Cat Electric Rope Shovel 465 Series IGBT Shovel HMI - WINCC Manual (Service Manual) - PDF DOWNLOAD

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IGBT SHOVEL HMI - WINCC MANUAL

COVERING IGBT SHOVELS 495 Series SIEMENS ENERGY & AUTOMATION ALPHARETTA, GA USA

IGBT Shovel HMI - WINCC Manual Revised: 01-Oct-2007

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TABLE OF CONTENTS STARTING WINCC .................................................................................................................................... 1 SCREENS ..................................................................................................................................................... 2 START SCREEN CONSTRUCTION .................................................................................................................. 2 SCREEN DESCRIPTIONS ......................................................................................................................... 4 MAIN BUTTON MENU .................................................................................................................................. 4 OVERVIEW SCREEN ..................................................................................................................................... 6 MOTION CONTROL STATUS SCREEN ........................................................................................................... 7 MOTION / AFE SELECTION SCREENS........................................................................................................... 8 SCREEN SELECTION BUTTON DESCRIPTIONS ............................................................................................... 8 MONITOR MOTION SCREENS ....................................................................................................................... 9 CONFIGURE TESTPOINTS ............................................................................................................................. 9 RUN MANUAL ........................................................................................................................................... 11 RUN VHZ .................................................................................................................................................. 13 GROUND FAULT MONITOR ........................................................................................................................ 16 SINGLE LINES ............................................................................................................................................ 16 SIBAS RACK SCREEN ................................................................................................................................ 16 ET200 ....................................................................................................................................................... 16 ACTIVE LOGIC SCREENS..................................................................................................................... 17 SWING START/STOP LOGIC ....................................................................................................................... 18 SWING DRIVE READY ................................................................................................................................ 19 SWING SYSTEM FAULT .............................................................................................................................. 20 SWING DELAYED SHUTDOWN ................................................................................................................... 21 MOTION CONTROL READY ........................................................................................................................ 22 ALL MOTIONS DELAYED STOP .................................................................................................................. 23 ALL I/O STATIONS HIGH TEMPERATURE ................................................................................................... 24 I/O STATIONS UNDER TEMPERATURE ....................................................................................................... 25 SHUTDOWN WITH ELECTRICAL BRAKE ..................................................................................................... 26 EMERGENCY SHUTDOWN .......................................................................................................................... 27 HOIST START/STOP LOGIC ........................................................................................................................ 28 HOIST DRIVE READY................................................................................................................................. 30 HOIST GEARCASE OIL ............................................................................................................................... 31 HOIST SYSTEM FAULTS ............................................................................................................................. 32 HOIST/PROPEL DELAYED SHUTDOWN ....................................................................................................... 33 CROWD START/STOP LOGIC ...................................................................................................................... 34 CROWD DRIVE READY .............................................................................................................................. 36 CROWD SYSTEM FAULT ............................................................................................................................ 37 CROWD DELAYED SHUTDOWN .................................................................................................................. 38 SWING BRAKE SOLENOID VALVE .............................................................................................................. 39 HOIST BRAKE SOLENOID VALVE............................................................................................................... 40 CROWD BRAKE SOLENOID VALVE ............................................................................................................ 41 PROPEL BRAKE SOLENOID VALVE ............................................................................................................ 42 SYSTEM READY LIGHT .............................................................................................................................. 44 DIPPER TRIP CONTACTOR ......................................................................................................................... 46 PROPEL HORN ........................................................................................................................................... 47 DIG / PROPEL TRANSFER CONTACTORS ..................................................................................................... 48 HIGH VOLTAGE CONTROL RELAY 1 (CR1) ............................................................................................... 49 DC BUS PRECHARGE ................................................................................................................................. 50 DC BUS INCOMPLETE SEQUENCE .............................................................................................................. 52

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LUBE SYSTEM A1 LUBE PUMP .................................................................................................................. 53 LUBE SYSTEM A1 MANUAL MODE ........................................................................................................... 54 LUBE SYSTEM A2 LUBE PUMP .................................................................................................................. 55 LUBE SYSTEM A2 MANUAL MODE ........................................................................................................... 56 LUBE SYSTEM B1 LUBE PUMP .................................................................................................................. 57 LUBE SYSTEM B1 MANUAL MODE............................................................................................................ 58 LUBE SYSTEM B2 LUBE PUMP .................................................................................................................. 59 LUBE SYSTEM B2 MANUAL MODE............................................................................................................ 60 LUBE SYSTEM C1 LUBE PUMP .................................................................................................................. 61 LUBE SYSTEM C1 MANUAL MODE............................................................................................................ 62 LUBE SYSTEM C2 LUBE PUMP .................................................................................................................. 63 LUBE SYSTEM C2 MANUAL MODE............................................................................................................ 64 CONTROL CABINET FAN CONTACTOR ....................................................................................................... 65 FRONT INTAKE FAN................................................................................................................................... 66 REAR INTAKE FAN .................................................................................................................................... 67 REAR INTAKE FAN .................................................................................................................................... 68 REAR INTAKE FAN REVERSE / FORWARD .................................................................................................. 69 FRONT INTAKE FANS REVERSE CONTACTORS ........................................................................................... 70 FRONT INTAKE FANS REVERSE CONTACTORS ........................................................................................... 71 STATUS SCREENS ................................................................................................................................... 72 MOTION CONTROL STATUS ....................................................................................................................... 72 MOTOR TEMPERATURE STATUS ................................................................................................................ 72 INVERTER TEMPERATURE ......................................................................................................................... 72 FAULT COUNTER / OPERATING HOURS SCREEN ........................................................................................ 73 FOOT PRINTS ............................................................................................................................................. 73 TROUBLE SHOOTING ................................................................................................................................. 75 NAVIGATION WITHIN THE TROUBLESHOOTING MANUAL SCREENS ........................................................... 75 FAULT HISTORY ........................................................................................................................................ 76 ACTIVE ALARMS ....................................................................................................................................... 80 BEARING STATUS OPTION .................................................................................................................. 82 BEARING STATUS DECK PLAN SCREEN ..................................................................................................... 82 BEARING STATUS DECK PLAN - HOIST LEFT HAND DETAIL SCREEN ........................................................ 83 BEARING STATUS DECK PLAN - HOIST RIGHT HAND DETAIL SCREEN ...................................................... 84 BEARING STATUS DECK PLAN - HOIST MOTOR DETAIL SCREEN .............................................................. 85 BEARING STATUS DECK PLAN - CROWD LEFT HAND DETAIL SCREEN...................................................... 86 BEARING STATUS DECK PLAN - CROWD RIGHT HAND DETAIL SCREEN ................................................... 87 BEARING STATUS DECK PLAN - CROWD MOTOR DETAIL SCREEN ............................................................ 88 BEARING STATUS DECK PLAN - SWING GEARCASE DETAIL SCREEN ........................................................ 89 BEARING STATUS DECK PLAN - SWING MOTOR 2 DETAIL SCREEN ........................................................... 90 BEARING TEMPERATURE SCREENS ................................................................................................ 92 HOIST BEARING TEMPERATURE SCREEN ................................................................................................... 92 CROWD BEARING TEMPERATURE SCREEN ................................................................................................ 93 CROWD SHAFT BEARING TEMPERATURE SCREEN ..................................................................................... 93 SWING GEARCASE BEARING TEMPERATURE SCREEN ................................................................................ 94 SWING MOTOR BEARING TEMPERATURE SCREEN ..................................................................................... 95 APPENDIX ................................................................................................................................................. 96 COMPUTER SETTINGS FOR TROUBLESHOOTING MANUAL ......................................................................... 96 WINCC INSTALLATION ........................................................................................................................ 99 PROJECT INSTALLATION.................................................................................................................. 102

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FAULTS .................................................................................................................................................... 104 REVISING FAULT TEXT ............................................................................................................................ 105 CREATING NEW FAULTS ......................................................................................................................... 106 INSTALLATION OF FAULT HISTORY CONTROL ......................................................................................... 113 INSTALLATION OF TRACE VIEWER .............................................................................................. 115

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Starting WinCC To start WinCC select the Start button in lower left-hand corner of the Windows Taskbar.

Select Simatic Æ WinCC Æ WinCC 6.0. This will start the program application.

An alternative way is to double-click the WinCC Explorer icon which is often on the desktop or the Quick Launch area. Its icon looks like this:

The program will default to the last project opened, if this is a new installation a prompt will appear and you can choose to open an existing project or start a new project. If you are selecting an existing project, go to the project directory, select the ".MCP" file and then Open. This will open WinCC Control Center and load the project.

To start Runtime press the arrowhead icon in the Toolbar.

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Screens

Start Screen Construction The initial or Start picture used in this project contains three Picture Windows. This allows the screen area to change, but the static portions such as the header and button menu to be created only once. Setting up the screen in this manner is helpful in terms of maintenance. The screen area is changed via scripts that reset the picture Window "Screens" on 0a.pdl The main screen (0a.pdl) is comprised of three main sections.

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Header (0a2_overview.pdl)

The header contains the Siemens logo, last revision date, current screen title, and current date and time. The screen title is changed via a text tag. This tag is attached to the font in the header. As a new screen opens the tag is reset changing the display. Pixel count for header is 1025 x 35.

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Screen ("PDL" name varies based on screen called.)

This section displays the currently selected screen. When runtime is initially started the "Overview.pdl" is the default screen. Pixel count is 1000 x 540, all PDL's for the screen area should be this size.

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Key - (0_key_22.pdl, 0_key_0z.pdl or 0_key_0z_Active.pdl) Displays screen selection buttons and the two most recent faults. Button Menu displayed depends on screen selection. The Fault History & Active Alarm screens display different menus. Fault History Menu buttons are used for configuring fault display. Pixel count for the keypads is 1025 x 190.

The following Picture Windows are also used on the main start screen (0A.pdl) for Submenus and Miscellaneous screens.

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Submenus - pop-up screens displaying secondary screen selections.

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Single Line (0_key_submenu_SL.pdl) (layer 4).

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Active Logic submenus

(0_key_submenu_AL.pdl) (layer 1) (0_key_submenu_AL_fans.pdl) (layer 2)

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(0_key_submenu_AL_lube.pdl) (layer 3).

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Ground Fault Monitor (0_key_submenu_test.pdl) (layer 4).

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ET200 submenu (0_key_submenu_ET200.pdl) (layer 5).

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Status screens submenu

(0_key_submenu_status.pdl) (layer 7).

