7A - Field - Trouble V5.0

s SPECIAL DRIVES / SE&A
AC DRIVE HAUL TRUCK
Using Sibas 32 for Basic Field Troubleshooting
Revision: 5.1
Date: 11/13/2006
Number of pages: 37
File Name: Field_Trouble.doc
AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

COPYRIGHT © Siemens Energy and Automation, Inc. All Rights Reserved. Page1 of 37
I: TABLE OF CONTENTS
I: DOCUMENT INFORMATION .......................................................................................................2

II: DISTRIBUTION LIST ........................................................................ Error! Bookmark not defined.
IV: REQUIREMENTS: ............................................................................... Error! Bookmark not defined.
1 INTRODUCTION......................................................................................................................3
2 START-UP .................................................................................................................................4
2.1 Problems connecting with SIBAS .....................................................................................................5
2.1.1 “Check Serial Connection” message ......................................................................................................... 5
2.1.2 “Timeout!!! Timeout!!! Timeout!!!” message......................................................................................... 5
3 PROCEDURES FOR COLLECTION OF DATA....................................................................6
3.1 Stringing a record file ........................................................................................................................6
3.2 What do I need to look at when there is a problem with the truck? .............................................7
3.2.1 Status of the AC Drive System.................................................................................................................. 7
3.2.2 Viewing the faults of the system ............................................................................................................... 8
3.2.3 Viewing the History .................................................................................................................................. 9
3.2.4 Viewing a Memory Long of a particular fault......................................................................................... 10
3.3 CLEARING THE FAULT HISTORY...........................................................................................33
4 WHAT TO DO WITH THE INFORMATION OBTAINED .................................................33
5 ENGINE LOAD TEST ............................................................................................................33
5.1 Manual Test......................................................................................................................................34
5.2 Automatic Test .................................................................................................................................36
5.3 WHAT DO THE RESULTS MEAN ..............................................................................................37
TABLE OF FIGURES
Figure 2-1: Start-Up Screen .....................................................................................................................4
Figure 5-2: Screen Capture of Engine Load Test...................................................................................37

1 INTRODUCTION
This document will provide information required for field maintenance personnel to retrieve data from
the Sibas traction control unit (computer) in order to make informed decisions about what action to
take in the event of an outage. The procedures in this document are to be performed before contacting
any Siemens Energy & Automation personnel. This information is required in order to make any
decision regarding the status of the drive system.
REQUIREMENTS:
• Laptop computer running Windows

• Procedures in this document are written assuming a functional mouse. (Can be done without using
different procedures)
• Sibas Customer Monitor software
• Basic knowledge of computer operation

2 START-UP
To connect to the Sibas computer a 9-pin serial male to female cable is required. One end of the cable
must be hooked up to the serial port on the laptop computer, and the other end of the cable must be
hooked up to the 9-pin port on the dashboard of the truck. This cable can be purchased at any Radio
Shack or computer hardware store. After this connection is made, the key switch can be turned to the
“ON” or “START” position. After the truck is powered up, the monitor program can be started. This
is done by double clicking on the “Sibas Monitor” icon on the desktop of your computer. This will
result in a screen similar to the following if completed successfully. The monitor program is simply a
way to communicate with the SiBAS. The number following “Version” is the software version on that
particular truck and must be recorded on the outage data sheet at the end of this document. The
numbers following “Monitor 32” and “Operating System” are the Operating system’s software
versions.
Figure 2-1: Start-Up Screen

2.1 Problems connecting with SiBAS
Occasionally, there are problems connecting with the TCU, but these only occur when something is not
done correctly and are easy to fix.
2.1.1 “Check Serial Connection” message
If the “Check Serial Connection” message appears when you try to open the Monitor program, then
one of 2 things can be wrong. Either there is already a Monitor program window open or you are
trying to open a second one, or the connection is loose on the dashboard or the port on the laptop.
2.1.2 “Timeout!!! Timeout!!! Timeout!!!” message
If this message appears, then either the Sibas computer is not on (key switch is not in the 24V
position), or your serial cable is not hooked up correctly.

3 PROCEDURES FOR COLLECTION OF DATA
3.1 Stringing a record file
The purpose of stringing a record file is so that all the information that scrolls across your screen can
be saved on your computer’s hard drive. This is helpful if you need to go back to an office and study
the files or if Siemen’s personnel need the files emailed to them. If this is not done correctly, then
once the information scrolls above the top of the screen, it is lost and cannot be seen once you
disconnect from the port on the dash. The information is not deleted; it just cannot be seen unless you
are on the truck. The procedure to string a record file is as follows:
• Click on the SET menu

• Click on STRING
• Click on RECORD on the pop up menu
• Begin typing a filename of your choice (Recommended formats ddmmyy.txt) e.g.: 010401.txt (Jan.
4, 2001). DO NOT put any strange characters like question marks (?) in the filename, only use
letters and numbers. DO NOT make the filename more than 8 characters long. The “.txt”
extension makes the file a notepad file, which is very easy to read or email.
• Press ENTER
• Click on SET
• Click on RECORD
• Click on CREATE in the pop up menu
• Press ENTER
Now you have started a record file and everything that scrolls across your screen will be saved in
010401.txt in your hard drive. This file can now be found in the SIBAS32 folder under the OS_MONI
subfolder.
Once you are finished downloading everything, simply do as follows to stop the file:
• Click on SET
• Click on RECORD
• Click on STOP in the pop up menu
• Press ENTER

3.2 What do I need to look at when there is a problem with the truck?
There are quite a few menus in the Monitor program, and most of them you will never have to worry
about. The following is a quick description of the procedure that a Siemen’s engineer goes through
when they are troubleshooting a problem with the drive system.
3.2.1 Status of the AC Drive System
Once the monitor program is up and running, the first step that is required to troubleshoot a problem is
to determine the internal state of the drive system. Following these simple steps can do this:
• Click on the USER menu
• Click on STAT_INTERN
• Press ENTER
If the AC drive system is ready to run and there are no problems, the following screen will appear. If
this screen has information other than that shown below, specifically under drive status, this
information must be recorded and relayed on to the appropriate service personnel. This is the first step
in determining the source of the problem.
State intern
SIEMENS AC DRIVE truck: status information

=============================================================
Vehicle number:
Powering system ... : "DIESEL ONLY"
TCU operation mode ... : NORMAL
DC-link contactor K104 : CLOSED
Field regulator status : ENABLED
Status gate unit power supply : ENABLED
Status auxiliary inverter : ENABLED
Drive status ... : IDLE
Inverter A ready for operation
Inverter B ready for operation
Figure 3-2: State Intern Screen Capture

3.2.2 Viewing the faults of the system
To view the faults (also called Statistics) on the drive system, both active and non-active do the
following:
• Click on EVENTS
• Click on STATISTICS
• Press ENTER
You should now see a list of faults on the drive system like the one seen below.
Statistics
Diagnosis memory statistics:
DC: 20 NO.: 6 SYS: TOTALLOCK

DC: 664 NO.: 1 UWSA: PEAK CURRENT PROTECTION INVERTER ACTIVE
DC: 720 NO.: 6 UWSB: GTO SWITCHING FAILURE A201-1
DC: 721 NO.: 1 UWSB: GTO SWITCHING FAILURE A201-2
DC: 764 NO.: 1 UWSB: PEAK CURRENT PROTECTION INVERTER ACTIVE
DC: 871 * NO.: 2 ETM: OPEN CIRCUIT PT100 ETM 1 (L131)
DC: 1519 NO.: 1 IUW: OVERCURRENT DC-LINK
DC: 1963 NO.: 3 BEF: SHIFT LEVER VALIDATION FAILURE
DC: 2389 NO.: 1 BM: SERVICE BRAKE APPLICATION ABOVE SPEED LIMIT
The numbers on the left are the “fault code numbers.” The asterisk next to fault code # 871 means that
code is currently active on the drive system. All the other codes have occurred on the system
previously but are not active at the moment. The next number is the amount of times the fault has
happened since the last time the faults were cleared. Finally, the phrase is a brief description of the
fault. More information can be gathered about a particular fault by looking in Section 6 and finding
the correct fault code.

