ABB - ACS800 Learning Guide - Drive Dimensioning For Cranes

ACS800
Learning Guide
Drive dimensioning for cranes
Tcont.hoist =
Tacc
(m0 + mL ) g v
mech
2

1
v

=
(Jm + Joth ) +
(m 0 + mL )
t acc
mech

ABB
ACS800
Frequency converters ACS800 with Direct Torque Control can easily be used on
demanding applications as cranes.
In this document we give some hints for selecting motors and drives, taking into
account some specific requirements on hoists and travel motions.
We consider as well new overhead traveling cranes as refurbishing jobs.
When using this document, actual drives and motors performances and compatibility
must be checked with suppliers latest information.
Feedback and comments about this dimensioning document can be sent to:
frans.busschots@be.abb.com
mikael.holmberg@fi.abb.com
Frans Busschots,
BE-ABB
Rev 1.0.EN
ABB
Rev 1.0.EN
17 April 2008
Sheet 2
N of sh 65
ACS800
Dimensioning theory motor basics

Crane basics
Motor choice, ACS800 Drive and brake resistor sizing
Example
Tools
ABB
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Sheet 3
N of sh 65
ACS800
Content (1)
Sheet
1 Introduction
2 General condition of a dimensioning procedure
10
3 Induction motor (AC) fundamentals

3.1 Torque / speed diagram with direct on line start
3.2 Torque / speed diagram with frequency converter
3.3 Maximum motor torque with frequency converter
3.4 Continuous motor torque with inverter
3.5 Rated motor torque / maximum motor torque
3.6 Relation power and torque
3.7 Relation power and torque: example
3.8 Operation in four quadrants (hoist)
3.9 Operation in four quadrants (long and cross travel)
3.10 Duty factor uprating
3.11 Duty factor uprating: example
3.12 Motor derating with ACS 800 and standard motors
3.13 Motor ambient conditions
3.14 Maximum motor speed
3.15 Motor with reinforced insulation and/or insulated N-bearing
3.16 Motor in DELTA connection at 87 Hz (230 V/ 400V)
3.17 Motors 400 V / 690 V
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11
12
13
13
14
16
17
18
19
21
22
23
24
25
26
27
29
ACS800
Content (2)
Sheet
4 Crane basics
4.1 Hoist
4.1.1 Torque and power needed to hoist a load at constant speed
4.1.2 Torque needed to lower a load at constant speed
4.1.3 Torque and power needed to accelerate/ decelerate a load
4.1.4 Total torque needed on a hoist drive
4.1.5 Maximum power needed on a hoist drive
4.1.6 Maximum braking power needed on a hoist drive
30
4.2 Gantry/trolley travel Long/cross travel
34
4.2.1 Torque and power needed to move a crane at constant speed

4.2.2 Acceleration torque from 0 to maximum speed
4.2.3 Maximum torque needed on a travel drive
4.2.4 Maximum power needed on a travel drive
4.2.5 Total braking torque/power needed on a travel drive
5 Particular cases
37
5.1 Motors in parallel

6 Motor choice
41
6.1 Hoist
6.2 Travel motions
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ACS800
Content (3)
7 Drive sizing Hoist and travel
43
7.1 Drive module

7.2 Brake chopper / resistor sizing for a hoist
7.2.1 Continuous braking power
7.2.2 Peak braking power
7.3 Brake chopper / resistor sizing for travel motions
7.3.1 Travel indoors
7.3.2 Travel outdoors with wind
7.4 Brake chopper sizing
7.5 Brake resistor sizing
7.6 Regenerative drive
7.7 Common DC-Bus
8 Redundant drives
51
9 Crane refurbishing
52
9.1 Total revamp

9.2 Partial revamp
9.3 Dimensioning replacement drives
9.3.1 Replacing DC-motors
9.3.2 Slipring motors
10 Crane Control
56
11 Examples (draft)
57
11.1 Hoist
11.2 Travel
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ACS800
Content (4)
12 Examples Motor and drive choice
62
13 Tools
65
13.1 Excel sheet for hoist

13.2 Excel sheet for travel
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ACS800
1 Introduction
E.O.T. Crane
Electrical Overhead Traveling Crane
Capacity typical 10 350 Tons

Mostly used indoors
Frequently used in power plants / paper and metals industry / waste handling
ABB
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ACS800
1 Introduction
An E.O.T. Crane has 3 motions:
Hoist: hook up and down
Cross travel (= short travel): trolley movement
Long travel (= crane travel): gantry movement
Sometimes there is an auxiliary hoist on a second trolley for tilting purposes, or an auxiliary hook to
handle smaller loads at higher speed
Some cranes have 2 identical hooks on 2 separate trolleys to handle long products or a special hook
with master/follower in synchro control
ABB
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2 General condition of a dimensioning procedure

1. Check the initial conditions of the network and the load
2. Choose a motor according to:
a. thermal loadability
b. speed range
c. maximum needed torque
3. Choose a drive according to
a. continuous and maximum current
b. network conditions
c. braking requirements
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ACS800
3 Induction (AC) motor fundamentals

3.1 Torque / speed diagram with direct on line start
Maximum torque
Thermally
dimensioned working
point
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ACS800

3.2 Torque / speed diagram with frequency converter
Power
Max mot Torque x 0,7
Rated motor torque
%
250
200
150
V constant
field weakening
V/Hz constant
100
50
0
0
10
20
30
40
50
60
70
80
90
100
Frequency (Hz)
Motor flux depends on V/Hz ratio:

From 0 Hz to rated motor frequency (typical 50 Hz), V/Hz ratio can be kept constant
If V/Hz ratio is kept constant, flux is constant
Motor torque is constant
Motor power goes up with increasing speed
Above rated motor frequency (typical 50 Hz), supply voltage normally corresponds to rated motor
voltage and can not be increased to follow the increasing frequency:
So V/Hz ratio will diminish, and flux goes down with increasing freq.
(field weakening)
Motor torque decreases with increasing freq, power is constant in this range
ABB
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ACS800

3.3 Maximum motor torque with a frequency converter:
3.3.1 Below nominal frequency (typically 0 to 50 Hz):
To have a safety margin, the maximum design torque should be 70% of maximum torque
TMAX Design = 0.7 x TMAX /TN

