. These interlocks usually come
from a higher control system (for example from the DCS) and they are process related faults or
alarms (not belonging to the GMD system) that require stopping the mill. For example: problems in
the flotation cells. In this case the behaviour is similar to a Non Critical Interlock

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4. Start Interlock
This type of interlock prevents the mill from being started. Once the mill is running, the start interlock
no longer inhibits its operation. Start interlock is also called “Permissive”. Most of the alarms also act
as a Start Interlock.
5. Hardwired Interlock
These interlocks are part of critical interlocks but due to safety reasons the trip action is sent directly
to the MV Circuit Breaker. These interlocks will protect the system even in the case of a Drive
Controller Failure.
Example of these interlocks are: Bucholz and pressure relief transformer faults, transformer protection
relay trips, emergency stop pushbuttons, power cabinet doors open, Drive Controller hardware
failure, stator overcurrent, etc.
All the hardwired interlocks are sent also in parallel to the cycloconverter thyristor firing control, so it
will have the minimum time required to eliminate the energy stored in the motor and in this way it will
prevented any damage to the converter power part.

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4.3.6.2 Device / Function Group Interlocks:
Device / Function Group interlocks are usually controlled by the overall ABB PLC. They will inhibit the
operation of specific auxiliary devices.
Start Interlock: They will prevent the starting of a device/group/mill. Once the device is running they
will not inhibit the operation. For example: Oil temperature low.
Interlock: They will prevent the device from running even in jog mode. A device interlock is not
stopping the started group.
Note that in most cases a device / function group interlock will generate a mill trip.
The interlocks or start interlocks for each device or function group are shown in the device / function
group faceplate in the VMS system

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4.3.7 GMD Start Sequence
The GMD start sequence has 3 steps: Auxiliaries Start-Up, Close Circuit Breakers, and Mill Start-Up.
! Important: Be sure you have switched on the main power supply and the low voltage
power supplies (MCC) before starting up the converter.
Check that there are no alarm or fault signals shown at the cycloconverter
control panel or at the VMS displays.
4.3.7.1 Auxiliaries Start-Up sequence
The auxiliaries start command is given, under normal operation (central mode), by the DCS. However,
it is also possible to have the command from the Drive Local Panel (E-House mode) or from the Motor
Local Control Panel (MLCP mode). This command is sent to the ABB PLC which will release the start
sequence of the Lubrication System, Brake System and the Ringmotor Auxiliaries. Once the
auxiliaries are available the PLC will send an Auxiliaries available feedback to the Drive Controller.
The Ringmotor Auxiliaries (cooling and make-up fans) have a particular behaviour, since the control is
based on the actual winding temperature. The ringmotor can start without having any fan running,
however they must be preselected and free of faults, otherwise the Auxiliaries Available signal will not
be set. At least one cooling fan per side must be preselected.
The detailed sequence is described below:
Step 1 Auxiliaries start-up sequence:

Step 1.1 All motors / heaters / valves have to be in “sequence” and “remote” mode (set from the
DCS);
Step 1.2 Preselect ringmotor cooling fans and lubrication pumps (set from the DCS);
Step 1.3 All selected drives are ready and no interlock is active;
Step 1.4 Start command for auxiliaries from DCS or E-House/ MLCP:
Step 1.4.1 Start from DCS: set mill to remote in the DCS and selection switch to “Central/E-House” in
the MLCP;
Step 1.4.2 Start from E-House/ MLCP: set the mill to local in the DCS and “Central/E-House” in the
MLCP or “MLCP” in the MLCP;
Step 1.5 Each auxiliary group starts according description;
Step 1.5.1 Lubrication system group starts;
Step 1.5.2 Brake system group starts;
Step 1.5.3 Ringmotor group is activated;
Step 1.6 All auxiliaries are running.
4.3.7.2 Close Circuit Breakers Command
Once the auxiliaries are started, the Drive Controller will be ready to close the MV Circuit Breakers.
During normal operation the close circuit breakers command is send by the DCS to the PLC (central
mode) and then forwarded to the drive controller.
In local modes (E-House or MLCP) it is also possible to close the MV Circuit Breakers directly from
the local panels.

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This command will close first the Stator Circuit Breaker and after 2 seconds the Rotor Circuit Breaker.
The drive controller will wait 1500 ms for the MV Circuit Breaker closed feedbacks. In case no
feedback is received, it will generate a fault.
Step 2 Close main circuit breaker sequence:

Step 2.1 All auxiliaries are running and no interlocks from them;
Step 2.2 Close command for MCB from DCS or E-House/ MLCP panels:
Step 2.2.1 Close from DCS: set mill to remote in the DCS and selection switch to “Central/E-House”
in the MLCP;
Step 2.2.2 Close from E-House/ MLCP: set mill to local in the DCS and “Central/E-House” in the
Step 2.3 Circuit Breakers are closed.
4.3.7.3 Mill Start Up
With the MV Circuit Breakers closed, the Drive Controller will be ready to start the mill. Under normal
operation (central mode) the command is send by the DCS to the ABB PLC, and then forwarded to
the Drive Controller. In local mode (E-House or MLCP mode) the order is given by the local control
panels.
Once the order is received by the Drive Controller, the thyristor pulses are released, and the mill will
start to turn slowly and will increase the speed until it reaches the Reference Speed. The mill speed
increase is done using the Drive Controller internal speed ramps (depending on the operating mode
Normal or Inching / Creeping).
The speed reference is set by the DCS, under normal operation (central mode). However, in local
mode (E-House or MLCP mode), it has to be set in the local drive control panel or in the Motor Local
Control Panel (MLCP), using the faster / slower buttons.
During the mill operation the speed reference can be changed at any moment to fulfil the process
requirements.
Step 3 Mill start-up:

Step 3.1 No interlocks/faults from anywhere;
Step 3.2 Start command from DCS or E-House/ MLCP:
Step 3.2.1 Start from DCS: set mill to remote in the DCS and selection switch to “Central/E-House” in
the MLCP;
Step 3.2.2 Start from E-House/ MLPC: set mill to local in the DCS and Central/E-House in the MLCP
or “MLCP” in the MLCP;
Step 3.3 Horn sounds, time delay of 10s to next step;
Step 3.4 Start excitation;
Step 3.5 Release thyristor pulses;
Step 3.6 Acceleration to minimal speed setpoint.

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4.3.8 GMD Stop Sequences:
The GMD stop sequence can be distinguished in 3 different stop sequences:
1. Normal stop;
2. Abnormal stop caused by auxiliaries;
3. E-Stop / Cycloconverter Fault / Fire Fighting Alarm;
4.3.8.1 Complete system shutdown
4.3.8.1.1 Mill Stop
Normal Mill Stop is done with the DCS Mill Stop Command (central mode) or by pressing the Mill Stop
pushbuttons in the Local Drive Panel (E-House mode) or in the MLCP (MLCP mode).
Once the Drive Controller receives the Mill Stop command, it will apply an electrical brake reducing
the speed smoothly until the mill reaches the standstill state. Mechanical brakes will not be applied.
4.3.8.1.2 Open Circuit Breaker Command
The Open Circuit Breaker Command is provided, under normal operation (central mode), by the DCS.
In E-House or MLCP mode the open command is provided by the local drive control panel or by the
MLCP.
Once the Open Command is received the Drive Controller will open both Stator and Rotor Circuit
Breaker immediately.
4.3.8.1.3 Auxiliaries Stop Sequence
The stop auxiliaries command is given by the DCS, under normal operation (central mode). In local
modes the command is given by the local drive control panel (E-House mode) or by the Motor Local
Control Panel (MLCP mode).
The ABB PLC will initiate the auxiliaries stop sequence (lubrication system, brake system).
Like in Start-Up sequence, the ringmotor auxiliaries will be stopped according to the ringmotor
winding temperature. In this way, after mill and auxiliaries stop, it is expected to have the ringmotor
cooling fans working for some time until the winding temperature reaches a preset value.
In short mill stops is not recommended to stop the auxiliaries. They can be running, even when the
mill is stopped.

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4.3.8.1.4 Converter Standstill
In the stand-by mode the converter may be de-energized for energy saving reasons. In that case
switch off the main power supply.
! Important: In the stand-by mode the low voltage power supplies (MCC, UPS, Lighting)
should not be switched off because the air conditioning system should always be
on in order to avoid damages caused by extreme external humidity or extreme
temperature differences.
4.3.8.2 Normal stop sequence
The normal stop sequence has 3 steps: Mill shutdown, Open Circuit Breakers and Auxiliaries Shut-
down. For a short stop of the mill there is no need to open the circuit breakers and to stop the
auxiliaries.
4.3.8.2.1 Mill shutdown
Step 1 Mill normal shutdown:

Step 1.1 Stop command from DCS or E-House/MLCP:
Step 1.1.1 Stop from DCS: set mill to remote in the DCS and selection switch to “Central/E-House” in
the MLCP;
Step 1.1.2 Stop from E-House/ MLPC: set mill to local in the DCS and “Central/E-House” in the
MLCP or “MLCP” in the MLCP
Step 1.2 Decelerate the mill to stop;
Step 1.3 Brakes are not applied;
Step 1.4 Block thyristor pulses;
Step 1.5 Stop excitation.
4.3.8.2.2 Open Circuit Breaker
It is not always required to open the circuit breaker, when you stop the mill.
Step 2 Open circuit breakers:

Step 2.1 Mill has stopped (Precondition);
Step 2.2 Open command from DCS or E-House/ MLCP:
Step 2.2.1 Open from DCS: set mill to remote in the DCS and selection switch to “Central/E-House”
in the MLCP;
Step 2.2.2 Open from E-House/ MLPC: set mill to local in the DCS and “Central/E-House” in the
MLCP or “MLCP” in the MLCP.
4.3.8.2.3 Auxiliaries stop sequence
It is not always required to stop the auxiliaries, when you stop the mill.
Step 3 Auxiliaries shutdown sequence:

Step 3.1 Mill has stopped;
Step 3.2 Stop command from DCS or E-House/ MLCP:
Step 3.2.1 Stop from DCS: set mill to remote in the DCS and selection switch to “Central/E-House” in
the MLCP;

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Step 3.2.2 Stop from E-House/ MLCP: set mill to local in the DCS and “Central/E-House” in the
Step 3.3 Each auxiliary group stops according description:
Step 3.3.1 Lubrication group stops;
Step 3.3.2 Brake group stops;
Step 3.4 All auxiliaries have stopped.
4.3.8.3 Abnormal stop sequence
Abnormal stop sequences occurs when a failure happens in a auxiliary system.

