SHOVEL

TROUBLESHOOTING

MANUAL (PART I)
COVERING
IGBT – HYBRID
RETROFIT 395BII

SIEMENS ENERGY & AUTOMATION

ALPHARETTA, GA
USA

REVISED: 02/21/04
 TABLE OF CONTENTS

CHAPTER 1 RECTIFIER FAULTS ------------------------------------------------------ 1-1

FAULT 1001 E01-Q01 IGBT BLOWER#1 BREAKER TRIPPED ----------------------------- 1-1
FAULT 1002 E01-Q02 IGBT BLOWER #2 BREAKER Tripped ------------------------------- 1-2
FAULT 1003 E02-Q03 RECTIFIER FAN BREAKER TRIPPED------------------------------- 1-2
FAULT 1004 E02-Q04 REGN RECT FAN BREAKER TRIPPED ----------------------------- 1-3
FAULT 1005 N30-Q05 SYNCH VOLTAGE BREAKER TRIPPED---------------------------- 1-4
FAULT 1006 E02-Q06 SCOTT-T XFMR BREAKER TRIPPED ------------------------------- 1-5
FAULT 1007 E02-Q08 GNDFLT/AIRFLO BREAKER TRIPPED ----------------------------- 1-6
FAULT 1008 E02-Q09 3UP7 SUPPLY BREAKER TRIPPED----------------------------------- 1-7
FAULT 1009 E02-Q10 DC-CT XDUCER BREAKER TRIPPED ------------------------------ 1-8
FAULT 1010 E02-Q11 FUSE MONITOR BREAKER TRIPPED------------------------------- 1-8
FAULT 1011 E02-Q12,Q13 24V-SE20.2 BREAKER(s) TRIPPED ----------------------------- 1-9
FAULT 1012 E02-Q34,Q15 24V-SIM-D I/O CB(s) TRIPPED --------------------------------- 1-10
FAULT 1013 E02-Q16 24V-OP1 BREAKER CONTACT FAULT---------------------------- 1-11
FAULT 1014 E02-Q18 SIBAS PWR SUPPLY BREAKER TRIPPED ----------------------- 1-12
FAULT 1015 E02-Q19 IGBT GATE PS BREAKER TRIPPED ------------------------------- 1-13
FAULT 1016 E02-Q20 PROPEL TACH XDUCER CB TRIPPED---------------------------- 1-14
FAULT 1017 SYSTEM FAULT –SIM-D PROCESSOR 1 -------------------------------------- 1-15
FAULT 1018 SYSTEM FAULT –SIM-D PROCESSOR 2 -------------------------------------- 1-15
FAULT 1019 SYSTEM FAULT –SIM-D PROCESSOR 3 -------------------------------------- 1-15
FAULT 1020 SYSTEM FAULT –SIM-D PROCESSOR 4 -------------------------------------- 1-15
FAULT 1021 LINE VOLTAGE MORE THAN 110% ------------------------------------------- 1-16
FAULT 1022 LINE VOLTAGE LESS THAN 70% ---------------------------------------------- 1-17
FAULT 1023 LOWLINE WARNING --------------------------------------------------------------- 1-18
FAULT 1024 SIM-D / PLC COMMUNICATION FAULT ------------------------------------- 1-18
FAULT 1025 HOIST OVERSPEED FAULT ------------------------------------------------------ 1-19
FAULT 1026 CROWD OVERSPEED FAULT---------------------------------------------------- 1-20
FAULT 1027 SWING OVERSPEED FAULT ----------------------------------------------------- 1-20
FAULT 1028 DPC INTERPOSING RLY OPEN BY SIM-D ----------------------------------- 1-21
FAULT 1033 RECTIFIER: SYNCHR. VOLTAGE MISSING (TG6)------------------------ 1-22
FAULT 1034 RECTIFIER: SYNCHR. VOLTAGE INCORRECT --------------------------- 1-23
FAULT 1035 RECTIFIER1: SYNCHR. VOLTAGE L1-L2 MISSING ---------------------- 1-23
FAULT 1036 RECTIFIER: SYNCHR. VOLTAGE L1-L3 MISSING------------------------ 1-24
FAULT 1037 RECTIFIER: PULSE POSITION INCORRECT (TG6)----------------------- 1-25
FAULT 1038 RECTIFIER: SYNCHR. VOLTAGE WRONG ROTATION ---------------- 1-26
FAULT 1039 RECTIFIER: ERROR-DISPLACEMENT ANGLE INPUT ------------------ 1-27
FAULT 1040 RECTIFIER: GATE CURRENT REGUL. CLOCK ERROR---------------- 1-28
FAULT 1041 RECTIFIER: CURRENT ACT HARDWARE FAULT (CAV) -------------- 1-28
FAULT 1042 RECTIFIER: FORWARD RECTIFIER OVERCURRENT ------------------ 1-28
FAULT 1043 REGEN RECTIFIER OVERCURRENT ----------------------------------------- 1-31
FAULT 1044 RECTIFIER: CURRENT ACT CONFIG FAULT (CAV) -------------------- 1-33
FAULT 1045 RECTIFIER: VOLTAGE ACT HARDWARE FAULT (EMF) -------------- 1-33
FAULT 1046 RECTIFIER: VOLTAGE ACT CONFIG FAULT (EMF) -------------------- 1-34
FAULT 1047 RECTIFIER: ZERO CURRENT SIG. MISSING (SOL) ---------------------- 1-34
FAULT 1048 RECTIFIER: AUTO REVERSE CONFIG. FAULT (SOL)------------------- 1-35
FAULT 1049 RECTIFIER: LINE VOLTAGE UNSTABLE (TGF) -------------------------- 1-35
FAULT 1050 RECTIFIER: SITOR FUSE FAILURE (TGF) ---------------------------------- 1-36
FAULT 1051 RECTIFIER: SITOR OVERTEMPERATURE (TGF) ------------------------ 1-37
FAULT 1052 RECTIFIER: LINE UNDERVOLT-24V FIRING PS (TGF) ----------------- 1-37
FAULT 1053 RECTIFIER: EXT PULSE BLOCK (PG16 JUMPER) ------------------------ 1-38

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TABLE OF CONTENTS

FAULT 1054 RECTIFIER: GROUP ERROR MESSAGE ------------------------------------- 1-39

FAULT 1055 RECTIFIER: FAULTY GATE CONTROL SET ------------------------------- 1-39
FAULT 1056 RECTIFIER: GROUP ERROR MESSAGE ------------------------------------- 1-39
FAULT 1065 E01-Q21 24V HST TACH BREAKER TRIPPED------------------------------- 1-40
FAULT 1066 E01-Q22 24V CRD TACH BREAKER TRIPPED ------------------------------ 1-41
FAULT 1067 E01-Q23 24V SWG TACH BREAKER TRIPPED------------------------------ 1-41
FAULT 1068 E01-Q26 +E1A AC CIRCUIT BREAKER TRIPPED ------------------------- 1-42
FAULT 1069 E01-Q27 +N1A AC CIRCUIT BREAKER TRIPPED ------------------------- 1-43
FAULT 1073 BEB PUSH BUTTON(S) PRESSED------------------------------------------------ 1-44
FAULT 1074 POEB PUSH BUTTON(S) ACTIVATED ----------------------------------------- 1-45
FAULT 1079 E01-TH01 +N1A CABINET HIGH TEMP FAULT ---------------------------- 1-46
FAULT 1080 E01-TH02 +E1A CABINET HIGH TEMP FAULT----------------------------- 1-47
FAULT 1081 GROUND FAULT DETECTED ---------------------------------------------------- 1-48
FAULT 1082 R11- G101 24V-RECT FIRING PWR SUPPLY FAULT ---------------------- 1-49
FAULT 1083 FWD RECTIFIER FUSE(S) LOSS------------------------------------------------- 1-50
FAULT 1084 REGEN RECTIFIER FUSE(S) LOSS --------------------------------------------- 1-52
FAULT 1085 RECTIFIER AIRFLOW FAULT--------------------------------------------------- 1-55
FAULT 1089 HOIST MOTOR OVERTEMP WARNING-------------------------------------- 1-56
FAULT 1090 HOIST MOTOR OVERTEMP FAULT------------------------------------------- 1-57
FAULT 1091 CROWD MOTOR OVERTEMP WARNING ----------------------------------- 1-59
FAULT 1092 CROWD MOTOR OVERTEMP FAULT ---------------------------------------- 1-60
FAULT 1093 SWING MOTOR#1 OVERTEMP WARNING ---------------------------------- 1-62
FAULT 1094 SWING MOTOR#1 OVERTEMP FAULT --------------------------------------- 1-63
FAULT 1095 SWING MOTOR#2 OVERTEMP WARNING ---------------------------------- 1-65
FAULT 1096 SWING MOTOR#2 OVERTEMP FAULT --------------------------------------- 1-66
FAULT 1097 CROWD MOTION FAULT --------------------------------------------------------- 1-67
FAULT 1098 HOIST MOTION FAULT------------------------------------------------------------ 1-68
FAULT 1099 SWING MOTION FAULT----------------------------------------------------------- 1-69
FAULT 1100 CHOPPER FAULT -------------------------------------------------------------------- 1-69
FAULT 1104 SIBAS SYSTEM FAULT ------------------------------------------------------------- 1-70
FAULT 1105 HOIST BRAKE SET BY SIBAS ---------------------------------------------------- 1-70
FAULT 1106 CROWD BRAKE SET BY SIBAS-------------------------------------------------- 1-71
FAULT 1107 SWING BRAKES SET BY SIBAS ------------------------------------------------- 1-72
FAULT 1108 PROPEL BRAKE SET BY SIBAS ------------------------------------------------- 1-73
FAULT 1109 MAIN CONTACTOR OPENED BY SIBAS ------------------------------------- 1-73
FAULT 1113 HIGH VOLTAGE CONTACTOR OPEN ---------------------------------------- 1-74
FAULT 1114 DC-BUS VOLTAGE ABOVE 1100 VDC ----------------------------------------- 1-75
FAULT 1115 RECTIFIER GATE BLOCKED (TGF) ------------------------------------------- 1-76
FAULT 1116 UPS OFF COMMAND FROM PLC ----------------------------------------------- 1-76
FAULT 1117 RECTIFIER GATE BLOCKING CMD------------------------------------------- 1-76
FAULT 1118 FAULT PRECHARGING (Ud<70%)---------------------------------------------- 1-77

CHAPTER 2 DEVICES --------------------------------------------------------------------- 2-1

AIR FLOW MONITOR ---------------------------------------------------------------------------------- 2-1
DC CURRENT TRANSDUCER------------------------------------------------------------------------ 2-1
DIGITAL TACHOMETER ----------------------------------------------------------------------------- 2-2
EM11 MIXED I/O CARD-------------------------------------------------------------------------------- 2-5
FUSE MONITOR BOARD ------------------------------------------------------------------------------ 2-6
GROUND FAULT MONITOR ------------------------------------------------------------------------- 2-7
MM11 MAILBOX MEMORY -------------------------------------------------------------------------- 2-8
PG16 RECTIFIER CONTROL PROCESSOR------------------------------------------------------ 2-8
PM16 GENERAL PROCESSOR --------------------------------------------------------------------- 2-10
PULSE DISTRIBUTION BOARD ------------------------------------------------------------------- 2-11
SE20.2 SITOR INTERFACE MODULE------------------------------------------------------------ 2-13

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 TABLE OF CONTENTS

SE26.1 SIGNAL ISOLATOR MODULE ----------------------------------------------------------- 2-14

SE4.1 24V BINARY I/O MODULE ------------------------------------------------------------------ 2-15
SE5.3 115/220VAC ISOLATED INPUT MODULE ---------------------------------------------- 2-16
SE6.1 RELAY OUTPUT MODULE ----------------------------------------------------------------- 2-17
SE7.1 TERMINAL BOARD MODULE------------------------------------------------------------- 2-18
SIMADYN-D CARD RACK--------------------------------------------------------------------------- 2-19
SITOR BLOCK ------------------------------------------------------------------------------------------ 2-20
THERMISTOR (3UP7) MONITOR ----------------------------------------------------------------- 2-23

CHAPTER 3 TEST PROCEDURES ----------------------------------------------------- 3-1

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

CHAPTER 4 ADDENDUMS --------------------------------------------------------------- 4-1

ADDENDUM-1--------------------------------------------------------------------------------------------- 4-1
ADDENDUM-2--------------------------------------------------------------------------------------------- 4-5

iii
 TABLE OF FIGURES
Figure 1 Digital Tachometer Problem #1 ............................................................................................... 2-3
Figure 2 Digital Tachometer Problem #2 ............................................................................................... 2-3
Figure 3 Digital Tachometer Problem #3 ............................................................................................... 2-4
Figure 4 EM11 Card ................................................................................................................................ 2-5
Figure 5 Fuse Monitor Board.................................................................................................................. 2-6
Figure 6 PG16 Card ................................................................................................................................. 2-8
Figure 7 PM16 Card .............................................................................................................................. 2-11
Figure 8 Pulse Distribution Board ........................................................................................................ 2-12
Figure 9 SE20.2 Interface Card ............................................................................................................ 2-13
Figure 10 SE24.1 Daughter Board........................................................................................................ 2-14
Figure 11 SE26.1 Isolator Module ........................................................................................................ 2-15
Figure 12 SE4.1 Interface Module ........................................................................................................ 2-16
Figure 13 SE5.3 Isolated Input Module................................................................................................ 2-17
Figure 14 SE6.1 Relay Output Module ................................................................................................ 2-18
Figure 15 SE7.1 Terminal Board Module ............................................................................................ 2-18
Figure 16 Simadyn-D Card Rack.......................................................................................................... 2-20
Figure 17 SITOR Block ......................................................................................................................... 2-21
Figure 18 SITOR SCR Clamping Detail .............................................................................................. 2-21
Figure 19 Thermistor Monitor .............................................................................................................. 2-24
Figure 20 Current Feedback Bridge #1.................................................................................................. 3-1
Figure 21 Firing Pulse Cable Routing (Chopper Machines) ................................................................ 3-5

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 RECTIFIER TROUBLESHOOTING

Chapter 1 RECTIFIER FAULTS

FAULT 1001 E01-Q01 IGBT BLOWER#1 BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q01 has tripped. This breaker, located in cabinet
+E1A, supplies 460vac to the IGBT Blower#1.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:1 and X2:51 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breaker E01-Q01 for a tripped condition.

2. If the breaker is tripped, check the trip point calibration. It should be set at 10.2 amp.

3. If the breaker was calibrated correctly, then measure the current drawn by the Blower motor.
If it is greater than 10.2 amps, Troubleshoot for blocked air path.

4. Replace the breaker.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts.
There should be no voltage drop across this contact. If the reading is 24vdc, clean the
contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H1 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:1 and X2:51. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

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 RECTIFIER TROUBLESHOOTING

FAULT 1002 E01-Q02 IGBT BLOWER #2 BREAKER Tripped

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q02 has tripped. This breaker, located in cabinet
+E1A, supplies 460vac to the IGBT Blower#2.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:2 and X2:52 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breaker E01-Q02 for a tripped condition.

2. If the breaker is tripped, check the trip point calibration. It should be set at 10.2 amp.

3. If the breaker was calibrated correctly, then measure the current drawn by the Blower motor.
If it is greater than 10.2 amps, Troubleshoot for blocked air path.

4. Replace the breaker.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts.
There should be no voltage drop across this contact. If the reading is 24vdc, clean the
contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is
not present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H2 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:2 and X2:52. If +24vdc is present, replace the SE4.1.
If it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1003 E02-Q03 RECTIFIER FAN BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q03 has tripped. Circuit breaker E02-Q03, located
in cabinet +E1A, supply 460vac to the cooling blower motor that sit atop of cabinet +R1A. Circuit
breaker has an adjustable trip level set to trip at 7.6 amps

Simadyn-D monitors the auxiliary NO contact on the circuit breaker to determine if it is tripped.
The contact is monitored by connectors X2:3 and X2:53 on SE4.1 card N61-A11 in cabinet +N1B.
This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

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 RECTIFIER TROUBLESHOOTING

CORRECTIVE PROCEDURE:

1. Check circuit breakers E02-Q03 for a tripped condition.

2. If breaker has tripped, check the trip point calibration. It should be set at 7.6 amps.

3. If breaker has tripped, isolate the load from the circuit breaker and reset the breaker. If the
breaker will not reset, replace the breaker.

4. If the breaker is O.K., then troubleshoot the wiring between the breaker and the blower
motor.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 13 and 14 on E02-Q03). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H3 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:3 and X2:53. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1004 E02-Q04 REGN RECT FAN BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q04 has tripped. Circuit breaker E02-Q04, located
in cabinet +E1A, supply 460vac to the cooling blower motor that sit atop of cabinet +R1B. Circuit
breaker has an adjustable trip level set to trip at 7.6 amps

Simadyn-D monitors the auxiliary NO contact on the circuit breaker to determine if it is tripped.
The contact is monitored by connectors X2:4 and X2:54 on SE4.1 card N61-A11 in cabinet +N1B.
This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breakers E02-Q04 for a tripped condition.

2. If breaker has tripped, check the trip point calibration. It should be set at 7.6 amps.

3. If breaker has tripped, isolate the load from the circuit breaker and reset the breaker. If the
breaker will not reset, replace the breaker.

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RECTIFIER TROUBLESHOOTING

4. If the breaker is O.K., then troubleshoot the wiring between the breaker and the blower
motor.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 13 and 14 on E02-Q04). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H4 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:4 and X2:54. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1005 N30-Q05 SYNCH VOLTAGE BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker N30-Q05 has tripped. This circuit breaker (found in
cabinet +E1A) supplies 460vac to the voltage synchronization module (device N30-A15) in
cabinet +N1B. This circuit breaker has an adjustable trip level set to trip at 0.16 amps. Since the
synchronization module is used to synchronize the rectifier firing pulses with the incoming
voltage, this fault will always cause a Gate Blocking condition.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it has tripped.
The contacts are monitored by connectors X2:5 and X2:55 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker N30-Q05 for a tripped condition.

2. If the breaker has tripped, check the trip point calibration. It should be set at 0.16 amps.

3. If the breaker has tripped, isolate the voltage synchronization module from the circuit breaker
and reset the breaker. If the breaker will not reset, replace the breaker.

4. If the breaker is O.K., then troubleshoot the wiring between the breaker and the voltage
synchronization module.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 13 and 14 on N30-Q05). There should be no voltage drop across this contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breakers if necessary.

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 RECTIFIER TROUBLESHOOTING

6. If the breakers are operating properly, check that the green LED 1P on the SE4.1 module is
lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H5 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:5 and X2:55. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1006 E02-Q06 SCOTT-T XFMR BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q06 has tripped. This circuit breaker (found in
cabinet +E1A) supplies 380vac to the Scott-T Transformer (device E02-T1) located in cabinet
+R1A. This circuit breaker has an adjustable trip level set to trip at 4 amps.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it has tripped.
The contacts are monitored by connectors X2:6 and X2:56 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

Since this Scott-T Transformer provides major control supply in the system, there would be NO
annunciation when the breaker really tripped.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E02-Q06 for a tripped condition.

2. If the breaker has tripped, check the trip point calibration. It should be set at 4 amps.

3. If the breaker has tripped, isolate the Scott-T Transformer from the circuit breaker and reset
the breaker. If the breaker will not reset, replace the breaker.

4. If the breaker is O.K., then troubleshoot the wiring between the breaker and the Scott-T
Transformer.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 13 and 14 on E02-Q06). There should be no voltage drop across this contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breakers if necessary.

6. If the breakers are operating properly, check that the green LED 1P on the SE4.1 module is
lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

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RECTIFIER TROUBLESHOOTING

7. Check that the red LED H6 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:6 and X2:56. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1007 E02-Q08 GNDFLT/AIRFLO BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q08 has tripped. This breaker, located in cabinet
+E1A, supplies 220vac to the ground fault and air flow monitors. Therefore, this fault will always
be accompanied with 1081 Ground Fault Detected. If the DC bus was up at the time of the trip, a
1085 Rectifier Airflow Fault will also be on the fault display of the OP1 Panel.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:7 and X2:57 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breaker E02-Q08 for a tripped condition.

2. If the breaker is tripped, check the trip point calibration. It should be set at 1.0 amp.

3. If the breaker was calibrated correctly, then isolate the fault between the two airflow monitors,
the ground fault monitor, or the wiring. Replace or repair the defective component.

4. Replace the breaker.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts.
There should be no voltage drop across this contact. If the reading is 24vdc, clean the
contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H7 on SE4.1 module N61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:7 and X2:57. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

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 RECTIFIER TROUBLESHOOTING

END OF PROCEDURE

FAULT 1008 E02-Q09 3UP7 SUPPLY BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q09 has tripped. This breaker, located in cabinet
+E1A, supplies 220vac to the thermistor monitors (3UP7). The breaker, which is mounted in
cabinet +E1A, is an adjustable breaker. The trip point should be set at 1.6 amps.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:8 and X2:58 on SE4.1 card N61-A11 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breaker E02-Q09 for a tripped condition.

2. If the breaker is tripped, check the trip point calibration. It should be set at 1.6 amps.

3. If the breaker was calibrated correctly, then isolate the load by disconnecting the thermistor
monitors (3UP7) one at a time until the fault load disappears. The 3UP7s are labeled N20-
A11 through N20-A32 and are located in cabinet +N1B.

4. If the devices are O.K., then troubleshoot the wiring between the breaker and the devices.

5. Replace the breaker.

6. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 13 and 14 on E02-Q09). There should be no voltage drop across this contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

7. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker D13-Q5 which supplies the +24vdc.

8. Check that the red LED H8 on SE4.1 module M61-A11 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:8 and X2:58. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

9. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

10. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

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RECTIFIER TROUBLESHOOTING

FAULT 1009 E02-Q10 DC-CT XDUCER BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q10 has tripped. This breaker, located in cabinet,
+E1A, supplies 220vac to the DC Current Transducer. Therefore, this fault will always cause a
Gate Blocking state.

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:1 and X2:51 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breaker E02-Q10 for a tripped condition.

2. If the breaker is tripped, check the trip point calibration. It should be set at 0.16 amps.

3. If the breaker was calibrated correctly, then measure the current drawn by the transducer. If
it is greater than 0.16 amps, replace the transducer.

4. Replace the breaker.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts.
There should be no voltage drop across this contact. If the reading is 24vdc, clean the
contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

7. Check that the red LED H1 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:1 and X2:51. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

9. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1010 E02-Q11 FUSE MONITOR BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q11 has tripped. This circuit breaker, located in
cabinet +E1A, is a double pole breaker that supplies +/24vdc to both Forward rectifier fuse
monitors (devices R11-A201 and R12-A202) and Regen rectifier fuse monitor (device R13-A203).
This breaker is located in cabinet +E1A. This fault will always cause a Gate Blocking condition.
This breaker is set at a non-adjustable 1.0 amp.

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 RECTIFIER TROUBLESHOOTING

Simadyn-D monitors the auxiliary NO contacts on the circuit breaker to determine if it is tripped.
The contacts are monitored by connectors X2:2 and X2:52 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E02-Q11 for a tripped condition.

2. If the breaker has tripped, isolate the loads by disconnecting terminals 1, 2, and 3 on the
rectifier fuse monitors one at a time. Try and reset the breaker. If the breaker will not reset,
disconnect the output wires (top and bottom) on the back of the breaker and try and reset.
Replace the breaker.

3. If the breaker is O.K., then troubleshoot the wiring between the breaker and the fuse
monitors.

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins C and NO on E02-Q11). There should be no voltage drop across this contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

6. Check that the red LED H2 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:2 and X2:52. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1011 E02-Q12,Q13 24V-SE20.2 BREAKER(s) TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q12 and/or E02-Q13 has tripped. E02-Q13 is a
single pole breaker that supplies +24vdc to the SE20.2, and E02-Q12 is a double pole breaker
that supplies +/- 24vdc to the SE20.2. Both breakers are located in cabinet +E1A while the
SE20.2 is located in cabinet +N1A. Because the SE20.2 is the main interface for the rectifier, a
fault on either of these breakers will cause numerous rectifier faults and always result in a Gate
Blocking condition. These breakers are set at a non-adjustable 1.0 amp.

