JS400 System Reference Manual. (Includes Shuttlecar and Continuous Miner)

Transcription

1 JS400 System Reference Manual (Includes Shuttlecar and Continuous Miner) Document #L Revision 1.0 June 2010

2 Table of Contents Warnings and Safety JS400 Shuttlecar A800821C System Drawing MCM (with display)...4 A800721C System Drawing Diagram...6 Control Connection and Harnesses General... 8 Tram (A800715)...10 Description...10 Specifications...11 A Display...12 Specifications...12 Diagram...13 A MCM (with display capability)...14 Master Control Module (MCM) Connector Pin-Outs...14 A MCM (no display)...15 Master Control Module (MCM) Connector Pin-Outs...15 Foot Switch (New- FS400 / Old- FS300)...16 Specifications...16 Diagram...16 Troubleshooting...17 OS400 Test Station...17 Operators Control Troubleshooting...19 Master control Module Troubleshooting...20 JS400 Troubleshooting with the OS JS400 Continuous Miner.22 A System Drawing Control Connection and Harnesses General...24 A Display...24 Tram (A800743)..24 Description...24 Specifications...25 A MCM Miner...26 Notes...27 SAMINCO

3 JS400 System Warnings and Safety Important! Please obey the following safety rules before installing, testing or operating the drive. 1. The JS400 system has been designed for installation in an explosion proof enclosure. Do not apply power to a unit that is not in a secured, explosion proof container. 2. Do not make any connections or measurements when the JS400 is under power. 3. Do not touch system components until main power has been turned off and the internal capacitors have discharged. Wait at least 10 minutes after removing main power before working on system components. 4. Do not connect or disconnect any wires or connectors while power is applied to the system or while capacitors are charged (when the charge LED is on). 5. Do not apply any Hi-Pot or Megger test on any part of the JS400 system. 6. If any external system requires a Hi-Pot or Megger test, disconnect the JS400 system completely prior to the test. 7. Never touch any printed circuit boards in the JS400 system. Static voltage discharge could destroy the components Grounding The JS400 system should operate properly on a floating or on a grounded system. It is recommended that if a grounded system exists, the unit should be grounded to that system in accordance with NEC and local codes. Storage of the JS400. If extended storage is expected, protect the equipment against moisture and maintain temperature in accordance with the environmental specifications (listed below). If the unit is stored longer than three months, inspect the equipment carefully before power is applied for water damage or wire insulation Safety Environmental Specifications Description Specification Temperature Ambient Operating Temperature -10 C (no frost) to + 50 C Storage Temperature -40 C to +60 C Relative Humidity <90% No Condensation Altitude Altitude 3300 Feet (1000 meters) De-Rate above 3000 meters. 3

4 Sys DWG A800821C System Drawing 4

5 JS400 Shuttlecar System Master Control Module (with Display) Sys DWG 5

6 A800721C System Drawing Diagram Sys DWG 6

7 JS400 Shuttlecar System Master Control Module (Without Display) Sys DWG 7

8 Connections Connections Control Connection and Harnesses General All control wiring interconnections are made via Saminco supplied wiring cables. See drawing A800821C, A800721C and A for Saminco cable part numbers and connection information. All power-wiring connections are supplied by the customer. Saminco drives are controlled by operator devices such as foot switches, tram direction switches, and convey direction switches. The supply voltage to these controls is an isolated low voltage supply typically in the range of 24V to 30V and is supplied via IS (Intrinsically/ Safe) barriers. However, the resultant control current is also low, of the order of 10mA, and this can cause problems if old style, high voltage / high current contacts are used. Signal Contacts / Logic Level Operation Old style contacts are often made of copper or silver cadmium oxide, and they depend on sufficient voltage being present to break down the oxide layer that forms on the contact surface for reliable and consistent operation. However, these contacts do not provide repeatable, consistent conduction for low voltage / low current operating and therefore, the new range of drives require a careful selection of operator device contact material. The Saminco FS-300 footswitch uses sealed micro-switches with gold cross point contacts, rated for currents and voltages up to 100mA, 125VAC. Operator devices such as push buttons and switches available from most vendors such as EATON Cutler-Hammer must be rated for logic level operation which is typically 5V / 1mA. EATON s range of heavy-duty industrial operator devices can be obtained with a surface modification called a reliability nib which makes them suitable for logic level operation. Other common contacts use Palladium for logic level operation in corrosive environments. Make sure that 8

9 JS400 Shuttlecar System every switching mechanism used with our drives is rated for signal or logic level operation. Application Example Section-47 of the Cutler-Hammer Pushbuttons and Indicators Lights Catalog gives ordering details for logic level contact blocks used with their 30.5mm heavy-duty oil tight contact blocks. Summary Table 1: Comparison of contact material / configuration for logic level duty: Connections Connections NOT ACCEPTABLE Copper Silver Silver Cadmium Oxide ACCEPTABLE Gold cross point or cross bar Platinum, Palladium Rhodium Reliability Nib configuration Silver Oxide Iron or Steel 9

