1 AC 200 282C ILT 001 Syllabus Introduction Appendices

Student Workbook
Litronic Plus AC Drive

System Programming
Procedures
For Training Purposes Only
The information, specification, and illustrations in this

Student Workbook are for Training Purposes Only.
Instructions and photo or drawings in this manual may not

be reproduced, used for any reason and or distributed
without written permission from LME Training
Department.
© Copyright, Liebherr Mining Equipment Newport News
Co.2013
All rights reserved.
Liebherr Mining Equipment Newport News Co.

4100 Chestnut Avenue
Newport News, Virginia
23607-2420
Email: technical.training.lme@liebherr.com
2013-06-28
Contents Student Workbook
Contents
1 Course Syllabus 5
1.1 Course Syllabus T282C Litronic Plus AC Drive System
Programming Procedures 5
2 Introduction 7
2.1 T 282 C Haul Truck Overview 7
2.2 Technical Data Sheet 1 9
2.3 Technical Data Sheet 2 10
3 Safety and Reference Documents 11

3.1 Litronic Plus DC Bus Voltage Discharge Procedure 11
3.1.1 Check that the Primary DC Bus has been
discharged 13
3.2 Litronics Plus AC Drive System Component Layout 17
3.3 Litronics Plus Control Box Layout Front View of Main Rectifier 19
3.4 Litronics Plus Control Box Layout Front 21
3.5 Litronics Plus Control Box Layout Rear View 23
3.6 Truck CAN Network Architecture 25
List of Acronyms 27
Glossary 29
LME/AC-200-282C-ILT-001/2013-06-28/en
Index 31
Illustration Index 33
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4 T282C-Litronic Plus AC Drive System

Programming Procedures
Student Workbook Course Syllabus
Course Syllabus T282C Litronic Plus AC Drive System

System Course T282C Litronic Plus AC Drive System Programming Procedures

Title
Course Number: AC-200-282C-ILT-001
Course Level: Level 2
Course Length: 4 Days
Class Size: Maximum: 10 students
Course Overview: This course is an intensive hands-on training session, which builds on the
fundamentals presented in the Litronic Plus Level 1 course. The training includes
instruction on basic programming procedures, interpretation of fault data analysis
for troubleshooting along with instructions on the use of the Service Diagnostic
Tools. This course concludes with each student being able to program the
Litronic Plus AC Drive system.
This training class incorporates a blend of lectures and practical exercises
resulting in students being able to describe the operation of the AC Drive
System.
Prerequisites: Litronic Plus AC Drive System Principle of Operations Course AC-110-282C-

ILT-001
Course Each student is required to have:

Requirements: • Laptop computer (with administrative access)
• Access to the Liebherr Intranet with a valid logon
Target Audience: Technicians with working knowledge of the Litronic Plus AC Drive Systems
Training • Training evaluation tools:

Evaluation:
• Pre-test
• Post-test
• Student must achieve an 85% or higher on the post-test to
successfully complete the course.
Methods of The course incorporates a blend of lecture, hands on/practical instruction,

Instruction: theoretical and logical troubleshooting.
Materials Provided: • Litronic Plus AC Drive System course student workbook

• Litronic Plus, and Electrical Schematics
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T282C-Litronic Plus AC Drive System 5
Course Syllabus Student Workbook
Course Objectives: • Upon completion of this course, students will be able to:
• Identify the major components, and describe the functionality of
each component within the AC Drive System
• Interpret the AC Drive System Schematics
• Identify the systems and sub-systems that interface with the AC
Drive System
• View the status of system faults of the AC Drive System
• Analyze data and demonstrate troubleshooting procedures in a
controlled scenario
• Perform uploading and downloading of files to the Main
programmable I/O Module
• Program Inverter Controllers (Frequency Converter Controllers)
• Troubleshooting the Controller Area Network (CAN)
Course Outline
Day 1 • Pre-test
• AC Drive System Components:
• Power Conversion and Inversion
• Control Systems
Day 2 • AC Drive System Components (cont’d)

• 24 VDC Electrical Systems
• Programming the Litronic Plus
Day 3 • Hands-on (Lab/Haul Truck)

• Downloading Frequency Controller (FC) Software
• Downloading FC Parameters
Day 4 • Perform system test/inspections on various components:

• Main Rectifier
• Rotating Rectifier Assembly
• Field Regulator
• Perform test/inspections on various components (cont’d)
• Course Wrap-up
• Course Review
• Post-Test; and
• Course Evaluation/Course Wrap-up
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Student Workbook Haul Truck Overview
T 282 C Haul Truck Overview
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T282C-Litronic Plus AC Drive System Programming Procedures 7
Haul Truck Overview Student Workbook
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8 T282C-Litronic Plus AC Drive System Programming Procedures

Student Workbook Haul Truck Overview
Technical Data Sheet 1
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Haul Truck Overview Student Workbook
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Student Workbook Litronics Plus DC Bus Voltage Discharge
Procedure
Litronic Plus DC Bus Voltage Discharge Procedure
WARNING
Working on the control box, Grid Box, Alternator or Axle Box, while the DC bus is charged is
not permitted at any time. The Litronic Plus system has been designed to discharge the DC
bus by firing the brake chopper modules during drive shutdown, thereby dissipating current
through the grid box. While this functionality has been included to discharge the bus, the
actual discharge of the DC bus voltage must be verified by completing steps 3-5 prior to
performing any maintenance or repair work on the drive system. Step 6 is recommended by
Liebherr, but not mandatory unless otherwise specified by local regulations.
► Opening the control box, Grid Box, Alternator or Axle Box while the engine is
running is not allowed.
► Only trained, qualified and certified service technicians are allowed to work on the
control box.
► Personal Safety equipment must be used at all times.
► Never work alone on the haul truck.
► Inform others that work on the truck is in progress.
Required Tools and Materials

Tools and Materials Liebherr Part Number Notes
High Voltage Detection Kit 11213147
Voltmeter N/A Commercially available
NOTE
Following the steps below in the exact order.
1. Shut down and disconnect power to the device

– Follow the mines predetermined procedure for truck shutdown.
– Allow the truck to go through a controlled shut down (DO NOT use the engine shutdown
switch).
– After the engine has stopped, turn OFF all the fuses in the battery disconnect box.
2. Secure truck against restart.
– Follow lockout and tag-out procedures to secure the battery disconnect switch and the starter
inhibit switch.
– Inform everyone around the truck that Electrical work is being performed.
3. Pre-check of the equipment:
– Always approach any area where high voltage may be present as if it were a live circuit.
– Before opening control box, prepare the equipment listed above.
– Perform a visual check of the equipment.
• If the equipment has been damaged, have it checked by qualified personnel before
using.
• If high voltage detector is disassembled, assemble voltage detector.
– Perform a Function Test of high voltage detector.
– Push the test button on the voltage detector, see below.
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Litronics Plus DC Bus Voltage Discharge Student Workbook
Procedure
– The device should switch ON and performs an internal function test.
– While the “Test” Button is pushed, the RED Lamp (“lightning bolt”) should illuminate.
– After releasing the “Test” Button, the GREEN Lamp (“0”) should illuminate.
– The voltage detector is now ready to use for approximately 40 to 60 seconds.
– After 60 seconds have elapsed, the function test must be performed again
Troubleshooting
If both Lamps are illuminated, the internal 1. DO NOT use the voltage detector.
battery is LOW
2. Change the Internal Battery
If no Lamp is illuminated, the function test was 1. DO NOT use the voltage detector.
not performed.
2. Perform Function Test (see above)
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Procedure
Check that the Primary DC Bus has been discharged
1. Open the door on the RIGHT side of the control box. (the side closest to the grid box).
– Secure the door to prevent it from closing
– With an ACTIVE High Voltage Detector, take the probe stick with the BLUE label in your left
hand, and the other probe with the RED label in your right hand.
– Touch the probe with the BLUE label (left hand) to the negative DC link bus (-), and with the
probe with the RED label (right hand) to the positive DC link bus +.
– Primary DC Link bus (+ & -) locations have fixed balls installed on the bus bars.
Fig. 2.1-0: Voltmeter Connected to the Fixed Balls
– While connected, monitor the indicator panel of the voltage detector.

