IGBT Retrofit Rectifier-SIM-D Device Manual - 1 PDF

SHOVEL
TROUBLESHOOTING
DEVICE MANUAL
MANUAL (PART I)
COVERING
IGBT – HYBRID
RETROFIT 395BII/495B
SIEMENS ENERGY & AUTOMATION

ALPHARETTA, GA
USA
REVISED: 06/28/07
TABLE OF CONTENTS
CHAPTER 1 DEVICES --------------------------------------------------------------------- 1-1

AIR FLOW MONITOR ---------------------------------------------------------------------------------- 1-1
DC CURRENT TRANSDUCER------------------------------------------------------------------------ 1-1
DIGITAL TACHOMETER ----------------------------------------------------------------------------- 1-2
EM11 MIXED I/O CARD-------------------------------------------------------------------------------- 1-5
FUSE MONITOR BOARD ------------------------------------------------------------------------------ 1-6
GROUND FAULT MONITOR ------------------------------------------------------------------------- 1-7
MM11 MAILBOX MEMORY -------------------------------------------------------------------------- 1-8
PG16 RECTIFIER CONTROL PROCESSOR------------------------------------------------------ 1-8
PM16 GENERAL PROCESSOR --------------------------------------------------------------------- 1-10
PULSE DISTRIBUTION BOARD ------------------------------------------------------------------- 1-11
SE20.2 SITOR INTERFACE MODULE------------------------------------------------------------ 1-13
SE26.1 SIGNAL ISOLATOR MODULE ----------------------------------------------------------- 1-14
SE4.1 24V BINARY I/O MODULE ------------------------------------------------------------------ 1-15
SE5.3 115/220VAC ISOLATED INPUT MODULE ---------------------------------------------- 1-16
SE6.1 RELAY OUTPUT MODULE ----------------------------------------------------------------- 1-17
SE7.1 TERMINAL BOARD MODULE------------------------------------------------------------- 1-18
SIMADYN-D CARD RACK--------------------------------------------------------------------------- 1-19
SITOR BLOCK ------------------------------------------------------------------------------------------ 1-20
THERMISTOR (3UP7) MONITOR ----------------------------------------------------------------- 1-23
CHAPTER 2 TEST PROCEDURES ----------------------------------------------------- 2-1

CALIBRATING BUS CURRENT FEEDBACK ---------------------------------------------------- 2-1
CALIBRATING BUS VOLTAGE FEEDBACK ---------------------------------------------------- 2-3
CALIBRATING LINE VOLTAGE FEEDBACK--------------------------------------------------- 2-3
SIM-D PROCESSOR ERROR CODES--------------------------------------------------------------- 2-4
TESTING RECTIFIER FIRING PULSES ----------------------------------------------------------- 2-5
CHAPTER 3 ADDENDUMS --------------------------------------------------------------- 3-1

ADDENDUM-1--------------------------------------------------------------------------------------------- 3-1
ADDENDUM-2--------------------------------------------------------------------------------------------- 3-5
i
RECTIFIER TROUBLESHOOTING
TABLE OF FIGURES
Figure 1 Digital Tachometer Problem #1 ............................................................................................... 1-3
Figure 4 EM11 Card ................................................................................................................................ 1-5
Figure 5 Fuse Monitor Board.................................................................................................................. 1-6
Figure 6 PG16 Card ................................................................................................................................. 1-8
Figure 7 PM16 Card .............................................................................................................................. 1-11
Figure 8 Pulse Distribution Board ........................................................................................................ 1-12
Figure 9 SE20.2 Interface Card ............................................................................................................ 1-13
Figure 10 SE24.1 Daughter Board........................................................................................................ 1-14
Figure 11 SE26.1 Isolator Module ........................................................................................................ 1-15
Figure 12 SE4.1 Interface Module ........................................................................................................ 1-16
Figure 13 SE5.3 Isolated Input Module................................................................................................ 1-17
Figure 14 SE6.1 Relay Output Module ................................................................................................ 1-18
Figure 15 SE7.1 Terminal Board Module ............................................................................................ 1-18
Figure 16 Simadyn-D Card Rack.......................................................................................................... 1-20
Figure 17 SITOR Block ......................................................................................................................... 1-21
Figure 18 SITOR SCR Clamping Detail .............................................................................................. 1-21
Figure 19 Thermistor Monitor .............................................................................................................. 1-24
Figure 20 Current Feedback Bridge #1.................................................................................................. 2-1
Figure 21 Firing Pulse Cable Routing (Chopper Machines) ................................................................ 2-5
1-1
DEVICES TROUBLESHOOTING
Chapter 1 DEVICES
AIR FLOW MONITOR
EXPLANATION:
The airflow monitor is used to make sure that the rectifier bridge and chopper bridge cooling fans
are working whenever the DC bus is energized.
The unit consists of two parts, the sensor unit or probe, and the monitoring unit. The monitoring
unit is mounted above the Forward rectifier bridge and Regen rectifier bridge. The probe is also
mounted there, but it is approximately flush with the rectifier face and the probe extends in
towards the center of the skid so it is directly in the airflow created by the fans.
The sensor unit is a "hot wire" system. The control unit puts a constant voltage on the probe, it
then measures the resistance (which is dependent on the probe temperature) by measuring the
current.
The trip level is set on the thumb-wheel on the airflow monitor. The correct setting for the unit is
5m/s and is in the prints for your machine. If the unit is in a tripped condition, the red led will be
off.
Because of the time for a fan to "spin up", the Simadyn-D doesn't begin monitoring the contacts
until 60 seconds after the DC bus is switched on. If the DC bus shuts off 60 seconds after it
comes on, the airflow circuit should be inspected.
It should also be noted that forward rectifier bridge and regen rectifier bridge airflow monitor units
are wired in series to the Simadyn-D. The control cannot distinguish which unit is sending the
fault. Therefore, the defective unit must be isolated by either observing the fault led or
temporarily jumping across contacts to isolate the bad unit.
WARNING!!!
RUNNING THE MACHINE WITHOUT PROPER AIRFLOW WILL RESULT IN PERMANENT
DAMAGE TO THE MACHINE
END OF PROCEDURE
DC CURRENT TRANSDUCER
EXPLANATION:
The DC Current Transducer is a fixed gain precision isolator and amplifier. It is a hermetically
sealed unit that is enclosed in a metal box for noise protection. It is located under the chopper
bridge on the SITOR side of the machine.
The unit is rated to put out exactly 10 volts with an input of 150mv and maintain a 1% accuracy
regardless of temperature.
REPLACING THE CURRENT TRANSDUCER:
1-1
There is no configuration or adjustment required on the module. All DC current transducers are
directly interchangeable with all others.
TESTING THE UNIT:
See DC Current Calibration.
END OF DESCRIPTION
DIGITAL TACHOMETER
EXPLANATION:
The digital tachometer is an important part of the shovel system. Its feedback is used for the
following functions:
1. Speed Regulation (SiBAS);