10 Tram SAMINCO Part Number: A New Model: 8.6 TRAM 8.4 Description Compact, solid state reversing included in module with same footprint as other popular SCR packages: 240VAC to 550VAC input 50/60 Hz (A800715H up to 660VAC) Up to 400A output for 30 seconds Can be used with DC series motors rated from 240VDC to 550VDC (up to 100HP rating) Regenerative braking capability Dual mode operation: Current control for torque sharing (shuttle cars) Voltage control for speed control 10

11 JS400 Shuttlecar System Specifications Input Supply: VAC, 3 Phase, 50/60 Hz Other voltages available. Please contact factory for details Output Voltage: 240VDC, 300VDC, 500VDC or 550VDC Other voltages available. Please contact factory for details Output Current: The following setups are available for the above ranges: Setup A: 240VAC 50/60Hz Input with 240VDC Output Setup B: 240VAC 50/60Hz Input with 300VDC Output Setup F: 380VAC 50/60Hz Input with 350VDC Output Setup C: 480VAC 50/60Hz Input with 500VDC Output Setup D: 500VAC 50/60Hz Input with 550VDC Output Setup E: 550VAC 50/60Hz Input with 550VDC Output TRAM Rating: 400 Amps for 30 Seconds Regen Braking: Amps - Factory setting at 95 Amps Control Logic: 110VAC, Single Phase (supplied separately) 11

12 A Display Display Diagram Specifications Input Supply: Self powered from JS-400 Drives Display: LED Status and Drive Indicators 3 Digit LED Voltage, Current and Reference Meters Mechanical: X/P Headlight Housing single gland 1/2 Packing ( Commonwealth of Pennsylvania No. BFE approval) available in steel (E ) for overseas, (Aluminum housing E ) Real Time Diagnostic Display for Saminco JS-400 AC/DC traction drives Supplied in X/P housing, can be mounted anywhere on vehicle Bright LED meter readout of motor current, motor voltage and reference voltage LED Indicators for Ready, Neutral, Forward, and Reverse display automatically detects and cycles through all drives in the system Automatic detection of current or voltage control mode of the JS-400 being monitored 12

13 Display Diagram JS400 Shuttlecar System Diagram: 13

14 A MCM (with Display capability) Master Control Module (MCM) Connector Pin-Outs Control Wiring Harnesses: MCM Connector Cable P/N Connects to Description C1 W C1 JS400 #1 Tram 1 Motor C2 W C1 JS400 #2 Tram 2 Motor C3 W C1 JS400 #3 Convey Motor Connectors C4 and C5: Tram and Convey Controls (Cable P/N: W ) Pin Name Signal Format Description MCM 1 +24V +24V +24V Source 2 NS Logic +24V Neutral Sensing Switch 3 DIR COM +24V Source 4 FWD Logic +24V Forward Switch 5 REV Logic +24V Reverse Switch 6 I Control Link Current Control 7 I Control Link Current Control 8 REF POT+ +12V +12V Source 9 REF Input Analog Reference Signal 10 REF POT GND GND Signal Ground FS Link Footswitch Link V +24V +24V Source 15 +5V +5V +5V Source 16 SHLD - Shield 14

15 JS400 Shuttlecar System Connector C6 (MCM): Display (refer to page 13 for wiring) Pin Name Signal Format Description 1 +5V +5V Supply 2 COM COM Common 3 S1 +Logic 5V Display selection switch 4 S2 +Logic 5V Display selection switch T1 +Logic 5V Tram 1 indicator 8 T2 +Logic 5V Tram 2 indicator 9 CNV +Logic 5V Convey indicator 10 V Analog Voltage Output (Display) 11 I Analog Current Output (Display) 12 REF Analog Tram Reference (Display) 13 RDY +Logic 5V System Ready Indicator 14 FWD +Logic 5V Tram Forward Indicator 15 NTRL +Logic 5V Tram Neutral Indicator 16 REV +Logic 5V Tram Reverse Indicator 17 VC +Logic 5V Voltage Control Indicator MCM A MCM (no display) Master control Module (MCM) Connector Pin-Outs Control Wiring Harnesses: MCM Connector Cable P/N Connects to Description C1 W C1 JS400 #1 Tram 1 Motor C2 W C1 JS400 #2 Tram 2 Motor C3 W C1 JS400 #3 Convey Motor Connectors C4 and C5: Tram and Convey Controls (Cable P/N: W ) Refer to table for the A MCM Connectors C4 and C5 on page

