Procedimentos de Teste

PREFACE
This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this
mining shovel. We recommend that such personnel review and become familiar with the general procedures and
information contained within this manual. In addition, we recommend that this manual be kept readily available
for reference when repairs or maintenance are necessary.
Due to the complexities of this mining shovel and the environment in which it operates, situations may arise which
are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of
equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H representative
is available to answer your questions and assist you upon request.
Please feel free to contact a P&H representative at any of the following locations to assist you as requested.
Copyright
Under the copyright laws, this documentation may not be copied, photocopied, reproduced,
translated, or reduced to any electronic medium or machine readable form, in whole or part, without
the prior written consent of the Harnischfeger Corporation.
© Copyright August 2000, HP&H Mining Equipment, Milwaukee, Wisconsin, USA
All rights reserved. Printed in the United States.
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iv
DANGERS, WARNINGS, CAUTIONS and NOTICES are used throughout this manual to emphasize important and critical
instructions. Dangers, Warnings and Cautions always precede the paragraph or item to which they apply; Notices always follow the
paragraph or item to which they apply. For the purpose of this manual Dangers, Warnings, Cautions, and Notices are defined as
follows:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
! DANGER death or serious injury. This signal word is to be limited to the most extreme situations.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
! WARNING
DANGER
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices.
! CAUTION
DANGER
NOTICE is used to indicate a statement of Company policy as the message relates directly or
indirectly to the safety of personnel or protection of property. This signal word is not associated
NOTICE directly with a hazard or hazardous situation and is not used in place of “DANGER”,
“WARNING” or “CAUTION”.
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P&H® MINING EQUIPMENT OFFICES
WORLD WIDE MINING HEADQUARTERS
Milwaukee, Wisconsin 53201-0310
Kilgore, TX
SM
NORTH P&H MinePro Services

106 Powderhorn Road
Kilgore, TX 75662
Phone: 903-983-7744; Fax: 903-983-2954
Milwaukee, WI (Home office )
P&H MinePro Services Negaunee, MI
4400 West National Avenue P&H MinePro Services
Milwaukee, WI 53214-3684 701 Everett Street
P O BOX 310, Milwaukee, WI 53201-0310 P.O. BOX 150
Phone: 414/671-4400; Fax: 414/671-7604 Negaunee, MI 49866
Phone: 906/475-6737; Fax: 906/475-7893
Bismarck, ND
P&H MinePro Services Ogden, UT
1938 Tahoe Drive P&H MinePro Services
Bismarck, ND 58504 7891 S. 1800 E.
Phone: 701/258-1442; Fax: 701/258-4477 Ogden, UT 84405
Phone: 801/476-3168; Fax: 801/476-3188
Bowling Green, FL
P&H MinePro Services St. Albans, WV
101 W. County Line Road, P.O. Box 339 P&H MinePro Services
Bowling Green, FL 33834 205 Smiley Drive
Phone: 863/375-3333; Fax: 863/375-3555 St. Albans, WV 25177-1587
Phone: 304/755-1007; 414/671-7609;
Casper, WY Fax: 304/755-8595
P&H MinePro Services
1935 North Loop Avenue,
P O BOX 296, (82602-0296) Canada
Casper, WY 82601 Harnischfeger Corporation of Canada, Ltd.
Phone: 307/237-1574; Fax: 307/235-7907 Calgary
7326 - 10th Street N.E.,Suite 300,
Evansville, WY Calgary, Alberta, T2E 8W1, Canada
P&H MinePro Services Phone: 403/730-9851; Fax: 403/730-9547
1180 Iron Street, P.O. BOX 459
Evansville, WY 82636 Sparwood (Parts)
Phone: 307/237-5144; Fax: 307/237-5147 621 Douglas Fir Road, P O BOX 1390
Sparwood, BC V0B 2G0, Canada
Gillette, WY Phone: 250/425-0863; Fax: 250/425-0665
5834 South Winland Drive Hinton (Parts)
Gillette, WY 82718 113 King Street, P.O. BOX 1040
Phone: 307/685-4100; Fax: 307/685-4101 Hinton, Alberta T7V 1G7 Canada
Phone: 780/865-5835; Fax: 780/865-8861
(Rebuild Operations) Toronto
811 Edwards Road 57 Beverly Glen Boulevard
Gillette, WY 82718 Toronto, ONT M1W 1W3 Canada
Phone: 307/682-0035; Fax: 307/682-0049 Phone: 416/499-5000; Fax: 416/499-5003
Hibbing, MN Cornwall
P&H MinePro Services 1411 Rosemount Avenue
3621 15th Avenue East Cornwall, ONT K6J 3E5, Canada
Hibbing, MN 55746 Phone: 613/930-4400; Fax: 613/930-4404
Phone: 218/262-3837; Fax: 218/262-6323
P&H Mining Institute - Technical Communication v

VER 07, 04-00
P&H® Mining Equipment - MinePro Services
SM
SOUTH SM
AUSTRALASIA
Mesa, AZ (Home office) Brisbane, Australia (Home office)

P&H MinePro Services (Mesa 2) Harnischfeger of Australia Pty. Ltd.
1811 S. Alma School Road, Ste 215 71 Lytton Road/P O BOX 7231
Mesa, AZ 85210-3004 E. Brisbane, Queensland 4169, Australia
Phone: 480/345-6007; Fax: 480/345-4040 Phone: 61-7/3240-4600; Fax: 61-7/3240-4666
P&H MinePro Services (Mesa 1) Hunter Valley - SE Region

112 West Iron Avenue Lot 11, Mount Thorley Road/PO BOX 455
Mesa, AZ 85210-6105 Singleton, NSW 2330 Australia
Phone: 480/834-7656; Fax: 480/834-7807 Phone: 61-2/6578-9800; Fax: 61-2/6578-9888
Fax: Rebuild Center - 480/834-2177
Mackay - NE Region
Elko, NV 44 Commercial Avenue, PO BOX 6534
(Warehouse) Mackay, Queensland 4741, Australia
P&H MinePro Services Phone: 61 7/4952 7800; Fax: 61 7/4952 7888
5244 East Idaho Street
Elko, NV 89801
Phone: 775-778-0740; Fax: 775-778-0744 Perth - Western Region
290 Collier Road/P O BOX 265
Bassendean 6054, W. Australia, Australia
Lone Butte, AZ Phone: 61-8/9270-0700; Fax: 61-8/9270-0777
P&H MinePro Services (Contract Services)
6640 W. Sundust Road
Chandler, AZ 85226
Phone: 520-796-1192; Fax: 520-796-1114
INTERNATIONAL
SM
Brazil /Service/Parts/Sales
Harnischfeger do Brazil
Avenida Portugal 4511/ Bairro Itapoa Milwaukee, WI (Home office)
Belo Horizonte, M.G., 31710-400 Brazil P&H MinePro Services
Phone: 55-31/491-7636; Fax: 55-31/491-6181 4400 West National Avenue
Milwaukee, WI, USA 53214-3684
Chile - Otero Antofagasta P O BOX 310, Milwaukee, WI, USA 53201-0310
c/o Otero SA P&H MinePro Services Phone: 414/671-7453; Fax: 414/671-7717
Av. Pedro Aguirre Cerda #6551
Antofagasta, Chile Beijing
Phone: 56-55/350200; Fax: 56-55/239188 P&H MinePro Services - China
Room 601, East Ocean Center; 24A Jianguo Menwai Dajie
Chile - Otero - Santiago Beijing, China 100004
Comercial Otero S.A Phone: 86-10/6515-5803/04; Fax: 86-10/6515-5762
Pte. Eduardo Frei Montalba #6239; Conchali
Santiago, Chile Great Britain
Phone: 56-2/ 620-8100; Fax: 56-2/624-0690 P&H MinePro Services-Eurasia Sales, Parts & Service
Harnischfeger (U.K.) Ltd.
Mexico P.O. Box 12, Seaman Way, Ince
Harnischfeger Mexico S.A. de C.V. Wigan WN1 3DD, United Kingdom
Paseo Valle Verde, No. 21; Col. Valle Verde Phone: 44-1942 614400; Fax: 44-1942 614419
83200,Hermosillo, Sonora Mexico
Phone: 52-62/180864, 180870; Fax: 52-62/180911 India
P&H MinePro Services - c/o Voltas Limited
Peru Gillander House 8, Netaji Subhas Road
P&H MinePro Services Peru S.A.C. Calcutta - 700,001, India
Calle Los Sauces #374, Office 704 Phone: 91 33/221-0232; Fax: 91-33/248 2517
San Isidro, Lima, 00027 Peru
Phone: 51-1/440-6541; Fax: 51-1/440-8042 Russia
Venezuela 11/2 Armyanski Peer
Harnischfeger Venezuela, S.A. (Warehouse) Moscow, Russia 101963
Zona Industrial Matanzas Sur Phone:7 095/937-4110; Fax: 7 095/247-9060
UD-321, Transversal “C”, Entre
Calles 2 y 3, Galpon 14-02
Puerto Ordaz, Edo, Bolivar, Venezuela
Phone: 58-86/942825/942931; Fax: 58-86/943437
P&H Mining Institute - Technical Communication VER 07, 04-00

vi
Harnischfeger Institute - Technical Communication P&H Mining Equipment
South Africa
P&H MinePro Services - Sales, Parts & Service
442 Heidelberg Road, Tulisa Park
Johannesburg, 2197, South Africa
P O BOX 83676, South Hills 2136, South Africa
Phone: 27-11/869-1335; Fax: 27-11/869-0566
P&H MinePro Services (Repair & Rebuild Division)

43-45 Lepus Road, Crown Mines Ext 8, Gauteng
Johannesburg, South Africa
P O BOX 259, Maraisburg, 1700, South Africa
Phone: 27-11/839 2713; Fax: 27-11/839-2798
P&H MinePro Services (Jwaneng, Botswana)

Jwaneng Mine, Jwaneng, Botswana
Private Bag 062, Jwaneng, Botswana
Phone: 267/384-483; Fax: 267/382-132
P&H MinePro Services (Orapa, Botswana)

Orapa Mine, Orapa, Botswana
Private Bag 01, c/o MinePro Services, Orapa, Botswana
Phone: 267/272-741; Fax267/276-210
P&H Mining Institute - Technical Communication vii

VER 07, 04-00
P&H Mining Institute - Technical Communication VER 07, 04-00

viii
Harnischfeger Institute - Technical Communication P&H Mining Equipment
Safe Operating Practices
for Mining Equipment Users
Preface Operator Qualifications

GENERAL. Only the following personnel should be
A review of many safety sources including MSHA,
permitted to operate a shovel or excavator:
OSHA, ANSI provisions and various individual mine
safety policies was conducted to develop these safe 1. Appointed qualified operators, who have met the
operating practices recommendations. The purpose of requirements of the operation tests and physical and
these recommendations is to assist and support our mental condition.
customers in their safety efforts in preventing
accidents. 2. Qualified maintenance and test personnel, when
required to do so in the performance of their duties.
3. Inspectors qualified to operate the machinery.

Introduction
OPERATION TESTS. Every employer should require
P&H shovels and excavators are carefully designed, that all persons who will be authorized to operate a
manufactured, and tested. When used properly by shovel or excavator first pass an examination which
qualified operators, they will give safe, reliable service. accurately measures practical knowledge of the
There are P&H offices world-wide to answer any equipment and proper methods to be used in operating
questions about P&H products or their safe use. The the shovel or excavator.
World Sales and Service headquarters for P&H Mining
Equipment is: PHYSICAL AND MENTAL CONDITION. An operator
must me et t he fo llo wi ng phy sical a nd ment al
qualifications:
P&H Mining Equipment
4400 West National Avenue 1. An operator must possess good hearing ability as
P.O. Box 310 well as good vision (corrected or uncorrected). Good
Milwaukee, WI 53201 USA depth perception is also required, especially where
Telephone: (414) 671-4400. truck loading is critical or must be accomplished at
some distance from the operator.
Because shovels and excavators are complex and 2. An operator must not be afflicted with any known
massive equipment and have the ability to lift and health condition or disability which could cause a
move heavy loads, they also have a potential for sudden inability to react quickly.
accidents if safe operating practices are not followed.
This booklet is intended to help prevent accidents 3. An operator who is taking medication prescribed by
which could result in injury, death, or property damage. a doctor must present written assurance from his
doctor that the medication will not affect the operator's
ability to operate the shovel or excavator in a safe
General safe practices for working on machinery must manner.
be followed as well as the safe operating practices. The
following recommendations are provided to 4. An operator who is known, or suspected, to be under
supplement customer/owner, local, or national safety the influence of alcohol or drugs must not be allowed to
codes, rules or procedures. operate equipment under any circumstances.
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5. The operator must have a good attitude towards is unsafe and consult his supervisor when safety is in
safety at all times. doubt.
He must read and understand the Operator's Manual,

Mine Management's Responsibility all instructions and signs on the equipment. He must
see that the machine is in proper order before
Management must ensure that operators are trained,
operating.
competent, physically fit and, if required, licensed.
Good vision is required, as are good judgement,
He must be alert, physically fit, and free from the
coordination and mental ability. Any person who lacks
influences of alcohol, drugs, or medications that might
any of these qualities must not be allowed to operate a
affect his sight, hearing, or reactions.
shovel or excavator.
He must ensure that people, equipment, and material
Management must maintain its equipment in a safe
are kept out of the work area. He must never operate
operating condition and must require the equipment's
the dipper or bucket over people. He must never use
operation to immediately stop if an unsafe condition is
the shovel or bucket to lift or transport people.
found.
Management must ensure that the ground crew have A warning signal must be given by the operator prior to
good vision and sound judgement, know standard starting, operating, or traveling the shovel or excavator.
signals and be able to give travel signals clearly. They
must have enough experience to be able to recognize Responsibilities Of All Crew Members
hazards and signal the operator to avoid them.
Any unsafe condition or practice must be corrected or
Management must assign a job supervisor at the site to reported to the job supervisor and equipment operator.
be responsible for overall job safety. Shovel or
excavator operators and crew members must know who Everyone who works around shovels or excavators,
has been assigned this responsibility. including support people and maintenance personnel,
must obey all warning signs and watch out for their
Crew members must be given specific safety
own safety and the safety of others. Crew members
responsibilities and instructed to report any unsafe
setting up machines or handling maintenance or
conditions to their supervisors.
repairs are expected to know proper procedures
Management must assign specific people to coordinate including lockout/tagout practices.
and di rect t he s erv ice, re p air, insp e ctio n and
Watch for hazards during operations and alert the
maintenance process for the shovel or excavator during
operator of dangers such as the unexpected presence of
each shift with specific methods to de-energize
people, other equipment, unstable ground and bank
equipment before starting the work and to lockout and
conditions or approaching storms.
tagout equipment until ready for operation.
Management must assign qualified people with proper Planning the Job
tools and protective equipment for specific work
assignments. Most accidents can be avoided by careful job planning.
The person in charge must have a clear understanding
Management must maintain a safety program which of the work to be done, consider dangers or hazards,
includes both instructions and training for employees develop a plan to do the job safely, and then explain the
on shovel or excavator safety. plan to all concerned. Factors such as the following
should be considered:
Management must ensure that during night operation,
suitable lighting is provided.
• How can the shovel tail cable be safely moved at the
work site?
Operator's Responsibility
• Is there other equipment, power lines or structures
Safety must always be the operator's most important which must be moved or avoided during movement of
concern. He must refuse to operate when he knows it the shovel?
xii
• Is the surface strong enough to support the machine • During operation, be alert for unusual noises or
and load? vibrations; look and smell for unusual smoke or
fumes.
• How and where will the removed materials be
unloaded?
Operating Instructions
• What steps will be taken to keep unnecessary people 1. Determine the load bearing capacity of the ground or
and equipment at a safe distance from the work other surface on which machines will be operating. Be
area? sure the machine is adequately supported. Avoid soft
or unstable ground, areas with high water tables, and
These factors are not meant to be exhaustive, but only
partially frozen ground. When machines are working
a starting point. Each job must be individually
near benches, the benches should be shored or sloped
considered.
by appropriate equipment to prevent cave-ins or slides.
Operator's Functional Checks 2. Shovels or excavators should never be used to lift

people. Use ladders, scaffolds, elevated work platforms
The operator must make a safety check before starting or other equipment designed to lift people.
to work each shift to see that the machine is in proper 3. Prior to servicing or repairing the shovel or
order. Some things to check are: excavator, follow lockout and tagout procedures. Both
OSHA and MSHA regulations require lockout/tagout
• Check for warning tags or lockout tags on the starting procedures. Injury, death, and damage can occur if the
controls; do not operate the controls until the tag has shovel or excavator is started before servicing is
been removed by the person who placed it there, or finished. Never start or operate the equipment if
by a qualified person. lockouts or tagouts are on the controls. Look inside,
outside, under and around the equipment to be sure
• Check with mine maintenance and operations everyone is clear.
management to see that periodic maintenance and
inspections have been performed and all necessary 4. Always start and stop swing movements smoothly
repairs made. and swing at speeds that will keep the dipper load from
spilling. Rapid swings, sudden starts or sudden stops
• Consult with mine management that scheduled can cause the load to sp ill and d amage swing
inspection of load carrying members such as wire machinery.
rope (dipper trip lines, hoist rope, suspension lines),
boom, dipper handle and dipper has been conducted. 5. Keep windows clean. Do not operate if you cannot
see clearly enough to operate. Dirty windows,
• Check that all equipment guards are in place and all darkness, bright sunlight, fog, rain, and other
inspection and cover plates are closed and locked. conditions can make it difficult for the operator to see.
6. Carelessness in getting on and off equipment can
• On hydraulic shovels, check for evidence of hydraulic
result in serious injuries. Always wait until the
oil leaks.
operator has been notified and the shovel or excavator
has stopped all movement before attempting to climb
• Look inside, outside and underneath the shovel or
onto the shovel or excavator. Do not jump on or off. Use
excavator to make sure everything is clear before
both hands and make sure you have good footing.
starting or energizing the machine.
7. Keep the machine clean and dry. Slippery floors and
• After starting the shovel or excavator, check all steps, tools, trash, or other loose items can cause slips
gauges and indicators for proper readings and and falls.
operation.
8. Exceeding the slope or grade limitations given for
• Test all controls for proper operation and control your specific shovel can cause a tip over or run away
ability before machine operation or travel including condition resulting severe injuries, death or property
a check of brakes. damage. Prior to propelling, always determine the
slope or grade limitations for your specific machine and
• Check audible warning devices and alarms used for never travel, park or operate on site slope conditions
backup warning for proper operation. which exceed these limitations.
xiii
9. As with all heavy equipment, care must be taken Establish clearances for the machine after each
when shovels or excavators are moved around the job relocation with job site procedures.
site. Watch for people, other equipment, low or narrow
clearances, ground bearing limits, and steep hills or 15. Cave-in can occur when excavating in a pit or along
uneven terrain. Use a signalman when traveling. a high wall. Do not undercut the bank but remove the
Know the height, width, and weight of the machine. uppermost material first or take other appropriate
Always secure equipment before traveling. Do not precautions.
travel with people riding on the outside of the machine 16. People can be pinched, entangled or crushed by
or inside the machinery house. moving machinery. Personnel should not place any part
10. Leaving a shovel or excavator unattended can be of their body or clothing on or near any rotating
very dangerous unless proper precautions are taken. machinery, gears, pinions, ropes, cables or crawlers
At night, or conditions of poor visibility, lights, flares, or while the machine is in operation.
other warning devices must be posted to identify the
parked shovel's location for other traffic. Before leaving Maintenance Work Precautions
his seat, the operator must take the following steps to
prevent the shovel or excavator from moving: Inspection, service and maintenance are essential
elements in the proper operation and performance of
• Lower the dipper to the ground. shovels and excavators. The following
recommendations are provided to supplement past
• Return all controls to the neutral position.
experience, knowledge and common sense of a
serviceman concerning potential hazards associated
• Set all brakes.
with inspection, service and maintenance.
Before leaving the shovel or excavator, in addition to 1. Prior to undertaking any work on the equipment, the
the previous steps required by the operator, the personnel performing the work shall notify the
following should be done: operator about the nature and location of the job.
Appropriate lockout and tagout procedures must be
• Shut off the master control power switch on determined and followed by all individuals involved to
electrically-powered shovels or excavators. guard against potential hazards.
• Verify that all electrical cabinets are closed and 2. Before maintenance or service is attempted, the
locked and that all electrical components guards are operator must park the machine in a location to avoid
installed. hazards such as falling rocks and unstable ground.
After parking the machine, the operator shall:
• Disengage the engine clutch and shut off the engine
on engine-powered shovels or excavators. • Set the dipper on the ground.
11. Wire rope running over drums and through sheaves
• Set all brakes.
create pinch points. Do not use your hands to guide
wire rope onto drums. Use rope guides or prescribed
• De-energize control functions.
procedures. Keep clothing and all parts of the body
away from running rope and the machinery that moves
• Comply with lockout and tagout procedures.
the rope.
3. Injury, death, and damage can occur if the machine
12. Rocks too large to be handled safely must be broken
is started before servicing is finished. Never start or
before loading to avoid the hazard of falling and
operate the equipment if lockouts or tagouts are on the
ricocheting rocks.
controls. Prior to starting the machine, look under,
13. Shovels or excavators with electric tail cables can within, and around the equipment to be sure everyone
break the cable connection or crush the cable when is clear.
traveling. Maintain cable slack while operating and
4. Specific inspection, service and maintenance
traveling. Use signalmen during traveling to prevent
instructions for P&H shovels or excavators are
damaging to the cable or cable connection.
available from product manuals and the P&H service
14. Make sure that the shovel or excavator house or network. Always read and follow instruction manuals
bucket does not hit obstructions when swinging. and use the P&H service network for assistance.
xiv
5. On hydraulic shovels, release system pressure before • Bird-caging or other distortion indicating uneven
attempting to make adjustments or repairs. Pressure distribution of load between rope strands.
in hydraulic systems can be retained for long periods of
time. If not properly released before maintenance • Evidence of severe corrosion, particularly in the
people attempt to work on the hydraulic system, this vicinity of attachments.
pressure can allow machinery to move or cause hot oil
and hose ends to shoot out at high speed. • Uneven stretch of multiple ropes.
6. Maintenance and service can involve the handling of • Heat damage from any source.
heavy parts or components which can injure personnel.
Use lifting and handling equipment along with • A rapid increase in the number of broken wires.
blocking to remove, support, and install heavy parts.
10. Wire rope end connections must be installed
7. Make sure both ends of booms or cylinders are properly and inspected daily.
supported and the boom suspension lines completely
slacked off before removing pins. Never stand on, • Wire rope secured with a wedge socket should be
inside, or under booms during erection or disassembly. installed so that the load line is in a straight line pull
Pin-connected booms may fall if not properly supported with the eye of the socket; and the loaded part of the
when removing or installing pins. rope is not kinked where it leaves the wedge. The
rope end should always protrude at least 6 to 9
8. In regard to inspection and retirement of wire rope inches beyond the socket. Attach a short piece of wire
used on surface mining machines: rope to the rope end with two wire rope clips to
prevent the rope end from slipping out of the wedge
• Mine management shall provide and appoint socket.
qualified personnel to inspect, prepare and retain
written reports on wire rope inspections. 11. Electrically powered shovels or excavators operate
using high voltage wiring, components and systems.
• An inspection procedure should be established by This voltage can kill or seriously injure people
Mine Management for each wire rope application on servicing, repairing or working on the machines.
their mining shovels or excavators. Inspection, maintenance or service of any electrical
component must be done by qualified personnel. All
• Unless instructed otherwise, the frequency of people working on or around the equipment should
inspections shall be established based upon read and obey hazard signs and always use lockout and
operating shifts, days, weeks or months depending tagout procedures.
upon anticipated rope life and working conditions.
12. All guards, signs, warning devices and guarding
• An average wire rope life shall be established based devices must be in place and in working conditions
upon the number of operating cycles, volume of before the shovel or excavator is placed back in
material handled or weight of material handled. operation after inspection, service and maintenance.
Replacement is determined from this established 13. Loose or missing hardware, bolts, or nuts should be
rope life analysis. properly tightened or replaced with the manufacturer's
9. MSHA procedures require all wire rope be inspected specified hardware. Refer to P&H Service and Parts
daily to determine whether it should be replaced. sources for replacement parts.
14. If there is not enough wire rope on the drum, the
As a minimum, wire rope replacement should be rope can be pulled off. Allow for at least two full wraps
performed when any of the following conditions exist: of wire rope on drums when replacing the rope.
• Severe abrasion, scrubbing, peening, or kinking, or 15. Electrical junction boxes for electrical motors can
broken outer wires. contain high voltage electrical power from multiple
sources. Before performing service on electrical
• Crushing, or other damage that distorts the rope's components within electrical junction boxes, determine
structure. that all electrical power from all sources has been
disconnected and locked out. Test the components
• Severe reduction of rope diameter or an observable within the electrical junction box to verify the electrical
increase in rope lay. power is disconnected.
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xvi
Electrotorque Plus®
TEST PROCEDURE
1. GENERAL 2. TEST EQUIPMENT
The following test procedure provides a guide for the 2.1 A digital multimeter, oscilloscope, two-chan-
inspection and adjustment of the electrical systems nel chart recorder, clamp-on ammeter, meg-
used on Harnischfeger ELECTROTORQUE-PLUS ger, and laptop PC are required to do the
mining excavators. This is the procedure to be followed
electrical tests outlined in this test proce-
to obtain the required test data and to insure accurate
test documentation.
dure. This same equipment should also be
considered as essential for field testing or
troubleshooting.
1.1 The test procedure is written in a step-by-
step sequence which should be followed dur-
ing the commissioning process. 2.2 The shop tests and start-up tests require
additional equipment to aid in performing
the necessary tests and to provide the nec-
1.2 The control tests for each machine motion
essary test information.
(hoist/propel, crowd/propel, or swing) are
usually sufficiently redundant to allow tests 2.2.1 A laptop PC with Rockwell PLC communica-
to be made for troubleshooting purposes tions hardware and software is required to com-
without starting at the beginning of the municate with the on-board Programmable
entire test procedure. Logic Controller.
1.3 The test procedure with proper interpreta- 2.2.2 A Push-button/Reference Unit is recommended
tion can be used for shop tests at the factory, to simplify control of the individual motions dur-
commissioning tests when the machine is ing testing. See Figure 2.2.2 in Appendix B.
started at the customer's site, start-up after
troubleshooting or replacement of electrical 2.2.3 A large resistor, 12.5 ohm 6000 watt, is
required to limit the armature current during
components, and testing of the control and
the start-up of each converter. See Figure 2.2.3
converter equipment when the entire elec- in Appendix B.
trical system is not complete.
2.2.4 For testing the Reactive Power Compensation,
1.4 The proper schematic diagrams should be a capacitor unit, as shown in Figure 2.2.4, is
utilized and consulted frequently for all required as a test load. See Figure 2.2.4 in
testing procedures. Appendix B.
2.2.5 A voltage divider, such as the one shown in Fig-

ure 2.2.5, should be used to aid in making high
Certain procedures require working on voltage measurements on the RPC. See Figure
live circuits. Proper CAUTION should 2.2.5 in Appendix B.
be observed at all times.
2.2.6 A 15A, 600V, molded case circuit breaker with
#12 wire connected to 1 pole should be used as a
shorting switch for ground fault checks.
2.2.7 Miscellaneous test leads, probes, clips, cables,

auxiliary push-buttons, switches, sealing lac-
quer, etc. should be available.
Copyright © 2000 P&H Mining Equipment