2. Allows brake setting to be done without excessive brake wear;
3. Is used to determine crowd impact loading;
4. Allows the Hoist reference reduction circuit to work.
The digital tachometer, sometimes called an optical pulse encoder, functions by putting out a
pulse frequency that is proportional to the speed of the motor. So that direction as well as speed
can be determined, two channels of pulses 90 electrical degrees apart are monitored in the
tachometer interface circuitry.
The tachometer is a hollow shaft design which fits over the motor shaft and allows the
mechanical brake to be mounted behind it. It is affixed to the shaft by a clamping sleeve that
must be tightened down according to the installation instructions in order to accomplish 2 things:
1. Keep the tachometer from slipping on the shaft

2. Maintain concentric alignment between the tachometer and the motor shaft.
Inside the tachometer is a precision etched encoder disk that is fixed to the rotating part of the
tachometer. This disk passes between a light source and a four quadrant light receiver which
generates 4 channels of pulses, all 90 electrical degrees apart. These pulses are normally
referred to as the 0, 90, 180, and 270 degree channels.
The SiBAS / Simadyn-D can use any 2 channels as long as they are 90 electrical degrees apart.
The following would be valid combinations of channels.
1. 0 & 90
2. 90 & 180
3. 180 & 270
4. 270 & 0
Please note that Simadyn-D uses 180 & 270 for monitoring overspeed and SiBAS uses 0 & 90 for
speed feedback for regulation.
The tachometer signal is received by SiBAS and the actual decoding of the tachometer signal is
done with circuitry and software on SiBAS.
1-2
GENERAL STEPS IN TROUBLESHOOTING A TACH PROBLEM:
Changing a tachometer is big job, if the tachometer is suspected as a problems source, do the
following before changing the tachometer:
1. Make sure that the tachometer is mechanically secure on the motor shaft and that the torque
arm is adjusted correctly.
2. Double check all connections from the tachometer to the SiBAS card including shield
connections.
3. Try and alternate set of tachometer channels.
Figure 1 Digital Tachometer Problem #1
1-3
TESTING A TACHOMETER:
In order to test a tachometer, its output must be displayed on an oscilloscope while running at a
constant speed. The best set up for this test is to have the motor uncoupled, and run the drive in
V/HZ mode. While it is not possible to uncouple the swing, it should still be tested in V/HZ mode.
1. Uncouple the motor under test if it's the crowd or the hoist.
2. Put the SiBAS in V/HZ mode, manually release the brake, and run at 30Hz.
3. Simultaneously display both tachometer channels on the scope.
4. The channel that is being triggered on should be steady on the scope display, while there will
be a small amount of movement or jitter in the other channel. If this jitter is over 5 usec, the
tachometer is probably bad (see Digital Tachometer Waveforms).
5. Observe the voltage levels of both channels, they should be around 22.7 vdc. If they are
both low, check the voltage (+24v) going to the tachometer. If one channel is low, try an
alternate set of channels. If the problem can't be corrected, the tachometer is probably bad
(see Digital Tachometer Waveforms2).
6. Observe the symmetry of the waveforms, the duty cycle of the pulses on both channels
should be identical. If they are not, the tachometer is probably bad (see Digital Tachometer
Waveforms2).
7. Check for missing pulses on either channel. If pulses are missing, try an alternate pair of
channels. If this doesn't clear up the missing pulses, the tachometer is bad (see Digital
Tachometer Waveforms).
8. If the symptoms were that the motion won't turn in n-control, but Torque is maximum, check
the scope for a dead tachometer channel. If this is the case, try an alternate set of
tachometer channels. If this won't clear up the problem, the tachometer must be replaced
(see Digital Tachometer Waveforms3).
1-4
9. If the symptoms were that the motion won't turn in n-control, but Torque is maximum, and the
tachometer channels look OK, the tachometer maybe phased incorrectly. With the motor
running in V/HZ, check speed feedback signal in SiBAS monitor. It should have the same
polarity as the Operator Panel reference. If not, reverse the leads on the TBTACH terminals
in the skid.
END OF DESCRIPTION
EM11 MIXED I/O CARD
EXPLANATION:
The EM11 is a multipurpose I/O card. Three functions of this card are used on the shovel:
X5 is used to interface Digital Tach to sense the speed of the motion
X6 is used to interface analog inputs
X7 is used to interface binary inputs
The Binary Inputs are interfaced through SE4.1 modules. The Analog Inputs are interfaced
through SE7.1 modules.
Figure 4 EM11 Card
REPLACING THE EM11:
There is no adjustment or configuration required for this card. All EM11's are directly
interchangeable with all others.
END OF DESCRIPTION
1-5
FUSE MONITOR BOARD
EXPLANATION:
The fuse monitor board monitors the status of the rectifier fuses to determine if any of the
fuses are open circuited. There are two fuse monitor boards (both located in cabinet +R1A):
device +R11-A201 which monitors the first forward bridge and device +R12-A202 which
monitor the second forward rectifier bridge. The fuse monitor card measures the voltage
across each fuse. If a voltage is measured across any one of the fuses, the Simadyn-D
controller will put the rectifier into a gate blocked condition, the main contactor will open, and
all motions will come to a stop and mechanical brakes will set.
Each fuse monitor card has a NO set of contacts. Simadyn-D monitors these contacts, which
are connected in series, to determine if a rectifier fuse has blown. To determine which fuse
has triggered the fuse monitor card, note the six LEDs on the upper left-hand edge of the
fuse monitor board. These LEDs are laid out in the same position that the fuses are in the
rectifier. Hence, if the middle LED on the bottom row is lit, the middle fuses on the bottom
row of the rectifier are blown.
Figure 5 Fuse Monitor Board
If the main contactor opens up while the drive is running, it is possible that the fuse monitor
board may erroneously indicate a blown fuse. Just push the reset button on the card to clear
the blown fuse indication. It may be necessary to remove the +/-24vdc supplying the card
(via circuit breaker E02-Q11 in cabinet +E1A) to clear an erroneous blown fuse indication. If
the fuse monitor board will not reset, then a fuse may actually be blown (the red pop-up
button on the fuse may not always indicate that a fuse has blown) or the fuse monitor card
may be faulty.
REPLACING THE FUSE MONITOR BOARD:
CAUTION: THERE ARE LETHAL VOLTAGES ON THIS CARD! ENSURE THAT THE MAIN
POWER CONTACTOR IS LOCKED OUT PRIOR TO CHANGING THIS CARD.
1. No calibration is necessary when replacing the fuse monitor board.
1-6
2. All fuse monitor boards are interchangeable.
END OF PROCEDURE
GROUND FAULT MONITOR
EXPLANATION:
The Ground Fault Monitor is used to test the leakage to Machine ground of the Incoming AC and
the DC bus. Both of these should be isolated from earth ground.
The monitor is connected to the incoming 800vac on phase 2. The connection to earth ground is
through fuse R10-F1, which is located next to the unit underneath the Regen rectifier bridge in
cabinet +R1B. The fuse is an indicator type with a large button that will pop up if blown.
The measurement is made by putting out a square wave pulse train between the incoming line
and earth ground and measuring the rise time of the pulses. In the case of a Ground Faults, the
unit will open a set of contacts and signal the Simadyn-D through the SE4.1 module N67-A11,
connector X2, terminal 1.
The following controls and indicators are on the unit:
1. System Capacity adjusts the unit for the system capacitance of the shovel.
2. Sensitivity adjusts for the trip point in kohms.
3. Bar type scale that indicates the measured resistance to ground.
4. Push-button for testing operation of the unit.