(0_key_submenu_status_BEARING_OPT.pdl) (layer 4 - displays for bearing option machines only).

•

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Footprint submenu (0_key_submenu_FOOT.pdl) (layer 6).

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Utilities (0_key_submenu_KEYS.pdl) (layer 8).

Miscellaneous Screens •

Motion_exit_request.pdl (layer 2)

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COLOR_KEY.pdl (layer 6)

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Language Menu (0_key_submenu_lang.pdl) (layer 5)

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0_menu_help.pdl (layer 1)

Screen names appear as close to the lower right hand corner as possible of each screen.

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Fault Objects

Layer 15 and 14 are dedicated to fault objects. These objects are part of the Fault History Save program. Sibas fault objects are located on layer 15 and CDA & ANF fault objects are on layer 14.

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SiRAS Transmitter

Layer 14 also contains the SiRAS transmitter.

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Screen Descriptions Main Button Menu

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Overview

This button changes the screen to the Overview Picture. General system information and Password functions are available on this screen.

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Motion Status

Opens the Motion Status screen, which displays general status information for individual motions. Machine mode status and voltage information is also available on this screen.

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Motion / AFE Selections

Opens a selection screen. From this screen selections can be made based on a specific machine motion. Selection options pertain to screen control and monitoring functions.

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Ground Fault Monitor

Opens the Ground Fault Monitor submenu. If all machine requirements have been met, the submenu will allow entry to the Ground Fault Monitor screen.

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Single Lines

Opens a submenu for screens displaying information in Single Line format.

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Active Logic

Activates a submenu allowing selection of troubleshooting screens displayed in logic form.

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SiBas Rack

Screen changes to a graphical representation of the SiBas Rack.

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ET200 Racks

Activates a submenu allowing a selection of the ET200 layout overview or a specific ET200 rack.

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Status

Activates submenu for selection of status screens displaying temperature, speeds, and control functions.

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Footprints

Activates a submenu allowing selection of footprint drawings based on location.

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Troubleshooting

Initiates the Troubleshooting Manual. The default page is the manual cover page.

From this page you can select fault descriptions, component descriptions, or general system information via the button menu.

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Previous

Returns display to the last screen displayed. This feature will not return to screens that require password or special conditions to enter. If a previous screen is password protected a message will display directing the user to enter the screen via the Main Button Menu.

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Fault History

Activates the Fault History screen and Fault History button menu.

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Active Faults

Activates the Active Fault screen Active Fault button menu.

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Language Selection

This key displays a menu allowing the WinCC system text to be toggled between English and an alternate language (if purchased).

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Utilities

Activates a submenu providing selections for saving files to external locations, color key, and help file for the Main Button Menu.

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Overview Screen

This screen was designed to display general system information at a glance. The indicators in the upper left-hand corner of the screen are green if a system is okay and red if there is a fault occurring within that system. Voltage, bus values, and hoist gearcase oil temps are also displayed.

Pressing the SET NEW PASSWORD button on this screen will open a sub-screen where the system password can be changed. The original password must be entered to enable the password change function. Passwords are made up of numeric characters only and cannot start with the number zero (0). The same password is used on all screens throughout the system.

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Motion Control Status Screen

The Motion Control Status screens provide general troubleshooting information for all Motions and the AFE. Status displays for each motion include ON/OFF, READY/NOT READY, FAULT/NO FAULT, WARNING and BRAKE SET/BRAKE RELEASE. Additional Status displays include: Line Volts HIGH/LOW/OK, WARNING, Actual Line Voltage & DC Bus Voltage.

The Shovel mode is displayed at the top of the screen. The Swing, AFE, Line Volts and DC Bus Volts displays are visible in both Dig and Propel modes. When the shovel is in Dig Mode the top two displays will be Hoist and Crowd statuses. When the shovel is in Propel mode, Right Propel and Left Propel statuses will be displayed in these positions.

This screen is also available from the Status submenu.

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Motion / AFE Selection Screens

This screen is for Motion and AFE control selections. On the right-hand side of the screen the current operating mode of the shovel is displayed. On the left-hand side of the screen, drive selections are available. In Dig Mode: Hoist, Crowd, Swing & AFE motions are available. In Propel Mode: Propel 1, Propel 2, Swing & AFE motions are available. Selecting one of these buttons will activate a menu in the center of the screen. From this menu, selections for control screens can be made. Screen selection buttons with an * require a password to enter the screen.

Screen Selection Button Descriptions • Monitor Motion Opens a screen displaying speed, setpoint, motor voltage and motor current information in numeric and trend formats.

• Configure Testpoints Opens a screen for selecting testpoints for the currently selected motion.

• Run Manual Opens a screen with control options for selected motion. This screen is password protected. (Not available for AFE).

• Run VHz Opens a screen with control options for selected motion. This screen is password protected. (Not available for AFE).

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• Menu Help Provides descriptions of function of each button displayed on this screen.

• Cancel Closes selection screen.

Monitor Motion Screens

These screens provide graphical representations and real time read outs. Selections can be made for individual or all AFEs or Drives. On the AFE Monitor Motion screen, pressing the Signal Monitor Detail button displays a screen showing just the trend portion of the screen. These screens can also be accessed from the Run Manual or Run VHz screens.

Configure Testpoints

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Testpoint Screens are available for all Motions. Buttons on this screen are arranged and labeled by column (vertical) and row (horizontal). Only one button per row can be selected at a time. Selecting a button will automatically deselect any other button on the same row. Selected buttons are green. Coding- all selections write to the same tag. The tag is set to a specific value for each selection. The Default key defaults the selection to each button in column 1. Last selections made will be displayed upon reentering the screen with the exception of the first time this screen is displayed after a system startup then no selections will be shown.

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Run Manual

This screen is password protected and should be entered by trained personnel only. All drives are switched to Manual Mode upon entry into this screen. Entry into this screen is only permitted if all drives are off and all brakes are set. A message will be displayed upon entry into this screen blocking all selections until the change to Manual Mode is complete. If at anytime Manual Mode fails, a screen will display blocking further activity and instructions for logging out of this screen. From this screen you can manually start and stop all swing drives, change speed and current limits, and monitor status and actual values. Monitor Motion screens can be accessed from this screen. To exit this screen all drives must be off and brakes set. Screen must be exited via "Exit Manual Mode" button to insure all conditions have been met.

• Entry conditions • Brakes Set • Drives Off • Correct Password •

Screen Options • Brake Mode The Brake Mode section is located in the upper-right hand side of the screen. The AUTO MODE/MANUAL MODE button is a toggle button, which allows the operator to change the brake mode from automatic to manual. The Status display below the button displays the actual brake mode. When the brake is in Automatic mode the status display displays the text AUTO MODE on a green background. When the brake is in Manual mode the text MANUAL MODE is displayed on a flashing red

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background indicating potentially dangerous condition. The brake mode must be in MANUAL to release the brakes.

• Brake Status The Brake Status section is located in the center portion of the screen. The RELEASE/SET BRAKE button is only visible when the Brake Mode is set to Manual.

The Brake Status display is located below the Brake release/set button is always visible. When the Brake is released this status display is red indicating potentially dangerous conditions and green when the brake is set.

• Motion On/Off Control & Status Display The Motion On/Off button allows the operator to start or stop the drive. The Status display below the button displays the actual drive condition. If the proper conditions for starting the drives are not set a message saying "Drive Not Ready" will be displayed over the stop/start button preventing the use of this button • DC Bus Status Display When the DC Bus is on this status display is red indicating potentially dangerous conditions and green when the DC Bus is off.

• Motor Amps Display Displays the actual motor current.

• Tach Speed Display Displays the actual tachometer speed of the motor in RPMs. This field is for display only.

• Current Limit Display Displays the actual Current Limit value while in manual mode. This value may be changed using the incremental buttons on either side of the value display field.

• Speed Command Display and Inc/Dec/Reverse Displays the actual Speed Command value. This value may be changed using the incremental buttons on either side of the value display field. The Reverse Speed button next to this field inverts the polarity of the displayed speed command and allows full speed reversals while in manual mode.

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Increase/Decrease Buttons

Pressing a button displaying a single arrowhead will increment the display value by +/- 1 depending on the arrow direction.

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Pressing a button displaying a double arrowhead will increment the display value by +/- 10 depending on the arrow direction.

• Monitor Motion Button Changes screen the Monitor Motion Detail screen. Screen exit is not allowed from the Monitor Motion Screen. To exit this screen return to the Run Manual screen.

• Screen Help Button Displays information about all the button functions on this screen.

• Exit Manual Mode Button Screen must be exited using this button. This button sets the appropriate exiting conditions. A Please Wait screen will appear until the proper conditions are set for exiting. When exit is available another screen will popup allowing you to exit the screen. Exiting this screen returns the display to Motion/AFE Selection Screen.

• •

Exit Conditions • Brakes Set • Drives Off Exit via Exit Manual Mode button only, if the screen is not exited in this manner a warning screen will appear.

Run VHz

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This screen is password protected and should be entered by trained personnel only. All drives are switched to Manual Mode upon entry into this screen. Entry into this screen is only permitted if all drives are off and all brakes are set. A message will be displayed upon entry into this screen blocking all selections until the change to Manual Mode is complete. If at anytime Manual Mode fails, a screen will display blocking further activity and instructions for logging out of this screen. From this screen you can manually start and stop all swing drives, change speed and current limits, and monitor status and actual values. Monitor Motion screens can be accessed from this screen. To exit this screen all drives must be off and brakes set. Screen must be exited via "Exit VHz Mode" button to insure all conditions have been met.

• Entry conditions • Brakes Set • Drives Off • Correct Password •

Screen Options • Brake Mode The Brake Mode section is located in the upper-right hand side of the screen. The AUTO MODE/MANUAL MODE button is a toggle button, which allows the operator to change the brake mode from automatic to manual. The Status display below the button displays the actual brake mode. When the brake is in Automatic mode the status display displays the text AUTO MODE on a green background. When the brake is in Manual mode the text MANUAL MODE is displayed on a flashing red background indicating potentially dangerous condition.

• Brake Status The Brake Status section is located in the center portion of the screen. The RELEASE/SET BRAKE button is only visible when the Brake Mode is set to Manual.

The Brake Status display is located below the Brake release/set button is always visible. When the Brake is released this status display is red indicating potentially dangerous conditions and green when the brake is set.

