Traction Electric Drive-Eng

8/6/2019 Traction Electric Drive-Eng

1/25

Traction electric drive for dump trucks withpayload capacity from 120 to 220 tonnes

Setup Manual


2/25

2

CONTENTS

1 Introduction...................................................................................................................................... 32 Safety requirements......................................................................................................................... 33 Control of completing products of the traction electric drive prior to the assembly of the dump

truck ................................................................................................................................................. 3

3.1 Each product which is a part of the traction electric drive should meet the requirements ofspecification and complete set of the design documentation for this product................................. 3

3.2 Traction motors and alternator ........................................................................................................ 33.3 Installation of ventilated brake resistors .......................................................................................... 43.4 Cabinet with start-controlling equipment ......................................................................................... 44 Description of adjustment process .................................................................................................. 44.1 Preparatory operations.................................................................................................................... 44.2 Editing of protection set points and logic signals in function of rotational speed of the traction

motor................................................................................................................................................ 44.3 Editing of external (traction and brake) characteristics of system traction alternator rectifier.. 75 Control of the traction electric drive after assembly of the dump truck before start-up of the diesel

engine............................................................................................................................................ 126 Control of the traction electric drive of the dump truck after start-up of the diesel engine at the

hung out driving wheels................................................................................................................. 157 Check of parameters of the traction electric drive......................................................................... 167.1 Check of functioning of the protection device at imitation of short circuit of power circuit on the

case of the dump truck .................................................................................................................. 167.2 Check of the protection device at excess of legitimate value of armature chain current of traction

motors M1 and 2 in traction mode.............................................................................................. 167.3 Check of functioning of the protection device at excess of legitimate value of output voltage of

rectifiers UZ1 or UZ2 in traction mode........................................................................................... 177.4 Check of functioning of the protection device at excess of admissible current of loading of

rectifiers UZ1 and UZ2 in traction mode on the limiting characteristic .......................................... 187.5 Check of functioning of the protection device at imitation of the electromotor-wheels skidding... 187.6 Check of functioning of the protection device at excess legitimate value of voltage on armature

chain of traction motors 1 and 2 in a traction mode ................................................................ 187.7 Check of functioning of the protection device at imitation of short circuit on entry (exit) of power

rectifier UZ1 or UZ2, or puncture of the valve in one of branches of rectifier bridges................... 197.8 Check of functioning of the device forming logic control signals by the traction electric drive in

function of rotational speed of traction motors .............................................................................. 197.9 Check of the device of smooth field reduction (smooth exciting current control) of traction electric

motors in traction mode ................................................................................................................. 207.10 Check of the device for restriction of the electromotor-wheels skidding ....................................... 207.11 Check of the channel of restriction of output voltage of rectifier UZ1 or UZ2 in traction mode..... 217.12 Check of the maximum loading current of rectifiers UZ1 and UZ2 in traction mode..................... 217.13 Check of the channel of restriction of power on exit of rectifiers UZ1 and UZ2 in traction mode . 217.14 Check of the max exciting current of traction motors in electronic braking mode......................... 217.15 Check of restriction of voltage (current) of brake resistor RB1.1 or RB1.2 in electro-dynamic

retardation mode............................................................................................................................ 227.16 Check of restriction of voltage (current) of traction motors in electro-dynamic retardation mode on

conditions of their commutation..................................................................................................... 22APPENDIX A .............................................................................................................................................. 23APPENDIX B .............................................................................................................................................. 24APPENDIX B .............................................................................................................................................. 25


3/25

3

1 Introduction

This Manual specifies procedures for setup of AC/DC traction electric drive for BELAZ dumptrucks with control system -01. The Manual is designed for carrying-out tasks for setup of tractionelectric drive prior to the assembly, and verification (if necessary) of traction electric drive setupparameters after the assembly of dump truck.

In addition, procedures specified in this Manual can be carried out during operation of dump truckin case due to any reason the values of one or more parameters do not meet the requirements specifiedin this Manual.

2 Safety requirements

2.1 Setup of traction electric drive can be carried out only by personnel familiarized with thisManual, appropriately trained and familiar with the operational and safety regulations.

2.2 Operations on check of parameters of adjustment of the traction electric drive should becarried out according to demands of acting User Rules for Operating Electrical Equipment (.:Energoatomizdat, 1987 648 p.) and User Safety Rules for Operating Electrical Equipment (.:Energoatomizdat, 1986 424 p.) by team of not less than two persons, knowing an arrangement of

electric equipment on dump truck, its device and circuit diagrams. One of them should have IV qualifyinggroup on electric security, others not below III.