CAT312_2.fm 1 TEST PROCEDURE
2.3 See Appendix A showing a list of recom- 3.2.7 Check that all plug type connectors are
mended test equipment. installed and locked in position. A loose locking
feel on the quarter turn connectors may indicate
the absence of the sealing o-ring.
3. VISUAL INSPECTION
3.1 Check that all electrical connections are

4. CONTINUITY TESTS
tight and that the wiring is properly bun-
4.1 When checking circuits containing
dled and secured. semiconductors, devices such as bells or buzzers
should not be used because of possible voltage
3.1.1 Check that the proper leads are connected to surges developed by these devices. Instead, a
the respective coil terminals on the main, auxil- DVM, continuity tester, ohmmeter, or lamp should
iary, field, lighting etc. transformers and that be used.
the primaries are connected for the correct oper-
ating and test voltage.
4.2 The entire system wiring must be checked
3.1.2 Check that the connections to the dc buswork and compared to the schematic diagrams
on the bottom of the thyristor cabinet are tight for that particular system.
and do not rub against any sharp edges.
4.3 Polarities on all dc circuits should be care-
3.1.3 Check that all overhead bus bar connections fully noted.
are tight and that the proper joint compound,
such as Alcoa No. 2 Electrical Joint Compound
has been used.
5. GROUND CHECKS
3.1.4 Check that the connections to all dc motors are 5.1 The power transformers have a resistance ground
properly made and that all motor brushes are in system connected from the secondary neutrals to
place with the brush springs properly secured. the shovel frame. Any circuit connected to the
transformers secondaries will have a resistance to
ground of approximately 250-500 ohms, therefore,
3.2 Check the electrical cabinets to assure that it is necessary to isolate the transformer neutrals
all components are properly mounted and to make ground checks.
secure.
3.2.1 Plug-in relays should be secured with a hold NOTICE

down spring or clamp.
When checking connections on the trans-
3.2.2 Check that the thermal overload elements on former secondaries, two leads must be dis-
the auxiliaries circuits are of the specified size connected from the transformer to avoid
and that the trip adjustments are set at the reading from phase to phase through the low
specified setting, on the motor starters. resistance transformer windings.
3.2.3 Check the thermal overload relays on the dc This check may also be made before the transformer
motor circuits, and that the overload elements secondaries are wired.
are of the specified size.
All transformers with high voltage primaries should
3.2.4 Check all major components of feedback and be “Megger” checked before high voltage is applied.
metering circuits for proper components. The check should be performed immediately prior to
placing the transformer into service.
3.2.5 Check the oil level in the lubrication system.
Before using the Megger, the primary and secondary
3.2.6 Check that all dc motor brakes are properly must be completely disconnected from all external con-
adjusted and operable. nections. A 1000V Megger with a 2000 megohm scale
is recommended. Readings should be taken between

TEST PROCEDURE 2 CAT312_2.fm
the low voltage winding and ground, low voltage and 6. TRANSFORMER VOLTAGE AND PHASE
high voltage windings, and high voltage winding and
ground.
SEQUENCE CHECKS
A value of 1000 megohms or one half the factory test

values, as posted on the interior of the transformer,
should be considered as the minimum obtained levels The tail cable must be disconnected
before the unit is energized. If a Megger test card is from the machine during the following
not available, all transformers, in general, must test to low voltage tests.
a minimum level of 500 Megohms.
6.1 The phase sequence relationship between
A reading of less than 500 megohms indicates mois- the main transformer, auxiliaries and field
ture or contamination. A proper clean-up procedure secondary windings must be correct. For ini-
and dry out procedure must be initiated to bring the
tial start-ups, a preliminary check-out of
resistance levels above 500 megohms. Refer to P&H
Service Bulletins for proper procedures.
voltages, phasing and possible ground
faults should be done by applying low volt-
age to the transformer primaries according
NOTICE to the following procedure.
If over potential tests are made, they must be 6.1.1 Open all circuit breakers on the main trans-
limited to 75% of the factory test, for a dura- former, auxiliaries and field secondaries to iso-
tion not to exceed 1 minute. Leakage must be late the secondaries from any loads.
controlled or monitored to prevent complete
breakover, tracking, etc., which will destroy 6.1.2 Short across the open power contacts on the
the transformer. Megger checks must always high voltage vacuum contactor.
be done prior to any over potential testing.
6.1.3 Short the neutral terminals on the ground fault
5.2 Circuits separated from the secondaries will circuits together for the main, auxiliaries and
have normal readings to the frame. field transformer secondaries.
5.2.1 500,000 ohms is considered as a low isolation 6.2 TRANSFORMER VOLTAGES.

resistance for average climatic conditions on the
low voltage circuits. 6.2.1 Apply a 3 phase test voltage to the main pri-
mary transformer and the auxiliaries and field
5.2.2 Extreme CAUTION should be observed in the primaries. The test voltage should not exceed
use of the Megger. 600V.
5.3 Proceed now with a systematic ground 6.2.2 Measure the secondary voltages and record the
check of all voltage systems and electrical voltage readings on the test data sheet for the
indicated test points.
equipment.
6.2.3 The following formula is used to determine the
5.4 All dc motor armatures should be checked voltages to be measured on the transformer sec-
using a 500V Megger. Readings should be ondaries when a low test voltage is applied to
in excess of 2 megohms. All leads directly the primary:
connected to the motor must be discon-
nected prior to the Megger check. VSEC = (VS rated / VP rated ) x VPRI
A reading of less than 2 megohms indicates
moisture or contamination. A proper clean-
up procedure and dry-out procedure must
be initiated to bring the resistance level
above 2 megohms.

Where: 6.3.5 Compare the measured readings to the values

determined using the calculation of step 6.3.4
VS rated = nameplate rated secondary volts These values should not vary more than +/–5%.
VP rated = nameplate rated primary voltage (OPTIONAL TEST)

VSEC = voltage measured at the secondary terminals
6.3.6 (OPTIONAL TEST) A more extensive test to
VPRI = voltage applied to the primary terminals determine the transformer phase relationship
can be made using a two channel oscilloscope.
Example:
VP rated = transformer connected for 4160VAC • 6.3.6.1 Set the trigger mode to LINE.
VS rated = 600VAC • 6.3.6.2 Make sure that the chassis of the

oscilloscope is isolated from the frame of the
VPRI = 460VAC machine, and that the AC line connection to the
VSEC = (VS rated / VP rated ) x VPRI oscilloscope is not grounded.
= 600 / 4160 x 460 = 66VAC • 6.3.6.3 Measure the phase displacement of two
secondary voltages; say A1 - B1 to C1 - B1 by
connecting the ground leads to B1, Channel A to
6.3 TRANSFORMER PHASE RELATION.
A1, and Channel B to C1. See the transformer
connections of Figure 6.3.6.3.
6.3.1 The phase relationship between the main
transformer, auxiliaries and field secondaries is
checked by measuring the voltage difference
between corresponding phases of each trans-
former.
6.3.2 Check that the transformer neutrals are

shorted together for this test.
6.3.3 Record the voltage readings on the test data

sheet for the indicated test points.
6.3.4 To determine the correct voltage difference

between transformer phases, use the formula
found in step 6.2.3 to find the secondary volt-
ages with the test voltage on the primary, then Figure 6.3.6.3 Transformer Connections
use this formula: • 6.3.6.4 Compare the pattern of the waveforms
from one transformer secondary to that of the
Vdiff = (Vsec1 - Vsec2) / 1.732 other taking care to connect the oscilloscope the
same on comparable terminals, i.e. probe on A1,
Example: ground on B1, probe on A2, ground on B2, etc.
Vsec1 (main xfmr) = 66V • 6.3.6.5 Voltages of like phases should give a trace
of the same position on the screen. See waveforms
Vsec2 (aux. xfmr) = 51V of Figure 6.3.6.5.
Vdiff = (66 - 51) / 1.732 = 8.7V
This is the voltage that should be measured between

the corresponding phases of the auxiliaries and main
transformer secondaries.

1. All Auxiliary Supplies

2. Control Supply
3. Relay Supply
4. Field Supplies
5. Lower Control Supply
6. Lighting Supply
7. Heater Supplies, etc.
Record these readings on the test data sheet.
NOTICE
Figure 6.3.6.5 Waveforms When the capacitors on the main trans-
former secondaries are energized, the supply
6.3.7 Remove shorting leads from high voltage con- voltage will tend to rise, causing the above
tactor and from the transformer neutral termi- voltages to read proportionately higher.
nals and reconnect the neutrals to the ground
fault circuits.
8. CONTROL SUPPLY VOLTAGES
7. HIGH VOLTAGE TO TRANSFORMER
8.1 Verify that the disconnect switch connected
PRIMARIES to the primary of the main transformer is
open.
8.1.1 Check that the test selector switch is set to

Double check Step 6.3.7. Notify and CONTROL TEST.
warn personnel, and observe all safety
precautions prior to applying high volt- 8.1.2 Open the relay and control supply circuit
age. breakers (RSCB, CSB), and the breaker supply-
ing 120VAC to the PLC power supply.
7.1 Check that all circuit breakers on the auxil-
iaries and field secondaries are open to iso- 8.1.3 Disconnect the wire from (open the circuit to)
late the loads. Open the main transformer each capacitor charging relay coil at the diverter
disconnect switch. circuit terminal board for each motion.
8.1.4 Use an ohmmeter to check each PLC input and

7.2 Set the test selector switch to CONTROL
each PLC output for shorts to machinery house
TEST position. ground (01021G). If any input or output is
grounded, troubleshoot and remove the ground
7.3 Check that the main air disconnect switch before applying power to any of the I/O circuits.
in the high voltage cabinet is closed.
8.2 120V Main Supply: 120V (60Hz) - 110V
7.4 Apply rated high voltage power to the (50Hz)
machine and check that the auxiliaries and
field transformer is energized. 8.2.1 If a separate lighting supply transformer is
used, close its primary supply circuit breaker.
7.5 Measure the following voltages on the line
side of the respective circuit breakers: 8.2.2 Close the lighting supply breakers. Check for
proper operation of the various lighting circuits.
(Refer to the schematics for all supplies.)
8.2.3 Close the 120V (110V) main circuit breaker
(MB). Measure the 120V main supply.

8.2.4 Verify that the PLC is properly wired for a ify proper communication between the PLC
120V supply. Close the branch circuit breaker and operator touch screens.
supplying the PLC constant voltage supply
(CVSB). Measure the PLC CVS supply and ver- 8.7 PLC INPUTS VERIFICATION.
ify that the power on indicator is lit on the PLC
power supplies. Confirm that power is being
Use the PLC I/O screen on the GUI to access the PLC
supplied to the control cabinet touch screen com-
input screens.
puter and the operator’s cab touch screen panel.
8.7.1 Refer to the schematics and data sheets as a
8.2.5 Close the 120V lower control cabinet supply cir-
guide to verifying the various PLC inputs. Actu-
cuit breaker (LSB). Measure the 120V lower
ate each input switch, push- button, etc., or sim-
supply.
ulate actuation of the input component or
device. Check for proper status indication on the
8.2.6 Close the dc contactor supply circuit breaker
touchscreen GUI.
(DCSB). Measure the dc contactor supply.
8.7.2 Verify each of the inputs on the first PLC input
8.2.7 Verify the level of all the ac and dc circuits sup- module. Repeat this procedure for each PLC
plied by the 120V branches. (Use your machine input module.
schematics as a guide).
8.2.8 Check the functions of each of the 120V devices 8.8 PLC OUTPUTS VERIFICATION.
supplied by the individual branch circuit break-
ers. (heaters, dc contactors, etc.)
8.3 120V RELAY SUPPLY When outputs are forced on, the con-
nected device will energize. Double
8.3.1 Close the relay supply circuit breaker (RSCB). check that the test selector switch is set
Measure the 120VAC supply. to the CONTROL TEST position, and the
high voltage disconnect switch is open.
Check that the master control relay (MCR) picks up The machine and motions should be at
when all of the emergency stop push-buttons are rest and not loaded i.e., no hoist ropes,
pulled out, and that MCR drops out when any one no handles, machine on level ground. If
emergency stop push-button is pressed. an output cannot be energized safely,
disconnect the output device and check
for actuation with a 120V test lamp.
8.4 230V CONTROL SUPPLY
Make sure the ground checks called for in Step 8.1.4
8.4.1 Close the 230V supply breaker (SB), and the
have been completed.
control supply breaker. (CSB)
8.8.1 Refer to the schematics and data sheets as a
Measure the 230V control supply.
guide to verifying the various PLC outputs.
Output verification is done by forcing an indi-
8.4.2 Measure the 28VDC diverter power supply.
vidual PLC output address using a laptop PC
and checking for the proper hardware response.
8.4.3 Measure both 120V kVAR transducer supplies.
8.8.2 Verify each of the outputs on the first PLC out-
8.4.4 Close the 120V constant voltage supply breaker
put module, by forcing each of the individual
(CVMSB). Measure the 120V C.V.S. supply.
PLC output addresses either on or off as
required. Repeat this procedure for each PLC
8.5 Check the schematics for all optional equip- output module.
ment and verify their operation.
8.8.3 When finished with PLC outputs verification
8.6 With the 120V main supply breaker (MB), remove all forces!
and PLC supply breaker (CVSB) closed, ver-

8.9 If a complete machine commissioning is to 8.12.10 Increase the swing reference to full positive
be performed, install a Reference/ Push-but- (+). Check that the swing operator’s reference
ton Unit at this time. Reference Figure 2.2.2 analog input and output respond correctly as
in Appendix B. seen on the GUI screens.
8.12.11 Repeat with the swing reference set to full

8.10 Close the suppression circuit breakers on
negative (–).
the suppression/capacitor monitor cabinet.
Close the RPC, auxiliary, and lower control 8.12.12 Set the swing brake. Press the STOP push-
cabinet breakers. button.
8.11 Check the crowd/propel transfer circuits. 8.12.13 Again, using the analog I/O screens on the
GUI, check the dc motor and bearing tempera-
8.11.1 Press the START push-button. ture monitoring. These RTD measurements
should read ambient temperatures at this time.
8.11.2 Alternately press the PROPEL and HOIST/
CROWD push-buttons and check that the arma- 8.13 Check that the trip settings on the following
ture and field contactors in transfer cabinet circuit breakers are adjusted to indicated
operate. settings (if adjustable):
8.11.3 Press the STOP push-button. Circuit Breaker Setting
8.12 PLC ANALOG I/O CHECKS. RPC Time Delay = 300mS

Current = 3X
Monitor the Analog I/O using the GUI Analog I/O
screens.
9. AUXILIARIES
8.12.1 Press the START push-button. Press the
HOIST BRAKE RELEASE push-button. 9.1 Set test selector switch to AUXILIARY
TEST.
8.12.2 Increase the hoist reference to full positive (+).
Check that the hoist operator’s reference analog 9.2 Open all auxiliary load breakers and all
input and output respond correctly as seen on motor starter breakers.
the GUI screens.
8.12.3 Repeat with the hoist reference set to full neg-

9.3 Close the main auxiliary breaker.
ative (–).
9.4 Check the auxiliary cabinet voltmeter for
8.12.4 Set the hoist brake. proper readings.
8.12.5 Release the crowd brake. 9.5 AUXILIARY LOADS BREAKER CHECK.
8.12.6 Increase the crowd reference to full positive 9.5.1 Individually close each auxiliary branch circuit
(+). Check that the crowd operator’s reference breaker. Refer to schematic.
analog input and output respond correctly as
seen on the GUI screens. 9.5.2 Check for proper voltage or operation of the
load.
8.12.7 Repeat with the crowd reference set to full neg-
ative (–). 9.5.3 Check the air compressor system.
8.12.8 Set the crowd brake. 9.5.4 Check for proper operation of the pressure
switches.
8.12.9 Release the swing brake.

9.6 AUXILIARY SYSTEM CHECKS. 9.7.2 Some machines may be equipped with a 30 sec-
ond ground fault shutdown system. See sche-
9.6.1 Set the test selector switch to AUXILIARIES matics. Repeat 9.7 in control test and observe
TEST. 30 second shutdown routine.
9.6.2 Close all relay supply, control and 230V supply 9.8 Check schematics for other auxiliary func-
circuit breakers. tions and supplies; verify for correct opera-
tion.
9.6.3 Close each of the auxiliary motor starter circuit
breakers individually:
10. SWING FIELD CONTROL
9.6.4 Press the START button. Check that the
motors on the closed breaker operate properly 10.1 TEST PREPARATION
and that the direction of rotation is correct.
Transfer to propel. Verify propel blower opera- 10.1.1 Check that all field circuit breakers are open.
tion.
10.1.2 Check that the field cables are connected to the
9.6.5 The instantaneous trip adjustment on the motors.
motor starters is set to nominal at the factory. If
tripping occurs due to starting inrush current, 10.1.3 Set the test selector switch to FIELD TEST.
adjust the instantaneous trip setting. Refer to
drawing R31892 for factory settings. 10.1.4 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
9.6.6 Press the STOP push-button. Open the agree with the shovel documentation.
breaker on the starter just tested, and close the
next. 10.2 SUPPLY VOLTAGES
9.6.7 Close the dipper trip motor starter circuit 10.2.1 Close the following circuit breakers:
breaker(s). Check that the dipper trip circuit
operates properly, and that motor rotation is cor- • 120V Main Breaker (MB)
rect. • Constant Voltage Supply Breaker (CVSB)
9.6.8 It may be necessary to make the final adjust- • DC Contactor Supply (DCSB)
ments on the dipper trip resistors after the • 230V Supply Breaker (SB)
machine is operational to obtain the proper
• Control Supply Breaker (CSB)
slack take up and tripping torque on the motor.
• Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
(CVMSB)
All resistor adjustments must be made
• Synchronizing Supply Breaker (SSB)
with the power off.
10.2.2 Using a DVM, check that the following voltages
9.7 Check the ground fault circuits by pressing are present at the fields drive module (field
the ground fault test push-buttons. Check AFM):
for appropriate fault indication.
120VAC control power at TB1-1 to TB1-2.
9.7.1 The fault indication will remain after the test
230VAC, 3ph, synchronizing voltage at P11-1 to
short is removed. The ground fault reset button
P11-16 to P11-3.
must be used to extinguish the light. See sche-
matics. 42VDC (approx. 50VDC no load) gate voltage at P11-
13 (+) to P11-14 (–).

10.3 AFM SOFTWARE 10.4.5 Calculate the expected dc voltage across the
feedback resistor at normal current levels:
10.3.1 When the field AFM is properly powered, its
LCD display should read: Vfb = Ifld / CT Ratio x Rfb
P&H Electrotorque-Plus Example:
Field Control 80A / 150 x 5 ohm = 2.7 VDC
10.4.6 Verify that the test selector switch is set to

This indicates that this AFM most likely has the cor- FIELD TEST, and that the meter selector switch
rect firmware installed. is set to SWING. Close the swing field circuit
breaker.
10.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using 10.4.7 Check that the swing field current remains at 0
the right arrow key and go to E007 SWR VER- amps.
SION. Confirm that the displayed software part
number agrees with the shovel documentation. 10.4.8 Press the START push-button.
10.4 AFM TESTING 10.4.9 Check that the swing field current increases to
the specified level, using the meter panel.
10.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board (A1) on your 10.5 PERFORMANCE CHECKS
right side.
10.5.1 Check the accuracy of the field current level by
Attach a digital voltmeter across test points TP1 measuring the dc voltage across the test jacks
(ACOM) and TP2 (VREF) which are located on the bot- for the swing field current on the test panel.
tom left side of the microprocessor board. Record the
measured voltage (approx. –7.000 VDC) as a negative The voltage measured should equal that calculated in
number. 10.4.5.
10.4.2 Use the drive keypad to go to the DRIVE CALI- 10.5.2 Swing field control should be documented by
BRATE sub-menu. Enter the sub-menu using connecting a chart recorder across the swing
the right arrow key and set the following param- field test jacks. Alternately START and STOP
eter: the machine while recording. Compare the
recordings to Figure 10.5.2.
X000: I/O V-REF = – VDC (Value measured in
10.4.1 ) 10.5.3 Press the STOP push-button.
Press the S key twice to save the value and exit the 10.5.4 Check the swing field voltage waveform by con-
edit mode. necting an oscilloscope across the dc terminals
of the swing field converter. Press the START
10.4.3 Reset the drive by cycling the drive power. push-button. Compare to Figure 10.5.4.
10.4.4 Verify that the EMERG STOP OK and DRIVE 10.5.5 Press the STOP push-button. Open the swing
READY LED’s are illuminated. field circuit breaker.

Figure 10.5.2 Swing Field Waveform Chart Recording

Figure 10.5.4 Swing Field Waveform Oscilloscope Display

11. CROWD / PROPEL FIELD CONTROL 11.3 AFM SOFTWARE

11.1 Test Preparation
LCD Display should read:
11.1.1 Check that all field circuit breakers are open.
P&H Electrotorque-Plus
11.1.2 Check that the field cables are connected to the Field Control
motors.
11.1.3 Set the test selector switch to FIELD TEST. This indicates that this AFM most likely has the cor-
rect firmware installed.
NOTICE 11.3.2 Use the drive keypad to go to the ACCESS

CODES sub-menu. Enter the sub-menu using
If you have just commissioned the swing the right arrow key and go to E007 SWR VER-
field, you can skip to step 11.4.4. SION. Confirm that the displayed software part
number agrees with the shovel documentation.
11.1.4 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they 11.4 AFM TESTING
agree with the shovel documentation.
11.2 SUPPLY VOLTAGES expose the microprocessor board (A1) on your
right side. Attach a digital voltmeter across TP1
11.2.1 Close the following circuit breakers: (ACOM) and TP2 (VREF) which are located on
• 120V Main Breaker (MB) the bottom left side of the microprocessor board.
Record the measured voltage (approx. –7.000
• Constant Voltage Supply Breaker (CVSB) VDC) as a negative number.
• DC Contactor Supply (DCSB)
11.4.2 Use the drive keypad to go to the DRIVE CALI-
• 230V Supply Breaker (SB) BRATE sub-menu. Enter the sub-menu using
• Control Supply Breaker (CSB) the right arrow key and set the following param-
eter:
• Constant Voltage Module Supply Breaker X000: I/O V-REF = – VDC (Value measured in
(CVMSB) 11.4.1 )
Press the S key twice to save the value and exit the
11.2.2 Using a DVM, check that the following voltages edit mode.
are present at the fields AFM:
11.4.3 Reset the drive by cycling the drive power.
120VAC control power at TB1-1 to TB1-2.
11.4.4 Verify that the EMERG STOP OK and DRIVE
230VAC, 3ph, synchronizing voltage at P11-1 to P11- READY LED’s are illuminated.
16 to P11-3.
11.4.5 Calculate the expected dc voltage across the
42VDC (approx. 50VDC no load) gate voltage at P11- feedback resistor at normal current levels:
13 (+) to P11-14 (–).
Vfb = Ifld / CT Ratio x Rfb
Examples:
70A / 150 x 5ohm = 2.3 VDC
150A / 150 x 5ohm = 5.0 VDC


FIELD TEST, and that the meter selector switch
is set to CROWD. Close the crowd field circuit
breaker.
11.4.7 Check that the crowd field current remains at 0

amps.
11.4.8 Press the START push-button.
11.4.9 Check that the crowd field current increases to

11.5 PERFORMANCE CHECKS
11.5.1 Check the accuracy of the field current level by

measuring the dc voltage across the test jacks
for the crowd field current on the test panel.
The voltage measured should equal that calculated in

11.4.5.
11.5.2 Press the PROPEL push-button.
11.5.3 Check that the propel field current increases to

11.5.4 Force a strong propel field level from the GUI

screen called AFM TEST SCREEN. Check that
the propel field current increases to the speci-
fied level, using the meter panel.
11.5.5 The crowd/propel field control should be docu-

mented by connecting a chart recorder across
the crowd/propel field test jacks. While record-
ing, start the machine, then after a few seconds,
transfer to the propel mode, then force a strong
propel field
Transfer back to crowd, press the STOP push-button.

Compare the recordings to Figures 11.5.5a, 11.5.5b,
and 11.5.5c.
11.5.6 Press the STOP push-button.
11.5.7 Check the crowd/propel field Voltage waveform

by connecting an oscilloscope across the dc ter-
minals of the crowd/propel field converter. Press
the START push-button. Compare to Figure
11.5.7.
11.5.8 Press the STOP push-button. Open the crowd/

propel field circuit breaker.

Figure 11.5.5a Crowd Field Current Recording

Figure 11.5.5b Propel Field Current Recording

Figure 11.5.5c Crowd/Propel Transfer Recording

Figure 11.5.7 Crowd/Propel Field Voltage Oscilloscope Display

12. HOIST FIELD CONTROL 12.3 AFM SOFTWARE

12.1 TEST PREPARATION
12.1.1 Check that all field circuit breakers are open.
P&H Electrotorque-Plus
12.1.2 Check that the field cables are connected to the Field Control
motors.
12.1.3 Set the test selector switch to FIELD TEST. This indicates that this AFM most likely has the cor-
NOTICE 12.3.2 Use the drive keypad to go to the ACCESS

If you have just commissioned the swing or the right arrow key and go to E007 SWR VER-
crowd/propel field, you can skip to step SION. Confirm that the displayed software part
12.4.4. number agrees with the shovel documentation.
12.1.4 Check the ID on the flash PROM (U8), and on 12.4 AFM TESTING
expose the microprocessor board (A1) on your
12.2 SUPPLY VOLTAGES right side. Attach a digital voltmeter across TP1
(ACOM) and TP2 (VREF) which are located on
12.2.1 Close the following circuit breakers: the bottom left side of the microprocessor board.
• 120V Main Breaker (MB) Record the measured voltage (approx. –7.000
VDC) as a negative number.
• Constant Voltage Supply Breaker (CVSB)
• DC Contactor Supply (DCSB) 12.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
• 230V Supply Breaker (SB)
the right arrow key and set the following
• Control Supply Breaker (CSB) parameter:
• Constant Voltage Module Supply Breaker 12.4.1 )
(CVMSB)
• Synchronizing Supply Breaker (SSB) Press the S key twice to save the value and exit the
edit mode.
are present at the fields AFM: 12.4.3 Reset the drive by cycling the drive power.
120VAC Control Power at TB1-1 to TB1-2. 12.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
230VAC, 3ph, Synchronizing Voltage at P11-1 to
P11-16 to P11-3. 12.4.5 Calculate the expected dc voltage across the
42VDC (approx. 50VDC no load) gate voltage at feedback resistor at normal current levels:
P11-13 (+) to P11-14 (–).
Vfb = Ifld / CT Ratio x Rfb
Examples:
50A / 150 x 5ohm = 1.7 VDC
140A / 150 x 5ohm = 4.7 VDC

12.4.6 Verify that the test selector switch is set to 13. HOIST ARMATURE CONTROL
FIELD TEST, and that the meter selector switch
is set to HOIST. Close the hoist field circuit
breaker.
12.4.7 Check that the hoist field current remains 13.1.1 Set the test selector switch to CONTROL TEST.
at 0 amps.
13.1.2 Open the circuit breakers on the RPC cabinet.
12.4.8 Press the START push-button. Open the constant voltage module supply circuit
breaker (CVMSB), and the control supply
12.4.9 Check that the hoist field current increases to breaker (CSB).
13.1.3 Connect a 12.5 ohm current limiting resistor in
series with hoist motor armature, H2.
13.1.4 Install a reference/push-button unit.
12.5.1 Check the accuracy of the field current level by Reference: Figure 2.2.2 in Appendix B.
measuring the dc voltage across the test jacks
for the hoist field current on the test panel. 13.1.5 Check the ID on the flash PROM (U8), and on
The voltage measured should equal that calculated in agree with the shovel documentation.
12.4.5.
13.1.6 Check for open or shorted thyristor firing pulse
12.5.2 Force a weak hoist field level from the GUI cables by measuring between the bridge inter-
screen called AFM TEST SCREEN. Check that face connector pins. A reading of 50 ohms is to
the hoist field current increases to the specified be expected between the following pins:
level, using the meter panel.
P9-1 to P9-2, P9-3 to P9-4,
12.5.3 The hoist field control should be documented by
connecting a chart recorder across the hoist field P9-5 to P9-6, P9-9 to P9-10,
test jacks. While recording, start the machine, P9-11 to P9-12, P9-13 to P9-14,
then after a few seconds force a strong hoist
P9-15 to P9-16, P9-17 to P9-18,
field, then a weak hoist field When completed
press the STOP push-button. Compare the P9-19 to P9-20, P9-23 to P9-24,
recordings to Figure 12.5.3. P9-25 to P9-26, P9-27 to P9-28
P10-1 to P10-2, P10-3 to P10-4,
P10-5 to P10-6, P10-9 to P10-10,
12.5.5 Check the hoist field voltage waveform by con- P10-11 to P10-12, P10-13 to P10-14,
necting an oscilloscope across the dc terminals
P10-15 to P10-16, P10-17 to P10-18,
of the hoist field converter. Press the START
push-button. Compare to Figure 12.5.5. P10-19 to P10-20, P10-23 to P10-24,
P10-25 to P10-26, P10-27 to P10-28
12.5.6 Press the STOP push-button. Open the hoist
field circuit breaker.