• Motion On/Off Control & Status Display The Motion On/Off button allows the operator to start or stop the drive. The Status display below the button displays the actual drive condition. If the proper conditions for starting the drives are not set a message saying "Drive Not Ready" will be displayed over the stop/start button preventing the use of this button • Motor Amps Display Displays the actual motor amps. This field is for display only.

• Tach Speed Display Displays the actual tachometer speed. This field is for display only.

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• Motor Frequency Display Displays the motor frequency. This field is for display only.

• Current Limit Display Displays the actual Current Limit value. This field is for display only.

• Frequency Displays the actual Frequency value. This value may be changed using the incremental buttons on either side of the value display field.

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Increase/Decrease Buttons

Pressing a button displaying a single arrowhead will increment the display value by +/- 1 depending on the arrow direction.

Pressing a button displaying a double arrowhead will increment the display value by +/- 10 depending on the arrow direction.

• Monitor Motion Button Changes screen the Monitor Motion Detail screen. Screen exit is not allowed from the Monitor Motion Screen. To exit screen return to the Run VHz screen.

• Screen Help Button Displays information about all the button functions on this screen.

• Exit VHz Mode Button Screen must be exited using this button. This button sets the appropriate exiting conditions. A Please Wait screen will appear until the proper conditions are set for exiting. When exit is available another screen will popup allowing you to exit the screen. Exiting this screen returns the display to Motion/AFE Selection Screen.

• • • •

Exit Conditions Brakes Set Drives Off Exit via Exit Manual Mode button only, if the screen is not exited in this manner a warning screen will appear.

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Ground Fault Monitor This screen is used to locate a ground fault. To enter this screen all drives must be off, the brakes must be set and the Bus must be off. Once a correct password is given and the screen is accessed, the bus must be brought up before Ground Fault testing can continue. The ground fault circuit is displayed in single line format. If no faults are detected the screen components will display green. When a fault is detected the affected area will display red.

Single Lines These screens are electrical representations of the system used for circuit information and identifying faults. Monitored components will display green if okay, red if faulted.

• System Single Line • Power System Single Line • Main Control Power Distribution Single Line This screen can also be accessed from the Main Auxiliary Power Distribution Single Line • Main Auxiliary Power Distribution Single Line This screen can also be accessed from the Main Control Power Distribution Single Line • Auxiliary Power Distribution Single Line SiBas Rack Screen This screen is a graphical representation of the SiBas rack. Pointing at a specific card will display a tool tip containing slot location and part number information. Pressing a card will open a new screen displaying specific information about the card selected. A button is available on each of these card specific screens for displaying backplane wiring information. Some cards will have additional buttons that will activate pop-up screens displaying more detail information about specific components of the card displayed ET200 From the selection menu you can go to an overview of the ET200 system or you can access individual ET 200 racks. From the System Overview screen you can see at a glance if a system is faulted, pressing a particular ET200 rack will take you to that rack.

On the individual rack screens detailed information is available. Working Leds are displayed making it possible to troubleshoot ET200 racks from the WinCC terminal. Selecting a specific card will display card specific information, including type of card, part number, and programming details. Working Leds are also displayed on these screens.

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Active Logic Screens These screens represent different machine actions in a simplified logic format and are mainly for use by Electricians. Components will display red or green depending on their state. Green denotes components that are energized and operating. Red denotes a de-energized state or a faulted condition. Pressing a component provides either an information screen or a new screen providing more detailed information. The "Close" button on any screen will return you to the previous Active Logic Screen.

The following main Active Logic screens are available.

• Hoist Start/Stop Logic • Crowd Start/Stop Logic • Swing Start/Stop Logic • Hoist Brake Valve Logic • Crowd Brake Valve Logic • Swing Brake Valve Logic • Dipper Trip Contactor • Propel Brake Valve Logic • System Ready • Fan Control • Propel Horn • DC Bus Precharge • Lube Screens • Propel Transfer Contactor • High Voltage Contactor Relay 1 • Hydraulic Crowd (optional, only shown if available on machine)

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Swing Start/Stop Logic

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Swing Masterswitch Left & Swing Masterswitch Right (I 29.7, I 29.6) These 2 inputs when on indicate Swing joystick is left or right. When both inputs are off, the joystick is centered. Centering the joystick is necessary condition to start the drive.

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Swing Drive Ready (DB3412.dbx0.5) Drive Ready Signal is a necessary condition to start the drive. Once started this signal is not needed.

See page 20 for detail screen.

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Control Reset Button (I 28.0) The drives will not start until this button is pressed

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Motion Control Ready (M11.0) See page 73 for detail screen.

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Swing System Fault (M 20.0) See page 21 for detail screen.

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Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

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•

Hoist Reeving Mode (Q 66.2) This signal generated by request from Operator Panel.

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Crowd Reeving Mode (Q 66.3) This signal generated by request from Operator Panel.

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Swing Incomplete Sequence Timer (T55)

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Swing Brake Switch (CAB) (I 29.0) This signal is a direct request from Operator Panel.

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Boarding Ladder (I 0.4) Boarding Ladder Limit Switch off when ladder is down. This will prevent starting or running of the Swing motion.

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Swing Drive On (To SiBas) (Q 24.2) This is a command bit to SiBas to turn on the swing drive.

Swing Drive Ready

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Swing On from SiBas (I 172.2) This is a hardwired signal from the SiBas. This block will turn red when the SiBas has detected a fault in the Swing inverter.

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•

Swing Brake Released (DB3402.dbx 0.6) Signal from SiBas drive has no faults.

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Swing Drive Fault (I172.5)

This is a hardwired signal from the SiBas. This block will turn red when the SiBas has detected a fault in the Swing inverter.

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Swing Speed < 2.5 Hz (DB3412.dbx1.7)

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Swing Drive Ready (DB3412.dbx0.5) Drive Ready Signal is a necessary condition to start the drive. Once started this signal is not needed.

Swing System Fault

•

Swing Delayed Shutdown (T20) Delayed 30 seconds.

See page 22 for detail screen.

•

Swing Drive Fault (I 172.5) This is a hardwired signal from the SiBas. This block will turn red when the SiBas has detected a fault in the Swing inverter.

•

Swing Shaft Dropped (M250.0)

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•

This contact will be green unless the PLC detects that one of the swing shafts is dropped.

Swing 1 Brake Release Fault (DB3200.dbx14.5) A swing 1 brake release fault has occurred.

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Swing 2 Brake Release Fault (DB3200.dbx14.6) A swing 2 brake release fault has occurred.

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Swing Tach Circuit Breaker (I 173.7) Fault when breaker is open.

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Swing System Fault (M34.0)

Swing Delayed Shutdown

•

Swing Motor 1 Temperature Shutdown (DB32.dbx2.4) The temperature of swing motor #1 has exceeded 150 degrees Centigrade.

•

Swing Motor 2 Temperature Shutdown (DB32.dbx2.5) The temperature of swing motor #1 has exceeded 150 degrees Centigrade.

•

Swing Brake Overtemperature (M25.1)

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Swing 1 Blower Control Fault (DB1.dbx7.7)

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Swing 2 Blower Control Fault (DB1.dbx8.0)

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• •

Swing 1 Low Oil (DB1.dbx21.3) Swing 2 Low Oil (DB1.dbx21.4)

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Swing Delayed Shutdown (M19.1)

Motion Control Ready

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All Motions Delayed Stop (T17) See page 24 for detail screen.

•

Shutdown with Electrical Braking (M19.3) See page 27 for detail screen.

•

Emergency Shutdown (M12.2) See page 28 for detail screen.

•

Hoist System Fault (M19.5) See page 33 for detail screen.

•

Swing System Fault (M20.0) See page 21 for detail screen.

•

Crowd System Fault (M20.2) See page 38 for detail screen.

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•

Motion Control Disable (M22.1)

•

Control Stop Pushbutton (I 33.4) The drives will not start if this button is pressed.

•

Bus Up with Brakes Set (M24.6) Bus is up all brakes are set.

•

Motion Control ready (M11.0) All conditions have been met to start motion.

All Motions Delayed Stop

•

Rear Intake Fan Fault (DB1.dbx8.6)

•

Drive Transformer 1 Blower (DB1.dbx20.1)

•

Drive Transformer 1 Temperature (DB1.dbx20.2)

•

Drive Transformer 2 Temperature (DB1.dbx21.1)

•

Drive Transformer 2 Blower (DB1.dbx21.2)

•

Hoist Oil Temperature Fault (DB1.dbx19.6)

•

Hoist Low Oil Pressure Fault (DB1.dbx19.7)

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•

Heat Exchanger 1 Circuit Breaker (I 169.3)

•

Heat Exchanger 2 Circuit Breaker (I 169.4)

•

Drive Cabinet temperature (I 32.6)

•

Reactor Temperature Shutdown (M47.1)

•

Blower 1 Circuit Breaker (I 169.6)

•

Blower 2 Circuit Breaker (I 169.7)

•

Air Flow 1 (I 33.5)

•

Air Flow 2 (I 33.6)

•

I\O Station Under Temperature (M30.0) See page 26 for detail screen

•

I\O Station Over Temperature (M30.1) See page 25 for detail screen

•

All Motions Delayed Stop (M18.5)

All I/O Stations High Temperature

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•

MCC Rack Temperature Too High (I 24.6)

•

Crowd Rack Temperature Too High (I 0.6)

•

Operators Cab Rack Temperature Too High (I 28.6)

•

Hoist Rack Temperature Too High (I 8.6)

•

Skid Rack Temperature Too High (TH2) (I 32.5)

•

Skid Rack Temperature Too High (TH1) (I 32.4)

•

Drive Cabinet Rack Temperature Too High (I 32.6)

•

Lube Rack Temperature Too High (I 17.6)

•

I/O Station Over-temperature (M30.1)

I/O Stations Under Temperature

•

Operators Cab Rack Temperature Too Low (I 28.7)

•

Crowd Rack Temperature Too Low (I 0.7)

•

MCC Rack Temperature Too Low (I 24.7)

•

Hoist Rack Temperature Too Low (I 8.7)

•

Lube Rack Temperature Too Low (I 17.7)

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•

Drive Cabinet Temperature (I 32.6)

•

I/O Station Under Temperature (M30.0)

Shutdown with Electrical Brake

•

Machine Stop Pushbutton (I 33.0) This normally closed pushbutton is off when pushed.

•

Low Air Pressure (DB1.dbx7.4) This fault occurs if normally closed Air Pressure Switch (I17.4) is off for 1 second while main contactor is on (I32.7).

