Cat Electric Rope Shovel 295HD/ HR Drive Converter Cabinet Bucyrus Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Description

Cat Electric Rope Shovel 295HD HR Drive Converter Cabinet Bucyrus Shovel Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Electric Rope Shovel 295HD HR Drive Converter Cabinet Bucyrus Shovel Operation & Maintenance Manual – PDF DOWNLOAD

 General Information

NOTES

• For reasons of transparency, this instruction manual does not include all detailed information and it does not take into account every conceivable situation regarding installation, operation or service.
•  If you require additional information, or if specific problems occur which are not handled in sufficient depth in the instruction manual, you can request the required information from:

Siemens Energy & Automation, Inc.
100 Technology Drive
Alpharetta, GA 30005-3900
UNITED STATES OF AMERICA
Tel.: +1 (770) 740 3000
Fax: +1 (770) 740 3899

Siemens Ltd
I&S IP1-NLC MINE –MM
Plot 2, Sector 2, Kharghar Node, Kharghar
Navi Mumbai – 410208
INDIA
Tel.:+91 22 2756 8000
Fax: +91 22 2756 8018

Siemens Ltd
C-1, Additional industrial area, MIDC, Ambad,
Nashik – 422010
INDIA
Tel.:+91 253 238 1325
Fax.:+91 253 238 1262

• • Furthermore, the contents of this manual are not part of any prior or existing agreement, commitment or legal relationship nor can they modify same.
• The sales contract contains all obligations entered into by Siemens. The warranty contained in the contract between the parties is the sole warranty granted by Siemens. Statements contained herein do not create new warranties nor modify the existing warranty.
• • This instruction manual refers exclusively to the converter equipment for the “Drive Converter Cabinet for Bucyrus Shovel 295HR /HD.” Thus, additional information regarding operating conditions and vehicle design is not part of this instruction manual.
• • The Drive Converter Cabinet is only operational as part of a complete system that includes external components such as a motor etc.

TABLE OF CONTENTS:

Cat Electric Rope Shovel 295HD HR Drive Converter Cabinet Bucyrus Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Safety Guidelines 14
A Definitions, Warnings 14
B Electrostatically Sensitive Devices (ESD) 16
1 List of Abbreviations 17
2 General Information 19
2 1 Warranty 20
2 2 Further Instructions 20
2 3 Safety Instructions for Handling Converters 21
2 3 1 The Five Safety Rules 21
2 3 2 Further Regulations 21
2 3 3 Unusual Incidents 22
2 3 4 Discharging and Grounding the Converter 22
2 3 5 Suggestions and Precautions 25
3 Product Description 26
3 1 Brief Description 26
3 2 Correct Use 26
3 3 Design and Cooling 27
3 3 1 Overview 27
3 3 2 Physical Data 28
3 3 3 Insulation Coordination 28
3 3 4 Cooling 31
3 3 5 Electrical Design 31
3 3 6 Cooling System 34
3 3 7 List of Components for Shovel 295HR DCC 36
3 3 8 List of Components for Shovel 295HD DCC 40
3 4 Electrical Design and Function 44
3 4 1 Functional sections of the DCC 44
3 4 2 Control Monitoring and Protection – SIBAS 32S 51
3 4 3 Control Monitoring and Protection – PLC S7 400 52
3 5 Technical Data 53
3 5 1 DCC for Shovel 295HD 53
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Edition 05 2009 Table of Contents
Siemens Ltd A5E01511750J/ 4M-2601-1645240 AC
Shovel 295HD/ HR DCC Operation & Maintenance Manual 4
3 5 2 DCC for Shovel 295HR 53
3 5 3 Physical data for Shovel DCC 295HR/ HD 54
3 5 4 Ambient conditions for Shovel DCC 295HD/HR 54
4 Transport / Storage 55
4 1 Transport 55
4 2 Storage 61
4 3 Long-time storage (> 6 months) 63
5 Installation & Commissioning 64
5 1 Installing in the Shovel 64
5 2 Removing the DCC from the Shovel 65
5 3 Electrical Connections 66
5 3 1 Power Connections 66
5 3 2 Control Circuit and Auxiliary Voltage Connections 69
5 3 3 Grounding Connections 71
5 4 Commissioning and Operation 72
6 Maintenance 73
6 1 Maintenance schedule 74
6 2 Maintenance activities 75
6 3 Visually checking and cleaning the heat exchanger (E02) 77
6 4 Cooling system: Checking the coolant level 78
6 5 Cooling system: Coolant specimen, analysis 79
6 6 Cooling system: Checking the seals at the coolant liquid connections80
6 7 Cooling system: Replacing the coolant 80
6 8 Coolant pump: Replacing the coolant pump and overhauling it in an
authorized workshop 85
6 9 Internal cooler: Replacing the motor 85
6 10 DC link capacitor: Checking the capacitance value 85
6 11 Main blower fan motor: Replacing the bearings 86
6 12 DCC: Cleaning the inner space 86
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 5
6 13 Checking the main and auxiliary contacts of the contactors, transfer
switch and the busbar connections in the DCC 87
6 14 Cooling system: Checking for porous hoses 88
6 15 DCC: Checking the painted surfaces 88
6 16 Replacing seals at the maintenance covers 88
6 17 Air conditioner: cleaning the heatsink fins 89
7 Maintenance, Trouble-Shooting and Repairs 90
7 1 Discharging and Grounding the Converter 90
7 2 Component locations in DCC 91
7 3 MOTOR MODULE,24VDC (62055593) 96
7 3 1 Description 96
7 3 2 Testing 96
7 3 3 Replacing 97
7 3 4 Drawing 99
7 3 5 Technical data 99
7 4 SWITCH MODULE (62055594) 100
7 4 1 Description 100
7 4 2 Testing 100
7 4 3 Replacing 100
7 4 4 Drawing 102
7 4 5 Technical data 102