Figure 12.5.3 Hoist Field Current Chart Recording

Figure 12.5.5 Hoist Field Voltage Waveform Display

13.2 SUPPLY VOLTAGES 13.4 AFM TESTING
13.2.1 Close the following circuit breakers: 13.4.1 Open the Electrotorque-Plus top door to
• 120V Main Breaker (MB) expose the microprocessor board (A1) on your
right side. Attach a digital voltmeter across TP1
• Constant Voltage Supply Breaker (CVSB) (ACOM) and TP2 (VREF) which are located on
• DC Contactor Supply (DCSB) the bottom left side of the microprocessor board.
• Relay Supply Circuit Breaker (RSCB) 13.4.2 Use the drive keypad to go to the DRIVE CALI-
• Constant Voltage Module Supply Breaker the right arrow key and set the following
(CVMSB) parameter:
13.2.2 Using a DVM, check that the following voltages 13.4.1 )
are present at the hoist AFM:
120VAC Control Power at TB1-1 to TB1-2. edit mode.
230VAC, 3ph, Synchronizing Voltage at P11-1 to 13.4.3 Reset the drive by cycling the drive power.
P11-16 to P11-3.
42VDC (approx. 50VDC no load) gate voltage at READY LED’s are illuminated.
P11-13 (+) to P11-14 (–).
13.5 AUTOCAL PROCEDURE (Operator’s Ref-
13.3 AFM SOFTWARE erence Calibration)
13.3.1 When the hoist AFM is properly powered, its 13.5.1 On the GUI, go to the AFM TEST SCREEN.
CONTROL TEST. Press the START push-but-
P&H Electrotorque-Plus ton, and the HOIST BRAKE RELEASE push-
Armature Control button.
13.5.3 Turn the hoist reference potentiometer to full

This indicates that this AFM most likely has the cor-
positive (+). At the AFM TEST SCREEN, press
the HOIST AUTOCAL ON touch button.
13.5.4 After the GUI touch button turns green, press
the HOIST AUTOCAL OFF touch button.
the right arrow key and go to E007 SWR VER-
13.5.5 When the touch button turns red, turn the hoist
reference potentiometer to full negative (–).
13.5.6 Press the HOIST AUTOCAL ON touch button.

After the GUI touch button turns green, press
the HOIST AUTOCAL OFF touch button.
13.5.7 Confirm that the reference signals are properly

calibrated by checking that the adjusted refer-
ence at A066 is +100% with the reference full

positive, and –100% with the reference full neg- 13.7.4 Set the test selector switch to ARMATURE
ative. Use the drive keypad to go to the OPER- TEST, and close the high voltage disconnect
ATE sub-menu. Enter the sub-menu using the switch.
right arrow key. Arrow up to reach the
BLOCKS ANALOG sub-menu, and enter it with 13.7.5 Set the reference to 0V.
the right arrow key. Arrow up to A066.
13.5.8 The hoist AUTOCAL procedure is complete. NOTICE

Press the STOP push-button. Press the drive S
key twice to exit the sub-menus. With a series armature resistor installed, a
nuisance ground fault indication may occur
13.6 THYRISTOR PULSE SEQUENCE after the firing pulses are phased advanced
in armature test. The series resistor is the
13.6.1 Verify that the test selector switch is set to cause of this indication, and the indication
can be ignored until the resistor is removed,
if:
ton, and the HOIST BRAKE RELEASE button.
1. The ground fault only occurs after the brake has been
13.6.2 With the reference in the full negative (lower) released.
position, use an oscilloscope to check the firing 2. The Main Transformer Secondary Neutral (MSN) to
pulse sequence of both hoist lower converters, ground voltage is less than 100VAC. (A true line-to-
Figure 13.6. ground fault would be approximately 350VAC)
3. Prior ground checks have proved negative.
13.6.3 Place the reference in the full positive (hoist)
position, and check the firing pulse sequence of 13.7.6 Press the START push-button.
both hoist Converters, Figure 13.6.
13.7.7 Check that the dc voltage across the series
13.6.4 Press the PROPEL push-button. Check that armature resistor is approximately 0VDC. (A
the firing pulses to the H1 converter remains higher voltage would indicate the possibility of a
present while the firing pulses to the H2 con- phasing error on the main transformer second-
verter are blocked. ary or on the synchronizing supply voltage.)
Reference: Figure 13.7.7 in Appendix B.
13.6.5 Press the HOIST/CROWD push-button, and
the HOIST BRAKE RELEASE push-button. 13.7.8 Press the HOIST BRAKE RELEASE push-but-
Firing pulses should again be present on both ton. Slowly increase the reference in the posi-
the H1 and H2 converters. tive (+) direction.
13.6.6 Press the STOP push-button. The voltage across the feedback resistor should
increase directly in proportion to the reference.
13.7 VOLTAGE CONTROL, HOIST
13.7.9 Slowly increase the reference in the negative
13.7.1 Disable OPEN SCR TEST. At the Hoist AFM (–) direction.
keypad, change Y058 from D149 TEST ARM to
D087 ZERO BIT. Reset drive. The voltage across the feedback resistor should
increase directly in proportion to the reference and
13.7.2 Connect a digital voltmeter (1kV range) across should have changed polarity.
the series armature resistor.
13.7.3 Remove the relay from the differential voltage

NOTICE
module (DVAH) to prevent a shutdown due to
The P1 propel armature circuit must be
unbalanced armature voltages.
intact for proper operation of the voltage
feedback circuit. See Figure 13.7.7 in Appen-
dix B.

Figure 13.6 Thyristor Pulse Sequence

13.8 CURRENT FEEDBACK, HOIST 13.10.2 Connect a digital voltmeter across the hoist
current feedback (IAFB) test jacks.
13.8.1 With the reference close to fully positive, check
that the current feedback signal at the AFM 13.10.3 Calculate the dc voltage to be expected across
connector P11 - terminal 10 to terminal 8 the IAFB test jack resistor:
(08351 to 01021C) is positive. This signal will
be very small, 0.1V or less, so use care in read- Istall / 300 = Vtest jack
ing the meter. Use of a strip chart recorder will
insure that the feedback polarity is correct. Example:
13.8.2 With the reference close to fully negative, check 2625A / 300 = 8.75 VDC
that the current feedback signal at the AFM
connector P11 - terminal 10 to terminal 8 13.10.4 Set the meter selector switches to monitor the
(08351 to 01021C) remains positive. hoist motion parameters.
13.8.3 Reduce the REFERENCE to 0V. Press the 13.10.5 Set the hoist reference potentiometer to 0
STOP push-button. VDC. Press the START push-button.
13.8.4 Remove the series armature resistor.
13.9 ARMATURE CURRENT RESPONSE, The motors should not be run at maxi-
HOIST mum stall current for more than 5 sec-
onds at a time. Longer periods will
13.9.1 Connect a strip chart or memory recorder cause localized commutator heating.
(Ch. 1) across the hoist current feedback (IAFB)
test jacks. 13.10.6 Press the HOIST BRAKE RELEASE push-
button.
13.9.2 On the GUI, at the AFM SCREEN, press the
HOIST CURRENT REGULATOR MODE touch 13.10.7 Increase the hoist reference to full positive
button. Press the START push-button. Press (hoist). Check the current value shown on the
the HOIST BRAKE RELEASE push-button. drive LCD display. Record the voltage seen
Increase the hoist operators reference until the across the IAFB test jacks.
armature current ammeter reads 500A.
13.10.8 Press the HOIST BRAKE SET push-button.
13.9.3 On the GUI, press the HOIST STEP REFER-
ENCE touch button. The PLC will cause the 13.10.9 Verify that values recorded in 13.10.7, agree
AFM to pulse the output current for a 10 Sec. with the I-A2 level shown In the Specified Elec-
period. During this period, record the IAFB out- trical Data sheet.
put, and compare the recording to Figure 13.9.
Overshoots or undershoots should not be 13.10.10 After the commutators have been allowed to
present. cool for at least one full minute, again, Press the
HOIST BRAKE RELEASE push-button and
13.9.4 Press the HOIST CURRENT REGULATOR increase the hoist reference to full negative
MODE touch button to disable. (lower).
13.9.5 Press the STOP push-button. 13.10.11 Verify that values recorded in 13.10.10, agree
with the I-A3 level shown in the Specified Elec-
13.10 STALL CURRENT, HOIST trical Data sheet. Press the HOIST BRAKE SET
push-button.
13.10.1 Use the drive keypad to go to the DRIVE
ANALOG sub-menu. Enter the sub-menu using 13.10.12 After the commutators have been allowed to
the right arrow key , then go to parameter A004: cool for at least one full minute, again, Press the
I ARM AMP. HOIST BRAKE RELEASE push-button and

Figure 13.9 IAFB Chart Recording

increase the hoist reference to full positive 13.13 DIVERTER CIRCUIT CHECKS.
(hoist).
13.13.1 Check that the relay and control supply cir-
13.10.13 Check that the analog armature current cuit breakers are closed.
panel meter also reads the stall level +/– 50A.
13.13.2 Set the test selector switch to CONTROL
13.10.14 Press the HOIST BRAKE SET push-button. TEST.
13.11 VOLTAGE CONTROL - RUN MODE, 13.13.3 Connect a voltmeter to (TB1-1) on the hoist
HOIST diverter control module and check that the sup-
ply voltage is +28VDC.
13.11.1 Set the test selector switch to RUN.
13.13.4 Press the START button.
13.11.2 Install the relay into the differential voltage
module (DVAH) (refer to 13.7.3). 13.13.5 Check that the READY light on the diverter
module is on.
13.11.3 Deactivate the RPC shutdown by forcing off
the RPC circuit breaker inputs. 13.13.6 Check that the DE-BLOCK LED on the AFM
(Alternative: Disconnect the RPC circuit is on. The LED’s on the pulse transformer
breaker interlock input to the PLC.) should also be on.
13.11.4 Close the hoist field circuit breaker. 13.13.7 Check the gate block circuit by shorting TB2-
10 to TB2-9 on the diverter module.
13.11.5 With the reference set to 0 VDC, press the
START push-button. 13.13.8 The pulse transformer LED at the converter
should not be illuminated.
13.11.6 Press the HOIST BRAKE RELEASE
push-button and check that the armature 13.13.9 Press STOP button. Remove the short on the
current is approximately 0 A. diverter module.
13.11.7 Check that the motors can be controlled with 13.14 DIVERTER CURRENT SENSOR
the reference by accelerating, decelerating and CHECKS, HOIST
changing direction. Do not exceed 50% of full
speed. 13.14.1 Connect a digital voltmeter to TP2 (–) and
TP3 (+) on the hoist diverter control module.
13.11.8 Set the hoist brakes. Press the STOP push-
button. 13.14.2 Set the test selector switch to ARMATURE
TEST.
13.12 CONVERTER PHASE FAULT DETEC-
TION, HOIST 13.14.3 Press START button, press HOIST BRAKE
RELEASE button and check that the meter
13.12.1 Remove an input lead from the phase monitor reads at full hoist:
in the hoist armature converter.
Volts = Iarmstall/300 (+/–0.5VDC)
13.14.4 Record this in the test data sheet.
13.12.3 Check that the machine shuts down and that
a hoist converter phase fault is indicated. 13.14.5 Press STOP button. Disconnect the meter.
13.12.4 Replace the phase lead.
13.12.5 Repeat the test for the opposite hoist con-

verter.

13.15 DIVERTER CAPACITOR CHECKS, 13.16.5 Press the START button. Press the HOIST
HOIST BRAKE RELEASE button.
13.15.1 Reconnect the wire (refer to 8.1.3) to the 13.16.6 Slowly increase the hoist reference to the full
capacitor charging relay at the terminal board hoist position.
on the hoist diverter circuit panels in the con-
verter cabinet to activate the capacitor charging 13.16.7 Check that the machine shuts down when the
power supply. meter reads about 3.5VDC.
13.16.8 Check that the capacitor voltage on the hoist

converter bridge drops instantly to approxi-
mately 0 volts.
Use extreme caution when making volt-
age measurements in this section of the
13.16.9 Press the STOP button.
test procedure. Voltages of approxi-
mately 1300V will be measured.
13.16.10 Adjust the current trip for normal operation.
13.15.2 Connect a digital voltmeter (1kV range) across
13.16.11 Reconnect the meter to TP1(+) and TP2(–) on
the H1 hoist diverter capacitor.
the control module.
13.15.3 Manually depress the hoist capacitor charging
13.16.12 Readjust the current trip adjust potentiome-
relay armature to close its contacts.
ter to its maximum clockwise position.
13.15.4 The voltage across the diverter capacitor
should begin to climb as the capacitor charges.
HOIST BRAKE RELEASE push-button.
Ultimately this voltage should be about 1300
VDC, but to avoid overvoltage on the DVM, we
13.16.14 Stall the hoist and turn down the current
will stop charging (release the relay armature)
trip potentiometer until the module trips. Do
at about 900 VDC. Check schematics for polar-
not stall motor for more than 5 seconds.
ity, and verify that the charging polarity is cor-
rect.
13.16.15 Check and read voltage at TP1-TP2.
13.15.5 When you release the charging relay, the volt-
13.16.16 Readjust level as follows.
age across the diverter capacitor must decay to
less than 50 VDC in less than 30 Sec.
Volts = (VTP1-VTP2) x 1.4
13.15.6 Repeat these tests for the H2 diverter capaci-
tor. Where:
13.16 CHECK DIVERTER CIRCUIT OPERA- VTP1 to VTP2 is from 13.16.15

TION, HOIST
13.17 OPERATE FROM THE OPERATOR’S
13.16.1 Connect a digital voltmeter to TP1(+) and COOP, HOIST
TP2(–) on the diverter control module.
13.17.1 Remove the reference/push-button unit (Fig-
13.16.2 Adjust the current trip adjust potentiometer ure 2.2.2 in Appendix B). Reconnect the PLC/
so that the meter reads +2.1VDC. coop cables.
13.16.3 Set the test selector switch to ARMATURE 13.17.2 REPEAT THE AUTOCAL PROCEDURE
TEST. (Operator’s Reference Calibration)
13.16.4 Reconnect the meter to TP3(+) and TP2(–) on 13.17.3 On the GUI, go to AFM TEST SCREEN.
the diverter control module.

13.17.4 Verify that the test selector switch is set to 13.18 VOLTAGE RESPONSE, HOIST. (With
CONTROL TEST. Press the START push-but- Hoist Ropes and Dipper attached)
ton, and the HOIST BRAKE RELEASE button.
13.18.1 Connect a chart recorder to record across the
13.17.5 Move the hoist controller potentiometer to full hoist armature voltage feedback (VAFB) test
positive (+). On the GUI, press the AUTOCAL jacks (Ch. 1), and the hoist armature current
HOIST ON touch button. feedback (IAFB) test jacks (Ch. 2).
13.17.6 After the GUI touch button turns green for a 13.18.2 Press the START push-button. Press the
few moments, press the AUTOCAL HOIST OFF HOIST BRAKE RELEASE button.
touch button.
13.18.3 Check that the armature voltage of each
13.17.7 When the touch button turns red, move the motor is correct for both full hoist and full lower
hoist controller potentiometer to full negative directions as spelled out in the Specified Electri-
(–). cal Data sheet.
13.17.8 On the GUI, press the AUTOCAL HOIST ON • 13.18.3.1 If the terminal voltage is significantly
touch button. After the GUI touch button turns lower than the voltage read at the AFM (A012
green for a few moments, press the AUTOCAL ARM VOLTS) then change the X003 parameter
HOIST OFF touch button. from 100 to something less. For example: If the
measured terminal voltage is 500V and A012
13.17.9 Confirm that the reference signals are prop- reads 550V then change X003 from 100 to 91
erly calibrated by checking that the ADJUSTED (500/550 x 100 = 91). Changes made to X
REFERENCE at A066 is +100% with the refer- parameters are activated immediately after
ence full positive, and –100% with the reference pressing the S key. Note: X004 is used for right
full negative. Use the drive keypad to go to the propel.
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach 13.18.4 Operate the hoist by alternately applying full
the BLOCKS ANALOG sub-menu, and enter it positive and full negative reference and compare
with the right arrow key. Arrow up to A066. the recordings of VAFB and IAFB with Figure
13.18.4.
13.17.10 The hoist AUTOCAL procedure is complete.
Press the STOP push-button. Press the drive S 13.18.5 Voltage response recordings will require two
key twice to exit the sub-menus. participants; an operator in the operator’s coop,
and a technician in the control room. Have the
13.17.11 Set the test selector switch to RUN. Start operator slowly raise the empty dipper at a con-
the machine and release the hoist brakes. stant speed.
13.17.12 Check that full control of the hoist motion is 13.18.6 As the dipper is slowly rising, press the
obtained by the operator's controller. HOIST STEP REFERENCE touch button on the
GUI. The PLC will pulse the output voltage for
13.17.13 Check that the hoist motion runs in the a 10 second time period. During this period,
proper direction in relation to the controller record the VAFB and IAFB signals and compare
position. with Figure 13.18.6. The VAFB signal should
have minimum response time without over-
If the motor rotation is wrong, check that the reference shoot. At any time during this procedure, the
is of the proper polarity. operator has the ability to override the step ref-
erence, should safety require it. In case satisfac-
The motor rotation may be reversed by reversing the tory recordings are not obtained on the first run,
motor field connections. you can instruct the operator to quickly lower
the dipper before it reaches the upper limit, and
then begin raising it again at a slow and steady
rate.

Figure 13.18.4 VAFB and IAFB Chart Recording

Figure 13.18.6 VAFB and IAFB Chart Recording

13.18.7 Set the dipper on the ground and press the 14. CROWD ARMATURE CONTROL
STOP push-button.
13.19 FIELD WEAKENING, HOIST
14.1.1 Set the test selector switch to CONTROL TEST.
13.19.1 Connect channel 2 of the recorder to the
HOIST FIELD FEEDBACK (IFFB) test jacks 14.1.2 Open the circuit breakers on the RPC cabinet.
and check that field weakening occurs when Open the constant voltage module supply circuit
lowering with an empty dipper at full speed. breaker (CVMSB), and the control supply
Compare with Figure 13.19.1. breaker (CSB).
13.19.2 Set the dipper on the ground and press the 14.1.3 Connect a 12.5 ohm current limiting resistor in
STOP push-button. series with crowd motor armature.
13.20 DIVERTER VAFB SIGNAL CHECKS, 14.1.4 Install a reference/push-button unit. See Fig-
HOIST ure 2.2.2 in Appendix B.
13.20.1 Connect a digital voltmeter from TB1-4 to 14.1.5 Check the ID on the flash PROM (U8), and on
TB1-5 on the hoist diverter control module. the EEPROM (U10) to make sure that they
13.20.2 With the test selector switch set to RUN, press
the START push-button and HOIST BRAKE 14.1.6 Check for open or shorted thyristor firing pulse
RELEASE push-button. cables by measuring between the bridge inter-
face connector pins. A reading of 50 ohms is to
13.20.3 Operate the hoist motion, and check that the be expected between the following pins:
voltage is –9.7V +/–1V at full speed in the hoist
direction and +8.9V +/–1V at full speed in the P9-1 to P9-2, P9-3 to P9-4,
lower direction.
P9-5 to P9-6, P9-9 to P9-10,
13.20.4 Set the dipper on the ground and press STOP P9-11 to P9-12, P9-13 to P9-14,
button.
P9-15 to P9-16, P9-17 to P9-18,
13.21 DIVERTER CIRCUIT OPERATION P9-19 to P9-20, P9-23 to P9-24,

P9-25 to P9-26, P9-27 to P9-28
13.21.1 If nuisance tripping occurs during normal
operation, use the procedure of 13.16.11 and
14.2 SUPPLY VOLTAGES
increase the trip setting by increments of 0.1V
until nuisance tripping does not occur. (It should
14.2.1 Close the following circuit breakers:
not be necessary to increase this setting more
than 0.5VDC. ) • 120V Main Breaker (MB)
• Constant Voltage Supply Breaker (CVSB)
13.22 THIS COMPLETES TESTING OF THE
HOIST ARMATURE CONTROL
13.22.1 Press the STOP push-button. • Control Supply Breaker (CSB)
13.22.2 Remove all PLC forces. • Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
13.22.3 Open the field circuit breakers. (CVMSB)
13.22.4 Enable OPEN SCR TEST. At the hoist AFM • Synchronizing Supply Breaker (SSB)
keypad, change Y058 from D087 ZERO BIT to
D149 TEST ARM. Reset the drive.

Figure 13.19.1 Hoist Field Weakening Chart Recording

14.2.2 Using a DVM, check that the following voltages 14.5 AUTOCAL PROCEDURE
are present at the crowd armature AFM: (Operator’s Reference Calibration)
A) 120VAC control power at TB1-1 to TB1-2. 14.5.1 On the GUI, go to the AFM TEST SCREEN.
B) 230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3. 14.5.2 Verify that the test selector switch is set to
C) 42VDC (approx. 50VDC no load) gate voltage at ton, and the CROWD BRAKE RELEASE but-
P11-13 (+) to P11-14 (–). ton.
14.3 AFM SOFTWARE 14.5.3 Turn the crowd reference potentiometer to full
positive (+). On the GUI, press the AUTOCAL
14.3.1 When the crowd AFM is properly powered, its CROWD ON touch button.
LCD display should read:
14.5.4 After the touch button turns green for a few
moments, press the AUTOCAL CROWD OFF
P&H Electrotorque-Plus touch button.
Armature Control
14.5.5 When the touch button turns red, turn the
crowd reference potentiometer to full negative
This indicates that this AFM most likely has the cor-
(–).
14.5.6 On the GUI, press the AUTOCAL CROWD ON
touch button. After the touch button turns
green for a few moments, press the AUTOCAL
CROWD OFF touch button.
calibrated by checking that the ADJUSTED
14.4 AFM TESTING REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
14.4.1 Open the Electrotorque-Plus top door to full negative. Use the drive keypad to go to the
expose the microprocessor board A1 on your OPERATE sub-menu. Enter the sub-menu
right side. Attach a digital voltmeter across TP1 using the right arrow key. Arrow up to reach
(ACOM) and TP2 (VREF) which are located on the BLOCKS ANALOG sub-menu, and enter it
the bottom left side of the microprocessor board. with the right arrow key. Arrow up to A066.
VDC) as a negative number. 14.5.8 The crowd AUTOCAL procedure is complete.
14.4.2 Use the drive keypad to go to the DRIVE CALI- key twice to exit the sub-menus.
the right arrow key and set the following
14.6 THYRISTOR PULSE SEQUENCE
parameter:
X000: I/O V-REF = – VDC (value measured in
14.4.1 )
ton, and the CROWD BRAKE RELEASE but-
ton.
edit mode.
14.6.2 With the reference in the full negative (–)
(retract) position, use an oscilloscope to check
the firing pulse sequence of the retract con-
verter, Figure 14.6.

Figure 14.6 Firing Pulse Sequence Oscilloscope Recording

14.6.3 Place the reference in the full positive (+) 14.7.8 Slowly, increase the crowd reference in the neg-
(crowd) position, and check the firing pulse ative direction.
sequence of the crowd converter, Figure 14.6
The voltage across the feedback resistor should
14.6.4 Press the STOP push-button. increase directly in proportion to the reference, and
should have changed polarity.
14.7 VOLTAGE CONTROL, CROWD
14.8 CURRENT FEEDBACK, CROWD
14.7.1 Disable OPEN SCR TEST. At the crowd AFM
keypad, change Y058 from D149 TEST ARM to 14.8.1 With the reference close to fully positive, check
D087 ZERO BIT. Reset drive. that the current feedback signal at the AFM
connector P11- terminal 10 to terminal 8 (12251
14.7.2 Connect a digital voltmeter (1kV range) across to 01021C) is positive. This signal will be very
the series armature resistor. small, 0.1V or less so use care in reading the
meter, or better still, use a strip chart recorder
14.7.3 Set the test selector switch to ARMATURE to assure that the feedback polarity is correct.
TEST, and close the high voltage disconnect
switch. 14.8.2 With the reference close to fully negative,
check that the current feedback signal at the
14.7.4 Set the reference to 0V. AFM connector P11- terminal 10 to terminal 8
(12251 to 01021C) remains positive.
NOTICE 14.8.3 Reduce the reference to 0V. Press the STOP

push-button.
With a series armature resistor installed, a
nuisance ground fault indication may occur 14.8.4 Remove the series armature resistor.
after the firing pulses are phased advanced
in armature test. The series resistor is the
cause of this indication, and the indication
can be ignored until the resistor is removed,
if:
1. The ground fault only occurs after the brake has been
released.
2. The Main Transformer Secondary Neutral (MSN) to
ground voltage is less than 100VAC. (A true line-to-
ground fault would be approximately 350VAC)
3. Prior ground checks have proved negative.
14.7.6 Check that the dc voltage across the series

armature resistor is approximately 0VDC. (A
higher voltage would indicate the possibility of a
phasing error on the main transformer second-
ary, or on the synchronizing supply voltage.)
14.7.7 Press the CROWD BRAKE RELEASE push-

button. Slowly, increase the crowd reference in
the positive direction.
The voltage across the feedback resistor should


14.9 ARMATURE CURRENT RESPONSE, 14.10 STALL CURRENT, CROWD

CROWD
14.10.1 Use the drive keypad to go to the DRIVE
14.9.1 Connect a strip chart or memory recorder (Ch. ANALOG sub-menu. Enter the sub-menu using
1 ) across the crowd current feedback (IAFB) the right arrow key , then go to parameter
test jacks. A004: I ARM AMP.
14.9.2 On the GUI, at the AFM TEST SCREEN, press 14.10.2 Connect a digital voltmeter across the crowd
the CROWD CURRENT REGULATOR MODE current feedback (IAFB) test jacks.
touch button. Press the START push-button.
Press the CROWD BRAKE RELEASE push-but- 14.10.3 Calculate the dc voltage to be expected across
ton. Increase the crowd Operators Reference the IAFB test jack resistor:
until the armature current ammeter reads
500A. Istall / 300 = Vtest jack
14.9.3 On the GUI, press the CROWD STEP REFER- Example:
ENCE touch button. The PLC will cause the
AFM to pulse the output current for a 10 sec. 1650A / 300 = 5.5 VDC
period. During this period, record the IAFB out-
put, and compare the recording to Figure 14.9. 14.10.4 Set the meter selector switch to monitor the
Overshoots or undershoots should not be crowd motion parameters.
present.
14.10.5 Set the crowd reference potentiometer to 0
14.9.4 Press the CROWD CURRENT REGULATOR VDC. Press the START push-button.
MODE touch button to disable.

