System Operation, Testing and Adjusting Manual
July 2012
SAFETY.CAT.COM BI006861
SN: 2U70X55/141377
Blast Hole Drill VOLUME of III BI006861
MD6640
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BI006861
MD6640 Blast Hole Drill
Table of Contents
This manual is divided into two books. Each book is further divided into major sections covering various systems and their electrical components of the MD6640 Blast Hole Drill. Refer to book 2 of this manual for PLC software.
No. BI006861 sn:141377 2U70X55
System Operation, Testing and Adjusting Manual Manual
Book 1: Section 1 - ELECTRICAL ADJUSTMENTS DATA SHEETS..............................CS141377 Section 2 - ELECTRICAL SCHEMATICS............................................................. 4042882 Section 3 - START-UP INSTRUCTIONS................................................................X-4138 Section 4 - SIMOREG DRIVE SET-UP INSTRUCTIONS.......................................X-4123 Section 5- OPERATOR DISPLAY MANUAL...........................................................X-4137 Section 6 - WATER INJECTION SYSTEM SET-UP INSTRUCTIONS...................X-4139 Section 7 - WATER INJECTION A.C. DRIVE USER’S MANUAL................ BULLETIN 161 SCHEMATIC - WATER INJECTION......................................... C119023 Section 8 - HYDRAULIC SCHEMATICS: HYDRAULIC PROPEL............................................................. 1546046 MAIN HYDRAULIC 1546046 LEVELING JACKS 1546046 MAST HYDRAULICS ................................................................ 1546046 SOLENOID VALVE & GAUGE PORT LOCATIONS.................E023596 Section 9 - AIR SCHEMATIC: AIR SCHEMATIC E023544 Book 2: Section 10 -PLC SOFTWARE...................................................................... CB141377_A BI006861
6 System Operation, Testing and Adjusting Manual MD6640 Blasthole Drill BI006861 BI006861
DANGER:
THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/ OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.
DANGER:
DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.
The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.
THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.
DANGER:
DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.
7 System Operation, Testing and Ajusting Manual MD6640 Blasthole Drill BI006861
BI006861
8 System Operation, Testing and Adjusting Manual MD6640 Blasthole Drill BI006861 BI006861
Caterpillar Global Mining, LLC. Electrical Adjustments For MD6640 Drill
This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.
© 2012 Caterpillar Global Mining, LLC. All rights reserved.
CUSTOMER: LOCATION:
Vale - Salobo
MODEL:FIGURES BY:A. Viesselmann
LOT:TESTED BY:
S/N:DATE:
DATE:APPROVED:
REV. DATE:DATE:
REFERENCE DOCUMENTS
MACHINE SCHEMATICS 4042882
SIEMENS DRIVE DRAWINGS & SCHEMATICS1M-22008
SIEMENS BASE DRIVE PANEL INSTRUCTIONSPUBLICATION NO.A1-126-008-001 (1M-22051)
START-UP INSTRUCTIONSX-4138
PHASE SEQUENCE RELAY SET-UP INSTRUCTIONSN/A
SIMOREG DC MASTER DRIVE SET-UP INSTRUCTIONSX-4123
CUSTOMER SOFTWARE DOCUMENTATIONCB141377.PDF
OPERATOR DISPLAY MANUALX-4137
WATER INJECTION SET-UP INSTRUCTIONSX-4139
PROGRAMMABLE DRILL CONTROL MANUALN/A
4,160(INCOMING) Check Transformer Connections Against Schematics
480(AUXILIARY)Measure Voltage At Line Side Of LV MCC Auxiliary Power Breaker
480(H/P DRIVE)Measure Voltage At Line Side Of H/P Drive Cabinet Breaker
480(ROTARY DRIVE)Measure Voltage At Line Side Of Rotary Drive Cabinet Breaker
Cold Temperature (-20C)
Cold Temperature (-40C)
Hydraulic Dust Curtain (DCOI)
Cable Reel (CROI)
Cable Reel Encoder (CREOI)
Angle Hole Drilling (AHOI)
Variable Volume Control (ACVVOI)
Pipe Thread Lubrication (PTLOI)
Bit Lubrication (BLOI)
MINIMUM POSSIBLE
Compressor Oil Cooler Louvers (LOI)
Water Injection (WIOI)
Centering Guide (CGOI)
Window Guard (WGOI)
Radio Remote Propel (RRPOI)
Pendant Remote Propel (PRPOI)
2 Pipe Racks (2PROI)
3 Pipe Racks (3PROI)
4 Pipe Racks (4PROI)
*These are Factory Pre-set
Program Drill Control (PDCOI)
Remote Winch (RWOI)
Shunt Trip (STOI)
Boarding Stair Switch (BSSOI)
Hydraulic Breakout Wrench (BOWOI)
Heated Mirros
Dry Dust Control
Fire Suppression System
Spare Option (SO1)
INPUT VOLTAGES STD. ACTUAL
INPUT FREQUENCY: 60 HZ ALTITUDE: 1,804 FT. 550 METERS TEMP. RANGE: 40 TO 104 DEG. F 4 TO 40 DEG. C PRESSURE SWITCH SETTINGS LUBE PANEL DEVICE ACTION STANDARD SETTINGS ACTUAL LLPSCLOSING PRESSURE 2,500 PSI LLPSOPENING PRESSURE AIR SYSTEM CIPSOPENING PRESSURE 15 PSI* CIPSCLOSING PRESSURE 19-21 PSI* COPSOPENING PRESSURE 15 PSI* COPSCLOSING PRESSURE 19-21 PSI*
Options
141377
Brazil MD6640 131
5/25/2012
CS141377.xls Page 1 of 25 7/9/2012 BI006861
Caterpillar Global Mining, LLC.