5. Tripped indicator is a red LED.
TESTING THE UNIT:
The unit can be functionally tested as follows:
1. If there is a ground fault indication, pull the ground fault fuse (with power off & the bus
discharged). If the ground fault indication doesn't clear, then replace the unit.
2. With the power off and the bus discharged, ground any incoming phase or the DC Bus, if this
doesn't cause the unit to trip, replace it.
3. Push the test push-button, if a ground fault indication doesn't appear on the unit replace it. If
a ground fault indication doesn't appear on the troubleshooting computer, troubleshoot the
interface circuitry.
END OF DESCRIPTION
1-7
MM11 MAILBOX MEMORY
EXPLANATION:
This card contains dual port RAM and is used for interprocessor communication in the Simadyn-
D rack. When processors have to communicate with each other, the sending processor writes to
the MM11 card while the receiving processor reads from it. The fact that dual port RAM is used
lets all processors operate asynchronously with respect to the other processors.
REPLACING THE MM11:
***********************************************************************************************
* WARNING---This card is extremely static sensitive *
* Handle with extreme care *
***********************************************************************************************
1. The MM11 is held into the rack by a screw at the top and bottom of the card, besides insuring
a good mechanical connection, these screws also serve to ground the front plate of the
processor providing noise immunity. These screws must always be used even for temporary
trouble shooting.
END OF DESCRIPTION
PG16 RECTIFIER CONTROL PROCESSOR
EXPLANATION:
The PG16 is a special purpose processor for Rectifier control.
Figure 6 PG16 Card
1-8
The front panel of the PM16 has the following connectors and indicators:
1. 7-segment display. Under normal operating conditions, this display shows the programmed
number of the processor. If it flashes, then there is a processor error (see Processor Error
Codes).
2. H10 Forward Bridge On. This green LED indicates that the forward (motoring) bridge is on.
3. H11 Regenerative Bridge On. This red LED indicates that the Regenerative Bridge is on (not
applicable on Shovel Systems using chopper bridge).
4. Fault Acknowledge button. This is the red button directly underneath the 7 segment display.
It is used to acknowledge a processor fault and clear the error code.
5. Test Jack X10 - M. This test point serves as common for the other test jacks.
6. Test Jack X11 - Reset. Jumpering this jack to X10 get will force a local reset of this card
only. As doing this normally results in a complete system crash, resets should be done using
the reset button on the Simadyn-D Card Rack.
7. Test Jack X12 Synch Voltage L1-L3. This is the synchronizing voltage that is used to time the
firing pulses. Because only the zero crossing points of the phase voltages are transmitted to
the Simadyn-D, the voltage is represented as a 24v square wave. This voltage originated on
the Synchronizing Module and is processed into zero crossings by the SE20.2 Module.
8. Test Jack X13 Analog DC Current. This is the Analog DC bus current signal. It has a range
of +/- 10v. 10volts represents 4200 amps. If the signal is positive, forward bridge current is
being shown. If it is negative, regenerative bridge current is being shown (not available on
chopper machines).
9. Test Jack X14 Pulse Enable. This signal shows where the pulses have been enabled. +5v
represents enabled, 0v is disabled.
10. Test Jack X15 Firing Pulse Simulation. This signal is a representation of the firing pulses.
The simulation is a series of square waves. The pulse that represents the firing of SCRs 6
and 1 is marked by putting fringe on the top of the pulse. If the fringe is on the top of the
pulse, the forward bridge is represented, if it is on the bottom, the regenerative bridge firing
pulses are being displayed (not available on chopper machines).
11. EPROM Module. This contains the control program for the processor. If processors are
swapped, the EPROM must stay with the processor in the physical location it came from.
12. Connector X5. This connector contains a blueberg jumper that is used to permit pulse
enabling. It is installed between pins 3 & 4 of the connector. If this jumper is not installed,
the bridge will never enable. Make sure to swap this jumper when swapping this card.
13. Connector X6. This connector is not used in the shovel configuration.
14. Connector X7. This connector is used for the cable between the PG16 and the SE20.2. This
cable carries firing pulses out and rectifier feedback signals back in. The connector has
posts on it for the cable locking mechanism. These locks must be engaged before the shovel
is run.
REPLACING THE PG16:
1-9
***********************************************************************************************
***********************************************************************************************
1. The PG16 is held into the rack by a screw at the top and bottom of the card, besides insuring
trouble shooting.
2. After replacing this card, the DC Bus Voltage must be recalibrated (see DC Bus Voltage
Calibration).
END OF DESCRIPTION
PM16 GENERAL PROCESSOR
EXPLANATION:
The PM16 is a general purpose Simadyn-D processor. It's function in the system depends
entirely on the program in it's EPROM. The processor is also fitted with communications
submodules that are necessary for the configuration.
The front panel of the PM16 has the following connectors and indicators:
1. 7-segment display. Under normal operating conditions, this display shows the programmed
number of the processor. If it flashes, then there is a processor error (see Processor Error
Codes).
2. Fault Acknowledge button. This is the red button directly underneath the 7 segment display.
It is used to acknowledge a processor fault and clear the error code.
3. Reset Jacks. Jumpering these jacks together will force a local reset of this card only. As
doing this normally results in a complete system crash, resets should be done using the reset
button on the Simadyn-D rack.
4. 4. Connectors X1 and X2. These connectors are used for external serial communications.
Each one of these connectors is programmed with a communication submodules which
determine the physical characteristics of the interface.
5. 5. Connector X5. This is a 40 pin connector for binary inputs and outputs. The interface
cable has a 40 pin connector on one end, and 4 10 pin connectors on the other end. The 10
pin ends are plugged into interface modules that act as a buffer between the processor and
the physical world.
6. EPROM Module. This contains the control program for the processor. If processors are
swapped, the EPROM must stay with the processor in the physical location it came from.
1-10
Figure 7 PM16 Card
REPLACING THE PM16
***********************************************************************************************
***********************************************************************************************
1. The PM16 is held into the rack by a screw at the top and bottom of the card, besides insuring
trouble shooting.
2. When replacing this card, the communication submodule configuration must stay the same.
Use care when swapping the submodules so the pins don't get bent. It is much easier to
swap these modules if the EPROM and the ribbon cable for connector X2 are temporarily
removed.
END OF DESCRIPTION
PULSE DISTRIBUTION BOARD
EXPLANATION:
The pulse distribution board receives pulses from the rectifier control, and firing pulse power from
the firing pulse power supply and feeds them to the Sitor Blocks.
The board has 2 functions:
1. To route firing pulses to the Sitor Blocks.
1-11
2. To route firing pulses through the board to another Pulse Distribution Board.
How the board functions depends on the cable connections. The following connectors are
involved in firing pulse routing:
X1- Receives active and inactive firing pulses.