Typical values for TMAX /TN for squirrel cage motors: 2.5 to 3.0
3.3.2 In field weakening area (typically 50 Hz to FMAX):

Maximum motor torque decreases with the square of the frequency ratio:
TMAX = TMAX
50 Hz /TN
x (50 Hz / FMAX )
maximum design torque should be only 70 %:
TMAX Design = 0.7 x TMAX /TN x (50 Hz / FMAX )

e.g. at 100 Hz:
TMAX Design = 0.7 x TMAX /TN x 1/4

At double frequency, maximum torque is divided by four!!!!
3.4 Continuous motor torque with a frequency converter:

see 3.12 Motor derating
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3.5 Rated motor torque / maximum motor torque
3.5.1 Motor catalogue
Motor M3BP 280 SMB

P: 90 kW
Speed: 1483 rpm
Tn = Nominal (rated) torque: 580 Nm
Maximum torque (also called breakdown torque):
TMAX/TN = 2.7 , so TMAX 580 x 2.7 Nm = 1566 Nm
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3.5.2 Below nominal frequency (0 to typically 50 Hz):
maximum design torque should be T = 0.7 x TMAX / TN
T = 580 x 2.7 x 0.7 = 1096 Nm
3.5.3 Above nominal frequency (50 Hz to ....Hz):

2
e.g. at 100 Hz : T = 0.7 x TMAX /TN x (50 Hz / 100 Hz) = 0.7 x 580 x 2.7 / 4 Nm
T = 274 Nm
In the field weakening range, the motor power is expected te be constant,
but the maximum available motor torque will be the limiting factor!!
Motor rated power is 90 kw
BUT: maximum available torque is only 274 Nm,
Maximum motor power:
P = T x n / 9550 = 274 x 3000 / 9550 = 86 kW, overload included
(instead 90 kW with 150% overload in heavy duty)
Power
Rated motor torque
Maximum Motor Torque x 0,7
250
200
150
100
290 Nm (90 kW)
50
274 Nm (86 kW)

0
0
10
20
30
40
50
60
70
80
90
100
Frequency
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ACS800

3.6 Relation power and torque
Relation Power Torque (on same shaft):
T =
T=
Nm
with
2
*n (rad/s)
60
P * 9550
Nm
n
Or:
P=T*
P =
T * n
Nm
9550
Important note: always consider torque and power on same shaft,

e.g. after a gearbox torque can be enormous at very low speed
Definitions:
F
P
T
v
ABB
Force(N)
Power
(w)
Torque
(Nm)
Velocity of the load
(m/s)
Efficiency
Angular velocity (rad/s)
(rpm)
Motor shaft speed
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3.7 Relation power and torque: example
motor M3BP 315 SMC-6, 110 kW, 991 rpm
rated torque: Tn =
ABB
110* 9550
P * 9550
Nm =
Nm = 1060 Nm
n
991
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3.8 Operation in four quadrants (hoist)
Speed
Up
Acc I
Down
Dec II
Acc III
Time
Dec IV
T
IV I
Deceleration when lowering
Braking
Acceleration when hoisting
Driving
III II
Acceleration when lowering
Driving
Braking
Deceleration when hoisting
With a suspended load on the hook, braking is also necessary during a normal lowering
of the load at steady speed !!!
Maximum braking torque is needed at the end of the lowering!
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ACS800

3.9 Operation in four quadrants (long and cross travel)
3.9.1 Travel movement without wind
Speed
Forward
Acc I
Backwards
Dec II
Acc III
Time
Dec IV
T
Deceleration backwards
IV I
Braking
Acceleration forwards
Driving
III II
Acceleration backwards
ABB
Driving
Braking
Deceleration forwards
Only braking power needed during deceleration (forwards and backwards)
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3.9.2 Travel movement with wind
When wind is blowing in opposite direction as the crane is moving, a lot of

pressure can be built up on the crane surface (e.g. 250 Nm/m!!): this effect gives
an extra load torque: acceleration will be more difficult!!
The wind torque can drive the crane by itself: after releasing the brakes the full
motor torque must be immediately available to prevent the crane rushing in the
wrong direction (safety !!)
When wind is blowing in the same direction as the crane is moving, the wind
torque can drive the crane by itself: after releasing the brakes the full motor torque
must be immediately available to prevent the crane to go in overspeed (safety !!)
(The situation can be compared with a hoist during lowering!)
Maximum braking torque is needed to stop the crane.

Attention when using braking resistors: a lot of energy must be evacuated
during total travelling time, not only at stopping the crane
At maximum wind force (above the safe working limit), it must be possible to
drive the crane to a safety position where the crane can be mechanically blocked
to the rails.
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ACS800

3.10 Duty factor uprating
On a crane not all motors are fully loaded all time. During a time lapse at no load or at standstill,
the motor temperature can cool down, so the average temperature will be lower as compared to a
motor that runs at full load continuously (S1).
In some cases a smaller motor can be chosen, but dont forget too take into consideration that
there is less cooling at low speed. See next pages.
The duty cycle can be very different for the different crane movements.
E.g. After a hoist movement to pick up a load the crane must travel to another point before the
load will be lowered.
Important note:
Duty factor uprating concerns only motor temperature rise, a smaller motor has a lower
breakdown torque: to be checked!!
The table below (ABB motors) can be different for different motor manufacturers.
Intermittent
duty, S3
15%
25%
40%
60%
ABB
Poles
2
4
6 -8
2
4
6 -8
2
4
6 -8
2
4
6 -8
Permitted output as %
of rated output in S1
for motor size: (ABB)
56-100
112-250
280-450
115
145
140
140
145
140
140
140
140
110
130
130
130
130
130
135
125
130
110
110
120
120
110
120
125
108
120
105
107
110
110
107
110
115
105
110
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ACS800

3.11 Duty factor uprating: example
Continuous motor power needed, based on the dimensioning calculation:
48 kW, 1480 rpm
Normal motor choice: 55 kW
But, hoist motion Duty Factor is estimated: S3 60%
We can check the smaller motor: M3BP 225SMC-4, 45 kW
In the table on page 20 we find the Uprating factor for shaft height 225: 107%
so motor M3BP 225SMB-4, 45 kW can be used for 45 x 1.07 = 48.15 kW
No need to use bigger motor.
Intermittent
duty, S3
15%
25%
40%
60%
ABB
Poles
2
4
6-8
2
4
6-8
2
4
6-8
2
4
6-8
Permitted output as %
of rated output in S1
for motor size:
56-100
112-250
280-450
115
145
140
140
145
140
140
140
140
110
130
130
130
130
130
135
125
130
110
110
120
120
110
120
125
108
120
105
107
110
110
107
110
115
105
110
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107 %
Sheet 22
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ACS800