Simadyn-D monitors the two auxiliary NO contacts, which are in series, on the circuit breakers to
determine if it is tripped. The contacts are monitored by connectors X2:3 and X2:53 on SE4.1
card N61-A12 in cabinet +N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon
cable N61-RC5.

CORRECTIVE PROCEDURE:

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RECTIFIER TROUBLESHOOTING

1. Check circuit breakers E02-Q12 and E02-Q13 for a tripped condition.

2. If any of these breakers has tripped, disconnect connectors X5 and X6 from the SE20.2 and
try and reset the breaker. If the breaker will not reset, disconnect the output wires (top and
bottom) the back of each breaker and try and reset. Replace the breaker.

3. If the breakers are O.K., then troubleshoot the wiring between the breakers and the SE20.2
card.

4. If the breakers have not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins C and NO on E02-Q12 and E02-Q13). There should be no voltage drop across either
contact. If the reading is 24vdc, clean the contacts and try again. Replace the breakers if
necessary.

5. If the breakers are operating properly, check that the green LED 1P on the SE4.1 module is
lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

6. Check that the red LED H3 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:3 and X2:53. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1012 E02-Q34,Q15 24V-SIM-D I/O CB(s) TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q34 and/or E02-Q15 has tripped. These
breakers, located in cabinet +E1A, supply +24vdc to the I/O interface modules located in cabinet
+N1B. The +24vdc is routed to small busbars in +N1B and +E1A before it is distributed to the I/O
interface modules. These breakers are set at a non-adjustable 4.0 amps (E02-Q34) and 1.0 amp
(E02-Q15).

Simadyn-D monitors the two auxiliary NO contacts, which are in series, on the circuit breakers to
determine if it is tripped. The contacts are monitored by connectors X2:4 and X2:54 on SE4.1
card N61-A12 in cabinet +N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon
cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breakers E02-Q34 and E02-Q15 for a tripped condition.

2. If one or both breakers has tripped, isolate the loads by pulling the +24vdc from the I/O
interface modules one at a time. Try and reset the breaker. If the breakers will not reset,

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 RECTIFIER TROUBLESHOOTING

disconnect the wires (top and bottom) from the back of each breaker and try to reset.
Replace the breaker.

3. If the breakers are O.K., then troubleshoot the wiring between the breakers and the I/O
interface boards.

4. If the breakers have not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins C and NO on E02-Q34 and E02-Q15). There should be no voltage drop across either
contact. If the reading is 24vdc, clean the contacts and try again. Replace the breakers if
necessary.

5. If the breakers are operating properly, check that the green LED 1P on the SE4.1 module is
lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

6. Check that the red LED H4 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:4 and X2:54. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1013 E02-Q16 24V-OP1 BREAKER CONTACT FAULT

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q16 has tripped. This breaker, located in cabinet
+E1A, supplies +24vdc to the OP1 Display Panel. This breaker is set at a non-adjustable 1.0
amp.

Simadyn-D monitors the auxiliary NO contacts, on the circuit breakers to determine if it is tripped.
The contacts are monitored by connectors X2:5 and X2:55 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

If the breaker has really tripped, OP1 display panel would be not displaying anything.

CORRECTIVE PROCEDURE:

1. Check breakers E02-Q16 for a tripped condition.

2. If the breaker has tripped, isolate the loads by pulling the +24vdc from the OP1 display panel.
Try and reset the breaker. If the breaker will not reset, disconnect the wires (top and bottom)
from the back of breaker and try to reset. Replace the breaker.

3. If the breaker is O.K., then troubleshoot the wiring between the breakers and the OP1 display
panel.

1-11
RECTIFIER TROUBLESHOOTING

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins C and NO on E02-Q16). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

6. Check that the red LED H5 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:5 and X2:55. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1014 E02-Q18 SIBAS PWR SUPPLY BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q18 has tripped. This breaker, located in cabinet
+E1A, supplies 220vac to the SIBAS power supplies. This breaker is set at a non-adjustable 16.0
amps.

Simadyn-D monitors the auxiliary NO contacts, on the circuit breakers to determine if it is tripped.
The contacts are monitored by connectors X2:6 and X2:56 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breakers E02-Q18 for a tripped condition.

2. If the breaker has tripped, isolate the loads by disconnecting the +220vac from the SIBAS
power supplies (device E01-G02), mounted in +E1A cabinet. Try and reset the breaker. If
the breaker will not reset, disconnect the wire (bottom) from the breaker and try to reset.
Replace the breaker.

3. If the breaker is O.K., then troubleshoot the wiring between the breaker and the SIBAS power
supplies.

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E02-Q18). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

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 RECTIFIER TROUBLESHOOTING

6. Check that the red LED H6 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:6 and X2:56. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1015 E02-Q19 IGBT GATE PS BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q19 has tripped. This breaker, located in cabinet
+E1A, supplies +220vac to the IGBT Gate unit power supply (device: E01-G03). This breaker is
set at a non-adjustable 10.0 amp.

Simadyn-D monitors the auxiliary NO contacts, on the circuit breakers to determine if it is tripped.
The contacts are monitored by connectors X2:7 and X2:57 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

If this breaker has really tripped, SIM-D and OP1 panel would not have 24V input power and this
fault cannot be displayed.

CORRECTIVE PROCEDURE:

1. Check breakers E02-Q19 for a tripped condition.

2. If the breaker has tripped, isolate the loads by pulling the +220vac from the IGBT Gate power
supply (device: E01-G03), mounted in +E1A cabinet. Try and reset the breaker. If the
breaker will not reset, disconnect the wire (bottom) from the back of breaker and try to reset.
Replace the breaker.

3. If the breaker is O.K., then troubleshoot the wiring between the breaker and the IGBT Gate
unit power supply.

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E02-Q19). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

6. Check that the red LED H7 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:7 and X2:57. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

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RECTIFIER TROUBLESHOOTING

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1016 E02-Q20 PROPEL TACH XDUCER CB TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E02-Q20 has tripped. This breaker, located in cabinet
+E1A, supplies +220vac to the Propel Tach transducer (device: E01-U455). This breaker is set at
a non-adjustable 0.5 amp.

Simadyn-D monitors the auxiliary NO contacts, on the circuit breakers to determine if it is tripped.
The contacts are monitored by connectors X2:8 and X2:58 on SE4.1 card N61-A12 in cabinet
+N1B. This signal is sent to Simadyn-D Processor #1 (PM16) via ribbon cable N61-RC5.

CORRECTIVE PROCEDURE:

1. Check breakers E02-Q20 for a tripped condition.

2. If the breaker has tripped, isolate the loads by pulling the +220vac from the Propel Tach
transducer (device: E01–U455), mounted in +E1A cabinet. Try and reset the breaker. If the
breaker will not reset, disconnect the wire (bottom) from the back of breaker and try to reset.
Replace the breaker.

3. If the breaker is O.K., then troubleshoot the wiring between the breaker and the Propel Tach
transducer.

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E02-Q20). There should be no voltage drop across either contact. If the
reading is 24vdc, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

6. Check that the red LED H8 on SE4.1 module N61-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:8 and X2:58. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breaker and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

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 RECTIFIER TROUBLESHOOTING

FAULT 1017 SYSTEM FAULT –SIM-D PROCESSOR 1

EXPLANATION:

Processor #1 (PM16) of the Simadyn-D rack has had an internal fault.

CORRECTIVE PROCEDURE:

1. See Processor Error Codes for the PM16.

END OF PROCEDURE

FAULT 1018 SYSTEM FAULT –SIM-D PROCESSOR 2

EXPLANATION:

Processor #2 (PM16) of the Simadyn-D rack has had an internal fault.

CORRECTIVE PROCEDURE:

1. See Processor Error Codes for the PM16.

END OF PROCEDURE

FAULT 1019 SYSTEM FAULT –SIM-D PROCESSOR 3

EXPLANATION:

Processor #3 (PG16) of the Simadyn-D rack has had an internal fault.

CORRECTIVE PROCEDURE:

1. See Processor Error Codes for the PM16.

END OF PROCEDURE

FAULT 1020 SYSTEM FAULT –SIM-D PROCESSOR 4

EXPLANATION:

Processor #4 (PM16) of the Simadyn-D rack has had an internal fault.

CORRECTIVE PROCEDURE:

1. See Processor Error Codes for the PM16.

END OF PROCEDURE

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RECTIFIER TROUBLESHOOTING

FAULT 1021 LINE VOLTAGE MORE THAN 110%

EXPLANATION:

Simadyn-D has detected that the incoming line voltage has exceeded 880vac (nominal voltage is
800vac). This voltage is not read directly from the 800vac secondary of the main power
transformer (DPT), but rather from the 460vac of the auxiliary transformer. This 460vac voltage
is monitored and scaled by the synchronization voltage module (device N30-A15 located at the
bottom of cabinet +N1B) on pins X1:2, X1:4, and X1:6. Once appropriately scaled, this signal is
sent out X2:18 of the synchronization voltage module to X2:31 and X2:32 of SE26.1 Isolator
Interface Module (device N64-A118 located on the side panel in cabinet +N1B). This signal is
output on SE26.1 pins U+ and U- to the SE7.1 I/O Interface Module (device N64-A13 located in
cabinet +N1B) pins X2:3 and X2:13. Ribbon cable N64-RC106 then connects SE7.1 pins X1:5
and X1:6 to the EM11 I/O Module (device N50-A11-D08 located in Slot 8 of the Simadyn-D rack
in cabinet +N1A) pins X6:5 and X6:6. The Simadyn-D software actuates the fault sequence.
This condition will put the rectifier control into a Gate Blocking condition and may also be
accompanied by several rectifier and Sibas faults.

CORRECTIVE PROCEDURE:

1. With the DC bus energized but no motions on, measure the incoming 800vac line voltage
with a voltmeter. Compare this to the line voltage displayed by OP1 display panel. If they do
not agree, follow the procedure for calibrating the line voltage (see Calibrating the Line
Voltage Feedback).

2. Measure the incoming line voltage with the DC bus de-energized. It should be somewhere
in the range of 800vac-840vac. If the voltage is much higher, adjust the taps at the
substation to reduce it.

3. If the line voltage appears O.K., but the trip appears to coincide with a particular time of day,
then it may be an external event causing the problem. This event should be isolated and
corrected. An external line monitor may be necessary to adequately monitor the line.

4. If the incoming voltage is, in fact, not exceeding 880vac, do the following:

a. Check connections from TBSYNC to circuit breaker E02-Q05 and from E02-Q05 to the
synchronization voltage module.

WARNING: THIS VOLTAGE IS ALWAYS HOT WHILE THE MAIN ON THE MCC IS
ON, USE EXTREME CAUTION WHEN CHECKING THESE CONNECTIONS!

Check that the jumpers and connections on the synchronization voltage module are as
per the prints. Make sure to turn off E02-Q05 while doing this.

b. Measure the output of the synchronization voltage module between connector X2:18 and
X2:3. This voltage should read in the range of 5.5vdc to 6.6vdc. If it does not read in
this range, disconnect the wire from the X2:18 and read again. If it is still not correct,
replace the synchronization voltage module.

c. If the voltage is correct with the wires removed, then disconnect the wires from SE26.1
pins X2:31 and X2:32 and again measure the voltage. If it is now correct, then replace
the SE26.1. If it is still incorrect, then remove the wire from the SE20.2 pin X6:5 (device

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 RECTIFIER TROUBLESHOOTING

N50-A11-D13 located in Slot 13 of the Simadyn-D rack in cabinet +N1A). If the voltage
now reads correctly, replace the SE20.2.

d. If the synchronizing voltage output is correct, then measure the input and output of the
SE26.1. This is an isolator module so the output should always be equal to the input.
The input is on pins X2:31 and X2:32 and the output is on pins X3:4 and X3:5. If the
output is not equal to the input, replace the SE26.1.

e. If the SE26.1 module is O.K., then read the voltage on the SE7.1 pins X2:3 and X2:13.
Also check the shield termination on this wire. If the voltage is O.K., then replace the
EM11 card.

END OF PROCEDURE

FAULT 1022 LINE VOLTAGE LESS THAN 70%

EXPLANATION:

Simadyn-D has detected that the incoming line voltage has gone below 560vac (nominal voltage
is 800vac). This voltage is not read directly from the 800vac secondary of the main power
transformer (DPT), but rather from the 460vac of the auxiliary transformer. This 460vac voltage
is monitored and scaled by the synchronization voltage module (device N30-A15 located at the
bottom of cabinet +N1B) on pins X1:2, X1:4, and X1:6. Once appropriately scaled, this signal is
sent out X2:18 of the synchronization voltage module to X2:31 and X2:32 of SE26.1 Isolator
Interface Module (device N64-A118 located on the side panel in cabinet +N1B). This signal is
output on SE26.1 pins U+ and U- to the SE7.1 I/O Interface Module (device N64-A13 located in
cabinet +N1B) pins X2:3 and X2:13. Ribbon cable N64-RC106 then connects SE7.1 pins X1:5
and X1:6 to the EM11 I/O Module (device N50-A11-D08 located in Slot 8 of the Simadyn-D rack
in cabinet +N1A) pins X6:5 and X6:6. The Simadyn-D software actuates the fault sequence.
This condition will put the rectifier control into a Gate Blocking condition and may also be
accompanied by several rectifier and Sibas faults.

CORRECTIVE PROCEDURE:

1. With the DC bus energized but no motions on, measure the incoming 800vac line voltage
with a voltmeter. Compare this to the line voltage displayed by OP1 Display panel. If they do
not agree, follow the procedure for calibrating the line voltage (see Calibrating the Line
Voltage Feedback).

2. Measure the incoming line voltage with the DC bus de-energized. It should be somewhere
in the range of 800vac-840vac. If the voltage is much lower, adjust the taps at the substation
to increase it.

3. If the line voltage appears O.K., but the trip appears to coincide with a particular time of day,
then it may be an external event causing the problem. This event should be isolated and
corrected. An external line monitor may be necessary to adequately monitor the line.

4. If the incoming voltage is, in fact, not going below 560vac, do the following:

a. Check connections from TBSYNC to circuit breaker E02-Q05 and from E02-Q05 to the
synchronization voltage module.

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RECTIFIER TROUBLESHOOTING

WARNING: THIS VOLTAGE IS ALWAYS HOT WHILE THE MAIN ON THE MCC IS
ON, USE EXTREME CAUTION WHEN CHECKING THESE CONNECTIONS!

Check that the jumpers and connections on the synchronization voltage module are as
per the prints. Make sure to turn off E02-Q05 while doing this.

b. Measure the output of the synchronization voltage module between connector X2:18 and
X2:3. This voltage should read in the range of 5.5vdc to 6.6vdc. If it does not read in
this range, disconnect the wire from the X2:18 and read again. If it is still not correct,
replace the synchronization voltage module.

c. If the voltage is correct with the wires removed, then disconnect the wires from SE26.1
pins X2:31 and X2:32 and again measure the voltage. If it is now correct, then replace
the SE26.1. If it is still incorrect, then remove the wire from the SE20.2 pin X6:5 (device
N50-A11-D13 located in Slot 13 of the Simadyn-D rack in cabinet +N1A). If the voltage
now reads correctly, replace the SE20.2.

d. If the synchronizing voltage output is correct, then measure the input and output of the
SE26.1. This is an isolator module so the output should always be equal to the input.
The input is on pins X2:31 and X2:32 and the output is on pins X3:4 and X3:5. If the
output is not equal to the input, replace the SE26.1.

e. If the SE26.1 module is O.K., then read the voltage on the SE7.1 pins X2:3 and X2:13.
Also check the shield termination on this wire. If the voltage is O.K., then replace the
EM11 card.

END OF PROCEDURE

FAULT 1023 LOWLINE WARNING

EXPLANATION:

This is not a fault, but a warning that line voltage is going below 700vac and staying below
700vac for longer than 100ms. While this lower input voltage will not cause commutation faults in
the rectifier, it may affect the peak power that is available to the motions. It can also be
responsible for erratic behavior in the motions.

CORRECTIVE PROCEDURE:

1. No action is necessary.

END OF PROCEDURE

FAULT 1024 SIM-D / PLC COMMUNICATION FAULT

EXPLANATION:

The Simadyn-D has detected a serial link communication loss with the PLC. This serial Link is
used to transfer operator commands and status bits between the PLC to the Simadyn-D.
Processor #1 (PM16) connector X02 of the Simadyn-D rack is connected via shielded cable N61-
RC2 to the PLC.

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 RECTIFIER TROUBLESHOOTING

If either the Simadyn-D or the PLC have been powered down independently of one other, it is
possible for them to lose communication.

CORRECTIVE PROCEDURE:

1. If the PLC or Simadyn-D have been powered down independently of each other, do the
following:

a. Observe the lights on the PLC Basic Module.

b. Using the Simadyn-D Card Rack Reset, reset the Simadyn-D rack. DO NOT reset the
rack if the DC bus is energized.

c. If the communication lights flash on the Basic Module, communication has been restored.

d. Remember to reset the Simadyn-D after the PLC has been off or has been in
programming mode.

2. Check continuity and insulation of shielded cable N61-RC2. Verify the cable wiring is
according to the prints. Verify that the jumper in the plug is installed on the PLC side.

3. Replace the communications submodule in connector X52 (type SS2 V.24 RS232) of
Processor #1 (PM16).

4. Replace Processor #1 (PM16). Be sure to install the EPROM from the original PM16 into the
new PM16.

END OF PROCEDURE

FAULT 1025 HOIST OVERSPEED FAULT

EXPLANATION:

Simadyn-D has detected from hoist tach feedback that the hoist motor speed has gone above
2500 rpm. Hoist motor speed is monitored by EM11 (device N50-A11-D08) - X5 connector. Hoist
Tachometer’s 180º and 270º channels are used by Simadyn-d to monitor the speed, whereas
Hoist Tachometer’s 0º and 90º channels are used by SiBas as speed feedback for motion
control.

CORRECTIVE PROCEDURE:

1. If the overspeed condition was the result of an overhauling load (i.e. the bank collapsing on
the machine), note it and continue operations.

2. If the fault occurred in conjunction with another fault, then troubleshoot the fault that
accompanied the overspeed fault.

3. Ensure that the wiring from the digital tachometer to the Siemens skid is good and all crimps
and connections are satisfactory.

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RECTIFIER TROUBLESHOOTING

4. Simadyn-d is set to detect this fault condition first to be able to provide display on OP1 panel.
To Isolate if the fault is in Simadyn-D or the tach channels used by Simadyn-D, disconnect
Hoist Tach feedback cable from X5 connector on EM11 (device: N50-A11-D08) and if SiBas
statistics still display Hoist Overspeed Faults, the the fault is real. Troubleshoot accordingly.

5. Monitor the Tach feedback signals using Scope as described in Devices section.

6. Replace EM11 (device N50-A11-D08), if necessary

END OF PROCEDURE

FAULT 1026 CROWD OVERSPEED FAULT

EXPLANATION:

Simadyn-D has detected from Crowd tach feedback that the Crowd motor speed has gone above
2500 rpm. Hoist motor speed is monitored by EM11 (device N50-A11-D09) - X5 connector.
Crowd Tachometer’s 180º and 270º channels are used by Simadyn-d to monitor the speed,
whereas Crowd Tachometer’s 0º and 90º channels are used by SiBas as speed feedback for
motion control.

CORRECTIVE PROCEDURE:

1. If the overspeed condition was the result of an overhauling load (i.e. crowd was run at full
speed when crowd stick was in vertical position), note it and continue operations.

2. If the fault occurred in conjunction with another fault, then troubleshoot the fault that
accompanied the overspeed fault.

3. Ensure that the wiring from the digital tachometer to the Siemens skid is good and all crimps
and connections are satisfactory.

4. Simadyn-d is set to detect this fault condition first to be able to provide display on OP1 panel.
To Isolate if the fault is in Simadyn-D or the tach channels used by Simadyn-D, disconnect
Crowd Tach feedback cable from X5 connector on EM11 (device: N50-A11-D09) and if SiBas
statistics still display Crowd Overspeed Faults, the the fault is real. Troubleshoot accordingly.

5. Monitor the Tach feedback signals using Scope as described in Devices section.

6. Replace EM11 (device N50-A11-D09), if necessary

END OF PROCEDURE

FAULT 1027 SWING OVERSPEED FAULT

EXPLANATION:

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 RECTIFIER TROUBLESHOOTING

Simadyn-D has detected from Swing tach feedback that the Swing motor speed has gone above
2500 rpm. Swing motor speed is monitored by EM11 (device N50-A11-D10) - X5 connector.
Swing Tachometer’s 180º and 270º channels are used by Simadyn-d to monitor the speed,
whereas Swing Tachometer’s 0º and 90º channels are used by SiBas as speed feedback for
motion control.

CORRECTIVE PROCEDURE:

1. If the fault occurred in conjunction with another fault, then troubleshoot the fault that
accompanied the overspeed fault.

2. Ensure that the wiring from the digital tachometer to the Siemens skid is good and all crimps
and connections are satisfactory.

3. Simadyn-d is set to detect this fault condition first to be able to provide display on OP1 panel.
To Isolate if the fault is in Simadyn-D or the tach channels used by Simadyn-D, disconnect
Swing Tach feedback cable from X5 connector on EM11 (device: N50-A11-D10) and if SiBas
statistics still display Swing Overspeed Faults, the the fault is real. Troubleshoot accordingly.

4. Monitor the Tach feedback signals using Scope as described in Devices section.

5. Replace EM11 (device N50-A11-D10), if necessary

END OF PROCEDURE

FAULT 1028 DPC INTERPOSING RLY OPEN BY SIM-D

EXPLANATION:

Simadyn-D is sensing that DPC Interposing relay (4th relay of N61-A13 Binary output card -
SE6.1) opened preventing from DPC to come ON. This relay is opened by SIM-D only on
Recttifier Gate block condition after 3 seconds. Reset for this is automatic when Gate blocking
condition is removed.

CORRECTIVE PROCEDURE:

1. Check 4th Relay of Binary output card SE6.1 (N61-A13) for open condition. Check to see if
H4 light is lit, if the light is OFF, Troubleshooting present Gate block condition.

2. If no Gate block condition is present, using Telemaster (Service) program, monitor the
connector
P1. SEQP1. L50. I4

If the value on the above connector is 1, Simadyn-D program is indicating that Rectifier Gate
block conditions do not exist

3. If gate block conditions not present, Check that the green LED 1P on the SE4.1 module is lit.
It should be lit indicating that +24vdc is supplying the SE6.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. Keep in
mind that E02-Q34 supplies the +24vdc to this SE4.1 module.

