CAT AC Traction Drive 1565916 & 1565924 Operation and Troubleshooting Manual

BI632639 June 2014

Operation and Troubleshooting Manual AC Traction Drive 1565916 & 1565924

SAFETY.CAT.COM

BI632639

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This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to AC traction, continuous miners with Super Simpson 1565916 and 1565924 version software. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements set forth in the sales order specification.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar‘ instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© Caterpillar 2014 ALL RIGHTS RESERVED

BI632639

Table of contents Safety Instructions ............................................................................. 4 Introduction ........................................................................................ 6 VFD System ...................................................................................... 7 AC Traction Adjustable Parameters .......................................... 8 AC Drive Encoder Removal ...................................................... 11 AC Drive Encoder Installation ................................................... 11 Traction Drive (VFD) Removal .................................................. 15 Traction Drive (VFD) Installation ............................................... 17 Inverter Fault and Warning Codes ............................................ 20 Rectifier Fault and Warning Codes ........................................... 24 AC Traction System Interfacing Connectors and Cabling ......... 26 Inverter Control Connector (CN2) ........................................ 26 Inverter Control Connector (CN1) ........................................ 26 CAN Connectors (Rectifier CN2/3 Inverter CN 3/4) ............. 27 RTD Corresponding Temperature Values ......................................... 28

BI632639

Safety Instructions_______________________________________________ Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed, as well as all applicable regulatory agency rules and regulations must be followed at all times.

!

DANGER

Do not make any type of temporary repairs to the trailing cable or trailing cable connections. Trailing cables may only be repaired under certain conditions and following specific guidelines.

!

DANGER

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

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WARNING Do not attempt to operate this continuous miner until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

WARNING Federal law requires that temporary roof supports be in place before approaching the machine to reset a circuit breaker. Under no circumstances should personnel be under unsupported roof. Failure to follow these regulations may result in serious injury or death.

WARNING Only use the Emergency Stop Override to tram the miner away from the rib, releasing the accidentally pushed Machine Stop button. Never use the Emergency Stop Override when a Machine Stop switch has been activated by personnel. Failure to comply with this warning may lead to severe injury or death of personnel.

WARNING The Continuous Miner is radio remote controlled during production operations. Manual operation via machine mounted controls is not permitted for production operations.

Manual operation is for troubleshooting and maintenance under supported roof only.

Operating the Continuous Miner with manual or pendant controls under unsupported roof may result in sever injury or death.

WARNING Before performing maintenance or repair work on this machine, the circuit breaker must be in the “OFF” position and the trailing cable disconnected. Follow all applicable rules and regulations regarding the lockout/tagout procedures. Accidental machine movement or electrical shock may result in serious injury or death to the operator or other personnel.

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

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_______________________________________________Safety Instructions

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WARNING Do not use an emergency or stop device as a means of disconnecting power to the miner. Whenever instructed to disconnect power, it is always meant to turn the main circuit breaker to the “OFF” position and to physically remove the trailing cable and lockout/ tagout the machine. Failure to do so may result in serious injury or death.

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

WARNING Do not rely on load holding valves when working under the cutter head or the conveyor.

Always block the cutter head and conveyor in the elevated position. Serious injury or death may occur if the cutter head or conveyor are not mechanically blocked.

WARNING Never work under any assembly or component of this machine that is elevated. Always install enough blocking to support t he machine or component or lower the component to ground level.

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Introduction_____________________________________________________ Introduction

The purpose of this manual is to give an overview the AC traction drive (VFD) system. This manual is only intended to familiarize the user with the VFD. All electrical maintenance must be performed by a qualified person.

VFD Overview

The variable frequency drive (VFD) system used 3-phase, 950 VAC motors for tramming. The motors respond to changes in frequency from the control system to tram the machine at infinitely variable speeds.

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_____________________________________________________VFD System Introduction

The variable frequency drive system (VFD) system is used to control tramming operations. The tram motors respond to changes in frequency to tram forward and reverse at varying speeds.