3.12 Motor derating with ACS 800 and standard motors
T/Tn
110%
Separate
cooling
100%
Class F temperature rise

used for Class B motor
90%
80%
Temperature rise
Class B
70%
60%
50%
40%
0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
Relative speed
Important notes:
Dont choose lowest point of speed range at ZERO speed:

Every crane starts at ZERO speed, but normally the lowest speed is only used for a short
time.
A hoist is a constant torque application, so, if zero speed is chosen as a working point, the
derating result will be exaggerated.
ADVICE: try to estimate the average motor speed during a cycle and consider also the duty
cycle as shown on page 20.
If not specified by the end-user and when ambient temperature is normal, class F temperature
rise can be used.
But dont forget: a motor winding temperature increase of 10K will divide expected lifetime
by factor 2
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ACS800

3.13 Motor ambient conditions
Normal rules about ambient motor conditions must be considered.
EOT cranes can be in very difficult situation:
always close to the roof: heat built up
sometimes above furnaces or hot coil or slabs: heat radiation
moisture and dirt in metallurgy: avoid dirt in cooling air
ABB
Ambient temperature
C
30
40
45
50
55
60
70
80
Permitted output
% of rated output
107
100
96,5
93
90
86,5
79
70
Height above see level

m
1000
1500
2000
2500
3000
3500
4000
Permitted output
% of rated output
100
96
92
88
84
80
76
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ACS800

3.14 Maximum motor speed
When a motor is connected to a drive, the output frequency can be set above 50 Hz (field
weakening area)
As seen on page XXX the maximum available motor torque decreases sharply, but also
mechanical factors must be considered when using motors above rated speed:
- centrifugal forces on the rotor
- bearing lubrication
- noise of motor fan (when no forced ventilation is used)
The table below indicates max. motor speed for standard motors without special arrangements,
for all individual cases the motor manufacturer must be consulted.
Frame Size ABB motor

80 - 90 - 100
112 - 132 - 160 -200
225 - 250 -280
315 (2p)
315 (4-12p)
355 - 400 (2p)
355 - 400 (4-12p)
ABB
Max speed (rpm)

6000
4500
3600
3600
3000
3600
2500
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3.15 Motor with reinforced insulation and/or insulated N-bearing
Motor nominal power PN or frame size

PN < 100 kW
PN 100 kW or
IEC 315
PN 350 kW or
IEC 400
UN 500 V
Standard motor
Standard motor
+ Insulated N-bearing
Standard motor
+ Common mode filter
UN 600 V
Standard motor
+ dU/dt - filter
Standard motor
+ dU/dt filter
OR
Reinforced insulation
Standard motor
+ dU/dt -filter
OR
+ dU/dt - filter
+ dU/dt -filter
OR
UN 690 V
ABB
+ dU/dt - filter
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ACS800

3.16 Motor in DELTA connection at 87 Hz
(230 V/ 400V)
A 3 phase motor designed 230 V/400 V, 50 Hz has all six leads connected to a terminal box.
Y or : depends on line voltage available
Y : for line supply 3 x 400 V, 50 Hz
: for line supply 3 x 230 V, 50 Hz
In configuration the V/Hz ratio is 230/50.
When we connect this motor to a drive with supply voltage 230V,
field weakening starts around 50 Hz.
But if we connect this motor to a drive with supply voltage 400V,
field weakening starts around 87 Hz, what means that between 50 and 87 Hz this motor can
deliver the same torque as below 50Hz.
Power
Rated motor torque
Motor voltage
87 Hz corresponds with 400V
Motor 400V, 87 Hz, D

400
350
Voltage
300
250
50 Hz corresponds with 230V
200
150
100
50
0
0
10
20
30
40
50
60
70
80
90 100
Frequency
ABB
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Summary:
Nominal voltage
Nominal frequency
Nominal current
Nominal power
Nominal speed
old rating plate

3 x 400 V, Y
50 Hz
11,5 A
11 kW
2930 rpm
new rating plate

3 x 400 V,
87 Hz
20 A
19 kW
5125 rpm
With same torque at higher speed, the motor can deliver more power.
Important remarks:
1.When changing the connection from Y to , the motor current is multiplied with 1.73, so a
bigger drive is needed!! (corresponding to the new motor power)
2.ID-run parameters in group 99 of the drive must be filled in with the old rating plate data (at 50
Hz). The drive calculates automatically the new field weakening point related to the available
DC-voltage.
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ACS800

3.17 Motor 400 V / 690 V
Motor nameplate:
When supply voltage is 400 V, this motor must be connected in and it is not
possible to use this motor at 87 Hz with constant flux
When supply voltage is 690 V, this motor can be connected in Y for normal use:
with constant flux till 50 Hz and above 50 Hz in field weakening area: with
constant power
OR:
The motor can be connected in and when supplied by an ACS800 at 690V with
constant flux to 87 Hz.
Motor power will be 11 kW x 1.73 = 19 kW
Speed: synchronous speed: 3000 rpm x 1.73 = 5190 rpm
Slip: same (constant flux): 3000 rpm 2930 rpm = 70 rpm
Real rated motor speed: 5190 rpm 70 rpm = 5120 rpm
Not 2930 rpm x 1.73 = 5069 rpm, as slip dont increase!
ABB
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ACS800
4 Crane basics
4.1 Hoist
Tcont.hoist =
or
Pcont.hoist =
(m0 + mL ) g v Nm (I)
mech
(m 0 + m L ) g v Watt
mech
Definitions:
m0 Mass of the lifting system (rope/hook..)
which is hoisted with load
(kg)
mL Mass of the load (kg) + ? overload (see local
conditions)
g
Gravity
(9.81 m/s2)
v
Hoist motion velocity (m/s)
mech Mechanical efficiency (typical 0.9)
n
Motor speed (rpm)
2 n
=
( rad / s )
60
ABB
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Speed
Tcont hoist I
Up
Down
Time
Tcont low. IV
4 Crane basics
Tcont.lower =
or
(m0 + mL ) mech g v
Nm (IV)
Pcont.lower = - (m 0 + mL ) g v mech Watt

