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ThismanualisintendedtoprovideGENERALoperatingandserviceprocedures for the Bucyrus 2000 motorvehicle solid-statecontroller.Theillustrations, descriptionsandprocedurescontainedinthispublicationapplyonlyto Bucyrus 2000motorvehiclesolid-statecontrollers. BucyrusAmerica,Inc. reservesthe righttorevisemodelsanddesignswithoutpriornotice.
This Bucyrus 2000motorvehiclessolid-statecontrollerwasmanufacturedunder theguidelines,proceduresandrequirementsoftheU.S.FederalCoalMine HealthandSafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart 0,Part75forundergroundcoalmines,andotherapplicablenon-U.S.regulatory agencystandards.
Atthecompletionofthemanufacturingprocess,the Bucyrus 2000motorvehicles solid-statecontrollerwasissuedtheappropriateapprovalnumbersand nameplatesindicatingitmetthetechnicalrequirementsoftheseregulatory agencies.Anychangeto thedesignorstructureofthe controller,withoutthe consentof BucyrusAmerica,Inc. andtheseregulatoryagencies,oranyrepairor replacementofpartscontraryto BucyrusAmerica,Inc.’s instructions,may invalidatetheseapprovalsandrenderthecontrollerunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulationsand practicesregardingthesafeoperationand maintenanceofundergroundmining equipmentandstrictadherencetotheinstructionsinthismanualisnecessaryfor thepersonalsafetyofthoseworkingonoraroundthiscontroller.
Whilethismanualattemptstoanticipatethemostimportantoperations and maintenanceneedsforthiscontroller,unforeseencircumstancesmayarisethat havenotbeenaddressedinthismanual.Ifanyconcernsorquestionsarise, pleasecontactyour Bucyrus America,Inc. ServiceRepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandotherintellectual propertylaws,andisprotectedundertheU.S.CopyrightActof1976,as amended.Thisworkisprovidedunderlicenseandthelicenseisnontransferable.Distributionandaccessislimitedonlytoauthorizedpersonnel. Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationof federalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
BucyrusAmerica,Inc. Allrightsreserved.
Throughoutthismanualtherearespecificnotationsthatareeither UPPERCASEBOLD, UNDERLINED or ITALICIZED fortheprimarypurposeofemphasis Pleasepayspecialattention tosuchstatementsastheyregardsafetyorcriticalmaintenanceinstallationinformation.
Youwillalsoseethefollowing:
NOTICE: THISNOTATIONDENOTESAREFERENCETOPREVIOUSLY STATEDINSTRUCTIONS.
IMPORTANT: THISSYMBOLDENOTESTHATSPECIALATTENTION MUSTBEADHEREDTOINTHEATTACHEDSTATEMENT.
CAUTION: THISSYMBOLDENOTESTHATFAILURETOCOMPLYWITH THEATTACHEDSTATEMENTCOULDRESULTINACUT,BRUISEOR ABRASION.
WARNING: THISSYMBOLDENOTESTHATFAILURETOCOMPLY WITHTHEATTACHEDSTATEMENTCOULDRESULTINALOSTTIME ACCIDENT.
DANGER: THISSYMBOLDENOTESTHATFAILURETOCOMPLY WITHTHE POINTSINTHETEXTMARKEDWITHTHISSYMBOLDRAW YOURATTENTIONTOIMMEDIATELYIMPENDINGDANGER INCLUDINGELECTRICALDANGERS.POSSIBLECONSEQUENCES ARE:VERYSERIOUSINJURY,DEATHORDEATHBY ELECTROCUTION.
ONLYTRAINEDAND/ORAUTHORIZEDPERSONNEL SHOULDPERFORMMAINTENANCEONTHE CONTROLLER.
FAILURETOADHERETODANGERS,WARNINGS ANDCAUTIONS,NOTEDINTHISMANUAL,COULD RESULTINSERIOUSINJURYORDEATH.
FAILURETOMAINTAINTHIS CONTROLLER IN STRICTADHERENCETOTHESEINSTRUCTIONS ANDWARNINGSINTHISMANUALCOULDVOIDTHE WARRANTY.
AREA
HAZARD
SAFEGUARDS WHEREHAZARD CANOCCUR WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED
MOTORSAND CONTROLLER
Electricalshockcouldcause irreparableinjuryordeath.
BATTERY
Thebatteryproduceslethal amountsofpowerwhether connectedtothemachineor charger,ornot.
Allelectricalsystemsshouldbe maintainedbycertifiedelectricians. Thebatteryshouldbedisconnected beforeservicingthemotorsor controller.Whenthecontroller coverisremoved,waitforone minuteforthecapacitorsto discharge.