Sump Tramming

The controller settings for sump tramming (tramming forward while cutting) can be adjusted through the graphics display AC traction parameters page, “SUMP SETUP MENU” (Fig. 1) which is accessed with a password. This screen allows the operator to tune the machine for individual mine conditions. A description of the parameters are given in Table 1.

Fig. 1: “SUMP SETUP MENU”, AC traction parameters page

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VFD System_____________________________________________________ Table 1: AC traction adjustable parameters Menu

Parameter

Description

Value

Traction Speed

FWD SPEED 1 (%)

Traction drive target speed forward - 1st speed

0 - 45%

1%

20

FWD SPEED 2 (%)

Traction drive target speed forward - 2nd speed

FWD Speed 1 80%

1%

40

FWD SPEED 3 (%)

Traction drive target speed forward - 3rd speed

FWD Speed 2 100%

1%

70

REV SPEED 1 (%)

Traction drive target speed reverse - 1st speed

0 - 45%

1%

20

REV SPEED 2 (%)

Traction drive target speed reverse - 2nd speed

REV Speed 1 80%

1%

40

REV SPEED 3 (%)

Traction drive target speed reverse - 3rd speed

REV Speed 2 100%

1%

70

MAX SUMP SPEED (%)

Determines maximum forward speed available when system has determined that the machine is cutting in the face

5 - 45%

1%

20

MIN SUMP SPEED (%)

Determines minimum forward speed available when system has determined that the machine is cutting in the face

0 - 20%

1%

5

AC SUMP DELTA (%)

Determines the rate of change in forwarded sump direction from minimum to maximum speeds when system has determined that the machine is cutting in the face

1 - 5%

1.00%

1

Sump Settings

Change Default

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_____________________________________________________VFD System Table 1, continued: AC traction adjustable parameters Menu

Parameter

Description

Value

Change Default

Sump Settings, continued

STOP SUMP CUTTER CURRENT (A)

Determines the threshold for cutter current at which the machine will halt until the current level drops below the Stop current value

150 400A

1A

400

STOP SHEAR UP CUTTER CURRENT (A)

Sets the threshold for cutter current that determines when to stop shear up control. When the current falls below this, shear up will restart

0 - 500A

1A

250

STOP SHEAR Determines the cutter current threshold DOWN CUTTER where the shear up solenoid output will CURRENT (A) be inhibited.

0 - 500A

1A

250

TARGET CUTTER CURRENT (A)

Determines the target cutter current threshold for sump algorithm.

40 - 200A

1A

120

HIGH SPEED REV PREVENT (YES/NO)

When set to YES, inhibits the maximum reverse speed to 2nd speed when cutters are running

YES/NO

N/A

NO

REV ANTI SLEW Determines the speed in the reverse diSPEED (%) rection when tramming in single track or pirouette when the system has determined that the machine is cutting in the face

20 - 75%

1%

20

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VFD System_____________________________________________________ Table 1, continued: AC traction adjustable parameters Menu VFD Setup

Parameter

Description

Value

Change Default

DRIVE Sets AC drive current limit setting for CURRENT LIMIT braking.

(A)

100 200%

1%

180

VFD BRAKE SETPOINT (V)

Bus voltage level setting

17001800V

1V

1700

BUSS VOLTAGE LIMIT ENABLE (YES/NO)

When set to YES, enables the bus voltage limit.

YES/NO

N/A

NO

BUSS VOLTAGE LIMIT (V)

The allowable BUSS voltage output from the rectifier

1700 – 1800V

1V

1700

BUSS VOLTAGE DELAY TIMER (s)

The allowed time that the BUSS voltage can be above the BUSS voltage limit setting.

0.0-5.0s

0.1

2.5

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_____________________________________________________VFD System AC Drive Encoder Removal

When removing the AC drive encoder, follow all applicable regulatory agency laws and regulations, including but not limited to: To remove the tram motor AC drive encoder (Fig. 2): 1. Disconnect and lock out electrical power to the miner.

