THE STORY OF THE P&H MODEL 2800

By     Richard “Chubby” Czubkowski

APPROX. YEAR

1969-1975

1975-1983

1982

1987

1988

1992

1999

2003

2006

2010

MODEL

2800MKI

2800MKII

2800XP

2800XP

2800XPA

2800XPB

2800XPB

2800XPB

2800XPC

2800 XPC


DC

DC

DC

AC

DC

DC

DC

DC

DC

AC

DIPPER CAPACITY

24-26 CY

26-28 CY

28-32 CY

28-32 CY

28-32 CY

44-46 CY

44-46 CY

44-46 CY

38-48 CY

38-48 CY












SUSPENDED LOAD RATING lbs.

80 sT

90 sT

110 sT

120 sT

120 sT

130 sT

130 sT

130 sT

135 sT

135 sT












APPROX. WEIGHT lbs.




2,050,000

2,112,000

2,250,000

2,250,000

2,250,000

2,380,000

2,380,000

CONV. COOLING

DRAWERS/
AIR

OIL COOLED

AIR COOLED

AIR COOLED

AIR COOLED

AIR COOLED

AIR COOLED

AIR COOLED

AIR COOLED

AIR COOLED

FEATURE

INDICATOR TRAY

INDICATOR LTS.

INDICATOR LTS.

INDICATOR LTS.

INDICATOR LTS.
PLC PMD

PLC

DIGITAL GUI
PLC

DIGITAL GUI

SUPERVISORY COMPUTOR

DIGITAL GUI

SUPERVISORY COMPUTOR

DIGITAL GUI

SUPERVISORY COMPUTOR"












ELECTROTORQUE

ASEA

ASEA/P&H

P&H/ABB

ABB/P&H

P&H/ABB

P&H/ABB





ELECTROTORQUE - PLUS







P&H/
AVTRON




CENTURION - ABB








P&H/ABB

P&H/ABB

P&H/ABB












HOIST 2 USED

F695

F695

K925


K-925


K-925

K-925


* CONT.@ 690 VAC

TOT. CONT.
@475 VDC



1450 HP TOT.


1450 HP


1450 HP

1450 HP


2772 HP TOT.

TOT. CONT.
@550 VDC

600

600









TOT. CONT.
@600 VDC









1600 HP


720RPM, 1170VAC, 24HZ




CONT. 1900HP







TOT. PEAK



2250 HP


2440 HP


2570 HP

2570 HP

2788 HP

3200 HP TOT.












SWING 2 USED

F172

F172

4 X K236


K-558A


K-558A

K-558A


* CONT. @ 690 VAC

TOT. CONT. @475 VDC



1020 HP


950 HP


950 HP

950 HP


1460 HP TOT.

TOT. CONT. @550 VDC

150

150







1000 HP


TOT. PEAK



1468 HP


1535 HP


1546 HP

1546 HP

1500 HP

1827 HP TOT.












CROWD

F368

F368

K300


K-925


K-925

K-489


* CONT. @ 690 VAC

CONT. @475 VDC



400 HP


400 HP


400 HP

400 HP


730 HP

CONT. @550 VDC

264

264







720 HP


PEAK



630 HP


630 HP


630 HP

630 HP

920 HP

932 HP












PROPEL ½ USED

F449

F449

K-408


K-408


K-408

K-408


* CONT. @ 690 VAC

TOT. 30 MIN. @475 VDC



405 / 810 HP


760 HP


760 HP

760 HP


1460 HP TOT.

TOT. CONT. @ 550 VDC

330

330







820 HP


TOT. PEAK



810 / 1465 HP


1355 HP


1440 HP

1440 HP

1958 HP

2645 HP TOT.












YEARS MFG.

