Technical Specification of Soft Startup Control Cabinet for

GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

Table of Contents

1. General.............................................................................................................................1
2. Product Type and Meaning...............................................................................................2
3. Operating Principle and Application................................................................................2
4. Functional Features..........................................................................................................4
5. Technical Indices..............................................................................................................4
6. Outline Dimensions and Installation................................................................................4
7. Environmental Conditions................................................................................................5
8. Normative Standards........................................................................................................6
9. Ordering Instructions........................................................................................................6
10. After-sales Services.........................................................................................................6

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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

1. General
GL-ZDRQ series control cabinet for soft startup of DC oil pump motor is an up-to-date
replacement product designed for generator lube oil system. The equipments in generator
lube oil control system consist of lube oil cabinet, main oil pump, AC lube oil pump, oil
injector, oil cooler, emergency DC oil pump, jacking oil pump system, oil-fume separator
and oil purifying system, etc. The lube oil control system is required to provide reliable
lubricating (sealing) oil source for various main bearings, thrust bearings, turning gears and
related sealing oil systems, and provide pressure oil control ensuring safe operation of the
system as well since the losses will be extremely serious due to shutdown of steam turbine
and generator for damages caused by out of control of the system. As a backup protection for
lube oil system, whether the emergency DC oil pump is capable of operating safely and
reliably or not in emergency state is quite important. During normal operation of the system,
all lube oil is supplied by main oil pump. When oil pressure decreases to a certain value due
to fault of main oil pump, AC and DC lube oil pumps automatically operate in linkage.

Traditional control systems for DC lubricating (sealing) oil pump motor of generator
realize step-down startup by means of DC contactor and connection in series of large-power
resistor in armature circuit of DC motor to limit starting current of motor via step-down by
resistor. As current or rotating speed reaches a certain ratio to the rated value, the resistor is
bypassed by DC contactor. To start DC motor in this way has the following advantages:
simple control and low cost; while the disadvantages are as follows: 1. Step-down startup by
resistor can only decrease the starting current of motor up to 2 times the rated current, this
will lead to instantaneous voltage dip of DC system, as a result, the stable operation of relay
protection devices is affected; 2. DC contact after multiple use produces adhesion and
carbonization due to electric shock; 3. Potential faults cannot be monitored and found in
time since the alarm function of protection is not available

The GL-ZDRQ series control cabinet for soft startup of DC oil pump motor (hereinafter
referred to as “the control cabinet”) researched and manufactured by our company is a new
hi-tech product integrating modern electric and electronic devices, micro electronic
technique, digital PWM technique, PLC technique and redundant adaptive technology as a
whole. The control cabinet carries out reliable control for smooth soft startup and soft
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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

shutdown of DC motor, and current curves smoothly go up or down based on optimal

control, thus eliminating impact and interference of motor startup to DC system; the
adoption of high-frequency and large-power IGBT switching elements replacing traditional
DC contactor to trigger switching essentially eliminates various drawbacks of DC contactor
employed for switching control; remote (DCS) and local control modes are incorporated,
and also the linkage of main pipe pressure low signals is available to start DC oil pump;
perfect fault self-diagnostic functions: start/stop protection, excitation wire break and over-
current protection, IGBT modules over-current and over-temperature alarm and armature
current/voltage over-limit alarm; large-screen Chinese man-machine interface (MMI),
simple and convenient touch operation.
2. Product Type and Meaning
GL — ZDRQ —X X / X

1: for DC110V;
2: for DC220V;
Adaptive motor power
(e.g.: 40 for 40kW)
Identification for soft startup of DC motor
GuoLi
3. Operating Principle and Application
All-digital pulse width modulation (PWM) is employed to collect current and voltage
of DC motor at high speed and in real time, digital PID and speed change integral algorithms
are used to analyze and process collected data, and correct control quantities are output to
adjust output duty cycle of IGBT, as a result, a smooth and flexible control for current of DC
motor is fulfilled so as to eliminate impact and interference to DC system. Thanks for
application of digital PID and speed change integral algorithms, static errors in speed
regulation during the whole close-loop feedback control are removed, and anti-interference
performance and reliability are greatly improved.
3.1 PWM control circuit

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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

To IGBT To IGBT

IGBT drive plate

±15V power 至IGBT 至IGBT

G2 E2 C2 G1 E1 C1
supply IGBT驱动板

4
±15V电源
GND INA

KM1 14 -12V
GND
GL-ZDRQ
±12V电源
4
+12V 控制板 GL
CON GR
GRI RES
GND

±12V power 40
温度检测
supply
Control panel

Temperature detection

Notes:
(1) GL is over-current signal output from control panel, which is transmitted to
over-current detecting side of PLC;
(2) GR is over-heat signal output from control panel, which is transmitted to
over-heat detecting side of PLC.