Dump truck operator participating in process on regulating of the traction electric drive shouldhave II qualifying group on electric security.

2.3 At accomplishment of works during regulating on motionless dump truck at its ladder theposter Warning! Dangerous! should be hung out. On dump truck there should be only set-up men(electricians) and operator. Dump truck should be braked by parking brake system, and under its wheelsfrom both sides there should be supports.

2.4 Dump truck operator on command of the head of team of set-up men (electricians) shouldmake start-up of the diesel engine, turning on and shut down of the traction electric drive. At the workingdiesel engine the operator should stay in operators cab of the dump truck.

2.5 At accomplishment of operations outside of cab of the dump truck on the dash panel in

the cab the prohibiting poster Do not turn on! Men in work! should be present.

2.6 Operations which are carried out on electric equipment of the traction electric drive whichcan appear energized, should be made with switches SA1 and SA2 in a neutral position on the dashpanel, and also disconnected switch QF1 in the control cabinet. On the handle of the switch theprohibiting poster Do not turn on! Men in work! should be present.

2.7 Wires detached from leading-outs and crimped locks of electric equipment should bereliably isolated.

2.8 Before extraction and the subsequent installation of sliding blocks in meshes it isnecessary to disconnect switches SF2 and SF3 in the control cabinet.

2.9 At work on motionless dump truck before turning on of voltage at its ladder the warningposter poster Warning! Dangerous! should be hung out.

2.10 It is necessary to remember that at turning on of switches SA1 and SA2 of the electricdrive the body is automatically hauled down. Therefore, if adjusting works are carried out with the liftedbody the latter should be fixed by safety wire ropes.

Notes Requirements stated in paragraphs 2.5, 2.6 and 2.9 are to be carried out if no otherrequirements are stipulated in the present instruction.

3 Control of completing products of the traction electric drive prior tothe assembly of the dump truck

3.1 Each product which is a part of the traction electric drive should meet the

requirements of specification and complete set of the design documentation for this product.3.2 Traction motors and alternator

Traction motors and the alternator should pass incoming inspection according to process ofincoming inspection.


4/25

4

3.3 Installation of ventilated brake resistors

Installation of ventilated brake resistors should be tested according to the program and method7512-2126004 .

3.4 Cabinet with start-controlling equipment

3.4.1 Examine the cabinet with start-controlling equipment. On the equipment there should not bemechanical injuries and fasteners that are not torqued.

3.4.2 Check fastening and a condition of locks, sealing of doors. Locks should be reliably fixedand at closing doors there should not be grooves between door and the case of the cabinet.

3.4.3 Check completeness of the spare parts set according to the accompanying documents.

4 Description of adjustment process

4.1 Preparatory operations

4.1.1 Adjustment is made after acceptance of the cabinet with start-controlling equipment byQuality Department.

4.1.2 For realization of adjustment before mounting of the power cabinet on dump truck it isnecessary to connect the power supply 24 V (table 1, appendix A) plus terminal on carrier socket 3,

minus terminal on 4.4.1.3 Preparatory operations listed in 4.1.4, should be performed prior to each operation or

group of operations that are carried out according to several subsections of the present instruction.

4.1.4 Prior to each adjustment operation, carried out with open doors of the control cabinet it isnecessary to block make contacts of cabinet door interlock switches SA5, SA6 and SA7. After completionof operations unblock switches SA5, SA6 and SA7.

4.1.5 Measure by voltage meter PV3 (table 1, appendix A) voltage serially in the placesspecified in table 4.1.

Table 4.1 1 Voltages

Parameter Place of measurementDesired voltage

value, V

Supply voltage 1: 301, 0 24

Supply voltage1: 303, 0

150.2

4.1.6 During adjustment disconnect switch QF1 on dump truck. Put switches SA1 and SA2 inpositions (ON) and (Forward) accordingly.

