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4100XPB Electrical Manual Preface

Preface

This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this mining shovel. We rec-
ommend that such personnel review and become familiar with the general procedures and information contained within this man-
ual. In addition, we recommend that this manual be kept readily available for reference when repairs or maintenance are necessary.

Due to the complexities of mining equipment and the environment in which it operates, situations may arise which are not directly
discussed in detail in this manual. When such a situation arises, past experience, availability of equipment, and common sense play
a large part in what steps are to be taken. In addition, a P&H MinePro Services Representative is available to answer your questions
and assist you upon request.

Please feel free to contact a P&H MinePro Services Representative at any of the locations shown in the P&H® Mining Equipment
Offices section of this manual.

Copyright
Copyright © 2001 Harnischfeger Corporation. All rights reserved. All materials contained herein are protected by
United States copyright law and international treaties, and may not be reproduced, distributed, transmitted, dis-
played, published or broadcast without the prior written permission of Harnischfeger Corporation. You may not
alter or remove any trademark, copyright or other notice from copies of the content. All rights in translations of
these materials shall remain exclusively with Harnischfeger Corporation.

Parts of this manual are reproduced with the permission of Rockwell Automation, Inc. Copyright © 2002 Rock-
well Automation. All rights reserved.

The information provided is an excerpt from a user manual and is not meant to replace the complete document. As
such, it may not contain all the safety precautions or all of the information necessary to configure your automation
system that is available in the complete user manual. Please refer to the full product installation and user docu-
mentation paying particular attention to all safety precautions prior to implementation.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


preface.fm -i- Preface, Version 02 - 9/02
Preface 4100XPB Electrical Manual

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


Preface, Version 02 - 9/02 - ii - preface.fm
4100XPB Electrical Manual Table of Contents

Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxv
P&H® Mining Equipment Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xli
Definition of Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xlv
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xlvii

SECTION 1, Introduction and General Information


1.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1
1.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1
1.1.2 Manual Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
1.2 4100XPB Electrical Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
1.3 Electrostatic Discharge Safety (ESD) Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
1.3.1 Preventing Electrostatic Discharge Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
1.3.2 ESD Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
1.3.3 Basic Principles of Static Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
1.3.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
1.3.5 Controlling Static on Personnel and Moving Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
1.4 Electrotorque Plus Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
1.4.1 Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
1.4.2 Crowd System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
1.4.3 Swing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
1.4.4 Propel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
1.5 Required Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
1.5.1 Other Related Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
1.6 Schematic Diagram Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
1.6.1 Wire Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
1.6.2 Referencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
1.6.3 Ground Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
1.6.4 Location Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
1.7 Six-Step Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
1.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
1.8 Safety For Electrical And Electronic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
1.8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
1.8.2 Maintenance Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
1.8.3 Electrical Safety Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
1.8.4 Electrical Shock Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27

SECTION 2, Power Distribution


2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1
2.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1
2.2 Air Disconnect Switch with Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

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2.2.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4


2.2.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
2.2.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
2.3 Collector Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
2.3.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
2.3.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
2.3.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
2.4 High Voltage Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
2.4.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
2.4.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
2.4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
2.5 Key Interlock System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
2.5.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
2.5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
2.6 Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
2.6.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
2.6.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
2.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
2.7 Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
2.7.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
2.7.2 Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
2.8 Auxiliary/Field Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
2.8.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
2.8.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
2.8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

SECTION 3, Cabinet Description and Operation


3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1
3.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1
3.1.2 Location Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1
3.2 Ground Fault and Suppression Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
3.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
3.2.2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
3.2.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
3.2.4 Ground Fault Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5
3.2.5 Suppression Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
3.3 Reactive Power Compensation Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3.2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3.4 RPC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
3.4 Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
3.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
3.4.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

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Table of Contents (Continued)

3.4.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21


3.4.4 Input Power Distribution and Protection Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
3.4.5 Current Feedback Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
3.4.6 Converter Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
3.4.7 Diverter Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
3.5 Transfer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
3.5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
3.5.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
3.5.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
3.5.4 Transfer Cabinet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
3.6 Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
3.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
3.6.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
3.6.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
3.6.4 Control Cabinet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
3.7 Auxiliary Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
3.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
3.7.2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
3.7.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
3.7.4 Auxiliary Cabinet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70
3.8 Motor Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
3.8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
3.8.2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
3.8.3 Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
3.8.4 Motor Control Cabinet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
3.9 Propel Motor Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
3.9.1 Propel Motor Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79

SECTION 4, Programmable Logic Controller


4.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1
4.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1
4.1.2 System Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1
4.2 Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
4.2.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
4.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3
4.3.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3
4.3.2 Input Voltage Selection and Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
4.3.3 Power Supply Undervoltage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
4.3.4 Power Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5
4.4 SLC 5/05 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6
4.4.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6
4.4.2 SLC 5/05 Processor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6
4.4.3 SLC 5/05 Processor Module Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7
4.4.4 Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8

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4.4.5 SLC 5/05 Keyswitch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9


4.4.6 SLC 5/05 Front Panel Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
4.4.7 Removing the Memory Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
4.4.8 Installing Your Memory Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
4.4.9 Downloading Firmware to the SLC 5/05 Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
4.4.10 Replacing the SLC 5/05 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
4.4.11 SLC 5/05 Status LED’s Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
4.5 Remote I/O Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
4.5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
4.5.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
4.5.3 Scanner I/O Image Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
4.5.4 How the Scanner Scans Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
4.5.5 SLC and Scanner Asynchronous Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
4.5.6 Baud Rate Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
4.5.7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
4.5.8 Scanner Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
4.5.9 Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
4.5.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
4.5.11 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
4.6 AMCI Resolver Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
4.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
4.6.2 Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
4.6.3 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
4.6.4 Tachometer Response Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
4.6.5 Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
4.6.6 Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
4.6.7 Programming from the Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.42
4.7 SST-PFB-SLC Profibus Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
4.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
4.7.2 Configuration Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
4.7.3 SYS and COMM LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
4.7.4 Profibus Downloading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
4.7.5 Upgrading Profibus Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.51
4.8 Discrete Input / Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.55
4.8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.55
4.8.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.55
4.8.3 Input Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.56
4.8.4 Output Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.57
4.8.5 Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.57
4.8.6 Terms and Symbols Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58
4.9 Sinking 24VDC Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.60
4.9.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.60
4.9.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.60
4.10 Sourcing 24VDC Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.61

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4.10.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.61


4.10.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.61
4.11 Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.62
4.11.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.62
4.11.2 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.62
4.11.3 Input Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63
4.11.4 Entering Module ID Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.65
4.11.5 Addressing Analog Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.65
4.11.6 Wiring Differential Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.66
4.11.7 Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.66
4.12 120VAC Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.67
4.12.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.67
4.12.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.67
4.13 120VAC/240VAC Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.68
4.13.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.68
4.13.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.68
4.14 Analog Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.69
4.14.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.69
4.14.2 Analog Output Module Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.69
4.14.3 Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.70
4.14.4 Entering Module ID Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.70
4.14.5 Addressing Analog Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.70
4.14.6 Wiring Differential Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.71
4.14.7 Voltage Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.15 Blank Slot Fillers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.15.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.16 36” Rack Interconnect Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.16.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.16.2 Chassis Interconnect Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.72
4.17 SLC 5/05 Instruction Set Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.73
4.17.1 Basic Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.73
4.17.2 Bit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.73
4.17.3 Timer/Counter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.73
4.18 Bit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.75
4.18.1 Instruction Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.75
4.18.2 Examine If Closed (XIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.75
4.18.3 Examine If Open (XIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.75
4.18.4 Output Energized (OTE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.76
4.18.5 Output Latch (OTL) and Output Unlatch (OTU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.76
4.18.6 One Shot Rising (OSR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.77
4.19 Timer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.77
4.19.1 Instruction Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.77
4.19.2 Entering Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.78
4.19.3 Timer On Delay (TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.78
4.19.4 Timer Off Delay (TOF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.79

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4.19.5 Retentive Timer On (RTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.79


4.20 Counter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.81
4.20.1 Instruction Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.81
4.20.2 Entering Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.81
4.20.3 Count Up (CTU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.81
4.20.4 Count Down (CTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.82
4.20.5 Reset (RES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.83
4.21 SLC 5/05 Processor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.85
4.21.1 Major Error Fault Codes, Address S:6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.85
4.21.2 Hexadecimal Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.85
4.21.3 Power-up Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.86
4.21.4 Going-to-Run Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.87
4.21.5 Run Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.89
4.21.6 User Program Instruction Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.92
4.21.7 I/O Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.93
4.22 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.98
4.22.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.98
4.22.2 Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.99
4.22.3 Configuring the Ethernet Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.99
4.22.4 Configuring via BOOTP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.101
4.22.5 Using Subnet Masks and Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.102
4.23 Flex I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.104
4.23.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.104
4.23.2 How FLEX I/O Modules Communicate with the SLC 5/05 . . . . . . . . . . . . . . . . . . . . . . . . .4.105
4.24 Flex I/O Remote I/O Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.107
4.24.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.107
4.24.2 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.109
4.24.3 Setting the Switch Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.110
4.24.4 Flex I/O Module Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.112
4.24.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.112
4.25 120VAC 8 Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.115
4.25.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.115
4.25.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.117
4.26 24VDC 16 Sink Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.117
4.26.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.117
4.26.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.119
4.27 120VAC 8 Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.119
4.27.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.119
4.27.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.121
4.28 8 Relay Sink/Source Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.121
4.28.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.121
4.28.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.123
4.29 24VDC RTD Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.124
4.29.1 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.124

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4.29.2 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.126


4.29.3 Module Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.127
4.29.4 Manually Calibrating the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.127
4.29.5 Calibration Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.128
4.29.6 Offset Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.129
4.29.7 Gain Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.129
4.30 RTD’s (Resistor Temperature Detector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.131
4.30.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.131
4.30.2 Resistance Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.132
4.31 Input/Output DC Block I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.133
4.31.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.133
4.31.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.134
4.31.3 Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.135
4.31.4 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.135
4.31.5 Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.135
4.31.6 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.137

SECTION 5, AC80 Advant Controller


5.1 AC80 Advant Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1
5.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1
5.1.2 AC80 Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
5.2 Module Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
5.2.1 Internal Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
5.2.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
5.2.3 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5
5.2.4 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
5.3 AC80 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8
5.3.1 AC80 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8
5.3.2 Checking the System Status Using Function Chart Builder (FCB) . . . . . . . . . . . . . . . . . . . . . .5.10
5.3.3 PC Element Error Terminals and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
5.3.4 Using Drive Debug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
5.3.5 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
5.4 NPBA-80 PROFIBUS Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
5.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
5.4.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
5.5 Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
5.5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
5.5.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
5.5.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
5.6 Digital Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
5.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
5.6.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
5.6.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
5.7 Analog Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19

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5.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19


5.7.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
5.7.3 Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
5.7.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
5.8 Digital Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
5.8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
5.8.2 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
5.8.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
5.9 Application and System Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
5.9.1 Loading Application Builder and Function Chart Builder on the PC . . . . . . . . . . . . . . . . . . . .5.23
5.9.2 Downloading AC80 Firmware to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
5.9.3 Adding the AC80 Libraries to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
5.9.4 Setting Up Add-Ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
5.9.5 Loading AC80 System Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.32
5.10 Loading the AC80 Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.35
5.10.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.35
5.10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.35
5.11 Control & Display Panel CDP 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
5.11.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
5.11.2 Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.48
5.11.3 Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50
5.11.4 Selecting Parameters and Changing Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.52
5.11.5 Data Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.53
5.11.6 Event Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.53

SECTION 6, Drive Control Module


6.1 Drive Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.1.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.2 Control and Communications Board (SDCS-AMC-DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.2.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.2.2 Circuit Board Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
6.2.3 SDCS-AMC-DC Hoist Speed Calculation Application Loading . . . . . . . . . . . . . . . . . . . . . . . .6.3
6.3 Control Board SDCS-CON-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5
6.3.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5
6.3.2 Memory Circuit and Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
6.3.3 ASIC Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
6.3.4 Watchdog Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
6.3.5 Seven Segment Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
6.3.6 Auxiliary Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
6.3.7 Supply Voltage Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
6.3.8 RS485 Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
6.3.9 DDCS Channel Integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
6.3.10 Flashing the SDCS-CON-2 Converter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
6.3.11 Downloading Firmware to the SDCS-CON-2 Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10

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6.3.12 Creating a Hyperterminal Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17


6.4 SDCS-POW-1 Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
6.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
6.5 Power Interface SDCS-PIN-21 Board (Field Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
6.5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
6.6 Power Interface SDCS-PIN-205 Board (Field Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
6.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
6.6.2 Compatibility / Differences of SDCS-PIN-21 compared to SDCS-PIN-205 . . . . . . . . . . . . . .6.23
6.6.3 How To Remove An Old Board And Mount A New One . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
6.6.4 Jumper / Resistor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
6.7 Power Interface SDCS-PIN-61 Board (Armature Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.27
6.7.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.27
6.8 Drive Control System Fault Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
6.8.1 Seven Segment Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
6.8.2 Fault Signals Referring to the SDCS-AMC-DC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
6.8.3 Alarm Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.37
6.8.4 Alarm Signals Referring to the SDCS-AMC-DC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.39
6.9 Restoring Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.40
6.9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.40
6.9.2 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.41
6.9.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.42
6.10 Parameter File Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.46
6.11 Signal List for the 4100XPB Electric Mining Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.47
6.11.1 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.47
6.11.2 Analog Output Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.48
6.11.3 Group Tables Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.48
6.11.4 Group 1 (Actual Values) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.50
6.11.5 Group 2 (Actual Values) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.54
6.11.6 Group 3 (Actual Values) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.57
6.11.7 Group 4 (Information) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.62
6.11.8 Group 5 (I/O Signals). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.67
6.11.9 Group 6 (Drive Logic Signals). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.69
6.11.10 Group 7 (Control Words) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.72
6.11.11 Group 8 (Status and Limit Words). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.75
6.11.12 Group 9 (Fault and Alarm Words) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.78
6.12 Parameter List for the 4100XPB Electric Mining Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.82
6.12.1 Parameter Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.82
6.12.2 Bit Packed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.84
6.12.3 Group 12 (Drive Logic I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.88
6.12.4 Group 13 (I/O Settings 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.91
6.12.5 Group 14 (I/O Settings 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.94
6.12.6 Group 15 (Drive Logic Parameters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.98
6.12.7 Group 16 (System Control Inputs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.106
6.12.8 Group 17 (Test Signal Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.107
6.12.9 Group 18 (LED Panel Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.108

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6.12.10 Group 19 (Data Storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.109


6.12.11 Group 20 (Limits). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.111
6.12.12 Group 21 (Start/Stop Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.113
6.12.13 Group 22 (Speed Ramp Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.115
6.12.14 Group 23 (Speed Reference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.116
6.12.15 Group 24 (Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.119
6.12.16 Group 25 (Torque Reference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.122
6.12.17 Group 26 (Torque Reference Handling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.123
6.12.18 Group 28 (Motor Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.125
6.12.19 Group 40 (Undervoltage Monitoring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.130
6.12.20 Group 41 (Motor Nominal Values) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.130
6.12.21 Group 42 (Measurement Settings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.134
6.12.22 Group 43 (Current Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.137
6.12.23 Group 44 (Field Excitation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.141
6.12.24 Group 45 (Field Excitation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.145
6.12.25 Group 46 (EMF Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.146
6.12.26 Group 47 (12-Pulse Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.150
6.12.27 Group 50 (Speed Measurement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.152
6.12.28 Group 51 (Communication Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.156
6.12.29 Group 70 (DDCS Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.158
6.12.30 Group 71 (DriveBus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.163
6.12.31 Group 90 (Dataset Receive Addresses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.163
6.12.32 Group 91 (Dataset Receive Addresses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.166
6.12.33 Group 92 (Dataset Transmit Addresses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.167
6.12.34 Group 93 (Dataset Transmit Addresses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.169
6.12.35 Group 94 (CON Communication (Actual Values)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.171
6.12.36 Group 95 (CON Communication (Reference Values)) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.172
6.12.37 Group 97 (Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.174
6.12.38 Group 98 (Option Modules). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.174
6.12.39 Group 99 (Start-up Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.175

SECTION 7, Motor Maintenance


7.1 Motor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1
7.1.1 Prior to First Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1
7.1.2 After Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
7.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
7.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
7.2.2 Lubrication Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
7.2.3 Shovel Erection Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7
7.2.4 Lubrication After Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8
7.2.5 Lubrication of Remanufactured Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8
7.3 Brush and Commutator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8
7.3.1 Brush Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8
7.3.2 Brush Spring Test Procedure (Does Not Apply to K-1690B Motors) . . . . . . . . . . . . . . . . . . . .7.11

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7.3.3 Recommended Brush Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12


7.3.4 Alternative Brush Replacement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
7.3.5 Brush Holder Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
7.3.6 Arc Director Maintenance (Does Not Apply to K-1690B Motors) . . . . . . . . . . . . . . . . . . . . . .7.14
7.3.7 Commutation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
7.3.8 Commutator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
7.3.9 Commutator Clean up by Air Curing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
7.3.10 Commutator Surface Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
7.4 Neutral Setting of Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
7.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
7.4.2 Procedures for Neutral Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
7.5 Field Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27
7.5.1 Assembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27
7.5.2 Field Coil Inspection (AC Drop Test Comparison) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.30
7.6 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
7.6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
7.6.2 Resistance and Connection Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
7.6.3 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
7.6.4 Insulation Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
7.6.5 Polarization Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.36
7.7 Suggested Maintenance Schedule - Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37
7.8 Suggested Maintenance Schedule - Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
7.9 Preventive Maintenance Inspections Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.39
7.9.1 Crowd Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.39
7.9.2 Swing Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.40
7.9.3 Hoist Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41
7.9.4 Propel Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41
7.9.5 Dipper Trip Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42
7.10 Modifications and Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43
7.10.1 K-558A Motor Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43
7.10.2 K-700B Motor Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.48
7.10.3 K-1690 RTD Configuration Change Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50
7.10.4 K-1690B Motor Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.53
7.11 Electrical Rotating Machinery Workmanship Standard (MPS-341) . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.4 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.6 Wire Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.7 Lugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
7.11.8 Tagging of Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.63
7.11.9 Conductor Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.63
7.11.10 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.63
7.11.11 Splicing of Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66

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7.11.12 Windings, End Turn Extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66


7.11.13 Stator and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66
7.11.14 Foreign Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66
7.11.15 Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.16 Seating of Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.17 Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.18 Frame Head Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.19 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.20 Field Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
7.11.21 Air Gaps and Shimming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.68
7.11.22 Torquing (Use Assembly Floor Micrometer Type Torque Wrenches) . . . . . . . . . . . . . . . . .7.68
7.11.23 Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.68
7.11.24 Bearing Caps and Chambers Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.68
7.11.25 Pipes and Lubrication Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.68
7.11.26 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.69
7.11.27 Grease Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.69
7.11.28 Bolt Locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.69
7.11.29 Locking Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.70
7.11.30 Hylomar, Permatex, and Other Sealants as Specified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.70
7.11.31 Lip Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.70
7.11.32 Disassembly and Reassembly After Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.71
7.11.33 Grounding Provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.71
7.11.34 Installation of Glastic Washers for Bearing Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.71
7.11.35 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.71

SECTION 8, Touch Panel


8.1 Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1
8.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1
8.1.2 Touchscreen Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
8.2 OSD (On Screen Display) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
8.2.1 General Inbformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
8.2.2 User Interface Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
8.2.3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
8.2.4 Miscelaneous Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
8.3 Software Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
8.3.1 Starting the Configuration Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
8.3.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
8.3.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.6
8.3.4 TouchSurround and Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
8.3.5 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7

SECTION 9, Mine Air Systems


9.1 Heater / Air Conditioner and Defroster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1
9.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1

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9.1.2 Standard Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2


9.1.3 Mine Logic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4
9.1.4 Floor Heater/Defroster (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7
9.1.5 Component Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.8
9.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
9.2.1 Maintenance Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
9.2.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
9.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
9.3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14

SECTION 10, i2T™ Remote Communications


10.1 GeneralInformation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1
10.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1
10.1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1
10.1.3 System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
10.1.4 How the System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
10.1.5 Basic System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
10.1.6 System Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
10.1.7 Quick Review of Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
10.1.8 TCP / IP Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
10.1.9 RSLinx Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
10.1.10 pcAnywhere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
10.1.11 RSView 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.11
10.2 Installation of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.12
10.2.1 ControlLogix Interface Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.12
10.2.2 Ethernet Modem Repeater Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.14
10.2.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.15
10.3 i2T Graphic User Interface (GUI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.16
10.3.1 Setup Connect System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.16
10.3.2 Setup GUI Ethernet Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.16
10.3.3 Adding New Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.18
10.3.4 Configure GUI Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.22
10.3.5 Set C Drive for Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.28
10.3.6 Map Drive A:\ of the Remote PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.30
10.3.7 Set GUI to Log Onto Base Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
10.3.8 Load Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
10.3.9 RSView 32 Runtime (Access the Remote PC CD Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
10.3.10 RSLinx OEM (Access the Remote PC CD Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
10.3.11 Move the RSView Source Code to the GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
10.3.12 Setup RSView to Start Automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
10.3.13 RSLinx Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.35
10.3.14 DHRIO Card Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.37
10.3.15 ENET Card Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.43
10.3.16 Changing ENET Card IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.46

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10.3.17 RSLinx Gateway Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.49


10.3.18 Setting TCP/IP Address on the OAP CP341 Ethernet Card . . . . . . . . . . . . . . . . . . . . . . . .10.49
10.3.19 Shovel OAP-CP312- RSLinx Gateway Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.55
10.3.20 i2T Base Server RSLinx Configuration (One Unit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.61
10.3.21 i2T Base Server RSLinx Configuration (Two Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.63
10.3.22 Setting i2T Base Server, RSView Project Node (One Unit) . . . . . . . . . . . . . . . . . . . . . . . .10.68
10.3.23 Setting i2T Base Server, RSView Project Node. (Two Units). . . . . . . . . . . . . . . . . . . . . . .10.71
10.3.24 3.1. Load PH_i2T Files Onto The GUI and Basestation . . . . . . . . . . . . . . . . . . . . . . . . . . .10.74
10.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.76
10.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.76
10.4.2 SIX-STEP TROUBLESHOOTING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.77
10.4.3 Flowchart Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.77
10.4.4 Remote Communications Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.79
10.4.5 ControlLogix Power Supply (R39555D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.80
10.4.6 ControlLogix 1756-ENET/B (R39555D3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.82
10.4.7 Data Highway Plus / Remote I/O Module (R39555D4) . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.88
10.4.8 Basic Computer Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.96
10.5 OptiDig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.99
10.5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.99
10.5.2 Tuning OptiDig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.99

SECTION 11, Miscellaneous Electrical


11.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1
11.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1
11.2 Fiber Optic Connectors and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1
11.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1
11.2.2 Connector Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1
11.3 Power Quality Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5
11.3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5
11.3.2 Features and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.6
11.3.3 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.7
11.3.4 PQMPC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.8
11.3.5 PQM Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.8
11.3.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.14
11.4 Powerware Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.63
11.4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.63
11.4.2 Uninstall CheckUPS II Advanced Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.64
11.4.3 Uninstall PowerChute Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.66
11.4.4 Powerware Software Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.68
11.4.5 Powerware Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.76
11.4.6 Powerware Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.77
11.5 Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.83
11.5.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.83
11.5.2 Left Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.83

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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4100XPB Electrical Manual Table of Contents

Table of Contents (Continued)

11.5.3 Right Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.84


11.5.4 Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.85

Index

Reader Comment Form

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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Table of Contents 4100XPB Electrical Manual

Table of Contents (Continued)

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


Table of Contents, Version 0 - 9/02 - xviii - 4100XPB_1_EMTOC.fm
4100XPB Electrical Manual List of Figures

List of Figures

SECTION 1, Introduction and General Information


Figure 1-1: P&H Mining Equipment - 4100XPB Electric Mining Shovel . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Figure 1-2: Common Point Ground Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Figure 1-3: ESD Susceptibility Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Figure 1-4: Electrotorque Plus “B” Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Figure 1-5: Hoist Electrical - One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Figure 1-6: Crowd Electrical - One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Figure 1-7: Swing Electrical - One Line Diagram - Swing 1&2 and Swing #3 . . . . . . . . . . . . . . . . . . . 1.16
Figure 1-8: Swing Electrical - One Line Diagram - Swing 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
Figure 1-9: Propel Electrical - One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
Figure 1-10: Location Code Subassembly or Panel Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22

SECTION 2, Power Distribution


Figure 2-1: Block Diagram of Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Figure 2-2: Electrical Power Distribution Single Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Figure 2-3: Tail Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Figure 2-5: Air Disconnect Switch with Earthing (L01OOO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Figure 2-4: Air Disconnect Switch - Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Figure 2-6: Collector Ring Assembly - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Figure 2-7: Collector Ring Assembly Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Figure 2-8: Collector Ring Assembly - High Voltage Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Figure 2-9: Collector Ring Assembly - Low Voltage Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Figure 2-10: Collector Ring Assembly - Top of Low Voltage Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Figure 2-11: Collector Ring Assembly - Communication Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Figure 2-12: High Voltage Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Figure 2-13: High Voltage Cabinet - Single Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Figure 2-14: Key Interlock System - Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Figure 2-15: M3BS Switch on Air Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Figure 2-16: Key Interlock System - High Voltage Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Figure 2-17: Main Transformer - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Figure 2-18: Main Transformer Primary - Vector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Figure 2-19: Main Transformer Secondaries - Vector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Figure 2-20: Main Transformer - Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Figure 2-21: Bus Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Figure 2-22: Auxiliary/Field Transformer - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Figure 2-23: Auxiliary/Field Transformer Primary - Vector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Figure 2-24: Auxiliary/Field Transformer Auxiliary Secondary - Vector Diagram . . . . . . . . . . . . . . . . 2.21
Figure 2-25: Auxiliary/Field Transformer Control Secondary - Vector Diagram . . . . . . . . . . . . . . . . . . 2.21
Figure 2-26: Auxiliary/Field Transformer Field Supply - Vector Diagram . . . . . . . . . . . . . . . . . . . . . . 2.22
Figure 2-27: Auxiliary/Field Transformer Lighting Supply - Vector Diagram . . . . . . . . . . . . . . . . . . . . 2.22
Figure 2-28: Auxiliary/Field Transformer - Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

SECTION 3, Cabinet Description and Operation

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 3-1: Location Code Subassembly or Panel Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2


Figure 3-2: Ground Fault and Suppression Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . 3.3
Figure 3-3: Ground Fault and Suppression Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Figure 3-4: Ground Fault Relay, GFRM, GFRA and GFRF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Figure 3-5: GFRM, Ground Fault Relay Main Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3-6: GFRA, Ground Fault Relay Main Auxiliary Schematic Diagram . . . . . . . . . . . . . . . . . . . . . 3.7
Figure 3-7: GFRF, Ground Fault Relay Field Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Figure 3-8: Main Transformer Suppression Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Figure 3-9: Reactive Power Compensation Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . 3.10
Figure 3-11: RPC Switching Cabinet and RPC Capacitor/Reactor Cabinet . . . . . . . . . . . . . . . . . . . . . . 3.11
Figure 3-10: RPC Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Figure 3-12: RPC Cabinet Bank 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Figure 3-13: KW, KVAR and KVA Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Figure 3-14: RPC Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Figure 3-15: RPC Firing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Figure 3-16: Pulse Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Figure 3-17: Thyristor Switch Section (½ Bank and Bank 2 Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Figure 3-19: RPC Indicator Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Figure 3-18: RPC Indicator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Figure 3-20: Harmonic Frequencies (60Hz Fundamental) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Figure 3-21: Converter Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Figure 3-22: Converter Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Figure 3-23: Input Power Distribution and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Figure 3-24: SCR Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Figure 3-26: 3Ø SCR Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Figure 3-25: SCR Controlled Rectification Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Figure 3-27: 3Ø SCR Reversing Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Figure 3-28: 3Ø SCR Series Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Figure 3-30: Hoist #1/Propel #1 Diverter Capacitor Charge Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Figure 3-29: Diverter Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Figure 3-31: Hoist #2 Diverter Capacitor Charge Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Figure 3-32: Swing 1 & 2 Diverter Capacitor Charge Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Figure 3-33: Swing #3 Diverter Capacitor Charge Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
Figure 3-34: Crowd/Propel #2 Diverter Capacitor Charge Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
Figure 3-35: Diverter Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Figure 3-36: Hoist #1/Propel #1 Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Figure 3-38: Swing 1 & 2 Forward Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . 3.34
Figure 3-37: Hoist #2 Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Figure 3-39: Swing 1 & 2 Reverse Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . 3.35
Figure 3-40: Swing #3 Forward Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . . . 3.35
Figure 3-41: Swing #3 Reverse Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . . . . . . . 3.36
Figure 3-42: Crowd/Propel #2 Forward Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . 3.36
Figure 3-43: Crowd/Propel #2 Reverse Bridge Diverter Trip Motor Dissipation Path . . . . . . . . . . . . . . 3.37
Figure 3-44: Transfer Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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4100XPB Electrical Manual List of Figures

List of Figures (Continued)

Figure 3-45: Transfer Cabinet Front Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39


Figure 3-46: Flex I/O Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Figure 3-47: Field and Armature Contactor Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Figure 3-48: Field and Armature Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Figure 3-49: Field and Armature Contactor Flex I/O Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Figure 3-50: Control Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Figure 3-51: Control Cabinet Front Door Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
Figure 3-52: Control Cabinet Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
Figure 3-53: Control Cabinet Front Panel Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
Figure 3-54: Control Cabinet Door Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Figure 3-55: Control Cabinet Front Top Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
Figure 3-56: Control Cabinet Front Bottom Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
Figure 3-57: Test Reference Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Figure 3-58: Control Cabinet Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Figure 3-59: Control Cabinet Inside Center Section Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
Figure 3-60: Control Cabinet Right Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
Figure 3-61: Master Drive Relay 60Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Figure 3-62: Master Drive Relay 50Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Figure 3-64: Main Phase Sensing Relay PLC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
Figure 3-63: Master Drive Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
Figure 3-65: Main Phase Sensing Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
Figure 3-66: Main Transformer Contactor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
Figure 3-68: Main Transformer Contactor - Holding Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
Figure 3-69: Master Control Relay 60Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
Figure 3-67: Main Transformer Contactor - Initial Shovel Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
Figure 3-71: Master Control Relay - 24VDC Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
Figure 3-72: Master Control Relay - AUXIOCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
Figure 3-70: Master Control Relay 50Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
Figure 3-73: Master Control Relay - IO2CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
Figure 3-74: Master Control Relay - IO1CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Figure 3-75: Master Control Relay - AXSTCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
Figure 3-76: Propel Strobe Light Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
Figure 3-77: Propel Strobe Lights - Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
Figure 3-78: Field Supply Door Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
Figure 3-79: Field Supply Door Relay - Field Breaker Shunt Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
Figure 3-80: Drive Synchronizing Voltage Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
Figure 3-81: SDCS-PIN-61 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
Figure 3-82: Hoist #1/Propel #1 and Hoist #2 Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . 3.64
Figure 3-84: Swing #3 Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
Figure 3-85: Crowd/Propel #2 Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
Figure 3-83: Swing 1&2 Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
Figure 3-86: Drive E-Stop Relay 60Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
Figure 3-87: Drive E-Stop Relay 50Hz Shovel One Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
Figure 3-88: Drive E-Stop Relay - SDCS-CON-2 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 3-89: Auxiliary Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67


Figure 3-90: Auxiliary Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
Figure 3-91: Motor Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71
Figure 3-92: Heater Interlock Relay (HIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72
Figure 3-93: Main Transformer Thermal Overloads (TTMT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
Figure 3-94: Instant Overload Relay (First 3 Seconds of Shovel Start) . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
Figure 3-95: Instant Overload Relay (3 Seconds after Shovel Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.74
Figure 3-96: Instant Overload Relay (QTTM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.74
Figure 3-97: Main Transformer Overload Adjust Relay (MTOAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75
Figure 3-98: Machine House Heater Relay (MHHR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
Figure 3-99: Motor Control Cabinet - (4100XPB Deck Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.77
Figure 3-100: Motor Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
Figure 3-101: Propel Motor Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79

SECTION 4, Programmable Logic Controller


Figure 4-1: SLC 5/05 System Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Figure 4-2: 10-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Figure 4-3: Module Installation Into Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Figure 4-4: Power Supply Inside Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Figure 4-5: SLC 5/05 Front Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Figure 4-6: SLC 5/05 Left Side Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Figure 4-7: SLC 5/05 Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Figure 4-8: SLC 5/05 Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Figure 4-9: SLC 5/05 Operating System Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
Figure 4-10: Scanner I/O Image Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
Figure 4-11: Scan Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
Figure 4-12: Scanner Asynchronous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
Figure 4-13: Scanner Baud Rate Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
Figure 4-14: Scanner Run Mode LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
Figure 4-15: AMCI Resolver Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Figure 4-16: Transducer Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
Figure 4-17: Input Word Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
Figure 4-18: Output Word Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
Figure 4-19: Prtofibus Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Figure 4-20: Profibus Adapter Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44
Figure 4-22: Hyperterminal Connect To Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
Figure 4-21: Hyperterminal New Connection - Connection Description . . . . . . . . . . . . . . . . . . . . . . . . 4.46
Figure 4-24: Hyperterminal Session Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
Figure 4-23: Hyperteminal Com1 Properties Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
Figure 4-26: Hyperterminal Response to Configuration File Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
Figure 4-25: Hyperterminal Status Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
Figure 4-28: Hyperterminal Final Send File Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49
Figure 4-27: Hyperterminal Send File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49
Figure 4-30: Hyperterminal Profibus Adapter Download Procedure Successful Completion Screen . . 4.50

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


List of Figures, Version 0 - 9/02 - xxii - 4100XPB_1_EMLOF.fm
4100XPB Electrical Manual List of Figures

List of Figures (Continued)

Figure 4-29: Hyperterminal Flash Updating Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50


Figure 4-31: Profibus Firmware Upgrade - Hyperterminal Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.51
Figure 4-33: Profibus Firmware Upgrade - Transfer Send File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.52
Figure 4-32: Profibus Firmware Upgrade - LoadFlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.52
Figure 4-34: Profibus Firmware Upgrade - Select File To Send . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.53
Figure 4-35: Profibus Firmware Upgrade - Send File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.53
Figure 4-36: Profibus Firmware Upgrade - File Transfer Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.53
Figure 4-37: Profibus Firmware Upgrade - Stored in Flash Successfully . . . . . . . . . . . . . . . . . . . . . . . . 4.54
Figure 4-38: Profibus Firmware Upgrade - Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.54
Figure 4-39: Discrete I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.55
Figure 4-40: Input Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.56
Figure 4-41: Output Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.57
Figure 4-42: Output Module with Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.58
Figure 4-43: Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.59
Figure 4-44: Sinking DC Input Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.60
Figure 4-45: Sourcing DC Output Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.61
Figure 4-46: Analog Input Module Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
Figure 4-47: Analog Input Module Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Figure 4-48: Analog Input Module Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Figure 4-49: 120VAC Input Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.67
Figure 4-50: 120VAC/240VAC Output Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.68
Figure 4-52: Analog Output Module Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Figure 4-51: Analog Output Module Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Figure 4-53: Analog Output Module Voltage Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72
Figure 4-54: Bit Instruction Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.75
Figure 4-55: Timer Instruction Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.77
Figure 4-56: Counter Instruction Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.81
Figure 4-57: Hexadecimal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.85
Figure 4-58: Hex Mask Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.85
Figure 4-59: Slot Numbers in Hexadecimal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93
Figure 4-60: Typical Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.98
Figure 4-61: Remote I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.104
Figure 4-62: Terminal Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.105
Figure 4-63: I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.105
Figure 4-64: Flex I/O Communication Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.106
Figure 4-65: Remote I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.107
Figure 4-66: Remote I/O Adapter Diagnostic Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.108
Figure 4-67: Daisy Chaining Using Adapter Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.109
Figure 4-68: Daisy Chaining with a Separate Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.110
Figure 4-69: 120VAC 8 Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.115
Figure 4-70: 120VAC 8 Input Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.117
Figure 4-71: 24VDC 16 Sink Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.117
Figure 4-72: 24VDC 16 Sink Input Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.119
Figure 4-73: 120VAC 8 Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.119

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 4-74: 120VAC 8 Output Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.121


Figure 4-75: 8 Relay Sink/Source Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.121
Figure 4-76: 8 Relay Sink/Source Output Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.123
Figure 4-77: 24VDC RTD Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.124
Figure 4-78: 24VDC RTD Input Module Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.126
Figure 4-79: 24VDC RTD Input Module Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.127
Figure 4-80: Calibration Setup Using a Decade Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.128
Figure 4-81: Calibration Setup Using Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.128
Figure 4-82: RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.131
Figure 4-83: RTD Resistance / Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.132
Figure 4-84: 16 Input 16 Output DC Block I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.133
Figure 4-85: Block I/O Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.134
Figure 4-86: Block I/O Dipswitch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.135
Figure 4-87: Block I/O Auxiliary Block #1 Dipswitch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.135
Figure 4-88: Block I/O Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.137

SECTION 5, AC80 Advant Controller


Figure 5-1: AC80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Figure 5-2: AC80 System Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Figure 5-3: AC80 Circuit Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Figure 5-4: AC80 LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Figure 5-5: AC80 Initialization and Station Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Figure 5-6: AC80 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Figure 5-7: S0 to S7 Example Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Figure 5-8: AC80 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Figure 5-9: NPBA-80 PROFIBUS Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Figure 5-10: Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Figure 5-11: Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Figure 5-12: Digital Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Figure 5-13: Digital Input Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Figure 5-14: Analog Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Figure 5-15: Analog Output Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Figure 5-16: Digital Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Figure 5-17: Digital Output Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Figure 5-18: User Information Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Figure 5-20: Choose Destination Location Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Figure 5-19: Select Product Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Figure 5-22: Choose Project Destination Directory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Figure 5-21: Choose Configuration Directory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Figure 5-23: Setup Complete Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Figure 5-24: Go To Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Figure 5-25: Username and Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Figure 5-26: FTP Site Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Figure 5-27: Download Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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4100XPB Electrical Manual List of Figures

List of Figures (Continued)

Figure 5-28: MinePro Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29


Figure 5-29: Save Link As . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Figure 5-31: AdvaBuild Compiler Application Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
Figure 5-30: Opening Setup Add-Ons 6.0-0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
Figure 5-32: Copy Additional Libraries From Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
Figure 5-33: Additional Libraries Installed Successfully Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
Figure 5-34: Opening MS-DOS Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
Figure 5-35: AC80 Program Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
Figure 5-37: Application Builder - Open Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
Figure 5-36: Starting Application Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
Figure 5-38: Application Builder - Open Project Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
Figure 5-39: Application Builder - Select Node Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
Figure 5-41: Function Chart Builder - Target Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Figure 5-40: Function Chart Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Figure 5-43: Function Chart Builder - Options Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
Figure 5-42: Function Chart Builder - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
Figure 5-44: Function Chart Builder - Status Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
Figure 5-46: Function Chart Builder - Status Report - Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
Figure 5-45: Function Chart Builder - Target Block Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
Figure 5-48: Function Chart Builder - Download User Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
Figure 5-47: Function Chart Builder - Target Load Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
Figure 5-50: Function Chart Builder - Online Mode Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Figure 5-49: Function Chart Builder - Load Application Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Figure 5-52: Function Chart Builder - Target RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
Figure 5-51: Function Chart Builder - Set Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
Figure 5-54: Function Chart Builder - Target PROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
Figure 5-53: Function Chart Builder - Target Save in PROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
Figure 5-55: Function Chart Builder - Deblock Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
Figure 5-56: Function Chart Builder - Status Report Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
Figure 5-57: Function Chart Builder - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
Figure 5-58: AC80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
Figure 5-59: Initial Display - Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
Figure 5-60: CDP 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
Figure 5-61: Event Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54

SECTION 6, Drive Control Module


Figure 6-1: Drive Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Figure 6-2: SDCS-AMC-DC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Figure 6-3: Selecting Download Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Figure 6-4: Motor Specific .ddf File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Figure 6-5: SDCS-CON-2 Jumper Coding Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Figure 6-6: SDCS-CON-2 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Figure 6-7: SDCS-CON-2 Seven Segment Display (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Figure 6-8: SDCS-CON-2 Auxiliary Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 6-9: SDCD-CON-2 Board S2 Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9