7 5 IGBT MODULE,DOUBLE,SD-1500WL (62048922) 103
7 5 1 Description 103
7 5 2 Testing 104
7 5 3 Replacing 105
7 5 4 Drawing 107
7 5 5 Technical data 108
7 6 IGBT MODULE,TRIPLE,ST-1500WL-HP (62052173) 109
7 6 1 Description 109
7 6 2 Testing 110
7 6 3 Replacing 111
7 6 4 Drawing 113
7 6 5 Technical data 114
7 7 CROWBAR MODULE,CBH-1500L (62055582) 115
7 7 1 Description 115
7 7 2 Testing 116
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 6
7 7 3 Replacing 116
7 7 4 Drawing 117
7 7 5 Technical data 117
7 8 DIODE, SWING BACK (62055588) (Only in HR) 118
7 8 1 Description 118
7 8 2 Testing 118
7 8 3 Replacing 118
7 8 4 Drawing 120
7 8 5 Technical data 120
7 9 CHOKE,400uH,3300V,358A,295HD (62057718 for HD) &
CHOKE,400uH,3300V,450A,295HR (62055598 for HR) 122
7 9 1 Description 122
7 9 2 Testing 122
7 9 3 Replacing 122
7 9 4 Drawing 124
7 9 5 Technical data 125
7 10 CONTACTOR,2P,1500V,650A (62055579) 126
7 10 1 Description 126
7 10 2 Testing 126
7 10 3 Replacing 126
7 10 4 Drawing 128
7 10 5 Technical data 128
7 11 CONTACTOR,1P,1500V,250A (62055578) 129
7 11 1 Description 129
7 11 2 Testing 129
7 11 3 Replacing 129
7 11 4 Drawing 130
7 11 5 Technical data 131
7 12 RES,CHOPPER,3 15,1000W (62055587) 132
7 12 1 Description 132
7 12 2 Testing 132
7 12 3 Replacing 132
7 12 4 Drawing 133
7 12 5 Technical data 134
7 13 BLOWER,3PH RADIAL,295HD (62057719 for HD) &
BLOWER,3PH RADIAL,295HR 62055597 for HR) 135
7 13 1 Description 135
7 13 2 Testing 135
7 13 3 Replacing 135
7 13 4 Drawing 137
7 13 5 Technical data 138
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 7
7 14 COOLER, 35 06KW AKG (62055590) 139
7 14 1 Description 139
7 14 2 Testing 139
7 14 3 Replacing 139
7 14 4 Drawing 141
7 14 5 Technical data 142
7 15 COOLER,AIR/WATER,6KW AKG (62048803) 143
7 15 1 Description 143
7 15 2 Testing 143
7 15 3 Replacing 143
7 15 4 Drawing 145
7 15 5 Technical data 145
7 16 PUMP,CENTRIF,460V,295HD (62056672 for HD) &
PUMP,CENTRIF,295HR (62057447 for HR) 146
7 16 1 Description 146
7 16 2 Testing 146
7 16 3 Replacing 146
7 16 4 Drawing 148
7 16 5 Technical data 150
7 17 CAP,MKP DC,3 mF,2050V (62055519) 151
7 17 1 Description 151
7 17 2 Testing 151
7 17 3 Replacing 151
7 17 4 Drawing 153
7 17 5 Technical data 154
7 18 CONVERTER,DC-DC,150W (62055580) 155
7 18 1 Description 155
7 18 2 Testing 155
7 18 3 Replacing 155
7 18 4 Drawing 156
7 18 5 Technical data 157
7 19 POWER SUPPLY,48V/20A (62055592) 159
7 19 1 Description 159
7 19 2 Testing 159
7 19 3 Replacing 160
7 19 4 Drawing 160
7 19 5 Technical data 161
7 20 CT,HALL EFFECT,LF2005-S/SP28 (62055586) 162
7 20 1 Description 162
7 20 2 Testing 162
7 20 3 Replacing 163
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 8
7 20 4 Drawing 164
7 20 5 Technical data 164
7 21 PCB ASSY,QPSW 2KV (62055581) 165
7 21 1 Description 165
7 21 2 Testing 165
7 21 3 Replacing 166
7 21 4 Drawing 167
7 21 5 Technical data 167
7 22 VOLTAGE TRANSDUCER,300V (62055573) 168
7 22 1 Description 168
7 22 2 Testing 168
7 22 3 Replacing 169
7 22 4 Drawing 169
7 22 5 Technical data 170
7 23 FILTER,74V,8A,40% (62055574) 171
7 23 1 Description 171
7 23 2 Testing 171
7 23 3 Replacing 172
7 23 4 Drawing 172
7 23 5 Technical data 172
7 24 PRESSURE TRANSDUCER (62055589) 173
7 24 1 Description 173
7 24 2 Testing 173
