CAT BUCYRUS 2000 OPERATION AND TROUBLESHOOTING GUIDE MANUAL - PDF DOWNLOAD

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OPERATIONAND TROUBLESHOOTINGGUIDE MODEL BUCYRUS 2000 DUALANDSINGLEMOTOR SOLIDSTATECONTROLLERS THISGUIDECONTAINS IMPORTANTOPERATIONANDSAFETY INFORMATIONANDSHOULDBEKEPTAVAILABLETOTHOSEPERSONNEL INSTALLINGANDOPERATINGTHISEQUIPMENT. P/NA6474X226 Revision 1, December/07  BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet: www.bucyrus.com

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BucyrusAmerica,Inc. Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 1 TABLEOFCONTENTS DESCRIPTION PAGE# PREFACE 2 SYMBOLSANDSPECIALNOTATIONS..............................................................................................3 MAJORHAZARDS 5 SAFETYPRECAUTIONSANDGUIDELINES ......................................................................................6 OVERVIEW 6 MAINTENANCE.................................................................................................................................6 INTRODUCTION 7 BUCYRUS 2000: INNOVATIVE SPEED CONTROL BY BUCYRUS AMERICA, INC........................7 GENERALSPECIFICATIONS 12 FAIL-SAFEOPERATIONWILLINCLUDETHEFOLLOWING: 12 DESCRIPTIONOFFEATURES ..........................................................................................................13 BUCYRUS 2000MOTORCONTROLLERCONSISTOF: 13 BUCYRUS 2000MOTORIGBTPANEL(POWERCONNECTIONS) .............................................13 MICROPROCESSORBASEDLOGICCARD(CONTROLINPUTS) 13 CONFIGURATION JUMPER TABLE 15 OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9)...............................................15 FAULT MESSAGE CHART 16 OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT......................................................18 PERSONALITY ADJUSTMENT PROCEDURE...............................................................................19 TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) 19 TRACTION STATUS DISPLAY .......................................................................................................21 TRACTION TEST DISPLAY 23 TRACTION BDI DISPLAY 24 ERROR CODE LEGEND (STATUS DISPLAY)................................................................................25 TROUBLESHOOTING 26 IGBTMEASUREMENTS..................................................................................................................27 INDIVIDUAL IGBT MEASUREMENTS 28 DIODE MEASUREMENTS...............................................................................................................29 DIODE MEASUREMENTS...............................................................................................................30 PANEL MEASUREMENTS 31 DRIVER MEASUREMENTS 32 IGBT DUAL MOTOR PANEL, FIGURE 16.......................................................................................34 IGBT SINGLE MOTOR PANEL,FIGURE 17 35 IGBT HEAT SINK ASSEMBLY, FIGURE 18....................................................................................36 SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19 37 DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 38 DASHBOARD DISPLAY, FIGURE 21..............................................................................................39 DUAL "Y" HARNESS, FIGURE 22 40 HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 41 CALIBRATOR UNIT, FIGURE 24.....................................................................................................42 BUCYRUS 2000 PUMP MOTOR SHUNT, FIGURE 25 42 BUCYRUS 2000 PANEL WIRING HARNESS, FIGURE 26 .............................................................43

BucyrusAmerica,Inc.

PREFACE

ThismanualisintendedtoprovideGENERALoperatingandserviceprocedures for the Bucyrus 2000 motorvehicle solid-statecontroller.Theillustrations, descriptionsandprocedurescontainedinthispublicationapplyonlyto Bucyrus 2000motorvehiclesolid-statecontrollers. BucyrusAmerica,Inc. reservesthe righttorevisemodelsanddesignswithoutpriornotice.

This Bucyrus 2000motorvehiclessolid-statecontrollerwasmanufacturedunder theguidelines,proceduresandrequirementsoftheU.S.FederalCoalMine HealthandSafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart 0,Part75forundergroundcoalmines,andotherapplicablenon-U.S.regulatory agencystandards.

Atthecompletionofthemanufacturingprocess,the Bucyrus 2000motorvehicles solid-statecontrollerwasissuedtheappropriateapprovalnumbersand nameplatesindicatingitmetthetechnicalrequirementsoftheseregulatory agencies.Anychangeto thedesignorstructureofthe controller,withoutthe consentof BucyrusAmerica,Inc. andtheseregulatoryagencies,oranyrepairor replacementofpartscontraryto BucyrusAmerica,Inc.’s instructions,may invalidatetheseapprovalsandrenderthecontrollerunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulationsand practicesregardingthesafeoperationand maintenanceofundergroundmining equipmentandstrictadherencetotheinstructionsinthismanualisnecessaryfor thepersonalsafetyofthoseworkingonoraroundthiscontroller.

