Cat Electric Rope Shovel Siemens 182M AC Drive Converter Cabinet Bucyrus Shovel Operation & Maintena

BI620028

Drive Converter Cabinet Bucyrus Shovel 182M AC Operation & Maintenance Manual

Doc No.: A5E02606385J/ 4M-2601-1645709 Order No: 102252549

Edition 06.2010

BI620028

Name

Company

Department

Released by

Mr. Holweck

Siemens AG

I DT LD T M

Checked by

Mr. Shinde

Siemens Ltd.

I DT LD NW PD

Edited by

Mr. Marathe

Siemens Ltd.

I DT LD NW PD

The reproduction, transmission or use of this document or its contents is not permitted without express written authority.

Offenders will be liable for damages. All rights, including rights created by patent grant or registration or a utility model or design, are reserved.

© Siemens Ltd. 2009 All rights reserved

Order No.: 102252549 Order to I DT LD NW Printed in India

Exclusion of Liability We have checked the contents of this manual to ensure conformance with the described hardware and software. However, since deviations cannot be completely ruled out, we do not guarantee complete conformance. The information in this document is regularly checked and the necessary corrections included in subsequent editions. Your recommendations and suggestions are welcome.

Subject to technical change without prior notice

BI620028

Edition 06.2010

Table of Contents

Table of Contents Safety Guidelines.................................................................................................... 15 A

Definitions, Warnings ........................................................................ 15

B

Electrostatically Sensitive Devices (ESD) ......................................... 17

1

List of Abbreviations........................................................................ 18

2

General Information ......................................................................... 20

2.1

Warranty............................................................................................. 21

2.2

Further Instructions ............................................................................ 21

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

Safety Instructions for Handling Converters....................................... 22 The Five Safety Rules ........................................................................ 22 Further Regulations............................................................................ 22 Unusual Incidents............................................................................... 23 Discharging and Grounding the Converter......................................... 23 Suggestions and Precautions ............................................................ 26

3

Product Description ......................................................................... 27

3.1

Brief Description ................................................................................. 27

3.2

Correct Use ........................................................................................ 27

3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7

Design and Cooling ............................................................................ 28 Overview ............................................................................................ 28 Physical Data ..................................................................................... 29 Insulation Coordination....................................................................... 29 Cooling ............................................................................................... 32 Electrical Design................................................................................. 32 Cooling System .................................................................................. 33 List of Components for Shovel 182MAC DCC ................................... 35

3.4 3.4.1 3.4.2 3.4.3

Electrical Design and Function........................................................... 39 Functional sections of the DCC.......................................................... 39 Control Monitoring and Protection – SIBAS 32S ............................... 46 Control Monitoring and Protection – PLC S7 400 .............................. 47

3.5

Technical Data ................................................................................... 48

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3.5.1 3.5.2 3.5.3

DCC for Shovel 182MAC ................................................................... 48 Physical data for Shovel DCC 182MAC............................................. 49 Ambient conditions for Shovel DCC 182MAC.................................... 49

4

Transport / Storage .......................................................................... 50

4.1

Transport ............................................................................................ 50

4.2

Storage............................................................................................... 56

4.3

Long-time storage (> 6 months) ......................................................... 58

5

Installation & Commissioning......................................................... 59

5.1

Installing in the Shovel ....................................................................... 59

5.2

Removing the DCC from the Shovel .................................................. 60

5.3

Welding of the DCC on the machine.................................................. 61

5.4 5.4.1 5.4.2 5.4.3

Electrical Connections........................................................................ 62 Power Connections ............................................................................ 62 Control Circuit and Auxiliary Voltage Connections ............................ 64 Grounding Connections...................................................................... 66

5.5

Commissioning and Operation........................................................... 67

6

Maintenance...................................................................................... 68

6.1

Maintenance schedule ....................................................................... 69

6.2

Maintenance activities ........................................................................ 70

6.3

Visually checking and cleaning the heat exchanger (E02) ................ 72

6.4

Cooling system: Checking the coolant level....................................... 73

6.5

Cooling system: Coolant specimen, analysis..................................... 74

6.6

Cooling system: Checking the seals at the coolant liquid connections75

6.7

Cooling system: Replacing the coolant .............................................. 75

6.8

Coolant pump: Replacing the coolant pump and overhauling it in an authorized workshop .......................................................................... 80

6.9

Internal cooler: Replacing the motor .................................................. 80

6.10

DC link capacitor: Checking the capacitance value ........................... 80

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6.11

Main blower fan motor: Replacing the bearings................................. 81

6.12

DCC: Cleaning the inner space.......................................................... 81

6.13

Checking the main and auxiliary contacts of the contactors, transfer switch and the busbar connections in the DCC ................................. 82

6.14

Cooling system: Checking for porous hoses...................................... 83

6.15

DCC: Checking the painted surfaces ................................................. 83

6.16

Replacing seals at the maintenance covers ...................................... 83

6.17

Air conditioner: cleaning the heatsink fins.......................................... 84

7

Maintenance, Trouble-Shooting and Repairs................................ 85

7.1

Discharging and Grounding the Converter......................................... 85

7.2

Component locations in DCC............................................................. 86

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5

MOTOR MODULE,24VDC ................................................................. 90 Description ......................................................................................... 90 Testing................................................................................................ 90 Replacing ........................................................................................... 91 Drawing .............................................................................................. 93 Technical data .................................................................................... 93

7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5

SWITCH MODULE............................................................................. 94 Description ......................................................................................... 94 Testing................................................................................................ 94 Replacing ........................................................................................... 94 Drawing .............................................................................................. 96 Technical data .................................................................................... 96

7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5

IGBT MODULE,DOUBLE,SD-1500WL .............................................. 97 Description ......................................................................................... 97 Testing................................................................................................ 98 Replacing ......................................................................................... 100 Drawing ............................................................................................ 102 Technical data .................................................................................. 102

7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.6.5

IGBT MODULE,TRIPLE,ST-1500WL-HP ........................................ 103 Description ....................................................................................... 103 Testing.............................................................................................. 104 Replacing ......................................................................................... 106 Drawing ............................................................................................ 108 Technical data .................................................................................. 108

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7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.7.5

CROWBAR MODULE,CBH-1500L .................................................. 109 Description ....................................................................................... 109 Testing.............................................................................................. 110 Replacing ......................................................................................... 110 Drawing ............................................................................................ 111 Technical data .................................................................................. 111

7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.8.5

CHOKE,400uH,3300V,358A,182MAC ............................................. 112 Description ....................................................................................... 112 Testing.............................................................................................. 112 Replacing ......................................................................................... 112 Drawing ............................................................................................ 114 Technical data .................................................................................. 114

7.9 7.9.1 7.9.2 7.9.3 7.9.4 7.9.5

CONTACTOR,2P,1500V,650A ........................................................ 115 Description ....................................................................................... 115 Testing.............................................................................................. 115 Replacing ......................................................................................... 115 Drawing ............................................................................................ 117 Technical data .................................................................................. 117

7.10 7.10.1 7.10.2 7.10.3 7.10.4 7.10.5

CONTACTOR,1P,1500V,250A ........................................................ 118 Description ....................................................................................... 118 Testing.............................................................................................. 118 Replacing ......................................................................................... 118 Drawing ............................................................................................ 119 Technical data .................................................................................. 120

7.11 7.11.1 7.11.2 7.11.3 7.11.4 7.11.5

RES,CHOPPER,3.15,1000W........................................................... 120 Description ....................................................................................... 120 Testing.............................................................................................. 120 Replacing ......................................................................................... 121 Drawing ............................................................................................ 122 Technical data .................................................................................. 122

7.12 7.12.1 7.12.2 7.12.3 7.12.4 7.12.5

BLOWER,3PH RADIAL,182MAC..................................................... 123 Description ....................................................................................... 123 Testing.............................................................................................. 123 Replacing ......................................................................................... 123 Drawing ............................................................................................ 125 Technical data .................................................................................. 125

7.13 7.13.1 7.13.2 7.13.3

COOLER, 35.06KW AKG................................................................. 126 Description ....................................................................................... 126 Testing.............................................................................................. 126 Replacing ......................................................................................... 126

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7.13.4 7.13.5

Drawing ............................................................................................ 128 Technical data .................................................................................. 129

7.14 7.14.1 7.14.2 7.14.3 7.14.4 7.14.5

COOLER,AIR/WATER,6KW AKG.................................................... 129 Description ....................................................................................... 129 Testing.............................................................................................. 129 Replacing ......................................................................................... 130 Drawing ............................................................................................ 131 Technical data .................................................................................. 131

7.15 7.15.1 7.15.2 7.15.3 7.15.4 7.15.5

PUMP,CENTRIF,415V,182MAC...................................................... 132 Description ....................................................................................... 132 Testing.............................................................................................. 132 Replacing ......................................................................................... 132 Drawing ............................................................................................ 134 Technical data .................................................................................. 134

7.16 7.16.1 7.16.2 7.16.3 7.16.4 7.16.5

CAP,MKP DC,3 mF,2050V .............................................................. 135 Description ....................................................................................... 135 Testing.............................................................................................. 135 Replacing ......................................................................................... 135 Drawing ............................................................................................ 137 Technical data .................................................................................. 137

7.17 7.17.1 7.17.2 7.17.3 7.17.4 7.17.5

CONVERTER,DC-DC,150W............................................................ 138 Description ....................................................................................... 138 Testing.............................................................................................. 138 Replacing ......................................................................................... 138 Drawing ............................................................................................ 139 Technical data .................................................................................. 140

7.18 7.18.1 7.18.2 7.18.3 7.18.4 7.18.5

POWER SUPPLY,48V/20A.............................................................. 142 Description ....................................................................................... 142 Testing.............................................................................................. 142 Replacing ......................................................................................... 143 Drawing ............................................................................................ 143 Technical data .................................................................................. 144

7.19 7.19.1 7.19.2 7.19.3 7.19.4 7.19.5

CT,HALL EFFECT,LF2005-S/SP28................................................. 145 Description ....................................................................................... 145 Testing.............................................................................................. 145 Replacing ......................................................................................... 145 Drawing ............................................................................................ 147 Technical data .................................................................................. 147

7.20

PCB ASSY,QPSW 2KV.................................................................... 148

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7.20.1 7.20.2 7.20.3 7.20.4 7.20.5

Description ....................................................................................... 148 Testing.............................................................................................. 148 Replacing ......................................................................................... 149 Drawing ............................................................................................ 150 Technical data .................................................................................. 150

7.21 7.21.1 7.21.2 7.21.3 7.21.4 7.21.5

VOLTAGE TRANSDUCER,300V..................................................... 151 Description ....................................................................................... 151 Testing.............................................................................................. 151 Replacing ......................................................................................... 152 Drawing ............................................................................................ 152 Technical data .................................................................................. 153

7.22 7.22.1 7.22.2 7.22.3 7.22.4 7.22.5

FILTER,74V,8A,40% ........................................................................ 154 Description ....................................................................................... 154 Testing.............................................................................................. 154 Replacing ......................................................................................... 155 Drawing ............................................................................................ 155 Technical data .................................................................................. 155

7.23 7.23.1 7.23.2 7.23.3 7.23.4 7.23.5

PRESSURE TRANSDUCER ........................................................... 156 Description ....................................................................................... 156 Testing.............................................................................................. 156 Replacing ......................................................................................... 156 Drawing ............................................................................................ 157 Technical data .................................................................................. 157

7.24 7.24.1 7.24.2 7.24.3 7.24.4 7.24.5

RES,WW,60R,1000W,5%................................................................ 158 Description ....................................................................................... 158 Testing.............................................................................................. 158 Replacing ......................................................................................... 158 Drawing ............................................................................................ 159 Technical data .................................................................................. 160

7.25 7.25.1 7.25.2 7.25.3 7.25.4 7.25.5

RES,WW,33K,300W,5% .................................................................. 160 Description ....................................................................................... 160 Testing.............................................................................................. 160 Replacing ......................................................................................... 161 Drawing ............................................................................................ 161 Technical data .................................................................................. 162

7.26 7.26.1 7.26.2 7.26.3 7.26.4

RES,WW,99K,300W,5% .................................................................. 163 Description ....................................................................................... 163 Testing.............................................................................................. 163 Replacing ......................................................................................... 163 Drawing ............................................................................................ 164

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7.26.5

Technical data .................................................................................. 165

7.27 7.27.1 7.27.2 7.27.3 7.27.4 7.27.5

CAP,MKV,0.22 Uf,5000V ................................................................. 166 Description ....................................................................................... 166 Testing.............................................................................................. 166 Replacing ......................................................................................... 166 Drawing ............................................................................................ 167 Technical data .................................................................................. 167

7.28 7.28.1 7.28.2 7.28.3 7.28.4

AUX. CONTACTORS FOR TRANSFER SWITCH .......................... 168 Description ....................................................................................... 168 Testing.............................................................................................. 168 Drawing ............................................................................................ 168 Technical data .................................................................................. 169

7.29 7.29.1 7.29.2 7.29.3 7.29.4

AUX. CONTACTOR, 120VAC.......................................................... 171 Description ....................................................................................... 171 Testing.............................................................................................. 171 Drawing ............................................................................................ 171 Technical data .................................................................................. 171

7.30 7.30.1 7.30.2 7.30.3 7.30.4

AUX. CONTACTOR, 24VDC ........................................................... 173 Description ....................................................................................... 173 Testing.............................................................................................. 173 Drawing ............................................................................................ 174 Technical data .................................................................................. 174

7.31 7.31.1 7.31.2 7.31.3 7.31.4

SIBAS,6FH4808-1A,182MAC .......................................................... 176 Description ....................................................................................... 176 Testing.............................................................................................. 176 Replacing ......................................................................................... 176 Technical data .................................................................................. 177

7.32 7.32.1 7.32.2 7.32.3 7.32.4 7.32.5

HEATER,800W ................................................................................ 178 Description ....................................................................................... 178 Testing.............................................................................................. 178 Replacing ......................................................................................... 179 Drawing ............................................................................................ 180 Technical data .................................................................................. 180

7.33 7.33.1 7.33.2 7.33.3

POWER SUPPLY (QUINT-PS-100-240AC/24DC/40A)................... 181 Description ....................................................................................... 181 Testing.............................................................................................. 181 Technical data .................................................................................. 182

7.34 7.34.1

SIMATIC S7-400, UR1 RACK WITH 18 SLOTS.............................. 183 Description ....................................................................................... 183

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7.34.2 7.34.3

Drawing ............................................................................................ 183 Technical data .................................................................................. 183

7.35 7.35.1 7.35.2 7.35.3

DIGITAL I/P MODULE (120VAC, 32 CH) ........................................ 184 Description ....................................................................................... 184 Drawing ............................................................................................ 184 Technical data .................................................................................. 185

7.36 7.36.1 7.36.2 7.36.3

DIGITAL O/P MODULE (120VAC, 32 CH)....................................... 185 Description ....................................................................................... 185 Drawing ............................................................................................ 186 Technical data .................................................................................. 187

7.37 7.37.1 7.37.2

DIGITAL I/P MODULE (24V DC 32 CH) ......................................... 188 Description ....................................................................................... 188 Technical data .................................................................................. 188

7.38 7.38.1 7.38.2

DIGITAL O/P MODULE (24V DC 32 CH) ....................................... 191 Description ....................................................................................... 191 Technical data .................................................................................. 191

7.39 7.39.1 7.39.2 7.39.3

SIMATIC S7-400, ANALOG INPUT SM 431, NON-ISOLATED 16 AI192 Description ....................................................................................... 192 Drawing ............................................................................................ 192 Technical data .................................................................................. 193

7.40 7.40.1 7.40.2 7.40.3

SIMATIC S7-400, ANALOG OUPUT SM 432, NON-ISOLATED 08 AO195 Description ....................................................................................... 195 Drawing ............................................................................................ 195 Technical data .................................................................................. 196

7.41 7.41.1 7.41.2 7.41.3

SIMATIC S7-400, PS 407 POWER SUPPLY, 10A.......................... 197 Description ....................................................................................... 197 Drawing ............................................................................................ 197 Technical data .................................................................................. 198

7.42 7.42.1 7.42.2 7.42.3

SIMATIC S7-400, CPU 416-2 .......................................................... 200 Description ....................................................................................... 200 Drawing ............................................................................................ 200 Technical data .................................................................................. 201

7.43 7.43.1 7.43.2

SIMATIC NET, CP 443-1 COMM PROCESSOR FOR ETHERNET CONNECTION ................................................................................. 206 Description ....................................................................................... 206 Technical data .................................................................................. 207

7.44 7.44.1

CAN DP COUPLER ......................................................................... 209 Description ....................................................................................... 209

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7.44.2 7.44.3 7.44.4

Testing.............................................................................................. 209 Drawing ............................................................................................ 210 Technical data .................................................................................. 211

7.45 7.45.1 7.45.2 7.45.3 7.45.4 7.45.5

SIMATIC PANEL PC 677B .............................................................. 212 Description ....................................................................................... 212 Testing.............................................................................................. 212 Replacing ......................................................................................... 214 Drawing ............................................................................................ 215 Technical data .................................................................................. 216

7.46 7.46.1 7.46.2 7.46.3 7.46.4 7.46.5

AIR CONDITIONER ......................................................................... 222 Description ....................................................................................... 222 Testing.............................................................................................. 223 Replacing ......................................................................................... 223 Drawing ............................................................................................ 224 Technical data .................................................................................. 224

7.47 7.47.1 7.47.2 7.47.3

CIRCUIT BREAKERS ...................................................................... 225 Description ....................................................................................... 225 Drawing ............................................................................................ 226 Technical data .................................................................................. 226

7.48 7.48.1 7.48.2 7.48.3 7.48.4

EMERGENCY STOP PUSH BUTTON ............................................ 227 Description ....................................................................................... 227 Testing.............................................................................................. 227 Drawing ............................................................................................ 228 Technical data .................................................................................. 228

7.49 7.49.1 7.49.2 7.49.3 7.49.4

RESET PUSH BUTTON................................................................... 229 Description ....................................................................................... 229 Testing.............................................................................................. 229 Drawing ............................................................................................ 229 Technical data .................................................................................. 230

7.50 7.50.1 7.50.2 7.50.3 7.50.4 7.50.5

SITOP DC UPS MODULE 24V ........................................................ 231 Description ....................................................................................... 231 Testing.............................................................................................. 231 Replacing ......................................................................................... 231 Drawing ............................................................................................ 232 Technical data .................................................................................. 232

7.51 7.51.1 7.51.2 7.51.3

UPS MODULE POWER SUPPLY (QUINT-PS-100-240AC/24DC/20A)233 Description ....................................................................................... 233 Testing.............................................................................................. 233 Replacing ......................................................................................... 233

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7.51.4 7.51.5

Drawing ............................................................................................ 234 Technical data .................................................................................. 234

7.52 7.52.1 7.52.2 7.52.3 7.52.4 7.52.5

SITOP POWER BATTERY MODULE 24V/7Ah ............................... 235 Description ....................................................................................... 235 Testing.............................................................................................. 235 Replacing ......................................................................................... 236 Drawing ............................................................................................ 236 Technical data .................................................................................. 237

7.53 7.53.1 7.53.2 7.53.3

FAN SUBASSEMBLY 28 SEP 1U ................................................... 238 Description ....................................................................................... 238 Replacing ......................................................................................... 238 Technical data .................................................................................. 239

7.54 7.54.1 7.54.2 7.54.3 7.54.4

INPUT/OUTPUT MODULE .............................................................. 240 Description ....................................................................................... 240 Replacing ......................................................................................... 240 Diagram............................................................................................ 240 Technical data .................................................................................. 241

7.55 7.55.1 7.55.2 7.55.3 7.55.4

INPUT VOLTAGE/ FREQUENCY.................................................... 243 Description ....................................................................................... 243 Replacing ......................................................................................... 243 Diagram............................................................................................ 244 Technical data .................................................................................. 244

7.56 7.56.1 7.56.2 7.56.3 7.56.4

INPUT CONVERTER BINARY 24V ................................................. 245 Description ....................................................................................... 245 Replacing ......................................................................................... 245 Diagram............................................................................................ 246 Technical data .................................................................................. 246

7.57 7.57.1 7.57.2 7.57.3 7.57.4

OUTPUT MEASURING AMPLIFIER................................................ 247 Description ....................................................................................... 247 Replacing ......................................................................................... 247 Diagram............................................................................................ 248 Technical data .................................................................................. 248

7.58 7.58.1 7.58.2 7.58.3 7.58.4

INPUT TEMPERATURE SENSOR PT100 ...................................... 250 Description ....................................................................................... 250 Replacing ......................................................................................... 250 Diagram............................................................................................ 251 Technical data .................................................................................. 251

7.59 7.59.1

DC/DC CONVERTER 72...110V/24V 100W .................................... 254 Description ....................................................................................... 254

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7.59.2 7.59.3 7.59.4 7.59.5

Testing.............................................................................................. 254 Replacing ......................................................................................... 254 Diagram............................................................................................ 255 Technical data .................................................................................. 255

7.60 7.60.1 7.60.2 7.60.3 7.60.4 7.60.5

DC/DC CONVERTER 72...110V/+-15V 100W................................. 257 Description ....................................................................................... 257 Testing.............................................................................................. 257 Replacing ......................................................................................... 257 Diagram............................................................................................ 258 Technical data .................................................................................. 258

7.61 7.61.1 7.61.2 7.61.3 7.61.4

BINARY OUTPUT 24V...36V/2 A..................................................... 259 Description ....................................................................................... 259 Replacing ......................................................................................... 259 Diagram............................................................................................ 260 Technical data .................................................................................. 260

7.62 7.62.1 7.62.2 7.62.3 7.62.4

INVERTER MONITORING CURRENT LINK ................................... 262 Description ....................................................................................... 262 Replacing ......................................................................................... 262 Diagram............................................................................................ 263 Technical data .................................................................................. 263

7.63 7.63.1 7.63.2 7.63.3 7.63.4

MAINBOARD SIP............................................................................. 265 Description ....................................................................................... 265 Replacing ......................................................................................... 265 Diagram............................................................................................ 266 Technical data .................................................................................. 267

7.64 7.64.1 7.64.2 7.64.3 7.64.4 7.64.5

CONVERTER 72..110V/5V 90W ..................................................... 268 Description ....................................................................................... 268 Testing.............................................................................................. 268 Replacing ......................................................................................... 268 Diagram............................................................................................ 269 Technical data .................................................................................. 269

7.65 7.65.1 7.65.2 7.65.3 7.65.4 7.65.5

POWER START-UP UNIT ............................................................... 270 Description ....................................................................................... 270 Testing.............................................................................................. 271 Replacing ......................................................................................... 271 Diagram............................................................................................ 272 Technical data .................................................................................. 273

7.66 7.66.1

CPU 586........................................................................................... 274 Description ....................................................................................... 274

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7.66.2 7.66.3 7.66.4

Replacing ......................................................................................... 274 Diagram............................................................................................ 275 Technical data .................................................................................. 276

8

Appendix ......................................................................................... 277

8.1

Appendix A: Special Tools ............................................................... 277

8.2

Appendix B: Tightening Torque........................................................ 279

8.3

Appendix C: Return authorization form ............................................ 280

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Safety Guidelines

Safety Guidelines A

Definitions, Warnings

Qualified personnel For the purpose of this instruction manual and the warning labels on the product itself, a qualified person is someone who is familiar with the installation, mounting, starting up and operation of the equipment and the hazards involved.

He or she must have the following qualifications.

• Trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in accordance with established safety procedures • Trained in the proper care and use of protective equipment in accordance with established safety procedures • Trained in rendering first aid

Safety guidelines This manual contains notes that you should observe to ensure your own personal safety, as well to protect the product and connected equipment. These notes are highlighted in the manual by a warning triangle. Notes regarding property damage alone are not accompanied by a warning triangle. Notes are marked as follows according to the level of danger.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death, severe injury or considerable property damage.

WARNING indicates a potentially hazardous situation which, if not avoided, may result in death, severe injury or considerable property damage.

CAUTION used with the warning triangle indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.

CAUTION used without the warning triangle indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE used without the warning triangle indicates a potential situation which, if not avoided, may result in an undesirable result or state.

NOTE highlights an important piece of information about the product or indicates a section of the instructions that requires careful attention.

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Safety Guidelines

Intended use Please note the following.

WARNING When in operation, electrical equipment contains components that are under dangerous voltage.

Failure to adhere to these instructions can result in severe bodily injury or property damage!

Only appropriately qualified personnel may work on this equipment or be in its vicinity.

These personnel must be completely knowledgeable about all warnings and service measures as specified in this instruction manual.

The successful and safe operation of this equipment is dependent on proper handling, installation, operation and service.

National safety guidelines and regulations must be carefully observed.

WARNING The magnetic field inside the Shovel from the DCC can disturb an active heart pacemaker and therefore entry of persons with active heart pacemakers in this area is forbidden. .

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B

Safety Guidelines

Electrostatically Sensitive Devices (ESD) CAUTION Electronic modules contain electrostatically sensitive devices. These components can easily be destroyed if they are incorrectly handled. However, if your work does involve the handling of such devices, please observe the following information.

• Electronic modules should not be touched unless work must be carried out on them.

• If it is essential for you to touch an electronic module, make sure that your body is electrostatically discharged immediately beforehand.

• Modules may not be allowed to come into contact with electrically insulating materials such as plastic parts, insulating table tops or clothing made of synthetic fibers.

• Modules may only be placed on electrically conducting surfaces.

• Modules and electronic components should always be packed in electrically conducting containers (such as metallized plastic boxes or metal canisters) before being stored or shipped.

• If packing containers are used which are not conductive, modules and boards must first be wrapped in conductive material. Examples of such materials include electrically conducting foam rubber or household aluminium foil.

For easy reference, the protective measures necessary when handling electrostatically sensitive devices are illustrated in the drawings below. − a = Conductive flooring

− d = Anti-static overalls

− b = Anti-static table

− e = Anti-static chain

− c = Anti-static footwear

− f = Grounding connections of cabinets

d

d

b

b

d

e

e f

a

f

f

c

c

Seated

Standing

a

f

f c

a

Standing / Seated

NOTES The IGBTs (Insulated Gate Bipolar Transistors) used in this equipment are sensitive to electrostatic discharge. These devices can be very easily destroyed if they are handled incorrectly. All of the measures specified above must be applied to the IGBTs to prevent damage to the drive converter and to ensure that it continues to function perfectly.

Furthermore, the gate and emitter connections of the IGBTs must always be shortcircuited before the devices are transported.

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List of Abbreviations

List of Abbreviations Abbreviation

Designation

AC

Alternating Current

AFE

Active Front End

BGR

Printed Circuit Board

BKZ

Equipment code

BOD

Break-Over-Device

BST

Braking controller or Brake choppers

COM

Serial interface

CP

Communication Processor

CT

Current transducer

DC

Direct Current

DCC

Drive Converter Cabinet

DCU

Drive Control Unit

DIN

Deutsche Industrie-Norm (German Industrial Standard)

DST

Double control unit

ESD

Electrostatically Sensitive Device (components which can be destroyed by electrostatic discharge)

EMC

Electromagnetic compatibility

EN

European Norm

EMI

Electromagnetic Interference

HST

Gate control unit

I DT LD T IEC IGBT

Industry Drive Technology Large drives Traction division International Electro technical Commission Insulated Gate Bipolar Transistor

I/O

Input/Output

MB

Dimensional drawing

PC

Personal computer

PG

Cable Gland

PLC

Programmable Logic Controller

PWMI

Pulse Width Modulation inverter

SIBAS

Siemens Bahn (Train) Automation System (TCU)

SIP

Signal processor board

SP

Circuit diagram

SRC

Converter cabinet (DCC)

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List of Abbreviations

Abbreviation

Designation

SRE

Converter unit (IGBT module)

UWSI

Monitoring board, converter protection

Z ZR

Assembly drawing Central processor board

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General Information

General Information NOTES • For reasons of transparency, this instruction manual does not include all detailed information and it does not take into account every conceivable situation regarding installation, operation or service.

•

If you require additional information, or if specific problems occur which are not handled in sufficient depth in the instruction manual, you can request the required information from: Siemens Energy & Automation, Inc. 100 Technology Drive Alpharetta, GA 30005-3900 UNITED STATES OF AMERICA Tel.: +1 (770) 740 3000 Fax: +1 (770) 740 3899 Siemens Ltd I&S IP1-NLC MINE –MM Plot 2, Sector 2, Kharghar Node, Kharghar Navi Mumbai – 410208 INDIA Tel.:+91 22 2756 8000 Fax: +91 22 2756 8018 Siemens Ltd C-1, Additional industrial area, MIDC, Ambad, Nashik – 422010 INDIA Tel.: +91 253 238 1325 Fax: +91 253 238 1262

•

Furthermore, the contents of this manual are not part of any prior or existing agreement, commitment or legal relationship nor can they modify same.

The sales contract contains all obligations entered into by Siemens. The warranty contained in the contract between the parties is the sole warranty granted by Siemens. Statements contained herein do not create new warranties nor modify the existing warranty.

•

This instruction manual refers exclusively to the converter equipment for the “Drive Converter Cabinet for Bucyrus Shovel 182MAC" Thus, additional information regarding operating conditions and vehicle design is not part of this instruction manual.

•

The Drive Converter Cabinet is only operational as part of a complete system that includes external components such as a motor etc.

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2.1

General Information

Warranty

NOTES If the Drive Converter Cabinet or its components are returned to Siemens under warranty conditions, the following information is absolutely necessary for the warranty claim to be honoured. While sending back the component, use the return authorization form, to give details about failure, which is enclosed in Annexure C. The filled form along with the data requested to be enclosed basically which contains following information: •

Fault memory log

•

Description of equipment failure

•

Installation location of component

•

Drive Converter Cabinet Serial number

Siemens reserves the right to request additional information.

The components must be packed carefully. Damages incurred during transport are not covered by the warranty.

Failure to comply with this instruction manual will limit the manufacturer's warranty coverage.

2.2

Further Instructions

WARNING • When in operation, electrical equipment contains components that are under dangerous voltage.

•

The magnetic field inside the Shovel from the DCC can disturb an active heart pacemaker and therefore entry of persons with active heart pacemakers in this area is forbidden.

•

Only appropriately qualified and trained personnel may work on this DCC or be in its vicinity.

•

This personnel must be completely knowledgeable about all warnings and service measures as specified in this instruction manual.

•

The successful and safe operation of this DCC is dependent on appropriate transportation and proper storage, erection and installation as well as careful operation and maintenance.

•

Failure to adhere to these safety warnings can result in death, severe bodily injury or property damage!

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2.3

Safety Instructions for Handling Converters

2.3.1

The Five Safety Rules

The 5 safety rules of electronics must be observed when carrying out any work on the converter or its environment.

1. Disconnect the equipment from the power.

2. Lock-out the equipment to prevent the power from being reconnected.

3. Check that the equipment is in a no-power state.

4. Short circuit and ground the system.

5. Adjacent parts that are live must be covered or precautions must be taken to ensure that they cannot be touched.

2.3.2

Further Regulations

Observe all safety regulations specified by the system manufacturer and operator.

This is a part of system or train manual or similar document.

When working in the DCC environment (e.g. on the motors, drive power transformer or main switch), be aware that the DCC is equipped with large capacitor batteries.

These batteries can retain dangerous voltages over an extended period of time (several hours) even after the vehicle has been disconnected from the catenary.

Therefore, it must be ensured that the system itself is safe for maintenance work even when working in its environment.

Anyone working on the DCC or in its environment is obligated to watch out for his/her own safety and the safety of others.

If system parts carry a voltage (including auxiliary power supply), wear approved insulating gloves and protective glasses (spectacles) Damaged components in DCC which are not sent back to manufacturer for analysis should be disposed off as per local rules & regulations.

CAUTION No welding should be done on the machine after mounting DCC on the base frame of machine. All critical electronic components must be disconnected & removed from DCC if welding needs to be done. Also refer chapter 5.3 for details regarding mounting of DCC using welding method.

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2.3.3

General Information

Unusual Incidents

Special care must be taken in the event of incidents that are not a part of normal operation.

Examples of such incidents: •

Physical damage to the container (caused by collision with objects, falling rocks or derailing)

•

Unauthorized manipulation by third parties (e.g., unauthorized opening of the converter)

•

Loose screws or loose cables inside the converter

•

Changes within the converter (e.g., discoloration of cables or bus bars, charring, burning smell)

•

Welding on the DCC mounted on the base frame.

Normal protective devices in the system may become damaged or non-operational as a consequence of such incidents. This may result in dangerous voltages arising under conditions that are otherwise known to be safe.

2.3.4

Discharging and Grounding the Converter

This chapter only applies when the state of the converter is unknown.

The system manufacturer must provide procedures that guarantee that the converter can be safely discharged under normal operating conditions.

If the state of the converter is unknown, it must be assumed that the DC link capacitors are charged to a high voltage. This also applies to system components in the converter environment (e.g. motors, drive power transformer or main switch).

Before any work is carried out on the converter, it must be ensured that the entire DC link is completely discharged.

NOTICE The DCC has High voltage inputs. Each of them must be removed, discharged and connected to ground separately.

NOTE Under normal operation or with a loss of the control voltage ( 120VAC ) the DC link is discharged as following - Open line contactors K1 and K2 - Firing brake chopper and discharge DC link with chopper resistors R33.1 and R33.2 - 100ms later, additional to the brake chopper the protective system (crow bar A7) fires

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WARNING Dangerous voltages may occur even after the DC link has been discharged.

Dangerous voltages can be generated in the incoming power.

If this is not carefully observed this can result in death, severe bodily injury and significant material damage.

If electrical connections within the converter are damaged/broken (visual check/attentiveness!), dangerous voltages can arise even if the grounding harness has been installed. In such cases, you must assume that the system is live even if the grounding harness has been installed.

If there is any doubt, consult a specialist provided by the manufacturer.

1. Ensure that the incoming power cannot reach the converter.

2. Ensure that the incoming power cannot become activated.

3. Switch off all auxiliary incoming power.

4. Use keys provided along with cabinet to open covers of PLC & SIBAS section & use spanner to open power section door’s bolts (see Fig. 2-1 & 2-2).

5. To have access to the discharging points provided in cabinet open doors with numbers 1 & 2 as shown in Fig. 2-1.

(1)

(2)

(5)

(3)

(4)

(6) Door nos Fig. 2-1

Converter (side view)

6. Prepare a digital multimeter (FLUKE 189 or similar with a 10 kV high voltage probe). Ensure that the meter is operational.

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7. Connect the ground measuring lead to the converter ground XE terminal.

8. Measure voltage in DC link with respect to ground with the high voltage probe by connecting second terminal of measuring probe to XP1 (positive of DC link) & then to XN1 (Negative of DC link) using ball track measuring points (see Fig. XP1, XN1).

Is the voltage at both points less than 20 V? Yes: Continue with point 10.

No: Continue with point 9.

9. If voltages greater than 20 V are measured on the DC link: The permanent discharge resistors in the converter discharge the DC link.

The voltage in the container reaches a safe level (< 50 V) after approx. 1 hour.

Repeat the measurements described in Points 6 to 8.

If the voltage has not dropped to a safe level after 1 hour, the discharge resistors in the converter are faulty. They must be repaired as soon as possible.

10. If the measured voltage lies below 20 V, a grounding harness (for details about type no Ref. to Annexure 8.1) can be applied to the ground points using grounding rod.

Wear protective glasses (spectacles) and gloves.

First attach the grounding harness to Earth (XE), then to XN1 and XP1 When applying the grounding harness, a minor arc discharge may occur if the DC link capacitors are not fully discharged.

11. Before putting the converter back into operation, the grounding harness must be removed. Any tools, meters and other objects must also be removed from the DCC. The covers must be properly closed after work is completed.

