IGBT Retrofit Inverters-SIBAS Device Manual - Rev1.1 PDF

Energy & Automation, Inc.
IGBT SHOVEL
DEVICE
MANUAL
COVERING
IGBT SHOVELS
495BI / 495 BII
SIEMENS ENERGY & AUTOMATION

ALPHARETTA, GA
USA
IGBT Shovel Device Manual Revised 08/11/06

Rev 1.1
TABLE OF CONTENTS
BLOWER,380/460V,3AC,5600CFM: A1103012109 ...................................................................... 1
CAPACITOR,150kµF,40VDC,B41458-B7150-M: A1110231015 .................................................. 3
CAPACITOR, 22mF, 160V DC, B43457- J1229M: A1110231016 ................................................ 6
CAPACITOR,2000µF,DC LINK,2050V: A1110201430.................................................................. 9
CAPACITOR,0.22µF,2500V,B25835-S2224-K017: 614685........................................................ 12
CIRCUIT BREAKER, 10-16A,MSP,W\AUX : 3VU13001MM00 ................................................... 15
MINI CIRCUIT BREAKER,277VAC,1A,1P: 5SX21017................................................................ 17
MINI CIRCUIT BREAKER, 277VAC, 3A, 1P: 5SX21037............................................................. 19
MINI CIRCUIT BREAKER,240VAC,4A,2P: 5SX22047................................................................ 21
MINI CIRCUIT BREAKER,277V/0.5A, 1P: 5SX21058 ................................................................. 23
MINI CIRCUIT BREAKER,1-POLE,10A,D-TRIP: 5SX21108....................................................... 25
MINI CIRCUIT BREAKER,277VAC/1.6A,1P: 5SX21158............................................................. 27
MINI CIRCUIT BREAKER,1-POLE,16A,D-TRIP: 5SX21168....................................................... 29
DIODE,1200V,81A,# DD90N12L: 254755.................................................................................... 31
DIODE BRIDGE MODULE, 40A, 1600V: A1110231012.............................................................. 33
DIODE, 1400A / 4.5 kV: 1007937 ................................................................................................. 36
HEAT EXCHANGER,8A,75W,KXHE120B: A1HEN00C004........................................................ 38
HEATER,ELECTRIC,115V,800W,6.5A,D-AH8001B: A1HTR00A003......................................... 40
IGBT MODULE, DOUBLE, COMPLETE: 4509019000.10........................................................... 42
POWER SUPPLY, LAMBDA- LZS-500-3: A1110231005 ........................................................... 50
MODULAR MOTOR CONTROLLER 1.6-2.4A: 3VH13321MH10K6 ........................................... 54
REACTOR,400µH,320A,2400V: A11103012056 ......................................................................... 56
RELAY,120VAC,DPDT,P&B K10P-11A15-120: A1RLAC0P023................................................ 58
RELAY,24VDC,DPDT,P&B K10P-11D15-24: A1RLAC0P024.................................................... 61
CURRENT LMT RESISTOR,1Ω,15W, 5%,7-24-1,VERTICAL MOUNT: A1110231069.............. 64
RESISTOR,2.0 OHM,1000KJ,46742: A110231008 ..................................................................... 66
RESISTOR,110 OHM,10W,+/-5%,DALE TYPECW10: A1110231191 ........................................ 68
RESISTOR,500 OHM,50W,+/-10%,METAL CLAD: A1110231192 ............................................. 70
RESISTOR,10K OHM,225W,5%: A1110231221.......................................................................... 72
RESISTOR,33KOHM,80W,1%: A1110231218............................................................................. 74
THERMOSTAT,SNAP DISC,32 DEG: A1THA00006................................................................... 76
THERMOSTAT,SNAP-DISC, CLOSE AT 35 DEG C: A1110231213 .......................................... 79
THERMOSTAT,80 DEG F,CLOSE: A1THAH00004 .................................................................... 82
DIGITAL TACH,93 DIA,S MOD: A103012114 ............................................................................. 85
DIGITAL TACH,150 DIA,K MOD: A103012115 ........................................................................... 91
PROPEL TACHOMETER,DC,HOLLOW SHAFT: A103012116 .................................................. 97
PROPEL TACH TRANSDUCER,VT7-005D,FLEX-CORE: A1110231263 ................................ 103
CURRENT TRANSDUCER, LF2005-S/SP1-2000A: 1007797................................................... 105
VOLTAGE TRANSDUCER,LV-100-2000/SP5,2000V: A1110231009....................................... 109
VOLTAGE TRANSDUCER,LV-100-300/SP9: A1110231010 .................................................... 114
MOTOR TRANSFER SWITCH, MOS220 TYPE 711: 14192625501 ......................................... 118
TRANSFER SWITCH, MOS 220 TYPE 712: 14192626502....................................................... 120
TRANSFORMER, 3 PHASE, 500VA, 600-380-440/500: A1110231013.................................... 122
SIMATIC DP INTERFACE ET200M: 6ES71531AA030XB0 ...................................................... 125
PS407 S7400 5VDC/120/230V/10A: 6ES74070KA010AA0 ...................................................... 129
S7400 RACK UR2 9-SLOT: 6ES74001JA010AA0.................................................................... 132
CONTROLLER CPU 416-2 2.8MB DP MPI: 6ES7-416-2XK04-0AB0....................................... 134
MODULE COMM. PROC. IE ADV. CP443-1: 6GK7 443-1EX40-0XE0 ..................................... 142
PS 307 POWER SUPPLY MODULES........................................................................................ 146
SM 331 Analog Input Modules, 6ES7 331-7KF01-0AB0; 8 inputs, 24 VDC .......................... 149
SM 321 Digital Input Modules, 6ES7 321-1BH02-0AA0; 16 Inputs, 24 VDC ......................... 152
SM 321 Digital Input Modules, 6ES7 321-1FH01-0AA0; 16 inputs, 120 VAC ....................... 155
SM 322 Digital Output Modules; 6ES7 322-1BH01-0AA0; outputs, 120 VAC, 0.5A............. 158
SM 322 Digital Output Modules, 6ES7 322-1FH01-0AA0; 16 outputs, 120 VAC, 0.5A ........ 160
OUTPUT MODULE SM 332; 6ES7 332-5HD01-0AB0, AO 4 _ 12BIT ...................................... 162
IGBT Shovel Device Manual i

Rev 1.0
COMPUTER,ROCKY MOBILE: TYZ: A1110315361 ................................................................. 165
DISPLAY, HOST COMPUTER, VAMP3-SH45-CN7-PS: A1110201456 ................................... 170
SIBAS 32, BI / IGBT, 6FH47667-3A........................................................................................... 173
POWER SUPPLY,85-132/110,1200W,ETAFHG-48-SX-MODULE: A1110231023................... 175
POWER START-UP UNIT 110V (PSU 110V): 6FH9295-3D...................................................... 177
POWER SUPPLY 110V/5V (PCS 5V): 6FH9130-3A.................................................................. 180
POWER SUPPLY 110V/15V (PCS 15V): 6FH9131-3A.............................................................. 184
POWER SUPPLY 110V/24V (PCS 24V): 6FH9133-3A.............................................................. 188
CENTRAL PROCESSING UNIT (CPU): 6FH9563-3A ............................................................... 192
SIGNAL PROCESSING UNIT 56002, 27 MHz: 6FH9265-3B .................................................... 198
INPUT/OUTPUT ANALOG (IOA): 6FH9306-3A......................................................................... 202
INPUT/OUTPUT MODULE ( IOM ): 6FH9288-3C ...................................................................... 205
INPUT TEMPERATURE SENSOR PT100 (ITS): 6FH9413-3A ................................................. 209
INPUT VOLTAGE/FREQUENCY (IVF): 6FH9305-3D................................................................ 213
INPUT COVERTER BINARY 24V: 6FH9371-3C........................................................................ 216
BINARY OUTPUT CONTACT DRIVE: 6FH9387-3A ................................................................. 219
OUTPUT PULSE AMPLIFIER 40mA (OPA 40mA): 6FH9357-3A ............................................ 222
OUTPUT MEASURING AMPLIFIER: 6FH9303-3A ................................................................... 225
OUTPUT MEASURING AMPLIFIER: 6FH9404-3B ................................................................... 228
INVERTER MONITORING (UWS): 6FH9405-3A ....................................................................... 232
TRANSIENT RECORDER (TRACO): 6FH9320-3A ................................................................... 235
MULTIFUNCTION VEHICLE BUS 32: 6FH9458-3A.................................................................. 239
MSP, TYPE E,S0,CL10,11-16A,SCREW,+ADAPT: 3RV1021-4AA10 ...................................... 243
S00 1.8-2.5A 120/110VAC PNL NR COMBO/AUX: 3RA11151CA151AK6.............................. 246
VARISTOR, 48-127VAC: 3RT1916-1BC00................................................................................ 250
IGBT Shovel Device Manual ii

Rev 1.0
BLOWER,380/460V,3AC,5600CFM: A1103012109
SIEMENS Part Number: A1103012109

Bucyrus Part Number:
Description
Features:
1. Aerofoil axial fan
2. Impeller positively attached to shaft
3. Fully adjustable pitch design
4. Punched flanges on both inlet and outlet
Application data:
These fans are used in the IGBT module forced cooling system to prevent exceeding the
maximum allowed temperature under normal operating conditions. The fans are labeled L01/E01,
and L01/E02. There are two fans, each operates for one half of the container.
Test the blower
1. Isolate the power supply by switching off the drive power transformer, and locking out the
main power supply and Auxiliary power supply.
2. Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use
an adequate meter for a DC level of 2000 V.
3. Isolate the wires from terminals 2, 4 and 6 (output) of the circuit breaker associated with the
blower you want to test. Use an ohmmeter to measure the continuity of each phase to phase
circuit. Verify that the resistance measured to ground is infinite.
4. If there is a problem with the continuity of the circuit, proceed to remove the air duct mounted
between the fan and the discharge resistor. Visually check the electrical connections in the
motor terminal box. If the measurements are not identical for each phase to phase circuit,
there is a problem with the motor. It will be necessary to replace the fan assembly
5. If there is no problem with the continuity of the circuit, remove the intermediate air duct
mounted between the fan and discharge resistor. Proceed with a visual inspection of the
fan’s mechanical assembly. The pitch angle of all 9 blades should be identical (24deg). As
long as the motor shaft is not stalled, the impeller should be easy to move by hand.
Replacing the blower
1. Ensure that the main and auxiliary power supplies are locked out.
3. Remove the air duct that is mounted between the fan and the discharge resistor
4. Disconnect the wiring from motor terminals and pressure switch. Isolate the conductors.
5. Unscrew the mounting bolts from the bottom flange of the fan housing and remove it from the
container.
6. Replace the defective fan with a spare and bolt it to the container.
7. Replace all electrical connections and remount the intermediate air duct.
IGBT Shovel Device Manual Page 1of 263

Rev 1.0
Outline drawing
Technical data
Fan:
Fan code 50JM/31/2/9
Air flow 5560 Ft3/min
No. of blades 9
Pitch angle 24 °
Static Pressure 2.75 In
Motor:
Nominal power 10 HP
Nominal voltage 575 V
No. of poles 2
Frequency 60 Hz
Nominal efficiency 85.8 % @ Full Load
FLA 12.7 A
Maximum ambient 40 °C

Rev 1.0
CAPACITOR,150kµF,40VDC,B41458-B7150-M:
A1110231015

Bucyrus Part Number: 62039622
Description
Features:
1. High reliability
2. Superior electrical characteristics and small dimensions
3. High ripple filtering capability
Application data:
These capacitors are used in IGBT Shovel as buffer in order to smooth the 24 VDC voltage
applied to gate units of the IGBT modules. The capacitors also store energy that is used to turn
off the IGBTs in the event of an incoming power failure.
These capacitors are labeled E01-C05, E01-C06, E01-C07, and E01-C08.
0
To Test the Capacitors
1. Isolate the power supply and the output circuits by switching off the drive power transformer
and by locking out the main power supply and auxiliary power supply.
2. Using a voltmeter, check for the presence of voltage at the capacitor terminals; verify that the
capacitors have discharged.
3. Visually inspect the capacitors; look for cracks, bulges, and deformation. Pay paticular
attention to the shape. If the shape is no longer a perfect cylinder, it is very likely the
capacitor is defective.
4. If there is no visual defect, disconnect the wiring from capacitor terminal (isolating the
conductors from the rest of circuit).
5. Connect a multi-meter to the terminals of the each single capacitor and check the
capacitance. Measured values shall be 150,000 µF ± 20 %. If these measured values are out
of range, the capacitor should be replaced.
6. If the multi-meter is not capable of measuring capacitance, the following test may be
performed:
A. Switch the meter to resistance measurement and check for an increasing resistance up
to MΩ, when the leads are connected to capacitor terminals.
B. When the leads are swapped, at first a negative resistance is visible, changing to positive
and increasing to MΩ again.
Replacing the Capacitors.

1. Isolate the 120VAC power by opening and locking out PLCTB on the MCC in the electrical
room.
2. Remove the wire connected to the capacitor.
3. Unscrew the mounting nut and remove the capacitor from support bracket.
4. Screw the new unit in place. Reuse the special insulating washers to insulate the capacitor
housing from ground. Tighten the bolts with the torque value mentioned in the table below.
5. Restore all electrical connections. Tighten the bolts with the torque mentioned in the table
below.

Rev 1.0
6. Pay special attention to correctness of the wiring.
Capacitor Outline

Rev 1.0
Technical Data
Capacitor rated 150000 µF @ 40 VDC

Rev 1.0
CAPACITOR, 22mF, 160V DC, B43457- J1229M:
A1110231016

Description
Features:
1. Welded construction ensures reliable electrical contact
2. High ripple filtering capability
Application data:
These capacitors are used in IGBT Shovel as a buffer to smooth the 110 VDC voltage applied to
SiBas. The capacitors store energy that is used to turn off the IGBTs in the event of an incoming
power failure.
These capacitors are labeled E01-C01, E01-C02, E01-C03, and E01-C04.
To Test the Capacitors

1. Isolate the power supply and the output circuits by switching off the drive power transformer
and locking out the main and auxiliary power supplies.
2. Using a voltmeter, check the presence of voltage at the capacitor terminals to verify that the
3. Visually inspect the capacitors by checking them for cracks, bulges, and deformation. Pay
special attention to the shape. If the shape is no longer a perfect cylinder, it is very likely the
capacitor is defective.
4. If there are no visual defects, disconnect the wiring from capacitor terminal (isolate the
conductors from the rest of circuit).
5. Connect a multi-meter to the terminals of the each capacitor and check the capacitance.
Measured values shall be 22,000 µF ± 20 %. If these measured values are out of range, the
capacitor must be replaced.
6. If the multi-meter cannot measure capacitance, the following test may be performed:
A. Switch the meter to measure resistance and check for an increasing resistance up to MΩ,
when the leads are connected to capacitor terminals.
B. When the leads are swapped, at first a negative resistance is visible, then it becomes
positive and increases to MΩ again.
Replacing the Capacitors.

1. Isolate the 120VAC power by opening and locking out PLCTB on the MCC in the electrical
room.
2. Remove the wire connected to the capacitor.
4. Screw the new unit in place. Reuse the special insulating washers to insulate the capacitor
housing from ground. Tighten the bolts with the torque value listed in the table below.
5. Restore all electrical connections. Tighten the bolts with the torque listed in the table below.
6. Verify the wiring has been completed correctly

Rev 1.0
Capacitor Outline

Rev 1.0
Technical Data
Capacitor rated 22000 µF @ 160 VDC

Rev 1.0
CAPACITOR,2000µF,DC LINK,2050V: A1110201430

Description
Features:
MKK DC capacitors in rectangular cases are used in DC loops of frequency inverters as harmonic
filters and DC link capacitors. The rectangular case and random mounting position of the MKK
DC capacitors allow easy combination to form compact capacitor banks.
The MKK DC capacitor consists of a stack of flat, metallized polypropylene windings in a stainless
steel case. The windings are connected in parallel and formed by bending by metal sheets. The
sheets are soldered direct to the bushings to guarantee the lowest inductance values. The oil-free
impregnation of the MKK DC capacitors ensures minimal weight and minimum risk of fire in
ecologically sensitive applications and traction systems.
The MKK DC capacitor safety system

1. Dry impregnation technology: The absence of liquid impregnating agents such as oil or PCB
eliminates the risk of fire caused by leaking liquid. Dry design is a must for ecologically
sensitive applications and for insurance reasons.
2. Self-healing technology in the metallized polypropylene film
3. Film metallization with segmentation and internal fusing prevents the capacitor from bursting
as a result of electrical or thermal overloads.
Application data:
These capacitors are used in IGBT Shovels as DC Link capacitors. There are a total of 8
capacitors connected in parallel across the DC Link and are labeled L01-C12, L01-C13, L01-C22,
L01-C23, L01-C32, L01-C33, L01-C42 and L01-C43.
Test the capacitor

To measure the capacitor from its connectors, the capacitor must be removed from the container.
1. Isolate the power supply by switching off the drive power transformer; lock out the Main and
Auxiliary power supplies.
3. Remove the M10 mounting bolts from the retaining brackets and remove the capacitor from
the container.
4. Visually inspect the capacitor by checking for cracks, bulges, and deformation. Verify the
condition of the terminals of the capacitor and make a visual inspection of the female
connectors mounted in cabinet. If there is no mechanical damage, proceed to measure the
capacitance.
5. Connect a capacitance-meter to the terminals of capacitor and measure the capacity.
Measured value shall be 2000 µF +10/-0 %. If the measured value is out of range, the
Note: The negative pole of the capacitor has two terminals and positive pole only one. Make
sure that you have connected the meter properly to test the capacitor.

Rev 1.0
Replacing the capacitor
1. Ensure that the main and auxiliary power supplies are disconnected and locked out.
3. Unscrew the M10 bolts from retaining brackets and remove the capacitor from container.
4. Replace the defective capacitor with a new one and secure it to the container. Make sure that
when inserting the capacitor that the terminals are easily inserted into the electrical
connectors.
Outline drawing

Rev 1.0
Technical Data
Nominal data:
Nominal capacity CN 2000 µF +10/-0 %
Rated voltage UN 2050 V
Rated current IN
115 A
Rated energy WN 4200 Ws
Self inductance L self 50 nH
Dielectric dissipation factor tan δ0 2 x 10 -4
Max. peak current
I∧ 23 kA
Max. surge current
IS 57 kA
Test data:
DC test voltage between terminals UTT DC 3100 V; 10 s

AC test voltage between terminals UTC AC 6000 V, 50 Hz,
and case 60 s
Self-discharge time constant Ri x C ≥ 10 000 s
Dissipation factor tan δ (50 Hz) ≤ 10 x 10-4
Climatic data:
Min. operating temperature - 25 °C

Max. operating temperature + 55 °C
Average relative humidity ≤ 95 %
Storage temperature limit - 55 °C / + 85 °C

Rev 1.0
CAPACITOR,0.22µF,2500V,B25835-S2224-K017: 614685
SIEMENS Part Number: 614685

Description
Features:
1. High dielectric strength
2. High peak-current capability
3. Especially suitable for snubber circuits
4. Construction
A. Self-healing
B. Plastic dielectric
C. Oil-impregnated tubular windings (no PCB)
D. Metal-sprayed end faces ensure reliable contacting
E. Cylindrical aluminum case
F. 1-pole version, ceramic lead-through
G. Mounting bolts M8 or M12
5. Terminals
A. Tab connector 6.3 mm
6. Grounding
A. 1-pole capacitors need not be grounded.
Application data:
This capacitor is used in IGBT Shovels in a standard DC Link ground fault detection circuit. The
capacitor is labeled L01-C151
Test the capacitor

1. Isolate the power supply by switching off the drive power transformer and lock out the Main
and Auxiliary power supplies.
3. Visually inspect the capacitor by checking it for cracks, bursts, and deformation. If there are
no visual defects, disconnect the leads from the capacitor terminal (isolating it from the rest of
circuit).
4. Connect a capacitance meter to the terminals of the capacitor and check the capacitance.
Measured values should be 0.22 µF ± 10 %. If the measured value is out of range, the
Replacing the capacitor

3. Remove the leads connected to the capacitor.
5. Mount the new unit in place and restore the proper electrical connection.

Rev 1.0
Capacitor outline drawing

Rev 1.0
Technical Data
Nominal capacity CN 0.22 µF ± 10 %
Nominal voltage UN 2500 VAC

Rev 1.0
CIRCUIT BREAKER, 10-16A,MSP,W\AUX :
3VU13001MM00
SIEMENS Part Number: 3VU13001MM00

Description
Features:
SIEMENS Motor Starter Protector (MSP) is an individual manual motor starter designed for
switching AC current. The 3VU are used to protect and manually control a motor. The 3VU type
has an adjustable bimetal thermal and a fixed magnetic trip device. The factory built-in
instantaneous (magnetic) trip is coordinated to protect the load and the load conductors at their
rated withstand levels without additional adjustments.
Application data:
Individual manual motor starters are used to protect main cooling fan motors.
The MSP’s are labeled E01/Q01, and E01/Q02.
Test the MSP
1. Isolate the power supply by switching off the drive power transformer and locking out the
Main and Auxiliary power supplies.
2. Using a voltmeter, check that all capacitors have discharged. Use an adequate meter for a
DC level of 2000 V.
3. Visually inspect the MSP. If there are no visual defects, disconnect wires from the terminals.
4. Switch on the breaker and using an ohmmeter measure the continuity of each phase circuit.
5. If the MSP shows mechanical defects or at least one phase circuit is not continuous then the
breaker needs to be replaced.
Replacing the MSP

DC level of 2000 V.
3. Disconnect the line side feeder bus from the terminals and remove it from the DIN Rail.
Replace it with a new one and replace the electrical connections.

Rev 1.0
Outline drawing
Technical data
Rated operational voltage 575 VAC
Rated power at 575 VAC 15 HP
Adj. current range 10.0 – 16.0 A
Number of Poles 3
Rated frequency 50/60 HZ
Auxiliary contacts 1 NO & 1NC

Rev 1.0
MINI CIRCUIT BREAKER,277VAC,1A,1P: 5SX21017
SIEMENS Part Number: 5SX21017

Description
SIEMENS 5SX Miniature Circuit Breakers are designed for protection of all types of electrical
systems. Breakers of this type used in IGBT Shovel are E01/Q16, E01/Q17, and E01/Q18. They
are used in the 24V DC circuits of hoist, crowd and swing motor tachometers.
Outline drawing
Technical data
Rated Voltage 277 VAC for single pole
Rated Current 1A
Rated Frequency 50/60 Hz
Number Poles 1
Tripping Characteristic Type C
Rated Interrupting capacity 14 kA at 120/240 VAC
Mounting Snap-on to 35 mm DIN rail
Housing Grey molded plastic, RAL 7035. Black handle
Mechanical Endurance 20,000 operations
Permitted Ambient Temperature -25 °C to +45 °C
Shock Resistance 30 g – half-sine shock load 6 ms
Vibration Resistance ≥ 6g

Rev 1.0
Time Current curve characteristic
Type C characteristic is for general device protection in

control circuits and all other supplementary circuit
protection systems. Magnetic trip point – 5 to 10 times
circuit breaker rating. Thermal trip point 1.13 to 1.45
circuit breaker rating.