X2 - Passes the same pulses as X1
X10 -Used to Pass inactive firing pulses
X20 - Receives inactive pulses and makes them active pulses.
The following sets of test points are used to measure both active and inactive test points:
X6 is used to view inactive firing pulses

X7 is used to view active firing pulses
With the configuration on the Shovel, Forward Rectifier pulses can be viewed on the Forward
Rectifier Pulse Distribution boards on test point X7 on either board.
The connections on the left side of the board are used for the Firing Pulse power supply
connection. This power is daisy-chained through the Pulse Distribution boards.
Figure 8 Pulse Distribution Board
REPLACING THE PULSE DISTRIBUTION BOARD
All Pulse Distribution Boards are directly interchangeable. However if a new board is installed,
the jumpers must be soldered in as shown in the prints.
Normally, problems with the firing pulses on the board are not the fault of the board, but of the
way the cables are plugged in. Check your machine prints for wiring details.
END OF DESCRIPTION
1-12
SE20.2 SITOR INTERFACE MODULE
EXPLANATION:
The SE20.2 is an interface board between the Sitor Bridge and the PG16 processor.
On the outgoing side, it takes firing pulses from the PG16, buffers and amplifies them, and sends
them to the pulse distribution boards.
On the incoming side, it takes DC Bus Voltage and Current Feedbacks, converts them to
frequencies, isolates them through transformers, and sends them to the PG16 for decoding.
Additionally, it takes the synch voltage from the synch module, detects the zero crossings, and
sends this information to the PG16. It also generates a "separate current equals zero" (I=0) and
sends this to the PG16 where it is used as a permissive for initially switching on the rectifier
bridges.
Because this card is involved in every phase of rectifier operations, it can be a suspect for any
rectifier problem.
Also, because it functions as the front end for the PG16, the troubleshooting of these 2 cards is
often handled as a set.
Figure 9 SE20.2 Interface Card
1-13
Figure 10 SE24.1 Daughter Board
REPLACING THE SE20.2:
When replacing the SE20.2, the easiest way to do the calibrations is to take the SE24 resistor
modules from the old card and install them on to the new card.
After doing this operation, or when keeping the new SE24 modules, the DC current and DC
voltage calibrations should be redone.
See also:
DC CURRENT FEEDBACK CALIBRATION

DC VOLTAGE FEEDBACK CALIBRATION
END OF DESCRIPTION
SE26.1 SIGNAL ISOLATOR MODULE
EXPLANATION:
The SE26.1 module is an isolator for analog signals in the range of -10v to +10v. The module
provides galvanic isolation between the input and outputs. It is used on the shovel for isolation of
the line voltage signal which comes from the synchronizing module to the EM11.
The following connections are used in the shovel System:
Terminal Group X2:
term 031 : Analog Input +

term 032 : Analog Input -
Terminal Group X3:
term L+: +24v

term M : 24v common
1-14
term 04: Analog Output +

term 05: Analog Output -
Figure 11 SE26.1 Isolator Module
TESTING THE MODULE:
1. Test the module for offset by doing the following:
a. Disconnect the input wires from terminals 031 and 032;