XP1

XE

XN1

Fig. 2-2

Position of converter DC link measuring & ground points

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Fig 2-3

Grounding harness (Left) and Grounding rod (Right)

2.3.5

Suggestions and Precautions

• • • • • • • • • • • • • •

Hold the components while removing them and take care that no nuts, bolts and screws fall off in the process.

Always aside the components and tools and keep it in place after usage.

Type of bolt is to be taken as hexagonal (grade 8.8) if not specified.

Always mark torque points with permanent marker pen, after applying torque.

Always erase torque marking after removal of hardware.

Wear ESD shoes and apron while working with Electrostatic Sensitive Devices.

Use Loctite (Grade-242) for locking screws and threads.

For an assembly with multiple screws and bolts provide the specified torque in stepped manner.

For details of tools refer to annexure 8.1 Special tools.

Torque wrenches used have the torque range of 0-100 Nm Always use new high tension (HT) spring washers.

All tools and torque values are as per DIN 25201 and RTBT 3047 For position nos. of material given refer to the assembly drawings and partlists.

Always make and check the electrical connections as per the circuit diagram.

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Product Description

Product Description

3.1

Brief Description

The Drive Converter Cabinet for "Bucyrus Shovel 182MAC" uses IGBT technology with water-cooled power semiconductors.

The complete device has the Type numbers For Shovel 182MAC: A5E02606385 (102252549)

3.2

Correct Use

The converter equipment is designed for supplying three-phase motors for Shovel 182MAC as specified. The DCC is used for controlling Hoist, Swing, Propel and Crowd motors.

The drive converter may only be used for board mounting on Shovel vehicles in conjunction with the components also required for a complete Shovel system.

WARNING The following operating conditions are not permissible.

•

Operation with open covers/panels

•

Operation without the main converter blower, pump, internal heat exchanger and air conditioner.

•

Operation with covered air inlet or covered air outlet to radiator

•

Operation outside the specified power line tolerances

•

Operation under ambient conditions other than those specified

•

Operation under any bypassed protection to drive

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Product Description

3.3

Design and Cooling

3.3.1

Overview

The container is designed for mounting in Bucyrus Shovel 182MAC with access from all sides.

The housing consists of corrosion-resistant steel (weatherproof).

All the components of the cabinet are accessible. The power connections for the modules and capacitors are in the form of busbar connections.

The electronics components, switching devices are installed inside the DCC in IP54 section where they are protected against dust.

The heat exchanger, pump, blower are part of DCC but located outside i.e. nonventilated area.

Table 3-1

Main components of the DCC

Ventilated Section

Unventilated Section

• Main converter fan

• IGBT modules with driving units

• Line choke for AFEs

• Switching devices

•

Heat exchanger

• Transducer

•

Pump

• Discharge resistors

•

Air conditioner outer side

•

Precharging resistors

•

Chopper resistor

•

Air conditioner inner side

•

HMI screen

•

Transfer switch

•

Control electronics

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3.3.2

Physical Data

Table 3-2

Physical data

Type of construction

Welded cabinet

Dimensions, external L x W x H

3300 x 1700 x 2300 mm

Weight

Approx. 4200 ±100 kg

Degree of protection Ventilated section

IP20, in acc. w. IEC 529 (Except for blower outlet duct)

Non-ventilated section

IP54, in acc. w. IEC 529

Color

RAL 7032

3.3.3

Insulation Coordination

Standards that are used as basis: IEC 61287-1: 2005 EN 50124 –1: 2001 + A1: 2003 + A2: 2005 IEC 60146-1-1: 1991 + A1: 1996 IEC 60349-2: 2002 IEC 60077-1: 1999 IEC 60571 Ed. 2.1: 2006 IEC 60146-1-1: 1991 IEC 60664-1: 2002

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Product Description

Definition of circuits: Name

Circuit Code

Nominal value

Input 3 Phase AC voltage from transformer secondary, AFE Reactors, AFE IGBT Modules, AC Input Current transducerDC Link circuit including the low inductive bus bar along with DC Link capacitor, Bus Diodes, Inverter IGBT modules, Over voltage Chopper IGBT Module, Over voltage chopper resistor, Pre-charge circuit output, Earth Fault circuit, Crowbar circuit, Output current transducers, Transfer Switch Over voltage Category OV 2

SK 1

DC 1800 V

3 Phase supply for ext. blower, pump for water cooling system, int. heat exchanger Over voltage category OV 2 3-phase-system, star point ungrounded

SK 2

Tolerance

Max: 1980V (+10%) Min: 1260V (-30%)

AC 3 x 415 V Max: 460V (+ 10%) Min: 290V (-30%)

Intermediate Voltage transducer, Intermediate Current transducer Over voltage category OV 2

SK 3

AC 110 V

Max: 121V (+10%) Min: 77V (-30%)

Stabilized single phase power supply Over voltage category OV 2

SK 4

AC 120 V

Max: 132V (+10%) Min: 84V (-30%)

Stabilized power supply for SIBAS,

SK 5

DC 110 V

IGBT driver supply (Input) Over voltage category OV 2 Stabilized power supply for current transducer, IGBT driver supply (Output) Over voltage category OV 2

Max: 113 V (+3%) Min: 107V (-3%)

SK 6

DC 24 V

Max: 24.7V (+3%), Min: 23.3V (3%)

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Product Description

Test voltages for the dielectric tests: Electric circuit (SK)

Test Voltage AC 50 Hz, application time

6510V, 10 s

SK1 against surroundings IEC 61287-1, Tab. F.1

Test Voltage DC

4600 V, 10 s

SK2 against surroundings

3260 V, 60 s

2121 V, 60 s 1500 V, 60 s

IEC 60077-1, Table 8: Ui=130 V

1500 V, 60 s

SK5 against surroundings IEC 60571, Ch.10.2.9.2: Un=DC110V

IEC 60571, Ch.10.2.9.2: Un=DC24V

≥ 1 MOHM / DC 500V

1410 V, 60 s 1000 V, 60 s

≥ 1 MOHM / DC 500V

710 V, 60 s

SK6 against surroundings

≥ 1 MOHM / DC 500V

2121 V, 60 s

SK4 against surroundings

≥ 1 MOHM / DC 500V

IEC 60349-2 Table 4: U rp/√2=460V IEC 60077-1, Table 8: Ui=120 V

≥ 2 MOHM / DC 500V

1920 V, 60 s SK3 against surroundings

Insulation Resistance as per IEC 60146-1-1

500 V, 60 s

≥ 1 MOHM / DC 500V

AC examination has preferably to be used for type checking.

If for any reason, it is necessary to repeat the dielectric test of the converter, the value of voltage for the second and the following tests shall be reduced to 80% of the Up take into consideration that the dielectric test affects the quality of insulation.

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3.3.4

Product Description

Cooling

Cooling type

Water cooling

Cooling medium composition

Water / Antifrogen N ratio- 56/44, refer to the chapter 6.7

Cooling water flow rate

220 l/min

Max. cooling water temperature at the intake 60 °C Quantity of water in the system

3.3.5

Approx. 63 l

Electrical Design

The DCC works on line input of 900VAC, 3ph, 50Hz AC for Shovel 182MAC machine which is fed by Drive Power Transformer. The converter consists of two AFE’s, two line contactors, one DC link, three PWM Inverters delivering Swing, Hoist, Crowd & Propel 1, Propel 2 motors. The converter also includes DC link capacitors, contactors, transducers, blowers, transfer switch, HMI etc. The function of the converter is controlled and monitored by Siemens’ Drive Control Unit (DCU) SIBAS® 32S. The master control of Shovel is through Simatic S7 400 PLC. The various remote I/O’s are connected to the PLC CPU through profibus. The PLC CPU with I/O’s required for interfacing with SIBAS system are also located in the DCC. Fig. 3-1

Schematic of the DCC for Shovel 182MAC

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3.3.6

Product Description

Cooling System

The cooling system pump draws the coolant from the central heat exchanger and pumps it into a coolant distribution system (Aluminium coolant pipes).

The pressure transducer to determine the coolant pressure is located in the coolant inlet to DCC. The coolant for the individual phase modules is distributed through the aluminium pipes and hoses. All IGBT modules and the internal cooler are connected in parallel. The coolant return pipes of all of the modules mentioned above are connected as shown in the fig. 3.3.1/2/3. Both of the pipes through which coolant returns, at the top and bottom are connected with one another. The coolant flows from the upper coolant distribution system to the central heat exchanger equipped with a fan. A reservoir with a volume of approximately 9 litre is located at the upper intake location of the central heat exchanger and the coolant distribution return is connected to the pump. This ensures that the cooling system is vented. This reservoir is equipped with a 2-stage level transducer that indicates the coolant level. The level of cooling liquid can be directly seen at two inspection windows. The main blower draws air through the central heat exchanger to cool the coolant.

Fig. 3.3.1

Cooling system

Manufacturer: KSB AG (water pump):

www.ksb.com

AKG (indoor cooler):

www.akg-gruppe.de

Mdexx GmbH & Co. KG (central fan):

www.mdexx.com

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Fig 3.3.2 Rear View of Cooling system used in Shovel

Blower

Pump

Connecting Hose

Fig 3.3.3 Front View of Cooling system used in Shovel

Reservoir Reservoir

Central Heat Exchanger

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3.3.7

Type no ST1500WL SD1500WL ST1500WL CBH1500L 4EU99520EF700BA0 LTHS06502SAO0 LTC-250-1P

Product Description

List of Components for Shovel 182MAC DCC

Description IGBT Module – Triple IGBT Module – Double IGBT Module – Triple Crowbar Module

2

62052173

A11, A13

2

62048922

PWM Inverters

A31, A51

2

62052173

Hard crowbar

A7

1

62055582

AFE Reactor

AFE

L1,L2

2

62057718

Line Contactor AC Pre-charging Contactor AC

AC Main-/Line Contactor Pre-charging Contactor AC Water cooling system Water cooling system Water cooling system Water cooling system

K1,K2

2

62055579

K4

1

62055578

E01

1

62057719

E02

1

62055590

E11

1

62048803

M01

1

62056672

C1, C2, C3

3

62055591

A91, A92

2

62055580

Heat Exchanger

AKG 0198.061.0000

Internal Cooler

KSB ESO-S 32125.1/12M

Centrifugal Pump

LEM LF2005-S/SP28 QPSW-2KV LV100-300/SP9 HUBBEL14-192-625503 HUBBEL14-192-625502 BNV 05.110.d/ 0.5 X2

DC Link Capacitor DC/DC Power Supply DC/DC Power Supply

62055592

10

62055586

U09, U10, U33

3

62055581

U34,U35

2

62055573

Motor Module

Transfer Switch

Q1

1

62055593

Switch Module

Transfer Switch

Q1.1,Q1.2, Q1.3

3

62055594

Z1

1

62055574

B2

1

62055589

R31.1, R31.2

2

62055583

R42

1

62055584

R41

1

62055585

C75

1

62055577

Blower Circuit

K15, K16

2

62006903

Auxiliary Circuit

K10-K14, K51K54

9

62056671

Auxiliary Circuit

K05-K09

5

62056670

Drive Control

A100

1

62059286

SIBAS Filter

PVR160 or GWS 300 SB 99K +/ 5%

Discharge Resistor

B25835-S2224-K057

Grounding Capacitor

6FH4808-1A

2

DC Voltage monitoring Synchronizing voltage feedback

Discharge Resistor

3RH1122-2AK20

A95,A96 U1, U2, U4, U5, U11, U12, U31, U32, U51, U52

Voltage Transducers Voltage Transducers

PVR160 or GWS 300 SB 33K +/-5%

3RH11222KB400LA0

IGBT Driver card power supply SIBAS power supply AC Input output currents

PVR900T or GBS 60/370 60R +/-5%

3RT10172KF420LA0

DC Link

Current Transducers

Pressure Transducer Pre-charging Resistor

TRAFAG 8253

Bucyrus spare part no

A1, A2

AKG 0198.105.0000

QUINT-PS-100240AC/48DC/20

Quantity per DCC

AFE

Main Blower

P354.1-IGBT

Designation in cabinet

PWM Inverters & Braking Chopper

2CS6502-1RK112EK1

TRAFIM 637-3mF

Functional unit

Contactors for Transfer switch Auxiliary Contactors Auxiliary Contactors SIBAS 32 S

SIBAS Power Supply Filter Water inlet pressure sensor Pre-charging Circuit DC Link Discharge and Earth Fault Detection DC Link Discharge and Earth Fault Detection DC Link Discharge and Earth Fault Detection

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Type no

Product Description

Designation in cabinet

Quantity per DCC

Bucyrus spare part no

E09

1

62039626

G01

1

62056738

A114

1

62056680

Simatic S7-400 UR1 Rack

D15

1

62056682

Simatic S7-400 UR1 Rack

D16

1

62056684

Simatic S7-400 UR1 Rack

D17, D21

2

62056681

Simatic S7-400 UR1 Rack

D18

1

62056683

D19

1

62056686

D20

1

62056685

Simatic S7-400 UR1 Rack

G11

1

62048867

Simatic S7-400 UR1 Rack

D13

1

62048127

Simatic S7-400 UR1 Rack

D14

1

62048867

Profibus DP to CAN coupler

A120

1

62059220

Description

Functional unit

Electric heater 115V 800W Power Supply 24VDC/40A Simatic S7-400 UR1 Rack Digital input module SM421, 32DI, DC/AC 120 Digital Output Module SM422, 16DO,DC/AC Digital input module SM421, 32DI, DC 24VDC Digital Output Module SM422, 32 DO, 24VDC Analog Output Module SM432 Analog Input Module SM431 Simatic Rack Power Supply PS407 Simatic S7-400 CPU 416-2, MPI, Communication Processor CP443 Profibus DP to CAN coupler

Electric heater 115V 800W Power Supply 24VDC/40A Simatic S7-400 UR1 Rack

Unit Hoffman D-AH8001B QUINT-PS-10024AC/24VDC/40 6ES7400-1TA010AA0 6ES7421-1EL000AA0 6ES7422-1FH000AA0 6ES7421-1BL010AA0 6ES7422-1BL000AA0 6ES7432-1HF000AB0 6ES7431-0HH000AB0 6ES7407-0KA020AA0 6ES7416-2XN050AB0 6GK7443-1GX200XE0 700-651-CAN01 6ES76476BH360BB3 (computer) A5E00708318 (screen) 6AV76711EA005AA1 (remote kit)

Simatic PC 677B with HMI Touch Screen Display

Simatic S7-400 UR1 Rack Simatic S7-400 UR1 Rack

Simatic PC 677B with HMI Touch Screen Display

A103 & A104 & A105

1

62059287 (computer) 62059288 (screen) 62059289 (remote kit)

Chopper resistor

R33.1& R33.2

2

62055587

Air conditioner UPS for host computer

E05

1

62057416

G10

1

62059290

UPS for host computer

G02

1

62059292

UPS for host computer

G09

1

12330814

SRES

1

62057418

P0EB4

1

62059221

Q05, Q33

2

62055576

Q06

1

62040290

4

62039637

9

62037679

7

62056687

RES,CHOPPER, 3.15,1000W Air conditioner SITOP DC UPS MODULE 24V UPS MODULE POWER SUPPLY SITOP POWER BATTERY MODULE 24V/7Ah Reset Push Button Emergency Stop Push Button CIRCUIT BREAKER 20A CIRCUIT BREAKER 3A CIRCUIT BREAKER 16A

Reset Push Button Emergency Stop Push Button CIRCUIT BREAKER 20A CIRCUIT BREAKER 3A CIRCUIT BREAKER 16A

5SX2110-8

CIRCUIT BREAKER 10A

CIRCUIT BREAKER 10A

6ES74921AL000AA0

SIMATIC S7-400, FRONT CONNECTOR

Simatic S7-400 UR1 Rack

6VPR500S-3R15-S AHP-1800XM 6EP1931-2EC42 QUINT-PS-100240AC/24DC/20A 6EP1935-6ME21 3SB3202-0AA11 3SB32031-CA21 5SX2120-7 5SX2103-7 5SX2116-8

Q07, Q22/23/24 Q08/10/ 21/25/26/27/28/ 34/35 D15..D21

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Type no 6ES79710BA00 A1THAH00006

6ES79521KK000AA0

6FH94843A 6FH94983A 6FH95603A 6FH95683AX880FU0 6FH93053DX880FU2 6FH93053DX880FU3

6FH93053DX880FU5

6FH93053DX880FU6 6FH93053DX880FU7 6FH93713DY60 6FH93713DY61 6FH95413BY60 6FH95413BY61 6FH95413BY62 6FH95413BY63 6FH94133BY60 6FH95433BY60 6FH95423CX880FU2 6FH95423CX880FU3 6FH95423CX880FU5 6FH95423CX880FU7 6FH95423CX880FU9

Product Description

Designation in cabinet

Quantity per DCC

Bucyrus spare part no

For G11

2

62048868

TH02

1

62031518

Simatic S7-400 UR1 Rack

For D13

1

62039646

SIBAS 32S rack

C025,C049,C0 73,C097

4

62052748

SIBAS 32S rack

C121

1

62056673

SIBAS 32S rack

C145

1

62053536

SIBAS 32S rack

C163

1

62056674

SIBAS 32S rack

G035

1

62056676

SIBAS 32S rack

G043

1

62057419

SIBAS 32S rack

G059

1

62057420

SIBAS 32S rack

G067

1

62057421

SIBAS 32S rack

G075

1

62057422

SIBAS 32S rack

G099

1

62052760

SIBAS 32S rack

G107

1

62052775

SIBAS 32S rack

G115

1

62056677

SIBAS 32S rack

G123

1

62056455

SIBAS 32S rack

G131

1

62056467

SIBAS 32S rack

G139

1

62057423

SIBAS 32S rack

G147

1

62052787

SIBAS 32S rack

L027, L067, L107, L115

4

62057424

SIBAS 32S rack

L035

1

62056678

SIBAS 32S rack

L043

1

62057427

SIBAS 32S rack

L075

1

62057429

SIBAS 32S rack

L091

1

62057430

SIBAS 32S rack

L123

1

62057431

Description

Functional unit

SIMATIC S7-400, BATTERY THERMOSTAT CLOSE AT 35 DEG F MEMORY CARD S7400 LONG VERSION 5V 1MB DC/DC Converter 72...110V/24V 100W DC/DC Converter 72...110V/+-15V 100W Converter 72..110V/5V 90W Power Start-up Unit Input Voltage/Frequenc y AFE 2 Input Voltage/Frequenc y AFE 1 Input Voltage/Frequenc y Crowd 1 / Propel 2 Input Voltage/Frequenc y Hoist / Propel 1 Input Voltage/Frequenc y Swing Input Converter Binary 24V Input Converter Binary 24V Binary output 24V...36V/2 A Binary output 24V...36V/2 A Binary output 24V...36V/2 A Binary output 24V...36V/2 A Input Temperature Sensor PT100

Simatic S7-400 UR1 Rack THERMOSTAT CLOSE AT 35 DEG F

Mainboard SIP Inverter Monitoring Current Link Inverter Monitoring Current Link Inverter Monitoring Current Link Inverter Monitoring Current Link Inverter Monitoring Current Link

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Type no 6FH94043BY60 6FH96043BY60 6FH92883DX880FU0 6FH60351A

Description Output Measuring Amplifier CPU 586 Input/Output Module Fan Subassembly 28 SEP 1U

Product Description

Functional unit

Designation in cabinet

Quantity per DCC

Bucyrus spare part no

SIBAS 32S rack

L131, L155, L163

3

62052764

SIBAS 32S rack

L139

1

62057432

SIBAS 32S rack

L147

1

62056679

SIBAS 32S rack

N000

1

62039607

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3.4

Product Description

Electrical Design and Function

The drive converter is delivered as a completely assembled unit. The Drive Control Unit (DCU) SIBAS 32S is situated inside of the cabinet, the operation and indication elements can be viewed and controlled form HMI display as well as display situated in the driver’s cab. The drive converter is designed for installation within the machine room and there are no indication elements available except for the HMI display. The DCC consists of mainly two major controllers, PLC S7 400 as a master controller & SIBAS 32S as a drive controller.

3.4.1

Functional sections of the DCC

The DCC consists of the following functional sections: • AFEs and pre-charging • DC link circuit • Capacitive earth fault detection • Pulse width modulated inverters & Braking chopper • Crowbar Circuit AFEs and pre-charging Refer to Fig. 3-4 for the schematic of the functional input section of DCC. Two poles (K1.1 and K1.2) of a double pole contactor (K1) isolate the transformer and one AFE module from secondary winding of the drive power transformer. A precharging unit is connected in parallel to main contactor (K1). The pre-charging unit consists of a pre-charging contactor (K4), the pole K4 connected in series with a parallel combination of precharging resistor R31.1 and R31.2.

When the converter is put into operation, first the DC link capacitor of the inverter is pre-charged before the main contactor is closed using diodes in AFE modules.

This prevents the high inrush current, which would result if the input voltage was suddenly switched onto the empty DC link. The main contactor is switched on after the DC link voltage has reached 90 % of the theoretical final charge (=√2 * UTrafo, sec).

Fig. 3-4 Input section - Precharging, AFE and DC link capacitor section

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Product Description

An AFE consists of a bridge as shown below in Fig. 3-5. The purpose of the AFE is to transform the input voltage (secondary of the Drive Power Transformer (DPT)) into a controlled direct voltage for the DC link circuit. The term AFE signifies that the phase angle between voltage and current is freely adjustable while driving as well as while braking. Through the combination of phase situation and mode of operation all four operational quadrants can be obtained.

Fig.3-5 Basic diagram of AFE section The IGBTs are used as switches with a high closing sequence. The function is described exemplarily for rectifier-operation starting from a current less situation: To build up a current in the self-inductance of the transformer LN one of the two IGBT’s A2 or A3 (positive half-wave, A1 or A4 at the negative half-wave) is triggered. During this the secondary side of the transformer is short-circuited. As soon as the current has reached the desired value the IGBT is blocked. The current continues to flow via the free wheeling diode into the DC link circuit and is reduced by this (UD > UN). Afterwards the process starts again and during it the IGBT’s are used alternately to put equal thermal burdens on them.

Fig.3-6 Voltage and current gradient at AFE In the DCC two AFE’s are used AFE1 & AFE2. Both these AFE’s are connected to two secondaries of drive power transformer as shown in fig. 3.2.

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Product Description

DC link circuit

Fig.3-7 DC link circuit The DC link capacitor is required as an energy storage unit. It provides the reactive power and serves to smooth the DC link voltage. Capacitor C1 to C3 each of 3mF is put in parallel as shown in Fig.3-7. Hence the total bank has a capacity of 9mF.

Capacitive Earth fault Detection In the DCC, DC link is connected to earth by resistors R41 and R42 and the earthleakage-detector is in the DC-link circuit. Resistor R41, R42, Capacitor C75 and Voltage Transducer (QPSW) U33 form the earth leakage detector. Fig. 3-8 below shows the scheme:

Fig. 3-8 Earth fault detection circuit Since R41 = 99K, R42 = 33K, during normal operation the transducer depicts ¼ of the total DC link voltage. A tolerance of ± 30 % (referring to ¼ of the DC link circuit voltage) is to be taken into consideration. (Refer to Fig. 3-12 for the waveform) In case of an earth fault the measured voltage changes because of process of reversal of charge.

Following circuits explains this phenomenon: Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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Product Description

Fig. 3-9 above shows the equivalent circuit in case of earth fault at the output of the ), Inverter (R E-ARTH

Fig. 3.10 above shows the equivalent circuit when the upper IGBT/ Diode of the PWM Inverter is conducting.

Fig. 3-11 above shows the equivalent circuit when the lower IGBT/ Diode of the PWM Inverter is conducting.

An earth fault can thus be detected by comparing the measured value of the DC link circuit voltage with reference in DCU.

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Product Description

Fig. 3-12 Earth fault detection

Pulse Width Modulated Inverter and Brake Chopper The PWM inverter comprises water cooled IGBT modules. At the output terminals U, V, W, the inverter provides a three-phase voltage system where frequency and voltage can be adjusted.

Fig. 3-13 Circuit diagram of the PWM inverter The IGBTs can be essentially defined as basic switches with a high clock frequency. The input to the PWMI is the DC link voltage. The switching sequences of IGBTs are selected so that a sinusoidal current is obtained. The voltages between two output terminals are calculated. The maximum possible amplitude of the phase-to-phase output voltage is a function of the magnitude of the DC link voltage Ud.

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Product Description

Fig. 3-14 PWM inverter in square-wave operation The RMS value of the output voltage can be reduced by clocking. This clocking comprises brief turn-off operations within a basic fundamental.

Fig. 3-15 PWM inverter in clocked operation When braking, the motor torque direction opposes the direction of rotation. There is considerable phase shift between the voltage and current. By entering the basic fundamental, the PWM inverter adjusts the phase between the voltage and current.

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Product Description

Fig. 3-16 Phase position of the current and voltage when braking Over voltage or Brake Chopper Overvoltage chopper resistors R33.1 and R33.2 are connected to the overvoltage chopper for DC link voltage control & protection. Overvoltage chopper is used to maintain the DC link voltage at constant set value. In DCC it is 1800VDC. Overvoltage chopper is activated when DC link voltage becomes 1990V and it is deactivated when it becomes 1890. Also overvoltage chopper is used to discharge the DC link in normal shutdown case.

Hard Crowbar A crowbar system is utilized for fast de-energizing of the DC-link in case of “Emergency-reactions” of the implemented protection system. It provides protection against short-circuit conditions by shorting the DCbus to reduce all fault currents before other protection devices sever power from the substation. The crowbar protects all power modules. The hard crowbar A7 (CBH-1500L) consists of thyristor, choke and control board. In case of fault condition SIBAS 32S sends control signal to module which fires thyristor. +VE DC Link

- VE DC Link Fig. 3-16 Crowbar circuit

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3.4.2

Product Description

Control Monitoring and Protection – SIBAS 32S

The SIBAS 32 system (SIemens Bahn Automation System with 32 bit microprocessor) is used for modulating and logic control functions in mass transit rolling stock (i.e. trams, underground railways, city and suburban railways and trolley), as well as in long-distance vehicles (i.e. electric locomotives, railway traction trains and diesel-electric locomotives) and in mining converters. The system controls, monitors and protects the vehicle drive in the area of the converter equipment. It also performs the information processing in a control level thus embracing the whole vehicle as the control unit. In addition to these functions, systems for vehicle diagnostics and systems which provide assistance for commissioning and maintenance are integrated. The system is based on modular design. The functions are divided into functional modules and implemented on single size and double size Euro-format of PCBs, for example, Central Processing Unit, communication interfaces, interface modules and input/output stages. Due to its steady development, a broad spectrum of module types is available for all aspects of vehicle control.

The system embodies the following basic features: • Application as drive control unit for DCC. • Modular design of functional modules in single-size and double-size Euro-format PCBs. • RFI shielding and mechanically robust design of the Siemens ES902 packaging system in accordance with international standards.

• Integrated diagnostics to support commissioning, service and troubleshooting.

Storage of traction- and vehicle states under error conditions.

• Readout of the memory and use of the service utility software via the diagnostic interfaces on any commercially available PC. • Use of high-density integrated circuits such as high-performance microprocessors (32 bit), signal processors and various types of programmable integrated circuits.

The following block diagrams (Fig.3-18) of a drive control unit (DCU) show a selection of the most important modules as well as coupling to a service unit (i.e.

PC/ Laptop), and the train and vehicle wiring via bus systems or single wiring.

In shovel machine, PLC is the master controller and SIBAS is a drive controller.

PLC controls & monitors overall machine & give commands to SIBAS. Inside SIBAS, ZR (central processor unit) is the main controller which gives commands to individual SIPs (Signal processor) which controls the drive. Hence in architecture, ZR is in between PLC and SIPs. Software in PLC, ZR & SIPs are different. ZR and PLC communicate with each other on CAN & Profibus using CAN-DP coupler which couples CAN of ZR to Profibus of PLC. Internally ZR communicates with SIPs on CAN bus.

For further details regarding the SIBAS cards descriptions, please refer to the chapter 7.

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Product Description

Fig. 3-18 Block Schematic of Drive control unit

3.4.3

Control Monitoring and Protection – PLC S7 400

The control system consists of a SIBAS 32S system in a four tier rack configuration as explained above and a SIMATIC S7- 400 PLC. Main functions for the SIBAS system are to provide firing pulses to the IGBTs and drive control, monitor and protect all inverters and AFEs in order to operate the drive motors. Diagnostic data can be recorded and analyzed through SIBAS built-in features. The Programmable Logic Control [PLC] system is the machine’s interface to the shovel (operator panel, Human Machine Interface [HMI], switches, lamps, sensor and other peripherals). The communication between the PLC and the SIBAS control allows access and control of drives and motors as well as protection functions.

The PLC system in DCC consists of UR1 rack, power supply module, CPU 416, communication processor CP443, digital I/O modules and analog I/O modules. All these modules are plugged in the UR1 rack. It also consists of CAN/DP coupler to get data from SIBAS system.

For detailed explanation on PLC modules please refer to the chapter 7.

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Product Description

3.5

Technical Data

3.5.1

DCC for Shovel 182MAC

Electrical data Input voltage (Nominal)

2x 3ph, 900 VAC, 50 Hz (-30% / +10%) -30% is only for short term operation, Normal operation is with -10%.

PWM inverter RMS currents (Duty cycle) Inverter 1 Hoist/ Propel 1

3ph, 334A

Inverter 3 Crowd/ Propel2

3ph, 114A

Inverter 5 Swing

3ph, 203A

DC link voltage

1800 V

DC link capacitance

9 mF, +10% -0%

Supply for blowers, pump, internal cooler Input voltage

3-ph. 415 VAC, 50 Hz (+/-10%)

Power requirement

21 kW

Control voltage Input voltage

120 VAC, 50 Hz (+/-10%)

Power requirement

10kW

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3.5.2

Product Description

Physical data for Shovel DCC 182MAC

Type of construction

Welded cabinet

Dimensions, external L x W x H

3300 x 1700 x 2300 mm

Degree of protection Ventilated section

IP20, in acc. w. IEC 529 (Except for main blower outlet duct)

Non-ventilated section

3.5.3

IP54, in acc. w. IEC 529

Ambient conditions for Shovel DCC 182MAC

Ambient temperature in normal operation

-25 °C to +50 °C

Storage and transport temperature

-40 °C to +70 °C

Max. operating altitude

< 2500 m

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4

Transport / Storage

Transport / Storage

4.1

Transport Note • The transport company should be immediately contacted if there is any visible damage incurred during transport.

•

The DCC is mounted on a wooden pallet (when stored, packaged in a PE foil) for normal transport by truck.

•

The DCC should only be transported in the position in which it will be mounted.

•

When transporting, it is important to observe the center of gravity data mentioned in the dimensional drawing.

•

Shocks and jolts must be avoided when transporting.

•

During transport, the DCC’s should neither be stacked on top of one another nor have other objects placed on them.

•

When transporting the DCC with hoisting platforms, cranes or forklift trucks, wooden beams or wooden pallets must be used. Only the hoisting/load application points specified below may be used.

Fig. 4-1: DCC complete

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Transport / Storage

The DCC will be packed in Siemens factory in a packing box on a transport pallet as shown in Fig 4-2.

Wooden Packing

Transport Pallet

Fig. 4-2: DCC packed in packing box.

The DCC along with the transportation pallet is transported by crane as shown in Fig 4-3. Without the transportation pallet, the DCC should be transported by using Ring Bolt with Metric thread which rotates in 360° (Recommended Type: RUD VLBG (4) Size: M20 Make: Carl Stahl ) Location for fixing the eyebolts is given on top side of the DCC as shown in Fig. 4-4.

Important Note: •

The crane harness must always be retained at all the four locations as shown in Fig. 4-4.

•

Fixed type eyebolts ( eyebolts which do not rotate) should never be used for lifting the DCC

•

The height of the crane harness used must be adjustable for each individual hoisting point. It must be adjusted so that when the DCC is hoisted, it remains in a horizontal position (observe the center of gravity).

•

The crane and crane harness must be as a minimum, suitable for the DCC weight (Approx. 5000 kg).

•

The crane harness must be long enough so that there is a minimum angle of 60° between the harness and the horizontal axis.

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Transport / Storage

SHOVEL_DCC CUBICLE COMPLETE LIFTED WITH CHAIN / SLING

Fig. 4-3: Transporting the DCC by crane. (LHS view)

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Transport / Storage

CORRECT METHOD FOR LIFTING CUBICLE COMPLETE WITH CHAIN

INCORECT METHOD FOR LIFTING CUBICLE COMPLETE WITH CHAIN

CHAIN D SHAKLE EYEBOLT CUBICLE

INCORRECT METHOD FOR LIFTING CUBICLE COMPLETE WITH CHAIN

CHAIN

EYEBOLT CUBICLE

REFERENCE IS: 4190

Fig. 4-4: Transporting the DCC using Eyebolts and chain Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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Transport / Storage

CORECT METHOD FOR LIFTING CUBICLE COMPLETE WITH SLING

INCORECT METHOD FOR LIFTING CUBICLE COMPLETE WITH SLING

SLING D SHAKLE EYEBO LT CUBICLE

INCORR ECT M ETH OD FOR LIFTING CUBICLE COM PLETE W ITH SLING

SLING D SHAKLE EYEBO LT CUBICLE

REFERENCE IS: 4190

Fig. 4-5: Transporting the DCC using Eyebolts and sling Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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Transport / Storage

Dimensional Details of Transportation Pallet 3500

211

Ø20.0

1900

Fig. 4-6: Transport pallet (3500x1900x211mm) Approx. Weight : 260 Kg

Note: Wood used for the Pallet is not protected for long term storage.

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4.2

Transport / Storage

Storage Note The instructions for transport essentially apply for storage with a few additional sub-points: •

When the DCC is stored, it is not permissible that temperature, moisture or dust has a negative impact on its function.

•

The DCC should only be stored in the position in which they are mounted.

• It is neither permissible to stack the DCC nor place objects on them.

The DCC should be stored at a location so that passing vehicles cannot damage them.

If the DCC is to be stored for longer than one week, it must be protected against humidity by wrapping or welding it in plastic foil.

Add a desiccant (Silica- Gel)!

Storage for < 3 months should be only on the original transport pallet (Fig. 4-6).

Note: Use suitable material for long term storage The storage space should be protected against •

Rain

•

Snow

•

Water

•

Extreme temperatures

•

Relative humidity exceeding 80 %

•

Animals from entering

•

Permissible temperature range during storage: -25°C to +80°C

(During transport, briefly up to +80°C)

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Transport / Storage

DCC CUBICLE COMPLETE MOUNTED ON TRANSPORT PALLET

Transport Pallet

Fig. 4-7: Example of DCC on Transport pallet.

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4.3

Transport / Storage

Long-time storage (> 6 months) When DCC is stored for long periods of time, the ambient temperature should be below 40°C (preferably below 25 °C).

A general inspection of the DCC must be carried-out after it has been stored for a long time (corrosion, rust, dust, cobwebs etc.)

If required: •

Clean the DCC

•

Carry-out an insulation test

•

Visual check for water hose – damages if any

•

Check the fan bearings in the DCC

•

Check the fan bearings in the SIBAS rack (refer to SIBAS documentation)

•

Test the SIBAS battery (refer to the SIBAS documentation)

•

Check the capacitors (electrolytic capacitors) in the SIBAS (refer to the SIBAS documentation)

•

Check the electrolytic capacitors in the IGBT Driver power supply.

•

Check the tantalum electrolytic capacitors in the IGBT Driver cards.

•

Check the electrolytic capacitors in the SIBAS filter:

The electrolytic capacitors must be re-formed (i.e. the electrolyte must be regenerated) if the DCC was stored for more than 2 years.

Procedure when forming capacitors: • Observe the filter polarity • Use a 100 Ohm series resistor • Connect a voltage of 120 V DC across the series resistor at connections from Channel 2 • (Duration: 1 hour).