Thebatteryshouldbemaintained byqualifiedpersonnel.(Referto Bucyrus America,Inc. "INSTALLATION,USE, MAINTENANCE,ANDREPAIROF MINEPOWERSTORAGE BATTERIES,”PARTNUMBER A6474X26,forcomplete instructions).
Batterycoverscouldfall crushinghandsorarms.
Batteryhold-downclamps couldcrushfingersorhands.
Batteriesproduceexplosive gasesthatcouldbeignited causingburnsorexplosions.
Batteriescontainstrongacid thatcouldcausesevereburns ifspilledorsplashedonbody partsorintheeyes.
Besurecoversupportsareinplace whenworkingonbattery.
Keepfingersandhandsawayfrom hold-downclamps.
Batteriesshouldbewellvented beforeservicingparticularlyif weldingorburningonthebattery. Batteriesshouldbemaintainedby qualifiedpersonnel.
Protectiveclothing,gloves,and eyewearmustbewornwhen workingonbatteries.Batteries shouldbemaintainedbyqualified personnel.
Overview
Beforeyoutest,troubleshoot,serviceorinanyotherway,usethisunit -
READ and STUDY thisguide. KNOW whatyoumustdoforsafemaintenance.
ALWAYS wearorusethepropersafetyitemsrequiredforyourpersonalprotection.
IfyouhaveANYQUESTIONSaboutthesafeuseormaintenanceofthisunit:
ASKYOUR SUPERVISOR - NEVERGUESS - ALWAYS CHECK
Maintenance
AVOID,wheneverpossible,servicing,cleaningorexaminingtheunitincongestedareas.
AVOID,wheneverpossible,servicingorprovidingmaintenancetotheunitunlessthewheelsare adequatelychoked.Ifthedrivemotor(s)istobe run,theunitmustbejackedclearoftheground andallfour(4)wheelsmustbefreetoturn.
DONOT altertheelectricalsettingsfromthatindicatedinthisguideorassetatthefactory.
ALWAYS replacedamagedorlostdecalsormetalinstructionplates.RefertothePartsManual fortheproperlocationandpartnumberofdecalsandplates.
DISCONNECT thebatterywhenworkingwithelectricalsystems,orwhenweldingontheunitto preventelectricalshock.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthisguidebethoroughly evaluatedfromthestandpointofsafetybeforeitisimplemented.
Somephotographsandillustrationsinthisguidemayshowguardsorcoversremovedfor purposesofclarity.Neveroperateunitwithoutall guardsandcoversinplace.
SOMEPHOTOGRAPHSORILLUSTRATIONSINTHISGUIDEMAYSHOW PROTOTYPEUNITSORUNITSWITHOPTIONALEQUIPMENT INSTALLEDTHATMAYORMAYNOTBEONYOURPARTICULAR MACHINE.PRODUCTIONMODELSMAYVARYINSOMEDETAIL. OPTIONALEQUIPMENTMAYBEPURCHASEDFROM BUCYRUS AMERICA,INC.
CONTINUINGIMPROVEMENTANDADVANCEMENTOFPRODUCT DESIGNMAYCAUSECHANGESTOYOURMACHINEWHICHMAYNOT BEINCLUDEDINTHISPUBLICATION.EACHPUBLICATIONIS REVIEWEDANDREVISED,ASREQUIRED,TOUPDATEAND INCLUDE THECHANGESINLATERADDITIONS. BUCYRUSAMERICA,INC. RESERVESTHERIGHTTOMODIFYORMAKECHANGESWITHINA SPECIFICMODELGROUPWITHOUTNOTICEANDWITHOUT INCURRINGANYLIABILITYTORETROFITUNITSPREVIOUSLY SHIPPEDFROMTHEFACTORY.CONTACTYOUR BUCYRUS DEALER FORMAINTENANCETHATISNOTCOVEREDINTHISPUBLICATION.
BUCYRUS 2000:InnovativeSpeedControlby Bucyrus America,Inc.
FIGURE 1 – SIMPLIFIEDBUCYRUS 2000CIRCUIT
Intheearly1970's,S&SCorporationleadthewayinmininginnovationwiththeintroductionof SolidStatespeedcontrolsforbattery-poweredundergroundminingequipment.SolidState controlsincreasedtherangeandreliabilityofthebatterypoweredvehiclesalongwithproviding smooth,steplessacceleration.Evenwithsolidstatespeedcontrol,directionchangewas achievedwiththeuseofelectromechanicalcontactors.Thesecontactorsprovidedanendless sourceofmaintenanceproblemsandconsumedexcessiveamountsofvaluable controller-box space.Also,mostsolidstatecontrollersofthepastutilizeanelectromechanical"bypass" contactortoconnectthemotordirectlytothebatterieswhichcausedmorecontactorproblems.