3.2.3 Viewing the History
The History of the system shows more detailed information about the last 20 faults that have occurred
on the drive system. To view the History use the following steps:
• Click on EVENT
• Click on HISTORY
• Press ENTER
After doing this, you should see a list like the one presented below.
History
! Diagnosis memory history!
Display: last event == older event
DC: 871: ETM: OPEN CIRCUIT PT100 ETM 1 (L131)

Time event occurred/disapp. 12.12.00 22:58:15 / 0.00.00 0:00:00
DC: 871: ETM: OPEN CIRCUIT PT100 ETM 1 (L131)
Time event occurred/disc. 12.12.00 22:51:33 / 12.12.00 22:58:12
DC: 1330: HL: GTO-PULSE-TEST: TEST STOPPED
DC: 720: UWSB: GTO SWITCHING FAILURE A201-1
DC: 20: SYS: TOTALLOCK
For the 4th fault, # 720, you can see that the fault appeared on the system on Dec. 12, 2000 (12.12.00)
at 17:38:26, which is 5:38 p.m. The next set of numbers is when the fault went away, Dec. 12, 2000
(12.12.00) at 17:38:33. This means that the fault lasted for 7 seconds. This particular fault is listed
below.
DC: 720: UWSB: GTO SWITCHING FAILURE A201-1

3.2.4 Viewing a Memory Long of a particular fault
If the information that was just gathered, Statistics and History, is not enough for you to find and fix
the fault, then you probably need more information about the fault. You can look at the state of the
drive system at the exact moment the fault happened to see what was going on with the truck at that
time. To do this, do the following:
• Click on EVENTS
• Click on DAL:DC,ALL L
• Press ENTER
• Type in the fault code that you would like to look at, which would be 720
• Press ENTER
You should now see the following scroll across your screen. The monitor program will scroll too fast
for you to read it during this step, which is why we strung a record file at the beginning. If you did not
string a record file at the beginning, you can pause the screen from scrolling by hitting the CTRL key
and ‘S’ at the same time. To continue scrolling, hit CTRL ‘S’ again.
DAL:DC,All L
Select diagnosis code: 720
AC HAUL TRUCK
=============
[Headline]
Vehicle / TCU number.... : 075 / 1

[vehicle number to be adjusted by monitor-command „USER IV:InpVeh-no“ / TCU-number = 1]
CPU software version.... : 208.01

[CPU software revision level]
Time of last memory delete. 10.05.99 8:22:20

[Time when diagnosis memory was deleted last]
Event code... 720

[Event code number]
Number of events... 1
[Number of events of this code occurred since last memory deletion]
UWSB: GTO SWITCHING FAILURE A201-1

[Event description]

[Time when event occurred and disappeared]
Memory event number... 32

[Diagnosis memory event counter]

Time of event reset... 12.12.00 17:38:33

[Time when event was reset by special action; same time as time when event disappeared, if no special
action for reset is required]
Vehicle status... 0004 H |0000|0000|0000|0100|

[Vehicle status identifier:
Bit 0.7: status when event occured
Bit 0: vehicle status PROPEL
Bit 1: vehicle status RETARD
Bit 2: vehicle status IDLE
Bit 3: inverter test mode
Bit 8...15: last status before status when event occurred
Bit 8: vehicle status PROPEL
Bit 9: vehicle status RETARD
Bit 10: vehicle status IDLE
Bit 11: inverter test mode]
status time (last/actual) : 0 ms / 1131000 ms

[Time duration for status when event occurred and last status before]
TCU switch OFF/ON time. : 926319795 s / 1131120 ms

[Time duration TCU was running and TCU was off before]
Environment group 1:
"Internal" status info 1: 003C H |0000|0000|0011|1100|

[Internal status information 1:
Bit 0: internal command „FORWARD“
Bit 1: internal command „REVERSE“
Bit 2: rotation direction motors 1 „FORWARD“
Bit 3: rotation direction motor 2 „FORWARD“
Bit 4: vehicle movement direction valid
Bit 15: crowbar IPM command by software ]
"Internal" status info 2: 0180 H |0000|0001|1000|0000|

[Internal status information 2:
Bit 3: command RETARD derived from pedal positions, cruise control and automatic speed
limitation
Bit 4: command PROPEL derived from pedal positions, cruise control and automatic speed
limitation
Bit 5: Internal command RETARD for motor control
Bit 6: Internal command PROPEL for motor control
Bit 7: status inverter A IDLE
Bit 8: status inverter B IDLE
Bit 9: pulse-enable inverter A for test
Bit 10: pulse-enable inverter B for test
Bit 11: start-up sequence running
Bit 12: power-down sequence running
Bit 13: transition to „drive shutdown“ active
Bit 14: transition to „standby idle“ active
Bit 15: IPM firing sequence active]
Status word TCU-selftest: FFE1 H |1111|1111|1110|0001|

[Status word TCU-selftest:
Bit 0: test stopped because of ADC-conversion fault IO
An error occurring during the plausibility check of the hardware port signals
CH1-CH4 regarding the address (xx340,xx342,xx344,xx346) is displayed by
means of the error signal ERR.

The waiting time for conversion of the analog values is 40µs and is monitored
internally. If the waiting time is exceeded, the error signal ERR is set.
During subsequent conversion within the waiting time, the error signal is reset again and
the values are output.
See program HDWV page 10
Bit 1: test stopped because of ADC-conversion fault UWS A
Three phases motor A current and DC link voltage A/D conversion wrong.
Bit 2: test stopped because of ADC-conversion fault UWS B
Three phases motor A current and DC link voltage A/D conversion wrong.
Bit 3: reserved
Bit 4: fault of hardware comparator 1 IO
DC-LINK voltage monitoring, 3000V to 3200VDC range, CPU sends out a ref. Under this
range, then compare hardware A/D reading with comparator reading. The input voltage
should be zero, this can check out if the transducer output is zero when there is no dc
voltage.
DC-LINK voltage monitoring, 3300V to 3500VDC range, CPU send out a ref. Under this
range, then compare hardware A/D reading with comparator reading.
DC-LINK voltage monitoring, 2900V to 3100VDC range, CPU send out a ref. Under this
range, then compare hardware A/D reading with comparator reading.
Chopper A current transducer, 1925 to 2075A range, CPU send out a ref. Under this range,
then compare hardware A/D reading with comparator reading. . The input current should be
zero, this can check out if the transducer output is zero when there is no current.