• After 1 hour: Disconnect the voltage, discharge the capacitor in the filter • Store the filter for 48 hours • The capacitors in the filter are now formed

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5

Installation & Commissioning

Installation & Commissioning

Note •

The DCC should only be unpacked briefly before it is installed / mounted in the shovel.

•

After the DCC has been unpacked, it must be carefully inspected to see if it has incurred any damage during transport or storage: 9 check the cabinet for dents.

9 check all of the doors and their seals.

9 check the paint finish.

9 check the power connections.

9 check the over voltage chopper resistor R33.1 & R33.2.

9 check the water level on heat exchanger.

9 check the HMI display 9 check the Air conditioner 9 check the blower 9 check the pump and water cooling hoses 9 check the terminal box and its connections

•

If the packaging material is damaged, the DCC must be cleaned: Neither solvents nor sharp objects may be used.

•

The packaging material must be disposed of in an environmentally friendly fashion according to the applicable domestic regulations and the wooden transport pallets must be returned to the manufacturer.

•

The labels indicating the center of gravity should be removed before the DCC is mounted in the vehicle.

5.1

Installing in the Shovel Note •

Only appropriately trained, knowledgeable personnel may install the DCC.

•

It is not permissible that the DCC is damaged when it is being mounted into the shovel. If it is damaged, it must be returned to the manufacturer.

•

When hoisting the DCC, always use hoisting supports with the largest possible surface area or a wooden pallet.

The DCC must be installed using proper grade of M16 screws. Refer for the latest dimensions drawing for details.

For installation details refer to installation guidelines.

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5.2

Installation & Commissioning

Removing the DCC from the Shovel

Warning Before removing the cabinet from the shovel, it must be ensured that: All of the electrical connections are in a no-voltage condition.

The connections cannot be re-connected and that the DCC can not be accidentally powered-up.

The discharge times of the capacitors are observed and protection against 9 9

discharge energy levels.

Note : In case of electrical fault, the maximum discharge time for DC link capacitors could be 75 minuets.

The following steps must be observed when removing the DCC from the floor (deck) of the shovel: •

Release the power connections.

•

Release the control connections.

•

Release the grounding connections.

•

Remove the ducting arrangement

•

Release the mounting bolts (located inside the bottom compartment)

•

Remove the DCC

Note •

The DCC is re-installed in the inverse sequence as when removing

•

Check the connections (according to the circuit diagram)

•

Check the tightening torques of the connections

•

Before the doors are closed, the seals must be checked for damage (if required, replace the seals)

•

If the cabinet paint finish is damaged when removing or re-installing the components, the associated areas must be re-painted.

Paint finish (color RAL 7032) 120 μm total paint thickness 50 μm primer, 2 x 30 μm top coat

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Installation & Commissioning

Welding of the DCC on the machine Shovel DCC for 182MAC is not designed to be directly welded on the machine on any type of surface. It is designed to be mounted on special base frame using nut and bolts. It is highly not recommended to do any welding activity directly on the DCC which may cause the failure of the electronics in the DCC. In case if it is must that DCC has to be welded on the machine then this activity must be carried out with extreme care under expert’s supervision. Following general notes should be considered: • • • • •

If any parts do not fit together, NEVER adjust the DCC housing by bending it or hammering it in form. Always adjust the counterpart, which must fit together with DCC. NEVER weld surface of DCC with paint.

Take all necessary ESD precautions while handling all sensitive electronic components as given in Operation & Maintenance Manual of DCC. Take care that during welding the covers of DCC are closed so that nothing inside gets damaged due to welding arcs.

Always connect the return line of the welding transformer as close as possible to the welded joint, so that the currents and voltage cannot spread.

Following procedure is given to avoid failures of electronics during mounting of DCC by welding method but it does not gives guarantee of non-failures.

1) Remove the paint from surface of DCC which is to be welded and clean it properly. Do not weld the surface of DCC with paint. Also protect the paint on other surface of DCC from being burned away.

2) Seal original DCC mounting holes provided in non ventilated sections of DCC to keep IP54 level intact.

3) Connect DCC and base frame to earth. Cabinet earthing points at AFE reactors and in PLC connection field.

4) Remove all power & control connections including screen connections to the DCC if they are connected at the customer connections provided.

5) Disconnect all cable connections (power cables, control cables including shield connections, earthing cables) from the maintenance station computer and its HMI. 6) Remove all the front plug connectors of the SIBAS controller.

7) Close all covers of DCC correctly before welding activity.

8) Put DCC on the base frame.

9) Take care that the DCC is oriented in correct way.

10) Take care that there is no gap between the DCC and the base frame. If there is a gap, put metal sheets between DCC and base frame, so that all gaps disappear.

11) Before welding check whether the cable entry locations from the bottom are as per proper.

12) Weld DCC to the base plate.

13) After welding clean the welding areas.

14) Remove welding cinder & rust.

15) Paint welded area with primer and later with the final paint.

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Installation & Commissioning

Electrical Connections 5.4.1 Power Connections

Fig. 5-1 Input Power Connections for DCC 182MAC

Clamps for holding cables

Ground Connection

Fig. 5-2 Input Power Connections for DCC 182MAC – Sectional Top View showing clamps for holding cables

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Refer to the latest version of circuit diagram, terminal diagram and dimensional drawing for the details of power connections.

The power connections for the input cables should enter from the bottom of the DCC through the opening provided in the AFE reactor compartment. Refer to fig. 52 for details.

Input termination 1U1, 1V1 and 1W1 are provided directly on the AFE reactor L1 terminals U1, V1, W1 respectively.

Bus bars for Input terminations 2U1, 2V1 and 2W1 are provided in the same area as shown in the fig.5-2.

Hole of diameter 14mm are provided on all these terminals suitable for fasteners of size M12. Suitable tubular cable lugs must be used for the input connections, which must be crimped on to the cables. The cables and the lugs is not part of scope of supply of the DCC. Clamps are provided as shown in fig. 5-2 for holding customer cables.

The motor connections are realized in the power connection area in the cabinet.

Refer to the Fig. 5-3. The connections are realized by using bus bars with pressed nuts suitable for fasteners of size M12. Suitable tubular cable lugs must be used for the input connections, which must be crimped on to the cables. The cables and the lugs is not part of scope of supply of the DCC. Fig. 5-3 Motor Connections for DCC 182MAC

Clamps are provided as shown in Fig. 5-4 for DCC for holding customer cables.

Fig. 5-4 Front view of customer connection section for DCC 182MAC

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5.4.2 Control Circuit and Auxiliary Voltage Connections The control connection terminals are located at the bottom of the cabinet in the PLC compartment as shown below Fig. 5-5.

The terminals are used to connect various control connections of Shovel electrics to PLC & power cabinet. Refer latest version of terminal diagram document number 4W-2601-1644714 and circuit diagram for details.

X69 HTB5

MTB1

MTB2

HTB2

LTB1

X70

HTB6 HTB1

GROUND CONECTION

Fig. 5-5 Control connections located at the bottom of PLC compartment

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Fig. 5-6 Terminal box to connect power supply to blower & pump Use terminal X68 to connect supply voltage to centrifugal pump and terminal X67 to connect supply to main blower as shown in Fig. 5-6 For Profibus & Ethernet connections, use rubber grommets provided in the PLC compartment. Out of these two connections one is to be used for connecting Profibus node and the other for connecting Ethernet cable coming from JLT operator panel display.

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5.4.3 Grounding Connections The grounding connections (1*M12, tightening torque 88 Nm, which conduct the fault current) are provided at the bottom side of the PLC compartment as shown in Fig. 5-5.

Also for incoming power grounding connection (1*M12, tightening torque 88 Nm, which conduct the fault current) are provided at the bottom side of the AFE reactor compartment as shown in Fig. 5-7.

All of the electrical connecting surfaces must be bare (unpainted).

Grounding connection Fig. 5-7 Input Power Connections for DCC 182MAC

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5.5

Installation & Commissioning

Commissioning and Operation Information regarding the commissioning and operation of the converter unit is provided in the instruction manual for the vehicle.

WARNING Only qualified personnel may commission the equipment. The general information in section 2 must be observed with special attention to the warnings.

Check the following before commissioning the equipment.

•

Check the container for damage.

•

Check that the container is tightly bolted to the vehicle.

•

Check that the fans have the correct direction of rotation.

•

Check that the air intake and outlet openings are not obstructed.

•

Check that all electrical connections are tight.

•

Check that all grounding connections are tight.

•

Check that all covers have been correctly closed.

•

Check all control connections are fitted and tight.

Before commissioning converter equipment that has been stored for an extended period of time, the following additional measures must be taken.

•

Check the non-ventilated sections for dirt and proper look.

•

Clean the ventilated section and the components located there.

•

Clean the contactor contacts.

•

Check the electrical connections, connectors and grounding connections for corrosion.

•

Observe chapter ("Long-Time Storage“).

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Maintenance

Maintenance WARNING Before starting any work, the following five safety rules must be observed.

1) Disconnect the equipment from the power.

2) Lock-out the equipment to prevent the supply from being reconnected.

3) Check that the equipment is in a no-power state.

4) Ground and short-circuit.

5) Adjacent parts that are live must be covered or precautions must be taken to ensure that they cannot be touched.

NOTES Dangerous voltages can still be present in the drive container for a long time even after it has been disconnected from the power supply.

•

Observe all information in this section and on the product itself.

•

Only use spare parts approved by the manufacturer.

•

Maintain the specified maintenance intervals and adhere to the instructions for repair and parts replacement.

Failure to observe these measures can result in death, severe bodily injury or considerable property damage.

NOTE

How to determine that the main circuit is free of power?

After the first two of the five safety rules have been carried out, the main circuit can be checked to ensure that it is in a no-power state.

For details about discharging DC link voltage refer to chapter 2.3.4 Parts and components that normally contain dangerous voltage levels and hence should not be touched directly

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6.1

Maintenance

Maintenance schedule

This schedule mentioned below is minimum required & generally based on previous experience. However maintenance intervals and the activities mentioned may change depending on actual site conditions in Shovel vehicle.

Code

Interval code

Operating hours

Time period

Activity

VI

Check

500 h

1.5 months

•

EI

Interval 1

1000 h

2...3 months

•

Visually check the heat exchanger for pollution, if required, clean.

•

Read-out the fault memory of the DCU

•

Check and clean insulators of PTB2 terminals & motor connection terminals on DCC for dirt accumulation.

•

Clean the heat sink fins of air conditioner from outer side of DCC

•

Cooling system: Check the liquid level, if required, top up

•

Cooling system: Cooling medium specimen, analysis.

•

Check that the seals of cooling system are not leaking

•

Check the coolant pump: For vibration, noise in operation, damage and leaks

•

Apply grease (jelly) on door gaskets to prevent adhesion/ sticking of gasket to cabinet

•

Check air conditioner fans

•

DC link capacitor: Check the capacitance value

•

Check the Blower for heat exchanger.

•

Check DCU fans

•

Bearings of main fan motor: Replace in qualified workshop

•

Electric motor of internal cooler (E11): Replace and overhaul in qualified workshop

•

Replace the gaskets on maintenance cover

I2

I3

I4

2 x I4

Interval 2

Interval 3

Interval 4

2000h

4000 h

8000 h

16000 h

6 months

1 year

2 years

4 years

Visually check the DCC for dust, dirt, any physical damages

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Code R2

Maintenance

Interval code

Operating hours

Overhaul 1

24000 h

4 x I4

32000 h

R3

Overhaul 2

6.2

48000 h

Time period 6 years

8 years

12 years

Activity •

Replace the coolant

•

Coolant pump: Replace and overhaul in an authorized workshop

•

Clean the DCC - inner spaces

•

Visibly check the power connections / glands for abnormal color

•

Check the main and auxiliary contacts of the contactors as well as the busbar connections in the DCC

•

Cooling system: Check all of the hose connections to ensure that they are not leaking and are not porous, if required, replace hoses

•

Check all of the painted surfaces of the DCC for damage, repair the paint finish

•

Replace the DCU fan assembly

Maintenance activities Check – VI

No. 1

Component Entire DCC

Maintenance work Visually check the DCC for dust, dirt, any physical damages

Cross-reference Nil

Interval 1 - EI No. 1

Component Main cooler

Maintenance work Clean

Cross-reference Refer to Chapter 6.3

Interval 2 – I2 No.

Component

Maintenance work

Cross-reference

1

Insulators

Check and clean insulators of PTB2 terminals & motor connection terminals on DCC for dirt accumulation

Nil

2

Air conditioner

Clean the heat sink fins of air conditioner from outer side of DCC

Refer to Chapter 6.17

Interval 3 – I3 No. 1

Component Cooling system

Maintenance work Check the level of the liquid and if required top up

Cross-reference Refer to Chapter 6.4

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2

Cooling system

Cooling medium specimen, analysis

Refer to Chapter 6.5

3

Cooling system

Check that the cooling medium connection seals for leaks

Refer to Chapter 6.6

4

Coolant pump

Check for vibration, noise in operation, damage Refer to the Operating and leaks Instructions of the coolant pump

5

Door gaskets

Apply grease (jelly) on door gaskets to prevent adhesion/ sticking of gasket to cabinet

Nil

6

Air conditioner

Check air conditioner fans

Nil

Interval 4 – I4 No.

Component

Maintenance work

Cross-reference

1

DC link capacitor

Check the capacitance value

Refer to Chapter 6.10

2

Blower

Check the Blower for heat exchanger

Refer to Chapter 6.11

3

DCU

Check DCU fans

SIBAS equipment manual

2 x I4 - the same activities as I4 - and in addition No.

Component

Maintenance work

Cross-reference

1

Main blower fan motor

Bearings of motor: Replace in qualified workshop

Refer to Chapter 6.11 and the Operating Instructions of the central fan

2

Internal cooler

Bearings of motor: Replace and overhaul in qualified workshop

Refer to Chapter 6.9 and the instructions of the indoor coolers

3

Door gaskets

Replace the gaskets on maintenance cover

Refer to Chapter 6.16

R2 – overhaul 1 No.

Component

Maintenance work

Cross-reference

1

Cooling system

Replace the cooling liquid

Refer to Chapter 6.7

2

Cooling medium pump

Replace the coolant pump and overhaul in an authorized workshop

Refer to Chapter 6.8

3

DCC

Clean the inside space

Refer to Chapter 6.12

4

Switching devices

Check the main and auxiliary contacts of the Refer to Chapter 6.13 contactors as well as the busbar connections in the converter

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4 x I4 - the same activities as I3 and 2 x I4 as well as in addition No.

Component

Maintenance work

Cross-reference

1

Cooling system

Check all of the hoses and hose connections for leaks and to ensure that they are not porous, if required, replace them

Refer to Chapter 6.14

2

DCC

Check all of the painted surfaces of the DCC for damage, repair any damaged paint surface

Refer to Chapter 6.15

3

Maintenance covers

Replace the seals at the maintenance covers

Refer to Chapter 6.16

R3– overhaul 2 No. 1

Component DCU fans

Maintenance work Replace the fans

Cross-reference SIBAS equipment manual

Note The special tools, operating and other materials that are required are now subsequently listed.

Ordering data and suppliers for the special tools, operating and other materials are listed in Chapter 8.1.

6.3

Visually checking and cleaning the heat exchanger (E02)

The heat exchanger should be visually checked for accumulated dirt (pollution). If dirt is found then it should be removed as follows: •

Use an industrial vacuum cleaner to remove coarse dirt from the air intake side

•

Use service cover on ventilation channel to remove fine dust by blowing it out with compressed air from blower side (dry, free of grease). The compressed air should be lightly swept over the cooler (do not concentrate just on one point) and must be in parallel with the fins so that they are not damaged. The maximum pressure of the compressed air may not exceed 8 bar.

At longer intervals (approx. R2 - overhaul), it may be necessary to clean using water. The following points should be carefully observed: •

Clean with water preferably with the main blower removed

•

Use high-pressure cleaner for cleaning with a maximum pressure of 50 bar.

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•

The cleaning effect can be reinforced by adding cleaning agents.

It must be carefully ensured that the cleaning agent does not damage/attack the cooler materials (a ph value of 4 – 8 is required).

•

The water jet should be vertically directed on the cooler surface from a minimum distance of 50 to 100 mm

•

The water jet must be fanned-out to at least 20 mm.

•

The water pistol should be held at the side and the water should be sprayed from the bottom to the top through the cooler; more specifically, starting at the outside at the highest point of the radiator. The water drains through the drain pipe and hose at the DCC.

Cooling system: Checking the coolant level

The cooling liquid level is checked at the equalization reservoir. At 25°C the liquid level must be at the mark provided. When required (liquid level below the mark or an alarm signal from the control unit), then the appropriate cooling medium must be topped-up by removing the cover in the equalization reservoir. The following steps must be carried-out: •

Remove the overflow hose at the cover of the equalization reservoir

•

Open the equalization reservoir cover

Warning The cooling system may be under pressure!

The cooling medium can reach temperatures of up to 60°C. Danger of burning!

Always carefully and slowly open the cover of the equalization reservoir to ensure slow pressure equalization!

•

Top-up the cooling liquid to the mark provided using a suitable container

•

Re-close the cover of the equalization reservoir

•

Re-attach the overflow hose and correctly tighten the hose clamp (3 Nm tightening torque)

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Caution Always fill the cooling system using an Antifrogen N/water mixture in the ratio of 44% to 56% Never add any other coolant!

Always ensure that the coolant is clean!

Suitably filter the coolant before filling the cooling system!

Take into consideration the general safety information and instructions when handling Antifrogen N (refer to Chapter 6.7)!

If the filling level specified is exceeded then it is possible that the equalization reservoir will overflow!

6.5

Cooling system: Coolant specimen, analysis

The cooling medium should be analyzed at regular intervals. In doing so, the specified antifreeze protection should be guaranteed and it should also be checked that the specified quantity of inhibitors are present. Inhibitors are chemical agents in the cooling medium that act to prevent corrosion.

The cooling medium specimen should be taken from the equalization reservoir.

The following steps must be carried-out: •

Remove the overflow hose at the cover of the equalization reservoir

•

Open the equalization reservoir cover

Warning The cooling system may be under pressure!

The cooling medium can reach temperatures of up to 60°C. Danger of burning!

Always carefully and slowly open the cover of the equalization reservoir to ensure slow pressure equalization!

•

Withdraw the required quantity of cooling medium (250 ml) using a suitable instrument

•

Replace the amount of cooling medium withdrawn so that the liquid level remains at the correct level (also refer to Chapter 6.4)

•

Re-close the equalization reservoir cover

•

Re-attach the overflow pipe and correctly tighten the pipe clamp (3 Nm tightening torque)

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Caution Ensure that all of the equipment and containers are clean! Other media or substances in the coolant specimen could interfere with the analysis!

Carefully take into account general safety information and instructions when handling Antifrogen N (refer to Chapter 6.7)!

The specimen should be analyzed in a test laboratory or by the manufacturer of the coolant Clariant GmbH, Werk Gendorf Division Functional Chemicals Frau Sieglinde Winkler, Bau 300 C 6/1 D-84504 Burgkirchen Tel.: 08679-7-3347 Fax: 08679-7-5085 The following properties should be tested: Property

Acceptance criterion

Antifreeze protection

Ice slush formation at T ≤ -35°C

Anti-corrosion protection

The specimen must contain a sufficient level of anti-corrosion inhibitors

If one or both of these properties is (are) no longer in the permissible range then the coolant must be completely replaced (refer to Chapter 6.7)

6.6

Cooling system: Checking the seals at the coolant liquid connections

All of the coolant connections must be checked to ensure that they are not leaking.

This is done by wrapping a white, dry and absorbent cloth around the connections and checking whether the cloth absorbs any cooling medium that may have leaked. Cooling medium that has leaked has a color ranging from bright yellow up to amber. If cooling medium has leaked, then the cause of the leak should be investigated and resolved.

6.7

Cooling system: Replacing the coolant

The Antifrogen N agent used in the DCC cooling system guarantees the required antifreeze protection when the DCC is operated at low temperatures. The inhibitors contained in Antifrogen N guarantee optimum anti-corrosion protection. These inhibitors have a limited life especially when they come into contact with oxygen. In order to guarantee the correct functioning of the cooling system, the complete Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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coolant must be replaced at regular intervals. This allows the optimum antifreeze and corrosion protection to be achieved.

Caution The coolant should not be replaced at temperatures < 5 °C. The reason for this is that the kinematic viscosity of the cooling medium at low temperatures increases significantly making it unnecessarily difficult to replace the cooling medium.

The pumps may never be allowed run dry. If this happens then the sleeve bearings will definitely be destroyed.

Approx. 63 l of cooling medium has to be replaced.

Only use suitable coolant.

When releasing the coolant coupling (coolant connection) a small amount of residual coolant can remain in the coupling. Suitable measures (absorbent paper, cloth, or similar) must be used to ensure that any remaining coolant does not run into the DCC.

Basic information on Antifrogen N Antifrogen N is used as antifreeze and anti-corrosion agent for water-cooled converters. If the antifreeze no longer has the specified concentration then the mixture promotes corrosion (e.g. for surfaces with just a film of antifreeze). This is the reason that coolant that has leaked must be immediately removed.

Caution Antifrogen N is corrosive. In addition, Antifrogen N that has leaked can cause shortcircuits. This is the reason that each time the cooling water connections are opened, the phase module must be carefully cleaned and especially the modules located below it.

Handling Antifrogen N involves the following working conditions: •

Your own personal protective equipment

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Warning The following protective procedures must be carefully applied when handling Antifrogen N: •

Do not breathe in any vapor

•

Keep away from foodstuffs and beverages

•

Hand protection: Protective gloves

•

Eye protection: Protective glasses

First Aid measures •

Immediately remove clothing that has come into contact with Antifrogen N.

•

After skin contact: If Antifrogen N comes into contact with the skin immediately wash off with a lot of water.

•

After eye contact: If Antifrogen N comes into contact with the eyes apply plenty of water and contact a doctor immediately.

•

After swallowing: Get the person to vomit under the assumption that he is fully conscious. Immediately contact a doctor.

•

Otherwise, the regulations laid down in the EC safety data sheet according to 91/155/ECC for Antifrogen N and the generally valid First Aid rules must be carefully observed.

The coolant is removed from cooling system in the following steps: •

Remove the overflow hose at the cover of the equalization reservoir

•

Open the cover of the equalization reservoir

Warning The cooling system may be under pressure!

The cooling medium can reach temperatures of up to 60°C. Danger of burning!

Always carefully and slowly open the cover of the equalization reservoir to ensure slow pressure equalization!

•

Remove the step protection plate above the fast release drain coupling at the lower end of the heat exchanger (radiator).

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•

Maintenance

Drain the cooling liquid using the drain hose at the cooler until cooling medium no longer flows.

Caution The cooler starts to drain immediately when the drain hose is inserted! This is the reason that a suitable container must be provided and the drain hose placed in this container before the fast release coupling is inserted!

•

Release all fast release couplings at the modules.

•

Connect the drain hose at the cooling medium intake hose of module A51 and drain until no cooling medium flows.

Caution The coolant distribution immediately drains when the drain hose is inserted! This is the reason that suitable containers must be provided and the drain hose placed in this container before the fast release coupling is inserted!

Even after the cooling system has been completely drained according to these Operating Instructions, small quantities of cooling medium can remain in the water distribution system. When continuing to work on the cooling system we recommend that you always have absorbent paper at hand so that this liquid can be quickly removed.

The coolant circuit is filled in the following steps: The cooling medium is filled using filling equipment.

The fast release coupling of the water intake of lowest level phase module is the filling point.

•

Connect the pressure hose of the filling equipment at the filling point

•

Open the cover at the equalization reservoir

•

Ensure that the drain hose has been removed from the heat exchanger

•

Ensure that all of the coolant hoses and all hose clamps are in place and secured

•

Connect the connector of the pump feed equipment to the coolant pump of the DCC.

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Caution When filling the cooling system only use Antifrogen N / water mixture in the ratio of 44%/ 56%!

Never use any other coolant!

Always ensure that the coolant is clean!

Suitably filter the coolant before filling it!

If dirty coolant is used to fill the cooling system then this can result in severe operational disturbances and can also destroy the DCC components!

•

Power-up pump of the filling equipment

•

Stop filling when the coolant level has reached the filling mark at the main heat exchanger.

•

Turn off pump of the filling equipment

•

Disconnect the pressurized hose at the filling location of the DCC

•

Power-up the coolant pump of the DCC using the pump feed equipment and circulate the coolant

•

Fill and circulate the coolant alternating until the level remains constant at the mark provided

•

Then disconnect the filling equipment and pump feed equipment from the DCC and re-connect the coolant hose used as filling point with phase module. Re-insert connector X68 at the pump and latch into place.

•

Close the cover on the equalization reservoir.

•

Re-locate the overflow hose and correctly tighten the hose clamp (3 Nm tightening torque)

Warning Carefully take into consideration general safety information and instructions when handling Antifrogen N!

Disposing of Antifrogen water mixtures There are several ways of disposing of Antifrogen water mixtures: The mixture is always disposed of in an incineration system; in addition, companies can also be contacted that specialize in recycling glycol water mixtures. You can request a list of glycol recyclers from the Clariant Company (www.clariant.de). Antifrogen water mixtures are bio-degradable (refer to the safety datasheet) and after prior discussion with the operating company can also be disposed of in a biological water treatment plant when the applicable regulations are complied with.

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6.8

Maintenance

Coolant pump: Replacing the coolant pump and overhauling it in an authorized workshop

The parts subject to wear used in the DCC cooling pump must be replaced at regular intervals. It is also necessary to carry-out the necessary maintenance and adjustment work at the pump. The coolant pump is removed as follows: •

Empty the cooling system as specified in Chapter 6.7

•

Remove the coolant pump as specified in Chapter 7

•

Install the new or overhauled coolant pump as specified in Chapter 7

•

Fill and vent the coolant as specified in Chapter 6.7

The coolant pump that has been removed should be sent to the manufacturer or an authorized workshop for inspection / overhaul. The nearest representative of the manufacturer can be taken from the following website www.ksb.com.

6.9

Internal cooler: Replacing the motor

The motor of internal cooler is not visible even if cabinet doors are opened. Hence it needs to remove the internal cooler to access its motor.

The motor in the indoor cooler must be replaced at regular intervals. The indoor cooler is disassembled/ removed as follows.

•

Remove the indoor cooler as specified in Chapter 7.14

•

Release the cable at the terminal box of the three-phase motor

•

After releasing the 4 retaining screws at the protective screen and 2 screws at the motor support assembly the three-phase motor - together with the impeller and the protective screen - can be separated from the cooling system.

•

Release the impeller from the motor shaft; the protective screen can then be removed.

•

Send the motor that has been removed to an authorized workshop for overhaul.

•

The motor is installed in the inverse sequence.

6.10

DC link capacitor: Checking the capacitance value

The values of all DC link sub-capacitances must be determined and compared with the reference value.

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Danger It must be absolutely ensured that the DC link is completely discharged!

If this is not carefully observed this can result in death, severe bodily injury and significant material damage.

Carefully observe the instructions provided by the equipment manufacturer!

We recommend using a capacitance measuring bridge to measure the capacitance of the complete DC link.

Total Capacitance of DC link C1,C2,C3

Test points

Permissible capacitance value

From

To

Min

Max

XP1

XN1

9 mF

9.9 mF

If value of capacitance of complete DC link is not in range then remove individual capacitors from DC link as given in 7.16 & measure capacitance value of each capacitor.

Capacitance

Individual Capacitor

Test points

Permissible capacitance value

From

To

Min

Max

2 or 3 terminals of capacitor (-ve)

1 or 4 terminals of capacitor (+ve)

3 mF

3.3 mF

If one or several capacitance values are no longer in the permissible range then they must be immediately replaced.

6.11

Main blower fan motor: Replacing the bearings

The bearings in the central fan must be replaced at regular intervals. To do this the main blower fan must be removed.

•

Remove the fan, refer to Chapter 7.12

•

A Siemens repair facility or another suitable specialist company should replace the motor bearings.

6.12

DCC: Cleaning the inner space

•

Open all of the covers

•

Remove coarse dirt using a vacuum cleaner

•

Blow-out the dirt from the edges and corners using compressed air (dry, free of grease, max. 8 bar). Never use compressed air to clean electronic modules!

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•

Vacuum again

•

If required, clean using dry cloths

6.13

Checking the main and auxiliary contacts of the contactors, transfer switch and the busbar connections in the DCC

Visual checks must be carried-out at regular intervals to check wearing parts associated with electromechanical switching devices and identify the effects of ageing at busbar connections.

Carry-out the following for contactor K1, K2: •

Remove the arc quenching chamber at contactor K1,K2

•

Check the main contactor contacts for erosion; when required, replace the main contacts (for instructions, refer to instruction manual for contactors)

•

Re-attach the arc quenching chamber

•

Check the auxiliary contacts for visible traces of erosion, when required, replace

Carry-out the following for transfer switch Q1.1, Q1.2, Q1.3 and motor module Q1: •

Check the main contacts of the switch modules for erosion, when required replace the switch modules (instructions on how to do this, refer to the chapter 7)

•

Check the auxiliary contacts on motor module for visible traces of erosion, when required, replace

Visually check the complete power section; in doing so, place give special emphasis on the following points: •

Are the cables damaged, is the insulation cracked or is there evidence of abrasion on the cables?

•

Are components visibly damaged (phase modules, crowbar thyristor module, transducers)?

•

Are the components and current-carrying parts discolored?

•

Can white, crystalline traces be seen (these signify that the cooling system has leaks)?

•

Are all of the cable lugs OK (none of the leads split, not discolored)?

•

Is the busbar OK (visual check: Straight; no discoloring; no bubbling; not de-laminated)?

If there is evidence of problems or defects then they must be resolved.

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6.14

Maintenance

Cooling system: Checking for porous hoses

The hoses must be regularly visibly checked for signs of aging.

All of the hoses used in the DCC must be visually inspected. If there are signs of cracking or porous hoses then they must replaced.

Caution Only use the original spare parts otherwise there is a danger of damage to the DCC as a result of leaks!

6.15

DCC: Checking the painted surfaces

The painted surfaces of the complete DCC must be visibly checked at regular intervals to identify the effects of aging and subsequent corrosion.

Not all of the painted surfaces in and on the DCC can be visually inspected. If paint damage is identified then the appropriate locations must be repaired. For reasons of compatibility the original paint should be used for touching-up work.

6.16

Replacing seals at the maintenance covers

The seals at the maintenance covers should be regularly replaced so that the DCC remains correctly sealed. The sealing effect can diminish as the sealant ages.

Note If necessary, repair damaged paint on the covers.

•

Remove all of the maintenance covers from the DCC

•

The following work is best carried-out away from the Shovel on a workbench

•

Carefully remove the flat seal from the cover taking care not to damage the paint. Remove remains of adhesive and seal (e.g. using paint thinners)

•

After removing the protective foil for the adhesive, attach the pre-fabricated seal to the cover

•

The two ends of the flat seal (the joints) should be located at the bottom and glued to one another (adhesive: Cyanoacrylate, e.g. SICOMET 8300)

•

Apply grease (jelly) to the seals.

•

Re-attach the covers to the DCC

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6.17

Maintenance

Air conditioner: cleaning the heatsink fins

Since the technology is solid-state, there are no filters, compressors, or fluorocarbons to maintain. The only moving parts are the fans. It is recommended for harsh or dirty environments that the heat sinks be cleaned from time to time.

This can be accomplished by directing compressed air over the external fins. This will increase the overall life and performance of the system.

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Maintenance, Trouble-Shooting and Repairs

Maintenance, Trouble-Shooting and Repairs Danger Before carrying-out any work the following five safety rules must under all circumstances be carefully observed: 1.

Disconnect from the power source

2.

Lock-out to prevent re-closure

3.

Ensure that the system really is in a no-voltage condition

4.

Ground and short-circuit

5.

Cover or partition off adjacent parts and components that are under voltage (live parts)

Please note the following: •

Even after it has been powered-down and disconnected, hazardous voltages can still be present in the DCC.

•

It takes at least 100 minutes for the DC link capacitors to discharge to nonhazardous voltage values if no additional discharge mechanism in function.

•

Carefully observe all of the information and instructions in these Operating Instructions and on the product itself.

•

Only use spare parts authorized by the manufacturer.

•

Carefully comply with the specified maintenance intervals as well as the instructions for repair and replacement.

If this is not carefully observed this can result in death, severe bodily injury and significant material damage.

7.1

Discharging and Grounding the Converter

WARNING Refer to the section 2.3.4

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Maintenance, Trouble-Shooting and Repairs

Component locations in DCC

Cabinet cover numbers assignment

(2)

(1) (5)

(4)

(3) (6)

(7) (10)

(9)

(8)

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Component locations in DCC lookup table Designation in cabinet

Description

Functional Unit

Mounted behind cover

A1, A2

IGBT Module – Triple

AFE

10

A11, A13

IGBT Module – Double

PWM Inverters & Braking Chopper

10

A31, A51

IGBT Module – Triple

PWM Inverters

10

A7 L1,L2

Hard crowbar AFE AC Main- /Line- Contactor

9 -

K1,K2

Crowbar Module AFE Reactor Line Contactor AC

2

K4

Pre-charging Contactor AC

AC Pre-charging Circuit

1

E01

Main Blower

Water cooling system

-

E02

Heat Exchanger

Water cooling system

-

E11

Internal Cooler

Water cooling system

8

M01

Centrifugal Pump

Water cooling system

-

C1, C2, C3

DC Link Capacitor

DC Link

2

A91, A92

DC/DC Power Supply

IGBT Driver card power supply

8

A95,A96

DC/DC Power Supply

SIBAS power supply

8

U1, U2, U4, U5, U11, U12, U31, U32, U51, U52

Current Transducers

AC Input output currents

10

U09, U10, U33

Voltage Transducers

DC Voltage monitoring

1

U34,U35

Voltage Transducers

Synchronizing voltage feedback

1

Q1

Motor Module

Transfer Switch

1

Q1.1,Q1.2, Q1.3

Switch Module

Transfer Switch

1

Z1

SIBAS Filter

SIBAS Power Supply Filter

8

B2

Pressure Transducer

Water inlet pressure sensor

10

R31.1, R31.2

Pre-charging Resistor

Pre-charging Circuit

1

R42

Discharge Resistor

R41

Discharge Resistor

C75

Grounding Capacitor

K15, K16

Contactors for Transfer switch

DC Link Discharge and Earth Fault Detection DC Link Discharge and Earth Fault Detection DC Link Discharge and Earth Fault Detection Blower Circuit

1 1 1 5

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Designation in cabinet

Description

Functional Unit

Mounted behind cover

K10-K14, K51-K54

Auxiliary Contactors

Auxiliary Circuit

8

K05-K09,

Auxiliary Contactors

Auxiliary Circuit

5

A100

SIBAS 32 S

Drive Control Unit

7

E09

Electric heater 115V 800W

Electric heater 115V 800W

5

G01

Power Supply 24VDC/40A

Power Supply 24VDC/40A

5

A114

Simatic S7-400 UR1 Rack

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

D15 D16 D17 D18

Digital input module SM421, 32DI, DC/AC 120 Digital Output Module SM422, 16DO,DC/AC Digital input module SM421, 32DI, DC 24VDC Digital Output Module SM422, 32 DO, 24VDC

D19

Analog Output Module SM432

Simatic S7-400 UR1 Rack

5

D20

Analog Input Module SM431

Simatic S7-400 UR1 Rack

5

Simatic Rack Power Supply PS407 Simatic S7-400 CPU 416-2, MPI, Communication Processor CP-443

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

Simatic S7-400 UR1 Rack

5

A120

Profibus DP to CAN coupler

Profibus DP to CAN coupler

5

A103, A104, A105

Simatic PC 677B panel PC

Simatic PC 677B panel PC

5

R33.1& R33.2

RES,CHOPPER,3.15,1000W

Chopper resistor

-

E05

Air conditioner

Air conditioner

5

G10, G02, G09

UPS system

UPS

5

SRES

Reset Push Button

Reset Push Button

5

P0EB4

Emergency Stop Push Button

Emergency Stop Push Button

5

Q05, Q33

CIRCUIT BREAKER 20A

CIRCUIT BREAKER 20A

5

Q06

CIRCUIT BREAKER 3A

CIRCUIT BREAKER 3A

5

Q07, Q22/23/24

CIRCUIT BREAKER 16A

CIRCUIT BREAKER 16A

5

G11 D13 D14

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Designation in cabinet Q08/10/ 21/25/26/27/28/34/ 35

Maintenance, Trouble-Shooting and Repairs

Description

Functional Unit

Mounted behind cover

CIRCUIT BREAKER 10A

CIRCUIT BREAKER 10A

5

D15..D20

SIMATIC S7-400, FRONT CONNECTOR

Simatic S7-400 UR1 Rack

5

For G11

SIMATIC S7-400, BATTERY

Simatic S7-400 UR1 Rack

5

TH02 For D13 C025,C049, C073,C097 C121

THERMOSTAT CLOSE AT 35 THERMOSTAT CLOSE AT DEG F 35 DEG F MEMORY CARD S7400 Simatic S7-400 UR1 Rack LONG VERSION 5V 1MB DC/DC Converter SIBAS 32S rack 72...110V/24V 100W DC/DC Converter SIBAS 32S rack 72...110V/+-15V 100W

5 5 7 7

C145

Converter 72..110V/5V 90W

SIBAS 32S rack

7

C163

Power Start-up Unit

SIBAS 32S rack

7

G035,G043,G051, G059,G067,G075

Input Voltage/Frequency

SIBAS 32S rack

7

G099, G107

Input Converter Binary 24V

SIBAS 32S rack

7

G115, G123, G131, G139

Binary output 24V...36V/2 A

SIBAS 32S rack

7

G147

Input Temperature Sensor PT100

SIBAS 32S rack

7

L027, L059, L067, L107, L115 L035, L043, L051, L075, L091, L123

Mainboard SIP

SIBAS 32S rack

7

Inverter Monitoring Current Link

SIBAS 32S rack

7

L131, L155, L163

Output Measuring Amplifier

SIBAS 32S rack

7

L139

CPU 586

SIBAS 32S rack

7

L147

Input/Output Module

SIBAS 32S rack

7

N000

Fan Subassembly 28 SEP 1U

SIBAS 32S rack

7

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Maintenance, Trouble-Shooting and Repairs

MOTOR MODULE,24VDC

Bucyrus Part no: 62055593 Component designation: Q1

7.3.1

Description

The type 711 motor module can drive upto six type 712 switch modules.