This is the continuous braking power !!
Definitions:
m0 Mass of the lifting system (rope/hook..)
(kg)
mL Mass of the load (kg) + ? overload (see local
conditions)
g
Gravity
(9.81 m/s2)
v
n
Motor speed (rpm)
ABB
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Crane basics
4.1.3 Torque during acceleration and deceleration
Acceleration torque from 0 to maximum speed (hoisting and lowering):
Tacc
2

1
v
=
(Jm + Joth ) +
(m 0 + mL )
Nm (I-III)
t acc
mech

Tdec
2

v
=
(Jm + Joth ) + mech (m 0 + mL )
t dec

Nm (II-IV)
Speed
Up
Acc I
Down
Dec II
Acc III
Dec IV
Time
Definitions:
m0
Mass of the lifting system (rope/hook..)
2 n
(rad / s )
60

(kg)
mL Mass of the load (kg) + ? overload (see local conditions)
g
Gravity
(9.81 m/s2)
v
tacc Acceleration
(sec)
tdec Deceleration
(sec)
(ramp) time
(ramp) time
2
Jm
Motor moment (kgm )
Joth Inertia for other (kgm2)
of inertia
rotating parts reduced to motor
n
Motor speed (rpm)
shaft
ABB
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4 Crane basics
TMax = Tcont.hoist + Tacc
(4.1.1 and 4.1.3)
If the deceleration time is shorter then the acceleration time, it is possible that
Tdec > Tacc

Then
TMax = Tcont.hoist + Tdec
(4.1.1 and 4.1.3)
Maximum braking torque
TMax braking = Tcont.lower + Tdec
(4.1.2 and 4.1.3)
Check if fast stop or emergency stop ramp is required! (Braking distance!)
P Max =
T Max * n
kW
9550
n: motor speed (rpm)
P Max
ABB
braking
T Max braking * n
kW
9550
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Sheet 33
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ACS800
4 Crane basics
4.2 Gantry/trolley travel Long/cross travel
4.2.1 Torque and power needed to move a crane at constant speed
(friction)
4.2.1.1 Torque due to rolling friction:
Tf =
(m 0 + m L ) w f v
Nm
mech
4.2.1.2 Torque due to wind
Tw =
vW
mech
Nm
Wind force is given by the wind velocity and the wind area:
W = A wind *
v wind
N
1.6
with W = 250 N/m at wind speed 20 m/s
Definitions:
m0
mL
wf
v
W
Awind
Weight of the crane part

which is moved with the
gantry
(kg)
Mass of the load (kg) + ? overload (see local conditions)
Friction coefficient
(N/kg)
2 n
Gantry velocity (m/s)
=
( rad / s )
60
Wind force (N)
Wind area (m2)
n
Motor speed (rpm)
Wheel diameter
(mm)
250
315
400
500
>500
Wheel friction
0 07
0 065
0 06
0 055
0 05
ABB
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Sheet 34
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ACS800
4 Crane basics
(4.2 Gantry/Trolley travel)
4.2.1.3 Total continuous torque (thermal motor load)
Tcont = Tf + Tw (rolling friction + wind)

4.2.2 Acceleration/deceleration torque from 0 to maximum speed
Tacc
2

1
v
=
(Jm + Joth ) +
(m 0 + mL )
t acc
mech

Tdec =
t dec
(Jm + Joth ) + mech (m 0 + m L )
Definitions:
m0 Mass of the crane / trolley
which is moved with the load (kg)
mL Mass of the load (kg) + ? overload (see local conditions)
v
Crane / trolley motion velocity
(m/s)
i
Gear ratio
tacc
tdec
Jm
Joth
Acceleration
(sec)
(ramp) time
Deceleration
(sec)
(ramp) time
Motor moment (kgm2)
of inertia
Inertia for other (kgm2)
ABB
Rev 1.0.EN
17 April 2008
2 n
( rad / s )
60
motor speed (rpm)
Sheet 35
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ACS800
4 Crane basics
4.2.3 Maximum torque needed on a travel drive during acceleration
TMax = Tf + Tw + Tacc
(4.2.1.1; 4.2.1.2; 4.2.2)
If the deceleration time is shorter then the acceleration time, it is possible that
Tdec > Tacc

Then check if deceleration with wind in same direction is worst case?
TMax = Tdec + Tw - Tf
(4.2.1.1; 4.2.1.2; 4.2.2)
4.2.4 Maximum power needed on a travel drive
P Max =
T Max * n
kW
9550
n: motor speed (rpm)
4.2.5 Total braking torque/power needed on a travel drive

4.2.5.1 Without wind forces
Tbraking = Tdec - Tf
(4.2.1.1; 4.2.2)
(only during deceleration time)

4.2.5.2 With wind forces during travel in same direction as wind
Tbraking = Tw
(4.2.2)
(contiously during travel in same direction as wind)

4.2.5.3 Peak braking power at end of travel in same direction as wind
TPeak braking = Tdec + Tw - Tf
(4.2.1.1; 4.2.1.2; 4.2.2)
(peak only during deceleration time)
ABB
Rev 1.0.EN
17 April 2008
Sheet 36
N of sh 65
ACS800
5 Particular cases
5.1 Motors in parallel
All gantry drives and most trolley drives have multimotor configuration.
As all this motors are mechanically connected (over the rail) and their load is more or less identical,
these motors can be connected as a group to ONE drive or in different groups to more drives in
master/slave connection.
5.1.1 Motor dimensioning
All basic torque and power calculations on previous pages remain valid, but dont forget to add all
motors and couplings inertia together.
Finally the needed torque can be divided by the number off motors installed
BUT: always check for the worst case scenario
E.g. gantry drive:
When the trolley is moved to extreme left or right position on the crane, the weight of the trolley and
the load will be very asymmetrical for the gantry motors. This can be seen when comparing the
reaction forces on the gantry wheels (info from crane maufacturer)
M1
M1
M2
Short travel
Short travel
M4
M3
Rail A
M4
M3
Rail B
Long travel
M2
Rail A
Rail B
Long travel
E.g. gantry weight : 100 ton, trolley 30 ton, load 40 ton