2. Remove the cover from end of the tram motor.

3. Remove the four screws that hold the rotor cover in place and remove the cover to expose the rotor and stator.

4. Remove the four screws that secure the rotor.

5. Remove the four screws that secure the stator.

6. Remove the stator and rotor from the motor.

AC Drive Encoder Installation

To install the encoder (Fig. 2): 1. Mount the stator over the motor shaft and secure with four bolts. Apply thread locking compound to the bolts and tighten to 34 N-m (25 ft-lb).

2. Mount the rotor inside the stator, making sure that the encoder and rotor are aligned on the front most edge (Fig. 3). Apply thread locking compound to the bolts and tighten to greater than 8 N-m (70 in-lb).

3. Ensure the wheel does not have excessive wobble (greater than 0.010 inch). Rotate the motor shaft by hand. It should rotate freely and not touch the frame at any time. If everything is mechanically correct, the resulting stator to rotor air gap will be a nominal 0.019 inches.

4. Mount the rotor cover and secure with four screws.

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VFD System_____________________________________________________ Fig. 2: Motor encoder

Rotor cover

Motor shaft

Stator Rotor

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_____________________________________________________VFD System Fig. 3: Encoder rotor and stator alignment

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VFD System_____________________________________________________ Caution: Reversing power and common will not damage the unit. However, applying power to any of the senor outputs may cause damage. Refer to Table 2, for signal coding. Note: pin outs are for sensors with the MS3102E-18-IT# connector.

Table 2: Encoder signal coding Signal

Connector Pin

Pigtail Cable

MS3102E-18-IT#

Common

1

Black

F

B

2

Green

B

A

3

Blue

A

Z*

4

Violet

C

No Connection

5

-------

E

Vcc (5-15 VDC)

6

Red

D

/B

7

Yellow

I

/A

8

Gray

H

/Z*

9

Orange

J

Shield

10

Braid

G

* Applies only to units with index pulse capability Note: the shield in the sensor module is isolated from the frame of the encoder for maximum noise immunity. The shield wire or pin should be connected to the shield of the cable and that of the drive or other receiving device.

Encoder connections The encoder connections should be made inside the traction enclosure and the traction case. Each motor encoder is interface to each drive via the CN2 connectors.

Note : 1. The encoder leads are phased AT THE TRACTION CASE END. 2. The electrician should not deviate from the machine schematics.

3. Both motors should be wired the same with the phase reversal performed inside the traction case.

_______________________________________________________________ 14 AC Traction Drive 1565916 & 1565924

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_____________________________________________________VFD System traction drive (VFD) removal

To remove a traction drive (VFD): 1. Disconnect and lock out electrical power to the miner. Follow all applicable Federal and mine regulations regarding lockout/tagout procedures.

2. Remove the pin that secures the rub rail in place in front of the VFD case (Fig. 4) and swing the rub rail out.

3. Remove the bolts that secure the VFD cover in place and remove the cover.

Fig. 4: Rub rail and cover (typical)

Cover bolts

Rub rail pin

Cover

Rub rail

4. Locate the five (5) power connections on the top of the VFD (Fig. 5).

5. Identify and tag the power cables to make sure they get reconnected correctly.

6. Remove the hex head nuts (Fig. 5) that secure the power cables to the VFD and remove all five (5) cables.

7. Disconnect the ground wire on the front of the VFD (Fig. 5).

8. Identify and tag all communication cables going to the drive (Fig. 5) to make sure they get reconnected correctly.

9. Remove the bolts that secure the VFD to the case. The drive is now free to remove from the case.

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VFD System_____________________________________________________ Fig. 5: VFD connections Communication cables

Mounting bolts

Hex nut (5)

Power connection (5)

Ground wire

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_____________________________________________________VFD System traction drive (VFD) installation

To install a traction drive (VFD): Note: There is a Thermal Interface Kit, part number 906546, that includes the materials necessary to apply the thermal compound. The kit includes the thermal compound, polyester mesh, plastic applicator, sand paper, solvent, WD40, white cleaning cloths, and electronic cleaning wipes.