Chopper B current transducer, 1925A to 2075A range, CPU sends out a ref. Under this
range, then compare hardware A/D reading with comparator reading. . The input current
should be zero, this can check out if the transducer output is zero when there is no current.
Trolley line current transducer, 1925A to 2075A range, CPU sends out a ref. Under this
range, then compare hardware A/D reading with comparator reading. . The input current
should be zero, this can check out if the transducer output is zero when there is no current.
Bit 10: fault of hardware comparator inverter currents GW3 UWSA
Three phase motor A current transducer, 1850 to 2350A range, -2350A to –1850A, CPU
send out ref. Under this range, then compare hardware A/D reading with comparator
reading. . The input current should be zero, this can check out if the transducer output is
zero when there is no current.
Bit 11: fault of hardware comparator inverter currents GW5 UWSA
Three phase motor A current transducer, 2400A to 2500A range, -2500A to –2400A, CPU
Bit 12: fault of hardware comparator DC-link voltage GW5 UWSA
DC-LINK voltage monitoring, 3520V to 36800VDC range, -3680V to –3520V, CPU sends
out a ref. Under this range, then compare hardware A/D reading with comparator reading.
Bit 13: fault of hardware comparator inverter currents GW3 UWSB
Three phase motor B current transducer, 1850A to 2350A range, -2350A to –1850A, CPU
zero when there is no current
Bit 14: fault of hardware comparator inverter currents GW5 UWSB

Three phase motor B current transducer, 2400A to 2500A range, -2500A to –2400A, CPU
Bit 15: fault of hardware comparator DC-link voltage GW5 UWSB]
DC-LINK voltage monitoring, 3520V to 36800VDC range, -3680V to –3520V, CPU sends
out a ref. Under this range, then compare hardware A/D reading with comparator reading.
Note: fault code 397, 697, 797 will be come out if one of the above bits is 1. First thing, it should check the
transducer.
Status word inverter test: 0000 H |0000|0000|0000|0000|

[Status word inverter test:
Bit 0: GTO test stop during start-up sequence
Bit 1: GTO test stop because of power-down sequence running
Bit 2: reserved
Bit 3: test stop because field regulator status is not disabled
Bit 4: reserved
Bit 5: reserved
Bit 6: test stop because DC-link contactor K104 is not open
Bit 7: test stop because DC-link voltage is not lower than 50V
Bit 8: test stop because gate unit power supply status is not ON
Bit 9: test stop because of totallock during inverter test A (start-up sequence)
Bit 10: test stop because of totallock during inverter test B (start-up sequence)
Bit 11: test stop because of totallock during test (after IPM firing)
Bit 12: reserved
Bit 13: reserved
Bit 14: reserved
Bit 15: reserved
Note: fault code 1330 will be come out if one of the above bits is 1. First thing, it should check the reason
why testing is stopped.
Information word initial. DSP A : 0020 H |0000|0000|0010|0000|

[Initialization information DSP A]
EI1 ==> Error in base address
EI2 ==> DSP does not respond
EI3 ==> Wrong software identifier
EI4 ==> Error in LCA1 loading
EI6 ==> Error in initialization of DSP
EI7 ==> Error in communications RAM test of DSP
Note: fault code 51 will be come out if one of the above bits is 1.
Information word initial. DSP B : 0010 H |0000|0000|0001|0000|

[Initialization information DSP B]
EI1 ==> Error in base address
EI2 ==> DSP does not respond
EI3 ==> Wrong software identifier
EI6 ==> Error in initialization of DSP
EI7 ==> Error in communications RAM test of DSP
Note: fault code 101 will be come out if one of the above bits is 1.
control word 1 DSP A .... : 0000 H |0000|0000|0000|0000|

control word 1 DSP B .... : 0000 H |0000|0000|0000|0000|
[DSP control word status 1]
Bit 0: 0
Bit 1: Impulse release / BIMPFSP
Bit 2: Impulse release Test / BIMFTSP
Bit 3: Engine teeth number
Bit 4: Peak-current-operator-action
Bit 5: Voltage stability required
Bit 6: SPH-Controller release / BFSPHSP
Bit 7: Desired-direction forward
Bit 8: 0
Bit 9: du/dt acknowledgement
Bit 10: 0/1, DSP number, 0=DSPA, 1=DSPB
Bit 11: 0, Trolley application?
Bit 12: Motor configuration, 1=Small motor, 0=big motor
Bit 13: Chopper duty cycle control by ZR
Bit 14: 0
Bit 15: Vehicle status in Propel
control word 2 DSP A.... : 0000 H |0000|0000|0000|0000|

control word 2 DSP B.... : 0000 H |0000|0000|0000|0000|
[DSP control word status 2]
Bit 0: 0/1, Voltage stability, 0=DSPA, 1=DSPB, required by DSP interface
Bit 1: 0
Bit 2: 0
Bit 3: Enable Ud-Compensation
Bit 4: 0
Bit 5: Trigger software traco
Bit 6: Motor Teeth number
Bit 7: 0
Bit 8: 1, speed sensor invertered
Bit 9: 0
Bit 10: 0
Bit 11: 0
Bit 12: Speed sensor OK
Bit 13: 0
Bit 14: 0
Bit 15: 0
Status PT100 open circuit : 00D6 H |0000|0000|1101|0110|

[Status of open circuit for each of PT100:
Bit 0: Inverter module A101
Bit 3: Chopper module A104
Bit 7: Chopper module A204
Bit 8: Inv Compartment
Bit 9: Snubber A resistor
Bit 10: Snubber B resistor
Bit 11: Motor A Stator
Bit 12: Motor B Stator
Bit 13: Grid A

Bit 14: Grid B
Bit 15: Alternator
Note: Either fault code 871 or 872 will be come out if one of the above bits is 1.
Status temp. APRS system : 00D6 H |0000|0000|1101|0110|

[Status of automatic power reduction system (APRS) due to component temperatures:
Bit 0: APRS due to inverter module overtemperature active

Bit 1: APRS due to chopper module overtemperature active
Bit 2: reserved
Bit 3: APRS due to traction motor overtemperature active
Bit 4: APRS due to retard grid overtemperature active
Bit 5: APRS due to alternator overtemperature active
Bit 6: APRS due to inverter compartment overtemperature active
Bit 7: reserved]
Please note: These bits cab be used to verify the setting for APRS.
Status temp. SHTS system: FD34 H |1111|1101|0011|0100|

[status of automatic inverter shutdown system (SHTS) due to component over.temp:
Bit 0: SHTS due to inverter module overtemperature active for PROPEL

Bit 1: SHTS due to inverter module overtemperature active for PROPEL and RETARD
Bit 2: SHTS due to chopper module overtemperature active for PROPEL
Bit 3: SHTS due to chopper module overtemperature active for PROPEL and RETARD
Bit 4: SHTS due to snubber resistor overtemperature active for PROPEL
Bit 5: SHTS due to snubber resistor overtemperature active for PROPEL and RETARD
Bit 6: SHTS due to traction motor overtemperature active for PROPEL
Bit 7: SHTS due to traction motor overtemperature active for PROPEL and RETARD
Bit 8: SHTS due to retard grid overtemperature active for PROPEL
Bit 9: SHTS due to retard grid overtemperature active for PROPEL and RETARD
Bit 10: SHTS due to alternator stator overtemperature active for PROPEL
Bit 11: reserved
Bit 12: SHTS due to inverter module overtemperature active for PROPEL
Bit 13: SHTS due to inverter compartment overtemperature active for PROPEL and RETARD
Bit 14: reserved
Bit 15: reserved]
Please note: These bits can be used to verify the setting for SHTS.
status temp. superv. INVA : 00FF H |0000|0000|1111|1111|

[status information temperature supervisions for inverter A:
Bit 0: overtemperature level 1 module A101

Bit 8: undertemperature module A101
Bit 12: reserved

Bit 13: reserved
Bit 14: reserved
Bit 15: reserved]
Status temp. superv. INVB : 00FF H |0000|0000|1111|1111|
[status information temperature supervisions for inverter B:

Bit 12: reserved
Bit 13: reserved
Bit 14: reserved
Bit 15: reserved]
Environment group 2:
contactor commands ...... : 0000 H |0000|0000|0000|0000|

[status contactor commands:
Bit 0: command “RAISE pantograph” active
Bit 1: 0, reserved
Bit 2: command “CLOSE K301 main circuit breaker” active
Bit 3: 0, reserved
Bit 4: command “CLOSE K303/K304 Contactor” active
Bit 5: 0, reserved
Bit 6: command “CLOSE K104 DC-link contactor” active
Bit 7: command “OPEN K104 DC-link contactor” active
Bit 8: command “CLOSE K141 auxiliary inverter contactor” active
Bit 10: command “CLOSE K105 preheat contactor” active
Bit 12: 0, reserved
Bit 13: 0, reserved
Bit 14: 0, reserved
Bit 15: 0, reserved]
contactor feedback ...... : 8FFF H |1000|1111|1111|1111|

[status contactor feedback signals:
Bit 0: feedback “pantograph position UP” active
Bit 1: feedback “pantograph position DOWN” active
Bit 2: feedback “main circuit breaker K301 CLOSED” active
Bit 3: feedback “main circuit breaker K301 OPEN” active
Bit 4: feedback “line contactor K303/K304 CLOSED” active
Bit 5: feedback “line contactorK303/ K304 OPEN” active
Bit 6: feedback “DC-link contactor K104 CLOSED” active
Bit 7: feedback “DC-link contactor K104 OPEN” active
Bit 8: feedback “auxiliary inverter contactor K141 CLOSED” active
Bit 10: feedback “preheat contactor K105 CLOSED” active

Bit 11: feedback “preheat contactor K105 OPEN” active
Bit 13: 0, reserved
Bit 14: 0, reserved
Bit 15: feedback „control power supply contactor K101 CLOSED” active]
device commands ......... : 0010 H |0000|0000|0001|0000|

[status device commands:
Bit 0: command „ENABLE auxiliary inverter“ active
Bit 1: command „ENABLE gate unit power supply“ active
Bit 2: command „ENABLE field regulator“ active
Bit 3: command „RELEASE park brake“ active
Bit 4: command „LATCH, ignition ON“ active]
device feedback ......... : 7FFF H |0111|1111|1111|1111|
[status device feedback signals:
Bit 0: feedback „auxiliary inverter status OK“ active
Bit 1: feedback „gate unit power supply status OK“ active
Bit 2: feedback „field regulator status OK“ active
Bit 3: feedback „park brake RELEASED“ active
Bit 4: feedback „ignition power ON“ active
Bit 5: feedback „request block heater ON“ active
Bit 6: feedback „dump body DOWN“ active
Bit 7: feedback „service brake ON“ active
Bit 8: feedback „load/dump brake ON“ active
Bit 9: feedback „differential oil pressure OK“ active
Bit 10: feedback „trolley position limit LEFT“ active
Bit 11: feedback „trolley position limit RIGHT“ active
Bit 12: feedback „main blower pressure OK“ active
Bit 13: feedback „grid blower pressure OK“ active
Bit 14: feedback „overtemperature battery charger“ active
Bit 15: reserved]
device feedback ......... : BFFF H |1011|1111|1111|1111|

[status device feedback signals:
Bit 0: feedback „bus-bars inverter A connected“ active
Bit 1: feedback „bus-bars inverter B connected“ active
Bit 2: feedback „shift lever position FORWARD“ active
Bit 3: feedback „shift lever position NEUTRAL“ active
Bit 4: feedback „shift lever position REVERSE“ active
Bit 5: feedback „dumpbody OVERRIDE“ active
Bit 6: feedback „payload status UNLOADED“ active
Bit 7: feedback „trolley command ENGAGE“ active
Bit 8: feedback „drive shutdown request“ active
Bit 9: feedback „grid dry mode ON“ active
Bit 10: feedback „torque boost request ON“ active
Bit 11: feedback „ENABLE propel“ active
Bit 12: feedback „engine speed boost request“ active
Bit 13: feedback „cruise control ON (wired)“ active
Bit 14: feedback „derate engine“ active
Bit 15: feedback „fault reset“ active]
environment group 3:
status ESH 1 ............ : 0707 H |0000|0111|0000|0111|

[internal status information power start-up unit 1]
Bit 0: reserved
Bit 1: reserved
Bit 2: reserved
Bit 3: total lock from power supply(G163)
Bit 4: FPGA block fault (G163)
Bit 5: +5V Power supply undervoltage fault
Bit 6: -15V Power supply undervoltage fault
Bit 8: reserved
Bit 9: reserved
Bit 10: reserved
Bit 11: hardware fault from power supply (G163)
Bit 14: -24V Power supply undervoltage fault
Bit 15: Power supply input undervoltage fault
status ESH 2 ............ : 0007 H |0000|0000|0000|0111|

[internal status information power start-up unit 2]
Bit 0: reserved
Bit 1: reserved
Bit 2: reserved
Bit 3: total lock from power supply(G163)
Bit 5: Power supply primary side fault
Bit 6: Reset signal
Bit 7: Clock failure (G163)
Bit 8: reserved
Bit 9: reserved
Bit 10: reserved
Bit 11: reserved
Bit 12: reserved
Bit 13: reserved
Bit 14: reserved
Bit 15: reserved
Note: Either fault code from 30 to 37 should be come out if one of the above bits is 1.
status IO xxx0C / xxx08 . : FFFF H |1111|1111|1111|1111|

[internal status information IO-module addresses xxx0C and xxx08]
Bit 0: COO3 card clock failed
Bit 1: CO11 card clock failed
Bit 2: front plug monitor
Bit 3: total lock from UWSA
Bit 4: total lock from UWSB
Bit 5: GND
Bit 6: Watchdog from CPU
Bit 7: Reset signal from CPU
Bit 8: Watchdog from DSPA
Bit 9: Watchdog from DSPB
Bit 10: TRIG_CRWBR_UWSA
Bit 11: C019 card clock failed
Bit 12: EN_TOT_K102
Bit 13: RES_KS
Bit 14: RES_GW1
Bit 15: GND

status IO xxx0E / xxx0A . : FFFF H |1111|1111|1111|1111|

[internal status information IO-module addresses xxx0E and xxx0A]
Bit 0: ABIN1F
Bit 1: ABIN2F
Bit 2: front plug monitor
Bit 3: TOTUWSAF
Bit 4: TOTUWSBF
Bit 5: GND
Bit 6: WDCF
Bit 7: RESOUTF
Bit 8: WDAF
Bit 9: WDBF
Bit 10: CBAF
Bit 11: ABIN3F
Bit 12: GND
Bit 13: GND
Bit 14: GW1SP
Bit 15: KSSP
status IO xxx12 / xxx10 . : FFFF H |1111|1111|1111|1111|

[internal status information IO-module addresses xxx12 and xxx10]
Bit 0: GW1, DC LINK comparator
Bit 3: GW4, Chopper A current comparator
Bit 4: GW5, Chopper B current comparator
Bit 5: GW6, DC link current comparator
Bit 6: GW7, Trolley Line voltage comparator
Bit 7: GW8, GND
Bit 8: GW9, Trolley line current comparator
Bit 9: GW10, GND
Bit 10: GW11, DC link current comparator
Bit 11: LS
Bit 12: LOCK1
Bit 13: TOT
Bit 14: FE
Bit 15: KS