•

AFE Fault (From SiBas) (I 172.6) This fault comes from SiBas.

•

Shutdown With Electrical Brake (M19.3)

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Emergency Shutdown

•

Power Off Emergency Button (POEB) (I 33.1) POEB button is a NC switch which is on when no emergency.

•

PLC Nodes 2 – 5 & 7- 8 (DB1.dbx0.3, DB1.dbx0.4, DB1.dbx0.5, DB1.dbx0.6, DB1.dbx1.0, DB1.dbx1.1) & PLC Node 10 (DB1.dbx1.3 – Bearing Temp Option Only) These signals indicate that each of the ET200 I/O stations have communication with the S7 416 CPU and have fully functioning I/O. The following will cause a node to be faulty: • Profibus cable connection faulty • Profibus terminating resistor switch set incorrectly • No 24 V power supplied to the node.

• An IM 153 interface module needs replacing

•

PLC Nodes 2 – 7 Analog I/O (DB1.dbx3.4, DB1.dbx3.5, DB1.dbx3.6, DB1.dbx3.7, DB1.dbx4.0, DB1.dbx4.1) & PLC Node 10 (DB1.dbx4.2 – Bearing Temp Option Only) These signals indicate that the analog cards of each of the 6 listed I/O stations are OK. If an analog card is faulty or 24 V supply is not connected, the signal will indicate not OK. (NOTE: after problem has been fixed it may be necessary to cycle the S7 CPU 416 to STOP mode and back to RUN mode to make the fault disappear.

Shovel must be taken out of service first.)

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•

UPS Circuit Breaker (I 169.0) Uninterruptible Power Supply circuit breaker is closed.

•

SiBas Circuit Breaker (I 169.1) SiBas power supply circuit breaker is closed.

•

24V Firing Pulse Circuit Breaker (I 169.2) Gate Firing Pulses power supply circuit breaker is closed.

•

AFE Fault (I 172.6)

•

Emergency Shutdown (M18.4)

Hoist Start/Stop Logic

•

Hoist Drive On (To SiBas) (Q 24.1) Status Hoist drive off from SiBas (I172.1)

•

Hoist Masterswitch Hoisting, (I 29.2), Hoist Masterswitch not lowering (I 29.3) These 2 inputs when on indicate Hoist joystick is hoisting or lowering. When both off, joystick is centered. Centering the joystick is a necessary condition only to start the drive.

•

Hoist Drive Ready (DB3410.DBX0.5) Drive Ready Signal from SIBAS is a necessary condition to start the drive. Once Hoist is started, this signal is not needed. * See page 35 for detail screen.

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•

Control Reset Button (I 28.0) The drives will not start until this button is pressed.

•

Dig Mode (Q66.0)

•

Hoist Brake Switch (CAB) (I 28.3)

•

Hoist Oil Cooling System (M46.5) Once Hoist started, this signal not needed. * See page 34 for detail screen.

•

Hoist Brake Valve (Q 16.0)

•

Propel Mode (Q 66.1)

•

Propel Brake Switch (CAB) (I 29.1)

•

Boarding Ladder (I 0.4) Boarding Ladder Limit Switch off when ladder is down. This will prevent starting or running of the Swing motion.

•

Motion Control Ready (M11.0) See page 23 for detail screen.

•

Hoist System Fault (M19.5) See page 33 for detail screen.

•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Crowd Reeving Mode (Q66.3) This signal generated by request from Operator Panel.

•

Center Pintle Nut Tightening Mode (Q66.4) This signal generated by request from Operator Panel.

•

Hoist Incomplete Sequence Timer (T53)

•

Hoist Drive On (To SIBAS) (DB3400.dbx0.1) This is a command bit to SIBAS to turn on the Hoist drive.

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Hoist Drive Ready

•

Hoist Drive On (DB3410.dbx0.0) Status Hoist Drive On from SiBas (I172.1)

•

Hoist Brake Released (DB3400.dbx0.6)

•

Hoist Drive Fault (I 172.4) Signal from SiBas

•

Hoist Speed < 2.5 Hz (DB3410.dbx1.7)

•

Hoist Drive Ready (DB3410.dbx0.5)

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Hoist Gearcase Oil

•

Hoist Oil Pump (DB1.dbx19.2)

•

Hoist Low Oil Pressure Fault (DB1.dbx19.7)

•

Hoist Radiator Fan (DB1.dbx19.3)

•

Hoist Radiator Fan (DB1.dbx19.4) Available with Fan 2 option only.

•

Hoist Gearcase Oil Temperature Below 225° F (M46.7) If Hoist Gearcase Oil is below 225 degrees Fahrenheit then Hoist Gearcase Oil = Not Okay. (PIW556 Hoist Gearcase Oil Temperature)

•

Hoist Gearcase Oil (M46.5)

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Hoist System Faults

•

Propel Delayed Shutdown (T18) Delayed 30 seconds.

•

Hoist Delayed Shutdown (T19) Delayed 30 seconds.

•

Hoist Drive fault (I 172.4)

•

Hoist Brake Release Fault (DB3200.dbx14.3) Fault if I 9.6 = 0 while Hoist Drive is on.

•

Heat Tach Circuit Breaker (I 173.6) Fault when breaker is open.

•

Hoist System Fault (M19.5)

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Hoist/Propel Delayed Shutdown

•

Propel Motor Overtemperature (T90)

•

Propel Blower Control Fault (DB1.dbx8.2)

•

Propel Delayed Shutdown (M18.6)

•

Hoist Motor Overtemperature (M32.1)

•

Hoist Blower Control Fault (DB1.dbx7.6)

•

Hoist Brake Overtemperature (I 8.2)

•

Hoist Delayed Shutdown (M19.0)

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Crowd Start/Stop Logic

•

Crowd Drive On (To SiBas) (Q24.0)

•

Crowd Masterswitch Crowding, Crowd Masterswitch Retracting (I29.4, I 29.5) These 2 inputs when on indicate Crowd joystick is Crowding or retracting. When both off, joystick is centered. Centering the joystick is necessary condition to start the drive.

•

Crowd Drive Ready (DB3411.DBX0.5) Drive Ready Signal from SIBAS is a necessary condition to start the drive. Once started this signal not needed. * See page 41 for detail screen.

•

Control Reset Button (I 28.0) The drives will not start until this button is pressed.

•

Dig Mode (Q66.0)

•

Crowd Release Brake Switch (I 28.5)

•

Propel Mode (Q66.1)

•

Propel Release Brake Switch (I 29.1)

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•

Boarding Ladder (I 0.4) Boarding Ladder Limit Switch off when ladder is down. This will prevent starting or running of the Swing motion.

•

Motion Control Ready (M11.0) See page 23 for detail screen.

•

Crowd System Fault (20.2) See page 38 for detail screen.

•

Drives Power Contactor (DPC) (I 32.7) The DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Hoist Reeving Mode (Q 66.2) This signal generated by request from Operator Panel.

•

Center Pintle Nut Tightening Mode (Q66.4) This signal generated by request from Operator Panel.

•

Crowd Incomplete Sequence Timer (T54)

•

Crowd Drive On (To SIBAS) (Q24.0) This is a command bit to SIBAS to turn on the Crowd drive.

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Crowd Drive Ready

•

Crowd Drive On (I172.0) Status Crowd Drive from SiBas.

•

Crowd or Brake Released Brake Released (DB3401.dbx0.6)

•

Crowd Drive Fault (I 172.3) Signal from SiBas

•

Crowd Speed < 2.5 Hz (DB3411.dbx1.7)

•

Crowd Drive Ready (DB3411.dbx0.5)

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Crowd System Fault

•

Propel Delayed Shutdown (T18) See Page 34 for details.

•

Crowd Delayed Shutdown (T21) See Page 39 for details.

•

Crowd Drive Fault (I 172.3)

•

Crowd Brake Release Fault (DB3200.dbx14.4) Fault if analog input PIW556 measures Hoist Gearcase Oil Temperature > 225 degrees Fahrenheit.

•

Crowd Tach Circuit Breaker (I 173.5)

•

Crowd System Fault (M20.2) See Page 38 for details.

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Crowd Delayed Shutdown

•

Crowd Motor Overtemp (M32.3)

•

Crowd Brake Overtemp (I 0.2)

•

Crowd Blower Control Fault (DB1.dbx8.1)

•

Crowd Delayed Shutdown (M19.2) See Page 39 for details.

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Swing Brake Solenoid Valve

•

Swing Minimum Current (DB3412.dbx0.4)

•

Swing Drive On (To SiBas) (Q 24.2) This is a command bit to SiBas to turn on the Swing drive.

•

Swing Break Valve (Q 17.0) A “1” at this output activates Swing Brake Solenoid Valve and releases brake.

•

Swing Speed < 2.5 Hz (DB3412.dbx1.7)

•

Swing In Regeneration (DB3418.dbx1.3)

•

Swing Gate Blocked (DB3418.dbx0.2) The Swing Gate Blocked signal from SiBas indicates either a Swing drive fault or Swing drive is not on.

•

Machine Stop Pushbutton (I 33.0)

•

Power Off Emergency Pushbutton (I 33.1) POEB button is a NC switch which is on when no emergency.

•

Drives Power Contactor ( I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

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•

Swing Break Valve (Q 17.0) A “1” at this output activates Swing Brake Solenoid Valve and releases brake.

Hoist Brake Solenoid Valve

•

Hoist Drive Minimum Current (DB3410.dbx0.4)

•

Hoist Drive On (To SiBas) (Q 24.1) This is a command bit to SiBas to turn on the Hoist drive.

•

Hoist Brake Valve (Q 16.0) A “1” at this output activates Hoist Brake Solenoid Valve and releases brake.

•

Hoist Speed < 2.5 Hz (DB3410.dbx1.7)

•

Hoist In Regeneration (DB3418.dbx1.1)

•

Hoist Gate Blocked (DB3418.dbx0.0) The Hoist Gate Blocked signal from SiBas indicates either a Hoist drive fault or Hoist drive is not on.

•

Machine Stop Pushbutton (I 33.0)

•

Power Off Emergency Pushbutton (I 33.1) POEB button is a NC switch which is on when no emergency..

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•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Transfer Switch in Dig (I37.0)

•

Hoist Brake Valve (Q 16.0) A “1” at this output activates Hoist Brake Solenoid Valve and releases brake.

Crowd Brake Solenoid Valve

•

Crowd Drive Minimum Current (DB3411.dbx0.4)

•

Crowd Drive On (To SiBas) (Q24.0) This is a command bit to SiBas to turn on the Crowd drive.