The motor voltage of 24VDC is required. Travel time from one end position to the other is approximately 2 sec. The switch module will not try to interrupt or change state with the motor operated switch design.

Upon loss of power, the motor remains in its location.The switch modules coupled to the motor module also remain in their existing closed position.

Three normally open and three normally closed contacts are available for customer use.

Between end positions all six auxiliary contacts are open.

This motor is used to drive the transfer switches connected in the output circuit of the hoist and crowd inverters, to commute the output of these inverters to the hoist and crowd motors or to right and left propel motors.

7.3.2 • • • • •

Testing Isolate the power supply by switching off the drive power contactor and lock out the Main and Auxiliary power supplies.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Visually inspect the quality of switch contacts. Also, verify the alignment of the switch shaft with the rest of subassembly. If there is no visual defect disconnect the power cables from switch terminals and isolate them.

Give 24VDC supply externally, -24VDC to z terminal and +24VDC to y terminal of the motor module. The transfer switch should move to position 1 in less than 2 sec.

Keeping the –24VDC connected to the z terminal of the transfer switch, connect the +24VDC of the power supply to the x terminal of the transfer switch. The transfer switch should move to position 2 in less than 2 sec.

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7.3.3

Maintenance, Trouble-Shooting and Repairs

Replacing

Removing • Remove power cable connection from output side busbar cable no.

11004(1x), 11005(1x), 11006(1x), 11110(2x), 11111(2x), 11112(2x), 11103(1x), 11102(1x), 11101(1x), 11108(1x), 11107(1x), 11109(1x) by unscrewing Hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Remove power cable connection from input side busbar cable no.

10901(1x), 10902(1x), 10903(1x), 10701(1x), 10702(1x), 10703(1x) by unscrewing hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Remove all electrical connections of motor module from shield bracket by unscrewing 4mm clamp (pos 692), Torx screw M3*89 (pos 648) using kombi screw driver.

• Remove switch module (pos 180) one by one by unscrewing hex screw M10, plain, spring washer (pos 631, 629, 630) using 16 no. bit & torque wrench.

• Remove motor module (pos 170) by unscrewing hex screw M10, plain, spring washer (pos 625, 629, 630) using 16 no. bit & torque wrench.

• Remove mounting bracket from cabinet by unscrewing hex screw M10, plain, spring washer (pos 631, 629, 630) using 16 no. bit & torque wrench.

Installing • Assembly of Switch module to be done outside of the panel • Take switch module, place it on table, Mount Busbar (Top rear-pos 26, Top front-pos 25, bottom rear-pos 29) (18x) on three modules by screwing Hex screw 3/8 " 16 UNC,plain,spring washer (pos 633, 629, 630) using 13 no bit & torque wrench.

• Apply torque 15 Nm, Mark torque points with marker pen.

• Mount bracket (pos 20) on cabinet by screwing hex screw M10, plain, spring washer (pos 625, 629, 630) using 16 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount motor module (pos 170) on bracket by screwing Hex screw M10, plain, spring washer (pos 625,629,630) using 16 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount three switch module(pos 180) one by one on bracket by screwing hex screw M10, plain, spring washer (pos 631,629,630) using 16 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount power cable connection to output side busbar (Top rear-pos 26, Top front pos-25) cable no.11004(1x), 11005(1x), 11006(1x), 11110(2x), 11111(2x), 11112(2x), 11103(1x), 11102(1x), 11101(1x), 11107(1x), 11108(1x), 11109(1x) by screwing Hex screw M12*35 (pos.620,for single connection), Hex screw M12*45 (pos 615 for double connection) , hex nut M12,plain,spring washer (pos 616, 613, 612) using 18 no bit & torque wrench.

• Also mount power cable connection to input side busbar (Bottom rear pos,29) cable no, 10901(1x), 10902(1x), 10903(1x), 10701(1x), 10702(1x), 10703(1x) by screwing Hex screw M12*35 (pos.620, for single connection), hex screw M12*45 (pos 615 for double connection), hex nut M12,plain,spring washer (pos,616,613,612) using 18 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Tie all power cable to tie rod using cable ties & tie gun.

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Maintenance, Trouble-Shooting and Repairs

Make all electrical connections of motor module with shield bracket using screwing 4mm clamp (pos, 692), Torx screw M3*89(pos, 648) using kombi screw driver.

Mounting of cable tie rod

Power cable connections

Cable tie rod

Bus bar

Electrical connections of motor module

Switch Module

Mounting of Switch Module

Motor Module

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7.3.4

Drawing

7.3.5

Technical data

Motor rating: Rated voltage

24 VDC

Minimum operating voltage 21.6 VDC Maximum current

22 A

Travel time:

2s

Capacity:

Up to 6 switch modules

Auxiliary contacts: positions)

3 NO and 3 NC at end positions (All NO between end

Mounting:

Mounts on 3 inch wide channel with two 3/8” screws.

Weight

12 Kg.

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7.4

Maintenance, Trouble-Shooting and Repairs

SWITCH MODULE

Bucyrus Part no: 62055594 Component designation: Q1.1, Q1.2, Q1.3

7.4.1

Description

The motor operated transfer switch is designed for use in DC systems, such as; transportation and mining equipment. The 1600 A, 1500 V DC Motor Operated Switch is created by coupling three Type 712 Switch Modules to one Type 711 Motor Module. The Type 712 Switch Module is a DPDT (double pole double throw) non-interrupting switch. Switch Module utilizes main contacts with a wiping action to provide exceptionally high reliability contact continuity and lower contact resistance. The main contacts are silver alloy. Major current carrying parts are silver plated for good electrical connections. Non current carrying steel parts are zinc plated with a dichromate finish for maximum corrosion protection.

These switches are used in the output circuit of the hoist and crowd inverters. The switches direct the output of these inverters to the hoist and crowd motors or to the right and left propel motors.

7.4.2 • • • • •

7.4.3

Testing Isolate the power supply by switching off the drive power contactor and lock out the Main and Auxiliary power supplies.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Visually inspect the quality of switch contacts. Also, verify the alignment of the switch shaft with the rest of subassembly. If there is no visual defect disconnect the power cables from switch terminals and isolate them.

Measure the value of the contact resistance for each pole and each position of the switch. Measured value of contact resistance should be less than 80 mΩ.

If the measured values of the resistance are greater than above value then the switch/switches needs to be replaced.

Replacing

Removing • Remove power cable connection from output side busbar cable no.

11004(1x), 11005(1x), 11006(1x), 11110(2x), 11111(2x), 11112(2x), 11103(1x), 11102(1x), 11101(1x), 11107(1x), 11108(1x), 11109(1x) by unscrewing Hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Remove power cable connection from input side busbar cable no.

10901(1x), 10902(1x), 10903(1x), 10701(1x), 10702(1x), 10703(1x) by unscrewing hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Remove all electrical connections of motor module from shield bracket by unscrewing 4mm clamp (pos 692), Torx screw M3*89 (pos 648) using kombi screw driver.

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Maintenance, Trouble-Shooting and Repairs

Remove switch module (pos 180) one by one by unscrewing hex screw M10, plain, spring washer (pos 631, 629, 630) using 16 no bit & torque wrench.

Remove motor module (pos 170) by unscrewing hex screw M10, plain, spring washer (pos 625, 629, 630) using 16 no. bit & torque wrench.

Remove mounting bracket from cabinet by unscrewing hex screw M10, plain, spring washer (pos 631, 629, 630) using 16 no. bit & torque wrench.

Installing • Assembly of Switch module to be done outside of the panel, • Take switch module, place it on table, Mount Busbar (Top rear-pos 26, Top front-pos 25, bottom rear-pos 29) (18x) on three modules by screwing Hex screw 3/8 " 16 UNC,plain,spring washer (pos 633, 629, 630) using 13 no bit & torque wrench.

• Apply torque 15 Nm, Mark torque points with marker pen.

• Mount bracket (pos 20) on cabinet by screwing Hex screw M10, plain, spring washer (pos 625, 629, 630) using 16 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount motor module (pos 170) on bracket by screwing Hex screw M10, plain, spring washer (pos 625, 629, 630) using 16 no. bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount three switch module(pos 180) one by one on bracket by screwing Hex screw M10, plain, spring washer (pos 631, 629, 630) using 16 no bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount power cable connection to output side busbar (Top rear-pos 26,Top front pos-25) cable no.11004(1x), 11005(1x), 11006(1x), 11107(1x), 11110(2x), 11111(2x), 11112(2x), 11103(1x), 11102(1x), 11101(1x), 11108(1x), 11109(1x) by screwing Hex screw M12*35 (pos 620, for single connection), Hex screw M12*45 (pos 615 for double connection), hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Also mount power cable connection to input side busbar (Bottom rear pos 29) cable no, 10901(1x), 10902(1x), 10903(1x), 10701(1x), 10702(1x), 10703(1x) by screwing hex screw M12*35 (pos 620, for single connection), hex screw M12*45 (pos 615 for double connection), hex nut M12, plain, spring washer (pos 616, 613, 612) using 18 no. bit & torque wrench.

• Apply torque 50 Nm, mark torque points with marker pen.

• Tie all power cable to tie rod using cable ties & tie gun.

• Make all electrical connections of motor module with shield bracket using screwing 4mm clamp (pos, 692), Torx screw M3*89(pos, 648) using kombi screw driver.

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7.4.4

Drawing

7.4.5

Technical data

Main contact rating: Contact arrangement

Double Pole Double Throw

Continuous current

1600 A @ 40 °C ambient, still air

Maximum voltage

1500 VDC

Thru-Current capability

30000 A

Mounting:

Mounts on 3 inch wide channel with two 3/8” screws.

Power connections:

Two 3/8”-16 tapped holes per terminal

Weight

13 Kg.

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7.5

Maintenance, Trouble-Shooting and Repairs

IGBT MODULE,DOUBLE,SD-1500WL

Bucyrus Part no: 62048922 Component designation: A11, A13

7.5.1

Description

The IGBT-module DOUBLE 1.5 kV is a water-cooled two-phase module. The following configuration can be adjusted alternatively: two phases, two braking controllers and one phase and one braking controller (the local assignment braking controller/phase on the module is selected freely). The assignment is done through bridges in the external control pin.

Beside the 4 IGBTs, there is a quadro control unit (QST), four high voltage sections (HST).

The electrical power connection (P, N) takes place through plug-in contacts at the back of the device.

Module supply: 24V±5% / ≤1A regular. Triggering signal: 40mA-current interface (only in connection with the corresponding SIBAS-control unit)

Block diagram

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Picture

7.5.2 • • • •

Testing Isolate the power supply by switching off the drive power contactor Keep the auxiliary supply ON. Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Check the error memory in SIBAS and check for the IGBT module related errors.

For diagnoses there are LED’s on HST and DST modules.

These have following functions: Diagnosis LED on HST

Name H11

Colour Status Green LED glows

H21

Red

LED glows

H31

Yellow LED glows

Information Control voltage (before Rg)<2V Control voltage (before Rg)<+2V HST power supply ok and no switch off due to short circuit

Diagnosis LED on DST/QST

Name H1

Colour Status Green LED glows

H2

Green

LED glows

H3

Yellow

LED glows

H4

Red

LED glows LED flashes

Information Control voltage (before Rg)<2V Control voltage (before Rg)<+2V HST power supply ok and no switch off due to short circuit Fault in HST A10 or A20(Phase L1) Braking chopper coded (Phase

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H5

Red

(2Hz) LED glows LED flashes (2Hz)

L1) Fault in HST A30 and A40 (Phase L2, only SD-1500WL) Braking chopper coded (Phase L2, only SD-1500WL)

Note: H1 and H3 will never glow simultaneously H4 and H5 display only HST faults, not the under voltage faults on DST/QST If nothing can be concluded looking at the above mentioned LED’s proceed with the following steps To make it possible to do measurements on the power connectors located in backside of module, the module must be removed from the container.

For this, first lock out the main power supply and Auxiliary power supply.

•

Dismantle the retaining brackets for the module and disconnect the control shielded cable from both ends (module and cabinet) to prevent any module damage.

Measuring points Collector- Emitter junctions of the transistors are connected to the power connector of the module Values that could be measured with an ohmmeter from backside of module power connections: Collector- Emitter: positive (red) test lead of ohmmeter in Collector resistance shall be “infinite”.

Emitter- Collector: positive (red) test lead of ohmmeter in Emitter – resistance shall be “zero” ( less than 1mΩ) because of anti-parallel diode.

Measurements shall be done for all 4 transistors in case of double module (SIBAC BB SD-1500WL) and all 6 transistors in case of triple module (SIBAC BB ST-1500WL).

Transistor #1 : collector connected in P and emitter in L1 Transistor #2 : collector connected in L1 and emitter in N Transistor #3 : collector connected in P and emitter in L2 Transistor #4 : collector connected in L2 and emitter in N Transistor #5: collector connected in P and emitter in L3 Transistor #6: Collector connected in L3 and emitter in N If the measured values of resistance are different than above, then the module is defective and needs to be replaced.

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7.5.3 •

Maintenance, Trouble-Shooting and Repairs

Replacing A11, A13 modules are of this type.

Removing modules •

All power connections are of busbars type and control connections are of plug connector type. All IGBT modules are pluged in on DC link low inductive busbar and the output connections are done with power cables as shown in the photo below.

Power connections

Control connections

Coolant pipe

•

Remove power cables of respective IGBT modules as follows

A13: 10703 (2x), 10704, 10706 A11: 10701 (2x), 10702 (2x) Using 18 no. bit and torque wrench and aside the power cables Remove Connectors from Module as follows: A13: A13X1, A13X2 A11: A11X2, A11X1 • • • • •

Remove connectors from positions X1, X2, X3 as shown in figure Remove input output coolant pipes from module.

Remove locking bracket from front by removing M8 screw, plain washer & spring washer with bit no 13 & torque wrench Loose the screws of IGBT module from inside by using extension tool (no.

101584869) Take IGBT module out from the panel.

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CAUTION • •

Weight of the IGBT module is 43 kg approximately.

Antifrogen N that has been used has a corrosive effect. Further, Antifrogen N that has leaked can cause short-circuits. This is the reason that each time the cooling water connections are opened, the phase module and especially the modules located below it, must be carefully cleaned and any Antifrogen N that has leaked must be removed.

Installing modules • • •

Mount IGBT module into the panel on FRP Guide rail Tight the screws in the panel by using extension tool 101584869 & torque wrench. Torque 10 Nm. Mount power cables of respective IGBT modules as follows.

A13: 10703 (2x), 10704, 10705 A11: 10701 (2x), 10702 (2x) • •

By screwing hex screw M12X30, HT spring washer and plain washer (pos.no110,111,125) Using 18 no bit and torque wrench and apply torque of 50 Nm Mount connector of respective IGBT module as follows:

A13: A13X1, A13X2 A11: A11X2, A11X1 • •

Mount respective coolant input output pipes Mount locking bracket at front by M8 screw, plain washer & spring washer with bit no 13 & torque wrench Torque 25 Nm

CAUTION When installing the phase module ensure that the color codes match. The color of the coding plate of the phase module to be installed must match that of the coding plate attached to the DCC frame.

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7.5.4

Drawing

7.5.5

Technical data

Surrounding conditions Air temperature in built in room: -40°C to +70°C Storage temperature: -40°C to +85°C

Condition Climatic ambient conditions Biological ambient conditions Chemically active materials Mechanically active materials Contaminating agents Pollution

Class Standard 5K2, temperatures - see above IEC 60721 - 1 - 3 -5 5B1

IEC 60721 - 1 - 3 -5

5C2, however no salt mist and IEC 60721 - 1 - 3 -5 salt water 5S1

IEC 60721 - 1 - 3 -5

5F1 PD 2

IEC 60721 - 1 - 3 -5 EN 50124 - 1

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Electrical load limits Maximum voltages Brief Description Minimum DC Link voltage in operation Nominal voltage Maximum short time allowable DC link voltage without triggering

7.6

Symbol

Value

-

1000 V

-

1500 V

-

2700 V

IGBT MODULE,TRIPLE,ST-1500WL-HP

Bucyrus Part no: 62052173 Component designation: A1, A2, A31, A51

7.6.1

Description

The IGBT-module Triple 1.5 kV is a water-cooled three-phase module. The following configuration can be adjusted alternatively: three phases, two phases and one braking controllers, one phase and two braking controller or three braking controllers (the local assignment braking controller/phase on the module is selected freely). The assignment is done through bridges in the external control pin.

Beside the 6 IGBTs, there is a quadro control unit (QST) and six high voltage sections (HST) and a DST. The electrical power connection (P, N) takes place through plug-in contacts at the back of the device.

Module supply: 24V±5% / ≤1A regular. Triggering signal: 40mA-current interface (only in connection with the corresponding SIBAS-control unit)

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Block diagram

7.6.2 • • • •

Testing Isolate the power supply by switching off the drive power contactor Keep the auxiliary supply ON. Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Check the error memory in SIBAS and check for the IGBT module related errors.

For diagnoses there are LED’s on HST and DST modules.

These have following functions: Diagnosis LED on HST Name

Colour

Status

Information

H11

Green

LED glows

H21

Red

LED glows

H31

Yellow LED glows

Control voltage (before Rg)<2V Control voltage (before Rg)<+2V HST power supply ok and no switch off due to short circuit

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Diagnosis LED on DST/QST Name

Colour

Status

H1

Green

LED glows

H2

Green

LED glows

H3

Yellow

LED glows

H4

Red

LED glows

Red

LED flashes (2Hz) LED glows

H5

LED flashes (2Hz)

Information

Control voltage (before Rg)<2V Control voltage (before Rg)<+2V HST power supply ok and no switch off due to short circuit Fault in HST A10 or A20(Phase L1) Braking chopper coded (Phase L1) Fault in HST A30 and A40 (Phase L2, only SD-1500WL) Braking chopper coded (Phase L2, only SD-1500WL)

Note: H1 and H3 will never glow simultaneously H4 and H5 display only HST faults, not the under voltage faults on DST/QST If nothing can be concluded looking at the above mentioned LED’s proceed with the following steps To make it possible to do measurements on the power connectors located in backside of module, the module must be removed from the container.

For this, first lock out the main power supply and Auxiliary power supply.

•

Dismantle the retaining brackets for the module and disconnect the control shielded cable from both ends (module and cabinet) to prevent any module damage.

Measuring points Collector- Emitter junctions of the transistors are connected to the power connector of the module Values that could be measured with an ohmmeter from backside of module power connections: Collector- Emitter: positive (red) test lead of ohmmeter in Collector resistance shall be “infinite”.

Emitter- Collector: positive (red) test lead of ohmmeter in Emitter – resistance shall be “zero” ( less than 1mΩ) because of anti-parallel diode.

Measurements shall be done for all 4 transistors in case of double module (SIBAC BB SD-1500WL) and all 6 transistors in case of triple module (SIBAC BB ST1500WL).

Transistor #1 : collector connected in P and emitter in L1 Transistor #2 : collector connected in L1 and emitter in N Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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Transistor #3 : collector connected in P and emitter in L2 Transistor #4 : collector connected in L2 and emitter in N Transistor #5: collector connected in P and emitter in L3 Transistor #6: Collector connected in L3 and emitter in N If the measured values of resistance are different than above, then the module is defective and needs to be replaced.

7.6.3 •

Replacing A1, A2, A31, A51 modules are of this type.

Removing modules •

All power connections are of busbars type and control connections are of plug connector type. All IGBT modules are pluged in on DC link low inductive busbar and the output connections are done with power cables as shown in the photo below.

Power connections

Control connections

Coolant pipe

•

Remove power cables of respective IGBT modules as follows

A1: 10208, 10209, 10210 A2: 10213, 10214, 10215 A31: 10901, 10902, 10903 A51: 10801, 10802, 10803 Using 18 no bit and torque wrench and aside the power cables Remove Connectors from Module as follows: A1: A1-A40-X2, A1-A50-X2, A1-A40-X1, A1-A50-X1 A2: A2-A40-X2, A2-A50-X2, A2-A40-X1, A2-A50-X1 Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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A31: A31-A40-X2, A31-A50-X2, A31-A40-X1, A31-A50-X1 A51: A51-A40-X2, A51-A50-X2, A51-A40-X1, A51-A50-X1 • • • • •

Remove connectors from positions X1, X2, X3 as shown in figure Remove input output coolant pipes from module.

Remove locking bracket from front by removing M8 screw, plain washer & spring washer with bit no 13 & torque wrench Loose the screws of IGBT module from inside by using extension tool (no.

101584869) Take IGBT module out from the panel.

CAUTION • •

Weight of the IGBT module is 43 kg approximately.

Antifrogen N that has been used has a corrosive effect. Further, Antifrogen N that has leaked can cause short-circuits. This is the reason that each time the cooling water connections are opened, the phase module and especially the modules located below it, must be carefully cleaned and any Antifrogen N that has leaked must be removed.

Installing modules • Mount IGBT module into the panel on FRP Guide rail • Tight the screws in the panel by using extension tool 101584869 & torque wrench. Torque 10 Nm. • Mount power cables of respective IGBT modules as follows.

A1: 10208, 10209, 10210 A2: 10213, 10214, 10215 A31: 10901, 10902, 10903 A51: 10801, 10802, 10803 • •

By screwing hex screw M12X30, HT spring washer and plain washer (pos. no. 110, 111, 125) Using 18 no. bit and torque wrench and apply torque of 50 Nm Mount connector of respective IGBT module as follows:

A1: A1-A40-X2, A1-A50-X2, A1-A40-X1, A1-A50-X1 A2: A2-A40-X2, A2-A50-X2, A2-A40-X1, A2-A50-X1 A31: A31-A40-X2, A31-A50-X2, A31-A40-X1, A31-A50-X1 A51: A51-A40-X2, A51-A50-X2, A51-A40-X1, A51-A50-X1 • •

Mount respective coolant input output pipes Mount locking bracket at front by M8 screw, plain washer & spring washer with bit no 13 & torque wrench Torque 25 Nm

CAUTION When installing the phase module ensure that the color codes match. The color of the coding plate of the phase module to be installed must match that of the coding plate attached to the DCC frame.

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7.6.4

Drawing

7.6.5

Technical data

Surrounding conditions Air temperature in built in room: -40°C to +70°C Storage temperature: -40°C to +85°C

Condition Climatic ambient conditions Biological ambient conditions Chemically active materials Mechanically active materials Contaminating agents Pollution

Class 5K2, temperatures - see above 5B1 5C2, however no salt mist and salt water 5S1 5F1 PD 2

Standard IEC 60721 - 1 - 3 -5 IEC 60721 - 1 - 3 -5 IEC 60721 - 1 - 3 -5 IEC 60721 - 1 - 3 -5 IEC 60721 - 1 - 3 -5 EN 50124 - 1

Electrical load limits Maximum voltages Brief Description Minimum DC link voltage in operation Nominal voltage Maximum short time allowable DC link voltage without triggering

Symbol

Value

-

1000 V

-

1500 V

-

2700 V

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7.7

Maintenance, Trouble-Shooting and Repairs

CROWBAR MODULE,CBH-1500L

Bucyrus Part no: 62055582 Component designation: A7

7.7.1

Description

Short circuit components SIBAC BB CBx-1500x, CBx-2600x and CBx3000x are conceived for the employment in static inverters with IGBT components SIBAC BB Sx-1500xL and Sx-3000xL. They are as hard short normally open contacts (CBH-xx00x), soft short normally open contacts (CBS-xx00) and as combined hard and soft short normally open contacts (CBD-xx00x) available. The hard short normally open contacts contain thyristor (EN), throttle, ignition transducer and ignition building group. The soft short normally open contacts contain thyristor, ignition transducer and ignition building group.

The control of the thyristors is made by an ignition building group. In the double short normally open contact one separate ignition building group each is used for the hard and soft short normally open contact.

Block diagram

Picture of similar type

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7.7.2 • • • • •

Testing Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Check the control wiring between the crow bar module and the SIBAS. It should be as per the circuit schematic of DCC. Check for any physical damage / burn marks. If it is not in order then you need to change the module.

Check the error memory from SWG sip for healthyness of crowbar module.

7.7.3

Replacing

Removing the module CAUTION The crowbar thyristor module weighs 40 kg.

• • • • •

Remove Power cable 10501 & 10502 from module by removing hex screw M12X30, HT spring washer and plain washer Using 18 no bit and torque wrench.

Remove connectors A7X6, A7X7 from module.

Remove locking bracket from front by removing M8 screw, plain washer & spring washer with bit no 13 & torque wrench Loose the screws of crowbar module from inside by using extension tool 101584869 Remove module from panel by sliding it on guide rail.

Installing the module • • • • •

Mount crowbar module into the panel on Guide rail.

Tight the screws in the panel by using extension tool 101584869 & torque wrench.

Mount power cables 10501 & 10502 on module by screwing hex screw M12X30, HT spring washer and plain washer using 18 no bit and torque wrench and apply torque of 50 Nm Mount connector A7-X6, A7-X7 on module.

Mount locking bracket at front by M8 screw, plain washer & spring washer with bit no. 13 & torque wrench Torque 25 Nm

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7.7.4

Drawing

7.7.5

Technical data

Surrounding conditions Air temperature in built in room: -40°C to +70°C Storage temperature: -40°C to +85°C Condition Climatic ambient conditions Biological ambient conditions Chemically active materials Mechanically active materials Contaminating agents Pollution

Class 5K2, temperatures - see above

Standard IEC 60721 - 1 - 3 -5

5B1

IEC 60721 - 1 - 3 -5

5C2, however no salt mist and salt water

IEC 60721 - 1 - 3 -5

5S1

IEC 60721 - 1 - 3 -5

5F1 PD 2

IEC 60721 - 1 - 3 -5 EN 50124 - 1

Electrical data Maximum average DC link voltage over the life span of the component Maximum DC link voltage at which the crowbar should fire Maximum DC link voltage which can be applied to the crowbar without ignition

1850 VDC 2600 VDC 3200 VDC

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7.8

CHOKE,400uH,3300V,358A,182MAC

Bucyrus Part no: 62057718 Component designation: L1, L2

7.8.1

Description

These three phase reactors are used in IGBT Shovels as AFE reactors part of a step up converter configuration, which converts 900 VAC three-phase systems to 1800 VDC. These reactors are used one per AFE and the 182 system has two AFEs.

7.8.2 • • • • •

Testing Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Using an LCR meter measure the inductance in each phase of AFE reactor.

The inductance measured should be 0.4 mH with a tolerance of ±5%.

If not then replace the reactor

7.8.3

Replacing

Removing • • • • • • • • •

Open perforated sheets by removing combi screw M6 x 16 (35x) by using combi screw driver T28.

Cut first cable ties of power cables from choke.

Remove power cable connections by removing hex screws M12 x 45 using 18 no. open and ring spanner.

Remove busbars by removing hex screw M10 x 20 and insulators by removing combi screw M6 x 16 using combi screw driver T28.

Remove earthig cable from choke by removing hex screw M12 x 30 using 18 no. open spanner.

Remove support angle of choke at top side by removing hex screw M12 x 40 using 18 no. bit and torque wrench.

Remove the hex screw M12 x 40 using 18 no. bit and torque wrench located at the bottom.

Mount fixture of choke by hex screw M12 x 40 using 18 no. bit and torque wrench on top side.

Remove choke by using stacker

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CAUTION Weight of a choke is 500 kg approximately.

Reactor

Insulators & busbar assembly

Choke mounting bracket

Installing • • • • • • • • •

Mount lifting fixture on choke with hex screw M12 x 40 using 18 no. bit.

Lift the choke and place it in the cabinet.

Mount the choke using hex screw M12 x 40 with 18 no. bit and torque wrench.

Torque 88 Nm. Mount support angle of choke at top side by using hex screw M12 x 40 using 18 no. bit and torque wrench. Torque 88 Nm. Connect earthing cable to choke by using hex screw M12 x 30 with 18 no. open spanner. Torque 50 Nm. Mount busbars by using hex screw M10 x 20. Torque 31 Nm. Mount insulators by using combi screw M6 x 16 using combi screw driver T28. Torque 6.5 Nm. Connect power cable connections by using hex screws M12 x 45 using 18 no. open and ring spanner. Torque 50 Nm. Route power cables and tie them on tie rods by using tie gun.

Place perforated sheets using combi screw M6 x 16 (35x) by using combi screw driver T28.Torque 10 Nm.

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7.8.4

Drawing

7.8.5

Technical data

Specification Reactor voltage: Reactor current: Rated inductance(µH): Class of insulation: Frequency (Hz): Degree of protection: Dimensions (LXWXH): Weight

54V@60Hz 358A 400 ±5% T50/H 50/60 Hz IP 00 approx 605X377X616 420Kg

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7.9

Maintenance, Trouble-Shooting and Repairs

CONTACTOR,2P,1500V,650A

Bucyrus Part no: 62055579 Component designation: K1, K2

7.9.1

Description

The line contactors are provided in the new 182MAC IGBT shovel system.

The line contactors connect the AFEs to the line. The main advantage of using line contactors is that the drive can be isolated easily from the line in case of a fault. Also in some cases the opening of the Drive power contactor can be avoided (main contact at the input) by simply opening the line contactors.

7.9.2 • • • • • • •

7.9.3

Testing Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Visual check of the main contacts for damage (charring or melting) Check magnetic components (e.g., coil) and insulating parts (e.g., components of plastic and ceramics) for dirt/dust and damage.

Check the disconnecting switch for smooth action (turn switch off/on by hand).

Give externally 24VDC to the coil of the contactor. The contactor should pick up. Check the contact resistance between the main contacts and the auxiliary contacts. It should be ideally 0 Ohms.

If the above conditions are not satisfied replace the contactor.

Replacing

Removing contactors • • • •

Remove power connections output side 10206, 10207, 10216 for K1 & 10211, 10212 for K2 from bus bars, Unscrewing M12 Nuts using 18 no. bit (open-end) wrench or open-end spanner Remove power connections input side from contactors by removing M12 bolts using 18 no. spanner, 18 no. open end bit and torque wrench to remove cables 10208, 10209, 10220 for K1 or 10213, 10214 for K2.

Remove all electrical connection of shield bracket & diode by using combi head screw driver-T10.

First loosen M10 bolts (4x) by using 16 no. open spanner and ring spanner, then holding the contactor against panel remove upper bolts, then lift the contactor and take it out and place it on the platform.

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CAUTION Weight of a line contactor is 25 kg approximately.

Installing contactors • Mount contactor K1 & K2 on mounting plate by using hex screw M10 x 30, plain, HT spring washers (pos.no. 625, 667, 630-4x for each contactor).

Use 16 no. bit and open-end torque wrench • Apply torque 50 Nm, mark torque points with marker pen.

• Lift the contactor by using stacker against panel. Then align mounting plate hole with panel by using hex screw M10 x 30, plain, spring washer (pos no.625, 621, 630-4x).

• Apply torque 50 Nm, mark torque points with marker pen.

• Mount shield bracket & resistor on mounting plate. Make electrical connections.

• Mount power connections output side 10206, 10207, 10216 for K1 & 10211, 10212 for K2 to bus bars, screwing M12x35 (4X) (pos. no. 620) nuts, plain & HT spring washer (pos.no. 616, 613, 612) using 18 no. openend bit, torque wrench, open-end spanner and apply torque of 50 Nm • Mount power connections input side 10208, 10209, 10220 for K1 or 10213, 10214 for K2 to bus bar by screwing M12x50(4x) (pos. no. 658) nuts, plain & HT spring washer (pos.no. 616, 613, 612) using 18 no. open-end bit, torque wrench, open-end spanner and apply torque of 50 Nm NOTE While replacing with new contactor, remove busbars at terminal 1 and 3 from old contactor and assemble them to new contactor as given below:

Take new contactor. Mount contactor busbars (2x) (pos. no. 28) on contactor. Use conical washers, hex nut, plane washer (2x for each busbar) (pos. no. 626, 616, 670) Apply torque of 50 Nm.

Mounting screws

Output side connection

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Electrical connection

Input side connection

7.9.4

Drawing

7.9.5

Technical data

Max. operating voltage: Thermal current: Mechanical life: Current direction: Breaking circuit: Coil voltage range: Max dynamic current:

1500 VDC+30% Ith=700A ≥106 operations one-way Indirect blowout coil Uc=-30%/+25% Ipeak=10KA

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Maintenance, Trouble-Shooting and Repairs

CONTACTOR,1P,1500V,250A

Bucyrus Part no: 62055578 Component designation: K4

7.10.1

Description

The pre charging contactor is used to pre charge the DC bus to a voltage level of 1275VDC before the AFE pulsing starts. The pre-charging circuit consists of a pre-charging contactor, pre-charging resistor and DC link capacitor.

7.10.2 • • • • • • •

7.10.3

Testing Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Visual check of the main contacts for damage (charring or melting) Check magnetic components (e.g., coil) and insulating parts (e.g., components of plastic and ceramics) for dirt/dust and damage.

Check the disconnecting switch for smooth action (turn switch off/on by hand).

Give externally 24VDC to the coil of the contactor. The contactor should pick up. Check the contact resistance between the main contacts and the auxiliary contacts. It should be ideally 0 Ohms.