Equally distributed load: left side 50 + 35 ton right side 50 + 35 ton:
85 85 ton
Trolley left position: 80 % of trolley + load extra to the left side: 50 + 56 ton
load to the right side: 50 + 14 ton:
106 56 ton
So 25 % more load on motors M1 and M3
The motor choice (max. torque) must be based on this worst case load
ABB
Rev 1.0.EN
17 April 2008
Sheet 37
N of sh 65
ACS800
5 Particular cases
5.1.2 Drive dimensioning
5.1.2.1 One single drive
When only 1 drive will feed all motors, the current absorbed by each motor will be related to the
(electrical) slip of this motor (slip is related to the load).
When some motors are loaded less because load is asymmetrical, the other motors will be loaded
less, so total current will be the same as presumed in the calculations.
Extra hint:
When connecting motors in parallel to 1 drive, always consider the sum of the maximum motor
currents to choose the appropriate drive and never motor powers, as the sum of the magnetizing
currents of a number of smaller motors is bigger than for 1 bigger motor.
(These effect increases with increasing motor pole pairs.)
E.g. 4 pcs motors M3BP 225 SMB-8, 22 kW, 730 rpm, 400 V, 45 A.
Total current 4 * 45 A = 180 A
Compared to a motor M3BP 315 SMC-8, 90 kW, 741 rpm, 400 V, 167 A.
Motor powers mentioned in the drive catalogue normally refer to 4p motors:
Motor M3BP 280 SMB-4, 90 kW, 1483 rpm, 400 V, 159 A so 13% difference
ABB
Rev 1.0.EN
17 April 2008
Sheet 38
N of sh 65
ACS800
5.1.2.2 Drives in Master/Slave connection

For each group of motors the worst case scenario must be considered:
When connecting all motors from one side of the gantry together (M1-M3 and M2-M4), load can be
asymmetrical and drives must be upgraded accordingly. Not only the position of the cross travel, but
also the structure of the crane can give different load.
M1
M2
Short travel
M4
M3
Rail A
Rail B
Long travel
When connecting the motors in the front and in the back of the gantry together (M1-M2 and M3M4), there is no influence from the trolley position, only the crane structure can cause a (permanent)
load difference.
Master alone can also move the crane. Attention for braking distance.
M1
M2
Short travel
M4
M3
Rail A
Rail B
Long travel
ABB
Rev 1.0.EN
17 April 2008
Sheet 39
N of sh 65
ACS800
5.1.2.2 Drives in Master/Slave connection (continuation)

For a good load distribution, a cross connection left/right front/back can also be used
Disadvantage: no speed correction left/right possible
M1
M2
Short travel
M3
M4
Rail A
Rail B
Long travel
ABB
Rev 1.0.EN
17 April 2008
Sheet 40
N of sh 65
ACS800
6 Motor choice
6.1 Hoist
6.1.1 Thermal motor load
Needed continuous motor torque T: see sh 30
(4.1.1)
Corrections with:
duty factor (uprating) sh 21
speed range (derating) sh 23
ambient conditions sh 24
(3.10)
(3.12)
(3.13)
Continuous motor torque at rated speed: continuous motor power
P =
T * n
Nm
9550
Motor can be chosen in motor catalogue.

For a hoist the cont. motor torque is normally the most demanding criterion, but check always the
maximum needed motor torque
6.1.2 Maximum motor torque

Needed maximum torque: sh 33
(4.1.4)
Corrections with: maximum design torque sh 13
(3.3)
Attention: Once a motor is chosen, all calculations where (estimated) motor inertia is
used (acceleration torque!!) most be reconsidered with the exact inertia
6.1.3 Real motor data:

Check motor rated current
Calculate motor current corresponding to max. motor torque needed.
Consider some saturation effect above rated motor torque (10% e.g.)
ABB
Rev 1.0.EN
17 April 2008
Sheet 41
N of sh 65
ACS800
6.2 Travel motions

Maximum motor torque T needed: see page 36
(4.2.3)
Choose motor according this maximum torque, taking into account the maximum design torque:
sh 13
(3.3)
Attention: Once a motor is chosen, all calculations where (estimated) motor inertia is
used (acceleration torque!!) most be reconsidered with the real motor inertia
For a travel motion (indoor) the maximum torque is normally the most demanding criterion, but
checks always the continuous motor power needed. For outdoor cranes the wind load can be
considerable, dimensioning with the data for the thermal load are on sh 35:
continuous motor torque
(4.2.1.3)
Continuous motor torque at rated speed: continuous motor power
P =
T * n
Nm
9550
Motor can be chosen in motor catalogue.
6.2.2 Real motor data:

Check motor rated current
Calculate motor current corresponding to max. motor torque needed.
Consider some saturation effect (10% e.g.)
ABB
Rev 1.0.EN
17 April 2008
Sheet 42
N of sh 65
ACS800
7 Drive sizing hoist and travel

7.1 Drive module
Choose drive ACS800 according the motor power in heavy duty use (6.3)
heavy duty usemeans:

Maximum drive current during 1 min is 150% of rated HD current.
If max. motor torque needed > 150% (travel!!)

a bigger drive must be chosen
Max. current needed / 1.5 < I hd
ABB
Rev 1.0.EN
17 April 2008
(6.3)
Sheet 43
N of sh 65
ACS800
7 Drive sizing
7.2 Brake chopper / resistor sizing for a hoist
7.2.1 Continuous braking power:
Braking
Power
Speed
Hoisting
Up
Down
Time
Lowering
Duty cycle:
- time for lowering: max. hoisting height / load speed (s)
pause:
- time for hoisting: max. hoisting height / load speed (s)
- time for connecting/disconnecting load to be added to cycle time
Remark: if braking continues over 30 seconds, braking is considered continuous
and not intermitted.
7.2.2 Peak braking power