•

Crowd Brake Valve (Q 17.7) A “1” at this output activates Crowd Brake Solenoid Valve and releases brake.

•

Crowd Speed < 2.5 Hz (Db3411.dbx1.7)

•

Crowd In Regeneration (DB3418.dbx 1.2)

•

Crowd Gate Blocked (DB3418.dbx0.1) Crowd Gate Blocked signal from SiBas indicates either a Crowd drive fault or Crowd drive is not on.

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•

Machine Stop Pushbutton (I 33.0)

•

Power Off Emergency Pushbutton (I 33.1) POEB button is a NC switch which is on when no emergency..

• Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Transfer Switch in Dig (I37.0)

•

Crowd Brake Valve (Q 17.7) A “1” at this output activates Crowd Brake Solenoid Valve and releases brake.

Propel Brake Solenoid Valve

•

Crowd Drive Minimum Current (DB3411.dbx0.4)

•

Crowd Brake Valve (Q 17.7) A “1” at this output activates Crowd Brake Solenoid Valve and releases brake.

•

Crowd Drive On (To SiBas) (Q24.0) This is a command bit to SiBas to turn on the Crowd drive.

•

Crowd Speed < 2.5 Hz (Db3411.dbx1.7)

•

Crowd In Regeneration (DB3418.dbx 1.2)

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•

Crowd Gate Blocked (DB3418.dbx0.1) Crowd Gate Blocked signal from SiBas indicates either a Crowd drive fault or Crowd drive is not on.

•

Hoist Drive Minimum Current (DB3410.dbx0.4)

•

Hoist Drive On (To SiBas) (Q24.1) This is a command bit to SiBas to turn on the Hoist drive.

•

Hoist Speed < 2.5 Hz (Db3410.dbx1.7)

•

Hoist In Regeneration (DB3418.dbx 1.1)

•

Hoist Gate Blocked (DB3418.dbx0.0) Hoist Gate Blocked signal from SiBas indicates either a Hoist drive fault or Hoist drive is not on.

•

Machine Stop Pushbutton (I 33.0)

•

Power Off Emergency Pushbutton (I 33.1) POEB button is a NC switch which is on when no emergency..

•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Transfer Switch in Propel (I37.1)

•

Propel Brake Valve (Q16.7) A “1” at this output activates Propel Brake Solenoid Valve and releases brake.

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System Ready Light

•

Power Off Emergency Button (I 33.1) POEB button is a NC switch which is on when no emergency.

•

Machine Stop Pushbutton (I 33.0) This normally closed Pushbutton is off when pushed.

•

AFE Faults (I 172.6) This fault comes from SiBas.

•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Latched System Run Pushbutton (M18.1) This signal latched when System Run pressed.

•

Low Air Pressure (I 17.4) This switch = 0 when pressure is low.

•

I/O Station Under Temperature (M30.0) Fault if any I/O Station temperature is too low. (I 17.7, I 8.7, I 24.7, I 0.7, I 28.7) See page 26 for detail screen.

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•

I/O Station Over Temperature (M30.1) Fault if any I/O Station temperature is too high. (I 17.6, I 32.6, I 32.4, I32.5, I 8.6, I 28.6, I 0.6, I 24.6) See page 25 for detail screen.

•

1 Precharge within 2 Minutes (T101) This PLC Timer signal will prevent precharge attempts occurring within 2 minutes of precharge contactors opening.

•

2 Precharges within 5 Minutes (T106) This PLC Timer signal will prevent precharge attempts for 5 minutes if 2 precharge attempts have been made within 5 minutes.

•

Precharge Breaker 1 Closed (I 37.4) Breaker must be on for System Ready.

•

Precharge Breaker 2 Closed (I 37.5) Breaker must be on for System Ready.

•

System Ready Light (Q1.6)

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Dipper Trip Contactor

•

Transfer Switch in Dig (I37.0)

•

Hoist Drive On (To SiBas) (Q24.1) This is a command bit to SiBas to turn on the Hoist drive.

•

Crowd Drive On (To SiBas) (Q24.0) This is a command bit to SiBas to turn on the Crowd drive.

•

Swing Drive On (To SiBas) (Q24.2) This is a command bit to SiBas to turn on the Swing drive.

•

Dipper Trip Switch (CAB) (I 28.4)

•

Dipper Trip Transformer Contactor (I 20.0)

•

Dipper Trip Stall Timer Done (DB400.dbx422.0)

•

Dipper Trip Contactor (I 21.7)

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Propel Horn

•

Propel Brake Switch (CAB) (I 29.1)

•

Propel Brake Pressure Switch (I 36.4) This input = 1 for pressure OK.

•

Propel Horn (Q 21.0) “1” activates horn.

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Dig / Propel Transfer Contactors

•

Hoist Gate Blocked (DB3418.dbx0.0) The Hoist Gate Blocked signal from SiBas indicates either a Hoist drive fault or Hoist drive is not on.

•

Crowd Gate Blocked (DB3418.dbx0.1) Crowd Gate Blocked signal from SiBas indicates either a Crowd drive fault or Crowd drive is not on.

•

Transfer Request Switch (I 28.2)

•

Transfer Switch In Dig (I 37.0)

•

Dig Transfer Contactor (Q20.0)

•

Transfer Request Switch (I 28.2)

•

Hoist Reeving Mode (Q 66.2) This signal generated by request from Operator Panel.

•

Crowd Reeving Mode (Q 66.3) This signal generated by request from Operator Panel.

•

Transfer Switch In Propel (I 37.1)

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•

Propel Transfer Contactor (Q20.7)

High Voltage Control Relay 1 (CR1)

•

Latched System Run Pushbutton (M18.1) This signal latched when System Run pressed.

•

DC Bus Precharged (I 173.2) This signal = 1 when SiBas determines DC Bus has reached the precharge level.

•

High Voltage Control Relay (CR1) (Q16.4) See page 50 for detail screen.

•

Emergency Shutdown (M12.2) See page 28 for detail screen.

•

Fire Suppression System Fault (DB1.dbx9.7) Indicates trouble if I 17.5 = 0.

•

Instantaneous Shutdown Timer (I33.2) This hardware timing device must = 1 for High Voltage Control Relay to be on.

•

AFE Fault (I 172.6) This fault comes from SiBas.

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•

Machine Stop and Brakes Set (M34.3) “Machine Stop and Brakes Set” used to drop DPC contactor out when "BEB" pushed only after motors have slowed and mechanical brakes are applied.

•

Incomplete Sequence DC Bus Start-up (Q1.5) See page 53 for detail screen.

•

Precharge Contactor 1 Closed (I 37.2)

•

Precharge Contactor 2 Closed (I 37.3)

•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

High Voltage Control Relay (CR1) (Q16.4)

DC Bus Precharge

•

Latched System Run Pushbutton (M18.1) This signal latched when System Run is pressed.

•

AFE Precharge Contactors K201, and K301 (Q16.2, Q16.1) These PLC outputs turn on the precharge contactor relays K201 and K301.

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•

Emergency Shutdown (M12.2) See page 28 for detail screen.

•

Shutdown with Electrical Brake (M19.3) See page 27 for detail screen.

•

DC Bus Precharged (I 173.2) This signal from SiBas indicates the DC Bus is over the precharge level of 1400 Volts.

•

Incomplete Sequence (M25.7) This PLC Timer signal will turn on if DC Bus precharge level not on within 20 seconds of System Run Button pushed. This signal would turn on for only one PLC scan and may be difficult to see.

•

High Voltage Control Relay (CR1) (Q16.4) This output from PLC will activate the Main Power Contactor (DPC). When this contactor is on, the Precharge contactors are dropped out.

See page 50 for detail screen.

•

1 Precharge Within 2 minutes) (T101) This PLC Timer signal will prevent precharge attempts occurring within 2 minutes of precharge contactors opening.

•

2 Precharges Within 5 Minutes (T106) This PLC Timer signal will prevent precharge attempts for 5 minutes if 2 precharge attempts have been made within 5 minutes.

•

AFE Precharge Contactor 1 Closed (I 37.2)

•

AFE Precharge Contactor 2 Closed (I 37.3)

•

AFE Precharge Contactor K301 (Q16.1)

•

AFE Precharge Contactors K201 (Q16.2)

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DC Bus Incomplete Sequence

•

System Run Pushbutton (M12.4) This Momentary Normally Open pushbutton is required for starting the DC bus precharge and BUS-UP sequence.

•

Emergency Stop (POEB) (I 33.1) POEB button is a NC switch which is on when no emergency.

•

System Ready (Q 1.6) See page 45 for detail screen.

•

DC Bus Precharged (M31.3) This signal from SiBas indicates the DC Bus is over the precharge level of 1400 Volts.

•

Precharge Incomplete Sequence Timer (20 sec) (M370.1) This PLC internal timer will = 1 indicating fault if DC Bus does not reach precharge level within 20 seconds of System Run button.

•

DC Bus Incomplete Sequence Timer (30 sec) (M370.0) This PLC internal timer will = 1 indicating fault if DC Bus is not up within 30 seconds of System Run button.

•

Incomplete Sequence set/reset latch and light (Q1.5)

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Incomplete Sequence is set if either the Precharge Incomplete Sequence or DC Bus Incomplete Sequence occurs. It is reset by System Run button.