In case of a critical interlock, the brake will apply. For a non-critical interlock the brake will not be
applied.
Step 1 Mill abnormal shutdown:

Step 1.1 Stop command from PLC due a failure of an auxiliary system;
Step 1.2 Decelerate the mill to stop;
Step 1.3 Brake control:
Step 1.3.1 Brake is not applied in non-critical interlocks;
Step 1.3.2 Brake is applied in critical interlocks;
Step 1.5 Stop excitation;
Step 2 Circuit breakers keep closed
Step 3 Auxiliaries keep running
4.3.8.4 E-stop / Cycloconverter Faults / Fire Fighting Alarm
The emergency stop push button is maintained when depressed. When depressed, only the
connected ring motor performs an emergency shutdown, all Mill Motor and Cyclo Converter auxiliaries
are not stopped. This ring motor is prohibited from restarting until the emergency stop push button is
released and the trip reset.
(Client must define the control philosophy for emergency shut down).
The brakes will be applied after an emergency stop is pressed.
Minimum two E-Stops are delivered by ABB, one of them is installed on the MLCP panel and the
second is mounted on the cabinet door +F01 in the E-House. All E-Stops are hardwired to the E-Stop
relay in +F02. Others E-Stops, which are not scope of supply from ABB but belongs as well to the
GMD, have to be wired in series to them.
For the following faults, the medium voltage circuit breakers opened and the brakes will be applied:
- Emergency Stop Pressed;

- Cycloconverter Faults;
- Fire Fighting Alarm.
Step 1 Mill shutdown because of E-Stop / Cycloconverter fault / Fire Fighting Alarm:
Step 1.1 Stop command from PSR due pressed E-Stop or Cycloconverter Fault or Fire Fighting
Alarm;
Step 1.3 Stop excitation;
Step 1.4 Open circuit breakers;
Step 1.5 Apply brakes;
Step 2 Auxiliaries keep running.

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4.4 Motor Local Control Panel (MLCP)
4.4.1 Layout
Tag-No.: MLCP Ball Mill: 3340-2110-01-C01
Tag No.
Stainless steel
Hinged Door
Central
500 mm
E- House Central\
MLCP
E-House
MLCP
Safe
Mode
Safe Mode
Key-Switch
EMERGENCY STOP PB
Turn to release
Cable Entry
Front Door Cut
200 mm
20 mm 25 mm 20 mm
400 mm
Cable Entry 20 mm: min/ max cable diameter: 8 / 13 mm

Cable Entry 25 mm: min/ max cable diameter: 11 / 17 mm

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01 Speed Setpoint ... RPM

. 20 . 40 . 60 . 80 . .. 100%.
. 20 . 40 . 60 . 80 .
100% .
02 Actual
. 20
Speed
. 40 . 60 . 80 . . 100%.
... RPM
04 Excitation Current ... A
. 20 . 40 . 60 . 80 .. 100%.
05 Motor Voltage 100 % .
... V
. 20 . 40 . 60 . 80 .
!! ! 123 #
F1 F2 F3 F4 F5 F6 F7 F8
F9 F10 F11 F12 F13 F14 F15 F16

English labels: Spanish labels:
English labels: Spanish labels:
F1: Auxiliaries ON Partida Auxiliar.

F9: Auxiliaries OFF Detenc. Auxiliar.
F2: MCB ON Interru. MV Cerrado
F10: MCB OFF Interru. MV-Abierto
F3: Mill Start Partida Molino
F11: Mill Stop Detenc. Molino
F4: Faster / Angle UP Mas Rapido / Angulo >
F12: Slower / Angle DOWN Mas Lento / Angulo <
F5: Forward Adelante
F13: Reverse Reversa
F6: Manual Lowering Liberar Freno
F14: Reduce Mill Rocking Reducir Balanceo Molino
F7: Lamp Test Prueba Luces
F15: Mill Creeping Mode Modo Creeping
F8: Mill Inching Mode Modo Inching
F16: Mill Normal Operation Modo Normal
RESET: Fixed Reset PB
4.4.2 Construction
Protection Class : IP 65
Size : Width X Height X Depth 400 x 500 x 200mm
Colour : n.a.
Cabinet : Stainless Steel
Shockproof up to 6Nm/mm2
Resistant against Corrosion, Chemicals
Inside the box a control and display panel (AF C094) is mounted.

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4.4.3 Control display panel AF C094
Features:
- ARCnet Fieldbus link to the ABB-PSR controller

- Display with 8 lines, each 40 characters (240x64 dots)
- 10 control keys for operation mode and function
- 16 keys with LED’s for plant specific controls
- 4 contact interrogation inputs with short circuit proof +24V supply voltage
- 3 relay outputs with changeover contact
- 3 auxiliary outputs +24V /0V
- Serial interface RS-485 for download
- Serial interface RS-232 for printer
4.4.4 Control Place Selection
The mill drive can be operated from different control places like:
- CCR (for production)
- MLCP (mainly for mill maintenance)
- E-House (mainly for commissioning & ABB service engineers)
The Control Place is initially set to CCR (Central Control Room) and can be changed as
follows:
CCR command Key Switch position Control place Remarks

at MLCP
Remote CENTRAL / E-HOUSE CCR
Remote MLCP CCR
Local MLCP MLCP / Pendant
At ABB-PSR control panel
Local CENTRAL / E-HOUSE E-HOUSE (+F02) in E-House
No switchover control place is
Remote MLCP MLCP / Pendant possible until key switch is set
back to CCR/E-HOUSE
Remote CENTRAL / E-HOUSE CCR
Remote or Local SAFE MODE - Mill is locked, (motor is off and
brake is engaged). No operation
is possible.
4.4.5 Key Switch
The control place selection is done by the CCR and the Key Switch position a the MLCP. When an
incompatible selection is made, the control made remains the same. For example: remote mode in
CCR and MLCP mode selected in the Key Switch. For safety reasons, the Key can be removed in
either position to prevent unauthorized control.

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4.4.6 Function Push Buttons
Action Effect
F1 Auxiliaries ON Initiates an automatic, normal start-up sequence for all Mill, Motor and
Cyclo Converter auxiliary drives.
F9 Auxiliaries OFF Initiates an automatic, normal shutdown sequence for all Mill, Motor
and Cyclo Converter auxiliary drives.
F2 MCB ON Main Circuit Breaker for Stator & Rotor are switched on
F10 MCB OFF Main Circuit Breaker for Stator & Rotor are switched off
F3 Start Mill start command; Effect is subject to the mill control mode
F11 Stop Mill stop command
F4 Faster / Angle up Normal Mode: Speed increase / Inching Mode: Angle is increasing
F12 Slower / Angle down Normal Mode: Speed decrease / Inching Mode: Angle is decreasing
F5 Forward Forward direction preselector; enabled during motor standstill
F13 Reverse Reverse direction preselector; enabled during motor standstill
F6 Manual Lowering Manual release of Brakes as long as Button is depressed (The
Function is enabled in each mode but only if the Mill is not operating)
F14 Reduce Mill Rocking Manual Brake soft-apply as long as Button is depressed (The Function
is enabled in each mode but only if the Mill is not operating)
F7 Lamp Test LED and Lamp test of the MLCP
F15 Mill Creeping Mode Selecting Creeping mode:
After the Start PB is pressed, the motor speed will increase up to
creeping speed. Pressing the Stop PB will cause immediate Stop.
Function Push Buttons F4/F12 are disabled.
F8 Mill Inching Mode Selecting positioning mode:
(For Positioning) The Angle can be preselected with the function push buttons F4/F12.
After the Start PB is pressed, the Motor speed will increase up to
inching speed. The Motor will stop immediately when the desired angle
setpoint is reached.
F16 Mill Normal Mode Selecting Normal mode:
Motor is started with the Start PB and Speed can be increased/
decreased between MIN and MAX speed with the function push
buttons F4/F12. Pressing the Stop PB will Stop the Mill.
4.4.7 Inching Mode (Positioning)
To position the mill drive to a specific angle, “Mill Positioning Mode” is selected. The angle can be
entered via the display using function keys F4 & F12. After the Start PB is pressed, the Mill will turn at
inching speed (~1 rpm) until the desired angle setpoint is reached. When switching from CCR / E-
HOUSE mode to MLCP, Positioning Mode automatically will be preselected.
The desired angular position can be set from 0°... 360°, the operator has to enter the angle plus
compensation for roll back.
Quick brakes will be applied in this mode.

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4.4.8 Creeping Mode
To test the drive locally with min. speed, “Mill Creeping Mode” is selected. By pushing the Start PB
the mill will increase to Creeping speed (~ 0.3 rpm) and can be turned until the Stop PB is pressed.
Quick brakes will be applied in this mode.
4.4.9 Normal Mode
To run the drive between MIN and MAX speed, Mill Normal Mode is selected and the Start PB is
pressed. Speed can be increased/ decreased with the function push buttons F4/F12 . When pressing
the Stop PB, the mill speed decreases according to a Ramp Function to eliminate Rocking. Brakes
will not be applied in this mode.
4.4.10 Reduce Mill Rocking
To prevent the Mill from the rocking, “Reduce Mill Rocking” is used. It is basically a manual Brake
quick -apply as long as the Button is depressed. Due to the fact, that Brake quick - apply
automatically takes place when stopping in Inching mode, Reduce Mill Rocking is used when
switching from “MLCP” to CCR/E-HOUSE mode or after an Emergency Stop has occurred. The
Reduce Mill Rocking - function is enabled in any mode but only if the motor is not running.
4.4.11 Manual Lowering
Brake engagement in a position, where cascading of the charge has not taken place yet puts a lot of
stress on the brake calipers. With manual lowering (which is basically a manual Brake release as long
as the Button is depressed) one can bring the mill into equilibrium. The Manual Lowering Function is
enabled in any mode but only if the Motor is not running, and the Lubrication System is running.
4.4.12 Safe Mode
Lock out mode for access into the mill. Brakes are engaged and the ring motor is de-energized. In the
Safe mode any kind of operation is disabled, all control panel pushbuttons are not active, brake
cannot be released and the mill ring motor cannot be energized. It secures, that mill is standing still,
while the selector Key switch is in the position “Safe Mode”. Safe mode is foreseen for the
maintenance personnel to “lock-out” the mill ring motor for their personal safety before they enter the
mill.
4.4.13 Frozen (locked) charge
Frozen charge protection is active in any mode for each start of the mill.