Rev 1.0
MINI CIRCUIT BREAKER, 277VAC, 3A, 1P: 5SX21037

Description
systems. The breaker of this type used in the IGBT Shovel is E01/Q06 and is used in the motion
cabinet PLC rack DI/DO, 120 VAC circuits.
Outline drawing
Technical data
Rated Current 3A
Number Poles 1
Tripping Characteristic Type C

Rev 1.0


Rev 1.0
MINI CIRCUIT BREAKER,240VAC,4A,2P: 5SX22047

Description
systems. The breaker of this type used in the IGBT Shovel is for the Host PC Power Supply
(E01/Q40).
Outline drawing
Technical data

Rev 1.0
Time Current Curve Characteristic


Rev 1.0
MINI CIRCUIT BREAKER,277V/0.5A, 1P: 5SX21058

Description
systems. The breaker of this type used in the IGBT Shovel is E01/Q15 and is used in the 120
VAC circuit of propel motor speed transducers.
Outline drawing
Technical data
Rated Current 0.5 A
Number Poles 1
Tripping Characteristic Type D

Rev 1.0

Type D characteristic is designed as a supplementary
protector of high inrush loads such as transformers and
motors. Magnetic trip point – 10 to 20 times circuit breaker
rating. Thermal trip point 1.13 to 1.45 circuit breaker rating.

Rev 1.0
MINI CIRCUIT BREAKER,1-POLE,10A,D-TRIP: 5SX21108

Description
systems. Breakers of this type used in the IGBT Shovel are:
- E01/Q05, E01/Q08, and E01/Q09 used for motion drive PLC rack power supply, UPS
and gate units power supply, 120 VAC circuits.
- E01/Q10, E01/Q13, and E01/Q14 used for Sibas room heater, cabinet lights and test
bench receptacle.
- E01/Q21, and E01/Q25 used for operator cab and MCC, ET 200 racks.
Outline drawing
Technical data

Rated Current 10 A
Number Poles 1

Rev 1.0


Rev 1.0
MINI CIRCUIT BREAKER,277VAC/1.6A,1P: 5SX21158

Description
systems. Breakers of this type used in the IGBT Shovel are E01/Q11 and E01/Q12 and are used
in the 120 VAC circuits of heat exchangers of control rooms.
Outline drawing
Technical data
Rated Current 1.6 A
Number Poles 1

Rev 1.0


Rev 1.0
MINI CIRCUIT BREAKER,1-POLE,16A,D-TRIP: 5SX21168

Description
systems. Breakers of this type used in the IGBT Shovel are:
- E01/Q07 used for Sibas rack power supply, 120 VAC circuits.
- E01/Q22, E01/Q23 and E01/Q24 used for lube room, crowd, and hoist, ET 200 racks.
Outline drawing
Technical data
Rated Current 16 A
Number Poles 1

Rev 1.0


Rev 1.0
DIODE,1200V,81A,# DD90N12L: 254755

Description
Features:
1. Rectifier diode module with ceramic isolated metal base plate. Hard soldered joints for
reliability.
2. The module is a 3 terminal device containing 2 series connected diodes
Application data:
These diodes are used in IGBT Shovel as rectifier diodes and provide protection against reverse
current in the DC power supplies for SiBas (110 VDC circuit) and for the IGBT module gate
amplifier (24 VDC circuit). These diodes are labeled E01-V51, E01-V52.
Test the diode

1. Isolate the power supply by switching off the drive power transformer and by locking out the
2. Using a voltmeter, check the DC output of the power supplies and the capacitors, verify that
all capacitors have discharged.
3. Isolate the Cathode and the Anode of diode under test by removing the wire connected to the
terminals. It is not necessarily to dismantle the diode from panel.
4. Check the Anode-Cathode resistance of the diode with a multimeter in both directions.
5. First measure the direction with the positive (red) test lead connected to Anode and the
negative (black) test lead to Cathode of the diode. In this direction the resistance should
show very low value – mΩ.
6. Second measure the direction with the negative (black) test lead connected to Anode and the
positive (red) test lead to Cathode of the diode. In this direction the resistance should show
very high value – hundreds of KΩ or MΩ.
7. If the measured values of resistance are different than above, the diode is defective and
needs to be replaced.
Replacing the diode

main and auxiliary power supplies.
2. Using a voltmeter, check the DC output of the power supplies to make sure that all capacitors
have discharged.
3. Disconnect the wires from the Cathode and the Anode terminals of diode.
4. Unscrew the M5 mounting screws from both ends of module.
5. Install a new module on panel and replace the electrical connections.

Rev 1.0
Diode outline drawing
Technical Data
Max. reverse repetitive voltage VRRM = 1400 V f = 50 Hz, tp = 10 ms
Max. average on-state current IFAVM = 90 A Half sine wave, Tc= 100 °C
Max. peak non-repetitive surge current IFSM = 2.4 kA tp = 10 ms, Tvj= 25 °C
Forward on voltage VF = 1.42 V IF = 300 A, Tvj = 150 °C
Slope resistance RT = 1.9 mΩ Tvj = 150 °C

Rev 1.0
DIODE BRIDGE MODULE, 40A, 1600V: A1110231012

0
Description
Features:
1. Isolated mounting
2. Metal base plate
3. Low thermal impedance
Application data:
These three phase diode-bridge modules are designed for use in applications requiring
rectification of three phase AC lines into DC Voltage. Each module consists of six diodes
internally connected to form a complete three-phase bridge circuit. Each diode is electrically
insulated from the mounting base plate for easy mounting on a common heat sink.
In an IGBT Shovel, these diode bridge are labeled L01- A201, L01-A202, L01- A301, and L01-
302.
To Test the Diode

1. Isolate the power supply by switching off the drive power transformer and by locking out the
main auxiliary power supplies.
3. Isolate the terminals of module you want to test it from the DC Bus and the AC system. Do
not dismantle the module from the heatsink.
4. Check the Anode-Cathode resistance of each internal diode with a multimeter in both
directions.
6. Second measure the direction with the negative (black) test lead connected to Anode and the
positive (red) test lead to Cathode of the diode. In this direction the resistance should show
very high value – hundreds of KΩ or MΩ.
7. If the measured values of resistance are different than above than module is defective and
0
Replacing the Diode
3. Remove the input and output electrical connections from the module.
4. Remove the 2 screws holding down the defective module and replace it with a new one.
5. Replace the electrical connections. Verify the connections have been properly made.

Rev 1.0
Diode Outline

Rev 1.0
Technical Data

Rev 1.0
DIODE, 1400A / 4.5 kV: 1007937

Description
Features:
1. Avalanche Rectifier Diode ABB 5SDA 14F4407
2. Low on-state voltage, narrow VF bands for parallel operation
3. Self-protected against transient over voltages
4. Guaranteed maximum avalanche power dissipation
5. Industry standard housing
Application data:
Used as reverse-polarity protection on the DC Link bus V11-V13, V21-V23, V31-V33, V41-V43.
Test the diode
1. Isolate the power supply by switching off the drive power transformer and by locking out
the main power supply and Auxiliary power supply.
2. Using a voltmeter, check the DC output of the power supplies and the capacitors, to
make sure that all capacitors have discharged.
3. Isolate the Cathode and the Anode of diode, which you want to test by removing the
diode from the mounting plane.
4. Check the Anode-Cathode resistance of the diode with a multi-meter in both directions.
6. Second measure the direction with the negative (black) test lead connected to Anode and
the positive (red) test lead to Cathode of the diode. In this direction the resistance should
show very high value – hundreds of KΩ or MΩ.
7. If the measured values of resistance are different than above, then the diode is defective
and needs to be replaced.
Replacing the diode

1. Isolate the power supply by switching off the drive power transformer and lock out the
2. Using a voltmeter, check the DC output of the power supplies to make sure that all
3. Disconnect the connectors from Cathode and the Anode terminals of diode.
4. Remove the diode module from the mounting plane.
5. Install a new module on the panel and reconnect the electrical connections.

Rev 1.0
Diode outline drawing
Technical Data
Max. reverse repetitive voltage VRRM = 4400 V f = 50 Hz, tp = 10 ms
Max. average on-state current IFAVM = 1410 A Half sine wave, Tc= 85 °C
Max. peak non-repetitive surge current IFSM = 17.5 kA tp = 10 ms, Tj= 160 °C
Forward on voltage VF = 2 V IF = 4000 A, Tj = 25 °C
Slope resistance RF = 0.44 mΩ Tj = 160 °C
Side Cooling Graph

Rev 1.0
HEAT EXCHANGER,8A,75W,KXHE120B: A1HEN00C004
SIEMENS Part Number: A1HEN00C004

Description
Features:
1. Air to air panel mounted heat exchanger
2. Precision Ball-bearing Motors
3. Closed-Loop Near-Ambient Cooling
4. Convoluted Aluminum Exchanger Element
5. Heavy-duty Steel Enclosure
6. Permanent Filters
7. Refrigerant-free
Application data:
These heat exchangers are used in IGBT Shovel’s forced cooling system of the control
compartments to prevent exceeding the maximum allowed temperature in these rooms under
normal operating conditions. There is quantity of two heat exchangers per container, one for each
room and they are labeled E01/E04, and E01/E05. A thermostat is used to turn each heat
exchanger on at 80 °F or off at 60 °F.
Test the heat exchanger

3. Isolate the wires from terminal block associated with the heat exchanger you want to test.
Measure the continuity of phase to neutral circuit with an ohmmeter.
4. If there is no problem with the circuit continuity, proceed to make a visual inspection of the
heat exchanger mechanical assembly.
5. If there is no problem with the circuit continuity and no mechanical damage, then the heat
exchanger should be tested with an auxiliary 120 VAC power supply.
6. If the heat exchanger does not pass one of the above tests it should be replaced.
Replacing the heat exchanger

3. Remove the wires from terminal block associated to heat exchanger you want to change.
4. Unscrew the heat exchanger assembly from the door and replace it with another one.
5. Restore electrical connections to the terminal block.

Rev 1.0
Outline drawing
Technical data
Approximate Weight: 20 lbs. [9.1 kg]

Rev 1.0
HEATER,ELECTRIC,115V,800W,6.5A,D-AH8001B:
A1HTR00A003
SIEMENS Part Number: A1HTR00A003

Description
Features:
1. Anodized aluminum housing
2. Thermostat adjustable from 0 °F to 100 °F ( -18 °C to 38 °C)
3. Fan draws cool air from the bottom of the enclosure and passes this air across the thermostat
and heating elements before being released into enclosure cavity
4. The heated air is discharged through the top of the heater unit
5. Ball bearing fan runs continuously for even temperature distribution
Application data:
This heater is used in IGBT Shovels in the SIBAS control compartments to prevent from going
under the minimum temperature in the room during normal operating conditions.
The heater is labeled E01/E03, and the thermostat is set at 40 °F (5 °C).
Test the heater

3. Isolate the wires from heater’s terminal block. Measure the continuity of phase to a neutral
circuit, L and N in terminal block with an ohmmeter (the thermostat should be adjusted to
minimum – less than ambient temperature).
4. If there is no problem with the circuit continuity, proceed to make a visual inspection of the
heater mechanical assembly.
5. If there is no problem of circuit continuity and no mechanical damage, the heater should be
tested with an auxiliary 120 VAC power supply (keep the thermostat in minimum position).
6. If the heater does not pass any of the above tests than it should be replaced.
Replacing the heater

3. Remove the wires from heater’s terminal block.
4. Unscrew the heater from the mounting bracket and replace it with another one.
5. Restore the electrical connections to the terminal block.

Rev 1.0
Outline drawing
Technical data

Rev 1.0
IGBT MODULE, DOUBLE, COMPLETE: 4509019000.10
SIEMENS Part Number: 4509019000.10

Description
The IGBT-module DOUBLE-IN 1.5 kVs is an air-cooled two-phase module. The following
configuration can be adjusted alternatively: two phases, two braking controllers, and one phase
and one braking controller (the local assignment braking controller/phase on the module is
selected freely). The assignment is done through bridges in the external control pin.
Beside the 4 IGBT’s, there is a quadro control unit (QST), four high voltage sections (HST) and
two temperature detectors (Pt-100 with two-wire connection). The two temperature detectors and
the saturation supervision of the IGBT’s enable an overload or short-circuit protection on the
power side. The quadro control unit (QST) guarantees overload protection for 2 seconds with
module short-circuits (HSTs and QST).
The electrical power connection (P,N,L1,L2) takes place through plug-in contacts at the back of
the device. A hood over the module’s components together with a suitable sealing in the area of
the plug-in contacts realizes the protection degree IP 54.
Module supply: 24V±5% / ≤1A regular.
Triggering signal: 40mA-current interface (only in connection with the corresponding SIBAS-
control unit)
Testing of IGBT power modules

To make it possible to do measurements on the power connectors located in backside of module,
the module must be removed from the container.
main auxiliary power supplies.
3. Dismantle the retaining brackets for the module and disconnect the control-shielded cable
from both ends (module and cabinet) to prevent any module damage.
Warning: Do not remove the module without removing the gate control cable.
Measuring points:
Collector-Emitter junctions of the transistors are connected to the power connector of the module
as shown below
(AC) L1 (+) P (AC) L2
(-) N
Rear view of module -

power connector layout

Rev 1.0
Values that could be measured with an ohmmeter from backside of module power connections:
Collector-Emitter: positive (red) test lead of ohmmeter in Collector - resistance shall be “infinite”.
Emitter-Collector: positive (red) test lead of ohmmeter in Emitter – resistance shall be “zero” (less
than 1mΩ) because of anti-parallel diode.
Measurements shall be repeated for all 4 transistors.
Transistor #1: collector connected in P and emitter in L1
Transistor #2: collector connected in L1 and emitter in N
Transistor #3: collector connected in P and emitter in L2
Transistor #4: collector connected in L2 and emitter in N
If the measured values of resistance are different than above, than the module is defective and
Testing of the gate trigger

Ensure that you have the correct connection of the gate control connector. Perform a verifying
wire check between the SiBas 32 and the IGBT module.
0
REPLACING THE IGBT MODULE
1. Shut down the DC Bus and lock out the main incoming power.
2. Switch off the auxiliary power supply and ensure the equipment is completely free of any
incoming supply. Lock out the Auxiliary incoming supplies.
3. Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged.
Use an adequate meter for a DC level of 2000 V.
4. Remove the plug connector.
5. Unscrew the fixing bolts and ensure the IGBT module is free from all connections and
fittings.
6. Pull the module out and exchange with a spare one. Use care when moving – the
module weighs 60kg.
7. Ensure the module is fully seated in and is in its proper location.
8. Secure the module firmly by tightening the fixing bolts.
9. Reconnect the plug connector ensuring the correct positioning of the connector and
taking care not to damage the pins.
OUTLINE DRAWING
(See Next Page)

Rev 1.0

Rev 1.0
AIR COOLED IGBT PHASE MODULE DOUBLE 1,5kV
BLOCK DIAGRAM

Rev 1.1
TECHNICAL DATA
• Mounted components
Mounted Components
Module characteristic Name Part number Revision
A5 Module unit 450 902 9000.00 A
A60 Quadro control unit 450.903.9003.00 A
A10, A20, A30, A40 High voltage section 450.903.9001.xx1 A
Power semiconductor component parts
Name Type Manufacturer
A1 to A4 IGBT 3,3 kV / 1200A FZ 1200 R 33 KF2 Eupec
A1 to A4 Equivalent type
• Surrounding Conditions
Air temperature in the built-in room (-40°C)1
-30°C. +70°C
Humidity strain in a non-ventilated room2 5K1 According to IEC 721-3-5 (1985)
Humidity strain in a ventilated room2 5K2 According to IEC 721-3-5 (1985)
Storage temperature -40°C...+85°C
Reference operational height over NN3 400m
Pollutants max. 10 mg/m3 Only in ventilated room
Sulfur dioxide max, 10 mg/m3
Sulfur hydrogen Near to the sea, salt
Salt mist
00
• Cooling
Notes
maximum coolant +40°C
temperature for nominal
performance
Coolant Air
Amount of coolant per Airstream cooling see diagram 1
time unit (nominal value)
Or
Forced cooling
Compound of coolant see surrounding
conditions
Temperature sensors 2 Pt-100 temperature detector
Connection: two-wire line

Rev 1.1
Diagram 1: Pressure loss in dependence on volume streams with forced cooling
300
Pressure loss [Pa]
250
200
150
100
50
0
0.00 0.10 0.20 0.30 0.40 0.50 0.60
Vol-Stream [m^3/s]
• Electrical load limits

Maximum voltages
Nominal voltages of the intermediate circuit
AC-Network 1800V
DC-Network 1500V
max. intermediate circuit in operation 1950V
dyn. Voltage maximum at the IGBT- typ. 2400V
connections
Braking controller "ON" 2050 V
Braking controller "OFF" 2000 V
Clock lock 2200V max. Braking controller
unity control-factor setting
Duration performance Sinus-triangle modulation
ϑamb=40°C, fp=450 Hz,
fM=50 Hz, cos(φ)=0,8 ,
Ausst.=0.99, no pre-
warming
Forced cooling (Rth4=13,4;Rth5=35,6) typ. 520 kW Ud=1500V
Airstream cooling (Rth4=13,4;Rth5=78,6) typ. 300 kW
Forced cooling (Rth4=13,4;Rth5=35,6) typ. 580 kW Ud=1800V
Airstream cooling (Rth4=13,4;Rth5=78,6) typ. 340 kW
Maximum Current
maximum commutable current On 1900 A ϑjunc≤ 125°C

Off 2200 A
Switch-off wave 2400 A ϑjunc≤ 125°C

Rev 1.1
Effective current to interpret power cross-

sections
Forced cooling 600 Aeff
Airstream cooling 400 Aeff
Overcurrent switch-off wave of the internal Typ.: 2,5...3,5
short-circuit protection kA
• Protection Type
Protection type according to DIN VDE IP00 PE-protective connections over
0470 part 1 coolant connection with the complete
device
IP 54 By installation in the converter a
sufficiently good pollution severity
must be saved through a suitable seal
in the area of the power plug-in
contacts.
• Test Voltage
SK1: main circuit (IGBTs, HST)
SK2: control circuit (DST, PT100)
Insulation capacity: AC 5,0 kV,

50Hz, 60s
Test voltages: AC 4,1 kV, The values apply to 5 test

Main circuit 50Hz, 60s maximum
Control circuit: AC 1050 V, According to requirements for

Each against a grounded 50Hz, 60s Japanese Market
coolant
TE-intermittent voltage (SK1) AC 2,4 kV At Q≤10pC
50Hz
• Installation Conditions / Mechanical

Mechanical strain
Vibration test: Pr EN 50 125-1
• Frequency range 5-150Hz
• Amplitude: a=4 m / s2
• Duration of strain per axle: 10 cycles
• Sweep rate: 1 Octave/min

Rev 1.1
Shocks: prEN 50 125
• Shock form Semisinus
• Shock duration 30ms
• Amplitude 30m/s2
• Duration of strain per axle 3 shocks per direction &
axle
Weight: 60 kg
Mounting position:
Preferred mounting position Cooling ribs down
Special case Cooling ribs up see topic 5.5
Dimensions See dimension drawing
450 901 9000.00 MB
Outside dimensions: L x B x H 640 x 460 x 250
mm3
Connection technique:
Load connections Blade contacts
2,5 ± 0,1 mm silver-plated
Coolant Air (no connections)
Intermediate circuit P-connection Blade contact
Intermediate circuit N-connection Blade contacts
Grounding Heat sink over 2 x M8 fixing screws
with contact washers.
Control pin Manufacturer:
Interconnectron
(26pol. Pin, ∅ 1mm,
surface gold-plated ),
Typ: KEJ A26C NN NN 000

Rev 1.1
POWER SUPPLY, LAMBDA- LZS-500-3: A1110231005

DESCRIPTION
Lambda's LZS and SE Series single output power supplies (250W to 1500W) are ideal for
industrial applications requiring reliable performance under harsh operating conditions.
This 24VDC Power Supply furnishes gate power for the IGBT modules to create the firing pulses
for the IGBT’s. It is fed from the 120V AC coming from the constant voltage transformer PLCT
through breaker E01-Q09 which is located in small cabinet on the upper left side of the machine.
On the output side, it is buffered by four capacitors E01-C05 - E01-C08. There are three resistors
across the distribution bus bars to make sure the capacitors discharge quickly on power off
conditions.
The power supply has the following features:

1. Voltage Sensing
2. Current Limiting
3. Adjustable Voltage
4. Local/Remote Operation
5. 115 VAC Input
6. Nominal +24 VDC output
This power supply circuit has 3 types of monitoring.

1. Internal monitoring. The red LED turns on if there is an internal fault in the power supply.
2. External monitoring. The SiBas unit monitors the power supply voltage to see that it is within
limits.
3. Circuit Breaker Monitoring. The PLC monitors the contacts of E01-Q09 to make sure it is
closed.
To Test the Unit

1. Isolate the unit by opening breaker E01-Q09
2. Test the output circuit with a meter to make sure the capacitors have discharged.
3. Disconnect the output wires on the 2 bus bars on the front of the unit.
4. Power up the unit by closing breaker E01-Q09.
5. If no LED’s are illuminated, then remove the protective cover over the input terminals and
measure the input voltage. If there is no voltage present, then troubleshoot the supply
network.
6. If the Red LED is on, there is an internal fault in the power supply and it must be
replaced. If the green LED is on, the unit should be OK.
7. Measure the output voltage on the output bus bars; it should be set at approximately
26VDC.

Rev 1.1
8. If the voltage is low, turn the output voltage adjustment until 26 volts is reached.
9. If the output voltage can not be adjusted, replace the unit.
10. If the tests are ok but the power supply continues to give trouble (Red LED on), then the
external circuit including the wiring to the IGBT modules should be checked. If the
external circuit is ok, the power supply should be replaced (faulty when it is loaded).
.
Replacing the Unit
1. In order to replace the unit, the mounting panel must be removed from the machine.
3. Remove the input and output electrical connections of both, the Gate Unit Power Supply and
the SiBas Power supply mounted on the panel.
4. Take out the Panel hold down bolts and tilt the panel up.
5. Remove the 4 screws holding down the power supply; remove and tag the defective unit.
6. Screw the new unit in place.
7. Mount the panel.
8. Install all connections except the power supply output.
9. Adjust the output voltage at 26 VDC per test procedure above.
10. Restore output connections.

Rev 1.1
Unit Outline

Rev 1.1
Technical Data

Rev 1.1
MODULAR MOTOR CONTROLLER 1.6-2.4A:
3VH13321MH10K6
SIEMENS Part Number: 3VH13321MH10K6

Description
Features:
SIEMENS MSP Modular Motor Controller (MMC) is a combination of an individual manual motor
starter (MSP) and a 3TF contactor that has been designed for switching AC current. It is possible
to use the MSP without additional branch circuit protection.
Application data:
Individual MSP combination motor starters are used to switch on/off and protect the precharge
transformers.
The modular motor controllers are labeled E01/MSP201, and E01/MSP301.
Test the MMC
DC level of 2000 V.
3. Visually inspect the MSP and the contactor. If there is no visual defect, disconnect the wires
from terminals.
4. Switch on the breaker and use an ohmmeter to measure the continuity of each phase circuit.
Force the contactor into the closed position and check the continuity for each phase circuit.
5. If the MSP or the contactor presents mechanical defects, or if one phase or more circuits are
not continuous, the modular motor controller needs to be replaced.
Replacing the MMC

DC level of 2000 V.
3. Disconnect line and load side wiring from terminals and unscrew the MCC from the support
panel. Replace it with a new MSP and replace the electrical connections.