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RECTIFIER TROUBLESHOOTING

4. Replace SE6.1

5. Check continuity and insulation of ribbon cable N61-RC5. Replace if necessary.

6. Replace Simadyn-D Processor #1 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1033 RECTIFIER: SYNCHR. VOLTAGE MISSING (TG6)

EXPLANATION:

The processor responsible for rectifier control (PG16) has not detected the synchronization
voltage. This synchronization voltage is used by the rectifier control to synchronize the SCR firing
pulses with the incoming 800vac line voltage. A 460vac voltage that is in phase with the 800vac
incoming line voltage is supplied from the main breaker on the Bucyrus MCC where it is fuse
protected. It is then cabled to terminal block TBSYNCH (on pins 31, 32, and 33) located at the
Terminal panel +CTA. It is then supplied by circuit breaker E02-Q05 to the synchronization
voltage module (device N30-A15 located at the bottom of cabinet +N1B) on pins X1:2, X1:4, and
X1:6. Circuit breaker E02-Q05 has an adjustable trip level and is set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (devices N50-
A11-D13) is located in the Simadyn-D rack (slots 13) in cabinet +N1A. The SE20.2 card sends
the signal to PG16 processor via shielded cable N63-RC7. The PG16 processor then evaluates
the signal and issue the fault. This fault will cause a Gate Blocking condition in the rectifier
control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH. If all phases do not measure 460vac,
then check the fuses and the wiring in the MCC main breaker. This is the large enclosure
located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker E02-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Examine the synchronization voltage module. Make sure that all connections are tight and
that jumpers are installed as per the prints. Also check the line voltage level on the OP1
Display panel. If this voltage is low or zero, this would also indicate a defective synchronizing
module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

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 RECTIFIER TROUBLESHOOTING

END OF PROCEDURE

FAULT 1034 RECTIFIER: SYNCHR. VOLTAGE INCORRECT

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected the synchronization voltage
as being faulty. This synchronization voltage is used by the rectifier control to synchronize the
SCR firing pulses with the incoming 800vac line voltage. A 460vac voltage that is in phase with
the 800vac incoming line voltage is supplied from the main breaker on the Bucyrus MCC where it
is fuse protected. It is then cabled to terminal block TBSYNCH (on pins 31, 32, and 33) located
at the Terminal panel +CTA. It is then supplied by circuit breaker E02-Q05 to the synchronization
voltage module (device N30-A15 located at the bottom of cabinet +N1B) on pins X1:2, X1:4, and
X1:6. Circuit breaker E02-Q05 has an adjustable trip level and is set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (devices N50-
A11-D13) is located in the Simadyn-D rack (slots 13) in cabinet +N1A. The SE20.2 card sends
the signal to the PG16 processor via shielded cable N63-RC7. The PG16 processor then
evaluates the signal and issue the fault. This fault will cause a Gate Blocking condition in the
rectifier control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH. If all phases do not measure 460vac,
then check the fuses and the wiring in the MCC main breaker. This is the large enclosure
located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker N30-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Examine the synchronization voltage module. Make sure that all connections are tight and
that jumpers are installed as per the prints. Also check the line voltage level on the OP1
Display panel. If this voltage is low or zero, this would also indicate a defective synchronizing
module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1035 RECTIFIER1: SYNCHR. VOLTAGE L1-L2 MISSING

EXPLANATION:

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RECTIFIER TROUBLESHOOTING

The processor responsible for rectifier control (PG16) has not detected the synchronization
voltage phase 1 and/or phase 2. This synchronization voltage is used by the rectifier control to
synchronize the SCR firing pulses with the incoming 800vac line voltage. A 460vac voltage that
is in phase with the 800vac incoming line voltage is supplied from the main breaker on the
Bucyrus MCC where it is fuse protected. It is then cabled to terminal block TBSYNCH (on pins
31, 32, and 33) located at the Terminal panel +CTA. It is then supplied by circuit breaker E02-
Q05 to the synchronization voltage module (device N30-A15) located at the bottom of cabinet
+N1B on pins X1:2, X1:4, and X1:6. Circuit breaker E02-Q05 has an adjustable trip level and is
set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (devices N50-
A11-D13) is located in the Simadyn-D rack (slot 13) in cabinet +N1A. The SE20.2 card sends the
signal to the PG16 processor via shielded cable N63-RC7. The PG16 processor then evaluates
the signal and issue the fault. This fault will cause a Gate Blocking condition in the rectifier
control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH. If all phases do not measure 460vac,
then check the fuses and the wiring in the MCC main breaker. This is the large enclosure
located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker E02-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Examine the synchronization voltage module. Make sure that all connections are tight and
that jumpers are installed as per the prints. Also check the line voltage level on the OP1
Display panel. If this voltage is low or zero, this would also indicate a defective synchronizing
module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1036 RECTIFIER: SYNCHR. VOLTAGE L1-L3 MISSING

EXPLANATION:

The processor responsible for rectifier control (PG16) has not detected the synchronization
voltage phase 1 and/or phase 3. This synchronization voltage is used by the rectifier control to
synchronize the SCR firing pulses with the incoming 800vac line voltage. A 460vac voltage that
is in phase with the 800vac incoming line voltage is supplied from the main breaker on the
Bucyrus MCC where it is fuse protected. It is then cabled to terminal block TBSYNCH (on pins

1-24
 RECTIFIER TROUBLESHOOTING

31, 32, and 33) located at the Terminal panel +CTA. It is then supplied by circuit breaker E02-
Q05 to the synchronization voltage module (device N30-A15) located at the bottom of cabinet
+N1B on pins X1:2, X1:4, and X1:6. Circuit breaker E02-Q05 has an adjustable trip level and is
set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (devices N50-
A11-D13) is located in the Simadyn-D rack (slot 13) in cabinet +N1A. The SE20.2 card sends the
signal to the PG16 processors via shielded cables N63-RC7. The PG16 processor then
evaluates the signal and issue the fault. This fault will cause a Gate Blocking condition in the
rectifier control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH. If all phases do not measure 460vac,
then check the fuses and the wiring in the MCC main breaker. This is the large enclosure
located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker E02-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Examine the synchronization voltage module. Make sure that all connections are tight and
that jumpers are installed as per the prints. Also check the line voltage level on the OP1
Display panel. If this voltage is low or zero, this would also indicate a defective synchronizing
module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1037 RECTIFIER: PULSE POSITION INCORRECT (TG6)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an error with rectifier pulse
timing. This can be related to a changing frequency on the synchronization voltage. This fault can
also be caused by propelling the machine with a motor-generator (MG) set instead of using trail
cable power. If the speed of the MG set has too much variance under load changes, this fault can
be generated (see Step 8 if this is the problem). This synchronization voltage is used by the
rectifier control to synchronize the SCR firing pulses with the incoming 800vac line voltage. A
460vac voltage that is in phase with the 800vac incoming line voltage is supplied from the main
breaker on the Bucyrus MCC where it is fuse protected. It is then cabled to terminal block
TBSYNCH (on pins 31, 32, and 33) located at the Termnial panel +CTA. It is then supplied by
circuit breaker E02-Q05 to the synchronization voltage module (device N30-A15) located at the

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RECTIFIER TROUBLESHOOTING

bottom of cabinet +N1B on pins X1:2, X1:4, and X1:6. Circuit breaker E02-Q05 has an adjustable
trip level and is set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (devices N50-
A11-D13) is located in the Simadyn-D rack (slot 13) in cabinet +N1A. The SE20.2 card sends the
signal to the respective PG16 processor via shielded cable N63-RC7. The PG16 processor then
evaluates the signal and issue the fault. This fault will cause a Gate Blocking condition in the
rectifier control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH. If all phases do not measure 460vac,
then check the fuses and the wiring in the MCC main breaker. This is the large enclosure
located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker E02-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Examine the synchronization voltage module. Make sure that all connections are tight and
that jumpers are installed as per the prints. Also check the line voltage level on the OP1
Display panel. If this voltage is low or zero, this would also indicate a defective synchronizing
module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

8. If the fault happens only when propelling while using an MG set, then the problem can
possibly be temporarily corrected by lengthening the propel ramp-up and ramp-down times to
decrease the severity of load hits on the generator. Remember to change them back to their
original settings when the machine is back on the trail cable.

END OF PROCEDURE

FAULT 1038 RECTIFIER: SYNCHR. VOLTAGE WRONG ROTATION

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected the synchronization voltage
phasing as being A-C-B. It must be A-B-C phasing and can be caused by incorrect wiring or
errors in the phase detection circuit. This synchronization voltage is used by the rectifier control
to synchronize the SCR firing pulses with the incoming 800vac line voltage. A 460vac voltage
that is in phase with the 800vac incoming line voltage is supplied from the main breaker on the
Bucyrus MCC where it is fuse protected. It is then cabled to terminal block TBSYNCH (on pins
31, 32, and 33) located at the Terminal panel +CTA. It is then supplied by circuit breaker E02-

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 RECTIFIER TROUBLESHOOTING

Q05 to the synchronization voltage module (device N30-A15) located at the bottom of cabinet
+N1B. Circuit breaker E02-Q05 has an adjustable trip level and is set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by SE20.2
SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (device N50-
A11-D13) is located in the Simadyn-D rack (slot 13) in cabinet +N1A. The SE20.2 card sends the
signal to the PG16 processor via shielded cables N63-RC7. The PG16 processor then evaluates
the signal and issue the fault. This fault will cause a Gate Blocking condition in the rectifier
control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH pins 31, 32, and 33. If all phases do not
measure 460vac, then check the fuses and the wiring in the MCC main breaker. This is the
large enclosure located in the upper left hand portion of the MCC. Also, with an oscilloscope
or phase sequence checker, ensure that the phase rotation is A-B-C at TBSYNCH.

2. Measure the voltage and phasing on the output of circuit breaker E02-Q05. If all phases do
not measure 460vac, check the breaker and the wiring.

3. Measure the voltage level and phasing at the synchronization voltage module pins X1:2,
X1:4, and X1:6. Make sure that all connections are tight and that jumpers are installed as per
the prints. Also check the line voltage level on the OP1 Display panel. If this voltage is low or
zero, this would also indicate a defective synchronizing module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1039 RECTIFIER: ERROR-DISPLACEMENT ANGLE INPUT

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal software failure.
The PG16 is located in slot 6 of the Simadyn-D rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

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RECTIFIER TROUBLESHOOTING

FAULT 1040 RECTIFIER: GATE CURRENT REGUL. CLOCK ERROR

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure. The PG16
is located in slot 6 of the Simadyn-D rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1041 RECTIFIER: CURRENT ACT HARDWARE FAULT (CAV)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure pertaining
to the circuitry that evaluates the rectifier current. The PG16 is located in slot 6 of the Simadyn-D
rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1042 RECTIFIER: FORWARD RECTIFIER OVERCURRENT

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an instantaneous overcurrent
on the forward rectifier bridges. For the 495B and 395B2 Shovel Systems, this value is 4200
amps dc.

Rectifier bridge measures the DC bus current via a current shunt (device R40-SH in cabinet
+R1A). The rating on this device is 100mv = 2500 amps. This signal is sent to a DC current
transducer (DCI transducer) pins 6 and 10 (device R40-A3 in cabinet +R1B). The gain of this
transducer is 150mvdc input = 10vdc output. The output of the DC current transducer is then
sent out pins 4 and 5 to a SITOR/Simadyn-D Interface Module (device R11-A501 located at the
bottom of cabinet +R1B) on pins b12 and z12 via shielded cable. Next, the signal is sent out on
connector X0 to a SE20.2 interface module (device N50-A11-D13 located in the Simadyn-D rack
Slot 13 in cabinet +N1A) via shielded cable N63-RC105. The current signal is scaled in the
SE20.2 and converted to a frequency where it is then sent to a PG16 card (device N50-A11-
D06_P3 located in the Simadyn-D rack Slot 6) on cable N63-RC7. This cable connects from X3
of the SE20.2 card to plug X7 of the PG16 card.

An overcurrent in the forward rectifier(s) (the motoring direction) can be caused by several things:

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 RECTIFIER TROUBLESHOOTING

1. Power section hardware failure

2. Current feedback calibration error
3. Severe incoming line voltage oscillations

Please see the appropriate CORRECTIVE PROCEDURE section below that applies to your
situation.

CORRECTIVE PROCEDURE:
POWER SECTION HARDWARE FAILURE

A power section hardware failure means that the overcurrents are caused by an SCR not firing or
misfiring.

1. Check all SCRs for shorts (see SITOR BLOCKS).

2. Check the SCR firing pulses with a current probe. Use Telemaster (Service) program to
initiate firing pulses.

a. LOCK OUT MAIN CONTACTOR.

b. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change
the following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

c. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card
located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

d. Using an oscilloscope with a small current probe, measure all pulses on the gate lead.
The gate lead is available on the upper left-hand corner of the cover the sitor block.
Have the scope "line triggered". Make sure that there are two pulses per block and that
the first pulse is 600 microseconds and the second pulse is 400 microseconds in
duration. By keeping the scope line triggered, the pulses should move from left to right
across the screen if the blocks are checked in numerical order. If any pulses have
significant deviation from the others, do the following:

1. Check the pulses on the pulse distribution board on test points 1.1, 1.2, 1.3, 1.4, 1.5,
and 1.6. If they all look O.K., replace the sitor block that has the bad pulse and
retest.

2. If the pulse looks bad on the pulse distribution board, pull the firing pulse cable from
the associated sitor block and retest. If the pulse distribution board waveform now
looks good, replace the sitor module. Otherwise, go to step 6.

3. If there are still no pulses, go to step 7.

3. Remove the sitor blocks and inspect them. Make sure that all connections are tight and that
all plastic insulators are in good condition. Inspect the copper buswork behind the sitor
blocks for loose connections, arcing to ground, proper clamping pressure, etc.

4. Inspect +24vdc connections on all pulse distribution boards (devices R11-A101 and R12-
A102 in cabinet +R1A). An intermittent connection on either of the pulse distribution boards
can affect both rectifier bridges.

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RECTIFIER TROUBLESHOOTING

5. Inspect all connections on the +24vdc firing pulse power supply (device R11-G101 in cabinet
+R1B).

6. Replace the SE20.2

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

CORRECTIVE PROCEDURE:
CURRENT FEEDBACK CALIBRATION ERROR

1. The current feedback can be checked by the following procedure.

a. LOCK OUT MAIN CONTACTOR.

b. Disconnect the pulse cables from all rectifier bridges.

c. Disconnect the top shunt lead of either shunt #1 (R40-SH) and hook a battery box across
it. Leave the battery box off.

d. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change
the following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

e. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card
located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

f. Turn the battery box connected to the shunt on. Carefully adjust this to 100.0mv. The
Troubleshooting Computer should read exactly 2500 amps for DC current. If it reads
zero, then reverse the polarity of the battery box.

g. If the OP1 Display panel does not display a value of 2500 amps, then adjust
potentiometer R7 on the SE24 adjustment board that is plugged into the SE20.2. There
are two SE24 modules, one has 3 fixed resistors, one has 1 fixed resistor. Adjust R7 on
the one with 3 fixed resistors.

h. Shut down the rectifier and return connections to normal.

2. If the SE20.2 cannot be adjusted to read 2500 amps, then put 150mv on the shunt and read
the output of the DCI Transducer. The output should be 10vdc +/- 0.1vdc. If this is not there,
replace the DCI Transducer.

3. Check the input of the SE24 mounted on the SE20.2. If the 10vdc is not there, check the
wiring. If it is there, replace the SE20.2.

4. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

CORRECTIVE PROCEDURE:
SEVERE INCOMING LINE VOLTAGE OSCILLATIONS

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 RECTIFIER TROUBLESHOOTING

1. This problem is external to the shovel. It may require reassigning other equipment that is
operating on the same substation or to power the shovel off of another substation. As a
general rule, it is best to keep trail cable lengths to less than 5,000 feet in length.

END OF PROCEDURE

FAULT 1043 REGEN RECTIFIER OVERCURRENT

EXPLANATION:

The PG16 has detected an instantaneous overcurrent on the regen bridge. For the 495B and
395B2 this value is 3500 amps dc.

Rectifier bridge measures the DC bus current via a current shunt (device R40-SH in cabinet
+R1A). The rating on this device is 100mv = 2500 amps. This signal is sent to a DC current
transducer (DCI transducer) pins 6 and 10 (device R40-A3 in cabinet +R1B). The gain of this
transducer is 150mvdc input = 10vdc output. The output of the DC current transducer is then
sent out pins 4 and 5 to a SITOR/Simadyn-D Interface Module (device R11-A501 located at the
bottom of cabinet +R1B) on pins b12 and z12 via shielded cable. Next, the signal is sent out on
connector X0 to a SE20.2 interface module (device N50-A11-D13 located in the Simadyn-D rack
Slot 13 in cabinet +N1A) via shielded cable N63-RC105. The current signal is scaled in the
SE20.2 and converted to a frequency where it is then sent to a PG16 card (device N50-A11-
D06_P3 located in the Simadyn-D rack Slot 6) on cable N63-RC7. This cable connects from X3
of the SE20.2 card to plug X7 of the PG16 card.

An overcurrent in T2, which is the braking or regen direction can be caused by several things:

1. Internal Hardware Problem

2. Miscalibration of Current Feedback
3. Severe Line Voltage Fluctuations

CORRECTIVE ACTION
MISCALIBRATION OF CURRENT FEEDBACK:

1. The current feedback can be checked by the following procedure.

a. LOCK OUT MAIN CONTACTOR.

b. Disconnect the pulse cables from all rectifier bridges.

c. Disconnect the top shunt lead of either shunt #1 (R40-SH) and hook a battery
box across it. Leave the battery box off.

d. Bring the Regen rectifier control ON, by using Telemaster (service) program.
Change the following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

e. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16
card located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

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RECTIFIER TROUBLESHOOTING

f. Turn the battery box connected to the shunt on. Carefully adjust this to 100.0mv.
The Troubleshooting Computer should read exactly 2500 amps for DC current. If
it reads zero, then reverse the polarity of the battery box.

g. If the OP1 Display panel does not display a value of 2500 amps, then adjust
potentiometer R7 on the SE24 adjustment board that is plugged into the SE20.2.
There are two SE24 modules, one has 3 fixed resistors, one has 1 fixed resistor.
Adjust R7 on the one with 3 fixed resistors.

h. Shut down the rectifier and return connections to normal.

2. If the SE20.2 cannot be adjusted to read 2500 amps, then put 150mv on the shunt and
read the output of the DCI Transducer. The output should be 10vdc +/- 0.1vdc. If this is
not there, replace the DCI Transducer.

3. Check the input of the SE24 mounted on the SE20.2. If the 10vdc is not there, check
the wiring. If it is there, replace the SE20.2.

4. Replace the PG16. Be sure to install the EPROM and submodules from the original
PG16 into the new PG16.

CORRECTIVE ACTION
INTERNAL HARDWARE FAILURE:

An internal failure means that overcurrents are caused by an SCR not firing or misfiring.

3. 1 Check all SCRs for shorts (see SITOR BLOCKS).

4. Check the SCR firing pulses with a current probe. Use Telemaster (Service) program to
initiate firing pulses.

i. LOCK OUT MAIN CONATCTOR.

j. Bring the Regen rectifier control ON, by using Telemaster (service) program. Change the
following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON2 Æ1

k. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card
located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Red Light).

l. Using an oscilloscope with a small current probe, measure all pulses on the gate lead.
The gate lead is available on the upper left-hand corner of the cover the sitor block.
Have the scope "line triggered". Make sure that there are two pulses per block and that
the first pulse is 600 microseconds and the second pulse is 400 microseconds in
duration. By keeping the scope line triggered, the pulses should move from left to right
across the screen if the blocks are checked in numerical order. If any pulses have
significant deviation from the others, do the following:

4. Check the pulses on the pulse distribution board on test points. If they all look O.K.,
replace the sitor block that has the bad pulse and retest.

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 RECTIFIER TROUBLESHOOTING

5. If the pulse looks bad on the pulse distribution board, pull the firing pulse cable from
the associated sitor block and retest. If the pulse distribution board waveform now
looks good, replace the sitor module. Otherwise, go to step 6.

6. If there are still no pulses, go to step 7.

8. Remove the sitor blocks and inspect them. Make sure that all connections are tight and that
all plastic insulators are in good condition. Inspect the copper buswork behind the sitor
blocks for loose connections, arcing to ground, proper clamping pressure, etc.

9. Inspect +24vdc connections on all pulse distribution boards (devices R11-A101 and R12-
A102 in cabinet +R1A). An intermittent connection on either of the pulse distribution boards
can affect both rectifier bridges.

10. Inspect all connections on the +24vdc firing pulse power supply (device R11-G101 in cabinet
+R1B).

11. Replace the SE20.2

12. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1044 RECTIFIER: CURRENT ACT CONFIG FAULT (CAV)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure pertaining
to the circuitry that evaluates the rectifier current. The PG16 is located in slot 16 of the Simadyn-
D rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1045 RECTIFIER: VOLTAGE ACT HARDWARE FAULT (EMF)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure pertaining
to the circuitry that evaluates the DC bus voltage. The PG16 is located in slot 6 of the Simadyn-D
rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

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RECTIFIER TROUBLESHOOTING

END OF PROCEDURE

FAULT 1046 RECTIFIER: VOLTAGE ACT CONFIG FAULT (EMF)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure pertaining
to the circuitry that evaluates the DC bus voltage. The PG16 is located in slot 6 of the Simadyn-D
rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1047 RECTIFIER: ZERO CURRENT SIG. MISSING (SOL)

EXPLANATION:

The processor responsible for rectifier control (PG16) checks for the "current equal zero" signal
(I=0) prior to turning on the rectifier. If this signal is not present, this fault occurs. The PG16 is
located in slot 6 of the Simadyn-D rack in cabinet +N1A. The I=0 signal is developed in the
SE20.2 (device N50-A11-D13 in the Simadyn-D rack in Slot 13 in cabinet +N1A) from the current
feedback. However, it should be noted that this is a digital signal and is separate from the
current feedback that goes to the processor for regulation purposes. Incorrect operation of this
circuit may result in DC bus related faults.

CORRECTIVE PROCEDURE:

1. The current feedback can be checked by the following procedure.

a. LOCK OUT MAIN CONTACTOR.

b. Disconnect the pulse cables from all rectifier bridges.

c. Disconnect the top shunt lead of either shunt #1 (R40-SH) and hook a battery
box across it. Leave the battery box off.

d. Bring the Regen rectifier control ON, by using Telemaster (service) program.
Change the following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

e. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16
card located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

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 RECTIFIER TROUBLESHOOTING

f. Turn the battery box connected to the shunt on. Carefully adjust this to 100.0mv.
The Troubleshooting Computer should read exactly 2500 amps for DC current. If
it reads zero, then reverse the polarity of the battery box.

g. If the OP1 Display panel does not display a value of 2500 amps, then adjust
potentiometer R7 on the SE24 adjustment board that is plugged into the SE20.2.
There are two SE24 modules, one has 3 fixed resistors, one has 1 fixed resistor.
Adjust R7 on the one with 3 fixed resistors.

h. Shut down the rectifier and return connections to normal.

2. If the SE20.2 cannot be adjusted to read 2500 amps, then put 150mv on the shunt and
read the output of the DCI Transducer. The output should be 10vdc +/- 0.1vdc. If this is
not there, replace the DCI Transducer.

3. Check the input of the SE24 mounted on the SE20.2. If the 10vdc is not there, check the
wiring. If it is there, replace the SE20.2.

4. Replace the PG16. Be sure to install the EPROM and submodules from the original
PG16 into the new PG16.

END OF PROCEDURE

FAULT 1048 RECTIFIER: AUTO REVERSE CONFIG. FAULT (SOL)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected an internal failure pertaining
to the circuitry that evaluates the rectifier bridge switchover (forward to regenerative bridge
operation and regenerative to forward bridge operation). The PG16 is located in slot 6 of the
Simadyn-D rack in cabinet +N1A.

CORRECTIVE PROCEDURE:

1. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1049 RECTIFIER: LINE VOLTAGE UNSTABLE (TGF)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected unexplained variations in the
synchronization voltage. The PG16 is located in slot 6 of the Simadyn-D rack in cabinet +N1A.
This synchronization voltage is used by the rectifier control to synchronize the SCR firing pulses
with the incoming 800vac line voltage. A 460vac voltage that is in phase with the 800vac
incoming line voltage is supplied from the main breaker on the Bucyrus MCC where it is fuse
protected. It is then cabled to terminal block TBSYNCH (on pins 31, 32, and 33) located at the
Terminal panel +CTA. It is then supplied by circuit breaker E02-Q05 to the synchronization

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RECTIFIER TROUBLESHOOTING

voltage module (device N30-A15 located at the bottom of cabinet +N1B). Circuit breaker E02-
Q05 has an adjustable trip level and is set at 0.16 amps.