4.2 Editing of protection set points and logic signals in function of rotational speed ofthe traction motor

For editing of protection set points and logic signals in function of rotational speed of the tractionmotor it is necessary:

- to connect special cable through COM port of the portable computer to connector XS5 on thecontrol cabinet or RS232 on the dash panel in the drivers cab;

- to start the program (AUTO VISUAL2)(Visualization for maintenance staff - AUTO VISUAL2) (see figure 1);

+6

4


5/25

5

Figure 1 Program (AUTO VISUAL2)(Visualization for maintenance staff - AUTO VISUAL2)

- section (Editing of parameters) in the field (Current parameter value) shows the value of the chosen factor in the controllersee figure 2;

Figure 2 Section (Editing of parameters)


6/25

6

- in order to choose a parameter for editing it is necessary to bring the mouse pointer to matchingwhite field and to push the left mouse button. After change of parameter press ENTER. If value of theentered parameter is beyond the necessary range a dialog box with the message about incorrect inputand necessary range will appear (see figure 3). Click OK;

- if value is true a dialog box with confirmation of the parameter change will appear forcontinuation it is necessary to move the mouse pointer to the necessary button: (Yes) to enter thevalue, (No) to exit, see figure 4;

- if the change is confirmed the value of parameter in the control unit will be rewritten;

- values of the entered parameters are specified in table 4.2 (in special cases change ofparameters for not more than 10 % is permitted), designations of abbreviation are specified in table 4.3.

Table 4.2 Values of the entered parameters

Designation

Parameters fordump trucks with

payload capacity120-125 tons





Units

.I 1450 1450 1870 A

.Ud1 1100 1200 1200 V

.Ud2 1100 1200 1200 V

Uyrb1 1100 1200 1200 V

Uyrb2 1100 1200 1200 V

Uym1 1100 1200 1200 V

Uym2 1100 1200 1200 V

Uopk1 650 650 650 V

Uopk2 650 650 650 V

.301 18 18 18 V

Uyd 325 325 325 V

Uydm 530 530 530 V

Uy 400 400 400 V

Uycdrb 325 325 325 V

OCON 95 78 62 Hz

OCOFF 92 72 56 Hz

Vmin1ON 50 33 22 Hz

Vmin1OFF 40 25 20 Hz

Vmin2ON 51 51 29 Hz

Vmin2OFF 49 49 27 Hz

Figure 3

(Incorrect range) dialog box

Figure 4 (Parameter Change) dialog box


7/25


8/25

8

Figure 5 Start of program StrimShell

4.3.4 At correct connection a dialog box (Controllersdata acquisition) should appear (see figure 6).

Figure 6 (Controllers data acquisition) dialogbox

4.3.5 Main dialog box of the program (see figure 7) incorporates:

- control console for opening/saving of working area file, start/stop of the system;

- set of indicators that represent the information that is transferred at present status via CAN.Each indicator has the name, according to its purpose. On indicators there are initial and final values ofthe scale, and also on some indicators there is a red zone which represents a zone of cut-off of the givenparameter;

- block of-02 controller;

- indicators of status;

- two blocks of controllers.


9/25

9

Figure 7 - Main dialog box of StrimShell

4.3.6 Move the mouse pointer to -01.1, press the right button of the mouse, choose (Parameters) option in the context menu (see figure 8).

Figure 8 Choosing (Parameters) option in StrimShell


10/25

10

4.3.7 In the dialog box (figure 9) move mouse pointer to (Load from ) button,press the left mouse button and choose a file with parameters depending on payload capacity of thedump truck (see figure 10).

Figure 9 Section (Parameters) in StrimShell

Figure 10 Choosing of a file with parameters depending on payload capacity of the dumptruck

4.3.8 Then click (Accept Values) button (see figure 9).

4.3.9 Repeat steps 4.3.6 - 4.3.8 for-01.2.

The parameters should match to the values specified in tables 4.4-4.7 (in the proved caseschange of parameters for no more 10 % is allowed).


11/25

11

Table 4.4 Parameters for dump trucks with payload capacity of 120-125 tonnes

Name, designation and units Values

Rotational speed of diesel engineN, RPM

700 900 1100 1300 1500 1700 1900

Power circuit current I, A 50 250 550 750 850 980 1200

Power rectifiers exit voltage U, V 140 260 380 500 640 810 950Power take-off P, kW 50 170 270 370 460 640 760

Restriction of exciting current indynamic braking modeIb, A

800

Restriction of brake resistorsvoltage Ub, V

910

Restriction of field reduction currentIop, A

420

Restriction of the maximum powercircuit current I., A

1200

Restriction of the maximum power

rectifiers exit voltage U, V

950

Voltage in dynamic braking modeU, V

910 910 910 910 910 910 910 765 660 580

Rotational speed of wheels N, Hz 20 25 30 40 50 60 70 80 90 100

Table 4.5 Parameters for dump trucks with payload capacity of 130-136 tonnes with -6