• If the GREEN Lamp “0” is on, then the DC-Bus is under 150V.
• Repeat the same test again, only this time, invert the voltage probes (blue
label to positive DC link bus (+), and the red label probe to the negative DC
link bus (-)
• Check indicator again and if the green Lamp “0” is still ON, continue to the
next step
• If the RED Lamp “lightning” is flashing, the DC-Bus voltage is above 150V.
• Wait and perform a second test.
• Continue to test and wait until the bus voltage is below 150V.
Indicator after Button test Meaning Result
Continues GREEN lamp Measuring device is active Measuring with voltmeter is

(Lamp “0”) voltage is under 150V permitted (check DC range of
voltmeter)
Flashing RED lamp (Lamp Measuring device is active Voltage is over 150V (wait, and
with “lightning”) voltage is over 150V perform measurement again)
Neither lamp is illuminated Measuring device is not Measuring device is not active,
active, Perform Function Test
Continues RED and GREEN Measuring device battery is Change the internal battery Perform
lamps (Lamp “0”) and (Lamp LOW Function Test
with “lightning”) on
2. When the High Voltage Detector indicates that the DC buses are under 150V, measure the exact
voltage on the Primary and Secondary DC Bus.
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Procedure
– Use a voltmeter and select to DC Volts
– Perform visual check of the voltmeter, the probes, and their connection to the meter. Check
the calibration sticker to insure its calibration is valid.
• If the equipment has been damaged or is out of calibration, have it checked by
qualified personnel before using.
– Take the negative lead and hold it to the negative DC link bus (-)
– Take the positive lead and hold it to the positive DC link bus (+)
– When the voltmeter reads 0 V, continue to the next step. If not wait, and retest until the DC link
bus voltage is reads 0V.
– Repeat for steps c-e for the Secondary Bus measurement
• Measure the secondary bus at the KEB inverter.
Fig. 2.1-1: Fixed Ball Connector
3. Grounding the DC link bus.
For further protection, the DC link bus bar + and – can be shorted together and to the ground of the
control box. This step is not necessary, but is recommended.
– Perform visual check on grounding rod, as well as grounding cable.
– Connect the Ground Clamp of the grounding cable to the control box.
Fig. 2.1-2: Connect to Ground Clamp
– Snap one of the Fixed Ball Connectors into the Grounding Rod.
– Direct the Grounding Rod to fix balls. See below.
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Procedure
Fig. 2.1-3: Voltmeter Connected to the Fixed Balls
– Connect the Fixed Ball Connector to the Grounding Rod. Attach to fixed balls plus (+). After
latching, turn the grounding rod until coupler screw secures the connection with the fixed ball.
Pull on the grounding rod to disconnect from the connector. [See Illustration Fixed Ball
Connector, page 14 ], and [See Illustration Connect to Ground Clamp, page 14 ]
Fig. 2.1-4: Fixed Ball Connector
– Repeat the above steps for the fixed ball (-)
After the complete installation, the Control Box should look like this.
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Procedure
Fig. 2.1-5: Completed Installation of the Grounding Cable
Now you can perform work inside the Control Box, Grid Box, Axle Box or Alternator. Be sure to
remove the grounding cable after work is completed and before removing LOCK-OUT TAG-
OUT equipment.
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Student Workbook Litronics Plus DC Bus Voltage Discharge Procedure
Litronics Plus AC Drive System Component Layout
Litronics Plus AC Drive System Component Layout
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Litronics Plus Control Box Layout Front View of Main Rectifier
Litronics Plus Control Box Layout Front View of Main Rectifier
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Litronics Plus Control Box Layout Front
Litronics Plus Control Box Layout Front
Legend:
1. Auxiliary frequency controller 4. Inverter controllers
2. Chopper module 5. Controller area network (CAN) communication module
3. IGBT — power stacks 6. Field regulator
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Litronics Plus Control Box Layout Rear View
Litronics Plus Control Box Layout Rear View
Fig. 2.5-6: Litronics Plus Control Box Layout Rear View
Legend:
1. Cooling Pump 3. DC/DC Converter
2. Reactor Core /Resistors, Capacitors, and Inductors ( RCL ) 4. Inductors for the DC/DC Converters
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Truck CAN Network Architecture
Truck CAN Network Architecture
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Student Workbook List of Acronyms
List of Acronyms
RCL....Resistors, Capacitors, and Inductors