The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
Figure 14.9 Crowd IAFB Chart Recording


button.
14.10.7 Increase the crowd reference to full positive The motors should not be run at maxi-
(crowd). Check the current value shown on the mum stall current for more than 5 sec-
drive LCD Display. Record the voltage seen onds at a time. Longer periods will
across the IAFB test jacks. cause localized commutator heating.
14.10.8 Press the CROWD BRAKE SET push-button. 14.11.3 Increase the crowd reference to full positive
(forward). Check the current value shown on
14.10.9 Verify that values recorded in 14.10.7, agree the drive LCD display. Record the voltage seen
with the I-A2 level shown in the Specified Elec- across the IAFB test jacks.
trical Data sheet.
14.11.4 Press the HOIST/CROWD button.
14.10.10 After the commutators have been allowed to
cool for at least one full minute, again, Press the 14.11.5 Verify that values recorded in 14.11.3, agree
CROWD BRAKE RELEASE push-button and with the I-A2 level shown in the Specified Elec-
increase the crowd reference to full negative trical Data sheet.
(retract).
14.10.11 Verify that values recorded in 14.10.7, agree cool for at least one full minute, again, press the
with the I-A3 level shown in the Specified Elec- PROPEL push-button and increase the crowd
trical Data sheet. Press the CROWD BRAKE reference to full negative (reverse). Check the
SET push-button. current value shown on the drive LCD Display.
Record the voltage seen across the IAFB test
14.10.12 After the commutators have been allowed to jacks.
cool for at least one full minute, again, Press the
CROWD BRAKE RELEASE push-button and 14.11.7 Press the HOIST/CROWD button.
increase the crowd reference to full positive
(crowd). 14.11.8 Verify that values recorded in 14.11.6, agree
14.10.13 Check that the analog armature current trical Data sheet.
panel meter also reads the stall level +/–50A.
14.11.9 Press the STOP push-button. Reduce the
14.10.14 Press the CROWD BRAKE SET push-but- crowd reference to 0 VDC.
ton. Reduce the crowd reference to 0 VDC.
14.12 STALL CURRENT, PROPEL (Hoist)
14.11 STALL CURRENT, PROPEL (CROWD)
14.12.1 Calculate the dc voltage to be expected across
14.11.1 Calculate the dc voltage to be expected across the hoist IAFB test jack resistor when in the
the crowd IAFB test jack resistor when in the propel mode:
propel mode:
Istall / 300 = Vtest jack
Istall / 300 = Vtest jack
Example:
Example:
1450A / 300 = 4.8 VDC
1450A / 300 = 4.8 VDC
14.12.2 Press the PROPEL push-button.
14.11.2 Press the PROPEL button.

14.13.6 Check that the motors can be controlled with

the reference by accelerating, decelerating and
The motors should not be run at maxi- speed.
onds at a time. Longer periods will 14.13.7 Set the crowd brakes. Press the STOP push-
cause localized commutator heating. button.
14.12.3 Increase the hoist reference to full positive

14.14 CONVERTER PHASE FAULT DETEC-
(forward). Check the current value shown on
the drive LCD display. Record the voltage seen TION, CROWD
across the IAFB test jacks.
14.14.1 Remove an input lead from the phase monitor
14.12.4 Press the HOIST/CROWD push-button. in the crowd armature converter.
14.12.5 Verify that values recorded in 14.12.3, agree 14.14.2 Press the START button.
trical Data sheet. 14.14.3 Check that the machine shuts down and that
a crowd converter phase fault is indicated.
cool for at least one full minute, again, press the 14.14.4 Replace the phase lead.
PROPEL push-button and increase the hoist
reference to full negative (reverse). Check the 14.15 DIVERTER CIRCUIT CHECKS.
current value shown on the drive LCD display.
Record the voltage seen across the IAFB test 14.15.1 Check that the relay and control supply cir-
jacks. cuit breakers are closed.
14.12.7 Press the HOIST/CROWD push-button. 14.15.2 Set the test selector switch to CONTROL
TEST.
14.12.8 Verify that values recorded in 14.12.6, agree
with the I-A2 level shown in the Specified Elec- 14.15.3 Connect a voltmeter to (TB1-1) on the crowd
trical Data sheet. diverter control module and check that the sup-
ply voltage is +28VDC.
14.12.9 Press the STOP push-button. Reduce the
hoist reference to 0 VDC. 14.15.4 Press the START button.
14.13 VOLTAGE CONTROL - RUN MODE, 14.15.5 Check that the READY light on the diverter
module is ON.
CROWD
14.15.6 Check that the DE-BLOCK LED on the AFM
is on. The LED’s on the pulse transformers
should also be on.
14.13.2 Deactivate the RPC shutdown by forcing the
RPC circuit breaker inputs, off. (Alternative:
14.15.7 Check the gate Block Circuit by shorting TB2-
Disconnect the RPC circuit breaker interlock
10 to TB2-9 on the diverter module.
input to the PLC.)
14.15.8 The pulse transformer LED at the converter
14.13.3 Close the crowd field circuit breaker.
14.15.9 Press STOP button. Remove the short on the
START button.
diverter module.
button and check that the armature current is 14.16 DIVERTER CURRENT SENSOR
approximately 0 A. CHECKS, CROWD

14.16.1 Connect a digital voltmeter to TP2 (–) and 14.17.6 Repeat these tests for the reverse bridge
TP3 (+) on the crowd diverter control module. crowd diverter capacitor.
14.16.2 Set the test selector switch to ARMATURE 14.18 CHECK DIVERTER CIRCUIT OPERA-
TEST. TION, CROWD
14.16.3 Press START button, press CROWD BRAKE 14.18.1 Connect a digital voltmeter to TP1(+) and
RELEASE button and check that the meter TP2(–) on the diverter control module.
reads at full crowd:
14.18.2 Adjust the current trip adjust potentiometer
Volts = Iarmstall/300 (+/–0.5VDC) so that the meter reads +2.1VDC.
14.16.4 Record this in the test data sheet. 14.18.3 Set the test selector switch to ARMATURE
TEST.
14.16.5 Press STOP button. Disconnect the DVM.
14.17 DIVERTER CAPACITOR CHECKS, the diverter control module.
CROWD
14.18.5 Press the START button. Press the CROWD
14.17.1 Reconnect the wire (refer to 8.1.3) to the BRAKE RELEASE button.
capacitor charging relay at the terminal board
on the crowd diverter circuit panels in the con- 14.18.6 Slowly increase the crowd reference to the full
verter cabinet to activate the capacitor charging crowd position.
power supply.
14.18.7 Check that the machine shuts down when the
meter reads about 3.5VDC.
14.18.8 Check that the capacitor voltage on the crowd

Use extreme caution when making volt-
mately 0 volts.
test procedure. Voltages of approxi-
14.18.9 Press the STOP button.
14.17.2 Connect a digital voltmeter (1kV range) across
the crowd diverter capacitor for the forward
bridge.
the control module.
14.17.3 Manually depress the crowd capacitor charg-
ing relay armature to close its contacts.
14.18.12 Readjust the current trip adjust potentiome-
ter to its maximum clockwise position.
14.17.4 The voltage across the diverter capacitor
should begin to climb at the capacitor charges.
CROWD BRAKE RELEASE button.
VDC, but to avoid overvoltage on the DVM, we
will stop charging (release the relay armature)
14.18.14 Stall the crowd and turn down the current
at about 900 VDC. Check schematics for polar-
trip potentiometer until the module trips. Do
not stall motor for more than 5 seconds.
rect.
14.18.15 Check and read voltage at TP1-TP2.
14.17.5 When you release the charging relay, the volt-
14.18.16 Readjust level as follows.
less than 50 VDC in less than 30 Sec.
Volts = (VTP1-VTP2) x 1.4

Where: 14.19.11 Set the test selector switch to RUN. Start

the machine and release the crowd brakes.
VTP1 to VTP2 is from 14.17.15
14.19.12 Check that full control of the crowd motion is
14.19 OPERATE FROM THE OPERATOR’S obtained by the operator’s controller.
COOP, CROWD
14.19.13 Check that the crowd motion runs in the
proper direction in relation to the controller
14.19.1 Remove the reference/push-button unit.
position. If the motor rotation is wrong, check
Reconnect the PLC/coop cables.
that the reference is of the proper polarity.
14.19.2 REPEAT THE AUTOCAL PROCEDURE
The motor rotation may be reversed by reversing the
(Operator’s reference Calibration)
motor field connections.
14.19.3 On the GUI, go to the AFM TEST SCREEN.
14.20 VOLTAGE RESPONSE, CROWD. (With
14.19.4 Verify that the test selector switch is set to Hoist Ropes and Dipper attached)
ton, and the CROWD BRAKE RELEASE but- 14.20.1 Connect a chart recorder to record across the
ton. crowd armature voltage feedback (VAFB) test
jacks (Ch. 1), and the crowd armature current
14.19.5 Move the crowd controller potentiometer to feedback (IAFB) test jacks (Ch. 2).
full positive (+). On the GUI, press the AUTO-
CAL CROWD ON touch button. 14.20.2 Press the START push-button. Press the
CROWD BRAKE RELEASE button.
14.19.6 After the GUI touch button turns green for a
few moments, press the AUTOCAL CROWD 14.20.3 Check that the armature voltage of each
OFF touch button. motor is correct for both full crowd and full
retract directions as spelled out in the Specified
14.19.7 When the touch button turns red, move the Electrical Data sheet.
crowd controller potentiometer to full negative
(–). • 14.20.3.1 If the terminal voltage is significantly
lower than the voltage read at the AFM (A012
14.19.8 On the GUI, press the AUTOCAL CROWD ARM VOLTS) then change the X003 parameter
ON touch button. After the GUI touch button from 100 to something less. For example: If the
turns green for a few moments, press the AUTO- measured terminal voltage is 500V and A012
CAL CROWD OFF touch button. reads 550V then change X003 from 100 to 91 (500/
550 x 100 = 91). Changes made to X parameters
14.19.9 Confirm that the reference signals are prop- are activated immediately after pressing the S key.
erly calibrated by checking that the ADJUSTED Note: X004 is used for left propel.
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference 14.20.4 Operate the crowd by alternately applying full
full negative. Use the drive keypad to go to the positive and full negative reference and compare
OPERATE sub-menu. Enter the sub-menu the recordings of VAFB and IAFB with Figure
using the right arrow key. Arrow up to reach 14.20.4.
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066. 14.20.5 Voltage response recordings will require two
participants; an operator in the operator’s coop,
14.19.10 The crowd AUTOCAL procedure is complete. and a technician in the control room. Have the
Press the STOP push-button. operator place the dipper handle (sticks) at a
position that is about 90 degrees to the boom
Press the drive S key twice to exit the sub-menus. with the handle fully extended. The operator
should then very slowly retract the empty dip-
per at a constant speed.

Figure 14.20.4 Crowd VAFB and IAFB Chart Recording

14.20.6 As the dipper is slowly retracting, press the 14.22 DIVERTER VAFB SIGNAL CHECKS,
CROWD STEP REFERENCE touch button on CROWD
the GUI. The PLC will pulse the output voltage
for a 10 second time period. During this period, 14.22.1 Connect a digital voltmeter from TB1-4 to
record crowd VAFB and IAFB signals and com- TB1-5 on the crowd diverter control module.
pare them with Figure 14.20.6. The VAFB sig-
nal should have minimum response time 14.22.2 With the test selector switch set to RUN, press
without overshoot. At any time during this pro- START button and CROWD BRAKE RELEASE
cedure, the operator has the ability to override button.
the step reference, should safety require it. In
case satisfactory recordings are not obtained on 14.22.3 Operate the crowd motion, and check that the
the first run, you can instruct the operator to voltage is –8.9V +/- 1V at full speed in the crowd
quickly crowd the dipper before it reaches the direction and +8.9V +/- 1V at full speed in the
retract limit, and then begin retracting it again retract direction.
at a slow and steady rate.
14.22.4 Set the dipper on the ground and press STOP
14.20.7 Set the dipper on the ground and press the button.
STOP push-button.
14.23 DIVERTER CIRCUIT OPERATION
14.21 VOLTAGE RESPONSE, PROPEL.
14.23.1 If nuisance tripping occurs during normal
14.21.1 Connect channel 1 of the chart recorder across operation, use the procedure of 14.18.11 and
Propel #1 armature voltage feedback (Hoist increase the trip setting by increments of 0.1V
VAFB) test jacks, and channel 2 to Propel #2 until nuisance tripping does not occur. (It should
(Crowd VAFB). not be necessary to increase this setting more
than 0.5VDC. )
Operate the machine from the operator’s seat.
14.24 THIS COMPLETES TESTING OF THE
CROWD ARMATURE CONTROL
PROPEL transfer button.
14.21.3 Record VAFB while alternately applying full
positive and full negative reference and compare
14.24.2 Remove all PLC forces.
the recordings with Figure 14.21.3.
14.24.3 Open the field circuit breakers.
14.24.4 Enable OPEN SCR TEST. At the crowd AFM
keypad, change Y058 from D087 ZERO BIT to
D149 TEST ARM. Reset drive.

Figure 14.20.6 Crowd VAFB and IAFB Chart Recording

Figure 14.21.3 Propel VAFB Chart Recording

15. SWING ARMATURE CONTROL 15.2.2 Using a DVM, check that the following voltages
are present at the swing armature AFM:
15.1 TEST PREPARATION A) 120VAC Control Power at TB1-1 to TB1-2.
15.1.1 Set the test selector switch to CONTROL TEST. B) 230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3.
15.1.2 Open the circuit breakers on the RPC cabinet. C) 42VDC (approx. 50VDC no load) gate voltage at
Open the constant voltage module supply circuit P11-13 (+) to P11-14 (–).
breaker (CVMSB), and the control supply
breaker (CSB).
15.3 AFM SOFTWARE
15.1.3 Connect a 12.5 ohm current limiting resistor in
series with the swing motor armature. 15.3.1 When the swing AFM is properly powered, its
15.1.4 Install a reference/push-button unit. See Fig-
ure 2.2.2 in Appendix B. P&H Electrotorque-Plus
Armature Control
15.1.5 Check the ID on the flash PROM (U8), and on
agree with the shovel documentation. This indicates that this AFM most likely has the cor-
15.1.6 Check for open or shorted thyristor firing pulse
cables by measuring between the bridge inter- 15.3.2 Use the drive keypad to go to the ACCESS
face connector pins. A reading of 50 ohms is to CODES sub-menu. Enter the sub-menu using
be expected between the following pins: the right arrow key and go to E007 SWR VER-
P9-1 to P9-2, P9-3 to P9-4, number agrees with the shovel documentation.
P9-5 to P9-6, P9-9 to P9-10,
15.4 AFM TESTING
P9-11 to P9-12, P9-13 to P9-14,
P9-15 to P9-16, P9-17 to P9-18, 15.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board A1 on your
P9-19 to P9-20, P9-23 to P9-24, right side. Attach a digital voltmeter across TP1
P9-25 to P9-26, P9-27 to P9-28 (ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
15.2 SUPPLY VOLTAGES Record the measured voltage (approx. –7.000
• 120V Main Breaker (MB) BRATE sub-menu. Enter the sub-menu using
• Constant Voltage Supply Breaker (CVSB) the right arrow key and set the following
parameter:
• 230V Supply Breaker (SB) X000: I/O V-REF = – VDC (value measured in
15.4.1 )
• Relay Supply Circuit Breaker (RSCB) Press the S key twice to save the value and exit the
• Constant Voltage Module Supply Breaker edit mode.
(CVMSB)

15.5 AUTOCAL PROCEDURE (Operator’s refer- 15.6.3 Place the reference in the full positive (+)
ence Calibration) (swing right) position, and check the firing pulse
sequence of the swing right converter, Figure
15.5.1 On the GUI, go to the AFM TEST SCREEN. 15.6.
15.5.2 Verify that the test selector switch is set to 15.6.4 Press the STOP push-button.
ton, and the SWING BRAKE RELEASE button. 15.7 VOLTAGE CONTROL, SWING
15.5.3 Turn the swing reference potentiometer to full 15.7.1 Disable OPEN SCR TEST. At the Swing AFM
positive (+). On the GUI, press the AUTOCAL keypad, change Y058 from D149 TEST ARM to
SWING ON touch button. D087 ZERO BIT. Reset drive.
15.5.4 After the GUI touch button turns green for a 15.7.2 Connect a digital voltmeter (1kV range) across
few moments, press the AUTOCAL SWING OFF the series armature resistor.
touch button.
15.7.3 Remove the relay from the differential voltage
15.5.5 When the touch button turns red, turn the module (DVAS) to prevent shutdown due to
swing reference potentiometer to full negative unbalanced armature voltage.
(–).
15.7.4 Set the test selector switch to ARMATURE
15.5.6 On the GUI, press the AUTOCAL SWING ON TEST, and close the high voltage disconnect
touch button. After the GUI touch button turns switch.
green for a few moments, press the AUTOCAL
SWING OFF touch button. 15.7.5 Set the reference to 0V.

calibrated by checking that the ADJUSTED NOTICE
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference With a series armature resistor installed, a
full negative. Use the drive keypad to go to the nuisance ground fault indication may occur
OPERATE sub-menu. Enter the sub-menu after the firing pulses are phased advanced
using the right arrow key. Arrow up to reach in armature test. The series resistor is the
the BLOCKS ANALOG sub-menu, and enter it cause of this indication, and the indication
with the right arrow key. Arrow up to A066. can be ignored until the resistor is removed,
if:
15.5.8 The swing AUTOCAL procedure is complete. 1. The ground fault only occurs after the brake has been
Press the STOP push-button. released.
2. The Main Transformer Secondary Neutral (MSN) to
Press the drive S key twice to exit the sub-menus. ground voltage is less than 100VAC. (A true line-to-
ground fault would be approximately 350VAC)
15.6 THYRISTOR PULSE SEQUENCE 3. Prior ground checks have proved negative.
15.6.1 Verify that the test selector switch is set to 15.7.6 Press the START push-button.
ton, and the SWING BRAKE RELEASE button. 15.7.7 Check that the dc voltage across the series
armature resistor is approximately 0VDC. (A
15.6.2 With the reference in the full negative (–) higher voltage would indicate the possibility of a
(swing left) position, use an oscilloscope to check phasing error on the main transformer second-
the firing pulse sequence of the swing left con- ary, or on the synchronizing supply voltage.)
verter, Figure 15.6.

Figure 15.6 Firing Pulse Sequence Oscilloscope Recording

15.7.8 Press the SWING BRAKE RELEASE push-but- put, and compare the recording to Figure 15.9.
ton. Slowly, increase the swing reference in the Overshoots or undershoots should not be
positive direction. present.
The voltage across the feedback resistor should 15.9.4 Press the STOP push-button.
15.10 STALL CURRENT, SWING
15.7.9 Slowly, Increase the swing reference in the neg-
ative direction. 15.10.1 Use the drive keypad to go to the DRIVE
ANALOG sub-menu. Enter the sub-menu using
The voltage across the feedback resistor should the right arrow key, then go to parameter A004:
increase directly in proportion to the reference, and I ARM AMP.
should have changed polarity.
15.10.2 Connect a digital voltmeter across the swing
15.8 CURRENT FEEDBACK, SWING current feedback (IAFB) test jacks.
15.8.1 With the reference close to fully positive, check 15.10.3 Calculate the dc voltage to be expected across
that the current feedback signal at the AFM the IAFB test jack resistor:
connector P11 - terminal 10 to terminal 8 (10251
to 01021C) is positive. This signal will be very Istall / 300 = Vtest jack
small, 0.1V or less so use care in reading the
meter, or better still, use a strip chart recorder Example:
to assure that the feedback polarity is correct.
2250A / 300 = 7.5 VDC
15.8.2 With the reference close to fully negative, check
that the current feedback signal at the AFM 15.10.4 Set the meter selector switch to monitor the
connector P11 - terminal 10 to terminal 8 (10251 swing motion parameters.
to 01021C) remains positive.
15.10.5 Set the swing reference potentiometer to 0
15.8.3 Reduce the reference to 0V. Press the STOP VDC. Press the START push-button.
push-button.
15.8.4 Remove the series armature resistor.

15.9 ARMATURE CURRENT RESPONSE,
SWING onds at a time. Longer periods will
cause localized commutator heating.
15.9.1 Connect a strip chart or memory recorder
(Ch. 1 ) across the Swing current feedback 15.10.6 Press the SWING BRAKE RELEASE push-
(IAFB) test jacks. button.
15.9.2 On the GUI, at the AFM TEST SCREEN, press 15.10.7 Increase the swing reference to full positive
the SWING CURRENT REGULATOR MODE (swing right). Check the current value shown
touch button. Press the START push-button. on the drive LCD Display. Record the voltage
Press the SWING BRAKE RELEASE push-but- seen across the IAFB test jacks.
ton. Increase the swing operator’s reference
until the armature current ammeter reads 15.10.8 Press the SWING BRAKE SET push-button.
500A.
15.10.9 Verify that values recorded in 15.10.7, agree
15.9.3 On the GUI, press the SWING STEP REFER- with the I-A2 level shown in the Specified Elec-
ENCE touch button. The PLC will cause the trical Data sheet.
AFM to pulse the output current for a 10 sec.
period. During this period, record the IAFB out-

Figure 15.9 Swing VAFB and IAFB Chart Recording

15.10.10 After the commutators have been allowed to 15.12.1 Remove an input lead from the phase monitor
cool for at least one full minute, again, Press the in the swing armature converter.
SWING BRAKE RELEASE push-button and
increase the swing reference to full negative 15.12.2 Press the START button.
(SW. LEFT).
15.12.3 Check that the machine shuts down and that
15.10.11 Verify that values recorded in 15.10.7, agree a swing converter phase fault is indicated.
trical Data sheet. Press the SWING BRAKE 15.12.4 Replace the phase lead.
SET push-button.
15.13 DIVERTER CIRCUIT CHECKS.
cool for at least one full minute, again, press the 15.13.1 Check that the relay and control supply cir-
SWING BRAKE RELEASE push-button and cuit breakers are closed.
increase the swing reference to full positive
(swing right). 15.13.2 Set the test selector switch to CONTROL
TEST.
15.10.13 Check that the analog armature current
panel meter also reads the stall level +/–50A. 15.13.3 Connect a voltmeter to (TB1-1) on the swing
diverter control module and check that the sup-
15.10.14 Press the SWING BRAKE SET push-button. ply voltage is +28VDC.
Reduce the swing reference to 0 VDC.
15.11 VOLTAGE CONTROL - RUN MODE,
SWING 15.13.5 Check that the READY light on the diverter
module is on.
15.13.6 Check that the DE-BLOCK LED on the AFM
15.11.2 Deactivate the RPC shutdown by forcing off is on. The LED’s on the pulse transformer
the RPC circuit breaker inputs. should also be on.
(Alternative: Disconnect the RPC circuit breaker inter- 15.13.7 Check the gate block circuit by shorting TB2-
lock input to the PLC.) 10 to TB2-9 on the diverter module.
15.11.3 Close the swing field circuit breaker. 15.13.8 The pulse transformer LED at the converter
START button. 15.13.9 Press STOP button. Remove the short on the
diverter module.
15.11.5 Press the SWING BRAKE RELEASE push-
button and check that the armature current is 15.14 DIVERTER CURRENT SENSOR
approximately 0. CHECKS, SWING
15.11.6 Check that the motors can be controlled with 15.14.1 Connect a digital voltmeter to TP2 (–) and
the reference by accelerating, decelerating and TP3 (+) on the swing diverter control module.
speed. 15.14.2 Set the test selector switch to ARMATURE
TEST.
15.11.7 Set the swing brakes. Press the STOP push-
button. 15.14.3 Press START button, press SWING BRAKE
RELEASE button and check that the meter
15.12 CONVERTER PHASE FAULT DETEC- reads at full swing:
TION, SWING

Volts = Iarmstall/300 (+/–0.5VDC) 15.16.3 Set the test selector switch to ARMATURE
TEST.
15.14.4 Record this in the test data sheet.
15.14.5 Press the STOP button. Disconnect the DVM. the diverter control module.
15.15 DIVERTER CAPACITOR CHECKS, 15.16.5 Press the START button. Press the SWING
BRAKE RELEASE button.
SWING
15.16.6 Slowly increase the swing reference to the full
15.15.1 Reconnect the wire to the capacitor charging
swing right position.
relay at the terminal board on the swing
diverter circuit panels in the converter cabinet
15.16.7 Check that the machine shuts down when the
to activate the capacitor charging power supply.
meter reads about 3.5VDC.
15.16.8 Check that the capacitor voltage on the swing

Use extreme caution when making volt- mately 0 volts.
test procedure. Voltages of approxi- 15.16.9 Press the STOP button.
15.15.2 Connect a digital voltmeter (1kV range)
across the swing diverter capacitor for the for- 15.16.11 Reconnect the meter to TP1(+) and TP2(–) on
ward bridge. the control module.
15.15.3 Manually depress the swing capacitor charg- 15.16.12 Readjust the current trip adjust potentiome-
ing relay armature to close its contacts. ter to its maximum clockwise position.
15.15.4 The voltage across the diverter capacitor 15.16.13 Press the START push-button. Press the
should begin to climb at the capacitor charges. SWING BRAKE RELEASE button.
VDC, but to avoid overvoltage on the DVM, we 15.16.14 Stall the swing and turn down the current
will stop charging (release the relay armature) trip potentiometer until the module trips. Do
at about 900 VDC. Check schematics for polar- not stall motor for more than 5 seconds.
rect. 15.16.15 Check and read voltage at TP1-TP2.
15.15.5 When you release the charging relay, the volt- 15.16.16 Readjust level as follows.
less than 50 VDC in less than 30 sec. Volts = (VTP1-VTP2) x 1.4
15.15.6 Repeat these tests for the reverse bridge Where:
swing diverter capacitor.
VTP1 to VTP2 is from 15.16.15
15.16 CHECK DIVERTER CIRCUIT OPERA-
TION, SWING 15.17 OPERATE FROM THE OPERATOR’S
COOP, SWING
15.16.1 Connect a digital voltmeter to TP1(+) and
TP2(–) on the diverter control module.
15.17.1 Remove the reference/push-button unit (Fig-
ure 2.2.2 Appendix B). Reconnect the PLC/coop
15.16.2 Adjust the current trip adjust potentiometer
cables.
so that the meter reads +2.1VDC.

