0010244216

• Hoisting, slewing, luffing, trolley and long travel gears as well as single and multi-motor drives
• The devices are ideally suited to crane modernization applications, because the existing components such as motors, resistors, cables, etc. can usually be reused.
• Devices are available in special versions for high ambient temperatures up to 65 °C.

The SIMOTRAS HD AC power controller is used for the open and closed-loop control of three-phase slip-ring rotor motors for cranes and hoisting gear.

SIMOTRAS HD is a fully-controlled digital, 3-phase thyristor controller in a compact design with stator phase control and electronic field reversal with ratings of between 20 and 580 kW for the open and closed-loop control of slip-ring rotor motors for cranes and hoisting gear.

All converters are equipped with a basic PMU operator panel in the door of the unit. The PMU can be used to perform all the adaptations, settings and measured value displays required for commissioning. The basic unit can also be operated via its serial service interface using a commercially available PC and suitable software. All device settings (e.g. controller parameters, limits, etc.) are stored in the device in a non-volatile memory.

The SIMOTRAS HD device comprises:

• The power unit
• Basic electronics

Power unit

The power unit is a 3-phase thyristor AC power controller in a compact design. Two additional thyristor modules in the lateral branch of the power unit enable reversing of the rotating field, and therefore 4Q operation of the drive. Current transformers in 2 phases generate the actual current value for current control.

Basic electronics

The basic electronics contains the gating unit that activates the thyristors. It generates line-synchronized firing pulses. The control electronics is isolated from the line potential via firing pulse transformers.

All device settings (e.g. controller parameters, limits, etc.) are stored in the device in a non-volatile memory. Adjustment is performed digitally, via the operator panel on the device. The values are therefore easy to reproduce at any time.

Depending on the load conditions, the converter operates in motor mode (driving direction of rotating field, 1st and 3rd quadrant) or in braking mode with reversing current braking (2nd and 4th quadrant). Through omission of the conventional stator contactors, fast torque reversal is possible, with resulting high control dynamics.

Supplementary modules

See the section Electronics options section.

The speed changes steplessly in the control range when the master switch is operated. The crane driver only detects the end of the control range through latching of the master switch. Furthermore, the final stage is reached sub-synchronously or super-synchronously, depending on the load, by traversing the characteristics that are determined by the resistor increments. Current control is always operating to ensure that the set maximum torques are not exceeded. It goes without saying that the circuits are protected against reversal.

Control characteristics for hoists

Up to 4 rotor resistor switching stages can be provided. If less than 4 stages are implemented, the top stages (S3/S4) remain unused.

If the upper stages S3/S4 are not used, the over-synchronized speed increases in accordance with the parameterized characteristic on lowering. This must be taken into account when selecting overspeed protection. For this reason, a speed corresponding to the characteristic can also only be achieved during lifting.

Control characteristics for gantries

Up to 4 rotor resistor switching stages can be provided. If less than 4 stages are implemented, the top stages (S3/S4) remain unused.

Master switch signals

The incoming signals from the master switch, such as setpoint and control enable, are loaded.

• A master switch with setpoint potentiometer can be connected direct to the SIMOTRAS HD.
• A 4‑stage master switch requires the CUD2 terminal expansion module for connection.

Ramp-function generator

The series-connected ramp-function generator with adjustable ramps forms the speed setpoint.

Speed controller

The speed controller with the subordinate current control circuit is connected down-circuit of the ramp-function generator and forms the actual control loop.

Start pulse

A start pulse is also generated so that the machine is activated in the hoisting direction of rotation immediately after power up. This prevents the load from dropping on start-up.

Sequencer

For switching through the rotor stages, a sequencer is installed that selects the planned stages speed-dependently and activates reversing.

Standstill monitoring

The integral zero-speed monitoring supports guided, electrical braking of the drive. For replacing the cable, e.g. in hoists, jog mode with creep speed is provided.

Operating states

The operating states are indicated in the device on a 5-digit, 7-segment display as well as the LEDs of the basic PMU operator panel.

Operating modes

The threshold for switchover between closed-loop and open-loop controlled operation can be defined in accordance with the control characteristic and set on the parameters of the device.

Parallel connection

To increase the performance, up to 6 devices can be connected in parallel. The terminal expansion option (CUD2) is required in this case for every device and (n-1) patch cable. Current splitting requires identical, separate parallel switching reactors for each SIMOTRAS device. The difference in reactor tolerances determines the current distribution. For operation without derating (current reduction), a tolerance of 5 % or better is recommended. Only devices with the same current ratings are permitted to be connected in parallel.

Crane technology

The drive-based (crane) control is integrated into the SIMOTRAS HD device. The SIMOTRAS HD device comprises:

• Power unit
• Electronics box with basic electronics

The drive-based (crane) control is designed to permit easy switchover between master switches with setpoint potentiometers and 4-stage master switches: The control functions can be specified by terminals.