Electrical Adjustments For MD6640 Drill
WATER INJECTION DRIVE CONTROL SETTINGS
PARAM DEFAULT STD. ACTUAL NO. DESCRIPTION VALUE VALUE VALUE A052JOG CONFIGURATION, (DIGITAL INPUT 2) 4 4 A065 ANALOG OUT CALIBRATION (ANALOG OUT SELECT) 010* A066ANALOG OUT CALIBRATION (ANALOG OUT HIGH) 100100 A067JOG ACCELERATION RAMP TIME , (ACCEL TIME 2) 20 2 A068JOG DECELERATION RAMP TIME, (DECEL TIME2) 20 2 A072INTERNAL PRESET FREQUENCY, (PRESET FREQ. 2) 1050 A091PWM CARRIER FREQUENCY, (PWM FREQ.) 4 2 A095REVERSE DISABLE/ ENABLE (REVERSE DISABLE) 0 1 P031DRIVE OUTPUT VOLTAGE, (MOTOR NP VOLTS) 230230 P033MOTOR FULL LOAD CURRENT, (MTR. OVERLOAD CURR.) 86.6 P034ANALOG FREQUENCY MINIMUM 015 P035ANALOG FREQUENCY MAXIMUM 6060 P036START FROM PLC (SOURCE START) 0 2 P038EXTERNAL PLC CONTROL, (SPEED REFERENCE) 0 2 P039ACCELERATION RAMP TIME, (ACCEL TIME 1) 10 2 P040DECELERATION RAMP TIME, (DECEL TIME 1) 10 2 A101LOCK, (PROGRAM LOCK) 0 1 *Set Analog Output Select DIP Switch To 0-20mA Position CS141377.xls Page 2 of 25 7/9/2012 BI006861
Caterpillar Global Mining, LLC. Electrical Adjustments For MD6640 Drill
PROPORTIONAL VALVE CONTROL ADJUSTMENTS (REF. DOCUMENT X-4138)
CARD POT
EHPC1RMP1OUTPUT CURRENT
(HOT SETTINGS)
RATE REV. AND FWD. SET FULLY CCW
EHPC1THR1PROPEL RIGHT THRESHOLD (DEADBAND) REV. AND FWD.-/+375 MILLIVOLTS*(1) EHPC1LO1PROPEL
-/+375 MILLIVOLTS*(1)
& FWD. -/+375 MILLIVOLTS*(1)
EHPC2LO1PROPEL LEFT REV. AND FWD. MINIMUM DC CURRENT 370 MILLIAMPERES(2)
EHPC2H1BPROPEL LEFT REV. MAXIMUM DC CURRENT
EHPC2H1APROPEL LEFT FWD. MAXIMUM DC CURRENT
EHPC2RMP2OUTPUT CURRENT RESPONSE RATE IN AND OUT SET FULLY CCW
EHCP2THR2PRPV THRESHOLD (DEADBAND) IN AND OUT -/+375 MILLIVOLTS*(1)
EHPC2LO2PRPV IN AND OUT MINIMUM DC CURRENT 475 MILLIAMPERES(2)
(1)TURN ON POINT OF CARD LIGHT.