1. Clean the VFD and enclosure mounting surfaces to ensure all burrs/defects are removed. Use WD40 and 1200 grit sandpaper to ensure the surface is smooth and defect free (Fig. 6).

2. Using a solvent, clean both the VFD and enclosure mounting surfaces to ensure that all dust, oil, rust, moisture, previous thermal compound, etc. is removed.

3. Apply thermal joint compound (Wakefield Engineering 120 Series). a. Apply thermal past to the VFD base plate only. Do not apply to the enclosure mounting surface. b. Spread paste using a plastic straight edge to minimize damage to the interface. c.

The thickness of the compound film should be approximately 0.8 mm (0.031 (1/32) inches). (Application of a polymer screen will assure this thickness and prevent error). Coverage should be sufficient to turn the base plate 90 % white, be free of inclusions, and should be evenly applied (Fig. 6).

d. If the surface is unable to hold both the surface flatness and roughness criteria, ensure that the thermal compound is applied such that it bonds the component to the enclosure. This is verified by applying the compound as instructed, installing the component, and then removing the component. The thermal paste is correct when a branch like structure become visible in the paste (Fig. 7).

4. Place the component on the enclosure surface and ensure that the thermal compound has bonded to both surfaces by slightly sliding the component side-to-side and front-to-back.

5. Install the bolts to secure the drive to the mounting plate (Fig. 8).

6. Connect the ground wire to the VFD (Fig. 8).

7. Reconnect the power leads to the VFD (Fig. 8).

8. Reconnect the communication cables to the VFD (Fig. 8).

9. Replace the cover on the traction case and secure with bolts (Fig. 5).

10. Close the rub rail and secure (Fig. 5).

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VFD System_____________________________________________________ Fig. 6: Thermal compound application

standard base plate condition

polished base plate condition

thermal compound application Fig. 7: Sufficient thermal compound application

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_____________________________________________________VFD System Fig. 8: VFD connections Communication cables

Mounting bolts

Hex nut (5)

Power connection (5)

Ground wire

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VFD System_____________________________________________________ AC Traction System Table 3: Inverter fault and warning codes

Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 0

No Fault

N/A

None

N/A

None

N/A

None

N/A

N/A

1

Current limit Warning N/A reduced below 150% by IGBT thermal protection

None

N/A

None

N/A

None

1. High heat sink temperature.

1. Improve coolant flow.

2. Sustained operation at high output current.

2. Reduce load.

2

Under voltage

N/A

Latched Left VFD None Fault Under voltage

Left VFD Pump Under shutdown / voltage inhibit

Left VFD Pump Under shutdown / voltage inhibit

3. Allow one minute to cool.

1. Supply voltage 1. Improve supply quality or reduce falls below total machine 750V while load. drive enabled.

2. Rectifier output 2. Replace rectifier. voltage too low.

4

5

Heatsink Trip

IGBT Short Circuit

Latched Left VFD None Fault Temp Trip

Latched Left VFD None Fault Short Circuit

Left VFD Pump Temp Trip shutdown / inhibit

Left VFD Pump Temp Trip shutdown / inhibit

Left VFD Pump Short shutdown / Circuit inhibit

Left VFD Pump Short shutdown / Circuit inhibit

3. Drive has faulty 3. Replace drive.

DC bus voltage measurement circuit.

1. Insufficient 1 Restore coolant coolant flow. flow.

2 Remove and re2. Poor thermal install with reccontact beommended tween drive base and enclo- thickness layer of heat sink sure surface, paste. too much or too little heat sink paste.

1. Operation in 1. Reset fault, alstall condition low drive one for more than minute to cool, one minute. remove cause of stall condition.

2. Motor winding fault or terminal- 2. Remove fault. to-terminal fault.

3. Reset fault and 3. Sudden incontinue. crease in me4. Replace drive. chanical load if running in open- 5. Replace drive. loop mode.

