Operationand Troubleshooting Manual HiPAC10Controller SAFETY.CAT.COM BI001951 A6474X328 April2012 VariableFrequencyDrive(VFD)forBatteryPoweredEquipment(HardwiredSystem)
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ThismanualisintendedtoprovideGENERALproductinformation. The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytothesemachines.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.
This VFDwasmanufacturedundertheguidelines,proceduresandrequirementsoftheappropriateregulatoryagencies.
Anychangetothedesignorstructureofthisunitwithouttheconsentof Caterpillarandtheseregulatoryagencies,oranyrepairorreplacement ofpartscontrarytoCaterpillar’sinstructions,mayrenderthisunitunsafetooperate.
Whilethismanualattemptstoanticipatethemostimportantoperations andtroubleshootingneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourServiceRepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
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© Caterpillar2012 ALLRIGHTSRESERVED
_________________________________________________ Tableofcontents A6474X328 REV06 BI001951 Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5
Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Repair..............................................................................2.4 Safetyinstructions 2.2 Generalrules 2.2 Storageandtransport 2.6 Maintenanceandrepair 2.7 Overviewofthesafetyinstructions 2.9 Chapter3:Operation 2.9 Chapter4:Technicaldata 2.11
Operation Operation 3.3 History 3.3 Innovatedmotorcontrol 3.3 BasicACmotoroperation 3.8 Generalspecifications 3.10 Features 3.11 Systemcomponents 3.15 Powerconnection 3.15 VFDcontrolhardinputs/outputs 3.16 Configurationchart 3.32 Controlsystemoperation 3.33 Controllerstart-up 3.33 Tractionbraking............................................................. 3.34 Neutralbraking 3.34 Directionbraking ........................................................... 3.34 Decelerationbraking 3.34 Drivabilityprofiles .......................................................... 3.35 Circuitbreakerclosetimerfeature 3.35 Pumpcutbacktimerfeature .......................................... 3.35 Payloadcounterfeature 3.35 Motorencoder ............................................................... 3.36 Roll-offparameter 3.36 Steerfeature(800seriesmachinesonly) ..................... 3.36 Tractioncontrolalgorithm 3.38 Display 3.39
1.
2.
3.
Tableofcontents _________________________________________________ ModelHiPAC10VariableFrequencyDrives BI001951 Troubleshooting 3.49 Faultinformationcodes 3.49 Ledfaultinformationflashcodes 3.59 Testmeasurements.......................................................3.63 Motors 3.67 Adjustments 3.73 Adjustableparameters 3.73 Partsreplacement 3.81 RemovalandinstallationofVFDs 3.81
Technicaldata Technicaldata 4.3 Tighteningtorques................................................................4.3
Foryourinformation Foryourinformation ..................................................................5.3 Ourservice 5.3 Serviceaddress 5.3 Rebuildfacilityaddress 5.4
4.
5.
_______________________________________________________________ 1 Aboutthismanual BI001951
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applicableoperatingmanual
machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
ThisoperatingmanualisintendedforthemodelHiPAC10Variable FrequencyDrives(VFD)forBatteryPoweredEquipmentandisonly permittedtobeusedforequipmentofthistype.
newoperationmanual
Theoperatingandtroubleshootingmanualmustbeaccessibleatall timestoallpersonsworkingonorwiththeVFD.Itshould,ifpossible, alwaysbeavailableattheplaceofoperation.
Sendforanewoperationandtroubleshootingmanualimmediatelyif thepresentmanualisnolongercompleteorhasbecomeillegible.
Whoisthismanualintendedfor?
Thismanualisintendedforthosepersonswhoworkwithoronbattery poweredequipmentwiththeHiPAC10Controller.
Thisincludespersonswho:
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
____________________________________________Beforestartingtowork A6474X328 REV06 1.3 BI001951
cost-effectiveness
Whatisthepurposeofthismanual?
Thismanualisintendedtohelpyouworkefficientlyandsafelywithour product.ItcontainsimportantinformationonoperatingandtroubleshootingtheHiPAC10controlsystem.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork____________________________________________ 1.4 ModelHiPAC10VariableFrequencyDrives BI001951
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
____________________________________________Beforestartingtowork A6474X328 REV06 1.5 BI001951
Beforestartingtowork____________________________________________ 1.6 ModelHiPAC10VariableFrequencyDrives BI001951
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2 Yoursafety
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Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Thismachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations.You andotherscan,nevertheless,beexposedtodangeroussituationse.g. asaresultofenvironmentalinfluences,machinedamage,oroperator errors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyCaterpillar.
Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantees.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities.
Personnel Repair
Asafundamentalrule,repairworkmayonlybecarriedoutbypersonnelwhohavebeenadequatelytrainedfortheseparticularrequirements.
Electricalrepairworkmayonlybecarriedoutbyserviceengineersor byspeciallyqualifiedpersonnelofthemine.Allelectricalworkistobe donebyqualifiedpersons,inaccordancewithallMSHA,Federal, State,andLocalregulations.
Exceptwhereallowedbyapplicableregulatoryagencies,beforeconductingelectricalworkonthismachine:
■ Themachinecircuitbreakershallbeturnedoff.
■ Thebatterycircuitbreakershallbeturnedoff.
■ Thebatteryplugshallbedisengaged/removed,andlocked/tagged out.
______________________________________________________ Personnel A6474X328 REV06 2.3 BI001951
stateoftheart
Personnel _______________________________________________________ 2.4 ModelHiPAC10VariableFrequencyDrives BI001951
Safetyinstructions
Generalrules
Alwaysworkwithfullconcentration. Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85dB(A).
Informyourcolleaguesof:
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.EMERGENCYSTOPdevices,cover plates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
Pressthemachine’sEMERGENCYSTOPswitchimmediatelyinthe eventoffaultorirregularitiesinoperation.Reportanypeculiarityto yoursuperiorsothatnecessarymeasurescanbetakenimmediately.
Disconnectthebatterywhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
Batteriesshouldbewellventedbeforeservicing,particularlyifwelding orburningonthebattery.
Disconnectthebatterywhenworkingwiththeelectricalsystemorwhen weldingontheunittopreventelectricalshock.
Whilewelding,thebatterymustbedisconnectedtobesurethatyoudo notdamagetheelectricalsystemand/oranyoftheelectricalcomponents.
WARNING!
Studyallwarning/cautionlabelsandnotesrelatedtoworkingwith batteriesandelectricmotors.Theselabelsmaybeonthebattery, themotor,and/oronthemachine,aswellasinthisOperator’s manual.Failuretocomplywiththesafetyinstructionsregarding workingwithbatteriesandelectricmotorscanresultindeathor seriousinjurybyelectrocution.
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A6474X328 REV06 2.5 BI001951
Safetyinstructions
general noiseemissions
symbolplates emergencystop disconnectbattery welding
safetyequipment
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchas:
■ falsebottoms
■ pivotpoints
■ batterylifts
Connectthesteeringlockoutdevicebeforeperformingmaintenanceor repairsonthemachine.
Storageandtransport
Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
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Safetyinstructions
transportsafetydevice meansofattachment
mobilehandlingequipment
movingparts steeringlockout
cordonoffworkingarea
Maintenanceandrepair
Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenanceandrepairoperations.Givetheminformationontheintended operationsandtheanticipatedduration.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectandlockoutthebatteryfromthemachinetopreventunauthorizedandunintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Disconnectandlockoutthebatteryfrommachinetopreventfromrestartingbeforereplacinganydefectivecomponents.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. Thisisonlyensuredwithoriginalspareparts.Pleaserefertothespare partslistsfortheordernumbers.
Forraisingthemachineuseonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity. Onlypersonswhohaveandcandemonstrateaspecialknowledgeof electricsareallowedtoworkontheelectricalsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlessthewheelsarechockedandsteeringlockoutdeviceisconnectedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalsettingsfromthatindicatedinthismanualor assetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates. Disconnectandlockoutthebatterywhenworkingwiththeelectrical system,orwhenweldingontheunittopreventelectricalshock.
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A6474X328 REV06 2.7 BI001951
Safetyinstructions
securing replacingcomponents originalparts lifting maintenance,repair
Besurethebatteryareaiswellventilated(clearoffumes)whenitis necessarytoconnectbatterycharger.Fumesfromthebatterycould ignitefromasparkandexplode.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
_______________________________________________ 2.8 ModelHiPAC10VariableFrequencyDrives BI001951
Safetyinstructions
• 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