3.2 Main control circuit

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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

Excitation current detection

DC220V
-

+
01
励磁电流检测
02

QF QF1 QF2

L1

04 Emergency stop
03
ZJ2
05
SB2 SB1
急停 09 10 06
KM
KM KM1

KM 至PLC 至¡ À
15V 至+24V ZJ1 DC3
08
开关电源 开关电源 PLC旁路

11 KM1
KM1 KM1 KM1
C1
PLC启动
12 ZJ1
DC1

To
输出电
PLC To ±15V To ±24V
PLC停止
ZJ2 13

流变送
switch switch
±12V电源
PLC bypass
14

输出电 power power

KM1

D1 流检测

PLC start

PLC stop
Output current
transmission

±12V power
Output current
detection

Notes: (1) KM is main contactor;

(2) KM1 is bypass contactor;
(3) L1 is power indicator lamp;
3.3 PLC control circuit

4
 1-1
Taken from
voltage/curr
ent signals Stop
Operatio indicatio
n n
HARBIN GUOLI ELECTRIC CO., LTD

Sens indicati
or
Chopped
Signal wave Excitation
processi detection v
Plate Fault Local Communication
ng
RES indicatio control/ St State interface
St Fa Byp
n remote o indicati
a u ass
on

5
Technical Specification of Soft Startup Control Cabinet for

Tuch
screen
GL-ZDRQ DC Oil Pump Motor

±24V
power Over- Over- Remo Remo
Local Local Therm Therm
contr contr current heat te te o- o-
ol ol detection detectio contr contr technic technic
startu startu ol ol al al
p p startu startu startup startup
Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

4. Functional Features
4.1 Ensure DC oil pump is in reliable linkage with DCS system when AC lube oil pump
system is in fault;
4.2 Overcome influences of impulse current during startup on DC power supply system in
traditional starting mode;
4.3 Eliminate contact sintering of contactor in traditional control system;
4.4 No loss of electric energy and generation of heat during startup by means of digital
chopped wave;
4.5 Flexible and convenient remote/local operations, also linkage of main pipe pressure low
signal available to start DC oil pump;
4.6 Chinese touch screen displays operational parameters and records various fault messages
with convenience for operation;
4.7 All electronic devices are imported original products;
4.8 Modular design, compact and reasonable structure convenient for installation and test,
operation and maintenance.
5. Technical Indices
5.1 Rated voltage of control motor: DC220V±10% or DC110V±10%;
5.2 Rated power of control motor: 4.5kW-75kW;
5.3 Starting current limit: less than 1.2 times the rated current of motor;
5.4 Soft startup time of motor: 0S～60S, settable;
5.5 Output signal: 4-20mA remote transmitted signal;
5.6 Communication interface: standard RS485 isolating serial interface;
5.7 Communication protocol: Modbus communication protocol.

6. Outline Dimensions and Installation

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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

1800

1620
1620

600 450

Panel dimensions: H×W×T=1800mm×600mm×450mm;

Installation: cabinet (box) should be vertical to the ground.
7. Environmental Conditions
7.1 Altitude: ＜2000m;
7.2 Ambient temperature: -10℃～+65℃;
7.3 Relative humidity: ≤ 90%RH;
7.4 There should have no conductive dust, corrosive gases and moulds, etc. damaging metal
or insulation in media around the installation places;
7.5 If the environmental conditions exceed the range in this specification, customization can
be made in accordance with actual situations on site.

8. Normative Standards
“Control Cabinet for Soft Startup of DC Oil Pump” Q/HGL004-2010
“General Technical Requirements for LV Complete Switchgears and Control Equipments,
Intelligent Complete Equipments” GB 7251.8-2008
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Technical Specification of Soft Startup Control Cabinet for
GL-ZDRQ DC Oil Pump Motor HARBIN GUOLI ELECTRIC CO., LTD

“General Technical Conditions for Relay Protection Cabinets and Panels in Electric Power
System” DL/T 720-2000
“Technical Procedures for Design of Secondary Wiring of Thermal Power Plants and
Substations” DL/T 5126-2001
“Technical Regulations for Design of Automatic Safety Devices in Electric Power System”
DL/T 5147-2001
“Basic Test Methods for Relay Protection and Automatic Safety Devices” GB/T 7261-2008

9. Ordering Instructions:
9.1 Provide the rated power and rated operating voltage of DC motor;
9.2 Indicate whether there are any special requirements for installation and dimensions of
control cabinet;
9.3 Indicate manufacturing materials and exterior color of control cabinet;
9.4 Provide communication protocol if remote communication is required.
10. After-sales Services
10.1 Free repair or replacement for quality defects within one year in normal use; and
lifelong maintenance.
10.2 Charge cost only for maintenance after the warranty period expires.