At the end of a lowering cycle the deceleration power must be added to the continuous power
due to gravity, but this power also decreases at decreasing speed.
PMaxbraking =
ABB
TMaxbraking* n
kW
9550
Rev 1.0.EN
17 April 2008
(4.16)
Sheet 44
N of sh 65
ACS800
7 Drive sizing
7.3 Brake chopper / resistor sizing for travel
7.3.1 Travel indoors
Braking
Power
Speed
Left
Dec
De c
Right
Time
Duty cycle:
- deceleration time left + deceleration time right
pause:
- time for traveling left and right
- time for connecting/disconnecting load to be added to cycle time (no load)
Braking power decrease with decreasing speed: triangular load with short duty cycle
ABB
Rev 1.0.EN
17 April 2008
Sheet 45
N of sh 65
ACS800
7 Drive sizing
7.3.2 Travel outdoors with wind
Speed
Braking
Power
Wind
in back
Wind
in front
Left
Dec
De c
Right
Time
Duty cycle:
- time for traveling left + deceleration time right + deceleration time left
pause:
- time for traveling right
- time for connecting/disconnecting load to be added to cycle time
Braking power is continuous during travel with wind in the back if wind torque is bigger as the
resistive torque: the length of the track will be determining the braking resistor capacity.
ABB
Rev 1.0.EN
17 April 2008
Sheet 46
N of sh 65
ACS800
7 Drive sizing
7.4 Brake chopper sizing:
Capacity of internal braking chopper (option code +D150) must be checked:
(certainly for frames R2 and R3 where the internal braking chopper is standard in all drives.)
Pbrcont = Phd . (30 seconds)
Max. continuous braking torque < continuous Pbrcont

If internal chopper is too small:
-
external braking chopper must be added

or a bigger drive can be chosen with higher Pbrcont
ABB
Rev 1.0.EN
17 April 2008
Sheet 47
N of sh 65
ACS800
7 Drive sizing
7.5 Brake resistor sizing:
Parameters to define a braking resistor:
1. Peakpower that the resistor must be able to absorb:
Pmax <
UDC
R
UDC : voltage over resistor during braking = 1.35*UAC *1.2

(1.2: chopper starting voltage)
R: resistor value in ohms: a too high value will limit braking power!
Remark: lowest resistor value allowed on brake chopper as mentioned in table (R)
ABB
Rev 1.0.EN
17 April 2008
Sheet 48
N of sh 65
ACS800
7 Drive sizing
2.Power than can be dissipated by heat transfer to the air, taking into account a cycle time,
Or:
continuous power capacity
intermittent power capacity
The power capacity of standard resistors in ABB drive table (sheet 48) is normally to small for
hoist applications and travel with wind.
In order too boost capacity with same resistance value 4 resistors can be put in series / parallel
to obtain four times thermal capacity.
Also other combinations are possible or resistors can be purchased from other manufactures, as
long as the minimum resistor value is respected.
ABB
Rev 1.0.EN
17 April 2008
Sheet 49
N of sh 65
ACS800
7 Drive sizing
7.6 Regenerative drive
7.7 Common DC-Bus
ABB
Rev 1.0.EN
17 April 2008
Sheet 50
N of sh 65
ACS800
8 Redundant drives
8.1 For each drive 1 extra drive: full redundant solution.
For very critical installations where interruptions in the process can not be allowed, an extra drive
can be installed for fast switch-over.
8.2 One drive as back-up for 2 drives with similar kVA.
A drive can have 2 parameter sets, so a redundant drive can be switched between 2 movements.
E.g. between main and auxiliary hoist, or between long and cross travel
8.3 No extra drives installed but switching between movements for alternative movements of the
crane.
ABB
Rev 1.0.EN
17 April 2008
Sheet 51
N of sh 65
ACS800
The metal structure of a crane has a longer lifetime as the electric and electronic components, so
after some years a crane can be modernized.
9.1 Total revamp:

All motors/drives will be replaced
9.2 Partial revamp:

In case of existing AC slipring or AC squirrel cage motors, these motors can sometimes be reused after cleaning and/or adaptations. New drives will be added.
9.3 Dimensioning replacement drives

Motor and drive dimensioning is the same as shown in previous pages, but often it is difficult
to find the old files with the original design criteria. In that case the dimensioning must be
based on the specifications of the existing motors and drives.
9.3.1 Replacing DC-motors
Try to find out what was max. overload allowed: 160% or 200% (?) and check field
weakening range, this can be higher than allowed for AC motors.
Motor base speed is normally not a standard synchronous speed.
Important remark:
9.3.1.1 When choosing an AC motor with higher base speed, motor power must be extra
derated accordingly the speed difference.
9.3.1.2 When choosing an AC motor with lower base speed, motor power is constant in the
field weakening area, but then max. speed must be checked.
9.3.1.3 DC-motors can have a wide field-weaking range. When replacing by AC-solution,
dont forget the limitations by the maximum motor torque at higher frequencies.
3.2.2 (sh 12)
ABB
Rev 1.0.EN
17 April 2008
Sheet 52
N of sh 65
ACS800
Some basic information:
Slipring motors can have high pull-out torque compared to squirrel cage motors.
This is never mentioned on the motor rating plate.
Other places where this data can be found:
motor manufacturer (motor serial number!)
original motor catalogue from date of purchase of the motor
original file about the crane (delivered by crane manufacturer, often kept in the
mechanical maintenance department
TMAX /TN : 4-5.5 is possible

Table ABB HXS slipring motors:
ABB
Rev 1.0.EN
17 April 2008
Sheet 53
N of sh 65
ACS800
Some basic information (continuing):
By changing rotor resistance maximum torque is available from start to rated speed
T
R2E
Definitions:
2 3
T
TL
n
nSn
R2E
1-4
TL
nsn
Motor torque
Load torque
Motor speed
Rated synchronous speed
External rotor resistance
Load points
This high starting torque is not well controlled. When nearly no torque is needed (at no load
conditions e.g.) the crane moves not gently but whit shocks at start.
Important remark:
1. Slip ring motors are typically rotor critical and originally designed for speed control in the
area 70-100 % of rated speed. With a drive the peed range goes to 0%. But lower speeds are
critical from loadability point of view
2. The choice of a slipring motor was normally based on the thermal load of the motor,
taking into account:
duty cycle
the number of starts per hour: every start causes an inrush current independent from
the actual load. This current causes heat:
resistance x ( current )
ABB
Rev 1.0.EN
17 April 2008
Sheet 54
N of sh 65
ACS800
Some basic information (continuing):
after choosing a motor a final check was made to see if the maximum motor
torque of this motor was sufficient also for the worst case in the working cycle: e.g.
starting torque with full load against the wind!
2 situations possible:
1. maximum motor torque is too small: a bigger motor will be chosen
2. maximum motor torque is sufficient: motor choice is OK,
but the full motor torque will never be needed
After e.g. 25 years it will be very difficult to find out the real need.
An oversized motor and drive will not cause problems for the crane behavior as the
motor torque will be adapted by the drive to the real need. Only
When connecting slipring motors to a drive, the rotor circuit must be short-circuited:
external in connection box
but: slipring and brushes remain in service and continue to wear
internally on rotor itself
motor must be opened and rotor must be dynamically rebalanced
on a hoist drive: encoder must be added on motor shaft

when re-using existing motors the use of du/dt filters is recommended to decrease the
voltage stress on the motor insulation
ABB
Rev 1.0.EN
17 April 2008
Sheet 55
N of sh 65
ACS800
9 Crane Control ACS 800