Bit 0: GWF1
Bit 1: GWF2
Bit 2: GWF3
Bit 3: GWF4
Bit 4: GWF5
Bit 5: GWF6
Bit 6: GWF7
Bit 7: GWF8
Bit 8: GWF9
Bit 9: GWF10
Bit 10: GWF11
Bit 11: FEPCLK
Bit 12: FEQCLK
Bit 13: LSF
Bit 14: KSF
Bit 15: TOT


Bit 0: VREG_CPU_1
Bit 1: VREG_CPU_2
Bit 2: K301_CPU_1
Bit 3: K301_CPU_2
Bit 4: EN_TOT_VREG
Bit 5: GND
Bit 6: GND
Bit 7: GND
Bit 10: GND
Bit 11: GND
Bit 12: ABIN4F
Bit 13: ABIN5F
Bit 14: GND
Bit 15: GND
ADC-failure ............. : 001F H |0000|0000|0001|1111|

[status information ADC-failures:
Bit 0: failure ADC-conversion IO 1

Note: This is from HDWI package A/D error bit, which is from hardware on I/0 card. This information similar
to TCU self-test byte bit 0.

status words UWS |UWSB G079|UWSA G071|
status UWS B/A xxx20 .... : FFDF H |1111|1111|1101|1111|

[internal status information UWS B/A address xxx20]
Bit 0: CUTOFF_INVA
Bit 1: M
Bit 2: TRIG_CRBR_IO
Bit 3: TOTBLOCK_PSU, fault code 603
Bit 4: TRG_CHOPA_IO
Bit 5: M
Bit 6: BLK_PLS_CPU
Bit 7: TOTBLOCK_IO
Bit 8: CUTOFF_INVB
Bit 9: GND
Bit 10: TRIG_CRBR_IO
Bit 11: CROWBAR Fired
Bit 12: TRG_CHOPA_IO
Bit 14: BLK_PLS_CPU
Bit 15: TOTBLOCK_IO
status UWS B/A xxx22 .... : BFD6 H |1011|1111|1101|0110|

Bit 0: CUTOFF_INVA
Bit 1: M
Bit 2: TRIG_CRBR_IO
Bit 3: TOTBLOCK_PSU
Bit 4: TRG_CHOPA_IO
Bit 5: M
Bit 6: BLK_PLS_CPU
Bit 7: TOTBLOCK_IO
Bit 8: CUTOFF_INVB
Bit 9: GND
Bit 11: CROWBAR Fired
Bit 12: TRG_CHOPA_IO
Bit 14: BLK_PLS_CPU
Bit 15: TOTBLOCK_IO
GTO-commands SAV xxx24 .. : BEBD H |1011|1110|1011|1101|

[internal status information UWS B/A address xxx24, GTO-commands latched]
Bit 0: AN1SP
Bit 1: AN2SP
Bit 2: AN3SP
Bit 3: AN4SP
Bit 4: AN5SP
Bit 5: AN5SP
Bit 6: AN6SP
Bit 7: AN7SP
Bit 8: AN1SP
Bit 9: AN2SP
Bit 10: AN3SP
Bit 11: AN4SP
Bit 12: AN5SP
Bit 13: AN6SP

Bit 14: AN7SP
Bit 15: AN8SP
GTO-commands ONL xxx26 .. : 0000 H |0000|0000|0000|0000|

[internal status information UWS B/A address xxx26, GTO-commands]
Bit 0: V1UW, RP INVA
Bit 1: V2UW, RN INVA
Bit 2: V3UW, SP INVA
Bit 3: V4UW, SN INVA
Bit 4: V5UW, TP INVA
Bit 5: V6UW, TN INVA
Bit 6: V7UW, CHOPPA
Bit 7: KSA
Bit 8: V1UW, RP INVB
Bit 9: V2UW, RN INVB
Bit 10: V3UW, SN INVB
Bit 11: V4UW, SN INVB
Bit 12: V5UW, TN INVB
Bit 13: V6UW, TN INVB
Bit 14: V7UW, CHOPPB
Bit 15: V8VW, CROWBAR
GTO-feedback ONL xxx2C .. : FFFF H |1111|1111|1111|1111|

[internal status information UWS B/A address xxx2C, GTO-feedback]
Bit 0: FB_RP_INVA
Bit 1: FB_RN_INVA
Bit 2: FB_SP_INVA
Bit 3: FB_SN_INVA
Bit 4: FB_TP_INVA
Bit 5: FB_TN_INVA
Bit 6: FB_CHOPPA
Bit 7: M
Bit 8: FB_RP_INVB
Bit 9: FB_RN_INVB
Bit 10: FB_SP_INVB
Bit 11: FB_SN_INVB
Bit 12: FB_TP_INVB
Bit 13: FB_TN_INVB
Bit 14: FB_CHOPPB
Bit 15: FB_CROWBAR
GTO-feedback SAV xxx2E .. : BF0F H |1011|1111|0000|1111|

[internal status information UWS B/A address xxx2E, GTO-feedbacks latched]
Bit 0: FB_RP_INVASP
Bit 1: FB_RN_INVASP
Bit 2: FB_SP_INVASP
Bit 3: FB_SN_INVASP
Bit 4: FB_TP_INVASP
Bit 5: FB_TN_INVASP
Bit 6: FB_CHOPPASP
Bit 7: M
Bit 8: FB_RP_INVBSP
Bit 9: FB_RN_INVBSP
Bit 10: FB_SP_INVBSP
Bit 11: FB_SN_INVBSP
Bit 12: FB_TP_INVBSP
Bit 13: FB_TN_INVBSP

Bit 14: FB_CHOPPBSP
Bit 15: FB_CROWBARSP
status limiter B/A xxx30 : F4B0 H |1111|0100|1011|0000|

[internal status information UWS B/A address xxx30, status limiter GW5]
Bit 0: GW51, Inverter A U101 Current greater than?
Bit 1: GW52, Inverter A U102 Current
Bit 2: GW53, Inverter A U103 Current
Bit 3: GW54, DC link voltage, U105
Bit 4: GW51SP, latched signal
Bit 5: GW52SP
Bit 6: GW53SP
Bit 7: GW54SP
Bit 8: GW51, Inverter B U201 Current
Bit 11: GW51, DC link voltage, U105
Bit 12: GW51SP
Bit 13: GW52SP
Bit 14: GW53SP
Bit 15: GW54SP
Note: fault code 642 to 645, 742 to 745 will come out if either bit is 1.
GTO-switch.-failure xxx32 : 0000 H |0000|0000|0000|0000|

[internal status information UWS B/A address xxx32, GTO-switching-failures]
Bit 0: L1 UP
Bit 1: L1 BOTTOM
Bit 2: L2 UP
Bit 3: L2 BOTTOM
Bit 4: L3 UP
Bit 5: L3 BOTTOM
Bit 6: Chopper
Bit 7: 1
Bit 8: L1 UP
Bit 9: L1 BOTTOM
Bit 10: L2 UP
Bit 11: L2 BOTTOM
Bit 12: L3 UP
Bit 13: L3 BOTTOM
Bit 14: Chopper
Bit 15: 1
Note: fault 620 to 626, 720 to 726 will come out if either bit is 1.
status UWS B/A xxx34 .... : FCFC H |1111|1100|1111|1100|