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4.4.14 Horn
Relay output (dry contact) foreseen to control an external mounted start-up warning horn.
(Horn not ABB scope of supply)
4.4.15 Control push button station
The MLCP includes a mill “control push button station” with a 16 meter long flexible cord.
The control via “pendant” will be only active in “Creeping Mode”.
Functions: -Start
-Stop
-Emergency STOP
4.4.16 Status, Fault & Alarm Signals
General faults and alarms will be indicated in the AF C094 display. Status of the mill during start
up and operation will be indicated due to the LED’s of the specific control keys of the control
display AF C094.
4.4.17 Analogue Signals indicated
The most frequently signals displayed are:
- Ring motor Actual Speed

- Ring motor Reference Speed
- Excitation Current
- Motor Voltage
- Motor Current
- Motor Power
- Network Voltage
- Air gap (12)
- Cycloconverter Cooling System Measurements

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4.5 Ring Motor
This section contains the control and supervision of all devices, auxiliaries and main equipment
related to the Ringmotor.
The Ringmotor has the followings subsystems, which are controlled and/or supervised by the ABB
PLC or the Drive controller.
- Air Gap Monitoring

- Dust Sealing
- Knife Switches
- Motor Winding Temperature
- Ringmotor Cooling System
For detailed information see “Ringmotor Maintenance Manual” OMM 07/012/E and “Ringmotor Setting
List”.
4.5.1 Airgap Supervision
The ringmotor has 12 capacitive type airgap sensors. The supervision of these signals is performed
by the Drive Controller since fast sampling is required to get an effective protection response. The
information is transmitted to the PLC and from there forwarded to the VMS and DCS.
Width: 64 mm
Triaxial cable 3 core shielded cable

outer diameter 3 mm outer diameter 4 mm
length 2 meters adaptable length up to 12 meters
Impedance Four pin connector

adapter
Mounting plate
Two(2) mounting holes inside the box

Capacitive sensor for mounting screws M4
AGS-530
Input for Power supply +24 VDC
and Outputs:
- Pole profile O/Ps 4-20mA or 2-10V
- Minimum gap O/P 2-10V
The Airgap Supervision System has the followings components:
- 12 capacitive airgap probes

- 2 airgap termination boxes mounted outside, at the stator housing (6 conditioner units in
each one respectively)
- 12 signals transducer (4 – 20 mA / 0 – 10 V) located in the Drive Controller cabinet (F02)
The Drive Controller is continuously monitoring each airgap and will generate an alarm or trip event
depending on the airgap measurement value. The Drive Controller receives a 0 – 10 V signal per
each airgap sensor.

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For the airgap supervision, follow the amount of Drive Controller analog inputs:
- 12 AI Capacitive Airgap Sensors (5 – 30 mm)
The settings for the Airgap signals are as follows:
- Alarm: 11,0 mm. This alarm will only be active while the mill is running.
- Trip: 10,0 mm
In case of airgap trip the controller will generate a mill critical interlock, applying the brakes in order to
stop immediately the mill and opening the MV Circuit Breakers.
Please do not change any trip or alarm setpoints, this can harm your ringmotor
badly !
For the location of the airgap sensors refer to the Ringmotor P&ID Diagrams: 41D8H009 and to the
Motor Wiring Diagrams 41D8G833 and 41D8G834.
For detail information about the air gap measuring system please check the user’s manual from MC
monitoring S.A. available inside the Ringmotor Maintenance Manual (Vol 15 of ABB Documentation
Set)
4.5.2 Dust Sealing
To protect the motor from the hostile environment in which they operate a greaseless sealing system
is provided. The sealing system uses Teflon to minimize the friction and a spring-loaded design. The
Teflon-metal seal has a 16-20,000 hours service life.

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The dust sealing is monitored by the ABB PLC, which is alarming the end of seal life aprox. 1500
hours in advance. The supervision of the dust sealing is only performed while the mill is running,
since this supervision is injecting AC voltage to the stator frame.
The following are ABB PLC I/O for the Dust Sealing supervision :
- 1 DO for releasing the supervision (while the mill is running)

- 1 DI for alarming wearing in the dust seal – feed side
- 1 DI for alarming wearing in the dust seal – discharge side
The dust sealing supervision can be disabled using a circuit breaker located in the PLC cabinet (F03).
Refer to circuit diagram: 3BHS235452.
4.5.3 Knife Switches
The ringmotor has two knife switches one for the stator (3 poles) and other for the rotor (2 poles).
They both are mounted at the ringmotor terminals.
The knife switches are used to isolate electrically the ringmotor for maintenance purposes. During
normal operation both switches must be closed and locked. In addition, the PLC is sending an
electrical interlock to the knife switches in order to prevent the opening of these knife switches while
the mill is running.
The PLC is monitoring continuously the state of both Knife Switches. The mill is not allowed to start if
one of the knife switches is in open position. In case of lost of closed feedback signal during normal
operation, the system will trip immediately and will open de circuit breakers.
The following PLC I/O signals are considered for Knife Switches control and supervision:
Digital Inputs:
- Stator Knife Switch Closed

- Stator Knife Switch Open
- Rotor Knife Switch Closed
- Rotor Knife Switch Open
Digital Outputs:
- Stator Knife Switch Release Command

- Rotor Knife Switch Release Command
More information about the Knife Switches can be found in the volume 15 of the Documentation Set.
4.5.4 Motor Winding Temperature Supervision
The ringmotor counts with 9 RTD sensors (3 per phase) to monitor winding temperature and to
prevent overheating of the motor windings.
The RTD signals are supervised by the PLC, which is generating alarm or trip signals in case of
overheating. The RTD signals are also used for the control of the main cooling fans.

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The following PLC RTD signal are supervised:
- Stator Winding Temperature Phase U1

- Stator Winding Temperature Phase V1
- Stator Winding Temperature Phase W1
The winding temperature settings are as follows:
- Alarm: 110 °C
- Trip: 120 °C
For the location of the winding RTDs refer to the Ringmotor P&ID Diagrams: 41D8H009 and to the
Motor Wiring Diagram 41D8G833 and 41D8G834.
4.5.5 Motor Cooling System
The Motor Cooling System has the following sub-systems:
- Cooling Fans and Overpressure Make-Up Fans

- Heat Exchanger
- Motor Space Heaters
4.5.5.1 Cooling Fans and Overpressure Make-Up Fans
The cooling fans are used to circulate the cooling air inside the motor. There are four main fans, two
per motor side. Each auxiliary motor fan is fed from an independent MCC cubicle.
The overpressure fans (or make-up fans) are intended to create an overpressure inside the motor to
prevent dust to come into. This system ensure that in case of a sealing system failure, air from inside
will flow outside avoiding the risk of incoming of particles, contamination, etc. There are two make-up
fans installed in the ringmotor, each one is fed from an independent MCC starter module. Running
time without the make-up fans depends on dirtiness of the surrounding air.
The fans are controlled by the ABB PLC. The operation logic of the ringmotor fans is as follows:
- Before the mill start the fans to operate must be preselected. At least a main fan per side
have to be preselected and ready to operate in order to release the mill for operating.
- The ringmotor will be started without any fan running, and when the winding temperature
reaches 55 °C (minimum 2 RTDs) then the selected main fans and make up fans will be
switched on.

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- In order to avoid the cold start, if the temperature decrease below 55°C the fans will be
disconnected.
- At least one main fan per side must be in operation. If not, the mill will trip.
- The motor can operate without any make-up fan running for certain time. However, if this
situation lasts more than a week, a mill trip will be generated.
- After the mill is stopped if the average temperature of the RTDs is above 90 °C all the fans
will keep working until the temperature goes below 90 °C with a maximum time of 5
minutes. If the average temperature is below 90 °C, the fans will be stopped.
4.5.5.2 Heat Exchanger
The ringmotor counts with 2 water - air heater exchangers located in the bottom of the frame. These
heat exchangers receive cooling water from the plant.
The heat exchanger system is supervised using the following PLC I/O signals:
- Cooling Water Inlet Right Side Temperature (RTD). Alarm over 20 °C

- Cooling Water Inlet Left Side Temperature (RTD). Alarm over 20 °C
- Cooling Water Outlet Right Side Temperature (RTD). Alarm over 26 °C
- Cooling Water Outlet Left Side Temperature (RTD). Alarm over 26 °C
- Water Low Flow Switch Right Side (DI). Switch set in 36.1 m3/h
- Water Low Flow Switch Left Side (DI). Switch set in 36.1 m3/h
- Water Leakage Detection Right Side (DI). Contact switch
- Water Leakage Detection Left Side (DI). Contact switch
- Cooling Air Temperature Right Side (RTD). Alarm over 57 °C
- Cooling Air Temperature Left Side (RTD). Alarm over 57 °C
- Hot Air Temperature Right Side (RTD). Alarm over 77 °C
- Hot Air Temperature Left Side (RTD). Alarm over 77 °C
These signals are permanently supervised by the PLC and it will generate the alarms accordingly the
specified values. The alarms also act as start interlocks.
4.5.5.3 Motor Space Heater
The ringmotor counts with 4 space heaters installed in the bottom part of the motor frame. That will
ensure that no humidity can be build up into the motor. All the heaters are fed by a common MCC
cubicle.
The PLC controls the heaters and it will switch them on if the Mill is not in operation and is bellow
certain temperature. Note that in case of maintenance or inspection inside the ringmotor the space
heaters must be switch off before to start any work.

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4.5.5.4 Humidity Sensor
The ringmotor has two humidity sensors located in the right and left side respectively. These sensors
will generate an alarm in case of high humidity.
The following PLC I/O are supervised:
- 2 AI Humidity Sensors
The humidity detection settings is as follows:
- Alarm: 70 % HR
- Trip: 80 % HR
The alarm also acts as start interlock.