(more doc to follow)
Uline
UDC
Uout
brake resistor
ACS800-Crane Control 0x
Rectifier
L
L1
Supply
Inverter
V1
L2
L3
DC link
+
V3
Ud
V4
RMIO motor and application ctrl
V6
Control Electronics
control, monitoring and communication
V2
U1
V1
W1
M3~
brake ctrl
encoder speed
ethernet ,internet
PLC fieldbus
stand-alone I/O
Motor
V5
PC
follower control , DDCS
ABB
Rev 1.0.EN
17 April 2008
Sheet 56
N of sh 65
ACS800
11 Examples (draft)
11.1 Hoist
T cont.hoist
( 780 + 19800 ) 9,8 0,417

102,6 0,929
= 882 Nm
or
Pcont.hoist =
(780 + 19800) 9,81 0,417

0,929
= 90 600 Watt
2 9 80
Values:
=
= 102.6
m0 780 (kg)
60
mL 18 000 (kg) + overload 10% = 19 800 kg
g
9.81 m/s2
v
25 m/min= 0.417 (m/s)
mech 0.929
Tcont.lower =
(580 + 20000) 0,929 9,81 0,417

= 762 Nm
102,6
or
Pcont.lower = - (580 + 20000) 9,81 0,417 0;929 = -78 210 Watt

Continuous braking power during lowering: 78.2 kW
ABB
Rev 1.0.EN
17 April 2008
Sheet 57
N of sh 65
ACS800
11 Examples (draft)
11.1.3 Torque and power needed to accelerate/ decelerate a load
Acceleration torque from 0 to maximum speed (hoisting and lowering):
2
1
0.417
7.44 +
(20580 )
= 413 Nm
0.929
102.6
Tacc
102.6
=
1.94
Tdec
102.6
=
1.94
0.417
7.44 + 0 .929 (20580 )

= 410 Nm
102.6
Definitions:
m0 780 kg
mL 18 000 (kg) + overload 10%= 19 800 kg
g
9.81 m/s2
v
25 m/min= 0.417 (m/s)
2 980
=
mech 0.929
60
i
Gear ratio
tacc 1.94 (sec)
tdec 1.94 (sec)
Jm
4.1 kgm2
Joth 3.34 kgm2
= 102.6

TMax = 882 Nm + 413 Nm = 1295 Nm
1295 * 980
P Max =
kW = 133 kW
9550
ABB
Rev 1.0.EN
17 April 2008
Sheet 58
N of sh 65
ACS800
11 Examples (draft)
Maximum braking torque
TMax braking = 762 Nm + 410 Nm
(4.1.2 and 4.1.3)
P Max
braking
1172 * 980
kW
9550
P Max braking = 120.3 kW
ABB
Rev 1.0.EN
17 April 2008
Sheet 59
N of sh 65
ACS800
11 Examples (draft)
11.2 Gantry travel
4.2.1 Torque and power needed to move a crane at constant speed (friction)
4.2.1.1 Steady state torque, due to rolling friction:
Tf =
(79000 ) 0.05 1.67

155 0.96
= 44
Nm
4.2.1.2 Torque due to wind
Tw =
1.6712500
= 140
155 0.96
Nm
Values:
m0 59 000 kg
mL 20 000 kg
0.05 N/kg
wf
v
1.67 m/s
W
25 000 N
Wheel diameter 710 mm
number of motors: 2
2 1480
60
= 155
Wheel diameter
(mm)
250
315
400
500
>500
Wheel friction
Wf (N/kg)
0,07
0,065
0,06
0,055
0,05
ABB
Rev 1.0.EN
17 April 2008
Sheet 60
N of sh 65
ACS800
11 Examples (draft)
11.2.2 Acceleration/deceleration torque from 0 to maximum speed
Tacc
2
155
1
1.67
=
(0.11 ) +
(79000 )

5.5
0.96
155
Tdec =
t dec
(Jm + Joth ) + mech (m 0 + m L )
Values:
m0
mL
v
59 000 kg
20 000 kg
1.67 m/s
mech 0.96
tacc 5.6 sec
tdec 5.6 sec
Jm
0.05 kgm2
Joth 0.06 kgm2
number of motors: 2
ABB
2 1480
60
Rev 1.0.EN
17 April 2008
= 155
Sheet 61
N of sh 65
ACS800
12 Examples: motor and drive choice

12.1.1 Thermal motor load
Needed continuous motor torque:
hoist: 882 Nm
travel: sh 25
(4.1.1)
(4.2.1.1) or (4.2.1.2)
corrections with:
duty factor (uprating) 60%: 1.07
speed range (derating) average speed 50%: 0.95
ambient conditions 40C: 1
(10.9)
(3.10)
(3.11)
corrected motor torque:

882 Nm / 1.07 /0.95 / 1 = 868 Nm
P= M*N/9550= 868 * 980 / 9550 = 89 kW
Motor choice: 90 kW, 992 rpm, 866 Nm, 163 A, Tmax/Tn 2.8

hoist:
1295 Nm
(4.1.4)
Available on chosen motor: 866 *2.8*0.7=1697 Nm OK
travel: sh 27
(4.2.3)
12.1.3 Final motor choice:

M3BP 315 SMB6, 90 kW, 992 rpm, 400V, 163A, 866 Nm, 4.1 kgm
motor current corresponding to max. motor torque needed : 163 *1295 / 866= 243 A
ABB
Rev 1.0.EN
17 April 2008
Sheet 62
N of sh 65
ACS800