Rev 1.1
Outline drawing
Technical data
Rated operational voltage 575 VAC
Rated power at 575 VAC 1 1/2 HP
Adj. current range for 3VU 1.6 – 2.4 A
Number of Poles 3
Rated frequency 50/60 HZ
Auxiliary contacts for 3VU 1 NO & 1NC
Coil voltage for 3TF 110/120 VAC, 50/60 Hz

Rev 1.1
REACTOR,400µH,320A,2400V: A11103012056

Bucyrus Part Number: ???????
Description
These three phase reactors are used in the IGBT Shovels as AFE reactors. They are part of a
step up converter configuration that converts the 900 VAC three-phase system to 1800 VDC. A
NC thermal switch that opens at 180 °C is used to monitor the temperature of each winding of the
reactor.
These reactors are used one per AFE and are labeled L01-L211, L01-L212, L01-L311, and L01-
L312.
Test the reactor

3. Visually inspect the reactor for leaks or deformations. If there are no visual defects,
disconnect the wiring from the reactor terminals and isolate the conductors.
4. Using an inductance meter, measure the value of inductance for each phase of the reactor;
the measurement should be 400 µH ± 20 µH.
5. If the measured values of inductance are different than above, the reactor is defective and
Replacing the reactor

3. Remove the top braces that keep the reactor secured to the cabinet frame.
4. Disconnect the wiring from the reactor terminals and isolate the conductors.
5. Remove the bottom mounting bolts of the reactor and slide it out of container.
6. Replace the defective reactor with a spare and bolt it to the bottom of container. Replace all
the electrical connections.
7. Install the top braces and secure them to both the reactor and the container.

Rev 1.1
Outline Drawing
Technical Data
Type 4EU56
Inductance 400 ± 5% µH Per phase
Nominal current I 300 A 50/60 Hz and 90 A harmonics current
Maximum current IMAX 550 A 50/60 Hz
Short-circuit current 4 kA 5 cycle
Maximum voltage VMAX 2400 V
Frequency 50/60 Hz
Protection degree IP00

Rev 1.1
RELAY,120VAC,DPDT,P&B K10P-11A15-120:
A1RLAC0P023
SIEMENS Part Number: A1RLAC0P023

Description
This is a SIEMENS - POTTER & BRUMFIELD K10 series, general purpose, 15A miniature relay.
It comes with a standard DPDT (double pole double throw) contact arrangement. The coil is rated
for use at 120 VAC and it is suitable for socket mounting.
In IGBT Shovels these relays are labeled E01/K04, E01/K05, E01/K06, E01/K07 and E01/K08.
The relays K05, K06, K07 are used for DPC status, Machine Stop and Emergency Power Off
circuits. The relays K04 and K08 are spares.
Test the Relay
2. Using a voltmeter, check the voltage level at the capacitor terminals to make sure the
capacitors have fully discharged. Use an adequate meter for a DC level of 2000 V.
3. Release the hold down spring, remove the relay from the socket and visually inspect the
contacts.
4. If there is no visual defect, use an ohmmeter to measure the value of coil resistance. The
expected value is 3900 Ω ± 585 Ω.
5. If the relay’s contacts display mechanical alterations or if the measured value of coil
resistance is different than above; the relay needs to be replaced.
Replacing the Relay

3. Release the hold down spring and remove the relay from the socket.
4. Insert a new relay in the socket and secure it with the hold down spring.

Rev 1.1
Outline Drawing

Rev 1.1
Technical Data
Contact data @ 25 °C
Materials Silver cadmium oxide
Expected life 10 million operations
Contact ratings 15 A @ 30 VDC resistive
15 A @ 120 VAC resistive
Coil data @ 25 °C
Nominal power 1.2 VA
Nominal voltage 120 VAC
Must operate voltage 85 % of nominal voltage
Resistance 3,900 Ω ± 15 %
Duty cycle Continuous
Environmental data
Operating temperature - 45 °C to +70 °C
Storage temperature - 60 °C to +105 °C
Mechanical data
Mounting Socket
Enclosure Smoke-color polycarbonate dust cover
Weight 1.8 oz (51 g)

Rev 1.1
RELAY,24VDC,DPDT,P&B K10P-11D15-24:
A1RLAC0P024
SIEMENS Part Number: A1RLAC0P024

Description
This is a SIEMENS - POTTER & BRUMFIELD K10 series, general purpose, 15A miniature relay.
It comes with a standard DPDT (double pole double throw) contact arrangement. The coil is rated
for use at 24 VDC and it is suitable for socket mounting.
In IGBT Shovels these relays are labeled E01/K09, E01/K10, E01/K11, E01/K12, E01/K13,
E01/K14 and E01/K15. The relays K09, K10, K11 and K12 are used to set the brake for motion
motors; K13 is used to close the DPC (drive power contactor) circuits. The relays K14 and K15
are spares.
Testing the Relay

1. Isolate the power supply by switching off the drive power transformer; lock out the Main and
Auxiliary power supplies.
3. Release the hold down spring, remove the relay from the socket and visually inspect the
contacts.
4. If there are no visual defects, use an ohmmeter to measure the value of coil resistance. The
coil resistance should be 160 Ω ± 24 Ω
5. If the relay’s contacts presents mechanical alterations or the measured value of coil
resistance is different than above then replace the relay.
Replacing the Relay

Release the hold down spring and remove the relay from the socket.
3. Reinsert in socket a new relay and secure it with the hold down spring.
Drawing0

Rev 1.1
Outline drawing

Rev 1.1
Technical Data
Contact data @ 25 °C
Materials Silver cadmium oxide
Expected life 10 million operations
Contact ratings 15 A @ 30 VDC resistive
15 A @ 120 VAC resistive
Coil data @ 25 °C
Nominal power 0.9 VA
Nominal voltage 24 VDC
Must operate voltage 75 % of nominal voltage
Resistance 160 Ω ± 15 %
Duty cycle Continuous
Environmental data
Operating temperature - 45 °C to +70 °C
Storage temperature - 60 °C to +105 °C
Mechanical data
Mounting Socket
Enclosure Smoke-color polycarbonate dust cover
Weight 1.8 oz (51 g)

Rev 1.1
CURRENT LMT RESISTOR,1Ω,15W, 5%,7-24-
1,VERTICAL MOUNT: A1110231069

Description
Features:
1. Round wire resistor. The wire is spot welded to the terminal bands and then locked onto the
core with vitreous enamel.
2. Through-bolt mounting hardware
Application data:
These resistors are used in DC Link capacitor’s pre-charge circuit, series with the pre-charge
power supply, to limit the charge of current for the capacitors and to help protect the DC Link
capacitors against damages due to inrush current.
There are a total of two used in IGBT Shovel container labeled: L01/R205 and L01/R305.
Test the resistor

Note: For access to the resistors, the top covers of the container should be removed.
3. Visually inspect the resistor by checking it for cracks or deformation. If there are no visual
defects, disconnect the wiring from resistor terminals and isolate the conductors.
4. Use an ohmmeter measure the value of resistance. The expected value is 15 Ω ± 0.75 Ω
5. If the resistor has mechanical alterations or the measured value is different than expected,
the resistor needs to be replaced.
Replacing the resistor
3. Disconnect the wiring from resistor terminals.
4. Remove the through-bolt that holds the resistor on the mounting brackets by removing the
nut from one side.
5. Exchange the resistor with a new one and secure it in place.
6. Restore the electrical connections.

Rev 1.1
Resistor outline
Core size:
O.D. x I.D. x L. 7/16” x 5/16” x 2”
Technical data
Rated Power 0000000 15 Watts
Resistance 00000000 1Ω ±5%
Max Temp Rise 000000 325 °C above an ambient of 25 °C.
Maximum voltage 750 VRMS per inch of winding length
0

Rev 1.1
RESISTOR,2.0 OHM,1000KJ,46742: A110231008

Description
Features:
1. Stainless Steel Stamped Grid Resistor
2. Grid banks are double insulated to guarantee reliable performance
Application data:
These resistors are used to discharge the energy from DC Link capacitors in a standard chopper
circuit (resistor is series connected with an IGBT).
There are two resistors mounted in each enclosure and are labeled: L01/R241, L01/R242 in the
first enclosure; L01/R341, and L01/R342 in the second enclosure.
Test the resistor

3. Remove the air duct that is mounted between the blower and the resistor.
4. Visually inspect the resistor by checking the stamped grids for cracks or deformations. If
there is no visual defect, disconnect the cables from resistor terminals and isolate them.
5. Using an ohmmeter, measure the value of resistance. The resistance should be 2 Ω +0.14Ω,
-0.1Ω at room temperature ( 20 °C).
6. If the resistor displays mechanical alterations or the measured value is different than above,

1. Note: For access to the resistors, air ducts mounted to the resistor enclosure should be
removed.
4. Disconnect the cables from resistor terminals.
5. Remove the bolts that hold the resistor on the mounting brackets welded to the container.
6. Exchange the resistor with a new one and tighten it in place.
7. Restore electrical connections.

Rev 1.1
Resistor outline
Technical data
Each enclosure contains two resistors with following data:
Nominal resistance @ 20 °C 2.0 Ω +7%, - 5 %

Energy absorption capacity 1000 KJ with a 300 °C temperature rise.
Nominal voltage
2100 VDC
Maximum hot resistance
2.50 Ω
Minimum cold resistance 1.90 Ω
Inductance < 15 µH
Test voltage 8500 VDC

Rev 1.1
RESISTOR,110 OHM,10W,+/-5%,DALE TYPECW10:
A1110231191

Description
Features:
1. High performance for low cost
2. High temperature silicone coating
3. Complete welded construction
4. Excellent stability in operation
5. High power to size ratio
Application data:
These resistors are used in 24 VDC power supply for IGBT gate unit as bleeding resistors. They
safely discharge the capacitors in a certain amount of time after the system shuts down.
The resistors are labeled E01/R03, E01/R04, and E01/05.
Test the resistor

DC level of 2000 V.
3. Visually inspect the resistor by checking it for cracks or deformation. If there is no visual
defect disconnect the resistor terminals from the support busbar.
4. Using an ohmmeter measure the value of resistance which should be 110 Ω ± 5.5 Ω.
If the resistor presents mechanical alterations or the measured value is different than above then

DC level of 2000 V.
3. Unscrew the resistor’s terminals from support busbar and replace it with a new one.

Rev 1.1
Resistor outline
Technical data

Rev 1.1
RESISTOR,500 OHM,50W,+/-10%,METAL CLAD:
A1110231192

Description
Features:
1. Molded construction for total environmental protection
2. Complete welded construction
3. Meets applicable requirements of MIL-PRF-18546
4. Available in non-inductive styles (type NH)with Aryton-Perry winding for lowest reactive
components
5. Mounts on chassis to utilize heat-sink effect
6. Excellent stability in operation
Application data:
These resistors are used in 110 VDC power supply for SIBAS unit as bleeding resistors. They
safely discharge the capacitors in a certain amount of time after the system shuts down.
The resistors are labeled E01/R01, and E01/02.
Test the resistor
DC level of 2000 V.
defects, unsolder wires from resistor terminals.
4. Using an ohmmeter, measure the value of resistance. The expected value is 500 Ω ± 5 Ω.
If inspection shows mechanical alterations or the measured value is different than above, the
resistor needs to be replaced.

DC level of 2000 V.
3. Unsolder wires from resistor terminals. Unscrew the resistor from support panel and replace it
with a new one. Replace the electrical connections.

Rev 1.1
Resistor outline
Technical data

Rev 1.1
RESISTOR,10K OHM,225W,5%: A1110231221

Description
Features:
Application data:
These resistors are used in the DC Link as a bleeding resistor. They safely discharge the DC Link
capacitors in a certain amount of time after the system shuts down.
There are two branches connected in parallel to the DC Link; each branch is built with four
identical resistors connected in series-parallel.
The resistors are labeled L01/R201, L01/R202, L01/R203, L01/R204, L01/R301, L01/R302,
L01/R303, and L01/R304.
Test the resistor

defects, disconnect the wiring from the resistor terminals and isolate the conductors.
4. Using an ohmmeter, measure the value of resistance. The expected value is 10 K Ω ± 500Ω.
5. If the resistor exhibits mechanical alterations or if the measured value is different than above,

4. Remove the through-bolt that holds the resistor on the mounting brackets by removing the
nut from one side.

Rev 1.1
Resistor outline
Core size:
O.D. x I.D. x L. 1 1/8” x 3/4” x 10 1/2”
Technical data
Resistance 000000000 10 KΩ ±5%
Max Temp Rise 00 325 ° C above an ambient of 25 °C.
Maximum voltage 750 VRMS per inch of winding length

Rev 1.1
RESISTOR,33KOHM,80W,1%: A1110231218

Description
Features:
Application data:
These resistors are used in a DC Link standard ground fault detection circuit and are labeled
L01/R151, L01/R152, L01/R153, and L01/R154.
Test the resistor

3. Visually inspect the resistor by checking it for cracks or deformation. If there is no visual
defect disconnect the wiring from the resistor terminals and isolate them.
4. Using an ohmmeter, measure the value of resistance. The expected value is 33 K Ω ± 330 Ω
5. If the resistor displays mechanical alterations or if the measured value is different than above,

4. Remove the trough-bolt that holds the resistor on the mounting brackets by removing the nut
from one side.

Rev 1.1
Resistor outline
Core size:
O.D. x I.D. x L. 1 1/8” x 3/4” x 4”
Technical data
Resistance 000000000 33 KΩ ±1%
Max Temp Rise 000 325 ° C above an ambient of 25 °C.
Maximum voltage 3000V 750 VRMS per inch of winding length

Rev 1.1
THERMOSTAT,SNAP DISC,32 DEG: A1THA00006
SIEMENS Part Number: A1THAH00006

Description
Features:
1. Ratings to 12A at 240VAC
2. 100,000 Cycle Rating
3. UL Component Recognized
4. Series 08-02 CSA Certified
5. Calibrated Settings from 10 to 350°F/-12 to 176°C
6. Automatic Reset
7. Vibration Resistant
Application data:
A snap-acting bimetal disc serves as the actuating element in this thermostat. As the temperature
reaches the tamper-proof predetermined set point, the disc snaps to provide rapid, positive
contact action.
This thermostat, labeled E01/TH05 is used to monitor the temperature in SIBAS control
compartment.
The thermostat prevents start up and operability of the system for room temperature lower than
normal operating conditions.
Test the thermostat

3. Only a visual inspection of the thermostat and of the electrical connections can be done with
the thermostat mounted in container, on the support busbar. A complete test can be done
only in laboratory conditions.
4. If the thermostat present any signs of mechanical damages of the electrical terminals or you
have any doubt about correct functionality, proceed to replace it.
Replacing the thermostat

3. Remove the wires from terminals of the thermostat that you want to change.
4. Unscrew the thermostat from the support busbar and replace it with another one.
5. Restore electrical connections to the terminals.

Rev 1.1
Outline drawing
Technical data
Contact closes at temperature higher than 50 ° F + 7 °F

Contact opens at temperature lower than 32 ° F + 7 °F

Rev 1.1

Rev 1.1
THERMOSTAT,SNAP-DISC, CLOSE AT 35 DEG C:
A1110231213

Description
Features:
6. Automatic Reset
Application data:
contact action.
These thermostats, labeled E01/TH01and E01/TH02 are used to monitor the temperature in
control compartments. They prevent start up and operability of the system for room temperature
above normal operating conditions.
Test the thermostat

the thermostat mounted in the container, on the support busbar. A complete test can be done
4. If the thermostat presents any signs of mechanical damage to the electrical terminals or you
have any doubt about correct functionality, proceed to replace it.

3. Remove the wires from the terminals of the thermostat that you want to change.
4. Unscrew the thermostat from the support busbar and replace it with a new thermostat.

Rev 1.1
Outline drawing
Technical data
Contact closes at temperature lower than 95 ° F + 7 °F

Contact opens at temperature higher than 115 ° F + 7 °F

Rev 1.1

Rev 1.1
THERMOSTAT,80 DEG F,CLOSE: A1THAH00004
SIEMENS Part Number: A1THAH00004

Description
Features:
6. Automatic Reset
Application data:
contact action.
These thermostats, labeled E01/TH03 and E01/TH04 are used to control the heat exchangers,
the forced cooling system of the control compartments to prevent exceeding the maximum
allowed temperature in these rooms under normal operating conditions.
Test the thermostat

the thermostat mounted in container, on the support busbar. A complete test can be done
4. If the thermostat presents any signs of mechanical damage or if you have any doubt about
correct functionality, proceed to replace it.

3. Remove the wires from terminals of the thermostat that you want to change.
4. Unscrew the thermostat from the support busbar and replace it with another one.

Rev 1.1
Outline drawing
Technical data
Contact closes at temperature higher than 80 ° F + 7 °F
Contact opens at temperature lower than 60 ° F + 7 °F

Rev 1.1

Rev 1.1
DIGITAL TACH,93 DIA,S MOD: A103012114

Description
Features:
1. Incremental hollow shaft encoder with exchangeable electronics and optics
2. Allows sensor exchange without removal/dismantling of encoder
3. Pulse disk can be cleaned through access of encoder housing
4. Suitable for extreme axial movement of motor shaft
5. Wide separation between pulse disk and scanner
Application data:
The optical pulse encoder, functions by supplying out a pulse frequency that is proportional to the
speed of the motor. In order for the direction as well as speed to be determined, two channels of
pulses 90 electrical degrees apart are monitored in the tachometer interface circuitry.
The tachometer is of hollow shaft design. It will fit over the motor shaft and allow 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. Prevent 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 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
This encoder is used in IGBT Shovels as speed feedback for the crowd and swing #1 motors.
Test the tachometer

In order to test the tachometer, the 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 manual mode.
1. Uncouple the motor under test if it is the crowd motor.

2. Put the crowd (swing) drive in manual mode, manually release the brake, and run at 30Hz.
3. Simultaneously display both tachometer channels on the scope.
4. The channel that is being used as the triggered 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
µsec, the tachometer is probably bad.

Rev 1.1
Figure 1 Channel jitters and unsymmetrical pulses
5. Observe the voltage levels of both channels; they should be around 22.7 VDC. If they are
low, check the voltage (+24VDC) supply 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.
Figure 2 Missing pulse and low voltage level
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 Figure 1).
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 Figure 2).
8. If there are large switching transients on the waveform, make sure that the filter capacitors on
the Q135 Sibas board are installed and working.

Rev 1.1
Figure 3 Switching spikes and dead channel
9. If the symptoms were that the motion won't turn in n-control, but draws high current, 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 Figure 3).
Replacing the tachometer

Changing a tachometer is large task. If the tachometer is suspected as a problem 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. Carefully clean the tachometer with high pressure air.
3. Double-check all connections from the tachometer to the Sibas Q135 input/output analog
card including shield connections.
4. Make sure that the filter capacitors on the Q135 card of Sibas are installed correctly, and are
functioning. The capacitors are C18 & C19 for crowd; C20 & C21 for swing. The capacitor
value should be 3.3 nF.
5. Try an alternate set of tachometer channels
6. If still is a problem, proceed to change the scanning system conform instructions below.

Rev 1.1

Rev 1.1
Tachometer outline drawing

Rev 1.1
Technical Data
Supply voltage + (12-30) VDC Ripple max. 10%
Pulse rate 720 Pulses/rev
No load current 70 mA At 30 VDC
Load 50 mA Per output
Outputs Push-pull final stages, resistant to sustained short circuit
Internal resistance 50 Ohm Per output
Pulse duty factor 1:1 ± 5%
Trace edge steepness 50 V/µs
Pulse height Approx. as supply voltage
Frequency range 0 - 100 kHz
Bore diameter 93 mm
Electronics -25 to +85 °C
temperature range
Approx. weight 22 kg
Degree of protection IP54

Rev 1.1
DIGITAL TACH,150 DIA,K MOD: A103012115

Description
Features:
1. Incremental hollow shaft encoder with exchangeable electronics and optics
2. Allows sensor exchange without removal/dismantling of encoder
3. Pulse disk can be cleaned through access of encoder housing
4. Suitable for extreme axial movement of motor shaft
5. Wide separation between pulse disk and scanner
Application data:
The optical pulse encoder, functions by putting out a pulse frequency that is proportional to the speed of
the motor. So that direction can be determined in addition to speed, two channels of pulses 90 electrical
degrees apart are monitored in the tachometer interface circuitry.
The tachometer is a hollow shaft design that 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. This is for 2 reasons:
1. Prevent the tachometer from slipping on the 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 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
This encoder is used in IGBT Shovels as speed feedback for the hoist motor.
Test the tachometer

In order to test the 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 manual
mode.
1. Uncouple the hoist motor under test.
2. Put the hoist drive in manual mode, manually release the brake, and run at 30Hz.
3. Simultaneously display both tachometer channels on the scope.
4. The channel that is being used to triggered the scope 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
µsec, the tachometer is probably bad.

Rev 1.1
Figure 4 Channel jitters and unsymmetrical pulses
5. Observe the voltage levels of both channels, they should be around 22.7 VDC. If they are low,
check the voltage (+24VDC) 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.
Figure 5 Missing pulse and low voltage level

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 Figure 1).
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 Figure 2).
8. If there are large switching transients on the waveform, make sure that the filter capacitors on the
Q127 Sibas board are installed and working.
Rev 1.1
Figure 6 Switching spikes and dead channel
2. If the symptoms were that the motion won't turn in n-control, but draws high current, 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 Figure 3).
Replacing the tachometer

Changing a tachometer is big job, if the tachometer is suspected as a problem 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. Careful, clean the tachometer with air-pressure.
3. Double-check all connections from the tachometer to the Sibas Q127 input/output analog card
including shield connections.
4. Make sure that the filter capacitors on the Q127 card of Sibas are installed correctly, and are
functioning. The capacitors are C20 and C21and the value is 3.3 nF.
5. Try and alternate set of tachometer channels
6. If still is a problem, proceed to change the scanning system conform instructions below.

Rev 1.1

Rev 1.1

Rev 1.1
Technical Data
Supply voltage + (12-30) VDC Ripple max. 10%
Pulse rate 720 Pulses/rev
No load current 70 mA At 30 VDC
Load 50 mA Per output
Outputs Push-pull final stages, resistant to sustained short circuit
Internal resistance 50 Ohm Per output
Pulse duty factor 1:1 ± 5%
Trace edge steepness 50 V/µs
Pulse height Approx. as supply voltage
Frequency range 0 - 100 kHz
Bore diameter 150 mm
Electronics -25 to +85 °C
temperature range
Approx. weight 22 kg

Rev 1.1
PROPEL TACHOMETER,DC,HOLLOW SHAFT: A103012116

Description
Features:
1. Low profile, short machine in A4 construction (without own bearings), in a mechanically robust
design
2. Torsionally-rigid connection between taco armature and drive machine, designed specially for
highly dynamic reversing
3. The possibility of passing the drive shaft through the tach so that an additional shaft extension is
available
4. Simple maintenance, easily accessible brush area; commutator contact surface can be checked,
cleaned and refurbished without dismantling the armature
5. Simple mounting and removal of the machine; the stator housing is pushed on over the fixed
armature
Application data:
The DC hollow shaft tach-generator functions by putting out DC voltage that is proportional to the speed
of the motor. The direction, by the polarity, as well as speed, by voltage value, can be determined.
The tachometer 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. Present the tachometer from slipping on the shaft
The Sibas is using this feedback value after it is converted to a lower value by DC/DC transducer with
ratio 100 V/10 V.
This tach-generator is used in IGBT Shovels as speed feedback for the propel motors - one for each
motor.
NOTE: After replacing the tach, the calibration procedure must be performed
Checking tachometer wiring

1. With a voltmeter, connect between the terminals MTB2-1 and MTB2-2 for the left propel motor or
connect between the terminals MTB2-5 and MTB2-6 for the right propel motor. The AC and DC
voltages should be approx. 0 V.
2. If voltage is measured between these two points, then a control ring problem is likely.
3. Isolate the power supply by switching off the drive power transformer and locking out the Main
4. Disconnect the tachometer wire from terminal MTB2-1 for the left propel motor or terminal MTB2-
5 for the right propel motor.
5. Connect an ohmmeter between the each wire removed in step 4, and terminal MTB2-2 for the left
propel motor or terminal MTB2-6 for the right propel motor.
6. The measured value should be between 600 and 700 ohms.
Rev 1.1
7. If the measured value is not between 600 and 700 ohms, then proceed under the machine to
junction box JB1 (see Figure 1).
Figure 7 Junction box JB1 location
8. Connect an ohmmeter between the following wires in JB1 for the motor experiencing trouble:
Left Propel: PT5 and PT7
Right Propel: PT1 and PT3
9. If the measurement is between 600 and 700 ohms and the measurement at MTB2 was not
between 600 and 700 ohms, then there is a problem in the control rings.
10. If the measurement value is not between 600 and 700 ohms at JB1 and at MTB2, then check the
tachometer brushes and wires at the tachometer.
11. 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.
12. When finished testing or repairing the problem, re-connect the wire removed in step 4 (MTB2
terminal 1 or 5).
Propel tachometer alignment

Proper propel tachometer alignment is essential for a good feedback signal, prevents premature 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).