The synchronization voltage module converts the 460vac voltage to logic level signals and sends
this information from pins X2:2, X2:12, X2:13, and X2:15. These signals are received by the
SE20.2 SITOR Interface Module on pins X6:7, X6:8, X6:9 and X6:10. The SE20.2 module (device
N50-A11-D13) is located in the Simadyn-D rack (slot 13) in cabinet +N1A. The SE20.2 sends the
signal to the PG16 via shielded cable N63-RC7. The PG16 then evaluates the signal and issues
the fault. This fault will cause a Gate Blocking condition in the rectifier control.

CORRECTIVE PROCEDURE:

1. Measure the voltage on terminal block TBSYNCH pins 31, 32, and 33. If all phases do not
measure 460vac, then check the fuses and the wiring in the MCC main breaker. This is the
large enclosure located in the upper left hand portion of the MCC.

2. Measure the voltage on the output of circuit breaker E02-Q05. If all phases do not measure
460vac, check the breaker and the wiring.

3. Measure the voltage level at the synchronization voltage module pins X1:2, X1:4, and X1:6.
Make sure that all connections are tight and that jumpers are installed as per the prints. Also
check the line voltage level on the OP1 Display panel. If this voltage is low or zero, this
would also indicate a defective synchronizing module.

4. Examine the connections between the synchronization module and the SE20.2.

5. Check continuity and insulation of shielded cable N63-RC7.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1050 RECTIFIER: SITOR FUSE FAILURE (TGF)

EXPLANATION:

This fault is not used on Shovel Systems. It is disabled at the SITOR/Simadyn-D Interface
Module (device R11-A501 located under Regen bridge in cabinet +R1B) by placing a jumper
between X1:b18 (+24vdc) and X1:b16 (FUSE SUPV).

CORRECTIVE PROCEDURE:

1. Ensure the jumper is connected as per the prints.

2. Measure from connector X1:b16 to chassis ground. If +24vdc is not present, then check for
+24vdc on terminal b18. This +24vdc is supplied from the SE20.2 (device N50-A11-D13 in
slot 13 of the Simadyn-D rack).

3. Check continuity and insulation on shielded cable N63-RC105. This cable runs between
connector X0 of the SITOR/Simadyn-D Interface Module and connector X2 of the SE20.2.

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 RECTIFIER TROUBLESHOOTING

Remove the heads of the cable and make sure that the pins and sockets are properly seated
and that the crimping is good.

4. Check continuity and insulation on ribbon cable N63-RC7. This cable runs from the SE20.2
connector X3 to the PG16 connector X7.

5. Replace the SE20.2.

6. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1051 RECTIFIER: SITOR OVERTEMPERATURE (TGF)

EXPLANATION:

This fault is not used on Shovel Systems. It is disabled at the SITOR/Simadyn-D Interface
Module (device R11-A501 located under the Regen bridge in cabinet +R1B) by placing a jumper
between X1:b18 (+24vdc) and X1:b8 (TEMP SUPV).

CORRECTIVE PROCEDURE:

1. Ensure the jumper is connected as per the prints.

2. Measure from connector X1:b8 to chassis ground. If +24vdc is not present, then check for
+24vdc on terminal b18. This +24vdc is supplied from the SE20.2 (device M50-A11-D13 in
slot 13 of the main Simadyn-D rack).

3. Check continuity and insulation on shielded cable N63-RC105. This cable runs between
connector X0 of the SITOR/Simadyn-D Interface Module and connector X2 of the SE20.2.
Remove the heads of the cable and make sure that the pins and sockets are properly seated
and that the crimping is good.

4. Check continuity and insulation on ribbon cable N63-RC7. This cable runs from the SE20.2
connector X3 to the PG16 connector X7.

5. Replace the SE20.2

6. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1052 RECTIFIER: LINE UNDERVOLT-24V FIRING PS (TGF)

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected intolerable variations in the
+24vdc (unregulated) firing pulse power supply (device R11-G101 located under the Regen

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RECTIFIER TROUBLESHOOTING

bridge in cabinet +R1B). The PG16 is located in slot 6 of the main Simadyn-D rack in cabinet
+N1A. This fault will cause a Gate Blocking condition in the Rectifier Control.

Terminal block TB380 (located at the bottom of cabinet +M1A) supplies 380vac from the UPS to
pins 1, 2, and 3 of the +24vdc firing pulse power supply through circuit breaker E02-Q07 in
cabinet +N1A. This +24vdc voltage is output on pins 8 and 9 of the +24vdc firing pulse power
supply and connects to pins X1:b30 and X1:z30 of the SITOR/Simadyn-D Interface Module
(device R11-A501 located under the Regen bridge in cabinet +R1B). Shielded cable N63-RC105
connects from the SITOR/Simadyn-D Interface Module connector X0 to the SE20.2 card (device
N50-A11-D13 in slot 13 of the Simadyn-D rack in cabinet +N1A). Connection X3 of the SE20.2 is
connected to X7 of the PG16 through ribbon cable N63-RC7.

The actual evaluation of an undervoltage condition is done internally by the SE20.2. Since firing
pulse power supplies are noisy, this signal is filtered on the SE20.2 module. Once the
undervoltage evaluation is made, the PG16 processor is notified through cable N63-RC7, which
is connected between the SE20.2 and the PG16.

CORRECTIVE PROCEDURE:

1. Check all the connections from TB380 to the power supply.

2. Check the connections from the power supply to the SE20.2 card.

3. Check the +24vdc connections on the pulse distribution boards. These are devices R11-
A101 and R12-A102. The cables should also be checked for grounded shields.

4. Check the connections on both ends of cable N63-RC105. This cable runs between
connector X2 of the SITOR/Simadyn-D Interface Module and connector X2 of the SE20.2.
Remove the both ends on the cable and make sure the pins and sockets are properly seated
and that the crimping is good.

5. Check continuity and insulation of shielded cable N63-RC7 that connects X3 of the SE20.2 to
X7 of the PG16.

6. Replace the SE20.2.

7. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1053 RECTIFIER: EXT PULSE BLOCK (PG16 JUMPER)

EXPLANATION:

The processor responsible for rectifier control (PG16), located in Slot 6 of the Simadyn-D rack,
has detected that the "pulse inhibit" jumper is missing. This jumper connects pin X5:3 to X5:4 on
the PG16 and must be there to disable this feature.

CORRECTIVE PROCEDURE:

1. Ensure that the small blueberg jumper is properly installed.

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 RECTIFIER TROUBLESHOOTING

2. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1054 RECTIFIER: GROUP ERROR MESSAGE

EXPLANATION:

The PG16 has detected an internal processor failure.

CORRECTIVE PROCEDURE:

1. Reseat the PG16 in Slot 6 of the Simadyn-D rack.

2. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1055 RECTIFIER: FAULTY GATE CONTROL SET

EXPLANATION:

The PG16 has detected an internal failure in the circuitry used to generate the SCR firing pulses.

CORRECTIVE PROCEDURE:

1. Reseat the PG16 in Slot 6 of the Simadyn-D rack.

2. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1056 RECTIFIER: GROUP ERROR MESSAGE

EXPLANATION:

The PG16 has detected an internal processor failure.

CORRECTIVE PROCEDURE:

1. Reseat the PG16 in Slot 6 of the Simadyn-D rack.

2. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

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RECTIFIER TROUBLESHOOTING

END OF PROCEDURE

FAULT 1065 E01-Q21 24V HST TACH BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q21 has tripped. This circuit breaker (located in
cabinet +N1A) supplies +24vdc to the hoist Digital Tachometer. This circuit breaker has a non-
adjustable trip level of 1.0 amps

The Simadyn-D rack monitors the auxiliary NO contacts on this circuit breaker to determine if it
has tripped. The contacts are monitored by connectors X2:1 and X2:51 on SE4.1 card N62-A11
in cabinet +N1B. This signal is sent to the Simadyn-D rack Processor #2 (PM16) via ribbon cable
N62-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E01-Q21 for a tripped condition.

2. Isolate the hoist tachometer from the circuit breaker by disconnecting the wiring load side of
the circuit breaker. Reset the breaker. If the breaker will not reset, replace this breaker.

3. If the breaker resets, reconnect the wiring at the load side of the breaker and disconnect
from the hoist tachometer at the Junction box. Reset the breaker. If the breaker still trips,
megger the wires between the breaker and the tachometer. Inspect the wiring and replace if
necessary.

4. If the wiring is O.K. and the breaker still trips, replace the tachometer.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E01-Q21). There should be no voltage drop across this contact. If
+24vdc is present, clean the contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module N62-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

7. Check that the red LED H1 on SE4.1 module is lit. If it is not lit, measure across connector
X2:1 and X2:51. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the NO auxiliary contact on breaker E01-Q21 and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

9. Replace Simadyn-D rack Processor #2 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

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 RECTIFIER TROUBLESHOOTING

FAULT 1066 E01-Q22 24V CRD TACH BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q22 has tripped. This circuit breaker (located in
cabinet +N1A) supplies +24vdc to the Crowd Digital Tachometer. This circuit breaker has a non-
adjustable trip level of 1.0 amps

The Simadyn-D rack monitors the auxiliary NO contacts on this circuit breaker to determine if it
has tripped. The contacts are monitored by connectors X2:2 and X2:52 on SE4.1 card N62-A11
in cabinet +N1B. This signal is sent to the Simadyn-D rack Processor #2 (PM16) via ribbon cable
N62-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E01-Q22 for a tripped condition.

2. Isolate the hoist tachometer from the circuit breaker by disconnecting the wiring load side of
the circuit breaker. Reset the breaker. If the breaker will not reset, replace this breaker.

3. If the breaker resets, reconnect the wiring at the load side of the breaker and disconnect from
the hoist tachometer at the Junction box. Reset the breaker. If the breaker still trips, megger
the wires between the breaker and the tachometer. Inspect the wiring and replace if
necessary.

4. If the wiring is O.K. and the breaker still trips, replace the tachometer.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E01-Q22). There should be no voltage drop across this contact. If
+24vdc is present, clean the contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module N62-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

7. Check that the red LED H2 on SE4.1 module is lit. If it is not lit, measure across connector
X2:2 and X2:52. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the NO auxiliary contact on breaker E01-Q22 and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

9. Replace Simadyn-D rack Processor #2 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1067 E01-Q23 24V SWG TACH BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q23 has tripped. This circuit breaker (located in

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RECTIFIER TROUBLESHOOTING

cabinet +N1A) supplies +24vdc to the Swing Digital Tachometer. This circuit breaker has a non-
adjustable trip level of 1.0 amps

The Simadyn-D rack monitors the auxiliary NO contacts on this circuit breaker to determine if it
has tripped. The contacts are monitored by connectors X2:3 and X2:53 on SE4.1 card N62-A11
in cabinet +N1B. This signal is sent to the Simadyn-D rack Processor #2 (PM16) via ribbon cable
N62-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E01-Q23 for a tripped condition.

2. Isolate the hoist tachometer from the circuit breaker by disconnecting the wiring load side of
the circuit breaker. Reset the breaker. If the breaker will not reset, replace this breaker.

3. If the breaker resets, reconnect the wiring at the load side of the breaker and disconnect
from the hoist tachometer at the Junction box. Reset the breaker. If the breaker still trips,
megger the wires between the breaker and the tachometer. Inspect the wiring and replace if
necessary.

4. If the wiring is O.K. and the breaker still trips, replace the tachometer.

5. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E01-Q23). There should be no voltage drop across this contact. If
+24vdc is present, clean the contacts and try again. Replace the breaker if necessary.

6. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module N62-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.
7. Check that the red LED H3 on SE4.1 module is lit. If it is not lit, measure across connector
X2:3 and X2:53. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the NO auxiliary contact on breaker E01-Q23 and the SE4.1 module.

8. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

9. Replace Simadyn-D rack Processor #2 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1068 E01-Q26 +E1A AC CIRCUIT BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q26 has tripped. This circuit breaker (located in
cabinet +E1A) supplies 110vac to the Control cabinet +E1A door-mounted Air conditioner (device
E01-E05). This circuit breaker has non-adjustable trip level of 10.0 amps.

Simadyn-D monitors the auxiliary NO contacts on this circuit breaker to determine if tripped. The
contacts are monitored by connectors X2:4 and X2:54 on SE4.1 card N62-A11 in cabinet +N1B.
This signal is sent to the Simadyn-D rack Processor #2 (PM16) via ribbon cable N62-RC5.

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 RECTIFIER TROUBLESHOOTING

CORRECTIVE PROCEDURE:

1. Check circuit breaker E01-Q26 for a tripped condition.

2. If the circuit breaker has tripped, isolate the door-mounted Air conditioner from the circuit
breaker. Reset the breaker. If the breaker will not reset, replace that breaker.

3. If the circuit breaker is O.K., then troubleshoot the wiring between circuit breaker E01-Q26
and the door-mounted Air conditioner. If the wiring is O.K., isolate the component that is
causing that circuit breaker to trip and replace it.

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E01-Q26). There should be no voltage drop across contacts. If +24vdc is
present, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module N62-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

6. Check that the red LED H4 on SE4.1 module is lit. If it is not lit, measure across connector
X2:4 and X2:54. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between both NO auxiliary contacts and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

8. Replace Simadyn-D rack Processor #2 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1069 E01-Q27 +N1A AC CIRCUIT BREAKER TRIPPED

EXPLANATION:

Simadyn-D is sensing that circuit breaker E01-Q27 has tripped. This circuit breaker (located in
cabinet +E1A) supplies 110vac to the SiBAS / Simadyn-D cabinet +N1A door-mounted Air
conditioner (device E01-E06). This circuit breaker has non-adjustable trip level of 10.0 amps.

Simadyn-D monitors the auxiliary NO contacts on this circuit breaker to determine if tripped. The
contacts are monitored by connectors X2:5 and X2:55 on SE4.1 card N62-A11 in cabinet +N1B.
This signal is sent to the Simadyn-D rack Processor #2 (PM16) via ribbon cable N62-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E01-Q27 for a tripped condition.

2. If the circuit breaker has tripped, isolate the door-mounted Air conditioner from the circuit
breaker. Reset the breaker. If the breaker will not reset, replace that breaker.

3. If the circuit breaker is O.K., then troubleshoot the wiring between circuit breaker E01-Q27
and the door-mounted Air conditioner. If the wiring is O.K., isolate the component that is
causing that circuit breaker to trip and replace it.

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RECTIFIER TROUBLESHOOTING

4. If the breaker has not tripped, measure with a voltmeter across the NO auxiliary contacts
(pins 23 and 24 on E01-Q27). There should be no voltage drop across contacts. If +24vdc is
present, clean the contacts and try again. Replace the breaker if necessary.

5. If the breaker is operating properly, check that the green LED 1P on the SE4.1 module N62-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

6. Check that the red LED H5 on SE4.1 module is lit. If it is not lit, measure across connector
X2:5 and X2:55. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between both NO auxiliary contacts and the SE4.1 module.

7. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

8. Replace Simadyn-D rack Processor #2 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1073 BEB PUSH BUTTON(S) PRESSED

EXPLANATION:

This message occurs each time the DC bus is shut down in the normal manner via the BEB
switch. There are two of these on the machine. One is on the Rectifier Control Console, labeled
MACHINE STOP, and the other is in the operator's cab labeled EMERGENCY STOP. These
NC (normally closed) momentary switches are wired in series to the Siemens skid through
terminal block TBIO pins 17 and 18 located at the Terminal Panel +CTA. For cross-referencing
to the Bucyrus prints, the switches are labeled BEB1 and BEB2. This 120vac signal is then
interfaced through the SE5.3 Interface Module (device N62-A12) pins X2:11 and X2:12 to
Simadyn-D Processor #2 (PM16) via ribbon cable N62-RC5.

The BEB function should cause the following actions if no motions are running:

1. All motions are issued with OFF command internally in the Simadyn-D Control.

2. The DC bus discharges through the Regen Rectifier to approximately 50 volts.

3. The main contactor opens up. NOTE: The main contactor drop-out time is controlled by
the PLC.

4. All blower motors and fans continue to run until the machine has cooled.

The BEB function should cause the following actions if motions are running:

1. All active motions brake electrically at maximum torque.

2. At 5% speed, the Siemens Control sends a signal to the PLC which sets the mechanical
brakes.

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 RECTIFIER TROUBLESHOOTING

3. All motions are Gate Blocked internally in the SiBas Control.

4. The DC bus then discharges through the Regen rectifier to approximately 50 volts.

5. The main contactor opens up. NOTE: the main contactor drop-out time is controlled by
the PLC.

6. All blower motors and fans continue to run until the machine has cooled.

CORRECTIVE PROCEDURE:

The following procedure assumes the bus is turning off unexpectedly and that Message 1073 is
displayed after the shutdown. CAUTION: the 120vac is supplied to the Siemens skid externally
by Bucyrus and may be present even though the Siemens skid may be de-energized.

1. Check the connections on TBIO pins 17 and 18. With both switches in their operating
position, measure with a voltmeter across pins 17 and 18. If 120vac is not present, see the
Bucyrus Troubleshooting Manual.

2. Check the connections on the SE5.3 Interface Module (device N62-A12) pins X2:11 and
X2:12 to ensure that they are tight and that 120vac is present.

3. If the switches, connections, and wiring are satisfactory, check that the green LED 1P on the
SE5.3 module is lit. It should be lit indicating that +24vdc is supplying the SE5.3 module. If it
is not, measure across terminals 1P and 1M for +24vdc. If it is present, replace the SE5.3
module. If it is not present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

4. Check that the red LED H1 on SE5.3 module N62-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:11 and X2:12. If +120vac is present, replace the SE5.3.
If it is not, check the wiring between TBIO and the SE5.3 module.

5. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

6. Replace Simadyn-D Processor #2 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1074 POEB PUSH BUTTON(S) ACTIVATED

EXPLANATION:

This message occurs each time the DC bus is shut down in the manner via the POEB switch.
There are three of these on the machine. One is on the Rectifier Control Console one is in the
operator's cab, and the third is mounted on the cabinet door of the Bucyrus PLC. These NC
(normally closed) latching switches are wired in series to the Siemens skid through terminal block
TBIO pins 18 and 19 located at the Terminal Panel +CTA. This 120vac signal is then interfaced
through the SE5.3 Interface Module (device N62-A12) pins X2:21 and X2:22 to Simadyn-D
Processor #2 (PM16) via ribbon cable N62-RC5.

When Simadyn-D senses that one of the POEB buttons has been pushed, it immediately shuts
off all rectifiers, inverters, and blower motors. Therefore, the DC bus cannot discharge. High

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RECTIFIER TROUBLESHOOTING

voltages may still be present on the bus as it slowly discharges! Activation of the POEB also puts
the drive into a Gate Blocking condition.

CORRECTIVE PROCEDURE:

The following procedure assumes the bus is turning off unexpectedly and that Message 1074 is
displayed after the shutdown. CAUTION: the 120vac is supplied to the Siemens skid externally
by Bucyrus and may be present even though the Siemens skid may be de-energized.

1. Ensure that all three switches are physically pulled out. This is their normal operating
position.

2. Check the connections on TBIO pins 18 and 19. With all switches in their operating position,
measure with a voltmeter across pins 18 and 19. If 120vac is not present, see the Bucyrus
Troubleshooting Manual.

3. Check the connections on the SE5.3 Interface Module (device N62-A12) pins X2:21 and
X2:22 to ensure that they are tight and that 120vac is present.

4. If the switches, connections, and wiring are satisfactory, check that the green LED 1P on the
SE5.3 module is lit. It should be lit indicating that +24vdc is supplying the SE5.3 module. If it
is not, measure across terminals 1P and 1M for +24vdc. If it is present, replace the SE5.3
module. If it is not present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

5. Check that the red LED H2 on SE5.3 module N62-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:21 and X2:22. If +120vac is present, replace the SE5.3.
If it is not, check the wiring between TBIO and the SE5.3 module.

6. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

7. Replace Simadyn-D Processor #2 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1079 E01-TH01 +N1A CABINET HIGH TEMP FAULT

EXPLANATION:

Simadyn-D has received an indication of an overtemperature in cabinet +N1A. The thermostat is

set to open at 115 (± 7) degrees Fahrenheit and will stay open until the temperature goes below
95 (± 7) degrees Fahrenheit.

The thermostat is monitored by connectors X2:71 and X2:74 on SE5.3 card N62-A12 in cabinet
+N1B. The signal is sent to Simadyn-D Processor #2 (PM16) via cable N62-RC5.

CORRECTIVE PROCEDURE:

1. Measure the actual temperature. If the thermostat is not operating as described above,
replace it.

2. If it is an actual overtemperature, ensure that the Air conditioner is running and thermostat is
set correctly.

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 RECTIFIER TROUBLESHOOTING

3. If it is not an actual overtemperature, check that the green LED 1P on the SE4.1 module is
lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not, measure
across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not
present, investigate circuit breaker E02-Q34, which supplies the +24vdc.

4. Check that the red LED H7 on the SE4.1.module N62-A12 located in cabinet +N1B, is lit. If
it is not lit, measure across connector X2:71 and X2:74. If +24vdc is present, replace the
SE5.3. If it is not, check the wiring between the thermostat and the SE4.1 module.

5. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

6. Replace Simadyn-D Processor #2 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1080 E01-TH02 +E1A CABINET HIGH TEMP FAULT

EXPLANATION:

Simadyn-D has received an indication of an overtemperature in cabinet +N1A. The thermostat is

set to open at 115 (± 7) degrees Fahrenheit and will stay open until the temperature goes below
95 (± 7) degrees Fahrenheit.

The thermostat is monitored by connectors X2:81 and X2:84 on SE5.3 card N62-A12 in cabinet
+N1B. The signal is sent to Simadyn-D Processor #2 (PM16) via cable N62-RC5.

CORRECTIVE PROCEDURE:

1. Measure the actual temperature. If the thermostat is not operating as described above,
replace it.

2. If it is an actual overtemperature, ensure that the Air conditioner is running and

thermostat is set correctly.

3. If it is not an actual overtemperature, check that the green LED 1P on the SE4.1 module
is lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not,
measure across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1
module. If it is not present, investigate circuit breaker E02-Q34, which supplies the
+24vdc.

4. Check that the red LED H8 on the SE4.1.module N62-A12 located in cabinet +N1B, is lit.
If it is not lit, measure across connector X2:81 and X2:84. If +24vdc is present, replace
the SE5.3. If it is not, check the wiring between the thermostat and the SE4.1 module.

5. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

6. Replace Simadyn-D Processor #2 (PM16). Be sure to install the EPROM and

submodules from the original PM16 into the new PM16.

END OF PROCEDURE

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RECTIFIER TROUBLESHOOTING

FAULT 1081 GROUND FAULT DETECTED

EXPLANATION:

The Ground Fault Monitor, device R10-A10 in cabinet +R1B, has detected low resistance and/or
low capacitance between the power section of the skid and ground. The power section includes
the secondary of the main power transformer, rectifier and Chopper (including the chopper
resistor), the DC bus cabling to the inverters, the inverter power sections, the motor lead cabling,
and the motors.

The ground fault detector measures from phase B of the incoming 800vac to chassis ground. It
functions by sending out a continuous stream of square wave pulses and measures the rise time.
This type of detector is very accurate but does not react instantaneously (approximately 120
seconds).

Simadyn-D monitors the NC contact on the ground fault monitor (pins 15 and 16) to determine if
there is a ground fault condition. This NC contact is monitored by connectors X2:1 and X2:51 on
SE4.1 card N67-A11 in cabinet +N1B. This signal is sent to Simadyn-D Processor #4 (PM16) via
ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If a fault 1007 E02-Q08 GNDFLT/AIRFLO BREAKER TRIPPED is also active, then the
problem is a tripped breaker. Follow the procedure for Fault 1007.

2. Check the trip settings of the Ground Fault Monitor according to Section R10 Sheet 2. The
normal setting for the capacitance switch is 5uF and the normal setting for the resistance
switch is 50kohms.

3. With the bus OFF and completely discharged, LOCK OUT MAIN CONTACTOR. Megger the
positive bus to ground and then the negative bus to ground. The readings should be in the
range of 100kohms to 150kohms. If the megger readings are O.K., but the ground fault
monitor shows a trip, pull fuse R10-F1. If the ground fault monitor still shows a trip, replace
the ground fault monitor.