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4.6 Medium Voltage System
The Medium Voltage System consists of the following units:
- Stator and Rotor Circuit Breaker

- Cycloconverter Transformers
- Excitation Transformer
4.6.1 Main Circuit Breakers (Medium Voltage)
The circuit breakers for stator and rotor are both controlled exclusively by the Drive Controller. Control
and supervision signals are connected to the Drive Controller.
The Drive Controller standard IO signals are the followings for both Circuit Breakers:
Digital Outputs:
- CB Order to Close
- CB Order to Open
- CB Trip Signal
Digital Inputs:
- CB Closed
- CB Open
- CB Available
- CB Relay Trip
Circuit breakers for Cycloconverter and Excitation are both controlled exclusively by the Drive
Controller, however, it is also possible to trip the breakers directly in critical conditions (trip feedback
is always provided to the Drive Controller). These critical conditions are the followings:
- Cycloconverter Transformer Buchholz Trip (cycloconverter circuit breaker)

- Cycloconverter Transformer Pressure Relief Trip Signal (cycloconverter circuit breaker)
- Transformer Protection Relay Trip Signal (cycloconverter circuit breaker)
- Circuit Breaker Protection Relay (Management Relay)
- Emergency Stop Loop
In the MV Cycloconverter circuit breaker cabinet is located the Synchronization Transformer (supplied
by client), which is in charge to provide the voltage reference to allow the thyristor control. The
voltage output of this transformer is set to 110 VAC and the vector group is Yy, in this way the
reference voltage is kept in phase with the network voltage.
Please refer to the manufacturer manuals for detailed information.
4.6.2 Cycloconverter Transformer
Each Phase (A, B, C) of the cycloconverter has a three-winding stator transformer on the line side,
fed from the medium voltage switchgear. The cycloconverter transformers are oil filled type and have
the vector group Dd0y1. For a capacitive decoupling of the primary and the secondary windings an
earthed screen between the primary and secondary winding is provided.

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The transformers supervision is performed by the ABB PLC. However critical protections are
hardwired and sent directly to open the Main Circuit Breaker. Information about the trip is provided to
the drive controller so it will have the minimum time to decrease the motor current.
Follow the critical protections hardwired directly to the Circuit Breaker trip coil:
- Trip signal from Transformer Protection Relay.

- Buchholz trip signal
- Pressure Relief trip signal
Signals (DI) supervised by the PLC are the followings:
- Buchholz alarm signal (ALARM)

- Oil Temp High (ALARM)
- Oil Level Low (ALARM)
- Oil Level High (ALARM)
- Winding Temp High (ALARM)
- Buchholz Device Trip (TRIP)
- Oil Temp High-High (TRIP)
- Pressure Relief Trip (TRIP)
- Winding Temp High High (TRIP)
For the complete technical information about the Cycloconverter Transformer please refer to the
Volume 02 of the Documentation Set.
4.6.3 Excitation Transformer
The excitation transformer is a two winding oil filled type, with vector group Dy5. Like the
cycloconverter this transformer is also provided with an earthed screen between the primary and
secondary winding.
The supervision is performed by the ABB PLC. In case of overcurrent the protection relay in the MV
Switchgear will generate the trip order
Signals supervised (DI) by the ABB PLC are the followings:
- Oil Temperature High (ALARM)

- Gas/Oil Level Alarm (ALARM)
- Tank Pressure High (TRIP)
- Oil Temp High High (TRIP)
For the complete technical information about the Excitation Transformer please refer to the Volume
02 of the Documentation Set.

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4.7 E-House
The E-House contains the following auxiliary subsystems:
- Air Conditioning Unit;

- Fire Fighting System;
- UPS System;
- Lighting System
The E-house temperature is monitored with a PT100 sensor. It is mounted in the upper of the wall and
sends the signal to the PLC.
4.7.1 Air Conditioning
The air conditioner is used to keep the E-House temperature constant, most of the time it is used for
cooling. The excitation converter and the MCC are air-cooled devices and represent the main E-
House heat source, once the cycloconverter is water-cooled and its heat is exchanged in the cyclo-
cooling unit.
Each E-House has two air conditioners (AC1 and AC2) installed.
The air conditioner operation is released by a PLC digital output. In normal operation, both units are
released. The only exception is when the fire fighting activated signal is detected by the PLC. In this
case, the air conditioners are stopped by disabling the release command.
Each air conditioner has an alarm signal wired to the PLC. The unit alarms when the air conditioner
control unit detects a failure/warning or its MCC feeder is turned off.
At least one unit must be running during the mill operation. If both units are stopped, a mill non-critical
interlock is generated.
Follow a summarize of the PLC IO for each air conditioner:
- 1 DO Air Conditioner Release;

- 1 DI Air Conditioner Alarm;
For more information, please check the Volume 10 of the ABB Documentation Set.
4.7.2 Fire Fighting System
The fire-fighting system (+F14) is used to detect and suppress fire inside of the E-House. The fire-
fighting system consist of:
- Six smoke detectors divided in two different zones;

- Two bottle of FM200 gas with automatic solenoid actuator and a manual gas release switch;
- Control panel,
- Two manual discharge stations;
- Two Manual FM200 abort switch.
When fire is detected in only one zone, an alarm is produced. To have the FM200 gas extinguished is
required that both zones indicate presence of fire.

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Fire-fighting activated signal is detected by the PLC and is sent to the drive controller generating a
mill critical-interlock and stator and rotor main circuit breakers open command.
Fire-fighting alarm and fault signal work as mill start interlocks.
Signals supervised by the ABB PLC are the followings:
- 1 DI Fire Fighting System Fault;

- 1 DI Fire Fighting System Alarm;
- 1 DI Fire Fighting System Activated.
More information regarding its operation can be found in the Fire Fighting folder - Volume 10 of the
ABB Documentation Set.
4.7.3 UPS
The UPS is responsible for supplying 120Vac to the PLC and Drive Controller panel. A separated
Bypass Switch allows the PLC and the drive controller to be directly connected to the incoming line,
and the UPS to be bypassed. This allows maintenance to be carried out on the UPS without shutting
down the Mill.
The following signals are wired to the PLC digital inputs:
- UPS Line Failure;

- UPS Bypassed;
- UPS Battery Low;
- UPS System Fault.
The battery low signal is only active when the system is battery operating. This signal acts as a non-
critical interlock stopping the mill. All others UPS signals are just alarms in the VMS screen.
More information can be found in the volume 3 of the ABB Documentation Set

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4.8 Motor Control Center (MCC)
4.8.1 MCC Incoming Breaker +F05
The incoming voltage level is 3-phase 380 Vac, supplied from the customer 480 Vac switchgear.
The incoming MCC circuit breaker feedback is monitored by the PLC.
The PLC digital inputs receive the following signals:
- Circuit Breaker Closed;

- Circuit Breaker Tripped.
4.8.2 MCC 120V Distribution Panel +F06
The 120Vac distribution is single phase (L-N) taken from the main MCC supply bus (L1-L2) and sent
to a low voltage transformer inside the MCC.
The 120 V low voltage distribution panel feeds the following items:
- UPS Supply;
- Fire-Fighting Control Panel +F14;
- Control Voltage +F02;
- Control Voltage +F03.
Each item is individually protected.
4.8.3 MCC 230V Distribution Panel +F06
The 230Vac distribution is single phase (L-N) taken from the main MCC supply bus (L1-L2) and sent
to a low voltage transformer inside the MCC.
The 230 V low voltage distribution panel feeds the following items:
- Cyclo Transformers Heat and Light;

- E-House Lighting Panel +F17;
- Control Panel Light and Sockets (+F01, +F02 and +F03);
- Excitation Converter Control Voltage and Fan +F01;
- Cycloconverter Cooling Unit Control Voltage +F15;
- Simocode Active Termination Module/ Supply Network Analyser;
Each item is individually protected.
4.8.4 MCC Motor / Heater Starter Module
Each starter module is withdrawable type and is equipped with circuit breaker; contactor; Simocode
intelligent relay and control voltage transformer. The type of each device changes according the size
of the motor/heater fed by the unit. The electrical protection is done by the circuit breaker and by the
Simocode Intelligent Relay. The Simocode relay communicates with the ABB PLC through Profibus
protocol.
The following signals are sent from each relay to the ABB PLC using the Profibus link:

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- Motor percentage current;

- Status On / Off;
- Starter Module - General Fault;
- Starter Module - Test Position;
- Cooling Time Active;
- Motor Overload;
- Control Voltage OK;
- Starter Module Circuit-Breaker Closed;
- Simocode Device OK;
- Local Jog Pressed.
The following signals are transferred from the ABB PLC to the starter modules:
- Turn On Command;
- Turn Off Command;
- Reset.
For each starter module, in the front panel there are three indicating lights:
- Yellow for Fault;

- Green for Motor Running;
- Red for Motor Stopped.
The field interface, local jog and emergency stop, for lube, brake and cycloconverter unit are
hardwired directly to the starter module. The emergency stop is a hardwired safety protection
stopping the motors in any control mode. The local jog instead is only available when the motor is in
local mode set by the DCS operator.
Safety motor interlocks are also enabled during local jog operation. The jog mode enables the motors
to turn when the local jog pushbutton is pressed and stop the motors when the button is released.
4.8.5 MCC Single Feeder

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Just the air conditioners are supplied by single feeders. These single feeders are equipped with a
circuit breaker inside. The ABB PLC does not supervise single feeders and the electrical protection is
done by the circuit breaker inside the drawer.
4.9 Excitation Converter – DCF600
The Excitation Converter is a 3-phase (6 pulse) thyristor power converter unit, which is in charge of
supply DC current to the Rotor. The main supply of the DCF600 comes from the Excitation
Transformer, the control and auxiliary power for the Excitation Converter is supplied by the MCC
distribution panel.
The excitation cabinet consist of the following equipments:
- DCF600 Excitation Converter

- Rotor Overvoltage Protection
- Earth Fault Supervision Unit
- Network Overvoltage Arresters
- Overload Relay (with CT)
- DriveWindow Monitoring Software (installed in the Transient Recorder Computer)
The control and supervision of the Excitation Converter is carried out by the Drive Controller. The
relevant signals are sent via serial link to the PLC.
Following signals are sent/received by the Drive Controller and the Excitation Converter DCF600:
Analog Outputs Analog Inputs Digital Outputs Digital Inputs

Drive Controller=>DCF 600 DCF600 =>Drive Controller Drive Controller=>DCF 600 DCF600 =>Drive Controller
(0 – 10 V) (0 – 10 V)
- Excitation Current - Excitation Actual - Reset - Ready for Operation

Reference (iwe) Current (ixe) - On / Off - DCF Fault (trip)
- Actual Converter - Disable On
Supply Voltage Command
- Fan Feedback
- Overvoltage arrester
triggered
For detailed information about the DCF600 converter please refer to the volume 08 of the ABB
Documentation Set.
4.9.1 Rotor Protection
Additional signals inputs from the Excitation Cabinet (F01) to the Drive Controller are wired, to ensure
a proper protection of the rotor. They are the following ones:
- Earth Fault Rotor (DI)

- Excitation Overload (DI)
- Overvoltage Arrester Rotor Side (DI)
- Network Overvoltage Arrester (DI)
- Auxiliary Power Circuit Breaker (DI)

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4.9.2 Rotor Overvoltage Arrester
Inside the excitation cabinet (F01) a Rotor Overvoltage Arrester is provided. This overvoltage arrester
will prevent damage in the excitation converter caused by overvoltage coming from the rotor, and is
necessary for decoupling between the excitation transformer and field.
The rotor overvoltage arrester is mainly equipped with two thyristors (in antiparallel configuration), a
discharge resistor, BODs (Breakover Diodes), magnetic detectors and pulse transformers. See table
bellow.
The following represents a simplified diagram of the excitation circuit.