b. Install a jumper between terminals 031 and 032;
c. Read the module output between terminals 04 and 05;
d. If the reading is not 0v, replace the module.
2. With a voltage going into terminals 031 and 032, read the output on terminals 04 and 05. If
they do not match exactly, replace the module.
END OF DESCRIPTION
SE4.1 24V BINARY I/O MODULE
EXPLANATION:
The SE4.1 is a general purpose Binary I/O card used to interface the PM16 card with +24vdc
inputs or outputs. Although the card can be used for either, each card is only INPUT or
OUTPUT. It cannot be both at the same time.
Whether a card is input or output depends on the addressing of the card. The addressing is
determined totally by what cable it is plugged into. The Simadyn-D binary cables are 40 pin at
the processor end. From there it splits into four 10 pin cables. These cables are then labeled
A,B,C and D. A and B are output connectors while C and D are input connectors.
This Module requires an external +24 vdc supply. It is connected to the terminals labeled 1P and
1M. The voltage is indicated on the module by a green LED.
1-15
All logic input and outputs are designated as positive logic. This means that if a signal is true
(indicated by the red status LED's), the input or output will be at +24v.
Figure 12 SE4.1 Interface Module
All SE4.1's are directly interchangeable with all others. There are no adjustments or
configurations required for this module.
END OF DESCRIPTION
SE5.3 115/220VAC ISOLATED INPUT MODULE
EXPLANATION:
The SE5.3 module is an isolated binary input module capable of receiving either 115vac or
220vac signals. It is used on the shovel to interface certain hard wired signals from the BE side
such as Main Contactor (DPC), POEB, and BEB signals. As such, it gets it's input from the PLC
control power that is derived from the UPS.
NEVER JUMPER ANY POWER TO THE CARD EXCEPT THE PLC CONTROL POWER.
MIXING PLC CONTROL POWER WITH ANOTHER 115V SCOURCE WILL RESULT IN
DISASTER ON THE SHOVEL.
The card also requires an external 24vdc supply which is wired to terminals 1P and 1M. The
presence of this voltage is indicated by a green LED.
All logic inputs on the card are designated as positive logic. This means that if the status light
(RED LED) for that input is on, voltage is present on the input.
If a voltage is present, and the corresponding LED is not lit, then the card is defective and must
be replaced.
1-16
Figure 13 SE5.3 Isolated Input Module
There is no adjustment or configuration necessary on the SE5.3. The card may be changed with
any other SE5.3 module.
END OF DESCRIPTION
SE6.1 RELAY OUTPUT MODULE
EXPLANATION:
The SE6.1 is an isolated binary output module that uses relays to achieve the isolation. Each
output has both a normally open and normally closed output. The module is used on the Shovel
to interface 115vac signals to the BE side. For instance, there is an SE6.1 contact in each brake
circuit.
NEVER JUMPER ANY POWER TO THE CARD EXCEPT THE PLC CONTROL POWER.
MIXING PLC CONTROL POWER WITH ANOTHER 115V SCOURCE WILL RESULT IN
DISASTER ON THE SHOVEL.
The card also requires an external 24vdc supply which is wired to terminals 1P and 1M. The
presence of this voltage is indicated by a green LED.
All logic inputs on the card are designated as positive logic. This means that if the status light
(RED LED) for that input is on, the relay is closed, the NO contact will be made and the NC
contact will be open.
1-17
Figure 14 SE6.1 Relay Output Module
There is no adjustment or configuration necessary on the SE6.1. The card may be changed with
any other SE6.1 module.
END OF DESCRIPTION
SE7.1 TERMINAL BOARD MODULE
EXPLANATION:
The SE7.1 is a terminal board that is used to interface the analog outputs of the EA12 and the
analog inputs and outputs of the EM11. The card itself has no active components.
On the card there is a three level terminal strip. On the top, the positive connection should go. In
the middle the negative connection belongs. The bottom row is the Shield Common and Must Be
Used.
Figure 15 SE7.1 Terminal Board Module
1-18
All SE7.1 modules are directly interchangeable with all others. There is no configuration or
adjustment necessary.
END OF DESCRIPTION
SIMADYN-D CARD RACK
EXPLANATION:
The Simadyn-D rack and power supply are used to power and connect the processors and
interface cards of the Rectifier and Central controls.
The power comes from an external 24 volt supply and is regulated down to +5, +15, and -15 volts
by the Simadyn-D power supply which is mounted under the rack. Additionally, the power supply
sends an OK signal to the processors, allowing them to boot up when the power supply senses
all voltages are within tolerances.
The power supply also contains a lithium battery that is used to only to maintain the internal time
in the Simadyn-D
The Rack consists of 2 separate buses. The upper bus is called the C-bus or communication bus.
It's function is entirely for interprocessor communication. The lower bus is called the L-Bus or
Local Bus, it's purpose includes interprocessor communication, but it is also used when the
Processors communicate with an I/O card like the EM11 or EA12.
Both busses have pins in between the connectors that must be configured for the card
arrangement in the rack. These jumpers are used to bridge control signals over empty slots.
1-19
Figure 16 Simadyn-D Card Rack
REPLACING THE RACK:
If the Rack is changed, the jumpers must be configured as shown in the Schematics.
END OF DESCRIPTION
SITOR BLOCK
EXPLANATION:
A sitor block is a single unit consisting of the following components:
1. SCR
2. Heatsinks & SCR Clamping mechanism
3. RC snubber network
4. Pulse Transformer & firing card
Each sitor unit has the following test points on the front cover:
1. Test point for the SCR Anode

2. Test point for the SCR Cathode
3. Test point for the SCR Gate
4. Gate lead for Gate Current Measurements
Each Sitor unit has the following connections:
1. Connection to the AC line through the buswork.

2. Connection to the DC bus through the buswork
1-20
3. Connection to firing control through the Pulse Distribution Card.
Figure 17 SITOR Block
Figure 18 SITOR SCR Clamping Detail
TESTING THE SCR:
Before testing the SCRs, the following safety conditions must be met:
1. The main contactor (DPC) must be switched off and locked out
2. The Bus must be completely discharged and verified with a Voltmeter.
After the safety conditions have been met, the test proceeds as follows:
1-21
1. With an ohm meter on the high ohms scale, read across the test points for the Anode and
Cathode. The meter should indicate a high ohms reading. It is normal for the ohm meter
reading to increase during the test, this is because the ohm meter will charge up the snubber.
2. All the blocks are linked through the transformer, DPT. Therefore, if one block shows a short,
they all will. It will then be necessary to isolate the bad block by either pulling it from the
cabinet, or removing the fuses to isolate it from the transformer.
3. Once the defective block is isolated, remove it from the unit and isolate the snubber by
disconnecting the wire between the snubber capacitors and snubber resistors.
4. If the unit now reads OK, then replace the defective snubber components. Otherwise,
replace the SCR.
5. Another test is to test the Gate-Cathode junction with an ohm meter. For this test, the ohm
meter should be on low ohms scale. Insert the test leads into the Gate and Cathode test
points on the sitor front cover, the ohms reading should be between 5 and 25 ohms. A
reading of zero is definitely bad, as is an open. Replace the SCR if the ohm meter reading
are incorrect.
TESTING THE FIRING CARD:
Follow the Testing Firing Pulses Procedure.
REMOVING A SITOR BLOCK:
The following steps should be used to remove a sitor block.
Before removing or installing SITOR blocks, the following safety conditions must be met:
1. The main contactor (DPC) must be switched off and locked out
2. The Bus must be completely discharged and verified with a Voltmeter.
3. Loosen but don't remove the 4 torxhead screws on the Sitor front cover.
4. Slide the screw heads over in the slots toward the center of the block.
5. The Sitor front cover should now be free to swing open.
6. With the front cover open, remove the bolts securing the sitor block to the buswork.
7. Pull the block straight out from the cabinet. If there is interference, it may be necessary to
remove the block underneath it and push up on the block while pulling it.
8. Installation is the reverse of this procedure.
CHANGING AN SCR:
1. Remove the Sitor Block from the skid.
2. Keep the front cover open, and disconnect the wire connecting the snubber resistors and the
snubber capacitors.
3. Loosen and remove the two large clamping bolts. Be careful not to damage the plastic
insulators for the bolts.
1-22
4. Separate the heatsink halves and observe the orientation of the SCR.
5. Remove the gate leads from the SCR.
6. Clean the heat sink halves.
7. Give the new SCR a very light coating of an approved heatsink oil, never use white silicon
paste.
8. Reconnect the gate leads, make sure the gate leads stay twisted and that the crimp
connections are secure.
9. Place the new SCR on the heatsink, making sure that the white centering pin is inserted into
the SCR. Place the plastic spacers on both ends of the heatsink halves and mount the upper
heatsink over the SCR. Make sure that both centering pins are correct.
10. Put the clamping bar on the bolts and make nuts finger tight. Then tightening each nut a little
at a time, tighten until the clamping bar is straight when measured with a straight edge.
11. To double check the clamping, measure the distance between heatsink halves on both ends,
they should be equal.
12. Reconnect the snubber capacitors and resistors.
13. Install the sitor block into the skid
END OF DESCRIPTION
THERMISTOR (3UP7) MONITOR
EXPLANATION:
The 3UP7 is used to monitor the motor thermistors in the Hoist, Crowd and Swing motions. The
monitoring is done for Monitoring the temperature for faults & warnings.
The motor temperature warning is set for 140 deg.C and the fault is set for 150 deg. C.
The following thermistor value correspond to the following temperature values:
Temp (deg C) Resistance (kohms)