1969-1975

1975-1983

1982-1994

1987-1989

1987 >>>

1992 >>>>>

1998 >>>

1999 >>>

(2008) >>>

2010 >>>












"TOTAL UNITS











APPROX. # AS OF JUNE 2019"

7

43

57

2

48

<<<<<<<<

66

>>>>>>>>>

45

9



2800 MKI

2800 MKII

2800 XP

2800 XP SER. A

2800XP SER. B

2800XPC --- DC



ELECTROTORQUE

ELECTROTORQUE

ELECTROTORQUE

ELECTROTORQUE

ELECTROTORQUE

CENTURION



CENTURION














MAIN TRANF0RMER


2000 KVA

2000 KVA

2000 KVA (+)

2000 KVA (+)

2000 KVA NEW

2000 KVA









RPC STEPS 60 HZ

FIXED

(900 KVAR)

600 KVAR FIXED

675 KVAR FIXED

675 KVAR FIXED



STEPS


4 STEP = 3600 KVAR

7 STEPS = 4725 KVAR

l5 STEPS = 3375

KVAR 6 STEPS = 4050

KVAR 7 steps = 4725 KVA









CONVERTOR POWER


FORWARD/REVERSE

FORWARD/REVERSE






KW AT 550 VDC

KW AT 550 VDC

KW AT 550VDC

KW AT 600 VAC

KW AT 600 VAC

KW AT 600 VAC









HOIST/PROPEL

CONT. ARM. CONV. KW

1760 KW / 500 KW

1965KW/500KW

2 X 935 KW

2 X 1020 KW

2 X 1320 KW

2 x 1860 KW








SHORT TIME Ia

30 SEC. @ 1930A. FRD.

30 SEC, @ 2100 A.

15 SEC. @ 3300 A.

15 SEC.@ 2700 A.

15 SEC.3100 A.

15 SEC, @ 3700 A.








CONT. FLD CONV.

( 150 A. )

( 150 A. )

150 A.

150 A.

150 A.

150 A.









SWING

CONT. ARM. CONV.

1 for each 2 motors

440KW / 440KW

935 KW

1020 KW

1320 KW

1860 KW


2 X 440KW













SHORT TIME Ia

30 SEC. @400 A.

15 SEC. @1600 A.

15 SEC. @ 3300 A,

15 SEC. @2700 A.

15 SEC. @ 3100 A.

15 SEC. @3700 A.








CONT. FLD CON.

(150 A.)

( 150 A. )

150 A.

150 A.

150 A.

150 A.









CROWD/PROPEL

CONT. ARM. CONV.

600KW / 600 KW

620 KW / 620 KW

750 KW

830 KW

830 KW

1860 KW








SHORT TIME Ia

30 SEC. @1500 A.

30 SEC. @ 1500 A.

15 SEC. @1650 A.

15 SEC. @1650 A.

15 SEC. @1650 A.

15 SEC. @3700 A.








CONT. FLD CON.

(150 A. )

( 150 A. )

150 A.

150 A.

150 A.

150 A.



















2800XP ---- AC

2800XPC --- IGBT







ELECTROTORQUE

CENTURION





MAIN TRANF0RMER


2000 KVA






















HOIST/PROPEL

CONT. INVERTER KVA

2 X 1200 KVA

IGBT SUPPLY UNIT(ISU)

4550 KVA











MAX. INVERTER Ia

640 A.















HOIST

1160 KVA











CONT. INVERTER Ia

600 A.














SWING

CONT. INVERTER KVA

1200 KVA















SWING

3480 KVA











MAX. INVERTER Ia

640 A.













CONT. INVERTER Ia

600 A.














CROWD/PROPEL

CONT. INVERTER KVA

1200 KVA















CROWD

1160 KVA











MAX. INVERTER Ia

640 A.















PROPEL

2320 KVA




CONT. INVERTER Ia

600 A, `






Acknowledgments --------------------------------------   


 Individual who contributed to the major designs of the 2800 and Electrotorque;


Matt Tietze---------- Mechanical designed of the main transform with shock mounted  coils and the first cooling air systems for motors and equipment  on the original 2800.