Figure 6-10: Group 42 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Figure 6-11: Checking Converter Software Version (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Figure 6-12: RS-232 to 485 Converter P&H Part Number R49117D1 . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Figure 6-13: SDCS-CON-2 Board with SDCS-AMC-DC Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
Figure 6-15: Seven Segment Display - Small U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Figure 6-14: CON2 Download - Hyperterminal Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Figure 6-16: CON2 Download - Communication Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Figure 6-17: CON2 Download - Erasing Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Figure 6-19: Seven Segment Display - Small R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
Figure 6-18: CON2 Download - Transfer Send Text File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
Figure 6-20: CON2 Download - Download Successful . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Figure 6-21: SDCS-POW-1 Power Supply Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Figure 6-22: SDCS-POW-1 Jumper Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Figure 6-23: SDCS-PIN-21 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
Figure 6-24: SDCS-PIN-205 Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Figure 6-25: SDCS-PIN-205 Board Jumper/Resistor Configuration Hoist/Crowd Motions Only . . . . . 6.25
Figure 6-26: SDCS-PIN-205 Board Jumper/Resistor Configuration Swing Motion Only . . . . . . . . . . . 6.26
Figure 6-27: SDCS-PIN-61 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
Figure 6-28: SDCS-CON-2 Board Seven Segment Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
Figure 6-29: Seven Segment Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29
Figure 6-30: Macro Loading to the Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40
Figure 6-31: System Configuration Window - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42
Figure 6-32: Drives Window - Drive Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43
Figure 6-33: Opening Signals and Paramaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43
Figure 6-35: Comparing Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44
Figure 6-36: Comparison Results - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44
Figure 6-34: Opening All Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.44
Figure 6-37: Set Parameter 99.11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45
Figure 6-38: Set Parameter 99.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45
Figure 6-39: Section of Group 14 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.84
Figure 6-40: Section of Group 14 Parameters (Changed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.84

SECTION 7, Motor Maintenance


Figure 7-1: Bearing Lube Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Figure 7-2: Carbon Brush-to-Brush Box Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Figure 7-3: Brush Spring Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Figure 7-4: Brush Holder Cross Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Figure 7-5: Brush Replacement Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Figure 7-6: Arc Director and Brush Box Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Figure 7-7: Commutator Surface Wear Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Figure 7-8: Light Tan Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Figure 7-9: Mottled Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Figure 7-10: Slot Bar Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21

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4100XPB Electrical Manual List of Figures

List of Figures (Continued)

Figure 7-11: Heavy Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22


Figure 7-12: Streaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Figure 7-13: Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Figure 7-14: Grooving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Figure 7-15: Copper Drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Figure 7-16: Pitch Bar Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Figure 7-17: Heavy Slot Bar Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Figure 7-18: Field Ring - Refer to Table 7-9 for A-E Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
Figure 7-19: Connection Diagram Interpole 4 Pole Shunt Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Figure 7-20: K-558A Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
Figure 7-21: K-558A 1/4-20 Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
Figure 7-22: K-558A Field Coil Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
Figure 7-23: K-700B Interpole Bolt and Shim Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
Figure 7-24: K-700B Lock Brush Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
Figure 7-25: Bearing Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
Figure 7-26: 1/4-20 Holes and Angle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.52
Figure 7-28: K-1690B CE Bearing Cartridge Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
Figure 7-27: K-1690B CE Bearing Cap Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
Figure 7-29: K-1690B OCE Bearing Cap Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
Figure 7-31: K-1690B Shaft Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Figure 7-30: K-1690B OCE Bearing Cartridge Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Figure 7-32: K-1690B Commutator Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
Figure 7-33: CE Bearing Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
Figure 7-34: OCE Bearing Parts Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.59
Figure 7-35: Lug Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64
Figure 7-36: Bolt Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70

SECTION 8, Touch Panel


Figure 8-1: User Interface Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

SECTION 9, Mine Air Systems


Figure 9-1: Mine Air Systems Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Figure 9-2: Standard Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Figure 9-3: Cool/Off/Heat Rocker Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Figure 9-5: Cooling Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Figure 9-6: Pressurizer Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Figure 9-4: Heat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Figure 9-8: Mine Logic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Figure 9-7: Fan Speed Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Figure 9-10: Power On/Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-11: Heat/Cool Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-9: LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-13: Pressurizer Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 9-12: Temperature Up and Temperature Down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6


Figure 9-15: Floor Heater/Defroster Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Figure 9-14: Fan Speed Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Figure 9-16: Control Cabinet Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
Figure 9-17: Mine Logic Controller (MLC) Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
Figure 9-18: Mine Air Systems Troubleshooting - No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Figure 9-20: Mine Air Systems Troubleshooting - No Heating - C1 Energized . . . . . . . . . . . . . . . . . . . 9.16
Figure 9-19: Mine Air Systems Troubleshooting - No Heating - C1 Deenergized . . . . . . . . . . . . . . . . . 9.16
Figure 9-21: Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Figure 9-22: MLS Relay Board Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

SECTION 10, i2T™ Remote Communications


Figure 10-1: Base Station Worstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Figure 10-2: Remote Equipment Basic Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Figure 10-3: Small Ethernet System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Figure 10-4: TCP/IP Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Figure 10-6: Drop Down Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Figure 10-5: TCP/IP Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Figure 10-7: Ethernet Adapter Information Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Figure 10-8: Ethernet Adapter Information - No IP Address or Subnet Mask . . . . . . . . . . . . . . . . . . . . 10.7
Figure 10-9: ControlLogix Interface Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
Figure 10-10: System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Figure 10-11: ControlLogix Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Figure 10-12: Modem and Antenna Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
Figure 10-13: Ethernet Modem and Antenna Assembly for Repeaters . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Figure 10-14: Component Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
Figure 10-16: Control Panel Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Figure 10-15: Desktop Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Figure 10-17: System Properties Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Figure 10-19: Control Panel - Network Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
Figure 10-18: Desktop Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
Figure 10-21: Select Network Component Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Figure 10-20: Network Screen - Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Figure 10-22: Select Network Adapters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Figure 10-23: Desktop Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Figure 10-24: Network Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
Figure 10-25: TCP/IP Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Figure 10-27: TCP/IP Properties Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
Figure 10-26: Network Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
Figure 10-29: Subnet Mask Type Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Figure 10-28: Specify and IP Address Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Figure 10-31: File and Print Sharing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
Figure 10-30: Network Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
Figure 10-32: Network Identification Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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List of Figures (Continued)

Figure 10-34: Windows Explorer Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29


Figure 10-33: Main Desktop Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
Figure 10-35: Properties Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
Figure 10-37: Windows Explorer Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Figure 10-36: Desktop Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Figure 10-38: Map Network Drive Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
Figure 10-39: Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
Figure 10-40: Registry Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Figure 10-42: Configure Drivers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
Figure 10-41: RSLinx Communications Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
Figure 10-43: Device Recognition Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
Figure 10-44: Backplane Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
Figure 10-46: New Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
Figure 10-45: No Module Selected Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
Figure 10-48: DH Configuration Screen - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Figure 10-49: Product Information Name Screen - DH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Figure 10-47: Open Screen (No Module Selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Figure 10-50: Product Information Name Screen - ENET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
Figure 10-51: Browse Network Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
Figure 10-53: ControlLogix Gateway - 1756 DHRIO Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
Figure 10-52: DHRIO Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
Figure 10-55: Programs Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Figure 10-56: Downloading Progress Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Figure 10-54: Send File to Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
Figure 10-57: No Module Selected Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
Figure 10-58: New Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
Figure 10-59: Browse Network Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
Figure 10-60: ENET Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Figure 10-61: Product Information Name Screen - ENET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Figure 10-63: Configuration Screen - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
Figure 10-62: Send File to Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
Figure 10-65: Module Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
Figure 10-64: Port Information Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
Figure 10-67: Port Configuration Tab Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
Figure 10-66: General Information Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
Figure 10-69: Current IP Address Screen - Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
Figure 10-68: Save to File Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
Figure 10-70: Port Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
Figure 10-71: CP341 Ethernet Card Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
Figure 10-73: Windows NT Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Figure 10-72: Opening Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Figure 10-75: Windows NT Network Protocol Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
Figure 10-74: Network Display on the Identification Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
Figure 10-76: Microsoft TCP/IP Properties Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

Figure 10-77: Microsoft TCP/IP Properties Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54


Figure 10-78: Configure Drivers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
Figure 10-79: Add New RSLinx Driver Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
Figure 10-80: Configure Remote Devices Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
Figure 10-81: Configure Browser Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
Figure 10-82: Configure Drivers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
Figure 10-83: Select Configure Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
Figure 10-85: Client Access List Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
Figure 10-84: Configure RSLinx Gateway Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
Figure 10-87: DDE/OPC Topic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
Figure 10-88: Topic Unit1 Update Confirmation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
Figure 10-86: Select Topic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
Figure 10-89: Advanced Communications Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60
Figure 10-90: RSWho Screen - Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60
Figure 10-91: RSWho-1 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
Figure 10-92: Select Configure Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
Figure 10-94: Add New RSLinx Driver Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
Figure 10-93: Configure Drivers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62
Figure 10-96: Add New RSLinx Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63
Figure 10-95: Configure Remote Driver via Linx Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63
Figure 10-97: Driver Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.64
Figure 10-98: Configure Drivers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.64
Figure 10-99: Topic Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.65
Figure 10-100: DDE/OPC Topic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.65
Figure 10-102: Advance Communications Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.66
Figure 10-101: DDE/OPC Topic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.66
Figure 10-104: Advanced Communications Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67
Figure 10-103: Data Source Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67
Figure 10-106: RSView Runtime Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.68
Figure 10-105: RSWho-1 Screen - Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.68
Figure 10-107: Node Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.69
Figure 10-108: Node Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.69
Figure 10-109: Channel Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.70
Figure 10-110: Primary Communication Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.70
Figure 10-111: RSView Runtime Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.71
Figure 10-112: Node Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.71
Figure 10-113: Node Selection Screen - Unit1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.72
Figure 10-114: Node Selection Screen - Unit2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.72
Figure 10-116: Notepad Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
Figure 10-115: Modify Shovel Serial # Here Desktop Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.73
Figure 10-117: Notepad Screen - Active = 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.74
Figure 10-119: Project Transport Wizard - Restor Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
Figure 10-120: Project Transport Wizard - Locate Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75
Figure 10-118: Project Transport Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.75

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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List of Figures (Continued)

Figure 10-121: Flow Chart Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.78


Figure 10-122: Shovel 1 Is Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.79
Figure 10-123: Shovel 1 Is Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.79
Figure 10-124: Shovel 1 Is In Fault Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.80
Figure 10-125: Shovel 1 Communication Difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.80
Figure 10-126: System Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.80
Figure 10-127: ControlLogix Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.81
Figure 10-128: Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.82
Figure 10-129: ControlLogix Ethernet Communication Interface Module . . . . . . . . . . . . . . . . . . . . . . 10.83
Figure 10-130: WWW.AB.COM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.84
Figure 10-132: TCP/IP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85
Figure 10-131: Module Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85
Figure 10-133: Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.86
Figure 10-134: ENET/IP Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.87
Figure 10-135: ENET/IP (CIP) Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.87
Figure 10-136: Current Chassis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.88
Figure 10-137: ControlLogix Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.89
Figure 10-138: Start-Program-Command Prompt Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.93
Figure 10-140: Ping Test Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.94
Figure 10-139: Command Prompt Opening Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.94
Figure 10-141: Close Program Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.97

SECTION 11, Miscellaneous Electrical


Figure 11-1: Strip the Fiber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Figure 11-2: Putting on the Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Figure 11-3: Duplex Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-4: Polishing Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-5: Fiber Optic Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
Figure 11-6: Power Quality Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Figure 11-7: PQM Single Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Figure 11-8: PQM Front Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
Figure 11-9: PQM Display Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
Figure 11-10: PQM - Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
Figure 11-11: Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
Figure 11-12: Message Key Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
Figure 11-13: Data Entry Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
Figure 11-14: Setpoint Message Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
Figure 11-15: PQM Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
Figure 11-16: PQM Setup/Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
Figure 11-17: Setpoint Acces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
Figure 11-18: Changing Setpoint Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24
Figure 11-19: RS484/RS232 Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
Figure 11-20: PQM Setup / DNP Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.26
Figure 11-21: PQM Setup/Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


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List of Figures (Continued)

Figure 11-22: Set Time/Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28


Figure 11-23: Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
Figure 11-24: PQM Setup - Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
Figure 11-25: Actual Values Message Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
Figure 11-26: Actual Values - Metering/Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
Figure 11-27: Actual Values - Metering / Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
Figure 11-28: Actual Vaues: Power (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
Figure 11-29: Actual Vaues: Power (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
Figure 11-30: Actual Vaues: Power (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
Figure 11-31: Power Measurement Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43
Figure 11-32: Actual Values - Metering/Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.44
Figure 11-33: Actual Values - Metering/Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
Figure 11-34: Actual Values - Metering/Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
Figure 11-35: Actual Values - Metering/Pulse Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
Figure 11-36: Pulse Input Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.49
Figure 11-37: Actual Values - Metering/Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50
Figure 11-38: Actual Values Page 2 - Satus/Alarms (Page 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51
Figure 11-40: Actual Values Page 2 - Satus/Alarms (Page 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
Figure 11-39: Actual Values Page 2 - Satus/Alarms (Page 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
Figure 11-41: Status/Switches Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.53
Figure 11-42: Status/Clock Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.53
Figure 11-43: Status/Programmable Message Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
Figure 11-44: Power Analysis/Power Quality Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
Figure 11-45: Total Harmonic Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
Figure 11-46: Actual Values - Data Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
Figure 11-47: Actual Values - Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.58
Figure 11-48: Actual Values Page 4 - Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.62
Figure 11-49: Opening Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.64
Figure 11-50: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.65
Figure 11-51: Add/Remove Programs Properties Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.65
Figure 11-53: Opening Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.66
Figure 11-52: Confirm File Deletion Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.66
Figure 11-55: Add/Remove Programs Properties Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.67
Figure 11-54: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.67
Figure 11-57: Start-Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68
Figure 11-56: Confirm File Deletion Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68
Figure 11-58: Run Window - A:\BestPowerRegKey.exe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.69
Figure 11-59: BestPowerRegKey Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.69
Figure 11-60: Run Window - A:\NtAnd95\setup.exe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.69
Figure 11-62: LanSafe III Setup Window - Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.70
Figure 11-63: LanSafe III Setup Window - Workstation Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.70
Figure 11-61: Run Window - E:\Lansafe\Lansafe\NtAnd95\setup.exe . . . . . . . . . . . . . . . . . . . . . . . . . 11.70
Figure 11-64: LanSafe III Setup - Introduction to UPS Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
Figure 11-65: LanSafe III Setup - UPS Model Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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4100XPB Electrical Manual List of Figures

List of Figures (Continued)

Figure 11-66: LanSafe III Setup - Communication Port Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.72


Figure 11-67: LanSafe III Setup - UPC Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.72
Figure 11-68: LanSafe III Setup - Zero-Length Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
Figure 11-69: LanSafe III Setup - Shutdown Timing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
Figure 11-71: LanSafe III Setup - Install Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.74
Figure 11-70: LanSafe III Setup - Automatic Load Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.74
Figure 11-73: LanSafe III Setup - Successfully Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
Figure 11-72: LanSafe III Setup - Copying Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
Figure 11-74: Powerware 9120 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.76
Figure 11-75: Start - Program - LanSafe III - LanSafe III Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.77
Figure 11-77: LanSafe III Console - Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.78
Figure 11-76: LanSafe III Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.78
Figure 11-79: LanSafe III Console - Custom Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.79
Figure 11-78: Maintenance Schedule Setup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.79
Figure 11-80: Customized Alerts for Windows NT (oap) Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.80
Figure 11-82: Customize Alerts - Shutdown Canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.81
Figure 11-81: Customize Alerts - 1 Minute Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.81
Figure 11-83: LanSafe III Console - Periodic Log Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82
Figure 11-84: Periodic Log Setup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82
Figure 11-85: 4100BOSS Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
Figure 11-86: Joystick Assemmbly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85
Figure 11-87: Top View of Controller and Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.86

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4100XPB_1_EMLOF.fm - xxxiii - List of Figures, Version 0 - 9/02
List of Figures 4100XPB Electrical Manual

List of Figures (Continued)

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


List of Figures, Version 0 - 9/02 - xxxiv - 4100XPB_1_EMLOF.fm
4100XPB Electrical Manual List of Tables

List of Tables

SECTION 1, Introduction and General Information


Table 1-1: Recommended Test Equipment List .......................................................................................1.19
Table 1-2: PLC Hardware and Software List ...........................................................................................1.20
Table 1-3: Ground Identification ..............................................................................................................1.21
Table 1-4: Location Code Letter Designation ..........................................................................................1.22
Table 1-5: Electrical Shock and Human Response ...................................................................................1.27

SECTION 2, Power Distribution


Table 2-1: Posi-Pin Connection ..................................................................................................................2.6

SECTION 3, Cabinet Description and Operation


Table 3-1: Location Code Letter Designation ............................................................................................3.2
Table 3-2: RPC Step Sequence (60Hz Shovels) .......................................................................................3.19
Table 3-3: RPC Step Sequence (50Hz Shovels) .......................................................................................3.19
Table 3-4: 4100XPB Auxiliary Motor Starters (60Hz Shovel) ................................................................3.68
Table 3-5: 4100XPB Auxiliary motor Starters (50Hz Shovel) .................................................................3.69

SECTION 4, Programmable Logic Controller


Table 4-1: Power Supply Specifications .....................................................................................................4.5
Table 4-2: SLC 5/05 Processor Specifications ...........................................................................................4.6
Table 4-3: SLC 5/05 Status LED’s General Description ..........................................................................4.11
Table 4-4: Remote I/O Scanner Operating Specifications ........................................................................4.33
Table 4-6: ScannerStatus LED Troubleshooting ......................................................................................4.38
Table 4-5: Scanner Status LED’s ..............................................................................................................4.38
Table 4-7: Profibus Scanner System LED ................................................................................................4.45
Table 4-8: Profibus Scanner Communications LED ................................................................................4.45
Table 4-9: Sinking DC Input Module Specifications ...............................................................................4.60
Table 4-10: Sourcing DC Output Module Specifications .........................................................................4.61
Table 4-11: Analog Input Module General Specifications .......................................................................4.62
Table 4-12: Analog Input Module Current Loop Input Specifications .....................................................4.62
Table 4-13: Analog Input Module Voltage Input Specifications ..............................................................4.63
Table 4-14: Analog Input A/D Characteristics .........................................................................................4.64
Table 4-15: Analog Input Module Input Characteristics ..........................................................................4.64
Table 4-16: Analog Input Module ID Code ..............................................................................................4.65
Table 4-17: 120VAC Input Module Specifications ..................................................................................4.67
Table 4-18: 120VAC/240VAC Output Module Specifications ................................................................4.68
Table 4-19: Analog Output Module Specifications ..................................................................................4.69
Table 4-20: Analog Output Module D/A Converter Characteristics ........................................................4.70
Table 4-21: Analog Output Module Output Characteristics .....................................................................4.70
Table 4-22: ID Code .................................................................................................................................4.70
Table 4-23: Bit Instructions ......................................................................................................................4.73
Table 4-24: Timer/Counter Instructions ...................................................................................................4.74

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4100XPB_1_EMLOT.fm - xxxv - List of Tables, Version 0 - 9/02
List of Tables 4100XPB Electrical Manual

List of Tables (Continued)

Table 4-25: Examine If Closed .................................................................................................................4.75


Table 4-26: Examine If Open ...................................................................................................................4.76
Table 4-27: Using Timer On Delay Status Bits ........................................................................................4.78
Table 4-28: Using Timer Off Delay Status Bits .......................................................................................4.79
Table 4-29: Using Retentive Timer On Status Bits ..................................................................................4.80
Table 4-30: Using Count Up Status Bits ..................................................................................................4.82
Table 4-32: Using The RES Instruction ...................................................................................................4.83
Table 4-31: Using Count Down Status Bits ..............................................................................................4.83
Table 4-33: Power-up Error Codes ...........................................................................................................4.86
Table 4-34: Going-to-Run Error Codes ....................................................................................................4.87
Table 4-35: Runtime Error Codes .............................................................................................................4.89
Table 4-36: User Program Instruction Error Codes ..................................................................................4.92
Table 4-37: I/O Error Fault Codes ............................................................................................................4.94
Table 4-38: SLC 5/05 Ethernet Connections ............................................................................................4.99
Table 4-39: Configuring the Ethernet Channel .......................................................................................4.101
Table 4-40: BOOTP Configuration File Update .....................................................................................4.102
Table 4-41: Subnet Masks and Gateways ...............................................................................................4.103
Table 4-42: Communication State and Module Display ........................................................................4.113
Table 4-43: Module Faults ......................................................................................................................4.113
Table 4-44: Configuration Faults ............................................................................................................4.114
Table 4-46: 120VAC 8 Input Module Specifications .............................................................................4.115
Table 4-45: Additional Faults and Module Displays ..............................................................................4.115
Table 4-47: 24VDC 16 Sink Input Module Specifications .....................................................................4.117
Table 4-48: 120VAC 8 Output Module Specifications ..........................................................................4.119
Table 4-49: 8 Relay Sink/Source Output Module Specifications ...........................................................4.121
Table 4-50: 24VDC RTD Input Module Specifications .........................................................................4.124
Table 4-51: 24VDC RTD Input Module Status Indicator ......................................................................4.127
Table 4-52: Wiring Connections for the RTD Module ...........................................................................4.128
Table 4-53: Read/Write Words for Calibration ......................................................................................4.129
Table 4-54: 24VDC RTD Input Module Gain Calibration .....................................................................4.130
Table 4-55: Block I/O COMM and STATUS LED’s .............................................................................4.134
Table 4-56: Block I/O Module Specifications ........................................................................................4.135

SECTION 5, AC80 Advant Controller


Table 5-1: General Purpose LED’s .............................................................................................................5.4
Table 5-2: AC80 Connection Description ..................................................................................................5.6
Table 5-3: AC80 Hexadecimal Fault Codes ...............................................................................................5.9
Table 5-4: NPBA-80 Terminal Block X2 .................................................................................................5.14
Table 5-5: Selecting Parameters and Changing Values Procedure ...........................................................5.52
Table 5-6: Function Key Files ..................................................................................................................5.54

SECTION 6, Drive Control Module


Table 6-1: SDCS-AMC-DC and SDCS-AMC-DC Classic Differences ....................................................6.3

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4100XPB Electrical Manual List of Tables

List of Tables (Continued)

Table 6-2: SDCS-CON-2 Error Messages ..................................................................................................6.7


Table 6-3: SDCS-CON-2 Supply Voltage Monitoring ...............................................................................6.8
Table 6-4: SDCS-POW-1 Supply Voltages ..............................................................................................6.20
Table 6-5: SDCS-PIN-21 Jumper Application .........................................................................................6.22
Table 6-6: SDCS-PIN-205 Board Jumper/Resistor Configuration ...........................................................6.24
Table 6-7: SDCS-PIN-61 Jumper Application .........................................................................................6.28
Table 6-8: SDCS-CON-2 General Messages ............................................................................................6.29
Table 6-10: SDCS-CON-2 Starting Errors ...............................................................................................6.30
Table 6-9: SDCS-AMC-DC General Messages .......................................................................................6.30
Table 6-11: SDCS-CON-2 Fault Signals ..................................................................................................6.31
Table 6-12: SDCS-AMC-DC Fault Signals ..............................................................................................6.36
Table 6-13: SDCS-CON-2 Alarm Signals ................................................................................................6.37
Table 6-14: SDCS-AMC-DC Alarm Signals ............................................................................................6.39
Table 6-15: Drive/Macro Definitions (2 Swing Converters) ....................................................................6.40
Table 6-16: Drive/Macro Definitions (1 Swing Converter) .....................................................................6.41
Table 6-17: Parameter File Assignments ..................................................................................................6.46
Table 6-18: Signal Groups ........................................................................................................................6.47
Table 6-19: Analog Output Scaling ..........................................................................................................6.48
Table 6-20: Group 1 Actual Values ..........................................................................................................6.50
Table 6-21: Group 2 Actual Values ..........................................................................................................6.54
Table 6-22: Group 3 Actual Values ..........................................................................................................6.57
Table 6-23: Group 4 Information ..............................................................................................................6.62
Table 6-24: Group 5 I/O Signals ...............................................................................................................6.67
Table 6-25: Group 6 Drive Logic Signals ................................................................................................6.69
Table 6-26: Group 7 Control Words .........................................................................................................6.72
Table 6-27: Main Control Word ...............................................................................................................6.72
Table 6-28: Auxiliary Control Word ........................................................................................................6.73
Table 6-29: Auxiliary Control Word 2 .....................................................................................................6.74
Table 6-30: Group 8 Status and Limit Words ...........................................................................................6.75
Table 6-31: Main Status Word ..................................................................................................................6.75
Table 6-32: Auxiliary Status Word ...........................................................................................................6.76
Table 6-33: Limit Word 1 .........................................................................................................................6.77
Table 6-34: DI Status Word ......................................................................................................................6.77
Table 6-35: Group 9 Fault and Alarm Words ...........................................................................................6.78
Table 6-36: Fault Word 1 ..........................................................................................................................6.79
Table 6-37: Fault Word 2 ..........................................................................................................................6.79
Table 6-38: System Fault Word ................................................................................................................6.80
Table 6-40: Alarm Word 2 ........................................................................................................................6.81
Table 6-39: Alarm Word 1 ........................................................................................................................6.81
Table 6-41: Fault Word 3 ..........................................................................................................................6.82
Table 6-42: Parameter Groups ..................................................................................................................6.82
Table 6-43: Group 19 Special Data Storage Signals ................................................................................6.85
Table 6-45: Bitpacked Words ...................................................................................................................6.86
Table 6-44: Group 19 Special Data Storage Signals (Swing Field Continued) ........................................6.86

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4100XPB_1_EMLOT.fm - xxxvii - List of Tables, Version 0 - 9/02
List of Tables 4100XPB Electrical Manual

List of Tables (Continued)

Table 6-46: Group 12 Drive Logic I/O .....................................................................................................6.88


Table 6-47: Group 13 I/O Settings 1 ........................................................................................................6.91
Table 6-48: Group 14 I/O Settings 2 ........................................................................................................6.94
Table 6-49: Group 15 Drive Logic Parameters .........................................................................................6.98
Table 6-50: Group 16 System Control Inputs .........................................................................................6.106
Table 6-51: Group 17 Test Signal Generator ..........................................................................................6.107
Table 6-52: Group 18 LED Panel Control ..............................................................................................6.108
Table 6-53: Group 19 Data Storage ........................................................................................................6.109
Table 6-54: Group 20 Limits ..................................................................................................................6.111
Table 6-55: Group 21 Start/Stop Functions ............................................................................................6.113
Table 6-56: Group 22 Speed Ramp Functions ........................................................................................6.115
Table 6-57: Group 23 Speed Reference ..................................................................................................6.116
Table 6-58: Group 24 Speed Control ......................................................................................................6.119
Table 6-59: Group 25 Torque Reference ................................................................................................6.122
Table 6-60: Group 26 Torque Reference Handling ................................................................................6.123
Table 6-61: Group 28 Motor Protection .................................................................................................6.125
Table 6-62: Group 40 Undervoltage Monitoring ....................................................................................6.130
Table 6-63: Group 41 Motor Nominal Values ........................................................................................6.130
Table 6-64: Group 42 Measurement Settings .........................................................................................6.134
Table 6-65: Group 43 Current Control ...................................................................................................6.137
Table 6-66: Group 44 Field Excitation ...................................................................................................6.141
Table 6-67: Group 45 Field Excitation ...................................................................................................6.145
Table 6-68: Group 46 EMF Control .......................................................................................................6.146
Table 6-69: Group 47 12-Pulse Operation ..............................................................................................6.150
Table 6-70: Group 50 Speed Measurement ............................................................................................6.152
Table 6-71: Group 51 Communication Mode .........................................................................................6.156
Table 6-72: Group 70 DDCS Control .....................................................................................................6.158
Table 6-73: Group 71 DriveBus .............................................................................................................6.163
Table 6-74: Group 90 Dataset Receive Addresses .................................................................................6.163
Table 6-75: Group 91 Dataset Receive Addresses .................................................................................6.166
Table 6-76: Group 92 Dataset Transmit Addresses ................................................................................6.167
Table 6-77: Group 93 Dataset Transmit Addresses ................................................................................6.169
Table 6-78: Group 94 CON Communication Actual Values ..................................................................6.171
Table 6-79: Group 95 CON Communication Reference Values ............................................................6.172
Table 6-80: Group 97 Drive ....................................................................................................................6.174
Table 6-81: Group 98 Option Modules ...................................................................................................6.174
Table 6-82: Group 99 Start-up Data .......................................................................................................6.175

SECTION 7, Motor Maintenance


Table 7-1: Bolt Tightening Torque Values - Metallic Parts .......................................................................7.2
Table 7-2: Bolt Tightening Torque Values - Non Metallic Parts to Metallic Parts ....................................7.3
Table 7-3: Bearing Specifications ...............................................................................................................7.5
Table 7-4: Brush Specifications ..................................................................................................................7.9
Table 7-6: Spring Tension and Color Code ..............................................................................................7.10

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List of Tables, Version 0 - 9/02 - xxxviii - 4100XPB_1_EMLOT.fm
4100XPB Electrical Manual List of Tables

List of Tables (Continued)

Table 7-5: Optional Brush Grade and Type ..............................................................................................7.10


Table 7-7: Arc Director Part Numbers ......................................................................................................7.14
Table 7-8: Commutator Surface Wear Limits ..........................................................................................7.17
Table 7-9: Mainpole and Interpole Dimensions .......................................................................................7.28
Table 7-10: Mainpole and Interpole Bolt Specifications ..........................................................................7.29
Table 7-11: Resistance and Connection Information ................................................................................7.32
Table 7-12: Effect of Temperature on Insulation Resistance ...................................................................7.34
Table 7-13: Recommended Maintenance Schedule - Monthly .................................................................7.37
Table 7-14: Recommended Maintenance Schedule - Semi-Annually ......................................................7.38
Table 7-15: K-558A Ball Bearing Upgrade Parts List ..............................................................................7.43
Table 7-16: K-558A Bearing RTD Upgrade Parts List ............................................................................7.44
Table 7-17: K-558A Field Coil Upgrade Parts List ..................................................................................7.46
Table 7-18: K-700B Interpole Bolt Upgrade Parts List ............................................................................7.48
Table 7-19: K1690 RTD Configuration Change Parts List ......................................................................7.50
Table 7-20: Modification From R44818D to R50400D ...........................................................................7.53
Table 7-21: Recommended Torque Values ..............................................................................................7.65
Table 7-22: Wire Gage ..............................................................................................................................7.69

SECTION 8, Touch Panel

SECTION 9, Mine Air Systems


Table 9-1: Preventive Maintenance - Daily ..............................................................................................9.12
Table 9-2: Preventive Maintenance - Every 250 Hours ............................................................................9.12
Table 9-3: Preventive Maintenance - Every 500 Hours ............................................................................9.12
Table 9-5: Preventive Maintenance - Seasonal Pre-Heating ....................................................................9.13
Table 9-4: Preventive Maintenance - Seasonal Pre-Cooling ....................................................................9.13

SECTION 10, i2T™ Remote Communications


Table 10-1: Troubleshooting the ControlLogix Power Supply ..............................................................10.82
Table 10-2: OK LED ..............................................................................................................................10.83
Table 10-3: Transmit and Receive LED’s ..............................................................................................10.84
Table 10-5: Power Supply Indicator Status ............................................................................................10.89
Table 10-4: Alphanumeric Status Indicator ............................................................................................10.89
Table 10-6: Alphanumeric Status Indicator Message .............................................................................10.90
Table 10-7: Module Status OK Indicator ...............................................................................................10.92

SECTION 11, Miscellaneous Electrical


Table 11-1: Fiber Optic Part Numbers .....................................................................................................11.1
Table 11-2: Current Input Table ...............................................................................................................11.8
Table 11-3: Voltage Inputs ......................................................................................................................11.9
Table 11-4: Sampling Modes ...................................................................................................................11.9
Table 11-5: Switch Inputs .........................................................................................................................11.9
Table 11-6: Analog Outputs .....................................................................................................................11.9

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4100XPB_1_EMLOT.fm - xxxix - List of Tables, Version 0 - 9/02
List of Tables 4100XPB Electrical Manual

List of Tables (Continued)

Table 11-7: Analog Input ........................................................................................................................11.10


Table 11-8: Output Relays ......................................................................................................................11.10
Table 11-9: Measured Values .................................................................................................................11.10
Table 11-10: Undervoltage Monitoring ..................................................................................................11.11
Table 11-11: Overvoltage Monitoring ....................................................................................................11.11
Table 11-12: Underfrequency Monitoring ..............................................................................................11.12
Table 11-13: Overfrequency Monitoring ................................................................................................11.12
Table 11-14: Power Factor Monitoring ..................................................................................................11.12
Table 11-15: Demand Monitoring ..........................................................................................................11.13
Table 11-16: Pulse Output ......................................................................................................................11.13
Table 11-17: Communications ................................................................................................................11.13
Table 11-18: Control Power ...................................................................................................................11.14
Table 11-19: PQM Indications and Information .....................................................................................11.18
Table 11-20: Flash Messages ..................................................................................................................11.24
Table 11-21: PQM Setup / Calculation Parameters ................................................................................11.28
Table 11-22: PQM Setup - Clear Data ....................................................................................................11.30
Table 11-23: List of Possible Events .....................................................................................................11.58
Table 11-1: Joystick Specifications ........................................................................................................11.83
Table 11-2: Joystick Parts List ................................................................................................................11.85

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List of Tables, Version 0 - 9/02 - xl - 4100XPB_1_EMLOT.fm
P&H® Mining Equipment Offices
World Wide Mining Headquarters
Milwaukee, Wisconsin 53201-0310

Kilgore, TX
SM

NORTH P&H MinePro Services


106 Powderhorn Road
Kilgore, TX 75662
Phone: 903-983-7744; Fax: 903-983-2954
Milwaukee, WI (Home office)
P&H MinePro Services Negaunee, MI
4400 West National Avenue P&H MinePro Services
Milwaukee, WI 53214-3684 701 Everett Street
P O BOX 310, Milwaukee, WI 53201-0310 P.O. BOX 150
Phone: 414/671-4400; Fax: 414/671-7604 Negaunee, MI 49866
Phone: 906/475-6737; Fax: 906/475-7893
Bismarck, ND
P&H MinePro Services Ogden, UT
1938 Tahoe Drive P&H MinePro Services
Bismarck, ND 58504 7891 S. 1800 E.
Phone: 701/258-1442; Fax: 701/258-4477 Ogden, UT 84405
Phone: 801/476-3168; Fax: 801/476-3188
Bowling Green, FL
P&H MinePro Services St. Albans, WV
101 W. County Line Road, P.O. Box 339 P&H MinePro Services
Bowling Green, FL 33834 205 Smiley Drive
Phone: 863/375-3333; Fax: 863/375-3555 St. Albans, WV 25177-1587
Phone: 304/755-1007; 414/671-7609;
Casper, WY Fax: 304/755-8595
P&H MinePro Services
1935 North Loop Avenue,
P O BOX 296, (82602-0296) Canada
Casper, WY 82601 Harnischfeger Corporation of Canada, Ltd.
Phone: 307/237-1574; Fax: 307/235-7907 Calgary
7326 - 10th Street N.E.,Suite 300,
Evansville, WY Calgary, Alberta, T2E 8W1, Canada
P&H MinePro Services Phone: 403/730-9851; Fax: 403/730-9547
1180 Iron Street, P.O. BOX 459
Evansville, WY 82636 Sparwood (Parts)
Phone: 307/237-5144; Fax: 307/237-5147 621 Douglas Fir Road, P O BOX 1390
Sparwood, BC V0B 2G0, Canada
Gillette, WY Phone: 250/425-0863; Fax: 250/425-0665
P&H MinePro Services
5834 South Winland Drive Hinton (Parts)
Gillette, WY 82718 113 King Street, P.O. BOX 1040
Phone: 307/685-4100; Fax: 307/685-4101 Hinton, Alberta T7V 1G7 Canada
Phone: 780/865-5835; Fax: 780/865-8861
P&H MinePro Services
(Rebuild Operations) Toronto
811 Edwards Road 57 Beverly Glen Boulevard
Gillette, WY 82718 Toronto, ONT M1W 1W3 Canada
Phone: 307/682-0035; Fax: 307/682-0049 Phone: 416/499-5000; Fax: 416/499-5003

Hibbing, MN Cornwall
P&H MinePro Services 1411 Rosemount Avenue
3621 15th Avenue East Cornwall, ONT K6J 3E5, Canada
Hibbing, MN 55746 Phone: 613/930-4400; Fax: 613/930-4404
Phone: 218/262-3837; Fax: 218/262-6323

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P&H® Mining Equipment Offices 4100XPB Electrical Manual

SM

SOUTH SM

AUSTRALASIA

Mesa, AZ (Home office) Brisbane, Australia (Home office)


P&H MinePro Services (Mesa 2) Harnischfeger of Australia Pty. Ltd.
1811 S. Alma School Road, Ste 215 71 Lytton Road/P O BOX 7231
Mesa, AZ 85210-3004 E. Brisbane, Queensland 4169, Australia
Phone: 480/345-6007; Fax: 480/345-4040 Phone: 61-7/3240-4600; Fax: 61-7/3240-4666

P&H MinePro Services (Mesa 1) Hunter Valley - SE Region


112 West Iron Avenue Lot 11, Mount Thorley Road/PO BOX 455
Mesa, AZ 85210-6105 Singleton, NSW 2330 Australia
Phone: 480/834-7656; Fax: 480/834-7807 Phone: 61-2/6578-9800; Fax: 61-2/6578-9888
Fax: Rebuild Center - 480/834-2177
Mackay - NE Region
Elko, NV 44 Commercial Avenue, PO BOX 6534
(Warehouse) Mackay, Queensland 4741, Australia
P&H MinePro Services Phone: 61 7/4952 7800; Fax: 61 7/4952 7888
5244 East Idaho Street
Elko, NV 89801
Phone: 775-778-0740; Fax: 775-778-0744 Perth - Western Region
290 Collier Road/P O BOX 265
Bassendean 6054, W. Australia, Australia
Lone Butte, AZ Phone: 61-8/9270-0700; Fax: 61-8/9270-0777
P&H MinePro Services (Contract Services)
6640 W. Sundust Road
Chandler, AZ 85226
Phone: 520-796-1192; Fax: 520-796-1114
INTERNATIONAL
SM

Brazil /Service/Parts/Sales
Harnischfeger do Brazil
Avenida Portugal 4511/ Bairro Itapoa Milwaukee, WI (Home office)
Belo Horizonte, M.G., 31710-400 Brazil P&H MinePro Services
Phone: 55-31/491-7636; Fax: 55-31/491-6181 4400 West National Avenue
Milwaukee, WI, USA 53214-3684
Chile - Otero Antofagasta P O BOX 310, Milwaukee, WI, USA 53201-0310
c/o Otero SA P&H MinePro Services Phone: 414/671-7453; Fax: 414/671-7717
Av. Pedro Aguirre Cerda #6551
Antofagasta, Chile Beijing
Phone: 56-55/350200; Fax: 56-55/239188 P&H MinePro Services - China
Room 601, East Ocean Center; 24A Jianguo Menwai Dajie
Chile - Otero - Santiago Beijing, China 100004
Comercial Otero S.A Phone: 86-10/6515-5803/04; Fax: 86-10/6515-5762
Pte. Eduardo Frei Montalba #6239; Conchali
Santiago, Chile Great Britain
Phone: 56-2/ 620-8100; Fax: 56-2/624-0690 P&H MinePro Services-Eurasia Sales, Parts & Service
Harnischfeger (U.K.) Ltd.
Mexico P.O. Box 12, Seaman Way, Ince
Harnischfeger Mexico S.A. de C.V. Wigan WN1 3DD, United Kingdom
Paseo Valle Verde, No. 21; Col. Valle Verde Phone: 44-1942 614400; Fax: 44-1942 614419
83200,Hermosillo, Sonora Mexico
Phone: 52-62/180864, 180870; Fax: 52-62/180911 India
P&H MinePro Services - c/o Voltas Limited
Peru Gillander House 8, Netaji Subhas Road
P&H MinePro Services Peru S.A.C. Calcutta - 700,001, India
Calle Los Sauces #374, Office 704 Phone: 91 33/221-0232; Fax: 91-33/248 2517
San Isidro, Lima, 00027 Peru
Phone: 51-1/440-6541; Fax: 51-1/440-8042 Russia
P&H MinePro Services
Venezuela 11/2 Armyanski Peer
Harnischfeger Venezuela, S.A. (Warehouse) Moscow, Russia 101963
Zona Industrial Matanzas Sur Phone:7 095/937-4110; Fax: 7 095/247-9060
UD-321, Transversal “C”, Entre
Calles 2 y 3, Galpon 14-02
Puerto Ordaz, Edo, Bolivar, Venezuela
Phone: 58-86/942825/942931; Fax: 58-86/943437

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South Africa
P&H MinePro Services - Sales, Parts & Service
442 Heidelberg Road, Tulisa Park
Johannesburg, 2197, South Africa
P O BOX 83676, South Hills 2136, South Africa
Phone: 27-11/869-1335; Fax: 27-11/869-0566

P&H MinePro Services (Repair & Rebuild Division)


43-45 Lepus Road, Crown Mines Ext 8, Gauteng
Johannesburg, South Africa
P O BOX 259, Maraisburg, 1700, South Africa
Phone: 27-11/839 2713; Fax: 27-11/839-2798

P&H MinePro Services (Jwaneng, Botswana)


Jwaneng Mine, Jwaneng, Botswana
Private Bag 062, Jwaneng, Botswana
Phone: 267/384-483; Fax: 267/382-132

P&H MinePro Services (Orapa, Botswana)


Orapa Mine, Orapa, Botswana
Private Bag 01, c/o MinePro Services, Orapa, Botswana
Phone: 267/272-741; Fax267/276-210

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


VER 07, 04-00 - xliii - Offices.fm
P&H® Mining Equipment Offices 4100XPB Electrical Manual

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


Offices.fm - xliv - VER 07, 04-00
4100XPB Electrical Manual Definition of Hazard Indicators

Definition of Hazard Indicators

DANGERS, WARNINGS, CAUTIONS, AND NOTICES are used throughout this manual to emphasize important and critical
instructions. DANGERS, WARNINGS, and CAUTIONS precede the paragraph or item to which they apply. NOTICES follow the
paragraph or item to which they apply. For the purpose of this manual DANGERS, WARNINGS, CAUTIONS, and NOTICES are
defined as follows:

! DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the most extreme situations.

! WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

! CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
major injury. Caution should be used without the signal alert symbol for hazards that result
only in property damage.

CAUTION
A Caution without a Safety Alert Symbol (Exclamation Point) is used to warn of hazards that
result only in property damage.

NOTICE
Used to indicate a statement of company policy directly or indirectly related to the safety of person-
nel or protection of property. This signal word shall not be associated directly with a hazard or haz-
ardous situation and shall not be used in place of DANGER, WARNING, or CAUTION.

SAFETY FIRST
Used to indicate general instructions relative to safe working practices, remind of proper safety pro-
cedures, and indicate the location of safety equipment.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


NewWarndef.fm - xlv - Definition of Hazard Indicators, Version 2 - 9/02
Definition of Hazard Indicators 4100XPB Electrical Manual

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


Definition of Hazard Indicators, Version 2 - 9/02 - xlvi - NewWarndef.fm
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SopEMS.fm - lv - Safe Operating Practices, Version 01 - 10/01
Safe Operating Practices 4100XPB Electrical Manual

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


Safe Operating Practices, Version 01 - 10/01 - lvi - SopEMS.fm
4100XPB Electrical Manual Introduction and General Information

SECTION 1

Introduction and General


Information

1.1 GENERAL DESCRIPTION

This manual covers the general description and operation of major electrical assemblies and
components used on the P&H 4100XPB Electric Mining Shovel.

1.1.1 Purpose

This manual provides guidance to MinePro Service Personnel in performing maintenance and
assists in troubleshooting the 4100XPB Electric Mining Shovel.

P&H Mining Equipment reserves the right to continually improve its products and associated
documentation. Therefore, physical alterations to the P&H 4100XPB Electric Mining Shovel
may not be identified in this current manual. Revisions will be made to this manual in an effort
to ensure that information contained within is current as alterations occur to the shovel.

Figure 1-1: P&H Mining Equipment - 4100XPB Electric Mining Shovel

This manual divides into eight (8) sections covering the following equipment and systems:

Section 1. Introduction and General Information

This section includes a general description of the shovel specifically detailing the following:

• Terminology

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.1 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

• Safety

• Electro-Static Discharge

• Electrotorque Drive System Overview

• Basic troubleshooting techniques

• Schematic diagram guidelines

Section 2. Power Distribution

This section provides information on the major components that distribute high voltage
throughout the shovel. This section highlights the following:

• H.V. Disconnect and Key Interlock systems

• Main and Auxiliary Transformers

• Power Distribution and Load Centers

• Suppression and Ground Fault systems

• Wiring and Distribution

Section 3. Cabinet Description and Operation

This section provides information on system components and indicators associated with the
major electrical cabinets on the 4100XPB Electric Mining Shovel. Specifically detailing the
following:

• Reactive Power Compensation (RPC) Cabinet

• Converter Cabinet

• Control Cabinet

• Auxiliary Cabinet

• Transfer Cabinet

• Lower Control Cabinet

Section 4. Programmable Logic Controller

This section provides information on the layout and operation of the Programmable Logic
Controller system. Specifically a block diagram view and module overview of the PLC on the
4100XPB Electric Mining Shovel. Information is provided on the following:

• SLC 5/05

• Remote I/O Modules

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 1, Version 0 - 9/02 - 1.2 - Section 1, Intro GI.fm
4100XPB Electrical Manual Introduction and General Information

• Flex I/O Modules

• Block I/O Modules

Section 5. AC80

This section provides information on the layout and operation of the Advant Controller AC80
used to control the Drive Control Modules, RPC, Meter Panel etc… Information is provided on
the following:

• Advant Controller AC80

• S800 I/O Modules

• CDP-80

Section 6. Drive Control Modules

This section covers the Electrotorque Plus “B” Drive Control Modules used on the 4100XPB
Electric Mining Shovel. This section provides a detailed descriptions of the following motion
control implementation scheme:

• Armature control

• Field control

Section 7. Motors Maintenance

This section covers the prime DC motors used for shovel motion on the 4100XPB Electric
Mining Shovel. Motors included in this section are:

• Hoist

• Crowd

• Propel

• Swing

Section 8. Touch Panels

This section details the operation, screens and maintenance for the Touch Panels associated
with the 4100XPB Electric Mining Shovel. The following Touch Panels are detailed:

• Control Cabinet Touch Panel

• Operators Cab Touch Panel

Section 9. Mine Air Systems

This section contains information on the Mine Air Systems air conditioner on the 4100XPB
Electric Mining Shovel.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.3 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

Section 10. i2T Remote Communications

This section covers the i2T™ Remote Communications installation and setup. This section
includes information on the following:

• I2T Installation and Setup

• I2T Troubleshooting

• OptiDig

Section 11. Miscellaneous Electrical

This section covers any miscellaneous electrical equipment that may not be associated with the
above sections. This equipment includes:

• Fiber Optic Cables

• Power Quality Meter

• Powerware UPS Software

• Operator Controllers (joysticks)

1.1.2 Manual Layout

Pages are numbered within each section. This information is located at the bottom of each page
and is formatted with the section identifier on the left side and actual page number on the right.
(i.e… 1.4) Throughout the manual you will notice that even numbered pages appear on the
right, odd pages on the right. You may also notice that, at the end of a section, you may often
find a blank page. This is to maintain the even-right, odd-left integrity, for two sided printing.
Each section is generously illustrated to support and clarify text coverage of the equipment and
maintenance procedures.

A. Each Section is broken down in the following items of discussion if applicable.

a. General Information - A simplified discussion of the system, operation (con-


trols and indicators), major components, and their related operating principles.
Each basic motion, hoist, crowd/propel, and swing, is presented.

b. Operation - A basic detailed discussion of the system, major components, and


their related operating principles.

c. Maintenance - Alignments and adjustments contains information on maintain-


ing equipment at its full operational potential.

d. Troubleshooting - Test procedures presented in a logical flow chart according


to the most probable malfunctions, in a recommended sequence of diagnosis.

e. Corrective Maintenance - contains information pertaining to maintenance pro-


cedures utilized to repair equipment.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 1, Version 0 - 9/02 - 1.4 - Section 1, Intro GI.fm
4100XPB Electrical Manual Introduction and General Information

f. Software Procedures - developed by P&H engineers or by subsystem manu-


facturer’s to provide detailed steps in programming, downloading and upload-
ing applications and data files.

NOTICE
Dangers, Cautions, Warnings, and Notices are important. They highlight conditions
and situations which could endanger personnel working on and around the shovel
due to carelessness and misuse. Refer to Definition of Hazard Indicators for any
clarification. Heed these warnings at all times.

1.2 4100XPB ELECTRICAL TERMINOLOGY

Certain terms are used in this manual. For better understanding, several are defined below:

BRIDGE - A configuration of diodes or silicon controlled rectifiers (SCR’s) designed to con-


vert input alternating current (AC) to output direct current (DC). The direct current output of a
bridge unit is applied to the motion motors.

CONTROL PULSES - The output signal of the Drive Control Modules (DCM’s) applied to
the gates of the SCR’s in a converter. Control pulses are a representation of the operator’s
requests and determine the shovel’s motion. The control pulses are synchronized to the incom-
ing high voltage/current phase to the bridge.

CONVERTER - See the term bridge above. These two terms indicate the same type of device.

DIVERTER SYSTEM - An electronic system detecting and dissipating possible fault over-
current in a motion bridge and/or a DC motion motor.

DRIVE CONTROL MODULE - A microprocessor-based control system responsible for


controlling the operation of the four or five armature converters and three field converters.

di/dt - A rating describing the response of an electronic devices ability react to the rate of
change of current applied the device with respect to time. This rating identifies a conducting
characteristics of the device. This rating response is compensated with inductors to prevent
possible inrush overcurrent heating during SCR turn on.

dv/dt - A rating describing the response of an electronic devices ability react to the rate of
change of applied voltage applied the device with respect to time. This rating identifies the
conducting characteristics of the device. This rating response is compensated with a capaci-
tive/resistive network to prevent possible undesirable SCR turn on or turn off caused by tran-
sient voltages.

ENERGY - The capacity to do work.

FEEDBACK - A current or voltage control signal resprentative of a larger current or voltage


from a final control element, i.e., a converter or motor. This feedback signal is evaluated by the
controlling device in the control loop for possible correction of the output current or voltage of
the final control element.

FILTER - A circuit offering little impedance or resistance to selected frequencies while offer-
ing high impedance or resistance to other frequencies. Filters are designed to prevent unwanted

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.5 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

frequencies from entering and affecting control circuitry and ultimately shovel operational
integrity.

I or O -Used in PLC programming to identify the interface module’s directionality to the PLC
as either an input module (I) or as an output module (O). Some PLC modules are bidirectional
and this (I) or (O) identifer still applies.

METER MODULE - A section of the control cabinet where the test selector switch and three
meters are located. The test selector puts the shovel in either RUN, ARMATURE TEST,
FIELD TEST, CONTROL TEST, or AUXILIARY TEST mode. This meter displays armature
currents, armature voltages, field currents, and control voltages.

MOTION CHARACTERISTIC - The speed versus torque relationship designed for opti-
mum motion efficiency and mechanical and electrical life.

OPERATOR’S CONSOLES- The stands in the Operator’s Coop on the either side of the
operator’s seat containing the shovel’s operational control push buttons. The left Operator’s
Console contains the START and STOP push-buttons, BRAKE RELEASE and SET push-but-
tons, the CROWD and PROPEL transfer push-buttons.

PHASE - The angular relationship between two alternating currents or voltages when the volt-
age or current is plotted as a function of time. When the two are in phase, the angle is zero;
both reach their peak simultaneously. When out of phase, one will lead or lag the other; that is,
at the instant when one is at its peak, the other will not be at peak value and (depending on the
phase angle) may differ in polarity as well as magnitude.

PHASING - A general term for the relationship between two AC voltages. The relationship
between the thyristor Anode (A)-Cathode (K) voltage and the gating pulse.

POWER - The rate at which energy is converted from one form to another.

POWER FACTOR - The ratio of the real power of an alternating or pulsating current, as mea-
sured by a wattmeter, to the apparent power, as indicated by ammeter and voltmeter readings.
The power factor of an inductor, capacitor, or insulator is an expression of their losses.

REACTANCE - The opposition offered to the flow of an alternating current by the induc-
tance, capacitance, or both, in any circuit.

REACTIVE POWER - The volt-amperes required to energize an inductive or capacitive


load.

REGULATE - Controlling the voltage or current output within a given percentage of the
desirable level.

RESISTANCE - The opposition of a device or material offers opposition to the flow of cur-
rent

RESONANCE - The condition in a circuit containing inductance and capacitance in which the
inductive reactance is equal and opposite to the capacitive reactance.

REVERSING BRIDGE - A connection of two SCR bridges where the anodes of one bridge
are common, or connected with the cathodes of the other bridge. This connection is designed to
produce bidirectional DC currents.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 1, Version 0 - 9/02 - 1.6 - Section 1, Intro GI.fm
4100XPB Electrical Manual Introduction and General Information

SOLENOID - An electromechanical device that changes electrical energy into mechanical


motion. This device’s operation is based upon the attraction of a movable iron plunger to the
core of an electromagnet.

THYRISTOR or SILICON CONTROLLED RECTIFIER (SCR) - The most common type


of thyristor. A semiconducting device that blocks current of either polarity, like a diode, until
an appropriate control voltage, called the gating signal, is applied to the gate. Once the polarity
is proper and the gate signal is applied this SCR device will conduct in the forward direction.
Once the SCR conducts, the gate signal has no influence on it’s operation. Conduction stops
when voltage across the anode-to-cathode reverses polarity or the current drops below a spe-
cific level to maintain conduction.

TORQUE - A force moving through a distance tending to produce rotation. The unit of mea-
sure is the Newton/meter.

TRANSDUCTOR - A passive electrical device used to measure large quantity DC currents.


These devices produce a unipolarity feedback signal proportional only to the measured current
regardless of the polarity of the large quantity DC current under measurement.

VARISTOR -A voltage variable resistance device used as surge protection, typically connect-
ing directly across an AC input to a sensitive electronic component or system. When a voltage
spike occurs and is applied across the varistor, its resistance rapidly decreases, creating an
instant shunt path, low impedance, for the over-current, and thereby saving the sensitive con-
trol panel components. Because the shunt path creates a short circuit, the varistor and the line
fuse are subject to be damaged or weakening in this out-of-design tolerance electrical situation.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.7 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

1.3 ELECTROSTATIC DISCHARGE SAFETY (ESD) INFORMATION

1.3.1 Preventing Electrostatic Discharge Damage

Electrostatic discharge (ESD) can damage or impair electrical circuitry and occurs when elec-
tronic components are handled improperly. Always follow ESD prevention procedures when
removing or replacing components.

1.3.2 ESD Terminology


A. Static Electricity - An electrical charge caused by an imbalance of electrons on the sur-
face of a material. This imbalance of electrons produces an electric field that can be
measured and that can influence other objects at a distance.

B. Electrostatic Discharge (ESD) - The transfer of charge between bodies at different elec-
trical potentials.

C. Catastrophic Failure - An electronic device exposed to an ESD even no longer func-


tion. The ESD event may have caused a metal melt, junction breakdown, or oxide fail-
ure. The device's circuitry is permanently damaged causing the device fail.

D. Latent Defect - A device exposed to an ESD event with partially degraded functionality
with possible reduced operating life expectancy. A product or system incorporating
devices with latent defects may experience premature failure after the user places them
in service. Such failures are usually costly to repair and in some applications may cre-
ate personnel hazards.

E. Protected Areas - An ESD protective area consists of the materials, equipment, and
procedures to control or minimize electrostatic charges (static voltage levels).

F. Common Point Ground - A system or method for connecting two or more grounding
conductors to the same electrical potential.

Figure 1-2: Common Point Ground Symbol

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 1, Version 0 - 9/02 - 1.8 - Section 1, Intro GI.fm
4100XPB Electrical Manual Introduction and General Information

1.3.3 Basic Principles of Static Control

At the Field Service level, the five basic principles of static control are:

• Define the level of control needed in your environment - Determine what is the sensi-
tivity level of the parts you are using and the products that you are manufacturing and
shipping.

• Identify and define the electrostatic protected areas (EPA) - These are the areas in
which you will be handling sensitive parts and the areas in which you will need to bond
or electrically connect all conductive and dissipative materials, including personnel, to
a known ground.

• Eliminate and Reduce Generation - Reducing as many static generating processes or


materials, such as the contact and separation of dissimilar materials and common plas-
tics, as possible from the work environment.

• Dissipate and Neutralize - Safely dissipate or neutralize those electrostatic charges that
do occur through proper grounding and the use of conductive or dissipative materials.

1.3.4 Grounding

Effective ESD grounds are of critical importance in any operation, and ESD grounding should
be clearly defined and regularly evaluated. A primary means of protecting of ESD susceptible
(ESDS) items is to provide a ground path to bring ESD protective materials and personnel to
the same electrical potential. All conductors in the environment, including personnel, must be
bonded or electrically connected and attached to a known ground or contrived ground, creating
an equipotential balance between all items and personnel.

Electrostatic protection can be maintained at a potential above a zero voltage ground reference
as long as all items in the system are at the same potential. It is important to note that non-con-
ductors in an Electrostatic Protected Area (EPA) cannot lose their electrostatic charge by
attachment to ground.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.9 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

1.3.5 Controlling Static on Personnel and Moving Equipment

People are one of the prime generators of static electricity. The simple act of walking around or
repairing a board can generate several thousand volts on the human body. If not properly con-
trolled, this static charge can easily discharge into a static sensitive device-a human body
model (HBM) discharge.

Electronic Equipment and assemblies sensitive to ESD are identified by the symbol shown in
Figure 1-3.

Figure 1-3: ESD Susceptibility Symbol

If the device under repair has the ESD symbol on it, then a Wrist Straps must be used to control
static charge on personnel. When properly worn and connected to ground, a wrist strap keeps
the person wearing it near ground potential. Because the person and other grounded objects in
the work area are at or near the same potential, there can be no hazardous discharge between
them. In addition, static charges are safely dissipated from the person to ground and do not
accumulate.

When handling ESD sensitive material use wrist straps, mats, chairs, garments, packaging, and
other items that provide ESD protection.

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1.4 ELECTROTORQUE PLUS DRIVE SYSTEM

Electrotorque Plus “B” is the process of controlling and converting AC power into DC power
to drive the hoist, crowd, propel and swing motion motors. The basic system block diagram is
shown in Figure 1-4.

Armature Motor Field


Converter Converter

IAFB IFFB

Feedback
Firing Pulses Board Firing Pulses

VAFB

Armature Field
Drive Drive
Reference
Control Control
Module Module
(DCM) Fiber Optic Cable (DCM)
Digital Control Signals

Inputs SLC 5/05 Outputs

Profibus Adapter

Fiber Optic Cable Fiber Optic Cable


Digital Control Signals AC80 Digital Control Signals

ES2125_01
Operator’s
Controllers

Figure 1-4: Electrotorque Plus “B” Block Diagram

The Electrotorque Plus “B” Control System design centers around the type of DC motors used
in all motions of the P&H 4100XPB Electric Mining Shovel. All motion motors have separate
armature and separate field windings receiving variable power from independently controlled
converters allowing for ideal motion control.

The armature converters for the motions are a set of two 6-pulse converters arranged in a back-
to-back configuration which controls voltage and current for motoring and regeneration in both
forward and reverse directions. The unique design of the Hoist motion provides the energy

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required for the digging (lifting) motion of the electric mining shovel. This vertical motion of
the dipper via a rotating drum and rope assembly is achieved by connecting the two DC motors
in series with two armature converters (Converter -Motor-Converter-Motor) and applying a
12-pulse sequential control logic. Therefore, the Hoist motion system uses two sets of 6-pulse
converters.

The SCR’s in the converters are the control point of the Electrotorque Plus “B” Control sys-
tem. The variable DC output of the converter depends on the gating signal which is controlled
by the operator and Drive Control Module (DCM) limits. Proportional current and voltage
feedback (Iaƒb) and (Vaƒb) are sampled by the Drive Control Modules which produce the
proper gating signals for the SCR’s.

The individual field converters for each motion are single 6-pulse converters controlling the
DC to the field winding of the of all motion motors. The output of the crowd and swing con-
verters is virtually a fixed value. The output of the hoist field converter changes dynamically
during normal hoisting and lowering. The hoist field converter current decreases, or weakens,
allowing the dipper to move faster allowing for a faster dig cycle. The hoist field converter cur-
rent increases during the hoisting portion of the dig cycle producing an increase of available
motor torque and bail pull. The output of the propel field converter can increase under specific
propelling conditions. This controlled field strengthening allows the shovel to walk out of
higher angled pit ramps.

The motors used in hoist, crowd, and propel motions are speed controlled. These motors
develop torque required within preset current limit to attain and maintain the speed called for
by the operator. For example: The Operator requests full speed movement through the control-
lers in the Operators cab, the control system develops the required torque within the limits to
maintain this requested speed. As the Operator returns the contoller to neutral, the control sys-
tem develops the required torque to attain and maintain zero speed.

The motors used in the swing motion are torque controlled. The operator controls the acceler-
ating time by calling for the amount of accelerating torque or current applied to the motors up
to maximum speed. For example: The Operator requests full torque and the shovel accelerates
rapidly to the right or left to maximum speed. As the Operator returns controller to the neutral
position, shovel continues to move in original requested direction until inertia overcomes the
weight of the revolving frame, stopping the shovel.

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1.4.1 Hoist System

The electrical system for the hoist motion contains the following major electrical components:

• Two Armature Converters

• One Field Converter

• Two Diverter Circuits

• Two DC Motors

Each armature converter receives 3Ø 600VAC from the secondary of the Main Transformer via
the overhead bus bars. Two Drive Control Modules (DCM’s) (Hoist/Propel #1 and Hoist #2)
produce the gate firing signals for the controlled conversion of AC to variable DC from both
hoist armature converters. The two armature converters and two DC motors connect electri-
cally in series across the two converters. The resulting armature current produces a magnetic
field around each armature that reacts with the magnetic field across the field winding produc-
ing armature rotation. Refer to Figure 1-5 for a one-line diagram of the Hoist electrical system.

Hoist #1 Hoist #2
Hoist Armature Diverter Hoist Armature Diverter
HAC Front Hoist Rear Hoist
Converter #1 Circuits Converter #2 Circuits
Hoist Motor Armature Motor Armature
Contactor
H1 H2

Current Feedback Front Hoist Rear Hoist


Iaƒb Motor Field Motor Field

Field
Converter

Current Feedback
Ifƒb

Circuit
Breaker

3Ø Main 3Ø
600VAC Transformer 600VAC
Auxillary
Transformer


High
Voltage
ES2126_01

Figure 1-5: Hoist Electrical - One Line Diagram

The armature shafts of the two DC motors couple to the ends of the hoist transmission first
reduction pinion shafts, which in turn drive the hoist transmission. These provide hoist motion
via the hoist drum and hoist cable system.

A resolver sensor mounts on the rear intermediate shaft assembly of the hoist transmission. A
limit switch control, accessed through the touch screen in the operator’s cab, can be pro-

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grammed to limit the range of hoist motion in conjunction with the crowd creating a protective
motion envelope.

1.4.2 Crowd System

The electrical system for the crowd motion contains the following major electrical compo-
nents:

• One Armature Converter

• One Field Converter

• One Diverter Circuit

• One DC Motor

The Crowd armature converter receives 3Ø 600VAC from the secondary of the Main Trans-
former via the overhead bus bars. A single DCM (Crowd/Propel #2) produces the required gate
firing signals for the controlled conversion of AC to variable DC from the armature converter.
The resulting armature current produces a magnetic field around the armature that reacts with
the magnetic field across the field winding producing armature rotation. Refer to Figure 1-6 for
a one-line diagram of the Crowd electrical system.

Crowd
Diverter Circuit

CAC
Crowd Armature
Crowd Crowd Motor
Converter
Armature Armature
Contactor
C
Current Feedback
Crowd
Iaƒb
Motor Field
CFC
Crowd Field
Contactor

Field
Converter

Current Feedback
Ifƒb

Circuit
Breaker

3Ø 3Ø
600VAC VAC
Main Auxillary
Transformer Transformer


High
Voltage ES2127_01

Figure 1-6: Crowd Electrical - One Line Diagram

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A DC motor drives the crowd system. It is mounted on the boom with the crowd machinery.
The crowd machinery is securely housed in the crowd gear case, which is an integral part of
the boom. A power band belt drive system couples the crowd motor to the crowd transmission.
This belt drive system affords shock protection while the crowd machinery provides the
machine with crowd motion.

A resolver type sensor is mounted on the crowd transmission intermediate shaft on the right
hand side of the crowd gearcase. A limit switch control, accessed through the touch screen in
the operator’s cab, can be programmed to limit the range of crowd motion in conjunction with
the hoist creating a protective motion envelope.

1.4.3 Swing System

There are two different versions of the Swing System on the 4100XPB. The first system con-
tains the following major electrical components:

• Two Armature Converters

• One Field Converter

• Two Diverter Circuits

• Three DC Motors

The second system contains the following major electrical components:

• One Armature Converters

• One Field Converter

• One Diverter Circuits

• Three DC Motors

In the first system:

The Swing armature converters receives 3Ø 600VAC from the secondary of the Main Trans-
former via the overhead bus bars. Two DCM’s (Swing 1 & 2 and Swing #3) produce the
required gate firing signals for the controlled conversion of AC to variable DC from the two
armature converters. The Swing 1 & 2 armature converters and the Swing #1 and #2 DC
motors are connected electrically in series. The Swing #3 armature converter and the Swing #3
DC motor are connected electrically in series and controlled seperately. The resulting armature
current produces a magnetic field around the armature that reacts with the magnetic field
across the field winding producing armature rotation. Refer to Figure 1-7 for a one-line dia-
gram of this swing electrical system.

In the second system:

The Swing armature converter receives 3Ø 600VAC from the secondary of the Main Trans-
former via the overhead bus bars. A single DCM (Swing 1, 2 & 3) produces the required gate
firing signals for the controlled conversion of AC to variable DC from the armature converter.
The Swing 1, 2 & 3 armature converters and the Swing 1, 2 & 3 motors are connected electri-
cally in series. The resulting armature current produces a magnetic field around the armature

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that reacts with the magnetic field across the field winding producing armature rotation. Refer
to Figure 1-8 for a one-line diagram of this swing electrical system.

Swing
Armature Swing #2 Swing #1
Converter Motor Motor
Armature Armature

S2 S1
Current Feedback
Ia b
Swing 1&2
Motor Fields
Swing
Armature Swing #3
Converter Motor
Field Converter
Armature

S3
Current Feedback Current Feedback
Ia b If b
Swing #3
Motor Fields
Circuit Breaker

3 3 3
600VAC 600VAC VAC

Main Main Auxillary


Transformer Transformer Transformer

3
High
Voltage ES2128_01

Figure 1-7: Swing Electrical - One Line Diagram - Swing 1&2 and Swing #3

Swing
Armature Swing #3 Swing #2 Swing #1
Converter Motor Motor Motor
Armature Armature Armature

S3 S2 S1
Current Feedback
Iaƒb
Swing #3 Swing #2 Swing #1
Motor Fields Motor Fields Motor Fields

Field Converter

Current Feedback
Ifƒb

Circuit Breaker

3Ø 3Ø
600VAC VAC

Main Auxillary
Transformer Transformer


High
Voltage ES2128a_01

Figure 1-8: Swing Electrical - One Line Diagram - Swing 1, 2 and 3

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The swing system uses three swing transmissions, two located in the front of the revolving
frame and one at the rear of the revolving frame. The vertically mounted DC swing motors
drive each transmission providing the mining shovel with swing motion.

1.4.4 Propel System

The electrical system for the propel motion contains the following major electrical compo-
nents:

• Two Armature Converters

• One Field Converter

• Two Diverter Circuits

• Two DC Motors

The Propel Motion uses the Hoist #1 armature converter as the source of the electrical energy
for the Propel #1 motor and the Crowd armature converter as the source of the electrical energy
for the Propel #2 motor. The Propel #1 armature converter and the Propel #2 armature con-
verter receive 3Ø 600VAC from the secondary of the Main Transformer via the overhead bus
bars. The two Drive Control Modules (DCM’s) produce the required gate firing signals for the
controlled conversion of AC to variable DC from the armature converters. The electrical
energy from the Hoist #1 armature converter and Crowd armature converter is redirected in the
Transfer Cabinet through contactors to the Propel #1and Propel #2 motors. The resulting arma-
ture current produces a magnetic field around the armature that reacts with the magnetic field
across the field winding producing armature rotation. Refer to Figure 1-9 for a one-line dia-
gram of the Propel electrical system:

Hoist #1 Hoist #2
Hoist Armature Diverter Hoist Armature Diverter
HAC Front Hoist Rear Hoist
Converter #1 Circuits Converter #2 Circuits
Hoist Motor Armature Motor Armature
Contactor
H1 H2

Current Front Hoist Rear Hoist


CAC Crowd
Feedback Motor Field Motor Field
Crowd Motor Armature
Iaƒb
Contactor
C
Crowd
Motor Field

Current Crowd/Propel #2
P1AC Propel #1 P2AC Propel #2
Propel Motor Armature Feedback Armature Converter Propel Motor Armature
Contactor Iaƒb Contactor
P1 P2

Propel #1 Propel #2
Motor Field Motor Field

PFC CFC
Propel Field Crowd Field
Contactor Contactor

Crowd/Propel
Field
Converter

Current Feedback Circuit


Ifƒb Breaker

3Ø Main 3Ø VAC
600VAC Transformer 600VAC
Auxillary
Transformer


High
Voltage
ES2129_01

Figure 1-9: Propel Electrical - One Line Diagram

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Section 1, Intro GI.fm - 1.17 - SECTION 1, Version 0 - 9/02
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To achieve forward and reverse propel motions and smooth differential steering, the propel
system uses two independent drive trains. Each drive train consists of a DC propel motor, a
planetary propel transmission, a propel brake assembly, a tumbler drive shaft, and a crawler
side frame and crawler belt assembly.

1.5 REQUIRED TEST EQUIPMENT

Test Equipment must be checked prior to performing any testing or troubleshooting proce-
dures. Test equipment should be verified as calibrated for the tasks being performed. The fol-
lowing is a list of the types of test equipment that may be used in testing or troubleshooting:

1. Digital Multimeter.

1. Oscilloscope.

1. Multi-Channel Chart Recorder.

1. Clamp-on Ammeter.

1. Megger.

1. Laptop PC.

Shop tests and start-up tests require additional equipment to aid in performing the necessary
tests and to provide the necessary test information:

1. Laptop PC with Allen-Bradley PLC communications hardware and software is required to


communicate with the on-board Programmable Logic Controller.

2. A Pushbutton/Reference Unit is recommended to simplify control of the individual


motions during testing.

3. A large resistor, 200Ω 6000W. This is reconfigured to 12.5Ω and is required to limit the
armature current during the start-up of each converter.

4. For testing the Reactive Power Compensation, a capacitor unit is required as a test load.

5. A voltage divider should be used to aid in making high voltage measurements on the RPC.

1.5.1 Other Related Test Equipment

The following test equipment should be available for testing or troubleshooting:

1. Test Leads.

2. Probes.

3. Cannon connector pins.

4. Clips.

5. Cables.

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6. Auxiliary pushbuttons.

7. Switches.

8. Screwdrivers.

9. Combination Wrench Set.

10. Any other items that are pertinent to testing or troubleshooting.

Refer to Table 1-1 and Table 1-2 for recommended and alternate types and manufactures of
test equipment and Hardware / Software requirements.

Instrument Recommend Alternate


Digital Multimeter Fluke Model 23 Fluke Model 87
Part No. 89Z514D12 Part No. 1089Z275
Clamp-on Ammeter Fluke Model i1010 Columbia Electric Type AX w/5 Current
(Range = 1 to 600A AC / 1000A DC Ranges

Part No.89Z514D15 Part No. R89Z367

Megger James D. Biddle, Catalog 21158


(Hand Crank) w/Case Part No. 89Z496
Oscilloscope Textronix Model THS 710 Any previously recommended Scope is
(Handheld, Dual Trace, Digital Scope w/ Storage, Battery Powered, Soft Case PART acceptable.
120V/60Hz Adapter) NO. 89Z515D15
(120V/50Hz AC Adapter) (240V available) Part No. 89Z515D30
(Hard Carrying Case) Part No. 89Z515D26
(×10 Probe 1kv) Part No. 89Z515D17
Isolation Transformer 115VAC P/115VAC S 50/60 Hz, 250VA
Part No. 75Z820D1
Chart Recorder Hioki Model 8807 Astro-Med, DASH 2 two channel w/ data
[Order each part seperately] capture. Astro-Med DASH2MT, Part No:
89Z835D3
Recorder [120/240V - 50/60Hz] Part No. R10945D1
Chart Paper, P/N 89Z835D4 (Z-fold)
(Carrying Case - Soft) Part No. R10945D2
(AC Adapter 90-250V, 50/60Hz) Part No. R10945D3
(Battery Pack, Rechargeable) Part No. R10945D4
(Recording Paper 10 rolls) Part No. R10945D5
Startup Limiting Resister 200Ω, 6000 Watt
Part No. 80Z984D1
RPC Capacitor Test Unit Part No. 89Z508D1
Reference Pushbutton Unit Part No. R40602D1
Voltage Divider Part No. R1192F1 Part No. 89Z510D1
Handheld Drive Programmer ABB CDP-312, Part No. R42375D27

Table 1-1: Recommended Test Equipment List

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Section 1, Intro GI.fm - 1.19 - SECTION 1, Version 0 - 9/02
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Instrument Recommend Alternate


SCR Thyristor Tester Part No. 89z511d1

Table 1-1: Recommended Test Equipment List

NOTE: P/N is the abbreviation for PART NUMBER.

PLC Communications Customer Use P&H Use


(Hardware And Software) (Order Through Parts) (Order Through Service)
Laptop PC N/A
1.4GB Hard (Min.), 120 MHz (Min.), Pentium, Windows
95, 16MB RAM, Floppy, 10X CD-ROM, Audio, PCM-
CIA, Carry Case
Drive Communications Software
RSLogix 500 (Customer Copy) Part No.79Z5311D6
RSLogix 500 (P&H Copy) Part No. 79Z4937D12
RSLinx (included with RSLogix)
PC Anywhere Software Part No. R41705D1
Drive Windows (includes specialized interface card)
PCMCIA Card and Cable (Included in Laptop) (A-B Part No. 79Z4936D6
1784-PCMC)
Required for Customer use.
PCMCIA Card and Cable (Included in Laptop) (A-B Part No. 79Z4937D9
1784-PCMC)
Required for P&H use.
Modem Serial Cable N/A

Table 1-2: PLC Hardware and Software List

1.6 SCHEMATIC DIAGRAM GUIDELINES

The information provided below is a guide for Technicians to use when troubleshooting with
schematics to the module/component level. These are the same guidelines used by the P&H
Mining Equipment Engineers.

1.6.1 Wire Numbers

Wire numbers are normally five digits. The first two digits reflect the sheet number of the sche-
matic diagram. The next two digits reflect the line number from that schematic sheet. The last
digit reflects the sequential number of the wire, starting with the number 1, from left to right, in
the line. For example, wire number 03241 refers to:

03 Sheet Number 3
24 Line Number 24
1 1st new wire from left

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One of the exceptions is the ground wire. Since there can be many different types of ground in
our system we differentiate them using wire numbers: 01GND, 02GND (UP TO 06GND),
01021 & 01021C.

1.6.2 Referencing

We can connect a wire, contact, relay or any other electrical component or signal from one
sheet to another using cross-references. This is done using the sheet number and line number
within parenthesis. For example, (23-17) means the mating signal, component, etc., can be
found on sheet 23 at line 17. Underline of cross-references (23-17), is only done when an elec-
trical component is considered a normally closed device that will open when activated.

1.6.3 Ground Identification

Numerous grounds are located throughout the 4100XPB Shovel. The information in Table 1-3
is a quick reference for ground identification.

It is important to note the difference between a neutral and ground. A neutral is an electrical
point which has a net electrical charge of 0. A ground is an electrical connection between
equipment or component and earth.

NOTICE
Schematic diagrams should always be utilized and checked prior to ground check
procedures.

NUMBER Symbol NAME/DESCRIPTION


01GND 1 Ground to Lower Frame
02GND 2 Ground to Upper Frame
03GND 3 Connect to Ground in Auxiliary Cabinet
04GND 4 Ground to Upper Frame at Control Cabinet Ground Bus Bar
05GND 5 Connect to Ground in Panel Board
** Only used in Australia **
06GND 6 Light Grounded in Console
** This ground is located in Operator’s Cab **
07GND 7 Connect to Ground in Control Cabinet
01021C NONE Control Cabinet Bus Bar Ground
NONE Grounded to High Voltage Cabinet Chassis

Table 1-3: Ground Identification

1.6.4 Location Codes

Each component in the electrical schematic diagrams has a location code associated with it.
The location code is intended to aid in locating electrical components on the 4100XPB Electric
mining Shovel. For example: P01D2

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The first letter in the location code identifies the cabinet or major assembly the component is
located in. In the example, P designates the Suppression Cabinet. Refer to Table 1-4 for a list
of the Letter Designators.

Letter Designator Location


A Auxiliary Cabinet
C Operator’s Cab
E Control Cabinet
F RPC Cabinet
H High Voltage Cabinet
K Converter Cabinet
P Suppression Cabinet
T Transfer Cabinet
B Boom Assembly
L Lower Assembly
U Upper Assembly

Table 1-4: Location Code Letter Designation

Following the Letter Designator is a number which signifies the subassembly or panel within
the cabinet or major assembly that the component is located. In the example, 01 designates the
01 Panel in the Transfer Cabinet.

Following the subassembly or panel number is a letter/number combination which provide


coordinates to assist in locating the component. Refer to Figure 1-10. In the example, D2 coor-
dinates are marked with an ×. This is a guide only. Actual grid lines are not provided on the
subassembly or panel.

1 2 3 4 5 6 7

B
y
bl

C
em
ss

D
ba

Pa or
l
ne

E
Su

ES1988_01

Figure 1-10: Location Code Subassembly or Panel Coordinates

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1.7 SIX-STEP TROUBLESHOOTING PROCEDURE

1.7.1 General Information

You may have the job of maintaining or helping to maintain some electrical or electronic unit,
subsystem, or system. Some of these jobs may be complex, but even a complex job can be bro-
ken down into simple steps. Basically, any repair of electric or electronic equipment should be
done in the following order:

1. Symptom recognition. This is the action of recognizing some disorder or malfunction in


electronic equipment.

2. Symptom elaboration. Obtaining a more detailed description of the trouble symptom is the
purpose of this step.

3. Listing probable faulty functions. This step is applicable to equipment that contains more
than one functional area or unit. From the information you have gathered, where could the
trouble logically be located?

4. Localizing the faulty function. In this step you determine which of the functional units of
the multiunit equipment is actually at fault.

5. Localizing trouble to the circuit. You will do extensive testing in this step to isolate the
trouble to a specific circuit.

6. Failure analysis. This step is multi-part. Here you determine which part is faulty, repair/
replace the part, determine what caused the failure, return the equipment to its proper
operating status, and record the necessary information in a record keeping book for other
maintenance personnel in the future. While not a part of this step, the technician should
reorder any parts used in repair of the faulty equipment.

Sometimes you may run into difficulty in finding (or troubleshooting) the problem. Some hints
that may help in your efforts are:

• Observe the equipment's operation for any and all faults

• Check for any defective components with your eyes and nose

• Analyze the cause of the failure for a possible underlying problem

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1.8 SAFETY FOR ELECTRICAL AND ELECTRONIC EQUIPMENT

1.8.1 General Information

The safety instructions given in this manual cover those problems encountered during normal
daily operation of the shovel. Additional precautions may be necessary to cover unusual cir-
cumstances. Be constantly alert for any potentially dangerous conditions and report them
immediately to your foreman or supervisor.

Working safely is the most important thing you can do. The following is a list of precautions.
Of course there are more precautions, but these are some you should think about. The keyword
here is THINK.