60............…..............7.16
70....................…......4.93
80......................…....3.46
90......................…....2.47
100............................1.80
110............................1.33
120............................1.00
130......................…...0.76
140............….............0.62...........WARNING LEVEL
150.............…............0.47...........TRIP LEVEL
160....................….....0.36
1-23
Figure 19 Thermistor Monitor
CALIBRATING THE 3UP7:
The 3UP7 is NOT calibrated for shovel applications in the factory. It must be calibrated for the
proper trip and warning levels. The following procedure will calibrate the module:
1. Calibrating the Warning Level:
a. Disconnect the motor thermistor leads from T0, T1, T2, and T3
b. Hook up three 620 ohm resistors. T0 will be the common point, and the individual
resistors will be hooked to terminals T1, T2, and T3.
c. If the red warning indicator light is on, then turn the top adjustment pot until it goes off. If
it will not go off, verify the resistor values and connections. If it will still not go off, replace
the 3UP7 unit.
d. With the light off, turn the adjustment pot until the LED just comes on. This is the proper
calibration point.
2. Calibrating the TRIP Level:
a. Disconnect the motor thermistor leads from T0, T1, T2, and T3
b. Hook up three 470 ohm resistors. T0 will be the common point, and the individual
resistors will be hooked to terminals T1, T2, and T3.
c. If the red warning indicator light is on, then turn the top adjustment pot until it goes off, if it
will not go off, verify the resistor values and connections. If it will still not go off, replace
the 3UP7 unit.
d. With the light off, turn the adjustment pot until the LED just comes on. This is the proper
calibration point.
1-24
3. Testing the Binary Interface:
a. Push the Push-to-Test button. The troubleshooting computer fault display should now
display both a motor temperature warning and fault for the motion in question.
b. If there is no faults, then find the corresponding SE4.1 module, and trouble shoot the
interface.
REPLACING THE 3UP7:
1. The 3UP7 module must be configured before it can be adjusted. When the module is new, it
comes with all resistors installed in the resistor window by the adjustment pots.
2. Clip out the extra resistors.
3. Do the adjustment procedure as listed above.
END OF DESCRIPTION
1-25
PROCEDURES TROUBLESHOOTING
Chapter 2 TEST PROCEDURES
CALIBRATING BUS CURRENT FEEDBACK
EXPLANATION:
Current measuring on the DC bus is done through the shunt (device R40-SH in cabinet +R1B).
The rating on this device is 100mv = 2500 amps. This signal is sent to the DC current transducer
(DCI Transducer) (device R40-A3 in cabinet +R1B) pins 6 and 10. The gain of this transducer is
150 millivolt in = 10v out. The output of the DC current transducer is then sent out pins 4 and 5 to
the SITOR/Simadyn-D Interface Module (device R11-A501 located at the bottom of cabinet
+R1B) on pins b12 and z12. Next, the signal is sent to the SE20.2 interface module plug X2
(located in the main Simadyn-D rack Slot 13 in cabinet +N1A) via shielded cable N63-RC105.
The signal is scaled in the SE20.2 and converted to a frequency where it is then sent to the PG16
card (located in the main Simadyn-D rack Slot 17) on cable N63-RC7. This cable connects from
X3 of the SE20.2 to plug X7 of the PG16 card.
Figure 20 Current Feedback Bridge #1
TO CALIBRATE THE CURRENT FEEDBACK:
LOCK OUT MAIN CONTACTOR (DPC)
1. Disconnect the pulse cables from all rectifier blocks.
2. Disconnect the Top Shunt lead and short with bottom lead.
3. Using Telemaster (Service) program, perform Zero Offset calibration.
a. Change P3. TSHEL3. D4. ISE Æ 1

b. Read P3. TSHEL3. D3. YF1 (value)
c. Change P3. TSHEL3. D3. XF1 Æ above value
and save only the last value in EEPROM.
2-1
4. Disconnect the shunt leads short and hook a battery box across it. Leave the battery box off.
5. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change the
following connectors in Simadyn-D.
Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1
6. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card located
in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).
7. Turn the battery box connected to the shunt on. Carefully adjust this to 100.0mv. The
Troubleshooting Computer should read exactly 2500 amps for DC current. If it reads zero,
then reverse the polarity of the battery box.
8. If the OP1 Display panel does not display a value of 2500 amps, then adjust potentiometer
R7 on the SE24 adjustment board that is plugged into the SE20.2. There are two SE24
modules, one has 3 fixed resistors, one has 1 fixed resistor. Adjust R7 on the one with 3
fixed resistors.
9. Shut down the rectifier and return shunt connections to normal.
2. If the SE20.2 cannot be adjusted to read 2500 amps, then put 150mv on the shunt and read
the output of the DCI Transducer. The output should be 10vdc +/- 0.1vdc. If this is not there,
replace the DCI Transducer.
3. Check the input of the SE24 mounted on the SE20.2. If the 10vdc is not there, check the
wiring. If it is there, replace the SE20.2.
10. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.
END OF PROCEDURE
2-2
CALIBRATING BUS VOLTAGE FEEDBACK
CALIBRATION PROCEDURE:
LOCK OUT MAIN CONTACTOR
Since Bus voltage transducers areread by SiBAS and DC Bus voltage information to Simadyn-D
is given by SiBAS, there is only zero offset calibration required.
1. With the DC bus down, hook up a DC meter capable of measuring 1000 vdc on the terminals
on the high voltage side of the board.
2. When DC Bus voltage is completely Zero, Using Telemaster (Service) Program, perform
Zero offset calibration.
a. Change P3. TSHEL3. D4. ISE Æ 1