Bit 0: FEPCLK, bus-clock, fault code 646
Bit 1: FEQCLK, PCB clock, fault code 647
Bit 2: TOTSP,
Bit 3: WRSP
Bit 4: KSA
Bit 5: LOCK
Bit 6: SIPSP
Bit 7: TOTL
Bit 8: FEPCLK
Bit 9: FEQCLK, fault code 746

Bit 10: TOTSP, fault code 747
Bit 11: WRSP
Bit 12: KSA
Bit 13: LOCK
Bit 14: SIPSP
Bit 15: TOTL
status UWS B/A xxx36 .... : 4909 H |0100|1001|0000|1001|

Bit 0: FEXT9SP
Bit 1: FEXT9
Bit 2: WAGEST
Bit 3: INT7874
Bit 4: GW4SP
Bit 5: SSESP
Bit 6: SSEGW
Bit 7: SSPESP
Bit 8: FEXT9SP
Bit 9: FEXT9
Bit 10: WAGEST
Bit 11: INT7874
Bit 12: GW4SP
Bit 13: SSESP
Bit 14: SSEGW
Bit 15: SSPESP
status UWS B/A xxx1A .... : B5FC H |1011|0101|1111|1100|

[internal status information UWS B/A address xxx1A]
Bit 0: SRSP
Bit 1: TSP
Bit 2: HKS
Bit 3: SSE4
Bit 4: SF1
Bit 5: SF2#
Bit 6: GW4
Bit 7: FEXT5
Bit 8: SRSP
Bit 9: TSP
Bit 10: HKS
Bit 11: SSE4
Bit 12: SF1
Bit 13: SF2#
Bit 14: GW4
Bit 15: FEXT5
status swit.freq.prot. 0 : 0000 H |0000|0000|0000|0000|
[internal status information UWS B/A, GTO switching frequency protection class 0]
Bit 0: Counter Z1
Bit 1: Counter Z2
Bit 2: Counter Z3
Bit 3: Counter Z4
Bit 4: Counter Z5
Bit 5: Counter Z6
Bit 6: Counter Z7
Bit 7: Counter Z8
Bit 8: Counter Z1
Bit 9: Counter Z2
Bit 10: Counter Z3

Bit 11: Counter Z4
Bit 12: Counter Z5
Bit 13: Counter Z6
Bit 14: Counter Z7
Bit 15: Counter Z8

Bit 0: Counter Z1
Bit 1: Counter Z2
Bit 2: Counter Z3
Bit 3: Counter Z4
Bit 4: Counter Z5
Bit 5: Counter Z6
Bit 6: Counter Z7
Bit 7: Counter Z8
Bit 8: Counter Z1
Bit 9: Counter Z2
Bit 10: Counter Z3
Bit 11: Counter Z4
Bit 12: Counter Z5
Bit 13: Counter Z6
Bit 14: Counter Z7
Bit 15: Counter Z8

Bit 0: Counter Z1
Bit 1: Counter Z2
Bit 2: Counter Z3
Bit 3: Counter Z4
Bit 4: Counter Z5
Bit 5: Counter Z6
Bit 6: Counter Z7
Bit 7: Counter Z8
Bit 8: Counter Z1
Bit 9: Counter Z2
Bit 10: Counter Z3
Bit 11: Counter Z4
Bit 12: Counter Z5
Bit 13: Counter Z6
Bit 14: Counter Z7
Bit 15: Counter Z8

Bit 0: Counter Z1
Bit 1: Counter Z2
Bit 2: Counter Z3
Bit 3: Counter Z4
Bit 4: Counter Z5
Bit 5: Counter Z6
Bit 6: Counter Z7
Bit 7: Counter Z8
Bit 8: Counter Z1
Bit 9: Counter Z2
Bit 10: Counter Z3

Bit 11: Counter Z4
Bit 12: Counter Z5
Bit 13: Counter Z6
Bit 14: Counter Z7
Bit 15: Counter Z8
Note: switching fault 662 and 762 will come out if either bit of last 4 word is 1.
status uC UWS B/A ...... : 1010 H |0001|0000|0001|0000|

[internal status information UWS B/A, microcontroller status]
Bit 0: CRC error in the uC-ROM
Bit 1: Incorrect SW version in the uC
Bit 2: uC watchdog test not started
Bit 3: uC watchdog has not responded
Bit 4: uC initialization error
Bit 5: CRC DATA error (after table loading)
Bit 6: Free
Bit 7: Free
Bit 8: CRC error in the uC-ROM
Bit 9: Incorrect SW version in the uC
Bit 10: uC watchdog test not started
Bit 11: uC watchdog has not responded
Bit 12: uC initialization error
Bit 13: CRC DATA error (after table loading)
Bit 14: Free
Bit 15: Free
Note: This is still related to switching fault, UWS A/B page 5.
status peak-curr. prot. 1 : 0000 H |0000|0000|0000|0000|

[internal status information UWS B/A, peak current counter protection status class 1]
Bit 0: SSE Phase 1
Bit 1: SSE Phase 2
Bit 2: SSE Phase 3
Bit 3: SSE Phase 4
Bit 4: Free
Bit 5: Free
Bit 6: Free
Bit 7: Free
Bit 8: SSE Phase 1
Bit 9: SSE Phase 2
Bit 10: SSE Phase 3
Bit 11: SSE Phase 4
Bit 12: Free
Bit 13: Free
Bit 14: Free
Bit 15: Free

Bit 0: SSE Phase 1
Bit 1: SSE Phase 2
Bit 2: SSE Phase 3
Bit 3: SSE Phase 4
Bit 4: Free
Bit 5: Free
Bit 6: Free
Bit 7: Free
Bit 8: SSE Phase 1
Bit 9: SSE Phase 2
Bit 10: SSE Phase 3
Bit 11: SSE Phase 4
Bit 12: Free
Bit 13: Free
Bit 14: Free
Bit 15: Free

Bit 0: SSE Phase 1
Bit 1: SSE Phase 2
Bit 2: SSE Phase 3
Bit 3: SSE Phase 4
Bit 4: Free
Bit 5: Free
Bit 6: Free
Bit 7: Free
Bit 8: SSE Phase 1
Bit 9: SSE Phase 2
Bit 10: SSE Phase 3
Bit 11: SSE Phase 4
Bit 12: Free
Bit 13: Free
Bit 14: Free
Bit 15: Free
Note: switching fault 669 and 769 will come out if either bit of last 3 word is 1.

status 2. fault reg. 4 .. : 0000 H |0000|0000|0000|0000|

[internal status information UWS B/A, second fault register address 4]
Bit 0: A38_0
Bit 1: A38_1
Bit 2: A38_2
Bit 3: A38_3
Bit 4: A38_4
Bit 5: A38_5
Bit 6: A38_6
Bit 7: A38_7
Bit 8: A38_0
Bit 9: A38_1
Bit 10: A38_2
Bit 11: A38_3
Bit 12: A38_4
Bit 13: A38_5
Bit 14: A38_6
Bit 15: A38_7
Bit 0: A38_0
Bit 1: A38_1
Bit 2: A38_2
Bit 3: A38_3
Bit 4: A38_4
Bit 5: A38_5
Bit 6: A38_6
Bit 7: A38_7
Bit 8: A38_0
Bit 9: A38_1
Bit 10: A38_2
Bit 11: A38_3
Bit 12: A38_4
Bit 13: A38_5
Bit 14: A38_6
Bit 15: A38_7
Bit 0: A38_0
Bit 1: A38_1
Bit 2: A38_2
Bit 3: A38_3
Bit 4: A38_4
Bit 5: A38_5
Bit 6: A38_6
Bit 7: A38_7
Bit 8: A38_0
Bit 9: A38_1
Bit 10: A38_2
Bit 11: A38_3
Bit 12: A38_4
Bit 13: A38_5
Bit 14: A38_6
Bit 15: A38_7
environment DSP A
fault status ............ : 0000 H |0000|0000|0000|0000|
[fault status word from DSP A]
Bit 0: Time Overflow in T1, fault code 57
Bit 1: Initialization error, fault code 56
Bit 2: Overcurrent, fault code 70
Bit 3: Parameter fault braking chopper frequency, fault 71
Bit 4: Voltage transducer U13 not OK, fault code 72
Bit 5: Voltage transducer U23 not OK, fault code 73
Bit 6: reserved
Bit 7: sum of three phase current not zero, fault code 76
Bit 8: communication with DSPB error, fault code 74,
Bit 9: reserved
Bit 10: Failure V/F card, L055, fault code 77
Bit 11: reserved
Bit 12: Unbalance current protection, >215A, fault code 85
status word 1 ........... : 0000 H |0000|0000|0000|0000|