If the above conditions are not satisfied replace the contactor.

Replacing

Removing the contactor

• • • •

Cut all cable ties by using cable tie cutter from LKC sockets.

Disconnect all electrical connections from contactor.

Remove combi screws M6 x 16 with combi screw driver T28.

Take out contactor from plate.

Installing the contactor

• Mount contactor on plate using combi screws M6 x 16 with combi screw driver T28.

• Make all electrical connections of contactor.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

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Contactor aux connections

Contactor K4 Shield bracket connections

7.10.4

Drawing

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7.10.5

Technical data

Nominal voltage: Max operating voltage: Thermal current per pole: Operating current per pole at 75 °C: Control coil voltage: Characteristics per pole Maximum Regular breaking breaking (occasional fault) Voltage (VDC) Current(A)

120

L/R (ms)

5

Power (kW)

120

7.11

1000

Voltage (VDC) Current (A) L/R (ms) Power (kW)

750 80 15 60

1500 V 2000 V 250A 200A 24VDC Control coil Short circuit Control coil power pickup(W) withstand Control coil power holding (W) Current(kA) 4 Opening time(msec) Duration 5 Closing time (msec) (ms) Mechanical life L/R when closed (msec) Opera 2X106 L/R when open (msec) tions

RES,CHOPPER,3.15,1000W

Bucyrus Part no: 62055587 Component designation: R33.1, R33.2

7.11.1

Description

When braking, the motors act as generators and feed energy back into the DC link causing the DC link voltage to increase. The main task of the overvoltage chopper and the overvoltage resistor is to limit the DC link voltage of the DCC to 1890 V when braking. Further, the overvoltage chopper protects the IGBTs in critical situations by quickly discharging DC link via the overvoltage resistor. In system two identical resistors units are connected in parallel.

7.11.2 • • •

Testing Isolate the power supply by switching off the drive power contactor and locking out the Main and Auxiliary power supplies.

Using a voltmeter, check that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Visually inspect both the resistors by checking it for cracks or deformation.

If there is no visual defect disconnect the resistor terminals.

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Using an ohmmeter measure the value of resistance which should be 3.15 Ohm (±5%).

If the resistor presents mechanical alterations or the measured value is different than above then the resistor/resistors needs to be replaced.

7.11.3

Replacing

Removing • Unscrew hex mounting screws M8 x 16 using 13 no. bit and torque wrench.

• Open the connection box of the resistor.

• Remove the power cable connections 10704, 10705 from connection box of the resistor R33.1 and 10706, 10707 from connection box of the resistor R33.2 .

• Remove the resistor box as a complete unit Installing • • • •

Mount resistor with hex mounting screws M8 x 16 using 13 no. bit and torque wrench. Torque 25 Nm. Open the connection box of resistor unit Connect the power cables 10704, 10705 to connection box of the resistor R33.1 and 10706, 10707 to connection box of the resistor R33.2.

Close the connection box properly

Mounting screws

Connection box

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7.11.4

Drawing

7.11.5

Technical data

Art. No. :

DEG 6VPR500S - 3R15 - S

R=

3.15 Ohm +/- 5 %

PD =

1000 W

Maximal Storage energy 401 kJ for 100 ms, 2 x during 10 s Degree of protection:

IP55

Weight:

12.15 kg

Dimension:

547 x 450 x 100 mm

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7.12

BLOWER,3PH RADIAL,182MAC

Bucyrus Part no: 62057719 Component designation: E01

7.12.1

Description

The blower is used to cool the hot coolant flowing through the radiator fins.

7.12.2 • • • • • •

Testing Isolate the power supply by switching off the drive power contactor.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. Check for the direction of rotation of blades of the blower. It should be counter clockwise looking from the end where the direction arrow sticker is placed on the blower.

If this is not the case, the phase sequence needs to be changed.

The pitch angle of all the blades should be identical and as long as the motor shaft is not stalled the impeller should be easy to move by hand.

If this is not the case the blower needs to be replaced.

7.12.3

Replacing

Removing • First remove all electrical connection of blower from terminal box.

• Cut cable ties for cable 24704 from the blower end .

• Remove hex spacers M6 x 40 and place the cable on the side of the panel.

• Remove all mounting screw of blower by unscrewing hex screw M8 x 16 and M10 x 30, using 13, 16 no. bit & torque wrench.

• Lift the blower from cabinet & place safely.

CAUTION Weight of a main blower is 190 kg approximately.

Installing • • • • • •

Lift the blower and align it with blower mounting sheet surface.

Mount blower using hex screw M10 x 30 (10x), plain washer M10, HT spring washer M10 using 16 no. bit and torque wrench.

Apply torque 50 Nm, mark torque points with marker pen.

Mount earthing connection of blower by screwing hex screw M8 x 16, plain washer M8, HT spring washer M8 (pos, 722,698,697) using 13 no. bit & torque wrench.

Apply torque 15 Nm, mark torque points with marker pen.

Make all electrical connections of blower.

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Blower

Ventilation channel

Blower earthing connection

Ventilation channel cover

Blower mounting

Ventilation channel earthing connection

Ventilation channel mounting

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7.12.4

Drawing

7.12.5

Technical data

Parameter Voltage (VAC)

415

Speed (1/min)

2940

Power (kW)

15

Frequency (Hz)

50

Volume flow rate

4.10 m3/s

Static pressure increase

1500 Pa

Sound power level

108 dB

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Maintenance, Trouble-Shooting and Repairs

COOLER, 35.06KW AKG

Bucyrus Part no: 62055590 Component designation: E02

7.13.1

Description

The heat exchanger is responsible for cooling the coolant in the cooling system of the DCC. The coolant flows into the heat exchanger at the top and at the bottom is pumped away by the pump.The coolant level should be located between the two sight glasses at the reservoir. A level sensor with two switching points is installed in the reservoir to signal the level of coolant. The PLC reads-in and evaluates the actual state of the sensor.

7.13.2 • • •

7.13.3

Testing Isolate the power supply by switching off the drive power contactor and lock out the Main and Auxiliary power supplies.

Visually check the fins of rasiator for any damages & leakage. If the damage is more or there is leakage change the radiator.

Check the water level, if it is below the lower indicator fill in the water misture (Water to Glycol ratio 56:44).

Replacing

Removing the heat exchanger • Drain all the coolant from cooling system. Ref chapter 6.7 In Operation & Maintenance manual.

• Remove connector X72 (located on side wall) with the help of screw driver.

• Remove earthing connection on the radiator (located on the front side) • (Hardware Pos. No. 710, 697, 698 – hex Screw M8 x 20, HT & Plain Washer) • Remove Hose of the Reservoir tank by loosening the clamp & cutting the cable ties.

• Remove half flange (Pos. No. 19) located on top side along with flange nipple –DN40 (Pos. No. 22) and O-Ring (Pos. no. 38) to release the hose coming from water pipe (Hardware Pos. No. 686, 688, 689 - hex screw M12 x 35, HT & Plain Washer).

• Remove half flange (Pos. No. 19) located on bottom side along with flange nipple –DN40 (Pos. No. 22) and O-Ring (Pos. no. 38) to release the hose coming from pump (Hardware Pos. No. 686, 688, 689 - hex screw M12 x 35, HT & Plain Washer).

• Remove LH bottom side mounting hardware (Hardware Pos. no. 693, 692, 689 – hex screw M12 x 45, Ht & Plain washer) • Remove RH bottom side mounting hardware ((Hardware Pos. no. 694, 691, 689 – hex screw M12 x 55, Ht & Conical washer) along with anti vibration bush (Pos. no. 49)

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Remove LH top side mounting hardware (Hardware Pos. no. 720, 719, 692,689 – hex screw M12*70, Nut, Ht & Plain washer) along with Anti vibration bush (Pos. no. 49) Remove RH top side mounting hardware (Hardware Pos. no. 694, 719, 692,689 – hex screw M12*55, Nut, Ht & Plain washer) Tilt the radiator on towards front side by approximately 15 deg. to remove the round spacer on the top side (Pos. no. 47 & 48).

Tilt the radiator on LHS for removing the round spacer (Pos. no. 47 & 48) on the bottom side of the radiator. Repeat the same procedure for removing the round spacer on RHS. Lift the radiator and place the same in a secure place (Special care to be taken for protruding parts & fins of radiator- Place the radiator in horizontal position on wooden block.

Remove the Ventilation channel (Pos. no. 14) mounted on the back side of radiator. (Hardware Pos. no. 695, 697, 698 – hex screw M8 x 30, Ht & Plain washer)

Installing the heat exchanger •

• • • • • • • • •

•

•

Mount the Ventilation channel (Pos. no. 14) mounted on the back side of radiator. (Hardware Pos. no. 695, 697, 698 – hex screw M8 x 30, Ht & Plain washer) Apply torque of 15 Nm and mark the torque with permanent marker (Torque wrench + bit 13) Lift the radiator and place the same on the cabinet.

Tilt & lift the radiator on LHS for mounting the round spacer (Pos. no. 47 & 48) on the bottom side of the radiator. Repeat the same procedure for removing the round spacer on RHS. Tilt the radiator on towards front side by approximately 15 deg. for mounting the round spacer on the top side (Pos. no. 47 & 48).

Secure the LH top side with mounting hardware (Hardware Pos. no. 720, 719, 692, 689 – hex screw M12 x 70, Nut, Ht & Plain washer) along with anti vibration bush (Pos. no. 49) Mount RH top side hardware (Hardware Pos. no. 694, 719, 692, 689 – hex screw M12*55, Nut, Ht & Plain washer) Mount LH bottom side mounting hardware (Hardware Pos. no. 693, 692, 689 – Hex screw M12*45, Ht & Plain washer) on LHS. Mount RH bottom side mounting hardware ((Hardware Pos. no. 694, 691, 689 – Hex screw M12*55, Ht & Conical washer) along with Anti vibration bush (Pos. no. 49) Apply torque of 88 Nm and mark the torque with permanent marker on all the 4 side of Radiator mountings (Torque wrench + bit no. 18) Mount the hose coming from the pump suction side with half flange (Pos. No. 19) to the bottom side of the radiator along with flange nipple –DN40 (Pos. No. 22) & O-Ring (Pos. no. 38) (Note : Use a fresh O-Ring) (Hardware Pos. No. 686, 688,689 - Hex Screw M12*35, HT & Plain Washer). Tighten the clamp of hose.(Re-tightened the clamp after 24 hrs.)

Apply torque of 50 Nm and mark the torque with permanent marker (Torque wrench + bit no. 18) Mount the hose coming from water pipe with half flange (Pos. No. 19) on top of the radiator side along with flange nipple –DN40 (Pos. No. 22) and O-Ring (Pos. no. 38) (Note : Use a fresh O-Ring) (Hardware Pos. No. 686, 688,689 - Hex Screw M12*35, HT & Plain Washer). Then tighten the clamp of hose. (Re-tightened the clamp after 24 hrs.)

Apply torque of 50 Nm and mark the torque with permanent marker (Torque wrench + bit no. 18)

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Maintenance, Trouble-Shooting and Repairs

Mount hose coming from the pump to the Reservoir tank inlet with clamp (Pos. no. ) & secure the hose with cable ties. (Re-tightened the clamp after 24 hrs.)

Mount earthing connection on the radiator (located on the front side) (Hardware Pos. No. 710,697,698 – Hex Screw M8*20, HT & Plain Washer) Apply torque of 15 Nm and mark the torque with permanent marker (Torque wrench + bit no. 13) Mount connector X72 (located on side wall) with the help of screw driver.

Mount the valve nut on the radiator. Ensure proper sealing of the nut.

Mount protection plate (Pos. no. 79) (Hardware Pos. No. 699 – Combi screw M6*16). Apply torque of 6.5 Nm and mark the torque with permanent marker (bit T28) Remove the cap located on the top of the reservoir tank & Pour the coolant form the Can with the help of funnel in the Reservoir tank.

Check for level of water on the water level meter provided on the front top side of the radiator. (Ensure the required level)

Drawing

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Technical data

Core height

1100 mm

Core width

661.8 mm

Core depth

140 mm

Total heat transfer rate

35.06 kW

Flow

Diagonal cross flow

7.14

COOLER,AIR/WATER,6KW AKG

Bucyrus Part no: 62048803 Component designation: E11

7.14.1

Description

The heat exchanger is used to cool the air in the DCC. It comprises a fan with three-phase motor and an air-to-water heat exchanger. The water connections have fast release couplings. Two temperature sensors (PT100) are integrated in the cooler. They measure the water temperature and the air intake (internal cabinet air) temperature. The electrical connection (2x) is established using an AMP connector.

7.14.2 • • • • • •

Testing

Isolate the power supply by switching off the Drive power contactor Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Check the air flow direction. The cooler should suck the air from front side of the heat exchanger fins area and throw out towards its motor side area.

If the direction is not proper the phase sequence needs to be changed.

Check the fan motor for play and noise.

The electric motor is permanently lubricated and is maintenance-free. It has to be visually checked as prescribed in the maintainance plan and if required replaced. If there is a significant level of pollution, clean the cooler as otherwise the cooling power could be too low.

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7.14.3

Replacing

Removing complete unit • • • • •

Drain all the coolant from cooling system. Ref chapter 6.7 In Operation & Maintenance manual.

Remove the input output coolant pipes.

Remove connectors E11-X1 and E11-X2.

Remove earthing wire .

Remove cooler by removing hex screw M6, plain washer & spring washer (4x) by using bit no. 10 & torque wrench.

CAUTION • •

Weight of the internal cooler is 32 kg approximately.

Antifrogen N that has been used has a corrosive effect. Further, Antifrogen N that has leaked can cause short-circuits. This is the reason that each time the cooling water connections are opened, the phase module, must be carefully cleaned and any Antifrogen N that has leaked must be removed.

Installing complete unit • Place the cooler in the panel, mount it with hex screw M6, plain washer & Spring washer (4 xs). By using bit no. 10 & torque wrench. Torque: 10 Nm • Mount the connector E11-X1 and E11-X2.

• Connect the earthing cable.

• Connect input output coolant pipes to cooler.

Coolant pipes

Electrical connections

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7.14.4

Drawing

7.14.5

Technical data Electrical data Rated voltage

415 V

Frequency

50 Hz

Power

1.1 kW

Protection class

IP55

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Maintenance, Trouble-Shooting and Repairs

PUMP,CENTRIF,415V,182MAC

Bucyrus Part no: 62056672 Component designation: M01

7.15.1

Description

The centrifugal pump is used in the DCC to circulate the coolant with a known pressure in the cooling system. Under normal operation of the pump and the cooling system a pressure of 1.2 bar is genrated.

The pump is used to circulate the cooling medium in the cooling system.

The pump pumps the cooling medium into the water distribution system.

Eight phase modules and the internal cooler are connected in parallel to the coolant distribution system. The coolant is collected using an additional water distribution system and fed to the heat exchanger at the top. The pump pumps away the coolant at the bottom of the heat exchanger.

The pump is connected using a Tyco connector (X1).

7.15.2 • • • •

7.15.3

Testing Isolate the power supply by switching off the Drive power contactor.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. For correct direction of rotation the pressure measured by SIBAS is 0.7 bar to 1.7 bar. For wrong direction of rotation of pump the pressure measured is 0.2-0.3 bar.

If the direction of rotation is found wrong the phase sequence of the supply voltage needs to be changed.

Replacing

Removing • Drain all the coolant from cooling system. Ref chapter 6.7 In Operation & Maintenance manual.

• Remove connector from pump M01-X1.

• Remove small pipe by untightening the clamp.

• Remove half flange for suction side by removing the hex screws M12 x 35 (4x) by using bit no. 18 and torque wrench.

• Similarly remove half flange for delivery port side by removing hex screw M12 x 35 (4x) by using bit no. 18 and torque wrench.

• Remove flange complete for suction side by removing the hex bolt M16 x 70 (4x).

• Remove flange complete for delivery side by removing the CSK screw M16 x 60 (4x).

• Remove pump by removing the hex screws M12 x 40 with 18 no. bit and torque wrench.

• Lift the pump and place it safely.

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CAUTION Weight of a DC link capacitor is 37 kg approximately.

Installing • Place the pump and align the mounting holes.

• Mount the pump by using the hex screws M12 x 40 with 18 no. bit and torque wrench. Torque 80 Nm. • Mount the flange complete for suction side using the hex bolt M16 x 70 (4x). and nut, plain and spring washer.

• Mount flange complete for delivery side using the CSK screw M16 x 60 (4x) and nut , plain and spring washer.

• Place O-Ring on 90º nipple for delivery port.

• Place 90º nipple on flange complete for delivery port and mount half flange on it with M12 x 35 (4x) by using 18 no. bit and torque wrench. Torque 90 Nm and retighten it after 24 hrs with a torque of 80 Nm. • Place 45º nipple on flange complete for suction port and mount half flange on it with M12 x 35 (4x) by using 18 no. bit and torque wrench. Torque 90 Nm and retighten it after 24 hrs with a torque of 80 Nm. • Mount connector M01-X1.

• Insert small pipe near suction port and tight the clamp.

90º nipple Delivery port

Small Pipe

Connector

45º nipple Suction port

Half flange

Flange complete

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7.15.4

Drawing

7.15.5

Technical data

Parameter Output flow rate

12 m3/h

Power required by motor

1.86 kW

Output number of revolutions 2870 1/min Voltage

415

Frequency

50Hz

Protection class

IP55

Switch on mode

Direct

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Maintenance, Trouble-Shooting and Repairs

CAP,MKP DC,3 mF,2050V

Bucyrus Part no: 62055591 Component designation: C1, C2, C3

7.16.1

Description

Three DC link capacitors each of 3 mF are connected in parallel giving an overall capacitance of 9 mF forming the intermediate DC link. The DC link stores the DC voltage of 1800 V and acts as an input supply to the motor inverters. During normal operation, the DC link is maintained at 1800VDC by the AFE’s.

7.16.2 • • • • • • 7.16.3

Testing Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Measure the capacitance across the P and N busbars which form the DC link. The capacitance value measured should be in the range 8.73 – 10.17mF. If not remove all the cables connected to the P and N busbar from all the four capacitors.

Measure the capacitance of each capacitor. The value measured for each capacitor should be in the range 3 to 3.3 mF. If any deviation is observed in the capacitance measurement of any or all of the four capacitors replace that capacitor / capacitors.

Replacing

Removing • First remove M12 nuts (4 xs) from IGBT module side on low inductive bus bar using 18 no. bit and torque wrench.

• Remove M8 bolts (4x) on capacitor supporting brackets which are used to mount capacitor assembly on panel, using 13 no. bit and torque wrench.

• To remove Capacitor C1, first remove capacitor C2 following the above two steps.

• Remove the inverter output connections from 3U1, 3V1, 3W1, 8U1, 8V1, 8W1, 9U1, 9V1 and 9W1.

• Remove cable support for the above cables.

• Follow the first two steps to remove capacitor C1.

• To remove capacitor C3, first remove the line contactor plate by following steps given in chapter 7.3 • Remove capacitor C3 by following the first two steps .

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DANGER • It must be absolutely ensured that the DC link is completely discharged!

• If this is not carefully observed this can result in death, severe bodily injury and significant material damage.

• Carefully observe the instructions provided by the equipment manufacturer!

Hex nut M12

Angle mounting on Panel Capacitor mounting on angle

CAUTION Weight of a DC link capacitor is 37.5 kg approximately.

Installing • Mount the capacitor bracket SS in the same manner as it was mounted for the one to be replaced. This is to be done outside the cabinet. Take capacitor, place it on table, mount bracket SS on capacitor (2x) by using hex nut SS M8 along with plain and spring washer . Apply torque 25 Nm, Mark torque points with marker pen.

• Lift, place and slide capacitors on L angles with the help of stacker, till the capacitor terminals come out of low inductive busbar assembly.

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Mount the M12 (SS) nut, plain & wave washer (pos.669, 670, 678) on capacitor terminals from IGBT side on low inductive busbar using 18 no. bit and torque wrench. Torque 15 Nm. Mount plate (pos.22) on capacitor angle plate (pos. 24) by using Hex screw M8*25, plain, HT spring washer (pos. 618, 606, 623).

Apply torque 25 Nm, Use 18 no bit, torque wrench. Mark torque points with marker pen.

Follow same procedure for mounting of reamaning capacitors.

Restore all the other components removed in order to take out the capacitor.

(Eg: Line contactor plate for removing C3 etc.)

7.16.4

Drawing

7.16.5

Technical data

Parameter

Value

Capacitance

3mF

Tolerance

-0/+10%

Nominal rated DC link voltage

2050VDC

Non recurrent surge voltage

2200V (+/-3%) (-3% of lifetime) 2800V (50msec 1/week)

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Ripple voltage

Upto 300V

Nominal current (RMS)

150A

Maximum current(RMS)

250A

Weight

37.5 Kg

7.17

CONVERTER,DC-DC,150W

Bucyrus Part no: 62055580 Component designation: A91, A92

7.17.1

Description

The DC-DC power supply (24VDC o/p) is used as a control supply for the IGBT modules.

7.17.2 • • • • •

Testing

Isolate the power supply by switching off the Drive power contactor.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Check the output between the terminals X2B and X2A for A91 and between X4A and X3A for A92.

Check the status of the LED on both the power supply. The status should be green. If the green LED blinks it indicates hiccup mode i.e. the equipment goes in current limit.

The output voltage measured for both the power supplies should be 24VDC (±3%).

7.17.3

Replacing

Removing • Remove A91X1 connector for A91 power supply or A92X2 for A92 power supply by gently pulling them out • Remove base mounting M6 Kombi screws (4x) using T30 bit, extension rod and torque wrench • Take it out Installing • Place power supply at exact position and align the holes • Mount base mounting M6 Kombi screws(4x) using T30 bit ,extension rod and torque wrench, apply torque of 10 Nm • Attach A91X1 connector for A91 power supply or A92X2 for A92 power supply by gently pushing them in to the respective socket

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7.17.4

Maintenance, Trouble-Shooting and Repairs

Drawing

Picture

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Maintenance, Trouble-Shooting and Repairs

Technical data

Input Nominal voltage Continuous input voltage Dynamic input voltage Under voltage limiting

Overvoltage limiting

Short circuit protection Reverse polarity protection

Output Rated value Output voltage tolerance Load regulation Line regulation Dynamic line regulation

110/96/72 VDC 50.4-138 VDC 43.2-154 VDC >48VDC Turn ON <43VDC Turn OFF >165VDC Turn OFF <155VDC Turn ON By input fuse By internal reverse bias diode and input fuse 24VDC, 6.3A ±1% ±1% ±1% ±0.3%

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Output voltage ripple Functions Inhibit function

DC output voltage detection level (low value) DC output voltage detection level (high value) Displays Equipment off Equipment ON Equipment in current limit

Environment conditions Operating temperature Short time operating temperature(15min) Transport and storage Humidity

Maintenance, Trouble-Shooting and Repairs

≤100 mVpp Switches ON or OFF the output voltage without switching OFF the input voltage <21VDC ≥21VDC Green LED off Green LED glows Green LED blinks(hiccup mode) -40 to +70°C +70 to +85°C -40 to 85°C Relative humidity≤75%, as annual average, 95% for 30 days in a year continuous, 95-100% on other days occassionally

Protection and monitoring functions Current limit Response to short circuit Output overvoltage protection

6.6<Ia<7.3A Hiccup mode 26 to 27V. Fixed, retentive switch OFF. Reset by switching OFF the input voltage or through inhibit.

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7.18

Maintenance, Trouble-Shooting and Repairs

POWER SUPPLY,48V/20A

Bucyrus Part no: 62055592 Component designation: A95, A96

7.18.1

Description

The power supply is used to give a 110 VDC supply required for the SIBAS. The output of the power supply is set to 55VDC. Such two power supplies are used in series to give an output of 110VDC. 7.18.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the main and auxiliary power supplies.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Remove the input and output cables from both the power supplies.

• Check continuity between the L and N on the input side and between + and – on the output side of both the power supplies. Continuity should not be observed.

• If above test is successful the power supplies should be tested individually with an input voltage of 120VAC. • Check the output voltage in each case. The output voltage should be 55VDC for each of the power supply.

• In case any deviation is observed in the output voltage, adjust the output voltage to 55VDC by adjusting the POT whose location on the power supply is shown at position 5 in the figure below.

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• Connect all the cables as per the DCC schematic.

• Check the continuity between the output terminals + and - of the power supply.

Continuity should not be observed.

• If the output terminals shows short then check for the wiring.

• If nothing solves the problem, replace the power supply.

7.18.3

Replacing

Removing • Disconnect all electrical & earthing connction from power supply.

• Remove power supply mounting combi screws M6 x 16 using Kombi screw driver T28 • Remove the power supply carefully & place it safely.

Installing • Mount power supply on plate by using M6 x 16 combi using combi screw driver T28 • Apply torque 10Nm, mark torque points with marker pen • Make all electrical & earthing connections on power supply plate as per the schematic.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

7.18.4

Drawing

Picture Mounting of power supply

Electrical connections

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7.18.5

Maintenance, Trouble-Shooting and Repairs

Technical data

Input data Nominal input voltage Input voltage range 120-350VDC Frequency Current consumption (for nominal values) 11A(120VAC)/5A(240VAC) Inrush current limiting/I2t(+25°C) Mains buffering for a nominal load(typical) Switch on time after applying the mains voltage Transient surge protection Input fuse internal Recommended backup fuse Discharge current for PE

110-240VAC 85-264VAC 45-65Hz

15A,approximately/ 3.2A2S,approximate ly >20ms <1s Varistor 20 AF, device protection 16A or 25A circuit breaker <3.5 mA

Output data Nominal output voltage UN/tolerance Setting range for the output voltage Nominal output current IN -25°C- +60°C Efficiency

48VDC±1% 30-56VDC 20A(Uout=48VDC) >92%

Climatic data Operating ambient temperature Storage ambient temperature Humidity Vibration According to IEC68-2-6

Shock According to IEC 68-2-27 Pollution degree 2 Climatic category

-25 °C-+70°C -40°C -++85°C 95% at +25°C, no condensation <15Hz, amplitude±2.5m m/15 Hz-150Hz, 2.3 g, 90 min 30g in all space directions 2 (according to EN 50178) 3K3(according to EN 60721)

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7.19

CT,HALL EFFECT,LF2005-S/SP28

Bucyrus Part no: 62055586 Component designation: U1, U2, U4, U5, U11, U12, U31, U32, U51, U52

7.19.1

Description

The current transducers are put in the U and V phase of output of all the inverters and also in the U and V phase at the input of AFE’s.

7.19.2 • •

Testing Isolate the power supply by switching off the drive power contactor and locking out the main and auxiliary power supplies.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. +24V +

24 VDC

24 VDC

+ +

0V

M -

mA

-24V

•

•

• • • • •

7.19.3

-

These current transducers works on compensation current principle. The current in primary winding produces a magnetic field which is compensated by the current in compensation coil of transducer. Turns ratio is 1:5000 (at 1000A of primary current, signal current is 200mA) Connect two 24V DC power supplies in series. Connect +ve of first power supply to + terminal of CT and –ve of second power supply to – terminal of CT. Connect central point to M terminal of CT with resistance R (of 5Ω) and ammeter (Fluke 189 or equivalent) in series as shown in diagram above. Set current limit of power supplies to 100mA. Now put one insulated wire (with cross section 16 sq. mm. or more) through CT for primary current.

If the primary current is 0A then current flowing through R should be 0A Now flow the primary current 100A DC in direction same as that of marked on CT. At this time current flowing through R should be +20mA. Now flow the primary current 100A DC in opposite direction as that of marked on CT. At this time current flowing through R should be -20mA. If these values are matching along with polarity, the transducer is working properly otherwise the transducer needs to be replaced.

Replacing

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Removing • Remove IGBT modules as per proceduer mention in IGBT module replacing section.

• Also remove IGBT module plate by removing M8 x 20 (4x) using torque wrench and bit no. 13.

• Remove all control connections of CT from shield bracket by unscrewing torx screw M3 x 8 & 5mm clamp using combi head screw driver T10.

• Remove mounting of shield bracket by removing combi screw M5 x 16 using combi screw driver T25.

• Remove power cable going through CT. • Remove mounting of CT by removing combi screw M6 x 16 using combi screw driver T28.

• Remove the CT carefully Installing

• Mount CT using combi screw M6 x 16 using combi screw driver T28.

Torque 5 Nm. • Mount shield bracket near CT by using combi screw M5 x 16 using combi screw driver T25.Torque 6 Nm. • Make all control connections of CT on shield bracket by using torx screw M3 x 8 & 5mm clamp using combi head screw driver T10.Torque 1.3 Nm. • Route power cable through CT as per circuit diagram.

• Check all connections.

• By using mounting fixture mount IGBT mounting plate on cabinet by using hex screw M8 x 20 using 13 no. bit & torque wrench.Torque 25 Nm. • Mount IGBT modules as per proceduer mention in IGBT module replacing section.

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7.19.4

Drawing

7.19.5

Technical data

Electrical data Primary nominal rms current 2000A Primary current measuring range 0…±3000A Secondary nominal rms current 400mA Conversion ratio 1:5000 Supply voltage (±5%) ±15…..±24VDC Overall accuracy at primary nominal rms current , ±0.5% TA=25°C Linearity <0.1% Frequency bandwidth DC-100KHz Ambient operating temperature -40…+85°C Ambient storage temperature -40…+85°C Mass 1.5Kg

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7.20

Maintenance, Trouble-Shooting and Repairs

PCB ASSY,QPSW 2KV

Bucyrus Part no: 62055581 Component designation: U9, U10, U33

7.20.1

Description

The QPSW is a potential transformer with a high impedance seperation between low voltage and high voltage side. The QPSW drives a current proportional to the primary voltage into the burden resistance.Both voltage polarities can be measured.

Block diagram

7.20.2

Testing

Testing of DC link voltage transducers +24V 1 24 VDC

24 VDC

+ +

0V R

PT

2

-24V

4

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• • • •

• • • • •

Maintenance, Trouble-Shooting and Repairs

Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Remove all the connectors connected to the transducer to be checked.

Connect two 24V DC power supplies in series. Connect +ve of first power supply to X1-1 of PT and –ve of second power supply to terminal X1-4 of PT. Connect central point to X1-2 of PT with resistance R (of 1KΩ) in series and voltmeter (Fluke 189 or equivalent) across R . Set current limit of power supplies to 100mA. This transducer is a voltage to current converter. When the primary voltage is 2000V at x10 and x20, it gives 20 mA current.

Now give 1000VDC at x10 and x20 (+ve to x10 and –ve to x20) of PT then measured voltage across resistance R should be 10V If the polarity of 1000VDC is changed (+ve to x20 and –ve to x10) then measured voltage across resistance R should be -10V If these values are matching along with polarity, the transducer is working properly.

If not the transducer needs to be replaced.

Test of earth fault transducer

• • •

Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. To test the earth fault transducer follow the same procedure as mentioned above for the testing of DC link voltage transducer.

7.20.3

Replacing

Removing

• Disconnect all electrical & earthing connction from resister plate.

• Remove mounting of QPSW by removing combi screw M4 x 10 using Kombi screw driver.

• Remove the QPSW carefully & place it safely.

Installing

• Mount QPSW using combi screw M4 x 10 using combi screw driver.

Torque 1.9 Nm. • Make all electrical connections on QPSW as per the schematics.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

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7.20.4

Maintenance, Trouble-Shooting and Repairs

Drawing

Plate drawing

DC link Voltage & Earth fault voltage transducers

7.20.5

Technical data

Dimensions (lxbxh) Weight Operating temperature No. of channels Nominal voltage Supply voltage Burden resistor Input output ratio Accuracy at +25°C and nominal voltage

160 x 100 x 20 mm3 70g -40 to +85°C 1 2000 VDC ±24V±5% 200 Ohm to 300 Ohm 2000V/20mA ±1%

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7.21

Maintenance, Trouble-Shooting and Repairs

VOLTAGE TRANSDUCER,300V

Bucyrus Part no: 62055573 Component designation: U34, U35

7.21.1

Description

These transducers are used to measure the line voltage as well as for the synchronization with the line voltage. Following is the electrical data of the synchronizing voltage transducers.

7.21.2

Testing

+24V + +

24 VDC

+

24 VDC

0V R

R

M

-

• • •

•

-

Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Connect two 24V DC power supplies in series. Connect +ve of first power supply to + terminal and –ve of second power supply to terminal - terminal.

Connect central point M of PT with resistance R (of 1KΩ) in series and voltmeter (Fluke 189 or equivalent) across R to the –ve of first power supply. Set current limit of power supplies to 100mA. Using a variac give a voltage of 150VAC between the input terminals +HT and –HT.

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•

•

7.21.3

Maintenance, Trouble-Shooting and Repairs

The transducers have a conversion ratio of 300V/50 mA i.e for a primary input voltage of 300VAC a current of 300mA is delivered. Therefore for a primary input voltage of 150VAC current of 25mA should flow through the 1K Ohm resitance thereby giving a drop of 25V across the resistor. Ensure that 25VAC is measured on the voltmeter.

Also check the nature of voltage waveform across the resistor on a DSO. It should be sinusoidal with a frequency equal to the frequency of input voltage.

Replacing

Removing the transducer

• Disconnect all electrical & earthing connection from line transducer.

• Remove the transducer by removing combi screw M6 x 16 (2x) using combi screw driver bit T28.

Installing the transducer

• Mount transducer by using combi screw M6 x 16 with combi screw driver bit T28. Torque 6.5 Nm. • Make over all electrical connections of transducer as per the schematics.

• Make earthing connections.

• Check all connections.

7.21.4

Drawing

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Line Voltage synchronizing transducers

7.21.5

Technical data

Electrical data: VPN- Primary nominal rms voltageVP-Primary voltage measuring rangeIPN- Primary nominal rms currentRM-Measuring resistance with ±15V

ISN Secondary nominal rms current KN Conversion ratio

@±300 Vmax @±450 Vmax

VC Supply voltage (±5 %) IC Current consumption Vd RMS voltage for AC isolation test,50Hz Accuracy-Dynamic performance data XG Overall accuracy @ VPN, TA=25 °C EL Linearity IO Offset current@IP=0, TA=25 ° C IOT Thermal drift of IO -40…..+85 ° C Response time @ 90% of VPN tr General data TA Ambient operating temperature TS Ambient storage temperature N Turns ratio P Toatal primary power loss R1 Primary resistance @ TA =25 °C RS Secondary coil resistance @ TA=85 °C m Mass

300 V 0..± 450V 25 mA RMmin 50 50 50 mA 300 V/50 mA

RMmax 195 110

±15V 30+Is mA 1mn 6KV ± 0.7% <0.1% Typ Max ±0.2 mA ±0.4 ±0.8 mA 100 µS -40…..+85 °C -50…..+100°C 4000:2000 7.5W 12K Ohm 65 Ohm 850g

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7.22

Maintenance, Trouble-Shooting and Repairs

FILTER,74V,8A,40%

Bucyrus Part no: 62055574 Component designation: Z1

7.22.1

Description

The filter is used before the 110VDC supply to SIBAS to ensure that a pure DC is fed to the SIBAS. Circuit Diagram

+E1

+A1

+E2

+A2 +

+

-A3

-E3

+ + Channel 2 Channel 1

+ Channel 1 + +Cext Channel 2 -

SI T 0,5 A

Input

+ + -

Channel 1 Channel 2

7.22.2 • • • •

+Cext

Output

-Channel 2 +Channel +1 +Cext.

Testing

Isolate the power supply by switching off the Drive power contactor.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Check the output voltage of filter on a DSO. The output waveform should be a pure DC without any noise, spikes or ripples and should be equal to 110VDC.