Whilethismanualattemptstoanticipatethemostimportantoperations and maintenanceneedsforthiscontroller,unforeseencircumstancesmayarisethat havenotbeenaddressedinthismanual.Ifanyconcernsorquestionsarise, pleasecontactyour Bucyrus America,Inc. ServiceRepresentative immediately

Thisworkcontainsinformationprotectedundertradesecretandotherintellectual propertylaws,andisprotectedundertheU.S.CopyrightActof1976,as amended.Thisworkisprovidedunderlicenseandthelicenseisnontransferable.Distributionandaccessislimitedonlytoauthorizedpersonnel. Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationof federalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 2
 BucyrusAmerica,Inc. Allrightsreserved.

BucyrusAmerica,Inc.

SYMBOLSANDSPECIALNOTATIONS

Throughoutthismanualtherearespecificnotationsthatareeither UPPERCASEBOLD, UNDERLINED or ITALICIZED fortheprimarypurposeofemphasis Pleasepayspecialattention tosuchstatementsastheyregardsafetyorcriticalmaintenanceinstallationinformation.

Youwillalsoseethefollowing:

NOTICE: THISNOTATIONDENOTESAREFERENCETOPREVIOUSLY STATEDINSTRUCTIONS.

IMPORTANT: THISSYMBOLDENOTESTHATSPECIALATTENTION MUSTBEADHEREDTOINTHEATTACHEDSTATEMENT.

CAUTION: THISSYMBOLDENOTESTHATFAILURETOCOMPLYWITH THEATTACHEDSTATEMENTCOULDRESULTINACUT,BRUISEOR ABRASION.

WARNING: THISSYMBOLDENOTESTHATFAILURETOCOMPLY WITHTHEATTACHEDSTATEMENTCOULDRESULTINALOSTTIME ACCIDENT.

DANGER: THISSYMBOLDENOTESTHATFAILURETOCOMPLY WITHTHE POINTSINTHETEXTMARKEDWITHTHISSYMBOLDRAW YOURATTENTIONTOIMMEDIATELYIMPENDINGDANGER INCLUDINGELECTRICALDANGERS.POSSIBLECONSEQUENCES ARE:VERYSERIOUSINJURY,DEATHORDEATHBY ELECTROCUTION.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 3

DANGER

ONLYTRAINEDAND/ORAUTHORIZEDPERSONNEL SHOULDPERFORMMAINTENANCEONTHE CONTROLLER.

FAILURETOADHERETODANGERS,WARNINGS ANDCAUTIONS,NOTEDINTHISMANUAL,COULD RESULTINSERIOUSINJURYORDEATH.

FAILURETOMAINTAINTHIS CONTROLLER IN STRICTADHERENCETOTHESEINSTRUCTIONS ANDWARNINGSINTHISMANUALCOULDVOIDTHE WARRANTY.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 4
BucyrusAmerica,Inc.

BucyrusAmerica,Inc.

MAJORHAZARDS

AREA HAZARD SAFEGUARDS WHEREHAZARD CANOCCUR WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED

HOWTOAVOID THEHAZARD

MOTORSAND CONTROLLER

Electricalshockcouldcause irreparableinjuryordeath.

Allelectricalsystemsshouldbe maintainedbycertifiedelectricians. Thebatteryshouldbedisconnected beforeservicingthemotorsor controller.Whenthecontroller coverisremoved,waitforone minuteforthecapacitorsto discharge.

BATTERY

Thebatteryproduceslethal amountsofpowerwhether connectedtothemachineor charger,ornot.

Thebatteryshouldbemaintained byqualifiedpersonnel.(Referto Bucyrus America,Inc. "INSTALLATION,USE, MAINTENANCE,ANDREPAIROF MINEPOWERSTORAGE BATTERIES,”PARTNUMBER A6474X26,forcomplete instructions).

Batterycoverscouldfall crushinghandsorarms.

Batteryhold-downclamps couldcrushfingersorhands.

Batteriesproduceexplosive gasesthatcouldbeignited causingburnsorexplosions.