Rotational speed of dieselengine N, RPM

700 900 1100 1300 1500 1700 1900


Power rectifiers exit voltage U,

V

140 260 380 500 640 810 1000

Power take-off P, kW 50 170 270 370 460 640 1000


800

Restriction of brake resistorsvoltage Ub, V

840

Restriction of field reductioncurrent Iop, A

580

Restriction of the maximumpower circuit current I., A

1200

Restriction of the maximum

power rectifiers exit voltageU, V 1000

Voltage in dynamic brakingmode U, V

840 840 840 840 840 840 840 840 840 840

Rotational speed of wheels N,Hz

20 25 30 40 50 60 70 80 90 100


12/25

12

Table 4.6 Parameters for dump trucks with payload capacity of 130-136 tonnes with -420


Rotational speed of diesel engine N,RPM

700 900 1100 1300 1500 1700 1900


Power rectifiers exit voltage U, V 140 260 380 500 640 810 1000Power take-off P, kW 50 170 270 370 460 640 1000


800

Restriction of brake resistors voltageUb, V

840


580


1200

Restriction of the maximum power

rectifiers exit voltage U, V

1000

Voltage in dynamic braking mode U,V

840 840 840 840 840 840 840 765 660 580


Table 4.7 Parameters for dump trucks with payload capacity of 200-220 tonnes


Rotational speed of diesel engine N,RPM

700 900 1100 1300 1500 1700 1900


Power rectifiers exit voltage U, V 150 650 700 770 900 950 1000

Power take-off P, kW 50 230 420 750 1000 1330 1510Restriction of exciting current indynamic braking modeIb, A

1250

Restriction of brake resistors voltageUb, V

880


725


1700

Restriction of the maximum powerrectifiers exit voltage U, V

1000

Voltage in dynamic braking mode U,V

880 880 880 860 820 800 790 765 660 580


5 Control of the traction electric drive after assembly of the dump truckbefore start-up of the diesel engine

5.1 Before check of the condition of the traction electric drive install accumulator batteries ondump truck. Make sure that connection of power wires to electric machines and apparatuses is executedaccording to basic and assembly circuit diagrams.

5.2 Check absence of ectogenic subjects in the cabinet with electro apparatuses and make sure

that switches SA8 and SA9 are in position (OFF), switch QF2 is in position (OFF), andswitches SF1-SF3 are in position (ON). Block make contacts of door switches SA5, SA6 and SA7.

5.3 Turn the ground on and check sequence of actuation of the control equipment at turning on ofa traction and brake modes.


13/25

13

Notes if pneumatic contactors are installed in the cabinet it is necessary preliminary to inject airin the receiver of pneumatic system.

5.3.1 At installation of switches SA1 and SA2 in the position (ON) and (FORWARD) contactors KM4, 5 should switch on accordingly.

5.3.2 After pressing of movement pedal the following should switch on: contactors KM8, 9,then (with time limit from 0.5 up to 2 s) contactors KM1, 2. The indicator U--02 (Appendix B) onfront panel should switch on.

Release movement pedal. Contactors KM8, 9 and (with time limit from 0.5 up to 2 s)contactors KM1, 2 should be disconnected. Indicator U- -02 should be disconnected.

5.3.3 Press electric retardation pedal. Contactors KM4 and 5 should be switched off, andcontactors KM6-KM9, contactor KM3, solenoid valve YB1 (installed only on the dump trucks with dieselengine KTA-38) should switch on. Press movement pedal. Contactor KM3 should be disconnected.

Release both pedals. Contactors KM8, 9, solenoid valve YB1 should be disconnected. Withtime limit from 0.5 up to 2 s contactors KM6 and 7 should be disconnected, and contactors KM4, 5should switch on.

5.3.4 Install switches SA1, SA2 in a neutral position. Contactors KM4, 5 should bedisconnected.

5.3.5 Install switches SA1 and SA2 in positions (ON) and (REVERSE)accordingly. Contactors KM6, 7 should switch on.

5.3.6 Install switches SA1, SA2 in neutral position. Contactors KM6, 7 should bedisconnected.

5.3.7 Control of actuation of the equipment in the cabinet can be carried out from the panel of theoperator in diagnostic mode of code tables. To perform it press button F3 for programmed logic matrix 1(1) and button F4 for programmed logic matrix 2 (2) according to the tables 5.1 and 5.2.