15.17.2 REPEAT THE AUTOCAL PROCEDURE The motor rotation may be reversed by reversing the
(Operator’s Reference Calibration) motor field connections.
15.17.3 On the GUI, go to the AFM TEST SCREEN. 15.18 VOLTAGE RESPONSE, SWING
15.17.4 Verify that the test selector switch is set to 15.18.1 Connect a chart recorder to record across the
CONTROL TEST. Press the START push-but- swing armature voltage feedback (VAFB) test
ton, and the SWING BRAKE RELEASE button. jacks (Ch. 1), and the swing armature current
feedback (IAFB) test jacks (Ch. 2).
15.17.5 Move the swing controller potentiometer to
full positive (+). On the GUI, press the AUTO- 15.18.2 Press the START push-button. Press the
CAL SWING ON touch button. SWING BRAKE RELEASE button.
15.17.6 After the GUI touch button turns green for a 15.18.3 Check that the armature voltage of each
few moments, press the AUTOCAL SWING OFF motor is correct for both full swing right and full
touch button. swing left directions as spelled out in the Speci-
fied Electrical Data sheet.
15.17.7 When the touch button turns red, move the
swing controller potentiometer to full negative • 15.18.3.1 If the terminal voltage is significantly
(–). lower than the voltage read at the AFM (A012
ARM VOLTS) then change the X003 parameter
15.17.8 On the GUI, press the AUTOCAL SWING ON from 100 to something less. For example: If the
touch button. After the GUI touch button turns measured terminal voltage is 500V and A012
green for a few moments, press the AUTOCAL reads 550V then change X003 from 100 to 91 (500/
SWING OFF touch button. 550 x 100 = 91). Changes made to X parameters
are activated immediately after pressing the S key.
15.17.9 Confirm that the reference signals are prop-
erly calibrated by checking that the ADJUSTED 15.18.4 Operate the swing by alternately applying full
REFERENCE at A066 is +100% with the refer- positive and full negative reference and compare
ence full positive, and –100% with the reference the recordings of VAFB and IAFB with 15.18.4.
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu 15.18.5 Set the dipper on the ground and press the
using the right arrow key. Arrow up to reach STOP push-button.
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
15.19 DIVERTER VAFB SIGNAL CHECKS,
SWING
15.17.10 The swing AUTOCAL procedure is complete.
15.19.1 Connect a digital voltmeter from TB1-4 to
key twice to exit the sub-menus.
TB1-5 on the swing diverter control module.
15.17.11 Set the test selector switch to RUN. START
15.19.2 With the test selector switch set to RUN, press
the machine and RELEASE the Swing brakes.
START button and SWING BRAKE RELEASE
button.
15.17.12 Check that full control of the swing motion is
obtained by the operator’s controller.
15.19.3 Operate the swing motion, and check that the
voltage is –9.7V+/–1V at full speed in the swing
15.17.13 Check that the swing motion runs in the
right direction and +9.7V+/–1V at full speed in
proper direction in relation to the controller
the swing left direction.
position.
15.19.4 Set the dipper on the ground and press STOP
If the motor rotation is wrong, check that the reference
button.
is of the proper polarity.

Figure 15.18.4 Swing VAFB and IAFB Chart Recording

15.20 DIVERTER CIRCUIT OPERATION
15.20.1 If nuisance tripping occurs during normal 50 Hz. Machines

operation, use the procedure of 15.16.11 and
increase the trip setting by increments of 0.1V STEP # 1 2 3 4 5 6
until nuisance tripping does not occur. (It should
not be necessary to increase this setting more 1/2 BANK | O | O | |
than 0.5VDC. )
BANK 1 O | | | | |
15.21 THIS COMPLETES TESTING OF THE BANK 2 O O O | | |

SWING ARMATURE CONTROL BANK 3 O O O O O |
15.21.1 Press the STOP push-button. TOTAL # OF 1/2 1 1 1/2 2 2 1/2 3

BANKS ON
15.21.2 Remove all PLC forces. KVAR’s 750 1500 2250 3000 3750 4500
15.21.3 Open the field circuit breakers.

| = Bank is ON O = Bank is OFF
15.21.4 Enable OPEN SCR TEST. At the Swing AFM
keypad, change Y058 from D087 ZERO BIT to 16.1 TEST PREPARATION
D149 TEST ARM. Reset drive.
16. REACTIVE POWER COMPENSATOR, 16.1.2 Open the constant voltage module supply cir-
(RPC). cuit breaker (CVMSB), and the control supply
breaker (CSB).
The RPC utilizes banks of tuned capacitors/reactors,
which are automatically switched in and out of the 16.1.3 Open the circuit breakers on the cabinet for the
600V power circuit. The number of banks used, Reactive Power Compensator.
depends on the individual shovel model served. A
combination of 1/2 and full banks are used for compen- 16.1.4 Install a reference/push-button unit. See Figure
sation. As can be seen in the following chart, the 1/2 2.2.2 in Appendix B.
bank is brought in to add compensation of smaller
increments between the full banks. 16.1.5 Check the ID on the flash PROM (U8), and on
60 Hz. Machines 16.1.6 Check for open or shorted thyristor firing pulse
cables by measuring between the bridge inter-
STEP # 1 2 3 4 5 6 7 face connector pins. A reading of 50 ohms is to
be expected between the following pins:
1/2 BANK | O | O | O |
P9-1 to P9-2, P9-3 to P9-4,
BANK 1 O | | | | | |
P9-5 to P9-6, P9-9 to P9-10,
BANK 2 O O O | | | |
P9-11 to P9-12, P9-13 to P9-14,
BANK 3 O O O O O | |
P9-15 to P9-16, P9-17 to P9-18,
TOTAL # OF 1/2 1 1 1/2 2 2 1/2 3 3 1/2
BANKS ON P9-19 to P9-20, P9-23 to P9-24,
KVAR’s 675 1350 2025 2700 3375 4050 4725 P9-25 to P9-26, P9-27 to P9-28
| = Bank is ON O = Bank is OFF

16.2 SUPPLY VOLTAGES Record the measured voltage (approx. –7.000

• 120V Main Breaker (MB) BRATE sub-menu. Enter the sub-menu using
• Constant Voltage Supply Breaker (CVSB) the right arrow key and set the following param-
eter:
• 230V Supply Breaker (SB) X000: I/O V-REF = – VDC (value measured in
• Control Supply Breaker (CSB) 16.4.1 )
• Relay Supply Circuit Breaker (RSCB) Press the S key twice to save the value and exit the
• Constant Voltage Module Supply Breaker edit mode.
(CVMSB)
are present at the RPC AFM:
A) 120VAC control power at TB1-1 to TB1-2. 16.5 LEVEL DETECTOR CHECKS
B) 230VAC, 3ph, synchronizing voltage at P11-1 to 16.5.1 Connect a digital voltmeter to the manual
P11-16 to P11-3. kVAR reference input to the RPC AFM at con-
nector P9-16 (+) to P9-17 (–). Set the Manual
C) 42VDC (approx. 50VDC no load) gate voltage at kVAR potentiometer to 0.00.
P11-13 (+) to P11-14 (–).
Press the START push-button. On the GUI, at
16.3 AFM SOFTWARE
the AFM TEST SCREEN, press the RPC MAN-
UAL MODE touch button.
16.3.1 When the RPC AFM is properly powered, its
16.5.3 Slowly increase the manual kVAR reference
until the first green LED (STEP 1) on the AFM
P&H Electrotorque-Plus illuminates. The voltmeter reading the kVAR
RPC Control reference should now read V-LEV1 as docu-
mented in the Specified Electrical Data sheet.
This indicates that this AFM most likely has the cor- 16.5.4 Increase the manual kVAR reference until each
rect firmware installed. successive LED on the AFM illuminates. As
each LED first turns on, the kVAR reference
16.3.2 Use the drive keypad to go to the ACCESS should read the appropriate V-LEV as docu-
CODES sub-menu. Enter the sub-menu using mented in the Specified Electrical Data sheet.
SION. Confirm that the displayed software part 16.5.5 Reduce the manual kVAR reference to 0VDC.
16.6 RPC FIRING CHECKS
16.4 AFM TESTING
16.6.1 Slowly increase the manual kVAR reference
16.4.1 Open the Electrotorque-Plus top door to until the first green LED (STEP 1) on the AFM
expose the microprocessor board A1 on your illuminates. Verify that the red LED’s for the
right side. Attach a digital voltmeter across TP1 1/2 BANK pulse transformers are illuminated
(ACOM) to TP2 (VREF) which are located on the (dimly).
bottom left side of the microprocessor board.

16.6.2 Connect an oscilloscope to the gate (G) and

cathode (K) of each pulse transformer. Firing
pulses should be similar to that shown in Figure
The recorder or oscilloscope being used
16.6.2.
should be isolated from its power sup-
ply through an isolation transformer
because of the high voltage to ground
(approximately 1000V). Isolate test
equipment from machine floor.
DO NOT TOUCH the instrument frames when power

is on the RPC.
DO NOT TOUCH live parts when obtaining measure-

Figure 16.6.2 Thyristor Pulse Waveform ments on the RPC equipment when power is on the
RPC.
16.6.3 As required, continue increasing the manual
kVAR reference until STEP 2 LED on the AFM 16.7.6 Press the START button.
illuminates. Verify that the red LED’s for the
BANK 1 pulse transformers are illuminated. 16.7.7 Check that the voltmeter indicates approxi-
Check firing pulses. mately 800V with reference set at 0.
Continue to the next bank by increasing the reference 16.7.8 Connect voltmeter between terminals MS2 and
to STEP 4 for BANK 2, and to STEP 6 for BANK 3. RCC and check that voltage is approximately
Check firing pulses after each bank. 800V.
16.6.4 Reduce the manual kVAR reference to 0VDC. 16.7.9 Connect the voltmeter to MS3 and RAC, repeat
On the GUI, press the RPC MANUAL MODE the above tests.
OFF touch button.
16.7 RPC OPERATION WITH CAPACITOR
TEST UNIT. 16.7.11 Connect a stripchart recorder across one of the
10 ohm resistors on the capacitor unit. The
16.7.1 Verify that the manual kVAR reference is set to recorder should be isolated from its power sup-
0VDC. Verify that all of the RPC circuit break- ply through an isolation transformer, or be bat-
ers are open on the RPC cabinets. tery operated, because of the high voltage to
ground (approximately 1000V).
16.7.2 Connect each leg of the capacitor test unit (Fig-
ure 2.2.5 in Appendix B) across the open con- DO NOT TOUCH the frame of the recorder while
tacts of the breaker on the 1/2 bank. Figure power is on the RPC.
16.7.2 shows the typical connections.
16.7.3 Short circuit each capacitor bank on this step
with jumper wires. (The reactors need not be 16.7.13 Record the voltage across the resistor when
shorted for this test.) the output voltage from the manual kVAR refer-
ence is changed rapidly from a setting just below
16.7.4 Set the test selector switch to ARMATURE the switching setpoint to a setting just above the
TEST. setpoint, and back with the kVAR reference
potentiometer. Compare the recording to Figure
16.7.5 Connect a digital (dc setting) voltmeter (1kV 16.7.13.
range) between terminals MS1 and RBC of the
capacitor unit to measure approximately Check that the first half cycle has the same amplitude
800VDC. as the subsequent cycles.

16.7.14 These tests should be performed on all three 16.7.17 Connect the capacitor unit across the open
resistors of the capacitor unit. The recorder contacts of the breaker on BANK 2. Repeat the
must be run at high speed for these tests. Chart tests of 16.7.1 through 16.7.15.
paper can be saved by rapidly changing the ref-
erence signal before starting the recorder. 16.7.18 Connect the capacitor unit across the open
contacts of the breaker on BANK 3. Repeat the
16.7.15 Press the STOP button. tests of 16.7.1 through 16.7.15.
16.7.16 Connect each leg of the capacitor test unit 16.7.19 Remove the capacitor unit, jumper wires, and
across the open contacts of the breaker on all test instruments.
BANK 1. Repeat the tests of 16.7.1 through
16.7.15.
Figure 16.7.2 Capacitor Test Typical Connections

Figure 16.7.13 RPC Chart Recording

16.8 TESTING RPC POWER CIRCUITS 16.8.9 Check that the capacitors have been switched
on by noting if an ac voltage appears across the
16.8.1 Check that the test selector switch is set to terminals as shown in Figure 16.8.9.
ARMATURE TEST.
16.8.10 Check that no overshoots occur when the
16.8.2 Connect a recorder, using a voltage divider, capacitors are switched on or off.
across phase A of the 1/2 BANK to measure the
capacitor voltage (approximately 850V). 16.8.11 Press the STOP push-button.
16.8.12 Connect the recorder across the capacitors of

phase B of the 1/2 BANK, and repeat the tests of
16.8.5 through 16.8.11.
The recorder or oscilloscope being used
should be battery powered or isolated
from its ac power supply through an iso-
lation transformer because of the high
voltage to ground (approximately Observe the DANGER on this page fol-
1000V). Isolate test equipment from lowing step 16.8.2.
machine floor.
16.8.13 Connect the recorder across the capacitors of
DO NOT TOUCH the instrument frames when power phase C of the 1/2 BANK, and repeat the tests of
is on the RPC. 16.8.5 through 16.8.11.
DO NOT TOUCH live parts when obtaining measure-

ments on the RPC equipment when power is on the
RPC. Observe the DANGER on this page fol-
lowing step 16.8.2.
16.8.3 Close the RPC circuit breaker for the 1/2 BANK
only. 16.8.14 Open the circuit breaker for the 1/2 BANK,
and close the breaker for BANK 1.
16.8.4 Start the recorder (5 sec/div). Press the
START push-button. 16.8.15 Repeat the tests of 16.8.5 through 16.8.13 for
BANK 1.
16.8.5 Check that the voltage across the capacitors
corresponds to the recording of Figure 16.8.5.
Check the schematics for polarity. Check that
overshoots at the start, do not exceed those
shown in Figure 16.8.5. Observe the DANGER on this page fol-
lowing step 16.8.2.
16.8.6 Press STOP push-button.
16.8.16 As required, close the circuit breaker succes-
16.8.7 Using the following procedure, check the RPC sively for BANK 2, and BANK 3, and open the
capacitor switching. breaker for the previous bank.
16.8.8 Increase the recorder speed to 100ms/div. Press Repeat the tests of 16.8.5 through 16.8.13 for each
the START button. Record the voltage across phase of each bank.
the capacitors when the output voltage from the
kVAR reference potentiometer is changed rap- NOTICE
idly from a setting just below the switching set-
point to a setting just above the setpoint, and
Do not energize more than one bank at a
back with the RPC reference potentiometer.
time.
16.8.17 Press the STOP Push-button.

Figure 16.8.5 RPC Switching Chart Recording

Figure 16.8.9 RPC Capacitor Chart Recording

16.9 REACTIVE POWER MEASUREMENT 16.10 CHECK THE RPC UNDER FULL POWER
CONDITIONS
These tests are made to check operation of the reactive
power measurement circuits. 16.10.1 Set the test selector switch to ARMATURE
TEST. Close all RPC circuit breakers.
16.9.1 Open all RPC Circuit Breakers. Check that the
test selector switch is set to ARMATURE TEST. 16.10.2 Press the START push-button. Press the
Connect two digital voltmeters. One between HOIST and CROWD BRAKE RELEASE push-
terminals 1 and 2 on the kVAR transducer to buttons.
measure its output voltage, VQ, and another to
measure the ac voltage (115V) between termi- 16.10.3 While someone is monitoring the RPC indica-
nals 3 and 4, or 5 and 6 on the kVAR transducer. tors, the RPC steps can be successively brought
in slowly by stalling the hoist and then adding
16.9.2 Press the START push-button. Press the the crowd.
CROWD BRAKE RELEASE push-button.

The motors should not be run at maximum stall current for more than 5 sec-
mum stall current for more than 5 seconds at a time. If repeated stall tests are
onds at a time. If repeated stall tests are required the motors should be operated
required the motors should be operated in the RUN position occasionally to
in the RUN position occasionally to eliminate the possibility of localized
eliminate the possibility of localized heating on the commutators.
heating on the commutators.
16.10.4 Reduce both the hoist and crowd reference
16.9.3 Set the crowd reference to the full positive (+) voltages to 0V. Set both brakes. Press the
position to give the specified stall armature cur- STOP push-button.
rent I-A2.
16.10.5 Refer to the RPC indicator decals to verify
16.9.4 Using two digital voltmeters, measure the out- proper operation.
put voltage, VQ, of the kVAR transducer at ter-
minals 1 and 2, and simultaneously, the ac 16.11 Remove test equipment.
voltage (115V) between terminals 3 and 4, or 5
and 6. 16.11.1 Remove all PLC forces if any exist. Discon-
nect and remove the PLC terminal.
16.9.5 Return the crowd reference voltage to 0V. Set
the crowd brake, and press the STOP push-but- 16.11.2 Remove the reference/push-button unit and
ton. reconnect the appropriate PLC cables. Remove
any and all external connections made to the
16.9.6 Verify that the output voltage, VQ, measured is: control circuits.
VQ = (0.000000141 x VAC x Iarmstall) +/–

0.002VDC
Where: VAC is the AC voltage measured in step 16.9.4.
Example:
VQ = (0.000000141 x 105 x 2650A) +/– 0.002VDC
= 0.392 VDC +/– 0.002 VDC


TEST EQUIPMENT LIST
INSTRUMENT RECOMMENDED ALTERNATE
Digital Multimeter Fluke, Model 23 Fluke, Model 87

Part No. 89Z514D12 Part No. 1089Z275
Clamp - On AC/DC Current Probe Fluke, Model 1010 Columbia Electric,

(Requires separate DVM) [Range=1 to 600A AC/1000A DC] Type AX with 5 Current Ranges
Part No. 89Z514D15 Part No. 89Z367
Megger James G. Biddle, Cat. 21158

[Hand-Crank w/ case] Part No. 89Z496
Oscilloscope
[Handheld, Dual Trace, Digital, Storage, Batt
Pwr’d, Soft Case]
Scope w/ 120V/60Hz Adaptor Part No. 89Z515D15
(120V / 50 Hz AC Adpator Part No. 89Z515D30 ------------------- -- 240V adapters available
(Hard Carrying Case) Part No. 89Z515D26
(X10 Probe [10kV]) Part No. 89Z515D17
Isolation Transformer 115VAC P / 115VAC

50/60 Hx, 250VA
Part No. 75Z820D1
Chart Recorder Hioki, Model 8804 Memory Recorder New Astro-Med, Dash 2
[Order wach part separately] w/ Data Capture
Recorder [120/240V - 50/60 Hz] Part No. R10945D1 Part No. 89Z835D3
(Carrying Case - Soft) Part No. R10945D2 Paper = Part No. 89Z835D4 (Z-Fold)
(AC Adaptor 90-250V, 50/60 Hz) Part No. R10945D3
(Battery Pack, Rechargable) Part No. R10945D4 Old Astro-Med Paper
Recording Paper [10 rolls]) Part No. R10945D5 Paper = Part No. 89Z835D2 (Rolls)
Start-Up Resistor 200 Ohm, 6000 Watt

Part No. 80Z984D1
RPC/Step Reference Unit Part No. 89Z866

Reference/Push-Button Unit Part No. R40602D1
Capacitor Unit Part No. 89Z508D1
Voltage Divider Part No. R1192F1 (was 89Z869) Part No. 89Z510D1
PLC COMMUNICATIONS CUSTOMER USE P&H USE

(Hardware & Software) (Order thru Parts) (Order thru Service)
Laptop PC
1.4GB Hard (Min.), 120MHz (Min.)
Pentium, Windows 95, 16MB RAM,
3.5” Floppy, 10X CD-ROM, Audio, PCMCIA,
Carrying Case
w/SLC-500 A.I. Software Part No. R24834D1 Part No. R29713D2

CAT312_2A.fm Appendix A - 1
PLC COMMUNICATIONS CUSTOMER USE P&H USE

(Hardware & Software) (Order thru Parts) (Order thru Service)
PLC Communications Software

SLC-500 A.I. Series Part No. 79Z5311D3 Part No. 79Z4937D9
PCMCIA Card and Cable

(Included in Laptop) [A-B 1784-PCMC] Part No. 79Z4936D6 Part No. 79Z4937D9
Drive Communications (Hardware and Software)
Modem Serial Cable Part No. R27280D1 Part No. R27280D1
ADDAPT Ver. 16 Communications Software Part No. R48058D1 P&H Site License Issued.
No Part No. Required

Appendix A - 2 CAT312_2A.fm
TEST EQUIPMENT SCHEMATICS

LIST OF FIGURES
Push-button/Reference Unit ( Figure 2.2.2 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Resistor Bank Schematics ( Figure 2.2.3 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Capacitor Unit ( Figure 2.2.4 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Voltage Divider ( Figure 2.2.5 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Hoist/Propel Voltage F.B. Circuit Schematic (Figure 13.7.7 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

CAT312_2B.fm Appendix B - 1
Figure 2.2.2 Push-button/Reference Unit

Appendix B - 2 CAT312_2B.fm
Standard Pre-Wired Resistor Bank Schematic
50 Ω 50 Ω 50 Ω 50 Ω
Modified Resistor Bank Schematic

for Digital Drive
50 Ω 50 Ω 50 Ω 50 Ω
Part No. 80Z984D1
Figure 2.2.3 Resistor Bank Schematics
Figure 2.2.4 Capacitor Unit

CAT312_2B.fm Appendix B - 3
Figure 2.2.5 Voltage Divider
Figure 13.7.7 Hoist/Propel Voltage F.B. Circuit Schematic

Appendix B - 4 CAT312_2B.fm
ELECTRICAL TEST DATA
The test given in within this Appendix is for Electric Mining Shovels with analog Electrotorque®
Plus Control Systems.
Variables, between models, are shown on the “Nominal Circuit Board Setting Data Sheets”, and the
“Specified Electrical Data Sheets”.
Note: Each machine has its own “Specified Electrical Data Sheet”, identified by machine Serial Number.
Consult the “Specified Electrical Data Sheets” for data marked <**>.
Consult the Machine Schematics for data marked ***.
Characteristics
Hoist Armature Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Hoist Field Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Swing Armature Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Crowd/Propel Armature Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Test Data (PLC Supplement)

Electrotorque-Plus Shovels with SLC 5/04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

CAT312_2C.fm Appendix C - 1
Characteristics

Appendix C - 2 CAT312_2C.fm
Characteristics

Test Data (PLC Supplement) - Electrotorque-Plus Shovels with SLC 5/04
LOCATION NORMAL STATUS/ACTION TO TEST

ADDRESS FUNCTION
(SHEET LINE) INTENDED RESULT OF ACTION
8.7 PLC INPUT SOURCE AND WIRING CHECKS

ACTUATE INPUT DEVICE; CHECK FOR PROPER PLC INPUT "LED" INDICATION.
53-02 I:1/0 MAIN TRANSFORMER OVER CURRENT N.O./CLOSE/FAULT
53-04 I:1/1 MAIN TRANSFORMER THERMAL MONITOR N.C./OPEN/FAULT
53-06 I:1/2 AUXILIARIES CABINET CIRCUIT BREAKER N.O./CLOSE/OK
53-12 I:1/5 DOOR INTERLOCK AUXILARIES CABINET N.O. HELD CLOSED/OPEN DOOR/FAULT
53-14 I:1/6 FRONT HOIST BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-16 I:1/7 REAR HOIST BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-26 I:1.1/0 FRONT SWING BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-28 I:1.1/1 REAR SWING BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-30 I:1.1/2 FRONT SWING LUBE PUMP N.O./MANUALLY CLOSE/START MOTOR
53-32 I:1.1/3 REAR SWING LUBE PUMP N.O./MANUALLY CLOSE/START MOTOR
53-34 I:1.1/4 RIGHT PROPEL BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-36 I:1.1/5 LEFT PROPEL BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-38 I:1.1/6 CROWD BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
53-40 I:1.1/7 HOIST CONVERTER BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
54-10 I:1.2/4 CONTROL CAB BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
54-14 I:1.2/6 RIGHT MACH. HOUSE BLOWER N.O./MANUALLY CLOSE/START MOTOR
54-16 I:1.2/7 LEFT MACHINERY HOUSE BLOWER N.O./MANUALLY CLOSE/START MOTOR

STARTER
53A-47 I:1.7/0 SWING/CROWD CONVERTER BLOWER N.O./MANUALLY CLOSE/START MOTOR
53A-51 I:1.7/2 RPC BLOWER STARTER #1 (BANK 1/2 & 1) N.O./MANUALLY CLOSE/START MOTOR
53A-53 I:1.7/3 RPC BLOWER STARTER #2 (SWITCH) N.O./MANUALLY CLOSE/START MOTOR
53A-55 I:1.7/4 RPC BLOWER STARTER #3 (BANK 2 & 3) N.O./MANUALLY CLOSE/START MOTOR
53A-57 I:1.7/5 HOIST LUBE PUMP STARTER N.O./MANUALLY CLOSE/START MOTOR
53A-59 I:1.7/6 DIPPER TRIP MOTOR STARTER 1 N.O./MANUALLY CLOSE/START MOTOR
53A-61 I:1.7/7 DIPPER TRIP MOTOR STARTER 2 N.O./MANUALLY CLOSE/START MOTOR
81-23 I:1.8/0 START PUSH BUTTON LEFT COOP N.O./PUSH/START
81-25 I:1.8/1 PROPEL TRANSFER PUSH BUTON N.O./PUSH/PROPEL


ADDRESS FUNCTION
81-28 I:1.8/2 HOIST BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
81-30 I:1.8/3 CROWD BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
81-33 I:1.8/4 SWING BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
81-35 I:1.8/5 SET ALL BRAKES PUSH BUTTON N.O./PUSH/BRAKE
81-38 I:1.8/6 HOIST/CROWD TRANSFER PUSH BUTTON N.O./PUSH/HOIST&CROWD
81-40 I:1.8/7 HOIST BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE
81-23 I:1.8/8 CROWD BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE
81-25 I:1.8/9 SWING BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE
81-28 I:1.8/10 RUN ENABLE KEY SWITCH LEFT COOP OPEN=OFF CLOSE=RUN ENABLE
81-30 I:1.8/11 STOP PUSH BUTTON(S) LEFT COOP N.C./PUSH/STOP
81-33 I:1.8/12 CONTROL FAULT RESET PUSH BUTTON N.O./PUSH/RESET
81-38 I:1.8/14 AIR HORN SWITCH LEFT COOP N.O./LEFT JOYSTICK-PUSH LEFT/
SOUND
81-40 I:1.8/15 DIPPER TRIP SWITCH PUSH BUTTON N.O./LEFT JOYSTICK-PUSH RIGHT/TRIP
79-23 I:1.10/0 START PUSH BUTTON N.O./PUSH/START
79-25 I:1.10/1 PROPEL TRANSFER PUSH BUTTON N.O./PUSH/PROPEL
79-28 I:1.10/2 HOIST BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
79-30 I:1.10/3 CROWD BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
79-33 I:1.10/4 SWING BRAKE SET PUSH BUTTON N.O./PUSH/BRAKE
79-35 I:1.10/5 SET ALL BRAKES PUSH BUTTON OPER CAB N.O./PUSH/BRAKE
79-38 I:1.10/6 HOIST/CROWD TRANSFER PUSH BUTTON N.O./PUSH/HOIST&CROWD
79-40 I:1.10/7 HOSIT BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE

79-23 I:1.10/8 CROWD BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE
79-25 I:1.10/9 SWING BRAKE RELEASE PUSH BUTTON N.O./PUSH/RELEASE
79-28 I:1.10/10 RUN ENABLE KEY SWITCH OPEN=OFF CLOSE=RUN ENABLE
79-30 I:1.10/11 STOP PUSH BUTTON N.C./PUSH/STOP
79-33 I:1.10/12 CONTROL FAULT RESET PUSH BUTTON N.O./PUSH/RESET
79-35 I:1.10/13 WINDSHIELD WIPER SWITCH INPUT
79-38 I:1.10/14 AIR HORN SWITCH N.O./LEFT JOYSTICK-PUSH LEFT/

SOUND
79-40 I:1.10/15 DIPPER TRIP SWITCH PUSH BUTTON N.O./LEFT JOYSTICK-PUSH RIGHT/TRIP
60-02 I:2/0 RIGHT LADDER LIMIT SWITCH N.O. HELD CLOSED/OPEN=DOWN

CLOSE=UP


ADDRESS FUNCTION
60-04 I:2/1 LEFT LADDER LIMIT SWITCH N.O. HELD CLOSED/OPEN=DOWN

CLOSE=UP
60-06 I:2/2 PROPEL ARMATURE CONTACTORS INTER- N.O./CLOSE/PROPEL

LOCK
60-08 I:2/3 CROWD ARM CONTACTOR INTERLOCK N.O./CLOSE/CROWD
60-10 I:2/4 HOIST ARM CONTACTOR INTERLOCK N.O./CLOSE/HOIST
60-12 I:2/5 CROWD FIELD CONTACTOR INTERLOCK N.O./CLOSE/CROWD
60-14 I:2/6 PROPEL FIELD CONTACTOR INTERLOCK N.O./CLOSE/PROPEL
60-16 I:2/7 DOOR INTERLOCK TRANSFER CABINET N.O. HELD CLOSED/OPEN DOOR/FAULT
60-26 I:2.1/0 BOARDING LADDER SIGNAL N.O./PULL CORD/SOUND
60-28 I:2.1/1 AUXILARIES CIRCUIT BREAKER N.O./CLOSE BREAKER/OK
56-03 I:2.8/0 HOIST DIVERTER OVER CURRENT TRIP N.O./CLOSE/FAULT
56-05 I:2.8/1 SWING DIVERTER OVER CURRENT N.O./CLOSE/FAULT
56-07 I:2.8/2 CROWD / PROPEL DIVERTER OVER CUR- N.O./CLOSE/FAULT

RENT
56-09 I:2.8/3 +28VDC DIVERTER SUPPLY 28V INPUT/OK
57-02 I:2.9/0 HOIST 1 DIVERTER SYSTEM PROTECT N.O./CLOSE/FAULT
57-04 I:2.9/1 HOIST 2 DIVERTER SYSTEM PROTECT N.O./CLOSE/FAULT
57-06 I:2.9/2 SWING DIVERTER SYSTEM PROTECT N.O./CLOSE/FAULT
57-08 I:2.9/3 CROWD / PROPEL DIVERTER SYSTEM PRO- N.O./CLOSE/FAULT

TECT
57-10 I:2.9/4 HOIST #1 CONVERTER PHASE N.O./CLOSE/FAULT
57-12 I:2.9/5 HOIST #2 CONVERTER PHASE N.O./CLOSE/FAULT
57-14 I:2.9/6 SWING CONVERTER PHASE N.O./CLOSE/FAULT
57-16 I:2.9/7 CROWD/PROPEL LF CONVERTER PHASE N.O./CLOSE/FAULT
57-26 I:2.10/0 DOOR INTERLOCK CONVERTER CABINET N.O. HELD CLOSED/OPEN DOOR/FAULT
PPL2
57-32 I:2.10/3 ONVERTER THERMAL SWITCH HOIST #1 N.C./OPEN/FAULT
57-34 I:2.10/4 ONVERTER THERMAL SWITCH HOIST #2 N.C./OPEN/FAULT
57-36 I:2.10/5 CONVERTER THERMAL SWITCH CROWD N.C./OPEN/FAULT


ADDRESS FUNCTION
57-38 I:2.10/6 CONVERTER THERMAL SWITCH SWING N.C./OPEN/FAULT
58-26 I:2.13/0 AC GROUND FAULT RELAY N.O./CLOSE/FAULT
58-28 I:2.13/1 GROUND FAULT RELAY AUXILARIES N.O./CLOSE/FAULT
58-30 I:2.13/2 GROUND FAULT RELAY FIELD N.O./CLOSE/FAULT
58-32 I:2.13/3 DC GROUND FAULT RELAY N.O./CLOSE/FAULT
58-34 I:2.13/4 SUPPRESSION CIRCUIT BREAKER SWITCH N.C./OPEN/OK
62-02 I:2.16/0 HOIST FIELD BREAKER SWITCH N.O./CLOSE/OK
62-04 I:2.16/1 SWING FIELD BREAKER SWITCH N.O./CLOSE/OK
62-06 I:2.16/2 CROWD/PPL FIELD BREAKER SWITCH N.O./CLOSE/OK
62-08 I:2.16/3 RPC BREAKER OPEN SWITCH BANK 1/2 N.C./OPEN/OK
62-10 I:2.16/4 RPC BREAKER OPEN SWITCH BANK 1 N.C./OPEN/OK
62-32 I:2.17/3 DOOR INTERLOCK CAPACITOR REACTOR N.O. HELD CLOSED/OPEN DOOR/FAULT
62-34 I:2.17/4 DOOR INTERLOCK CAPACITOR REACTOR N.O. HELD CLOSED/OPEN DOOR/FAULT
62-36 I:2.17/5 DOOR INTERLOCK RPC SWITCH CABINET N.O. HELD CLOSED/OPEN DOOR/FAULT
63-02 I:2.18/0 CAPACITOR PRESSURE SWITCH PHASE AB, N.C./OPEN/FAULT

HALF BANK
63-04 I:2.18/1 CAPACITOR PRESSURE SWITCH PHASE BC, N.C./OPEN/FAULT

HALF BANK
63-06 I:2.18/2 CAPACITOR PRESSURE SWITCH PHASE CA, N.C./OPEN/FAULT

HALF BANK
63-08 I:2.18/3 CAPACITOR PRESSURE SWITCH PHASE AB, N.C./OPEN/FAULT

BANK 1
63-10 I:2.18/4 CAPACITOR PRESSURE SWITCH PHASE BC, N.C./OPEN/FAULT

BANK 1
63-12 I:2.18/5 CAPACITOR PRESSURE SWITCH PHASE CA, N.C./OPEN/FAULT

BANK 1
62-26 I:2.19/0 CAPACITOR PRESSURE SWITCH PHASE AC, N.C./OPEN/FAULT

BANK 2
62-28 I:2.19/1 CAPACITOR PRESSURE SWITCH PHASE BA, N.C./OPEN/FAULT

BANK 2


ADDRESS FUNCTION
62-30 I:2.19/2 CAPACITOR PRESSURE SWITCH PHASE CB, N.C./OPEN/FAULT

BANK 2
62-32 I:2.19/3 CAPACITOR PRESSURE SWITCH PHASE AC, N.C./OPEN/FAULT

BANK 3
62-34 I:2.19/4 CAPACITOR PRESSURE SWITCH PHASE BA, N.C./OPEN/FAULT

BANK 3
62-36 I:2.19/5 CAPACITOR PRESSURE SWITCH PHASE CB, N.C./OPEN/FAULT

BANK 3
26A-71 I:2.20/0 PROPEL BRAKE AIR PRESSURE SWITCH - N.O./CLOSE/OK

RIGHT
26A-73 I:2.20/1 PROPEL BRAKE AIR PRESSURE SWITCH - N.O./CLOSE/OK

LEFT
26A-81 I:2.20/5 RIGHT PROPEL BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
26A-83 I:2.20/6 LEFT PROPEL BLOWER STARTER N.O./MANUALLY CLOSE/START MOTOR
25A-47 I:2.23/0 LOWER AUXILIARY POWER BREAKER N.O./CLOSE/OK
25A-49 I:2.23/1 LOWER HEATER SUPPLY BREAKER N.O./CLOSE/OK
25A-51 I:2.23/2 LOWER CONTROL SUPPLY BREAKER N.O./CLOSE/OK

25A-53 I:2.23/3 LOWER CONTROL DOOR INTERLOCK N.O. HELD CLOSED/OPEN DOOR/FAULT
25A-55 I:2.23/4 LOWER CONTROL POWER GROUND FAULT N.O./CLOSE/FAULT

PROTECTION
25A-57 I:2.23/5 LOWER CONTROL CABINET THERMOSTAT N.O./CLOSE/WARNING

LOW END
25A-59 I:2.23/6 LOWER CONTROL CAB THERMOSTAT HIGH N.O./CLOSE/WARNING

END
25A-61 I:2.23/7 LOWER ACCESS COVER LIMIT SWITCH N.O. HELD CLOSED/OPEN/FAULT
64-02 I:2.24/0 MAIN AIR PRESSURE SWITCH N.C./OPEN/OK
64-04 I:2.24/1 HOIST BRAKE AIR PRESSURE SWITCH #1 N.O./CLOSE/OK
64-06 I:2.24/2 HOIST BRAKE AIR PRESSURE SWITCH #2 N.O./CLOSE/OK
64-08 I:2.24/3 SWING BRAKE AIR PRESSURE SWITCH #1 N.O./CLOSE/OK
64-10 I:2.24/4 SWING BRAKE AIR PRESSURE SWITCH #2 N.O./CLOSE/OK
64-12 I:2.24/5 CROWD BRAKE AIR PRESSURE SWITCH N.O./CLOSE/OK
64-26 I:2.25/0 SILENCE LUBE ALARM PUSH BUTTON N.C./PUSH/SILENCE
64-28 I:2.25/1 UPPER LUBE MANUAL PUSH BUTTON N.O./PUSH/CYCLE START
64-30 I:2.25/2 LOWER LUBE MANUAL PUSH BUTTON N.O./PUSH/CYCLE START


ADDRESS FUNCTION
64-32 I:2.25/3 OPEN GEAR LUBE MANUAL PUSH BUTTON N.O./PUSH/CYCLE START
64-36 I:2.25/4 LUBE PRESSURE SWITCH UPPER N.O./CLOSE/OK
64-38 I:2.25/5 LUBE PRESSURE SWITCH LOWER N.O./CLOSE/OK
64-40 I:2.25/6 LUBE PRESSURE SWITCH OPEN N.O./CLOSE/OK
65-02 I:2.26/0 FARVAL SYSTEM LIMIT SWITCH UPPER 1A TOGGLE/CYCLE END
65-04 I:2.26/1 FARVAL LIMIT SWITCH UPPER 1B
65-06 I:2.26/2 FARVAL SYSTEM LIMIT SWITCH LOWER 2A TOGGLE/CYCLE END
65-08 I:2.26/3 FARVAL SYSTEM LIMIT SWITCH LOWER 2B
65-10 I:2.26/4 FARVAL SYSTEM LIMIT SWITCH OPER TOGGLE/CYCLE END

GEAR 3A
65-12 I:2.26/5 FARVAL SYSTEM LIMIT SWITCH OPEN

GEAR 3B
33-00 I:3/12 RESOLVER CARD EEPROM MEMORY FAULT

INPUT
33-00 I:3/13 CROWD TRANSDUCER FAULT INPUT PULL INPUT PLUG/FAULT
33-00 I:3/14 HOIST TRANSDUCER FAULT INPUT PULL INPUT PLUG/FAULT
41A-47 I:5.0 HOIST ARM VOLTAGE CHECK INPUT VS. GUI
41A-53 I:5.1 HOIST ARM CURRENT CHECK INPUT VS. GUI
41A-59 I:5.2 HOIST FIELD CURRENT CHECK INPUT VS. GUI
41A-71 I:6.0 SWING ARMATURE VOLTAGE CHECK INPUT VS. GUI
41A-77 I:6.1 SWING ARMATURE CURRENT CHECK INPUT VS. GUI

41A-83 I:6.2 SWING FIELD CURRENT CHECK INPUT VS. GUI
44A-48 I:7.0 CROWD ARMATURE VOLTAGE CHECK INPUT VS. GUI
44A-54 I:7.1 CROWD ARMATURE CURRENT CHECK INPUT VS. GUI
44A-60 I:7.2 CROWD FIELD CURRENT CHECK INPUT VS. GUI
44A-66 I:7.3 RPC STEP NUMBER FROM AFM DRIVE4 CHECK INPUT VS. GUI
42-03 I:8.0 HOIST/ PROPEL CONTROLLER REFERENCE CHECK INPUT VS. GUI & DRIVE
42-08 I:8.1 HOIST/ PROPEL CONTROLLER REFERENCE CHECK INPUT VS. GUI & DRIVE
42-14 I:8.2 SWING CONTROLLER REFERENCE CHECK INPUT VS. GUI & DRIVE


ADDRESS FUNCTION
42-20 I:8.3 SWING CONTROLLER REFERENCE CHECK INPUT VS. GUI & DRIVE
42-27 I:9.0 CROWD/PROPEL CONTROLLER REFER- CHECK INPUT VS. GUI & DRIVE
ENCE
42-32 I:9.1 CROWD/ PROPEL CONTROLLER REFER- CHECK INPUT VS. GUI & DRIVE
ENCE
42-38 I:9.2 REMOTE HOIST RAISE ANALOG INPUT (0- CHECK INPUT VS. GUI & DRIVE
10V)
42-44 I:9.3 REMOTE HOIST LOWER ANALOG INPUT (0- CHECK INPUT VS. GUI & DRIVE
10V)
39-03 I:10/0 REF BOX STOP PUSHBUTTON JUMPER IN/OPEN/STOP
39-13 I:10/5 LUBE SYSTEM TIMING SWITCH OPEN=RUN CLOSE=PROGRAM
39-15 I:10/6 KEYSWITCH HOIST/CROWD LIMIT ENABLE OPEN=RUN CLOSE=PROGRAM
39-17 I:10/7 OPERATOR CAB CONTROL KEYSWITCH OPEN=RH CLOSE=LH
40-09 I:11/0 UNDER VOLTAGE RELAY (TURN CNTRL N.O./CLOSE/OK

BKR OFF&ON)
40-11 I:11/1 MAIN PHASE SENSING MONITOR N.O./CLOSE/OK
40-13 I:11/2 CONTROL FAULT RESET PUSH BUTTON N.O./PUSH/RESET
40-15 I:11/3 TEST SWITCH RUN SELECT/CLOSE/RUN MODE
40-17 I:11/4 TEST SWITCH ARMATURE SELECT/CLOSE/ARM TEST MODE
40-19 I:11/5 TEST SWITCH FIELD SELECT/CLOSE/FIELD TEST MODE
40-21 I:11/6 TEST SWITCH CONTROL SELECT/CLOSE/CONTROL TEST MODE
40-23 I:11/7 TEST SWITCH AUXILARIES SELECT/CLOSE/AUX TEST MODE
40-29 I:11/8 DIFFERENTIAL VOLTAGE HOIST ARMA- N.O./CLOSE/FAULT

TURE
40-31 I:11/9 DIFFERENTIAL VOLTAGE SWING ARMA- N.O./CLOSE/FAULT

TURE
40-33 I:11/10 GROUND FAULT SHUTDOWN JUMPER NO JUMPER/CLOSE/SEE SCHEMATIC
40-35 I:11/11 24VDC RELAY RELAY SUPPLY MONITOR 24V INPUT/OPEN/FAULT
47-03 I:12/0 HOIST/PROPEL_RT DRIVE 1 DRIVE OK N.O./CLOSE/OK
47-05 I:12/1 HOIST/PROPEL RT CONTROL FAULT N.O./CLOSE/FAULT
47-07 I:12/2 HOIST/PROPEL RT THERMAL OVERLOAD N.C./OPEN/FAULT
47-09 I:12/3 HOIST/PROPEL RT AFM TEST MODE N.O./CLOSE/FAULT

47-11 I:12/4 SWING DRIVE #2 DRIVE OK N.O./CLOSE/OK


ADDRESS FUNCTION
47-13 I:12/5 SWING THERMAL OVERLOAD N.C./OPEN/FAULT
47-15 I:12/6 SWING AFM TEST MODE N.O./CLOSE/FAULT
47-17 I:12/7 CROWD/PROPEL LF DRIVE #3 DRIVE OK N.O./CLOSE/OK
47-19 I:12/8 CROWD/PROPEL LF THERMAL OVERLOAD N.C./OPEN/FAULT
47-21 I:12/9 CROWD/PROPEL LF AFM TEST MODE N.O./CLOSE/FAULT
47-23 I:12/10 FIELD CONTROL DRIVE #4 DRIVE OK N.O./CLOSE/OK
47-25 I:12/11 HOIST/PROPEL RT FIELD OK N.O./CLOSE/FAULT
47-27 I:12/12 SWING FIELD OK N.O./CLOSE/FAULT
47-29 I:12/13 CROWD/PROPEL LF FIELD OK N.O./CLOSE/FAULT
47-31 I:12/14 RPC CONTROL DRIVE #5 DRIVE OK N.O./CLOSE/OK
47A-48 I:13/0 OFF STATE FIELD FAULT N.O./CLOSE/FAULT
47A-50 I:13/1 RPC OFF STATE FAULT N.O./CLOSE/FAULT
47A-52 I:13/2 10% UNDER VOLTAGE WARNING FROM N.O./CLOSE/FAULT

AFM
44-02 I:20/0 120 VAC RELAY SUPPLY MONITOR 120V INPUT/OK
44-04 I:20/1 HOIST/PROPEL RT FIELD THERMAL OVER- N.C./OPEN/FAULT

LOAD
44-06 I:20/2 SWING FIELD THERMAL OVERLOAD N.C./OPEN/FAULT
44-08 I:20/3 CROWD/PROPEL LF FIELD THERMAL N.C./OPEN/FAULT

OVERLOAD
44-10 I:20/4 DOOR INTERLOCK FIELD SUPPLY CABINET N.O. HELD CLOSED/OPEN DOOR/FAULT
44-12 I:20/5 MOTOR HEATER CONTACTOR N.O./CLOSE/HEATERS ON
44-14 I:20/6 MAIN TRANSFORMER CONTACTOR N.O./CLOSE/OK
44-16 I:20/7 BOOM LIMIT SWITCH STAGE 2 N.C. HELD OPEN/OPEN/FAULT
44-22 I:20/8 BOOM LIMIT SWITCH STAGE 1 N.O. HELD CLOSED/CLOSE/FAULT
44-26 I:20/10 FIRE SUPPRESSION ZONE 1 SEE PLC PROGRAM
44-36 I:20/15 STROBE LIGHT SWITCH - RIGHT HAND TOGGLE/CLOSE/FLASH

CONSOLE
45-02 I:21/0 REMOTE HOIST CONTROL RAISE N.O./PUSH/RAISE


ADDRESS FUNCTION
45-04 I:21/1 REMOTE HOIST CONTROL LOWER N.O./PUS/LOWER
45-06 I:21/2 REMOTE HOIST STOP BUTTON CONTROL N.C./PUSH/STOP
45-08 I:21/3 REMOTE HOIST CONTROL HOIST BRAKES N.O./PUSH/RELEASE

RELEASE
45-10 I:21/4 REMOTE HOIST CONTROL HOIST BRAKES N.C./PUSH/SET

SET
45-12 I:21/5 REMOTE HOIST CONTROL ENABLE SELEC- SELECT/CLOSE/ENABLE

TOR
8.8 PLC OUTPUT DESTINATION AND WIRING CHECKS

FORCE AN INDIVIDUAL PLC OUTPUT; CHECK FOR PROPER DEVICE RESPONSE.
54-28 O:1.3/1 FRONT HOIST BLOWER MOTOR STARTER
54-30 O:1.3/2 REAR HOIST BLOWER MOTOR STARTER
54-32 O:1.3/3 FRONT SWING BLOWER MOTOR STARTER
54-34 O:1.3/4 REAR SWING BLOWER STARTER
54-36 O:1.3/5 FRONT SWING LUBE PUMP MOTOR

STARTER
54-38 O:1.3/6 REAR SWING LUBE PUMP MOTOR
STARTER
54-40 O:1.3/7 WINDSHIELD WIPER STARTER
55-06 O:1.4/2 CROWD BLOWER MOTOR STARTER
55-08 O:1.4/3 HOIST CONVERTER BLOWER MOTOR
55-10 O:1.4/4 SWING/CROWD CONVERTER BLOWER

MOTOR
55-14 O:1.4/6 RPC CAB. BLOWER 1/2-1 BANK
55-16 O:1.4/7 RPC BLOWER SWITCH
55-26 O:1.5/0 RPC CAB. BLOWER 2-3 BANK
55-28 O:1.5/1 HOIST LUBE PUMP STARTER
55-30 O:1.5/2 DIPPER TRIP MOTOR STARTER #2
55-32 O:1.5/3 DIPPER TRIP MOTOR STARTER #1


ADDRESS FUNCTION
55A-48 O:1.6/0 MAIN TRANSFORMER OVER CURRENT

RELAY
55A-52 O:1.6/1 MACHINERY HOUSE HEATER INTERLOCK-

ING
55A-56 O:1.6/2 CONTROL CABINET BLOWER STARTER
55A-60 O:1.6/3 MACH. HOUSE BLOWER #1 FORWARD
55A-64 O:1.6/4 MACH. HOUSE BLOWER #1 REVERSE
55A-68 O:1.6/5 MACH. HOUSE BLOWER #2 FORWARD
55A-70 O:1.6/6 MACH. HOUSE BLOWER #2 REVERSE
82-23 O:1.8/0 SYSTEM RUN INDICATOR LEFT COOP
82-25 O:1.8/1 PROPEL INDICATOR LEFT COOP
82-28 O:1.8/2 CONTROL FAULT INDICATOR
82-30 O:1.8/3 HOIST BRAKE INDICATOR RELEASED
82-33 O:1.8/4 CROWD BRAKE RELEASED INDICATOR
82-35 O:1.8/5 SWING BRAKE RELEASED INDICATOR
82-38 O:1.8/6 HOIST/CROWD INDICATOR LEFT COOP
82-40 O:1.8/7 ALL BRAKES SET INDICATOR
82-23 O:1.8/8 HOIST BRAKE SET INDICATOR
82-25 O:1.8/9 CROWD BRAKE SET INDICATOR
82-28 O:1.8/10 SWING BRAKE SET INDICATOR
82-30 O:1.8/11 BOARDING SIGNAL INDICATOR LEFT COOP
82-33 O:1.8/12 30 SEC DELAY SHUTDOWN ALARM
82-35 O:1.8/13 WARNING BUZZER LEFT COOP
82-38 O:1.8/14 BOARDING BUZZER LEFT COOP
82-40 O:1.8/15 ELAPSED TIME METER LH COOP
80-23 O:1.10/0 SYSTEM RUN INDICATOR RIGHT COOP
80-25 O:1.10/1 PROPEL INDICATOR OPER CAB
80-28 O:1.10/2 CONTROL FAULT INDICATOR
80-30 O:1.10/3 HOIST BRAKE RELEASED INDICATOR
80-33 O:1.10/4 CROWD BRAKE RELEASED INDICATOR
80-35 O:1.10/5 SWING BRAKE RELEASED INDICATOR
80-38 O:1.10/6 HOIST/ CROWD INDICATOR OPER CAB


ADDRESS FUNCTION
80-40 O:1.10/7 ALL BRAKES SET INDICATOR
80-23 O:1.10/8 HOIST BRAKE SET INDICATOR
80-25 O:1.10/9 CROWD BRAKE SET INDICATOR
80-28 O:1.10/10 SWING BRAKE SET INDICATOR
80-30 O:1.10/11 BOARDING SIGNAL INDICATOR
80-33 O:1.10/12 DELAY SHUTDOWN INDICATOR
80-35 O:1.10/13 WARNING BUZZER
80-38 O:1.10/14 BOARDING BUZZER
80-40 O:1.10/15 ELAPSED TIME METER RH COOP
61-02 O:2.2/0 DIPPER TRIP CONTACTOR 1
61-04 O:2.2/1 DIPPER TRIP CONTACTOR 2
61-26 O:2.3/0 CROWD FIELD CONTACTOR RELAY
61-28 O:2.3/1 PROPEL FIELD CONTACT RELAY
61-30 O:2.3/2 HOIST/CROWD ARM CONTACTOR
61-32 O:2.3/3 PROPEL ARM CONTACTOR
61-36 O:2.3/4 HOIST FIELD BREAKER SHUNT TRIP
61-38 O:2.3/5 SWING FIELD BREAKER SHUNT TRIP
61-40 O:2.3/6 CROWD/PROPEL FIELD BREAKER
58-02 O:2.3/2 HOIST DIVERTER CHARGING
58-04 O:2.11/1 SWING DIVERTER CHARGING
58-06 O:2.11/2 CROWD/PROPEL DIVERTER CHARGING
59-03 O:2.12/0 DIVERTER ENABLE
26-24 O:2.21/0 MOTOR HEATERS LOWER - RELAY
26-29 O:2.21/2 RIGHT PROPEL BRAKE SOLENOID
26-32 O:2.21/3 LEFT PROPEL BRAKE SOLENOID
26-35 O:2.21/4 AIR CABLE REEL SOLENOID
26-41 O:2.21/6 RIGHT PROPEL BLOWER MOTOR STARTER
26-42 O:2.21/7 LEFT PROPEL MOTOR BLOWER STARTER


ADDRESS FUNCTION
66-02 O:2.27/0 HOIST BRAKE SOLENOID LOCATED IN
66-04 O:2.27/1 SWING BRAKE SOLENOID LOCATED IN
66-06 O:2.27/2 CROWD BRAKE SOLENOID LOCATED IN
66-08 O:2.27/3 HOIST BRAKE EXHAUST SOLENOID 1
66-10 O:2.27/4 HOIST BRAKE EXHAUST SOL AT REAR