Lube System A1 Lube Pump

•

A1 Dig Mode Timed Lube (DB100.dbx0.1)

•

A1 Manual Lube (DB100.dbx0.2)

•

A1 Test Mode (Q 67.0)

•

A1 On/Off Switch (I 16.0)

•

A1 Pressure Less Than Maximum (M47.2)

•

Lube System A1 Fault (Q 4.1)

•

Instantaneous Shutdown Relay (I 33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

A1 Lube Pump Valve (Q 4.0)

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Lube System A1 Manual Mode

•

A1 On/Off Switch (I 16.0)

•

A1 Test Mode (Q 67.0)

•

A1 Dig Mode Timed Lube (DB100.dbx0.1)

•

Lube System A1 Fault (Q 4.1)

•

B1 Lube Pump Valve (Q 4.4)

•

A1 Pressure Less Than Maximum (M47.2)

•

A1 Manual Lube Pushbutton (I16.1)

•

A1 Manual Lube (DB100.dbx0.2)

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Lube System A2 Lube Pump

•

A2 Dig Mode Timed Lube (DB100.dbx0.4)

•

A2 Propel Mode Timed Lube (DB100.dbx0.7)

•

A2 Manual Lube (DB100.dbx0.5)

•

A2 Test Mode (Q 72.6)

•

A2 On/Off Switch (I 16.2)

•

A2 Pressure Less Than Maximum (M47.3)

•

Lube System A2 Fault (Q 4.3)

•

Instantaneous Shutdown Relay (I 33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

A2 Lube Pump Valve (Q 4.2)

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Lube System A2 Manual Mode

•

A2 On/Off Switch (I 16.2)

•

A2 Test Mode (Q 72.6)

•

A2 Dig Mode Timed Lube (DB100.dbx0.4)

•

Lube System A2 Fault (DB100.dbx0.7)

•

B1 Lube Pump Valve (Q 4.3)

•

A2 Pressure Less Than Maximum (Q4.6)

•

A2 Manual Lube Pushbutton (I 16.3)

•

A2 Manual Lube (DB100.dbx0.5)

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Lube System B1 Lube Pump

•

B1 Dig Mode Timed Lube (DB100.dbx1.0)

•

B1 Manual Lube (DB100.dbx1.1)

•

B1 Test Mode (Q 67.1)

•

B1 On/Off Switch (I 16.4)

•

B1 Pressure Less Than Maximum (M47.4)

•

Lube System B1 Fault (Q 4.5)

•

Instantaneous Shutdown Relay (I 33.20 This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

B1 Lube Pump Valve (Q 4.4)

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Lube System B1 Manual Mode

•

B1 On/Off Switch (I 16.4)

•

B1 Test Mode (Q 67.1)

•

B1 Dig Mode Timed Lube (DB100.dbx1.0)

•

Lube System B1 Fault (Q 4.5)

•

A1 Lube Pump Valve (Q 4.0)

•

B1 Pressure Less Than Maximum (M47.4)

•

B1 Manual Lube Pushbutton (I 16.5)

•

B1 Manual Lube (DB100.dbx1.1)

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Lube System B2 Lube Pump

•

B2 Dig Mode Timed Lube (Db100.dbx1.3)

•

B2 Manual Lube (DB100.dbx1.4)

•

Dipper Handle Manual Lube (DB100.dbx0.0)

•

B2 Test Mode (Q 72.7)

•

B2 On/Off Switch (I 16.6)

•

B2 Pressure Less Than Maximum (M47.5)

•

Lube System B2 Fault (Q 4.7)

•

Instantaneous Shutdown Relay (I 33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

B2 Lube Pump Valve (Q 4.6)

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Lube System B2 Manual Mode

•

B2 On/Off Switch (I 16.6)

•

B2 Test Mode (Q 72.7)

•

B2 Dig Mode Timed Lube (DB100.dbx1.3)

•

Lube System B2 Fault (Q 4.7)

• •

A2 Lube Pump Valve (Q 4.2) See page B2 Pressure Less Than Maximum (M47.5)

•

B2 Manual Lube Pushbutton (I 132.6)

•

B2 Manual Lube (DB100.dbx1.0)

•

Handle Lube Pushbutton (I 132.6)

•

Dipper Handle Manual Lube (DB100.dbx0.0)

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Lube System C1 Lube Pump

•

C1 Dig Mode Timed Lube (DB100.dbx1.6)

•

C1 Manual Lube (DB100.dbx1.7)

•

C1 Test Mode (Q 67.2)

•

C1 On/Off Switch (I 17.0)

•

C1 Pressure Less Than Maximum (M47.6)

•

Lube System C1 Fault (Q 5.1)

•

Instantaneous Shutdown Relay (I 33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

C1 Lube Pump Valve (Q 5.0)

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Lube System C1 Manual Mode

•

C1 On/Off Switch (I 17.0)

•

C1 Test Mode (Q 67.2)

•

C1 Dig Mode Timed Lube (DB100.dbx1.6)

•

Lube System C1 Fault (Q 5.1)

•

C2 Lube Pump Valve (Q 5.2)

•

C1 Pressure Less Than Maximum (M47.6)

•

C1 Manual Lube Pushbutton (I 17.1)

•

C1 Manual Lube (DB100.dbx1.7)

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Lube System C2 Lube Pump

•

C2 Dig Mode Timed Lube (DB100.dbx2.1)

•

C2 Manual Lube (DB100.dbx2.2)

•

C2 Test Mode (Q 73.0)

•

C2 On/Off Switch (I 17.2)

•

C2 Pressure Less Than Maximum (M47.7)

•

Lube System C2 Fault (Q 5.3)

•

Instantaneous Shutdown Relay (I 33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Low Air Pressure (I 17.4)

•

C2 Lube Pump Valve (Q 5.2)

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Lube System C2 Manual Mode

•

C2 On/Off Switch (I 17.2)

•

C2 Test Mode (Q 67.2)

•

C2 Propel Mode Timed Lube (DB100.dbx2.1)

•

Lube System C2 Fault (Q 5.3)

•

C1 Lube Pump Valve (Q 5.0)

•

C2 Pressure Less Than Maximum (M47.7)

•

C2 Manual Lube Pushbutton (I 17.3)

•

C2 Manual Lube (DB100.dbx2.2)

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Control Cabinet Fan Contactor

•

System Run Pushbutton (Latched) (M18.1) This signal latched when System Run pressed.

•

System Run Pushbutton (Latched) Off Delay 5 Minutes Timer

•

Emergency Stop (POEB) (I 33.1) POEB button is a NC switch which is on when no emergency.

•

Drives Power Contactor (I 32.7) DPC signal is an auxiliary contact input of the DPC output contactor. DPC Contactor is the main contactor for power delivery to all Active Front Ends (AFEs) and all drives.

•

Instantaneous Shutdown Timer (I33.2) This hardware timing device must = 1 for fan contactor to be on.

•

Incomplete Sequence DC Bus Start-up (Q1.5) See page 53 for detail screen.

•

Control Cabinet Fan Contactor (Q9.3) Control Cabinet Fan Contactor turns off 5 minutes after DPC contactor dropped out if all other elements in rung are active.

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Front Intake Fan (This screen is only accessible if DB200.dbx1.0 = False and DB200.dbx1.2 = False.)

•

Control Cabinet Fans On (DB400.dbx342.0)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Front Intake Fan 1 Contactor (Q 9.1)

•

Front Intake Fan 1 Contactor (Q 9.1)

•

Front House Thermostat (I 1.6)

•

Front Fan 5 Minute Off-Delay (DB400.dbx390.2)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Front Intake Fan 2 Contactor (Q 9.4)

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Rear Intake Fan (This screen is only accessible if DB200.dbx1.0 = False and DB200.dbx1.2 = False.)

•

Front Intake Fan 1 On (DB400.dbx374.0)

•

Control Room Thermostat (I 24.2)

•

Rear Fan 3 Minute Off-Delay (DB400.dbx414.2)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Rear House Thermostat (I 24.1)

•

Rear Intake Fan High Speed (Q 8.1)

•

Rear Intake Fan Low Speed (Q 8.2)

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Rear Intake Fan (This screen is only accessible if DB200.dbx1.0 = true or DB200.dbx1.1 = true.)

•

Rear Intake Fan Forward (Q 8.3)

•

Control Room Thermostat (I 24.2)

•

Rear Fan 3 Minute Off-Delay (DB400.dbx414.2)

•

Rear Intake Fan Control Reverse Contactor (I 20.4)

•

Rear Intake Fan Reverse (Q 8.4)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Rear House Thermostat (I 24.1)

•

Rear Intake Fan High Speed (Q 8.1)

•

Rear Intake Fan Low Speed (Q 8.2)

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Rear Intake Fan Reverse / Forward (This screen is only accessible if DB200.dbx1.0 = true or DB200.dbx1.1 = true.)

•

Front Intake Fan 2 Reverse (Q 9.5)

•

Rear Fan Restart Timer Done (DB400.dbx470.0)

•

Intake Fan Reverse Timer Done (DB400.dbx438.0)

•

Fire Suppression System Fault (I 33.2)

•

Rear In Take Fan Reverse (Q 8.4)

•

Front Intake Fan 1 On (DB400.dbx374.0)

•

Rear Intake Fan Control Reverse Contactor (I 20.4)

•

Fire Suppression System Fault (I 33.2)

•

Rear In Take Fan Forward (Q 8.3)

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Front Intake Fans Reverse Contactors (This screen is only accessible if DB200.dbx1.1 = true or DB200.dbx1.2 = true.)

•

Control Cabinet Fans On (DB400.dbx342.0)

•

Intake Fan Reverse Timer Done (DB400.dbx438.0)

•

Front Intake Fan 1 Contactor (Q 9.1)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Front Intake Fan 1 Reverse Contactor (Q 9.2)

•

Front Intake Fan 1 Reverse Contactor (Q 9.2)

•

Intake Fan Reverse Timer Done (DB400.dbx438.0)

•

Front Intake Fan 2 Contactor (Q 9.4)

•

Fire Suppression System Fault (DB1.dbx9.7)

•

Front Intake Fan 2 Reverse Contactor (Q 9.5)

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Front Intake Fans Reverse Contactors (This screen is only accessible if DB200.dbx1.1 = true or DB200.dbx1.2 = true.)

•

Spin Down Timer (DB400.dbx454.0)

•

Front Intake Fan 1 Reverse Contactor (Q 9.2)

•

Fire Suppression System Fault (DB1.bdx9.7)

•

Front Intake Fan 1 Contactor (Q 9.1)

•

Front Intake Fan 1 Contactor (Q 9.1)

•

Front House Thermostat (I 1.6)

•

Front Fan 5 Minute Off-Delay (DB400.dbx390.2)

•

Front Intake Fan 2 Reverse Contactor (Q 9.5)

•

Fire Suppression System Fault (DB1.bdx9.7)

•

Front Intake Fan 2 Contactor (Q 9.4)

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Status Screens

Motion Control Status The Motion Control Status screen can be accessed from the Main Menu as well as the Status screen Submenu. See page 9 "Motion Control Status Screen" for more detailed information.

Motor Temperature Status

This screen displays temperatures for Hoist, Crowd and Swing drives. Speeds for all motions are individually displayed. Motor speeds are displayed for current machine mode. Hoist and Crowd speeds are available in Dig mode; Propel speeds are available in Propel mode.

Inverter Temperature Temperatures for Inverters are displayed relative to their location on a front view of the cabinet. All Temperatures are displayed in Celsius.