• Never work alone.

• Never receive an intentional shock.

• Only work on, operate, or adjust equipment if you are authorized.

• Don't work on energized equipment unless absolutely necessary.

• Keep loose tools, metal parts, and liquids from above electrical equipment.

• Never use steel wool or emery cloth on electric and electronic circuits.

• Never attempt to repair energized circuits except in an emergency.

• Never measure voltage in excess of 300 volts while holding the meter wire or probe.

• Use only one hand when operating circuit breakers or switches.

• Use proper tag-out/lockout procedures for regular and preventive maintenance.

• Be cautious when working in voids or unvented spaces.

• Beware the dangers of working in elevated areas.

• Keep protective closures, fuse panels, and circuit breaker boxes closed unless you are
actually working on them.

• Never bypass an interlock unless you are authorized to do so by competent authority,


and then properly tag the bypass.

1.8.2 Maintenance Work Precautions

Inspection, service and maintenance are essential elements in the proper operation and perfor-
mance of shovels and excavators. The following recommendations are provided to supplement
past experience, knowledge and common sense of servicemen concerning potential hazards
associated with inspection, service and maintenance.

1. Prior to undertaking any work on the equipment, the personnel performing the work shall
notify the operator about the nature and location of the job. Appropriate lockout and

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tagout procedures must be determined and followed by all individuals involved to guard
against potential hazards.

2. Before maintenance or service is attempted, the operator must park the machine in a loca-
tion to avoid hazards such as falling rocks and unstable ground. After parking the
machine, the operator shall:

A. Set the dipper on the ground.

B. Set all brakes.

C. De-energize control functions.

D. Comply with lockout and tagout procedures

3. Injury, death, and damage can occur if the machine is started before servicing is finished.
Never start or operate the equipment if lockouts or tagouts are on the controls. Prior to
starting the machine, look under, within, and around the equipment.

4. Specific inspection, service and maintenance instructions for P&H shovels or excavators
are available from product manuals and the P&H service network. Always read and follow
instruction manuals and use the P&H service network for assistance.

5. On hydraulic systems, release system pressure before attempting to make adjustments or


repairs. Pressure in hydraulic systems can be retained for long periods of time. If not prop-
erly released before maintenance people attempt to work on the hydraulic system, this
pressure can allow machinery to move or cause hot oil to shoot out of the hose ends at
high speed.

6. Maintenance and service can involve the handling of heavy parts or components, which
can injure personnel. Use lifting and handling equipment along with blocking to remove,
support, and install heavy parts.

7. Ensure both ends of booms or cylinders are supported and the boom suspension lines com-
pletely slacked off before moving pins. Never stand on, inside, under booms during erec-
tion or disassembly. Pin-connected booms may fall if not properly supported when
removing or installing pins.

8. When inspecting and retireing wire rope used on surface mining machines:

A. Mine management shall provide and appoint qualified personnel to inspect, prepare
and retain written reports on wire rope inspections.

B. An inspection procedure should be established by Mine Management for each wire


rope application on their mining shovels or excavators.

C. Unless instructed otherwise, the frequency of inspections shall be established based


upon operating shifts, days, weeks or months depending upon anticipated rope life and
working conditions.

D. An average wire rope life shall be established based upon the number of operating
cycles, volume of material handled or weight of material handled. Replacement is
determined from the this established rope life analysis.

9. MSHA procedures require all wire rope be inspected daily to determine whether it should
be replaced.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 1, Intro GI.fm - 1.25 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

As a minimum, wire rope replacement should be performed when any of the following condi-
tions exist:

A. Severe abrasion, scrubbing, peening, or kinking, or broken outer wires.

B. Crushing, or other damage that distorts the rope's structure.

C. Severe reduction of rope diameter or an observable increase in rope lay.

D. Bird-caging or other distortion indicating uneven distribution of load between rope


strands.

E. Evidence of severe corrosion, particularly in the vicinity of attachments.

F. Heat damage from any source.

G. A rapid increase in the number of broken wires.

10. Wire rope end connections must be installed properly and inspected daily.

A. Wire rope secured with a wedge socket should be installed so that the load line is in a
straight-line pull with the eye of the socket; and the loaded part of the rope is not
kinked where it leaves the wedge. The rope end should always protrude at least 6 to 9
inches beyond the socket. Attach a short piece of wire rope to the rope end with two
wire rope clips to prevent the rope end from slipping out of the wedge socket.

11. Electrically powered shovels or excavators operate using high voltage wiring, components
and systems. This voltage can kill or seriously injure people servicing, repairing, or work-
ing on the machines. Inspection, maintenance or service of any electrical component must
be done by qualified personnel. All people working on or around the equipment should
read and obey hazard signs and always use lockout and tagout procedures.

12. All guards, signs, warning devices and guarding devices must be in place and in working
conditions before the shovel or excavator is placed back in operation after inspection, ser-
vice and maintenance.

13. Loose or missing hardware, bolts, or nuts should be properly tightened or replaced with
the manufacturer's specified hardware. Refer to P&H Service and Parts sources for
replacement parts.

14. If there is not enough wire rope on the drum, the rope can be pulled off. Allow for at least
two wraps of wire rope on drums when replacing the rope.

15. Electrical junction boxes for electrical motors can contain high voltage electrical power
from multiple sources. Before performing service on electrical junction boxes, determine
that all electrical power from all sources has been disconnected and locked out. Test the
components within the electrical junction box to verify the electrical power is discon-
nected.

1.8.3 Electrical Safety Principles

When planning and performing work on electrical systems and equipment, keep these princi-
ples in mind:

A. Plan every job

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4100XPB Electrical Manual Introduction and General Information

B. Think about what could go wrong

C. Use the right tools for the job

D. Use procedures, drawings and other documents as tools to do the job

E. Isolate the equipment from energy sources

F. Identify the electric shock and arc flash, as well as other hazards that may be present

G. Minimize the hazard by guarding or approach limitations

H. Test every circuit, every conductor, every time before you touch

I. Use personal protective equipment (PPE) as a last line of defense in case something
goes wrong

J. Ensure service personnel have the skills, knowledge, tools, and experience to do this
work safely.

1.8.4 Electrical Shock Dynamics

When working on the 4100XPB, service personnel must be aware of three important character-
istics of possible exposure to electrical shock. The three factors are:

A. PATH - of current into and out of the body

B. AMOUNT - of current or energy flowing in the body

C. DURATION OF EXPOSURE - degree of injury also depends on the duration and fre-
quency of the current.

60Hz AC Current Response


0.5 - 3 mA Start to feel the energy, tingling sensation
3 - 10 mA Experience pain, muscle contraction
10 - 40 mA Grip paralysis threshold (brain says let go, but
physically cannot do so)
30 - 75 mA Respiratory systems shuts down
100 - 200 mA Experience heart fibrillation
200 - 500 mA Heart clamps tight
Over 1500 mA Tissue and organs burn
Table 1-5: Electrical Shock and Human Response

NOTICE
“SHOCK” injuries can resemble an “Iceberg” where most of the injuries are inter-
nal, with only an entry and exit wound visible. Prompt attention is required by indi-
viduals specifically trained to treat electrical injuries.

Accident victims can incur the following injuries from electrical shock:

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Section 1, Intro GI.fm - 1.27 - SECTION 1, Version 0 - 9/02
Introduction and General Information 4100XPB Electrical Manual

A. Low-voltage contact wounds

B. High-voltage contact wounds from entry and exit of electrical current

C. Burns

D. Respiratory difficulties (the tongue may swell and obstruct the airway; or vaporized
metal or heated air may have been inhaled)

E. Infectious complications

F. Injury to bone through falls, heat necrosis (death of tissue), and muscle contraction.

G. Injury to the heart such as ventricular fribillation, cardiac arrest, or stoppage

H. Internal organ injuries

I. Nerve and neurological damage

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SECTION 1, Version 0 - 9/02 - 1.28 - Section 1, Intro GI.fm
4100XPB Electrical Manual Power Distribution

SECTION 2

Power Distribution

2.1 INTRODUCTION

2.1.1 General Information

This section details the distribution of electrical power on the 4100XPB Electric Mining
Shovel. The shovel converts input electrical energy to output mechanical energy in the DC
motion motors to move the mechanical components and assemblies of the shovel in the process
of loading.

The first electrical connection and isolation device on the shovel is the Air Disconnect Switch
with Earthing found on the rear of the shovel Lower Assembly. This assembly receives the
high voltage supply of alternating current (AC) from a substation connected to the mine’s elec-
trical distribution network.

The Shovel Lower remains stationary during the digging cycle while the revolving Upper
Assembly rotates on the center gudgeon and swing circle. The converters supplying electrical
energy to the DC motion motors are located on the Upper Assembly therefore, the electrical
energy must be transferred from lower to upper through a Collector Ring Assembly.

An installed Kirk-key interlock system limits exposure to high energy electrical power located
in the high voltage enclosures and asemblies.

The High Voltage Cabinet provides electrical connection and isolation on the revolving Upper
Assembly. This cabinet also contains lightning protection devices, fuses, current and voltage
feedback transformers, and an electric high voltage supply meter.

A three phase, dry type, air cooled, delta-to-wye Main Transformer provides the supply volt-
age to the armature converters by stepping down the high voltage supply to 600VAC. Bus bars
distribute the 3Ø, 600VAC to the Reactive Power Compensation Cabinet and Armature Con-
verter Cabinets.

A three phase, dry type, air cooled, delta-to-wye Auxiliary/Field Transformer provides various
supply voltages by stepping down the high voltage supply to 480VAC, 365VAC, 240VAC, and
120VAC.

Refer to Figure 2-1 for a block diagram detailing the components associated with this section.
The shaded area identifies all the components found on the stationary Lower Assembly. All
other devices represented by blocks are found on the revolving Upper Assembly.

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Section 2, Pwr Dist.fm - 2.1 - SECTION 2, Version 0 - 9/02
Power Distribution 4100XPB Electrical Manual

Converters
Armature

Bus Bars

Transformer
Transformer

Auxillary
Main

ES1349_01
High Voltage
Isolator
Disconnect
Upper Air

Switch
Collector
Rings
Disconnect
Lower Air

Switch

Figure 2-1: Block Diagram of Power Distribution

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Figure 2-2 shows the single line diagram of the electrical power distribution.

Tail Cable
Supply To Ground
Check Wire
in Tail Cable

A2 A2 A1
Air Disconnect
A2

Switch with
Earthing

A1
(LO1OOO)
A2

A1
Upper
High Voltage
Low Voltage
Slip-Ring
Collector
A2

Assembly
(LO4OOO)
Ground
Check Circuit

Upper High Voltage Cabinet (HOXXX)

C.T.
Meter
Main High
Voltage
A3 A3 A2

Disconnect
Switch (HO2X4)
A2

HV
Main Transformer Potential Supply
High Voltage Isolator Transformer Meter
Switch (HO4X4) (HO8X1) (H12X1)

Lightning Lightning Main


Arrestor Arrestor Transformer
(Line to (Line to Contactor
Ground) Line)

600 VAC Armature Converters

Main Transformer

Themal & Armature Converters


600 VAC
Overload
Protection

460 VAC

Auxiliary Supply
Circuit Breaker

208 VAC

Fuse Lighting Secondary


Circuit Breaker

240 VAC

Supply Control Supply


Circuit Breaker Circuit Breaker

365 VAC

195VAC

Crowd Field Swing Field Hoist Field


ES1367C_01 Circuit Circuit Circuit
Breaker Breaker Breaker

Field Converters

Figure 2-2: Electrical Power Distribution Single Line Diagram

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Section 2, Pwr Dist.fm - 2.3 - SECTION 2, Version 0 - 9/02
Power Distribution 4100XPB Electrical Manual

2.2 AIR DISCONNECT SWITCH WITH EARTHING

2.2.1 General Description

This assembly provides permanent connection and complete isolation capabilities of the high
voltage supply to the shovel. A four conductor cable carrying the 3 phase voltage and ground
enters this cabinet for initial distribution to assemblies throughout the shovel. Incorporating a
kirk-key lockout mechanism insures electrical isolation when servicing is required. Refer to
subsection 2.5 for details on the Key Interlock System operation.

The earthing functions allows for applying ground through the Collector Ring Assembly when
the high voltage contacts of the Air Disconnect Switch is open.

2.2.2 Location

This assembly connects directly to the Carbody on the right rear of the Lower Assembly. The
right propel motor and right propel transmission are directly in front of this cabinet.

2.2.3 Operation

The tail cable carrying the high voltage supply, ground, and ground circuit check wires enters
this cabinet through cable clamp and armored cable connector on the front of the cabinet door.
A cable sheath to ground connection reduces insulation degradation due to high voltage corona
effects. Refer to Figure 2-3 and Figure 2-4.

Yellow Ground
Check Conductor

Bare Conductor
Ground (2)

Shielded
Phase
Conductors
Sheilded - Ground Check
Tail Cable
(Yellow)
Ground Ground Check

Phase Conductors ES1375a_01


(3) Shielded

Ground

Cable Cross Section

Figure 2-3: Tail Cable

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4100XPB Electrical Manual Power Distribution

High Voltage Switch Box


mounted on Carbody Posi-Pin

Tail Cable entrance


into Air Disconnect
Switch Assembly

Ground Bus

Cable Clamp Cable Connector


Connect Ground braid
from Cable Shield to
Ground Bus (Typical)
ES1374a_01

Figure 2-4: Air Disconnect Switch - Cable Connection

Each shielded phase conductor of the tail cable connects to a bus bar bolted to the top of the
Air Disconnect Switch (LO1OOO). Refer to Figure 2-5 for the Air Disconnect Switch.

Figure 2-5: Air Disconnect Switch with Earthing (L01OOO)

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Section 2, Pwr Dist.fm - 2.5 - SECTION 2, Version 0 - 9/02
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2.2.3.1 13.8 KV Systems

The 13.8 kV systems shielded phase conductor of the tail cable connects to a bus bar bolted to
the top of the High Voltage Load Interrupter Switch (LO1OOO) with a posi-pin connector.
Refer to Figure 2-4 for the posi-pin connection. Refer to Table 2-1 for the correct pin size for
each phase conductor posi-pin.

AØ BØ CØ
.62in .75in .875in

Table 2-1: Posi-Pin Connection

2.3 COLLECTOR RING ASSEMBLY

2.3.1 General Description

This assembly provides continuous electrical connections allowing the Lower Assembly and
Upper Revolving Assembly to rotate and maintain electrical continuity throughout 360º of
rotation during the dig cycle. This assembly can be divided into three sections:

• Communication - Bidirectional data connection for the Data Highway Plus [DH+]
communication used in the PLC remote I/O system.

• Low Voltage/Field - Connection for the distribution of 480VAC, Propel Fields, Propel
Armature, 120VAC control, and brake supply voltage from Upper Assembly to Lower
Assembly.

• High Voltage -Connection for the distribution of the three phase high voltage supply
from the Lower Assembly to the Upper Assembly.

2.3.2 Location

ES1826_01

Figure 2-6: Collector Ring Assembly - (4100XPB Deck Plan)

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The Collector Ring Assembly has a protective metal enclosure which surrounds it. An inner
plexiglass viewing door allows for inspections during shovel operation.

2.3.3 Operation

The three sections of the Collector Ring Assembly are shown in Figure 2-7.

Communication

Low Voltage

High Voltage

ES1480_01

Figure 2-7: Collector Ring Assembly Sections

The high voltage section contains the four (4) High Voltage ring-brush connections carrying
the three phase high voltage supply and ground. Refer to Figure 2-8.

04

03

02

01

ES1481a_01

Figure 2-8: Collector Ring Assembly - High Voltage Section

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Section 2, Pwr Dist.fm - 2.7 - SECTION 2, Version 0 - 9/02
Power Distribution 4100XPB Electrical Manual

LEGEND:
01. (01GRND) Ground Connection
02. (L31) Tail Cable Supply - CØ
03. (L21) Tail Cable Supply - BØ
04. (L11) Tail Cable Supply - AØ

The low voltage section of the Collector Ring Assembly contains the connections for supply-
ing the Propel armature and field current, 460VAC or 480VAC, 120VAC, Brake Supply volt-
age, and ground monitor for use by assemblies and components located in the Lower. Refer to
Figure 2-9.

01
02

03

04

05

06

ES1483a_01

Figure 2-9: Collector Ring Assembly - Low Voltage Section

LEGEND:
01. Right Propel Field
02. Left Propel Field
03. Right Propel Armature
04. Right Proel Armature
05. Left Propel Armature
06. Left Propel Armature

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4100XPB Electrical Manual Power Distribution

The eight brush-ring connectors at the top of the low voltage section carry voltages and signals
at lower current values than the lower part of the low voltage section therefore, they are
smaller in size. Refer to Figure 2-10.

08
07
06
05
04
03
02
01
ES1489a_01

Figure 2-10: Collector Ring Assembly - Top of Low Voltage Section

LEGEND:
01. 460VAC or 480VAC Auxiliary Supply - CØ
02. 460VAC or 480VAC Auxiliary Supply - BØ
03. 460VAC or 480VAC Auxiliary Supply - AØ
04. 120VAc Supply Neutral
05. Brake Supply
06. 120VAC Constant Voltage supply - Control Supply Neutral
07. 120VAC Constant Voltage Supply
08. Ground Monitor System

The Communication section, located on the top of the Collector Ring Assembly, contains three
brush/commutator connections carrying the remote input-output data associated with the SLC
system to and from the Lower Control Cabinet assemblies. Refer to Figure 2-11.

03

02

01

ES1492a_01

Figure 2-11: Collector Ring Assembly - Communication Section

LEGEND:
01. Clear
02. Shield
03. Blue

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Section 2, Pwr Dist.fm - 2.9 - SECTION 2, Version 0 - 9/02
Power Distribution 4100XPB Electrical Manual

2.4 HIGH VOLTAGE CABINET

2.4.1 General Description

The High Voltage Cabinet provides the components and circuits required for distributing the
high voltage supply from the Collector Ring Assembly to the Main Transformer and Auxiliary/
Field Transformer. A Main High Voltage Disconnect Switch, Main Transformer High Voltage
Isolator Switch, Lightning Arrestors, Main Transformer Contactor, and the Power Quality
Meter (PQM) are located in this cabinet.

2.4.2 Location

ES1826a_01

Figure 2-12: High Voltage Cabinet - (4100XPB Deck Plan)

2.4.3 Operation

The Main High Voltage Disconnect Switch (H02X4) receives the high voltage supply from the
Collector Ring Assembly. Opening the Main High Voltage Disconnect Switch deenergizes and
isolates the entire Upper Assembly of the shovel. Current Transformers (H07X1, H07X2, and
H07X3) are rated at 200:5 and Potential Transformers (H08X1 and H08X2) provide the Power
Quality Meter (H12X1) with a sample of the voltage and current on conductors LL1, LL2, and
LL3. Refer to subsection 11.3 for a detailed operational description of the Power Quality
Meter.

The high voltage is applied to the primary of the Main Transformer through the Main Trans-
former High Voltage Isolator Switch (H04X4) and directly to the primary winding of the Aux-
illary/Field Transformer. During servicing or maintenance, the Main Transformer High
Voltage Isolator Switch disconnects power to the Main Transformer and armature converters
preventing shovel motion. The in-line fuses, (H02X1, H02X2, and H02X3) protect the Main
Transformer from excessive in-rush current. The Main Transformer Contactor (H05X1) is
energized via a Rack I/O output card and Main Transformer Contactor Relay (E10A3). After a
proper machine start-up sequence, this allows the high voltage supply to be applied to the pri-
mary of the Main Transformer.

Figure 2-13 shows a single line diagram of the high voltage cabinet.

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4100XPB Electrical Manual Power Distribution

Main Transformer
High Voltage
Isolator Switch
Main Transformer
Power Quality Main Transformer (2500/3500 kVA)
Meter Contactor

High Voltage Main High Voltage


AØ to BØ Potential
From Collector Discconect Switch
BØ to CØ Transformers
Ring Assembly
Current
Ground Transformers 120V / 110V
Line-to-Ground
Lightning
Line-to-Line Power Quality
Ground Check Arrestors
Lightning Meter
Arrestors

Auxilary - Field
Transformer
(350/435 kVA)

Mark "GC" Terminal


DIS-1 DIS-2 DIS-3 DIS-4

ES1350a_01

Figure 2-13: High Voltage Cabinet - Single Line Diagram

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Section 2, Pwr Dist.fm - 2.11 - SECTION 2, Version 0 - 9/02
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2.5 KEY INTERLOCK SYSTEM

2.5.1 General Description

The following applies to a standard 7.5 KV system with above deck slip-rings and lower high
voltage isolator with an earthing feature.

2.5.2 Operation

The shovel is provided with a series of special locks to prevent entry into areas which could
pose an electrocution hazard to personnel. Figure 2-14 is a schematic diagram of the Key Inter-
lock System. The information provided is intended to provide an understanding of the system
which will enable personnel to function in cooperation with the system and with all applicable
Federal, State, Local and Mine specific safety regulations.

Tail Cable To Ground Check


Supply Wire in Tail Cable

M3BS

A2
D

A2 A2

Air Disconnect SK
Switch with Earthing A1 A1
3 - Entrances

Low Voltage A1
A2 Collector

D
Ground Check
High Voltage Circuits
A2
Collector

M3B
D
Main High A3
A3
Voltage Key A2
Disconnect From Lower
Switch A3 Disconnect

A2 A2

Main Transformer
High Voltage
Isolator Switch

To Main
Transformer
MTC Primary

ES1827_01 To Aux Thermal and


Transformer Instantaneous
Primary Overload Protection

Figure 2-14: Key Interlock System - Schematic Diagram

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! WARNING
This Key Interlock System must not be defeated and must be maintained in the
“as provided” condition. The padlocks supplied are a convenience and are not
intended to replace lock out - tag out procedures.

2.5.2.1 Entering High Voltage Areas

Use the following procedure when entering the Collector Ring Assembly area, Air Disconnect
Switch area, High Voltage Cabinet, and Main and Auxiliary/Field Transformer enclosures.

! DANGER
Entering the hazardous voltage areas of a mining shovel is extremely danger-
ous and can result in severe injury or death by electrocution. All Federal, State,
Local and Mine safety regulations must be adhered to when entering and exit-
ing areas and enclosures containing hazardous operating voltage and the fol-
lowing procedure must be understood.

1. Notify the proper mining maintenance authority that work will be performed in a high or
low voltage area of a specific mining shovel.

! CAUTION
Removing the tail cable voltage can result in unexpected stopping or abnormal
performance and can cause personal injury and property damage. Opening the
Air Disconnect Switch or turning Supervisory Key A1 to remove access Keys
A2 will stop the shovel. Operate the switch or turn the key only if the shovel is
shut down and safely parked.

2. Open the mining shovel power supply at the switch house. Use proper lock out - tag out
procedures.

3. Open the Air Disconnect Switch in the lower. Refer to Figure 2-5. Have an authorized
Supervisor insert Supervisory Key A1 in M3BS. Turn Key A2 at the opposite end of the
block counterclockwise to lock the Air Disconnect Switch in the OPEN position. Turning
Key A2 also opens the ground check circuit at the customer’s switch house, if available.
Key A1 is held in the lock and two Keys A2 now can be removed. Refer to Figure 2-15.

! WARNING
Make sure that the switch house has removed the tail cable voltage. Be aware
of possible voltage in the tail cable due to cable capacitance, and discharge the
cable properly.

4. For redundant safety, disconnect the tail cable at the shovel. Visually check all High Volt-
age isolating switches to assure that all phases are open.

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Section 2, Pwr Dist.fm - 2.13 - SECTION 2, Version 0 - 9/02
Power Distribution 4100XPB Electrical Manual

5. The A2 Keys can be used for the following purposes.

A. Access the high voltage section of the upper voltage slip-ring assembly.

B. Lock open the main disconnect switch in the upper main high voltage cabinets. See
subsection 2.5.2.3.

! CAUTION

Unexpected stopping or
abnormal performance
can cause
personal injury
and property damage.
Turning supervisory key
to remove access keys,
stops machine.
Turn keys only when
the machine is not
running.

Type M3BS Label Mounted on


Lock Right Side of Wall
! CAUTION

Unexpected stopping or
abnormal performance
can cause
personal injury
and property damage.

Turning supervisory key


to remove access keys,
OPEN
stops machine.

Turn keys only when CLOSED


the machine is not
running.

Type D Lock

Right Side Wall

TC0190A

Figure 2-15: M3BS Switch on Air Disconnect Switch

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2.5.2.2 Exiting High Voltage Areas

Exit high voltage areas as follows:

1. After restoring all equipment to proper working order, close all doors, covers, and close
switches to allow the release of the A2 Keys.

2. Reconnect the tail cable at the mining shovel.

3. Place A2 Keys in M3BS lock. Turn Key A2 at the end opposite of the block clockwise to
unlock the Air Disconnect Switch.

4. Close the Air Disconnect Switch. The authorized supervisor can now remove Supervisory
Key A1.

! WARNING
Use the proper mine working procedures before energizing the tail cable volt-
age.

2.5.2.3 High Voltage Cabinet Entrance Procedure

See subsection 2.5.2.1 for disconnecting shovel power in the lower and obtaining Key A2. The
High Voltage Cabinet can not be entered without Key A2 (from M3BS switch in the lower)
being present and retained in lock M3B on the High Voltage Cabinet. Enter the High Voltage
Cabinet as follows, refer to Figure 2-16:

1. Open the Main High Voltage Disconnect Switch. Insert Key A2 into the M3B lock. Turn
Key A3 to extend the bolt to lock the switch in the open position. Key A2 is now held in
the lock and Key A3 is free for removal and insertion in D Lock on the High Voltage
Cabinet door.

2. Turn Key A3 to withdraw the lock bolt and open cabinet doors. Key A3 is always held in
the lock whenever the locking bolt is withdrawn, allowing the doors to open.

! DANGER
Hazardous voltage will cause severe injury or death. Do not enter the cabinet if
tail cable high voltage is present. Ensure that all high voltage is removed from
the shovel before entering any high voltage area or enclosure. Visually check
all high voltage isolating switches to assure that all phases are open.

3. When the doors are closed, Key A3 can be turned to extend the lock bolt. After the bolt is
extended, Key A3 can be removed.

4. The A3 Key is inserted into the switch M3B lock. Turning the key unlocks the switch
from the open position and allows removal of the A2 Key.

5. The switch can now be closed.

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Section 2, Pwr Dist.fm - 2.15 - SECTION 2, Version 0 - 9/02
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Main Transformer Main High Voltage


Main High Voltage High Voltage Disconnect Switch
Disconnect Switch Isolator Switch
High Voltage Cabinet
L1 L1
A3 A3 A3 A3 A2

L2 L2

L3 L3

GND

A3 A3

A3 A3 Door
A3 H.V. Cabinet Doors
(see "Type D Lock")
A3
Main High Voltage
Seal Strip
A2
Disconnect Switch
L.H. Door R.H. Door
M3B
Main
Body

A3
Latching
Block ES1828_01
"Type D Lock"

Figure 2-16: Key Interlock System - High Voltage Cabinet

2.5.2.4 Padlocks

Two types of padlocks are provided. They are:

1. Special keyed padlock for the Earthing Switch (when provided) in the Lower High
Voltage Isolator (disconnect) Switch Cabinet. This is operated by Key A3. The Earthing
Switch is mechanically interlocked with the Isolator Switch

NOTICE
It is recommended that the Earthing Switch, when provided, be locked in the closed
position when the Air Disconnect Switch is open. The Earthing Switch should be
locked in the open position prior to closing the Air Disconnect Switch.

2. Commonly keyed padlocks are provided as a general means to inhibit access to cabinets or
panels by unauthorized personnel. These padlocks are not intended to take the place of
personal safety locks required for lock out - tag out procedures. These padlocks are
intended primarily for access doors.

NOTICE
Padlocks should not be used to lock closed safety and disconnect switches which
may require immediate opening.

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2.6 MAIN TRANSFORMER

2.6.1 General Description

The Main Transformer receives the three phase high voltage supply from the High Voltage
Cabinet components. The high voltage is stepped down to 600VAC which is applied to the bus
bars feeding the four Armature converters.

2.6.2 Location

ES1826b_01

Figure 2-17: Main Transformer - (4100XPB Deck Plan)

2.6.3 Operation

The 3000KVA delta wound primary receives the high voltage supply from the switches and
contactors located in the High Voltage Cabinet. Refer to Figure 2-18 for the vector diagram of
the primary winding of the Main Transformer.

MT2

MT1 MT3

ES1383b_01

Figure 2-18: Main Transformer Primary - Vector Diagram

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Section 2, Pwr Dist.fm - 2.17 - SECTION 2, Version 0 - 9/02
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The 2400KVA wye wound secondaries each output 600VAC to the Armature converters via
the bus bars. Refer to Figure 2-19.

MS12 MS22

MS11 MSN MS21 N2

MS13 MS23

ES1517a_01

Figure 2-19: Main Transformer Secondaries - Vector Diagram

As the voltage is applied and current flows through the primary, magnetic lines of force are
generated. During the time current is increasing in the primary, magnetic lines of force expand
outward from the primary and cut the secondary. A voltage is induced into a coil when mag-
netic lines cut across it. Therefore, the voltage across the primary causes a voltage to be
induced across the secondary.

The secondary voltage of a transformer may be either in phase or out of phase with the primary
voltage. This depends on the direction in which the windings are wound and the arrangement
of the connections to the external circuit. This means that the two voltages may rise and fall
together or one may rise while the other is falling.

The Main Transformer secondary voltage is in phase with the primary and is referred to as a
like-wound transformer. Phase indicating dots are used to indicate points on a transformer
schematic symbol that have the same polarity. Refer to Figure 2-20 for a schematic diagram of
the Main Transformer.

MT1 MT2 MT3


X11 X12 X13

3 4 3 4 3 4

75 1 2 68 75 1 2 68 75 1 2 68

MSN MS11 MS12 MS13

N2 MS21 MS22 MS23

ES1382a_01

Figure 2-20: Main Transformer - Schematic Diagram

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The total voltage induced into the secondary winding of a transformer is determined by the
ratio of the number of turns in the primary to the number of turns in the secondary, and by the
amount of voltage applied to the primary.

2.7 BUS BARS

2.7.1 General Description

The Bus Bars deliver 600VAC from the Main Transformer secondaries to the five Armature
Converters in the Converter Cabinet and the Reactive Power Compensation Cabinet. A total of
six bars carry the 3 phase power on an inboard set (1L1, 1L2, 1L3) and outboard set (2L1, 2L2,
2L3). The bus bars are totally contained within a sealed enclosure for the entire run length
from the Main Transformer to the RPC Cabinet.

2.7.2 Layout

Figure 2-21: Bus Bar Assembly

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Section 2, Pwr Dist.fm - 2.19 - SECTION 2, Version 0 - 9/02
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2.8 AUXILIARY/FIELD TRANSFORMER

2.8.1 General Description

The Auxillary/Field Transformer receives the high voltage supply from the High Voltage Cab-
inet components, converts by transformer action to 460VAC or 480VAC, 365VAC, 240VAC,
and 120VAC. These voltages are distributed to the loads located throughout the shovel.

2.8.2 Location

The Auxillary/Field Transformer is located in the right rear of the machinery house. Refer to
Figure 2-22.

ES1826c_01

Figure 2-22: Auxiliary/Field Transformer - (4100XPB Deck Plan)

2.8.3 Operation

The 435 kVA delta wound primary receives the high voltage supply from the switches and con-
tactors located in the High Voltage Cabinet. Refer to Figure 2-23.

AT2
8 7
6 5
4 3
2 1
1 2
3 4
5 6
7 8

AT1 AT3
8 6 4 2 1 3 5 7

ES1530a_01

Figure 2-23: Auxiliary/Field Transformer Primary - Vector Diagram

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The list below identifies the outputs that are associated with the AS1, AS2 and AS3 wye
wound secondary of the Auxillary Field Transformer. Refer to the electrical prints for the spe-
cific voltage associated with the shovel. Refer to Figure 2-24.

• 3Ø, 480VAC, 60Hz.

• 3Ø, 435VAC, 50Hz.

• 3Ø, 415VAC, 50Hz.

AS2

ASN
AS1

AS3

ES1533a_01

Figure 2-24: Auxiliary/Field Transformer Auxiliary Secondary - Vector Diagram

The list below identifies the outputs that are associated with the CS1, CS2 and CS3 wye wound
secondary of the Auxillary Field Transformer. Refer to the electrical prints for the specific
voltage associated with the shovel. Refer to Figure 2-25.

• 3Ø, 240VAC, 60Hz.

• 3Ø, 230VAC, 50Hz.

CS2

CSN
CS1

CS3

ES1534a_01

Figure 2-25: Auxiliary/Field Transformer Control Secondary - Vector Diagram

The list below identifies the outputs that are associated with the FS11, FS12 and FS13, FS21,
FS22 and FS23, FS31, FS32 and FS33 wye wound secondary of the Auxillary Field Trans-
former. Refer to the electrical prints for the specific voltages associated with the shovel. Refer
to Figure 2-26.

• 3Ø, 365VAC, 60Hz for FS11, FS12 and FS13.

• 3Ø, 365VAC, 50Hz for FS11, FS12 and FS13.

• 3Ø, 195VAC, 60Hz for FS21, FS22 and FS23.

• 3Ø, 195VAC, 50Hz for FS21, FS22 and FS23.

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• 3Ø, 240VAC, 60Hz for FS31, FS32 and FS33.

• 3Ø, 240VAC, 50Hz for FS31, FS32 and FS33.

FS12
FS22
FS21 FS32
FS11 FSN

FS31 FS33
FS23
FS13
ES1535a_01

Figure 2-26: Auxiliary/Field Transformer Field Supply - Vector Diagram

The list below identifies the outputs that are associated with the LS1, LS2 and LS3, HS1, HS2
and HS3 wye wound secondary of the Auxillary Field Transformer. Refer to the electrical
prints for the specific voltages associated with the shovel. Refer to Figure 2-27.

• 3Ø, 208VAC, 60Hz for LS1, LS2 and LS3.

• 3Ø, 435VAC, 50Hz for LS1, LS2 and LS3.

• 3Ø, 415VAC, 50Hz for LS1, LS2 and LS3.

• 3Ø, 190VAC, 50Hz for HS1, HS2 and HS3.

LS2

HS1 HS2
LS1 LSN

HS3
LS3
ES1535b_01

Figure 2-27: Auxiliary/Field Transformer Lighting Supply - Vector Diagram

As the voltage is applied and current flows through the primary, magnetic lines of force are
generated. During the time current is increasing in the primary, magnetic lines of force expand
outward from the primary and cut the secondary. A voltage is induced into a coil when mag-
netic lines cut across it. Therefore, the voltage across the primary causes a voltage to be
induced across the secondary.

The secondary voltage of a transformer may be either in phase or out of phase with the primary
voltage. This depends on the direction in which the windings are wound and the arrangement
of the connections to the external circuit. This means that the two voltages may rise and fall
together or one may rise while the other is falling.

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The Auxiliary/Field Transformer secondary voltages are in phase with the primary and is
referred to as a like-wound transformer. Phase indicating dots are used to indicate points on a
transformer schematic symbol that have the same polarity. Refer to Figure 2-28 for a schematic
diagram of the Auxiliary/Field Transformer.

AT1 AT2 AT3

7 5 3 1 2 4 6 8 7 5 3 1 2 4 6 8 7 5 3 1 2 4 6 8

ASN AS1 AS2 AS3

CSN CS1 CS2 CS3

FSN FS21 FS31 FS11 FS22 FS32 FS12 FS23 FS33 FS13

FSN HS1 LS1 HS2 LS2 HS3 LS3

ES1386a_01

Figure 2-28: Auxiliary/Field Transformer - Schematic Diagram

The total voltage induced into the secondary winding of a transformer is determined mainly by
the ratio of the number of turns in the primary to the number of turns in the secondary, and by
the amount of voltage applied to the primary.

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Section 2, Pwr Dist.fm - 2.23 - SECTION 2, Version 0 - 9/02
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SECTION 2, Version 0 - 9/02 - 2.24 - Section 2, Pwr Dist.fm
4100XPB Electrical Manual Cabinet Description and Operation

SECTION 3

Cabinet Description and


Operation

3.1 INTRODUCTION

3.1.1 General Information

Input high voltage is applied via a tail cable to a dry type, air cooled Main Transformer which
steps down input power to 600VAC and supplies it to the Armature Converters. Refer to Sub-
section 2.6 for more details on the Main Transformer. The input high voltage is also applied to
a dry-type, air cooled Auxiliary/Field Transformer which supplies the auxiliary voltages and
the field converter voltages throughout the shovel. Refer to Subsection 2.8 for more details on
the Auxiliary/Field Transformer.

The Ground Fault and Suppression Cabinet contains components providing transient voltage
suppression for the 600VAC converter voltages. Components for sensing ground faults in the
secondaries of the main and auxiliary transformers mount in this cabinet.

Control of reactive power inherent to static converter operation is achieved by a synchronously


switched array of tuned capacitor banks. This system of capacitive bank switching is referred
to as the Reactive Power Compensation system. This RPC system compensates for the reactive
power demand of the converter system and also acts as a broad band tuned filter for the pre-
dominant harmonics produced by the converters

The P&H 4100XPB electric mining shovel converts the 600VAC to DC via the armature con-
verters controlled by a microprocessor based control system referred to as Digital Control
Modules. The motion characteristics for optimizing the digging function are contained in soft-
ware located in every motion DCM. The Main Control Cabinet contains the motion controlling
DCM’s, Programmable Logic Controller system with Touch Panel unit and field converters.

Routing electrical energy from the Hoist #1 and Crowd armature converters via the Transfer
Cabinet to the two propel motors eliminates the need for a set of dedicated Propel armature
converter. This shovel design feature prevents hoisting and crowding during the propel mode
of shovel operation.

The Auxiliary Cabinet located in the Right Hand Room provides distribution and control of the
electrical power required to run the machinery house and motor blowers, converter, RPC, con-
trol cabinet blowers, dipper trip motor, motor heaters, transformer heaters and floodlight con-
tactors.

3.1.2 Location Codes

Each component in the electrical schematic diagrams has a location code associated with it.
The location code is intended to aid in locating electrical components on the 4100XPB Electric
mining Shovel. For example: P01D2

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The first letter in the location code identifies the cabinet or major assembly the component is
located in. In the example, P designates the Suppression Cabinet. Refer to Table 3-1 for a list
of the Letter Designators.

Letter Designator Location


A Auxiliary Cabinet
C Operator’s Cab
E Control Cabinet
F RPC Cabinet
H High Voltage Cabinet
K Converter Cabinet
P Suppression Cabinet
T Transfer Cabinet
B Boom Assembly
L Lower Assembly
U Upper Assembly

Table 3-1: Location Code Letter Designation

Following the Letter Designator is a number which signifies the subassembly or panel within
the cabinet or major assembly that the component is located. In the example, 01 designates the
01 Panel in the Transfer Cabinet.

Following the subassembly or panel number is a letter/number combination which provide


coordinates to assist in locating the component. Refer to Figure 3-1. In the example, D2 coor-
dinates are marked with an ×. This is a guide only. Actual grid lines are not provided on the
subassembly or panel.

1 2 3 4 5 6 7

B
y
bl

C
em
ss

D
ba

Pa or
l
ne

E
Su

ES1988_01

Figure 3-1: Location Code Subassembly or Panel Coordinates

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3.2 GROUND FAULT AND SUPPRESSION CABINET

3.2.1 General Information

The Ground Fault and Suppression Cabinet contains sensing components for detecting ground
faults occurring in both Main Transformer secondaries and the auxiliary supply secondary,
control supply secondary and field supply secondary of the Auxiliary Transformer. This cabi-
net also contains the components providing transient voltage suppression on the 600VAC bus
bars. Transient voltage suppression is required because of the transients produced by the DC
motion motor mechanical commutation and the natural commutation of the four Armature
Converter thyristor assemblies.