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7.22.3

Maintenance, Trouble-Shooting and Repairs

Replacing

Removing • Remove terminals (6x) from +E1, +E2,-E3 and +A2, +A1, -A3 by removing M6 nuts using 10 no. bit and torque wrench • Remove base mounting M6 combi screws (4x) using combi screw driver T28.

• Take it out and place safely.

Installing • Place filter at exact position and align the holes • Mount base mounting M6 combi screws (4x) using T28 and give torque of 10 Nm. • Restore wires to +E1, +E2,-E3 and +A2, +A1, -A3 as per the schematics by mounting M6 nuts using 10 no. spanner and hand tighten it

7.22.4

Drawing

7.22.5

Technical data

Nominal voltage channel1, channel2 Nominal current channel2 Nominal current at switch on command channel1 Nominal voltage drop Ambient temperature Storage temperature Pollution level Weight Dimensions(LXBXH)

110VDC±40% 5A ≤0.5A ≤3VDC -40….+85°C -55….+85°C 3 3.5Kg 268X110X70 mm

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7.23

Maintenance, Trouble-Shooting and Repairs

PRESSURE TRANSDUCER

Bucyrus Part no: 62055589 Component designation: B2

7.23.1

Description

The pressure transducer measures the pressure of coolant flowing in the cooling system. It gives a current signal depending on the pressure of the coolant.

7.23.2 • • • • • • • • • •

Testing

Isolate the power supply by switching off the Drive power contactor.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Check the value of pressure when the pump is in off state When the pump is off that time pressure value will be 0 bar When the pump is on then in normal conditions pressure value will be in range 0.7 to 1.7 bar When the pump is on & pressure value is not in limits then check coolant level & any leakages in cooling system.

If there are no leakages and coolant level is proper then check error memory of SIBAS for errors related to value of pressure of coolant Remove the IGBT module in front of the pressure transducer Remove the connector of pressure transducer and check wiring If error present with other normal conditions, then replace the pressure sensor

7.23.3

Replacing

Removing • Drain all the coolant from cooling system. Ref chapter 6.7 In Operation & Maintenance manual.

• Remove coolant from cooling system as per procedure given.

• Remove the IGBT module & moduel plate in front of the pressure transducer as per procedure mention in IGBT module & CT replacing section.

• Remove the connector of pressure transducer.

• Remove transducer mounted on central aluminium pipe in DCC using 13 no open end bit.

Installing • After removing old transducer, mount the new transducer on aluminium pipe 3, while mounting apply loctite 572 properly only on threads. st • Apply torque 15 Nm in 1 step & 25 Nm in 2nd step.

• Restore the connector of pressure transducer properly.

• If connector is damaged then replace the connector also.

• Ensure that mounting of transducer is leak free • Fill the coolant in cooling as per given procedure.

• Restore the IGBT module & module plate in front of transducer as per procedure mention in section 18.3.

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7.23.4

Drawing

7.23.5

Technical data Technical data

Measuring range

0 to 6 bar

Supply voltage

24 V DC (12 to 30 V)

Output signal

4 to 20 mA

Accuracy @+25°C

±0.3% FS typ

Thread

1/4“

Operating temperature

-40…..+125°C

Media temperature

-40…..+125°C

Protection

IP65

Humidity

max 95% relative

Vibration

40g (20…..2000Hz)

Shock

100g/11ms Connector assignment

Pin 1

0V

Pin 2

+24 V

Ground

Ground

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7.24

Maintenance, Trouble-Shooting and Repairs

RES,WW,60R,1000W,5%

Bucyrus Part no: 62055583 Component designation: R31.1, R31.2

7.24.1

Description

The pre-charging resistor in series with the contact of pre-charging contactor along with the DC link capacitor forms the pre-charging circuit.

7.24.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the Main and Auxiliary power supplies.

• Using a voltmeter, check that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Visually inspect both the resistors by checking it for cracks or deformation. If there is no visual defect disconnect the resistor terminals.

• Using an ohmmeter measure the value of resistance which should be 57 Ω to 63 Ω.

• If the resistor presents mechanical alterations or the measured value is different than above then the resistor/resistors needs to be replaced.

7.24.3

Replacing

Removing the resistor

• Disconnect all electrical connction from resistor.

• Take out resistor from clamps by removing hex nut M5 using 8 no. bit and torque wrench.

• Remove resistor clamps on both sides by removing hex screw M8 x 12 using 13 no. bit and torque wrench.

Installing the resistor

• Mount resistor clamps on plate both sides by using hex screw M8 x 12 with 13 no. bit and torque wrench. Torque 15 Nm. • Mount resistor on clamps by using hex nut M5 with 8 no. bit and torque wrench. Torque 3.7 Nm. Use special clinger washer between metal clamp & resistor.

• For details refer assembly drawing for precharging plate assembly.

• Make over all electrical connections of resistor as per circuit diagram.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

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7.24.4

Maintenance, Trouble-Shooting and Repairs

Drawing

Precharging resistors

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7.24.5

Maintenance, Trouble-Shooting and Repairs

Technical data

Resistance Power rating Weight

7.25

60 Ohm 1000W 1200 g

RES,WW,33K,300W,5%

Bucyrus Part no: 62055584 Component designation: R42

7.25.1

Description

This resistor is used in earth fault detection circuit to creat voltage divider circuit across DC link voltage.

7.25.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the Main and Auxiliary power supplies.

• Using a voltmeter, check that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Visually inspect both the resistors by checking it for cracks or deformation. If there is no visual defect disconnect the resistor terminals.

• Using an ohmmeter measure the value of resistance R41 which should be 99KΩ (±5%) and that of R42 should be 33KΩ (±5%).

• If the resistors presents mechanical alterations or the measured value is different than above then the resistor/resistors needs to be replaced.

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7.25.3

Maintenance, Trouble-Shooting and Repairs

Replacing

Removing the resistor

• Disconnect all electrical connction from resistor.

• Take out resistor from ceramic guide clamps by removing hex nut M4 using 7 no. bit and torque wrench.

• Remove cramic guide clamps on both sides by removing hex screw M6 x 16 using 10 no. bit and torque wrench.

Installing the resistor

• Mount cramic guide clamps on plate both sides by using hex screw M6 x 16 with 10 no. bit and torque wrench. Torque 10 Nm. • Mount resistor on clamps by using hex nut M4 with 7 no. bit and torque wrench. Torque 1.9 Nm. Use ceramic & special clinger washer between ceramic clamp & resistor.

• For details refer assembly drawing for precharging plate assembly.

• Make over all electrical connections of resistor as per circuit diagram.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

7.25.4

Drawing

Earth fault resistor 33K R42

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7.25.5

Maintenance, Trouble-Shooting and Repairs

Technical data

Resistance Power rating at 40 °C Limiting voltage

33K±5% 300W 2500V

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7.26

Maintenance, Trouble-Shooting and Repairs

RES,WW,99K,300W,5%

Bucyrus Part no: 62055585 Component designation: R41

7.26.1

Description

This resistor is used in earth fault detection circuit to creat voltage divider circuit across DC link voltage.

7.26.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the Main and Auxiliary power supplies.

• Using a voltmeter, check that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Visually inspect both the resistors by checking it for cracks or deformation. If there is no visual defect disconnect the resistor terminals.

• Using an ohmmeter measure the value of resistance R41 which should be 99KΩ (±5%) and that of R42 should be 33KΩ (±5%).

• If the resistors presents mechanical alterations or the measured value is different than above then the resistor/resistors needs to be replaced.

7.26.3

Replacing

Removing the resistor

• Disconnect all electrical connction from resistor.

• Take out resistor from ceramic guide clamps by removing hex nut M4 using 7 no. bit and torque wrench.

• Remove cramic guide clamps on both sides by removing hex screw M6 x 16 using 10 no. bit and torque wrench.

Installing the resistor

• Mount cramic guide clamps on plate both sides by using hex screw M6 x 16 with 10 no. bit and torque wrench. Torque 10 Nm. • Mount resistor on clamps by using hex nut M4 with 7 no. bit and torque wrench. Torque 1.9 Nm. Use ceramic & special clinger washer between ceramic clamp & resistor.

• For details refer assembly drawing for precharging plate assembly.

• Make over all electrical connections of resistor as per circuit diagram.

• Tie all cables using cable tie to LKC socket properly.

• Check all connections.

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7.26.4

Maintenance, Trouble-Shooting and Repairs

Drawing

Earth fault resistor 99K R41

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Maintenance, Trouble-Shooting and Repairs

Technical data

Resistance Power rating at 40°C Limiting voltage

99K±5% 300W 2500V

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7.27

Maintenance, Trouble-Shooting and Repairs

CAP,MKV,0.22 Uf,5000V

Bucyrus Part no: 62055577 Component designation: C75

7.27.1

Description

This capacitor is used in earth fault circuit and is connected across the earth fault voltage resistor and voltage across this capacitor is measured using DC voltage transducer.

7.27.2 • • • • • •

Testing

Isolate the power supply by switching off the Drive power contactor and lock out the main power supply and auxiliary power supply.

Using a voltmeter check the DC bus to make sure that all capacitors have discharged. Use adequate meter so as to measure a voltage of 2000VDC. Visually inspect the capacitor by checking it for cracks, deformation or any other mechanical damage.

If there is nothing found in visual check remove all the cables connected to the capacitor terminals.

Measure the capacitance of the capacitor. The value measured for the capacitor should be 0.22 µF(±10%) .

If any deviation is observed in the capacitance measurement of the capacitor replace the capacitor replaces the capacitor.

7.27.3

Replacing

Removing the capacitor

• Disconnect all electrical connction from capacitor.

• Remove clamps of capacitor by removing combi screw M5 x 12 using combi screw driver T25.

• Take out capacitor safely .

Installing the capacitor

• Mount capacitor using clamps on isolator by using M5 x 12 with combi screw driver T25. Torque 3.7 Nm. • Make over all electrical connections of capacitor.

• Check all connections.

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7.27.4

Maintenance, Trouble-Shooting and Repairs

Drawing

Grounding capacitor C75

7.27.5

Technical data

Electrical data: 0.22µF,1400 VAC CN= 0.22µF ± 10% UN=AC 1400 V Imax=18A Lself=190nH Rs=7.6 mOhm Climatic data: Tmin=-25°C Tmax=+85°C Humidity <95% Storage temperature= -55 to +85 °C

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7.28

Maintenance, Trouble-Shooting and Repairs

AUX. CONTACTORS FOR TRANSFER SWITCH

Bucyrus Part no: 62006903 Component designation: K15, K16

7.28.1

Description

The contactors K15 & K16 are used in dig/propel mode selection circuit. In this circuit, K15 is used for dig mode & K16 for propel mode. The contactors are driven by PLC output channels of module D18.

7.28.2

Testing

• Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Visual check of the main contacts for damage (charring or melting) • Check magnetic components (e.g., coil) and insulating parts (e.g., components of plastic) for dirt/dust and damage.

• Check the disconnecting switch for smooth action (turn switch off/on by hand).

• Give externally 24VDC to the coil of the contactor. The contactor should pick up.

Check the contact resistance between the main contacts and the auxiliary contacts. It should be ideally 0 Ohms.

• If the above conditions are not satisfied replace the contactor.

7.28.3

Drawing

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7.28.4

Maintenance, Trouble-Shooting and Repairs

Technical data

General details: Number of poles

2

Item designation / according to DIN 40719 extendable after IEC 204-2 / according to IEC 750

K

Item designation / according to DIN EN 61346-2

Q

Protection class IP

IP00

Ambient temperature •

during the operating phase

55 °C…-25 °C

Control circuit: Type of voltage

DC

Control supply voltage •

at DC / rated value / minimum

•

at DC / rated value / maximum

24 V 24 V

Supply voltage frequency / for auxiliary and control current circuit / rated value •

minimum

•

maximum

0 Hz 0 Hz

Main circuit: Number of NO contacts / for main contacts

2

Number of NC contacts / for main contacts

0

Operating current •

at DC-3 / at DC-5 / at 440 V / rated value

•

at DC-3 / at DC-5 / at 220 V / rated value

•

at DC-3 / at DC-5 / at 600 V / rated value

29 A 32 A 21 A

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•

at DC-3 / at DC-5 / at 750 V / rated value

Maintenance, Trouble-Shooting and Repairs

7.5 A

Service power •

at DC-3 / at DC-5 / at 110 V / rated value

•

at DC-3 / at DC-5 / at 220 V / rated value

•

at DC-3 / at DC-5 / at 440 V / rated value

•

at DC-3 / at DC-5 / at 600 V / rated value

•

at DC-3 / at DC-5 / at 750 V / rated value

2.5 kW 5 kW 9 kW 9 kW 4 kW

Auxiliary circuit: Identification number and letter for switching elements

21

number of NO contacts / for auxiliary contact

2

number of NC contacts / for auxiliary contact

1

Connection type: Design of the electrical connection / for main current circuit

screw-type terminals

design of the electrical connection / for auxiliary and screw-type terminals control current circuit Mechanical design: Type of fixing/fixation

screw and snap-on mounting onto 35 mm standard mounting rail according to DIN EN 50022

Type of fixing/fixation / Series installation

Yes

Width

82 mm

Height

115 mm

Depth

145 mm

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7.29

Maintenance, Trouble-Shooting and Repairs

AUX. CONTACTOR, 120VAC

Bucyrus Part no: 62056670 Component designation: K5, K6, K7, K8, K9

7.29.1

Description

3RH1122-2AK20 is an auxiliary contactor with 120 VAC coil used in control circuit.

7.29.2

Testing

• Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Check magnetic components (e.g., coil) and insulating parts (e.g., components of plastic) for dirt/dust and damage.

• Check the disconnecting switch for smooth action (turn switch off/on by hand).

• Give externally 120VAC to the coil of the contactor. The contactor should pick up. Check the contact resistance between auxiliary contacts. It should be ideally 0 Ohms.

• If the above conditions are not satisfied replace the contactor.

7.29.3

Drawing

7.29.4

Technical data

General details: Size of the contactor

S00

Item designation •

according to DIN EN 61346-2

•

according to DIN 40719 extendable after IEC 204-2 / according to IEC 750

K K

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Protection class IP

IP20

Ambient temperature •

during the operating phase

-25 °C…60 °C

Control circuit: Type of voltage

AC

Control supply voltage •

at 50 Hz / at AC / rated value / minimum

•

at 50 Hz / at AC / rated value / maximum

•

at 60 Hz / at AC / rated value / minimum

•

at 60 Hz / at AC / rated value / maximum

120 V 120 V 120 V 120 V

Supply voltage frequency / for auxiliary and control current circuit / rated value •

minimum

•

maximum

50 Hz 60 Hz

Operating current •

at AC-14 / at AC-15 / at 230 V / rated value

6A

Auxiliary circuit: Identification number and letter for switching elements

22 E

number of NO contacts / for auxiliary contact

2

•

delayed switching

•

asynchronous switching

number of NC contacts / for auxiliary contact •

delayed switching

•

asynchronous switching

0 0 2 0 0

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number of change-over switches / for auxiliary contact

0

design of the electrical connection •

for auxiliary and control current circuit

Cage Clamp terminals

Mechanical design: Type of fixing/fixation

screw and snap-on mounting

Depth

73 mm

Height

60 mm

Width

45 mm

7.30

AUX. CONTACTOR, 24VDC

Bucyrus Part no: 62056671 Component designation: K10, K11, K12, K13, K14, K51, K52, K53, K54

7.30.1

Description

3RH1122-2KB40-0LA0 is a auxiliary contactor with 24VDC coil voltage & is used in auxiliary control circuit.

7.30.2

Testing

• Isolate the power supply by switching off the drive power contactor and lock out the main power supply and Auxiliary power supply.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Check magnetic components (e.g., coil) and insulating parts (e.g., components of plastic) for dirt/dust and damage.

• Check the disconnecting switch for smooth action (turn switch off/on by hand).

• Give externally 24VDC to the coil of the contactor. The contactor should pick up.

Check the contact resistance between the main contacts and the auxiliary contacts. It should be ideally 0 Ohms.

• If the above conditions are not satisfied replace the contactor.

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7.30.3

Drawing

7.30.4

Technical data

General details: Size of the contactor

S00

Item designation •

according to DIN EN 61346-2

•

according to DIN 40719 extendable after IEC 204-2 / according to IEC 750

Protection class IP

K K

IP20

Ambient temperature •

during the operating phase

-25 °C…60 °C

Control circuit:

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Type of voltage

Maintenance, Trouble-Shooting and Repairs

DC

Control supply voltage •

at DC / rated value / minimum

•

at DC / rated value / maximum

Design of the surge suppressor

24 V 24 V with varistor

Operating current •

at AC-14 / at AC-15 / at 230 V / rated value

6A

Auxiliary circuit: Identification number and letter for switching elements

22 E

number of NO contacts / for auxiliary contact

2

•

delayed switching

•

asynchronous switching

number of NC contacts / for auxiliary contact •

delayed switching

•

asynchronous switching

number of change-over switches / for auxiliary contact

0 0 2 0 0 0

Connection type: •

for auxiliary and control current circuit

Cage Clamp terminals

Mechanical design: Type of fixing/fixation

screw and snap-on mounting

Depth

73 mm

Height

60 mm

Width

45 mm

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7.31

Maintenance, Trouble-Shooting and Repairs

SIBAS,6FH4808-1A,182MAC

Bucyrus Part no: 62059286 Component designation: A100

7.31.1

Description

SIBAS 32S is the control system for the power converter drives. It controls inverters and AFEs. For description of individual cards in details please refer to separate equipment manual for SIBAS.

7.31.2 • • • •

Testing

In healthy condition check whether Red & yellow both LEDs on following cards are bright (L027, L067, L107, L115, L139) Check whether power supplies in rack are working and are in healthy condition by measuring voltage output at their test points provided on front panel.

See the error memory from SIBAS. In case of fault in Sibas rack refer Sibas fault manual.

7.31.3

Replacing

Removing from cabinet

•

Open the side cover from DCC compartment using keys provided with panel.

CAUTION SIBAS is sensitive to Electrostatic Discharge. After mounting SIBAS in cabinet no welding should be done on machine.

•

• • •

Detach connectors gently C163, G035-X2, G043-X2, G059-X2, G067X2, G075-X2, G099-X2, G107-X2, L035-X3, L043-X3, L075-X3, L091-X3, L123-X3, L035-X4, L043-X4, L075-X4, L091-X4, L123-X4, L139-X3, L139-X5, L155-X3, L163-X3, G115-X2, G123-X2, G131X2, G139-X2, G147-X2 by removing M 2.5 x 35 screw using screw driver (plain 912) and secure hanging upper connectors above SIBAS rack Remove M6x20 mounting bolts (16X) from SIBAS housing, use 10 no. socket bit and torque wrench Remove SIBAS assembly from cabinet Removed SIBAS assembly must be covered with ESD bags

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CAUTION Weight of a SIBAS is 30Kg approximately.

Mounting screws

Installing into cabinet

• • •

Place SIBAS assembly in the housing provided in the cabinet and align the mounting holes Mount M6x20 bolts with HT spring and plane washers with 10 no. socket bit and torque wrench. Tighten the bolt with a torque of 6.5 Nm. Connect connectors gently C163, G035-X2, G043-X2, G059-X2, G067X2, G075-X2, G099-X2, G107-X2, L035-X3, L043-X3, L075-X3, L091-X3, L123-X3, L035-X4, L043-X4, L075-X4, L091-X4, L123-X4, L139-X3, L139-X5, L155-X3, L163-X3, G115-X2, G123-X2, G131X2, G139-X2, G147-X2 by tighting M2.5 x 35 screw using screw driver (plain 912) and secure hanging upper connectors above SIBAS rack

7.31.4

Technical data

For detailed data please refer to separate equipment manual for SIBAS. This manual gives only short descriptions about individual cards.

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7.32

Maintenance, Trouble-Shooting and Repairs

HEATER,800W

Bucyrus Part no: 62039626 Component designation: E09

7.32.1

Description

The PLC section of the DCC contains the simatic S7-400 modules whose operating temperature is from 0-60 °C. Since the specification of DCC asks for a lower operating temperature of -25°C, an electric heater is provided to cope up with the problem.

The temperature at which the electric heater should start its operation can be set using the knob provided on the heater and is set at 5°C.Following are some of the features of the heater.

• • •

•

7.32.2

Anodized aluminum housing Thermostat adjustable from 0 °F to 100 °F ( -18 °C to 38 °C) Fan draws cool air from the bottom of the enclosure and passes this air across the thermostat and heating elements being released into enclosure cavity, before the heated air is discharged through the top of the heater unit Ball bearing fan runs continuously for even temperature distribution

Testing

• Isolate the power supply by switching off the drive power contactor and lock out the main and auxiliary power supplies.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Ensure that the MCB Q34 is not tripped.

• Isolate the wires from heater’s terminal block. Measure with an ohmmeter the continuity of phase to a neutral circuit, L and N in terminal block (the thermostat should be adjusted to minimum less than ambient temperature).

• If there is no problem with the circuit continuity, proceed to make a visual inspection of the heater mechanical assembly.

• If there is no problem of circuit continuity and no mechanical damage, the heater should be tested with an auxiliary 120 VAC power supply (keep the thermostat in minimum less than ambient temp. position). Hot air should be felt at top of the heater.

• If the heater does not pass any of the above tests then it should be replaced.

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7.32.3

Maintenance, Trouble-Shooting and Repairs

Replacing

Removing

• Remove all electrical connections safely from heater terminal.

• Remove earthing connection by removing hex nut M8 x 16, HT Spring washer M8, Plain washer M8 using 13 no. bit & torque wrench.

• Remove heater by removing combi screw M5 x 16 using combis screw driver T-25.

Installing

• Mount heater by using combi screw M5 x 16 with combi screw driver T25.

• Apply torque 3.7 Nm, mark torque points with marker pen.

• Make all electrical connections safely with heater terminal.

• Make earthing connection by using hex nut M8 x 16, HT Spring washer M8, plain washer M8 using 13 no. bit & torque wrench.

• Apply torque 15 Nm, mark torque points with marker pen.

Earthing connection

Mounting of Heater

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7.32.4

Drawing

7.32.5

Technical data

Input supply voltage: Input supply frequency: Input current: Watts: Weight in Kg:

115VAC 50/60Hz 6.5A 800W 2.72 Kg

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7.33

Maintenance, Trouble-Shooting and Repairs

POWER SUPPLY (QUINT-PS-100240AC/24DC/40A)

Bucyrus Part no: 62056738 Component designation: G01

7.33.1

Description

The power supply is used to provide 24VDC voltage required for the simatic I/O’s, to operate the main and auxiliary contactors, to operate the transfer switch.

Circuit diagram

7.33.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the main and auxiliary power supplies.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Remove the input and output cables from the power supplies.

• Check continuity between the L and N on the input side and between + and – on the output side of both the power supplies. Continuity should not be observed.

• If above test is successful the power supplies should be tested individually with an input voltage of 120VAC. • Check the output voltage in each case. The output voltage should be 24VDC (+/-1%).

• In case any deviation is observed in the output voltage, adjust the output voltage to 24VDC by adjusting the POT whose location on the power supply is shown at position 5 in the figure below.

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• Connect all the cables as per the DCC schematic.

• Check the continuity between the output terminals + and - of the power supply.

Continuity should not be observed.

• If the output terminals shows short then check for the wiring.

• If output is not adjustable to 24VDC the power supply is faulty and needs to be replaced.

• If nothing solves the problem, replace the power supply.

7.33.3

Technical data

Input data:

Nominal input voltage 110-240VAC Input voltage range 85-264 VAC 120-350 VDC Frequency 45-65Hz 0Hz Current consumption 11A (120VAC)/4.5A(230VAC) Switch on time after applying themains voltage <1s Transient surge protector Varistor Recommended backup fuse 16A or 25A circuit breaker Discharge current for PE <3.5mA Output data:

Nominal output voltage Setting range for the output voltage Nominal output current Efficiency

24VDC±1% 22.5-29.5 VDC 40A >92%

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7.34

Maintenance, Trouble-Shooting and Repairs

SIMATIC S7-400, UR1 RACK WITH 18 SLOTS

Bucyrus Part no: 62056680 Component designation: A114

7.34.1

Description

The UR1 rack is used for assembling both central rack and expansion rack.

The UR1 rack has both I/O bus and communication bus.

Following modules can be used in the UR1 racks: When the S7-400 is used as a central rack all the S7-400 modules can be used with the exception of receive IM’s.

When the UR1 rack is used as an expansion rack all the S7-400 modules except the CPU and send IM’s can be used.

7.34.2

Drawing

7.34.3

Technical data

Number of single width slots Dimensions(WXHXD in mm) Weight in Kg Buses

18 482.5X290X27.5 3 I/O bus and communication bus

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7.35

Maintenance, Trouble-Shooting and Repairs

DIGITAL I/P MODULE (120VAC, 32 CH)

Bucyrus Part no: 62056682 Component designation: A114-D15

7.35.1

Description

Digital input modules convert the levels of the external digital signals transmitted from the process to the internal S7-400 signal levels. The modules are suitable for the connection of switches and 2-wire BERO proximity switches.

7.35.2

Drawing

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7.35.3

Technical data

7.36

DIGITAL O/P MODULE (120VAC, 32 CH)

Bucyrus Part no: 62056684 Component designation: A114-D16

7.36.1

Description

The SM422, DO 16X120/230VAC is a digital output module with the following characteristics • 16 outputs isolated in four groups of four channels.

• Nominal output voltage:120/230VAC. The status LED indicates the system state even if the front connector is not plugged in.

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7.36.2

Maintenance, Trouble-Shooting and Repairs

Drawing

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7.36.3

Maintenance, Trouble-Shooting and Repairs

Technical data

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7.37

Maintenance, Trouble-Shooting and Repairs

DIGITAL I/P MODULE (24V DC 32 CH)

Bucyrus Part no: 62056681 Component designation: A114-D17, D21

7.37.1

Description

The SM 421; DI 32 x 24 VDC is a digital input module with the following characteristics: • 32 inputs, isolated in a group of 32, that is, all inputs are connected to a common ground.

• Nominal load voltage: 24 VDC • Suitable for switches and 2-wire proximity switches (BEROs, IEC1131 Type 2).

7.37.2

Technical data

SIMATIC S7-400, SM 421 DIGITAL INPUT MODULE, OPTIC. ISOLATED, 32 DI, 24V DC Current consumption from backplane bus DC 5 V, max.

20 mA

Current consumption/power loss Power loss, max.

6W

Digital inputs Number of digital inputs

32

Number of simultanneously controllable inputs [nicht versorgt: TAK_ABP289_001_000] Number of simultaneously controllable inputs, up to 40 °C

32

Number of simultaneously controllable inputs, up to 60 °C

32

Input voltage Rated value, DC

24 V

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for signal "0"

-30 to +5 V DC

for signal "1"

13 to 30 V DC

Input current for signal "0", max. (permissible quiescent current)

1.3 mA

for signal "1", typ.

7 mA

Input delay (for rated value of input voltage) for standard inputs at " to "1", min.

1.2 ms

at "0" to "1", max.

4.8 ms

Cable length cable length, shielded, max.

1000 m

Cable length unshielded, max.

600 m

Encoder Connectable encoders 2-wire BEROS

Yes

permissible quiescent current (2-wire BEROS), max.

1.5 mA

Isolation Isolation checked with

500 VDC

Isolation Galvanic isolation, digital inputs between the channels, in groups of

32

between the channels and the backplane bus

Yes

Dimensions Dimensions Width

25 mm

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Height

290 mm

Depth

210 mm

Weights Weight, approx.

500 g

Status

01/12/2009

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7.38

Maintenance, Trouble-Shooting and Repairs

DIGITAL O/P MODULE (24V DC 32 CH)

Bucyrus Part no: 62056683 Component designation: A114-D18

7.38.1

Description

The SM 422; DO 32 x 24 VDC/0.5 A is a digital output module with the following characteristics • • •

7.38.2

32 outputs, isolated in a group of 32, that is, all outputs are connected to a common ground Output current 0.5 A Nominal load voltage: 24 VDC

Technical data

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7.39

Maintenance, Trouble-Shooting and Repairs

SIMATIC S7-400, ANALOG INPUT SM 431, NON-ISOLATED 16 AI

Bucyrus Part no: 62056685 Component designation: A114-D20

7.39.1

Description

The SM 431; AI 16 x 13 Bit has the following characteristics: • • •

7.39.2

16 inputs for current/voltage measurement with 13 bit resolution Non-isolated (no isolation between bus section and analog section) Permissible common-mode voltage 2 VDC/VAC

Drawing

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Technical data

Adapting to Different Sensors To adapt the analog input module to different sensors, follow the steps outlined below: 1. Insert the measuring range module into the module. One measuring range module adapts two inputs channels to a sensor type.

2. Set the relevant measuring range for the channels of the module when you set the module parameters.

Using the Measuring Range Modules With the measuring range modules supplied, you can adapt two successive input channels or one resistance channel to one sensor type.

The following table shows the assignments of individual measuring range module positions to the relevant sensor types.

Position

Sensor Types

A

Voltage sensors; 1 V

B

Voltage sensors; 1 to 5 V, 10 V

C

Current sensors;20 mA, 4 to 20 mA 4-wire transducer with current output

D

2-wire transducer; 4 to 20 mA To apply current to these transducers, you must connect 24 V to the front connector terminals L+ and M.

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Maintenance, Trouble-Shooting and Repairs

SIMATIC S7-400, ANALOG OUPUT SM 432, NON-ISOLATED 08 AO

Bucyrus Part no: 62056686 Component designation: A114-D19

7.40.1

Description

The SM 432; AO 8 x 13 Bits is an analog input module with the following characteristics • • • • • • •

7.40.2

8 outputs Resolution 13 bits Output ranges for voltage Output ranges for current Supply voltage: 24 VDC Isolated Permissible common-mode voltage 3 VDC

Drawing

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Technical data

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SIMATIC S7-400, PS 407 POWER SUPPLY, 10A

Bucyrus Part no: 62048867 Component designation: A114-G11

7.41.1

Description

The PS 407 10 A power supply module is designed for connecting to either an AC line voltage of 85 to 264 VAC or a DC line voltage of 88 to 300 VDC and supplies 5 VDC / 10 A and 24 VDC /1 A on the secondary side.

•

7.41.2

The power supply module delivers a making current in accordance with NAMUR.

Drawing

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Technical data

Backup Battery The PS 407 10 A contains a battery compartment for two batteries. If you use two batteries and set the switch to 2BATT, the PS 407 10 A defines one of the batteries as the backup battery. This assignment remains in force until the battery is empty.

When the backup battery is completely discharged, the system switches to the reserve battery which is then in turn used as the backup battery for the duration of its life. The status “backup battery” is also stored in the event of a power failure.

Note on FM Approval The PS 407 10 A meets the requirements for temperature class T4 at 60°C ambient temperature.

Low-Voltage Directive The PS 407 10 A meets the requirements of the EU directive 73/23/EEC “LowVoltage Directive”. Adherence to this EU directive was tested in accordance with IEC 1131-2.

Line Voltage Interference The PS 407 10 A meets the requirements of the following standards with regard to line voltage interference: Harmonic currents: EN 61000-3-2 Reverse voltage transfer ratio and flickering EN 61000-3-2

Polarity Reversal of L+ and L– The polarity reversal of L+ and L– with supply voltages of between 88 VDC and 300 VDC has no effect on the function of the power supply.

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SIMATIC S7-400, CPU 416-2

Bucyrus Part no: 62048127 Component designation: A114-D13

7.42.1

Description

The CPU has two DP ports. The CPU is the master controller of the system and interacts with the other remote nodes, SIBAS ZR (central processor) and the HMI. 7.42.2

Drawing

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Technical data

Mode Selector Switch You can select the operating mode of the CPU using the mode selector switch.

The mode selector is a key switch with three settings. You can use different protection levels and restrict program changes or startup possibilities (transition from STOP to RUN) to specific personnel.

Receptacle for memory cards You can insert memory cards into this receptacle.

There are two types of memory cards: •

RAM cards With the RAM card, you can expand the load memory of a CPU.

•

Flash cards With the Flash card, you can store your user program and your data safe from power failures (even without a backup battery). You can program the Flash card either in the programming device or in the CPU. The Flash card also expands the load memory of the CPU.

Multipoint Interface (MPI) You can connect the following devices, for example, to the multipoint interface: • • •

Programming devices Operator interface devices Further S7-400 or S7-300 programmable controllers.

Use bus connectors with slanted outgoing cables.

You can also use the MPI interface as a PROFIBUS-DP interface. For this purpose you can reconfigure the MPI interface under STEP 7 in the SIMATIC manager.

PROFIBUS-DP Interface You can connect the distributed I/O, programming devices/operator panels, and other DP master stations to the PROFIBUS-DP interface.

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Maintenance, Trouble-Shooting and Repairs

SIMATIC NET, CP 443-1 COMM PROCESSOR FOR ETHERNET CONNECTION

Bucyrus Part no: 62048867 Component designation: A114-D14

7.43.1

Description

This communication processor module enables UR1 rack to communicate with its all RIOs on profibus. Also it has got built in ethernet hub with four slots for ethernet connection.

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Technical data

Baud rate

10/100 Mbit/s Autosensing

Interfaces · 10BaseT, 100BaseTX

4x RJ45

Supply voltage

DC +5 V (+/- 5%) from the back plane bus

Power input From back plane bus

max. 1,8 A

Power dissipation

7.25 W

Permissible environment conditions · Operating temperature

0 °C bis +60 °C

· Transport-storage temperature

-40 °C bis +70 °C

· Relative humidity

max. 95% at +25 °C

Constructional structure · Dimensions (B x H x T) in mm

25 x 290 x 217

· Weight

approx 750 g

Project software

· STEP 7 V5.3 + SP1*

Memory capacity · Flash Memory File-System

32 MByte

· RAM

32 MByte, additionally 512kbyte buffered over central buffer battery

PG/OP-communication · No. of PG connections

max. 2

· No. of OP connections

max. 30

S7-communication · No. connected

max. 128

S5-compatible communication (SEND/RECEIVE) · Sum of all TCP/UDP connections operating at the same time

max. 64

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- ISO or TCP/IP

max. 8 kByte

- UDP

max. 2 kByte

- E-Mail

max. 2 kByte

PROFINET- IO-Controller · No. of operable IO-Devices

max. 125

· No. of external IO-Strands in one centralrack

max. 4

· Size of the entire IO data areas - IO-input area

max. 4 KByte

- IO-output area

max. 4 KByte

· Size of the I/O data areas per attached IO device - IO-input area

max. 244 Byte

- IO-output area

max. 244 Byte

FTP-communication · No. of Client-connected

max. 20

· No. of Server-connected

max. 10

HTTP-communication · No. of Server-connected

max. 4

Multiple protocol operations · Sum of all the same time operable max. 128 connections

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Maintenance, Trouble-Shooting and Repairs

CAN DP COUPLER

Bucyrus Part no: 62059220 Component designation: A120

7.44.1

Description

The DP/CAN coupler from system Helmholz allows connecting any CAN stations to the Profibus DP. The DP/CAN coupler must be parametrized as a profibus station in the Hardware configurator. The necessary GSD files are supplied with the device. The profibus side is configured as a DP slave.The interfaces meet EN 50170 and are electrically isolated.The baud rate 9.6 Kbaud to 12Mbaud is detected automatically. The maximum volume of input and output information is 320 bytes. The CAN-open side is configured as an independent master that can be controlled via the profibus.This allows upto 15 CAN-open slave modules to be operated in one CAN-open network.

All parametrized modules are detected, started up and monitored for theiroperating status by the CAN-open master. Alternatively the DP/CAN coupler can also be configured in layer 2 mode.

7.44.2 • • • • • • • •

Testing Isolate the power supply by switching off the drive power contactor.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. If coupler is not configured properly then green LED on coupler do not glow continuously.

If there is any profibus problems then red LED on coupler glows.