Rev 1.1
Figure 8 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
setscrews (Item #19). Check shaft alignment at point X1 and X2 use either a single dial indicator
or 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 setscrew 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, set with Locktite, and proper shaft alignment
achieved.
7. The torque arm (Item #5) should be 90 degrees out from the tachometer shaft extension
centerline. The mount 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.

Rev 1.1
Figure 9 Torque arm mounting

Rev 1.1

Rev 1.1
Technical Data
Nominal voltage 100 VDC Per 1000 rev/min
Maximum speed 2500 Rev/min
Optimum load 240 kΩ
Armature resistance 670 Ω At 20 °C
Maximum load 8 mA At 1000 rev/min
Drive shaft diameter 25 mm
Approx. weight 3 kg
Isolation class B

Rev 1.1
PROPEL TACH TRANSDUCER,VT7-005D,FLEX-CORE:
A1110231263

Description for transducer

Features:
1. Provides output which is directly proportional to input voltage.
2. Output is electrically isolated from the input and is proportional to the input amplitude and
frequency (ac. in/out, dc. in/out).
3. DC to better than 10 kilohertz frequency response.
4. Provides 1500volt isolation.
Application data:
These transducers are used in propel motors speed feedback, converting the output voltage of the
analog tachometers 0-150 V, to lower level of 0-10 V. Output circuit of transducers is connected to
SiBas cards Q087 and Q071. The transducers are labeled E01-U455 and E01-U456.
Test the transducer

1. Isolate the power supply by switching off the drive power transformer and locking out the main
power supply and Auxiliary power supply.
2. Test the appropriate circuits with a meter to make sure power is off and the capacitors have
discharged. Use an adequate meter for a DC level of 2000 V.
3. Disconnect and isolate the wiring from the input circuit of tachometer (terminals 1 & 2). Keep
the burden resistor connected.
4. Keep outputs connected to SiBas (terminals 5 & 6) and connect a voltmeter on this circuit with
positive test lead in terminal 6.
5. Connect a DC-voltage source (125 VDC from transfer switch motor could be used) to the input
terminals of the transducer (to plus 2 and to minus 1).
6. Feed container with 120 VAC from PLCT. Power up the transducer by closing E01/-Q15 in
order to feed the transducer.
7. The output voltage measured between terminals 6 and 5 shall be + 8.33 V ± 0.25%
(corresponding to +125 VDC input).
8. Note: Transducer ratio is Uo = Ui x 10/150. Use that ratio for a different value of input voltage.
9. Repeat this test by reversing the polarity on the input side of transducer. Measured voltage on
the output circuit shall be now – 8.33 V ± 0.25% (corresponding to -125 VDC input).
10. Last step is to verify offset output for 0 VDC input voltage. Disconnect the 125 VDC power
supply wire and jump input terminals. Power up transducer. The measured offset voltage shall
be adjusted to zero from the potentiometer.
11. If at least one of the measured values of output circuit are different than above than transducer
is defective and needs to be replaced.
Replacing the transducer


Rev 1.1
4. Test the appropriate circuits with a meter to verify power is off and the capacitors have
5. Disconnect the wires on the terminals.
6. Remove the screws that hold the transducer down on the mounting plate.
7. Exchange the transducer for a new one.
8. Insert and fasten the mounting screws.
9. Restore all electrical connections.
10. Restore the power.
Transducer outline drawing
Technical Data
INPUT
Input voltage VDC 0-150 V
Frequency Range DC to 10000 Hz
Overload 1.2 times full-scale rating
Dielectric test 1500 VAC
OUTPUT
Output voltage VDC ±10 V
Accuracy ±0.25 %F.S.@d.c.
Response (90%) 50 µs
Output loading 2 kΩ min.
Field adjustable CAL ±10 %

Rev 1.1
CURRENT TRANSDUCER, LF2005-S/SP1-2000A: 1007797

Description
General
The Current Transducers (CT’s) are used for monitoring the currents in drives, AFE’s, and chopper
circuits. They are installed in the power section of the container in section L01. The SiBas32 input
board powers the measuring circuit. So in fact there are two circuits, the primary circuit in the
power section and the secondary circuit in the controls. The control circuits are shown in section
N01.
There are three terminals on the control circuit:

1. +, for +24 VDC supply from the SiBas32 input board
2. -, for -24VDC supply also from the input board
3. M, for measurement signal, a current signal to burden resistor in the SiBas board.
Working Principle of Closed Loop (feedback) Current Transducers
The magnetic flux created

by the primary current (Ip)
is balanced through a
secondary coil using a
Hall device and
associated electronic
circuit. The secondary
(compensating) current is
an exact representation of
the primary current.
The primary current is
thus converted into a
secondary current with a
ratio of 2000 A to 400 mA.

Rev 1.1
To Test the Current Transducer

1. Isolate the main power by opening and securing the MDC.
3. Measure on the test point box to make sure that the signal is zero. If it’s not, then there is an
offset in the device. The offset can be caused by a missing or out of tolerance power supply
or by a defective sensor.
4. Check all the connections on the control connector for mechanical damages.
5. Check the cable connector (LEMO) and the SiBas32 rack front connector.
6. An electrical test for transducer is very hard to be done in container and if no wiring problems
are found, proceed to change the transducer.
Replacing the Current Transducer

3. Disconnect the power cable that runs through the CT that has to be exchanged on one side. It
is recommended for this to be done on the incoming terminals for the CTs of the AFEs. The
CTs that are located on the motor-side should be done on either the motor-terminals or the
transfer switches. The best way to reach the CT’s for the choppers is by disconnecting the
cables at the chopper-resistors. For the drawings, see section L01.
4. Pull the power cable through the CT. Take special notice of the direction the cable runs
through the CT in relation the arrow marked on the CT.
5. Disconnect the LEMO connector for the control circuit by pulling back the diced ring in order to
unlock the connector.
6. Disconnect the grounding bracket.
7. Remove the screws that hold the CT down on the mounting plate.
8. Exchange the CT with a new one.
10. Re-connect the grounding bracket.
11. Re-connect the LEMO connector. The red dots should be aligned for proper connection.
12. Pull the power cable back through the CT. Make sure that the direction in which the cable runs
through the CT is the same as before.
13. Re-connect the power cable at its terminal.

Rev 1.1
The Current Transducer Outline

Rev 1.1
Technical Data
00

Rev 1.1
VOLTAGE TRANSDUCER,LV-100-2000/SP5,2000V:
A1110231009

Description
General
The Voltage Transducers are used to measure the DC-link voltage and for Ground Fault
monitoring. They are installed in the power section of the container in section =L01. The SiBas32
input board powers the measuring circuit. So in fact there are two circuits, the input circuit in the
power section and the output circuit in the control. The control circuits are shown in section =N01.
The terminals for the connection to the power circuit are marked +HT and –HT. There are three
terminals on the control circuit:
2. .-, for – 24 VDC supply also from the input board
3. M, for measurement signal, a current signal to burden resistor in the SiBas board.

Rev 1.1
Working Principle of Closed Loop (feedback) Voltage Transducers
A very small current (few milliamperes) is taken from the voltage line to be measured and is driven
through the primary coil. The magnetic flux created by this primary current (Ip) is balanced through
a secondary coil using a Hall device and associated electronic circuit. The secondary
(compensating) current is an exact representation of the primary current.
00
DC-link Monitor
The DC-link monitor is straight forward, just measuring the voltage across the bus bar. This is
performed by =L01/-U152 and =L01/-U452. During normal operation the actual value of the DC-
link is measured by –U152. This value is cross-checked with –U452. In case of a major deviation
between the two measured signals, a shutdown will be performed.
Ground Fault Monitor
A standard ground fault detection circuit is used in DC Link, using the voltage transducer labeled
=L01/-U151.
To Test the Voltage Transducer

1. Isolate the main power by opening and securing the DPC.
2. Shut-off and secure the 480 VAC supply to the pre-charge circuits by opening =L01/–Q301
and =L01/–Q201.
3. Shut off the 120 VAC supply that indirectly powers the SiBas32 rack by switching off =E01/-
Q7.
discharged. Using a voltmeter, check the DC Bus to make sure that all capacitors have
5. Check all the electrical connections of the transducer (input and output) to verify the
appropriate connections.
6. Check the electrical connections on the SiBas32 rack connector cards Q135 for U151, Q071
for U152 and Q079 for U452.
7. Check the electrical connections on the DC Link bus system and around ground fault resistors
for high voltage for wiring.
8. If no faults are found here, proceed with the following tests.

Rev 1.1
9. Disconnect the high voltage wires on the primary connections of the transducer (terminals +HT
/ –HT).
10. Connect a multi-meter in series with the signal M on the output of transducer, in current mode
(mA DC). Plus lead of meter to be connected to transducer and minus lead to wire.
11. Connect a DC-voltage source (could use 125 VDC from transfer switch motor) to the primary
terminals of the transducer (plus to +HT and minus to –HT).
12. Power up the SiBas32 rack by closing =E01/-Q7 in order to feed the transducer. Wait until the
rack is initialized.
13. Measured current on the output circuit shall be +3.125 mA (corresponding to +125 VDC input).
14. Note: The secondary nominal current is 50 mA for a primary input nominal voltage of 2000 V.
Use that ratio for a different value of input voltage.
15. Repeat this test by reversing the polarity on the input side of transducer.
16. Measured current on the output circuit shall be now -3.125 mA (corresponding to -125 VDC
input).
17. Last step is to verify offset current for 0 VDC input voltage. Disconnect the 125 VDC power
supply wire and jump +HT with –HT. Power up Sibas rack. The measured offset current shall
be less than ± 0.2 mA.
18. If at least one of the measured values of output current are different than above than
transducer is defective and needs to be replaced.
Replacing the Voltage Transducer

1. Isolate the main power by opening and securing the DPC.
2. Shut-off and secure the 480 VAC supply to the pre-charge circuits by opening =L01/–Q301
and =L01/–Q201.
3. Shut off the 120 VAC supply that indirectly powers the SiBas32 rack by switching off =E01/-
Q7.
discharged.
5. Disconnect the wires on the terminals and the grounding wire.
6. Remove the screws that hold the PT down on the mounting plate.
7. Replace the PT with the new one.
9. Re-connect the grounding wire (max toque is 2.2 Nm).
10. Restore all connections (max torque is 2.2 Nm)
11. Restore all the power supplies.

Rev 1.1
The Voltage Transducers Outline

Rev 1.1
Technical Data

Rev 1.1
VOLTAGE TRANSDUCER,LV-100-300/SP9: A1110231010

Description
General
The Voltage Transducers are used for conditioning the Synchronization Voltage that cannot be fed
to the SiBas32 control directly. They are installed in the power section of the container in section
=L01. The SiBas32 input board powers the measuring circuit. So in fact, there are two circuits: the
primary circuit in the power section and the secondary circuit in the controls. The control circuits
are shown in section =N01.
The synchronization transducers are labeled =E01/-U251 and =E01/-U252.
The terminals for the connection to the power circuit are marked +HT and –HT. There are three
terminals on the control circuit:
2. -, for -24 VDC supply also from the input board
3. M, for measurement signal, a current signal to burden resistor in the SiBas32 board.
Working Principle of Closed Loop (feedback) Voltage Transducers

Rev 1.1
A very small current (few milliamperes) is taken from the voltage line to be measured and is driven
through the primary coil. The magnetic flux created by this primary current (Ip) is balanced through
a secondary coil using a Hall device and associated electronic circuit. The secondary
(compensating) current is an exact representation of the primary current
To Test the Voltage Transducer

3. These PT’s are located in the resistor room on top-right of the container.
4. Check all the connections on the transducer for tightness and correct connection. The
secondary wiring should be: +: black, -: red, M: Brown.
5. Check the electrical connections on the SiBas32 rack connector card Q095.
6. Check the electrical connections to the terminal block HTB9.
7. If no faults are found here, proceed with the following tests.
8. Disconnect and isolate the HV wires on the primary connections of the transducer (terminals
+HT / –HT).
9. Connect a multi-meter in series with the signal M on the output of transducer, in current mode
(mA DC). Plus lead of meter should be connected to the transducer and minus lead to the
wire.
10. Connect a DC-voltage source (possibly the 125 VDC from transfer switch motor) to the
primary terminals of the transducer (plus to +HT and minus to –HT).
11. Close the MDC and feed container with 120 VAC from PLCT Power up the SiBas32 rack by
closing =E01/-Q7 in order to feed the transducer. Wait until the rack is initialized.
12. Measured current on the output circuit shall be +20.83 mA (corresponding to +125 VDC input).
13. Note: The secondary nominal current is 50 mA for a primary input nominal voltage of 300 V.
Use that ratio for a different value of input voltage.
14. Repeat this test by reversing the polarity on the input side of transducer. Measured current on
the output circuit should now be – 20.83 mA (corresponding to -125 VDC input).
15. Last step is to verify offset current for 0 VDC input voltage. Disconnect the 125 VDC power
supply wire and jump +HT with –HT. Power up Sibas rack. The measured offset current
should be less than ± 0.2 mA.
16. If at least one of the measured values of output current are different than above than the
transducer is defective and needs to be replaced.
0
Replacing the Voltage Transducer
discharged.
3. Disconnect the wires on the terminals and the grounding wire.
4. Remove the screws that hold the PT down on the mounting plate.
5. Exchange the PT for the new one.
7. Re-connect the grounding wire (max toque is 2.2 Nm).
8. Restore all connections (max torque is 2.2 Nm)

Rev 1.1
The Voltage Transducer Outline

Rev 1.1
Technical Data

Rev 1.1
MOTOR TRANSFER SWITCH, MOS220 TYPE 711:
14192625501

Description
The motor operated transfer switch is designed for use in DC systems such as transportation and
mining equipment.
The 1600 A, 1500 V DC Motor Operated Switch is created by coupling three Type 712 Switch
Modules to one Type 711 Motor Module. The motor operated Type 711 module works with 125 V
DC. Travel time from one end position to the other is approximately 2 seconds.
The switch module will not try to interrupt or change state with this motor operated design. Upon
loss of power the motor remains in its local position. The switch modules coupled to the motor
module also remain in their existing closed (non-interrupting) position.
Three NO and three NC auxiliary contacts are available for use.
Application data:
This motor is used to drive the transfer switches connected in the output circuit of the hoist 1 and
crowd inverters, to commute the output of these inverters to the hoist and crowd motors or to right
and left propel motors. The motor is labeled E01/M45.
Test the motor

Note: For access to the transfer switches assembly, the front, bottom, right covers of the
container should be removed.
3. Visually inspect the condition of the coil and electrical connections to auxiliary contacts x-
w and y-v. Also verify the alignment of the motor shaft with the rest of subassembly. If
there is no visual defect, disconnect the wiring from the motor terminals and isolate them.
4. Using a wrench, turn manually the motor in position 1 and measure with an ohmmeter the
continuity of circuit x-z (contact x-w shall be closed in pos. 1). Turn manually the motor in
position 2 and measure the continuity for circuit y-z (contact y-v shall be closed in pos.2).
If there is no problem with the continuity of the circuits, the motor should be tested with an
auxiliary 125 VDC, minimum 3A-power supply.
5. Connect the common pole of the DC power supply to z terminal of the motor and the
positive to y terminal, and turn on the power supply. The motor should travel to position 1
in less than 2 seconds. Turn off the power supply and connect the positive to terminal x.
After turning on the power supply, the motor should travel to position 2 in same amount of
time.
6. If any of the measurements are different than above, then the motor needs to be replaced.

Rev 1.1
Replacing the motor
3. Disconnect the wiring from motor terminals and isolate the conductors.
4. Remove the mounting bolts of motor and slide it out of container.
5. Replace the defective motor by a spare one and bolt it to the support bracket in the
container. Pay attention to the shaft alignment with the rest of subassembly. Restore all
electrical connections.
Outline drawing
Technical Data
Motor rating:
Rated voltage 125 VDC
Minimum operating voltage 100 VDC
Maximum current 3A
Travel time: 2s
Capacity: Up to 6 switch modules
Auxiliary contacts:
3 NO and 3 NC at end positions ( all NO between end positions)
Resistive load 125 VDC or less, 10 A
Mounting:
Mounts on 3-inch wide channel with two 3/8” screws.
Connections: ¼” Fastons
Weight 26 lbs.

Rev 1.1
TRANSFER SWITCH, MOS 220 TYPE 712: 14192626502

Description
The motor operated transfer switch is designed for use in DC systems such as transportation and
mining equipment.
The1600 A, 1500 V DC Motor Operated Switch is created by coupling three Type 712 Switch
Modules to one Type 711 Motor Module. The Type 712 Switch Module is a DPDT (double pole
double throw) non-interrupting switch.
Switch Module utilizes main contacts with a wiping action to provide exceptionally high reliability
contact continuity and lower contact resistance. The main contacts are silver alloy. Major current
carrying parts are silver plated for good electrical connections. Non current carrying steel parts are
zinc plated with a dichromate finish for maximum corrosion protection.
Application data:
These switches are used in the output circuit of the hoist 1 and crowd inverters. The switches
direct the output of these inverters to the hoist and crowd motors or to the right and left propel
motors.
The switches are labeled L01/TS451, L01/TS452 and L01/TS453.
Test the switch

2. Using a voltmeter, check the DC Bus to make sure that all capacitors have discharged. Use an
adequate meter for a DC level of 2000 V.
3. Visually inspect the quality of switch contacts. Also, verify the alignment of the switch shaft
with the rest of subassembly. If there is no visual defect disconnect the power cables from
switch terminals and isolate them.
4. Using a micro-ohmmeter measure the value of the contact resistance for each pole and each
position of the switch. Maximum value of contact resistance should be 80 µΩ.
5. If the measured values of the resistance are greater than above value then the switch needs
to be replaced.
Replacing the switch

3. Disconnect the power cables from switch terminals and isolate them.
4. Remove the mounting bolts of the switch and slide it out of the container.

Rev 1.1
5. Replace the defective switch with a spare one and bolt it to the support bracket in the
container. Pay attention to the shaft alignment with the rest of subassembly. Redo all electrical
connections.
Outline drawing
Technical Data
Main contact rating:

Contact arrangement Double Pole Double Throw
Continuous current 1600 A @ 40 °C ambient, still air
Maximum voltage 1500 VDC
Thru-Current capability 30, 000 A
Mounting:
Mounts on 3-inch wide channel with two 3/8” screws.
Power connections:
Two 3/8”-16 tapped holes per terminal
Weight 27 lbs.

Rev 1.1
TRANSFORMER, 3 PHASE, 500VA, 600-380-440/500:
A1110231013

Description
These limited current transformers are used to charge the DC Link capacitors before the AFEs
come on. This protects the DC Link capacitors against damage due to inrush current.
There is a total of four step up, three phase, high impedance transformers, used in the IGBT
Shovel container labeled: L01/T201, L01/T202, L01/T301 and L01/T302.
To Test the Transformer

Note: For access to the transformers, the back, bottom covers of the container should be removed.
3. Disconnect and isolate the wires from the primary and secondary circuits (including the
jumpers located in primary).
4. Using an ohmmeter, check the continuity of the primary (each phase) and secondary (each
phase reported to neutral) circuits of the transformer. If you find interrupted circuits or
difference of resistance between primary or secondary windings, proceed to change the
transformer. In the event that the ohmic measurements are OK, proceed to do an electrical
test of the transformer.
5. Use a 120 VAC, single phase, power supply and connect it in the primary circuit between
terminals X0 and X3, phase 1. Connect a voltmeter in the secondary circuit between terminal
H1 and neutral. The measured value shall be 100 VAC.
6. Repeat this measurement for phase 2 and phase 3.
7. If the measured values are not identical for all three phases, then the transformer should be
replaced.
Replacing the Transformer

Note: For access to the transformers, the back, bottom covers of the container should be
removed.
1. Isolate the power supply by switching off the drive power transformer and lock out the
3. Disconnect and isolate the wires from the primary and secondary circuits (including the
jumpers located in primary).
4. Unscrew the mounting bolts for transformer and replace it with a new one.
5. Secure the new transformer to the mounting panel and restore all electrical connections.

Rev 1.1
Transformer Outline

Rev 1.1
Technical Data
3 Phase, D/Y, 50/60Hz, 500VA, 11%

Rev 1.1
SIMATIC DP INTERFACE ET200M: 6ES71531AA030XB0
SIEMENS Part # 6ES71531AA030XB0

Bucyrus Part # 62039587
DESCRIPTION:
The IM 153-1 links the S7-300 modules to the PROFIBUS-DP.
Features
The IM 153-1 is characterized by the following features:
• Slave interface for up to 8 modules in the S7-300 family. The IM 153-1 can be used with
up to 8 signal modules (SM), function modules (FM) or communications processors (CP).
• S7-300 modules can be connected or withdrawn while the ET 200M is operating (in a
configuration with active bus units)
... with a CPU 413-2 DP, 414-2 DP or 416-2 DP as the DP master: these modules are
able to evaluate the connection and withdrawal alarms (OB 83).
... with another DP master: the DP master receives a message concerning the
connection or withdrawal event, but is not able to evaluate the connection or withdrawal
alarm.
• Behavior like a DP slave in accordance with EN 50170, Volume 2, PROFIBUS
• Possible baud rates: 9.6 kbaud to 12 Mbaud
• Can be configured, for example, with COM PROFIBUS or COM ET 200 Windows (Version
2.1 or higher) or with STEP 7 (Version 3.0 or higher)
• Optical fiber cables can be connected (see L2/L2FO System Components Manual)
Components of the IM 153-1
Configuration of the ET 200M (example)

Rev 1.1
Configuration of the ET 200M distributed I/O device (example)

① Power supply module PS 307
② Interface module IM 153-x
③ up to 8 I/O modules (SM/ FM/ CP) 0
Connections
The IM 153-1 has the following supply connections:
The DC 24 V supply for the IM 153-1 must satisfy the requirements of the PS 307 power supply
module.
We recommend using the PS 307 power supply module for the DC 24 V power supply. This
module is supplied with a connecting comb that will simplify the wiring
Status and Error Displays of the IM 153-1

Rev 1.1
Setting the PROFIBUS Address of the IM 153 Definition

Each bus device must be given a PROFIBUS address to enable it to be uniquely identified on the
PROFIBUS-DP.
Wiring:
The modules are wired by means of a plug-in front connector. When the connector is plugged in
for the first time, a code element engages so that the connector can only be plugged into modules
of the same type. When the module is replaced, the front connector can be used in its fully wired
state for the new module of the same type.
Terminal Connection Diagram and Block Diagram
Block Diagram of the Interface Module

Rev 1.1
Technical Data

Rev 1.1
PS407 S7400 5VDC/120/230V/10A: 6ES74070KA010AA0
SIEMENS Part Number: 6ES74070KA010AA0

Description
The power supply module PS 407 10A (standard) is designed for connection to an AC line voltage
of 85 to 264 V or DC line voltage of 88 to 300 V and supply 5 VDC/10 A and 24 VDC/1 A on the
secondary side.
Diagram
The figure below illustrates the front connectors and displays of the PS 407 10A.
Polarity Reversal of L+ and L

The polarity reversal of L+ and L- with supply voltages of between 88 VDC and 300 VDC has no
effect on the function of the power supply. The connection should be made as described in the
shovel schematics.