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In case of overvoltage detection or a desexcitation pulse, one of the thyristors will be

triggered/conducting and the rotor energy will be discharged in the resistor.
The rotor overvoltage protection can be triggered either by the Drive Controller (desexcitation pulse)
or by itself when overvoltage is detected by the BOD. In any case the magnetic detectors (read relay)
will send a digital signal to the drive controller to generate a trip and stop the converter.
The Drive Controller will generate the desexcitation pulse in the following cases:
- Hardware fault detection, detected by the hardware protection print boards (CS A463 or
CS A465), such as: PSR print board faulty, open doors, hardware overcurrent detection.
- Whenever an open command to the rotor circuit breaker is sent.
Rotor Overvoltage Circuit Diagram:
The following table shows the rotor overvoltage arrester parts:
Pos. Description Ident. Number

V141 / V241 Thyristor 3600V/50mm HUEL412304P0001
N143 / N243 BOD 1300V 3BHB003694R0015
K10 / K11 Magnetic Detector (Reed Relay) 3BHB001606R0004
T161 / T261 Impulse Transformer HIES308849P0001
C111 MKV Capacitor 0.47 PF, 2100 V HIES307857P0001
R1S1 Resistor 22:, 50 w NBT300208P0033
A101 / A201 Print Board HIER449459R0001
A143 / A243 Print XVA 540 HIES418699R0001

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4.9.3 Diagnostic Software Tool
It is possible to use the Drive Windows software tool to monitor the Excitation Converter. This
software tool is mainly intended for maintenance purposes and offers a complete supervision of all
actual signals and parameters. The communication link between the DCF600 and the VMS computer
is done through Fibre Optic.
4.10 PLC
The ABB PLC AC800M is used for controlling the following tasks:
- Control of Lubrication System;

- Control of Brake System (Partially implemented in the PLC);
- Control of Ringmotor Auxiliary System;
- Alarm / Events handling;
- Communication with DCS;
- Communication with the Drive Controller (PSR).
For an overview about the ABB PLC interfaces, see the “Network Architecture for GMD”
(3BHS235469).
4.10.1 Profibus Communication
Three Profibus master modules (CI854A) are connected to the ABB PLC.
These modules are responsible for the interface between the PLC and:
- The Input/Output Modules;

- The Intelligent MCC ;
- The Customer DCS.
4.10.2 Input /Outputs
The first CI854 - PLC Profibus Master is connected to the Input/Output Modules.
There are three Profibus Slave modules (CI801) for the IO, as described below:
- One for Digital Inputs;

- One for Digital Outputs;
- One for Analogue Inputs and RTD.
Digital inputs and outputs are 120Vac,
For more information, see the “PLC Bill of Material” (3BHS235470) and the “PLC IO Signal List”
(3BHS235471).
4.10.3 MCC Link
The second CI854 - PLC Profibus Master in the PLC Bus is responsible for the communication link
with the intelligent MCC.

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Motor and heater starter modules are equipped with the Simocode Relay. Each Simocode Relay has
a specific node number in the Profibus network. All data exchanged between the ABB PLC and the
MCC is done in Profibus.
4.10.4 DCS Link
The third CI854 - PLC Profibus Master in the PLC Bus is responsible for the communication link with
the DCS. All data exchanged between the DCS and the ABB PLC is done through this link.
For more information regarding the exchanged data please see the “PLC IO Signal List”
(3BHS235471).
4.10.5 Modbus Communication
The drive controller communicates with the ABB PLC in Modbus. The ABB PLC also acts as a
gateway between DCS and the Drive controller, forwarding all necessary information in both
directions. The ABB PLC has a native modbus interface.
In this communication the following information is exchanged:
- Drive Controller Fault signals;

- Drive Controller Warning Signals;
- Drive Controller Status Signals;
- Drive Controller On/Off Signals;
- PLC On/OFF Signals.
- Drive Controller Analog Values (Current, Airgaps, Power, etc)
For more information regarding the exchanged data please see the “PLC IO Signal List”
(3BHS235471).
4.10.6 VMS
VMS stands for Video Monitoring System and is based on the ABB IndustrialIT800xA System. The
VMS is used as a maintenance and troubleshooting tool and is present in each Ball Mill ABB E-
House. In the VMS is possible to:
- View trends of the ABB PLC controlled variables;

- Check alarm and events lists;
- View active interlocks;
- Monitor the cycloconverter cooling unit;
- Monitor the ringmotor;
- Monitor the stator and rotor medium voltage system;
- Monitor the lubrication system;
- Monitor the brake system;
- Monitor the E-House equipments like: fire-fighting, UPS, air conditioners;
- Check the drive controller for faults, warnings and status messages.
The VMS is not designed for plant control; all control must be done by the DCS operator.
4.11 Seismic Recorder

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The process equipment installed like the Gearless Mill Drives, E-House, converter etc., is
qualifying itself by withstanding the following dynamic behaviours:
- The expected magnitude of excitation, taking into consideration the operation in

a predefined earthquake prone zone.
- The configuration of the equipment, which in generally means, as taller, as
heavier, the construction, as lower is their natural resonance frequency and as
more close is this frequency to the typical earthquake frequency. In consequence
of that as higher is the risk of excitation from the earthquake frequency.
- The functional aspect of the equipment during and after the earthquake, which is
influenced by the importance of the equipment inside the production process and
the predefined level of the acceptable risk.
4.11.1 Triaxial Sensor
The AC-23 sensor package is a triaxial accelerometer designed for free field and industrial
applications. This sensor is well suited for applications where a high sensitivity is required.
The accelerometer must be firmly mounted to a surface and levelled, as the application requires. The
sensor housing has to be mounted with one of its axis in the upright position. Usually the other both
axis are directed to the N/S axis and the W/E axis. For the purpose in this installation the two
horizontal sensors will directed axially and radial to the axis of the mill bodies. The orientation
definitions as shipped are X=East, Y=North and Z=UP.

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4.11.2 SED Seismic Event Detector (Recorder / Trigger / Evaluation)
The SED is installed in E-house and powered with UPS. If power is cutting, the recorder will remain
operable and active with its charged battery over a few days time.
3 relay contacts are connected to the ABB PLC:
- Low level alarm

- High level alarm
- Equipment fault
SED Housing
Level Setting Indication
TRIAXAL WARNING
ACCELEROMETER LED PLC
x
TRIP
x,y,z
y
FAULT
Cable 100/240V~
30 - 100 m z
RS-232
Laptop
Configuration of the Seismic Event Detector
The instrument is configured as a seismic recorder, which detects events and keeps them locally in
the instrument memory (128MByte). A computer equipped with GeoDAS software can be connected
to the SED via the RS232 communications port and used for general tasks:
- Setup of the instrument. One can change any parameters of the instrument.
- State of health monitoring. GeoDAS performs permanent or periodical monitoring of an
instrument status.
- Download of the event files from the instrument.
- Off-line event data view and simple data analysis.
The memory must be erased periodically. It is wise to check the instrument frequently during the first
several days of operation after each set-up, to see if there are previously unsuspected sources of
noise which are triggering the instrument and using up the memory.

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4.11.3 Function
The Seismic Event Detector (SED) is a 12 Bit data acquisition system. One Sensor (Accelerometer) is
used which is installed out side of the Seismic Event Detector. The Sensor package is a triaxial
accelerometer made for free field installation, suitable for industrial application regarding strong motion
earthquake survey.
Alarm, trip and fault contacts from SED are wired to the PLC:
- Event with low level movement produce an alarm message to the main Control Room
(MCR)
- Event with high level movement provokes a mill shut-down. In the same time, the MCR
is informed by the PLC and can stop other equipment.
- The third signal received by PLC concern the SED fault; this information produce a
alarm message as well.
In the meantime, the SED will record any event
4.11.3.1 Suggested Set points
For the set-points we recommend the following values (valid for Zone 3 and 4 due to UBC)
- low level alarm 0,1 g

- high level alarm (shut down) 0,20 ÷ 0,22 g

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4.12 Lubrication System
The Lubrication System is responsible for the bearings oil supply. The lube system has its own oil
reservoir and pumps. Lube system must be on during the mill operation, otherwise the bearing and
axial guide could be damaged.
To prevent problems due to low oil flow, each lube system is equipped with an accumulator bank,
which is able to supply oil in order to guarantee a safe mill stop in case of trouble. In this case, the
accumulator valves (normally closed) are de-energized, letting the oil from accumulator flow to the
bearing.
4.13 Brake System
The brake system is supervised by the ABB PLC and controlled by the driver controller.
As the brake control valves are controlled directly by the drive controller, the control signals are sent
in addition to the PLC digital inputs informing about the status of the valves:
- PSR Quick brake command;

- PSR Normal brake command.
The drive controller needs fast feedbacks regarding the open or closed status of the brake, the
following PLC digital outputs have been hardwired to the PSR I/O:
- Brake Released;
- Brake Fault;

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5. Regulation
5.1 Principle of regulation
All the regulation, except excitation current regulator is done in the software of the PSR
(Programmable High Speed Controller) (see block diagrams of the regulation circuit diagram
drawing 3BHS235452 pag. 24 thr 28).
5.2 Overview
The whole regulation program is divided in four event controlled interrupt levels with four
priorities, and the self controlled Background interrupt processed independent of event. The
different priorities are shown in Figure 5.1. The filter programmes and the switching over of actual
current values have the highest priority.
Interrupt priority interrupt time 50Hz interrupt time 60Hz

Background (BKG) lowest priority
Interrupt 0 (INT0) highest level 0,833 ms 0,694 ms
Interrupt 1 (INT1) high level 1.667 ms 1,389 ms
Interrupt 2 (INT2) low level 5.00 ms 4,167 ms
Interrupt 3 (INT3) lowest level 20.00 ms 16,667 ms
INT 2/1
INT 0 INT 1
INT 2
detection trapez
INT 0 regulation
generation
filter current INT 2 INT 2/1 iwe
switching INT 2
voltage INT 2
integration INT 1
Speed INT 1
current
detection
regulator
speed generation R
INT 2 regulator references
phase
shifting switching
Speed over
reference S command
BKG generation BKG
Service output
Box adaption
Fig. 5.1 Blockdiagram of regulation with reference to the interrupt levels.