3.2.2 Location

ES1826d_01

Figure 3-2: Ground Fault and Suppression Cabinet - (4100XPB Deck Plan)

3.2.3 Cabinet Layout

The Main Transformer Suppression Circuit Breakers, P00X1 and X2, mount on the left side
panel of the cabinet. The Ground Fault Trip Indicators, P00X10, X11 and X12, Ground Fault
Test push buttons, P00X13, X14 and X15 and Ground Fault Reset push buttons, P00X16, X17
and X18, mount on the inside of the front door panel. Refer to Figure 3-3. All of these items
are accessible from the outside of the cabinet for required maintenance and servicing by quali-
fied personnel.

Internal components group into either Ground Fault or Suppression components internally in
the cabinet. The Ground Fault components includes resistors, relays, current sensors, filtering
capacitors and inductive chokes. The Suppression components includes resistors, capacitors,
and circuit breakers. Refer to Figure 3-3.

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P01A1A P01A2A

P01A1B P01A2B

Suppression P01B1A P01B2A

Resistors P01B2B

P01C1A P01C2A

P01C1B P01C2B
Suppression
Capacitors
P01D1 P01D2 P01D3 P01D4 P01D5 P01D6

P02E1A P02E2A

P02E1B P02E2B
P00X1
P02E1C P02E2C
1L1 1L2 1L3

P02E1D P02E2D
S1SB Ground Fault
Resistors
P02F1A P02F2A

P02F1B P02F2B

P02F1C P02F2C

P02F3D P02F2D P02F1D FIELD AUXILIARY MAIN


TRIP TRIP TRIP
P00X10 P00X11 P00X12
P00X2 P01G1A P01G2A

2L1 2L2 2L3 Suppression


P01G1B P01G2B
Resistors
S2SB P01G1C P01G2C
FIELD AUXILIARY MAIN
Suppression TEST TEST TEST
Capacitors P00X13 P00X14 P00X15

P01K1 P01K2 P01K3 P01K4 P01K5 P01K6

FIELD AUXILIARY MAIN


RESET RESET RESET
P00X16 P00X17 P00X18

P02M1 P02M2 P02M3


GFRM GFRA GFRF

LEFT SIDE P02N1 P02N3 P02N5


CURRENT SENSOR CURRENT SENSOR CURRENT SENSOR
OF CABINET P02N2 P02N4
GND FLT RELAY RECTIFIER

Capacitors
P02P1 P02P2 P02P3 P02P4 P02P5 P02P6

Chokes
P02R1 P02R2 P02R3 P02R4 P02R5

INSIDE OF DOOR

ES1989_01
P02S1
BACK PANEL

Figure 3-3: Ground Fault and Suppression Cabinet Layout

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3.2.4 Ground Fault Operation

02 115 1
03
0.1 POWER
T 0.2 VAC 2
(SEC) 0.4
+0.05 0.8
- - - - 1.6 NO 3

01 INHIBIT

0.1
TRIP 4
0.2 G/F RELAY 5
1
(A)
+0.1
0.4
0.8
NC 6
04
1.6 TRIP
- - - - 3.2 7
RESET
OFF ON 8
05
G/F 9
13 G/F
TEST 10
06
14 IN
G/F 11
15 ** OUT 12

ES1990_01
Figure 3-4: Ground Fault Relay, GFRM, GFRA and GFRF

LEGEND
01. Set Dipswitch 0.2 and 0.8 to ON for 1.0 Amp trip. All other Dipswitches should be set
to OFF.
02. Set Dipswitch 0.2 and 0.4 to ON for 0.6 second trip time. All other dipswitches should
be set to OFF.

Cover Removed

03. Position jumper “D” for TLPL (Trip Latched at Power Loss).
04. Position jumper “C” for FS (Fail-Safe).
05. Leave jumper “A” in.
06. Leave jumper “B” in.

3.2.4.1 Main Transformer Ground Fault Circuits

Refer to Figure 3-5. The main transformer is a dual secondary winding unit. The windings on
the transformer are extremely closely coupled. When a ground fault current flows in the non-
monitored winding, MS21, MS22 and MS23, a fault current is reflected in the monitored sec-
ondary, MS11, MS12 and MS13, activating the ground fault system.

The main transformer ground fault system consists of current limiting resistors, P02E1A, E1B,
E1C and E1D which are connected to earth ground from transformer secondary terminal MSN
and two sensing systems, GFRM Ground Fault Relay Main, P02M1 and Ground Fault Relay
P02N2. If there is a ground fault, current will flow in the series resistors to ground. This cur-
rent will produce a voltage drop across the resistors in the chain. The voltage developed across
P02E1D is sampled by the Ground Fault circuitry.

A filter is used to allow only the AC component of current to pass through to the GFRM Cur-
rent Sensor, P02N1. Current is limited to about 2 amps, with GFRM Ground Fault Relay Main
sensing set to pick up at 1 amp. This first sensing system is sensitive to ground faults on the
AC side of the Power Converters.

Ground faults on the DC side produce a peculiar current waveform. A filter is used to attenuate
the base frequency components, 50 or 60 Hz. The output of the filter produces an AC voltage

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Section 3, Cab Des and Op.fm - 3.5 - SECTION 3, Version 0 - 9/02
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that is rectified by bridge rectifier P02N4, and the resultant DC voltage level is sensed by the
DC Ground Fault Relay, P02N4. The level of the voltage is proportional to the current through
the series resistor chain, which is the fault current.

This system of filters and separate sensing devices discriminates between AC and DC ground
faults.

The Test push button, P00X15, is on the outside of the cabinet door. The contacts of the push
button connect to a check circuit in the GFRM Ground Fault Relay Main. The Reset push but-
ton, P00X18, is also located on the cabinet door. The Ground Fault Relay Main is reset by
pressing the Reset push button after a true ground fault is detected or the Test push button has
been pressed.

Figure 3-5: GFRM, Ground Fault Relay Main Schematic Diagram

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3.2.4.2 Auxiliary Transformer Ground Fault Relay

Refer to Figure 3-6. The Auxiliary/Field Transformer ground fault system consists of current
limiting resistors, P02E2A, E2B, E2C and E2D which are connected to earth ground from the
transformer secondary terminals ASN and CSN.

A Current Sensor, P02N3, samples the ground fault current. The signal is fed into the GFRA,
Ground Fault Relay Main Auxiliary, P02M2. This relay is set for 1A. When this level of
ground fault current exists, GFRA will pick up and a Auxiliary Ground Fault will be indicated.

Two pushbuttons, P00X14 and P00X17, are located on the cabinet door. These push buttons
perform the Test and Reset functions described in Subsection 3.2.4.1.

ES1992_01

Figure 3-6: GFRA, Ground Fault Relay Main Auxiliary Schematic Diagram

3.2.4.3 Field Secondary Ground Fault Relay

Refer to Figure 3-7. The fields secondary ground fault system is located on the Auxiliary/Field
Transformer and consists of current limiting resistors, P02F1A, F1B, F1C, F2A, F2B and F2C
which are connected to earth ground from the transformer secondary terminal FSN.

A Current Sensor, P02N5, samples the ground fault current. The signal is fed into the GFRF,
Ground Fault Relay Field, P02M3. This relay is set for 1A. When this level of ground fault
current exists, GFRF will pick up and a Field Ground Fault will be indicated.

Two pushbuttons, P00X13 and P00X16, are located on the cabinet door. These push buttons
perform the Test and Reset functions described in Subsection 3.2.4.1.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.7 - SECTION 3, Version 0 - 9/02
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ES1993_01

Figure 3-7: GFRF, Ground Fault Relay Field Schematic Diagram

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3.2.5 Suppression Circuit Operation

Two types of suppression circuits connect to each Main Transformer secondary. A phase to
phase RC notch filter with each phase circuit consisting of two 6Ω resistors in parallel and one
20µF capacitor in series with the resistors. These RC notch filters are connected in a delta con-
figuration across each secondary. Their purpose is to suppress the ringing on the commutation
notches produced by the converters. Refer to Figure 3-8.

The second RC filter consists of a 1µF capacitor in parallel with a 12KΩ resistor which con-
nects each phase-to-ground across each Main Transformer secondary. This phase to ground RC
filter reduces the effects of distributed capacitance present on the bus bar distribution system
when the Main Transformer connects to the 600VAC bus bar.

ES1994_01

Figure 3-8: Main Transformer Suppression Circuit

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Section 3, Cab Des and Op.fm - 3.9 - SECTION 3, Version 0 - 9/02
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3.3 REACTIVE POWER COMPENSATION CABINET

3.3.1 General Information

The Reactive Power Compensation Cabinet contains the components which provide a means
of controlling the reactive power demanded by the converters and simultaneously provides a
filter for predominant harmonics generated in the electrical system during normal shovel oper-
ation.

3.3.2 Location

ES1826e_01

Figure 3-9: Reactive Power Compensation Cabinet - (4100XPB Deck Plan)

3.3.3 Cabinet Layout

The Reactive Power Compensation Cabinet divides into eight sections. The cabinet contains
five banks of capacitors, F19, F11, F32, F33 and F42 and related distribution and control com-
ponents (F21, F41 and F22). Refer to Figure 3-10 and Figure 3-11.

The first cabinet contains the capacitors, reactors and circuit breakers for the ½ Bank and Bank
1. The ½ Bank is on the inboard side and Bank 1 is on the outboard side.

The second cabinet contains the switching components for the ½ Bank, Bank 1, Bank 2 and
Bank 3. This cabinet contains the dV/dT circuits and SCR’s and diodes used for charging and
discharging the capacitors. The ½ Bank and Bank 2 components are on the inboard side and
Bank 1 and Bank 3 components are on the outboard side.

The third cabinet contains the capacitors, reactors and circuit breakers for Bank 2 and Bank 3.
Bank 2 is on the inboard side and Bank 3 is on the outboard side.

Refer to Figure 3-12. The final cabinet contain all components associated with Bank 4. Bank 4
switching components are located on the inboard side and capacitors on the outboard side.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.10 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

Front of
Shovel

Thyristors For
Flex I/O and
Bank 4

Bank 4
Bank 2
Bank 3

½ Bank and Bank 2


Bank 1 and Bank 3
Thyristors for

Thyristors for
½ Bank
Bank 1

ES1996_01

Figure 3-10: RPC Cabinet Layout

Figure 3-11: RPC Switching Cabinet and RPC Capacitor/Reactor Cabinet

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.11 - SECTION 3, Version 0 - 9/02
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Figure 3-12: RPC Cabinet Bank 4

3.3.4 RPC Operation

3.3.4.1 Power Factor Correction

The load for the armature and field converters is the inductive motors requiring electromag-
netic fields to operate. These inductive loads require two components of electrical power to
operate:

• Working power, KW, to perform the actual work of creating motion.

• Reactive power, KVAR, to sustain the electromagnetic field.

Working power, KW, consumes watts readable with a wattmeter. Reactive power, KVAR, does
not perform useful work because the reactive current circulates between the converter and
motor placing a heavier drain on the power source and distribution system. KW and KVAR
together make up Apparent Power, AP, measurable in kilovolt-amperes, KVA. Refer to Figure
3-13 for a graphical representation of KW, KVAR and KVA.

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SECTION 3, Version 0 - 9/02 - 3.12 - Section 3, Cab Des and Op.fm
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KW

KVAR
KVA

ES1197_01

Figure 3-13: KW, KVAR and KVA Relationship

Power Factor, PF, is the ratio of actual KW to the total KVA of the flowing current. By formula
Power Factor is:

PF = KW ÷ KVA

A Power Factor of one (1) indicates all of the current flowing between the source and load is
consumed in the production of work in the load. As reactive current increases, and the Power
Factor decreases, the amount of current performing work decreases. This is not a desirable
electrical condition or economical situation and can be overcome through the use of a reactive
power compensation system.

The Reactive Power Compensation System takes advantage of a capacitor’s natural tendency
to draw leading current when connected to an AC line. The RPC system, via an electronic
switch, controls the level of compensating leading VAR by connecting and disconnecting
banks of capacitors from the line.

The leading capacitive current, now added to the line, compensates for the lagging inductive
reactive current inherent in operation of the motion converters. The result is that total line cur-
rent equals the active current. In terms of power the active power equals the apparent power or
volt-amperes where the Power Factor now achieves unity or one (1).

3.3.4.2 Reactive Power Compensation

The RPC System consists of the following basic components:

• Summing Transformer

• KVAR Sensing Potential Transformer

• KVAR Transducer

• AC80

• RPC Firing Board

• Pulse Transformers

• Switching Components, Reactors and Capacitors

Refer to Figure 3-14 for a block diagram of the RPC System.

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Section 3, Cab Des and Op.fm - 3.13 - SECTION 3, Version 0 - 9/02
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Summing
Transformer 240VAC, 3Ø

Phase A
KVAR Sensing
1L1 1L2 1L3
Potential Transformers
CT

CT

½ Bank ½ Bank
KVAR Pulse Thyristor
2L1 2L2 2L3
Transducer Transformers Switches
CT

CT

Bank 2 Bank 2
AC80 RPC Pulse Thyristor
½ Bank Firing Transformers Switches
Analog Digital Board
Summing Input Output Bank 2
Transformer Module Module
Phase C Bank 1 Bank 1 Bank 1
Pulse Thyristor
Bank 3 Transformers Switches

Bank 4
Bank 3 Bank 3
Pulse Thyristor
Transformers Switches

Bank 4 Bank 4
Pulse Thyristor
Transformers Switches

ES1998_01

Figure 3-14: RPC Block Diagram

The KVAR Transducer, E10D9, compares the phase relationship of the voltage and current in
the bus bars feeding the armature converters. The transducer receives two input signals and
produces an output error signal proportional to the phase differences between the voltage and
current on the 600VAC bus bars. Under no load conditions, the output signal will be at or near
zero, as the voltage and current on the AC bus bars remain in phase. Under increasing load
conditions, when the shovel starts to dig and hoist and crowd motions are being used, the out-
put of the transducer increases as the voltage and current phase relationship changes.

The KVAR Transducer receives 115VAC from the KVAR Sensing Potential Transformers,
E10D7 and E10D8. This input serves as supply power and a voltage reference. The current
sensing inputs come from the Summing Transformers, K02E1and K06E1. Summing Trans-
former Phase A, K02E1, uses Current Transformers to measure the AØ line current from both
1L1 and 2L1 bus bars. Summing Transformer Phase C, K06E1, also uses Current Transform-
ers to measure the CØ line current from both 1L3 and 2L3 bus bars. Internally the KVAR
transducer analyses the voltage from the KVAR Sensing Potential Transformers and the cur-
rent from the Summing Transformers. The output error voltage represents the required KVAR
correction factor and is applied to the AC80 Analog Input Module, E20F5, position 2.

The AC80 evaluates the KVAR feedback signal and outputs digital control signals from a Dig-
ital Output Module, E20F8, position 5, to the RPC Firing Board, E10B12.

The RPC Firing Board, refer to Figure 3-15, produces control pulses to the Pulse Transformers
in the proper phase relationship to the 600VAC line voltage.

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ES1978a_01

Figure 3-15: RPC Firing Board

The Power Supply and Line Sync circuit receives a +24VDC input from the 24VDC Supply,
E00X3, and 34VAC from the RPC Synchronizing Voltage Transformer, E10A13. This circuit

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provides all operating voltages for the RPC Firing Board and also provides the B-A, A-B, C-B,
B-C, A-C, and C-A synchronizing signals to the Pulse Generators. The synchronizing signals
ensure that the Pulse Generator produces control pulses in the proper phase relationship to the
600VAC line voltage.

The 100KHz Oscillator and On-Signal Interface generates a 100KHz OSC signal to be used by
the Pulse Generators in producing the control pulses to the Pulse Transformers. The digital
control signals, from the AC80, are used to synchronize the on-signals, ON1, ON2, ON3, ON4
and ON5 which tell the Pulse Generator when to turn on and produce an output.

The Pulse Generators compare the OSC signals, B-A, A-B, C-B, B-C, A-C, and C-A synchro-
nizing signals and on-signals to generate the control pulses for the Pulse Transformers. The
control pulses are generated at the proper phase relationship to the 600VAC line voltage. This
allows the RPC capacitors to be connected to the line in a synchronous manner without pro-
ducing transients.

The Pulse Transformers, refer to Figure 3-16, conditions the control pulses into firing pulses
which are applied directly to the gate and cathode circuit of the RPC Thyristors. An LED on
the Pulse Transformer illuminates when a firing pulse is being applied to the thyristor.

ES1999_01

Figure 3-16: Pulse Transformer

The Thyristor Switch section contains three thyristor switches for each bank of capacitance.
Each thyristor switch consists of an SCR and diode in parallel configuration which is in series
with the reactor and capacitor bank. Refer to Figure 3-17.

When the Main Transformer energizes, the diode in each bank leg allows the capacitors to
charge to the peak of the line-to-line voltage. When reactive power compensation is required,
the thyristor is gated by the RPC Firing Board via a Pulse Transformer at the peak of the AC
line, connecting the capacitor banks to the AC bus bar without any transients.

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Charge
Discharge

ES1966a_01

Figure 3-17: Thyristor Switch Section (½ Bank and Bank 2 Shown)

Each of the four Reactor - Capacitor sections consist of a single 1200 Amp circuit breaker,
three air core reactors, three capacitor circuits with associated set of two 1200V, 200A fuses.
The handle of the circuit breaker extends through the front panel door for ease of maintenance
when resetting is required. One pole of the breaker and single air core reactor connect in series
with three capacitors connected in parallel. The reactors and capacitors form a tuned circuit to
filter out the predominant harmonics generated by the thyristor converters. The capacitors con-
nect to the outbound bus via two fuses.

Bank indicators, refer to Figure 3-18, located on the front door of each reactor-capacitor sec-
tion, consists of a series of directional diodes and LED’s connected across the capacitor banks
on each phase. One light illuminated, per phase, indicates the capacitors are charged. One light
illuminated, per phase, indicates the capacitors are in circuit. Three LED’s are used to indicate
that the 3 phase-to-phase capacitor circuits are charged. Three more LED’s are used to indicate
that the 3 phase-to-phase capacitor circuits are being used. A decal shows the combination of
indicator lights and meaning of that indication. Refer to Figure 3-19.

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LED 1
D1 R2

LED 2
D2 R3

Charge
Discharge R1

A1 B1 C1

R4 R5 A1 B1 C1

ES2000_01

Figure 3-18: RPC Indicator Circuit

= Off
= On RPC Indication
Mode of Phase
Condition Description
Operation A-C C-B B-A

Yellow lights are on.


Normal
Position important, only one light per phase.
15 Seconds
After Start-up Capacitors are not charged.
and During Fault Power diodes are not responding.
Machine Idling Open circuit breaker.
Any two lights on any phase are on.
Fault The thyristor controlling the capacitor banks
on that phase are shorted.
All capacitor banks should be on line and all
Hoist, Crowd Normal six indicator lights for each step should be
and Swing on.
Motors Stalled All or any one step as shown. This indicates
Fault step not being brought on line. Faulty KVAR
Transducer or electronics.
Motors Stalled in All six indicator lights for each step should go
Sequence Slowly, Normal on as the step becomes active. If not, check
i.e. Hoist, Crowd, RPC electronics and KVAR Transducer for
Swing proper operation.

ES1969_01

Figure 3-19: RPC Indicator Decal

Implementing the Reactive Power Compensation requires varying levels of capacitance as the
KVAR requirements increase and decrease depending on the load requirements of the shovel.
In order to achieve the varying levels of KVAR, the RPC switches parallel banks of capacitors
into the electrical system. Five banks of capacitors are placed on the shovel to meet this vary-
ing KVAR requirement. Each bank consists of three capacitors that add together defining the
amount of VAR compensation. The banks are identified below with their KVAR values:

• ½ Bank - 675 KVAR (60Hz) 750 KVAR (50Hz)

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4100XPB Electrical Manual Cabinet Description and Operation

• Bank 1 - 1350 KVAR (60Hz) 1500 KVAR (50Hz)

• Bank 2 - 1350 KVAR (60Hz) 750 KVAR (50Hz)

• Bank 3 - 1350 KVAR (60Hz) 1500 KVAR (50Hz)

• Bank 4 - 1350 KVAR (60Hz) 1500 KVAR (50Hz)

The RPC System sequences the banks on in a controlled manner to effectively produce steps of
compensation. This system consists of five independently controlled banks of capacitance. In
this implementation a total of nine incremental steps of compensation are available throughout
the digging cycle. Table 3-2 displays the steps of implementation for a 60Hz shovel, Table 3-3
for a 50Hz shovel.

Banks Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9
on off on off on off on off on
½ Bank
off on on on on on on on on
Bank 1
off off off on on on on on on
Bank 2
off off off off off on on on on
Bank 3
off off off off off off off on on
Bank 4

Table 3-2: RPC Step Sequence (60Hz Shovels)

Banks Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9
on off on off on off on on on
½ Bank
off on on on on on on on on
Bank 1
off off off on on on on on on
Bank 2
off off off off off on on on on
Bank 3
off off off off off off off on on
Bank 4

Table 3-3: RPC Step Sequence (50Hz Shovels)

3.3.4.3 Harmonic Filtering

NOTICE
The Reactors and Capacitors form tuned circuits. It is imperative that all the compo-
nents be kept in proper working order. Blown capacitor fuses, removed or leaking
capacitors will upset the tuning which may lead to faulty operation of the shovel or
unnecessary disturbances on the supply network.

If any one bank of capacitors cannot be completely maintained as designed, the


entire bank should be disconnected from service.

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The RPC system also filters predominant undesirable harmonic frequencies produced by the
converters. The converters used on the shovel are phase controlled and the line currents lag the
voltage and are not pure sine waves. Mathematically this non-sinusoidal waveform can be bro-
ken down into a series of sinusoidal waveforms that vary in peak amplitude, phase relation-
ship, and frequency. These frequencies are called harmonics. A three-phase six thyristor
converter current generates definite frequencies or harmonics. The formula for generated har-
monics (h) is:

h = pn ± 1

p = number of firing pulses, e.g. 6 thyristors, 6 pulses.

n = 1,2,3,4,5,etc.

Harmonics for a 6 thyristors converter are as follows:

• h = 6 × 1 ± 1 = 5,7 or,

• h = 6 × 2 ± 1 = 11, 13 or

• h = 6 × 3 ± 1 = 17, 19 etc…

The capacitor banks are connected in series with air core reactors. This L-C circuit is approxi-
mately tuned to the 4.5 harmonic, (4.5 × 60 = 270Hz) for 60Hz systems and (4.5 × 50 =
225Hz) for 50 Hz systems. Refer to Figure 3-20.

17 13 11 7 5 5 7 11 13 17

ES1198a_01

Figure 3-20: Harmonic Frequencies (60Hz Fundamental)

The higher the number of the harmonic the lower the percentage of the fundamental current.
The filter tuning is to the 4.5 harmonic to prevent the resonance problems causing extremely
high currents. Because of the size and tuning of the RPC system to the 4.5 harmonic, the pre-
dominant harmonics of 5, 7, 11, 13, are greatly attenuated.

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3.4 CONVERTER CABINET

3.4.1 General Information

The Converter Cabinet contains the power electronics and associated components supplying
direct current to the armatures of each motion motors. The Converter Cabinet contains four
major sections: Input Power Distribution and Protection, Current Feedback, Converters and
Diverter Circuitry.

3.4.2 Location

ES1826f_01

Figure 3-21: Converter Cabinet - (4100XPB Deck Plan)

3.4.3 Cabinet Layout

Refer to Figure 3-22. The Converter Cabinet contains eight sections:

Inboard side

• Hoist #1/Propel #1 Converter section.

• Hoist #1/Propel #1 - Swing 1&2 Input Power Distribution and Protection, Diverter Cir-
cuitry.

• Swing 1&2 Converter section.

• Crowd/Propel #2 Converter section.

Outboard side

• Crowd/Propel #2 Input Power Distribution and Protection, Diverter Circuitry.

• Swing #3 Converter section.

• Swing #3/Hoist #2 Input Power Distribution and Protection, Diverter Circuitry.

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• Hoist #2 Converter section.

Inboard Side View

Hoist #1 / Propel #1 Converter Cabinet Swing 1&2 Crowd/Propel #2

RPC Cabinet
Side

Hoist #1 H1/P1 - S1&2 Swing 1&2 Crowd/Propel #2


Propel #1 Input Power
Distribution and
Protection
Diverter Circuitry

Outboard Side View

Swing #3 Converter Cabinet Hoist #2

RPC Cabinet
Side

C/P2 Swing #3 S3 - H2 Hoist #2


Input Power Input Power
Distribution and Distribution and
Protection Protection
ES2001_01
Diverter Circuitry Diverter Circuitry

Figure 3-22: Converter Cabinet Layout

The sections are cooled by top mounted vane axial blowers. These blowers draw in filtered
machinery air through the cabinet doors and over thyristors for cooling and ventilation.

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3.4.4 Input Power Distribution and Protection Circuit Operation

The Input Power Distribution and Protection Section contains bus bars, fuses, varistors, and a
Phase Monitor Relay. The bus bars distribute the three-phase power from the overhead bus
bars to the Thyristor section. The bus bar fuses protect the converter from over current condi-
tions. The varistors protect the converter and Phase Monitor Relay from voltage spikes. The
Phase Monitor Relay detects phase loss.

Refer to Figure 3-23. Each bus bar phase has two fuses, rated at 800V/1500A, wired in parallel
providing overcurrent protection for the SCR’s in the converter.

Branching off of the 600VAC bus bars to the Phase Monitor Relay are 700V/50A fuses which
are used in conjunction with the Phase Monitor Relay to detect a loss of incoming 600VAC
phase.

Metal Oxide Varistors, or MOV’s, provide transient voltage protection for the converter.

3Ø 600 VAC

Line
Fuses

Output to
B PLC System

Fuses Metal Oxide Phase Monitor


Varistors Relay
ES1170a_01

Figure 3-23: Input Power Distribution and Protection

3.4.5 Current Feedback Operation

Current Transformers are used on the 600VAC bus input to the Converters and provide a cur-
rent feedback signal to the Digital Control Modules. This current feedback signal is propor-
tional to the current at the motor. The CT’s have a turns ratio of 4000:5. Refer to Subsection
6.1 for a description of the Digital Control Modules.

3.4.6 Converter Operation

The five Armature Converters have a Forward and Reverse bridge containing six SCR’s each.
A total of twelve SCR’s produce the voltage and current required to run the armature circuit of
the DC motors.

The converter/motor combination operate together in two basic modes of operation, Converter
or Inverter. During the converter mode of operation, the converters supply direct current to the
motors for motion through controlled thyristor gating.

During the inverter mode of operation, the motors supply the converter with stored energy
from the armature’s collapsing magnetic field. The converter inverts this energy back into AC

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energy through controlled thyristor gating. The inverted AC current is applied onto the over-
head bus bars. It can be used by other motions or fed back through the Main Transformer back
onto the mine’s power distribution grid. This inverting of stored energy from the motors back
into AC energy is referred to as regeneration.

3.4.6.1 SCR Theory

An SCR, or Thyristor, is an electronic switch, it only conducts when it is gated on. Refer to
Figure 3-24.

Gate Lead (G) Cathode Lead (K)

Anode (A) Cathode (K)

ES2002_01

Figure 3-24: SCR Symbol

The Anode must be positive with respect to the Cathode to bias an SCR for conduction how-
ever, this alone does not make an SCR conduct. The Gate Lead must also have a positive volt-
age applied, again, with respect to the Cathode, to make the SCR conduct.

If all biasing conditions are correct, the SCR will conduct for as long as the Anode to Cathode
relationship remains, even if the Gate to Cathode relationship is removed. Only when the Cath-
ode becomes positive, with respect to the Anode, will the SCR turn off.

The important thing to remember is that a small current from Gate to Cathode can fire the
SCR. The only way to stop the SCR from conducting is to reduce the load current to a value
less than the minimum forward bias current. Gate current is required only until the Anode cur-
rent has completely built up to a point sufficient to sustain conduction. After conduction from
Cathode to Anode begins, removing the Gate current has no effect.

Refer to Figure 3-25. When alternating current is applied to an SCR, the controlled rectifier
may be turned on at any time during the half cycle, thus controlling the amount of DC power
available from zero to maximum.

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4100XPB Electrical Manual Cabinet Description and Operation

Input

Output

Gate Lead

Input

Output

Gate Lead

Input

Output

Gate Lead

ES2003_01

Figure 3-25: SCR Controlled Rectification Example

3.4.6.2 Converters

When SCR’s are used in a 3Ø Bridge Rectifier, the DC output can be controlled by controlling
when the SCR’s are fired. Refer to Figure 3-26.

T1

Motor

ES2005_01

Figure 3-26: 3Ø SCR Bridge Rectifier

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In the example shown in Figure 3-26, the red line shows which SCR’s would be fired at T1.
The AØ is the most positive phase, CØ the most negative phase. In this standard six SCR 3Ø
Bridge Rectifier, DC current can only flow in one direction through the Motor.

In order to reverse the current, a twelve SCR 3Ø Bridge Rectifier is required. Refer to Figure
3-27.

T1

Motor

Forward

Reverse

ES2006_01

Figure 3-27: 3Ø SCR Reversing Bridge Rectifier

In a twelve SCR 3Ø Bridge Rectifier, current can flow in either the forward or reverse direc-
tion through the motor depending on which SCR’s are fired. When forward direction of the
motor is required, the forward bridge SCR’s are fired. The reverse bridge SCR’s are in a
“blocked” condition. No firing pulses are applied to the gate. When reverse direction of the
motor is required, the reverse bridge SCR’s are fired. The forward bridge SCR’s are in a
“blocked” condition. No firing pulses are applied to the gate.

The hoist motor armatures are connected across two 12 SCR 3Ø Bridge Rectifiers. To double
the voltage output of the converter a series bridge arrangement is used. Refer to Figure 3-28.

T1

Forward
Motor Motor
Reverse

T1

ES2007_01

Figure 3-28: 3Ø SCR Series Bridge Rectifier

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3.4.7 Diverter Circuit Operation

The Diverter Circuit discharges a capacitor to block, or force off, Armature Converter SCR’s
when over current conditions are detected. It also provides a path to dissipate the built up mag-
netic field across the motor armature. The Diverter Circuit is adjusted at shovel commissioning
to initiate a diverter trip at 140% of stall armature current. The three stages of operation in the
Diverter system are as follows:

• Diverter Capacitor Charging.

• Overcurrent Detection.

• Diverter Capacitor Discharge and Motor Dissipation.

Diverter protection is provided for the following bridges:

• Hoist #1/Propel #1 Converter - Forward bridge protection only.

• Hoist #2 Converter - Forward bridge protection only.

• Swing 1&2 Converter - Forward and reverse bridge protection.

• Swing #3 Converter - Forward and reverse bridge protection.

• Crowd/Propel #2 Converter - Forward and reverse bridge protection.

In the Hoist converters, only one capacitor requires charging because only the forward bridge
produces enough current capable of flashing the motors. In the Crowd and Swing Converters,
either direction is capable of producing enough current to flash the motors therefore, two
capacitors require charging to protect both the forward and reverse converters. The Propel #1
motor is excited by the Hoist #1 converter and the Propel #2 motor by the Crowd converter.
Diverter protection is provided by those respective systems.

3.4.7.1 Diverter Capacitor Charging

240VAC is applied through normally open contacts of the Diverter Charging Relay Hoist
(DCH), Diverter Charging Relay Swing (DCS) and Diverter Charging Relay Crowd/Propel
(DCCP) to the Diverter Power Supplies Front and Rear Hoist, Front and Rear Swing and
Crowd Propel. Refer to Figure 3-29.

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Section 3, Cab Des and Op.fm - 3.27 - SECTION 3, Version 0 - 9/02
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3Ø 240VAC

DCH

DCH
Front Rear
Hoist Hoist
K07B5 K03B4

Rectifier Rectifier
K07C6 K03C3

DCS3

DCS3
DCS

DCS Front Rear


Swing Swing
K07B4 K03B5

Rectifier Rectifier
K07C3 K03C6
DCCP

DCCP

Crowd/
Propel ES2010_01
K12B5
Rectifier
K12C6

Figure 3-29: Diverter Power Supplies

The 240VAC is rectified and applied to the Diverter Capacitors in the correct polarity to pro-
tect either the forward or reverse bridges. Each capacitor charges to approximately 1300 VDC.
Refer to Figure 3-30, Figure 3-31, Figure 3-32, Figure 3-33 and Figure 3-34.

HOIST #1/ PROPEL


ARMATURE CONVERTER

LOWER (REVERSE)

HOIST (FORWARD)

K06B4D K06B4E

DPH1

K08G4 K06B4A K06B4B

K08K1 K06B2 K06K7

K08G2 K07A7D K07A7C K07A7B


DCH DCH DCH POSITIVE
NEGATIVE

K07A7A

HAC
HOIST MOTOR ARMATURES
AND FEEDBACK CIRCUITS

ES1814a_01

Figure 3-30: Hoist #1/Propel #1 Diverter Capacitor Charge Polarity

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HOIST ARMATURE
CONVERTER #2

HOIST (FORWARD)

LOWER (REVERSE)

K02B3E K02B3D

DPH2

K02B3A K02B3B K01G1

K02R5 K02B1 K01K1

K03A4B K03A4D K03A4C


DCH DCH DCH K01G4
POSITIVE
NEGATIVE
K03A4A

HOIST MOTOR ARMATURES


AND FEEDBACK CIRCUITS
ES1815b_01

Figure 3-31: Hoist #2 Diverter Capacitor Charge Polarity

SWING 1&2 ARMATURE


CONVERTER

REVERSE (LEFT)

FORWARD (RIGHT)

K07A4A
K07A4C K07A4D
DCS DCS DCS

K05K1
K07A4B FORWARD BRIDGE
K05G2 PROTECTION
K05G4 K06B1 K06K5
DPS1
K06B3D K06B3E K06B3A
K05L1
K05H4 K06K6 K06B3B REVERSE BRIDGE
K07A5C K07A5D PROTECTION
K05H1
K07A5A DCS DCS DCS

POSITIVE

K07A5B NEGATIVE

LEFT FRONT RIGHT FRONT

A1 A2 A1 A2
S1 S2

ES1824b_01

Figure 3-32: Swing 1 & 2 Diverter Capacitor Charge Polarity

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SWING #3 ARMATURE
CONVERTER

REVERSE (LEFT)

FORWARD (RIGHT)

K03A5D
K03A5H K03A5G
DCS3 DCS3 DCS3

K04K1
K03A5C REVERSE BRIDGE
K02R6 K02B2 K04G1 K04G4 PROTECTION

DPS3
K02B4E K02B4D
K02B4A
K04L1
K02R7 K04H1
K02B4B FORWARD BRIDGE
K03A5F K03A5E K04H3 PROTECTION
DCS3 DCS3 DCS3 K03A5A

K03A5B POSITIVE

NEGATIVE

A1 A2
S3

ES1825a_01

Figure 3-33: Swing #3 Diverter Capacitor Charge Polarity

CROWD/PROPEL #2 ARMATURE
CONVERTER

FORWARD (CROWD)

REVERSE (RETRACT)

K12A5D
K12A5H K12A5G
DCCP DCCP DCCP
K13K1
K12A5C FORWARD BRIDGE
K11R6 K11B2 K13G1 K13G4 PROTECTION
DPCP
K11B4A K11B4E K11B4D
K13L1
K11B4B K11R7 K13H1 REVERSE BRIDGE
K12A5F K12A5E K13H3 PROTECTION
DCCP DCCP DCCP K12A5A

POSITIVE
K12A5B
NEGATIVE

CAC
A2 C A1
P2AC
A2 P2 A1

ES1817b_01

Figure 3-34: Crowd/Propel #2 Diverter Capacitor Charge Polarity

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At shovel start, the normally closed contacts of the Diverter Charging Relay Hoist (DCH),
Diverter Charging Relay Swing (DCS) and Diverter Charging Relay Crowd/Propel (DCCP)
open allowing the Diverter Capacitors to charge to 1300VDC. This charge will be maintained
on the Diverter Capacitors until an overcurrent condition is detected and a diverter trip is initi-
ated or, when the shovel is shutdown. Refer to Subsection 3.4.7.3 for a description of capacitor
discharge, motor dissipation.

When the shovel is shutdown, the Diverter Charging Relay Hoist (DCH), Diverter Charging
Relay Swing (DCS) and Diverter Charging Relay Crowd/Propel (DCCP) de-energize allowing
the Diverter Capacitors to discharge through the normally closed contacts.

3.4.7.2 Diverter Control Modules

Figure 3-35 shows a typical Diverter Control Module with all possible inputs. The Diverter
Control Module Hoist (DCMH) does not require inputs at TB1-8, 9 and 10 due to protection
only being provided for the forward bridge.

+15VDC
A
-15VDC
B
Output
C
Common
D

Current Sensor

+28VDC Gate

CCOM Cathode

DELR Gate
Diverter Enable Logic Cathode

+24VDC

Diverter Trip Signal

Reverse

Forward Gate Block Signal

CCOM CCOM

ES1975a_01

Figure 3-35: Diverter Control Module

Inputs

• Current Sensor - The Current Sensor is basically a transducer which works on the
Hall Effect principle. It produces a voltage proportional to the current flowing through
it. Pins A, B and D are supply voltage inputs to the Current Sensor from the Diverter
Control Module. The Current Sensor output, Pin C, is equal to 1VDC for every 500A
of current flowing through the motor.

• +28VDC - This input is a supply voltage to the Diverter Control Module from the
Diverter Power Supply, K07D4.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.31 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

• Diverter Enable Logic - This is a PLC input which enables the Diverter Control Mod-
ule for operation at shovel start.

• Reverse Signal - This input comes from the Drive Control Module SDCS-PIN-61
board. It tells the Diverter Control Module that the reverse bridge is conducting. This
signal is not required on the Diverter Control Module Hoist (DCMH).

• Forward Signal - This input comes from the Drive Control Module SDCS-PIN-61
board. It tells the Diverter Control Module that the forward bridge is conducting. This
signal is not required on the Diverter Control Module Hoist (DCMH).

• +24VDC - When an overcurrent condition is detected, this input, at TB2-5, is routed


through the Diverter Control Module internal relay contacts (DCM) to the PLC.

Outputs

• Firing Pulse Outputs - When an overcurrent condition is detected and a diverter trip is
initiated, the Pulse Transformers receive firing pulse signals from the Diverter Control
Module and produce gate firing pulses to the Diverter SCR’s. When the Diverter SCR
turns on, the respective Diverter Capacitor discharges placing 1300VDC on the cath-
odes of the conducting Converter SCR’s. This Diverter Capacitor discharge reverse
biases the conducting Converter SCR’s forcing them off.

• Diverter Trip Signal - +24VDC is routed through an internal relay contact, DCM,
when an overcurrent condition is detected and a diverter trip is initiated. When the PLC
receives the Diverter Trip Signal, an instant shutdown of the shovel is initiated by the
PLC. The PLC prevents a complete shovel startup for 60 seconds to allow the motor
and Diverter Capacitor to completely dissipate and the Diverter Grid Resistor to cool
down.

• Diverter Gate Block - When an overcurrent condition is detected and a diverter trip is
initiated, this signal is sent to the SDCS-PIN-61 board and tells the Drive Control Mod-
ule to stop generating gate pulses.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.32 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

3.4.7.3 Diverter Capacitor Discharge, Motor Dissipation

When an overcurrent condition is detected and a diverter trip is initiated, the Diverter Control
Module sends gate firing pulses to the proper Diverter SCR providing a path for the Diverter
Capacitor and the built up motor armature magnetic field to discharge. When the Diverter
Capacitor discharges, 1300VDC is placed on the cathodes of the conducting Converter SCR’s.
This reverse biases the conducting Converter SCR’s causing them to turn off.