4. If, with the fuse pulled, the ground fault monitor does not indicate a trip, but Simadyn-D does,
measure with a voltmeter across the NC auxiliary contacts (pins 15 and 16 on R10-A10).
There should be no voltage drop across this contact. If the reading is 24vdc, clean the
contacts and try again. Replace the monitor if necessary.

5. If the monitor is operating properly, check that the green LED 1P on the SE4.1 module N67-
A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34 which
supplies the +24vdc.

6. Check that the red LED H1 on SE4.1 module N67-A11 located in cabinet +N1B is lit. It will
be lit if there is no fault condition. If it is not lit, measure across connector X2:1 and X2:51. If
+24vdc is present, replace the SE4.1. If it is not, check the wiring between the ground fault
monitor and the SE4.1.

7. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

8. Replace Simadyn-D Processor #4 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

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 RECTIFIER TROUBLESHOOTING

9. If the megger reading from the positive bus to ground or from the negative bus to ground
indicates a short circuit, the grounded point must be found and corrected. To completely
isolate the bus from ground, the following points must be isolated (disconnected):

a. DC bus shunt current feedback (+R1B R40-A3 pins 6, 7 and 10)

b. DC bus voltage feedbacks (Refer Schematics L01-Sheet 3))
c. Rectifier fuse monitors (+R1A R11-A201 pins 11, 12, 21, 22, 31, 32, 41, 42, 51, 52, 61,
and 62; +R1A R12-A201 pins 11, 12, 21, 22, 31, 32, 41, 42, 51, 52, 61, and 62; +R1B
R13-A201 pins 11, 12, 21, 22, 31, 32, 41, 42, 51, 52, 61, and 62)
d. Chopper Resistor wires (Refer schematics L01- Sheet 1 & 2)
e. Ground Fault Monitor (+R1B R10-A10 pin 5)

The power section can be divided into subsections to aid in locating the ground fault. Isolate the
secondary of the main power transformer by disconnecting the input cables or by removing all
rectifier fuses. Isolate the rectifiers from the inverters by disconnecting the 4/0 cables that are
bolted to the horizontal bus bars in the bottom of cabinet +R1B. Complete removal of this
horizontal bus bar can further isolate the forward rectifiers from the Regen Rectifier. Isolate the
chopper resistors by disconnecting its cabling. Isolate the motors by disconnecting the motor
leads or by manually moving the transfer switch to the center position.

END OF PROCEDURE

FAULT 1082 R11- G101 24V-RECT FIRING PWR SUPPLY FAULT

EXPLANATION:

Simadyn-D is sensing that the unregulated +24vdc power supply (R11-G101) to the pulse
distribution boards has failed. E02-Q07 supplies 380vac to the unregulated +24vdc power supply
used by the pulse distribution boards. Circuit breaker E02-Q07 is in cabinet +E1A and has an
adjustable trip level set to trip at 1.0 amps. The unregulated +24vdc power supply (device R11-
G101) is located in the back of cabinet +R1B under the Regen blocks and supplies all Forward
rectifier and Regen rectifier sitor blocks with firing pulse power via the pulse distribution boards.
This fault will always cause a Gate Blocking condition.

Simadyn-D monitors the auxiliary NO contacts on the power supply board to determine if it has
tripped. The contacts are monitored by connectors X2:2 and X2:52 on SE4.1 card N67-A11 in
cabinet +N1B. This signal is sent to Simadyn-D Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. Check circuit breaker E02-Q07 for a tripped condition.

2. If the breaker has tripped, check the trip point calibration. It should be set at 1.0 amp.

3. If the breaker was calibrated correctly, then isolate the fault between the unregulated 24vdc
power supply, the pulse distribution boards, the sitor blocks, and the wiring. Repair or
replace the defective component or wiring.

4. Replace the breaker.

5. Check for +24vdc output from the power supply (R11-G101) at pins 7 and 8.

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RECTIFIER TROUBLESHOOTING

6. If there is no voltage at pins 7 and 8, check the 3.5 amp fuse F1. Replace the fuse if
necessary.

7. Replace the +24vdc unregulated power supply.

8. If the breaker or the +24vdc power supply has not tripped, measure with a voltmeter across
NO auxiliary contacts (pins 4 and 6 on R11-G101). There should be no voltage drop across
contacts. If the reading is 24vdc, clean the contacts and try again. Replace the power
supply if necessary.

9. If the breaker and power supply are operating properly, check that the green LED 1P on the
SE4.1 module N67-A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc
is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc.
If it is present, replace the SE4.1 module. If it is not present, investigate circuit breaker E02-
Q34, which supplies the +24vdc.

10. Check that the red LED H2 on SE4.1 module N67-A11 located in cabinet +N1B is lit. If it is
not lit, measure across connector X2:2 and X2:52. If +24vdc is present, replace the SE4.1. If
it is not, check the wiring between the breakers and the load.

11. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

12. Replace Simadyn-D Processor #4 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1083 FWD RECTIFIER FUSE(S) LOSS

EXPLANATION:

Simadyn-D has sensed that one or more fuses have blown in one or both of the forward rectifier
bridges located in cabinet +R1A. The fuses that are blown are indicated on the fuse monitor
cards (R11-A201 and R12-A202) by LED's. There is also a blown fuse indicator on each fuse.
This is a red pop-up button that pops when blown.

A blown fuse condition is detected by the fuse monitor card by measuring the voltage across the
fuse. With a good fuse, there is approximately zero volts. With a bad fuse the voltage is much
higher. This means that the fuse monitor card will only detect a bad fuse when the 800vac
incoming voltage is present (DPC is closed). For this reason, a blown fuse condition is stored on
the fuse monitor card by latching relays and must be reset manually. The reset button is located
on the fuse monitor card.

Simadyn-D monitors the two auxiliary NO contacts, which are in series, on the fuse monitor cards
to determine if either is indicating a blown fuse. The contacts are monitored by connectors X2:3
and X2:53 on SE4.1 card N67-A11 in cabinet +N1B. This signal is sent to Simadyn-D Processor
#4 (PM16) via ribbon cable N67-RC5.

Remember to use the same type fuses as Forward Rectifier and Regen Rectifier use different
ratings.

CORRECTIVE PROCEDURE:

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 RECTIFIER TROUBLESHOOTING

1. Using a voltmeter to verify the DC bus is discharged.

2. Lockout the main contactor.

3. Verify that all fuses are good. Use an ohm meter as the red button on the fuse may not
pop-up very high and could be overlooked.

4. If the fuses are good:

a. If all fuses are good, short together the leads on the fuse monitor card for the fuse that is
indicated as having blown. If it is possible to reset the fuse monitor card, the problem is
in the wiring from the fuse monitor card to the fuse bus bar. If it is necessary to replace
this wiring, use 2000v Teflon wire. If the fuse monitor card will not reset with the inputs
shorted together, replace the fuse monitor card.

b. If both fuse monitor cards are O.K., measure with a voltmeter across both NO auxiliary
contacts (pins 5 and 6 on R11-A201 and on R12-A202). If the fuse monitor cards are
reset, there should be no voltage drop across either contact. If the reading is 24vdc,
clean the contacts and try again. Replace the fuse monitor cards if necessary.

c. If the fuse monitor cards are operating properly, check that the green LED 1P on the
SE4.1 module N67-A11 located in cabinet +N1B is lit. It should be lit indicating that
+24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M
for +24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate
circuit breaker E02-Q34, which supplies the +24vdc.

d. Check that the red LED H3 on SE4.1 module N67-A11 located in cabinet +N1B is lit. If it
is not lit, measure across connector X2:3 and X2:53. If +24vdc is present, replace the
SE4.1. If it is not, check the wiring between the fuse monitor cards and the SE4.1.

e. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

f. Replace Simadyn-D Processor #4 (PM16). Be sure to install the EPROM and

submodules from the original PM16 into the new PM16.

5. If an actual blown fuse condition exists:

a. Replace fuses in pairs whether or not they are both blown. Also, be sure to use fuses
with the proper rating.

b. The cause of the fuse loss should be found. The first step is to record all Simadyn-D
messages. Any other rectifier faults that are on the display can provide useful
information. Refer to those fault messages for specifics.

c. Test all SCRs in the rectifier bridges (see SITOR Blocks). Inspect the blocks for cracked
insulators or damaged insulation. Also, check the condition of the snubber circuits. Also,
check for proper and even compression of the blocks by checking that the clamp bar is
straight.

d. Check all bus capacitors for abnormal contacts and deformed enclosures.

e. Check all connections from the SITOR Blocks to the Pulse Distribution Boards (R11-
A101, R12-A102, and R13-A103). These are the cables from connector X1 on the sitor
blocks to connectors X3, X4, and X5 on the pulse distribution boards.

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RECTIFIER TROUBLESHOOTING

f. Check all connections from the pulse distribution boards to the +24vdc power supply.
These include the crimp connections on terminals 1 and 2 on the pulse distribution
boards and terminals 7, 8, and 9 on the rectifier firing pulse power supply (device R11-
G101 located in the bottom of cabinet +R1B).

g. Check cable connections between the pulse distribution boards for both forward
rectifiers, Simadyn-D/Sitor Interface Module (R11-A501 in cabinet +R1B) and the
SE20.2. (N50-A11-D13 in cabinet +N1A). These are cables R11-RC102, R11-RC103,
N63-RC101, and N63-SC105. Remove cable connector covers to check connections.

h. Check the cable connection N63-RC7 between the SE20.2 and Processor #3 (PG16).
The connectors have slide locks. Make sure they are engaged.

i. Check all connections on the Synchronizing Voltage Module. The synchronizing voltage
originates in the MCC main cubicle and feeds TB Synch on the skid (Terminal panel
+CTA), circuit breaker E02-Q05 (cabinet +E1A), the synchronizing voltage module
(device N30-A15 located in cabinet +N1B), and the SE20.2 (device N50-A11-D13).

j. Check the bolts on all DC buswork for tightness.

k. Check the main power transformer leads. If necessary, disconnect from the skid and
megger or hi-pot at 5KV.

l. Check connections on DPC with the substation off. Make sure the auxiliary contacts are
adjusted correctly.

m. Check the high voltage collector rings with the substation off. Burrs on the collector rings
can cause arcing resulting in rectifier problems.

n. With the machine operating, monitor on a chart recorder the power supply E01-G03. If
the fuse failure seems to correspond to disturbances in either of the power supply,
carefully inspect the power supply wiring. If nothing is found, replace the power supply.

o. Test firing pulses (see procedure - Testing Firing Pulses).

p. Test current feedbacks (see procedure - Calibrating Current Feedback).

q. Megger the positive and negative DC bus to ground. Readings should be 100kohms or
greater (see Fault 1081 GROUND FAULT DETECTED).

r. Replace and recalibrate the SE20.2.

s. Replace the PG16. Be sure to install the EPROM and submodules from the original
PM16 into the new PM16.

END OF PROCEDURE

FAULT 1084 REGEN RECTIFIER FUSE(S) LOSS

EXPLANATION:

Simadyn-D has sensed that one or more fuses have blown in Regen rectifier bridge located in
cabinet +R1B. The fuses that are blown are indicated on the fuse monitor card (R13-A203) by

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 RECTIFIER TROUBLESHOOTING

LED's. There is also a blown fuse indicator on each fuse. This is a red pop-up button that pops
when blown.

A blown fuse condition is detected by the fuse monitor card by measuring the voltage across the
fuse. With a good fuse, there is approximately zero volts. With a bad fuse the voltage is much
higher. This means that the fuse monitor card will only detect a bad fuse when the 800vac
incoming voltage is present (DPC is closed). For this reason, a blown fuse condition is stored on
the fuse monitor card by latching relays and must be reset manually. The reset button is located
on the fuse monitor card.

Simadyn-D monitors the two auxiliary NO contacts, which are in series, on the fuse monitor cards
to determine if either is indicating a blown fuse. The contacts are monitored by connectors X2:4.
and X2:54 on SE4.1 card N67-A11 in cabinet +N1B. This signal is sent to Simadyn-D Processor
#4 (PM16) via ribbon cable N67-RC5.

Remember to use the same type fuses as Forward Rectifier and Regen Rectifier use different
ratings.

CORRECTIVE PROCEDURE:

1. Using a voltmeter to verify the DC bus is discharged.

2. Lockout the main contactor.

3. Verify that all fuses are good. Use an ohm meter as the red button on the fuse may not pop-
up very high and could be overlooked.

4. If the fuses are good:

a. If all fuses are good, short together the leads on the fuse monitor card for the fuse that is
indicated as having blown. If it is possible to reset the fuse monitor card, the problem is
in the wiring from the fuse monitor card to the fuse bus bar. If it is necessary to replace
this wiring, use 2000v Teflon wire. If the fuse monitor card will not reset with the inputs
shorted together, replace the fuse monitor card.

b. If fuse monitor card is O.K., measure with a voltmeter across NO auxiliary contacts (pins
5 and 6 on R13-A203). If the fuse monitor card is reset, there should be no voltage drop
across either contact. If the reading is 24vdc, clean the contacts and try again. Replace
the fuse monitor cards if necessary.

c. If the fuse monitor cards is operating properly, check that the green LED 1P on the SE4.1
module N67-A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is
supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

d. Check that the red LED H4 on SE4.1 module N67-A11 located in cabinet +N1B is lit. If it
is not lit, measure across connector X2:4 and X2:54. If +24vdc is present, replace the
SE4.1. If it is not, check the wiring between the fuse monitor cards and the SE4.1.

e. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

f. Replace Simadyn-D Processor #4 (PM16). Be sure to install the EPROM and

submodules from the original PM16 into the new PM16.

5. If an actual blown fuse condition exists:

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RECTIFIER TROUBLESHOOTING

a. Replace fuses in pairs whether or not they are both blown. Also, be sure to use fuses
with the proper rating.

b. The cause of the fuse loss should be found. The first step is to record all Simadyn-D
messages. Any other rectifier faults that are on the display can provide useful
information. Refer to those fault messages for specifics.

c. Test all SCRs in the rectifier bridges (see SITOR Blocks). Inspect the blocks for cracked
insulators or damaged insulation. Also, check the condition of the snubber circuits. Also,
check for proper and even compression of the blocks by checking that the clamp bar is
straight.

d. Check all bus capacitors for abnormal contacts and deformed enclosures.

e. Check all connections from the SITOR Blocks to the Pulse Distribution Boards (R11-
A101, R12-A102, and R13-A103). These are the cables from connector X1 on the sitor
blocks to connectors X3, X4, and X5 on the pulse distribution boards.

f. Check all connections from the pulse distribution boards to the +24vdc power supply.
These include the crimp connections on terminals 1 and 2 on the pulse distribution
boards and terminals 7, 8, and 9 on the rectifier firing pulse power supply (device R11-
G101 located in the bottom of cabinet +R1B).

g. Check cable connections between the pulse distribution boards for both forward
rectifiers, Simadyn-D/Sitor Interface Module (R11-A501 in cabinet +R1B) and the
SE20.2. (N50-A11-D13 in cabinet +N1A). These are cables R11-RC102, R11-RC103,
N63-RC101, and N63-SC105. Remove cable connector covers to check connections.

h. Check the cable connection N63-RC7 between the SE20.2 and Processor #3 (PG16).
The connectors have slide locks. Make sure they are engaged.

i. Check all connections on the Synchronizing Voltage Module. The synchronizing voltage
originates in the MCC main cubicle and feeds TB Synch on the skid (Terminal panel
+CTA), circuit breaker E02-Q05 (cabinet +E1A), the synchronizing voltage module
(device N30-A15 located in cabinet +N1B), and the SE20.2 (device N50-A11-D13).

j. Check the bolts on all DC buswork for tightness.

k. Check the main power transformer leads. If necessary, disconnect from the skid and
megger or hi-pot at 5KV.

l. Check connections on DPC with the substation off. Make sure the auxiliary contacts are
adjusted correctly.

m. Check the high voltage collector rings with the substation off. Burrs on the collector rings
can cause arcing resulting in rectifier problems.

n. With the machine operating, monitor on a chart recorder the power supply E01-G03. If
the fuse failure seems to correspond to disturbances in either of the power supply,
carefully inspect the power supply wiring. If nothing is found, replace the power supply.

o. Test firing pulses (see procedure - Testing Firing Pulses).

p. Test current feedbacks (see procedure - Calibrating Current Feedback).

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 RECTIFIER TROUBLESHOOTING

q. Megger the positive and negative DC bus to ground. Readings should be 100kohms or
greater (see Fault 1081 GROUND FAULT DETECTED).

r. Replace and recalibrate the SE20.2.

s. Replace the PG16. Be sure to install the EPROM and submodules from the original
PM16 into the new PM16.

END OF PROCEDURE

FAULT 1085 RECTIFIER AIRFLOW FAULT

EXPLANATION:

The Air Flow Monitor contacts have not closed within 30 seconds of the fans coming on. The air
flow monitor is a "hot wire" system. This means that the sensor, which is inserted beneath the
Forward rectifier bridge and Regen Rectifier bridge cooling fans, conducts current which heats
the sensor. When the fans come on, they cool the sensor increasing the resistance and causing
less current to flow.

The air flow contacts are monitored by Simadyn-D Processor #1 (PM16) through the SE4.1 card
+N67-A11. The signal is connected to connector X2:5. The Forward Rectifier and Regen
Rectifier air flow contacts are connected in series.

CORRECTIVE PROCEDURE:

1. Verify correct operation of the fans. This includes proper fan phasing. The fans should be
phased so that the fans rotate clockwise when looking down on the fans from above. NOTE:
Air will drawn in from the bottom of the cabinets regardless of fan rotation.

2. Verify correct setting of the air flow monitors. The correct setting is 5m/s and is listed in the
prints Section R11 Sheet 5, and Section R13 Sheet 5.

3. Verify that both airflow monitors have 220vac on terminals A1 and A2.

4. Isolate the defective air flow monitor by jumping together air flow contacts 11 and 14 on one
air flow monitor at a time. Replace the defective module. WARNING--Running without the
airflow monitors is an equipment hazard to the rectifier.

5. If the air flow monitors are operating properly, check that the green LED 1P on the SE4.1
module is lit. It should be lit indicating that +24vdc is supplying the SE4.1 module. If it is not,
measure across terminals 1P and 1M for +24vdc. If it is present, replace the SE4.1 module.
If it is not present, investigate circuit breaker E02-Q34 which supplies the +24vdc.

6. Check that the red LED H5 on SE4.1 card (N67-A11) is lit. This is best done with the air flow
contacts jumpered because they will not close until the fans are on - i.e. the bus is up. If the
LED is not on, measure on the SE4.1 between terminals X2:5 and X2:55. If +24vdc is
present and LED H2 is still not on, replace the SE4.1. If there is no +24vdc, then check the
wiring between the airflow monitors and the SE4.1.

7. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

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RECTIFIER TROUBLESHOOTING

8. Replace Simadyn-D Processor #4 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1089 HOIST MOTOR OVERTEMP WARNING

EXPLANATION:

Simadyn-D has received a hoist motor overtemperature warning. This means that the
temperature of the stator windings is above 140 degrees Celsius (284 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A11 in cabinet +N1B). The 3UP7 thermistor operates a NO contact to enunciate an
overtemperature warning and another NO contact to enunciate an overtemperature fault (see
Fault 1090 HOIST MOTOR OVERTEMP FAULT). The adjustment points for the warning and fault
have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature warning condition. This NO contact is monitored by connectors X2:1
and X2:51 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the hoist blower motor and its
associated circuitry is working properly. If the blower is working, then the possibility of motor
damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature warning indication (the LED on
the left will be off for an overtemperature warning condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 11 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 11 and 14 on the 3UP7 thermistor monitor. If the left hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a Turn off control power.

b Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

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 RECTIFIER TROUBLESHOOTING

d If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H1 on SE4.1 module is off (it will be off if there is no
overtemperature warning condition). If it is lit, disconnect the wires connected to pins X2:1
and X2:51. If H1 is still lit, replace the SE4.1. If H1 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1090 HOIST MOTOR OVERTEMP FAULT

EXPLANATION:

Simadyn-D has received a hoist motor overtemperature fault. This means that the temperature of
the stator windings is above 150 degrees Celsius (302 degrees Fahrenheit). The motor
temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A11 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning (see Fault 1089 HOIST MOTOR OVERTEMP WARNING) and
another NO contact to enunciate an overtemperature fault. The adjustment points for the warning
and fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature fault condition. This NO contact is monitored by connectors X2:2
and X2:52 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

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RECTIFIER TROUBLESHOOTING

1. If the motor is HOT to the touch (not warm), make sure that the hoist blower motor and its
associated circuitry is working properly. If the blower is working, then the possibility of motor
damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature fault indication (the LED on the
right will be off for an overtemperature fault condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 21 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 21 and 24 on the 3UP7 thermistor monitor. If the right hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a Turn off control power.

b Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H2 on SE4.1 module is off (it will be off if there is no
overtemperature fault condition). If it is lit, disconnect the wires connected to pins X2:2 and
X2:52. If H2 is still lit, replace the SE4.1. If H2 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

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 RECTIFIER TROUBLESHOOTING

FAULT 1091 CROWD MOTOR OVERTEMP WARNING

EXPLANATION:

Simadyn-D has received a crowd motor overtemperature warning. This means that the
temperature of the stator windings is above 140 degrees Celsius (284 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A21 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning and another NO contact to enunciate an overtemperature fault (see
Fault 1092 CROWD MOTOR OVERTEMP FAULT). The adjustment points for the warning and
fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature warning condition. This NO contact is monitored by connectors X2:3
and X2:53 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the crowd blower motor and its
associated circuitry is working properly. If the blower is working, then the possibility of motor
damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature warning indication (the LED on
the left will be off for an overtemperature warning condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 11 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 11 and 14 on the 3UP7 thermistor monitor. If the left hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a Turn off control power.

b Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,

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RECTIFIER TROUBLESHOOTING

2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H3 on SE4.1 module is off (it will be off if there is no
overtemperature warning condition). If it is lit, disconnect the wires connected to pins X2:3
and X2:53. If H3 is still lit, replace the SE4.1. If H3 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace crowd Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1092 CROWD MOTOR OVERTEMP FAULT

EXPLANATION:

Simadyn-D has received a crowd motor overtemperature fault. This means that the temperature
of the stator windings is above 150 degrees Celsius (302 degrees Fahrenheit). The motor
temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A21 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning (see Fault 1091 CROWD MOTOR OVERTEMP WARNING) and
another NO contact to enunciate an overtemperature fault. The adjustment points for the warning
and fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature fault condition. This NO contact is monitored by connectors X2:4
and X2:54 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

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 RECTIFIER TROUBLESHOOTING

1. If the motor is HOT to the touch (not warm), make sure that the crowd blower motor and its
associated circuitry is working properly. If the blower is working, then the possibility of motor
damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature fault indication (the LED on the
right will be off for an overtemperature fault condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 21 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 21 and 24 on the 3UP7 thermistor monitor. If the right hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a. Turn off control power.

b. Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c. With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d. If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e. Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f. If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H4 on SE4.1 module is off (it will be off if there is no
overtemperature fault condition). If it is lit, disconnect the wires connected to pins X2:4 and
X2:54. If H4 is still lit, replace the SE4.1. If H4 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

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RECTIFIER TROUBLESHOOTING

FAULT 1093 SWING MOTOR#1 OVERTEMP WARNING

EXPLANATION:

Simadyn-D has received a swing motor #1 overtemperature warning. This means that the
temperature of the stator windings is above 140 degrees Celsius (284 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A31 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning and another NO contact to enunciate an overtemperature fault (see
Fault 1094 SWING MOTOR #1 OVERTEMP FAULT). The adjustment points for the warning and
fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature warning condition. This NO contact is monitored by connectors X2:5
and X2:55 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the swing blower motor #1 and
its associated circuitry is working properly. If the blower is working, then the possibility of
motor damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature warning indication (the LED on
the left will be off for an overtemperature warning condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 11 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 11 and 14 on the 3UP7 thermistor monitor. If the left hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a. Turn off control power.

b. Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c. With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d. If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

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 RECTIFIER TROUBLESHOOTING

e. Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f. If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H5 on SE4.1 module is off (it will be off if there is no
overtemperature warning condition). If it is lit, disconnect the wires connected to pins X2:5
and X2:55. If H5 is still lit, replace the SE4.1. If H5 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1094 SWING MOTOR#1 OVERTEMP FAULT

EXPLANATION:

Simadyn-D has received a swing motor #1 overtemperature fault. This means that the
temperature of the stator windings is above 150 degrees Celsius (302 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A31 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning (see Fault 1093 SWING MOTOR #1 OVERTEMP WARNING) and
another NO contact to enunciate an overtemperature fault. The adjustment points for the warning
and fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature fault condition. This NO contact is monitored by connectors X2:6
and X2:56 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the swing blower motor #1 and
its associated circuitry is working properly. If the blower is working, then the possibility of
motor damage must be considered.