16 Foot Switch (New- FS400 / Old FS300) SAMINCO Part Number: (New) A / (Old) A Specifications Input Supply: 20V to 20mA Output Voltage: 0V to 4VDC = 0-100% Reference Output current: up to 10mA Neutral sensing contact Missing gnd/com wire protection Diagram Footswitch 16

17 JS400 Shuttlecar System System Troubleshooting OS400 Test Station SAMINCO Part Number: A CAUTION ONLY QUALIFIED TECHNICIANS SHOULD TROU- BLESHOOT THE JS400. THE POSSIBILITY OF TOUCHING OR SHORTING LIVE COMPONENTS CAN CAUSE SERIOUS INJURY OR DEATH. Follow applicable safety codes in your region. In the USA, CFR30, 01 Jul 88, Part 75, subparts F through K lay down allowable equipment procedures for maintenance and troubleshooting of electrical equipment. ALWAYS EXERCISE EXTREME CAUTION AND NEVER TROUBLESHOOT ALONE. MAKE SURE THERE IS A PERSON NEARBY AT ALL TIMES WHO CAN DISCONNECT POWER AND PROVIDE HELP IN THE EVENT OF AN ACCIDENT. AL- WAYS WEAR GOGGLES AND PROPERLY INSU- LATED GLOVES. The JS400 is designed to provide many years of reliable, trouble-free service. In the rare event that the drive fails to function properly, check the following: Check presence of 120VAC control voltage at TB1 of JS400. Check presence of all 3-phases at A-B-C power terminals of JS400. Check motor connections. Make sure that there is no ground fault in the motor. Troubleshooting 17

18 C1 C1 Troubleshooting TB1 Use the W test cable to by-pass the Master Control Module (MCM) to localize problems in the module itself. For example: JS400#1 is not working. Refer to A800721C Diagram on page 6. Disconnect W from C4 and W from C1 on the Master Control Module (MCM). Use the W test cable to connect disconnected cables together. Now all control signals from the Operators Tram control station will be delivered directly to JS400#1 bypassing the Master control Module (MCM). W OPERATOR CONTROL OPERATOR CONTROL A OR A MASTER CONTROL MODULE JS400 1 JS400 2 JS

19 JS400 Shuttlecar System NOTE: This test must be performed with 120VAC only!! Make sure that parking brakes are applied during all tests!! 1. Operators Control Troubleshooting OPERATOR CONTROL C2 OS400 C1 A OR A MASTER CONTROL MODULE JS400 1 JS400 2 OPERATOR CONTROL JS Disconnect operator control cable (W ) from Master Control Module (MCM) and connect it to C2 of the OS Take additional W , previously tested, and connect C1 on OS400 with control plug under test on the Master control module (MCM). 3. Set I REF potentiometer fully CCW and FWD/REV switch to neutral position on the OS Apply 120VAC-control voltage to the system. 5. The POWER and CONTROL POWER green LEDs on OS400 should come ON. This indicates that MCM internal power supply comes ON. 6. The NEUTRAL LATCHED green LED will be ON when the footswitch is set to neutral position. 7. Otherwise, check neutral switch and its wiring. 8. The SYSTEM READY green LED will be ON when JS400 internal neutral sensing circuit latches. 9. Turn directional switch to FWD. The FWD red LED indicates that direction signal is passed to the MCM. 10. Confirm that red REV LED lights up when directional switch turned to REV. 11. Otherwise, check directional switch and its wiring. 12. Connect digital voltmeter to TB1 on OS400. (Voltmeters positive lead to pin 2). 13. Voltage at TB1 rises from 0 to V when footswitch is fully depressed. 14. If there is no voltage change then check footswitch wiring and its potentiometer. 15. If all tests are passed then disconnect OS400 and reconnect control cable to the MCM. Troubleshooting 19

20 2. Master Control Module Troubleshooting C2 C1 OPERATOR CONTROL A OR A MASTER CONTROL MODULE OS400 JS400 1 OPERATOR CONTROL JS400 2 JS400 3 Troubleshooting 1. Disconnect W control cable from C1 (C2/C3) of the MCM and connect it to C1 of the OS400. Connect plug C2 of the OS400 with disconnected MCM plug with additional, previously tested, W cable. 2. The POWER and CONTROL POWER green LEDs on OS400 should light up. 3. This will indicate that JS400 internal power supply is functioning. 4. Otherwise, there is a possibility of faulty JS400. Refer to STP184 for troubleshooting or contact Saminco representative for further instructions. 5. If the footswitch is in neutral position and neutral sensing circuitry in the JS400 latches, then the NEUTRAL LATCHED and SYSTEM READY green LEDs will come ON. 6. Otherwise, press NEUTRAL push button on the OS400 and if LEDs will light up and control neutral switch passed previous test then the master control module should be replaced 7. Turn directional switch to FWD. The FWD red LED indicates that direction signal is passed from operators control through the MCM to the JS Confirm that red REV LED lights up when directional switch turned to REV. 9. Connect digital voltmeter to TB1 on OS400. (Voltmeter positive lead to pin 2). 10.Voltage at TB1 rises from 0 to 0.7V-0.9V when footswitch is fully depressed. 11.If one of described above tests fail, then change MCM. 12.If all tests are passed, then disconnect OS400 and reconnect control cable to the MCM. 13.Remove 120VAC. 20