When the Converter SCR’s stop conducting, the motor loses current flow. Since the motor
armature is a coil, it’s inherent characteristic is to oppose any change in current flow. To pre-
vent this loss in current flow, the motor armature reverses polarity and the magnetic field
across the motor armature discharges through the Diverter SCR and is dissipated across the
Diverter Grid Resistor. Refer to Figure 3-36, Figure 3-37, Figure 3-38, Figure 3-39, Figure 3-
40, Figure 3-41, Figure 3-42 and Figure 3-43 for motor armature dissipation paths.

HOIST #1/ PROPEL


ARMATURE CONVERTER

LOWER (REVERSE)
1300VDC

HOIST (FORWARD)

K06B4D K06B4E

DPH1

K08G4 K06B4A K06B4B

K08K1 K06B2 K06K7

K07A7D K07A7C K07A7B


K08G2
DCH DCH DCH

K07A7A

HAC
HOIST MOTOR ARMATURES
AND FEEDBACK CIRCUITS

Capacitor Discharge Path ES1814b_01


Motor Armature Discharge Path

Figure 3-36: Hoist #1/Propel #1 Diverter Trip Motor Dissipation Path

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.33 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

1300VDC
HOIST ARMATURE
CONVERTER #2

HOIST (FORWARD)

LOWER (REVERSE)

K02B3E K02B3D

DPH2

K02B3A K02B3B K01G1

K02R5 K02B1 K01K1

K03A4B K03A4D K03A4C


DCH DCH DCH K01G4

K03A4A

HOIST MOTOR ARMATURES


AND FEEDBACK CIRCUITS
ES1815c_01 Capacitor Discharge Path
Motor Armature Discharge Path

Figure 3-37: Hoist #2 Diverter Trip Motor Dissipation Path

SWING 1&2 ARMATURE


CONVERTER

REVERSE (LEFT)
1300VDC

FORWARD (RIGHT)

K07A4A
K07A4C K07A4D
DCS DCS DCS

K05K1
K07A4B FORWARD BRIDGE
PROTECTION
K05G4 K06B1 K06K5
K05G2
DPS1
K06B3D K06B3E K06B3A
K05L1
K05H4 K06K6 K06B3B REVERSE BRIDGE
K07A5C K07A5D PROTECTION
K05H1
K07A5A DCS DCS DCS

K07A5B

LEFT FRONT RIGHT FRONT

A1 A2 A1 A2
S1 S2

Capacitor Discharge Path


Motor Armature Discharge Path
ES1824c_01

Figure 3-38: Swing 1 & 2 Forward Bridge Diverter Trip Motor Dissipation Path

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.34 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

SWING 1&2 ARMATURE

1300VDC
CONVERTER

REVERSE (LEFT)

FORWARD (RIGHT)

K07A4A
K07A4C K07A4D
DCS DCS DCS

K05K1
K07A4B FORWARD BRIDGE
PROTECTION
K05G4 K06B1 K06K5
K05G2
DPS1
K06B3D K06B3E K06B3A
K05L1
K05H4 K06K6 K06B3B REVERSE BRIDGE
K07A5C K07A5D PROTECTION
K05H1
K07A5A DCS DCS DCS

K07A5B

LEFT FRONT RIGHT FRONT

A1 A2 A1 A2
S1 S2

Capacitor Discharge Path


Motor Armature Discharge Path
ES1824d_01

Figure 3-39: Swing 1 & 2 Reverse Bridge Diverter Trip Motor Dissipation Path

SWING #3 ARMATURE
CONVERTER

REVERSE (LEFT)
1300VDC

FORWARD (RIGHT)

K03A5D
K03A5H K03A5G
DCS3 DCS3 DCS3

K04K1
K03A5C REVERSE BRIDGE
K02R6 K02B2 K04G1 K04G4 PROTECTION

DPS3
K02B4E K02B4D
K02B4A
K04L1
K02R7 K04H1
K02B4B FORWARD BRIDGE
K03A5F K03A5E K04H3 PROTECTION
DCS3 DCS3 DCS3 K03A5A

K03A5B

A1 A2
S3

Capacitor Discharge Path


Motor Armature Discharge Path ES1825b_01

Figure 3-40: Swing #3 Forward Bridge Diverter Trip Motor Dissipation Path

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.35 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

SWING #3 ARMATURE

1300VDC
CONVERTER

REVERSE (LEFT)

FORWARD (RIGHT)

K03A5D
K03A5H K03A5G
DCS3 DCS3 DCS3

K04K1
K03A5C REVERSE BRIDGE
K02R6 K02B2 K04G1 PROTECTION
K04G4
DPS3
K02B4E K02B4D
K02B4A
K04L1
K02R7 K04H1
K02B4B FORWARD BRIDGE
K03A5F K03A5E K04H3 PROTECTION
DCS3 DCS3 DCS3 K03A5A

K03A5B

A1 A2
S3

Capacitor Discharge Path


Motor Armature Discharge Path ES1825c_01

Figure 3-41: Swing #3 Reverse Bridge Diverter Trip Motor Dissipation Path

CROWD/PROPEL #2 ARMATURE

1300VDC
CONVERTER

FORWARD (CROWD)

REVERSE (RETRACT)

K12A5D
K12A5H K12A5G
DCCP DCCP DCCP
K13K1
K12A5C FORWARD BRIDGE
K11R6 K11B2 K13G1 PROTECTION
K13G4
DPCP
K11B4A K11B4E K11B4D
K13L1
K11B4B K11R7 K13H1 REVERSE BRIDGE
K12A5F K12A5E K13H3 PROTECTION
DCCP DCCP DCCP K12A5A

K12A5B

CAC
A2 C A1
P2AC
A2 P2 A1

Capacitor Discharge Path


Motor Armature Discharge Path ES1817c_01

Figure 3-42: Crowd/Propel #2 Forward Bridge Diverter Trip Motor Dissipation Path

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.36 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

CROWD/PROPEL #2 ARMATURE
CONVERTER

FORWARD (CROWD)

1300VDC

REVERSE (RETRACT)

K12A5D
K12A5H K12A5G
DCCP DCCP DCCP
K13K1
K12A5C FORWARD BRIDGE
K11R6 K11B2 K13G1 PROTECTION
K13G4
DPCP
K11B4A K11B4E K11B4D
K13L1
K11B4B K11R7 K13H1 REVERSE BRIDGE
K12A5F K12A5E K13H3 PROTECTION
DCCP DCCP DCCP K12A5A

K12A5B

CAC
A2 C A1
P2AC
A2 P2 A1

Capacitor Discharge Path


Motor Armature Discharge Path ES1817d_01

Figure 3-43: Crowd/Propel #2 Reverse Bridge Diverter Trip Motor Dissipation Path

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.37 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

3.5 TRANSFER CABINET

3.5.1 General Information

The Transfer Cabinet contains six contactors, interfacing relays and power supply components
for the 100VDC contactor coil supply. An isolated section of the cabinet contains a Remote I/O
assembly.

3.5.2 Location

ES1826g_01

Figure 3-44: Transfer Cabinet - (4100XPB Deck Plan)

3.5.3 Cabinet Layout

Two mechanically interlocked universal type contactors are used to direct field current. The
Crowd Field Contactor (CFC) connects the Crowd/Propel field supply to the Crowd motor.
The Propel Field Contactor (PFC) connects the Crowd/Propel field to the Propel motor.

Four heavy duty transportation type DC contactors are used to direct armature current. The
Hoist Armature Contactor (HAC) connects the Hoist #1/Propel #1 armature converter current
to the Hoist motor. The Propel #1 Armature Contactor (P1AC) connects the Hoist #1/Propel #1
armature converter current to the Propel motor. The Crowd Armature Contactor (CAC) con-
nects the Crowd/Propel #2 armature converter current to the Crowd motor. The Propel #2
Armature Contactor (P2AC) connects the Crowd/Propel #2 armature converter current to the
Propel motor.

Refer to Figure 3-45 for cabinet layout.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.38 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

06 07

05
08

04 09

10

03

02
11

01
12

ES2012_01

Figure 3-45: Transfer Cabinet Front Door Open

LEGEND
01. Propel #2 Armature Contactor (P2AC).
02. Propel #1 Armature Contactor (P1AC).
03. Flex I/O Cabinet.
04. Crowd Field Contactor Relay (CFCR).
05. Propel Armature Contactor Relay (PACR).
06. Contactor Supply 100VDC Rectifier.
07. Hoist/Crowd Armature Contactor Relay (HCACR).
08. Propel Field Contactor Relay (PFCR).
09. Propel Field Contactor (PFC).
10. Crowd Field Contactor (CFC).
11. Hoist Armature Contactor (HAC).
12. Crowd Armature Contactor (CAC).

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.39 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

A separate compartment contains the Flex I/O Assembly panel. This assembly consists of the
terminal bases, various I/O modules, RTD Modules and the power supply for the RTD’s. Refer
to Figure 3-46.

04
03
05

05
02

06

06

07

07

01

08

ES2013_01

Figure 3-46: Flex I/O Cabinet

LEGEND
01. Heater.
02. Wire Duct.
03. Thermostat.
04. Remote I/O Adapter.
05. 120VAC Input Module.
06. 120VAC Output Module.
07. 120VAC RTD Input Module.
08. 24VDC Power Supply.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.40 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

3.5.4 Transfer Cabinet Operation

Refer to Figure 3-47, Figure 3-48 and Figure 3-49 for this explanation.

120VAC
Flex I/O Transfer Cabinet

CFCR Crowd Field


Contactor Relay

PFCR Propel Field


Contactor Relay
Hoist/Crowd
HCACR
Armature Contactor
Relay
PACR Propel Armature
Contactor Relay

ES2017_01

Figure 3-47: Field and Armature Contactor Relays

+100VDC -100VDC

PFCR PFCR
PFC Propel Field
Contactor
CFCR CFCR CFC Crowd Field
Contactor

PACR PACR HAC


P1AC Propel #1 Armature
Contactor
PACR PACR CAC P2AC Propel #2 Armature
Contactor

HCACR HCACR P1AC


HAC Hoist Armature
Contactor
HCACR HCACR P2AC CAC Crowd Armature
Contactor

ES2016_01

Figure 3-48: Field and Armature Contactors

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.41 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

120VAC
Flex I/O Transfer Cabinet

P1AC P2AC
Propel Armature
Contactors
CAC
Crowd Armature
Contactor
HAC
Hoist Armature
Contactor
CFC
Crowd Field
Contactor
PFC
Propel Field
Contactor

Transfer Cabinet
Door Interlock

ES2018_01

Figure 3-49: Field and Armature Contactor Flex I/O Inputs

A Flex I/O 120VAC Output Module in the Transfer Cabinet provides the output to energize the
Crowd Field Contactor Relay (CFCR), Propel Field Contactor Relay (PFCR), Hoist/Crowd
Armature Contactor Relay (HCACR) and/or Propel Armature Contactor Relay (PACR). Refer
to Figure 3-47.

The Contactor Relays have normally open contacts in series with the Propel Field Contactor
(PFC), Crowd Field Contactor (CFC), Propel #1 Armature Contactor (P1AC), Propel #2
Armature Contactor (P2AC), Hoist Armature Contactor (HAC) and/or Crowd Armature Con-
tactor (CAC). When the relays are energized, the normally open contacts close providing con-
tinuity to energize the associated contactor. Refer to Figure 3-48.

As long as the HAC and CAC Contactors are de-energized, normally closed contacts associ-
ated with these contactors allow P1AC and P2AC to energize. If HAC and CAC are energized,
the normally closed contacts open preventing P1AC and P2AC from energizing. Refer to Fig-
ure 3-48.

As long as the P1AC and P2AC Contactors are de-energized, normally closed contacts associ-
ated with these contactors allow HAC and CAC to energize. If P1AC and P2AC are energized,
the normally closed contacts open preventing HAC and CAC from energizing. Refer to Figure
3-48.

When the contactors are energized, a normally open contact associated with the contactor
closes providing an input to a Flex I/O 120VAC Input Module in the Transfer Cabinet. Refer to
Figure 3-49. This input confirms with the PLC Program that the associated contactor is either
energized or de-energized.

The 120VAC RTD Input Modules monitor temperature for the following group of RTD’s:

• Hoist Drum Side Stand Bearing End.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.42 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

• Hoist Drum Gear Box Bearing.

• Rear Swing Motor Bearing, Drive End.

• Rear Swing Motor Bearing, Commutator End.

• Rear Swing Motor Interpole.

• Rear Swing Motor Shunt Field.

• Front Hoist Motor Bearing, Drive End.

• Front Hoist Motor Bearing, Commutator End.

• Front Hoist Motor Interpole.

• Front Hoist Motor Shunt Field.

• Rear Hoist Motor Bearing, Drive End.

• Rear Hoist Motor Bearing, Commutator End.

• Rear Hoist Motor Interpole.

• Rear Hoist Motor Shunt Field.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.43 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

3.6 CONTROL CABINET

3.6.1 General Information

The Control Cabinet contains the electronic systems and components for controlling the shovel
motions. The cabinet has windowed doors on the left side for monitoring status indicators on
the Drive Control Modules. The Control Cabinet on the 4100XPB Shovel contains the follow-
ing subassemblies:

• External maintenance meters, switches, pushbuttons and circuit breakers.

• Armature control Drive Control Modules.

• Field control Drive Control Modules.

• SLC 5/05 and associated components.

• AC80 drive controller.

• Touch Panel for commissioning, service, maintenance and troubleshooting.

3.6.2 Location

ES1826h_01

Figure 3-50: Control Cabinet - (4100XPB Deck Plan)

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.44 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

3.6.3 Cabinet Layout

3.6.3.1 External Components

The Control Cabinet contains external components used by MinePro Service Personnel to
assist in shovel maintenance. There are two separate areas of external indicating and/or control
devices found on the cabinet. Refer to Figure 3-51.

ES2019_01

Figure 3-51: Control Cabinet Front Door Controls

The center door contains analog meters which display motor Field Current, Armature Current
and Armature Voltage. The Armature Voltage Meter also doubles as a voltmeter to be used in
conjunction with the Meter Selector Switch. Elapsed time meters accumulate the operating
times for the Hoist, Crowd, Swing and Propel motions after their brakes are released.

Two selector switches are provided. The Test Selector Switch sets or defines the operational
mode of the shovel. The Test Selector Switch can be set to the following positions:

• Run - This is the normal position for operation of the shovel.

• Armature Test - This position is used to perform motor armature testing. Only armature
current is applied to the motors during this test.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.45 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

• Field Test - This position is used to perform motor field testing. Only field current is
applied to the motors during this test.

• Control Test - This position is used in testing the control system of the shovel. No cur-
rent is applied to the motors, only control voltages are present in the control system
during this test.

• Auxiliary Test - This position is used to test all shovel auxiliary motors and systems.

The Meter Selector Switch selects the motion to be displayed on the analog meters. The Man-
ual KVAR Reference or RPC Step Indication Level can also be displayed on the Armature
Voltage Meter when selected with this switch. Refer to Figure 3-52.

ES2020_01

Figure 3-52: Control Cabinet Meter Panel

On the bottom half of the middle door, the Operator Cab Control keyswitch is used to select
which cab, Left Hand or Right Hand, is to operate the shovel. This keyswitch is only available
with dual cab shovels. If this is a single cab shovel, this keyswitch position will be plugged.
Refer to Figure 3-53.

EMERGENCY
STOP
OPERATOR CAB CONTROL FAULT LUBE/PLS TEST SCREEN
CONTROL RESET
LH CAB RH CAB RUN PROGRAM RUN ENABLE
E
OP
T

ST
ES

OP
P
TO

E
S

S TO
E P

ES2021_01

Figure 3-53: Control Cabinet Front Panel Pushbuttons

The Control Fault Reset pushbutton provides input to the control system for clearing fault con-
ditions.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.46 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

The Emergency Stop pushbutton (E-Stop) is used in shutting down the entire shovel in emer-
gency conditions.

The Lube/PLS keyswitch is used to access programming screens on the Touch Panel for the
Lube System Timing and Programmable Limit Switches.

The Test Screen keyswitch is used to access the Commissioning Test Screen on the Touch
Panel during shovel commissioning and testing.

The right door contains the Power Circuit 1 I/O Circuit Breaker (IO1CB), Open Architecture
Platform Breaker (OAP), Power Circuit 2 I/O Circuit Breaker (IO2CB), Auxiliary Cabinet I/O
Circuit Breaker (AUX IO CB), Relay Supply Circuit Breaker (RSCB) and Auxiliary Cabinet
Starter Power Circuit Breaker (AXSTCB). Refer to Figure 3-54.
AUXIOCB

AXSTCB
IO1CB

IO2CB

RSCB
OAP

ON
ON ON ON ON ON

10 10 10 10 15
20

OFF
OFF OFF OFF OFF OFF

ES2023_01

Figure 3-54: Control Cabinet Door Circuit Breakers

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.47 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

3.6.3.2 Internal Components

The front left side of the control cabinet is a three part windowed door which opens to reveal
the Armature Drive Control Modules, Touch Panel, relays, fuses, transformers, Feedback
Board, AC outlets and RPC Firing Board.

The top half of the left side of the cabinet houses the Armature Drive Control Modules and
Touch Panel. Refer to Figure 3-55.

04

05
03

02

01

06

ES2024_01

Figure 3-55: Control Cabinet Front Top Left Side

LEGEND
01. Hoist #2 Armature Drive Control Module.
02. Swing 1&2 Armature Drive Control Module.
03. Hoist #1/Propel #1 Armature Drive Control Module.
04. Touch Panel.
05. Crowd/Propel #2 Armature Drive Control Panel.
06. Laptop Table Work Center.

Note: The Swing #3 Armature Drive Control Module is behind the Laptop Table Work
Center and is not visible from this angle in the picture.

The bottom half of the left side of the cabinet contains relays, fuses, transformers, Feedback
Board, AC outlets and RPC Firing Board. Refer to Figure 3-56.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.48 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

01 02 03 04 05 06 07 08 09 10

ES2025_01
11 12 13 14 15 16

Figure 3-56: Control Cabinet Front Bottom Left Side

LEGEND
01. Master Drive Relay (MDR).
02. Main Phase Sensing Relay (PSR).
03. Main Transformer Contactor Relay (MTCR).
04. Master Control Relay (MCR).
05. Propel Strobe Lights Relay (SLR).
06. Field Supply Door Relay (FSDO).
07. Fuse Block.
08. Fuse Block.
09. Drive Synchronizing Voltage Transformer.
10. RPC Synchronizing Transformer.
11. Motion Feedback Circuit Board.
12. KVAR Sensing Potential Transformer.
13. KVAR Transducer.
14. KVAR Sensing Potential Transformer.
15. Drive E-Stop Relay (DER).
16. RPC Firing Board.

When the Control Cabinet center section door is open, on the back inside of the door is the Test
Reference Panel. Refer to Figure 3-57. The Test Reference Panel includes test jacks to monitor
the following signals:

• Armature Voltage Feedback (Vaƒb) for each motion.

• Armature Current Feedback (Iaƒb) for each motion.

• Field Current Feedback (Ifƒb) for each motion.

• Field Reference for each motion.

• Operator Reference for each motion.

• KVAR signal.

• RPC Step Reference.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.49 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

• An RPC Manual Input potentiometer is provided for testing the RPC Step Reference.

VAFB IAFB IFFB FLD REF OPER REF

TH1 TH2 TH3 TH4 TH5

HOIST

TC1 TC2 TC3 TC4 TC5

CROWD

TS1A TS2A TS3 TS4 TS5

SWING 1&2

RPC

KVAR STEPS
TS1B TS2B TR1 TR2

SWING 3

MANUAL
INPUT

ES2028_01

Figure 3-57: Test Reference Panel

The center section of the Control Cabinet houses the SLC 5/05 Programmable Logic Control-
ler and associated I/O Modules, AC80 Drive Controller and associated I/O Modules, circuit
breakers and filters. Refer to Figure 3-58.

03

04

02

01

01

ES2029_01

Figure 3-58: Control Cabinet Center Section

LEGEND
01. Line Filters for Constant Voltage Supply Transformer.
02. Circuit Breakers, Refer to Figure 3-59.
03. SLC 5/05 and associated I/O Modules.
04. AC80 and associated I/O Modules.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.50 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

24VSCB
CVSCB

PGCB
CSCB

IRCB
ON ON ON ON ON

15 15 15 10 10

OFF OFF OFF OFF OFF

ES2030_01

Figure 3-59: Control Cabinet Inside Center Section Circuit Breakers

The right side of the Control Cabinet houses the Field Drive Control Modules. Refer to Figure
3-60.

04

03

05

02

06

01

ES2031_01

Figure 3-60: Control Cabinet Right Section

LEGEND
01. Varistors.
02. Crowd/Propel Field Drive Control Module.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.51 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

03. Swing Field Drive Control Module.


04. Hoist Field Drive Control Module.
05. Field Converter Fan Transformer.
06. Resistors.

3.6.4 Control Cabinet Operation

Some of the items in the Control Cabinet are discussed in other sections of this Electrical Man-
ual. Refer to the following sections for a detailed description:

• RPC Components - Subsection 3.3.

• SLC 5/05 - Section 4.

• AC80 - Section 5.

• Drive Control Modules - Section 6.

• Touch Panel - Section 8.

3.6.4.1 Master Drive Relay (MDR)

Figure 3-61 and Figure 3-62 show the path to energize the Master Drive Relay (MDR).

Relay Supply Emergency Emergency


Lighting Secondary Circuit Breaker Stop Stop Master
Circuit Breaker RSB RSCB Operators Control Drive
Console Cabinet Relay
3 MDR
208VAC

Main 120VAC
Panelboard
Shunt
ES2032_01
Trip

Figure 3-61: Master Drive Relay 60Hz Shovel One Line Diagram

Auxiliary Transformer Relay Supply Emergency Emergency


Secondary Circuit Breaker Stop Stop Master
Circuit Breaker RSB RSCB Operators Control Drive
Console Cabinet Relay
3Ø MDR
200VAC

Main 110VAC
Panelboard
Shunt
ES2032a_01
Trip

Figure 3-62: Master Drive Relay 50Hz Shovel One Line Diagram

When de-energized, MDR disables the Armature Drive Control Modules by removing power
to the Drive Synchronizing Voltage Transformer, ultimately removing power to the SDCS-
PIN-61 Board on the Armature DCM’s. However, since power is still being applied to the
SDCS-POW-1 Board, the Armature DCM’s are able to retain all fault logs and data recordings.
Refer to Figure 3-63.

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SECTION 3, Version 0 - 9/02 - 3.52 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

3 VAC

SB

To Drive Control
Module Power Supplies
SDCS-POW-1 Board
CSCB MDR

PSR

RPC Synchronizing
Transformer
Drive Synchronizing
Voltage Transformer

ES2033_01
To Armature Drive Control
Module Power Supplies
SDCS-PIN-61 Board

Figure 3-63: Master Drive Relay

3.6.4.2 Main Phase Sensing Relay (PSR)

The Main Phase Sensing Relay (PSR), shown in Figure 3-63, monitors the Control Supply sec-
ondary of the Auxiliary/Field Transformer for proper phase sequencing. The relay energizes
when phase sequencing is correct. A normally open contact associated with PSR closes telling
the PLC that phase sequencing is correct. Refer to Figure 3-64.

+24VDC Rack I/O


Input Module

PSR Main Phase


Sensing Relay

ES2035_01

Figure 3-64: Main Phase Sensing Relay PLC input

PSR is factory set to drop out at 170VAC between phases. If PSR senses incorrect phase
sequence, it will remain de-energized and prevent the shovel from starting. A Main Phase
Sensing Relay fault will be displayed on the Touch Panel Fault Screen.

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Section 3, Cab Des and Op.fm - 3.53 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

Two Status LED’s are located on PSR. During normal conditions the NORM LED will be illu-
minated. When incorrect phase sequence is detected the TRIP LED will be illuminated. Refer
to Figure 3-65.

3
PHASE
POWER MONITOR

NORM TRIP

4 5
3 6
2 7
1 8

ES2034_01

Figure 3-65: Main Phase Sensing Relay

3.6.4.3 Main Transformer Contactor Relay (MTCR)

The Main Transformer Contactor Relay is energized by the PLC at shovel start. Refer to Figure
3-66.

120VAC
Rack I/O
Output Module

MTCR
Main Transformer
Contactor Relay

ES2036_01

Figure 3-66: Main Transformer Contactor Relay

When energized, normally open contacts associated with MTCR close providing a path to
energize the Main Transformer Contactor. Refer to Figure 3-67.

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SECTION 3, Version 0 - 9/02 - 3.54 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

120VAC Neutral

MTC CC
CC

CC

MTCR
MTCR

ES2037_01

Figure 3-67: Main Transformer Contactor - Initial Shovel Startup

When MTCR contacts close, initial start up current flow is through MTC coils and the nor-
mally closed contacts of MTC, CC. When MTC energizes, the normally closed contacts open,
routing current flow through the series resistors. The series resistors limit the current flow
through MTC establishing a holding current to maintain MTC energized. Refer to Figure 3-68.

120VAC Neutral

MTC CC
CC

CC

MTCR
MTCR

ES2037a_01

Figure 3-68: Main Transformer Contactor - Holding Current

When MTC energizes, normally open contacts associated with MTC close applying high volt-
age to the primary of the Main Transformer. Refer to Subsection 2.4 for a description of the
High Voltage Power Distribution after MTC energizes.

3.6.4.4 Master Control Relay

Figure 3-69 and Figure 3-70 show the path to energize the Master Control Relay (MCR).

Relay Supply Emergency Emergency


Lighting Secondary Circuit Breaker Stop Stop Master
Circuit Breaker RSB RSCB Operators Control Control
Console Cabinet Relay
3Ø MCR
208VAC

Main 120VAC
Panelboard
Shunt ES2032b_01
Trip

Figure 3-69: Master Control Relay 60Hz Shovel One Line Diagram

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.55 - SECTION 3, Version 0 - 9/02
Cabinet Description and Operation 4100XPB Electrical Manual

Auxiliary Transformer Relay Supply Emergency Emergency


Secondary Circuit Breaker Stop Stop Master
Circuit Breaker RSB RSCB Operators Control Control
Console Cabinet Relay
3Ø MCR
200VAC

Main 110VAC
Panelboard
Shunt ES2032c_01
Trip

Figure 3-70: Master Control Relay 50Hz Shovel One Line Diagram

When the MCR energizes, normally open contacts associated with MCR close applying two
phases of the Control Supply VAC to the 24VDC Supply. Refer to Figure 3-71.

3
VAC

24VDC
SUPPLY
24VSCB MCR
AC OUT (+)
MCR
AC OUT (-)

ES2038_01

Figure 3-71: Master Control Relay - 24VDC Supply

Normally open contacts associated with MCR close applying 120VAC from the CVS Trans-
former through the Auxiliary Cabinet I/O Circuit Breaker (AUXIOCB) to the Instant Overload
Relay (QTTM) and some of the Flex I/O Modules in the Auxiliary Cabinet. Refer to Figure 3-
72. Refer to Subsection 3.7.4.4 for an operational description of QTTM.

From CVS
Transformer

Main
TTMT Transformer
O.L.

AUXIOCB MCR

Flex I/O
IO2CB MCR Auxiliary
Cabinet QTTM Instant
O.L.
1 2 3 4 5 Relay
IO1CB MCR

MTOAR

ES2039_01

Figure 3-72: Master Control Relay - AUXIOCB

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SECTION 3, Version 0 - 9/02 - 3.56 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

Normally open contacts associated with MCR close applying 120VAC from the CVS Trans-
former through the Power Circuit 2 I/O Circuit Breaker (IO2CB) to the Ground Fault Relay
Main, Ground Fault Relay Main Auxiliary and Ground Fault Relay Field. Refer to Subsection
3.2.4 for an operational description of the Ground Fault Relays.

This path also provides 120VAC to SLC 5/05 Rack I/O Modules, Flex I/O Modules in the Con-
verter Cabinet, Flex I/O Modules in the Transfer Cabinet, Flex I/O Modules in the RPC Cabi-
net and Flex I/O Modules in the Lube Room. Refer to Figure 3-73.

1 4
3 T10H2 2
24VDC
Power Supply
From CVS
Flex I/O
Transformer
Rack I/O RPC
Cabinet

AUXIOCB MCR

IO2CB MCR

IO1CB GFRM Flex I/O


MCR
Transfer
Cabinet

GFRA

1 4
3 U18C2 2
24VDC
Power Supply

GFRF
Flex I/O
Lube

Flex I/O
Converter
ES2040_01 Cabinet

Figure 3-73: Master Control Relay - IO2CB

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Section 3, Cab Des and Op.fm - 3.57 - SECTION 3, Version 0 - 9/02
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Normally open contacts associated with MCR close applying 120VAC from the CVS Trans-
former through the Power Circuit 1 I/O Circuit Breaker (IO1CB) to the Flex I/O Lower
through the Collector Ring Assembly. Refer to Figure 3-74.

From CVS
Transformer

AUXIOCB MCR

IO2CB MCR

IO1CB MCR LCSB


17

16

LINE
LOAD

1 4
3 LO51D5 2
24VDC
Power Supply

Flex I/O
Lower

ES2041_01

Figure 3-74: Master Control Relay - IO1CB

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SECTION 3, Version 0 - 9/02 - 3.58 - Section 3, Cab Des and Op.fm
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Normally open contacts associated with MCR close applying one phase of the Control Supply
VAC through the Auxiliary Cabinet Starter Power Circuit Breaker to the Auxiliary Cabinet
Flex I/O. Refer to Figure 3-75.


VAC

Relay Supply
Circuit Breaker
RSCB SLPB
Shunt Auxiliary Contact
Trip

Auxiliary Cabinet
Starter Power
Circuit Breaker Flex I/O
AXSTCB MCR Auxiliary Cabinet

ES2042_01

Figure 3-75: Master Control Relay - AXSTCB

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.59 - SECTION 3, Version 0 - 9/02
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3.6.4.5 Propel Strobe Light Relay (SLR)

Propel Strobe Lights are an option available for the 4100XPB Shovel. The Propel Strobe Light
Relay, SLR, is energized via the Rack I/O when the Operator transfers to Propel. Refer to Fig-
ure 3-76.

SLR
Propel Srobe
Lights (Optional)

ES2044_01

Figure 3-76: Propel Strobe Light Relay

When energized, normally open contacts associated with SLR close providing a path to ener-
gize the strobe lights. The strobe lights are a visible warning that the shovel has been trans-
ferred to Propel. Refer to Figure 3-77.

SLR

SLR
Strobe
Lights
SLR

ES2045_01

Figure 3-77: Propel Strobe Lights - Optional Equipment

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


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4100XPB Electrical Manual Cabinet Description and Operation

3.6.4.6 Field Supply Door Relay (FSDO)

The Field Supply Door Relay, (FSDO) is energized via the Rack I/O when the Control Cabinet
Door is closed. Refer to Figure 3-78.

Control Cabinet
Door Interlock FSDO

ES2046_01

Figure 3-78: Field Supply Door Relay

As long as the Control Cabinet doors are closed, FSDO will remain energized. Normally
closed contacts associated with FSDO open breaking the current path through the Flex I/O
Module in the Transfer Cabinet. This prevents the Field Breaker Shunt Trips from energizing.
The Hoist Field, Swing Field and Crowd/Propel Field Circuit Breakers will remain closed.
Refer to Figure 3-79.

120VAC
Flex I/O Transfer Cabinet

Field Breaker
Control Cabinet
Shunt Trip
Door Interlock FSDO HFCB
Hoist

FSDO SFCB
Swing

FSDO CFCB
Crowd/Propel

ES2017a_01

Figure 3-79: Field Supply Door Relay - Field Breaker Shunt Trip

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Section 3, Cab Des and Op.fm - 3.61 - SECTION 3, Version 0 - 9/02
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If the Control Cabinet doors are opened, FSDO will de-energize. The normally closed contacts
associated with FSDO close completing the path for current through the Flex I/O Module in
the Transfer Cabinet to energize the Field Breaker Shunt Trips. The Hoist Field, Swing Field
and Crowd/Propel Field Circuit Breakers will trip open.

3.6.4.7 Drive Synchronizing Voltage Transformer

The Drive Synchronizing Voltage Transformer steps down 3Ø 240VAC to 3Ø 34VAC to be


used as a supply voltage by the Armature Drive Control Modules. Figure 3-80 shows a sche-
matic diagram of the transformer.

3 VAC

SB

To Drive Control
Module Power Supplies
SDCS-POW-1 Board
CSCB MDR

PSR

RPC Synchronizing
Transformer
Drive Synchronizing
Voltage Transformer

ES2033_01
To Armature Drive Control
Module Power Supplies
SDCS-PIN-61 Board

Figure 3-80: Drive Synchronizing Voltage Transformer

As the voltage is applied and current flows through the primary, magnetic lines of force are
generated. During the time current is increasing in the primary, magnetic lines of force expand
outward from the primary and cut the secondary. A voltage is induced into a coil when mag-
netic lines cut across it. Therefore, the voltage across the primary causes a voltage to be
induced across the secondary.

The secondary voltage of a transformer may be either in phase or out of phase with the primary
voltage. This depends on the direction in which the windings are wound and the arrangement
of the connections to the external circuit. This means that the two voltages may rise and fall
together or one may rise while the other is falling.

The Drive Synchronizing Voltage Transformer secondary voltage is in phase with the primary
and is referred to as a Like-Wound Transformer. Phase indicating dots are used to indicate
points on a transformer schematic symbol that have the same polarity.

The 34VAC induced into the secondary winding of the transformer is determined mainly by
the ratio of the number of turns in the primary to the number of turns in the secondary and by
the amount of voltage applied to the primary.

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The 3Ø 34VAC is used by the SDCS-PIN-61 Board in the Armature DCM’s as a supply volt-
age and to synchronize the firing pulses to the Converter SCR’s. Refer to Figure 3-81. Refer to
Subsection 6.7 for an operational description of the SDCS-PIN-61 Board.

3 34VAC
Drive Synchronizing
Voltage Transformer

3 34VAC to
Armature Drive
Control Modules
SDCS-PIN-61 Board

ES2047_01

Figure 3-81: SDCS-PIN-61 Board

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Section 3, Cab Des and Op.fm - 3.63 - SECTION 3, Version 0 - 9/02
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3.6.4.8 Motion Feedback Circuit Board

The Motion Feedback Circuit Board contains precision high voltage resistors used to provide
armature voltage feedback to the Armature Drive Control Modules. The circuit board contains
the following types of resistors:

• 8MΩ ± 0.5%

• 100KΩ ± 1%

• 499KΩ ± 1%

The resistors are arranged in voltage divider networks. The voltage divider networks are sepa-
rated into six sections specific to each motion. Refer to Figure 3-82, Figure 3-83, Figure 3-84
and Figure 3-85.

Hoist #1/Propel #1
Armature Voltage
Feedback

Hoist #2 Armature
Voltage Feedback

ES2048_01

Figure 3-82: Hoist #1/Propel #1 and Hoist #2 Armature Voltage Feedback

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SECTION 3, Version 0 - 9/02 - 3.64 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

Swing #1 Armature
Voltage Feedback

Swing #2 Armature
Voltage Feedback

ES2049_01

Figure 3-83: Swing 1&2 Armature Voltage Feedback

Swing #3 Armature
Voltage Feedback

ES2050_01

Figure 3-84: Swing #3 Armature Voltage Feedback

Crowd/Propel #2
Armature Voltage
Feedback

ES2051_01

Figure 3-85: Crowd/Propel #2 Armature Voltage Feedback

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Section 3, Cab Des and Op.fm - 3.65 - SECTION 3, Version 0 - 9/02
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3.6.4.9 Drive E-Stop Relay (DER)

Figure 3-86 and Figure 3-87 show the path to energize the Drive E-Stop Relay (DER).

Relay Supply Emergency Emergency


Lighting Secondary Circuit Breaker Stop Stop Drive
Circuit Breaker RSB RSCB Operators Control E-Stop
Console Cabinet Relay
3Ø DER
208VAC

Main 120VAC
Panelboard
Shunt
ES2032d_01
Trip

Figure 3-86: Drive E-Stop Relay 60Hz Shovel One Line Diagram

Auxiliary Transformer Relay Supply Emergency Emergency


Secondary Circuit Breaker Stop Stop Drive
Circuit Breaker RSB RSCB Operators Control E-Stop
Console Cabinet Relay
3Ø DER
200VAC

Main 110VAC
Panelboard
Shunt
ES2032e_01
Trip

Figure 3-87: Drive E-Stop Relay 50Hz Shovel One Line Diagram

When DER energizes, normally open contacts associated with DER close applying 24VDC
from the 24VDC Supply to the SDCS-CON-2 boards on all five Armature Drive Control Mod-
ules. Refer to Figure 3-88.

DER
24VDC

24VDC to other
Armature DCM's

ES2052_01

Figure 3-88: Drive E-Stop Relay - SDCS-CON-2 Board

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SECTION 3, Version 0 - 9/02 - 3.66 - Section 3, Cab Des and Op.fm
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The 24VDC input enables the Drive Control Module to produce control pulses to the Con-
verter SCR’s. When the 24VDC is removed, the ability of the Drive Control Module to
develop control pulses is suppressed.

3.7 AUXILIARY CABINET

3.7.1 General Information

The Auxiliary Cabinet contains thermal overload protection for the Main Transformer, Instant
Overload Relay (QTTM), motor starters and circuit breakers for auxiliary motors, relays for
the heater systems and Dipper Trip circuit breaker, motor starter and contactor.

3.7.2 Location

ES1826i_01

Figure 3-89: Auxiliary Cabinet - (4100XPB Deck Plan)

3.7.3 Cabinet Layout

Auxiliary motor starters occupy the majority of the Auxiliary Cabinet. Refer to Table 3-4 and
Table 3-5.

The top left panel of the Auxiliary Cabinet houses the Heater Interlock Relay (HIR), Machine
House Heater Relay (MHHR), Main Transformer Overloads (TTMT) and Instant Overload
Relay (QTTM).

The top right panel of the Auxiliary Cabinet houses the Flex I/O Remote I/O Adapter and I/O
Modules.

Refer to Figure 3-90 for component locations in the Auxiliary Cabinet.

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Section 3, Cab Des and Op.fm - 3.67 - SECTION 3, Version 0 - 9/02
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Figure 3-90: Auxiliary Cabinet Layout

LEGEND:
01. Heater Interlock Relay (HIR).
02. Main Transformer Thermal Overloads (TTMT).
03. Instant Overload Relay (QTTM).
04. Machine House Heater Relay (MHHR).
05. Remote I/O Adapter Module.
06. 120V Input Module.
07. Relay Output Module.
08. Relay Output Module.