If fault always occurs at the instant the drive is enabled: 4. IGBT failure 5. Current transducer failure.

Note: Left side drive - for right drive, replace “left” with “right”

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_____________________________________________________VFD System Table 3 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 6

13

Warning Left VFD None Over voltage

Left VFD Pump Over shutdown / voltage inhibit

Left VFD Pump Over shutdown / voltage inhibit

Motor Overload Latched Left Tract None Fault Motor Overload

Left Tract Pump Motor shutOverload down / inhibit

Left Tract Pump Motor shutOverload down / inhibit

Overvoltage

1. Supply voltage 1. Reduce supply exceeds 1200V. voltage.

2. Dynamic brake 2. Wait for dynamresistor thermal ic brake resistor cut-out has to cool. occurred while 3. Put machine in braking. air and check braking opera3. The dynamic tion. Replace brake unit is not rectifier/brake operating. module if no braking observed..

1. Traction motor 1. Wait for cool load too high. down period and resume operation at lower speed.

2. Incorrect motor 2. Check motor parameter setsetup in menu tings C. 3. Motor stalled.

20

Left Motor Instantaneous Overload

Latched Left Tract None Fault Motor Inst Overload

Left Tract Pump Motor Inst shutOverload down / inhibit

Left Tract Pump Motor Inst shutOverload down / inhibit

1. Operation in stall condition for more than one minute.

2. Motor winding fault or terminalto-terminal fault.

27

Overvoltage Trip Latched Left VFD None Fault Overvoltage Trip

Left VFD Pump Overvolt- shutage Trip down / inhibit

Left VFD Pump Overvolt- shutage Trip down / inhibit

3. Remove cause of stalled motor.

1. Remove machine from stall condition.

2. Check motor windings and replace motor if necessary.

3. Sudden in3. Check compocrease in menent configurachanical load if tion with drive running in open- programmer and loop mode. examine conditions around If fault always machine. occurs at the in- If fault always stant the drive is occurs at the inenabled. stant the drive is enabled.

4. IGBT failure 4. Replace unit.

5. Current transducer failure.

5. Replace unit.

1. Supply voltage 1. Reduce supply exceeds 1200V. voltage 2. Dynamic brake 2. Wait for dynamresistor thermal ic brake resistor cut-out has to cool. occurred while 3. Replace rectifibraking. er/brake mod3. The dynamic ule. brake unit is not operating.

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VFD System_____________________________________________________ Table 3 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 34