b. Read P3. TSHEL3. D4. YF (value)
c. Change P3. TSHEL3. D4. XF Æ above value
and save only the last value in EEPROM
END OF DESCRIPTION
CALIBRATING LINE VOLTAGE FEEDBACK
EXPLANATION:
The Siemens system uses the output of the BE Auxiliary Transformer for both line voltage
feedback and synchronizing voltage.
The voltage comes directly off of the Main panel on the MCC, through 3 fuses, and enters the
Siemens skid on TBSYNCH which is located in the bottom of cabinet +M1A (the breaker cabinet).
The voltage maybe either 460 or 380 volts depending of the machine configuration.
From TBSYNCH, the voltage is fed into the Synchronizing Voltage Monitor (Device N30-A15)
located in the bottom of cabinet +N1B. The calibration is done using pot R34 in SE49.1 Module,
which is the lowest of the two pot located on this module.
The line voltage signal is then fed into an SE26.1 isolator module (N64-A118). The isolator
output goes to the SE7.1 module (N64-A13) where is connected to the EM11 (D08) module
through ribbon cable N64-RC106.
This calibration must always be done after changing taps on DPT, the main transformer.
PROCEDURE:
1. Bring up the DC bus. All motions must have the brakes set.
2. Read the actual line to line voltage on the fuses in cabinet +R1A. Note: Many meters are
only good for 750vac--use an appropriate meter.
3. On the OP1 Display panel , look at line voltage.
2-3
4. Adjust R34 on the Synch Voltage Module until the OP1 Display panel reads line voltage
display, same as the meter.
END OF PROCEDURE
SIM-D PROCESSOR ERROR CODES
The PM16 and PG16 processors indicate error codes on the seven segment display. Normally
this display shows the processor number. If the processor number is not displayed, an error
code will be flashing. The following error codes are common to both the PG and PM16
processors:
“b”
This code means that the power supply battery has run down. This battery is located behind a
screw type cover on the Simadyn-D Rack Power Supply. It is a 3.6v Lithium battery. Note: This
is the same battery used in the Simovert.
“H”
The H means that a non maskable interrupt has occurred. This normally means that there is a
bad piece of hardware in the rack. If only one processor shows this code--replace it. If the entire
rack shows H's, then swap the one that's blinking. If more than one are blinking, swap the
leftmost processor that's blinking.
For example, if the entire rack shows H's, but 5, 6, and 7 are blinking, then swap processor #5.
“E”
The E represents a scan time over run. This means that the processor was unable to complete
its work in the time allowed. In most cases this means a programming error. However, it is
possible when using the Service program, to generate this error. In this case, there is no
problem. Acknowledge the fault & continue operation.
“0”
A flashing 0 means that the EPROM failed to initialize. This error should only occur on power up
or after a reset. In all cases, it means a defective EPROM module.
“U”
A flashing U means an unknown op-code (instruction) was encountered. This could mean a bad
EPROM or Processor.
2-4
“C”
A "C" means that there is an internal communication fault in the Simadyn-D Rack. This could be
the result of a bad MM11 or processor.
“-”
The - means that the rack is in the process of initialization and is a normal occurrence on power
up or after a reset. If the - stays, then reset the rack again. If this doesn't help, check power
supply voltages.
“.”
The . means that the initialization state was never reached. Make sure that the EPROM is
plugged in. If this state occurs on one processor only, then the problem is in the EPROM or that
processor. If this is the state of the entire rack, then check the power supply.
TESTING RECTIFIER FIRING PULSES
EXPLANATION:
The rectifier firing pulses are used to turn-on the forward rectifier SITOR blocks at the proper time
in order to regulate the DC bus voltage. The proper time is determined by the rectifier control
processor (PG16) based on the motoring and braking needs of the shovel. If the firing pulses are
not correct, then the DC bus regulation and the Simoverts will not work properly.
Figure 21 Firing Pulse Cable Routing (Chopper Machines)
2-5
HOW TO CHECK THE FORWARD RECTIFIER:
1. Check the SCR firing pulses with a current probe. Use Telemaster (Service) program to
initiate firing pulses.
2. LOCK OUT MAIN CONTACTOR.
3. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change
the following connectors in Simadyn-D.
Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1
4. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card
located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).
5. Using an oscilloscope with a small current probe, measure all pulses on the gate lead.
The gate lead is available on the upper left-hand corner of the cover the sitor block.
Have the scope "line triggered". Make sure that there are two pulses per block and that
the first pulse is 600 microseconds and the second pulse is 400 microseconds in
duration. By keeping the scope line triggered, the pulses should move from left to right
across the screen if the blocks are checked in numerical order. If any pulses have
significant deviation from the others, do the following:
a. Check the pulses on the pulse distribution board on test points 1.1, 1.2, 1.3, 1.4,
1.5, and 1.6. If they all look O.K., replace the sitor block that has the bad pulse
and retest.
b. If the pulse looks bad on the pulse distribution board, pull the firing pulse cable
from b. the associated sitor block and retest. If the pulse distribution board
waveform now looks good, replace the sitor module. Otherwise, go to step 9.
c. If there are still no pulses, go to step 10.
6. Remove the sitor blocks and inspect them. Make sure that all connections are tight and
that all plastic insulators are in good condition. Inspect the copper buswork behind the
sitor blocks for loose connections, arcing to ground, proper clamping pressure, etc.
7. Inspect +24vdc connections on all pulse distribution boards (devices R11-A101 and R12-
A102 in cabinet +R1A). An intermittent connection on either of the pulse distribution
boards can affect both rectifier bridges.
8. Inspect all connections on the +24vdc firing pulse power supply (device R11-G101 in
cabinet +R1B).
9. Replace the SE20.2
10. Replace the PG16. Be sure to install the EPROM and submodules from the original
PG16 into the new PG16.
END OF PROCEDURE
2-6
ADDENDUMS
Chapter 3 ADDENDUMS
ADDENDUM-1
Control Ring Troubleshooting
The first indication that a control ring problem has occurred, is that the Propel motor slowly turns,
but will not gain in speed (propel tachometer signal). Failure of the propel motor brushes could
cause over currents and shutdown the drive.
Checking Propel Tachometer Wiring
1. With a voltmeter, connect between the tachometer terminals at TB-TACH, terminals #11 and
#12. The AC and DC voltages should be approx. 0v.
2. If voltage is measured between these two points, then a control ring problem is likely.
3. With the MPS and UPS power turned off, disconnect the tachometer wire from TB-TACH,
terminal #11.
4. Connect an ohmmeter between the wire removed in step 3, and TB-TACH, terminal # 12.
The measured value should be between 600 and 700 ohms.
5. If the measured value is not between 600 and 700 ohms, then proceed under the machine to
junction box JB1 (see Figure A-1).
Figure A-1 Junction box JB1 location
6. Connect an ohmmeter between the following wires in JB1for the motion having trouble:
Left Propel: PT5 and PT7
Page3-1
Right Propel: PT1 and PT3
7. If the measurement value is between 600 and 700 ohms and the measurement at TB-TACH
was not between 600 and 700 ohms, then there is a problem in the control rings.
8. If the measurement value is not between 600 and 700 ohms at JB1 and at TB-TACH, then
check the tachometer brushes and wires at the tachometer.
9. If the brushes are popped out or broken, this will indicate that the tachometer is not aligned
properly. See “Propel Tachometer Alignment” for proper adjustment.
10. When finished testing or repairing the problem, re-connect the wire removed in step 3 (TB-
TACH terminal #11).
Checking Propel Motor Brushes
1. With the machine stopped and DC Bus off, pull down the Drive Power Disconnect (DPD) on
the High Voltage cabinet (ZHV) and lock.
2. In the Transfer Switch Cabinet, connect a meter between the R phase and S phase leads for
the propel motor.
3. If the ohmmeter measures greater than 20 ohms, there is likely a ring problem.
4. Connect a meter between the S phase and T phase leads for the propel motor.
5. If the ohmmeter measures greater than 20 ohms, there is likely a ring problem.
6. When finished testing or repairing the problem, remove the lock on DPD.
Propel Tachometer Alignment
Proper propel tachometer alignment is essential for a good feedback signal, prevents pre-mature
bearing wear in the tachometer, and prevents brush problems.
1. Assemble the tachometer drive shaft (Item #7) onto the propel motor shaft using a
retaining compound (Locktite; Bucyrus part # 82833859). Tighten drive shaft to 300ft.-lbs
(0.407 kN-m).
2. Assemble the tachometer drive shaft extension (Item #18) onto the tachometer drive shaft
(Item #7) using the setscrews (Item #19). If properly assembled, the tachometer drive
shaft extension (Item #18) will protrude beyond the tachometer drive shaft (Item #7) by
3.63 inches (92.9mm) with a tolerance of +0.13, -0.00 inches (+3.3, -0.0 mm). If the
tachometer drive shaft extension (Item #18) shaft protrudes more than 3.63 inches
(92.9mm) with a tolerance of +0.13, -0.00 inches (+3.3, -0.0 mm), disassemble and check
assembly for a depth of 2.75 inches (69.85mm).
3-2
ADDENDUMS
Figure A-2. Propel Brake Assembly and Tachometer Alignment
3. If the tachometer shaft and tachometer extension shaft assemblies are within the
tolerances listed in step 2, release the propel motor brake. The motor shaft can be rotated
back and forth for tach alignment without breaking the motor coupling.
4. While rotating the motor shaft, using a dial indicator, center the shaft extension (Item #18)
using the set screws (Item #19). Check shaft alignment at point X1 and X2 using a single
dial indicator or using one at each location (X1 and X2). Align shaft extension within
0.005-inch or better total run-out at X1 and X2.
Dial indicator magnetic bases can be mounted to bolt heads and to tach bracket guard.
5. When the shaft alignment is acceptable, remove one set screw at a time and reinstall using
a retaining compound (Locktite; Bucyrus part # 82833859). With dial indicator still
mounted on the shaft, make sure alignment stays within allowable tolerances.
6. When completed, all eight screws should be tight, loctited and proper shaft alignment
achieved.
7. The torque arm (Item #5) should be 90 degrees out from the tachometer shaft extension
centerline. The mounting should include two (2) fiber washers (Item #24) between the
mounting plate and the torque arm turnbuckle. When properly tightened, the torque arm
should be able to turn by hand in the turnbuckles.
Page3-3
Figure A-3. Torque Arm Mounting
3-4
ADDENDUMS
ADDENDUM-2
Greasing and Relubricating Instructions for Blower Motors used on top of