BRAKE
66-12 O:2.27/5 SWING BRAKE EXHAUST SOLENOID 1
66-14 O:2.27/6 SWING BRAKE EXHAUST SOLENOID 2
66-26 O:2.28/0 BRAKE SUPPLY RELAY
66-28 O:2.28/1 ALARM SILENCE LIGHT
66-30 O:2.28/2 REMOTE ALARM LUBE ALARM
67-02 O:2.29/0 UPPER LUBE GREASE SOLENOID
67-04 O:2.29/1 LUBE LOWER GREASE SOLENOID
67-06 O:2.29/2 OPEN GEAR LUBE SOLENOID
67-08 O:2.29/3 LUBE SPRAY SOLENOID
67-10 O:2.29/4 AIR COMPRESSOR DRAIN SOLENOID
67-12 O:2.29/5 UPPER LUBE INDICATOR
67-14 O:2.29/6 LOWER LUBE INDICATOR
67-16 O:2.29/7 OPEN GEAR LUBE INDICATOR
O:3.1 FACTOR TRANSDUCER #1

O:3.14 FACTOR TRANSDUCER #2
43-07 O:4.0 ANALOG OUT CH1 HOIST/ PROPEL REFER-

ENCE
43-11 O:4.1 ANALOG OUT CH2 SWING
43-015 O:4.2 ANALOG OUT CH3 CROWD
41-13 O:14/0 HOIST MOTION TIME METER
41-15 O:14/1 SWING MOTION TIME METER
41-17 O:14/2 CROWD MOTION TIME METER
41-19 O:14/3 PROPEL MOTION TIME METER


ADDRESS FUNCTION
41-21 O:14/4 UNDER VOLTAGE SENSOR ADJUSTABLE
41-41 O:14/14 PROPEL BRAKE AIR PRESSURE SWITCH
48-04 O:15/0 HOIST ARMATURE GATE DEBLOCK
48-08 O:15/2 BRAKE RELEASE SIGNAL TO HOIST AFM
48-10 O:15/3 HOIST PHASE ADVANCE
48-12 O:15/4 HOIST MODE SIGNAL TO HOIST AFM
48-14 O:15/5 PROPEL MODE SIGNAL TO HOIST AFM
48-16 O:15/6 HOIST AFM FAULT RESET
48-18 O:15/7 TEST MODE SIGNAL TO HOIST AFM
48-20 O:15/8 UNISON FIRE SIGNAL TO HOIST AFM
48-22 O:15/9 AUTOCAL SIGNAL TO HOIST AFM
48-24 O:15/10 LOW FIELD SIGNAL TO HOIST AFRM
48-26 O:15/11 HOIST CURRENT REGULATOR MODE

SELECT TO HOIST
44-28 O:15/12 HOIST STEP REF.
44-30 O:15/13 ARM TEST SIGNAL TO HOIST AFM
49-04 O:16/0 SWING ARMATURE GATE DEBLOCK
49-08 O:16/2 BRAKE RELEASE SIGNAL TO SWING AFM
49-10 O:16/3 SWING PHASE ADVANCE
49-14 O:16/5 PROPEL MODE SIGNAL TO SWING AFM
49-16 O:16/6 SWING AFM FAULT RESET
49-18 O:16/7 TEST MODE SIGNAL TO CROWD AFM
49-20 O:16/8 ARM TEST SIGNAL TO SWING AFM
49-22 O:16/9 AUTOCAL SIGNAL TO SWING AFM
49-24 O:16/10 SWING STEP REF.
49-24 O:16/11 SWING V-A RESPONSE SELECT SIGNAL TO
50-04 O:17/0 CROWD ARMATURE GATE DEBLOCK
50-08 O:17/2 BRAKE RELEASE SIGNAL TO CROWD
50-10 O:17/3 CROWD PHASE ADVANCE
50-12 O:17/4 HOIST MODE SIGNAL TO CROWD AFM


ADDRESS FUNCTION
50-14 O:17/5 PROPEL MODE SIGNAL TO CROWD AFM
50-16 O:17/6 CROWD AFM FAULT RESET
50-18 O:17/7 TEST MODE SIGNAL TO CROWD AFM
50-20 O:17/8 ARM TEST SIGNAL TO CROWD AFM
50-22 O:17/9 AUTOCAL SIGNAL TO CROWD AFM
50-24 O:17/10 LOW FIELD SIGNAL TO PROPEL AFM
50-26 O:17/11 CROWD CURRENT REGULATOR MODE

SELECT TO
50-28 O:17/12 CROWD STEP REF.
50-30 O:17/13 LOAD SHARE ENABLE AFM
51-04 O:18/0 HOIST FIELD GATING DEBLOCK
51-06 O:18/1 HOIST FIELD PHASE ADVANCE
51-08 O:18/2 SWING FIELD GATING DEBLOCK
51-10 O:18/3 SWING FIELD PHASE ADVANCE
51-12 O:18/4 CROWD/PROPEL FIELD GATING DEBLOCK
51-14 O:18/5 CROWD/PROPEL FIELD PHASE ADVANCE
51-16 O:18/6 FIELDS AFM FAULT RESET
51-18 O:18/7 FIELDS FORCE ON SIGNAL TO FIELD AFM
52-04 O:19/0 RPC NORMAL GATING DEBLOCK
52-14 O:19/5 MANUAL MODE SIGNAL TO RPC AFM
52-18 O:19/6 RPC AFM FAULT RESET
46-10 O:22/0 MAIN TRANSFORMER CONTACTOR
46-12 O:22/1 PROPEL BRAKE HORN 1
46-14 O:22/2 PROPEL BRAKE HORN 2
46-16 O:22/3 AIR HORN SOLENOID
46-18 O:22/4 REMOTE HOIST BRAKES RELEASED INDI-

CATING LITE
43A-60 O:23/4 ELECTRIC HORNS #1
43A-62 O:23/5 ELECTRIC HORN #2
43A-64 O:23/6 PROPEL STROBES RELAY


TEST DATA (PLC Supplement)

Electrotorque-Plus XPB and 4100 Shovels
TEST READINGS
TEST FUNCTION TEST SW. METER SW. TEST INST. TEST POINTS
SPECIFIED MEASURED
6.2.2 TRANSFORMER SEC. VOLTS.

VSEC=(VS Rated ÷ VP Rated) x VPRI
AUXILIARY SUPPLY AC DVM 02122-02123

AC DVM 02123-02124
AC DVM 02124-02122
CONTROL SUPPLY AC DVM 02221-02222

AC DVM 02222-02223
AC DVM 02223-02221
LIGHTING SUPPLY AC DVM 02361-02362

AC DVM 02362-02363
AC DVM 02363-02361
FIELD SUPPLY AC DVM 2272-2274

AC DVM 2274-2276
AC DVM 2276-2272
AC DVM 2271-2273
AC DVM 2273-2275
AC DVM 2275-2271
MAIN TRANSFORMER SEC. AC DVM 1L1-1L2

AC DVM 1L2-2L2
AC DVM 1L3-1L1
AC DVM 2L1-2L2
AC DVM 2L2-2L3
AC DVM 2L3-2L1
6.3.3 TRANSFORMER PHASE

RELATIONSHIP
( V sec 1 – V sec 2 )
Vdiff = ------------------------------------------
3
MAIN TRANSFORMER SECONDARY AC DVM 1L1-2L1 0V

AC DVM 1L2-2L2 0V
AC DVM 1L3-2L3 0V
CONTROL to MAIN AC DVM 2221-1L1

AC DVM 2222-1L2
AC DVM 2223-1L3
CONTROL to FIELD AC DVM 2221-2272
AC DVM 2222-2274
AC DVM 2223-2276
*** CONSULT SCHEMATICS <**> CONSULT SCHEMATICS

CAT312_2D.fm Appendix D - 1
TEST READINGS
SPECIFIED MEASURED
7.5 TRANSFORMER RATED CONTROL

SECONDARY VOLTAGES
AUXILIARY SUPPLY AC DVM 02122-02123 ***

AC DVM 02123-02124 ***
AC DVM 02124-02122 ***
CONTROL SUPPLY AC DVM 02221-02222 ***

AC DVM 02222-02223 ***
AC DVM 02223-02221 ***
208VAC SUPPLY AC DVM 02361-02362 ***

AC DVM 02362-02363 ***
AC DVM 02362-02361 ***
FIELD SUPPLY AC DVM 02271-02273 ***

AC DVM 02273-02275 ***
AC DVM 02275-02271 ***
AC DVM 02272-02274 ***
AC DVM 02274-02276 ***
AC DVM 02276-02272 ***
8.1 OPEN THE HIGH VOLTAGE CONTROL

ISOLATOR SWITCH
8.1.2 OPEN THE RELAY, CONTROL, &

PLC SUPPLY CIRCUIT BREAKERS
8.1.3 DISABLE EACH DIVERTER

CHARGING RELAY
8.1.4 CHECK EACH PLC INPUT and

OUTPUT FOR GROUNDS
8.2.1 CHECK 120VAC LIGHTING

SUPPLY [IF USED]
8.2.3 CLOSE THE 120V (110V) MAIN AC DVM 24101-01021

BREAKER - MB AC DVM 24102-01021
AC DVM 24103-01021
8.2.4 VERIFY 120V PLC OPERATION CONTROL AC DVM 24231-01021

AC DVM 2411-01021
8.2.5 CLOSE THE LOWER SUPPLY

CIRCUIT BREAKER - LSB AC DVM 24281-01021 ***
8.2.6 CLOSE THE DC CONTACTOR

SUPPLY BREAKER - DCSB DVM 24331-24371 100VDC
8.2.7 VERIFY ALL OF THE 120VAC

BRANCH CIRCUITS ***
8.3.1 CLOSE THE RELAY SUPPLY

CIRCUIT BREAKER - RSCB AC DVM 31071-1021 ***
AC DVM 31072-1021 ***
AC DVM 31073-1021 ***

Appendix D - 2 CAT312_2D.fm
TEST READINGS
SPECIFIED MEASURED
VERIFY E-STOP PUSHBUTTON

CONTROL
8.4.1 CLOSE THE 230V SUPPLY CONTROL

BREAKER - SB and THE CONTROL
SUPPLY BREAKER - CSB AC DVM 28111-28112 ***
AC DVM 28112-28113 ***
AC DVM 28113-28111 ***
- 28VDC DIVERTER SUPPLY DC DVM 29151-01021C 28VDC
- KVAR TRANSDUCER AC DVM 30081-30083 115VAC

AC DVM 30083-30084 115VAC
- CONSTANT VOLT. SUPPLY - CVMSB AC DVM 28382-01021C 120VAC

AC DVM 28383-01021C 120VAC
AC DVM 28384-01021C 120VAC
8.5 CHECK ALL OPTIONAL 120VAC

EQUIPMENT
8.6 VERIFY PLC COMMUNICATIONS
8.7 PLC INPUTS VERIFICATION USE

PLC I/O SCREEN ON GUI AND THE
SCHEMATICS
8.8 PLC OUTPUTS VERIFICATION

FORCE OUTPUTS USING THE
SCHEMATICS AS A GUIDE (OBSERVE
WARNINGS)
8.9 INSTALL REF./PUSHBUTTON UNIT
8.10 CLOSE THE SUPPRESSION

CIRCUIT BREAKERS
8.11 H/P & C/P TRANSFER CRKTS CONTROL
8.11.1 START
8.11.2 TRANSFER HC/P, P/HC CHECK THAT THE FIELD & ARMATURE CONTACTORS OPERATE
8.11.3 STOP
8.12 ANALOG I/O CHECKS CONTROL
8.12.1 START
8.12.2 RELEASE HOIST BRAKE

MONITOR HOIST PLC I/O
w/REFERENCE FULL POS + GUI +10V
w/REFERENCE FULL NEG - -10V
8.12.4 SET HOIST BRAKE

TEST READINGS
SPECIFIED MEASURED
8.12.5 RELEASE CROWD BRAKE

MONITOR CROWD PLC I/O
w/w/REFERENCE FULL POS + GUI +10V
REFERENCE FULL NEG - -10V
8.12.8 SET CROWD BRAKE
8.12.9 RELEASE SWING BRAKE

MONITOR SWING PLC I/O
w/REFERENCE FULL POS + GUI +10V
w/REFERENCE FULL NEG - -10V
8.12.12 SET SWING BRAKE STOP
8.12.13 CHECK ALL RTD GUI

MEASUREMENTS
8.13 CHECK CIRCUIT BREAKER RPC T.D. =

SETTINGS 300mS
CURRENT =
3X
9.0 AUXILIARIES TESTING
9.2 OPEN ALL AUXILIARY LOAD AUX

BREAKRES & MOTOR STARTER
BREAKERS
9.3 CLOSE THE MAIN AUXILIARY

BREAKER - ACCB
9.4 CHECK THE AUX VOLTMETER AC VM ***
9.5 AUX BRANCH CRKTS CHECKS
9.5.2 CHECK: OPTIONAL CIRCUITS

AIR CONDITIONER
ELECTRIC ZIP LIFT
HEATERS, ETC.
9.5.3 AIR COMPRESOR CHECK
9.5.4 AIR COMPRESSOR PRESSURE

SW. CHECKS
9.6 AUX MOTOR CHECKS AUX

CHECK EACH AUX MOTOR
INDIVIDUALLY FORPROPER
OPERATION AND ROTATION
9.6.4 TRANSFER TO PROPEL

CHECK PROPEL BLOWER OP.
9.6.6 STOP
9.6.7 CHECK THE DIPPER TRIP

SYSTEM

TEST READINGS
SPECIFIED MEASURED
9.7 CHECK THE AUX and FIELD

GROUND FAULT SYSTEMS
10.0 SWING FIELD CONTROL FIELD
10.1.1 OPEN FIELD CRKT. BRKRS.
10.1.4 CHECK “FLASH PROM” and FLASHPROM Version = ____________

“EEPROM” IDENTIFICATION EEPROM Version = ___________
10.2.1 CLOSE THE FOLLOWING C.B.’s:

- 120V Main Breaker [MB]
- Const. Volt PLC Supply [CVSB]
- D.C. Contactor Supply [DCSB]
- Relay Voltage Supply [RSB]
- 230V Supply [SB]
- Control Supply [CSB]
- Const. Volt. Module Supply [CVMSB]
- Synchronizing Supply [SSB]
10.2.2 MEASURE THE FOLLOWING FIELD

SUPPLY VOLTAGES: AC DVM TB1-1 to TB1-2 120VAC
- 120VAC SUPPLY AC DVM P11-1 to P11-16 230VAC
- 230VAC, 3Ph., SYNC SUPPLY AC DVM P11-16 to P11-3 230VAC
- 42VDC GATE SUPPLY P11-13(+) to 42VDC

DC DVM P11-14(-)
10.3 AFM SOFTWARE
10.3.2 CHECK SOFTWARE VERSION E007 SWR VER = __________
10.4 AFM TESTING
10.4.1 MEASURE THE AFM FIELD DC DVM TP1 (ACOM) to -7.0VDC

REFERENCE SUPPLY TP2 (VREF)
10.4.2 SET THE DRIVE V-REF X000:I/O V-REF

PARAMETER
10.4.3 RESET THE DRIVE
10.4.4 VERIFY: EMERG STOP OK and

DRIVE READY LED’s ARE ON
10.4.5 CALCULATE VALUE EXPECTED Vfb = lfld ÷ C.T. ratio x Rfb CALC =
ACROSS Rfb
10.4.6 CLOSE THE SWING FIELD FIELD SWING

CIRCUIT BREAKER
10.4.7 SWING FIELD = 0A PNL MTR 0A
10.4.8 START

TEST READINGS
SPECIFIED MEASURED
10.4.9 VERIFY CORRECT CURRENT PNL MTR <**>

LEVEL ON PANEL METER
10.5.1 CHECK THAT VfB EQUALS THE DC DVM Fb RESISTOR <**>

VALUE CALCULATED
10.5.2 CURRENT WAVEFORMS - FIELD RECORDER SW FLD TEST Figure 10.5.2

START, STOP, START, STOP CH1 JACKS
10.5.4 VOLTAGE WAVEFORMS O’SCOPE 14301-14162 Figure 10.5.4
10.5.5 STOP
OPEN THE SWING FIELD BRKR.
11.0 C/P FIELD CONTROL FIELD
11.1.4 CHECK “FLASH PROM” and FLASHPROM Version =___________

“EEPROM” IDENTIFICATION EEPROM Version =___________
11.2.1 CLOSE THE FOLLOWING C.B.’s

- 230V Supply [SB]
11.2 SUPPLY VOLTAGES FIELD

- 120VAC SUPPLY AC DVM TB1-1 to TB1-2 120VAC
AC DVM P11-16 to P11-3 230VAC
P11-13(+) to
- 42VDC GATE SUPPLY DC DVM P11-14(-) 42VDC
11.3 AFM SOFTWARE
11.3.2 CHECK SOFTWARE VERSION E007 SWR VER =__________
11.4 AFM TESTING


PARAMETER


TEST READINGS
SPECIFIED MEASURED
ACROSS Rfb
11.4.6 CLOSE THE C/P FIELD CIRCUIT FIELD C/P

BREAKER
11.4.7 C/P FIELD = 0A PNL MTR 0A
11.4.8 START


VALUE CALCULATED
11.5.3 VERIFY PROPEL CURRENT PNL MTR <**>
11.5.4 FORCE STRONG FIELD PNL MTR <**>
11.5.5 CURRENT WAVEFORMS - FIELD RECORDER C/P FLD TEST Figure 11.5.5
START, PROPEL, STRONG, CROWD, CH1 JACKS
STOP
11.5.8 STOP
OPEN THE C/P FIELD BRKR.
12.0 HOIST FIELD CONTROL FIELD


- 230V Supply [SB]
12.2.2 MEASURE THE FOLLOWING FIELD

SUPPLY VOLTAGES:
- 42VDC GATE SUPPLY DC DVM P11-13(+) to 420VDC

P11-14(-)

TEST READINGS
SPECIFIED MEASURED
12.3 AFM SOFTWARE
12.3.2 CHECK SOFTWARE VERSION E007 SWR VER =___________
12.4 AFM TESTING


PARAMETER

ACROSS Rfb
12.4.6 CLOSE THE HOIST FIELD FIELD HOIST

CIRCUIT BREAKER
12.4.7 HOIST FIELD = 0A PNL MTR 0A
12.4.8 START


VALUE CALCULATED
12.5.2 FORCE STRONG FIELD PNL MTR <**>
12.5.3 CURRENT WAVEFORMS FIELD RECORDER HOIST FLD Figure 12.5.3

- START, STRONG, WEAK, STOP CH1 TEST JACKS
12.5.6 STOP
OPEN THE HOIST FIELD BRKR.
13.0 HOIST ARMATURE CONTROL CONTROL
13.1.2 OPEN RPC CRKT. BRKRS.

OPEN “CSB” and “CVMSB”
13.1.3 CONNECT CURRENT LIMITING 6166

RESISTOR
13.1.4 INSTALL REF/PB UNIT
13.1.5 CHECK “FLASH PROM” and FLASHPROM Version =_____________

“EEPROM” IDENTIFICATION EEPROM Version =____________
13.1.6 GATE CIRCUIT RESISTANCE CONTROL DVM 50 OHMS

TEST READINGS
SPECIFIED MEASURED
P9-1 to P9-2 P9-3 to P9-4 P9-5 to P9-6 P9-9 to P9-10



- 230V Supply [SB]

- 42VDC GATE SUPPLY P11-13(+) to
DC DVM P11-14(-) 42VDC
13.3 AFM SOFTWARE
13.3.2 CHECK SOFTWARE VERSION E007 SWR VER= ___________

13.4 AFM TESTING
13.4.1 MEASURE THE AFM CONTROL DC DVM TP1 (ACOM) to -7.0VDC


PARAMETER

13.5 AUTOCAL PROCEDURE CONTROL

- GO TO “AFM TEST SCREEN”
- START
- HOIST BRAKE RELEASE
- FULL POS(+) REFERENCE
- HOIST AUTOCAL ON
- HOIST AUTOCAL OFF
- FULL NEG(-) REFERENCE
- HOIST AUTOCAL ON
- HOIST AUTOCAL OFF

TEST READINGS
SPECIFIED MEASURED
13.5.7 CONFIRM AUTOCAL

- CHECK DRIVE PARAMETER A066
- w/FULL POS(+) REFERENCE A066 +100%
- w/FULL NEG(-) REFERENCE A066 -100%
13.5.8 STOP
PRESS DRIVE “S” KEY TWICE
13.6 THYRISTOR PULSE SEQUENCE CONTROL

- START
- HOIST BRAKE RELEASE ARM SCR’s Figure 13.6
- FULL POS(+) REFERENCE O’SCOPE G to K Figure 13.6
- FULL NEG(-) REFERENCE O’SCOPE G to K
13.6.4 THYRISTOR PULSE CHECKS CONTROL

- PROPEL O’SCOPE
- H1 PULSES BLOCKED ARM SCR’s
- H2 PULSES PRESENT H1 & H2
- HOIST/CROWD O’SCOPE ARM SCR’s
- H1 PULSES REAPPEAR H1 & H2
13.6.6 STOP
13.7 HOIST VOLTAGE CONTROL

- DISABLE OPEN SCR TEST Y058 D087
- CONNECT A DVM ACROSS THE DC DVM ACROSS ARM 1kV RANGE
SERIES ARM. RESISTOR RESISTOR
- REMOVE DIFF. V. RELAY
- CLOSE H.V. DISCONNECT
- SET HOIST REFERENCE to 0V ARM
13.7.6 START
13.7.7 CHECK ARM. RES. VOLTAGE DC DVM ACROSS ARM 0V

R

- REFERENCE POS(+) DC DVM ACROSS ARM +
- CHECK VAfb R ARM V TEST -
PTS
13.7.9
- REFERENCE NEG(-) DC DVM ACROSS ARM -
- CHECK VAfb R ARM V TEST +
PTS
13.8 HOIST REF FULL POS(+)

- CHECK IAfb DC DVM P11-10 to P11-8
13.8.2 HOIST REF FULL NEG(-)

13.8.3 HOIST REF TO 0V

STOP
13.8.4 REMOVE THE SERIES LIMITING

RESISTOR

TEST READINGS
SPECIFIED MEASURED
13.9 ARM. CURRENT RESPONSE ARM HOIST

- CONNECT CHART RECORDER RECORDER ARM I TEST
PTS
13.9.2 ON THE GUI: HOIST

PRESS THE HOIST CURRENT REGU-
LATOR MODE PB
START
- RELEASE HOIST BRAKE
- SET ARM. CURRENT to 500A
13.9.3 PRESS THE STEP REFERENCE RECORDER ARM I TEST Figure 13.9
PB and RECORD THE IAfb CHAN1 PTS
13.9.5 STOP
13.10 STALL CURRENT

- CHECK DRIVE PARAMETER A004 ARM HOIST
- MEASURE IAfb DC DVM ARM I TEST
PTS
13.10.3 CALCULATE Vfb

I stall ÷ 300 = V test jacks CALC =_______________
13.10.4 SET REFERENCE TO 0V

- START ARM HOIST
13.10.7 HOIST REFERENCE to FULL+

5 SEC MAX
- CHECK DRIVE PARAMETER A004 <**> A004 =____________
PTS

- WAIT ONE MINUTE
13.10.10 HOIST REFERENCE to FULL -

5 SEC MAX
PTS

- WAIT ONE MINUTE
13.10.12 HOIST REFERENCE to FULL +

5 SEC MAX
- CHECK ANALOG PANEL METER PNL MTR <**>
13.11 VOLTAGE CONTROL - RUN RUN

- DISABLE RPC SHUTDOWN
“FORCE: RCBS OFF)
13.11.2 INSTALL RELAY in DVAH

TEST READINGS
SPECIFIED MEASURED
13.11.4 CLOSE FIELD CRKT BRKR
13.11.5 HOIST REFERENCE to 0V

- START
13.11.7 CHECK HOIST MOTION

CONTROL - POS & NEG (<50%)
13.11.8 SET HOIST BRAKES

STOP
13.12 CONVERTER PHASE FAULT RUN

DETECTION
- REMOVE INPUT LEAD (HOIST #1)
- START
- SHUTDOWN SHOULD OCCUR
- REPEAT FOR (HOIST #2)
- STOP
13.13 DIVERTER CRKT CHECKS CONTROL
13.13.3 CHECK/ADJ/28V SUPPLY
13.13.4 START
13.13.5 CHECK “READY” LIGHT “READY” ON

LIGHT
13.13.6 CHECK THE “DE-BLOCK” LED DE-BLOCK ON

ON THE HOIST AFM LED
ALSO CHECK PULSE TRANSFORMER PULSE XFMR ON
LED’S LED’S
13.13.7 SHORT GATE BLOCK CRKT

(SHORT TB2-9 to TB2-10)
13.13.8 CHECK THE PULSE TRANS- PULSE XFMR OFF

FORMER LED’S LED’S
13.13.9 STOP
- REMOVE SHORTING JUMPER
13.14 DIVERTER I SENSOR CHECKS ARM HOIST DIVERTER

- CONNECT DVM DC DVM MOD TP2(-) to
TP3(+)
13.14.3 START
- STALL HOIST (+)
- READ METER DC DVM TP2(-) to
STOP TP3(+)
13.14.4 METER SHOULD READ: TP2(-) to CALC ± 0.5V

VOLTS = IA stall ÷ 300 TP3(+)

TEST READINGS
SPECIFIED MEASURED
13.15 DIVERTER CAP CHECKS CONTROL

- RECONNECT CAP CHG CRKT REF 8.1.3
- CONNECT DVM ACROSS H1 CAPS DC DVM 6302(+) to
DANGER - READ TEXT!! 6166(-)
13.15.3 MANUALLY CLOSE THE CONTROL

CHARGING RELAY CONTACTS
- READ THE DVM DC DVM 6302(+) 6166(-) >900VDC
- RELEASE RELAY CONTACTS @
ABOUT 900 VDC
- CHECK CAP VOLT DECAY DC DVM <50V in
DANGER - READ TEXT!! 30SEC
13.15.6 REPEAT FOR H2

- CHECK CAP VOLT DECAY DC DVM 7301(+) 7161(-) >900VDC
<50V in
30SEC
13.16 CHECK DIVERTER CONTROL

- ADJUST TRIP SETPOINT ARM DC DVM TP1(+) to TP2(-) 2.1VDC
- DVM to DIVERTER OUTPUT TP3(+) to TP2(-)
- START ARM
- SLOWLY INCREASE REF (+) UNTIL
SHUTDOWN OCCURS
- DVM READING AT SHUTDOWN DC DVM TP3(+) to TP2(-) 3.5VDC
- CAP DISCHG AT SHUTDOWN DC DVM 6302(+) 6166(-) 0VDC < 5SEC
7301(+) 7161(-) 0VDC < 5SEC
13.16.9 STOP
13.16.10 ADJUST CURRENT TRIP

- SET TRIP LEVEL FULL CW ARM
- START
13.16.14 SET HOIST REF FULL +

5 SEC MAX
- REDUCE TRIP SETPOINT UNTIL
SHUTDOWN OCCURS
13.16.15 MEASURE TRIP LEVEL DC DVM TP1(+) TP2(-)
13.16.16 READJUST SETPOINT:

DVM reading [13.16.16] x 1.4 = DC DVM TP1(+) TP2(-) ADJ per
CALC
13.17 RUN FROM OP COOP

- REMOVE REF/PB UNIT
- RECONNECT PLC/COOP CABLES

TEST READINGS
SPECIFIED MEASURED
13.17.2 REPEAT AUTOCAL CONTROL

- START
- HOIST BRAKE RELEASE
- FULL POS (+) REFERENCE
- HOIST AUTOCAL ON
- HOIST AUTOCAL OFF
- FULL NEG (-) REFERENCE
- HOIST AUTOCAL ON
- HOIST AUTOCAL OFF