(2)SET INPUT VOLTAGE 50 MILLIVOLTS ABOVE CARD LIGHT TURN ON POINT TO MAKE MINIMUM CURRENT ADJUSTMENTS (IE: -/ + 425 MILLIVOLTS).
*RELATIVE TO "REF" POINT ON BOARD. DO NOT CONNECT "REF" TO FRAME GROUND.
STANDARD
FUNCTION
RESPONSE
RIGHT REV. AND FWD. MINIMUM DC CURRENT 370 MILLIAMPERES(2) EHPC1H1BPROPEL RIGHT REV. MAXIMUM DC CURRENT 690 MILLIAMPERES EHPC1H1APROPEL RIGHT FWD. MAXIMUM DC CURRENT 690 MILLIAMPERES
CURRENT RESPONSE
EHPC1LO2WCV/MRV LOWER AND RAISE MINIMUM DC CURRENT 240 MILLIAMPERES(2) EHPC1H2BWCV/MRV LOWER MAXIMUM
760
EHPC1RMP2OUTPUT
RATE LOWER AND RAISESET FULLY CCW EHCP1THR2WCV/MRV THRESHOLD (DEADBAND) LOWER AND RAISE
DC CURRENT
MILLIAMPERES
760
EHPC1H2AWCV/MRV RAISE MAXIMUM DC CURRENT
MILLIAMPERES EHPC2RMP1OUTPUT CURRENT RESPONSE RATE REV. AND FWD. SET FULLY CCW EHCP2THR1PROPEL LEFT THRESHOLD (DEADBAND) REV.
690 MILLIAMPERES
690 MILLIAMPERES
610
EHPC2H2BPRPV IN MAXIMUM DC CURRENT
MILLIAMPERES
MAXIMUM
CURRENT 610 MILLIAMPERES
EHPC2H2APRPV OUT
DC
ACTUAL CS141377.xls Page 3 of 25 7/9/2012 BI006861
Caterpillar Global Mining, LLC.
Electrical Adjustments For MD6640 Drill
E-STOP CIRCUIT
E-STOP OPERATION PROVIDES A PLC INPUT AND DROPS OUT EMPCR EMPCR ALSO KILLS POWER TO PLC OUTPUTS
CONTINUITY - ESPB1-A - 1 AND EMSCR - A1
CONTINUITY - ESPB1-B - 1 AND PLC Node 1 - I 0.4
ESPB1 - Operator's Seat Left Console (ZCSL)
ESPB2 - PLC Cabinet (ZPCA)
ESPB3 - Right-Rear Machine (JB90)
ESPB4 - Right-Front Machine (JB91)
ESPB5 - Left-Rear Machine (JB92)
ESPB6 - Left-Front Machine (JB93)
CIRCUIT BREAKERS
INITIAL OK
VOLTAGE ON LOAD SIDE OF CIRCUIT BREAKER AND FUSES TO COMMON Standard Value Shop Value
CB2419 - 15A 220VAC CB2425 - 20A 24VDC CB2513 - 15A 220VAC CB2517 - 15A 120VAC CB2523 - 10A 24VDC CB2525 - 10A 24VDC CB2527 - 10A 24VDC CB2529 - 10A 24VDC CB2604 - 10A 24VDC CB2607 - 2A 24VDC CB4106 - 5A 24VDC CB4149 - 7A 24VDC CB51004 - 7A 24VDC LTB80006 - 20A 120VAC LTB80019 - 20A 120VAC LTB80105 - 15A 120VAC LTB80111 - 20A 220VAC CB80115 - 20A 120VAC CB80119 - 10A 12VDC LTB80205 - 20A 220VAC LTB80222 - 20A 120VAC LTB80305 - 20A 220VAC LTB80404 - 20A 220VAC LTB80503 - 20A 220VAC LTB80607 - 20A 220VAC LTB80613 - 15A 120VAC CB81004 - 15A 220VAC CB81013 - 15A 220VAC CB81025 - 15A 220VAC CB81103 - 15A 220VAC CB81114 - 15A 120VAC CS141377.xls 4 of 25 7/9/2012 BI006861
Caterpillar Global Mining, LLC. Electrical Adjustments For MD6640 Drill
PROFIBUS STATUS CHECK
NODE 1 - MAIN FRAME RACK 1
NODE 2 - MAIN FRAME RACK 2
NODE 3 - MAIN FRAME RACK 3
NODE 5 - OPERATOR'S CAB RACK
INSTRUMENT INPUT CHECK Shop Value
ACAPT - AIR COMPRESSOR AIR PRESSURE
TRANSDUCER BETWEEN JB22 TB1_2 AND TB1_11
ACATT - MAIN COMPRESSOR AIR TEMPERTURE
TRANSDUCER BETWEEN 2 AND 1
ACOTT - MAIN COMPRESSOR OIL TEMPERTURE TRANSDUCER BETWEEN 2 AND 1
HTOLLS - PIN D +24 WITH OIL
HTOLLS - PIN D -24 WITHOUT OIL
Test HTOLLS with Field Test 6.