7 24 3 Replacing 173
7 24 4 Drawing 174
7 24 5 Technical data 174
7 25 RES,WW,60R,1000W,5% (62055583) 175
7 25 1 Description 175
7 25 2 Testing 175
7 25 3 Replacing 175
7 25 4 Drawing 176
7 25 5 Technical data 177
7 26 RES,WW,33K,300W,5% (62055584) 178
7 26 1 Description 178
7 26 2 Testing 178
7 26 3 Replacing 178
7 26 4 Drawing 179
7 26 5 Technical data 180
7 27 RES,WW,99K,300W,5% (62055585) 181
7 27 1 Description 181
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7 27 2 Testing 181
7 27 3 Replacing 181
7 27 4 Drawing 182
7 27 5 Technical data 183
7 28 CAP,MKV,0 22 Uf,5000V (62055577) 184
7 28 1 Description 184
7 28 2 Testing 184
7 28 3 Replacing 184
7 28 4 Drawing 185
7 28 5 Technical data 185
7 29 AUX CONTACTORS FOR TRANSFER SWITCH (62006903) 186
7 29 1 Description 186
7 29 2 Testing 186
7 29 3 Drawing 186
7 29 4 Technical data 187
7 30 AUX CONTACTOR, 120VAC (62056670) 189
7 30 1 Description 189
7 30 2 Testing 189
7 30 3 Drawing 189
7 30 4 Technical data 189
7 31 AUX CONTACTOR, 24VDC (62056671 ) 191
7 31 1 Description 191
7 31 2 Testing 191
7 31 3 Drawing 192
7 31 4 Technical data 192
7 32 SIBAS,6FH4794-1A,295HD (62057720 for HD) &
SIBAS,6FH4807-1A,295HR (62055596 for HR) 194
7 32 1 Description 194
7 32 2 Testing 194
7 32 3 Replacing 194
7 32 4 Technical data 195
7 33 HEATER,800W (62039626) 196
7 33 1 Description 196
7 33 2 Testing 196
7 33 3 Replacing 197
7 33 4 Drawing 198
7 33 5 Technical data 198
7 34 POWER SUPPLY,24V/40A (62056738) 199
7 34 1 Description 199
7 34 2 Testing 199
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 10
7 34 3 Technical data 201
7 35 SIMATIC S7-400, UR1 RACK WITH 18 SLOTS
(62056680) 202
7 35 1 Description 202
7 35 2 Drawing 202
7 35 3 Technical data 202
7 36 DIGITAL I/P MODULE (120VAC, 32 CH) (62056682) 203
7 36 1 Description 203
7 36 2 Drawing 203
7 36 3 Technical data 204
7 37 DIGITAL O/P MODULE (120VAC, 32 CH) (62056703) 205
7 37 1 Description 205
7 37 2 Drawing 205
7 37 3 Technical data 206
7 38 DIGITAL I/P MODULE (24V DC 32 CH) (62056681) 207
7 38 1 Description 207
7 38 2 Technical data 207
7 39 DIGITAL O/P MODULE (24V DC 32 CH) (62056683) 210
7 39 1 Description 210
7 39 2 Technical data 210
7 40 SIMATIC S7-400, ANALOG INPUT SM 431, NON-ISOLATED 16 AI
(62056685) 211
7 40 1 Description 211
7 40 2 Drawing 211
7 40 3 Technical data 212
7 41 SIMATIC S7-400, ANALOG OUPUT SM 432, NON-ISOLATED 08 AO
(62056686) 214
7 41 1 Description 214
7 41 2 Drawing 214
7 41 3 Technical data 215
7 42 SIMATIC S7-400, PS 407 POWER SUPPLY, 10A
(62048867) 215
7 42 1 Description 215
7 42 2 Drawing 216
7 42 3 Technical data 216
7 43 SIMATIC S7-400, CPU 416-2 (62048127) 219
7 43 1 Description 219
7 43 2 Drawing 219
7 43 3 Technical data 220
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Edition 05 2009 Table of Contents
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 11
7 44 SIMATIC NET, CP 443-1 COMM PROCESSOR FOR ETHERNET
CONNECTION (62048873 & 62057100) 226
7 44 1 Description 226
7 44 2 Technical data 226
7 45 CAN DP COUPLER (62057415) 228
7 45 1 Description 228
7 45 2 Testing 228
7 45 3 Drawing 229
7 45 4 Technical data 230
7 46 SIMATIC PANEL PC 677B & REMOTE KIT (62057414) 231
7 46 1 Description 231
7 46 2 Testing 231
7 46 3 Replacing 233
7 46 4 Drawing 234