Batteriescontainstrongacid thatcouldcausesevereburns ifspilledorsplashedonbody partsorintheeyes.

Besurecoversupportsareinplace whenworkingonbattery.

Keepfingersandhandsawayfrom hold-downclamps.

Batteriesshouldbewellvented beforeservicingparticularlyif weldingorburningonthebattery. Batteriesshouldbemaintainedby qualifiedpersonnel.

Protectiveclothing,gloves,and eyewearmustbewornwhen workingonbatteries.Batteries shouldbemaintainedbyqualified personnel.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 5

BucyrusAmerica,Inc.

SAFETYPRECAUTIONSANDGUIDELINES

Overview

Beforeyoutest,troubleshoot,serviceorinanyotherway,usethisunit -

READ and STUDY thisguide. KNOW whatyoumustdoforsafemaintenance.

ALWAYS wearorusethepropersafetyitemsrequiredforyourpersonalprotection.

IfyouhaveANYQUESTIONSaboutthesafeuseormaintenanceofthisunit: ASKYOUR SUPERVISOR - NEVERGUESS - ALWAYS CHECK

Maintenance

AVOID,wheneverpossible,servicing,cleaningorexaminingtheunitincongestedareas.

AVOID,wheneverpossible,servicingorprovidingmaintenancetotheunitunlessthewheelsare adequatelychoked.Ifthedrivemotor(s)istobe run,theunitmustbejackedclearoftheground andallfour(4)wheelsmustbefreetoturn.

DONOT altertheelectricalsettingsfromthatindicatedinthisguideorassetatthefactory.

ALWAYS replacedamagedorlostdecalsormetalinstructionplates.RefertothePartsManual fortheproperlocationandpartnumberofdecalsandplates.

DISCONNECT thebatterywhenworkingwithelectricalsystems,orwhenweldingontheunitto preventelectricalshock.

Itisimportantthatanyprocedurenotspecificallyrecommendedinthisguidebethoroughly evaluatedfromthestandpointofsafetybeforeitisimplemented.

Somephotographsandillustrationsinthisguidemayshowguardsorcoversremovedfor purposesofclarity.Neveroperateunitwithoutall guardsandcoversinplace.

SOMEPHOTOGRAPHSORILLUSTRATIONSINTHISGUIDEMAYSHOW PROTOTYPEUNITSORUNITSWITHOPTIONALEQUIPMENT INSTALLEDTHATMAYORMAYNOTBEONYOURPARTICULAR MACHINE.PRODUCTIONMODELSMAYVARYINSOMEDETAIL. OPTIONALEQUIPMENTMAYBEPURCHASEDFROM BUCYRUS AMERICA,INC.

CONTINUINGIMPROVEMENTANDADVANCEMENTOFPRODUCT DESIGNMAYCAUSECHANGESTOYOURMACHINEWHICHMAYNOT BEINCLUDEDINTHISPUBLICATION.EACHPUBLICATIONIS REVIEWEDANDREVISED,ASREQUIRED,TOUPDATEAND INCLUDE THECHANGESINLATERADDITIONS. BUCYRUSAMERICA,INC. RESERVESTHERIGHTTOMODIFYORMAKECHANGESWITHINA SPECIFICMODELGROUPWITHOUTNOTICEANDWITHOUT INCURRINGANYLIABILITYTORETROFITUNITSPREVIOUSLY SHIPPEDFROMTHEFACTORY.CONTACTYOUR BUCYRUS DEALER FORMAINTENANCETHATISNOTCOVEREDINTHISPUBLICATION.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 6

BucyrusAmerica,Inc.

INTRODUCTION

BUCYRUS 2000:InnovativeSpeedControlby Bucyrus America,Inc.

Intheearly1970's,S&SCorporationleadthewayinmininginnovationwiththeintroductionof SolidStatespeedcontrolsforbattery-poweredundergroundminingequipment.SolidState controlsincreasedtherangeandreliabilityofthebatterypoweredvehiclesalongwithproviding smooth,steplessacceleration.Evenwithsolidstatespeedcontrol,directionchangewas achievedwiththeuseofelectromechanicalcontactors.Thesecontactorsprovidedanendless sourceofmaintenanceproblemsandconsumedexcessiveamountsofvaluable controller-box space.Also,mostsolidstatecontrollersofthepastutilizeanelectromechanical"bypass" contactortoconnectthemotordirectlytothebatterieswhichcausedmorecontactorproblems.