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Fault Counter / Operating Hours Screen

This screen displays the fault counters and operating hours for the machine. To access this screen, select the STATUS button from the Main Menu. This will open a Sub Menu.

Select the FAULT COUNTER / OPERATING HRS button.

Foot Prints These drawings are primarily used for displaying locations of components. Main screens have selections available for more detailed views. Fuse cabinet screens show faulted fuses. If fuse faulted it will flash red.

• Cabinet Front View This screen displays the cabinet as seen from the front. Selecting sections of the cabinet will switch screen to a more detailed screen of the section selected.

• Cabinet Back View This screen displays the cabinets as seen from the back. Selecting sections of the cabinet will switch screen to a more detailed screen of the section selected.

• Top View This screen displays the cabinet as seen from the top. Selecting sections of the screen will switch screen to a more detailed view of the area selected.

•

Deck Plan

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This is an overview of the Shovel deck. Displays locations of Siemens equipment.

ET200 locations are identified by green symbols. Selecting an area around a green symbol will open another screen to provide more detailed information.

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Trouble Shooting

495 SERIES

The Troubleshooting screen accesses Html files for display. This screen can be accessed in the following ways: • Troubleshooting button on the Main Menu • Troubleshooting buttons located on screens • Selecting a fault on the fault history screen then selecting the "Troubleshoot Current Alarm" button. When the Troubleshooting Manual is accessed from the Fault History screen the Troubleshooting menu buttons are not available.

Navigation within the Troubleshooting Manual screens Pressing a button on the Troubleshooting menu will open a listing pertaining to that topic. Once in this listing select the title of the document you wish to view from the screen, the selected document will open.

Pressing the “Page UP” or “Page Down” button on the button menu will allow you to scroll through the current document. Pressing any blue, underlined text will take you to another location within the current document or to a new document. Pressing the arIGBT Shovel HMI - WINCC Manual

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rows ously viewed.

located at the top of the screen will take you back to documents previ-

Fault History The fault History screen displays historical fault information. Faults can be viewed in order of receipt, or sorted by, date, time, or fault type. The fault history screen displays a different Button menu across the bottom of the screen. This menu is specific to the fault display.

• Next Message Moves the selection bar down the screen one fault at a time.

• Previous Message Moves selection bar up the screen one fault at a time.

• Page Up Scrolls screen up and sets selection bar at the top of the screen.

• Page Down Scrolls screen down and sets selection bar at the top of the screen.

• List Start Resets display and selection bar to the first fault in the list.

• List End Resets display and the selection bar to the last fault in the list.

• Short Time Archive Displays last 250 messages.

• Long Time Archive Displays all messages occurring in the last 30 days.

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• Filter By Date / Time Opens the following pop-up window.

When the screen initially opens if no selections are currently in effect only the From and To buttons will be visible. If a filter for date or time is currently in effect the displays will show the date and time that is currently selected. To make or change a filter selection press the up or down arrows. Press the OK button to set filter. The Filter by Date / Time button on the main menu will turn green and a message will be displayed to indicate that the filter is set. Filters can be used together or individually.

• Filter By Fault No. Opens the following pop-up window.

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This screen is used to set the Fault History Filter to display all instances of one particular alarm. Input the fault type first (ANF, CDA, SIB) then input the numerical characters and press ENTER. Only one fault number can be selected at a time. The Filter by Fault No button on the main menu will turn green and a message will be displayed to indicate that the filter is set. Filters can be used together or individually.

• Filter By Fault Type Opens the following pop-up window.

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This screen is used to sort the Fault History by Fault type. Select the type and press okay. The Filter by Type button on the main menu will turn green and a message will be displayed to indicate that the filter is set. Filters can be used together or individually.

• Filter Off Resets Fault History to display all faults. Resetting display returns background on “Filter By” buttons to gray and removes filter message.

•

Troubleshoot Current Alarm

More information can be obtained about a displayed fault by selecting the fault and pressing the Troubleshooting button. A fault is selected by pressing either the arrow keys on the main menu (Previous Message, Next Message) or by selecting the desired fault from the touch screen. Troubleshooting information will be displayed in the center portion of the screen.

• Exit Fault History Returns display to Overview Screen and standard button menu.

• Save Fault History to A:\ Pressing this button initiates a program that will save the fault history to the A:\ drive. A maximum of 10,000 entries can be stored to disk.

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Active Alarms The Active Alarms screen displays current fault information. When the faulted condition is corrected the message will be removed from this screen and appear in the Fault History. The Active Alarms screen displays a different Button menu across the bottom of the screen. This menu is specific to the Active Alarm display.

• Next Message Moves the selection bar down the screen one fault at a time.

• Previous Message Moves selection bar up the screen one fault at a time.

• Page Up Scrolls screen up and sets selection bar at the top of the screen.

• Page Down Scrolls screen down and sets selection bar at the top of the screen.

• List Start Resets display and selection bar to the first fault in the list.

• List End Resets display and the selection bar to the last fault in the list.

• Troubleshoot Current Alarm More information can be obtained about a displayed fault by selecting the fault and pressing the Troubleshooting button. A fault is selected by pressing either the arrow keys on the main menu (Previous Message, Next Message) or by selecting the desired

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fault from the touch screen. Troubleshooting information will be displayed in the center portion of the screen.

• Exit Active Alarms Returns display to Overview Screen and standard button menu.

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Bearing Status Option Bearing Status Deck Plan Screen

This screen shows each bearing's status and location. From this screen it is possible to see at a glance if there are temperature problems on any bearing. When a bearing reaches a critical temperature the location number will turn red. Selecting a location number from the screen will open a detail screen. Descriptions for each location number are on the right hand side of the screen.

To access this screen, select the STATUS button from the Main Menu on the bottom of the screen. This will open a Sub Menu. Select the BEARING STATUS DECK PLAN button.

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Bearing Status Deck Plan - Hoist Left Hand Detail Screen

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This screen displays a detail of item 1 from the Bearing Status Deck Plan Screen. The bearing will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE.

Bearing Status Deck Plan - Hoist Right Hand Detail Screen

This screen displays details of items 2, 5 and 6 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE.

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Bearing Status Deck Plan - Hoist Motor Detail Screen

This screen displays details of items 3 and 4 from the Bearing Status Deck Plan Screen.

The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. The tachometer is displayed for reference only. To return to main screen press CLOSE.

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Bearing Status Deck Plan - Crowd Left Hand Detail Screen

This screen displays details of items 7, 11, 13 and 15 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE.

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Bearing Status Deck Plan - Crowd Right Hand Detail Screen

This screen displays details of items 8, 12, 14 and 16 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE.

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Bearing Status Deck Plan - Crowd Motor Detail Screen

This screen displays details of items 9 and 10 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. The tachometer is displayed for reference only. To return to main screen press CLOSE.

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Bearing Status Deck Plan - Swing Gearcase Detail Screen

This screen displays details of items 17, 18, 19 and 20 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE. Bearing Status Deck Plan - Swing Motor 1 Detail Screen

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This screen displays details of items 21 and 22 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE. Bearing Status Deck Plan - Swing Motor 2 Detail Screen

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This screen displays details of item 23 and 24 from the Bearing Status Deck Plan Screen. The bearings will be green unless the temperature exceeds 250° F, then the bearing will turn red. To return to main screen press CLOSE.

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Bearing Temperature Screens These Screens show each bearing temperature in Bar Chart and digital format. If a bearing temperature gets too high the temperature indicator on the bar chart will turn red.

Hoist Bearing Temperature Screen

To access this screen, select the STATUS button from the main Menu. This will open a Sub Menu. Select the HOIST BEARING TEMP button.

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Crowd Bearing Temperature Screen

To access this screen, select the STATUS button from the main Menu. This will open a Sub Menu. Select the CROWD BEARING TEMP button.

Crowd Shaft Bearing Temperature Screen

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To access this screen, select the STATUS button from the main Menu. This will open a Sub Menu. Select the CROWD SHAFT BEARING TEMP button.

Swing Gearcase Bearing Temperature Screen

To access this screen, select the STATUS button from the main Menu. This will open a Sub Menu. Select the SWING GEARCASE BEARING TEMP button.

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Swing Motor Bearing Temperature Screen

To access this screen, select the STATUS button from the main Menu. This will open a Sub Menu. Select the SWING MOTOR BEARING TEMP button.

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Appendix

Computer Settings for Troubleshooting Manual •

Internet Options

From the Taskbar select "Start", Control Panel", then select the Internet options Icon, this will open following screen.

This setting creates the default screen for the Troubleshooting Manual when it is initially opened.

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If English is the default language, set this to C:/Siemens/HTMLfiles_eng/Cover.htm (as shown).

If Spanish is the default language, set this to C:/Siemens/HTMLfiles_esp/Cover.htm.

If French is the default language, set this to C:/Siemens/HTMLfiles_fra/Cover.htm.

If Portuguese is the default language, set this to C:/Siemens/HTMLfiles_por/Cover.htm.

If Chinese is the default language, set this to C:/Siemens/HTMLfiles_chi/Cover.htm.

If Swedish is the default language, set this to C:/Siemens/HTMLfiles_sve/Cover.htm.

If Russian is the default language, set this to C:/Siemens/HTMLfiles_rus/Cover.htm.

From this screen you also need to change the settings for Color and Font.

On the Colors screen under the heading Links set the color for both Visited and Unvisited to blue. Select OK.

On the Colors screen under the heading Links set the Web page font to Arial. Select OK.

•

Touch Screen Settings

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From the Taskbar select "Start", "Programs", "Touch", "Touch Screen Control". When the Touch Screen Control window is open select "Button Modes". In the Button Modes window select "Set". In the "Current Button Mode" field select Touch Down Click. Accept changes and close the Touch Screen Control window.

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WinCC Installation Before starting installation of WinCC be sure to disable Virus Software and shut down all other Windows programs. These can corrupt the installation process.

Insert the WinCC installation CD. The installation program will start automatically. The following screens will appear.

When the install screen appears, press Install SIMATIC WinCC. This will start the installation process.

The next screen to appear will be Installation / Deinstallation.

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Select the components for installation or deinstallation.

Make the following selections: WinCC - select all boxes Help - select all boxes Communication – select SIMATIC Device Drivers, Object Manager, and AS-OS Engineering OPC Server – select Data Access, Alarms & Events, and Historical Data Access Options - deselect all boxes IGBT Shovel HMI - WINCC Manual

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After you have made your selections press Next.

Next you will choose the main language to be used. English should be the default language if not select English.