Inthe1980’s Bucyrus America, Inc., inconjunction withSevcon,developedacontactorlessmotor controller(X90)tobeusedexclusivelyon Bucyrus equipment.TheX90systemusedadual-field motorincombinationwithSCR's(SiliconeControlledRectifier)toachievesolidstatedirection change.
Now Bucyrus America, Inc., inconjunctionwithSevcon,hasdevelopedtheBucyrus2000motor controller.TheBucyrus 2000systemusesIGBT’s(InsulatedGateBipolarTransistors)toachieve motorcontrolanddirectionchange.UnlikeanSCR,anIGBTisturnedONand OFFviaagating electronicsignal.Thiseliminatedcommutatingcapacitorbanksandcoils.Themicroprocessor basedBucyrus 2000LogicCardprovidescompletemotorcontrol,anddrivesbothaDiagnostic DashboardDisplayalongwithahandheldCalibrator/DiagnosticUnit.
TheIGBTswitchoperatessofastthatitcanconnectanddisconnectthemotorinlessthan 1/1700second.Thisissuchashorttimeperiodthatthedual-fieldmotordoesnothavetimeto move.EachtimetheIGBTswitchclosesand reopens thefullbatteryvoltageisappliedtothe motorterminalsforabout1/1700second.Thisiscommonlyreferredtoasa"pulse."
TheIGBTspeedcontrolworksbyfeedingtothemotorarapidseriesofpulses.Thenumberof pulsesperseconddeterminesthe averagevoltageatthemotorterminals
Sincethewindingsofthemotorareinductive,thecurrentinthemotorcannotchangequickly. WhentheIGBTswitchisclosed,thecurrentbuildsupslowlyandwhentheswitchopens,the inductancewantstokeepthecurrentflowing.Forthisreason,the"flywheel"diodeisprovided. Figures3and4illustratethecurrentpathswiththeswitchclosedinbothforward(Figure3)and reverse(Figure4)modes.
FIGURE4
AsseeninFigure 5,thedirectionofthecurrentthroughthemotordoesnotchange.More important,whentheswitchopens,althoughthebatterycurrentstops,themotorcurrentcontinues toflowviathe"flywheel"diode.Themotorcurrentisthereforemadeupoftwocomponents:
1. ThebatterycurrentwhentheIGBTswitchisclosed.
2. The"flywheel"currentwhentheIGBTswitchisopen.
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Theamountofthemotorcurrentsuppliedfromthebatteryvarieswiththepulsefrequency. Figure6illustratesatypicalsituationatlowspeed.Itcanbeseenfromtheillustrationthatthe "flywheel"current,becauseitisflowingforalongerperiod,formsalargerpartofthemotor currentthandoesthebatterycurrent.However,athighspeeds(Figure7),themotorcurrentis madeupofalmostallbatterycurrent.
FIGURE6
Tosummarize,themotorcurrentismadeupofacombinationofbatterycurrentand"flywheel" currentsothatunderallconditionstheaveragemotorcurrentisalwaysgreaterthantheaverage batterycurrent.
Atlowspeedsthemotorcurrentcanbeseveraltimesgreaterthanthebatterycurrent.
Athighspeeds,whentheIGBTswitchisopenonlyforshortperiodsbeforeclosing,themotor currentismadeupalmostentirelyofbatterycurrent.
The Bucyrus 2000MotorControllerisdesignedtooperateat128voltsDC,1200 Ampsmaximum currentlimitpermotorandcontrolsoneortwodual-fieldelectricmotors.
The maximum currentdefaultsettingsare:800A,1100Aand1200A
Tractionfunctionsoperateataspeedthatisdirectlyproportionaltotheaccelerator(FS1) demand.(SeeFigure8)
Tractionmotorcurrentwillbecontinuouslymonitoredinthemotor.Currentlimitispresetand isadjustableviatheoptionalhandhelddiagnostics/calibratorunitandispasswordprotected.
Fail-safeoperationwillincludethefollowing:
IntheeventofashortedIGBT,thecircuitbreakerwillbeopened,disconnectingpowerfrom thetractionmotors.
Operationofthecircuitbreakerwillalwaysbesensed,andiffaulty,drivewillbeinhibited.
Wheneverthevehicleispower-cycled,power-updiagnosticswillbeexecutedtotestthetram drivecircuitry.Iffaulty,drivewillbeinhibited.
Thetemperatureofthe Bucyrus 2000MotorControllerwillbecontinuouslymonitoredandifit risesabove95Cthemotorcurrentwillbelimitedtoamaximumof300ampsofmotorcurrentwill beallowed.