When coupler receives the telegram from the SIBAS then yellow LED on coupler blinks which shows the CAN bus is healthy.

Check communication error with PLC in error memory of the SIBAS. Also check the configuration errors of coupler in PLC software.

If communication is not working even with proper configuration then replace the module

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Glows green continuously if config ok

Blinks yellow if telegram received from SIBAS

Glows red if profibus fault occurs

7.44.3

Drawing

Picture

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Technical data

DIP switches: The 8-switch DIP switch on the housing frontis used for setting the profibus address of the device and the CAN operating mode.

The switches are counted from bottom to top.

Switch 8 7 6 5 4 3 2 1

Function Mode

Profibus address

ON=CANopen 26 25 24 23 22 21 20

OFF= Layer 2 +64 +32 +16 +8 +4 +2 +1

Dimensions

114 x 18 x 108 mm (LxWxH)

Weight Approx.

120 g

CAN interface Type:

ISO/DIN 11898-2, CAN high speed physical layer

Transmission rate:

10kbps to 1Mbps

Protocol:

CAN open master CAN 2.0A(11 bit)

Pin:

3 way screw type terminal.

Profibus DP interface Type:

Profibus DPto EN50 170

Transmission rate:

19.2 kbps to 12 Mbps

Pin:

SUB D-connector, 9-Way

Power supply: Voltage:

+24VDC

Current consumption:

180 mA(type)

Permissible ambient conditions:

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Operating temperature: Storage temperature: Degree of protection:

0 °C …….. 60 °C -25°C…….75°C IP 20

Maintenance-free ( No battery , rechargeable or non-rechargeable)

7.45

SIMATIC PANEL PC 677B

Bucyrus Part no: 62059287 for Computer, 62059288 for Touch screen, 62059289 for Remote kit Component designation: A103, A104, A105

7.45.1

Description

The key features of the Panel PC 677 B are as follows: • Color display with backlighting: – 12'' TFT technology with 800 x 600 resolutions – 15'' TFT technology with 1024 x 768 resolutions • Membrane keyboard with alphanumeric keys, numeric keys, cursor keys and control keys • Function keys and softkeys • Integrated mouse • LEDs for power supply, temperature, softkeys, <Shift> and <ACK> function keys and buttons • Front-mounted USB 2.0 interface for connecting external I/O devices.

All fronts are also available without USB interfaces accessible from the front

7.45.2 • • •

Testing Isolate the power supply by switching off the drive power contactor.

Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. The table below mentions the possible occurring problems and their remedy

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Temperature limits If the device is used for its intended purpose, the temperature threshold values are not exceeded or fallen below. When the LED "Temp" on the upper left side of the operator control unit lights up, check the following: ● Are the fan apertures covered? ● Has the fan failed (check speed display in the SOM or on the DiagMonitor)? ● Is the ambient temperature higher than the allowed value (see "Technical data")? ● Is the total output of the power supply within the specified limit? ● Are the heatsinks inside the PC covered with dust?

Remedy The temperature error is retained until the temperatures have fallen below the thresholds and you have acknowledged the error alarm in the SOM program. Click on the button with the “small broom” icon. When the error alarm has been acknowledged, the “TEMP” LED on the devices goes off and the title bar and “SOM” icon in the status bar of the SOM program changes from red to green. If you have not installed the SOM program or DiagMonitor, you must restart the PC. • •

If any of the things mentioned in the table above does not solve the problem, refer the operating manual for the SIMATIC Panel PC 677B sent along with the DCC cabinet.

If nothing solves the problem replace the computer.

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Maintenance, Trouble-Shooting and Repairs

Replacing

Removing HMI

• • • • •

Remove mounting bracket of remote kit by unscrewing Torx Screw Kombi M5*12, specia plain washer M5, special washer (od-17mm, Id7.5mm, Hight -3.9mm) by using kombi screw driver T25.

Disconnect all cables from remote kit.

Remove remote kit by unscrewing Screw Kombi M4*12 (pos,666) using kombi screw driver T-25 Remove HMI display from door by unscrewing locking screw.

Lift HMI display & place safely.

Computer

• • • •

Remove power cable brackets by unscrewing Screw kombi M3*12 (pos, 708) using kombi screw driver.

Disconnect all cables from computer.

Remove L- angle(pos,38) by unscrewing Screw Kombi M4*12, Screw Kombi M4*8, Screw Kombi M6*16 (pos,666,685,617) using kombi screw driver T-25 Lift computer & place safely.

Installing HMI

• Place HMI display on table, take remote kit and mount on HMI display by screwing screw kombi M4*12(pos, 666) using kombi screw driver T25.

• Lift HMI & place correctly in door cut out & tighten the locking screw.

• Mount mounting bracket for remote kit by screwing Torx Screw Kombi M5*12, specia plain washer M5, special washer (od-17mm, Id-7.5mm, Hight -3.9mm) by using kombi screw driver T25.

• Connect all cables to remote kit.

Computer

• Lift computer & place in to plc compartment safely.

• Mount L- angle(pos,38) by screwing Screw Kombi M4*12, Screw Kombi M4*8, Screw Kombi M6*16 (pos,666,685,617) using kombi screw driver T-25 • Apply torque 3 Nm, mark torque points with marker pen.

• Connect all cables to computer.

• Mount power cable brackets by screwing Screw kombi M3*12 (pos, 708) using kombi screw driver.

• Finally check all connections.

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Maintenance, Trouble-Shooting and Repairs

Drawing

HMI Display Bracket for power cable

Electrical connections

Remote kit

Computer

L-angle & its mounting

Mounting bracket for remote kit

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Maintenance, Trouble-Shooting and Repairs

Technical data

Electrical specifications Supply voltage AC

Nominal 100 - 240 V AC (-15% / +10%), autorange

Supply voltage DC

Nominal 24 V DC (-15% / + +20%), SELV

AC device: Frequency

50 to 60 Hz, 47 to 63 Hz

Input current AC

Continuous current to 2.3 A (to 50 A for 1 ms at startup)

Input current DC

Continuous current to 9 A (to 14 A for 30 ms at startup)

Line voltage frequency

50 to 60 Hz (47 to 63 Hz)

Transient voltage interruption Namur

Max. 20 ms to (93 to 264 V) Max. 10 events per hour, min. recovery time 1 s

Maximum power consumption AC and DC

Effective power 190 W / 210 W Apparent power 250 VA / 275 VA

Maximum current

16.5 A (peak 18.5 A) at +5 V 8.5 A at +3.3 V The total power of the +5 V and 3.3 V voltage is 90 W maximum.

6.5 A (peak 8 A) at +12 V 0.3 A at -12 V The total power of all voltages is 150 W maximum.

Degree of protection Complete unit, rear

IP 20

Degree of protection on front, screw mounted and backing plate (17" and 19") (does not apply to 12" touch panel)

IP 54

Degree of protection on front, clamp mounted

IP 65

Electromagnetic compatibility (EMC) AC device: Emitted interference

EN 55011 Class A, EN 61000-3-2 Class D EN 61000-3-3

DC device: Emitted interference

EN 55022 Class A

Noise immunity: Mains borne disturbance variables on supply lines

± 2 kV, according to IEC 61000–4–4, burst ± 1 kV, according to IEC 61000–4–5, surge sym. ± 2 kV, according to IEC 61000–4–5, surge asym.

Noise immunity on signal lines

± 1 kV, according to IEC 61000–4–4, burst, length < 5 m ± 2 kV, according to IEC 61000–4–4, burst, length > 5 m ± 2 kV, according to IEC 61000–4–5, surge, length > 30

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m Immunity to discharges of static electricity

± 6 kV contact discharge according to IEC 61000–4–2 ± 8 kV air discharge according to IEC 61000–4–2

Immunity to RF interference

10 V/m 80–1000 MHz, 80% AM according to IEC 61000– 4–3 10 V/m 900 MHz and 1.89 GHz, 50% ED according to IEC 61000–4–3 10 V/m 9 KHz-80 MHz according to IEC 61000–4–6

Magnetic field

30 A/m, 50 Hz according to IEC 61000–4–8

Climatic conditions Temperature • Operation1) • Installed in cabinet: – With outside temperature of 40° C – With outside temperature of 45° C • Storage, transportation • Gradient

1)When

Tested to IEC 60068-2-1, IEC 60068-2-2, IEC 60068-214 • +5° to +45° C (with maximum configuration) • Inside temperature max. 50° C (with total load of the slots with max. 15 W) • Inside temperature max. 45° C • -20° to +60° C • Maximum 10° C / h in operation, 20° C / h storage, no condensation

DVD burner is in operation, an ambient temperature of +5° to +40° C is applicable.

Relative humidity

Tested to IEC 60068–2–78, IEC 60068–2–30

• During operation

• 5 to 80% at 25° C (no condensation)

• Storage, transportation

• 5 to 95% at 25° C (no condensation)

• Gradient

• Maximum 10° C / h, no condensation

Mechanical environmental conditions Vibration • Operation • Storage, transportation

Tested to DIN IEC 60068-2-6 • 10 to 58 Hz: 0.075 mm, 58 to 500 Hz: 9.8 m/s2= 1 g(10 cycles) • 5 to 9 Hz: 3.5 mm, 9 to 500 Hz: 9.8 m/s2= 1 g (10 cycles)

Shock resistance

Tested to IEC 60068-2-27, IEC 60068-2-29

• Operation

• 50 m/s2approx. 5 g, 30 ms (3 cycles per axis)

• Storage, transportation

• 250 m/s2approx. 25 g, 6 ms (3 cycles per axis)

Noise emission

< 55 dB(A) according to DIN 45635-1

Motherboard Chipset

Intel 945 GM and ICH7R

Processor

•

Intel ® Celeron M 440 1.86 GHz 533 MHz Front Side Bus (FSB), 1024 KB Second Level Cache

•

Intel ® Core 2 Duo 1.66 GHz T5500 667 MHz Front Side Bus 2048 KB Second Level

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Cache

•

RAM

Intel ® Core 2 Duo 2.16 GHz T7400 667 MHz Front Side Bus, 4096 KB Second Level Cache

2 sockets maximum 2 GB SDRAM DDR2 533 MHz See order documentation for expansion memory

Buffer memory

512 KB SRAM 128 KB can be buffered over time

Free expansion slots

••

1 x PCI 265 mm long and 1x PCI 175 mm long 1 x PCI 265 mm long and 1 x PCI express x4 174 mm long

Maximum permissible current consumption per PCI slot

•• •

5 V / 2 A or 3.3 V / 2 A, 12 V / 0.3 A, -12 V / 0.05 A

The total consumption (all slots) may not exceed 30 W. Disk drives Hard disks

2.5'' or 3.5'' Serial ATA, hard disk capacity see order documentation 3 Gbps data transfer rate Supports NCQ (Native Comman

d Queuing) SATA II

property DVD burner

ATA 33, See order documentation for features

Ports DVI-I

Port for external CRT / LCD monitor

USB

•

External: 4 x USB 2.0 on the port side (max.

2 can be simultaneously operated as high current)

•

Front panel ports: USB 2.0 high current

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PROFIBUS/MPI interface • Transmission rate • Operating mode • Physical interface – Memory address area – Interrupts

9-pin sub-D socket • 9.6 Kbps to 12 Mbps, configured per software Electrically isolated: • Data channels A, B Control lines RTS AS, RTS_PG 5 V supply voltage (maximum 90 mA) Grounded: Shielding of the DP12 connection line • RS485, electrically isolated (within SELV) – Configured automatically – Configured automatically

Ethernet

2x Ethernet interface (RJ45) 10/100/1000 Mbps Intel 82573 L

COM1

Serial interface, 9-pin Cannon plug

Compact Flash

Slot for Compact Flash card

Status displays Control unit

Computer unit

•

Power LED

•

Temperature LED

••

Ethernet LEDs Optical drive LED

Display Graphics controller

Intel

Graphics memory

Graphics memory; 8 to 132 MB, taken from RAM.

Resolutions, frequencies, color depth

VGA: 1600 x 1200, 32-bit color depth, 85 Hz DVI-I: 1600 x 1200 / 32-bit color depth, 60 Hz LCD: 1280 x 1024, 18-bit color depth

12" TFT Key panel

15" TFT Key panel

12" TFT Touch panel

15" TFT Touch panel

17" TFT Touch panel

19" TFT Touch panel

Resolution

800 x 600

1024 x 768

800 x 600

1024 x 768

1280 x 1024

1280 x 1024

Contrast ratio, typ.

600:1

450:1

450:1

450:1

800:1

700:1

Max. light density cd/m², typ.

350

250

350

250

300

300

Horizontal viewing angle right/left/typ./min.

70° / 60°

60° / 50°

70° / 60°

60° / 50°

typically 80°

typically 80°

45° / 35°

40° / 30°

45° / 35°

40° / 30°

typically 80°

typically 80°

Color display*)

Vertical viewing angle l above / typ. /

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min.

Vertical viewing angle l below / typ. / min.

55° / 45°

60° / 35°

55° / 45°

60° / 35°

typically 80°

typically 80°

*)A small number of faults in the display is unavoidable. However, the displays do comply with the described quality standards of the ISO standard 134062, class 2. *)

Bad pixels

Permissible number

•

Permanently bright, dark pixels

• ≤ 12

•

Permanently bright, green pixels

•≤5

Front

Service life of backlighting

12" TFT

15" TFT

12" TFT

15" TFT

17" TFT

19" TFT

Key panel

Key panel

Touch panel

Touch panel

Touch panel

Touch panel

50,000 h for 24 h continuous operation, temperature dependent, remaining brightness 50%

Membrane keyboard

X

—

with alphanumeric and numeric keys Function keys

36 with LED

—

Direct control key module

optional

—

Actuating force (test pen with 3 mm radius)

Maximum 3 N

—

Cycles (operation)

> 1 million

—

Resistive analog touch screen

—

X

Touch force (with test pen 2 mm diameter)

—

5N

Slide-in labels for

X

—

function keys

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Front-mounted

Maintenance, Trouble-Shooting and Repairs

X

—

integrated mouse Power loss *) 12" TFT

15" TFT

12" TFT

15" TFT

17" TFT

19" TFT

Key panel

Key panel

Touch panel

Touch panel

Touch panel

Touch panel

Efficiency of the power supply 86% Control unit

30 W

30 W

30 W

30 W

50 W

53 W

Computer unit

75 W

75 W

75 W

75 W

75 W

75 W

PCI cards

35 W

35 W

35 W

35 W

35 V

35 W

Panel PC 677B

105 W

105 W

105 W

105 W

125 W

128 W

Panel PC with 2 PCI

140 W

140 W

140 W

160 W

163 W

(17.5 W each)

140 W

plug-in cards *)

The specified values apply to the maximum configuration of the device

Weight 12" TFT

15" TFT

12" TFT

15" TFT

17" TFT

19" TFT

Key panel

Key panel

Touch panel

Touch panel

Touch panel

Touch panel

Weight of complete unit

11.89 kg

16.01 kg

12.51 kg

14.44 kg

17.2 kg

16.8 kg

Control unit

4.89 kg

9.01 kg

5.51 kg

7.44 kg

10.2 kg

9.8 kg

Panel PC 677B

Panel PC 677B Complete unit

Temperature in cabinet

Ambient temperature Cabinet

Comment

Installed in cabinet, different temperatures

50 °C

40 °C

• Maximum PCI load 15 W • Optical drives may not be operated with a temperature > 40° C.

Installed in cabinet, same temperature inside and outside

45 °C

45 °C

• Complete configuration, maximum PCI load 30 W (2

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slots) Computer unit and control unit separated, using Remote Kit 12" control unit

50° C

45° C

15" control unit

50° C

45° C

17" control unit

50° C

45° C

19" control unit

50° C

45° C

The USB port of the Remote Kit (rear USB port) may not be used when the 19" panel is operated in an enclosure with an inside temperature between 45° and 50° C.

Computer unit 677B, Intel ® Core 2 Duo

55° C

-

• No PCI modules plugged. • Optical drives may not be operated with a temperature > 40° C.

These values are applicable for vertical installation and when air is flowing through the cabinet.

7.46

AIR CONDITIONER

Bucyrus Part no: 62057416 Component designation: E05

7.46.1

Description

Since the simatic components operate in the temperature range of 0°C to 60 °C an air conditioner is used to maintain the temperature inside the PLC section of the DCC. Following are the features of the air conditioner used in the PLC section of the DCC. Compact, (18” L X 12.35” W X 9.69”D) • Excels in high ambient temperatures • Environmentally Safe • Dual voltage versions available, consult factory.

• No compressor, fluorocarbons or filters • Virtually maintenance-free operation • Stainless steel exterior housing

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• Versions to withstand corrosive environments, shock and vibration • Mounts and operates in any orientation

7.46.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the main and auxiliary power supplies.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Ensure that the MCB Q33 is not tripped.

• Isolate the wires from the air conditioners terminal block. Measure with an ohmmeter the continuity of phase to a neutral circuit, L and N in terminal block (the thermostat should be adjusted to continuous cooling position).

• If there is no problem with the circuit continuity, proceed to make a visual inspection of the air conditioner mechanical assembly.

• If there is no problem of circuit continuity and no mechanical damage, the air conditioner must be tested with 120 VAC auxiliary supply.

• Ensure that both the hot side and cold side fans are working. The hot side fans are those which are exposed to the environment whereas the cold side fans are those which are on the enclosure side.

• If not the air conditioner needs to be replaced.

7.46.3

Replacing

Removing

• Remove all electrical connection from terminal.

• Remove earthing connection by removing SS hex screw M6 x 16, plain washer SS M6, HT spring washer M6 using combi screw driver-T28 • Loose all locknuts & remove drip pan from A.C. • Remove A.C. safely from cabinet.

Installing

• • • • •

Lift A.C. & place in to cabinet cutout.

Mount drip pan at bottom side of A.C. Mount A.C. by tightening all locking nuts.

Make all electrical connections with terminal.

Make earthing connection by screwing SS hex screw M6 x 16, plain washer SS M6, HT spring washer M6 using combi screw driver-T28 • Apply torque 6.5 Nm, mark torque points with marker pen.

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Drawing

Picture:

7.46.5

Technical data

Performance rating Voltage 50/60 HZ Current 240VAC Weight Temp control Operating ambient

1035-1180 BTU/hr 120/240 VAC 7.5 A at 120VAC and 5A at 23.6 Kg TC-6F -28/+70 °C

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Performance curve

7.47

CIRCUIT BREAKERS

Bucyrus Part no: 62037679 (10A), 62040290 (3A), 62039637 (16A), 62055576 (20A) Component designation: Q05, Q06, Q07, Q08, Q10, Q21, Q22, Q23, Q24, Q25, Q26, Q27, Q28, Q33, Q34, Q35

7.47.1

Description

SIEMENS 5SX Miniature Circuit Breakers are designed for protection of all types of electrical systems. In DCC cabinet total 4 types of these MCBs are used.

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7.47.2

Drawing

7.47.3

Technical data

Tripping characteristics No. of poles Rated voltage Operaional voltage (min) Operational voltage (max) Operational voltage(max) Rated breaking capacity as per EN 60898 Insulation coordination Rated insulation voltage Degree of soiling for overvoltage category III Sealable in handle end position Device depth acc. to DIN 43880 Degree of protection CFC and silicon free Mounting technique 35mm Terminals

B,C 1 to 4 230/400 VAC 4 VAC/DC 60VDC/pole 440 VAC 6kA AC 250/440 VAC 2 Yes 55mm IP00 acc. to DIN 40050, IP40 for installation in distribution boards yes can be snapped onto Standard mounting rails (DIN EN 60715) Combined terminals at the bottom for a simultaneous connection of bus bars and feeder cables

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Terminal tightening torque Conductor cross sections Solid and stranded max.

• Upper terminal • Lower terminal

16 mm2 25 mm2

Conductor cross sections Finely stranded wit end sleeves max • Upper terminal • Lower terminal

10 mm2 16 mm2

Service life

2.5…3 Nm

an average 20000 operations at rated load -25….+45 °C , occassionally +55°C,

Ambient temperature max

95% humidity, storage temp -40…..+75 °C 6 cycles acc to IEC 60068-2-30 60 m/s2 at 10

Resistance to climate Resistance to vibrations Hz….150Hz

Acc. to IEC 60068-2-6.

7.48

EMERGENCY STOP PUSH BUTTON

Bucyrus Part no: 62059221 Component designation: POEB4

7.48.1

Description

This is used as an emergency stop button for the system. When this button is pressed, immediately system is isolated from the line, motions are stopped and DCC DC link is discharged immediately. This is to be pressed in any emergency condition to stop the machine. This button gets latched when it is pressed.

7.48.2

Testing

• Press this button and check whether machine makes an emergency stop.

• When this push button is pressed and if nothing happens then manually stop machine, isolate from the line, and ensure that the DC link is discharged.

• Then check the wiring of this button.

• Check the I/O card of PLC whether it is receiving status of the switch properly or not.

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7.48.3

Drawing

7.48.4

Technical data

Design of the operating mechanism Manner of function/ of the activation element • Arresting lock • Tentative

Yes No

Button Design of the button Color of the button

flat red

Front ring Material of the front ring Color of the front ring

plastic black

Enclosure Shape of the housing front Material of the housing

round plastic

General technical details Type of operating voltage Operating voltage/rated value Min Max No. of NC contacts for auxiliary contact No. of NO contacts for auxiliary contact No. of change over switches for auxiliary contact No .of switching positions

Mushroom push-pull button

AC/DC 5V 400V 1 0 0 2

Mechanical design Design of electrical connection Installation width Mounting diameter Width Height Depth

screw type terminals 30mm 22mm 40mm 40mm 76.5 mm

Ambient conditions Ambient temp. during operation Protection class IP

-25°C…..+70°C IP66

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Maintenance, Trouble-Shooting and Repairs

RESET PUSH BUTTON

Bucyrus Part no: 62057418 Component designation: SRES

7.49.1

Description

This is used as a system reset push button which makes software reset to the SIBAS drive control. When this button is pressed, PLC sends the reset command to SIBAS and in turn SIBAS makes the software reset which restores the original status of latches in software. Normally after acknowledgement of error this button is pressed to make a reset.

7.49.2

Testing

• Press this button and check whether machine makes reset.

• When this push button is pressed and if nothing happens then manually stop machine, isolate from the line, and ensure that the DC link is discharged.

• Then check the wiring of this button.

• Check the I/O card of PLC whether it is receiving status of the switch properly or not.

7.49.3

Drawing

Picture

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Technical data

Actuator Design of the operating mechanism Manner of function of the activating element • Arresting lock • Tentative

No Yes

Button Design of the button Color of the button

flat black

Front ring Material of the front ring Color of the front ring

plastic black

Enclosure Shape of the housing front Material of the housing

round plastic

General technical details Type of operating voltage

AC/DC

Operating voltage rated value • Minimum • Maximum

5V 400V

No of NC contacts for auxiliary contact No of NO contacts for auxiliary contact No of changeover switches for auxiliary contact No. of switching positions Product extension/optional/fluorescent materials

0 1 0 2 No

pushbutton with flat button

Mechanical design Design of the electrical connection Installation width Mounting diameter Width Height Depth

screw type terminals 30mm 22mm 30mm 36.5mm 57mm

Ambient conditions Ambient temperature during operation Protection class IP

-25°C…..+70°C IP66

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Maintenance, Trouble-Shooting and Repairs

SITOP DC UPS MODULE 24V

Bucyrus Part no: 62059290 Component designation: G10

7.50.1

Description

This UPS module is used to give backup power & do safe shut down of host computer in DCC. It communicates with host computer with USB interface and gives information about supply conditions. Communication software in host computer can make safe shut down in case of supply power failure to UPS.

7.50.2

Testing

UPS module sends 3 hardwired signals to PLC DI module from which PLC monitors the status of UPS. In normal operation, the green LED (o.k.) is illuminated and relay contact X2.2 – X2.3 (o.k.) is closed. In floating operation, the yellow LED (Bat) is illuminated and relay contact X2.1 – X2.2 (Bat) closed. When the "Battery not ready" signal is active, the red LED (Alarm) is illuminated and relay contact X2.4 – X2.5 (Alarm) closed. Alarm signal can be due to "OFF" operating state, no battery module connected, reversed polarity or defective battery (battery voltage < 18.5V) or open circuit between battery and UPS module.

7.50.3

Replacing

Removing

• Remove the UPS module connections cables from connectors X1, X2 & X3 on UPS module.

• Remove the UPS module pluged on the DIN rail channel.

• Take out the UPS module from DCC

Installing

• Mount the UPS module in DCC on DIN rail channel • Make the connections to UPS as per circuit diagram

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7.50.4

Drawing

7.50.5

Technical data

Input quantities: Rated input voltage:

24V DC

Operating voltage range:

22 to 29V DC

Max. input current at 24V and battery charging:

16.0A DC

Max. input current at 24V and charged battery:

15.1A DC

Battery current in floating operation:

15.1A DC

Max. quiescent current consumption of the battery appr. 0.3mA Power loss at 24V and battery charging: appr.

16.0W

Power loss at 24V and charged battery: appr.

14.0W

Power loss in floating operation: appr.

15.0W

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Output quantities: Rated output DC voltage: VA1 =

24V DC

Rated output direct current: IA1 =

15A DC

Output current range: IA1 =

0 … 15A DC

Output characteristic of charging regulator: charged at an adjustable constant current until the set end-of-charge voltage is reached.

The battery module is

End-of-charge voltage: VA2 =

26.3 to 29.3V DC

Charging current: IA2 =

0.35 or 0.7A DC

7.51

UPS MODULE POWER SUPPLY (QUINT-PS100-240AC/24DC/20A)

Bucyrus Part no: 62059292 Component designation: G02

7.51.1

Description

This is a power supply which supplies 24VDC to the UPS module. Its used for charging of the battery module.

7.51.2

Testing

• Isolate the power supply by switching off the drive power contactor and locking out the main and auxiliary power supplies.

• Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an adequate meter for a DC level of 2000 V. • Remove the input and output cables from the power supply.

• Check continuity between the L and N on the input side and between + and – on the output side of both the power supplies. Continuity should not be observed.

• If above test is successful the power supplies should be tested individually with an input voltage of 120VAC. • Check the output voltage. The output voltage should be 24VDC.

7.51.3

Replacing

Removing

• Remove the Power supply module connections cables for input 120VAC and cables for output 24VDC. • Remove the Power supply module pluged on the DIN rail channel.

• Take out the UPS module from DCC

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Installing

• Mount the power supply module in DCC on DIN rail channel • Make the connections as per circuit diagram

7.51.4

Drawing

7.51.5

Technical data

Input Data Nominal input voltage range 100...240 V AC Frequency range 45...65 Hz (0 Hz at DC input) Current consumption 4.76 A (at 120 V AC (nominal load)) Inrush current surge < 15 A (typical), inrush current limiting/Ι2t (25°C): < 3.2 A²s Mains buffering (for nominal load) > 30 ms (at 120 V AC) Typical switch-on time < 1 s Protective circuit Transient surge protection varistor Input fuse 12 A (slow-blow, internal) Recommended backup fuse Circuit breaker 16 A or 25 A, Characteristic B Discharge current to PE < 3.5 mA Connection method Screw connection Stripping length 7 mm

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Output Data Nominal output voltage 24 V DC ±1% Setting range for the output voltage 22.5...28.5 V DC Output current 20 A (-25...+60°C) Derating Above +60°C: 2.5% per Kelvin Current limit IBOOST = 26 A (for short circuit), approximately Maximum capacitive load Unlimited System deviation < 1% (static load change 10...90%) < 2% (dynamic load change 10...90%) < 0.1% (input voltage change ±10%) Power dissipation Maximum nominal load 44 W Efficiency > 92% for 230 V AC and nominal values Parallel connection Yes, to create redundant systems and increase efficiency

7.52

SITOP POWER BATTERY MODULE 24V/7Ah

Bucyrus Part no: 12330814 Component designation: G09

7.52.1

Description

The battery module 24V/7Ah with accessories consists of a battery receptacle with 2 pcs. Maintenance free sealed lead gel batteries and terminals for the connection lines with the uninterruptible SITOP power supply (UPS).

7.52.2

Testing

The health of the battery is monitored by UPS module to which it is connected. On the UPS module when the "Battery not ready" signal is active, the red LED (Alarm) is illuminated and relay contact X2.4 – X2.5 (Alarm) closed. Alarm signal can be due to "OFF" operating state, no battery module connected, reversed polarity or defective battery (battery voltage < 18.5V) or open circuit between battery and UPS module.

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Maintenance, Trouble-Shooting and Repairs

Replacing

Removing

• Remove the battery module • Remove the battery module mounting screws • Take out the UPS module from DCC Installing

• Mount the power supply module in DCC using its mounting screws • Make the connections as per circuit diagram 7.52.4

Drawing

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Technical data

Weight: approx. 6 kg (incl. connection cable) Overall dimensions: width 186 mm; height 168 mm; depth approx. 121 mm Battery: 2 pcs Maintenance free lead gel battery 12V/7Ah type: ROCKET ES7-12 Fa.YUASA Fuse: FK2 15A/32V // 20A/32V or FKS 15A/80V // 20A/80V Admissible temperature: operation +5...+40°C

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7.53

FAN SUBASSEMBLY 28 SEP 1U

Bucyrus Part no: 62039607 Component designation: A100-N000

7.53.1

Description

The module FAN (6FH6035-1A) is used for forced ventilation of SIBAS 32 subracks. It possesses the following main properties: -

Buffer battery for RAM back-up supply of the central processing unit;

-

Rated supply voltage range from 24V to 110V;

-

No isolated power supply necessary;

-

Secondary supply voltage 5V, M;

-

Separate inhibit input;

-

Isolation by means of optocoupler (O.C.);

-

Fuse for fire protection.

The fan subassembly has the function of providing forced ventilation of SIBAS subracks. It is constructed as a withdrawable module and incorporates 3 axial-flow fans.

7.53.2 • • • •

Replacing Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the Fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch ON the breaker Q07 and check the module for correct operation.

Diagram

2 pulling handles

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Technical data

Order number: Backplane connector

X1

Slot width: Weight: Component ambient temperature: Current supply: Structure: Standards (if applicable): Number of inputs at X1 Input direct voltage at X1 Input current Air flow Inhibit input, "INH" UInhibit UInhibit referred to MUE Fault output "LUEFUW" UOUT referred to M Battery Electrical isolation: Maintenance notes:

6FH6035-1A 32-pin SUB-MIN-D plug connector Hybrid connector 84 TE Approx. 2400 g - 40 °C ... + 85 °C +5V ±5% approx. 5 mA 19 inch withdrawable module 426.72mm * 44.45mm * 220mm Railway type according to BN 411 002 EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160 5 13V ≤ UIN 158V/175V dynamic 2A ≤ IIN ≤ 0.16A 480m3/h "LOW" ≤ 0.4V/0.5mA unit ON, "HIGH" ≥ 3.0V unit OFF, TTL level, o.c. activation possible UOUT 2.0V fault UOUT 0.4V no fault Lithium battery 3.6V according to IEC: typ R14 according to ANSI: typ C Optocoupler Lithium battery change, see Chapter 9 of SIBAS hardware manual

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Maintenance, Trouble-Shooting and Repairs

INPUT/OUTPUT MODULE

Bucyrus Part no: 62056679 Component designation: A100-L147

7.54.1

Description

The IOM module (6FH9288-3D) serves as an interface between the central processing unit and the input/output modules in SIBAS 32. It is connected to the central processing unit via the data bus (DB[00-15]) and address bus (AB[01-16]).

With this module, it is possible to convert analog voltages to digital values. It permits analog/digital conversion (12 bits, +/-10V) of 23 external analog signals (AIN[01-23]) and two internal analog signals. From these 23 analog inputs, 10 signals (AIN[01-10]) are passed to limits monitors. An automatic test facility is provided for these limit monitor signals.

7.54.2 • • • •

Replacing Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch on the breaker Q07 and check the module for correct operation.

Caution: The module must not be plugged in or removed during operation.

7.54.3

Diagram

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2 bushes: bridged = "EEPROM can be written on"

7segment-display

2 LEDs: red = TOTAL INHIBIT yellow = RESET

0 2 BCD switches

0

8 LEDs (yellow)

7.54.4

Technical data

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Order number: Backplane connector:

6FH9288-3D X1, X2

64-pin plug connector to DIN 41612 large SIBAS bus

Front panel connector:

Not present

Slot width:

4 TE

Weight:

Approx. 500g

Component ambient temperature:

- 40 °C ... + 85 °C

Power supply:

+ 5V ±5% approx. 300mA +15V ±5% approx. 200mA - 15V ±5% approx. 200mA

Structure:

Printed circuit board in double-size Euroformat 233.4mm * 160mm varnished on both sides 6-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002

Standards (if applicable):

EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160

Number of digital inputs for control signals

up to 64

Number of digital outputs for control signals

up to 46

Number of analog inputs

23

Number of limit monitors

10

Most important functions

Binary input/output, Analog input/output, Limit signaling of analog signals, Frequency and pulse duration acquisition, Frequency and pulse duration output, Speed measurement with direction of rotation detection, Detection module temperature, Logic operations in FPGA

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Input voltage range of control signals

HCMOS level

Output voltage range of control signals

HCMOS level

Input voltage range of analog inputs

±10V

Processing of analog signals

S&H ADC with 12 bits, ± 5 LSB absolute

Maintenance notes:

None

7.55

INPUT VOLTAGE/ FREQUENCY

Bucyrus Part no: 62056676 for G035, 62057419 for G043, 62057420 for G059, 62057421 for G067, 62057422 for G075 Component designation: A100-G035, G043, G059, G067, G075

7.55.1

Description

The IVF module is located in the SIBAS rack. It is used for conversion of analog voltages to frequencies. Seven analog actual values can be digitized on the signal processing unit board. The measurement signals are each passed via the front panel connector to a common difference amplifier whose gain is determined by 2 resistors located on solder tags.

7.55.2 • • • • • •

Replacing Ensure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack.

Compare and ensure the resistors on the solder tags on the new module are identical to those in the removed card.

Insert the new module after mounting correct resistors.

Switch ON the breaker Q07 and check for operation.

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Maintenance, Trouble-Shooting and Repairs

Diagram

48-pole

7.55.4

Technical data

Order number: Backplane connector: X1 Front panel connector: X2 Slot width: Weight: Component ambient temperature: Power supply:

Structure:

6FH9305-3D 64-pin plug connector to DIN 41612 48-pin plug connector to DIN 41612 4 TE Approx. 180g - 40 °C ... + 85 °C + 5V ±5% approx. 25mA +15V ±5% approx. 50mA - 15V ±5% approx. 50mA Printed circuit board in Euroformat 100mm * 160mm varnished on both sides 4-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002

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Standards (if applicable): Inputs Input voltage range of analog inputs Input voltage range of control signals Outputs Maintenance notes:

7.56

EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160 7 analog difference amplifier inputs 5 binary control inputs ±10V HCMOS level 7 analog outputs 7 frequency outputs 1 reference frequency output None

INPUT CONVERTER BINARY 24V

Bucyrus Part no: 62052760 for G099, 62052775 for G107 Component designation: A100-G099, G107

7.56.1

Description

The Input converter binary 24V (ICBP) is located in the SIBAS rack. It is used for input of binary signals with a nominal level of 24V. The input module receives 12 input channels on the front panel connector X2, each input has a separate positive (BINP) and a separate negative (BINN) input pin. These inputs are isolated from the SIBAS side through optocouplers. There are no adjustments to be made in this module.

7.56.2

• • • •

Replacing

Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch on the breaker Q07 and check for operation.