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PSR2- drive controler

Filter
3 =
ixR,S,T
Speed Controller Current controller

/\x / \D 2 \E 2 nw kp kp
Gate control unit Pulse amplifier
=
3 Ust 6 6
\ flux & speed - nx
calculation
R,S,T bridge A bridge A bridge B
Voltage iw 3 U
integration id, iq iw R,S,T Bridge commutating Pulse amplifier
Int. dq d,q SWI
RUB 6
SUB
bridge B
TUB
3
Filter
UxM R,S,T 3
Excitation converter
iwe calculation Pulse amplifier
\w \ 6
iwe
flux SM
\x controler
Fig. 5.1a General Overview of the Regulation Blockdiagram

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5.3 Current regulators (INT1 - S16..S18)
Function : Each current regulator controls one stator phase.

The principle is explained in the blockdiagram of the stator phase R (Fig. 5.2)
The difference between iWR and the filtered current actual value /ixR/ is the input of the current
regulator (PI-Type). At the output of this regulator the anticipatory voltage U* is added.
The summation UR is limited to the value of the rectifier limit position. From this limited output
UbR the voltages 'us and 'uT are subtracted (linearization), see fig. 5.2
+
duR
-
uaR Ui
kp TN kt Tt ks Ts
+
iwR
UstR Ud ixR
uR ubR
- - -
current- rectifier- rectifier- converter motor
regulator limit position limit position
/ixR/ duS duT
ixR
filter
Fig. 5.2 Current regulation circuit of stator phase R
The limit indication signals of the three stator current regulators (Rlimited, Slimited, Tlimited) are
connected to the trapeze logic and influence the trapeze regulator.
The limited outputs (UStR, UStS, UStT) are rectified in accordance with the bridge commutating
commands.

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6. Thyristor Supervision
6.1 Introduction
The Thyristor control system is the link between the closed-loop control and the thyristors. The
system checks the proper function of the MP and the thyristors. If a thyristor or a MP is faulty, a
switch-off command is generated (TRIP).
The principle of the TM Li is shown in fig.6.1.

Control-Unit
Release TM
ON
via fibre optic Receiver 12

Receiver 2
the XT B750B06
Report pulses fom
READY
Receiver 1
ALARM
CLOCK
TRIP SER/PAR
RESET
SET AL
DATA_OUT
DATA_IN
Fig. 6.1 Principle diagram of the TM Li

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The thyristor control system performs the following tasks:
- Supervision of the blocking capability of all thyristor places.

This enables continuous information to be obtained on the state of the thyristor valves. If the
blocking capability of a valve can no longer be assured, the thyristor control system generates
a TRIP-signal.
- Detection and localization of faulty thyristors resp. defective MP during energizing.

If the thyristors are able to block the voltage, the MP send report signals back to the TM Li. In
case of malfunction of thyristors or of the MP the TM Li generates ALARM and TRIP signals.
6.2 The thyristor control system
The thyristor control system can be divided into 3 parts :

- Thyristormonitoring ( TM Li )
- Fibre optic ( FOP )
- Monitoring PCB : XT B750 B06 ( MP ) close to the thyristor
FOP
MP
Thyristormonitoringsystem TM Li
MP
Fig. 6.2: Blockdiagram of the Thyristor Control System

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6.2.1 Monitoring PCB (MP)
The MP is close to the thyristors on high voltage potential. Every pair of thyristors is equipped
with one XT B750 B06. It is connected to the TM Li via a fibre optic cable.
A A
XT B750B06
4 K
The required energy to power the XT B750 B06 is derived from the voltage across the thyristor.
If the thyristors work properly, there is voltage across the thyristor for one halfwave of the sinus curve,
the XT B750 B06 has enough power to generate a report pulse. This report pulse with the width of
3μs is transmitted via fibre optic cable to the TM Li system. Every 20ms (when frequency of the AC
network is 50 Hz ) or 16,6 ms (when frequency of the AC network is 60 Hz ) a report pulse is
generated.
If the thyristor has failed, i.e. short-circuited, no pulse can be generated because there is no energy
on the board.
6.2.2 Thyristor Monitoring (TM Li)
a) Introduction
Every MP generates report signals, if supplied sufficiently with power. A faulty thyristor behaves like a
short circuit, the power supply of the MP is interrupted and therefore no report pulses can be
generated any more.
A faulty MP is usually not able to generate a report pulse.
The report pulses of all thyristor-pairs are checked periodically by the TM Li. In case of faulty thyristor
an ALARM and a TRIP is generated, and the location of the faulty thyristor is displayed.

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b) Description
After powering up the TM Li rack, the system automatically starts with checking the report pulses from
the MPs. As long as the signal Release TM is low no ALARM is generated if a report pulse is missing.
When the Release TM signal is set high the monitoring system begins to work after an ON delay of
100ms. The memories of the opto receivers XV C513A are cleared. Then the report signals from the
MPs set these memories again within 20ms / 16,6ms. If after a waiting period of 30ms the release
signal is still high, the data of the memories is loaded into a shift register and get scanned by the
Control-Unit XV C512AE.
After loading the data of the memories into the shift register, the memories of the opto receivers are
cleared and the same procedure starts again.
The Control-Unit compares the current content of the shift register with the content of the previous
run. If there is no difference between, the Control-Unit evaluates the data and generates an ALARM
and a TRIP if one or more report pulses are missing.
If there is a difference between the current content and the content of the latest run, the Control-Unit
does not evaluate the data. If the data of the following run is similar to the data of the current run the
Control-Unit will evaluate the data at the next run.
c) Meaning of the LED’s on the front panel of the Control-Unit XV C512AE
There are 4 LED’s on the front panel of the Control-Unit XV C512AE:
READY :
The Control-Unit checks the shift register and the serial data transfer between the units. If an
error occurs the ‘READY LED’ gets dark and the ‘READY’ relay opens the contact between
X601 PIN 15 and PIN 19 ( lower D-SUB connector on the left side of the rack ), resp. closes
the contact between X601 PIN 15 and PIN 17
ALARM :
If one or more report pulses from the XT B750 B06 are missing, the ‘ALARM LED’ is ON. The
‘ALARM’ relay opens the contact between X601 PIN 1 and PIN 5 ( lower D-SUB connector on
the left side of the rack ), resp. closes the contact between X601 PIN 1 and PIN 3. The
ALARM is stored until the R/LT button on the front panel of the XV C512A is pressed.
TRIP :
If one or more report pulses from the XT B750 B06 are missing, the ‘TRIP LED’ is ON. The
‘TRIP’ relay opens the contact between X601 PIN 9 and PIN 13 ( lower D-SUB connector on
the left side of the rack ), resp. closes the contact between X601 PIN 9 and PIN 11. The TRIP
is stored until the R/LT button on the front panel of the XV C512A is pressed.
BUSY :
The ‘BUSY LED’ is ON as long as more than 18 XT B750 B06 send their report pulses
periodically to the TM Li rack. This happens as soon as the thyristors are energized.

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6.2.3 Indication of a faulty thyristor
If a thyristor is faulty the corresponding XT B750 B06 ( MP ) has no energy, so it is not able to
generate a report pulse.
The green and red LEDs above the fiber optic cable connector indicate the status of the
corresponding thyristor pair. The green LED is ON as long as report pulses appear periodically. If a
report pulse is missing, the red LED turns ON and stays ON until the R/LT (Reset/LED Test) button
on the corresponding front panel is pressed.
6.2.4 Fibre optic (FOP)
Each pair of thyristors is supervised by one XT B750 B06 (MP).

The report pulses generated by the MP are transmitted via fibre optic cable to the receiver XV C513 in
the TM Li rack. Each single fibre optic cable (FOP) consists of a strand of 280 fibres with a diameter
of 55 μm. The strands are protected by a special plastic sheath. The ends are encased in an optical
plug and are ground plane.
6.2.5 Power supply
The TM Li rack needs an unstabilized voltage of 19......31 V DC (nominal 24V).

The current consumption (U = 24V) is: max. 1,0 A for the TM LI
6.3 Operation
6.3.1 Preparational operations
Before switching on the power supply, check if every PCB is correctly inserted and if all
cables are plugged in.
6.3.2 Checks before start up
Tampering by unauthorised personnel during operation must be prevented absolutely. PCB's

must not be removed during operation until the appropriate monitoring processor is
disconnected. Care must be taken to ensure that no short circuits are caused by a defect in
the measuring equipment as this may cause important signals to be suppressed, thus
endangering the system.

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7. Frozen Charge Protection
In order to protect the equipment against dropping charges a software package is used.
The function is the following:
The torque required consists of:
1. Torque for the empty mill

2. Torque for the milling of the material
3. Torque to lift up the frozen material
As the torque is proportional to the stator current, an increase of the current would be detected as
soon as the material does not start to cascade, when the position of 45 degree is reached and
overpassed.
After a turn of the mill up to 45 degrees (5 to 7 sec.) the current incrementation should come to
standstill, because the material starts to cascade.
If it does not do so, the charge could be frozen. If after a turning angle of 75 degrees (10 to 12 sec.)
the current does still not do decrease, the acceleration will be stopped and the drive shut down
immediately.
Angle Normal Frozen

Operation Charge
Torque Torque
S1 S2
15 0.33 0.33
1.5
30 0.43 0.43
1.3
45 0.59 0.59
60 0.48 0.80 1.1
75 0.45 1.00 0.9
90 0.45 1.30 0.7
0.5
0.3
0.1 S2
-0.1
15 S1
30 45
60
75
90
Values are estimated with speed of 20 % n Nominal.

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7.1 Precalculation and Comparison
The torque course and consequently the course of the RMS value of a GMD for a frozen charge can
be calculated with knowing the increase of the current at low degrees. This precalculated current
value at evaluation point is compared with actual current value. If the actual value is not lower than a
certain percentage, the drive will indicate a frozen charge and shut down immediately. The following
chart is showing the calculated comparing to the actual course of the torque for different loads.
frozen and normal charge
120
Margin of
Current reduction
100
80
torque (%)
60
40
20
0
0 20 40 60 80 100 120 140 160 180
angle (degree)
Figure 1 Actual and calculated course with the evaluation points
The limits of the system are the high demand on the RMS current and position accuracy to measure
the current increase at the evaluation point with the necessary precision. The mechanical
configuration in our application does not allow to mount a tacho or an other type of angle pick up on
the mill. Therefore, the angle measuring is done by using the signal of given air gap sensors. This is
the only way, except of the direct calculation using the motor conditions, which will result in worse
resolution when the drive is started. Neither one of this methods can fulfill the required accuracy.
Therefore the dropping charge protection is not implemented in this way.