35

38

43

44

60

Motor RTD Trip Latched Motor None Fault RTD Trip

Motor TSAT Trip Latched Motor None Fault TSAT Trip

Overspeed 10% Latched Left Tract None Fault Motor Overspeed

Output Phase Loss

Latched N/A Fault

None

Lost CAN comm Latched Left VFD None Fault Comms Fail

Encoder Loss Latched Left Motor None (Position Error) Fault Encoder Fault

Motor Pump RTD Trip shutdown / inhibit

Motor TSAT Trip

Pump shutdown / inhibit

Left Tract Pump Motor shutOverdown / speed inhibit

Left VFD Pump Phase shutdown / Loss inhibit

Left VFD Pump Comms shutdown / Fail inhibit

Left Motor Encoder Fault

Pump shutdown / inhibit

Motor Pump RTD Trip shutdown / inhibit

Motor Pump TSAT Trip shutdown / inhibit

Left Tract Pump Motor shutOverdown / speed inhibit

Left VFD Pump Phase shutdown / Loss inhibit

Left VFD Pump Comms shutdown / Fail inhibit

Left Motor Pump Encoder shutdown / Fault inhibit

1. Traction motor load too high.

2. Insufficient motor cooling water flow

1. Traction motor load too high.

2. Insufficient motor cooling water flow

1. Wait for cool down period and resume operation at lower speed.

2. Restore cooling water flow 1. Wait for cool down period and resume operation at lower speed.

2. Restore cooling water flow 1. Severe electri- 1. Check connections and shieldcal noise on ing. encoder signal.

2. Incorrect setting 2. Check motor of encoder setup in C pulse number or menu. motor pole 3. Remove cause. number.

3. Machine running downhill or dragged by external cause.

1. Output phase 1. Check motor connection. disconnected.

2. Output current very low.

2. Reset and resume operation.

3. Inverter output 3. Replace inverter phase not working.

1. CAN link dis1. Reconnect CAN connected. link.

2. Severe electrical noise on CAN link.

2. Check connections and shielding.

3. Drive has no control power

3. Restore control power.

4. Drive has hard- 4. Replace inverter ware fault.

1. Encoder failure. 1. Check encoder wiring 2. Encoder power supply lost.

2. Replace encoder 3. Encoder signal disconnected.

Note: Left side drive - for right drive, replace “left” with “right”

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_____________________________________________________VFD System Table 3 (continued): Inverter fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 61

Error 61

Latched Left VFD None Fault Undefined Fault Code

Left VFD Pump Left VFD Pump 1. Instantaneous 1. Reset fault and Undeshutdown/ Undefined shutdown/ overload has resume operafined occurred but tion.

Inhibited Fault Inhibited Fault Code duration not Code long enough to determine source of indication.

67

Encoder Ride Thru

Latched Left VFD None Fault in Encoder Ride Thru

Left VFD None in Encoder Ride Thru

Left VFD None in Encoder Ride Thru

68

Stall Fault

Warning Left Motor None Stalled

Left Mo- None tor Stalled

Left Motor None Stalled

69

Auto Encoderless Operation

Warning Left VFD None in Encoderless Mode

Left VFD Limit in EnTram to coderless First Mode Speed

Left VFD Limit in EnTram to coderless First Mode Speed

Unde- Undefined Fault N/A fined Code

Left VFD None Undefined Fault Code

1. Temporary loss 1. Continue to of encoder operate the signal. miner until secondary fault occurs.

1. Machine stuck. 1. Remove machine from stall 2. Loss of encoder position signal.

2. Continue to operate the miner until secondary fault occurs.

1. Machine run1. Check encoder ning in encoder- wiring and cycle less until power power. cycle and en2. Replace encodcoder fixed. er and cycle power.

Left VFD Pump Left VFD Pump 1. Internal unUndeshutdown/ Undefined shutdown/ known fault to fined Fault component. inhibit inhibit Fault Code 2. Fault occurred Code faster than component could register.

1. Restart system and operate normally.

2. Replace component if error persists.

NOTE: Fault and Error messages are given for the Left-side drive. The set of messages for the right drive will be identical, except for message numbers and the replacement of the text "Left" with the text "Right".

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VFD System_____________________________________________________ Table 4: Rectifier fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 0

No Fault

None

N/A

1

Heatsink Alarm Warning Rectifier Temp Warning

None

Rectifier None Temp Warning

Under voltage

None

2

4

5

Heatsink Trip

IGBT Short Circuit

N/A

N/A

Latched None Fault until Healthy

None

N/A

None

Rectifier Temp Warning

None

Rectifier If present Rectifier Under for >1 sec Under voltage after first voltage 5 sec of pump start, inhibit drive function

1. Restore coolant flow.

2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclo- thickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

If present 1. Supply voltage 1. Restore supply, improve supply for >1 sec below 460V or quality or reduce after first disconnected. total machine 5 sec of 2. CAN control load. pump board is applystart, ing precharge 2. Replace rectifiinhibit inhibit signal. er. drive 3. Replace rectififunction 3. SCR control circuit failure. er.

Latched Rectifier None Fault Temp Trip until Healthy

Rectifier Pump Temp shutdown / Trip inhibit

Rectifier Pump Temp Trip shutdown / inhibit

Latched Rectifier Fault Short until Circuit Healthy

Rectifier Pump Short shutdown / Circuit inhibit

Rectifier Short Circuit

None

1. Insufficient coolant flow.

Pump shutdown / inhibit

4. Drive has faulty 4. Replace rectifiDC bus voltage er. measurement circuit.

1. Restore coolant 1. Insufficient flow coolant flow.

2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclo- thickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

1. Damaged brake 1. Check braking by placing maresistor. chine in air, run 2. Dynamic brake in second speed IGBT failure. and then return to neutral. If tracks coast excessively, replace brake resistor.