LME/AC-200-282C-ILT-001/2013-06-28/en
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LME/AC-200-282C-ILT-001/2013-06-28/en
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Student Workbook Glossary
Glossary
LME/AC-200-282C-ILT-001/2013-06-28/en
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LME/AC-200-282C-ILT-001/2013-06-28/en
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Index
L
Litronic Plus DC Bus Voltage Discharge
Test 11
LME/AC-200-282C-ILT-001/2013-06-28/en
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LME/AC-200-282C-ILT-001/2013-06-28/en
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Student Workbook Illustration Index
Illustration Index
Completed Installation of the Grounding Cable 16

Connect to Ground Clamp 14
Fixed Ball Connector 14
Fixed Ball Connector 15
Litronics Plus Control Box Layout Rear View 23
Voltmeter Connected to the Fixed Balls 13
Voltmeter Connected to the Fixed Balls 15
LME/AC-200-282C-ILT-001/2013-06-28/en
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LME/AC-200-282C-ILT-001/2013-06-28/en
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Liebherr Mining Equipment Newport News Co.
4100 Chestnut Ave
Newport News, VA 23607 USA
Bus.: 757-245-5251 Fax.: 757-928-8753

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Student Workbook

Litronic Plus AC Drive

The information, specification, and illustrations in this

Instructions and photo or drawings in this manual may not

Liebherr Mining Equipment Newport News Co.

3 Safety and Reference Documents 11

4 T282C-Litronic Plus AC Drive System

Course Syllabus T282C Litronic Plus AC Drive System

System Course T282C Litronic Plus AC Drive System Programming Procedures

Course Number: AC-200-282C-ILT-001

Course Level: Level 2

Course Length: 4 Days

Class Size: Maximum: 10 students

Prerequisites: Litronic Plus AC Drive System Principle of Operations Course AC-110-282C-

Course Each student is required to have:

Training • Training evaluation tools:

Methods of The course incorporates a blend of lecture, hands on/practical instruction,

Materials Provided: • Litronic Plus AC Drive System course student workbook

Day 2 • AC Drive System Components (cont’d)

Day 3 • Hands-on (Lab/Haul Truck)

Day 4 • Perform system test/inspections on various components:

6 T282C-Litronic Plus AC Drive System

T 282 C Haul Truck Overview

8 T282C-Litronic Plus AC Drive System Programming Procedures

Technical Data Sheet 1

Technical Data Sheet 2

10 T282C-Litronic Plus AC Drive System

Litronic Plus DC Bus Voltage Discharge Procedure

Required Tools and Materials

High Voltage Detection Kit 11213147

Voltmeter N/A Commercially available

1. Shut down and disconnect power to the device

12 T282C-Litronic Plus AC Drive System

Check that the Primary DC Bus has been discharged

Fig. 2.1-0: Voltmeter Connected to the Fixed Balls

– While connected, monitor the indicator panel of the voltage detector.

Indicator after Button test Meaning Result

Continues GREEN lamp Measuring device is active Measuring with voltmeter is

Fig. 2.1-1: Fixed Ball Connector

3. Grounding the DC link bus.

Fig. 2.1-2: Connect to Ground Clamp

14 T282C-Litronic Plus AC Drive System

Fig. 2.1-3: Voltmeter Connected to the Fixed Balls

Fig. 2.1-4: Fixed Ball Connector

– Repeat the above steps for the fixed ball (-)

Fig. 2.1-5: Completed Installation of the Grounding Cable

16 T282C-Litronic Plus AC Drive System

Litronics Plus AC Drive System Component Layout

18 T282C-Litronic Plus AC Drive System Programming Procedures

Litronics Plus Control Box Layout Front View of Main Rectifier

20 T282C-Litronic Plus AC Drive System Programming Procedures

Litronics Plus Control Box Layout Front

22 T282C-Litronic Plus AC Drive System Programming Procedures

Litronics Plus Control Box Layout Rear View

Fig. 2.5-6: Litronics Plus Control Box Layout Rear View

24 T282C-Litronic Plus AC Drive System Programming Procedures

Truck CAN Network Architecture

26 T282C-Litronic Plus AC Drive System Programming Procedures

RCL....Resistors, Capacitors, and Inductors

28 T282C-Litronic Plus AC Drive System

30 T282C-Litronic Plus AC Drive System

32 T282C-Litronic Plus AC Drive System

Completed Installation of the Grounding Cable 16