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7.2 System Description
The chosen option to implement a dropping charge protection is a system that monitors the course of
the current, because the torque is a function of the current following the equation.
mU
M I
2S n
Extended to:
mU ª U P U § 1 1 ·¸ º
M « sin - ¨ sin 2- »
2S n ¬« X d 2 ¨X ¸
© q Xd ¹ ¼»
with:
m: number of phases Xp: stator reactance d axis
n: motor speed Xq: stator reactance q axis
U: supply voltage Up: pole wheel voltage
-: pole wheel angle M: motor torque
The mill has to be on constant speed to evaluate only the static component of the torque. Therefore,
the mill will be accelerated to about 20% of the nominal speed within the first 35 degrees. Then the
mill will be turning at constant speed up to about 85 degrees. The actual evaluation of the current will
start at 40 degree. This is necessary to settle the fluctuations in current and speed.
With no acceleration and other additional torque, the current will only be a function of lifting the load.
The torque for a frozen charge will increase all the time up to 90 degree otherwise it will suddenly
drop with the moment of cascading. The system will indicate a frozen charge, when not detecting an
inversion of the slope from rising to falling within a defined point. Or, if it distinguishing more of this
points, if the actual values of the indicated cascading points are increasing all the time.
This will be backed up if the actual current at the end of the evaluation is higher than a single
indicated cascading point. In this cases the drive will be immediately shut down, otherwise the control
will be released to allow a normal operation of the drive.
The system allows the operation in both directions, because the current and the charge will behave
the same in either direction.
7.3 Advantages
This solution is chosen because of several advantages. The adaptation of this kind of dropping
charge protection to the existing system is reasonable uncomplicated. We can easy supply the
required conditions with a synchronous motor and it does not need any additional sensors or
modifications on the mill shell itself. Further does the system cope with the fact of the comparatively
bad resolution of the angular position and the RMS - current feedback.
The implementation does not demand high processor performance or storage capacity, as for
recursive calculations and curve recording, which need to be done if using more curve comparing
procedures.
If the defined conditions, as constant speed and no additional torque is provided, the system is
supposed to indicate all dangerous situations if even the torque is not rising continuously.
A further advantage is its easy adaptation to already running sites. Only the software of the drive
needs to be changed.

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7.4 Limits
The dropping charge protection can only indicate a frozen charge, when the mill is turning at least 75
degrees and it starts with the load in ‘natural position’.
‘Natural position’ means the mill is not braked and the moment of inertia of the load is vertical to the
ground (mill is balanced). Therefore ‘manual lowering’ must be utilized to bring back the mill into
‘natural position’ if the mill was stopped with the brakes due to an emergency stop. The same is valid
when creeping or inching was used and the mill was stopped with the brakes.
7.5 Implementation of DCP
The implementation of the DCP (Dropping Charge Protection) is done in the software of the PSR
(Programmierbarer Schneller Rechner). The first generation of the PSR was developed to control and
supervise the first gearless mill drive in 1983. The current version, the PSR II is modular control
system which includes the following components:
x PSR II processing units

x High speed I/O - modules
x Digital firing pulse generators
x Universal modulators for GTO-Inverter
x Fieldbus and Communication Interfaces
The components are parallel linked with an internal high speed bus that allows the operation of up to
31 processor units. The processor units consist of two printed circuit boards . The communication
board is based on the Intel 80186 processor with application program and parameter memory. It does
include the interface to the parallel bus, an Intel standard interface iSBX and a serial communication
to the programming and diagnoses tool. The high speed processor board is based on an ABB design
RISC processor in extended Harvard architecture. Its features are:
x Application program control
x Micro program control
x Two separate data-busses and one address-bus
x Several parallel calculation units
x Interrupt controller
The interrupt controller allows the processing of different parts of the application software with
different cycle times. A change of the program parts is possible within 200ns after every processed
function block.
The available function blocks are defined directly in a high speed subroutine.
The PSR II unit will control the processing of the signal inputs as current and angle feedback and will
further supervise the speed of the mill while the DCP is active. Finally it will evaluate the current
course and decide whether the load is frozen or not.

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7.6 Frozen charge application software.
7.6.1 Angle detection.
For better resolution three air gap probes are used for the angle detection.
Usually the signals from the air gap sensors located at 3 o’clock position are selected, but as well other
positions can be used.
Probe no. 8
Probe no. 7
Probe no. 9
42 41
43
Probe no. 6
36
View from
Probe no. 10 Feed Side
44 35 Probe no. 5
45 34
Probe no. 11 Probe no. 4
46
Probe no. 12
31 32 33
Probe no. 3
Probe no. 1
Probe no. 2

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7.6.2 Frozen charge detection.
There are two major conditions to detect frozen charge.

1. Mill turning angle
- Angle of turning.
- Torque reference higher than specified starting torque (e.g. 130% nominal)
- Time delay 2 seconds
2. Rising edge of current signal
The frozen charge will be detected under following condition:

- At min speed 0.5rpm
- The mill is turning over a specified angle limit (ParamGrp_POLE-NUMBER1)
The default limit is set to: 75°
- The torque reference higher than specified starting torque (ParamGrp_iw-DCP-Limit).
Specified starting torque for this project is: 143%
If these two conditions are active for longer than 2 seconds frozen charge (trip) will be
detected.
The mill will remain minimum 30 seconds at minimum speed after material was cascading.
The frozen charge protection will be disabled as following:

- The torque reference has decreased. “Cascading has started”
- The torque reference is lower than nominal torque. (As specified)
- Supervision time is over. Setting is 30sec. after the first cascading.
- After the mill has turned over 130 degrees.

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Airgap no.1
Motor Voltage
Mill turned for 38 degrees
Cascading Started
Excitation Current
Motor Current
Speed Actual

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8. Trouble Shooting
8.1 Safety Instructions
High Voltage
Danger
1. High voltage in the incoming cubicle (+CA, +CB, +CC)!

2. Never remove the protecting shields.
3. Before you attempt any converter maintenance task:
- switch off the converter
- disconnect the converter from the main power supply
- take steps against unintentional energizing
- check that HV has disappeared
- be sure the converter is disconnected from all machine side power supplies.
4. Be sure there is no high voltage at the incoming bars of +CA,+CB,+CC (line side) and at the
outgoing bars of +CA, +CB, +CC (machine side) before you attempt any earth connection.
5. Connect the incoming bars of +CA,+CB,+CC (line side) to earth according the User’s Manual
3BHS 246003 instructions.
6. Connect the outgoing bars of +CA,+CB,+CC (machine side U,V,W) to earth according the
Cycloconverter User’s Manual instructions.
Low Voltage
Danger
Always low voltage (380 VAC, 240 VAC and 120 VAC) applied, if you disconnect the converter from
the main power supply.
Observe all local safety rules and regulations!

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!
Trouble Shooting
If you try to do trouble shooting work on the converter without knowing enough about it, you could be
hurt and the converter could be damaged. Be sure you have sufficient knowledge, experience, and
the proper replacement parts and tools before you attempt any converter trouble shooting.
Notice
Do not add any replacement part to the converter unless you check with the recommended spare
parts list or with ABB Industrie AG. None original parts can damage the converter. Some can just
keep other things from working as they should. Your warranty would not cover that.
8.2 Why You Should Read this Chapter
In this chapter you will find the best ways to deal with troubles and to keep the converter module
operating without any problems. Be sure you follow the instructions exactly or you could cause a
damage to the converter. Do not hesitate to call the hotline if any question arises (see paragraph 8.5
of this manual). Pay special attention to all safety instructions.

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8.3 Dealing with Troubles
If a fault occurs, the ABB Switzerland Ltd trouble shooting support is at your disposal. Please proceed
along the following steps. In any case of fault or malfunction please send form 1 (see paragraph 8.6
of this manual) to ABB Switzerland.
1. Find out the fault and put the converter into normal operation with the help of
your User’s Manual.
2. Ask your local ABB service organisation for support.
3. Ask ABB Switzerland for on-line support by phone.

(hotline: see paragraph 8.5 of this manual)
4. Ask ABB Switzerland for support on site.
8.4 Scope
The trouble shooting program only applies to the ABB equipment as specified below:
1. Converter Module
Manufacturer: ABB Switzerland Ltd

Type: Megadrive Cycloconverter
ABB order-No:: 1-1046221
Year: 2007
8.5 SupportLine
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If your local ABB service organization is not able to solve your problem, a hotline is at your disposal
every day for 24 hours.
Switzerland: Phone 0844 845 845
Other countries: Phone +41 (0) 844 845 845
In case of emergency the best is to contact our SupportLine. In the following a brief information is given about
the way technical support is usually provided by ABB Building Material and Mining Industries. In order to make
life easier for you we have a 24 hours, 7 days per week support hotline. The SupportLine records your problem
and immediately contacts the right person with the necessary technical skills within our organisation. This helps
you to avoid a sometimes cumbersome search to find out these things yourself and assures that you get the
support you need as fast as possible.
Here is the basic information on the supportline:

Phone No. Switzerland +41 ( 0 ) 844 845 845
Fax No: +41 ( 0 ) 58 586 73 08
e-mail: bmi.supportline@ch.abb.com
Clients with annual ABB Service Agreements have priority access to BMI SupportLine services, and have a
guaranteed response time depending on the level of the Service Agreement. Support requests from clients
without an annual ABB Service Agreement, are also handled by BMI SupportLine on an urgency basis, but
without a guaranteed response time, and at an hourly rate.
A SupportLine Agreement provides a single access point to ABB and our experts worldwide, via telephone, fax
and email, including priority handling. When necessary, SupportLine engineers offer a rapid escalation process
to worldwide specialists and products developers for additional assistance. The result is a rapid and competent
response to customer requests. This service is provided 24 hours per day, all year round.
An ABB SupportLine Agreement, will also provide a basis for future extension of Support Services, such as
parts, on-site service, remote diagnostics, and preventive maintenance packages, which you may require in the
future.
Please prepare the following information before calling the supportline:
- Specify the location of the plant (customer, country)

- Specify the plant (converter type, ABB order number, ABB block serial number, year of delivery)
- Your name and your phone/fax/telex number
- Describe the problem as follows (use form 1 next page):
What / When / Where / How / Why did it happen?