2. If brakes do not coast excessively, replace rectifier.

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_____________________________________________________VFD System Table 4(continued): Rectifier fault and warning codes Alarm Code

Description

Device Action

System Error (if detected when pump off)

System Fault (if detected when pump on / traction idle)

System Fault (if detected when pump on / traction active)

Control Control Control System System System Message Reaction Message Reaction Message Reaction Possible Cause Possible Solution 15

17

19

Rectifier IGBT Over Temp

Brake Resistor Thermal Trip

Rectifier Input Instantaneous Overload

Latched Rectifier Fault IGBT until Over Healthy Temp

None

Latched Brake Fault Resistor until Thermal Healthy Trip

None

Latched None Fault until Healthy

None

Rectifier IGBT Over Temp

Pump shutdown / inhibit

Brake Inhibit Resistor Drive Thermal Function Trip

Rectifier IGBT Over Temp

Pump shutdown / inhibit

Brake Resistor Thermal Trip

Inhibit Drive Function

Rectifier If present Rectifier Input Inst >1 sec, Input Inst Overload Overload Pump shutdown / inhibit

1. Insufficient coolant flow.

1. Restore coolant flow.

2. Poor thermal 2. Remove and recontact beinstall with rectween drive ommended base and enclo- thickness layer sure surface, of heat sink too much or too paste. little heat sink paste.

1. Braking resis- 1. Allow the systors overheated. tem to cool and/ or set second 2. Thermal switch speed to above malfunction.

66% to remove braking action.

2. Replace thermal switch.

1. Restore all input phases.

If present 1. No supply or missing input >1 sec, phase during Pump shutstartup. down / 2. DC bus connec- 2. Eliminate incorinhibit tion reversed on rect polarity. rectifier or inverter.

3. Short-circuit on 3. Remove shortDC bus. circuit.

4. Two failed IGBTs in an inverter module.

4. Replace faulty inverter module.

5. Dynamic brake 5. Replace rectifier IGBT failure. module.

42

Rectifier Phase Warning None Sync Loss Fault

Unde- Undefined Fault N/A fined Code

None

Rectifier None Undefined Fault Code

If present Rectifier If present 1. No supply or for >10 Phase for >10 missing input phase after sec after Sync Loss sec after first 5 sec first 5 sec startup of pump of pump 2. Fault in synstart, start, chronization inhibit inhibit circuit. drive drive function function Rectifier Pump Rectifier Pump 1. Internal unUndeshutdown/ Undefined shutdown/ known fault to fined Fault component. inhibit inhibit Fault Code 2. Fault occurred Code faster than component could register.

Rectifier Phase Sync Loss

1. Restore all input phases.

2. Replace rectifier.

1. Restart system and operate normally.

2. Replace component if error persists.

______________________________________________________________ REV 0 25

BI632639

VFD System_____________________________________________________ AC Traction System Interfacing Connectors and Cabling Table 5: Inverter control connector (CN2) Cable

Cable Marker

15C + SHIELD

CONTROL

6C + SHIELD

3C + SHIELD

ENCODER

AUXREF

Pin

Description

Wire Marker

Color

S

RTD RED (2 or 3 wire)

RTD1

BLK

P

RTD WHITE (3 wire only)

RTD2A

WHT

R

RTD WHITE (2 or 3 wire)

RTD2B

RED

M

TSTAT+

TSTAT+

GRN

N

TSTAT-

TSTAT-

ORG

A

LOGIC COM (+24V)