Rev 1.1
Technical Specifications
Backup Battery
The power supply modules of the S7-400 have a battery compartment for two backup batteries. If
backup batteries have been installed, the set parameters and the memory contents (RAM) will be
backed up via the backplane bus in CPUs and programmable modules if the supply voltage fails.
The battery voltage must be within the tolerance range. In addition, the backup battery enables
you to carry out a restart of the CPU after power-on. Both the power supply module and the
protected modules monitor the battery voltage.
To use two batteries, set the switch to 2BATT, the power supply module defines one of the two
batteries as the backup battery. This assignment remains in effect until the battery has been
discharged. When the backup battery is completely discharged, the system switches to the
reserve battery which is then used as the backup battery for the duration of its life. The status
“backup battery” is also stored in the event of a power failure.
Backup Battery
Order number 6ES7971-0BA00
Bucyrus P/N 62048868
Type 1x lithium AA
Rated voltage 3.6 V

Rev 1.1
Rated capacity 1.9 Ah
Backup Times
The maximum backup time is based on the capacity of the backup batteries used and the backup
current in the rack. The backup current is the sum of all individual currents of the inserted
protected modules as well as the requirements of the power supply module when the power is
switched off.
Example for the Calculation of Backup Times

The capacity of the batteries is listed in the technical specifications of the power supply. The
typical and maximum backup current of the protected module is listed in the technical
specifications of the module. The typical backup current of a CPU is an empirically determined
value. The maximum backup current is a worst-case value that is calculated based on the
corresponding manufacturer specifications for the memory blocks. The following technical
specifications produce backup times for a CR with a PS 407 4A and a CPU 417-4 as the only
protected module:
Capacity of the backup battery: 1.9 Ah
Maximum backup current (including own requirement at power off) of the power
supply:100 µA
Typical backup current of the CPU 417-4: 600 µA
A rated capacity of less than 100% is to be assumed when calculating the backup time because
the backup battery is also affected at power on by regular passivation.
A battery capacity of 63% of the rated capacity produces the following values:
Backup time = 1.9 Ah * 0.63 / (100 + 600) µA = (1.197 / 700) * 1 000 000 = 1710 h
This produces a maximum backup time of 71 days.

Rev 1.1
S7400 RACK UR2 9-SLOT: 6ES74001JA010AA0
SIEMENS Part Number: 6ES74001JA010AA0

Description
The UR2 racks are used for assembling central racks and expansion
racks. The UR2 racks have both an I/O bus and a communication bus.
Suitable Modules for UR2

You can use the following modules in the UR2 racks:
• When the UR2 is used as a central rack:
All S7-400 modules with the exception of receive IMs
• When the UR2 is used as an expansion rack:
All S7-400 modules with the exception of CPUs and send IMs
Special case: Power supply modules cannot be used in conjunction with the
IM 461-1 receive IM.
Structure of the UR2

Rev 1.1
Caution!
Danger of damage to equipment.
If you insert a power supply module in a slot that is not permitted for power supply modules, the
module may be damaged. Slots 1 to 4 are permitted, whereby power supply modules starting
from slot 1 must be inserted without leaving gaps.
Technical Specifications
Rack UR2
Number of single-width slots 9
Dimensions W x H x D (in mm) 257.5 x 290 x 27.5
Weight (in kg) 2.15
Buses I/O bus and
communication bus

Rev 1.1
CONTROLLER CPU 416-2 2.8MB DP MPI: 6ES7-416-
2XK04-0AB0
SIEMENS Part # 6ES7 416-2XK04-0AB0

Bucyrus Part #
Description
The S7400 CPU Controller is the master controller for machine shovel synchronization. The CPU
also coordinates all start / stop requests.0

Rev 1.1
LED Designations

Rev 1.1
Position Selector
The mode selector switch can be used to set the CPU to RUN or STOP mode, or to reset the CPU
memory. STEP 7 offers further mode selection options. The mode selector switch is a toggle
switch. The figure below shows the positions of the mode selector switch.
The following table describes the positions of the mode selector switch. In the event of a fault or if
there are problems preventing a startup, the CPU goes into STOP or retain this mode, regardless
of the position of the mode selector switch.

Rev 1.1
Error Messages

Rev 1.1
CPU Memory Reset

Case A: You want to download all data of a new user program to the CPU.
1. Set the switch to STOP.
Result: The STOP LED is lit.
2. Set the switch to MRES setting and hold it at this position.
Result: The STOP LED performs this cycle: 1 sec OFF --> 1 sec ON --> 1 sec
OFF --> continuous signal.
3. Reset the switch to STOP, then set MRES again within the next 3 seconds,
then reset it to STOP.
Result: The STOP LED flashes at least 3 seconds at 2 Hz (memory reset is
being executed), then its signal is set continuously.
Case B: The CPU requests memory reset, indicated by the flashing STOP
LED (5 Hz). The system requests a CPU memory reset after a memory card
was removed or inserted, for example.
Set the switch to MRES and then return it to STOP.
Result: The STOP LED flashes at least 3 seconds at 2 Hz (memory reset is
being executed), then its signal is set continuously.
For detailed information on CPU memory reset refer to chapter 6 of the manual
CPU sequence for memory reset

The CPU performs the following processes for memory reset:
• It deletes the user program from work memory and in load memory (integrated
RAM or RAM Card).
• It deletes all counters, flags and timers (except the time).

Rev 1.1
• It performs a hardware self-test.
• It initializes the hardware and system program parameters, that is, its internal
default settings. Some of the configured defaults are taken into account.
• When a FLASH Card is inserted and after the CPU memory reset is completed,
the CPU loads the user program and the system parameters from the FLASH
Card to work memory.
What is retained after a CPU memory reset...
The following data are retained:
• The contents of the diagnostics buffer can be read by uploading it to the PG in
STEP 7.
• The parameters of the MPI interface (MPI address and highest MPI address).
Note the special features shown in the table below.
• The time
• The status and value of the operating hours counter
Technical Data

Rev 1.1

Rev 1.1

Rev 1.1
MODULE COMM. PROC. IE ADV. CP443-1: 6GK7 443-
1EX40-0XE0
SIEMENS Part # 6GK7 443-1EX40-0XE0

Bucyrus Part #
Description
The CP 443-1 Advanced communications processor is designed for operation in an S7-400 (not
fault-tolerant) programmable logic controller. It allows the S7-400 to be attached to Industrial
Ethernet.
To set up small local area networks or to connect several Ethernet devices, a 4-port switch with
auto crossing and auto sensing has been integrated in the CP 443-1 Advanced.
0
Outline Figure
LED Display
The display on the front panel has seven LEDs to display the mode has been extended by an
additional display with two LEDs beside the RJ-45 jack to display the communication status
(covered by the front flap).

Rev 1.1
CP Mode / LED Displays
CP Communication Status
In addition to the LEDs that signal the CP mode, the front panel and the RJ-45 socket also include
LEDs that provide information about the status of the CP interface to Industrial Ethernet.
Mode Selector
With the mode selector, you can set the following modes:
• Switch from STOP to RUN:
The CP reads the configured and/or downloaded data into the work memory and then
changes to the RUN mode.
• Switch from RUN to STOP:
The CP changes to STOP with the following results:
− Established connections (ISO transport, ISO-on-TCP, TCP connections) are terminated
(transitional phase with LED display “STOPPING”);
The reaction is as follows in STOP:
− All connections are terminated

Rev 1.1
− The configuration and diagnostics of the CP is possible (system connections for
configuration, diagnostics, and PG channel routing are retained);
− The downloading of interconnections for PROFINET CBA communication is not
possible;
− FTP access to the file system is possible
− HTTP access is possible
− The routing function is active
− The time of day is not forwarded
− PROFINET CBA is disabled;
− PROFINET IO is disabled.
C-PLUG
Inserting in the C−PLUG Slot
The slot for the C−PLUG is on the rear panel of the device.
The C−PLUG is inserted in the receptacle.
Function
If the C−PLUG has not yet been written to (as shipped), when the device starts up, all the
configuration data of the CP is saved automatically on it.
If the C−PLUG is inserted, the basic device automatically uses the configuration data of the
C−PLUG. This assumes that the data was written by a compatible device type.
If a fault occurs, the basic device can then be replaced much faster and more simply. If a device
needs to be replaced, the C−PLUG is simply taken from the failed component and inserted in the
replacement. As soon as it starts up, the replacement automatically has the same device
configuration as the failed device.
Using a C−PLUG with old Configuration Data

Use only C−PLUGs that are formatted for the CP 443−1 advanced. C−PLUGs that have already
been used and formatted in other device types must first be formatted for the CP 443−1
Advanced.
You do this with STEP 7 / NCM Diagnostics. For more detailed information, refer to the online help
in the topic ”General Diagnostics Functions − C−PLUG Diagnostics Object”.
After formatting, all data areas are deleted on the C−PLUG. Project engineering data is adopted
by the CPU only after reloading or after turning on the power supply again.
Removing the C−PLUG

It is only necessary to remove the C−PLUG if a fault occurs on the CP (see above figure).

Rev 1.1
Technical Data

Rev 1.1
PS 307 POWER SUPPLY MODULES
SIEMENS Part Number: 6ES73071BA000AA0 / 6ES73071EA000AA0 / 6ES73071KA000AA0

Bucyrus Part Number: 62041491 / 62039585 / 62039586
0
DESCRIPTION
Load power supply modules are mounted in the DIN rail (slot 1) immediately to the left of the CPU
or the first module (on expansion racks). The connection to the CPU or IM 361 is established using
a power connector (included).
Located on the front panel of the modules are:
• An LED indicating the 24 V DC output voltage;
• A line voltage selector switch:
• A switch with a protective cap enables selection of a line voltage of 120 V AC or 230 V
AC.
• On/off switch for 24 V DC.
Also located on the front of the module, protected by a cover, are:
• Connecting terminals
• The line-power cables
• Output voltage cables
• Protective ground can be connected to these terminals.
0
• Voltage Sensing
• Current Limiting
• Adjustable Voltage
• Local/Remote Operation
• 115 VAC Input
• Nominal +110 VDC output

1. Internal monitoring. The red LED turns on if there is an internal fault in the power supply.
2. External monitoring. The SiBas unit monitors the power supply voltage to see that it is
within limits.
closed.
Atypical Conditions
The following table illustrates the response of the PS307 modules to atypical operating conditions.

Rev 1.1
Basic Circuit Diagram
Wiring Schematic

Rev 1.1
Technical Data
Technical specifications
PS307 1B 000000 1E 000000 1K PS307 1B 000000 1E 000000 1K
Input Output
Input voltage Output voltage
• Rated value 120/230 VAC • Rated value 24 VDC
• Acceptable range 93 to 132 VAC / 187 to 264 VAC • Acceptable range 24 V - 5%, stable at no load
Line outage Output Current
Buffering min 20ms • Rated value 2A000000 5 A 000000 10 A
Line frequency Short Circuit protection electronic, non latching
• Rated value 50/60 Hz
• Acceptable range 47 to 63 Hz General data
Input current Protection classes (IEC 536)
• Rated value at 230 V 0.5 A000000 1 A000000 1.7A Efficiency
• Acceptable range at 120 V 0.8 A000000 2 A000000 3.5A Power loss typ. 000 000000
Inrush current 20 A000000 45 A000000 65 A Dimensions 1, with protective conductor
(W x H x D) in mm
Weight approx. 83%00000 87%000000 89%
Conductor cross section 10W 00000 18W 00000 30W
50x125x1200050x125x1200200x125x120
420 g000000 740g000000 1200g
2 x 0.5 to 2.5 mm;
flexible, with wire and ferrules
Ordering Data Order no. Order no.
PS 307 load power supply mod Mounting adaptor for PS 307 -1B 6ES7 390-6BA00-0AA0
Incl. Power connector: For snapping PS307 onto a
120/230 V AC : 24 V DC 35mm/1.3 in DIN rail (EN 50 022)
• PS 307-1B; 2A 6ES7 307-1BA00-0AA0 PS-CPU power connector 6ES7 390-7BA00-0AA0
• PS 307-1E; 5A 6ES7 307-1EA00-0AA0 (replacement item)
• PS 307-1K; 10A 6ES7 307-1KA00-0AA0

Rev 1.1
SM 331 Analog Input Modules, 6ES7 331-7KF01-0AB0; 8
inputs, 24 VDC
SIEMENS Part # 6ES7 331-7KF01-0AB0

Description
Analog input modules convert analog signals from the process to digital signals for internal
processing within the S7-300. Voltage and current sensors, thermocouples, resistors and
resistance thermometers can be connected as sensors.
Mechanical Features:
Compact design: The rugged plastic housing contains:
1. Red LEDs for group faults/errors.
2. Front connector protected by the front cover
3. Labeling area on the front cover
Assembly:
The modules are mounted on the DIN rail and connected to the adjacent modules via bus
connectors. There are no slot rules: the slot numbers defines the input addresses.
User-friendly wiring: The modules are wired by means of a plug-in front connector. When the
connector is plugged in for the first time, a code element engages so that the connector can only
be plugged into modules of the same type. When the module is replaced, the front connector can
be used in its fully wired state for the new module of the same type.
Wiring:
Features also include:
1. Configurable resolution from 9 to 14 bits + sign (for different conversion times).
2. A variety of measuring ranges: The basic current/voltage measuring ranges are set
mechanically with range cards; advanced settings are made with the STEP 7 "S7
Configuration" function on a programming device.
3. Interrupt capability: The module transmits diagnostic and limit value interrupts to the
programmable controller's CPU.
Diagnostics:
The module sends extensive diagnostic information to the CPU.

Rev 1.1
Technical Data
SM 331 digital input modules S7 331- 7KF01-0AA0
Number of inputs 8
• For resistance measurements 4
Rated load voltage L+1 24 V DC
• Polarity reversal protection yes
Input ranges and input resistance
• Voltage ± 80 mV/10M
± 250 mV/10M
± 500 mV/10M
± 1 V/10M
± 2.5 V/100M
± 5 V/100M
1 to 5 V/100M
• Current ± 10 V/100M
± 10 mA/25
± 3.2 mA/25
± 20 mA/25
0 to 20 mA/25
• Resistance
4to 20 mA/25
150 µ 10M
• Thermocouples
300 µ 10M
600 µ 10M
• Resistance Thermometers
type E, N, J, K / 10 M
Pt 100 standard / 10 M
Ni 100 standard
Acceptable input voltage for voltage input max. 20 V
Acceptable input current for current input max. 40 mA
Optical isolation to backplane bus yes
Characteristic linearization
• Configurable -
• At rated input voltage 1.2 to 4.8 mS
Number of inputs that can be addressed
simultaneously
• For thermocouples type E, N, J, K
• For resistance thermometers Pt 100 standard / 10 M
Ni 100 standard
Temperature Compensation Configurable
• Internal Possible
• External with Compensation socket Possible
• External with Pt 100 -
Integration time1)/ and resolution per channel
• Integration time 2.5 16.6 20 100 ms
• Resolution (S= sign) 9 12 12 14 bits
Unipolar 9+S 12+S 12+S 14+S bits
Bipolar
• Interference voltage suppression for 400 60 50 10 Hz
interference frequency
• Cable Length (Shielded) 200m / 656 ft (50m / 164 ft at 80 mV)
Power Consumption
60 mA

Rev 1.1
• From backplane bus max. 200 mA
• From L+ max.
Power Loss typ. 1.3 W
Insulation tested at 500 V DC
Dimensions (W x H x D) in mm 40 X 125 x 120
Weight 250 g

Rev 1.1
SM 321 Digital Input Modules, 6ES7 321-1BH02-0AA0; 16
Inputs, 24 VDC
SIEMENS Part # 6ES7 321-1BH02-0AA0

Description
Digital input modules convert the levels of the external digital signals transmitted from the process
to the internal S7-300 signal levels. The modules are suitable for the connection of switches and
2/3/4-wire BERO proximity switches.
1. Green LEDs to indicate signal status at the inputs
Assembly:
connectors. There are no slot rules: The input addresses are defined by the slots.
0
Wiring:

Rev 1.1
Technical Data
Dimensions and Weight
Dimensions W x H x D (in millimeters) 40 x 125 x 117
Weight Approx. 200 g
Data for Specific Module
Supports clocked operation No
Number of inputs 16
Length of cable
Unshielded max. 600 m
Shielded max. 1000 m
Voltages, Currents, Potentials
Number of inputs that can be
triggered simultaneously
Horizontal configuration Up to 60 °C 16
Vertical configuration Up to 40 °C 16
Isolation between channels and Yes
backplane bus
Permitted potential difference between 75 VDC / 60 VAC
the different circuits
Insulation tested with 500 VDC
Current consumption
From the backplane bus max. 10 mA
Power dissipation of the module typ. 3.5 W
Status, Interrupts, Diagnostics
Status display Green LED per channel
Interrupts None
Diagnostic functions None
Data for Selecting a Sensor
Input voltage

Rev 1.1
Rated value 24 VDC
For signal “1” 13 to 30 V
For signal “0” –30 to + 5 V
Input current
At signal “1” typ. 7 mA
Input delay
At “0” to “1” 1.2 to 4.8 ms
At “1” to “0” 1.2 to 4.8 ms
Input characteristic curve According to
IEC 61131, type 1
Connection of Two-Wire Possible
BEROs max. 1.5 mA
Permitted bias current

Rev 1.1
SM 321 Digital Input Modules, 6ES7 321-1FH01-0AA0; 16
inputs, 120 VAC
SIEMENS Part # 6ES7 321-1FH01-0AA0

Description
Digital input modules convert the levels of the external digital signals transmitted from the process
to the internal S7-300 signal levels. The modules are suitable for the connection of switches and
2-wire BERO proximity switches.
1. Green LEDs to indicate signal statuses at the inputs
Assembly:
connectors. There are no slot rules: The input addresses are defined by the slots.
0
Wiring:

Rev 1.1
Technical Data
SM 321 digital input modules S7 321- 1EH01-0AA0
Number of inputs 16
Input voltage
1. Rated value AC 120 V
2. for "1 " signal 79 to 132 V
3. for "0 " signal 0 to 20 V
4. Frequency 47 to 63 Hz
Optical isolation to backplane bus Optocoupler
5. in groups of 4
Input current
6. for "1 " signal typ 6 mA
00000000
Input Delay
7. Configurable -
8. At rated input voltage 25 mS
Number of inputs that can be addressed
simultaneously 16
9. Up to 40 ° C 16
10. Up to 60 ° C
Connection of 2 wire Bero sensor Possible
11. Acceptable quiescent current Max 1 mA
Cable Lengths
12. Unshielded 600m
13. Shielded 1000m
Power Consumption
14. From backplane bus max. 16 mA

Rev 1.1
15. From l+/L1 max. -
(without load)
Power Loss typ. 4.1 W
Weight 225 g

Rev 1.1
SM 322 Digital Output Modules; 6ES7 322-1BH01-0AA0;
outputs, 120 VAC, 0.5A
SIEMENS Part # 6ES7 322-1BH01-0AA0

Description
Digital output modules convert the internal signal levels of the S7-300 to the external signal levels
required for the process. The modules are suitable for the connection of such equipment as
solenoid valves, contactors, small motors, lamps and motor starters.
1. Green LEDs to indicate signal statuses at the outputs
Assembly:
connectors. There are no slot rules: The output addresses are defined by the slots.
Wiring:

Rev 1.1
Technical Data
SM 322 digital output modules S7 322- 1BH01-0AA0
Number of outputs 16
Rated load voltage L+/ L1 120 V AC
1. Acceptable range 93 to 132 V
Output voltage
2. for "1 " signal L - 1.5 V
3. in groups of 8
Output current
4. for "1 " signal
rated value at 60 °C 0.5 A
minimum current min 10 mA
5. for "0" signal 1mA
Sum of output currents
(per group) 2A
6. Up to 60 °C (horizontal installation)
Lamp load max. 25 W
Switching frequency of contacts
7. Resistive loads max 10Hz
8. Inductive loads max. 0.5Hz
9. Lamp loads max. 1Hz
10. Mechanical max.
Short Circuit Protection fuse
Cable Lengths
11. Unshielded 600m
12. Shielded 1000m
Diagnostics Red LED for fuse or no L1/N
Power Consumption
14. From l+/L1 max. 3mA
(without load)
Power Loss typ. 9W
Weight 300g

Rev 1.1
SM 322 Digital Output Modules, 6ES7 322-1FH01-0AA0;
16 outputs, 120 VAC, 0.5A
SIEMENS Part # 6ES7 322-1EH01-0AA0

Description
Digital output modules convert the internal signal levels of the S7-300 to the external signal levels
required for the process. The modules are suitable for the connection of such equipment as
solenoid valves, contactors, small motors, lamps and motor starters.
1. Green LEDs to indicate signal statuses at the outputs
Assembly:
Wiring:

Rev 1.1
Technical Data
SM 322 digital output modules S7 322- 1EH01-0AA0
Number of outputs 16
Rated load voltage L+/ L1 120 V AC
1. Acceptable range 93 to 132 V
Output voltage
2. for "1 " signal L - 1.5 V
3. in groups of 8
Output current
4. for "1 " signal
rated value at 60 °C 0.5 A
minimum current min 10 mA
5. for "0" signal 1mA
Sum of output currents
(per group) 2A
6. Up to 60 °C (horizontal installation)
Lamp load max. 25 W
Switching frequency of contacts
7. Resistive loads max 10Hz
8. Inductive loads max. 0.5Hz
9. Lamp loads max. 1Hz
10. Mechanical max.
Short Circuit Protection fuse
Cable Lengths
11. Unshielded 600m
12. Shielded 1000m
Diagnostics Red LED for fuse or no L1/N
Power Consumption
14. From l+/L1 max. 3mA
(without load)
Power Loss typ. 9W
Weight 300g

Rev 1.1
OUTPUT MODULE SM 332; 6ES7 332-5HD01-0AB0, AO 4
_ 12BIT
SIEMENS Part # 6ES7 332-5HD01-0AB0

Description
The analog output module SM 332; AO 4 _ 12 Bit has the following characteristic features:
1. 4 outputs in 4 channel groups
2. The individual output channels can be programmed as
A. voltage outputs
B. current outputs
3. Resolution 12 bits
4. Programmable diagnostics
5. Programmable diagnostics interrupt
6. Programmable substitute value output
7. Galvanic isolation to CPU and load voltage
Note: When switching on and off the rated load voltage (L+), incorrect intermediate values can be
present at the output for approx. 10 ms.
0
15. Red LEDs for group faults/errors.
Assembly:
0
Wiring:
Features also include:
1. 11bit resolution from + sign (for different conversion times).
2. A variety of voltage and current ranges: Ranges are set independently for each channel by
means of parameterization software.
3. Interrupt capability: The module transmits diagnostic and limit value interrupts to the
programmable controller's CPU on occurrence of errors.