Dave Stone----------  RPC Module   

Garry Morris --------- Diverter Circuit  

Bob Mierendorf –-------- Miscellaneous circuit design, field control electrics

Paul Phillips -------------- Circuit analysis, Specialty circuit design, Early AC shovel  

Frank Clewell ----- ELECTROTORQUE design, Air cooled converters, RPC Reactors  and RPC cabinets, Order Configuration Engineer

Richard Czubkowski -- ELECTROTORQUE design, First PLC, Digital Control application, Technical sales; Electrotouque Shovels Manuals

Charles Miesner ----- Lab Technician, Servicemen, Programmable Massage Display  (PMD)

Steve Jasso ------ Commissioned and educated servicemen on the first digital control;  ELECTROTORQUE PLUS

Don Daniels ------ GUI programming contributor

Engineers at –

 ASEA/ABB – original control

 AVTRON/Idec-- first digital control, Electrotorque-Plus

 Sorgel/SquareD and NECO/Hammond -- transformers


Tom Weber  and the Mechanical Group----- Designed structures to increase capacity,

planetary transmissions, dippers, structural analysis, lower works and shoes, machinery

and operators cabs, etc. ( The writer  apologizes  for not giving credit to the names of

individuals who contributed to the designs and analysis.)


The servicemen who, in the early days of ELECTROTOQUE, dedicated their efforts to

make it work; Ed Taylor – P&H, Aaron Blenco – P&H and Olaf Lonegren –

ASEA/P&H.   


 

Ps -------- A special thank you to Mark Emerson, Ed Meyer, Dave Wendt and Craig Dickson for

filling in the writer memory and R. Profio who found , in his closet, the forgotten words of the

founder Henry Harnischfeger, H.S Jacobs and Henry Harnischfeger’s speech on the  100th

Anniversary of the Harnischfeger Corp.   


 

For  history purposes ------–


Philippine Engineering & Construction Forum


73 Years of Free Enterprise – October 1957


This is the story of one company grown and served America well under the rich heritage of freedom.  But, in a sense, it is far more than that.  For it mirrors the history of many hundreds of American businesses which have had their own small beginnings … which through courage, imagination, and initiative, have contributed so much to the American way of life.


It is a tribute to the spirit of service that springs from our system of free enterprise … to the men who create new products to do things better, because they have the genuine incentive of reward for their labors.


Most of all, it is a reaffirmation of faith in the system that has enabled this country to surpass the productive achievements of every other country, and to establish the high standard of living that is a source of pride to every American.

 


 Harnischfeger Corporation, Milwaukee 14, Wisconsin


 

From the address by;


Henry Harnischfeger on the 100th anniversary of Harnischfeger Corp.


 December 1, 1984


“The Will to Succeed” A Centennial History of the Harnischfeger Corporation by Henry Harnischfeger – Harnischfeger Corporation, Milwaukee, WI 53201


For all the changes, however, this company has had a basic character from the very first day.
At its roots, I’m convinced; the mature tree is not much different from the seedling. Henry Harnischfeger and Alonzo Pawling had specific principles: Superior engineering and craftsmanship in every quality product.  A commitment to service after the sale.  A deep concern for employees and customers.  A determination to find new opportunities and to aggressively pursue them. In other words, the will to succeed.


The immigrant’s dream is still valid.  Looking back at our first century and looking ahead to our second, I re-dedicate This Company to those principles.  I look back with pride.  I look ahead with confidence.



 FINAL WORDS -----


It all started in the 60‟s.  Almost six decades later, THE P&H has progressed;



 A half century of progress.


The new 2800XPC digs the dirt faster, more economical due to the ingenuity of the present group of Engineers.  The new control system also provides safer operation, less prone to damage, and remotely monitoring. It makes a poor operator look good and a good operator look excellent   


The object of this story was to emphasize that the big loading shovel concept was started by the Harnischfeger Corp. The names mentioned in the story are for history. What is most important is that these men, with archaic tools, used their experience, ingenuity and desire to design a big shovel, the 2800.   


The Harnischfeger Corp. during the last 25 years has gone to many changes. The name and the people have changed. The hope is that the principles of Alonzo Pawling and Henry Harnischfeger, Workmanship, Quality and Service, will never be changed.

    

The first 2800 was innovative.The 2800XPC is a product of further innovation. It is the product of the development   of tools, materials, software and electronics.  But  most of all, it is the product of  dedicated Engineers , with new ideas, that will keep THE P&H number one In the shovel industry like the men who designed the first 2800 almost six decades ago.



The Writer ---------


I started in 1957 as a co-op student attending MSOE. During my break terms I worked in Central Engineering, Industrial Engineering, Purchasing and Sales


After graduation in 1961 I received an offer of employment from Harnischfeger and accepted it. Electrical Engineers were needed for the crane and shovel divisions. From my sales assignment, shovel work was my first and only choice.   