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7.56.3

Maintenance, Trouble-Shooting and Repairs

Diagram

32-pole

7.56.4

Technical data

Order number: Backplane connector:

X1

Front panel connector: X2 Slot width: Weight: Component ambient temperature: Power supply: Structure:

Standards (if applicable): Number of inputs at X2

6FH9371-3D 64-pin plug connector to DIN 41612 small SIBAS bus 32-pin plug connector to DIN 41612 4 TE Approx. 200g - 40 °C ... + 85 °C + 5V ±5% approx. 90mA Printed circuit board in Euroformat 100mm * 160mm varnished on both sides 4-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002 EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160 12 each with 2 pins (BINP and BINN)

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DC input voltage at X2

16.8V ≤ UIN

Input current

7mA ≤ IIN ≤ 18mA

Smoothing time constant TS

Channels 1 to 10: approx. 1ms, Channels 11,12:

Cut-off frequency fcut-off

Output level at X1 Electrical isolation Maintenance notes:

7.57

approx. 0.5ms

Channels 1 to 10: approx. 80Hz, Channels 11,12:

Operating points

≤ 30V

approx. 500Hz

UIN ("H") > 13V (IIN = 3.0mA) UIN ("L") < 6V UOUT: HCMOS level, IOUT < 8mA Optocouplers None

OUTPUT MEASURING AMPLIFIER

Bucyrus Part no: 62052764 Component designation: A100-L131, L155, L163

7.57.1

Description

The OMES module (6FH9404-3B) is used as a commissioning and diagnostic module. It is connected to the central processing unit via the data bus (DB[0-15]) and the address buses (AB[1-3], AB[12-15]) .

For the purpose of identification, the output measuring amplifier possesses a hardware identifier which can be read out via the data bus.

The module incorporated 8 D/A converter channels which are connected to the data bus. The resolution of the converters is 12 bits. The analog output signals (AOUT[16-23]) are decoupled via output amplifiers and are present at the front panel connector. The voltage range of the output signal is -10V...+10V. The output measuring amplifier possesses 16 analog and 16 digital measuring channels. The input signals connected to the backplane connector are decoupled on the module and passed to the front panel connector.

7.57.2 • • • •

Replacing Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch on the breaker Q07 and check for operation.

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Caution: The module must not be plugged in or removed during operation.

7.57.3

Diagram

50 -pin SUB-MIN-D-plug connector (sockets)

7.57.4

Technical data

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Order number: Backplane connector:

Maintenance, Trouble-Shooting and Repairs

X1, X2

Front panel connector: X3 Slot width: Weight: Component ambient temperature: Power supply:

Structure:

6FH9404-3B 64-pin plug connector to DIN 41612 large SIBAS bus 50-pin SUB-MIN-D plug connector, sockets 4 TE Approx. 400g - 40°C ... + 85°C + 5V ±5% approx. 110mA +15V ±5% approx. 100mA - 15V ±5% approx. 70mA Printed circuit board in double-size Euroformat 160mm * 233.4mm varnished on both sides 4-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002

Standards (if applicable):

EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160

Number of D/A converter channels Number of analog measuring channels, differential inputs Number of analog measuring channels, single inputs Number of digital measuring channels Voltage range, analog inputs Voltage range, analog outputs Voltage range, digital inputs Voltage range, digital outputs

08 12 04 16 -10V...+10V -10V...+10V 0V...+30V HCMOS level

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Maintenance, Trouble-Shooting and Repairs

INPUT TEMPERATURE SENSOR PT100

Bucyrus Part no: 62052787 Component designation: A100-G147

7.58.1

Description

The ITS module is located in SIBAS rack. It is used to acquire temperatures using temperature dependent resistors made of platinum (PT100). It has the following main features: • 8 measuring channels with the associated 8*(2mA) constant current sources • Current line and measuring line are separate • Maximum measuring resistance of 500 ohms • Two switchable temperature ranges per measuring channel • Matching of the temperature measured values to the voltage range of +10V There is a high precision current source for each measuring channel. The current source feeds the temperature-dependent measuring resistor RPT100 via the front panel connections and the current sink "IIN [01-08] must also be connected to the front panel. The temperature-dependent voltage drop on the current-carrying measuring resistance (PT100) is measured with two measuring wires independent of the current lines at the two measuring inputs "AIN[01-08]P " and "AIN[01-08]N ".

7.58.2 • • • •

Replacing Ensure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch ON the breaker Q07 and check for operation.

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7.58.3

Maintenance, Trouble-Shooting and Repairs

Diagram

48-pole

7.58.4

Technical data

Order number:

6FH9413-3B

Backplane connector:

X1

Front panel connector:

X2

64-pin plug connector to DIN 41612 small SIBAS bus 48-pin plug connector to DIN 41612

Slot width:

4 TE

Weight:

Approx. 200g

Component ambient temperature:

- 40 °C ... + 85 °C

Power supply:

+ 5V ± 5%,

approx. 10mA

+ 15V ± 3%

approx. 85mA

- 15V ± 3%

approx. 85mA

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Structure:

Printed circuit board in Euroformat 100mm * 160mm varnished on both sides 2-layer artwork design in 35µ technology can be encoded mechanically Railway type according to BN 411 002

Standards (if applicable):

VDE 0160 VDE 0110 LES-DB

EN 50155 Number of inputs at

X1

SIBAS bus signals + 5 additional input signals

Input DC voltage at

X1

≤ HCMOS level 5V

Number of inputs at

X2

24 (16 measuring points and 8 current sinks)

Input values at

X2

Input voltage of the measuring points

UIN ≤ 1V when RPT100 ≤ 500ohms

AIN[01-08]P/N Input current of the current sink IIN[01-08]

IIN = -2.000mA

Number of outputs at

SIBAS bus signals

X1

+ 1 analog signal "TEMPOUT" Output DC voltage, digital at

X1

Output current for each digital signal

≤ HCMOS level 5V IOUT ≤ 5mA IOUT ≤ 10mA for bus driver signals

Output voltage, analog at Number of outputs at

X1 X2

Output current of the current source

UTEMPOUT ≤ ± 15V Rload ≥ 2Kohms 8 current sources IOUT[01-08] IOUT = -2.000mA ± 1.1%

IOUT[01-08] Times, time constants, measuring quantities

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Temperature range, channels A, TEMP[1-8]A

- 39oC ≤ T ≤ +127oC

Temperature range, channels B, TEMP[1-8]B

- 60oC ≤ T ≤ +540oC

Delay time constant TN , TP

16.6ms

TN = RN*CN, TP = RP*CP Delay time Tmux

< 8µs

Reference voltage UOFFSA/B

+10.000V ± 27.5mV

PRECISION: Measuring error channel A

≤ ±2.5oC

meas.current IOUT = -2.000mA

Measuring error channel B

≤ ±3.4oC

meas.current IOUT = -2.000mA

Measuring error through current tolerance, channel ≤ ± 3.3oC A Measuring error through current tolerance, channel ≤ ± 5.7oC B Electrical isolation

Not required

Maintenance notes:

None

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7.59

Maintenance, Trouble-Shooting and Repairs

DC/DC CONVERTER 72...110V/24V 100W

Bucyrus Part no: 62052748 Component designation: A100-C025, C049, C073, C097

7.59.1

Description

The PCS 24V unit (6FH9484-3A) is used to provide a constant 24V source to SIBAS racks. The 110V/24V, 100W Power Supply receives an input voltage of 110V DC via the backplane connector and generates a precise and stabilized voltage of 24V. The Power Supply has electrical isolation and polarity reversal protection.

The Power Supply is enabled when the signal at pin d22 (Inhibit) goes LOW. A HIGH signal at pin d22 disables the power supply. The output voltage of the Power Supply can be measured at sockets provided on the front panel (+Uout, -Uout) Yellow LED on the front panel lights up when the power supply is ON.

7.59.2 • • • • •

7.59.3 • • • •

Testing Ensure Q07 breaker (located in PLC compartment) is ON. With this breaker ON, 110V DC is supplied to the Power Start-Up Unit of the Sibas rack.

Ensure the yellow LED on the Front Panel of all the individual Power Supplies are ON. Using a multimeter measure the voltage across terminals X1A & X1D. The Voltage measured should be approximately 110V DC + 5%.

Measure the voltage at the socket +Uout, -Uout on the front panel. This should be 24V+ 1%.

If the Sibas rack is powered with 110V DC but the 110V/24V Power Supply module is not able to produce a constant 24V DC Output Voltage, then the Power Supply module is defective and must be replaced.

Replacing Switch OFF the breaker Q07 and ensure there is no voltage across terminals X1A & X1D. Unscrew the top and bottom screws on the front panel.

Pull out the defective module and replace it with a new module.

Switch on the breaker Q07. Measure the voltage at the measuring socket +Uout, -Uout. This should be 24V+1%

Caution: The module must not be plugged in or removed during operation.

The unit is fitted with polarity reversal protection, but not with a temperature monitor.

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7.59.4

Maintenance, Trouble-Shooting and Repairs

Diagram

ON

6FH9484-3A

VIN 72...110V DC

+VOUT 24V DC

SIEMENS

-VOUT

WRC

7.59.5

Technical data

Order number: Backplane connector : Front panel connector: Slot width: Weight: Ambient temperature:

X1 X2

Structure:

Standards (if applicable):

Input voltage UIN Ramp-up time at R nominal load

6FH9484-3A High-current plug connector H15 to DIN 41612 Pin 24 leading (primary earth) Not present 12 TE Approx. 850g - 40 °C ... + 70 °C + 70 °C ... + 85 °C for t ≤ 10min Connection to a module location prepared for converters, can be encoded mechanically 100mm x 60mm x 160mm EN 50155, BN 411002, EN 50140-142, EN 50121-3-2, EN 50178, prEN50123-1, DIN VDE0435T.303, EN61000-4-3/4/5, ENV50204, SN29500, EN60559, IEC68T.2.27, IEC529, IEC571-1 40V ≤ UIN ≤ 154V ≤ 100ms

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Standby current IIN0 Inhibit input INHIBIT UINHIBIT

Output voltage UOUTnom Output current IOUTnom Current limiting Overvoltage protection (internal) atIOUTnom Monitoring UOUT POWERFL, open-collector Efficiency Storage time Dynamic system deviation at load change 50%100%-50% Correction time with load change 50%-100%50% Residual ripple Maintenance notes:

Maintenance, Trouble-Shooting and Repairs

≤ 15mA "LOW" ≤ 0.4V/0.5mA unit ON, "HIGH" ≥ 2.4V unit OFF, TTL level, o.c. control possible Signal referred to "NUE" input 24V ± 3% 4.0A Approx. 1.1 * IOUTnom ≤ 1.25 * UOUTnom 0.95 * UOUTnom ± 1.5% Signal referred to "FNUA" output > 87% > 1.5ms at -25°C < 100mV 1ms < 100mVpp None

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7.60

Maintenance, Trouble-Shooting and Repairs

DC/DC CONVERTER 72...110V/+-15V 100W

Bucyrus Part no: 62056673 Component designation: A100-C121

7.60.1

Description

The PCS 15V unit (6FH 9498-3A) is used to provide constant 15V source to the SIBAS racks. The 110V/15V, 100W Power Supply receives an input voltage of 110V DC via the backplane and generates a precise and stabilized voltage of 15V. The Power Supply has electrical isolation and polarity reversal protection.

The Power Supply is enabled when the signal at pin d22 (Inhibit) goes LOW. A HIGH signal at pin d22 disables the power supply. The output voltage of the Power Supply can be measured at sockets provided on the front panel (+Uout, -Uout) There is an LED on the front panel that lights up when the power supply is ON.

7.60.2 • • • • •

7.60.3 • • • •

Testing Ensure the Q07 breaker (located in PLC compartment) is ON. With this breaker ON, 110V DC is supplied to the Power start-up unit of the Sibas rack.

Ensure all the yellow LEDs on all the individual power supplies are ON. If not this would indicate a problem with the 110V DC Power Supply or the Power Start-Up unit.

Using a multimeter, measure the voltage across terminal X1A & X1D. This should be approximately 110V DC + 5%.

Measure the voltage at the socket +Uout, -Uout on the front panel. This should be 15VDC+1%.

If the Sibas rack is powered with 110V DC but the 110V/15V Power Supply module is not able to produce a constant 15V Output voltage then the Power Supply module is defective and must be replaced

Replacing Switch OFF the breaker Q07 and ensure there is no voltage across terminals X1A & X1D. Unscrew the top and bottom screws on the front panel.

Pull out the defective module and replace it with a new module.

Switch on the breaker Q07. Measure the voltage at the measuring socket +Uout, -Uout. This should be 15V+ 1%.

Caution: The module must not be plugged in or removed during operation.

The unit is fitted with polarity reversal protection, but not with a temperature monitor.

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7.60.4

Maintenance, Trouble-Shooting and Repairs

Diagram

ON

6FH9498-3A

VIN 72...110V DC

+VOUT 15V DC

SIEMENS

COM -VOUT 15V DC

SBB

7.60.5

Technical data

Order number: Backplane connector : Front panel connector: Slot width: Weight: Ambient temperature:

X1 X2

Structure:

Standards (if applicable):

Input voltage UIN Ramp-up time at R nominal load

6FH9498-3A High-current plug connector H15 to DIN 41612 Pin 24 leading (primary earth) Not present 12 TE Approx. 850 g - 40 °C ... + 70 °C + 70 °C ... + 85 °C for t ≤ 10 min Connection to a module location prepared for converters, can be encoded mechanically 100 mm x 60 mm x 160 mm EN 50155, BN 411002, EN 50140-142, EN 50121-3-2, EN 50178, prEN50123-1, DIN VDE0435T.303, EN61000-4-3/4/5, ENV50204, SN29500, EN60559, IEC68T.2.27, IEC529, IEC571-1 40 V ≤ UIN ≤ 154 V ≤ 200 ms

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Standby current IIN0 Inhibit input, INHIBIT UINHIBIT

Output voltage UOUTnom Output current IOUTnom Total current monitoring Load unbalance with an output voltage tolerance of Overvoltage protection (internal) atIOUTnom Monitoring UOUT POWERFL, open-collector Efficiency Storage time Dynamic system deviation at load change 50 %100 %-50 % Correction time with load change 50 %-100 %50 % Residual ripple Maintenance notes:

7.61

≤ 15 mA "LOW" ≤ 0.4 V/0.5 mA unit ON, "HIGH" ≥ 2.4 V unit OFF, TTL level, o.c. control possible Signal referred to "NUE" input ±15 V ± 3 % ±3.5 A 7.7 A to 7.8 A IOUT+ = +4.8 A, IOUT- = -2.2 A or IOUT+ = +2.2 A, IOUT- = -4.8 A ±5% ≤ 1.25 * UOUTnom 0.95 * UOUTnom ± 1.5 % Signal referred to "FMUA" output > 87% > 1.2 ms at -25 °C < 100 mV 1 ms < 100 mVpp None

BINARY OUTPUT 24V...36V/2 A

Bucyrus Part no: 62056677 for G115, 62056455 for G123, 62056467 for G131, 62057423 for G139 Component designation: A100-G115, G123, G131, G139

7.61.1

Description

The Binary Output Contactor Drive (BOCD) module is located in the SIBAS rack. It is used for output of binary signals. It has 8 separate output channels that are isolated from each other. The binary output signals are enabled by making the MOS switch V1 conduct upon receiving the command signals. There are no adjustments to be made in this module.

7.61.2

Replacing

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• • • •

7.61.3

Maintenance, Trouble-Shooting and Repairs

Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch ON the breaker Q07 and check for operation

Diagram

32-pole

7.61.4

Technical data

Order number: Backplane connector X1 Front panel connector X2 Slot width: Slot: Front panel connector coding: Weight:

6FH9541-3B 64-pin plug connector to DIN 41612 32-pin plug connector to DIN 41612 4 TE Connection in SIBAS subrack on the small bus or without bus, can be encoded mechanically Mechanical Approx. 200 g

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Component ambient temperature: Structure: Standards (if applicable):

Power supply: Inputs (X1) Input voltage Connection of port inhibit input BINEN[01-08]# Control voltage UANST Outputs (X2) Number of outputs DC voltage at X2 Permissible output current IA Leakage current in the disabled state Switching frequency Ohmic load Effect of short-circuit protection Maximum resistance RL of the entire conductor loop for shortcircuit protection Minimum length lLTGMIN of the battery supply lines Overload strength Voltage USCHUTZ of the overvoltage protection Parallel connection of outputs Number of parallel branches Current reduction factor KP in the case of parallel connection

Maintenance, Trouble-Shooting and Repairs

-40 oC to +85 oC Printed circuit board in single-size Euroformat (100 mm * 160 mm) VDE 0160, VDE 0110, LES-DB, EN 50155, IEC 60571, EN 50121-3-2, Ed. 2000, EN 60000-45 +5 V ± 5 %, max. current consumption 200 mA 5 V HCMOS level Do not connect (open) or wrap to "M" 3 V < UANST ≤ 15.5 V, max. current consumption 10 mA 8 ≤ 55 V ≤ 2.0 A ≤ 250 µA ≤ 2.5 kHz > 45 A < 0.2 Ω 3m Outputs are not continuously overloadproof ≥ 95 V Maximum of two channels each (four pairs) 0.85 i. e. IP ≤ 1.7* IA

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Maintenance, Trouble-Shooting and Repairs

INVERTER MONITORING CURRENT LINK

Bucyrus Part no: 62056678 for L035, 62057427 for L043, 62057429 for L075, 62057430 for L091, 62057431 for L123 Component designation: A100-L035, L043, L075, L091, L123

7.62.1

Description

The INVMC module (6FH9542-3C) is a peripheral module of the signal processing unit in the SIBAS 32 system. It outputs eight valve control signals as 40 mA current signals through the front panel connector X3 and receives the checkback signals again as 40 mA current signals.

Essential parts of the system-specific static inverter protection are located on this module. The programmable logic is accommodated on a plug-on module (AFA) in an FPGA with antifuse technology. Analog inputs can be accommodated via several comparators.

Up to four speed sensors can be connected on the front panel connector X4. A maximum of six track signals is filtered and is available as 5 V signals on the backplane connector.

The link to the signal processing unit is established via an internal serial bus.

7.62.2 • • • •

Replacing Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch ON the breaker Q07 and check for operation

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7.62.3

Maintenance, Trouble-Shooting and Repairs

Diagram

X3

X4

2 * 48-pole

7.62.4

Technical data

Order number: Backplane connector: X1, X2 Front panel connector: X3, X4 Slot width: Weight: Component ambient temperature:

6FH9542-3C 64-pin plug connector to DIN 41612 48-pin plug connector to DIN 41612 4 HP Approx. 500 g -40 °C to +85 °C

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Power supply:

Maintenance, Trouble-Shooting and Repairs

P5:

200 mA

P15: 100 mA (without external speed sensor)

Structure:

Standards (if applicable): Number of valve checkback inputs Input current per channel Number of valve control outputs Output current per channel Continuous short-circuit current per channel CAN controller Speed sensor signals Speed sensor supply Binary inputs for protection Binary outputs for protection Analog inputs Maintenance notes:

N15:

50 mA

P24I:

400 mA

Printed circuit board in double Euroformat 160 mm * 233.4 mm varnished on both sides 6-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002 EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160 8 channels, 2 push-pull inputs each 35 mA ≤ Iin ≤ 42 mA, corresponds to Iout 8 channels, 2 push-pull outputs each 35 mA ≤ Iout ≤ 42 mA 35 mA ≤ Ish ≤ 42 mA, corresponds to Iout Atmel T89C51CC01, 1 CAN channel, bus terminal can be connected 6 tracks 4, short-circuit-proof, 100 mA each 23, TTL level 21, CMOS level 7, voltage range ±10 V None

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7.63

Maintenance, Trouble-Shooting and Repairs

MAINBOARD SIP

Bucyrus Part no: 62057424 Component designation: A100-L027, L067, L107, L115

7.63.1

Description

The SPU SHARC module (6FH9543-3B) consists of the motherboard SPU (SIPG) and the SPU_FLOAT processor module plugged into it. This combination is a powerful computer in the SIBAS 32 system in the double-size Euroformat.

The processor provides the following formats: • • • • • • • • • •

Output of up to 12 valve control pulses by means of a CAM file Protection functions A/D conversion Evaluation of analog actual value recording via voltage/frequency converter Evaluation of temperature measurement Speed measurement Binary inputs and outputs Serial interfaces D/A conversion for commissioning Communication through two serial CAN buses

An LCA serves for the processing of digital signals: it is loaded with its drivers from its own flash EPROM. The following are located on the front panel: • • • • • • •

7.63.2 • • • •

7-segment display for reading out program status information Yellow LED, which illuminates if no reset signal is present Red LED, which illuminates if the watchdog is triggered regularly Jumper, which must be plugged in for programming the flash EPROMs Pushbutton with red cap for reset (recessed) Pushbutton with black cap for "Monitor Only" mode together with reset 9-pin plug connector for serial service interface (RS232)

Replacing Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch on the breaker Q07 and check the module for correct operation.

Caution: The module must not be plugged in or removed during operation.

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7.63.3

Maintenance, Trouble-Shooting and Repairs

Diagram

2 b ush es: brid ged = "F lash E P R O M can b e w ritten o n "

7-seg m ent disp lay (softw are-w ritab le)

2 L E D s: red = W A T C H D O G yellow = R E S E T

1 p ush button (black ): m o nitor only m od e

1 p ush button (red , recessed ): R E S E T

T erm inal for service P C 9 -p in S U B -M IN -D co nnecto r (m ale)

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7.63.4

Maintenance, Trouble-Shooting and Repairs

Technical data

Order number: Backplane connectors: X1, X2 Front panel connector: X3 Connectors: X10 – X13

6FH9543-3B 64-pin plug connector to DIN 41612 9-pin SUB-MIN-D connector (male) 40-pin plug connectors (2 * 20-pin each at a distance of 2.54 mm) for plugging on a processor board (SPU_FLOAT) Slot width: 4 TE Weight: 350 g (with front panel, without plug-in card) Component ambient temperature: -40 °C to +85 °C Power supply: +5 V ±5 % approx. 1.3 A +15 V ±5 % approx. 50 mA -15 V ±5 % approx. 50 mA Structure: Printed circuit board in double-size Euroformat 160 mm * 233.4 mm, varnished on both sides 6-layer artwork design in 18µ technology can be coded mechanically Railway type according to BN 411 002 Standards (if applicable): EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160 Memory module Flash EPROM 4 Mbytes Other modules FPGA LCA with the functions Trigger equipment High Speed Serial Communication HSSC Synchronization Evaluation of speed tracks Voltage/frequency converter evaluation 4 A/D converters CAN controller, 2 channels, with RAM, flash EPROM and DPR Evaluation of temperature measurement Power supply monitoring Board identification Display elements and operator controls on 2 2 mm sockets the front panel 7-segment display 2 LEDs red: WATCHDOG yellow: RESET Pushbutton (black): Monitor only mode Pushbutton (red): RESET Maintenance notes: None

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CONVERTER 72..110V/5V 90W

Bucyrus Part no: 62053536 Component designation: A100-C145

7.64.1

Description

The PCS 5V unit (6FH 9560-3A) is used to provide a constant 5V source to the SIBAS rack. The 110V/5V, 90W Power Supply receives an input voltage of 110V DC via the backplane and generates a precise and stabilized voltage of +5V. The Power Supply has electrical isolation and polarity reversal protection.

The Power Supply is enabled when the signal at pin d22 (Inhibit) goes LOW. A HIGH signal at pin d22 disables the power supply. The output voltage of the Power Supply can be measured at sockets provided on the front panel (+Uout, -Uout) The YELLOW LED on the front panel lights up when the power supply is ON (UOUT > 95 %).

7.64.2 • • • • •

7.64.3 • • • •

Testing Ensure the Q07 breaker (located in the PLC compartment) is ON. With this breaker ON, 110V DC is supplied to the Power Startup Unit of the Sibas rack.

Ensure the yellow LED on the Front Panel of all the individual Power Supplies are ON. If not, this would indicate a problem with the 110V DC Power supply or the Power Start-up Unit.

Using a multimeter measure the voltage across terminals X1A and X1D. These terminals are located below the SIBAS on SIBAS filter plate. The voltage measured should be approximately 110V DC + 5% Measure the voltage at the socket +Uout, -Uout on the front panel. This should be 5V+ 0.5%.

If the Sibas rack is powered with 110VDC but the 110V/ 5V Power Supply module is not able to produce a constant 5V Output voltage then the Power Supply module is defective and must be replaced.

Replacing Switch OFF the breaker Q07 and ensure there is no voltage across terminals X1A and X1D. Unscrew the top and bottom fixing screws on the front panel.

Pull out the defective module and replace it with a new module.

Switch on the breaker Q07. Measure the voltage at the measuring socket +Uout, -Uout. This should be 5V+0.5%.

Caution: The module must not be plugged in or removed during operation.

The unit is fitted with polarity reversal protection, but not with a temperature monitor.

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7.64.4

Diagram

7.64.5

Technical data

Order number: Backplane connector : Front panel connector: Slot width: Weight: Ambient temperature:

X1 X2

Structure:

6FH9560-3A High-current plug connector H15 to DIN 41612 Pin 24 leading (primary earth) Not present 9 TE Approx. 600 g - 40 °C ... + 70 °C + 70 °C ...+ 85 °C for t ≤ 10 min Connection to a module location prepared for converters, can be encoded mechanically 100 mm x 45 mm x 160 mm

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Standards (if applicable):

Input voltage UIN Ramp-up time at R nominal load Standby current IIN0 Inhibit input INHIBIT UINHIBIT

Output voltage UOUTnom Output current IOUTnom Current limiting Overvoltage protection (internal) atIOUTnom Monitoring UOUT POWERFL, open collector Efficiency Storage time Dynamic system deviation at load change 50 %70 %-50 % Correction time with load change 50 %-70 %-50 % Residual ripple Maintenance notes:

7.65

EN 50155, BN 411002, EN 50140-142, EN 50121-3-2, EN 50178, prEN50123-1, DIN VDE0435T.303, EN61000-4-3/4/5, ENV50204, SN29500, EN60559, IEC68T.2.27, IEC529, IEC571-1 66 V ≤ UIN ≤ 154 V ≤ 100 ms ≤ 10 mA "LOW" ≤ 0.4 V/0.5 mA unit ON, "HIGH" ≥ 2.4 V unit OFF, TTL level, o.c. control possible Signal referred to "NUE" input 5.1 V ± 2 % 18.0 A Approx. 1.1 * IOUTnom ≤ 1.25 * UOUTnom 0.95 * UOUTnom ± 1.5 % Signal referred to "FNUA" output > 85 % > 0.35 ms at -25 °C < 100 mV 1 ms < 100 mVpp None

POWER START-UP UNIT

Bucyrus Part no: 62056674 Component designation: A100-C163

7.65.1

Description

The PSU 110V module (6FH9568-3A) is located in the SIBAS rack (C163) located in the right most cabinet and is used for under-voltage monitoring of the primary and secondary supply voltages. It is also used for controlled starting and stopping of the system. All the SIBAS rack power supplies are routed through this PSU. The start-up of the controller is activated by applying the primary supply voltage or by means of a separate starting signal (ESB). The module incorporates six monitoring channels for monitoring under-voltage of the secondary supply voltages. The supply voltages monitored are P24, N24, UZ and P5, P15, N15.

After the PSU has been powered-up, a positive Switch-ON of the power supply units takes place for a definite period (waiting time). If after the elapse of this Siemens Ltd. A5E02606385J/ 4M-2601-1645709 AB Shovel 182MAC DCC Operation & Maintenance Manual

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waiting time, the voltages still have not stabilized then the PSU is switched off. In the event of a fault, the inverter pulses are inhibited and the power supply units are switched off.

7.65.2 • • • • • •

7.65.3 • • • •

Testing Ensure the breaker Q07 is OFF. The 110V DC power supply is connected to the PSU at the Front panel Connector. Check for loose connection and ensure the connections are good.

Switch ON the breaker Q07. Check the 110V DC Power Supply to the card with a multimeter. The measured voltage should be 110V + 5%. The power 110V DC can be measured across terminals X1A & X1D. If the 110V DC is available, then the PSU will generate the six Power supply voltages for the SIBAS rack.

Check individual power supply units by observing the yellow LED on the Front panel of each power supply. If the LED is ON, it indicates the power supply is OK. Flip the Q07 breaker ON and OFF as many times to ensure all the individual power supplies are OK. If the power supplies do not get ON at all, then the PSU unit is defective then replace the PSU unit

Replacing Switch off the 110V DC supply by making the breaker Q07, OFF. Also ensure that there is no voltage across terminals X1A & X1D. Pull out the card from the rack by unscrewing the top and bottom fixing screw.

Replace the PSU unit with a new unit.

Switch ON breaker Q07. Check all the individual power supply modules are ON

Caution: The module must not be plugged in or removed during operation.

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Maintenance, Trouble-Shooting and Repairs

Diagram

15-pole

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Maintenance, Trouble-Shooting and Repairs

Technical data

Order number: Backplane connector:

6FH9568-3A X1

31-pin plug connector to DIN 41612 (24+7)

Front panel connector:

X2

15-pin plug connector to DIN 41612

Slot width: Weight:

4 TE Approx. 250 g

Component ambiant temperature:

- 40 °C ... + 85 °C

Power supply:

+ 5 V ±5 % approx. 45 mA +15 V ±5 % approx. 35 mA - 15 V ±5 % approx. 8 mA Printed circuit board in Euroformat 100 mm * 160 mm varnished on both sides 4-layer artwork design in 18µ technology can be encoded mechanically Railway type according to BN 411 002

Structure:

Standards (if applicable):

EN 50155 LES-DB Isolation to VDE 0110 and VDE 0160

Primary supply voltage, starting signal Nominal value Voltage range continuous Voltage range ≤ 1 s

Number of secondary voltage monitors disconnectable, adjustable threshold non-disconnectable, fixed threshold Number of control signals Number of fault signals Voltage range, digital inputs and outputs Inhibit output Pulse inhibit Voltage range, ASA supply Electrical isolation Maintenance notes:

+110 V 66.0 V*…137.5 V 137.5 V…154.0 V * Adjustment shutdown threshold settings UAUS supply voltage, starting signal to follow 6 3 3 3 3 HCMOS level Open-collector Open-collector +5 V ... +24 V Optocoupler None

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CPU 586

Bucyrus Part no: 62057432 Component designation: A100-L139

7.66.1

Description

The CPU 6FH9604-3B is the terminal and function-compatible successor module for the CPU 6FH9604-3A. The module consists of a central processing unit motherboard (MBCPU), which is equipped with a CPU 586 adapter (ACPU 586).

The slot for the communication adapter is equipped with an CAN adapter (ACAN).

Consequently, the front panel connectors X5 and X6 are assigned with the CAN bus signals

7.66.2

• • • •

Replacing

Make sure the SIBAS rack power supply is switched off, by switching off the breaker Q07.

Unscrew the top and bottom fixing screws.

Pull out the module from the SIBAS rack and replace it with a new module.

Switch ON the breaker Q07 and check the module for correct operation.

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Maintenance, Trouble-Shooting and Repairs

Diagram

7-segment display (can be set by software)

2 LEDs: red = WATCHDOG yellow = RESET -

0

BCD switch (can be read in as software)

+

1 pushbutton (red): RESET 1 pushbutton (black): MONITOR only mode

X6

Bus terminal for ACAN 9-pin SUB-MIN-D plug connector (female)

X5

Bus terminal for ACAN 9-pin SUB-MIN-D plug connector (female)

X4 Modem terminal 9-pin SUB-MIN-D plug connector (male)

X3 Terminal for service PC 9-pin SUB-MIN-D plug connector (male)

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Maintenance, Trouble-Shooting and Repairs

Technical data

Order number:

6FH9604-3B

Slot width:

4 TE

Weight:

Approx. 650 g

Power supply:

+ 5 V ±5 % approx. 1100 mA

Structure:

Modular printed circuit board on the basis of the central processing unit motherboard

Central processing unit motherboard

-

CPU adapter

-

Communication adapter

-

Bus interface (front panel connectors X5 and X6)

CAN

Maintenance notes:

None

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Appendix

Appendix

8.1

Appendix A: Special Tools

Sr. No. 1 2 3

Description

Type no/ Size

Recommended Manufacturer Panduit Panduit -

Cable tie gun Cable tie gun Star head Screw Driver

GS2B GS4H12W T10, T20, T25, T30

4

Open spanner

6-7, 8-9(2x), 10-11, 12-13, 14-15, 16-17, 18-19, 25-28, 30-32, 41-46

-

5

Ring spanner

6-7, 10-11, 12-13, 14-15, 16-17, 18-19

-

6 7

Adjustable spanner Scrapper

8

Screw Driver

828, 902, 936

-

9 10

Scissor Ratchet set

1/4"

-

11

Extension rod

1/4"- 4", 10", 16" 32" long

-

12 13 14

T handle Tap wrench Chuck type tap wrench

up to M10

-

15

Tap set

M6, M8, M10

-

16

Tap

3,4,5,6,8,10,12

-

17

Hammer (500)

18

Ratchet for Torque Wrench

735/10,735/5

-

19 20

Measuring Steel tape Allen key set

3m

-

21

Cutter

fine & medium

-

22

Open sockets (hex)

7,8,10,13,16,17,18,19

-

23

Open sockets (1/4)

8,10,13

-

24

Ring Sockets

8,10,13,14,16,17,18,19

-

25

Punch (10mm)

-

-

-

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Appendix

Drill (11 mm)

27

File

28 29 30 31

Wire Stripper Torque wrench Torque wrench Torque wrench Extension Tool For IGBT Mounting IGBT Module alignment fixture 202009 IGBT Module alignment fixture 205173 Pump "Lutz" make with accessories

32 33 34 35

small, middle round, 4" flat, 12" flat

-

0-1 Nm 0-20 Nm 20-100 Nm

Saltus Stahlwille Stahlwille

101584869

Siemens Ltd. NW

101965051

Siemens Ltd. NW

101965052

Siemens Ltd. NW

101923387

Siemens Ltd. NW DEHN+SÖHNE, Germany

36

Grounding Harness

794377

37

Grounding Rod

761015

38 39

Digital Multimeter (DMM) High voltage probe

189 P6015A

DEHN+SÖHNE, Germany Fluke Tektronix Inc.

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8.2

Appendix B: Tightening Torque Electrical connection

May carry operating current

Mechanical connection

May carry operating Fault Current

Minimum Grade

≥ 5.8

≥ 5.8

≥ 8.8

≥ 5.8

≥ 8.8

Application

Soft Materials

Soft Materials

Hard Materials

Soft Materials

Hard Materials

M3

0.8 Nm

0.8 Nm

1.3 Nm

0.8 Nm

1.3 Nm

M4

1.9 Nm

1.9 Nm

3 Nm

1.9 Nm

3 Nm

M5

3.7 Nm

3.7 Nm

6 Nm

3.7 Nm

6 Nm

M6

6.5 Nm

6.5 Nm

10 Nm

6.5 Nm

10 Nm

M8

15 Nm

15 Nm

25 Nm

15 Nm

25 Nm

M 10

31 Nm

31 Nm

50 Nm

31 Nm

50 Nm

M 12

50 Nm

50 Nm

88 Nm

50 Nm

88 Nm

M 16

130 Nm

130 Nm

215 Nm

130 Nm

215 Nm

Thread Size

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8.3

Appendix

Appendix C: Return authorization form

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The following editions have been published to date.

Edition

Internal Document Number

06.2010 NBG- A5E02606385J NW- 4M-2601-1645709

Edition 06.2010 consists of the following chapters.

Chapter

Changes

Date of Edition

1

List of Abbreviations

Second edition

06.2010

2

General Information

Second edition

06.2010

3

Product Description

Second edition

06.2010

4

Transport and Storage

Second edition

06.2010

5

Installation & Commissioning

Second edition

06.2010

6

Maintenance

Second edition

06.2010

7

Maintenance, Trouble-Shooting and Repairs

Second edition

06.2010

8

Appendix

Second edition

06.2010

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