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RECTIFIER TROUBLESHOOTING

2. Check the 3UP7 thermistor monitor for an overtemperature fault indication (the LED on the
right will be off for an overtemperature fault condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 21 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 21 and 24 on the 3UP7 thermistor monitor. If the right hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a. Turn off control power.

b. Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c. With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d. If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e. Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f. If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H6 on SE4.1 module is off (it will be off if there is no
overtemperature fault condition). If it is lit, disconnect the wires connected to pins X2:6 and
X2:56. If H6 is still lit, replace the SE4.1. If H6 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

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 RECTIFIER TROUBLESHOOTING

FAULT 1095 SWING MOTOR#2 OVERTEMP WARNING

EXPLANATION:

Simadyn-D has received a swing motor #2 overtemperature warning. This means that the
temperature of the stator windings is above 140 degrees Celsius (284 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A32 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning and another NO contact to enunciate an overtemperature fault (see
Fault 1096 SWING MOTOR #2 OVERTEMP FAULT). The adjustment points for the warning and
fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature warning condition. This NO contact is monitored by connectors X2:7
and X2:57 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the swing blower motor #2 and
its associated circuitry is working properly. If the blower is working, then the possibility of
motor damage must be considered.

2. Check the 3UP7 thermistor monitor for an overtemperature warning indication (the LED on
the left will be off for an overtemperature warning condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 11 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 11 and 14 on the 3UP7 thermistor monitor. If the left hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a. Turn off control power.

b. Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c. With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d. If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

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RECTIFIER TROUBLESHOOTING

e. Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f. If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit
indicating that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals
1P and 1M for +24vdc. If it is present, replace the SE4.1 module. If it is not present,
investigate circuit breaker E02-Q34, which supplies the +24vdc.

8. Check that the red LED H7 on SE4.1 module is off (it will be off if there is no
overtemperature warning condition). If it is lit, disconnect the wires connected to pins X2:7
and X2:57. If H7 is still lit, replace the SE4.1. If H7 goes out, inspect the wiring between the
3UP7 thermistor monitor and the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1096 SWING MOTOR#2 OVERTEMP FAULT

EXPLANATION:

Simadyn-D has received a swing motor #2 overtemperature fault. This means that the
temperature of the stator windings is above 150 degrees Celsius (302 degrees Fahrenheit). The
motor temperature is sensed by three thermistors that are built into the windings during motor
manufacture. The characteristics of the thermistors are such that their electrical resistance
decreases as temperature increases and visa versa. Therefore, a short circuit will correspond to
a high motor winding temperature and an open circuit will correspond to a low motor winding
temperature. The thermistor sends this temperature information to the 3UP7 thermistor monitor
(device N20-A32 in cabinet +N1B). The 3UP7 thermistor also operates a NO contact to enunciate
an overtemperature warning (see Fault 1095 SWING MOTOR #2 OVERTEMP WARNING) and
another NO contact to enunciate an overtemperature fault. The adjustment points for the warning
and fault have to be calibrated (see 3UP7 description).

Simadyn-D monitors one of these NO contact on the 3UP7 thermistor monitor to determine if
there is an overtemperature fault condition. This NO contact is monitored by connectors X2:8
and X2:58 on SE4.1 card N67-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack
Processor #4 (PM16) via ribbon cable N67-RC5.

CORRECTIVE PROCEDURE:

1. If the motor is HOT to the touch (not warm), make sure that the swing blower motor #2 and
its associated circuitry is working properly. If the blower is working, then the possibility of
motor damage must be considered.

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 RECTIFIER TROUBLESHOOTING

2. Check the 3UP7 thermistor monitor for an overtemperature fault indication (the LED on the
right will be off for an overtemperature fault condition). If the LED is lit, go to step 7.

3. Measure across A1 and A2 on the 3UP7 thermistor monitor. If 220vac is not present,
investigate circuit breaker E02-Q09.

4. Measure from pin 21 to ground to see if +24vdc is present. If +24vdc is not present,
investigate circuit breaker E02-Q15.

5. Measure across pins 21 and 24 on the 3UP7 thermistor monitor. If the right hand LED is off
and +24vdc is present, replace the 3UP7 thermistor monitor.

6. Measure the value of the thermistors by the following procedure:

a. Turn off control power.

b. Remove the lead from terminal T0 on the 3UP7 thermistor monitor.

c. With an ohmmeter, measure between the T0 lead and terminals T1, T2, and T3
individually. If the motor is at room temperature (approximately 80 degrees Fahrenheit),
the thermistors should each read approximately 40kohms to 55kohms.

d. If there is a large deviation between the readings (i.e. 2:1 ratio), inspect the connections
in the motor junction box. There are 680kohm resistors between each thermistor (pins 1,
2, and 3) and common (pin 4) in the junction box. Ensure that they are in place and there
are no short or open circuits.

e. Recalibrate the 3UP7 thermistor monitor. Replace the thermistor monitor if it cannot be
calibrated according to the procedure.

f. If no cause for the deviation can be found, change to the spare set of thermistors on pins
5, 6, 7, and 8 in the hoist motor junction box. Also, connect the three 680kohm resistors
across pin 5 and pin 8, pin 6 and pin 8, and pin 7 and pin 8.

7. If the thermistors and 3UP7 thermistor monitor are operating properly, check that the green
LED 1P on the SE4.1 module N67-A12 located in cabinet +N1B is lit. It should be lit indicating
that +24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit breaker
E02-Q34, which supplies the +24vdc.

8. Check that the red LED H8 on SE4.1 module is off (it will be off if there is no overtemperature
fault condition). If it is lit, disconnect the wires connected to pins X2:8 and X2:58. If H8 is still lit,
replace the SE4.1. If H8 goes out, inspect the wiring between the 3UP7 thermistor monitor and
the SE4.1.

9. Check continuity and insulation of ribbon cable N67-RC5. Replace if necessary.

10. Replace Simadyn-D rack Processor #4 (PM16). Be sure to install the EPROM and
submodules from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1097 CROWD MOTION FAULT

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RECTIFIER TROUBLESHOOTING

EXPLANATION:

Simadyn-D is sensing that Crowd motion has a fault.

The Simadyn-D rack monitors the hardwired input from SiBAS to determine if there is a Crowd
motion fault. The input from SiBAS is connected to connectors X2:1 and X2:51 on SE4.1 card
N64-A11 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check SiBAS statistics for crowd motion fault and related messages and Troubleshoot.

2. If SiBAS statistics does not indicate any crowd related faults, check that the green LED 1P
on the SE4.1 module N64-A11 located in cabinet +N1B is lit. It should be lit indicating that
+24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

3. Check that the red LED H1 on SE4.1 module is lit. If it is not lit, measure across connector
X2:1 and X2:51. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the SiBAS G155 card and the SE4.1 module.

4. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

5. Replace Simadyn-D rack EM11 (N50-A11-D08).

END OF PROCEDURE

FAULT 1098 HOIST MOTION FAULT

EXPLANATION:

Simadyn-D is sensing that Hoist motion has a fault.

The Simadyn-D rack monitors the hardwired input from SiBAS to determine if there is a Hoist
motion fault. The input from SiBAS is connected to connectors X2:2 and X2:52 on SE4.1 card
N64-A11 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check SiBAS statistics for Hoist motion fault and related messages and Troubleshoot.

2. If SiBAS statistics does not indicate any Hoist related faults, check that the green LED 1P on
the SE4.1 module N64-A11 located in cabinet +N1B is lit. It should be lit indicating that
+24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

3. Check that the red LED H2 on SE4.1 module is lit. If it is not lit, measure across connector
X2:2 and X2:52. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the SiBAS G155 card and the SE4.1 module.

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 RECTIFIER TROUBLESHOOTING

4. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

5. Replace Simadyn-D rack EM11 (N50-A11-D08).

END OF PROCEDURE

FAULT 1099 SWING MOTION FAULT

EXPLANATION:

Simadyn-D is sensing that Swing motion has a fault.

The Simadyn-D rack monitors the hardwired input from SiBAS to determine if there is a Swing
motion fault. The input from SiBAS is connected to connectors X2:3 and X2:53 on SE4.1 card
N64-A11 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check SiBAS statistics for Swing motion fault and related messages and Troubleshoot.

2. If SiBAS statistics does not indicate any Swing related faults, check that the green LED 1P
on the SE4.1 module N64-A11 located in cabinet +N1B is lit. It should be lit indicating that
+24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

3. Check that the red LED H3 on SE4.1 module is lit. If it is not lit, measure across connector
X2:3 and X2:53. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the SiBAS G155 card and the SE4.1 module.

4. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

5. Replace Simadyn-D rack EM11 (N50-A11-D08).

END OF PROCEDURE

FAULT 1100 CHOPPER FAULT

EXPLANATION:

Simadyn-D is sensing that Chopper circuit has a fault.

The Simadyn-D rack monitors the hardwired input from SiBAS to determine if there is a Chopper
circuit fault. The input from SiBAS is connected to connectors X2:4 and X2:54 on SE4.1 card
N64-A11 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

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RECTIFIER TROUBLESHOOTING

1. Check SiBAS statistics for Chopper circuit fault and related messages and Troubleshoot.

2. If SiBAS statistics does not indicate any Chopper related faults, check that the green LED 1P
on the SE4.1 module N64-A11 located in cabinet +N1B is lit. It should be lit indicating that
+24vdc is supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE4.1 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

3. Check that the red LED H4 on SE4.1 module is lit. If it is not lit, measure across connector
X2:4 and X2:54. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the SiBAS G155 card and the SE4.1 module.

4. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

5. Replace Simadyn-D rack EM11 (N50-A11-D08).

END OF PROCEDURE

FAULT 1104 SIBAS SYSTEM FAULT

EXPLANATION:

Simadyn-D is sensing that SiBAS system has a fault.

The Simadyn-D rack monitors the hardwired input from SiBAS to determine if there is a SiBAS
system fault. The input from SiBAS is connected to connectors X2:8 and X2:58 on SE4.1 card
N64-A11 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check SiBAS statistics for SiBAS system faults and related messages and Troubleshoot.

2. If SiBAS statistics does not indicate any faults, check that the green LED 1P on the SE4.1
module N64-A11 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is
supplying the SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If
it is present, replace the SE4.1 module. If it is not present, investigate circuit breaker E02-
Q34, which supplies the +24vdc.

3. Check that the red LED H8 on SE4.1 module is lit. If it is not lit, measure across connector
X2:8 and X2:58. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between the SiBAS G155 card and the SE4.1 module.

4. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

5. Replace Simadyn-D rack EM11 (N50-A11-D08).

END OF PROCEDURE

FAULT 1105 HOIST BRAKE SET BY SIBAS

EXPLANATION:

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 RECTIFIER TROUBLESHOOTING

Simadyn-D is sensing that Hoist brake is set by SiBAS.

The Simadyn-D rack monitors the NO contacts of control relay (E01-K06) to determine if the
Hoist Brake is set by SiBAS. The contacts are monitored by connectors X2:1 and X2:51 on
SE4.1 card N64-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card
(device: N50-A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check control relay E01-K06 for a tripped condition.

2. If the control relay has tripped, Check SiBAS Statistics and troubleshoot any related faults.

3. If the control relay E01-K06 is ON, measure with a voltmeter across the NO auxiliary contacts
(pins 4 and 6 on E01-K06). There should be no voltage drop across contacts. If +24vdc is
present, replace the control relay.

4. If the Control relay is operating properly, check that the green LED 1P on the SE4.1 module
N64-A12 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

5. Check that the red LED H1 on SE4.1 module is lit. If it is not lit, measure across connector
X2:1 and X2:51. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between E01-K06 relay’s NO auxiliary contacts and the SE4.1 module.

6. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

7. Replace Simadyn-D rack EM11 (D08).

END OF PROCEDURE

FAULT 1106 CROWD BRAKE SET BY SIBAS

EXPLANATION:

Simadyn-D is sensing that Crowd brake is set by SiBAS.

The Simadyn-D rack monitors the NO contacts of control relay (E01-K07) to determine if the
Crowd Brake is set by SiBAS. The contacts are monitored by connectors X2:2 and X2:52 on
SE4.1 card N64-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card
(device: N50-A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check control relay E01-K07 for a tripped condition.

2. If the control relay has tripped, Check SiBAS Statistics and troubleshoot any related faults.

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RECTIFIER TROUBLESHOOTING

3. If the control relay E01-K07 is ON, measure with a voltmeter across the NO auxiliary contacts
(pins 4 and 6 on E01-K07). There should be no voltage drop across contacts. If +24vdc is
present, replace the control relay.

4. If the Control relay is operating properly, check that the green LED 1P on the SE4.1 module
N64-A12 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

5. Check that the red LED H2 on SE4.1 module is lit. If it is not lit, measure across connector
X2:2 and X2:52. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between E01-K07 relay’s NO auxiliary contacts and the SE4.1 module.

6. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

7. Replace Simadyn-D rack EM11 (D08).

END OF PROCEDURE

FAULT 1107 SWING BRAKES SET BY SIBAS

EXPLANATION:

Simadyn-D is sensing that Swing brakes are set by SiBAS.

The Simadyn-D rack monitors the NO contacts of control relay (E01-K08) to determine if the
Swing Brakes are set by SiBAS. The contacts are monitored by connectors X2:3 and X2:53 on
SE4.1 card N64-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card
(device: N50-A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check control relay E01-K08 for a tripped condition.

2. If the control relay has tripped, Check SiBAS Statistics and troubleshoot any related faults.

3. If the control relay E01-K08 is ON, measure with a voltmeter across the NO auxiliary contacts
(pins 4 and 6 on E01-K08). There should be no voltage drop across contacts. If +24vdc is
present, replace the control relay.

4. If the Control relay is operating properly, check that the green LED 1P on the SE4.1 module
N64-A12 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

5. Check that the red LED H3 on SE4.1 module is lit. If it is not lit, measure across connector
X2:3 and X2:53. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between E01-K08 relay’s NO auxiliary contacts and the SE4.1 module.

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 RECTIFIER TROUBLESHOOTING

6. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

7. Replace Simadyn-D rack EM11 (D08).

END OF PROCEDURE

FAULT 1108 PROPEL BRAKE SET BY SIBAS

EXPLANATION:

Simadyn-D is sensing that Propel brake is set by SiBAS.

The Simadyn-D rack monitors the NO contacts of control relay (E01-K09) to determine if the
Propel Brake is set by SiBAS. The contacts are monitored by connectors X2:4 and X2:54 on
SE4.1 card N64-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card
(device: N50-A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check control relay E01-K09 for a tripped condition.

2. If the control relay has tripped, Check SiBAS Statistics and troubleshoot any related faults.

3. If the control relay E01-K09 is ON, measure with a voltmeter across the NO auxiliary contacts
(pins 4 and 6 on E01-K09). There should be no voltage drop across contacts. If +24vdc is
present, replace the control relay.

4. If the Control relay is operating properly, check that the green LED 1P on the SE4.1 module
N64-A12 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

5. Check that the red LED H4 on SE4.1 module is lit. If it is not lit, measure across connector
X2:4 and X2:54. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between E01-K09 relay’s NO auxiliary contacts and the SE4.1 module.

6. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

7. Replace Simadyn-D rack EM11 (D08).

END OF PROCEDURE

FAULT 1109 MAIN CONTACTOR OPENED BY SIBAS

EXPLANATION:

Simadyn-D is sensing that Main Contactor (DPC) is opened by SiBAS.

The Simadyn-D rack monitors the NO contacts of control relay (E01-K10) to determine if the DPC
is opened by SiBAS. The contacts are monitored by connectors X2:5 and X2:55 on SE4.1 card

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RECTIFIER TROUBLESHOOTING

N64-A12 in cabinet +N1B. This signal is sent to the Simadyn-D rack EM11 card (device: N50-
A11-D08) via ribbon cable N64-RC107.

CORRECTIVE PROCEDURE:

1. Check control relay E01-K10 for a tripped condition.

2. If the control relay has tripped, Check SiBAS Statistics and troubleshoot any related faults.

3. If the control relay E01-K10 is ON, measure with a voltmeter across the NO auxiliary contacts
(pins 4 and 6 on E01-K10). There should be no voltage drop across contacts. If +24vdc is
present, replace the control relay.

4. If the Control relay is operating properly, check that the green LED 1P on the SE4.1 module
N64-A12 located in cabinet +N1B is lit. It should be lit indicating that +24vdc is supplying the
SE4.1 module. If it is not, measure across terminals 1P and 1M for +24vdc. If it is present,
replace the SE4.1 module. If it is not present, investigate circuit breaker E02-Q34, which
supplies the +24vdc.

5. Check that the red LED H5 on SE4.1 module is lit. If it is not lit, measure across connector
X2:5 and X2:55. If +24vdc is present, replace the SE4.1. If it is not, check the wiring
between E01-K10 relay’s NO auxiliary contacts and the SE4.1 module.

6. Check continuity and insulation of ribbon cable N64-RC107. Replace if necessary.

7. Replace Simadyn-D rack EM11 (D08).

END OF PROCEDURE

FAULT 1113 HIGH VOLTAGE CONTACTOR OPEN

EXPLANATION:

Simadyn-D has sensed that the high voltage contactor (DPC in the Bucyrus prints) has opened
while the rectifier was on. This will result in a rectifier Gate Blocking condition.

Simadyn-D monitors the high voltage contactor directly. The high voltage contactor's auxiliary
NO contact is wired to terminal block TBIO pins 18 and 21 located at the Terminal panel +CTA.
This 120vac signal is then interfaced through the SE5.3 Interface Module (device N62-A12) pins
X2:31 and X2:32 to Simadyn-D Processor #2 (PM16) via ribbon cable N62-RC5.

CORRECTIVE PROCEDURE:

1. Determine if the high voltage contactor is actually open or closed by checking for the
presence of 800vac with a voltmeter on the incoming rectifier supply. NOTE: The OP1
Display panel does not measure the 800vac incoming voltage directly but instead measures
the 480vac transformer and scales that voltage to 800vac. If the high voltage contactor is
closed, measure on terminal block TBIO pins 21 and 18 for 120vac.

2. If, with the high voltage contactor closed, the auxiliary contacts are closed and there is no
120vac present, see the Bucyrus Troubleshooting Manual. If, with the high voltage contactor

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 RECTIFIER TROUBLESHOOTING

closed, the auxiliary contacts are not closed, they must be adjusted. See the Bucyrus
Troubleshooting Manual for details on this procedure.

3. If the high voltage contactor and the auxiliary contacts are operating O.K., check the
connections on the SE5.3 Interface Module (device N62-A12) pins X2:31 and X2:32 to
ensure that they are tight and that 120vac is present. If not, check the wiring from TBIO to
the SE5.3.

4. Check that the green LED 1P on the SE5.3 module is lit. It should be lit indicating that
+24vdc is supplying the SE5.3 module. If it is not, measure across terminals 1P and 1M for
+24vdc. If it is present, replace the SE5.3 module. If it is not present, investigate circuit
breaker E02-Q34, which supplies the +24vdc.

5. Check that the red LED H3 on SE5.3 module N62-A12 located in cabinet +N1B, is lit. If it is
not lit, measure across connector X2:31 and X2:32. If +120vac is present, replace the SE5.3.
If it is not, check the wiring between TBIO and the SE5.3 module.

6. Check continuity and insulation of ribbon cable N62-RC5. Replace if necessary.

7. Replace Simadyn-D Processor #2 (PM16). Be sure to install the EPROM and submodules
from the original PM16 into the new PM16.

END OF PROCEDURE

FAULT 1114 DC-BUS VOLTAGE ABOVE 1100 VDC

EXPLANATION:

The processor responsible for rectifier control (PG16) has detected a DC bus voltage above
1100vdc. The Regen bridge is responsible for returning power from the DC bus back through the
main power transformer in order to keep the DC bus voltage within an acceptable range. If there
is a problem associated with the Regen bridge, its feedback, or its control, this fault may happen.
Since the Chopper controllers will also act at 1000vdc level, this fault is not commonly seen and
is indicative of a very fast rise in DC bus voltage.

The DC bus voltage is measured on two DC bus voltage transducers (device L01-U152- and
L01-U452 in cabinet +E1A). These transducers are connected to SiBAS rack cards Q071 and
Q079 respectively. SiBas sends the DC Bus voltage information from G051 card to Simadyn-D
directly at SE20.2 card (device: N50-A11-D13) X2: b4 / z4 (refer Schematics N63-Sheet1). The
SE20.2 converts this voltage to a frequency signal and sends is out connector X3 via ribbon
cable N63-RC7 to connector X7 of processor #3 (PG16) for decoding.

CORRECTIVE PROCEDURE:

1. If the rectifier section has been worked on recently, ensure that all the forward SITOR blocks,
chopper blocks, fuses, and firing cables are plugged in correctly.

2. Recalibrate the DC bus voltage feedback (see DC Bus Calibration).

3. Replace the DC Bus Voltage Transducer(s).

4. Replace the SE20.2.

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RECTIFIER TROUBLESHOOTING

5. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

FAULT 1115 RECTIFIER GATE BLOCKED (TGF)

EXPLANATION:

This is not a fault, but is a condition that is set in the Simadyn-D by any circumstance that will
keep the rectifier from operating properly. The following types of conditions cause Gate Blocking:

1. Problems in the rectifier;

2. Problems with the power supplies for the rectifier;
3. Problems with the rectifier interface;
4. Loss of PLC communications;
5. Activation of the POEB button;
6. Loss of UPS power.

CORRECTIVE PROCEDURE:

1. Refer to the other messages that occur at the same time.

END OF PROCEDURE

FAULT 1116 UPS OFF COMMAND FROM PLC

EXPLANATION:

This is not a fault but a message from the PLC to the Simadyn-D over the serial link. It informs
Simadyn-D that the power is about to go off, and to Gate Block the rectifier and inverters.

CORRECTIVE PROCEDURE:

1. No action is necessary.

END OF PROCEDURE

FAULT 1117 RECTIFIER GATE BLOCKING CMD

EXPLANATION:

This is not a fault, but is a condition that is set in the Simadyn-D by any circumstance that will
keep the rectifier from operating properly. The following types of conditions cause Gate Blocking:

1. Problems in the rectifier

2. Problems with the power supplies for the rectifier
3. Problems with the rectifier interface
4. Loss of PLC communications
5. Activation of the POEB button

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 RECTIFIER TROUBLESHOOTING

6. Loss of UPS power

CORRECTIVE PROCEDURE:

1. Refer to the other messages that occur at the same time.

END OF PROCEDURE

FAULT 1118 FAULT PRECHARGING (Ud<70%)

EXPLANATION:

Simadyn-D has not detected that the DC bus voltage has reached 70% of its nominal voltage of
910vdc within 6 seconds after the main contactor (DPC) has closed.