skid cabinets
• Replenishment grease should have a wide usable temperature range

(-20 deg F to +350 deg F) and be made with Polyurea thickener and high
quality oil with an NLGI #2 efficiency. Chevron SRI #2 meets these
requirements.
• Relubrication frequency:
1. 3 Months for Heavy-duty in dirty, dusty locations, high ambient,

moisture laden atmosphere or increased vibration levels.
• Grease Capacity:
Shaft End Bearing Æ 0.3 oz

Opposite End Bearing Æ 0.3 oz
(The grease capacity given is for that space in the bearing housing between the
shield and the outside of the motor)
• Normal Lubrication Sequence
1. Stop the Motor

2. Lock out the supply Switch.
3. Thoroughly clean off and remove the grease inlet and drain pipe plugs from
the bearing housing.
4. Remove hardened grease from drains with stiff wire or rod.
5. Add grease to inlet until a small amount of new grease is forced out drain.
6. Remove excess grease from ports.
7. Replace inlet plugs and run motor for 30 minutes before replacing the drain
plugs.
CAUTION:
DO NOT LET GREASE DROP INTO THE CABINETS AS POWER BLOCKS

MAY GET DAMAGED BY SHORT CIRCUIT
Page3-5

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SHOVEL

SIEMENS ENERGY & AUTOMATION

CHAPTER 1 DEVICES --------------------------------------------------------------------- 1-1

CHAPTER 2 TEST PROCEDURES ----------------------------------------------------- 2-1

CHAPTER 3 ADDENDUMS --------------------------------------------------------------- 3-1

AIR FLOW MONITOR

REPLACING THE CURRENT TRANSDUCER:

TESTING THE UNIT:

See DC Current Calibration.

1. Speed Regulation (SiBAS);

1. Keep the tachometer from slipping on the shaft

GENERAL STEPS IN TROUBLESHOOTING A TACH PROBLEM:

3. Try and alternate set of tachometer channels.

Figure 1 Digital Tachometer Problem #1

Figure 2 Digital Tachometer Problem #2

Figure 3 Digital Tachometer Problem #3

3. Simultaneously display both tachometer channels on the scope.

EM11 MIXED I/O CARD

X5 is used to interface Digital Tach to sense the speed of the motion

X6 is used to interface analog inputs

X7 is used to interface binary inputs

Figure 4 EM11 Card

REPLACING THE EM11:

FUSE MONITOR BOARD

Figure 5 Fuse Monitor Board

REPLACING THE FUSE MONITOR BOARD:

1. No calibration is necessary when replacing the fuse monitor board.

2. All fuse monitor boards are interchangeable.

GROUND FAULT MONITOR

The following controls and indicators are on the unit:

2. Sensitivity adjusts for the trip point in kohms.

3. Bar type scale that indicates the measured resistance to ground.

4. Push-button for testing operation of the unit.

5. Tripped indicator is a red LED.

TESTING THE UNIT:

The unit can be functionally tested as follows:

MM11 MAILBOX MEMORY

REPLACING THE MM11:

PG16 RECTIFIER CONTROL PROCESSOR

The PG16 is a special purpose processor for Rectifier control.

Figure 6 PG16 Card

REPLACING THE PG16:

PM16 GENERAL PROCESSOR

Figure 7 PM16 Card

REPLACING THE PM16

PULSE DISTRIBUTION BOARD

The board has 2 functions:

1. To route firing pulses to the Sitor Blocks.

X1- Receives active and inactive firing pulses.

X6 is used to view inactive firing pulses

Figure 8 Pulse Distribution Board

REPLACING THE PULSE DISTRIBUTION BOARD

SE20.2 SITOR INTERFACE MODULE

Figure 9 SE20.2 Interface Card

Figure 10 SE24.1 Daughter Board

REPLACING THE SE20.2:

DC CURRENT FEEDBACK CALIBRATION

SE26.1 SIGNAL ISOLATOR MODULE

The following connections are used in the shovel System:

Terminal Group X2:

term 031 : Analog Input +

Terminal Group X3:

term L+: +24v