Inthe1980’s Bucyrus America, Inc., inconjunction withSevcon,developedacontactorlessmotor controller(X90)tobeusedexclusivelyon Bucyrus equipment.TheX90systemusedadual-field motorincombinationwithSCR's(SiliconeControlledRectifier)toachievesolidstatedirection change.

Now Bucyrus America, Inc., inconjunctionwithSevcon,hasdevelopedtheBucyrus2000motor controller.TheBucyrus 2000systemusesIGBT’s(InsulatedGateBipolarTransistors)toachieve motorcontrolanddirectionchange.UnlikeanSCR,anIGBTisturnedONand OFFviaagating electronicsignal.Thiseliminatedcommutatingcapacitorbanksandcoils.Themicroprocessor basedBucyrus 2000LogicCardprovidescompletemotorcontrol,anddrivesbothaDiagnostic DashboardDisplayalongwithahandheldCalibrator/DiagnosticUnit.

TheIGBTswitchoperatessofastthatitcanconnectanddisconnectthemotorinlessthan 1/1700second.Thisissuchashorttimeperiodthatthedual-fieldmotordoesnothavetimeto move.EachtimetheIGBTswitchclosesand reopens thefullbatteryvoltageisappliedtothe motorterminalsforabout1/1700second.Thisiscommonlyreferredtoasa"pulse."

TheIGBTspeedcontrolworksbyfeedingtothemotorarapidseriesofpulses.Thenumberof pulsesperseconddeterminesthe averagevoltageatthemotorterminals

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 7
FIGURE 1 – SIMPLIFIEDBUCYRUS 2000CIRCUIT

BucyrusAmerica,Inc.

Sincethewindingsofthemotorareinductive,thecurrentinthemotorcannotchangequickly. WhentheIGBTswitchisclosed,thecurrentbuildsupslowlyandwhentheswitchopens,the inductancewantstokeepthecurrentflowing.Forthisreason,the"flywheel"diodeisprovided. Figures3and4illustratethecurrentpathswiththeswitchclosedinbothforward(Figure3)and reverse(Figure4)modes.

FIGURE2

FIGURE3

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 8

FIGURE4

AsseeninFigure 5,thedirectionofthecurrentthroughthemotordoesnotchange.More important,whentheswitchopens,althoughthebatterycurrentstops,themotorcurrentcontinues toflowviathe"flywheel"diode.Themotorcurrentisthereforemadeupoftwocomponents:

1. ThebatterycurrentwhentheIGBTswitchisclosed.

2. The"flywheel"currentwhentheIGBTswitchisopen.

FIGURE5

BucyrusAmerica,Inc. Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 9

BucyrusAmerica,Inc.

Theamountofthemotorcurrentsuppliedfromthebatteryvarieswiththepulsefrequency. Figure6illustratesatypicalsituationatlowspeed.Itcanbeseenfromtheillustrationthatthe "flywheel"current,becauseitisflowingforalongerperiod,formsalargerpartofthemotor currentthandoesthebatterycurrent.However,athighspeeds(Figure7),themotorcurrentis madeupofalmostallbatterycurrent.

FIGURE6

Tosummarize,themotorcurrentismadeupofacombinationofbatterycurrentand"flywheel" currentsothatunderallconditionstheaveragemotorcurrentisalwaysgreaterthantheaverage batterycurrent.

Atlowspeedsthemotorcurrentcanbeseveraltimesgreaterthanthebatterycurrent.

Athighspeeds,whentheIGBTswitchisopenonlyforshortperiodsbeforeclosing,themotor currentismadeupalmostentirelyofbatterycurrent.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 10
BucyrusAmerica,Inc. Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 11
FIGURE7

GENERALSPECIFICATIONS

The Bucyrus 2000MotorControllerisdesignedtooperateat128voltsDC,1200 Ampsmaximum currentlimitpermotorandcontrolsoneortwodual-fieldelectricmotors.

 The maximum currentdefaultsettingsare:800A,1100Aand1200A

 Tractionfunctionsoperateataspeedthatisdirectlyproportionaltotheaccelerator(FS1) demand.(SeeFigure8)

 Tractionmotorcurrentwillbecontinuouslymonitoredinthemotor.Currentlimitispresetand isadjustableviatheoptionalhandhelddiagnostics/calibratorunitandispasswordprotected.