Starter Number Auxiliary Motor Description H.P. Reference


1 Front Hoist Blower Motor 20
2 Rear Hoist Blower Motor 20
3 Left Front Swing Blower Motor 7.5
4 Right Front Swing Blower Motor 7.5

Table 3-4: 4100XPB Auxiliary Motor Starters (60Hz Shovel)

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Starter Number Auxiliary Motor Description H.P. Reference


5 Rear Swing Blower Motor 7.5
6 Hoist Lube Pump Motor 1.0
7 Motor Heater Contactor 1800W
8 Transformer Heater Contactor 1500W
9 Crowd Blower Motor 15
10 Hoist Converter Blower Motor 2.0
11 Swing Converter Blower Motor 2.0
12 Crowd Converter Blower Motor 2.0
13 RPC ½ & 1 Bank Blower Motor 2.0
14 RPC Switch Blower Motor 2.0
15 RPC Bank 2 & 3 Blower Motor 2.0
16 RPC Bank 4 Blower Motor 2.0
17 Dipper Trip Motor #1 15
18 Dipper Trip Motor #2 15
19 Left Filter Bleed Blower 5
20 Right Filter Bleed Blower 5
21 Windshield Wiper Motor 1
22 Not Used
23 Control Cabinet Blower 0.5
24 Crowd Belt Adjust Pump Motor 1.5
25 Left Machinery House Blower 30
26 Dipper Trip Contactor #1 15
27 Lighting Contactor 45A
28 Spare
29 Dipper Trip Contactor #2 15
30 Right Machinery House Blower 30

Table 3-4: 4100XPB Auxiliary Motor Starters (60Hz Shovel)

Starter Number Auxiliary Motor Description H.P. Reference


1 Front Hoist Blower Motor 15
2 Rear Hoist Blower Motor 15
3 Left Front Swing Blower Motor 5
4 Right Front Swing Blower Motor 5
5 Rear Swing Blower Motor 5
6 Hoist Lube Pump Motor 1.0

Table 3-5: 4100XPB Auxiliary motor Starters (50Hz Shovel)

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 3, Cab Des and Op.fm - 3.69 - SECTION 3, Version 0 - 9/02
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Starter Number Auxiliary Motor Description H.P. Reference


7 Motor Heater Contactor 1800W
8 Transformer Heater Contactor 1500W
9 Crowd Blower Motor 10
10 Hoist Converter Blower Motor 2.0
11 Swing Converter Blower Motor 2.0
12 Crowd Converter Blower Motor 2.0
13 RPC ½ & 1 Bank Blower Motor 2.0
14 RPC Switch Blower Motor 2.0
15 RPC Bank 2 & 3 Blower Motor 2.0
16 RPC Bank 4 Blower Motor 2.0
17 Dipper Trip Motor #1 15
18 Dipper Trip Motor #2 15
19 Left Filter Bleed Blower 5
20 Right Filter Bleed Blower 5
21 Windshield Wiper Motor 1
22 Not Used
23 Control Cabinet Blower 0.5
24 Crowd Belt Adjust Pump Motor 1.5
25 Left Machinery House Blower 30
26 Dipper Trip Contactor #1 15
27 Lighting Contactor 45A
28 Spare
29 Dipper Trip Contactor #2 15
30 Right Machinery House Blower 30

Table 3-5: 4100XPB Auxiliary motor Starters (50Hz Shovel)

3.7.4 Auxiliary Cabinet Operation

The Auxiliary Cabinet contains the Motor Starters for all the auxiliary motors, relays for the
heater system, thermal overload relay for the Main Transformer, a Control Transformer for
shunt tripping the Main Auxiliary Circuit Breaker, fuses to protect the wiring to the voltmeter
and Remote I/O modules.

Refer to Subsection 4.23 for a detailed description o the Flex I/O Modules.

3.7.4.1 Motor Starters

The lower panel of the Auxiliary Cabinet contain the motor starters for all auxiliary motors.

Many of the motor starters consist of the same basic components. Protection for a particular
motor is achieved by the correct trip level setting on the breaker and the correct heater ele-

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.70 - Section 3, Cab Des and Op.fm
4100XPB Electrical Manual Cabinet Description and Operation

ments for the Thermal Overloads. When replacing starters the trip settings and heater elements
must remain the same value as before.

The motor starters receive 120VAC from the Flex I/O Relay Output Modules in the Auxiliary
Cabinet. The 120VAC is applied to the motor starter coil causing the motor starter to energize.
When the motor starter energizes, normally open contacts associated with the motor starter
close applying 3Ø VAC to the auxiliary motor. Refer to Figure 3-91.

Motor Starter Neutral

Auxiliary
MS
Motor
3 MS
VAC
MS

120VAC
Flex I/O Relay Output Module Motor Starter
Auxiliary Cabinet Coil
MS

ES2054_01

Figure 3-91: Motor Starter

Refer to the 4100XPB Commissioning Manual for an explanation on programming Cutler-


Hammer Motor Starters.

3.7.4.2 Heater Interlock Relay (HIR)

The Heater Interlock Relay is energized at shovel start by a Flex I/O Relay Module in the Aux-
iliary Cabinet. When energized, normally closed contacts associated with HIR open preventing
the Main Transformer Heater Contactor, Motor Heater Contactor and Machine House Heater
Relay (MHHR) from energizing. Refer to Figure 3-92.

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Section 3, Cab Des and Op.fm - 3.71 - SECTION 3, Version 0 - 9/02
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120VAC Neutral
Flex I/O
Auxiliary Cabinet THC To Main
Transformer
THC Heaters
VAC
THC
HIR
Transformer Heater
HIR Contactor
VAC

MHC
MHC To Crowd,
VAC Swing and Hoist
MHC Motor Heaters

Motor Heater
HIR MHT1 Contactor

Motor Heaters
Switch

HIR MHES1 MHHR

House Heaters
Switch Machine House
Heater Relay
ES2055_01

Figure 3-92: Heater Interlock Relay (HIR)

When the shovel is shutdown, HIR is de-energized, the normally open contacts associated with
HIR close applying VAC to the Transformer Heater Contactor. The Transformer Heater Con-
tactor energizes and normally open contacts associated with the Transformer Heater Contactor
close applying VAC to the Main Transformer Heaters.

With the shovel shutdown, normally closed contacts associated with HIR close applying VAC
to the Motor Heater Switch (MHT1) on the Right Hand Operator Console. The Operator can
close MHT1 applying VAC to the Motor Heater Contactor. Normally open contacts associated
with the Motor Heater Contactor close applying VAC to the Crowd, Swing and Hoist Motor
Heaters. Refer to Subsection 3.9 for a detailed description of the Propel Motor Heaters.

With the shovel shutdown, normaly closed contacts associated with HIR close applying VAC
to the House Heaters Switch (MHES1) on the Right Hand Operator Console. The Operator can
close MHES1 applying VAC to the Machine House Heater Relay (MHHR). The VAC applied
to MHHR causes the relay to energize. Refer to Subsection 3.7.4.5 for a detailed description of
MHHR.

3.7.4.3 Main Transformer Thermal Overloads (TTMT)

The Main Transformer Thermal Overloads are heater element type thermal overload relays
connected to the Main Transformer Primary via Current Transformers.

The heat producing element of TTMT is brazed to a eutectic alloy actuator assembly. A ratchet
wheel is attached to one end of the actuator. The ratchet wheel engages a paw1 which holds the
relay contacts closed. As current flows through the heat producing element, heat is transferred
to the actuator by conduction and radiation. A sustained current flow will cause the eutectic
alloy to melt. When the eutectic alloy melts the ratchet wheel turns and normally closed con-
tacts associated with the TTMT are opened. The eutectic alloy in the heater element melts at
125°C.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 3, Version 0 - 9/02 - 3.72 - Section 3, Cab Des and Op.fm
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The normally closed contacts associated with TTMT provide an input to a Flex I/O Input Mod-
ule in the Auxiliary Cabinet. When these contacts open, a 30 second delayed shutdown of the
shovel will be initiated. Refer to Figure 3-93.

Flex I/O Module


Auxiliary Cabinet

TTMT MTTS Main Transformer


T.O.L.

ES2058_01

Figure 3-93: Main Transformer Thermal Overloads (TTMT)

3.7.4.4 Instant Overload Relay (QTTM)

The QTTM relay provides instantaneous overcurrent protection for the main transformer. It is
triggered by a monitoring circuit comprised of CT's, a three phase diode bridge and a precision
resistor. This resistor value varies depending upon the transformer it is associated with. Refer
to Figure 3-94.

3Ø VAC

CT's
CT's
CT's

TTMT

QTTM
1 2 3 4 5
ES2059_01

47KΩ
120VAC First 3 seconds of shovel start
MTOAR

Figure 3-94: Instant Overload Relay (First 3 Seconds of Shovel Start)

During the first 3 seconds of shovel start, refer to Figure 3-94, the Main Transformer Overload
Adjust Relay (MTOAR) is de-energized. Normally open contacts associated with MTOAR
remain open. With MTOAR open, the Instant Overload Relay (QTTM) is less sensitive to
compensate for the higher inrush of current through the Main Transformer at shovel start.
QTTM pick up voltage during this first 3 seconds is 15VDC which represents approximately

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450% overcurrent. QTTM drop out voltage is 2VDC. If QTTM picks up, normally open con-
tacts associated with QTTM close providing an input to a Flex I/O Module in the Auxiliary
Cabinet, refer to Figure 3-96. With this input active to the Flex I/O Module an instant shut-
down will be initiated.

3 seconds after shovel start, refer to Figure 3-95, MTOAR energizes. With MTOAR energized,
the normally open contacts associated with MTOAR close. This increases the sensitivity of
QTTM to compensate for the decreased current rush through the Main Transformer. QTTM
pick up is reduced to 5VDC which represents approximately 150% overcurrent. QTTM drop
out voltage is reduced to 0.4VDC.

3Ø VAC

CT's
CT's
CT's

TTMT

QTTM
1 2 3 4 5
ES2059a_01

47KΩ
120VAC First 3 seconds of shovel start
MTOAR 3 seconds after shovel start

Figure 3-95: Instant Overload Relay (3 Seconds after Shovel Start)

If QTTM picks up, normally open contacts associated with QTTM close providing an input to
a Flex I/O Module in the Auxiliary Cabinet. With this input active to the Flex I/O Module an
instant shutdown will be initiated. Refer to Figure 3-96.

Flex I/O Module


Auxiliary Cabinet
QTTM Main Transformer
Over Current

ES2060_01

Figure 3-96: Instant Overload Relay (QTTM)

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MTOAR contacts are a function of a Flex I/O Relay Module in the Auxiliary Cabinet.
MTOAR contacts close 3 seconds after shovel start. Refer to Figure 3-97.

VAC VDC Flex I/O Module


Auxiliary Cabinet

Main Transformer
Overload Adjust
Relay

ES2061_01

Figure 3-97: Main Transformer Overload Adjust Relay (MTOAR)

3.7.4.5 Machine House Heater Relay (MHHR)

The Machine House Heater Relay controls the Machinery House Heaters. The relay is con-
trolled by a switch on the Operators Console. Refer to Figure 3-92.

When the shovel is shutdown, the Heater Interlock Relay (HIR) is de-energized. Normally
closed contacts associated with HIR remain closed allowing the operator control of the
Machinery House Heaters via the House Heater Switch on the Right Hand Operator Console.
Refer to Figure 3-98.

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HIR MHES1 MHHR

House Heaters
Switch Machine House
Heater Relay

Figure 3-98: Machine House Heater Relay (MHHR)

When the Operator closes the House Heater Switch on the Right Hand Operators Console the
Machine House Heater Relay (MHHR) energizes. Normally open contacts associated with
MHHR close enabling the Machinery House Heaters.

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3.8 MOTOR CONTROL CABINET

3.8.1 General Information

The Motor Control Cabinet is similar in location, function and operation to the Auxiliary Cab-
inet detailed in Subsection 3.7. The difference between the two cabinets is cabinet layout. The
Motor Control Cabinet contains thermal overload protection for the Main Transformer, Instant
Overload Relay (QTTM), motor starters and circuit breakers for auxiliary motors, relays for
the heater systems and Dipper Trip circuit breaker, motor starter and contactor.

The 4100XPB Shovel will have either the Auxiliary Control Cabinet or the Motor Control
Cabinet, not both.

3.8.2 Location

ES1826i_01

Figure 3-99: Motor Control Cabinet - (4100XPB Deck Plan)

3.8.3 Cabinet Layout

Auxiliary motor starters occupy the majority of the Motor Control Cabinet.

The top left panel of the Motor Control Cabinet houses the Main Transformer Overloads
(TTMT) and Instant Overload Relay (QTTM). The panel below this houses the Heater Inter-
lock Relay (HIR), Flex I/O Remote I/O Adapter and I/O Modules.

Refer to Figure 3-100 for panel description and location in the Motor Control Cabinet.

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14

13 15
12 16
11 MAIN TRANSFORMER
PROTECTION 17
FRONT HOIST L FRONT SWING HOIST CONVERTER R.P.C. BLOWER
BLOWER 7.5HP BLOWER 2HP (SWITCH) 2HP
10 BLOWER 20HP
18
SPARE

09 19
REAR HOIST R.P.C. BLOWER
DIPPER TRIP (BANK 2-3) 2HP
BLOWER 20HP
CONTROL SYSTEM MOTOR 15HP
20
08 R.P.C.
BLOWER
07 (BANK 4/SV) 21
SWING 2HP
MACHINERY HOUSE
06 BLOWER LEFT R FRONT SWING
BLOWER 7.5HP
CONVERTER
BLOWER 2HP
22

05 LEFT
FILTER 23
BLEED BLOWER 5HP
CROWD
04 REAR SWING
BLOWER 7.5HP
CONVERTER
BLOWER 2HP 24

03 WINDSHIELD
CONTROL
RIGHT
FILTER 25
WIPER 1 HP BLEED BLOWER 5HP
02 MACHINERY HOUSE HOIST LUBE
CABINET
BLOWER 0.5HP
BLOWER RIGHT PUMP 1HP
26
01
R.P.C. CROWD BELT
BLOWER TENSIONING 1.5HP
MAIN ISOLATOR CROWD MOTOR NO 1 (1/2-1 BANK)
BLOWER - 15HP 2HP

ES2056_01

Figure 3-100: Motor Control Cabinet

LEGEND:
01. Main Isolator.
02. Machinery House Blower Right.
03. Crowd Motor Blower.
04. Windshield Wiper.
05. Hoist Lube Pump.
06. Machinery House Blower Left.
07. Rear Swing Blower.
08. Control System. Flex I/O Modules.
09. Right Front Swing Blower.
10. Rear Hoist Blower.
11. Main Transformer Protection.
12. Dipper Trip Motor.
13. Front Hoist Blower.
14. Left Front Swing Blower.
15. Hoist Converter Blower.
16. Reactive Power Compensation Blower (Switch).
17. Spare.
18. Reactive Power Compensation Blower (Bank 2-3).
19. Swing Converter Blower.
20. Reactive Power Compensation Blower (Bank 4).
21. Crowd Converter Blower.
22. Left Filter Bleed Blower.
23. Control Cabinet Blower.
24. Right Filter Bleed Blower.
25. Reactive Power Compensation Blower (½ Bank and Bank 1).
26. Crowd Belt Tensioning.

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3.8.4 Motor Control Cabinet Operation

Refer to Subsection 3.7.4 for a detailed description of components located in the Motor Con-
trol Cabinet.

3.9 PROPEL MOTOR HEATERS

The propel motor heaters and motor heater circuits are located on the Lower Assembly of the
4100XPB shovel.

3.9.1 Propel Motor Heater Operation

Refer to Figure 3-101.

3Ø VAC

Lower Auxiliary
Supply Circuit Breaker
(LASCB)

Neutral

LSTPB

Lower Supply
Transformer
Primary
Breaker
Lower Supply
Transformer

Lower Supply LSTSB


Transformer
Secondary
Breaker
Neutral

Motor Heater
Contactor - Lower Propel Motor
MHCL
Heaters
MHCL
Right
MHCL

MHCL
Left

Flex I/O
Lower

To Motor Heater
Contactor - Lower

ES2063_01

Figure 3-101: Propel Motor Heaters

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The Motor Heater Contactor - Lower (MHCL) is controlled by a Flex I/O Relay Module in the
Lower Assembly. The output from the Flex I/O Relay Module is active when the shovel is
shutdown causing MHCL to energize. When MHCL is energized, normally open contacts
associated with MHCL close supplying VAC to the Propel Motor Heaters. This allows the Pro-
pel Motors to stay warm when the shovel is shutdown.

When the shovel is running, the output from the Flex I/O Relay Module is inactive. MHCL
remains de-energized. The normally open contacts associated with MHCL remain open. The
Propel Motor Heaters are de-energized.

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4100XPB Electrical Manual Programmable Logic Controller

SECTION 4

Programmable Logic Controller

4.1 GENERAL DESCRIPTION

4.1.1 General Information

Programmable Logic Controllers or PLC’s are used to automate some basic functions on the
4100XPB Electric Mining Shovel. The Programming structure of PLC’s is called ladder logic
and is very similar to electrical circuit design. PLC’s are very versatile and durable. They are
built to withstand harsh conditions. There are many different kinds of accessories for PLC’s.
With the proper devices and programming, PLC’s can operate most any routine process. The
PLC uses several different kinds of input, output cards to interface with external devices. A
card can be selected to be able to use high voltage (120VAC) or low voltage (24VDC), as input
or output. The inputs and outputs are designated on the PLC by card number slash bit number.
One may use as many cards as needed for the expandability of the process being controlled.
The ladder logic is organized like digital logic using NOT, AND, OR gates, etc. . . Ladder logic
also has additional functions such as timers, counters, analog to digital converters and math
functions to name a few.

4.1.2 System Component Identification

Figure 4-1 identifies the location of major components associated with the SLC 5/05 Program-
mable Logic Controller on the 4100XPB Electric Mining Shovel.

01 02 03 03 04 05 06 07 08 08 09

01 10 09 11 10 06 06 12 12 12 12

ES2064_01

Figure 4-1: SLC 5/05 System Component Location

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Programmable Logic Controller 4100XPB Electrical Manual

LEGEND:
01. Power Supply, 5A @ 5VDC, 0.96A @ 24VDC.
02. SLC 5/05 Processor with 32K.
03. Remote I/O Scanner.
04. AMCI Resolver Module.
05. Profibus Scanner.
06. Sinking 24VDC Input Module.
07. Sourcing 24VDC Output Module.
08. Analog Input Module.
09. 120VAC Input Module.
10. 120VAC/240VAC Output Module.
11. Analog Output Module.
12. Blank Slot Fillers.

4.2 MODULAR CHASSIS

4.2.1 General Description

The modular chassis, refer to Figure 4-2, houses the processor and the I/O modules. Features
and benefits of the modular chassis include:

• Modules easily slide into chassis slots. No tools are required for module installation.

• Up to three chassis can be interconnected. Locally, the processor can address up to 30


slots.

01 02 03 04

ES0805_01

Figure 4-2: 10-Slot Modular Chassis

LEGEND:
01. Power supply slot connector.
02. If this is Rack1, this slot is reserved for the SLC 5/05 Processor. If this is Rack 2, this
slot will be filled with an I/O Module.
03. Module guide.
04. I/O Module backplane connector.

Refer to Figure 4-3. Self-locking tabs secure the module in the chassis. No tools are necessary
to install or remove a module from the chassis. To install a module, you slide it into the chassis
until it latches in place.

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4100XPB Electrical Manual Programmable Logic Controller

01
02

ES0806_01

Figure 4-3: Module Installation Into Chassis

LEGEND:
01. Module circuit card. Inserts into the module guide on the chassis for proper inser-
tion.
02. Self locking tabs secure the module into the chassis.

4.3 POWER SUPPLY

4.3.1 General Description

Each chassis requires a power supply to provide power to the processor and each I/O slot. The
current requirements for all the modules in each chassis have been totalled to avoid overload-
ing the power supply or the I/O chassis backplane.

Power supply features and benefits include:

• The power supply has an LED that indicates proper supply power. Monitoring this
LED can tell whether the supply is operating properly.

• The power supply has a hold-up time (the time the system is operational during a brief
power loss) typically between 20 milliseconds and 3 seconds. This eliminates nui-
sance-type shutdowns due to momentary power interruptions.

• A jumper allows selection of either 120VAC or 240VAC operation. No special wiring


is required.

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Programmable Logic Controller 4100XPB Electrical Manual

4.3.2 Input Voltage Selection and Fuse Location

Refer to Figure 4-4. The 120V/240V selection is made by a jumper. Place the jumper to match
the input voltage. A diagram on the backside of the Power Supply front cover will show where
the jumper should be installed.

POWER

02

100V/120V

03

04

01 05

06

07

200V/240V
ES0761_01

Figure 4-4: Power Supply Inside Front Cover

LEGEND:
01. Input voltage selection jumper.
02. Fuse, 250V, 3A.

TERMINAL STRIP:
03. +24VDC power output.
04. Common.
05. 120VAC/240VAC input power.
06. Neutral.
07. Chassis ground.

NOTICE
The fuse is intended to guard against fire hazard due to short circuit conditions and
may not protect the supply from damage under overload conditions.

4.3.3 Power Supply Undervoltage Operation

The SLC 5/05 continues to operate (hold-up) for a short period of time if the input voltage to
the power supply drops below the recommended operating voltage range. The controller con-
tinues to scan the user program and control I/O during this time.

The controller will turn OFF (stop scanning and disable outputs) if input voltage to the power
supply is removed or drops below the recommended operating range for a period exceeding the
CPU hold-up time. The controller resumes operation automatically when the input voltage is
restored to normal.

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4.3.4 Power Supply Specifications

Refer to Table 4-1 for Power Supply specifications.

Description Specification
Line Voltage 85-132/170-265VAC 47-63 Hz

Typical Line Power Requirement 180 VA

Maximum Inrush Current 20A

Internal Current Capacity 5A at 5VDC - 0.96A at 24VDC

Fuse Protection 1746-F2 or equivalent: 250V-3A Fuse SANO SOC SD4


or BUSSMANN AGC 3
24VDC User Power Current Capacity 200 mA
24VDC User Power Voltage Range 18-30VDC

Operating Temperature 0°C to +60°C (+32°F to +140°F) Current capacity derated


5% above +55°C.
Isolation 1800VAC RMS for 1 s
CPU Hold-up Time 20ms (full load) 3000ms (no load)
Storage Temperature –40°C to +85°C (–40°F to +185°F)

Humidity Rating 5-95% (non-condensing)

Wiring Two #14 AWG wires per terminal (maximum)

Certification UL listed, CSA certified, CE compliant for all applicable


directives, Class I Division 2 Hazardous Environment
Certification
Hazardous Environment Certification Class 1
Division 2

Table 4-1: Power Supply Specifications

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Programmable Logic Controller 4100XPB Electrical Manual

4.4 SLC 5/05 PROCESSOR MODULE

4.4.1 General Description

The SLC 5/05 processor supplies system throughput times of .9 ms for a typical 1K user pro-
gram. A built–in RS–232 channel gives the flexibility to connect to external intelligent devices
without the need for additional modules. Ethernet communication takes place at 10 Mbps, pro-
viding for a high performance network for program upload/download, on–line editing, and
peer–to–peer messaging.

4.4.2 SLC 5/05 Processor Specifications

Refer to Table 4-2 for SLC 5/05 Processor specifications.

Description Specification
Program Memory (words) 32K
I/O Capacity 4096 Discrete
Remote I/O Capacity Processor memory and chassis power limit up to
4096 inputs and 4096 outputs.
Maximum Chassis/Slots 3/30
Standard RAM Lithium battery, 2 years
Memory Backup Options Flash EPROM
LED Indicators Run, CPU Fault, Forced I/O, Battery Low, RS-232
and Ethernet
Typical Scan Time .9ms/1k
Bit Execution (XIC) .37µs
Power Supply Loading 1A @ 5VDC, 200mA @ 24VDC
Clock/Calendar Accuracy ±54 sec/month at +25°C (+77°F), ±81 sec/month at
+60°C (+140°F)
Program Scan Hold-up Time after loss of 20ms to 3 seconds (dependent on power supply load-
power ing)
Noise Immunity NEMA Standard ICS 2-230
Temperature Rating Operating: 0°C to +60°C (+32°F to +140°F)
Storage: -40°C to +85°C (-40°F to +185°F)
Humidity 5 to 95% without condensation
Shock (operating) 30Gs
Vibration Displacement: .015in., peak to peak at 5-75Hz
Acceleration: 2.5Gs at 57-2KHz
Certification UL listed/CSA approved, Class 1, Groups A, B, C or
D, Division 2, CE compliant for all applicable direc-
tives

Table 4-2: SLC 5/05 Processor Specifications

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4.4.3 SLC 5/05 Processor Module Identification

Refer to Figure 4-5. The SLC 5/05 front panel has the following items:

05 SLC 5/05 CPU 06


04 07
RUN FORCE
03 FLT ENET 08
BATT RS232
RUN REM PROG
09

02

01

ES0760c_01

Figure 4-5: SLC 5/05 Front Panel Identification

LEGEND:
01. Channel 0, RS232 (DH485, DF1, or ASCII).
02. Channel 1, Ethernet (10Base-T).
03. Battery LED.
04. Fault LED.
05. Run LED.
06. Force LED.
07. Ethernet LED.
08. RS232 LED.
09. Keyswitch.

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Figure 4-6 shows the left side view of the SLC 5/05.

01 02 03

ES0807_01

05 04

Figure 4-6: SLC 5/05 Left Side Identification

LEGEND:
01. Battery (battery provides back-up power for the CMOS RAM).
02. Memory module.
03. Keyswitch.
04. Location of serial and catalog numbers.
05. Operating system memory module download protection jumper.

4.4.4 Communication Options

The SLC 5/05 processor supports different types of communication options.

Ethernet TCP/IP Protocol. Standard Ethernet, utilizing the TCP/IP protocol is used as the
backbone for many minesites. Ethernet is a local area network that provides communication
between various devices at 10 Mbps. This network provides the same capabilities as DH+ or
DH-485 networks, plus:

• SNMP support for Ethernet network management.

• Optional dynamic configuration of IP addresses using a BOOTP utility.

• SLC 5/05 Ethernet data rate up to 40 times faster than DH+ messaging.

• Ability to message entire SLC 5/05 data files.

• Much greater number of nodes on a single network possible compared to DH-485 (32)
and DH+ (64).

DH–485 Protocol. The SLC 5/05 processor has a DH-485 channel that supports the DH-485
communication network. This network is a multi-master, token-passing network protocol capa-
ble of supporting up to 32 devices (nodes). This protocol allows:

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• Monitoring of data and processor status, along with program uploading and download-
ing of any device on the network from one location.

• Operator interface devices on the network to access data from any SLC processor on
the network.

• Configurable communication rates up to 19.2K baud.

• Electrical isolation.

• Maximum network length of 1219m (4,000 ft.).

• RS–485 electrical specifications.

• Belden 9842 or Belden 3106A cable connection between nodes (daisy chain connec-
tion).

DF1 Full–Duplex Protocol. DF1 Full-Duplex protocol (also referred to as DF1 point-to-point
protocol) allows two devices to communicate with each other at the same time. This protocol
allows:

• Transmission of information across modems (dial-up, leased line, radio, or direct cable
connections).

• Communication to occur between the SLC 5/05 and third–party products.

DF1 Half–Duplex Protocol (Master and Slave). DF1 Half–Duplex protocol provides a
multi–drop single master/ multiple slave network capable of supporting up to 255 devices
(nodes). This protocol also provides modem support and is ideal for SCADA (Supervisory
Control and Data Acquisition).

ASCII Protocol. The ASCII protocol provides connection to other ASCII devices, such as bar
code readers, weigh scales, serial printers, and other intelligent devices.

4.4.5 SLC 5/05 Keyswitch Operation

The processor includes a 3-position keyswitch on the front panel that lets you choose from
three different modes of operation: Run, Program, and Remote. You can remove the key in
any of three positions. Refer to Figure 4-7.

! CAUTION
Depending on the size of your user program, the processor can take up to 2.5
seconds to change modes when you change the position of the keyswitch from
RUN to PROG or to REM. Do not use the keyswitch in place of a hard wired
master control relay or an emergency-stop switch.

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Section 4, PLC.fm - 4.9 - SECTION 4, Version 0 - 9/02
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SLC 5/05 CPU


Run Force
FLT Enet
Batt RS232
Run Rem Prog

ES2065_01

Figure 4-7: SLC 5/05 Keyswitch

RUN Mode. This position places the processor in the RUN mode. The processor scans/exe-
cutes the ladder program, monitor input devices, energizes output devices, and acts on enabled
I/O forces. You can only change the processor mode by changing the key position. You cannot
perform online program editing.

To change the mode to RUN, turn the key from PROG or REM to RUN. When the key is in
the RUN position, you cannot use a programmer/operator interface device to change modes.

PRG Mode. This position places the processor in the Program mode. The processor does not
scan/execute the ladder program, and the controller outputs are de-energized. You can perform
online program editing. You can only change the mode by changing the key position.

To change the processor mode to Program, turn the key from RUN or REM to PROG. When
the key is in the PROG position, you cannot use a programmer/operator interface device to
change modes.

REM Mode. Figure 4-7 shows the keyswitch in this position. This position places the proces-
sor in Remote mode: either the REMote Run, REMote Program, or REMote Test mode. You
can change the processor mode by changing the keyswitch position or by changing the mode
from a programmer/operator interface device. You can perform online program editing in this
position.

To change the mode to REM, turn the key from RUN or PROG to REM. When the key is in the
REM position, you can use a programmer/operator interface device to change modes.

4.4.6 SLC 5/05 Front Panel Status LED’s

Between the time you apply power to the SLC 5/05 processor and the communications are
established via the connected programming device, the only form of communication between
you and the processor is through the LED display on the front panel. Refer to Figure 4-8.

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4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


Run Force
FLT Enet
Batt RS232
Run Rem Prog

ES2065_01

Figure 4-8: SLC 5/05 Status LED’s

When power is applied, all of the LED’s flash on and then off while the processor conducts
hardware tests. This is part of the normal power-up sequence. Following the self test by the
processor, all the LED’s again flash on momentarily. If a user program is in a running state, the
RUN LED will be on. If a fault exists within the processor, the FLT LED is on.

Toggle the keyswitch from RUN to PROG and then back to RUN; this clears the fault. If the
keyswitch is left in the RUN position, the processor mode cannot be changed from a program-
mer/operator interface device. If you return the keyswitch to the REM position, you can then
use a programmer/operator interface device to change the processor mode. Refer to Table 4-3
for a general explanation of the SLC 5/05 LED’s.

Processor LED Status Indicates


RUN On steady The processor is in the Run mode.
Flashing The processor is transferring a program from RAM to the memory mod-
ule.
Off The processor is in a mode other than Run.
FLT red Flashing (at start-up) The processor has not been configured.
Flashing (during operation) The processor detects a major error either in the processor, expansion
chassis or memory.
On A fatal error is present (no communications).
Off There are no errors.
BATT On The battery voltage has fallen below a threshold level, or the battery or
the battery jumper is missing or not connected.
Off The battery is functional, or the battery jumper is present.
FORCE amber Flashing One or more input or output addresses have been forced to On or Off
state but the forces have not been enabled.
On The forces have been enabled.
Off No forces are present or enabled.

Table 4-3: SLC 5/05 Status LED’s General Description

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Processor LED Status Indicates


ENET green or red Solid green The Ethernet port is functioning properly and is connected to an
active Ethernet network.
Flashing green The Ethernet port is functioning properly, connected to an active
Ethernet network and is transmitting packets.
Flashing red A hardware or software fault has occurred and is being reported
via a code. Contact the local MinePro Services Office.
Off No Ethernet connection or the processor is halted.
RS232 green On DF1 mode The SLC 5/05 processor is transmitting on the network.
Off DF1 mode The SLC 5/05 processor is not transmitting on the network.
On ASCII mode The SLC 5/05 processor is transmitting on the network.
Off ASCII mode The SLC 5/05 processor is not transmitting on the network.
On DH485 mode The Communications Active Bit (S:33/4) is set in the System
Status file and the processor is actively communicating on the
network.
Flashing DH485 mode The processor is trying to establish communications, but there are
no other active nodes on the network.
Off DH485 mode A fatal error is present (no communications).

Table 4-3: SLC 5/05 Status LED’s General Description

4.4.7 Removing the Memory Module

To remove a memory module use the following procedure:

Step 1: Remove power and pull out the processor.

Step 2: Grasp the connector with your thumb and index fingers, then gently but firmly lift
upwards on either end of the memory module carrier.

Step 3: When the end is partially raised, begin lifting the other end in the same manner.
Repeat this until the memory module has been completely removed from the socket.

4.4.8 Installing Your Memory Module

Always turn off power to the controller before removing the processor or inserting or removing
the memory module. This guards against possible damage to the module and also undesired
processor faults. Memory modules are mounted in carriers or have connectors that are “keyed”
to guard against improper installation. Refer to Figure 4-6.

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SECTION 4, Version 0 - 9/02 - 4.12 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

! CAUTION
To avoid damage to the memory modules, handle them by the ends of the car-
rier or edges of the plastic housing. Skin oil and dirt can corrode metallic sur-
faces, inhibiting electrical contact. Also, do not expose memory modules to
surfaces or areas that may typically hold an electrostatic charge. Electrostatic
charges can alter or destroy memory.

Step 1: If the processor module is installed in the chassis, remove the module by pressing
the retainer clips at both the top and bottom of the module and sliding it out.

Step 2: Locate the connector on the processor board. Then place the memory module into
the socket or onto the connector and press firmly in place.

Step 3: Install the processor module into the chassis.

Step 4: Restore power to the controller.

4.4.9 Downloading Firmware to the SLC 5/05 Processor

Step 1: Save the current SLC 5/05 processor program to your hard drive using your
programming software.

NOTICE
The user program is cleared as part of the operating system upgrade process. You
must restore your program after successfully loading the operating system upgrade.
Also, all communication ports are returned to default parameters.

Step 2: Remove the communication cable between the SLC 5/05 processor and your
programming terminal.

Step 3: Remove power from the chassis containing the SLC 5/05 processor.

Step 4: Remove the SLC 5/05 processor from the chassis.

Step 5: Plug the operating system upgrade pack into the memory module socket.

Step 6: Move the operating system write-protect jumper (J4) to the unprotected, or program,
position.

Step 7: Firmly seat the SLC 5/05 processor back into the chassis.

Step 8: Apply power to the chassis containing the processor while watching the LED
display. All the LED’s should flash on and then turn off. The download process of
the operating system by the SLC 5/05 processor takes approximately 45 seconds.
While the download is in progress, the RUN and FLT LED’s remain off. The other
four LED’s , RS232, ENET, FORCE, and BATT turn on and off in a walking bit
sequence. If the download is successful, these four LED’s remain on together. If the
FLT LED turns on and a combination of LED’s flash on and off indicating an error
condition, refer to Subsection 4.4.11.

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Section 4, PLC.fm - 4.13 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

Step 9: Following the successful completion of the download, remove power from the
chassis containing the SLC 5/05 processor.

Step 10: Remove the SLC 5/05 processor from the chassis.

! CAUTION
Do not remove the processor from the chassis until all power is removed.

Step 11: Carefully remove the operating system upgrade pack and place it in anti-static
packaging.

Step 12: Move the operating system write-protect jumper (J4) back to the protected position.

Step 13: Apply the enclosed operating system upgrade label to the SLC 5/05 processor
nameplate. Refer to Figure 4-9.

Step 14: Firmly seat the SLC 5/05 processor back into the chassis.

Step 15: Attach the communication cable between the SLC 5/05 processor and your
programming terminal.

Step 16: Apply power to the chassis containing the SLC 5/05 processor while watching the
LED display. All the LED’s should flash on and then turn off except for the FLT
LED which should remain flashing. If the FLT LED turns on and a combination of
LED’s flash on and off indicating an error condition, refer to Subsection 4.4.11.

Step 17: Restore your program after successfully loading the operating system upgrade.

4.4.10Replacing the SLC 5/05 Battery

Your SLC 5/05 processor provides back-up power for RAM through a replaceable lithium bat-
tery. This battery provides back-up for approximately 2 years. A BATT LED on the front of the
processor alerts you when the battery voltage has fallen below a threshold level.

To replace the lithium battery follow these steps:

! CAUTION
Do not remove the processor from the chassis until all power is removed.

Step 1: Remove power from the power supply.

Step 2: Remove the processor from the chassis by pressing the retainer clips at both the top
and bottom of the module and slide it out.

! CAUTION
Do not expose the processor to surfaces or other areas that may typically hold
an electrostatic charge. Electrostatic charges can alter or destroy memory.

Step 3: Unplug the battery connector. Refer to the Figure 4-6 for battery connector location.

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SECTION 4, Version 0 - 9/02 - 4.14 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

NOTICE
The SLC 5/05 processor has a capacitor that provides at least 30 minutes of battery
back-up while the battery is disconnected. Data in RAM is not lost if the battery is
replaced within 30 minutes.

Step 4: Remove the battery from the retaining clips.

Step 5: Insert a new battery into the battery retaining clip.

Step 6: Plug the battery connector into the socket.

Step 7: Re-insert the module into the chassis.

Step 8: Restore power to the power supply.

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Section 4, PLC.fm - 4.15 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

4.4.11SLC 5/05 Status LED’s Troubleshooting

The SLC 5/05 processor helps to simplify troubleshooting procedures. By observing the diag-
nostic indicators on the front of the power supply, processor unit and I/O modules, the majority
of faults can be located and corrected. These indicators help trace the source of the fault to the
user’s input/output devices, wiring, or the controller.

Program Alteration. There are several causes of alteration to the user program, including
extreme environmental conditions, Electromagnetic Interference (EMI), improper grounding,
improper wiring connections, and unauthorized tampering. If you suspect the memory has
been altered, check the program against a previously saved program on an EEPROM,
UVPROM or Flash EPROM module before continuing.

To receive the maximum benefit from this troubleshooting section, it is recommended that you
follow these steps:

Step 1: Identify the status of your processor LED’s. Refer to Table 4-3.

Step 2: Using the figures and tables on the following pages, match your processor and
power supply LED’s with the LED’s in the drawings.

Step 3: Once the status LED’s are matched to the appropriate figure, simply refer to the
table below the figure to identify an error description and probable causes.

Step 4: Follow the recommended action steps for each probable cause until the cause is
identified.

Step 5: If recommended actions do not identify the trouble cause, contact your local
MinePro Service Office.

Clearing SLC 5/05 Processor Faults. Using the Keyswitch, toggle the keyswitch from RUN
to PROG and then back to RUN; this clears the fault. If the keyswitch is left in the RUN posi-
tion, the processor mode cannot be changed from a programmer/operator interface device. If
you return the keyswitch to the REM position, you can then use a programmer/operator inter-
face device to change the processor mode.

NOTICE
If you clear a processor fault using the keyswitch, the processor immediately enters
the Run mode.

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SECTION 4, Version 0 - 9/02 - 4.16 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066_01

The Following
Error Exists Probable Cause Recommended Action
Inadequate No line power 1. Verify proper line voltage and connections on the power termi-
system power nals.
2. Verify proper 120/240V power supply jumper selection.
Power supply 1. Check the incoming power fuse, check for proper incoming
fuse blown power connections. Replace fuse.
2. If fuse blows again, replace the power supply.
Power supply 1. Remove line power to power supply. Remove several output
overload modules from the chassis. Wait five minutes. Reapply power.
2. If condition reoccurs, re-calculate module configuration power
required and verify proper power supply selection. This problem
can occur intermittently if power supply is overloaded when out-
put loading and temperature varies.
Defective power 1. Recheck other probable causes.
supply 2. Monitor the line power to chassis power supply for possible
transient or shorting.
3. Replace the power supply.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066a_01

The Following
Error Exists Probable Cause Recommended Action
Inadequate Improper line Verify proper 120/240V power supply jumper selection.
system power power voltage
selection

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Section 4, PLC.fm - 4.17 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066b_01

The Following
Error Exists Probable Cause Recommended Action
Processor not Either improper 1. Verify selected processor mode.
in run mode mode selected or 2. If the processor is in the Program/Test modes, attempt Run
user program mode entry:
logic
• If keyswitch is in the REM position and there is no
key, use the programmer.

• If keyswitch is in REM or PROG position, and you


have the key, toggle to the RUN position.
3. If in the suspend mode, check user program logic for suspend
instructions.
Line power out of 1. Check proper 120/240V power supply jumper selection and
operating range incoming power connections.
2. Monitor for proper line voltage at the incoming power connec-
tions.
Improper seating 1. Remove power and inspect the power supply chassis connec-
of power supply tions and the processor chassis connections.
and/or processor 2. Re-install the devices and re-apply power. Important: The
in chassis processor only operates in slot 0 of chassis #1.
Defective proces- 1. Attempt Run mode selection of Processor in existing chassis:
sor, power supply
or chassis • If keyswitch is in the REM position and there is no
key, use the programmer.