[status word 1 from DSP A]
Bit 0: Control locked up because of the fault, fault code 82
Bit 1: du/dt too high
Bit 2: Frequency-limitation
Bit 3: Lock by DSPA, shutdown machine without fault
Bit 4: Active Current control in Limitation, fault code 79
Bit 5: Active Current reference in Limitation, fault code 80
Bit 6: Brake-control-limitation, fault code 81
Bit 7: Added-Synchronize is done for flux, see SWPA page 5
Bit 8: reserved
Bit 9: reserved
Bit 10: software traco triggered, code 107
Bit 11: reserved
Bit 12: dn/dt is over the limit, fault code 1788
Bit 13: reserved
Bit 14: dn/dt is over the limit, fault code 1790
Bit 15: reserved
program counter ......... : 0000 H |0000|0000|0000|0000|

[program counter from DSP A]
It counts the address where the program is interrupted when there is Time slice overflow T1.
This can help to analyze the fault code 57
pulse pattern identifier : 0000 H |0000|0000|0000|0000|

[pulse pattern identifier DSP A]
0000:
0010:
1020:
environment DSP B

fault status ............ : 0000 H |0000|0000|0000|0000|

[fault status word from DSP B]
Same as DSPA
status word 1 ........... : 0000 H |0000|0000|0000|0000|

[status word 1 from DSP B]
Same as DSPA
program counter ......... : 0000 H |0000|0000|0000|0000|

[program counter from DSP B]
Same as DSPA
pulse pattern identifier : 0000 H |0000|0000|0000|0000|

[pulse pattern identifier DSP B]
Same as DSPA
values DSP DSPB G027 / DSPA G019

duty cycle inverter ..... : 0.0 % / 0.0 %
[duty cycle inverter B/A]
stator frequency reference: 0.0 Hz / 0.0 Hz

[stator frequency reference inverter B/A]
speed signal control loop : 0.0 1/s / 0.0 1/s

[motor speed value for inverter control]
current component flux .. : 0.0 A / 0.0 A

[magnetizing current component inverter B/A]
current component torque : 0.0 A / 0.0 A

[torque-producing current component inverter B/A]
calculated torque ....... : 0.0 % / 0.0 %

[calculated torque percentage traction motor B/A:
100% = 26975 Nm for traction motor 1TB2830
100% = 22756 Nm for traction motor 1TB2826]
calculated flux ......... : 0.0 % / 0.0 %

[calculated flux percentage traction motor B/A]
duty cycle braking chopper: 0.0 %

[duty cycle braking chopper]
voltage/current/speed values:
trolley voltage/current : 0.0 V / 0.0 A
[trolley voltage (transducer U301) / trolley current (transducer U108)]
$UN / $IN
engine speed setpoint/act.: 12.5 1/s / 0.0 1/s

[engine speed setpoint / measured engine speed]]
$NSD / $NIDSBG

DC-link voltage setp./ch. : 0.0 V / 0.0 V

[DC-link voltage setpoint for alternator control / for chopper control]
$UDS / $UDSCHSA (Chopper setpoint)
DC-link voltage / current : 0.0 V / 0.0 A

[DC-link voltage (transducer U105), DC-link current filtered (transducer U107)]
$UDI_IO / $IDIGHW
excitation current setp. : 0.0 A

[excitation current setpoint (field regulator reference)]
$ISEXC
ground-voltage : 0.0 V / 0.0 V

[filtered voltage values for ground fault detection: ground voltage (transducer U106), DC-link voltage
(transducer U105)]
$UGG / $UDIGHW2
chopper currents (B/A) .. : 0.0 A / 0.0 A

[smoothed current values chopper B/A (transducer U204 / U104)]
$IBTGZB / $IBTGZA
blower setpoint frequency : 0.0 Hz

[main blower setpoint frequency (auxiliary inverter reference)]
$FBLWSPT
flux reference (B/A) .... : 0.0 % / 0.0 %

[flux reference percentage for DSP motor control B/A]
$OSOLLSB / $OSOLLSA
torque reference DSP (B/A): 0 Nm / 0 Nm

[torque reference for DSP motor control B/A]
$MS1B / $MS1A
torque reduction SSC (B/A): 0 % / 0 %

[torque reduction factor slip/slide control motor B/A]
$XMRFSSB / $XMRFSSA,
truck speed ............. : 0 mph

[truck speed derived from traction motor speed values]
$VIB
motor currents ph.1 (B/A) : 0 A / 2 A

[motor current phase 1 B (transducer U201) / A (transducer 101)]

$IL1PWRB / $IL1PWRA

$IL2PWRB / $IL2PWRA

$IL3PWRB / $IL3PWRA
module temperature values inverter B / inverter A
invert. modules A201/A101 : 22 øC / 23 øC

[inverter module temperature phase 1 B/A]


chopper modules A204/A104 : 24 øC / 21 øC

[chopper module temperature B/A]
snubber resistor ........ : 20 øC / 19 øC

[snubber resistor temperature B/A]
inverter compartment .... : 21 øC

[inverter compartment temperature]
motor temperature B/A ... : 25 øC / 26 øC

[traction motor temperature B/A]
retard grid temperat. B/A : 27 øC / 27 øC

[retard grid temperature B/A]
alternator stator temp. : 26 øC

[alternator stator temperature]

3.3 CLEARING THE FAULT HISTORY
From the previously discussed menus, the problem with the drive system should be able to be solved.
Once the fault is found and solved, the fault history needs to be cleared. The statistics and fault history
can be very easily cleared in order to eliminate an overwhelming amount of data. This should also be
done periodically in order to keep the fault archive relatively clean so in the event of an outage the
cause of the problem can be easily found. The procedures below will allow you to clear all faults from
the archive except for faults that are still active.
• Click on EVENTS menu
• Click on CLEAR_NORM
• Press ENTER
4 WHAT TO DO WITH THE INFORMATION OBTAINED

With the information given by “STATE _INTERN” you will clearly know if the drive is ready of
operation or if it has a problem and is inhibited. If the drive has an inhibit, it must be cleared by
Siemens Personnel using a laptop and the monitor program. The AC drive system will function
normally when the drive status message in state intern clearly says that inverter A & B are ready for
operation as in Figure 3-2.
Information obtained from statistics and history can be used to clearly isolate where the problem has
occurred. For example, if the auxiliary inverter fails, you will get a fault that says “auxiliary inverter
failure” in the fault archive, which allows the problem to be isolated and appropriate action to be taken.
Many of the problems that will occur can be solved very quickly by mine personnel if this procedure is
followed. By stringing a Record file, Siemens Energy & Automation personnel will have a good idea
of the scale of the problem and can respond accordingly if the problem is not able to be solved onsite.

