DCS800 Lift Magnet Supply

ADC3 EN REVA 2009

supply Multiple magnet supply Emergency backup configurations

AC input 3-ph

Application notes

I>>

K01

electronics-, fan- supply

DCS800

+ -

Many cranes lift ferrous material by using a magnet instead of a hook. Nowadays new cranes, like small tower cranes or overhead bridge cranes (EOT), are equipped with AC drives and a thyristor-based DC supply for the lift magnet. Lift magnets are used for a wide range of applications. They are also used in metals plants for lifting rods and coils. Iron Scrap cranes and iron rod and bar handling cranes use magnetic force for the iron goods. When replacing the magnet supply, the new magnet supply must have an application program that adapts to all different control concepts and handles the original relay logic.

service switch K02.0

K03D

K04B

K02.1

K02.2

Many different load and operation types are required

Simple scrap magnets Complex metal sheet stacks Demagnetization control One magnet
AC input 3-ph

Typical lift magnet system with load from several switched magnet and back-up battery

Demagnetization
The physical remnants of the magnets create a residual force even if the input current of the magnet is zero. The release of light weight loads is done by demagnetization. Decreasing alternating (positive and negative) magnet current will erase the residual force. A four-quadrant converter which can supply current in either direction is required for this operation.

I>>

K01

electronics-, fan- supply

DCS800

+ -

Flux forcing for higher dynamic

The electrical circuit characteristic of this type of magnet consists of a high amount of inductance in series with a resistance. This ends up in a very long time constant when switching the magnet's input current ON and OFF. This will lengthen the cycle times of the operation and decrease the total crane efficiency. The time constant can be decreased by increasing the input voltage during current changes. For example, a 200 V DC magnet

Minimum lift magnet supply with one magnet

ADC3 EN REVA 2009

is powered by a 440 V DC supply system. During continuous operation, the converter provides 200 V DC to the magnet. When energizing and de-energizing the magnet, the converter is able to provide maximum or minimum output voltage which, in this case, is positive 440 V DC or negative 440 V DC. This decreases the current ramp time by 80%.

Voltage

Current Time

Typically, magnet installations have more than one magnet connected in parallel. The number of magnets used depends on the load and will be switched ON and OFF with contactors controlled by the operator. This saves energy for the whole installation. The converter controls the output voltage and not the output current. The output voltage is independent from the number of connected magnets. Newer cranes usually do not use contactors. They use independent converters for each magnet. This redundancy provides higher safety for the user. Be aware that normal contactors are not able to switch the magnet current. Only the switch ON can be handled by the contactors. The installation must be equipped with an overvoltage protection to clamp the maximum output voltage of the converter when switching the contactors.

Customer benefits
Easy to handle - less training Full current range Fits on classic lift magnet installations Meet all requirements for modern and

new installations All common serial communication interfaces Upgrade of old systems by adaptation via IEC 61131 programming Voltage and current control mode Synergy with DCS800 crane drives Synergy with ACS800 drives

ABB Automation Products Wallstadter Strae 59 68526 Ladenburg GERMANY Phone +49(0)6203-71-0 Fax +49(0)6203-71-7609 www.abb.com/motors&drives dc-drives@de.abb.com

Copyright 2009 ABB. All rights reserved. Specifications subject to change without notice.

Application notes

Step by step release

If the load is a stack of sheet metal, the operator can unload the crane sheet by sheet by slowly reducing the magnetic force. The converter can simply reduce the output voltage and thus the output current. This is a big advantage compared to traditional diode magnet supplies.
Current controlled switch ON magnet Add magnets by contactor Reduce magnet force by reducing Voltage / current Switch OFF magnet by reversing current for demagnetization

Emergency battery backup operation

Falling material can always be dangerous and can also waste a lot of money. Therefore, some crane systems are equipped with an emergency back-up battery. This battery can supply the DC current to the magnets for a short while. The batteries are connected via a contactor in case of mains loss.

Emergency backup battery charge

In some configurations the magnet supply converter is also used to charge the emergency backup battery during crane standby. The different configurations will be switched by contactors.

Switched parallel operation of several magnets depending on load

The DCS800 converter can handle the lift magnet application and meet customer's requirements. Additional functions are controlled by the CoDeSys IEC 61131 program, especially magnetic specific functions. It can customize the application to the customer's requirements and IO functions. New small tower cranes or new bridge cranes (EOT) are equipped with AC drives nowadays. ACS800 drives for the hoist and the trolley together with a DCS800 lift magnet supply provide convenient synergies to the customer. The control interfaces, serial communication, the monitor and maintenance equipment is the same. That means less training and easy support. Older crane installations are equipped with DC drives for hoist and trolley. The DCS800 meets the requirements of large cranes like a container crane or a garb ship unloader. A DCS800 crane drive application module provides all required functions like shared motion for hoists and gantry as well as brake control, power optimization and stand alone joystick interface.