Fail-safeoperationwillincludethefollowing:

 IntheeventofashortedIGBT,thecircuitbreakerwillbeopened,disconnectingpowerfrom thetractionmotors.

 Operationofthecircuitbreakerwillalwaysbesensed,andiffaulty,drivewillbeinhibited.

 Wheneverthevehicleispower-cycled,power-updiagnosticswillbeexecutedtotestthetram drivecircuitry.Iffaulty,drivewillbeinhibited.

Thetemperatureofthe Bucyrus 2000MotorControllerwillbecontinuouslymonitoredandifit risesabove95Cthemotorcurrentwillbelimitedtoamaximumof300ampsofmotorcurrentwill beallowed.

The Bucyrus 2000MotorControllerfeatures adataloggingcapabilitythatstorescriticaldatainto non-volatiledataRAM.Thestoreddataisdisplayedinthetractionstatusdisplayoftheoptional handhelddiagnostics/calibratorunit.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 12
BucyrusAmerica,Inc.
FIGURE8 – ACCELERATORVOLTAGE

DESCRIPTIONOFFEATURES

The Bucyrus 2000SolidStateControllerincorporatesavarietyofindependentprotection systems.Theseimprovereliability,shieldthemotorsandcontrollerfromoverload,protectthe machinefrominadvertentabusebytheoperator,andhelptoprotectworkersfrompotentialharm frommalfunctioningequipment.

Bucyrus 2000MotorControllerConsistof:

 DualMotorIGBTPanelorsinglemotorIGBTPanelor2-singlemotorIGBTpanels

 MicroprocessorBasedLogicCard

 OptionalDashboardDisplay

 OptionalHandheldDiagnostics/CalibratorUnit

 “Y”connectingharness(usedonlywith2-singlemotorpanelsystems)

Bucyrus 2000MotorIGBTPanel(PowerConnections)

 Batterypositive

 Batterynegative

 4motorconnectionsforeachmotor(S1,S2,A1andA2)

(ForPowerCircuitLayoutseeMachineWiring diagramandschematic)

MicroprocessorBasedLogicCard(ControlInputs)

 Inputappliesbatteryvoltagetologiccard(Pin16)

 Proportionalcontrolaccelerator,5000OHMS(Pins1and2)

 Tramdirectionselect(Pin7)

 Tramdirectionselect(Pin8)

 Parkbrakecondition(set/release)(Pin14)

 Circuitbreakerdriver(Pin6)

 Circuitbreakercondition(Pin11)

 Currentlimitdefaultsetting(Pin12)

 Accelerator(FS1)inputswitch(Pin4)

 CANCommunicationInputPortforoptionalhandhelddiagnostics/calibrator unit

 CANCommunicationInputPortforoptionaldashboarddisplay

 AnalogInputforconnectiontopumpmotorshunttoallowpumpmotorcurrentmeasurement

The Bucyrus 2000Microprocessor-BasedLogicCardwillcontroldualtwo-quadrantIGBT devices,controlledbyPWM(PULSEWIDTHMODULATED)switching,providingforwardand reversedirectioncontrol.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 13
BucyrusAmerica,Inc.

BucyrusAmerica,Inc.

ThereisanLEDonthelogiccardwhichservesasanindicatorofthestatusofthecontroller.The followingdiagnosticsshallapply:

 LEDon Controlleroperational

 LEDoff Power-upfault – checkdisplayorcalibrator.Ifallisblank,thenreplacelogic.

 1Flash PersonalityCRCEEPROMError.

Usingthehand-heldcalibrator,changeapasswordtoanynumberthenrecycle power

shouldclear,otherwisereplace logic.

 2Flash ProcedureFAULT

FS1closedbeforepoweron,2DirectionalFaultorCurrentimbalancefault. RecyclethroughNEUTRALtoclear.

 3Flash IGBTpermanentlylow(IGBTShortCircuitFAULT).

ThisincludesIGBTshortcircuitorIGBTopencircuit.Thisfaultshutsdownall modes.RecyclethroughNEUTRALtoclear.

 4Flash Motorneitherlownorhigh(BreakerOpenFAULT).

ThisincludesbreakeropencircuitorIGBTopencircuit.Thisfaultshutsdownall modes.RecyclethroughNEUTRALtoclear.

 5Flash Motorpermanentlyhigh.