7 46 5 Technical data 235
7 47 AIR CONDITIONER (62057416) 242
7 47 1 Description 242
7 47 2 Testing 242
7 47 3 Replacing 243
7 47 4 Drawing 243
7 47 5 Technical data 244
7 48 CIRCUIT BREAKERS (62055576, 62040290, 62039637, 62039679) 245
7 48 1 Description 245
7 48 2 Drawing 245
7 48 3 Technical data 246
7 49 EMERGENCY STOP PUSH BUTTON (62055575) 247
7 49 1 Description 247
7 49 2 Testing 247
7 49 3 Drawing 247
7 49 4 Technical data 248
7 50 RESET PUSH BUTTON (62057418) 249
7 50 1 Description 249
7 50 2 Testing 249
7 50 3 Drawing 249
7 50 4 Technical data 250
7 51 UPS RS 500VA 120V BR500 (62057417) 251
7 51 1 Description 251
7 51 2 Testing 251
7 51 3 Replacing 252
7 51 4 Drawing 252
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 12
7 51 5 Technical data 253
7 52 FAN SUBASSEMBLY 28 SEP 1U (62039607) 254
7 52 1 Description 254
7 52 2 Replacing 254
7 52 3 Technical data 255
7 53 INPUT/OUTPUT MODULE (62056679) 256
7 53 1 Description 256
7 53 2 Replacing 256
7 53 3 Diagram 257
7 53 4 Technical data 258
7 54 INPUT VOLTAGE/ FREQUENCY (62056676, 62057417, 62057419 – 22) 260
7 54 1 Description 260
7 54 2 Replacing 260
7 54 3 Diagram 261
7 54 4 Technical data 261
7 55 INPUT CONVERTER BINARY 24V (62052760, 62052775) 263
7 55 1 Description 263
7 55 2 Replacing 263
7 55 3 Diagram 264
7 55 4 Technical data 264
7 56 OUTPUT MEASURING AMPLIFIER (62052764) 266
7 56 1 Description 266
7 56 2 Replacing 266
7 56 3 Diagram 267
7 56 4 Technical data 268
7 57 INPUT TEMPERATURE SENSOR PT100 (62052787) 269
7 57 1 Description 269
7 57 2 Replacing 269
7 57 3 Diagram 270
7 57 4 Technical data 270
7 58 DC/DC CONVERTER 72 110V/24V 100W (64052748) 273
7 58 1 Description 273
7 58 2 Testing 273
7 58 3 Replacing 273
7 58 4 Diagram 274
7 58 5 Technical data 274
7 59 DC/DC CONVERTER 72 110V/+-15V 100W (62056673) 276
7 59 1 Description 276
7 59 2 Testing 276
7 59 3 Replacing 276
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Edition 05 2009 Table of Contents
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Shovel 295HD/ HR DCC Operation & Maintenance Manual 13
7 59 4 Diagram 277
7 59 5 Technical data 277
7 60 BINARY OUTPUT 24V 36V/2 A (6206454 – 55, 62056467, 62057423) 279
7 60 1 Description 279
7 60 2 Replacing 279
7 60 3 Diagram 280
7 60 4 Technical data 280
7 61 INVERTER MONITORING CURRENT LINK (62056678, 62057427 – 31) 282
7 61 1 Description 282
7 61 2 Replacing 282
7 61 3 Diagram 283
7 61 4 Technical data 283
7 62 MAINBOARD SIP (62057424) 285
7 62 1 Description 285
7 62 2 Replacing 285
7 62 3 Diagram 286
7 62 4 Technical data 287
7 63 CONVERTER 72 110V/5V 90W (62053536) 288
7 63 1 Description 288
7 63 2 Testing 288
7 63 3 Replacing 288
7 63 4 Diagram 289
7 63 5 Technical data 289
7 64 POWER START-UP UNIT (62056674) 291
7 64 1 Description 291
7 64 2 Testing 291
7 64 3 Replacing 291
7 64 4 Diagram 292
7 64 5 Technical data 293
7 65 CPU 586 (62057432) 295
7 65 1 Description 295
7 65 2 Replacing 295
7 65 3 Diagram 296
7 65 4 Technical data 297
8 Appendix 298
8 1 Appendix A: Special Tools 298
8 2 Appendix B: Tightening Torque 300

CAT ELECTRIC ROPE SHOVEL 295HD/ HR DRIVE CONVERTER CABINET BUCYRUS SHOVEL OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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