CORRECTIVE PROCEDURE:

1. Ensure that the main contactor is closing.

2. Ensure that the SITOR blocks are bolted securely and correctly.

3. Ensure that the firing pulse cables are securely and correctly connected to the SITOR blocks.

4. Ensure that the forward rectifier fuses are installed.

5. Ensure that the DC bus voltage information is read and sent by SiBAS

END OF PROCEDURE

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 DEVICES TROUBLESHOOTING

Chapter 2 DEVICES

AIR FLOW MONITOR

EXPLANATION:

The airflow monitor is used to make sure that the rectifier bridge and chopper bridge cooling fans
are working whenever the DC bus is energized.

The unit consists of two parts, the sensor unit or probe, and the monitoring unit. The monitoring
unit is mounted above the Forward rectifier bridge and Regen rectifier bridge. The probe is also
mounted there, but it is approximately flush with the rectifier face and the probe extends in
towards the center of the skid so it is directly in the airflow created by the fans.

The sensor unit is a "hot wire" system. The control unit puts a constant voltage on the probe, it
then measures the resistance (which is dependent on the probe temperature) by measuring the
current.

The trip level is set on the thumb-wheel on the airflow monitor. The correct setting for the unit is
5m/s and is in the prints for your machine. If the unit is in a tripped condition, the red led will be
off.

Because of the time for a fan to "spin up", the Simadyn-D doesn't begin monitoring the contacts
until 60 seconds after the DC bus is switched on. If the DC bus shuts off 60 seconds after it
comes on, the airflow circuit should be inspected.

It should also be noted that forward rectifier bridge and regen rectifier bridge airflow monitor units
are wired in series to the Simadyn-D. The control cannot distinguish which unit is sending the
fault. Therefore, the defective unit must be isolated by either observing the fault led or
temporarily jumping across contacts to isolate the bad unit.

WARNING!!!
RUNNING THE MACHINE WITHOUT PROPER AIRFLOW WILL RESULT IN PERMANENT
DAMAGE TO THE MACHINE

END OF PROCEDURE

DC CURRENT TRANSDUCER

EXPLANATION:

The DC Current Transducer is a fixed gain precision isolator and amplifier. It is a hermetically
sealed unit that is enclosed in a metal box for noise protection. It is located under the chopper
bridge on the SITOR side of the machine.

The unit is rated to put out exactly 10 volts with an input of 150mv and maintain a 1% accuracy
regardless of temperature.

REPLACING THE CURRENT TRANSDUCER:

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DEVICES TROUBLESHOOTING

There is no configuration or adjustment required on the module. All DC current transducers are
directly interchangeable with all others.

TESTING THE UNIT:

See DC Current Calibration.

END OF DESCRIPTION

DIGITAL TACHOMETER

EXPLANATION:

The digital tachometer is an important part of the shovel system. Its feedback is used for the
following functions:

1. Speed Regulation (SiBAS);

2. Allows brake setting to be done without excessive brake wear;
3. Is used to determine crowd impact loading;
4. Allows the Hoist reference reduction circuit to work.

The digital tachometer, sometimes called an optical pulse encoder, functions by putting out a
pulse frequency that is proportional to the speed of the motor. So that direction as well as speed
can be determined, two channels of pulses 90 electrical degrees apart are monitored in the
tachometer interface circuitry.

The tachometer is a hollow shaft design which fits over the motor shaft and allows the
mechanical brake to be mounted behind it. It is affixed to the shaft by a clamping sleeve that
must be tightened down according to the installation instructions in order to accomplish 2 things:

1. Keep the tachometer from slipping on the shaft

2. Maintain concentric alignment between the tachometer and the motor shaft.

Inside the tachometer is a precision etched encoder disk that is fixed to the rotating part of the
tachometer. This disk passes between a light source and a four quadrant light receiver which
generates 4 channels of pulses, all 90 electrical degrees apart. These pulses are normally
referred to as the 0, 90, 180, and 270 degree channels.

The SiBAS / Simadyn-D can use any 2 channels as long as they are 90 electrical degrees apart.
The following would be valid combinations of channels.

1. 0 & 90
2. 90 & 180
3. 180 & 270
4. 270 & 0

Please note that Simadyn-D uses 180 & 270 for monitoring overspeed and SiBAS uses 0 & 90 for
speed feedback for regulation.

The tachometer signal is received by SiBAS and the actual decoding of the tachometer signal is
done with circuitry and software on SiBAS.

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 DEVICES TROUBLESHOOTING

GENERAL STEPS IN TROUBLESHOOTING A TACH PROBLEM:

Changing a tachometer is big job, if the tachometer is suspected as a problems source, do the
following before changing the tachometer:

1. Make sure that the tachometer is mechanically secure on the motor shaft and that the torque
arm is adjusted correctly.

2. Double check all connections from the tachometer to the SiBAS card including shield
connections.

3. Try and alternate set of tachometer channels.

Figure 1 Digital Tachometer Problem #1

Figure 2 Digital Tachometer Problem #2

2-3
DEVICES TROUBLESHOOTING

Figure 3 Digital Tachometer Problem #3

TESTING A TACHOMETER:

In order to test a tachometer, its output must be displayed on an oscilloscope while running at a
constant speed. The best set up for this test is to have the motor uncoupled, and run the drive in
V/HZ mode. While it is not possible to uncouple the swing, it should still be tested in V/HZ mode.

1. Uncouple the motor under test if it's the crowd or the hoist.

2. Put the SiBAS in V/HZ mode, manually release the brake, and run at 30Hz.

3. Simultaneously display both tachometer channels on the scope.

4. The channel that is being triggered on should be steady on the scope display, while there will
be a small amount of movement or jitter in the other channel. If this jitter is over 5 usec, the
tachometer is probably bad (see Digital Tachometer Waveforms).

5. Observe the voltage levels of both channels, they should be around 22.7 vdc. If they are
both low, check the voltage (+24v) going to the tachometer. If one channel is low, try an
alternate set of channels. If the problem can't be corrected, the tachometer is probably bad
(see Digital Tachometer Waveforms2).

6. Observe the symmetry of the waveforms, the duty cycle of the pulses on both channels
should be identical. If they are not, the tachometer is probably bad (see Digital Tachometer
Waveforms2).

7. Check for missing pulses on either channel. If pulses are missing, try an alternate pair of
channels. If this doesn't clear up the missing pulses, the tachometer is bad (see Digital
Tachometer Waveforms).

8. If the symptoms were that the motion won't turn in n-control, but Torque is maximum, check
the scope for a dead tachometer channel. If this is the case, try an alternate set of
tachometer channels. If this won't clear up the problem, the tachometer must be replaced
(see Digital Tachometer Waveforms3).

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 DEVICES TROUBLESHOOTING

9. If the symptoms were that the motion won't turn in n-control, but Torque is maximum, and the
tachometer channels look OK, the tachometer maybe phased incorrectly. With the motor
running in V/HZ, check speed feedback signal in SiBAS monitor. It should have the same
polarity as the Operator Panel reference. If not, reverse the leads on the TBTACH terminals
in the skid.

END OF DESCRIPTION

EM11 MIXED I/O CARD

EXPLANATION:

The EM11 is a multipurpose I/O card. Three functions of this card are used on the shovel:

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

X6 is used to interface analog inputs

X7 is used to interface binary inputs

The Binary Inputs are interfaced through SE4.1 modules. The Analog Inputs are interfaced
through SE7.1 modules.

Figure 4 EM11 Card

REPLACING THE EM11:

There is no adjustment or configuration required for this card. All EM11's are directly
interchangeable with all others.

END OF DESCRIPTION

2-5
DEVICES TROUBLESHOOTING

FUSE MONITOR BOARD

EXPLANATION:

The fuse monitor board monitors the status of the rectifier fuses to determine if any of the
fuses are open circuited. There are two fuse monitor boards (both located in cabinet +R1A):
device +R11-A201 which monitors the first forward bridge and device +R12-A202 which
monitor the second forward rectifier bridge. The fuse monitor card measures the voltage
across each fuse. If a voltage is measured across any one of the fuses, the Simadyn-D
controller will put the rectifier into a gate blocked condition, the main contactor will open, and
all motions will come to a stop and mechanical brakes will set.

Each fuse monitor card has a NO set of contacts. Simadyn-D monitors these contacts, which
are connected in series, to determine if a rectifier fuse has blown. To determine which fuse
has triggered the fuse monitor card, note the six LEDs on the upper left-hand edge of the
fuse monitor board. These LEDs are laid out in the same position that the fuses are in the
rectifier. Hence, if the middle LED on the bottom row is lit, the middle fuses on the bottom
row of the rectifier are blown.

Figure 5 Fuse Monitor Board

If the main contactor opens up while the drive is running, it is possible that the fuse monitor
board may erroneously indicate a blown fuse. Just push the reset button on the card to clear
the blown fuse indication. It may be necessary to remove the +/-24vdc supplying the card
(via circuit breaker E02-Q11 in cabinet +E1A) to clear an erroneous blown fuse indication. If
the fuse monitor board will not reset, then a fuse may actually be blown (the red pop-up
button on the fuse may not always indicate that a fuse has blown) or the fuse monitor card
may be faulty.

REPLACING THE FUSE MONITOR BOARD:

CAUTION: THERE ARE LETHAL VOLTAGES ON THIS CARD! ENSURE THAT THE MAIN
POWER CONTACTOR IS LOCKED OUT PRIOR TO CHANGING THIS CARD.

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

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 DEVICES TROUBLESHOOTING

2. All fuse monitor boards are interchangeable.

END OF PROCEDURE

GROUND FAULT MONITOR

EXPLANATION:

The Ground Fault Monitor is used to test the leakage to Machine ground of the Incoming AC and
the DC bus. Both of these should be isolated from earth ground.

The monitor is connected to the incoming 800vac on phase 2. The connection to earth ground is
through fuse R10-F1, which is located next to the unit underneath the Regen rectifier bridge in
cabinet +R1B. The fuse is an indicator type with a large button that will pop up if blown.

The measurement is made by putting out a square wave pulse train between the incoming line
and earth ground and measuring the rise time of the pulses. In the case of a Ground Faults, the
unit will open a set of contacts and signal the Simadyn-D through the SE4.1 module N67-A11,
connector X2, terminal 1.

The following controls and indicators are on the unit:

1. System Capacity adjusts the unit for the system capacitance of the shovel.

2. Sensitivity adjusts for the trip point in kohms.

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

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

5. Tripped indicator is a red LED.

TESTING THE UNIT:

The unit can be functionally tested as follows:

1. If there is a ground fault indication, pull the ground fault fuse (with power off & the bus
discharged). If the ground fault indication doesn't clear, then replace the unit.

2. With the power off and the bus discharged, ground any incoming phase or the DC Bus, if this
doesn't cause the unit to trip, replace it.

3. Push the test push-button, if a ground fault indication doesn't appear on the unit replace it. If
a ground fault indication doesn't appear on the troubleshooting computer, troubleshoot the
interface circuitry.

END OF DESCRIPTION

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DEVICES TROUBLESHOOTING

MM11 MAILBOX MEMORY

EXPLANATION:

This card contains dual port RAM and is used for interprocessor communication in the Simadyn-
D rack. When processors have to communicate with each other, the sending processor writes to
the MM11 card while the receiving processor reads from it. The fact that dual port RAM is used
lets all processors operate asynchronously with respect to the other processors.

REPLACING THE MM11:

***********************************************************************************************
* WARNING---This card is extremely static sensitive *
* Handle with extreme care *
***********************************************************************************************

1. The MM11 is held into the rack by a screw at the top and bottom of the card, besides insuring
a good mechanical connection, these screws also serve to ground the front plate of the
processor providing noise immunity. These screws must always be used even for temporary
trouble shooting.

END OF DESCRIPTION

PG16 RECTIFIER CONTROL PROCESSOR

EXPLANATION:

The PG16 is a special purpose processor for Rectifier control.

Figure 6 PG16 Card

2-8
 DEVICES TROUBLESHOOTING

The front panel of the PM16 has the following connectors and indicators:

1. 7-segment display. Under normal operating conditions, this display shows the programmed
number of the processor. If it flashes, then there is a processor error (see Processor Error
Codes).

2. H10 Forward Bridge On. This green LED indicates that the forward (motoring) bridge is on.

3. H11 Regenerative Bridge On. This red LED indicates that the Regenerative Bridge is on (not
applicable on Shovel Systems using chopper bridge).

4. Fault Acknowledge button. This is the red button directly underneath the 7 segment display.
It is used to acknowledge a processor fault and clear the error code.

5. Test Jack X10 - M. This test point serves as common for the other test jacks.

6. Test Jack X11 - Reset. Jumpering this jack to X10 get will force a local reset of this card
only. As doing this normally results in a complete system crash, resets should be done using
the reset button on the Simadyn-D Card Rack.

7. Test Jack X12 Synch Voltage L1-L3. This is the synchronizing voltage that is used to time the
firing pulses. Because only the zero crossing points of the phase voltages are transmitted to
the Simadyn-D, the voltage is represented as a 24v square wave. This voltage originated on
the Synchronizing Module and is processed into zero crossings by the SE20.2 Module.

8. Test Jack X13 Analog DC Current. This is the Analog DC bus current signal. It has a range
of +/- 10v. 10volts represents 4200 amps. If the signal is positive, forward bridge current is
being shown. If it is negative, regenerative bridge current is being shown (not available on
chopper machines).

9. Test Jack X14 Pulse Enable. This signal shows where the pulses have been enabled. +5v
represents enabled, 0v is disabled.

10. Test Jack X15 Firing Pulse Simulation. This signal is a representation of the firing pulses.
The simulation is a series of square waves. The pulse that represents the firing of SCRs 6
and 1 is marked by putting fringe on the top of the pulse. If the fringe is on the top of the
pulse, the forward bridge is represented, if it is on the bottom, the regenerative bridge firing
pulses are being displayed (not available on chopper machines).

11. EPROM Module. This contains the control program for the processor. If processors are
swapped, the EPROM must stay with the processor in the physical location it came from.

12. Connector X5. This connector contains a blueberg jumper that is used to permit pulse
enabling. It is installed between pins 3 & 4 of the connector. If this jumper is not installed,
the bridge will never enable. Make sure to swap this jumper when swapping this card.

13. Connector X6. This connector is not used in the shovel configuration.

14. Connector X7. This connector is used for the cable between the PG16 and the SE20.2. This
cable carries firing pulses out and rectifier feedback signals back in. The connector has
posts on it for the cable locking mechanism. These locks must be engaged before the shovel
is run.

REPLACING THE PG16:

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DEVICES TROUBLESHOOTING

***********************************************************************************************
* WARNING---This card is extremely static sensitive *
* Handle with extreme care *
***********************************************************************************************

1. The PG16 is held into the rack by a screw at the top and bottom of the card, besides insuring
a good mechanical connection, these screws also serve to ground the front plate of the
processor providing noise immunity. These screws must always be used even for temporary
trouble shooting.

2. After replacing this card, the DC Bus Voltage must be recalibrated (see DC Bus Voltage
Calibration).

END OF DESCRIPTION

PM16 GENERAL PROCESSOR

EXPLANATION:

The PM16 is a general purpose Simadyn-D processor. It's function in the system depends
entirely on the program in it's EPROM. The processor is also fitted with communications
submodules that are necessary for the configuration.

The front panel of the PM16 has the following connectors and indicators:

1. 7-segment display. Under normal operating conditions, this display shows the programmed
number of the processor. If it flashes, then there is a processor error (see Processor Error
Codes).

2. Fault Acknowledge button. This is the red button directly underneath the 7 segment display.
It is used to acknowledge a processor fault and clear the error code.

3. Reset Jacks. Jumpering these jacks together will force a local reset of this card only. As
doing this normally results in a complete system crash, resets should be done using the reset
button on the Simadyn-D rack.

4. 4. Connectors X1 and X2. These connectors are used for external serial communications.
Each one of these connectors is programmed with a communication submodules which
determine the physical characteristics of the interface.

5. 5. Connector X5. This is a 40 pin connector for binary inputs and outputs. The interface
cable has a 40 pin connector on one end, and 4 10 pin connectors on the other end. The 10
pin ends are plugged into interface modules that act as a buffer between the processor and
the physical world.

6. EPROM Module. This contains the control program for the processor. If processors are
swapped, the EPROM must stay with the processor in the physical location it came from.

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 DEVICES TROUBLESHOOTING

Figure 7 PM16 Card

REPLACING THE PM16

***********************************************************************************************
* WARNING---This card is extremely static sensitive *
* Handle with extreme care *
***********************************************************************************************

1. The PM16 is held into the rack by a screw at the top and bottom of the card, besides insuring
a good mechanical connection, these screws also serve to ground the front plate of the
processor providing noise immunity. These screws must always be used even for temporary
trouble shooting.

2. When replacing this card, the communication submodule configuration must stay the same.
Use care when swapping the submodules so the pins don't get bent. It is much easier to
swap these modules if the EPROM and the ribbon cable for connector X2 are temporarily
removed.

END OF DESCRIPTION

PULSE DISTRIBUTION BOARD

EXPLANATION:

The pulse distribution board receives pulses from the rectifier control, and firing pulse power from
the firing pulse power supply and feeds them to the Sitor Blocks.

The board has 2 functions:

1. To route firing pulses to the Sitor Blocks.

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DEVICES TROUBLESHOOTING

2. To route firing pulses through the board to another Pulse Distribution Board.

How the board functions depends on the cable connections. The following connectors are
involved in firing pulse routing:

X1- Receives active and inactive firing pulses.

X2 - Passes the same pulses as X1
X10 -Used to Pass inactive firing pulses
X20 - Receives inactive pulses and makes them active pulses.

The following sets of test points are used to measure both active and inactive test points:

X6 is used to view inactive firing pulses

X7 is used to view active firing pulses

With the configuration on the Shovel, Forward Rectifier pulses can be viewed on the Forward
Rectifier Pulse Distribution boards on test point X7 on either board.

The connections on the left side of the board are used for the Firing Pulse power supply
connection. This power is daisy-chained through the Pulse Distribution boards.

Figure 8 Pulse Distribution Board

REPLACING THE PULSE DISTRIBUTION BOARD

All Pulse Distribution Boards are directly interchangeable. However if a new board is installed,
the jumpers must be soldered in as shown in the prints.

Normally, problems with the firing pulses on the board are not the fault of the board, but of the
way the cables are plugged in. Check your machine prints for wiring details.

END OF DESCRIPTION

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 DEVICES TROUBLESHOOTING

SE20.2 SITOR INTERFACE MODULE

EXPLANATION:

The SE20.2 is an interface board between the Sitor Bridge and the PG16 processor.

On the outgoing side, it takes firing pulses from the PG16, buffers and amplifies them, and sends
them to the pulse distribution boards.

On the incoming side, it takes DC Bus Voltage and Current Feedbacks, converts them to
frequencies, isolates them through transformers, and sends them to the PG16 for decoding.
Additionally, it takes the synch voltage from the synch module, detects the zero crossings, and
sends this information to the PG16. It also generates a "separate current equals zero" (I=0) and
sends this to the PG16 where it is used as a permissive for initially switching on the rectifier
bridges.

Because this card is involved in every phase of rectifier operations, it can be a suspect for any
rectifier problem.

Also, because it functions as the front end for the PG16, the troubleshooting of these 2 cards is
often handled as a set.

Figure 9 SE20.2 Interface Card

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DEVICES TROUBLESHOOTING

Figure 10 SE24.1 Daughter Board

REPLACING THE SE20.2:

When replacing the SE20.2, the easiest way to do the calibrations is to take the SE24 resistor
modules from the old card and install them on to the new card.

After doing this operation, or when keeping the new SE24 modules, the DC current and DC
voltage calibrations should be redone.

See also:

DC CURRENT FEEDBACK CALIBRATION

DC VOLTAGE FEEDBACK CALIBRATION

END OF DESCRIPTION

SE26.1 SIGNAL ISOLATOR MODULE

EXPLANATION:

The SE26.1 module is an isolator for analog signals in the range of -10v to +10v. The module
provides galvanic isolation between the input and outputs. It is used on the shovel for isolation of
the line voltage signal which comes from the synchronizing module to the EM11.

The following connections are used in the shovel System:

Terminal Group X2:

term 031 : Analog Input +

term 032 : Analog Input -

Terminal Group X3:

term L+: +24v

term M : 24v common

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 DEVICES TROUBLESHOOTING

term 04: Analog Output +

term 05: Analog Output -

Figure 11 SE26.1 Isolator Module

TESTING THE MODULE:

1. Test the module for offset by doing the following:

a. Disconnect the input wires from terminals 031 and 032;

b. Install a jumper between terminals 031 and 032;
c. Read the module output between terminals 04 and 05;
d. If the reading is not 0v, replace the module.

2. With a voltage going into terminals 031 and 032, read the output on terminals 04 and 05. If
they do not match exactly, replace the module.

END OF DESCRIPTION

SE4.1 24V BINARY I/O MODULE

EXPLANATION:

The SE4.1 is a general purpose Binary I/O card used to interface the PM16 card with +24vdc
inputs or outputs. Although the card can be used for either, each card is only INPUT or
OUTPUT. It cannot be both at the same time.

Whether a card is input or output depends on the addressing of the card. The addressing is
determined totally by what cable it is plugged into. The Simadyn-D binary cables are 40 pin at
the processor end. From there it splits into four 10 pin cables. These cables are then labeled
A,B,C and D. A and B are output connectors while C and D are input connectors.

This Module requires an external +24 vdc supply. It is connected to the terminals labeled 1P and
1M. The voltage is indicated on the module by a green LED.

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DEVICES TROUBLESHOOTING

All logic input and outputs are designated as positive logic. This means that if a signal is true
(indicated by the red status LED's), the input or output will be at +24v.

Figure 12 SE4.1 Interface Module

REPLACING THE SE4.1:

All SE4.1's are directly interchangeable with all others. There are no adjustments or
configurations required for this module.

END OF DESCRIPTION

SE5.3 115/220VAC ISOLATED INPUT MODULE

EXPLANATION:

The SE5.3 module is an isolated binary input module capable of receiving either 115vac or
220vac signals. It is used on the shovel to interface certain hard wired signals from the BE side
such as Main Contactor (DPC), POEB, and BEB signals. As such, it gets it's input from the PLC
control power that is derived from the UPS.

NEVER JUMPER ANY POWER TO THE CARD EXCEPT THE PLC CONTROL POWER.
MIXING PLC CONTROL POWER WITH ANOTHER 115V SCOURCE WILL RESULT IN
DISASTER ON THE SHOVEL.

The card also requires an external 24vdc supply which is wired to terminals 1P and 1M. The
presence of this voltage is indicated by a green LED.

All logic inputs on the card are designated as positive logic. This means that if the status light
(RED LED) for that input is on, voltage is present on the input.

If a voltage is present, and the corresponding LED is not lit, then the card is defective and must
be replaced.

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 DEVICES TROUBLESHOOTING

Figure 13 SE5.3 Isolated Input Module

REPLACING THE SE5.3:

There is no adjustment or configuration necessary on the SE5.3. The card may be changed with
any other SE5.3 module.

END OF DESCRIPTION

SE6.1 RELAY OUTPUT MODULE

EXPLANATION:

The SE6.1 is an isolated binary output module that uses relays to achieve the isolation. Each
output has both a normally open and normally closed output. The module is used on the Shovel
to interface 115vac signals to the BE side. For instance, there is an SE6.1 contact in each brake
circuit.

NEVER JUMPER ANY POWER TO THE CARD EXCEPT THE PLC CONTROL POWER.
MIXING PLC CONTROL POWER WITH ANOTHER 115V SCOURCE WILL RESULT IN
DISASTER ON THE SHOVEL.

The card also requires an external 24vdc supply which is wired to terminals 1P and 1M. The
presence of this voltage is indicated by a green LED.

All logic inputs on the card are designated as positive logic. This means that if the status light
(RED LED) for that input is on, the relay is closed, the NO contact will be made and the NC
contact will be open.

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DEVICES TROUBLESHOOTING

Figure 14 SE6.1 Relay Output Module

REPLACING THE SE6.1:

There is no adjustment or configuration necessary on the SE6.1. The card may be changed with
any other SE6.1 module.