Thisincludesbreakerwelded.Thisfaultshutsdownallmodes.Recycle“KEY” toclear.

 6Flash FaultyTRACTIONaccelerator.

Thisincludestheacceleratorgreaterthan15%atpoweronandwire-off.Ifwireoffoccursduringactivefunctionthenthemotorspeedwillsettozero.Thisfault auto-clears.

 7Flash BatteryvoltageFAULT.

Thisincludesbatterybelowapredeterminedvalue.RecyclethroughNEUTRAL toclear.

 8Flash Thermalcut-back(Over-TemperatureFAULT)

ThisincludesHeatsinktemperatureabove95 centigrade.

ASTEMPERATURERISESABOVE95 CENTIGRADE,THE CONTROLLERWILLLIMITTHECURRENTTO300AMPS REGARDLESSOFDEMAND.

 9Flash UVRcoilover-currentFAULT(CoilshortcircuitFAULT). Clearedwith“KEY”recycled.

 10Flash BrakeonFAULT

WilltripDirectionalandFS1areenergizedwithoutreleasingbrake.Recycle throughNEUTRALtoclear.

 15Flash CurrentTransducerFAULT.

Occurswhencurrentoutputisreadduringpower-uporifnocurrentisread duringdriveabove50%demand.“KEY”recycletoclear.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 14

MAX.CURRENTCONFIG.

– 1200AMP

OPTIONALDASHBOARD DISPLAYFEATURES(SeeFigure9)

 Abatterydischargeindicator

 Anhourmeterdisplayingtram-onhours

 Anhourmeterdisplayingpump-onhours

 Arotatingdisplayshowing:

1. Batteryvoltage

2. Pumpmotorcurrent

3. Diagnosticfaultstatus,whenapplicable.Rotatingdisplaywilllockononeofthe followingfaultmessages:(SeeFaultMessageChart,page 19)

BucyrusAmerica,Inc. Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 15
ConfigurationJumperTable
LOGICPIN12 VEHICLE TYPE OPEN SINGLEMOTOR
GROUND
SINGLEMOTOR
OPEN DUALMOTORS 1100AMPPERMOTOR – ADJUSTABLETO1200 AMP GROUND
DUALMOTORS 800AMPPERMOTOR
(CLOSED)
– 1100AMP
(CLOSED)
BATTERY DISCHARGE FUNCTION ROTATING DISPLAY TRAM – ON PUMP – ON HOURS
FIGURE9 – OPTIONALDASHBOARDDISPLAY

FaultMessageChart

DASHBOARD DISPLAY CALIBRATOR DISPLAY

“RotatingDisp.” “OK” Nofault

“Testing” “Testing”

“SystemOK” “SystemOkay”

“OverTemp.” “ThermalCutback”

“BrkrOpen” “BreakerOpen”

“BrkrWeld” “BreakerWeld”

“UVRCoil” “UVRCoil”

“CapFault” “CapacitorFault”

“AccelFlt.” “AccelFlt.”

“Seq.Fault” “SequenceFault”

“2DirFault” “2DirFault”

“TramFault” “TramFault”

“BatLow” “BatLow”

“CRCError” “CRCError”

“IGBTs/c” “IGBTs/c”

“IGBTs/c” “IGBTs/c”

“Brakeon” “Brakeon”

“CurXducer” “CurXducerFlt”

“BadLogic” “BadLogic”

“BadLogic” “BadLogic”

“PTAShort” “P.UpPTAShort”

DESCRIPTION

Onlyvisiblewhenpower-updiagnosticsisrunning.Check connectionsifnotclearing.

Power-upcheckcompleted,waitingtoclosureofCircuit Breaker

Controllerinthermalcut-back.

Circuitbreakerfailedtoclose.FaultyCircuitbreaker,UVR, CBAuxiliaryorfaultylogicboard.

Circuitbreakerwelded close.FaultyCBauxiliaryswitchor faultylogicwillgivethisfaultalso.

UVRcoildriverover-currentsensed.

Capsfailedtochargeafterpower-up.

Acceleratorfaultsensed.Faultyaccelerator(accelerator voltage4.0v;acceleratorvoltagebelow1.2vinNEUTRAL). FaultyFS1orlogicboard.

FS1closedatpower-up.Possiblecircuitbreakerauxiliary switchnotclosing

Bothdirectionalswitchesactive.

Motorcurrentimbalancesensed.

Batteryfellbelowpersonalitylevel.