Rev 1.1
Terminal Connection Diagram
Diagnostics:
The module sends extensive diagnostic information to the CPU.
Technical Data
SM 332 digital output modules S7 332- 5HD01-0AB0
Number of outputs 4
18. Rated load voltage 24 V DC
Output ranges
19. Voltage outputs 0 to 10 V; ± 10 V; 1 to 5 V
20. Current outputs 4 to 20 mA; ± 20 mA
Load Impedance
21. Voltage Inputs 0 to 20 mA
22. Current Outputs
23. Capacitive loads 1 kp
24. Inductive loads 0.5 kIA
Voltage output Max. 1F
Short Circuit protection yes
Short Circuit current 25 mA
Power Output
Open-circuit voltage 18 V
Optical isolation to backplane bus resolution yes 11 bits + sign (at ± 10 V; ± 20 mA; 4 to 20 mA;
1 to 5 V)
Conversion time per channel 0.8 ms 0000000
Setting Timel
25. Resistive loads E).1 ms
26. Capacitive loads 3.3 ms
27. Inductive loads 0.5 ms
Substitute values configurable

Rev 1.1
Power Consumption
29. From L+ max. 240 mA
Cable length (shielded) 200 m
Optical isolation tested at 500 V DC
Weight 250 g

Rev 1.1
COMPUTER,ROCKY MOBILE: TYZ: A1110315361

Description
The AMREL Rocky Mobile PC replaces the host computer for the IGBT Shovel. The Rocky
Mobile has no moving parts and is designed to withstand hazardous environments and IP54
pollution degree.
Outline Drawing
CD-ROM Drive Configuration:
1. CD-ROM eject button

2. CD-ROM in use
Controls and Indicators (Left)-Standard model
1. Modem Jack (NOT USED)

2. IEEE1394 port (Fire Wire)
3. External Keyboard + PS/2 port (NOT USED)
4. IEEE1394 port
5. External Speaker (NOT USED)
6. LAN Jack
7. Line In port (NOT USED)
8. USB port
9. Microphone port (NOT USED)
10. USB port (Universal Serial Bus)
11. PCMCIA slots
Controls and Indicators (Rear)

Rev 1.1
1. DC Power Jack
2. Serial Port COM1
3. External RGB Monitor Port
4. Docking Port
5. Printer/External FDD Port
6. Serial Port COM2 (or COM3 by optional configuration)
Technical Data
CPU
Intel Pentium M 1.5GHz (Dothan)
CPU runs at multiple speeds dependent on CPU type and operating system:
The CPU speed switches automatically by detecting AC adapter/battery operation and busy state.
Memory
System memory Standard: 512MB
Cache memory Internal level-2 1 MB(Dothan 2MB)
Video memory 64MB (shared RAM)
Display output
No matter RGB or DVI output, MT786EX only supports XGA, 1024 x 768 dots (horizontal x
vertical) or SVGA 800 x 600 dots with 16, 24 or 32 bit color depth.
Floppy Disk Drive (Swappable)
Standard:
Size: 3.5"
Capacity: 1.44MB (formatted)
Rotation: 300 RPM
Transfer Rate: 500KB/sec
Average Access: 94 ms (with settling)
DVD/CD-RW (Swappable)
Speed:
Interface:
Data transfer rate:
Modes:
Dimensions:
Weight:
Hard Disk Drive
Type: Extended Range Solid State
Storage: 8GB (Shipped with separate spare)
Interface: IDE Ultra DMA 33 compliant
I/O ports
• 2x Serial ports
• External RGB monitor port
• 2x DVI port
• External PS/2+Keyboard port
• Audio ports (External Speaker/Earphone, Microphone, Line-in)
• RJ45 jack for internal LAN card
• 2 type II or 1 type-III PCMCIA slots
• Printer/External FDD port
• Docking port

Rev 1.1
• 2xUSB 2.0 port
• 2x1394 port
Battery
Primary Battery:
Capacity: 11.1V 5400mAH
Dimension: 103 mm(W) x 73 mm(D) x 38 mm(H)
Weight: 435 g (0.95 1b.)
AC Adapter (G01)
Voltage: AC 100~240 V 1.2A nom (fused @ 250v 15A)
Frequency: 50/60 Hz
Output Voltage: DC 19V 4.7A
System Unit Dimensions and Weight
Width: 312.6mm (12.3”)
Depth: 246.5mm (9.7”)
Height: 56mm (2.3”)
Weight: 3.2Kg (7 lb. including CD-ROM drive and primary battery)
Note: Weight varies depending on system configurations.
Environmental
Temperature: -20 ~ 50ºC (32 ~ 113ºF) operating
-40 ~ 70ºC (-40 ~ 158ºF) storage
Humidity: 5~95% Non-condensing operating
95% maximum storage
Altitude: 0 ~ 12,180 meters (0 ~ 70,000 feet) operating
Basic Operation
Entering BIOS Setup: Press [F2] at boot up to enter BIOS setup.
Boot Up and POST

The computer turns ON and loads the operating system (such as Windows) into the system
memory. This start-up procedure is called “boot up”.
The ROM BIOS Power On Self-Test (POST)

Each time the computer powers on, it automatically performs a self-test of its memory and
hardware devices.
Real Time Clock/Calendar

Battery backed up Real Time Clock/Calendar (RTC) is built in an on-board CMOS
(Complementary Metal Oxide Semiconductor) chip. The RTC keeps track of the time and date
while the computer is off. The CMOS chip also stores system setup information.
RTC battery is also recharged when vehicle or AC adapter is attached. Recharge the computer
approximately once per month to ensure RTC operation.
Power Conservation
This computer consumes much less power than conventional computers; however, power
consumption may be reduced by properly configuring the Power Management Setups.
It is recommended that the power saving functions be enabled even when not running on battery
power. Power Management generally does not degrade system performance while saving
power.
Replacing Modules
To remove the modules:
1. Turn OFF the computer or hibernate.
2. Disconnect all cables from the computer.
3. Use a coin to turn loose the screws on the modules.
4. Remove the battery from the compartment.

Rev 1.1
5. Push the latch knob to release the CD-ROM or HDD module and push them outward.
6. Remove the module from the computer.
To re-install the modules:

Gently push the module into the slot. Fasten the screw to fix the module.
Troubleshooting
To shutdown the Rocky PC, turn the E01/Q40 breaker off.
1. If Rocky does not shut down, navigate the menus with the touch screen or keyboard to
determine if the Rocky is frozen.
a. If Rocky is not frozen:
Select Start>Shutdown and choose the Shutdown option to shut Windows XP down.
b. If Rocky is frozen:
Reach across Rocky and on the Far left side, hold the power switch (#14 on the
above drawing) in for 3-5 seconds. Rocky will perform a hard shutdown and the
display will go blue with the message “no video detected”.
To start the Rocky PC, turn the E01/Q40 breaker on, rocky will boot automatically.
2. If Rocky does not boot and the display still shows a blue screen, press the eject button on
the Rocky’s CD-Rom drive (under left rubber flap, closest to cabinet door).
a. If the DVD will eject, check the connections between the rocky and the display
(troubleshoot the display).
b. If the DVD will not eject, check for voltage at the Q40 breaker – 19VDC should
be present.
c. Check voltage in the power supply cable at the Rocky (Pin #1 on the rear of the
rocky). Positive voltage will be present on the pin closest to the RGB Monitor
port. There should be 19VDC between the pins.
d. If voltage is present, remove the battery (see Replace Modules procedure) and
check the battery voltage. If the battery is good, contact Siemens for a
replacement Rocky. If battery is bad, contact Siemens for a replacement Battery.
3. If the Keyboard does not work:
a. Check the connection between the Keyboard and the Rocky PC.
b. Verify that Num Lock, Caps Lock, and Scroll Lock are in the off position
4. If the Mouse is not working:
a. Check the keyboard mouse to determine if the problem is hardware or software
b. Verify that the External USB Hub is powered and properly connected
c. Try using the Mini-USB mouse on another computer or laptop – if this does not
work, replace the mouse.
5. Rocky PC will turn on, but Windows does not boot
a. Try a hard (power off) reset.
b. Replace the rocky hard drive with the spare hard drive (under the right rubber
flap closest to the cabinet door.

Rev 1.1
If these solutions do not work, or if you have a problem not covered in this guide, please contact
Siemens for assistance.

Rev 1.1
DISPLAY, HOST COMPUTER, VAMP3-SH45-CN7-PS:
A1110201456

Description
The VAMP-SlimVista™ is an enclosed, multi-sync video digitizer with LCD display and resistive
touchscreen. The system is designed for use as a display and input device for the standard PC
Host Computer. The system includes a VAMP XGA3 main board, touchscreen controller,
backlight inverter and flat panel display adapter.
The VAMP-XGA3 main board incorporates the components necessary to digitize analog RGB,
VGA, SVGA and XGA video input signals. Video processing includes input video frame rate
conversions, video scaling from low resolution inputs to higher resolution LCD panels, with output
timing and control to maintain a set output frame rate required by the LCD target panel. An on-
board micro-controller functions as the main system controller, responsible for system
initialization, input mode auto-detection, and other housekeeping functions.
Block Diagram
The figure above shows the system block diagram.
Interface Cables
The following sections define the connections for each of the interface cables.
A. Video Interface
Video inputs are supplied via a standard DB-15 connector using a High Density, 15 pin,
Male, SHIELDED D-shell connector, the pinouts are shown in the following table:
Pin Function Pin Function Pin Function
1 Red 6 Gnd 11 Monitor ID 0
2 Green 7 Gnd 12 Monitor ID 1
3 Blue 8 Gnd 13 Hsync
4 Monitor ID 2 9 N/C 14 Vsync

Rev 1.1
5 Self Test-Gnd 10 Gnd 15 Monitor ID 3
B. Serial Port
One serial port is provided on the Interface cable for communication of Touchscreen data to the
host computer. It supports 16C550 compatible enhanced serial ports. Cable has a standard
Female DB-9 connector using a SHIELDED D-shell, the pinouts are shown in the following table:
Pin Signal Pin Signal
1 DCD 6 DSR
2 Rx Data 7 RTS
3 Tx Data 8 CTS
4 DTR 9 RI
5 Gnd
C. Power Connector
Power for the VAMP-SlimVista is supplied via a 3 conductor cable as defined below:
Conductor Function
Brown +120VAC
Blue -120VAC
Green Ground
TROUBLESHOOTING
A. Major System Failures
No Response on Power-up
1. Check Power Supply
With Power applied, check for 120 VAC supply power at the Host Computer connector.
Ensure the system provides good power grounding.
2. Check Power Cabling
Visually check Power connector and cabling for any signs of damage.
No Display with Backlight lit

1. Check Video Cabling
Make sure the video cable is securely seated in its socket on the host computer Video Card.
Make sure the Video Card is also secured in the host computer bus connector.
Visually check Interface cable for any signs of damage.
2. Check Video Card
Temporarily connect the Video output of the host computer to a standard monitor.
B. Touch Panel
No response from Touch Panel
1. Check Touch Panel cabling
Make sure the serial cable is securely seated in its socket on the host computer.
Visually check the cable for any signs of damage.
2. Check Power Supply
With Power applied check for 120 VAC power supply at the power connector.
Insure the system provides good power grounding.
3. Run TouchTst software and recalibrate the touch panel.
Missed Touches
Improper placement of Cursor upon Touch


Rev 1.1
C. Flat Panel Display
Visual Noise in Display
1. Make sure that all of the latest drivers have been installed on the host computer.
2. Make sure that the proper Resolution and Refresh Rates have been selected on the host
computer.
3. Check Video Cabling
Make sure the video cable is securely seated in its socket on the host computer Video Card.
Make sure the Video Card is also secured in the host computer bus connector.
Visually check Interface cable for any signs of damage.
4. Please contact the support department for further support.

Rev 1.1
SIBAS 32, BI / IGBT, 6FH47667-3A
SIEMENS Part # A5E00462673

Bucyrus Part #
Description
The SIBAS 32 system [ Siemens Bahn (Railway) Automation System with 32 bit microprocessor ]
is used for modulating and logic control functions in mining applications. The system is of modular
design. The functions are divided into function modules and implemented in single-size and
double-size Euroformat units. The modules are installed in panel-in units in an internationally
standardized 19" subrack.
Technical Features
1. Modular design of system of components.
2. 19" design based on national and international standards for dimensions of printed circuit
boards, panel connectors, front panels, subrack, assembly racks, mounts and cabinets.
3. Stable frame construction of surface pickled, colorlessly passivated, aluminum extrusion.
4. The front panels of the modules are likewise aluminum and are surface treated like the
subracks.
5. Special forming of the mechanical connection between the constructional parts and a good
electrical contact ensure a high degree of shield against electromagnetic interference.
6. Guide rails for insertion and securing of the printed circuit boards.
7. Individual locking of each module at the front panel with integrated extraction grip and a
coding system for avoidance of insertion at an incorrect mounting position.
8. Panel connectors provided at the base area of the subrack for making electric contact to the
modules.
9. Electrical connection of the modules by means of printed circuit busses, wire-wrap
connections and cable harness.
10. Shielding and mechanical protection of the internal wiring by means of horizontal perforated
covers and a screening cover on the rear side.
11. The rack is designed to be suitable for IP20 degree of protection.

Rev 1.1
Unit Outline

Rev 1.1
POWER SUPPLY,85-132/110,1200W,ETAFHG-48-SX-
MODULE: A1110231023

0
Description
This 110 VDC Power Supply (E01-G02) furnishes the primary supply voltage to the SIBAS. It is
fed from the 120 V AC coming from the constant voltage transformer PLCT through breaker E01-
Q07, which is located in small cabinet on the upper left hand side of the machine. The output side
is buffered by four capacitors E01,C01 - E01, and C04 There are several resistors across the
capacitors to make sure the capacitors discharge quickly on power off conditions.

1. Voltage Sensing
2. Current Limiting
3. Adjustable Voltage
4. Local/Remote Operation
5. 115 VAC Input
6. Nominal +110 VDC output (for two 55 VDC, 600 W power supplies connected in series)

1. Internal monitoring. The V OUT LED turns off if there is an internal fault in the power supply.
2. External monitoring. The SiBas power startup unit monitors the power supply voltage to see
that it is within limits.
closed.
To Test the Unit

1. Isolate the unit by opening breaker E01-Q07
2. Test the output circuit with a meter to make sure the capacitors have discharged.
3. Disconnect the output wires from the 2 bus bars on the front of the units.
4. Power up the unit by closing breaker E01-Q07.
5. If no LED’s are illuminated, then remove the protective cover over the input terminals and
measure the input voltage. If there is no voltage present, then troubleshoot that symptom.
6. If the red LED is on, there is an internal fault in the power supply and it must be replaced. If
the green LED is on, the unit should be OK.
7. Measure the output voltage across the output terminals. It should be 110 VDC+ 10%
8. If the tests are ok, but the power supply continues to give trouble, then the external circuit
including the wiring to capacitors and SIBAS shall be checked. If the external circuit is ok, the
power supply should be replaced (faulty when is loaded).
Replacing the Unit

In order to replace the unit, the mounting panel must be removed from the machine.
2. Remove the input and output electrical connections of the Power Supply unit.
3. Take out the Panel hold down bolts and tilt up the panel.

Rev 1.1
4. Remove the screws holding down the power supply modules (both of them) and remove and
tag the defective unit.
5. Screw the new unit in place.
6. Mount the panel.
7. Install all connections except the power supply output.
8. Adjust the output voltage at 110 VDC.
9. Restore output connections.
55 VDC Unit Outline
Technical Data
INPUT
Voltage nominal 115-230 VAC
Voltage range 85- 255 VAC
Frequency 50 / 60 Hz
Current on full load 7.5 / 4 A
Phase Single
OUTPUT
Adjustable voltage ±10% typical
Ripple and noise (Output Vx0.5%) +100 mVp-p max
ENVIRONMENT
Operating temperature -5 ∼50 °C
Storage temperature -20 ∼85 °C
Humidity 85 %

Rev 1.1
POWER START-UP UNIT 110V (PSU 110V): 6FH9295-3D
SIEMENS Part # EA 463125929566

Description
General
The PSU 110V module ( 6FH9295-3D ) is located in the SIBAS rack ( G163 ) located in the right
most cabinet and is used for under-voltage monitoring of the primary and secondary supply
voltages. It is also used for controlled starting and stopping of the system. All the SIBAS rack
power supplies are routed through this PSU. The start-up of the controller is activated by applying
the primary supply voltage or by means of a separate starting signal
( ESB ). The module incorporates six monitoring channels for monitoring under-voltage of the
secondary supply voltages. The supply voltages monitored are P24, N24, UZ and P5, P15, N15.
Function
After the PSU has been powered-up, a positive Switch-ON of the power supply units takes place
for a definite period (waiting time). If after the elapse of this waiting time, the voltages still have
not stabilized then the PSU is switched off.
In the event of a fault, the inverter pulses are inhibited and the power supply units are switched
off
To Test the Power Start-up Unit:

1. Ensure the breaker E1-Q07 is OFF.
2. The 110V DC power supply is connected to the PSU at the Front panel Connector. Check for
loose connection and ensure the connections are good.
3. Switch ON the breaker E1-Q07. Check the 110V DC Power Supply to the card with a
multimeter. The measured voltage should be 110V + 5%. The power 110V DC can be
measured across terminals MTB1-3, 4 (located in the left most cabinet at the top).
4. If the 110V DC is available across terminals MTB1- 3, 4, then the PSU will generate the six
Power supply voltages for the SIBAS rack.
5. Check individual power supply units by observing the yellow LED on the Front panel of each
power supply. If the LED is ON, it indicates the power supply is OK.
6. Flip the E01/Q07 breaker ON and OFF as many times as necessary to ensure all the
individual power supplies are OK. If the power supplies do not get ON at all, then the PSU
unit is defective.
7. Replace the PSU unit.
Replacing the PSU Module
1. Switch off the 110V DC supply by turning the E01-Q07 breaker OFF. Also ensure that there
is no voltage across terminals MTB1-3, 4
2. Pull out the card from the rack by unscrewing the top and bottom fixing screw. Replace the
PSU unit with a new unit.
3. Switch ON breaker E1/Q07. Check all the individual power supply modules are ON.
Caution: The module must not be plugged or removed during operation.

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
Order number: 6FH9295-3E
Backplane connector: X1 31-pin plug connector to DIN 41612
(24+7)
Front panel connector: X2 15-pin plug connector to DIN 41612
(14+1)
Slot width: 4 TE
Weight: Approx. 250g
Component ambient temperature: - 40 °C ... + 85 °C
Power supply: + 5V ± 5% approx. 45mA
+15V ± 5% approx. 35mA
- 15V ± 5% approx. 8mA
Structure: Printed circuit board in Euroformat
100mm * 160mm
varnished on both sides
4-layer artwork design in 18µ technology
can be encoded mechanically
Railway type according to BN 411 002
Standards (if applicable): EN 50155
LES-DB
Isolation to VDE 0110 and VDE 0160
Primary supply voltage, starting signal +110V
Number of secondary voltage monitors 6
disconnectable, adjustable threshold 3
non-disconnectable, fixed threshold 3
Number of control signals 3
Number of fault signals 3
Voltage range, digital inputs and outputs HCMOS level
Inhibit output Open-collector
Pulse inhibit Open-collector
Voltage range, ASA supply +5V ... +24V
Electrical isolation Optocoupler
Maintenance notes: None

Rev 1.1
POWER SUPPLY 110V/5V (PCS 5V): 6FH9130-3A

Description
General
The PCS 5V unit (6FH 9130-3A) is used to provide a constant 5V source to the SIBAS rack. The
110V/5V, 60W Power Supply receives an input voltage of 110V DC via the backplane and
generates a precise and stabilized voltage of +5V.
The Power Supply has electrical isolation and polarity reversal protection.
Function
The Power Supply is enabled when the signal at pin d22 (Inhibit) goes LOW. A HIGH signal at pin
d22 disables the power supply.
The output voltage of the Power Supply can be measured at sockets provided on the front panel
(+Uout, -Uout)
The YELLOW LED on the front panel lights up when the power supply is ON (UOUT > 95 %).
Front Panel

Rev 1.1
To Test the Power Supply Module
1. Ensure the E01-Q07 breaker (located in the left most cabinet) is ON. With this breaker ON,
110V DC is supplied to the Power Startup Unit (6FH9295) of the SIBAS rack.
2. Ensure the yellow LED on the Front Panel of all the individual Power Supplies are ON. If not,
this would indicate a problem with the 110V DC Power supply or the Power Start-up Unit.
3. Using a multimeter, measure the voltage across terminal MTB1 # 3, 4. These terminals are
located in the left most cabinet at the top. The voltage measured should be approximately
110V DC + 5%.
4. Measure the voltage at the socket +Uout, -Uout on the front panel. This should be 5V+ 0.5%.
5. If the SIBAS rack is powered with 110VDC but the 110V/ 5V Power Supply module is not
able to produce a constant 5V Output voltage then the Power Supply module is defective and
must be replaced.
Replacing the Power Supply Module
1. Switch the E01-Q07 breaker OFF and ensure there is no voltage at terminal MTB1 # 3,4.
2. Unscrew the top and bottom fixing screws on the front panel.
3. Pull out the defective module and replace it with a new module.
4. Switch the E01-Q07 breaker on. Measure the voltage at the measuring socket +Uout, -Uout.
This should be 5V+0.5%.
Caution: The module must not be plugged in or removed during operation. The unit is
fitted with polarity reversal protection, but not with a temperature monitor.