 I was assigned to a training program which entailed work on the crane floor; motor winding and shovel

assemble in the old Bld. 65.  In Bld. 65 I learned to assemble cabinets, wire them and carry out machine

testing. Field testing was done outside in a “test field” along National Avenue.  


My last assignment was in Central Service working on various model machines with a variety of controls. I leaned Impedance Controls and Thyraton Controls. I worked on full electric and diesel-electric machine

from Models 1600 to 1855. I worked on the only 1855, twin diesel, shovel front machine, ever built. By the time I was through with my training, I was known as “Chubby” because Czubkowski was difficult to say properly. I remained “Chubby” to my P&H associates and customers.  


I was assigned to Progress Hall; the so called R&D office on 38th and Burnham street. My first assignment was to develop a “fast” Magnetic Amplifier to control the emerging device called a Silicon

Controlled Rectifier or SCR. The object was to develop a large controlled DC rectified to directly control a DC motor. In 1963, the writer and Frank Clewell, under the direction of Les Price, a proposed prototype system of a large DC motor, powered by a controlled DC converter was to be built. Many problems existed.  The Magnetic Amplifier‟s response was too slow to control the dynamic response required of the motor.  


 In 1965 a joint venture was entered into with ASEA of Sweden and a new shovel system, Electrotorque,

was born. In 1969 a Model 1900B was the first complete static DC motor shovel control. It was commissioned and put to work in a Taconite mine in Michigan. In later years the system, Electrotorque, evolved as Mark I, Mark II, Air Cooled and Plus.


JOB DESCRIPTION:

 Product Engineer,

 Project Engineer,

 Sr. Project Engineer,

 Chief Engineer Development, Mining Electrical Systems,

 Engineering Manager, Electric Excavator Engineering

 Consulting Engineer ---- Consulting to: Electrical Excavator Group, Dragline Engineering, Drill

 Engineering, special projects and customers.


In 1968, I started to give technical sales presentations and customer consultations because Electrotorque was new and revolutionary to the mining industry. I represented P&H shovels to mines around the world.

 

Professional Affiliations: IEEE - Senior Member  
WMEA - Western Mining Electrical Association


Technical Presentations: IEEE - International Converter Conference And technical writings:
Application of Thyristors Converters to Electric Mining Shovels” 1977

 

 Western Canada Mining Symposium –

 “Performance Efficiency

 “The marriage of the mechanical and electrical systems for

 optimum performance.” 1989



VARIOUS PRESENTATIONS:
 ISA- Various presentations on DC Static Drive applications.
              Local Chapters

 WMEA - Various presentations concerning  mining subjects.


“Modern Control Systems for Electric Mining” Excavators”

 (Presentations to)
 Russian Ministry of Coal
 Coal India
 Chinese Coal Industry

 

 Various presentations to customers on their specific

 needs. (Too many customers to mention)


 INTERNAL WRITINGS: First Care & Op Electrotorque Manuals

 Technical sales Brochures. Coined to phase;
 “Simple and Effective”

 

 “Here‟s Watt Counts” Energy /ton data paper
 highlighting P&H shovels.

 

 “Electrotorque –plus Shovel Drive System”
 New digital drive system.

 

 VIDEO RECORDINGS: Recordings were made in the old Bld. 65 to show  actual control equipment and the new PLC addition to  shovel control. These were distributed to field  salesmen.


 

My career was marked by memorable moments in P&H history; the 1900B, fist 2800, MKI, MKII, Air Cooled, PLC‟s, 5700LR, 5700DR, Electrotorque-Plus(digital control), 4100 and !5,000volt shovels. Besides  promoting  P&H in the US and Canada, travel took me to; Russia, China, India, Africa, Turkey, Australia, Norway, Sweden, Switzerland, England, France, Kobe Japan ,Chili, Peru, Brazil, Spain etc.


I started working when shovels had a dipper of 11Cu. Yd.  I retired in 2001 where shovels were rated at 72 Cu. Yd. Oddly enough; the time to fill a dipper and deposit it in a truck was about the same, 25 to 35 seconds.  

Richard     “Chubby”   Czubkowski

Size progression-----–

2800 power data -------

Summaries -------–


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