Duringpower-upapersonalityCRCerroroccurred.Try adjustingoneofthepasswords(1or2)thenpowerrecycle. Ifnotclearedreplacelogicboard.

AnIGBTshorthasbeendetected – SM.

AleftorrightIGBTshorthasbeendetected – DM.

ThevehicleBRAKES areonwhilethereisadirectionand demandselected.

Thecontrollerreadscurrentwhenitisfirstpowered-upor doesnotreadanycurrentwhendemandfordriveover50%.

Aninternalerrorshasoccurredinthesoftwarestate machine.Faultylogicboard.

Invalidstatusstateencountered(internalerror).Faultylogic board.

****POWERUPTESTSTATUS****

“CapFault” “CapFault” Capsfailedtochangeafterpower-up.

“RPTAShort” “P.UpR.PTAShort”

BucyrusAmerica,Inc. Revised12

Singlemotor

Block0point“A”short MotorshorttogroundorIGBTshorted Otherelectricalcomponent(coil/etc.)shortedorgrounded notallowingvoltagetocomeuptoorabove64VDConIGBT panel.

Dualmotor Block0point“A”short MotorshortedtogroundorRIGHTIGBTshorted Otherelectricalcomponent(coil/etc.)shortedorgrounded notallowingvoltagetocomeuptoorabove64VDConIGBT panel.

MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 16
07

BucyrusAmerica,Inc.

FaultMessageChart

“LPTA Short” “P.UpL.PTAShort”

(Continued)

Dualmotor Block1point“A”short MotorshortedtogroundorLEFTIGBTshorted Otherelectricalcomponent(coil/etc.)shortedorgrounded notallowingvoltagetocomeuptoorabove64VDConIGBT panel.

“I.D.Fault” “Vehicle IDFlt” VehicleConfigurationIDinvalid

“BadLogic” “BadLogic”

“RFWDON” “TractR.FWDon”

Diagnosticpoint“A”tripfailedtodisableUVRcoil.Faulty logicboard.

DiagnosticRIGHTFWDpoint“A”tripfailedtobedisabled.. Faultylogicboard,shortedmotortogroundorshortedIGBT.

“FWDON” “TractFWDon” Singlemotor Point“A”tripfailedtodisableFWDIGBT.Faultylogic board,shortedmotortogroundorshortedIGBT.

“RREVON” “TractR.REVon”

DiagnosticRIGHTREVpoint“A”tripfailedto bedisabled. Faultylogicboard,shortedmotortogroundorshortedIGBT.

“REVON” “TractREVon Singlemotor

DiagnosticREVpoint“A”tripfailedtobedisabled.Faulty logicboard,shortedmotortogroundorshortedIGBT.

“LFWDON” “TractL.FWDon”

“LREVON” “TractL.REVon”

DiagnosticLEFTFWDpoint“A”tripfailedtobedisabled. Faultylogicboard,shortedmotortogroundorshortedIGBT.

DiagnosticLEFTREVpoint“A”tripfailedtobedisabled. Faultylogicboard,shortedmotortoground orshortedIGBT.

“Driveoff” Drive0offFlt”: DiagnostictesttoenableUVRcoildriverfailed.Faultylogic board.

“RFWDOFF” “TractR.FWDoff”

DiagnosticRIGHTFWDpoint“A”tripfailedtodisable PWMO.Faultylogicboard.

“FWDOFF” “TractFWDoff” Singlemotor

DiagnosticFWDpoint“A”tripfailedtodisablePWMO. Faultylogicboard.

“RREVOFF” “TractR.REVoff”

DiagnosticRIGHTREVpoint“A”tripfailedtodisable PWMO.Faultylogicboard.

“REVOFF” “TractREVoff” Singlemotor DiagnosticREVpoint“A”tripfailedtodisablePWMO. Faultylogicboard.

“LFWDOFF” “TractL.FWDoff”

“LREVOFF” “TractL.Revoff”

DiagnosticLEFTFWDpoint“A”tripfailedtodisablePWM1. Faultylogicboard.

DiagnosticLEFTREVpoint“A”tripfailedtodisablePWM1. Faultylogicboard.

“BADLOGIC” “BADLOGIC” Internalerror (SoftwareOnly) Faultylogicboard.

Revised12 – 07 MODELBUCYRUS 2000SINGLEANDDUALMOTORSSTSGUIDE 17

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