TERMINAL BOARD JUMPER CONTINUITY CHECK INITIAL OK
Check continuity between first jumpered terminal and each terminal in the jumpered string. For consecutive strings of jumpers, make sure there is no continuity between last terminal of first string and first terminal of second string.
CB81128 - 15A 220VAC CB81206 - 20A 220VAC CB81218 - 20A 220VAC CB81304 - 15A 220VAC CB81318 - 15A 120VAC CB81330 - 15A 120VAC CB81335 - 20A 220VAC CB81505 - 15A 24VDC CPCB - 50A 220VAC
Shop Value PS1 - CONTROL
24VDC PS2 - UTILITY (ZPCA) 24VDC PS4 - MASTERSWITCH 10VDC PS6 - RADIO (ZCCC) 12VDC
POWER SUPPLIES
(ZPCA)
INITIAL OK
24VDC
24VDC
24VDC
24VDC
0 VDC
CS141377.xls 5 of 25 7/9/2012 BI006861
INPUT AND OUTPUT TESTS
MAIN FRAME RACK 1 - NODE
Electrical Adjustments For MD6640 Drill
Shop Verified COMMENTS
Caterpillar Global Mining, LLC.
1 SLOT 4 I 0.0 I 0.1 I 0.2 I 0.3 I 0.4 I 0.5 I 0.6 I 0.7 I 1.0 I 1.1 I 1.2 I 1.3 I 1.4 I 1.5 I 1.6 I 1.7 I 2.0 I 2.1 I 2.2 I 2.3 I 2.4 I 2.5 I 2.6 I 2.7 I 3.0 I 3.1 I 3.2 I 3.3 I 3.4 I 3.5 I 3.6 I 3.7 SLOT 5 I 4.0 I 4.1 I 4.2 I 4.3 I 4.4 I 4.5 I 4.6 I 4.7 I 5.0 I 5.1 I 5.2 I 5.3 I 5.4 I 5.5 I 5.6 I 5.7 I 6.0 I 6.1 I 6.2 I 6.3 I 6.4 I 6.5 I 6.6 I 6.7 I 7.0 I 7.1 I 7.2 I 7.3 I 7.4 I 7.5 I 7.6 I 7.7 SLOT 6 I 8.0 I 8.1 I 8.2 I 8.3 I 8.4 I 8.5 I 8.6 I 8.7 I 9.0 I 9.1 I 9.2 CS141377.xls 6 of 25 7/9/2012 BI006861
Caterpillar Global Mining, LLC.
Electrical Adjustments For MD6640 Drill
I 9.3 I 9.4 I 9.5 I 9.6 I 9.7 I 10.0 I 10.1 I 10.2 I 10.3 I 10.4 I 10.5 I 10.6 I 10.7 I 11.0 I 11.1 I 11.2 I 11.3 I 11.4 I 11.5 I 11.6 I 11.7 SLOT 7 I 12.0 I 12.1 I 12.2 I 12.3 I 12.4 I 12.5 I 12.6 I 12.7 I 13.0 I 13.1 I 13.2 I 13.3 I 13.4 I 13.5 I 13.6 I 13.7 I 14.0 I 14.1 I 14.2 I 14.3 I 14.4 I 14.5 I 14.6 I 14.7 I 15.0 I 15.1 I 15.2 I 15.3 I 15.4 I 15.5 I 15.6 I 15.7 SLOT 8 I 16.0 I 16.1 I 16.2 I 16.3 I 16.4 I 16.5 I 16.6 I 16.7 I 17.0 I 17.1 I 17.2 I 17.3 I 17.4 I 17.5 I 17.6 I 17.7 I 18.0 I 18.1 I 18.2 I 18.3 I 18.4 I 18.5 I 18.6 I 18.7 I 19.0 I 19.1 CS141377.xls 7 of 25 7/9/2012 BI006861
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