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8.6 Converter Fault or Malfunction - What to Do
If a fault or malfunction occurs, please send form 1 by fax to ABB Switzerland Ltd, Department
ATBDE, CH-5405 Dättwil/Switzerland, Fax +41 58 586 7323. You will help ABB Switzerland Ltd. to
continuously improve the product quality.
Form 1 / Page 1
Fault Description
ABB MEGADRIVE CYCLO
Return to:
ABB Switzerland, Department ATBDE, CH-5405 Dättwil/Switzerland
Fax +41 58 586 7323
Company/Address...............................................................................................................
Location of plant...................................................................................................................
Reporting person (Name / Phone/ Fax):...............................................................................
Type of plant:....................................…… Type of drive:.......................................................
ABB block serial number:......................... ABB order number:...............................................
Year of delivery:................................…… Date of provisional acceptance:............................
Covered by warranty:..........……….......... Yes No
1. Define the fault(s) by filling in page 3 and 4.
2. At which operating phase did the fault occur? Please specify:
during start-up cont. operation acceleration deceleration
speed = ...............rpm power = ................kW line volt. = .............kV
3. What did happen just before the fault has occurred? Please specify:
lightning voltage dip start-up of other consumers
others / please specify....................................................................................................
............................................................................................................................................
4. Brief description / Your comments:
.......................................................................…...................................................................
..............................................................................................................................................

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Form 1 / Page 2
Fault Description
ABB MEGADRIVE CYCLO
5. When did the fault occur? (year, month, day, time)......................................................
6. Did the fault occur for the first time? Yes No
7. Could you localize and clear the failure and restart the drive? Yes No
8. Do you need assistance by ABB Switzerland Ltd? Yes No
Date.....………………………………. Signature.......................................................................

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Form 1 / Page 3
Fault Description
ABB MEGADRIVE CYCLO
Fault Indications at the Cyclo-Converter Control Display (Panel +F02)

Tier 1
(press or to show additional faults):
No. Text
First Fault*
*first message on the Drive Controller display AFC094

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Form 1 / Page 4
Fault Description
ABB MEGADRIVE CYCLO
Fault Indications at the PCB's in the PSR Rack- Tier 4

(if LED is "on" cross the box)
-A PCB type LED On? -A PCB type LED On? -A PCB type LED On?
13 NU 8976 a ON 45 UA C326 ON 69 GD B021 ON
FAULT READY READY
MOD ERR MOD ERR
21 PP C322 ON 49 UDA 327 M1 73 GD B021 ON
READY M2 READY
MOD ERR 53 UDA 327 M1 MOD ERR
BUS ERR M2 77 GD B021 ON
33 PMA324 ON 57 GD B021 ON READY
M1 READY MOD ERR
M2 MOD ERR
37 UA C326 ON 61 GD B021 ON
READY READY
MOD ERR MOD ERR
41 UA C326 ON 65 GD B021 ON
READY READY
MOD ERR MOD ERR
Fault Indications at the Protection PCB's in the PSR Rack - Tier 6

CS A463/-A09 CS A465/-A01
LED Protection Function On? LED Protection Function On?
04 Cycloc.Overcurrent R1 03 HW Error PPC322
07 Cycloc.Overcurrent S1 04 HW Error PMA324
10 Cycloc.Overcurrent T1 05 HW Error UAC326 .1
28 Cycloc.Overcurrent R2 06 HW Error UAC326.2
31 Cycloc.Overcurrent S2 07 HW Error UAC326.3
34 Cycloc.Overcurrent T2 08 HW Error UDA327.1
09 HW Error UDA327.2
10 HW Error GDB021.1
30 HW Error DDA353
31 HW Error FM 9925 *
32 HW Error LT8978 Disex.
33 Cyclo doors open
-A PCB Type LED On? -A PCB Type LED On?

13 FM 9925 * 10 45 LT 8978 15
17 DDA353 15 49 LT 8978 15
21 LT 8978 15 53 LT 8978 15
25 LT 8978 15 57 LT 8978 15
29 LT 8978 15 61 LT 8978 15
33 LT 8978 15 65 LT 8978 15
37 LT 8978 15 69 LT 8978 15
41 LT 8978 15
* Optional

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Form 1 / Page 5
Fault Description
ABB MEGADRIVE CYCLO
Fault Indications at the Thyristor Monitoring Rack- (+Tier 8)

-A Unit Lamp/LED On? -A Unit Lamp/LED On?

09 XV C512 Alarm 53 XV C513 X1 RED
Trip X2 RED
Ready X3 RED
Busy X4 RED
X5 RED
X6 RED
Fault indication at XV C513 -A49 X7 RED
-A53 X8 RED
-A57 X9 RED
X10 RED
X11 RED
-A Unit Lamp/LED On? X12 RED
49 XV C513 X1 RED 57 XV C513 X1 RED
X2 RED X2 RED
X3 RED X3 RED
X4 RED X4 RED
X5 RED X5 RED
X6 RED X6 RED
X7 RED X7 RED
X8 RED X8 RED
X9 RED X9 RED
X10 RED X10 RED
X11 RED X11 RED
X12 RED X12 RED
8.7 Converter Fault Finding and Trouble Shooting Chart
please refer to chapter 4.3.4

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9. Training
9.1 General
ABB University in Switzerland training programs are specially designed to give the appropriate
support to the customer for the fault-free and safe operation of the converter . The training programs
cover fundamentals on technology as well as practical exercises in order to optimize the man-
machine communication.
9.2 Basic Training (1 day / compulsory)
This compulsory 1-day basic training is held on site at the end of the commissioning phase. ABB
recommends training at least three persons. They should have sufficient technical or electrotechnical
knowledge and experience. The training program covers the three steps 'Operation Instructions',
'Fundamentals Part 1 on Technology' and 'Safety Instructions'. This training is always part of the
delivery.
9.3 Maintenance Training (3 to 5 days / optional)
In accordance with the customer's needs ABB holds this additional training either in Switzerland or at
the customer's office. ABB recommends training at least three persons at the same time. They should
be experienced professionals in the electrotechnical field. The training program covers the four steps
'Trouble Shooting', 'Maintenance', 'Fundamentals Part 2 on Technology' and 'Safety Instructions'. The
training will last between three and five days according to the customer's demands and will be
charged separately.

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10. Special tools
Necessary tools for service and commissioning

Quant.
Pos.
Description, Comments
1 1 HIOKI Memory Recorder 8855 (8 channels, with printer)

2 1 PC, Notebook (DOS & windows 2000, XP)
3 1 Interface Converter SSV-3E / RS232/485
4 1 CMT for DCS/DCF500&600
5 1 PT100 Simulator SE45
6 1 AC Current probe P602I, Tektronix
7
8
9 1 Megger Insulation Tester Metriso 5000
10 1 Clamp-Amperemeter L H1040
11 1 Digital Multimeter Metra Hit 18 S
12 1 Thermometer noncontact (Raytek)
13 1 Three-phase Sequence Tester
14
15 1 Volt/mA Calibrator (Muter)
16 1 AC Current Probe 80i 1000s
17 1 RC–Dekade GG0101
18 3 Differential probe SI 9005
19 1 Extension Print, XB9599a
20 1 Maxi-Thermipoint Tool, incl. wire, clamps
21 1 Set of Hand Tools & diff. small Parts
22 1 Soldering Station
23 1 Various Test Cables, Plugs, Clamps

Print date:16/12/2009 16:15:00

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Title: Drwg No:

Gearless Mill Drive Manual 3BHS 235 454

CHIND / ATBDE 28.07.2009 en Volume 4 - 1/115

TITLE: Ball Mill Drive Operation Manual

ORDER NO.: 1-9501271

Issued: Released: Revision:

Gearless Mill Drive Manual 3BHS 235 454

CHIND / ATBDE 28.07.2009 en Volume 4 - 2/115

1.1 Why You Should Read this Manual 6

1.2 How to Read The ‘Operation Manual’ 7

1.3 ABB GMD Documentation Set 9

2. ABB RING MOTOR TECHNOLOGY 10

2.1 Good reason to go gearless 10

2.2 The Cycloconverter-Fed Synchronous Motor 10

2.3 Design and Operation 12

2.5 Static Converter 13

2.6 Methods of Controlling the Cycloconverter 14

2.7 Static Flux Model 17

2.8 Dynamic Flux Model 19

2.9 Current Control Circuit 20

2.10 Trapezoidal Mode 21

2.11 Specific System Features 21

2.12 Network Reactions 22

3.1 Design datas 23

3.2 System Overview 27

4.1 Safety Instructions 29

4.2 Why You Should Read this Chapter 31

ABB Switzerland Ltd. / ATBDE Andina Ball Mill Op Manual_3BHS235454_EN_rev-.doc

Gearless Mill Drive Manual 3BHS 235 454

CHIND / ATBDE 28.07.2009 en Volume 4 - 3/115

4.3 Operation Instructions 32

4.4 Motor Local Control Panel (MLCP) 63

4.5 Ring Motor 69

4.6 Medium Voltage System 75

ABB Switzerland Ltd. / ATBDE Andina Ball Mill Op Manual_3BHS235454_EN_rev-.doc

Gearless Mill Drive Manual 3BHS 235 454

CHIND / ATBDE 28.07.2009 en Volume 4 - 4/115

4.8 Motor Control Center (MCC) 79

4.9 Excitation Converter – DCF600 81

4.11 Seismic Recorder 86

4.12 Lubrication System 89

4.13 Brake System 89

5.1 Principle of regulation 90

5.3 Current regulators (INT1 - S16..S18) 92

6.2 The thyristor control system 94

7. FROZEN CHARGE PROTECTION 98

7.1 Precalculation and Comparison 99

ABB Switzerland Ltd. / ATBDE Andina Ball Mill Op Manual_3BHS235454_EN_rev-.doc

Gearless Mill Drive Manual 3BHS 235 454

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7.2 System Description 100

7.3 Advantages 100

7.4 Limits 101

7.5 Implementation of DCP 101

7.6 Frozen charge application software. 102

8. TROUBLE SHOOTING 105

8.1 Safety Instructions 105

8.2 Why You Should Read this Chapter 106

8.3 Dealing with Troubles 107

8.4 Scope 107

8.5 SupportLine 108

8.6 Converter Fault or Malfunction - What to Do 109

8.7 Converter Fault Finding and Trouble Shooting Chart 113