There will be three installation options. Select the User Defined Installation. This will send you to a screen where you will define the WinCC components you want installed.

On the left-hand side of this screen are the main categories. The right hand portion of this screen shows the options associated with the highlighted component.

The Authorizations screen is next, select No. Licenses will be added after the installation process. You will be asked to check your setup information. If everything is correct select Next and the installation will be completed.

When the installation is finished you will be asked if you want to restart your computer select No, you will install your licenses before restarting your computer.

Under START Æ Simatic Programs, there is a group called License Management. Inside this group is a program called Automation License Manager. This starts the license installation program. The license is contained on a yellow 3-½” floppy disk. Use Automation License Manager to install the license file from the floppy disk.

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Project Installation There are 4 directories of files included on the installation CD. Insert the CD containing the project and through Windows Explorer select the project and copy to the following locations: Shovel_HMI_v4_4_1.exe: This is a self extracting file. When double-clicked, select unzip and it will install into the correct directory.

HTMLfiles_xxx.exe

This is a self extracting file. When double-clicked, select unzip and it will install into the correct directory. Select the correct file for the language you want to install.

Textfiles.zip

Project associated files. Copy to C:\Siemens\textfiles.

FaultHistory.zip

Files required for the Fault History backup.

C:\Siemens\textfiles.

Copy to

Note: Be sure each directory is transferred to the correct drive as this is critical to the proper operation of the project.

Once your project directories are properly copied close Windows Explorer. Go to the Start button on your Windows Taskbar. Select Start Æ Simatic Æ WinCC Æ WinCC 6.0. This will open the WinCC Control Center.

Select File Æ Open.

WinCC applications are stored in C:\Program Files\Siemens\WinCC\WinCCProjects. Open the project directory and select the file with .MCP extension, double click or select open.

Once Control Center is open, you may be asked to “Start server locally”. If so, click this button, wait for WinCC to start completely. Next, shut down WinCC are restart.

Your project should be ready to run. Press the arrowhead icon in the Toolbar to start Runtime.

Troubleshooting "Grayed Out" symbols.

When the HMI is not communicating properly, status displays and fields will appear "grayed out".

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The symbol on the left is an example of a "grayed out" field. This field has lost communication with the PLC. The symbol on the right is communicating properly with the PLC. If you have followed all the above steps and you are sure communication is established between WinCC and the PLC but your I/O fields are "grayed" out when Runtime is initialized do the following steps.

In the left-hand section of the Control Center screen select Tag Management. In the right-hand section of the screen there will now be two selections, Internal tags and SIMATIC S7 PROTOCOL SUITE.

Double click on "SIMATIC S7 PROTOCOL SUITE"; there will be several selections in the right-hand portion of your screen, double click on "TCP/IP". This will bring up "tcpip" in the right-hand section of the screen. Hold your mouse over “tcpip” and a box should display that says “Status: OK”. If not, troubleshoot the TCP/IP connection from the PC to the PLC.

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Faults

There are primarily two types of faults, faults that originate in the SiBas or the PLC. There are subclasses in each of these categories that are used for sorting purposes and display purposes

• Fault Classes Fault classes are used primarily for the sorting function of the Fault system. Each class can contain one or more subclasses to allow a more detailed sort. There are 3 message classes used in this system.

• SiBas These faults are displayed in the fault system with a yellow background and black text. The SiBas class contains only faults generated by the SiBas. There is 1 subcategory, Alarm High.

• Alarms These faults are displayed in the fault system with a yellow background and black text. The Alarms class contains only ANF faults. There are 2 subclasses, Alarm High and Alarm Low. • PLC Messages These faults are displayed in the fault system with a blue background and yellow text. This class contains only CDA faults. There are 2 subclasses, System and Error.

•

Fault Numbering Convention Fault numbers are derived from a combination of alpha characters and numeric values. The first three characters of any fault number are SIB, ANF or CDA. Faults generated by the SiBas have a prefix of SIB followed by three numbers. SiBas faults are numbered 1 through 999; leading zeros are always used. ex:

SIB021

SIB ↑ SiBas Fault

021 ↑ Fault 21

PLC faults are identified by the Prefix CDA and are numbered 1001 through 1299. ex:

CDA001

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CDA ↑ CDA Fault

001 ↑ Fault 001

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ANF faults are identified by the Prefix ANF and are numbered from 1301. ex:

ANF001

ANF ↑ ANF Fault

1301 ↑ Fault 1301

• Fault Structure Three components are required for a fault to operate properly in the HMI system.

There must be a tag to trigger the fault, a description of the fault and an HTML file for the Troubleshooting manual.

Revising Fault Text There are three steps required to revise fault text. Text changes can be made without stopping Runtime, but changes will not be applied until Runtime has been stopped and restarted.

•

Fault Text must be revised in the Alarm Logging Editor.

Double-Click to Open Alarm Logging

•

Once the editor is open select the Fault Description to be changed by double clicking on the field. After the changes have been made you must select a different field before WinCC accepts the changes. When you select a new field the following window will appear.

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Select "Change applies only to the selected text", then OK. This will add the updated text to the Text Library.

•

If the application has multiple languages, in Alarm Logging, select View Æ Language and choose the other language. Make any necessary edits just as before.

•

Last the updates must be added to file "File_D.txt". This file is located in the directory C:\Siemens\FaultHistory. Open the file with Notepad. Locate the alarm number and make the appropriate changes to the description.

Creating New Faults •

Fault Tags This applies only to ANF faults and CDA faults; fault tags already exist for SiBas faults 1 to 799.

To create a new tag, select the appropriate tag directory, CDA_Faults or ANFfaults.

Double click the appropriate directory, then right click in the right-hand side of the screen. In the popup window select New Tag. This will open the Tag Properties box.

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Type in the Tag name in the Name: field. Spaces and symbols cannot be used in tag names.

Next select the Datatype. The proper datatype for CDA and ANF tags will be binary.

Press "Select" to set the address of the tag. The following screen will appear.

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In the "Data" field select, DB, Bit Memory, Input or Output. Enter the address and select OK. This will return you to the Tag Properties screen. Check the information and Press OK. • Fault Description Creating the fault description is done in the Alarm Logging section of WinCC. Go to Control center, select Editor, and then select Alarm Logging.

Right click on Alarm Logging and select Open. The Alarm Logging Editor will open.

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To add new fault number and description right click lower portion of the screen. Select Append New Line. A new line will be added to bottom of list. Scroll to bottom of list.

The first column is for the WinCC fault number in this project will correspond with the numeric portion of the system fault number. Select the field you want to edit and Double click to make an entry. When you are finished select a new field to accept the changes. If you close the Alarm Logging tool without deselecting the last field changed that change will not be accepted by the system. The following fields are used in the fault system: • Number This is the WinCC fault number. When the new line is created WinCC will automatically fill in this field with the next fault number. To change this number double click on the field and type in the new number. As soon as you deselect the field WinCC will reorder the faults to be in numeric order. If you are adding several faults it is sometimes best to do this last.

• Class When the new line is created WinCC will automatically fill in this field. To change the Class double click on the field, an arrow will appear at the right hand side of the field, press the arrow for more options. Select the class, the selection window will close and the new class will appear in the field. See page 83 for descriptions of available classes.

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• Type This field is for the fault subclass. When the new line is created WinCC will automatically fill in this field. To change the Type double click on the field, an arrow will appear at the right hand side of the field, press the arrow for more options. The option selection will only display the subtypes of the Class selected. Select the type, the selection window will close and the new subclass will appear in the field. See page 83 for descriptions of available subclasses.

• Event Tag In this field you will enter tag that is used to trigger the fault. To insert the Event Tag, double click on the field. The Select Tag screen will open. A search for the tag can be done manually searching all tag directories or in a specific directory. If all or part of the tag name is know the fault filter at the top of the screen can be used. Wildcard characters can be used in this filter. Select the correct tag and select OK or double click on your selection.

• Event Bit This column relates to the Event Tag. This column is used for selecting the bit status or position. If the tag selected in the Event Tag column is a binary type tag WinCC will set the event bit to 0 this setting cannot be changed. When this tag has a value of 0 the fault will display. If the Event Tag type is anything other than binary then this column is used to identify which bit position of the tag is used to initiate the fault. It is assumed that when the bit value is 0 the fault will be displayed.

• Fault Description This column is used to input the actual text message that will be displayed when this fault occurs. Double click the field and type in the text, deselect the field to enter.

Characters +, -, \ or / cannot be used as the initial character in this text string.

• Fault Number This field is used for the assigned Siemens fault number. To enter the text double click the field, deselect to enter the text.

• Help Text This column is not used in this system and can be left at the default setting of Not Set. • Parameters The default setting of SET for this column will be used no further action is required.

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• Loop in Alarm This column is used for setting the variables needed to activate the link to the Troubleshooting Manual. WinCC will default this field to Not Set. Double click on this field, this will open the Loop in Alarm input window.

In the Picture Name / Parameter field of the Loop In Alarm window type in the Siemens

Fault Number. To fill in the Function Name field click the browse button right hand side of this field, this will open the screen for function selection.

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at the

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Double click on the Project functions directory to expand the selection. Select AlarmLoopAll

Select the correct function then press OK. The function selection screen will close.

Press OK on the Loop In Alarm window to accept your selections. The value in the Loop in Alarm column in the main Alarm Logging screen should change to SET. in the main tool bar. To After all new alarms are created select the Save button, close the Alarm Logging screen press File in the tool bar, then Exit from the drop down menu.

Accept the changes to the ".MCP" file. Alarms can be added or updated even if Runtime is active. Runtime does not have to be reactivated to see the changes.

Last the updates must be added to file "File_D.txt". This file is located in the directory C:\Siemens\FaultHistory. Open the file with Notepad. Locate the alarm number and make the appropriate changes to the description.

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Installation of Fault History Control Close any programs you may have running. From the Start Menu select run and type or browse to “C:\Siemens\WinCC\projects\Shovel\Fault History Setup\Setup.exe”. Select the Open button. The following window will be displayed select OK.

select the Change Directory button.

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Change Path to C\WINNT\system32\ and click OK.

Next select the Button to Install Fault History Control Software.

When the program has been successfully installed you will see the following screen.

Click OK. This ends the setup of your active X control.

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Installation of Trace Viewer Close any programs you may have running. From the Start Menu select run and type or browse to “C:\Siemens\WinCC\projects\Shovel\Trace Viewer Setup\Setup.exe”. Select the Open button. The following window will be displayed select OK.

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