The Bucyrus 2000MotorControllerfeatures adataloggingcapabilitythatstorescriticaldatainto non-volatiledataRAM.Thestoreddataisdisplayedinthetractionstatusdisplayoftheoptional handhelddiagnostics/calibratorunit.
The Bucyrus 2000SolidStateControllerincorporatesavarietyofindependentprotection systems.Theseimprovereliability,shieldthemotorsandcontrollerfromoverload,protectthe machinefrominadvertentabusebytheoperator,andhelptoprotectworkersfrompotentialharm frommalfunctioningequipment.
Bucyrus 2000MotorControllerConsistof:
DualMotorIGBTPanelorsinglemotorIGBTPanelor2-singlemotorIGBTpanels
MicroprocessorBasedLogicCard
OptionalDashboardDisplay
OptionalHandheldDiagnostics/CalibratorUnit
“Y”connectingharness(usedonlywith2-singlemotorpanelsystems)
Bucyrus 2000MotorIGBTPanel(PowerConnections)
Batterypositive
Batterynegative
4motorconnectionsforeachmotor(S1,S2,A1andA2)
(ForPowerCircuitLayoutseeMachineWiring diagramandschematic)
MicroprocessorBasedLogicCard(ControlInputs)
Inputappliesbatteryvoltagetologiccard(Pin16)
Proportionalcontrolaccelerator,5000OHMS(Pins1and2)
Tramdirectionselect(Pin7)
Tramdirectionselect(Pin8)
Parkbrakecondition(set/release)(Pin14)
Circuitbreakerdriver(Pin6)
Circuitbreakercondition(Pin11)
Currentlimitdefaultsetting(Pin12)
Accelerator(FS1)inputswitch(Pin4)
CANCommunicationInputPortforoptionalhandhelddiagnostics/calibrator unit
CANCommunicationInputPortforoptionaldashboarddisplay
AnalogInputforconnectiontopumpmotorshunttoallowpumpmotorcurrentmeasurement
The Bucyrus 2000Microprocessor-BasedLogicCardwillcontroldualtwo-quadrantIGBT devices,controlledbyPWM(PULSEWIDTHMODULATED)switching,providingforwardand reversedirectioncontrol.
ThereisanLEDonthelogiccardwhichservesasanindicatorofthestatusofthecontroller.The followingdiagnosticsshallapply:
LEDon Controlleroperational
LEDoff Power-upfault – checkdisplayorcalibrator.Ifallisblank,thenreplacelogic.
1Flash PersonalityCRCEEPROMError.
Usingthehand-heldcalibrator,changeapasswordtoanynumberthenrecycle power – shouldclear,otherwisereplace logic.
2Flash ProcedureFAULT
FS1closedbeforepoweron,2DirectionalFaultorCurrentimbalancefault. RecyclethroughNEUTRALtoclear.
3Flash IGBTpermanentlylow(IGBTShortCircuitFAULT).
ThisincludesIGBTshortcircuitorIGBTopencircuit.Thisfaultshutsdownall modes.RecyclethroughNEUTRALtoclear.
4Flash Motorneitherlownorhigh(BreakerOpenFAULT).
ThisincludesbreakeropencircuitorIGBTopencircuit.Thisfaultshutsdownall modes.RecyclethroughNEUTRALtoclear.
5Flash Motorpermanentlyhigh.
Thisincludesbreakerwelded.Thisfaultshutsdownallmodes.Recycle“KEY” toclear.
6Flash FaultyTRACTIONaccelerator.
Thisincludestheacceleratorgreaterthan15%atpoweronandwire-off.Ifwireoffoccursduringactivefunctionthenthemotorspeedwillsettozero.Thisfault auto-clears.
7Flash BatteryvoltageFAULT.
Thisincludesbatterybelowapredeterminedvalue.RecyclethroughNEUTRAL toclear.
8Flash Thermalcut-back(Over-TemperatureFAULT)
ThisincludesHeatsinktemperatureabove95 centigrade.
ASTEMPERATURERISESABOVE95 CENTIGRADE,THE CONTROLLERWILLLIMITTHECURRENTTO300AMPS REGARDLESSOFDEMAND.
9Flash UVRcoilover-currentFAULT(CoilshortcircuitFAULT). Clearedwith“KEY”recycled.
10Flash BrakeonFAULT
WilltripDirectionalandFS1areenergizedwithoutreleasingbrake.Recycle throughNEUTRALtoclear.
15Flash CurrentTransducerFAULT.
Occurswhencurrentoutputisreadduringpower-uporifnocurrentisread duringdriveabove50%demand.“KEY”recycletoclear.
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