END OF DESCRIPTION

SE7.1 TERMINAL BOARD MODULE

EXPLANATION:

The SE7.1 is a terminal board that is used to interface the analog outputs of the EA12 and the
analog inputs and outputs of the EM11. The card itself has no active components.

On the card there is a three level terminal strip. On the top, the positive connection should go. In
the middle the negative connection belongs. The bottom row is the Shield Common and Must Be
Used.

Figure 15 SE7.1 Terminal Board Module

2-18
 DEVICES TROUBLESHOOTING

REPLACING THE SE7.1:

All SE7.1 modules are directly interchangeable with all others. There is no configuration or
adjustment necessary.

END OF DESCRIPTION

SIMADYN-D CARD RACK

EXPLANATION:

The Simadyn-D rack and power supply are used to power and connect the processors and
interface cards of the Rectifier and Central controls.

The power comes from an external 24 volt supply and is regulated down to +5, +15, and -15 volts
by the Simadyn-D power supply which is mounted under the rack. Additionally, the power supply
sends an OK signal to the processors, allowing them to boot up when the power supply senses
all voltages are within tolerances.

The power supply also contains a lithium battery that is used to only to maintain the internal time
in the Simadyn-D

The Rack consists of 2 separate buses. The upper bus is called the C-bus or communication bus.
It's function is entirely for interprocessor communication. The lower bus is called the L-Bus or
Local Bus, it's purpose includes interprocessor communication, but it is also used when the
Processors communicate with an I/O card like the EM11 or EA12.

Both busses have pins in between the connectors that must be configured for the card
arrangement in the rack. These jumpers are used to bridge control signals over empty slots.

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DEVICES TROUBLESHOOTING

Figure 16 Simadyn-D Card Rack

REPLACING THE RACK:

If the Rack is changed, the jumpers must be configured as shown in the Schematics.

END OF DESCRIPTION

SITOR BLOCK

EXPLANATION:

A sitor block is a single unit consisting of the following components:

1. SCR
2. Heatsinks & SCR Clamping mechanism
3. RC snubber network
4. Pulse Transformer & firing card

Each sitor unit has the following test points on the front cover:

1. Test point for the SCR Anode

2. Test point for the SCR Cathode
3. Test point for the SCR Gate
4. Gate lead for Gate Current Measurements

Each Sitor unit has the following connections:

1. Connection to the AC line through the buswork.

2. Connection to the DC bus through the buswork

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 DEVICES TROUBLESHOOTING

3. Connection to firing control through the Pulse Distribution Card.

Figure 17 SITOR Block

Figure 18 SITOR SCR Clamping Detail

TESTING THE SCR:

Before testing the SCRs, the following safety conditions must be met:

1. The main contactor (DPC) must be switched off and locked out
2. The Bus must be completely discharged and verified with a Voltmeter.

After the safety conditions have been met, the test proceeds as follows:

2-21
DEVICES TROUBLESHOOTING

1. With an ohm meter on the high ohms scale, read across the test points for the Anode and
Cathode. The meter should indicate a high ohms reading. It is normal for the ohm meter
reading to increase during the test, this is because the ohm meter will charge up the snubber.

2. All the blocks are linked through the transformer, DPT. Therefore, if one block shows a short,
they all will. It will then be necessary to isolate the bad block by either pulling it from the
cabinet, or removing the fuses to isolate it from the transformer.

3. Once the defective block is isolated, remove it from the unit and isolate the snubber by
disconnecting the wire between the snubber capacitors and snubber resistors.

4. If the unit now reads OK, then replace the defective snubber components. Otherwise,
replace the SCR.

5. Another test is to test the Gate-Cathode junction with an ohm meter. For this test, the ohm
meter should be on low ohms scale. Insert the test leads into the Gate and Cathode test
points on the sitor front cover, the ohms reading should be between 5 and 25 ohms. A
reading of zero is definitely bad, as is an open. Replace the SCR if the ohm meter reading
are incorrect.

TESTING THE FIRING CARD:

Follow the Testing Firing Pulses Procedure.

REMOVING A SITOR BLOCK:

The following steps should be used to remove a sitor block.

Before removing or installing SITOR blocks, the following safety conditions must be met:

1. The main contactor (DPC) must be switched off and locked out

2. The Bus must be completely discharged and verified with a Voltmeter.

3. Loosen but don't remove the 4 torxhead screws on the Sitor front cover.

4. Slide the screw heads over in the slots toward the center of the block.

5. The Sitor front cover should now be free to swing open.

6. With the front cover open, remove the bolts securing the sitor block to the buswork.

7. Pull the block straight out from the cabinet. If there is interference, it may be necessary to
remove the block underneath it and push up on the block while pulling it.

8. Installation is the reverse of this procedure.

CHANGING AN SCR:

1. Remove the Sitor Block from the skid.

2. Keep the front cover open, and disconnect the wire connecting the snubber resistors and the
snubber capacitors.

3. Loosen and remove the two large clamping bolts. Be careful not to damage the plastic
insulators for the bolts.

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 DEVICES TROUBLESHOOTING

4. Separate the heatsink halves and observe the orientation of the SCR.

5. Remove the gate leads from the SCR.

6. Clean the heat sink halves.

7. Give the new SCR a very light coating of an approved heatsink oil, never use white silicon
paste.

8. Reconnect the gate leads, make sure the gate leads stay twisted and that the crimp
connections are secure.

9. Place the new SCR on the heatsink, making sure that the white centering pin is inserted into
the SCR. Place the plastic spacers on both ends of the heatsink halves and mount the upper
heatsink over the SCR. Make sure that both centering pins are correct.

10. Put the clamping bar on the bolts and make nuts finger tight. Then tightening each nut a little
at a time, tighten until the clamping bar is straight when measured with a straight edge.

11. To double check the clamping, measure the distance between heatsink halves on both ends,
they should be equal.

12. Reconnect the snubber capacitors and resistors.

13. Install the sitor block into the skid

END OF DESCRIPTION

THERMISTOR (3UP7) MONITOR

EXPLANATION:

The 3UP7 is used to monitor the motor thermistors in the Hoist, Crowd and Swing motions. The
monitoring is done for Monitoring the temperature for faults & warnings.

The motor temperature warning is set for 140 deg.C and the fault is set for 150 deg. C.

The following thermistor value correspond to the following temperature values:

Temp (deg C) Resistance (kohms)

60............…..............7.16
70....................…......4.93
80......................…....3.46
90......................…....2.47
100............................1.80
110............................1.33
120............................1.00
130......................…...0.76
140............….............0.62...........WARNING LEVEL
150.............…............0.47...........TRIP LEVEL
160....................….....0.36

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DEVICES TROUBLESHOOTING

Figure 19 Thermistor Monitor

CALIBRATING THE 3UP7:

The 3UP7 is NOT calibrated for shovel applications in the factory. It must be calibrated for the
proper trip and warning levels. The following procedure will calibrate the module:

1. Calibrating the Warning Level:

a. Disconnect the motor thermistor leads from T0, T1, T2, and T3

b. Hook up three 620 ohm resistors. T0 will be the common point, and the individual
resistors will be hooked to terminals T1, T2, and T3.

c. If the red warning indicator light is on, then turn the top adjustment pot until it goes off. If
it will not go off, verify the resistor values and connections. If it will still not go off, replace
the 3UP7 unit.

d. With the light off, turn the adjustment pot until the LED just comes on. This is the proper
calibration point.

2. Calibrating the TRIP Level:

a. Disconnect the motor thermistor leads from T0, T1, T2, and T3

b. Hook up three 470 ohm resistors. T0 will be the common point, and the individual
resistors will be hooked to terminals T1, T2, and T3.

c. If the red warning indicator light is on, then turn the top adjustment pot until it goes off, if it
will not go off, verify the resistor values and connections. If it will still not go off, replace
the 3UP7 unit.

d. With the light off, turn the adjustment pot until the LED just comes on. This is the proper
calibration point.

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 DEVICES TROUBLESHOOTING

3. Testing the Binary Interface:

a. Push the Push-to-Test button. The troubleshooting computer fault display should now
display both a motor temperature warning and fault for the motion in question.

b. If there is no faults, then find the corresponding SE4.1 module, and trouble shoot the
interface.

REPLACING THE 3UP7:

1. The 3UP7 module must be configured before it can be adjusted. When the module is new, it
comes with all resistors installed in the resistor window by the adjustment pots.

2. Clip out the extra resistors.

3. Do the adjustment procedure as listed above.

END OF DESCRIPTION

2-25
 PROCEDURES TROUBLESHOOTING

Chapter 3 TEST PROCEDURES

CALIBRATING BUS CURRENT FEEDBACK

EXPLANATION:

Current measuring on the DC bus is done through the shunt (device R40-SH in cabinet +R1B).
The rating on this device is 100mv = 2500 amps. This signal is sent to the DC current transducer
(DCI Transducer) (device R40-A3 in cabinet +R1B) pins 6 and 10. The gain of this transducer is
150 millivolt in = 10v out. The output of the DC current transducer is then sent out pins 4 and 5 to
the SITOR/Simadyn-D Interface Module (device R11-A501 located at the bottom of cabinet
+R1B) on pins b12 and z12. Next, the signal is sent to the SE20.2 interface module plug X2
(located in the main Simadyn-D rack Slot 13 in cabinet +N1A) via shielded cable N63-RC105.
The signal is scaled in the SE20.2 and converted to a frequency where it is then sent to the PG16
card (located in the main Simadyn-D rack Slot 17) on cable N63-RC7. This cable connects from
X3 of the SE20.2 to plug X7 of the PG16 card.

Figure 20 Current Feedback Bridge #1

TO CALIBRATE THE CURRENT FEEDBACK:

LOCK OUT MAIN CONTACTOR (DPC)

1. Disconnect the pulse cables from all rectifier blocks.

2. Disconnect the Top Shunt lead and short with bottom lead.

3. Using Telemaster (Service) program, perform Zero Offset calibration.

a. Change P3. TSHEL3. D4. ISE Æ 1

b. Read P3. TSHEL3. D3. YF1 (value)
c. Change P3. TSHEL3. D3. XF1 Æ above value
and save only the last value in EEPROM.

3-1
PROCEDURES TROUBLESHOOTING

4. Disconnect the shunt leads short and hook a battery box across it. Leave the battery box off.

5. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change the
following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

6. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card located
in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

7. Turn the battery box connected to the shunt on. Carefully adjust this to 100.0mv. The
Troubleshooting Computer should read exactly 2500 amps for DC current. If it reads zero,
then reverse the polarity of the battery box.

8. If the OP1 Display panel does not display a value of 2500 amps, then adjust potentiometer
R7 on the SE24 adjustment board that is plugged into the SE20.2. There are two SE24
modules, one has 3 fixed resistors, one has 1 fixed resistor. Adjust R7 on the one with 3
fixed resistors.

9. Shut down the rectifier and return shunt connections to normal.

5. If the SE20.2 cannot be adjusted to read 2500 amps, then put 150mv on the shunt and read
the output of the DCI Transducer. The output should be 10vdc +/- 0.1vdc. If this is not there,
replace the DCI Transducer.

6. Check the input of the SE24 mounted on the SE20.2. If the 10vdc is not there, check the
wiring. If it is there, replace the SE20.2.

10. Replace the PG16. Be sure to install the EPROM and submodules from the original PG16
into the new PG16.

END OF PROCEDURE

CALIBRATING BUS VOLTAGE FEEDBACK

CALIBRATION PROCEDURE:

LOCK OUT MAIN CONTACTOR

Since Bus voltage transducers areread by SiBAS and DC Bus voltage information to Simadyn-D
is given by SiBAS, there is only zero offset calibration required.

1. With the DC bus down, hook up a DC meter capable of measuring 1000 vdc on the terminals
on the high voltage side of the board.

2. When DC Bus voltage is completely Zero, Using Telemaster (Service) Program, perform
Zero offset calibration.

a. Change P3. TSHEL3. D4. ISE Æ 1

3-2
 PROCEDURES TROUBLESHOOTING

b. Read P3. TSHEL3. D4. YF (value)

c. Change P3. TSHEL3. D4. XF Æ above value
and save only the last value in EEPROM

END OF DESCRIPTION

CALIBRATING LINE VOLTAGE FEEDBACK

EXPLANATION:

The Siemens system uses the output of the BE Auxiliary Transformer for both line voltage
feedback and synchronizing voltage.

The voltage comes directly off of the Main panel on the MCC, through 3 fuses, and enters the
Siemens skid on TBSYNCH which is located in the bottom of cabinet +M1A (the breaker cabinet).
The voltage maybe either 460 or 380 volts depending of the machine configuration.

From TBSYNCH, the voltage is fed into the Synchronizing Voltage Monitor (Device N30-A15)
located in the bottom of cabinet +N1B. The calibration is done using pot R34 in SE49.1 Module,
which is the lowest of the two pot located on this module.

The line voltage signal is then fed into an SE26.1 isolator module (N64-A118). The isolator
output goes to the SE7.1 module (N64-A13) where is connected to the EM11 (D08) module
through ribbon cable N64-RC106.

This calibration must always be done after changing taps on DPT, the main transformer.

PROCEDURE:

1. Bring up the DC bus. All motions must have the brakes set.

2. Read the actual line to line voltage on the fuses in cabinet +R1A. Note: Many meters are
only good for 750vac--use an appropriate meter.

3. On the OP1 Display panel , look at line voltage.

4. Adjust R34 on the Synch Voltage Module until the OP1 Display panel reads line voltage
display, same as the meter.

END OF PROCEDURE

SIM-D PROCESSOR ERROR CODES

The PM16 and PG16 processors indicate error codes on the seven segment display. Normally
this display shows the processor number. If the processor number is not displayed, an error
code will be flashing. The following error codes are common to both the PG and PM16
processors:

“b”

3-3
PROCEDURES TROUBLESHOOTING

This code means that the power supply battery has run down. This battery is located behind a
screw type cover on the Simadyn-D Rack Power Supply. It is a 3.6v Lithium battery. Note: This
is the same battery used in the Simovert.

“H”

The H means that a non maskable interrupt has occurred. This normally means that there is a
bad piece of hardware in the rack. If only one processor shows this code--replace it. If the entire
rack shows H's, then swap the one that's blinking. If more than one are blinking, swap the
leftmost processor that's blinking.

For example, if the entire rack shows H's, but 5, 6, and 7 are blinking, then swap processor #5.

“E”

The E represents a scan time over run. This means that the processor was unable to complete
its work in the time allowed. In most cases this means a programming error. However, it is
possible when using the Service program, to generate this error. In this case, there is no
problem. Acknowledge the fault & continue operation.

“0”

A flashing 0 means that the EPROM failed to initialize. This error should only occur on power up
or after a reset. In all cases, it means a defective EPROM module.

“U”
A flashing U means an unknown op-code (instruction) was encountered. This could mean a bad
EPROM or Processor.

“C”

A "C" means that there is an internal communication fault in the Simadyn-D Rack. This could be
the result of a bad MM11 or processor.

“-”

The - means that the rack is in the process of initialization and is a normal occurrence on power
up or after a reset. If the - stays, then reset the rack again. If this doesn't help, check power
supply voltages.

“.”

The . means that the initialization state was never reached. Make sure that the EPROM is
plugged in. If this state occurs on one processor only, then the problem is in the EPROM or that
processor. If this is the state of the entire rack, then check the power supply.

TESTING RECTIFIER FIRING PULSES

EXPLANATION:

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 PROCEDURES TROUBLESHOOTING

The rectifier firing pulses are used to turn-on the forward rectifier SITOR blocks at the proper time
in order to regulate the DC bus voltage. The proper time is determined by the rectifier control
processor (PG16) based on the motoring and braking needs of the shovel. If the firing pulses are
not correct, then the DC bus regulation and the Simoverts will not work properly.

Figure 21 Firing Pulse Cable Routing (Chopper Machines)

HOW TO CHECK THE FORWARD RECTIFIER:

1. Check the SCR firing pulses with a current probe. Use Telemaster (Service) program to
initiate firing pulses.

2. LOCK OUT MAIN CONTACTOR.

3. Bring the Forward rectifier control ON, by using Telemaster (service) program. Change
the following connectors in Simadyn-D.

Change P3. TSHEL3. E1A. I2 Æ 1

Change P3. TSHEL3. E2. ISE Æ1
Change P3. TSHEL3. E2. ON1 Æ1

4. Verify the Simadyn-D rectifier control is on by looking at the front panel of PG16 card
located in Slot 6 of the Simadyn-D rack in cabinet +N1A (Green Light).

5. Using an oscilloscope with a small current probe, measure all pulses on the gate lead.
The gate lead is available on the upper left-hand corner of the cover the sitor block.
Have the scope "line triggered". Make sure that there are two pulses per block and that
the first pulse is 600 microseconds and the second pulse is 400 microseconds in
duration. By keeping the scope line triggered, the pulses should move from left to right
across the screen if the blocks are checked in numerical order. If any pulses have
significant deviation from the others, do the following:

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PROCEDURES TROUBLESHOOTING

a. Check the pulses on the pulse distribution board on test points 1.1, 1.2, 1.3, 1.4,
1.5, and 1.6. If they all look O.K., replace the sitor block that has the bad pulse
and retest.

b. If the pulse looks bad on the pulse distribution board, pull the firing pulse cable
from b. the associated sitor block and retest. If the pulse distribution board
waveform now looks good, replace the sitor module. Otherwise, go to step 9.

c. If there are still no pulses, go to step 10.

6. Remove the sitor blocks and inspect them. Make sure that all connections are tight and
that all plastic insulators are in good condition. Inspect the copper buswork behind the
sitor blocks for loose connections, arcing to ground, proper clamping pressure, etc.

7. Inspect +24vdc connections on all pulse distribution boards (devices R11-A101 and R12-
A102 in cabinet +R1A). An intermittent connection on either of the pulse distribution
boards can affect both rectifier bridges.

8. Inspect all connections on the +24vdc firing pulse power supply (device R11-G101 in
cabinet +R1B).

9. Replace the SE20.2

10. Replace the PG16. Be sure to install the EPROM and submodules from the original
PG16 into the new PG16.

END OF PROCEDURE

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 ADDENDUMS

Chapter 4 ADDENDUMS

ADDENDUM-1

Control Ring Troubleshooting

The first indication that a control ring problem has occurred, is that the Propel motor slowly turns,
but will not gain in speed (propel tachometer signal). Failure of the propel motor brushes could
cause over currents and shutdown the drive.

Checking Propel Tachometer Wiring

1. With a voltmeter, connect between the tachometer terminals at TB-TACH, terminals #11 and
#12. The AC and DC voltages should be approx. 0v.

2. If voltage is measured between these two points, then a control ring problem is likely.

3. With the MPS and UPS power turned off, disconnect the tachometer wire from TB-TACH,
terminal #11.

4. Connect an ohmmeter between the wire removed in step 3, and TB-TACH, terminal # 12.
The measured value should be between 600 and 700 ohms.

5. If the measured value is not between 600 and 700 ohms, then proceed under the machine to
junction box JB1 (see Figure A-1).

Figure A-1 Junction box JB1 location

6. Connect an ohmmeter between the following wires in JB1for the motion having trouble:

Left Propel: PT5 and PT7

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PROCEDURES TROUBLESHOOTING

Right Propel: PT1 and PT3

7. If the measurement value is between 600 and 700 ohms and the measurement at TB-TACH
was not between 600 and 700 ohms, then there is a problem in the control rings.

8. If the measurement value is not between 600 and 700 ohms at JB1 and at TB-TACH, then
check the tachometer brushes and wires at the tachometer.

9. If the brushes are popped out or broken, this will indicate that the tachometer is not aligned
properly. See “Propel Tachometer Alignment” for proper adjustment.

10. When finished testing or repairing the problem, re-connect the wire removed in step 3 (TB-
TACH terminal #11).

Checking Propel Motor Brushes

1. With the machine stopped and DC Bus off, pull down the Drive Power Disconnect (DPD) on
the High Voltage cabinet (ZHV) and lock.

2. In the Transfer Switch Cabinet, connect a meter between the R phase and S phase leads for
the propel motor.

3. If the ohmmeter measures greater than 20 ohms, there is likely a ring problem.

4. Connect a meter between the S phase and T phase leads for the propel motor.

5. If the ohmmeter measures greater than 20 ohms, there is likely a ring problem.

6. When finished testing or repairing the problem, remove the lock on DPD.

Propel Tachometer Alignment

Proper propel tachometer alignment is essential for a good feedback signal, prevents pre-mature
bearing wear in the tachometer, and prevents brush problems.

1. Assemble the tachometer drive shaft (Item #7) onto the propel motor shaft using a
retaining compound (Locktite; Bucyrus part # 82833859). Tighten drive shaft to 300ft.-lbs
(0.407 kN-m).

2. Assemble the tachometer drive shaft extension (Item #18) onto the tachometer drive shaft
(Item #7) using the setscrews (Item #19). If properly assembled, the tachometer drive
shaft extension (Item #18) will protrude beyond the tachometer drive shaft (Item #7) by
3.63 inches (92.9mm) with a tolerance of +0.13, -0.00 inches (+3.3, -0.0 mm). If the
tachometer drive shaft extension (Item #18) shaft protrudes more than 3.63 inches
(92.9mm) with a tolerance of +0.13, -0.00 inches (+3.3, -0.0 mm), disassemble and check
assembly for a depth of 2.75 inches (69.85mm).

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 ADDENDUMS

Figure A-2. Propel Brake Assembly and Tachometer Alignment

3. If the tachometer shaft and tachometer extension shaft assemblies are within the
tolerances listed in step 2, release the propel motor brake. The motor shaft can be rotated
back and forth for tach alignment without breaking the motor coupling.

4. While rotating the motor shaft, using a dial indicator, center the shaft extension (Item #18)
using the set screws (Item #19). Check shaft alignment at point X1 and X2 using a single
dial indicator or using one at each location (X1 and X2). Align shaft extension within
0.005-inch or better total run-out at X1 and X2.

Dial indicator magnetic bases can be mounted to bolt heads and to tach bracket guard.

5. When the shaft alignment is acceptable, remove one set screw at a time and reinstall using
a retaining compound (Locktite; Bucyrus part # 82833859). With dial indicator still
mounted on the shaft, make sure alignment stays within allowable tolerances.

6. When completed, all eight screws should be tight, loctited and proper shaft alignment
achieved.

7. The torque arm (Item #5) should be 90 degrees out from the tachometer shaft extension
centerline. The mounting should include two (2) fiber washers (Item #24) between the
mounting plate and the torque arm turnbuckle. When properly tightened, the torque arm
should be able to turn by hand in the turnbuckles.

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PROCEDURES TROUBLESHOOTING

Figure A-3. Torque Arm Mounting

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 ADDENDUMS

ADDENDUM-2

Greasing and Relubricating Instructions for Blower Motors used on top of

skid cabinets

• Replenishment grease should have a wide usable temperature range

(-20 deg F to +350 deg F) and be made with Polyurea thickener and high
quality oil with an NLGI #2 efficiency. Chevron SRI #2 meets these
requirements.
• Relubrication frequency:

1. 3 Months for Heavy-duty in dirty, dusty locations, high ambient,

moisture laden atmosphere or increased vibration levels.

• Grease Capacity:

Shaft End Bearing Æ 0.3 oz

Opposite End Bearing Æ 0.3 oz

(The grease capacity given is for that space in the bearing housing between the
shield and the outside of the motor)

• Normal Lubrication Sequence

1. Stop the Motor

2. Lock out the supply Switch.
3. Thoroughly clean off and remove the grease inlet and drain pipe plugs from
the bearing housing.
4. Remove hardened grease from drains with stiff wire or rod.
5. Add grease to inlet until a small amount of new grease is forced out drain.
6. Remove excess grease from ports.
7. Replace inlet plugs and run motor for 30 minutes before replacing the drain
plugs.

CAUTION:

DO NOT LET GREASE DROP INTO THE CABINETS AS POWER BLOCKS

MAY GET DAMAGED BY SHORT CIRCUIT

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