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
Order number: 6FH9130-3A
Backplane connector: X1 High-current plug connector H15 to DIN
41612
Pin 24 leading (primary earth)
Front panel connector: X2 Not present
Slot width: 9 TE
Structure: Connection to a module location prepared for
converters,
100mm x 45mm x 160mm
Standards (if applicable): EN 55011, EN 50140-EN 50142,
EN 50155, EN 60801-2/93, EN 60559,
DIN IEC 68-1-1 and -2, DIN IEC 68-1-6 and -
27,IEC 529, IEC 571-1, IEC 801-2,
IEC 801-4, SN29500, VDE 0160/12.90,
VDE 0470 T.1, BN 411002
Input voltage UIN 65V ≤ UIN ≤ 154V
Standby current IIN0 ≤ 10mA
Inhibit input INHIBIT UINHIBIT "LOW" ≤ 0.4V/0.5mA unit ON,
"HIGH" ≥ 2.0V unit OFF,
TTL level, o.c. control possible
Signal referred to "NUE" input
Output voltage UOUTnom +5V ± 0.5%
Output current IOUTnom 12A
Current limiting Approx. 1.1 * IOUTnom
Monitoring UOUT 0.95 * UOUTnom ± 1.5%
POWERFL, open collector Signal referred to "FNUA" output
Efficiency 80%
Mains buffering time 0.4ms at -25°C;
at -40° C <Ta <-25° C, an external
capacitor circuit is necessary *)
Dynamic system deviation at load change 50%- < 100mV
100%-50%
Correction time with load change 50%-100%-50% 1ms
Residual ripple < 100mVpp

Rev 1.1

Description
General
The PCS 15V unit (6FH 9131-3A) is used to provide constant 15V source to the SIBAS racks.
The 110V/15V, 60W Power Supply receives an input voltage of 110V DC via the backplane and
generates a precise and stabilized voltage of 15V.
Function
d22 disables the power supply. The output voltage of the Power Supply can be measured at
sockets provided on the front panel (+Uout, -Uout)
There is an LED on the front panel that lights up when the power supply is ON.
Front Panel (6FH9131-3A)

Rev 1.1

1. Ensure the E01-Q07 breaker (located in the left most cabinet) is ON. With this breaker ON,
110V DC is supplied to the Power start-up unit (6FH9295) of the SIBAS rack.
2. Ensure all the yellow LEDs on all the individual power supplies are ON. If not this would
indicate a problem with the 110V DC Power Supply or the Power Start-Up unit.
3. Using a multimeter, measure the voltage at terminal MTB1 # 3, 4. These terminals are
located in the left most cabinet at the top. This should be approximately 110V DC + 5%.
4. Measure the voltage at the socket +Uout, -Uout on the front panel. This should be
15VDC+1%.
5. If the SIBAS rack is powered with 110V DC but the 110V/15V Power Supply module is not
able to produce a constant 15V Output voltage then the Power Supply module is defective
and must be replaced.
1. Switch the E01-Q07 breaker OFF and ensure there is no voltage at terminal MTB1 # 3,4.
2. Unscrew the top and bottom screws on the front panel.
4. Switch the E01-Q07 breaker ON. Measure the voltage at the measuring socket +Uout, -
Uout. This should be 15V+ 1%.

Rev 1.1
Block Diagram
Technical Data
41612

Rev 1.1
Slot width: 9 TE
converters,
EN 50155, EN 60801-2/93, EN 60559,
27,IEC 529, IEC 571-1, IEC 801-2,
IEC 801-4, SN29500, VDE 0160/12.90,
VDE 0470 T.1, BN 411002
Input voltage UIN 65V £ UIN £ 154V
Standby current IIN0 £ 10mA
Inhibit input INHIBIT UINHIBIT "LOW" £ 0.4V/0.5mA unit ON,
"HIGH" ³ 2.0V unit OFF,
Output voltage UOUTnom 15V ± 0.5%
Efficiency 85%
100%-50%

Rev 1.1

Description
General
The PCS 24V unit (6FH 9133-3A) is used to provide a constant 24V source to SIBAS racks. The
110V/24V, 100W Power Supply receives an input voltage of 110V DC via the backplane
connector and generates a precise and stabilized voltage of 24V.
Function
d22 disables the power supply. The output voltage of the Power Supply can be measured at
sockets provided on the front panel (+Uout, -Uout).
Yellow LED on the front panel lights up when the power supply is ON.
Front Panel (6FH 9133–3A)

Rev 1.1
1. Ensure E01-Q07 breaker (located in the left most cabinet) is ON. With this breaker ON, 110V
DC is supplied to the Power Start-Up Unit (6FH9295) of the SIBAS rack.
2. Ensure the yellow LED on the Front Panel of all the individual Power Supplies are ON.
3. Using a multimeter, measure the voltage at terminal MTB1 # 3, 4. These terminals are
located in the left most cabinet. The Voltage measured should be approximately 110V DC +
5%.
4. Measure the voltage at the sockets: +Uout, -Uout on the front panel. This should be 24V+
1%.
5. If the SIBAS rack is powered with 110V DC but the 110V/24V Power Supply module is not
able to produce a constant 24V DC Output Voltage, the Power Supply module is defective
and must be replaced.
1. Switch OFF the breaker E01-Q07 and ensure there is no voltage at terminal MTB1 # 3,4.
2. Unscrew the top and bottom screws on the front panel.
4. Switch on the breaker E01-Q07. Measure the voltage at the measuring socket +Uout, -Uout.
This should be 24V+1%.

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
41612
Slot width: 9 TE
converters,
EN 50155, EN 60801-2/93, EN 60559,
27,IEC 529, IEC 571-1, IEC 801-2,
IEC 801-4, SN29500, VDE 0160/12.90,
VDE 0470 T.1, BN 411002
Input voltage UIN 65V ≤ UIN ≤ 154V
Standby current IIN0 ≤ 10mA
Inhibit input INHIBIT UINHIBIT "LOW" ≤ 0.4V/0.5mA unit ON,
"HIGH" ≥ 2.0V unit OFF,
Output voltage UOUTnom 24V ± 1%
Efficiency 85%
100%-50%

Rev 1.1
CENTRAL PROCESSING UNIT (CPU): 6FH9563-3A
SIEMENS Part # 6FH95633AY6000C

DESCRIPTION
The CPU module (6FH9563-3A) is the processor module for the SIBAS 32 control system. An
Am486DX-2 is used as the microprocessor. In addition to the control logic and data storage
elements, the module incorporates the internal peripherals.
The module is connected to the system by means of two backplane connectors. The SIBAS bus
(16 bit data width, 2 Mb address space) is at connector X1. The Central Processing Unit is the
only BUS master in the SIBAS system. The peripheral signals are present at connector X2.
The real-time clock and the battery-backed RAM are buffered by a Supercap. In the event of
battery voltage failure, the capacitor will retain charge for at least 30 minutes. The CPU monitors
the charge state of the external battery. When the monitor circuit on the Central Processing Unit
indicates, the external battery should be replaced as soon as possible.
The following are located on the front panel:
- 7-segment display for program status
- BCD switch, suitable for software input
- Yellow LED which illuminates if no reset signal is present
- Red LED which illuminates if the watchdog is being triggered regularly
- Jumper which must be plugged in for programming the FLASH EPROMs
- Pushbutton with red cap for reset (recessed)
- Pushbutton with black cap for "Monitor Only" together with reset
- Pushbutton with black cap for "Boot" (recessed)
- 9-pin plug connector for serial service interface (RS232)
- 15-pin plug connector for a modem interface (RS232)
- 9-pin plug connector with direct cables for the plug-in module
AETH Module
The AETH module is a plug-in communication card for the Ethernet. The card contains an
Ethernet microcontroller responsible for all Ethernet communication activities. The AETH Module
also has a DPRAM that acts as an interface to the host computer.
Data exchange via HTTP is done by using a HTTP-server/client. The following functions are
realized:
1. Transfer from vehicle side to land side, on demand of land side.
2. Transfer from vehicle side to land side, on demand of vehicle side.
3. Transfer from land side to vehicle side, on demand of land side.
4. Transfer from land side to vehicle side, on demand of vehicle side.

Rev 1.1
The module’s hardware supports 10/100 Mbit Ethernet. The bus interface is electrically isolated.
Loading Software
Please reference the most recent version of the software load procedure to replace the software.

Rev 1.1
Front Panel

Rev 1.1
Block Diagram
0
Replacing the CPU module
1. Make sure the SIBAS rack power supply is de-energized, by switching the E01-Q07 breaker
OFF.
2. Unscrew the top and bottom fixing screws.
3. Pull out the module from the SIBAS rack and replace it with a new module.
4. Switch the E01-Q07 breaker ON and check the module for correct operation.
Caution: The module must not be plugged in or removed during operation.
The software must be reloaded after the CPU Module has been replaced.

Rev 1.1
Technical Data

Rev 1.1
Service Cable
A commercially available serial interface cable (null modem) with a maximum length of 10m can
be employed for the connection to the service interface of this module.
The figure shows wiring of interface cable for the service interface from the module. A positive
voltage with V24 level (+ 5 V to +14.3 V) is present at Pin 4 of the module. Only V24 signal levels
may be connected to Pin 6 and Pin 8 of the module. (These signals are not evaluated in the
module)
The wiring for a cable that can also be employed with a reduced number of conductors is
illustrated in the following figure. This cable length may not exceed 3m.
The figure shows interface cable wiring with a reduced number of conductors for the service
interface from the module. The connection of the Pins 4-6-8 (9-pole SUB-MIN-D plug connector)
necessary on the Service unit side is not needed on the module side; however, this should be
executed to ensure a symmetrical cable.

Rev 1.1
SIGNAL PROCESSING UNIT 56002, 27 MHz: 6FH9265-3B

Description
General
The SPU module is located in the SIBAS rack. It is a high-speed processing unit in the SIBAS
system. A dual-port RAM and the large SIBAS bus link the SPU as a slave to the central
processing unit. On the SPU module are a Motorola DSP56002 signal processing unit with a
clock frequency of 27 MHz, 96 kbyte RAM, 1.5Mbyte FLASH EPROM. 4 D/A converters also
make it possible to follow internal processor unit variables in analog form. 2 serial interfaces
permit point to point connection with a maximum baud rate of 750kbaud.
The following are located on the front panel:
1. 7 segment-display for readout of program statuses
2. Yellow LED illuminates if no reset signal is present
3. Red LED illuminates if the watchdog is triggered regularly
4. Jumper which must be plugged in for programming the FLASH EPROMS
5. Pushbutton with red cap for reset (recessed)
6. Pushbutton with black cap for "monitor only" together with reset
7. Pushbutton with black cap for "Dual-port RAM booting" via CPU together with reset
(recessed)
8. 9 Pin plug connector for serial interface.

Rev 1.1
Front Panel (6FH9265)

Rev 1.1
Replacing the SPU Module
1. Make sure the SIBAS rack power supply is switched off, by switching the E01-Q07 breaker
off.
4. Switch the E01-Q07 breaker on and check the module for correct operation.
Caution: The module must not be plugged in or removed during operation.
Block Diagram

Rev 1.1
Technical Data
Backplane connector: 1, X2 64-pin plug connector to DIN 41612
large SIBAS bus
Front panel connector: 3 9-pin SUB-MIN-D plug connector (pin)
Service interface
Slot width: 4 TE
Weight: Approx. 550 g
Power supply: + 5V ± 5% approx. 750 mA
+15V ± 5% approx. 40 mA
- 15V ± 5% approx. 40 mA
Structure: Printed circuit board in double-size
Euroformat
233.4 mm * 160 mm
LES-DB
Processing unit DSP 56001 with 27 MHz clock frequency
Memory 96 kb RAM
768 kb FLASH EPROM
4 kb dual-port RAM
Peripherals 2 timer 71054
2 DAC
7segment-display
Serial high-speed interface, 2 channels
Serial service interface
2 LCA
Inputs 8 bit input port
12 inputs LCA1
3 inputs LCA2
Outputs 8 bit output port
Watchdog output
16 outputs LCA2
Input/outputs 4 input/outputs LCA1
4 input/outputs LCA2

Rev 1.1
INPUT/OUTPUT ANALOG (IOA): 6FH9306-3A

Description
General
The IOA is located in the SIBAS rack. It is used for processing various analog and digital/ binary
signals. It has the following main features
• 5 difference amplifiers with adjustable gain (R) and time delay (C)
• 1 minimum select between two analog voltages
• 2 absolute-value generators with negative output voltage
• 2 voltage / constant current transformers for output to peripherals
• 2 voltage / voltage transformers for output to peripherals
• 1 positive summer
• 4 digital inputs with adjustable filter time constants for speed measurement
• 2 isolated output signal converters
• 6 load resistors for measuring transducer signals
• 8 connecting leads from the front panel to the backplane connector, including for transformer
power supply
• 2 connecting leads with power blocking diodes ( positive and negative )
• plug-in monitoring possible at front panel ( X2 ) and backplane connector ( X1 )
Replacing the IOA Module

1. Ensure the SIBAS rack power supply is de-energized, by switching the E01-Q07 breaker OFF.
3. Pull out the module from the SIBAS rack.
4. Compare and ensure the resistors on the solder tags on the new module are identical to those
in the removed card.
5. Insert the new module after mounting correct resistors.
6. Switch the E01-Q07 breaker ON and check for operation.
Caution:
The module must not be plugged in or removed during operation.
Block Diagram
(See Next Page)

Rev 1.1

Rev 1.1
Technical Data
Front panel connector: X2 48-pin connector to DIN 41612
Power Supply + 5V ± 5%, approx. 50mA
+ 15V ± 3%, approx. 90mA
- 15V ± 3%, approx. 70mA
Structure Printed circuit board in Euroformat
100mm * 160mm
Varnished on both sides
2-Layer artwork design in 35µ-Technology
Slot width 4 TE
Weight approx. 200g
Component ambient temperature -40 oC....+85 oC
INPUTS
Number of inputs -11 through connection
-15 Analog inputs
-4 Speed inputs
-2 Digital inputs for output signal converter
-6 load inputs
Input DC voltage
Through connections £ 30V (Current: see. Output)
Analog inputs at: X1 £ ± 15V RIN ³ 2kW
Speed inputs at: X2 £ + 15V IIN£ 18mA
Digital inputs at: X1 TTL-level IIN £ 1.6mA
Load inputs at: X2 £ ± 15V PV £ 280mW (R105)
PV £ 2.5W (R100-R104)
OUTPUTS
Number of outputs -11 through connections
-13 Analog outputs
-4 digital outputs for speed
-2 isolated outputs
-6 load outputs
Output DC voltage
8 through-connections £ 30V IOUT £ 1.5A
2 through-connection to diodes £ 30V IOUT £ 1A
1 through-connection to protective diodes £ 30V IOUT £ 300mA
Analog outputs (Voltage) at X1 and X2 ³ 10V RLOAD ³ 2kW
Analog outputs (Current) at X2 £ ± 20mA RB £ 500W
Digital outputs at X1 TTL-level IOUT £ 4mA
Isolated outputs (Transistor): X2 £ + 30V IOUT £ 70mA
Load outputs at: X1 £ ± 15V RLOAD ³ 2kW

Rev 1.1
INPUT/OUTPUT MODULE (IOM): 6FH9288-3C

Description
General
The IOM is located in the SIBAS rack. It serves as an interface between the central processing
unit and the input/output modules in SIBAS 32. It is connected to the CPU via the data bus (DB)
and address bus (AB). With this module, it is possible to convert analog voltages to digital values.
It provides analog/digital conversion (+/- 10V, 12 bits) of 23 analog signals. From these 23 analog
inputs, 10 signals (AIN [1-10]) are passed to limit monitors. For output of analog signals (AOU[1-
4]), the module has 4 digital/analog converters (12bits, + 10V). In addition, the module is capable
of reading 64 binary signals. The module provides 10 LEDs that are installed on the front panel.
Eight of these are addressable directly via data bus (software). The other two LEDs indicate
status "reset" and "total inhibit". Also provided on the module are a temperature sensor, two BCD
switches, and a 7 segment-display which may be accessed via the data bus (software). The
module is also provided with the facility for plugging in an EEPROM. For programming the
EEPROM, it is necessary to bridge the connection between the two bushes provided on the Front
panel.

(See Next Page)

Rev 1.1
Replacing the input/output Module

off.
3. Pull the module from the SIBAS rack and replace it with a new module.
4. Switch the E01-Q07 breaker on and check the module for proper operation.

Rev 1.1
Caution:
Block Diagram

Rev 1.1
Technical Data
Backplane connector: X1, X2 64-pin plug connector to DIN 41612
large SIBAS bus
Front panel connector: Not present
Slot width: 4 TE
+15V ± 5% approx. 200mA
- 15V ± 5% approx. 200mA
Structure: Printed circuit board in double-size Euroformat
233.4mm * 160mm
LES-DB
Number of digital inputs for control signals up to 64
Number of digital outputs for control signals up to 38
Number of analog inputs 23
Number of limit monitors 10
Most important functions Binary input/output,
Analog input/output,
Limit indication of analog signals,
Frequency and pulse duration acquisition,
Frequency and pulse duration output,
Speed measurement with direction of rotation
detection,
Detection module temperature,
Logic operations in FPGA
Input voltage range of control signals HCMOS level
Output voltage range of control signals HCMOS level
Input voltage range of analog inputs ± 10V
Processing of analog signals S&H ADC with 12 bits, ± 5 LSB absolute

Rev 1.1
INPUT TEMPERATURE SENSOR PT100 (ITS): 6FH9413-
3A

Description
General
The ITS module is located in SIBAS rack. It is used to acquire temperatures using temperature-
dependent resistors made of platinum (PT100). It has the following main features:
1. 8 measuring channels with the associated 8*(2mA) constant current sources
2. Current line and measuring line are separate
3. Maximum measuring resistance of 500 ohms
4. Two swappable temperature ranges per measuring channel
5. Normalization of the temperature measured values to the voltage range of +10V
There is a high precision current source for each measuring channel. The current source feeds
the temperature-dependent measuring resistor RPT100 via the front panel connections. The
current sink "IIN [01-08]” must also be connected to the front panel.
The temperature-dependent voltage drop on the current-carrying conductor measures the
resistance of the PT100. This voltage drop is measured at the two measuring inputs "AIN[01-
08]P" and "AIN[01-08]N" with two measuring wires that are independent of the current lines.
Replacing the Defective ITS Module

1. Ensure the SIBAS rack power supply is de-energized, by switching the E01-Q07 breaker off.
4. Switch the E01-Q07 breaker on and check for proper operation.
Caution:

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
small SIBAS bus
Slot width: 4 TE
Power supply: + 5V ± 5%, approx. 10mA
+ 15V ± 3% approx. 80mA
- 15V ± 3% approx. 80mA
100mm * 160mm
Standards (if applicable): VDE 0160
VDE 0110
LES-DB
EN 50155
Number of inputs at X1 SIBAS bus signals
+ 5 additional input signals
Input DC voltage at X1 £ HCMOS level 5V
Number of inputs at X2 24 (16 measuring points and 8 current sinks)
Input values at X2
Input voltage of the measuring points UIN £ 1V when RPT100 £ 500ohm
AIN[01-08]P/N
Input current of the current sink IIN[01-08] IIN = -2.000mA
Number of outputs at X1 SIBAS bus signals
+ 1 analog signal "TEMPOUT"
Output DC voltage, digital at X1 £ HCMOS level 5V
Output current for each digital signal IOUT £ 5mA
IOUT £ 10mA for bus driver signals
Output voltage, analog at X1 UTEMPOUT £ ± 15V Rload ³ 2Kohm
Number of outputs at X2 8 current sources IOUT[01-08]
Output current of the current source IOUT = -2.000mA ± 1.1%
IOUT[01-08]
Times, time constants, measuring quantities
Temperature range, channels A, TEMP[1-8]A - 39oC £ T £ +127oC
Temperature range, channels B, TEMP[1-8]B - 60oC £ T £ +540oC
Delay time constant TN , TP 16.6 ms
TN = RN*CN, TP = RP*CP
Delay time Tmux < 8µs
Reference voltage UOFFSA/B +10.000V ± 27.5mV
PRECISION:

Rev 1.1
Measuring error channel A £ ± 2.5oC meas.current IOUT = -2.000mA
Measuring error channel B £ ± 3.4oC meas.current IOUT = -2.000mA
Measuring error through current tolerance, channel £ ± 3.3oC
A
Measuring error through current tolerance, channel £ ± 5.7oC
B
Electrical isolation Not required

Rev 1.1
INPUT VOLTAGE/FREQUENCY (IVF): 6FH9305-3D

Description
General
The IVF module is located in the SIBAS rack. It is used for conversion of analog voltages to
frequency signals. Seven analog actual values can be digitized on the signal processing unit
board. The measurement signals are each passed via the front panel connector to a common
difference amplifier whose gain is determined by 2 resistors located on solder tags.
Replacing the IVF Module

1. Ensure the SIBAS rack power supply is de-energized by switching the E01-Q07 breaker off.
3. Pull out the module from the SIBAS rack.
4. Compare and ensure the resistors on the solder tags on the new module are identical to those
in the removed card.
5. Insert the new module after mounting correct resistors.
Caution:

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
Order number: 6FH9305-3D
Slot width: 4 TE
+15V ± 5% approx. 50 mA
- 15V ± 5% approx. 50 mA
100 mm * 160 mm
4-Layer artwork design in 18µ-technology
LES-DB
Inputs 7 analog difference amplifier inputs
5 binary control inputs
Input voltage range of control signals HCMOS-level
7 analog outputs
Outputs 7 Frequency outputs
1 Reference frequency output

Rev 1.1
INPUT COVERTER BINARY 24V: 6FH9371-3C

Description
General
The Input converter binary 24V (ICBP) is located in the SIBAS rack. It is used for input of binary
signals with a nominal level of 24V. The input module receives 12 input channels on the front
panel connector X2; each input has a separate positive (BINP) and a separate negative
(BINN) input pin. These inputs are isolated from the SIBAS through optocouplers. There are no
adjustments to be made in this module.
Replacing the defective ICBP module

off.
4. Switch on the breaker E01-Q07 and check for operation.
Caution:

Rev 1.1
Block Diagram
Technical Data
Order number: 6FH9371-3C
small SIBAS bus
Slot width: 4 TE
100mm * 160mm

Rev 1.1
LES-DB
Number of inputs at X2 12
each with 2 pins (BINP and BINN)
DC input voltage at X2 16.8V £ UIN £ 30V
Input current 7mA £ IIN £ 18mA
Smoothing time constant TS Channels 1 to 10: approx. 1ms,
Channels 11,12: approx. 0.5ms
Cut-off frequency fcut-off Channels 1 to 10: approx. 80Hz,
Channels 11,12: approx. 500Hz
Operating points UIN ("H") > 13V
UIN ("L")< 6V
Output level at X1 UOUT: HCMOS level, IOUT < 10mA
Electrical isolation Optocouplers

Rev 1.1
BINARY OUTPUT CONTACT DRIVE: 6FH9387-3A

BuCyrus Part # 62039573
Description
General
The Binary Output Contactor Drive (BOCD) module is located in the SIBAS rack. It is used for the
output of binary signals. It has 8 separate output channels that are isolated from each other; the
binary output signals are created by the MOS switch V1. There are no adjustments to be made in
this module.
Replacing the Defective BOCD module

1. Make sure the SIBAS rack power supply is de-energized by switching the E01-Q07 breaker
off.
4. Switch the E01-Q07 breaker ON and check for proper operation.
Caution:

Rev 1.1
Block Diagram
Technical Data
small SIBAS bus
Slot width: 4 TE
Power supply: P5 + 5V ± 5% approx. 75mA

Rev 1.1
UActivate +15V ± 3% £ 200mA
100mm * 160mm
LES-DB
Number of outputs at X2 8 channels
each with 2 pins ( BOUTP and BOUTN )
DC output voltage at X2 UOUT £ 36V + 30%
Output current IOUT £ 2.0A
Short-circuit current per channel No limitation
Inductive load Possible *)
Suppresser diode used: 1.5KE68A
Operating frequency £ 2.5kHz with resistive load
£ 4 per minute with inductive load
Connection of "BINEN[01-08]#" input to X1 Do not connect or wrap to M.
Other modes of activation are
non-permissible
Electrical isolation Optocoupler, pulse transformer

Rev 1.1
OUTPUT PULSE AMPLIFIER 40mA (OPA 40mA): 6FH9357-3A

Description
GENERAL
The OPA 40mA module is used for the output of firing pulses (current signals for power
semiconductors) and for the reception of acknowledgement signals from the triggering stage. The
firing pulses are also used to carry information. The firing acknowledgement signal is feedback
from the ALH via the same current loop.
Replacing the OPA module