12.2.1 Single drive choice
Choose drive ACS800 according the motor power in heavy duty use
(6.3)
90 kw HD : ACS800-01-0135-3 (R6), 163 A

Max current 1 min/ 5 min: 163A *1.5 = 244 A
This is very close to what is calculated. Taking into account some current saturation effect in the
motor, better choice is next module:
110 kw HD : ACS800-01-0165-3 (R6), 215 A
Max current 1 min/ 5 min: 215A *1.5 = 244 A
Braking chopper in module:
PBrcont = 132 kW , minimum resistance: 2.7 ohm
ABB
Rev 1.0.EN
17 April 2008
Sheet 63
N of sh 65
ACS800

12.2.2 Brake chopper / resistor sizing
Braking cycle needed:
Hook path: 15 m, speed: 25 m/min, max. cycle: 25 sec
total cycle time estimated: 60 sec
Cont. braking power needed during lowering with short peak at end of lowering: 85 kW
This corresponds with a resistor 44 kW permanent use.
Braking capacity for standard resistor: 13.5 kW cont not sufficient, but OK when connecting 4 pcs
in series parallel (same total resistance, power times 4)
ABB
Rev 1.0.EN
17 April 2008
Sheet 64
N of sh 65
ACS800
13 Tools
Excel sheet to convert mechanical crane data to motor torque and power needed
13.1 Excel sheet for hoist:
Drive:
Levage 70 T
Load/Motor speed:
m/min
720
RPM
Drum diameter:
Hoisting speed:
m/min
750
RPM
Number of ropes:
560
mm
Nominal load:
68,0
tons
+empty mass:
2,0
tons
Total load:
70,0
tons
Motor inertia 5,000 kgm^2
tons
External inertia/motor 2,000 kgm^2
+overload:
Max. load:
70,0
Gear ratio 1:
Vmax:
4,7
m/min
Mechanical efficiency:
tons
85
Total inertia/motor
CALCULATED POWER & TORQUE REQUIREMENTS:
7,07
kgm^2
MOTOR DATA:
No load (at Vmax):
1,8
kW
23,0
Nm
Static
Number of poles:
Nominal load:
63,1
kW
803,6
Nm
-"-
Nominal frequency:
50
Max. load :
63,1
kW
803,6
Nm
-"-
Number of motors:
Nom. load acceleration:
85,0
kW
Max. load acceleration:
85,0
kW
1081,7
Nm
Dynamic
1081,7
Nm
-"-
acceleration:
Overload:
21,8
kW
kW
=
=
278,1
Nm
Nm
-"Static
Hz
Max. Frequency:
50
Hz
Nmax:
750
RPM
Acceleration time:
TLmax/Tnrl:
2,00
1,35
sec.
Acceleration time 0-max:
2,00
sec.
13.2 Excel sheet for travel

Drive:
Chariot
Travel speed/Mot. speed:
30
m/min
1000
RPM
Travelling speed:
30
m/min
1000
RPM
Weight of load+hook:
21,50
tons
Weight of gantry/trolley:
13,8
tons
Total mass:
35,3
tons
50
N/ton
Rolling friction:
Wind force:
Wheel diameter:
30,0
m/min
kN
Inclination:
kW
3,9
Nm
Static
Nominal load:
1,0
1,0
kW
Nm
kW
9,9
9,9
5,0
5,0
kW
kW
4,0
kW
kW
=
=
acceleration:
Wind etc. load:
ABB
85
0,10
%
kgm^2
External inertia/motor
0,05
kgm^2
Total inertia/motor
0,95
kgm^2
MOTOR DATA:
0,4
Max. load acceleration:
Mechanical efficiency:
Motor inertia
No load (at Vmax):
Nom. load acceleration:
mm
Gear ratio 1: 263,19

Vmax:
CALCULATED POWER & TORQUE REQUIREMENTS:
Max. load(wind etc.) :
400
Number of poles:
-"-
Nominal frequency:
50
Nm
-"-
Number of motors:
48,2
48,2
Nm
Dynamic
Nm
-"-
38,3
Nm
Nm
-"Static
Max. Frequency:
Nmax:
50
Hz
Hz
1000 RPM
Acceleration time:
TLmax/Tnrl:
3,00
4,86
sec.
Acceleration time 0-max:
3,00
sec.
Rev 1.0.EN
17 April 2008
Sheet 65
N of sh 65

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ABB - ACS800 Learning Guide - Drive Dimensioning For Cranes

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ACS800

Drive dimensioning for cranes

Drive dimensioning for cranes

Dimensioning theory motor basics

Drive dimensioning for cranes

2 General condition of a dimensioning procedure

3 Induction motor (AC) fundamentals

Drive dimensioning for cranes

4.2 Gantry/trolley travel Long/cross travel

4.2.1 Torque and power needed to move a crane at constant speed

5.1 Motors in parallel

Drive dimensioning for cranes

7.1 Drive module

9.1 Total revamp

Drive dimensioning for cranes

13.1 Excel sheet for hoist

Drive dimensioning for cranes

Capacity typical 10 350 Tons

Drive dimensioning for cranes

Drive dimensioning for cranes

2 General condition of a dimensioning procedure

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Rated motor torque

Motor flux depends on V/Hz ratio:

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

TMAX Design = 0.7 x TMAX /TN

3.3.2 In field weakening area (typically 50 Hz to FMAX):

maximum design torque should be only 70 %:

TMAX Design = 0.7 x TMAX /TN x (50 Hz / FMAX )

TMAX Design = 0.7 x TMAX /TN x 1/4

3.4 Continuous motor torque with a frequency converter:

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Motor M3BP 280 SMB

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

3.5.3 Above nominal frequency (50 Hz to ....Hz):

290 Nm (90 kW)

274 Nm (86 kW)

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Important note: always consider torque and power on same shaft,

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Deceleration when lowering

Acceleration when hoisting

Acceleration when lowering

Deceleration when hoisting

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

Only braking power needed during deceleration (forwards and backwards)

Drive dimensioning for cranes

3 Induction (AC) motor fundamentals

When wind is blowing in opposite direction as the crane is moving, a lot of

Maximum braking torque is needed to stop the crane.

Drive dimensioning for cranes