5 ENGINE LOAD TEST

The engine load test is an invaluable tool for either eliminating the diesel engine or the AC drive
system as a possible problem. By running the load test and examining the RPM range of the diesel on
the onboard computer, one can make a determination concerning the status of the diesel. A full load
engine test can be run using the following sequence of steps in the Monitor program. Please read the
entire procedure before starting the load test.
Note: Before starting a load test verify that the system status is okay, Select User – State Intern. With
the engine running and start up sequence complete everything should be enabled and K104 closed. If
not, the reset button should be pressed and the status should be viewed again. Once the State intern
shows that everything is enabled and K104 is closed the load test can be started.
5.1 Manual Test
• Click on USER menu

• Click on ENGINE TEST
• Press ENTER
• Type “slt” when prompted for password
• Press ENTER (After pressing enter you will hear the diesel pick up RPM)
• Type “L” *** set parasitic loss compensation
• Press ENTER
• Type “150” *** defines the parasitic loss to be 150 Hp
• Press ENTER
• Type “p” *** set the power level
• Press ENTER
• Type “500” *** define the amount to load the engine, example 500Hp
• Press ENTER
• Type “m” *** starts the manual load test, the engine will ramp up and gird motor turn
• Press ENTER (You will hear the engine RPM come up as well as see the grid fan spin)
At this point, you can enter any of the following letters, “d”, “e”, to look at the diesel engine values or
electrical values, respectively. All entries must be followed by pressing enter. All scrolling of the
screen can be stopped by pressing CTRL 'C'. After pressing CTRL C you must select User _Engine
test and get the sub menu to do the other options. To increase the power select “p” and enter in a
increased value.

The following procedures must be completed to stop the test and take the computer out of self-load test
mode.
When stopping the test do the following.
• Type “p”
• Press ENTER
• Type “500”
• Press ENTER **** allow the engine to ramp down a little if power was >1500Hp prior to this
• Type “f” *** stops the engine test
• Press ENTER
• Type “t” *** exits the self load test mode, allows use of the throttle pedal and movement
• Press ENTER
• Type “q” and press ENTER to exit the self load test menu

5.2 Automatic Test
In this mode, the software will automatically regulate the chopper module duty-cycle to keep loading
the engine as much as possible while keeping engine speed at 1810rpm.
• Click on USER menu

• Click on ENGINE TEST
• Press ENTER
• Type “slt” when prompted for password
• Press ENTER (After pressing enter you will hear the diesel pick up RPM)
• Type “a” (at this point the engine test will begin and continue on its own)
At this point, you can enter any of the following letters, “d”, “e”, to look at the diesel engine values or
electrical values, respectively. All entries must be followed by pressing enter. All scrolling of the
screen can be stopped by pressing CTRL 'C'. The following procedures must be completed to stop the
test and take the computer out of self-load test mode.
• Type “f”
• Press ENTER
• Type “t”
• Press ENTER
• Type “q” and press ENTER to exit the self load test menu
Immediately below this section of text can be found a screen capture showing what the engine load test
command list looks like. When the test is completed, the test mode must be exited using the “t”
command followed by pressing ENTER. This is critical, as the drive will not operate properly if it is in
engine load test mode. The power set point must also be ramped up and down in steps to limit stress
on electrical components. All of this is done in the above procedure and is simply being explained in
this section of text. The example test above uses a full power set point, when in reality the test can be
done using any power set point value up to 2550 hp (this number takes into account the 150 hp
parasitics for the main blower hp, 2550 + 150 = 2700 hp engine). For set points other than 2550 hp,
the engine RPM will vary depending on the power requirement and should not be expected to be at
1810 RPM. This full RPM can only be expected when running a load test at full power (2550 hp).

Figure 5-2: Screen Capture of Engine Load Test
5.3 WHAT DO THE RESULTS MEAN
The most important information that can be gained by running this test is whether or not the diesel is
turning at full RPM when full power is needed. If the diesel is turning at less than 1810 RPM while
the load test is at 2550 hp, there is quite possibly a problem with the diesel engine. This is the most
common use for the load test when troubleshooting and can usually be used to eliminate one of the two
systems as the source of the problem at hand.


7A - Field - Trouble V5.0

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7A - Field - Trouble V5.0

Uploaded by

Copyright:

Available Formats

s SPECIAL DRIVES / SE&A

AC DRIVE HAUL TRUCK

Using Sibas 32 for Basic Field Troubleshooting

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

I: DOCUMENT INFORMATION .......................................................................................................2

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

• Laptop computer running Windows

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

Figure 2-1: Start-Up Screen

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

2.1 Problems connecting with SiBAS

2.1.1 “Check Serial Connection” message

2.1.2 “Timeout!!! Timeout!!! Timeout!!!” message

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

3 PROCEDURES FOR COLLECTION OF DATA

3.1 Stringing a record file

• Click on the SET menu

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

3.2.1 Status of the AC Drive System

SIEMENS AC DRIVE truck: status information

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

3.2.2 Viewing the faults of the system

DC: 20 NO.: 6 SYS: TOTALLOCK

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

3.2.3 Viewing the History

DC: 871: ETM: OPEN CIRCUIT PT100 ETM 1 (L131)

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

3.2.4 Viewing a Memory Long of a particular fault

Vehicle / TCU number.... : 075 / 1

CPU software version.... : 208.01

Time of last memory delete. 10.05.99 8:22:20

Event code... 720

UWSB: GTO SWITCHING FAILURE A201-1

Time event occurred/disapp. 12.12.00 17:38:26 / 12.12.00 17:38:33

Memory event number... 32

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

Time of event reset... 12.12.00 17:38:33

Vehicle status... 0004 H |0000|0000|0000|0100|

status time (last/actual) : 0 ms / 1131000 ms

TCU switch OFF/ON time. : 926319795 s / 1131120 ms

"Internal" status info 1: 003C H |0000|0000|0011|1100|

"Internal" status info 2: 0180 H |0000|0001|1000|0000|

Status word TCU-selftest: FFE1 H |1111|1111|1110|0001|

means of the error signal ERR.

Bit 8: fault of hardware comparator 5 IO

AC Haul Truck SiBAS 32 Customer Monitor User Guide Revision: 5.1

Status word inverter test: 0000 H |0000|0000|0000|0000|

Information word initial. DSP A : 0020 H |0000|0000|0010|0000|

Information word initial. DSP B : 0010 H |0000|0000|0001|0000|

control word 1 DSP A .... : 0000 H |0000|0000|0000|0000|

control word 2 DSP A.... : 0000 H |0000|0000|0000|0000|

Status PT100 open circuit : 00D6 H |0000|0000|1101|0110|

Bit 13: Grid A

Status temp. APRS system : 00D6 H |0000|0000|1101|0110|

Bit 0: APRS due to inverter module overtemperature active

Status temp. SHTS system: FD34 H |1111|1101|0011|0100|

Bit 0: SHTS due to inverter module overtemperature active for PROPEL

status temp. superv. INVA : 00FF H |0000|0000|1111|1111|

Bit 0: overtemperature level 1 module A101

Bit 12: reserved

Bit 0: overtemperature level 1 module A201

contactor commands ...... : 0000 H |0000|0000|0000|0000|

contactor feedback ...... : 8FFF H |1000|1111|1111|1111|