Notes on configuration

Rated current of the device I_rated

In crane operation, the motors are not operated continuously, but with variable load, at varying speeds, and with different ON durations. Under these conditions, it is sufficient when the rated current for the device I_rated is greater than the motor rated current. In intermittent duty with appropriate pauses in operation, the devices can carry twice the rated device current of I_rated greater than the rated motor current for 20 s. In intermittent duty with appropriate pauses in operation, the devices can carry twice the rated device current of I_rated for 20 s. This covers all the normal acceleration situations that occur with cranes. The SIMOTRAS HD devices can be operated continuously at the rated current for the device I_rated; the limit temperature for the thyristors will, however, be reached. Acceleration is not permitted from this operating state since the thyristors could be overloaded.

Rotor contactors

To ensure a reliable ramp-up from the closed-loop control characteristic to rated speed, it is recommended that 4 rotor contactors are used. Activation of the rotor contactors through contactor relays.

Permissible ON duration

Under unusual operating conditions, such as traversing with full load at extremely low speed for a long time, motors, resistors and SIMOTRAS HD must be dimensioned appropriately. When phase angle control is used, a higher stator current flows to achieve the necessary torque due to the reduced magnetization. The motors may become thermally overloaded, because the thermal power losses rise with the quadrant of the current. The resistors are overloaded when the closed-loop control characteristic is traversed for an extended period.

Rotor resistances

Since the speed is influenced with additional rotor resistors, the rotor performance is largely converted into heat in the external resistor. This ensures that excessive heating of the motor is avoided when traversing at low speed over long periods.

Emergency or safety limit switch

Due to the lack of stator contactors, the motor can no longer be galvanically isolated from the AC power controller, e.g. when an operational limit switch is actuated. If the controller is then not able to block the thyristors due to a device fault, this could result in an impermissible operating state.
It is therefore recommended that emergency or safety limit switches are used. These respond when the operational limit switch is passed and act on a line contactor or the crane switch.

D400/60‑180 Mre device type

¹⁾ Minimum clearance for air circulation. An adequate flow of cooling air must be provided.

D400/225‑360 Mre device type

¹⁾ Minimum clearance for air circulation. An adequate flow of cooling air must be provided.

D400/525 Mre device type

¹⁾ Minimum clearance for air circulation. An adequate flow of cooling air must be provided.

D400/680 Mre device type

¹⁾ Minimum clearance for air circulation. An adequate flow of cooling air must be provided.

D400/900 Mre device type

¹⁾ Minimum clearance for air circulation, customer connection and fan replacement. An adequate flow of cooling air must be ensured.

²⁾ Remove transport plate before commissioning by removing 6 M6 hexagon bolts.

• Compact design
  with the open-loop control integrated in the drive
• Favorably-priced solution in the retrofit area
  by using slip-ring rotor motors that already exist in the plant or system

The SIMOTRAS HD converters can be ordered with the following options:

Operating Instructions in German are supplied with every device.

AC power controller in the basic version

¹⁾ The fuses listed are not included with the device. The fuses listed are recommended fuses that must be ordered separately.

²⁾ It is permissible to operate the device without interruption with the rated connection current I_rated. This will cause the thyristors to reach their limit temperature. It is not possible to accelerate, i.e. increase the current from this operating state.

¹⁾ The fuses listed are not included with the device. The fuses listed are recommended fuses that must be ordered separately.

²⁾ Fuses included with device. No semiconductor fuses are necessary.

³⁾ It is permissible to operate the device without interruption with the rated connection current I_rated. This will cause the thyristors to reach their limit temperature. It is not possible to accelerate, i.e. increase the current from this operating state.

AC power controller in the special version

¹⁾ The fuses listed are not included with the device. The fuses listed are recommended fuses that must be ordered separately.

²⁾ It is permissible to operate the device without interruption with the rated connection current I_rated. This will cause the thyristors to reach their limit temperature. It is not possible to accelerate, i.e. increase the current from this operating state.

¹⁾ The fuses listed are not included with the device. The fuses listed are recommended fuses that must be ordered separately.

²⁾ Fuses included with device. No semiconductor fuses are necessary.

³⁾ It is permissible to operate the device without interruption with the rated connection current I_rated. This will cause the thyristors to reach their limit temperature. It is not possible to accelerate, i.e. increase the current from this operating state.

Option H78:

Operation at an ambient temperature higher than +65 °C is not possible. The rated current, reduced compared to the standard version, must be maintained across the entire temperature range of 0 ... 65 °C.

Load values depending on the temperature of the coolant and installation altitude

Reduction factor for load values at installation altitudes above 1000 m

Reference to SIMOTRAS HE

SIMOTRAS HD is almost fully compatible with SIMOTRAS HE (6GA4625... series).