24V

BLU

B

MASTER ENABLE

ENABLE

WHT/BLK

f

CAN ADDRESS LSB

CANLSB

RED/BLK

g

CAN ADDRESS MSB

CANMSB

GRN/BLK

C

MANUAL TRAM FWD

EFWD

ORG/BLK

D

MANUAL TRAM REV

EREV

BLU/BLK

T

SPARE

SPARE

BLK/WHT

E

RELAY NO

RLYNO

RED/WHT

Y

RELAY NC

RLYNC

GRN/WHT

L

RELAY COM

RLYCOM

BLU/WHT

b

DIGITAL SHIELD

SHD

SHIELD

Z

ENCODER SUPPLY+

ENCV+

BLK

G

ENCODER A

ENCA

WHT

H

ENCODER A\

ENCA\

RED

J

ENCODER B

ENCB

GRN

K A F

ENCODER B\ ENCODER SUPPLYENCODER SHIELD

ENCB\ ENCVSHD

ORG BLU SHIELD

U

TRAM REF SUPPLY (+5V)

5V

BLK

V

MANUAL TRAM REF

REF

WHT

W

ANALOG COMMON

0V

RED

X

ANALOG SHIELD

SHD

SHIELD

Fig. 31: Inverter control connector (CN2) NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

A

T

S

U

R

e

V

f

d

P

B

g

C W

j c

N M

h b

L

a K

D E

X Y Z

F

G

J H

_______________________________________________________________ 26 AC Traction Drive 1565916 & 1565924

BI632639

_____________________________________________________VFD System Fig. 32: Inverter/rectifier power connector (CN1)

A

B

D

C NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

Table 6: Inverter/rectifier power connector (CN1)

Cable 4C

Cable Marker POWER

Pin

Description

A

120VAC

Wire Marker L

B

NEUTRAL

N

BLK

C

EMERGENCY TRAM

ETRAM

WHT

D

GROUND

GND

BLU

Color RED

Table 7: CAN Connectors (Rectifier CN2/3 Inverter CN3/4) Cable 2C+S HIELD

Cable Marker CAN

CAN H

Wire Marker CANH

WHT/BLU

B

CAN L

CANL

BLU/WHT

C

0V

0V

SHIELD

Pin

Description

A

Color

NOTE: Colors indicated follow primary/secondary where the secondary color is a stripe.

Fig. 33: CAN Connectors (Rectifier CN2/3 Inverter CN3/4) A

B

C

______________________________________________________________ REV 0 27

BI632639

VFD System_____________________________________________________ Table 8: RTD Corresponding Temperature Values Resistance (Ohms)

Temperature (°C)

Resistance (Ohms)

Temperature (°C)

Resistance (Ohms)

Temperature (°C)

100

0.0

135

89.3

170

178.6

101

2.6

136

91.8

171

181.1

102

5.1

137

94.4

172

183.7

103

7.7

138

96.9

173

186.2

104

10.2

139

99.5

174

188.8

105

12.8

140

102.0

175

191.3

106

15.3

141

104.6

176

193.9

107

17.9

142

107.1

177

196.4

108

20.4

143

109.7

178

199.0

109

23.0

144

112.2

178.4

200.0

110

25.5

145

114.8

179

201.5

111

28.1

146

117.3

112

30.96

147

119.9

113

33.2

148

122.4

114

35.7

149

125.0

115

38.3

150

127.6

116

40.8

151

130.1

117

43.4

152

132.7

118

45.9

153

135.2

119

48.5

154

137.8

120

51.0

155

140.3

121

53.6

156

142.9

122

56.1

157

145.4

123

58.7

158

148.0

124

61.2

159

150.5

125

63.8

160

153.1

126

66.3

161

155.6

127

68.9

162

158.2

128

71.4

163

160.7

129

74.0

164

163.3

130

76.5

165

165.8

131

79.1

166

168.4

132

81.6

167

170.9

133

84.2

168

173.5

134

86.7

169

176.0

_______________________________________________________________ 28 AC Traction Drive 1565916 & 1565924

BI632639

_____________________________________________________VFD System

______________________________________________________________ REV 0 29