• If keyswitch is in REM or PROG position, and you


have the key, toggle to the RUN position.
2. Place processor in another chassis not in the existing system.
Apply power, reconfigure and attempt Run mode selection. If
unsuccessful, replace processor.
3. Try existing power supply in test chassis. If unsuccessful,
replace power supply. If entry into the Run mode is allowed,
replace the existing chassis.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.18 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066c_01

The Following
Error Exists Probable Cause Recommended Action
System inoper- User program 1. Monitor logic in Run mode and verify desired I/O status.
able, no major logic error 2. Check for minor CPU faults.
CPU faults
detected Defective I/O Test inputs and outputs according to I/O troubleshooting proce-
devices or I/O dures.
wiring

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.19 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066d_01

The Following
Error Exists Probable Cause Recommended Action
CPU fault CPU memory Cycle power.
error
Fault memory 1. Remove power and then remove the memory module from the
module processor.
2. Re-install the processor and re-apply power to the power sup-
ply. If steady FLT LED changes to flashing, replace the existing
memory module with a replacement module.
Faulty CPU 1. Place the processor in another chassis not in the existing system
power supply and cycle power. If steady FLT LED reappears, replace the pro-
cessor.
2. If FLT LED clears, monitor the line power going to the power
supply in existing system.
3. Replace existing system power supply if line power checks
OK.
Processor firm- If upgrading the processor to a different firmware level, verify
ware installed firmware chip orientation matches the upgrade kit directions.
incorrectly

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.20 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066e_01

The Following
Error Exists Probable Cause Recommended Action
CPU major Initial CPU fac- 1. Refer to chapter 8 and follow the start-up procedures.
fault tory power-up 2. Clear processor memory to get rid of the flashing FLT LED.
condition in
effect
Hardware/soft- 1. Use programmer to monitor and clear the fault (or if keyswitch
ware major fault in REM):
detected a. Monitor Status File Word S:6 for major error code.
b. Remove hardware/software condition causing fault.
Erratic repetitive c. Clear Status File S:1/13 major error bits, if set.
power cycling
can cause a CPU d. Clear Status File S:5 minor error bits, if set.
major hardware e. Clear Status File S:6 major error code (optional).
fault.
f. Attempt a processor Run mode entry. If unsuccessful, repeat
recommended action steps above.
2. Use the keyswitch to clear the fault. Toggle the keyswitch to
PROG and back to RUN. If FAULT occurs again, use program-
mer to get error code and determine the source of problem.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.21 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066f_01

The Following
Error Exists Probable Cause Recommended Action
System does User forced I/O 1. Monitor program file online and identify forced I/O.
not operate per disabling opera- 2. Disable appropriate forces and test system conditions again.
ladder logic tion

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066g_01

The Following
Error Exists Probable Cause Recommended Action
System does User pro- 1. Monitor program file online and identify programmed forces.
not operate per grammed forces 2. Enable appropriate forces and test system conditions again.
programmed are not enabled Once forces are enabled, the FORCE LED goes on steady.
forces

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.22 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066h_01

The Following
Error Exists Probable Cause Recommended Action
CPU major Loss of RAM 1. Verify battery is connected.
error with low during power 2. Replace the battery if you want RAM battery backup.
or no battery down period
back-up 3. Refer to CPU major fault action steps.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066i_01

The Following
Error Exists Probable Cause Recommended Action
Fatal error and Inadequate sys- 1. Check line power.
no communi- tem power 2. Check 120/240V power supply jumper selection.
cation
3. See the recommended actions for Inadequate system power.
Communication Check communication channel configuration with your program-
channel is shut ming software.
down
Communication Replace the processor.
channel is dam-
aged

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.23 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066j_01

The Following
Error Exists Probable Cause Recommended Action
An ENET fault A hardware fault Contact the local MinePro Service Office.
is being has occurred.
reported via a
code. (The
LED is flash-
ing red)

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066k_01

The Following
Error Exists Probable Cause Recommended Action
Fatal error and Inadequate sys- 1. Check line power.
no communi- tem power 2. Check 120/240V power supply jumper selection.
cation
3. See the recommended action for Inadequate system power.
Communication Check communication channel configuration with your program-
channel is shut ming software.
down
Communication Replace processor.
channel is dam-
aged

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.24 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066l_01

The Following
Error Exists Probable Cause Recommended Action
The SLC 5/05 DH-485 commu- 1. Check communication parameters of programmer. Programmer
processor is nication parame- and processor baud rate must match. Programmer and processor
trying to estab- ters are node addresses must be different.
lish communi- improperly set up 2. Try different combinations of:
cation but
cannot find a. baud rate (Processor default is 19200.)
other active b. node address (Processor default is 1.)
nodes
3. Try to increase the maximum node address. (Default is 31.)
Bad connection 1. Check cable continuity.
2. Check cable connections between programmer and processor.
Low or no power 1. Verify proper power supply selection and backplane loading.
to communica- (The 1747-PIC and 1747-AIC draw power off the backplane.)
tion device 2. Verify proper 120/240V power supply jumper selection.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.25 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066n_01

The Following
Error Exists Probable Cause Recommended Action
A fatal error Excessive noise 1. Cycle power to obtain flashing FLT LED and default program.
has occurred or a faulty SLC 2. Examine the error code following the power cycle.Take appro-
5/05 processor priate action.
3. Reload your program.
4. Contact the local P&H MinePro Office if the error persists.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.27 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

Identifying Processor Errors while Downloading an Operating System. The download


process of the operating system by the SLC 5/05 processor takes approximately 45 seconds.
While the download is in progress, the RUN and FLT LED’s remain off. The other four LED’s,
RS232, ENET, FORCE, and BATT turn on and off in a walking bit sequence. If the download
is successful, these four LED’s remain on together.

NOTICE
Jumper J4, located on the bottom corner of the motherboard, provides write protec-
tion from any download of a new operating system. The “out of the box” position of
this jumper is “PROTECT,” or write protect. Without the jumper, the processors are
write protected. Refer to Figure.

03

02 04

PROTECT

PROGRAM
J4

01

05 or

06

ES0807a_01

Figure 4-9: SLC 5/05 Operating System Download

LEGEND:
01. Operating system upgrade/memory module socket.
02. Catalog and serial number label.
03. Place the operating system upgrade label here.
04. Diagram of jumper J4 configurations.
05. With J4 in these configurations, the SLC 5/05 processor is write protected from the
operating system download.
06. With J4 in this configuration, the SLC J4 processor accepts the operating system
download.

If the download is not successful, the FLT LED turns on and a combination of LED’s flash on
and off indicating an error condition. The following LED diagrams and tables provide you
with information regarding error messages, possible causes for the error, and recommended
action to take to resolve the error.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.28 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066_01

The Following
Error Exists Probable Cause Recommended Action
NVRAM error Major hardware Cycle power and see if the error repeats itself. If the error clears,
failure due to you should be able to download the operating system. If the error
noise, improper persists, contact your local MinePro Services Office.
grounding, or
poor power
source.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066p_01

The Following
Error Exists Probable Cause Recommended Action
Hardware Major hardware Cycle power and see if the error repeats itself. If the error clears,
watchdog tim- failure due to you should be able to download the operating system. If the error
eout noise, improper persists, contact your local MinePro Services Office.
grounding, or
poor power
source.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.29 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066q_01

The Following
Error Exists Probable Cause Recommended Action
Fatal hard- Major hardware Cycle power and see if the error repeats itself. If the error clears,
ware error failure due to you should be able to download the operating system. If the error
noise, improper persists, contact your local MinePro Services Office.
grounding, or
poor power
source.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066r_01

The Following
Error Exists Probable Cause Recommended Action
Corrupted The operating Cycle power and see if the error repeats itself. If the error persists,
operating sys- system on the either contact your local MinePro Services Office for a new oper-
tem memory Flash EPROM is ating system memory module, or download the old operating sys-
module corrupt. tem.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.30 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066s_01

The Following
Error Exists Probable Cause Recommended Action
Flash EPROM The processor Cycle power and see if the error repeats itself. If the error clears,
error flash is corrupt. you should be able to download the operating system. If the error
persists, contact your local MinePro Services Office.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066t_01

The Following
Error Exists Probable Cause Recommended Action
Corrupt or The operating Cycle power. If error clears, you should be able to download the
missing oper- system is miss- operating system. If the error persists, contact your local MinePro
ating system ing or has Service Office for a new operating system.
become cor-
rupted.

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.31 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066u_01

The Following
Error Exists Probable Cause Recommended Action
Downloadable Failure during Download the operating system.
operating sys- transmission of
tem failure downloadable
operating system.

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066v_01

The Following
Error Exists Probable Cause Recommended Action
Incompatible The upgrade of Use an operating system that is compatible with your processor
Platform the operating sys- hardware.
tem is incompati-
ble with the
processor hard-
ware.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.32 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SLC 5/05 CPU


POWER Run Force Refer to the following key to determine
FLT Enet the status of the LED indicators:
Batt RS232 Indicates the LED is OFF.
Run Rem Prog
Indicates the LED is ON.

Indicates the LED is FLASHING.

Status of LED does not matter.

ES2066w_01

The Following
Error Exists Probable Cause Recommended Action
Memory write An attempt was Change the jumper on the processors to the program position.
protected made to down-
load the operat-
ing system onto
write–protected
memory.

4.5 REMOTE I/O SCANNER

4.5.1 General Information

The Remote I/O (RIO) Scanner enables communication between an SLC 5/05 processor and
remotely located I/O chassis and other RIO compatible operator interface and control devices.

The Remote I/O Scanner communicates with remotely located devices using the Remote I/O
link. The RIO link consists of a single master (scanner) and multiple slaves (adapters). Com-
munication between devices occurs over twisted pair cable with the devices daisy-chained
together. The scanner can reside in any slot of the local SLC chassis except for slot 0.

The Remote I/O Scanner can be configured for and transfer a maximum of 4 logical racks of
discrete data on the RIO link. The scanner provides discrete and block I/O transfers to any
combination of quarter, half, three quarter, or full logical rack devices.

The SLC processor transfers the scanner's 4 logical racks (32 input image and 32 output image
words) of discrete remote I/O image data into the SLC input and output image files. The scan-
ner input and output image file can be adjusted during configuration of the SLC system so that
the scanner only transfers the discrete I/O data required by the application program. Configura-
tion is done through the configuration file (G file).

It is important to note that the SLC 5/05 processor supports multiple scanners in its local I/O
chassis. The maximum number is dependent on the following:

• Backplane power requirements (power supply dependent).

• SLC 5/05 processor I/O data table limit (4,096 I/O).

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• Processor memory to support the application (SLC 5/05 processor dependent).

4.5.2 Specifications

Table 4-4 list the Remote I/O Scanner operating specifications.

Description Specification
Backplane current consumption 600mA @ 5VDC
Operating temperature +32°F to 140°F (0°C to +60°C)
Storage temperature -40°F to +180°F (-40°C to +85°C)
Humidity 5 to 95% without condensation
Noise immunity NEMA standard ICS 2-230
Agency Certification CSA certified, CSA class 1 division 2 groups
A, B, C and D certified. UL listed. CE
marked for all applicable directives.

Table 4-4: Remote I/O Scanner Operating Specifications

4.5.3 Scanner I/O Image Division

The scanner allows each adapter to use a fixed amount (user defined) of the scanner's input and
output image. Local I/O uses part of the SLC processor's image, the other portion is used by
the scanner for remote I/O.

Refer to Figure 4-10. The scanner remote I/O image is divided into logical racks and further
divided into logical groups. A full logical rack consists of eight input and eight-output image
words. A logical group consists of one input and one output word in a logical rack. Each logi-
cal group is assigned a number from 0-7.

Local I/O

Logical Rack 0

Logical Rack 1
Remote I/O

Logical Group 0
Logical Rack 2
Logical Group 7
Processor I/O Image Scanner I/O Image Adapter Image

ES0766_01

Figure 4-10: Scanner I/O Image Division

The scanner image contains the image of each adapter on the remote I/O link. The adapter is
assigned a portion of the scanner image, which is referred to as the adapter image.

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4.5.4 How the Scanner Scans Remote I/O

The Remote I/O Scanner communicates with each logical device in a sequential fashion. Refer
to Figure 4-11. First, the scanner initiates communication with a device by sending output data
to the device. The device then responds by sending its input data back to the scanner. This
exchange is referred to as a discrete I/O transfer. After the scanner completes its discrete I/O
transfer with the last configured network device, it begins another discrete I/O transfer with the
first device.

It is important to understand that the scanner transfers remote I/O data on a logical device basis
not on an adapter basis. A logical device is a full logical rack or portion of a logical rack
assigned to an adapter.

Scanner
Input Remote I/O
Image File Scanner Scan

Output Input
Device 3 Device 1
The scanner updates its
Input Image file each time Input Output
it scans a logical device. Device 3 Device 1

Output Input
Device 2 Device 2

Scanner Output
Image File ES0767a_01

Figure 4-11: Scan Cycle

4.5.5 SLC and Scanner Asynchronous Operation

The SLC processor scan and the Remote I/O Scanner scan are independent (asynchronous) of
each other, they cannot scan at the same instant. Refer to Figure 4-12. The SLC processor reads
the scanner input image file during its input scan and writes the output image file to the scanner
during its output scan. The RIO scanner continues reading inputs and writing outputs to the
scanner I/O image file, independent of the SLC processor scan cycle.

Depending on the SLC processor, RIO link configuration, and application program size, the
scanner may complete multiple scans before the SLC processor reads the scanner's input image
file. The RIO scanner updates its I/O files on a per logical rack basis.

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SLC Input Scanner


SLC Processor Image File Input Remote I/O
Image File Scanner Scan Cycle

Output Input
Image Image The scanner updates its
Device 3 Device 1 input image file each time
The SLC processor reads the
it scans a logical device.
scanner input image file into the
Input Output The scanner may scan all
SLC input image file, processes
Program Image Image of its configured logical
it, and creates an SLC output
Device 3 Device 1 devices several times
image file. The SLC processor
before the SLC processor
transfers its output file to the
Output Input read the scanner's input
scanner.
Image Image image file.
Device 2 Device 2

Scanner Output
SLC Output Image File ES0767_01
Image File

Figure 4-12: Scanner Asynchronous Operation

It is important to note that the outputs of the Remote I/O Scanner are updated after the end of
the first SLC processor scan.

The scanner's I/O image consists of RIO logical racks and I/O groups. A full RIO logical rack
consists of eight input image and eight output image words. (A word consists of 16 bits of
data.) Each word within an RIO logical rack is assigned an I/O group number from 0 to 7.

Input and output image data and command information are quickly exchanged between a scan-
ner and adapter using RIO discrete transfers. RIO discrete transfers are the simplest and fastest
way a scanner and adapter communicate with each other.

RIO discrete transfers, which are transparent to the user, consist of the scanner sending the out-
put image data to the adapter, and the adapter transmitting input data to the scanner. Each RIO
discrete transfer also contains scanner commands for the adapter.

The control program tells the SLC processor to initiate RIO block transfers, which directs the
scanner to exchange large amounts of data to and from an adapter. Block Transfers (BT’s) use
the basic RIO discrete transfer mechanism of the RIO link. However, the actual transfer of
data occurs asynchronous to the discrete transfers. It is possible for several discrete transfers to
occur before the scanner processes a block transfer.

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4.5.6 Baud Rate Selection

Figure 4-13, shows the location of the DIP switches on the scanner. The 4100XPB Remote I/O
Scanner should be set for 57.6K baud rate. Set both switch 1 and 2 to on.

NOTICE
For proper RIO link system operation, all devices must be configured for the same
baud rate.

01

Off On
1
2

ES0764_01

Figure 4-13: Scanner Baud Rate Setting

4.5.7 Start-up

The following steps will assist you in the start up of your RIO system.

Step 1: Apply power to your SLC 5/05 processor. If you powered down with the SLC 5/05
processor in Program, Test, or Fault mode, you will have to place your processor in
Run mode. When power is applied to your scanner it requires about three seconds to
complete its power up diagnostics. During this time, the FAULT and COMM LED’s
cycle on and off. After the diagnostics are complete and the SLC processor is in the
Run mode, the scanner’s LED’s are in the following states:

• The FAULT LED is off.

• The COMM LED is green.

NOTICE
The above states are true only if the scanner is configured properly and all RIO link
devices are communicating.

Step 2: Make sure you have configured your SLC processor and downloaded an application
program. Refer to Subsection 4.4.

Step 3: Make sure power is applied to all devices on the RIO link.

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4.5.8 Scanner Operation

Below is a description of the scanner’s operation at power up, RUN mode, and when changing
from run mode to program or test mode.

At Power Up. The the scanner’s communication LED (green LED) is off until the SLC 5/05
is changed to Run or Test mode.

In Run Mode. During normal scanner operation (SLC 5/05 in Run mode), the scanner’s
LED’s illuminate as shown in Figure 4-14.

SCANNER
01 02
COMM FAULT

ES0817_01

Figure 4-14: Scanner Run Mode LED’s

LEGEND:
01. Communication LED. Will be green in the RUN Mode.
02. Fault LED. Will be off in the RUN Mode.

When Changing From Run Mode. When the SLC5/05 processor is changed from Run mode,
to Program or Test mode the following occurs:

• The scanner’s COMM LED remains green.

• The scanner continues to read its input devices and send output data to its RIO adapt-
ers.

• The scanner instructs adapters to either clear all outputs or hold them in their last state
(depending on their configuration). Refer to the user manual included with each RIO
device for specific information relating to the Hold Last State setting.

4.5.9 Status LED’s

The scanner has two LED’s that indicate its operating status, FAULT and COMM. The FAULT
LED indicates the scanner’s overall status. The COMM LED indicates the RIO link communi-
cation status.

The FAULT LED is off whenever the scanner is configured and operating properly. The
COMM LED state is valid only when the FAULT LED is off.

Table 4-5 provides the scanner and communication status as indicated by the FAULT and
COMM LED’s.

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Fault LED Comm LED Status Information


Flashing Red N/A Scanner configuration error.
No RIO link communication attempted.
Duplicate scanner detected on RIO link.
Red N/A Major fault on scanner.
No RIO link communication attempted.
Off Red Hardware fault detected.
Off Off Scanner is operating properly.
Scanner is offline. (no RIO link communication
attempted.)
Off Green Scanner is operating properly.
Scanner is online. (active communication estab-
lished with all devices.)
Off Flashing Green Scanner is operating properly.
At least one configured RIO link device is not
communicating.
Off Flashing Red Scanner is operating properly.
None of the configured RIO link devices are com-
municating.

Table 4-5: Scanner Status LED’s

4.5.10Troubleshooting

The FAULT LED is off whenever the scanner is operating properly. The COMM LED state is
valid only when the FAULT LED is off. When the scanner’s LED’s change state, refer to Table
4-6.

LED Error
Condition Problem Solution Code
FAULT LED G file is missing. Enter configuration information in G file. 62H
flashing red
Invalid G file configura- Check configuration for proper G file size and 63H
tion. settings.
Duplicate node detected. Disconnect the RIO link from the scanner and 64H
either cycle the scanner power or re-enter the
run mode. Look for another scanner on the same
network. If the condition persists, replace the
scanner.
FAULT LED Hardware error on scan- Replace the scanner. 68H -
red ner. 6FH
COMM LED SLC 5/05 powered up in Return to run mode. N/A
off program mode.

Table 4-6: ScannerStatus LED Troubleshooting

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LED Error
Condition Problem Solution Code
COMM LED A device is not properly Check the RIO link connections, power and N/A
flashing green configured, connected, switch settings. A device may be too light or too
powered or is faulted. small.
COMM LED Scanner is incorrectly Check the RIO link wiring at the scanner. Check N/A
flashing red connected or all devices the device configurations, power status and net-
are incorrectly config- work baud rate.
ured, have no power or
are faulted.
COMM LED Hardware error on scan- Replace the scanner. N/A
red ner.

Table 4-6: ScannerStatus LED Troubleshooting

4.5.11Error Codes

The SLC 5/05 processor reports error codes in word 6 of the SLC processor status file. Refer to
Subsection 4.21 for an explanation of these error codes.

4.6 AMCI RESOLVER INTERFACE MODULE

4.6.1 General Information

The AMCI Resolver Interface Module accepts one or two transducer inputs and plugs directly
into the SLC chassis. Communicating through I/O registers assigned to the slot, these modules
supply absolute position and tachometer data to the SLC 5/05 processor from AMCI resolver
based transducers.

4.6.2 Front Panel Description

Two LED’s on the front panel shows the modules operating status. Refer to Figure 4-15.

RESOLVER
INTERFACE
RUN
FAULT 1532

ES0768_01

Figure 4-15: AMCI Resolver Interface Module

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• RUN: This green LED is on when the module is operational.

• FAULT: This red LED is blinking when there is a transducer fault, or on when there is
a module fault.

There are four major causes of a transducer fault:

• Broken transducer cable.

• Non-compatible transducer.

• Improperly wired cable.

• Faulty transducer.

The transducer input connector accepts an 8 pin Phoenix connector from the transducer cable.
Refer to Figure 4-16. The AMCI Resolver Interface Module uses C2T-(x) transducer cable.

RESOLVER
INTERFACE
RUN
FAULT 1532

ES0768a_01

Figure 4-16: Transducer Input Connector

4.6.3 Power Requirements

The AMCI Resolver Interface Module requires 0.130A @ 5VDC and 0.075A @ 24VDC.

4.6.4 Tachometer Response Setup

The jumper located behind the display on the AMCI Resolver determines how often the
Resolver updates the tachometer data. With the jumper installed, the tachometer updates every
120ms. This is the correct setting for the 4100XPB Electric Mining Shovel. With the jumper
removed the tachometer updates every 32ms.

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4.6.5 Software Configuration

Before an AMCI Resolver Interface Module can communicate with the SLC 5/05 processor, it
must be set to the proper ID Code in the programmable controllers Processor File. This is done
with a Hand Held Terminal or ASP software.

The ID Code for the AMCI Resolver Interface Module is “3513”. This ID Code reserves 8
input and 8 output words for the module.

NOTICE
Newer versions of the ASP software list the 1746-NR4: 4 Ch. RTD/Resistance Input
Module when you set the slot ID Code to 3513. Disregard this message. It is an
error and the AMCI Resolver module will still operate correctly.

NOTICE
Use the SPIOGA configuration option to reduce the number of input words and out-
put words scanned by the processor. This will significantly decrease the access time
for the module. For the AMCI Resolver Interface Module, set the number of input
words to five and the number of output words to five.

NOTICE
If you are using Rockwell Software programming software it must be version 7.03
or above. A lower version will not allow you to set the ID Code as high as 3513.

4.6.6 Data Format

The format of the fault diagnostic, position, and tachometer data is shown in Figure 4-17. A
fault diagnostic bit is set to “1” when indicating an error. Position and tachometer data is trans-
ferred in binary format.

Word 0 Word 1 Word 2 Word 3 Word 4


15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00
SF2 Err

SF1 Err
T1 Err
T2 Err
E² Err

MSG IGN
ACK

SPIOGA Err

Position Tachometer Position Tachometer


0 0 0 0 0 0 0 0
Transducer 1 Transducer 1 Transducer 2 Transducer 2
ES0769_01

Figure 4-17: Input Word Data Format

Bit 0: Scale Factor 1 Error - Set when programming an invalid Scale Factor for Transducer 1.

Bit 3: Scale Factor 2 Error - Set when programming an invalid Scale Factor for Transducer 2.

Bit 6: SPIOGA Error - Set on SPIOGA communications error with processor.

Bit 7: Message Ignored - If an error bit is set, the error must be cleared by programming the
affected parameter. This bit is set if you attempt to program a different parameter before clear-
ing the error.

Bit 12: E² Error - Set on EEPROM Memory Fault.

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Bit 13: Transducer 2 Error - Set when there is a transducer fault on the second channel.

Bit 14: Transducer 1 Error - Set when there is a transducer fault on the first channel.

Bit 15: Acknowledge Bit - Used to acknowledge a program transfer.

Use the eight output words assigned to the AMCI Resolver to program its position resolution,
reset the position to zero, and clear EEPROM memory faults. The format of the data is shown
in Figure 4-18.

Word 0 Word 1 Word 2 Word 3 Word 4


15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00
Scale Factor RESERVED RESERVED Scale Factor
Reset 2
Reset 1
TRMT
E² Clr

SF2

0 0 0 0 0 0 0 0 0 0
SF1

Transducer 1 Set to Zero Set to Zero Transducer 2


ES0769a_01

Figure 4-18: Output Word Data Format

Bit 0: Reset Transducer 1 - Set to force the position data of Transducer 1 to zero.

Bit 1: Reset Transducer 2 - Set to force the position data of Transducer 2 to zero.

Bit 2: Scale Factor Transducer 1 - Set when programming the Scale Factor of Transducer 1
to the value in Output Word 1.

Bit 5: Scale Factor Transducer 2 - Set when programming the Scale Factor of Transducer 2
to the value in Output Word 4.

Bit 14: E² Clr - Set to clear an EEPROM Memory fault.

Bit 15: Transmit Bit - Used to initiate a program transfer.

4.6.7 Programming from the Processor

To program the module, simply write the data into the correct output words, set the proper bits
in output word zero and then set the TRMT Bit to 1. The AMCI Resolver accepts new com-
mands only on a 0 to 1 transition of the TRMT bit. The AMCI Resolver will process the com-
mands in the following order:

1. Clear EEPROM Memory Fault.

2. Program Scale Factor, Transducer 1.

3. Reset Transducer 1 Position.

4. Program Scale Factor, Transducer 2.

5. Reset Transducer 2 Position.

Once the AMCI Resolver has accepted and processed the commands, it will set/reset the
appropriate fault diagnostic bits and then set the Acknowledge (ACK) Bit. Once the ACK bit is
set, check the bits of input word 0 for errors and reset the TRMT bit. The module will respond
by resetting the ACK bit. The programming cycle is now complete and a new cycle can begin.

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If the AMCI Resolver encounters an error while storing data, the module will stop processing
commands. For example: you command a AMCI Resolver to change both Scale Factors and
reset the position values to zero in a single cycle. The Scale Factor for Transducer 1 is set to
2048. (Outside the valid range of 2-1024.) The AMCI Resolver will respond by setting the
‘SF1 Err’ Bit. Both scale factors will be ignored and neither position value will be reset to
zero. You can program the module while it is in transducer fault but you cannot preset the posi-
tion values.

! WARNING
The EEPROM used to store the parameters is guaranteed for approximately
100,000 write cycles before writing to it will cause it to fail. Therefore continu-
ously resetting the position or writing new parameters should be avoided. If
your application requires you to continuously preset the position, consider cal-
culating and applying the required position offset in the ladder logic program.

4.7 SST-PFB-SLC PROFIBUS SCANNER

4.7.1 General Information

The Profibus Scanner enables communication between the SLC 5/05 processor and DP remote
I/O devices on a Profibus network. It acts as a Profibus DP Remote I/O Scanner to scan up to
96 slaves. The scanner supports up to 244 bytes of input data and 244 bytes of output data per
slave. It can reside in any slot in the local SLC chassis. You can have multiple scanners in the
same rack. The scanner supports all standard ProfiBus baud rates (9600, 19200, 93.75K,
187.5K, 500K, 750K, 1.5M, 3M, 6M, 12M). Refer to Figure 4-19.

Profibus Scanner
COMM SYS

ES0771_01

Figure 4-19: Prtofibus Adapter Module

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4.7.2 Configuration Tool

The SST configuration tool exports the configuration to a *.bss file (binary). You upload the
configuration to the scanner via the serial port on the scanner, using an Xmodem transfer from
any serial communications software. The scanner stores this configuration in flash memory on
the scanner so you don't need to upload the configuration every time you start the SLC.

The scanner maintains the following status information about the network and the I/O modules
on the network:

• Slave status for each slave.

• Network diagnostic counters.

• DP master diagnostic counters.

• FDL diagnostic counters.

Opening the front cover will provide access to the Configuration connector and Profibus con-
nector. Refer to Figure 4-20.

Profibus Scanner
COMM SYS
CONFIG RS232

5-GND
3-TxD
2-RxD
Profibus

5-IGND
8-A
3-B
1-SHLD

SST-PFB-SLC

ES0774_01

Figure 4-20: Profibus Adapter Connectors

Configuration connector. Used for uploading I/O configuration data to the scanner.

Profibus connector. Used for connecting to the Profibus network.

4.7.3 SYS and COMM LED’s

There are two LED’s on the scanner, the SYS LED and the COMM LED.

The SYS LED, refer to Table 4-7, indicates overall status of scanner operations. The COMM
LED, refer to Table 4-8, indicates communication status.

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Color Indication

DP Master
Red One or more slaves is reporting a fault condition.
Amber The module is in program or test mode.
Green The module is scanning in run mode.

DP Slave
Red The slave is not being scanned or is faulted.
Amber The slave is being scanned in program mode.
Green The slave is being scanned in run mode.

FDL
Red A fault has occurred.
Green The system is functioning normally.

Table 4-7: Profibus Scanner System LED

Color Indication
Red A network error has occurred. The LED flashes
red at one second intervals.
Green No network errors exist.

Table 4-8: Profibus Scanner Communications LED

4.7.4 Profibus Downloading Procedure

In order for a new Profibus Adapter to properly communicate with external Profibus devices, it
must first have a configuration file downloaded and stored into its flash memory.

If this is the first time this process is being done, a Hyperterminal session may need to be set up
on the Laptop PC. Complete Step 1 and Step 2 first. If a session has already been setup, con-
tinue on to Step 3.

Step 1: Start Hyperterminal and make a new session, refer to Figure 4-21. This example
names the new session SST-Profibus. A new icon may also be selected if desired.
When exiting, you will be asked if you want to save the session you have just
created. Do so to eliminate this step in the future.

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Figure 4-21: Hyperterminal New Connection - Connection Description

Step 2: When the “Connect To” or “Phone Number” window appears, refer to Figure 4-22,
select “Direct to COM1”. Once you click the OK button, the COM1 properties
window will appear, refer to Figure 4-23. Change the default Bits per second to
115200 and the flow control to None. once this is completed and you click OK, the
session will open and the lower left hand crner of the window will indicate that you
are connected and time the connection. Refer to Figure 4-24.

Figure 4-22: Hyperterminal Connect To Window

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Figure 4-23: Hyperteminal Com1 Properties Window

Figure 4-24: Hyperterminal Session Connected

Step 3: To load the Profibus Adapter module, connect a null-modem serial cable between
the COM1 port on the Laptop PC and the RS232 Configuration Port on the Profibus
Adapter. Refer to Figure 4-20 for the location of RS232 port. The SLC 5/05
processor must be in program mode and the hyperterminal session must be started
and indicating it is connected.

Step 4: Type an asterick (*) to get the Adapters attention. It may take several astericks for
the Profibus Adapter to properly auto detect the baud rate being used. When
communication is established, the hyperterminal will indicate the status of the
Profibus Adapter. Refer to Figure 4-25.

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Figure 4-25: Hyperterminal Status Communication

Step 5: To initiate the transfer of the configuration file type in the following command:
recbssxmodem. Figure 4-26 shows the response on the hyperterminal. Next, use the
TRANSFER pull down menu to select SEND FILE.

Figure 4-26: Hyperterminal Response to Configuration File Transfer

Step 6: After selecting SEND FILE, Figure 4-27 shows the window that appears. In this
example, the file name is 41xpb_1.bss. The file will always have a .bss extension.
Ensure you change the Files of type pull down menu to all files (*.*) when browsing
for the correct file.

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Figure 4-27: Hyperterminal Send File Menu

Step 7: When the proper file has been selected, the final Send File window will appear, refer
to Figure 4-28. Use the Protocol pull down menu to select Xmodem prior to clicking
the SEND button.

Figure 4-28: Hyperterminal Final Send File Window

Step 8: The file, 41xpb_1.bss, will be sent to the Profibus module and upon completion, a
successful report will be returned. At this time the flash memory has not been
updated. Type the command updflash at the prompt and hit enter. Refer to Figure 4-
29.

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Figure 4-29: Hyperterminal Flash Updating Screen

Step 9: A report of the flash updating with a successful conclusion will appear on the
hyperterminal. Refer to Figure 4-30. This completes the Profibus Adapter download
procedure. Use the File pull down menu and exit and disconnect the hyperterminal
connection.

Figure 4-30: Hyperterminal Profibus Adapter Download Procedure Successful Comple-


tion Screen

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4.7.5 Upgrading Profibus Firmware

Upgrading Profibus Firmware will generally not be required on new installations. Should an
upgrade become necessary the following procedure may be used as a guideline for the process.

In order to upgrade the firmware of the SST Profibus Scanner, a properly configured Hyperter-
minal session, appropriate firmware file and a null modem serial cable connecting the Laptop
PC and the RS232 Configuration Port of the Profibus Scanner is required. Refer to the SST
Profibus Downloading Procedure, Subsection 4.7.4, Step 1 through Step 2, for the creation of a
Hyperterminal session.

Step 1: Connect a null-modem serial cable between the COM1 port on the Laptop PC and
the RS232 Configuration Port on the Profibus Adapter. Refer to Figure 4-20 for the
location of RS232 port. Start the Hyperterminal session but leave the power feeding
the SLC 5/05 and Profibus Scanner off.

Step 2: Energize the SLC 5/05 and the Profibus Scanner. When the SLC 5/05 is powering
up, verify the SYS LED on the scanner flashes for 2 approximately seconds.

While the SYS LED is flashing, use the Laptop PC keyboard to enter an exclamation
mark (!) in the Hyperterminal session. This may have to be repeated several times
for the Profibus Scanner to properly detect the correct baud rate. When communica-
tion is established, the LED’s on the Profibus Scanner will flash alternately red to
indicate that it is in configuration mode. Figure 4-31 shows the display on the
Hyperterminal session.

SST Profibus - Hyperterminal


File Edit View Call Transfer Help

PFB-SLC Boot Utility


Copyright (c) 1996 S-S Technologies Inc.
Ver. 2.00

; Commands:
; LoadFlash, Run, RunAux, Ver, Help

;›_

Connected 0:1:22 Auto detect Auto detect SCROLL CAPS NUM Capture Print echo

ES1193f_01

Figure 4-31: Profibus Firmware Upgrade - Hyperterminal Connect

Step 3: Type in the command LoadFlash. On the Hyperterminal session a message will
appear asking you to confirmation that you want to replace the Module in the Flash
memory. Type in Y for yes. Refer to Figure 4-32.

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.52 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

SST Profibus - Hyperterminal


File Edit View Call Transfer Help

PFB-SLC Boot Utility


Copyright (c) 1996 S-S Technologies Inc.
Ver. 2.00

; Commands:
; LoadFlash, Run, RunAux, Ver, Help

;›LoadFlash
Are You Sure You Want to REPLACE the Module in FLASH? (y/n)

Connected 0:1:22 Auto detect Auto detect SCROLL CAPS NUM Capture Print echo

ES1193g_01

Figure 4-32: Profibus Firmware Upgrade - LoadFlash

Step 4: After typing Y for yes, you will be requested to start sending your file by starting the
XModem. On the Hyperterminal menu bar, click on Transfer, Send File. Refer to
Figure 4-33.

The Select File to Send screen will open. Find the appropriate .ssf file. Make sure
that All Files (*.*) is selected in the Files of type text box. Refer to Figure 4-34.

SST Profibus - Hyperterminal


File Edit View Call Transfer Help

Send File. . .
Receive File. . .
PFB-SLC Boot Utility
Capture Text. . .
Copyright (c) 1996 S-S Technologies Inc.
Ver. 2.00 Send Text-File. . .
Capture to Printer

; Commands:
; LoadFlash, Run, RunAux, Ver, Help

;›LoadFlash
Are You Sure You Want to REPLACE the Module in FLASH? (y/n) y
Start Your XMODEM Send, Ctrl-X to Cancel

Connected 0:4:51 Auto detect Auto detect SCROLL CAPS NUM Capture Print echo

ES1193h_01

Figure 4-33: Profibus Firmware Upgrade - Transfer Send File

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.53 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

Select File to Send

Look in: Profibus-Loading

Pfbslc.ssf

File name: Pfbslc.ssf Open


Files of type: All Files (*.*) Cancel

ES2122_01

Figure 4-34: Profibus Firmware Upgrade - Select File To Send

Step 5: When the appropriate file is open, Pfbslc.ssf is used in this example and may differ
from actual, the Send File window will open. Refer to Figure 4-35. Verify that the
Protocol text window shows Xmodem before clicking the Send button.

The Hyperterminal session will report the process of the file transfer after clicking
on the Send button. Refer to Figure 4-36.

Send File

Folder: C:\Profibus-Loading

Filename:
C:\Profibus-Loading\Pfbslc.ssf Browse. . .

Protocol:
Xmodem

Send Close Cancel

ES2123_01

Figure 4-35: Profibus Firmware Upgrade - Send File

Xmodem file send for SST-Profibus

Sending: C:\Profibus-Loading\PFBSLC.SSF

Packet: 707 Error checking: CRC

Retries: 0 Total retries: 0

Last error:

File: 52k of 129k

Elapsed: 00:00:09 Remaining: 00:00:14 Throughput: 5112cps

Cancel cps/bps

ES2124_01

Figure 4-36: Profibus Firmware Upgrade - File Transfer Progress

P&H Mining Equipment - Technical Communications Copyright © 2002 Harnischfeger Corporation


SECTION 4, Version 0 - 9/02 - 4.54 - Section 4, PLC.fm
4100XPB Electrical Manual Programmable Logic Controller

Step 6: Using the Laptop PC keyboard, type Y for yes when prompted to transfer the loaded
file into the actual Flash memory of the Scanner. Refer to Figure 4-37.

SST Profibus - Hyperterminal


File Edit View Call Transfer Help

; LoadFlash, Run, RunAux, Ver, Help

;›LoadFlash
Are You Sure You Want to REPLACE the Module in FLASH? (y/n) y
Start Your XMODEM Send, Ctrl-X to Cancel.
XMODEM Receive Successful
About to PROGRAM new Module:

; Profibus Module (DP, FDL)


; Copyright (c) 1995-2000 SST/Woodhead Canada Ltd.
; For SST-PFB-SLC Card
; Version 1.70

Into FLASH, Are You Sure? (y/n) y


Programming Flash. . . .Please Wait
New Module Stored in FLASH Successfully
:›_
Connected 0:15:37 Auto detect Auto detect SCROLL CAPS NUM Capture Print echo

ES1193i_01

Figure 4-37: Profibus Firmware Upgrade - Stored in Flash Successfully

Step 7: When the New Module Stored in Flash Successfully message appears, exit by typing
the RUN command. Refer to Figure 4-38. This will exit the system configuration
mode of the Scanner and complete the process.

SST Profibus - Hyperterminal


File Edit View Call Transfer Help

; LoadFlash, Run, RunAux, Ver, Help

;›LoadFlash
Are You Sure You Want to REPLACE the Module in FLASH? (y/n) y
Start Your XMODEM Send, Ctrl-X to Cancel.
XMODEM Receive Successful
About to PROGRAM new Module:

; Profibus Module (DP, FDL)


; Copyright (c) 1995-2000 SST/Woodhead Canada Ltd.
; For SST-PFB-SLC Card
; Version 1.70

Into FLASH, Are You Sure? (y/n) y


Programming Flash. . . .Please Wait
New Module Stored in FLASH Successfully
:›Run
Connected 0:15:37 Auto detect Auto detect SCROLL CAPS NUM Capture Print echo

ES1193j_01

Figure 4-38: Profibus Firmware Upgrade - Run

Copyright © 2002 Harnischfeger Corporation P&H Mining Equipment - Technical Communications


Section 4, PLC.fm - 4.55 - SECTION 4, Version 0 - 9/02
Programmable Logic Controller 4100XPB Electrical Manual

4.8 DISCRETE INPUT / OUTPUT MODULES

4.8.1 General Information

I/O modules are available in a wide variety of densities including 4-, 8-, 16-, and 32-point and
can interface to AC, DC, and TTL voltage levels. Output modules are available with solid state
AC, solid state DC and relay contact type outputs. Combination modules are available in 2-
input/2-output, 4-input/4-output, and 6-input/6-output versions.

The modules feature input filtering, optical isolation, and built-in surge protection to enhance
the reliability of operation in noisy industrial environments.

4.8.2 Features

IN0
IN1

IN2
IN3

IN4
IN5

IN6
IN7

IN8
IN9

IN10