21 3. JS400 Troubleshooting with OS400 JS400 Shuttlecar System Make sure that parking brakes are applied!! C1 C1 OS400 JS400 Apply clamp-on current meter around motor armature wire. Disconnect the W control cable from C1 of the JS400. Use additional W , previously tested, to connect C1 of the OS400 with control plug C1 of the JS400 under test. Contact Saminco representative for further instructions if one of following steps fails. Step 1 1.Set I REF potentiometer fully CCW and FWD/REV switch to neutral position on the OS Apply 120VAC-control voltage. 3.The POWER and CONTROL POWER green LEDs on OS400 should light up. Step 2 1.Apply main 3-phase power. 2.Depress NEUTRAL push button on OS The green NEUTRAL LATCHED and SYSTEM READY LEDs should light up. Step 3 1.Press and hold DMS push button on the left side of the OS400. NOTE: At any time, you can interrupt signals to JS400 by releasing the DMS push button. 2.Flip the directional switch to FWD. The red FWD LED should come ON. 3.Slowly turn the I REF knob CW. Monitor the motor armature current. 4.Confirm that the motor armature current rises up. Do not exceed 50A of armature current. 5.Confirm that the same smooth control of the motor armature current is in REV direction. Troubleshooting Consult the factory at (239) or (304) for additional information. 21

22 A800721CM-RevC System Drawing Sys DWG 22

23 JS400 Continuous Miner System Continuous Miner System Sys DWG 23

24 Control Connection and Harnesses General Same as page 8. A Display Same as page 12. Tram SAMINCO Part Number: A TRAM Description Compact, solid state reversing included in module with same footprint as other popular SCR packages: 240VAC to 550VAC input 50/60 Hz Up to 400A output for 30 seconds Can be used with DC series motors rated from 240VDC to 550VDC (up to 100HP rating) Regenerative braking capability Voltage control for continuous miners 24

25 JS400 Continuous Miner System Specifications Input Supply: VAC, 3 Phase, 50/60 Hz Other voltages available. Please contact factory for details Output Voltage: 240VDC, 300VDC, 500VDC or 550VDC Note: Maximum output voltage is manually adjustable. Output Current: The following setups are available for the above ranges: Setup B: 240VAC 50/60Hz Input with 300VDC Output Setup F: 380VAC 50/60Hz Input with 350VDC Output Rating: 400 Amps for 30 Seconds TRAM Regen Braking: Amps - Factory setting at 95 Amps Control Logic: 110VAC, Single Phase (supplied separately) 25

26 A MCM Miner Master Control Module (MCM) Connector Pin-Outs Control Wiring Harnesses: MCM Connector Cable P/N Connects to Description C1 W C1 JS400 #1 Tram 1 Motor C2 W C1 JS400 #2 Tram 2 Motor Connector C3: Miner Controls MCM Pin Name Signal Format Description 1 L FWD 120VAC Left Forward 1st Speed 2 L REV 120VAC Left Reverse 1st Speed 3 R FWD 120VAC Right Forward 1st Speed 4 R REV 120VAC Right Reverse 1st Speed 5 2-SPEED 120VAC Left 2nd Speed 6 3-SPEED 120VAC Left 3rd Speed 7 CUTTERS-ON 120VAC Cutter On 8 POWER 120VAC Pump Start 9 AC-COMMON 120VAC Common CUTTERS-FB 0-5V Cutter Current FB 12 CUTTERS-FB 0-5V Cutter Current FB Connector 4 (MCM): Display (Refer to page 13 for wiring) 26

27 JS400 System Notes: NOTES 27

28 Saminco Technical Support Name Service Area Phone # Saminco Lavalette North America (304) After Hours On- Call Rex Bramel All Locations (304) Midwest (Illinois/Indiana/ W Kentucky) (618) Kenny Boles West Virginia (304) Gary Beard Eastern Kentucky/Virginia (606) John Richardson Pennsylvania (304) Lane Cerise Western States (CO/WY/NM/AZ) (970) Philippe Maillard International (239) Visit us on the web at Document #L