1. Make sure the SIBAS rack power supply is switched off, by switching off the breaker E01-Q07.
3. Unscrew the fixing screws of the plug-in connectors X1, X2 and take out the plug-in
connectors.
5. Restore the plug-in connectors X1 and X2.
6. Switch ON the breaker E01-Q07 and check for operation.
Caution:
Block Diagram
(See Next Page)

Rev 1.1
Technical Data

Rev 1.1
Backplane connector X1 64-pin plug connector to DIN 41612
Front Panel connector X2 48-pin plug connector to DIN 41612
Slot width 4 TE
Weight Approx. 250g
Component ambient temperature -40 oC....+85 oC
Power Supply P5 +5V ± 5%, Approx. 50mA
Power Supply P24 +24V ± 5%, Approx. 430mA
100mm * 160mm
4-Layer artwork in 18µ-Technology
Standards (if applicable) EN 50155
LES-DB
Number of inputs at X2 9 Channel
each with 2 push-pull outputs
(40MAIN[01-09], 40MAIN[01-09]#)
Input current at X2 35mA £ IIN £ 42mA
Number of outputs at X2 9 Channel
each with 2 push-pull outputs
("40MA[01-09]", "40MA[01-09]#")
Output current at X2 35mA £ Ia £ 42mA

Sustained short-circuit current per channel 35mA £ Ik £ 42mA, Correspond to IOUT
Input level at X1 Triggering possible via "open-collector"
IMP[01-09]# (Send out firing pulse) "H" ³ 2,4V "L" £ 0,8V
IMPSP[01-09]# (Firing pulse inhibit) "H" ³ 2,4V "L" £ 0,4V
Output signal level at X1 HCMOS-level
IMPRM[01-09] (Firing pulse acknowledgement)
Delay time between output of "IMP[01-09]#" tv £ 4µs,
And reception of "IMPRM[01-09]" Output directly linked to input
Electrical isolation None
Maintenance notes None

Rev 1.1
OUTPUT MEASURING AMPLIFIER: 6FH9303-3A

Description
General
The Output Measuring Amplifier (OMES) is located in the SIBAS rack and is used to measure
different analog signals and two digital signals. It is also used to form various logic functions. The
module can receive 16 analog inputs (AIN 7-22) from the back plane connector; 16 analog
outputs (AOUT 9-24) are available at the front panel connector X2; these outputs pass through
unity gain amplifiers. In addition, the module has two voltage/current transformers which are used
to transform an analog voltage into a constant current output. The constant current outputs are
available on the front panel connector X2.
Replacing the Defective OMES module

off.
3. Pull the module out from the SIBAS rack and replace it with a new module.
Caution:

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
Slot width: 4 TE
+15V ± 5% approx. 18 mA + IL *)
- 15V ± 5% approx. 18 mA + IL *)
100mm * 160mm
LES-DB
Value range of Rx: T = Rx * Cx 1KW £ Rx £ 1MW
Number of inputs -20 analog inputs, AIN[03-22]
- 2 digital inputs for output signal
converter, BIN[01-02]
-21 digital inputs, BIN[23-43]
D.C. input voltage
Analog inputs £ ± 15V RIN ³ 200KW
Digital inputs (X1) HCMOS level IEL £ 1mA
can also be activated via o.c.
Number of outputs -2 analog current outputs, AOUT[05-06]
-18 analog voltage outputs, AOUT[07-24]
-2 voltageless outputs, BOUT[01-04]
-10 digital outputs, BOUT[25-34]
-2 digital/analog outputs, BOUT[35-36]
-3 open-collector dig.outputs,BOUT[37-39]
D.C. output voltage
Analog voltage outputs (X2 and X1) ³ 10V RLOAD ³ 2KW
Analog current outputs (X2) £ ± 20mA RBURDEN £ 500W
Voltageless outputs (transistors) £ + 30V IOUT £ 125mA
Digital outputs HCMOS level IOUT £ 4mA
Digital outputs with o.c. output £ + 15V IOUT £ 30mA

Maintenance notes None

Rev 1.1
OUTPUT MEASURING AMPLIFIER: 6FH9404-3B
SIEMENS Part # 6FH9404-3B

Bucyrus Part #
Description
General
The OMES module (6FH9404-3B) is used as a commissioning and diagnostic module. It is
connected to the central processing unit via the data bus (DB[0-15]) and the address buses
(AB[1-3], AB[12-15]) .
For the purpose of identification, the output measuring amplifier has a hardware identifier that
may be read via the data bus.
The module incorporates 8 D/A converter channels; these are connected to the data bus. The
resolution of the converters is 12 bits. The analog output signals (AOUT[16-23]) are de-coupled
via output amplifiers and are present at the front panel connector. The voltage range of the output
signal is -10V...+10V.
The output measuring amplifier possesses 16 analog and 16 digital measuring channels. The
input signals connected to the backplane connector are de-coupled on the module and passed to
the front panel connector.
Of the 16 analog channels, 12 take the form of differential inputs (AINX[00-11]). The remaining 4
channels (AIN[12-15]) have single inputs with BS as the reference potential. The output signals
(AOUT[00-15]) are referenced to M. Both the analog input and output levels are
-10V...+10V. The outputs may also be loaded with load resistances > 20Kohm.
The digital inputs (BIN[00-15]) are designed for levels of 0V...+30V. The digital outputs
(BOUT[00-15]) have HCMOS level. The analog and digital outputs are protected against both
short-circuit and over voltage.

Rev 1.1
Front Panel

Rev 1.1
Block Diagram
Technical Data
Order number: 6FH9404-3B

Rev 1.1
Backplane connector: X1, X2 64-pin plug connector to DIN 41612
large SIBAS bus
Front panel connector: X3 50-pin SUB-MIN-D plug connector, sockets
Slot width: 4 TE
Component ambient temperature: - 40°C ... + 85°C
+15V ± 5% approx. 100mA
- 15V ± 5% approx. 70mA
Structure: Printed circuit board in double-size
Euroformat
160mm * 233.4mm
LES-DB
Number of D/A converter channels 08
Number of analog measuring channels, differential 12
inputs
Number of analog measuring channels, single 04
inputs
Number of digital measuring channels 16
Voltage range, analog inputs -10V...+10V
Voltage range, analog outputs -10V...+10V
Voltage range, digital inputs 0V...+30V
Voltage range, digital outputs HCMOS level

Rev 1.1
INVERTER MONITORING (UWS): 6FH9405-3A

Description
General
The INVM module is located in the SIBAS rack. It is used for monitoring and protection of the
inverters. The module is connected between the trigger equipment and the actual valve control
(Gate unit). It permits monitoring of four inverter phases and the control of eight valves.
Function
The following quantities are monitored:
1. The four phase currents of the inverter phases or the phase voltages
2. The operating time of the valves for ON time and OFF time.
3. The set-point/actual value comparison of the control and check-back signals
4. The actual operating frequency of the valves.
Replacing the INVM

off.
4. Switch the E01-Q07 breaker ON and check for proper operation.
Caution:

Rev 1.1
Block Diagram
Technical Data
Backplane connector X1 64-pin plug connector to DIN 41612
small SIBAS bus
Front panel connector X2 48-pin plug connector to DIN 41612
Slot width: 4 TE
Power supply: + 5V ± 5% approx. 300mA w/o OF
+ 5V ± 5% approx. 500mA with OF
+15V ± 5% approx. 100mA
- 15V ± 5% approx. 100mA

Rev 1.1
100mm * 160mm
LES-DB
Number of external error inputs 17
Number of digital inputs for control signals 4
Input voltage range of control signals HCMOS level
Number of analog inputs 4
Processing of analog signals S&H ADC with 12 bit, ± 5 LSB absolute
Number of monitorable valves 8
Output driver of valve control signals - Optical fiber
- Cables

Rev 1.1
TRANSIENT RECORDER (TRACO): 6FH9320-3A
SIEMENS Part #
Bucyrus Part #
Description
General
The TRACO module (6FH9320-3A) is used as a commissioning and diagnostic module. It may be
used to continuously record 10 Analog and 32 Binary signals. The sampling rate can be adjusted
between the range of 2.8µs and 1.6ms. The TRACO Unit has the capability to record signals
before and after the trigger point. A binary signal is used as the trigger signal. The trigger signal
can be initiated by either a LOW or a HIGH signal. A PC connected via the service interface on
the front panel is used to set the Transient Recorder. The PC is also used to display, analyze,
and store the data.
There are two LEDs on the front panel. The red LED indicates that the recorder is operating.
The yellow LED will indicate that data is present in memory (steady) and will indicate when the
memory is full (blinking).

Rev 1.1
Replacing the Module

1. Make sure the SIBAS rack power supply is switched off by the E01-Q07 breaker.
3. Pull the module out of the SIBAS rack and replace it with a new module.
4. Switch the E01-Q07breaker ON and check the module for correct operation.
Caution:

Rev 1.1
Block Diagram

Rev 1.1
Technical Data
Backplane connector: X1 64- pin plug connector to DIN 41612
Front panel connector: X4 9-pin SUB-MIN-D connector, pins
Slot width: 4 TE
Component ambient temperature: 30. 40 °C ... + 85 °C
Except memory: 0 …+70 °C
+15V ± 5% approx. 30mA
- 15V ± 5% approx. 70mA
100 mm * 160mm with Double-height Euroformat
front panel
4- layer artwork design in 18µ technology
LES-DB
Analog measuring inputs 10 analog difference amplifier inputs
+ 10V Voltage range
20Kohm input resistance
Binary measuring inputs 16 binary inputs, HCMOS level
16 binary inputs, extended high level upto
30V
Outputs 1 binary signal: "TRIGOUT"(high-active
HCMOS signal)
Processor DSP56001 (Motorola)
Memory 6 RAM, 128 bytes each
1 EPROM 128 bytes
Battery Lithium, size AA, 3.6V
Type: R6according to IEC
with axial connection wires
Maintenance notes: Lithium battery has to be exchanged every 2
years.

Rev 1.1
MULTIFUNCTION VEHICLE BUS 32: 6FH9458-3A

Description
General
The MVB 32 card is located in the SIBAS rack. This is a sub computer for a communication
protocol. It consists of a processor and an interface card. It is connected to the SIBAS bus via a
64-pin backplane connector X1. The interface card is screwed on to the processor card.
Function
There are 4 LEDs on the processor card. 2 LEDs (red & green) indicate the status of the MVB 32
card and 2 LEDs (yellow & green) are provided for signal transmitting and receiving of the MVB
Controller.
The red LED is always illuminated and indicates that the card is ready. The green LED flashes
cyclically. The yellow LED lights up during transmit operation and the second green LED as data
is being received.

Rev 1.1
Replacing the MVB 32

1. Make sure the SIBAS rack power supply is switched off, by switching off the breaker E01-
Q07.
4. Switch on the breaker E01-Q07 and check for operation.
Caution:

Rev 1.1
Block Diagram
Technical Data
large SIBAS bus
Front panel connector: X4 9-pin SUB-MIN-D connector (female)
X5 9-pin SUB-MIN-D connector (female)
X3 7-pin LEMO EPG.0B.307.HLN (female)
Slot width: 4 TE
Power supply: + 5V ± 5%, approx. 700 mA
Structure: Printed circuit board fixed with screws
Processor card (100mm * 158mm)
6-layer artwork design
Interface card (98mm * 60mm)

Rev 1.1
4-layer artwork design
LES-DB
TCN-Draft Part 3 (MVB)
Baud rate: X4, X5 1.5 M (Manchester Coding)
X3 9600
Processor: SAF 80C165
20 MHz clock frequency
16 bit data bus
24 bit address bus
Memory modules: RAM (256 KB)
RAM traffic memory (256 KB)
DPRAM (64 KB)
FLASH EPROM (1 MB)
Other modules: Multifunction vehicle bus controller MVBC
X3 Multifunction vehicle bus driver MVBD113
Service interface
Electrical isolation: Transformer

Rev 1.1
MSP, TYPE E,S0,CL10,11-16A,SCREW,+ADAPT:
3RV1021-4AA10
SIEMENS Part Number: 3RV1021-4AA10

Description
The tripping characteristics of the 3RV1 circuit breaker/MSPs are designed primarily to protect
three-phase induction motors. The circuit breaker/MSPs are therefore also referred to as motor
protecting switches.
Outline drawing

Rev 1.1
3RV19155A Connector Lug
3RV19 15-5A is used to connect the 3RV1021 MSP.

Connections
3RV1 circuit breakers/MSPs with frame sizes S00 and S0 have terminals with captive screws and
terminal washers that enable you to connect 2 conductors, even if they have different cross-
sections.
Technical data
Output power of the

Frame Max. rated operational
Width three-phase induction
size current
motor
S0 45 mm 25 A 11 kW
Type 3RV1. 1 3RV1. 2 3RV1. 3 3RV1. 4
Specifications
• IEC 60 947-1, EN 60 947-1 (VDE 0660 Part 100) Yes
• IEC 60 947-2, EN 60 947-2 (VDE 0660 Part 101) Yes
• IEC 60 947-4-1, EN 60 947-4-1 (VDE 0660 Part 102) Yes
Frame size S00 S0 S2 S3
Pole number 3
Max. rated current Inmax (= max. rated operational current Ie) A 12 25 50 100
Permissible ambient temperature
Storage/transportation °C -50 to +80

Operation °C -20 to +70 1
Permissible rated current with the following internal cubicle temperature:

•+60 °C % 100
•+70 °C % 87
Circuit breaker in housing

Permissible rated current with the following ambient housing temperature:
•+35 °C % 100
•+60 °C % 87
Rated operational voltage Ue V 690 2)
Rated frequency Hz 50/60
Rated insulation voltage Ui V 690
Rated impulse strength Uimp kV 6

Rev 1.1
Utilization category
• IEC 60 947-2 (circuit breaker) A
• IEC 60 947-4-1 (motor starter) AC-3
CLASS In acc. with IEC 60 947-4-1 10 10 10/20 10/20
Direct current short-circuit breaking (time constant τ= 5 ms)

capacity (time constant t = 5 ms)
• 1 conducting path 150 VDC kA 10
• 2 conducting paths in series 300 VDC kA 10
• 3 conducting paths in series 450 VDC kA 10
Power loss (Pv) per circuit breaker In -> to 1.25 A W 5 — — —

Depends on rated current In In -> 1.6 A to 6.3 A W 6 — — —
(Upper setting range) In -> 8 A to 12 A W 7 — — —
In -> to 0.63 A W — 5 — —
In -> 0.8 A to 6.3 A W — 6 — —
Rper conducting path= P/I2 ×3
In -> 8 A to 16 A W — 7 — —
In -> 20 A to 25 A W — 8 — —
In -> to 25 A W — — 12 —
In -> 32 A W — — 15 —
In -> 40 A to 50 A W — — 20 —
In -> to 63 A W — — — 20
In -> 75 A and 90 A W — — — 30
In -> to 100 A W — — — 38
Type 3RV1. 1 3RV1. 2 3RV1. 3 3RV1. 4
Shock resistance In acc. with IEC 68 Part 2-27 g/ms 25/11 (rectangular and sine pulse)
Degree of protection In acc. with IEC 60 529 IP20 IP20 3)

Shock protection protected against touching by fingers
In acc. with DIN VDE 0106 Part 100
Temperature compensation In acc. with IEC 60 947-4-1 °C -20 to +60
Phase loss sensitivity In acc. with IEC 60 947-4-1 Yes

Explosion protection In acc. with DIN VDE 0165 and EN 50 019 Yes for 3RV10 (Class 10), 3RV11(Class 10)
Isolating function In acc. with IEC 60 947-2 Yes
Main and emergency-stop switch features4) Yes
In acc. with IEC 60 204-1 (VDE 0113)
Safe isolation between the main circuit and the In acc. with DIN VDE 0106 Part 101
auxiliary circuit required for PELV applications
•to 400 V + 10 % Yes
• to 415 V+ 5 % (higher voltage on request) Yes
Operating cycles
Mechanical life Electrical life 100,000 100,000 50,000 25,000
1/h 15
Max. switching frequency per hour (motor star-tups)
Reduction in current above +60 °C

1) With molded-plastic housing 500
2) V 3)4) Connection room IP00 With corresponding accessories

Rev 1.1
S00 1.8-2.5A 120/110VAC PNL NR COMBO/AUX:
3RA11151CA151AK6
SIEMENS Part Number: 3RA11151CA151AK6

Description
The pre-assembled 3RA fuseless unit is a load feeder/combination starter. In the smaller frame
sizes, these combinations can be mounted directly to DIN rail. The combinations for high ratings
come with mounting adapters for DIN rail mounting or on Busbar adapter shoes (Fastbus).
Depending on the design, these meet coordination type "1" or "2".
• Frame size S00: width 45 mm; for three-phase induction motors up to 0.75 kW / 400 V,
coordination type "2" and 5.5 kW / 400 V, coordination type "1"
Outline drawing

Rev 1.1
3RV1011-1CA10
The 3RV1 circuit breaker/MSP is marked E01/Q301.
Output power of the

Frame Max. rated operational
Width three-phase induction
size current
motor
S00 45 mm 12 A 5.5 kW
3RV1 circuit breaker/MSPs have:

• Inverse-time delay, thermal overload releases
• Instantaneous short-circuit releases
The overload releases can be set to the load current.
The short-circuit releases are set permanently to 13 times the rated current, which allows motors
to start up without problems. Circuit breaker/MSPs used for transformer protection are set to 19
times the rated current to avoid being tripped by the high inrush current.
When the circuit breaker/MSPs are tripped, in the case of frame size S00 the toggle switch goes
into the tripped position, and in the case of frame sizes S0 to S3 the rotary switch switches to the
tripped position. Before it is switched on again, the rotary switch must be put in the 0 position
manually (reset) to avoid switching to the fault inadvertently.
In the case of circuit breaker/MSPs with a rotary switch, the tripping operation can also be
reported electrically by means of an alarm switch.
Tripping classes In acc. with IEC 947-4-1:

• Frame sizes S00 to S3: class 10
• Frame sizes S2/S3: class 20
3RT1015-1AK61
The 3RT1 Contactor is marked E01/K301

Rev 1.1
Contactor relays are available in the SIRIUS modular system for switching motors and auxiliary
circuits for the purpose of smooth interaction with electronic controllers. These are variants of the
3RT10/3RH11 contactor series with the following features:
• Low power input
• Wide operating range of the magnet coil 0.7 to 1.25 x µs
• High contact reliability of the auxiliary contacts
• Integrated or attachable over voltage damping
Contact reliability: The high contact reliability of the auxiliary contacts ensures that false signals
do not occur even at low switching capacities. With a voltage of 17 V and a current of 1 mA, there
is on average less than one contact fault per 100 million switching operations.
Over Voltage Damping: Over voltage damping protects sensitive output levels of electronic
controllers against switching over voltage of the coil.

Rev 1.1
Technical data

Rev 1.1
VARISTOR, 48-127VAC: 3RT1916-1BC00
SIEMENS Part Number: 3RT1916-1BC00

Description
SIEMENS 3RT1916-1BC00 surge suppressors are used to protect the K201 and K301 contactors
from voltage transients. They are labeled V201 and V301 and are located on the MSP201 and
MSP301 enclosures.
When contactor coils are de-energized, over voltage occurs (inductive load).
Voltage peaks of up to 4 kV with a rate of rise in voltage of 1 kV/ms can result (showering arcs).
The consequences of this are:
• Heavy contact erosion and thus premature wearing of the contacts that switch the coil
• Unwanted signals can occur that may cause false signals in electronic controllers.
All contactor coils, therefore, should be damped against switching over voltages, particularly
when working with electronic controllers.
Outline drawing
Technical data
AC Voltage 48-127 VAC
DC Voltage 70-150 VDC
Illustrated above is what happens when a coil is de-energized that is connected to a varistor
(voltage-dependent resistor):

Rev 1.1
Voltage peaks still occur. They are cut off at approximately 400 V and have a shorter overall
duration (approximately 50 µs).
(Note: The oscillogram is cut off, and the voltage is reduced to zero after approximately 3 ms.)
A varistor is suitable for AC and DC operation.
The Opening time of the contactor is extended by approximately 2 to 5 ms.
Replacing the Suppressor

To replace the 3RT1916-1BC00,
7. Using a voltmeter, check the DC output of the power supplies to make sure that all capacitors
have discharged.
8. Pull the varistor module out of the contactor
9. Install a new module into the contactor, ensuring it is completely seated.

Rev 1.1

IGBT Retrofit Inverters-SIBAS Device Manual - Rev1.1 PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

IGBT Retrofit Inverters-SIBAS Device Manual - Rev1.1 PDF

Caricato da

Copyright:

Formati disponibili

Energy & Automation, Inc.

SIEMENS ENERGY & AUTOMATION

IGBT Shovel Device Manual Revised 08/11/06

IGBT Shovel Device Manual i

IGBT Shovel Device Manual ii

SIEMENS Part Number: A1103012109

IGBT Shovel Device Manual Page 1of 263

IGBT Shovel Device Manual Page 2of 263

SIEMENS Part Number: A1110231015

Replacing the Capacitors.

IGBT Shovel Device Manual Page 3of 263

IGBT Shovel Device Manual Page 4of 263

IGBT Shovel Device Manual Page 5of 263

CAPACITOR, 22mF, 160V DC, B43457- J1229M:

SIEMENS Part Number: A1110231016

To Test the Capacitors

Replacing the Capacitors.

IGBT Shovel Device Manual Page 6of 263

IGBT Shovel Device Manual Page 7of 263

IGBT Shovel Device Manual Page 8of 263

CAPACITOR,2000µF,DC LINK,2050V: A1110201430

SIEMENS Part Number: A1110201430

The MKK DC capacitor safety system

Test the capacitor

IGBT Shovel Device Manual Page 9of 263

IGBT Shovel Device Manual Page 10of 263

DC test voltage between terminals UTT DC 3100 V; 10 s

Min. operating temperature - 25 °C

Average relative humidity ≤ 95 %

Storage temperature limit - 55 °C / + 85 °C

IGBT Shovel Device Manual Page 11of 263

SIEMENS Part Number: 614685

Test the capacitor

Replacing the capacitor

IGBT Shovel Device Manual Page 12of 263

IGBT Shovel Device Manual Page 13of 263

IGBT Shovel Device Manual Page 14of 263

CIRCUIT BREAKER, 10-16A,MSP,W\AUX :

SIEMENS Part Number: 3VU13001MM00

Replacing the MSP

IGBT Shovel Device Manual Page 15of 263

IGBT Shovel Device Manual Page 16of 263

MINI CIRCUIT BREAKER,277VAC,1A,1P: 5SX21017

SIEMENS Part Number: 5SX21017

IGBT Shovel Device Manual Page 17of 263

Time Current curve characteristic

Type C characteristic is for general device protection in

IGBT Shovel Device Manual Page 18of 263

MINI CIRCUIT BREAKER, 277VAC, 3A, 1P: 5SX21037

SIEMENS Part Number: 5SX21037

IGBT Shovel Device Manual Page 19of 263

Time Current curve characteristic

IGBT Shovel Device Manual Page 20of 263

MINI CIRCUIT BREAKER,240VAC,4A,2P: 5SX22047

SIEMENS Part Number: 5SX22047

IGBT Shovel Device Manual Page 21of 263

Time Current Curve Characteristic

Type C characteristic is for general device protection in

IGBT Shovel Device Manual Page 22of 263

MINI CIRCUIT BREAKER,277V/0.5A, 1P: 5SX21058

SIEMENS Part Number: 5SX21058

IGBT Shovel Device Manual Page 23of 263

Time Current curve characteristic