- w/FULL POS (+) REFERENCE A066 +100%
- w/FULL NEG (-) REFERENCE A066 -100%
13.17.10 STOP
13.17.10 TEST SELECTOR TO RUN RUN HOIST

- START
- RELEASE HOIST BRAKES
13.17.13 CHECK MOTOR ROTATION

- STOP
13.18 VOLTAGE RESPONSE RUN HOIST RECORDER }

- CONNECT CHART RECORDER CHAN. 1 ARM V TST PTS
CHAN. 2 ARM I TST PTS
13.18.3 CHECK MOTOR VOLTS AT FULL RUN HOIST 6166 - 7166 <**>
SPEED HOIST & LOWER
13.18.3.1 ADJUST SCALE FACTOR X003

(X004 PPL)
13.18.5 RECORD HOIST OPERATION RECORDER

VAfb _____ CHAN. 1 ARM V TST PTS Figure
IAfb _____ CHAN. 2 ARM I TST PTS 13.18.4
13.18.6 S-L-O-W-L-Y OPERATE THE RUN HOIST

HOIST MOTION FROM THE
OPERATOR’s COOP
- APPLY STEP REF WHILE RECORDER
RECORDING CHAN. 1 ARM V TST PTS Figure
CHAN. 2 ARM I TST PTS 13.18.6
13.18.7 SET DIPPER ON GROUND

STOP
13.19 CHECK FIELD WEAKENING RUN HOIST RECORDER

- RECONNECT RECORDER
CHAN. 2 TO THE FIELD CURRENT CHAN. 2 CUR REG: TP6
REGULATOR

TEST READINGS
SPECIFIED MEASURED
13.19.1 RAISE & LOWER THE EMPTY RECORDER Figure

DIPPER AT FULL SPEED WHILE CHAN. 1 VOLT REG: 13.19.1
RECORDING TP18
CHAN. 2 CUR REG: TP6

STOP
13.20 CHECK VAfb @ DIVERTER RUN HOIST

- RUN HOIST & LOWER AT FULL DC DVM TB1-4 to TB1-5
SPEED

STOP
13.21 NUISANCE TRIPPING ADJUST REF

13.16.12
13.22 REMOVE ALL “FORCES” Y058 D149

OPEN FIELD CRKT BRKRS
ENABLE OPEN SCR TEST
14.0 CROWD/PROPEL ARMATURE CONTROL
CONTROL


RESISTOR



- 230V Supply [SB]

TEST READINGS
SPECIFIED MEASURED

14.3 AFM SOFTWARE
14.4 AFM TESTING


PARAMETER


- START
- CROWD BRAKE RELEASE
- CROWD AUTOCAL ON
- CROWD AUTOCAL OFF
- CROWD AUTOCAL ON
- CROWD AUTOCAL OFF

14.5.8 STOP

- START
- CROWD BRAKE RELEASE ARM SCR’s Figure 14.6
14.6.4 STOP
14.7 CROWD VOLTAGE CONTROL

- SET CROWD REFERENCE to 0V ARM

TEST READINGS
SPECIFIED MEASURED
14.7.5 START

R

PTS
14.7.8
- REFERENCE NEG(-) DC DVM ACROSS ARM -
- CHECK VAfb R ARM V TEST +
PTS
14.8 CROWD REF FULL POS(+)

14.8.2 CROWD REF FULL NEG(-)

14.8.3 CROWD REF TO 0V

STOP

RESISTOR
14.9 ARM. CURRENT RESPONSE ARM CROWD

PTS
14.9.2 ON THE GUI:

PRESS THE CROWD CURRENT
REGULATOR MODE PB
START CROWD
- RELEASE CROWD BRAKE
14.9.3 ON THE GUI:

PRESS THE STEP REFERENCE PB and RECORDER ARM I TEST Figure 14.9
RECORD THE IAfb CHAN1 PTS
14.9.5 STOP
14.10 STALL CURRENT

- CHECK DRIVE PARAMETER A004 ARM CROWD
PTS

14.10.5 SET REFERENCE TO 0V ARM CROWD

- START

TEST READINGS
SPECIFIED MEASURED
14.10.7 CROWD REFERENCE to FULL+

5 SEC MAX
PTS

- WAIT ONE MINUTE
14.10.10 CROWD REFERENCE to

FULL -
5 SEC MAX <**> A004 =____________
- CHECK DRIVE PARAMETER A004 DC DVM ARM I TEST
- MEASURE IAfb PTS

- WAIT ONE MINUTE
14.10.12 CROWD REFERENCE to

FULL +
5 SEC MAX PNL MTR <**>
- CHECK ANALOG PANEL METER
14.11 PROPEL STALL CURRENT ARM

14.11.3 CROWD REFERENCE to FULL +

5 SEC MAX
- CHECK DRIVE PARAMETER A004 <**> A004 = ____________
PTS
14.11.4 TRANSFER TO H/C

- WAIT ONE MINUTE

- CROWD REFERENCE to FULL -
5 SEC MAX
PTS
14.11.9 STOP
14.12 PROPEL STALL CURRENT ARM


TEST READINGS
SPECIFIED MEASURED
14.12.3 HOIST REFERENCE to FULL +

5 SEC MAX
- CHECK DRIVE PARAMETER A004 <**> A004 = ____________
PTS

- WAIT ONE MINUTE

- HOIST REFERENCE to FULL -
5 SEC MAX
PTS
14.12.9 STOP

“FORCE: RCBS OFF)
14.13.4 CROWD REFERENCE to 0V

- START
14.13.6 CHECK CROWD MOTION

14.13.7 SET CROWD BRAKES

STOP

DETECTION
- REMOVE INPUT LEAD
- START
- STOP
14.15.4 START

LIGHT

ON THE CROWD AFM LED
LED’s LEDs

TEST READINGS
SPECIFIED MEASURED


FORMER LED AT THE CONVERTER LED
14.15.9 STOP
14.16 DIVERTER I SENSOR CHECKS ARM CROWD DIVERTER

TP3(+)
14.16.3 START
- STALL CROWD (+)
STOP TP3(+)


- CONNECT DVM ACROSS FWD DC DVM 11291(+) to
BRIDGE CAPS 11161(-)
DANGER - READ TEXT!!
- READ THE DVM DC DVM 11291(+) >900VDC
- RELEASE RELAY CONTACTS @ 11161(-)
ABOUT 900 VDC
14.17.6 REPEAT FOR REV BRIDGE

CAPS DC DVM 11161(+) >900VDC
- CHECK CAP VOLT DECAY 11321(-) <50V in
30SEC

- START ARM
SHUTDOWN OCCURS
- CAP DISCHG AT SHUTDOWN DC DVM 11291(+) 0VDC < 5SEC
11161(-)
11161(+) 0VDC < 5SEC
11321(-)
14.18.9 STOP

TEST READINGS
SPECIFIED MEASURED

- START
14.18.14 SET CROWD REF FULL +

5 SEC MAX
SHUTDOWN OCCURS

CALC


- START
- CROWD BRAKE RELEASE
- CROWD AUTOCAL ON
- CROWD AUTOCAL OFF
- CROWD AUTOCAL ON
- CROWD AUTOCAL OFF
14.19.10 STOP
14.19.11 TEST SELECTOR TO RUN RUN CROWD

- START
- RELEASE CROWD BRAKES

- STOP
14.20 VOLTAGE RESPONSE RUN CROWD RECORDER

14.20.3 CHECK MOTOR VOLTS AT FULL RUN CROWD 11166 - 11372 <**>
SPEED CROWD & RETRACT

(X004 PPL)

TEST READINGS
SPECIFIED MEASURED
14.20.4 RECORD CROWD OPERATION RECORDER

14.20.6 S-L-O-W-L-Y OPERATE THE RUN CROWD

CROWD MOTION FROM THE
OPERATOR’s COOP
- APPLY STEP REF WHILE RECORDER
RECORDING CHAN. 1 ARM V TST PTS Figure
CHAN. 2 ARM I TST PTS 14.20.6

STOP
14.21 VOLTAGE RESPONSE, PROPEL RUN CROWD RECORDER

(HOIST VAFB)
(CROWD VAFB)
14.21.2 START
PROPEL
14.21.3 RECORD VAFB WHILE RUN PROPEL RECORDER

ALTERNATING FULL POSITIVE CHAN. 1 ARM V TST PTS Figure
AND NEGATIVE FEEDBACK (HOIST VAFB) 14.21.3
(CROWD VAFB)
14.21.4 STOP
14.22 CHECK DIVERTER VAfb IN RUN CROWD

- RUN CROWD & RETRACT AT FULL DC DVM TB1-4 to TB1-5
SPEED

14.18.11
14.24 REMOVE ALL “FORCES”

ENABLE OPEN SCR TEST Y058 D149
15.0 SWING ARMATURE CONTROL CONTROL


RESISTOR
15.1.5 CHECK “FLASH PROM” and FLASHPROM Version =____________


TEST READINGS
SPECIFIED MEASURED


- 230V Supply [SB]

15.3 AFM SOFTWARE
15.4 AFM TESTING


PARAMETER


- START
- SWING BRAKE RELEASE
- SWING AUTOCAL ON
- SWING AUTOCAL OFF
- SWING AUTOCAL ON
- SWING AUTOCAL OFF


TEST READINGS
SPECIFIED MEASURED
15.5.8 STOP

- START
- SWING BRAKE RELEASE ARM SCR’s Figure 15.6
15.6.4 STOP
15.7 SWING VOLTAGE CONTROL

- REMOVE DIFF. V. RELAY
- SET SWING REFERENCE to 0V ARM
15.7.6 START

R

PTS
- REFERENCE NEG(-) DC DVM

- CHECK VAfb ACROSS ARM -
R ARM V TEST +
PTS
15.8 SWING REF FULL POS(+)

15.8.2 SWING REF FULL NEG(-)

15.8.3 SWING REF TO 0V

STOP

RESISTOR
15.9 ARM. CURRENT RESPONSE ARM SWING

PTS
15.9.2 ON THE GUI:

PRESS THE SWING CURRENT REGU-
LATOR MODE PB
START SWING
- RELEASE SWING BRAKE

TEST READINGS
SPECIFIED MEASURED
15.9.3 ON THE GUI:

PRESS THE STEP REFERENCE PB and RECORDER ARM I TEST Figure 15.9
RECORD THE IAfb CHAN1 PTS
15.9.4 STOP
15.10 STALL CURRENT

- CHECK DRIVE PARAMETER A004 ARM SWING
PTS

15.10.4 SET REFERENCE TO 0V

- START ARM SWING
15.10.7 SWING REFERENCE to FULL+

5 SEC MAX
PTS
15.10.8 SET SWING BRAKE

- WAIT ONE MINUTE
15.10.10 SWING REFERENCE to FULL -

5 SEC MAX
PTS

- WAIT ONE MINUTE
15.10.12 SWING REFERENCE to FULL +

5 SEC MAX
- CHECK ANALOG PANEL METER PNL MTR <**>

(“FORCE” RCBS OFF)
15.11.4 SWING REFERENCE to 0V

- START
15.11.6 CHECK SWING MOTION

15.11.7 SET SWING BRAKES

STOP

TEST READINGS
SPECIFIED MEASURED

DETECTION
- REMOVE INPUT LEAD
- START
- STOP
15.13.4 START

LIGHT

ON THE SWING AFM LED
LED’S LED’S


FORMER LED’S AT THE CONVERTER LED’S
15.13.9 STOP
15.14 DIVERTER I SENSOR CHECKS ARM SWING DIVERTER

TP3(+)
15.14.3 START
- STALL SWING (+)
STOP TP3(+)


- CONNECT DVM ACROSS FWD DC DVM 09313(+) to
BRIDGE CAPS 09166(-)
- READ THE DVM DC DVM 09313(+) >900VDC
- RELEASE RELAY CONTACTS @ 09166(-)
ABOUT 900 VDC

TEST READINGS
SPECIFIED MEASURED
15.15.6 REPEAT FOR REV BRIDGE

CAPS
- CHECK CAP VOLT DECAY DC DVM 09166(+) >900VDC
09343(-) <50V in
30SEC

- START ARM
- REALSE HOIST BRAKE
SHUTDOWN OCCURS
- CAP DISCHG AT SHUTDOWN DC DVM 09313(+) 0VDC < 5SEC
0966(-)
09166(+) 0VDC < 5SEC
09343(-)
15.16.9 STOP

- START
15.16.14 SET SWING REF FULL +

5 SEC MAX
SHUTDOWN OCCURS

CALC


- START
- SWING BRAKE RELEASE
- SWING AUTOCAL ON
- SWING AUTOCAL OFF

- SWING AUTOCAL ON
- SWING AUTOCAL OFF

TEST READINGS
SPECIFIED MEASURED

15.17.10 STOP
15.17.11 TEST SELECTOR TO RUN RUN SWING

- START
- RELEASE SWING BRAKES

- STOP
15.18 VOLTAGE RESPONSE RUN SWING RECORDER }

15.18.3 CHECK MOTOR VOLTS AT FULL
SPEED RIGHT & LEFT RUN SWING 09161 - 09393 <**>
15.18.4 RECORD SWING OPERATION RECORDER


STOP
15.19 CHECK DIVERTER VAfb in RUN

SWING RIGHT & SWING LEFT AT FULL
SPEED

15.16.11
15.21 REMOVE ALL “FORCES”

ENABLE OPEN SCR TEST Y058 D149
16.0 REACTIVE POWER COMPENSA-
TOR
16.1.2 OPEN “CSB” and “CVMSB” CONTROL
16.1.3 OPEN RPC CIRCUIT BREAKERS
16.1.5 CHECK “FLASH PROM” and FLASHPROM Version =____________


TEST READINGS
SPECIFIED MEASURED


- 230V Supply [SB]

16.3 AFM SOFTWARE
16.4 AFM TESTING
16.4.1 MEASURE THE AFM CONTROL DC DVM TP1 (ACOM) to

REFERENCE SUPPLY TP2 (VREF) -7.0VDC

PARAMETER

16.5 LEVEL DETECTOR CHECKS
16.5.1 SET KVAR POTENTIOMETER TO DC DVM P9-16(+)

ZERO P9-17(-)
16.5.2 PRESS START CONTROL

ON THE GUI, AT THE AFM TEST
SCREEN:
PRESS RPC MANUAL MODE TOUCH
BUTTON
16.5.3 SLOWLY INCREASE MANUAL

KVAR REFERENCE UNTIL FIRST
GREEN LED (STEP 1)
RECORD READING DC DVM P9-16(+) **
P9-17(-)

TEST READINGS
SPECIFIED MEASURED
16.5.4 RECORD ALL STEPS V-LEV1

V-LEV2
V-LEV3
16.5.5 REDUCE MANUAL REFERENCE V-LEV4
TO ZERO V-LEV5
V-LEV6
V-LEV7
16.6 RPC FIRING CHECKS CONTROL
16.6.1 SLOWLY INCREASE MANUAL

KVAR REFERENCE UNTIL FIRST LED
(STEP 1) ILLUMINATES
16.6.2 CONNECT OSCILLOSCOPE O-SCOPE RPC SCR’s Figure 16.6

COMPARE FIRING PULSES G to K
1/2 BANK
16.6.3 CONTINUE TO INCREASE REF- BANK 1

ERENCE UNTIL ALL BANKS CHECKED BANK 2
BANK 3
16.7 RPC OP. WITH CAPACITOR TEST

UNIT
16.7.1 MANUAL KVAR REFERENCE

SET TO ZERO
ALL RPC BREAKERS ARE OPEN
16.7.2 CONNECT CAPACITOR TEST Figure 2.2.4 Figure 16.7.2

UNIT CAP. UNIT 1/2 BANK
16.7.3 SHORT CAP. BANKS
16.7.4 ARMATURE TEST ARM DC DVM MS1 to

(1kV) RBC
16.7.5 CONNECT METER

16.7.6 PRESS START MS1 to 800V
RBC
MS2 to 800V
RCC
MS3 to 800V
RAC
16.7.10 PRESS STOP

TEST READINGS
SPECIFIED MEASURED
16.7.11 CONNECT RECORDER RECORDER ACROSS 10

DANGER - READ TEXT OHM PHASE
- START “A”
- USING THE REF, TURN STEP ON & ARM Figure
OFF RAPIDLY 16.7.13
- STOP
REPEAT FOR PHASE “B” ACROSS 10 Figure
OHM PHASE 16.7.13
“B”
REPEAT FOR PHASE “C” ACROSS 10 Figure
OHM PHASE 16.7.13
“C”
16.7.15 PRESS STOP

16.7.16 REPEAT 16.7.1 through 16.7.15 RECORDER 10 OHM Figure
FOR BANK 1 “A” PHASE 16.7.13
“B” PHASE
“C” PHASE
REPEAT 16.7.1 through 16.7.15 FOR RECORDER 10 OHM Figure

BANK 2 “A” PHASE 16.7.13
“B” PHASE
“C” PHASE
REPEAT 16.7.1 through 16.7.15 FOR RECORDER 10 OHM Figure

BANK 3 “A” PHASE 16.7.13
“B” PHASE
“C” PHASE
16.7.19 REMOVE JUMPERS AND

CAPACITOR TEST UNIT
16.8 RPC POWER TESTS
16.8.1 ARMATURE TEST ARM
16.8.2 CONNECT A RECORDER w/ RECORDER ACROSS

VOLTAGE DIVIDER CHAN.1 CAPS
DANGER - READ TEXT!! PHASE “A”
16.8.3 CLOSE 1/2 STEP RPC CIRCUIT

BREAKER
16.8.4 START RECORDER (5S/DIV) RECORDER ACROSS Figure 16.8.5

START MACHINE CHAN. 1 CAPS
PHASE “A”
16.8.8 INCREASE RECORDER SPEED RECORDER ACROSS Figure

(100mS/DIV) CHAN. 1 CAPS 16.8.9
- STEP REF. ON & OFF PHASE “A”
16.8.11 STOP

TEST READINGS
SPECIFIED MEASURED
16.8.12 REPEAT 16.8.4 thru 16.8.11 FOR RECORDER ACROSS Figure 16.8.5
PHASE “B” CAPS CHAN. 1 CAPS & 16.8.9
PHASE “B”
PHASE “C” CAPS CHAN. 1 CAPS PHASE & 16.8.9
“C”
16.8.14 OPEN 1/2 STEP RPC BRKR. ARM

CLOSE BANK 1 RPC CRKT BRKR
BANK 1 CAPS CHAN. 1 CAPS PHASE & 16.8.9
“A,B,C”
16.8.16 OPEN BANK 1 RPC BRKR. ARM

REPEAT 16.8.4 thru 16.8.13 FOR BANK 2

CAPS
OPEN BANK 2 RPC BRKR. ARM
REPEAT 16.8.4 thru 16.8.13 FOR BANK 3 RECORDE ACROSS Figure 16.8.5
CAPS R CHAN. 1 CAPS PHASE & 16.8.9
“A,B,C”
16.8.17 STOP
16.9 RPC POWER MEASUREMENTS ARM
16.8.1 OPEN ALL RPC BREAKERS

CONNECT A DVM TO KVAR XDUCER DC DVM XDUCER: T1 -
VQ OUTPUT T2
CONNECT A DVM TO kVAR XDUCER AC DVM XDUCER: T3 -
AC INPUT T4
16.9.2 START
RELEASE CROWD BRAKE
CAUTION! - READ TEXT
FULL CROWD REF (+)
RECORD DVM READINGS DVM XDUCER: T1 -
T2
DVM XDUCER: T3 -
T4
16.9.5 CROWD REF to 0V

STOP
16.9.6 CALCULATE EXPECTED VQ

OUTPUT
VQ = 0.000000141 x VAC x IAstall CALC VQ =
MEASURED = CALC VQ ± 0.002VDC
16.10 RPC OPERATION, FULL POWER
16.10.1 CLOSE ALL RPC BREAKERS ARM

TEST READINGS
SPECIFIED MEASURED
16.10.2 START
RELEASE HOIST & CROWD BRAKES
CAUTION! - READ TEXT
STALL HOIST, THEN ADD CROWD RPC 1/2 BANK
WHILE MONITORING THE STEP RPC INDICATORS BANK 1
INDICATORS BANK 2
BANK 3
SET BRAKES
STOP
16.11.1 REMOVE ALL PLC FORCES
16.11.2 REMOVE ALL TEST EQUIP


MODELS 2800XPB, 4100A, 4100TS READER
ELECTROTORQUE PLUS® TEST PROCEDURES COMMENT
BULLETIN NUMBER: CATALOG 312-2 FORM
To assist us in providing you, the user, with the most useful publications, we ask that you use this form to
express your views concerning this publication, its organization or subject matter, with the understanding
that Harnischfeger may use or distribute whatever information you supply in any way it believes appropriate
without any obligation to you. All comments and suggestions are both welcome and appreciated.
Please do not use this form to report machine problems or to request additional publications. Machine prob-
lems should be reported on Service Reports, addressed to the Service Engineering Department. Requests for
published materials should be addressed to the Technical Publications Department.
YES NO
• Does the publication meet your needs? ............................................................ ❏ ❏
• Did you find the information:

Accurate? ................................................................................................... ❏ ❏
Easy to read and understand?.................................................................. ❏ ❏
Organized for convenient use? ................................................................. ❏ ❏
Complete? .................................................................................................. ❏ ❏
Well illustrated? ........................................................................................ ❏ ❏
Written for your technical level? .............................................................. ❏ ❏
• How do you use this publication:

As an introduction to the machine? ......................................................... ❏ ❏
To learn about operating procedures? ...................................................... ❏ ❏
As an instructor’s guide during class? ..................................................... ❏ ❏
As a student in class?................................................................................ ❏ ❏
As a reference manual?............................................................................. ❘❏ ❏
Which of the following best describes your job:
❏ Operator ❏ Partsman ❏Instructor

❏ Serviceman ❏ Engineer ❏ Other
Please use the space below to write comments and explanations, suggest changes and identify errors.
Please include page numbers.
Fold and Tape Please Do Not Staple Fold and Tape
PLACE
STAMP
HERE

P.O. Box 310
Milwaukee, WI 53201
ATTN: Technical Communications

MODELS 2800XPB, 4100A, 4100TS READER
ELECTROTORQUE PLUS® TEST PROCEDURES COMMENT
BULLETIN NUMBER: CATALOG 312-2 FORM
To assist us in providing you, the user, with the most useful publications, we ask that you use this form to
express your views concerning this publication, its organization or subject matter, with the understanding
that Harnischfeger may use or distribute whatever information you supply in any way it believes appropriate
without any obligation to you. All comments and suggestions are both welcome and appreciated.
Please do not use this form to report machine problems or to request additional publications. Machine prob-
lems should be reported on Service Reports, addressed to the Service Engineering Department. Requests for
published materials should be addressed to the Technical Publications Department.
YES NO
• Does the publication meet your needs? ............................................................ ❏ ❏
• Did you find the information:

Accurate? ................................................................................................... ❏ ❏
Easy to read and understand?.................................................................. ❏ ❏
Organized for convenient use? ................................................................. ❏ ❏
Complete? .................................................................................................. ❏ ❏
Well illustrated? ........................................................................................ ❏ ❏
Written for your technical level? .............................................................. ❏ ❏
• How do you use this publication:

As an introduction to the machine? ......................................................... ❏ ❏
To learn about operating procedures? ...................................................... ❏ ❏
As an instructor’s guide during class? ..................................................... ❏ ❏
As a student in class?................................................................................ ❏ ❏
As a reference manual?............................................................................. ❘❏ ❏
Which of the following best describes your job:
❏ Operator ❏ Partsman ❏Instructor

❏ Serviceman ❏ Engineer ❏ Other
Please use the space below to write comments and explanations, suggest changes and identify errors.
Please include page numbers.
PLACE
STAMP
HERE

P.O. Box 310
Milwaukee, WI 53201
ATTN: Technical Communications

Procedimentos de Teste

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PREFACE

© Copyright August 2000, HP&H Mining Equipment, Milwaukee, Wisconsin, USA

All rights reserved. Printed in the United States.

NORTH P&H MinePro Services

P&H Mining Institute - Technical Communication v

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

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

P&H Mining Institute - Technical Communication VER 07, 04-00

P&H MinePro Services (Repair & Rebuild Division)

P&H MinePro Services (Jwaneng, Botswana)

P&H MinePro Services (Orapa, Botswana)

P&H Mining Institute - Technical Communication vii

P&H Mining Institute - Technical Communication VER 07, 04-00

for Mining Equipment Users

Preface Operator Qualifications

3. Inspectors qualified to operate the machinery.

He must read and understand the Operator's Manual,

Operator's Functional Checks 2. Shovels or excavators should never be used to lift

2.2.5 A voltage divider, such as the one shown in Fig-

2.2.7 Miscellaneous test leads, probes, clips, cables,

Copyright © 2000 P&H Mining Equipment

3.1 Check that all electrical connections are

3.2.1 Plug-in relays should be secured with a hold NOTICE

Copyright © 2000 P&H Mining Equipment

A value of 1000 megohms or one half the factory test

5.2.1 500,000 ohms is considered as a low isolation 6.2 TRANSFORMER VOLTAGES.

Copyright © 2000 P&H Mining Equipment

Where: 6.3.5 Compare the measured readings to the values

VP rated = nameplate rated primary voltage (OPTIONAL TEST)

VS rated = 600VAC • 6.3.6.2 Make sure that the chassis of the

6.3.2 Check that the transformer neutrals are

6.3.3 Record the voltage readings on the test data

6.3.4 To determine the correct voltage difference

Vdiff = (66 - 51) / 1.732 = 8.7V

This is the voltage that should be measured between

Copyright © 2000 P&H Mining Equipment

1. All Auxiliary Supplies

Record these readings on the test data sheet.

8.1.1 Check that the test selector switch is set to

8.1.4 Use an ohmmeter to check each PLC input and

Copyright © 2000 P&H Mining Equipment

Copyright © 2000 P&H Mining Equipment

8.12.11 Repeat with the swing reference set to full

8.12 PLC ANALOG I/O CHECKS. RPC Time Delay = 300mS

8.12.3 Repeat with the hoist reference set to full neg-

Copyright © 2000 P&H Mining Equipment

Copyright © 2000 P&H Mining Equipment

P&H Electrotorque-Plus Example:

Field Control 80A / 150 x 5 ohm = 2.7 VDC

10.4.6 Verify that the test selector switch is set to

Copyright © 2000 P&H Mining Equipment

Figure 10.5.2 Swing Field Waveform Chart Recording

Copyright © 2000 P&H Mining Equipment

Figure 10.5.4 Swing Field Waveform Oscilloscope Display

Copyright © 2000 P&H Mining Equipment

11. CROWD / PROPEL FIELD CONTROL 11.3 AFM SOFTWARE

11.3.1 When the field AFM is properly powered, its

NOTICE 11.3.2 Use the drive keypad to go to the ACCESS

Copyright © 2000 P&H Mining Equipment

11.4.6 Verify that the test selector switch is set to

11.4.7 Check that the crowd field current remains at 0

11.4.8 Press the START push-button.