Table 5.1 Identification of entries of a programmed logic matrix 1 (1) and logic signals1 Status of the movement controller

2 Status of the retardation controller

3 Status of speed restriction signal. 1 off, 0 on

5 Assignment of movement direction. 1 forward, 0 neutral, 2 reverse

6 Status of signal matching to turning on of any protection device. 1 off

8 Status of feedback signal of contactor KM8






14 Memory (programmed)15 Delay 1 (programmed)

16 Delay 2 (programmed)

1 Signal on turning on of contactor KM8

2 Signal on turning on of contactors KM1, 2



6 Memory

7 Delay 1

8 Delay 2


14/25

14

Table 5.2 Identification of entries of2 and logic signals

1 Status of speed restriction signal. 1 off, 0 on

2 Status of signal on formation of operating modes of field reduction





7 Status of signal matching to turning on of any protection device. 1 off8 Status of the retardation controller

9 Status of the movement controller 2 position

10 Feedback signal of contactor KM9

12 Movement direction

13 Memory

14 Control signal on turning on of contactor KM8

15 Control signal on turning on of contactor KM1

16 Delay 3

2 Signal on turning on of contactor KM3

3 Status of traction mode or forced electric retardation mode signal

4 Status of signal of running-out mode ()5 Status of separate excitation signal

6 Status of reverse protection signal

7 Status of field reduction signal

8 Delay 3

5.4 On the operators panel enter into diagnostic mode of code tables. Check status of logiclevels according to table 5.3

Table 5.3 Controlled logic levels

ParameterOperation which is

necessary for execution

before measurement

Place of the control Logic level

Control signalRUNNING-OUTMODE

2: 4 1

Control signalMOVEMENT MODE

1: 2 1


2: 4 0

Control signal of scaling

Press movement pedal againstthe stop

2: 3 1

____Release movement pedal

____ ___


2: 4 0Press electric retardation pedal

2: 5 1Control signalSEPARATEEXCITATION

HB

Press movement pedal 2: 5 0

Control signal

MOVEMENT MODE

Release pedals of an electric

retardation and a course 1: 2 0


15/25

15

The dialog box of programmed logic matrix () diagnostic is shown in figure 11

. 1 * * 1 0 : 4 4

* 1 * 2 * 3 * 4 * 5 * 6 * 7 * 8 * * 0 * 1 * 1 * * 2 * 0 * * 1 * * 0 * 0 * 0 * 0 * * 1 * 0 * 0 *

Figure 11 Dialog box of programmed logic matrix () diagnostic

5.5 Adjust the sensor of electro-dynamic braking pedal. On the operators panel enter intomonitoring mode by pressing button F8, with the help of transition buttons (F9 next, F12 previous)open dialog box 4 (see figure 12).

* * * * * 1 0 : 4 7U b c = . *

U z = . B U r s = . B

Figure 12 Dialog box of monitoring4

Make sure that indications Ubc are within the limits of 0 ... 60 degrees. At completely pushedpedal of electro-dynamic braking Ubc should match to value (0+2) degrees. At completely released pedal not below 60 degrees. If indications Ubc exceed specified limits make adjustment of the position anglesensor of the brake pedal. For adjustment it is necessary to turn at completely pushed pedal the case ofthe sensor concerning its shaft until indication Ubc is close to null.

6 Control of the traction electric drive of the dump truck after start-upof the diesel engine at the hung out driving wheels

6.1 Disconnect excitation circuit of the traction alternator by switch QF1. Install switch SA1 inposition (ON), and switch SA2 in position (FORWARD). Press movement pedaland achieve rotational speed of the crankshaft of the diesel engine of not more than 1200 RPM.

Make sure that wheels of the dump truck rotate in the same direction, providing movement of thedump truck forward. Release movement pedal. After a dead stop of wheels install switch SA2 in position (REVERSE). Press movement pedal and achieve rotational speed of the crankshaft of thediesel engine of not more than 1200 RPM. Make sure that wheels of the dump truck rotate in the samedirection, providing reverse movement of the dump truck. Release movement pedal.

6.2 Changing length of a tie-rod of the movement controller achieve turning on of circuits of thetraction electric drive at a rotational speed of the crankshaft of the diesel engine (900+100) RPM.

6.3 Press electric retardation pedal. The rotational speed of the crankshaft of the diesel engineshould increase up to (130010) RPM. For diesel engines with a mechanical regulator, at misfit of arotational speed adjust it changing length of a tie-rod of the executive pneumatic cylinder under a cab.Release electric retardation pedal, install switches SA1 and SA2 in neutral position.

6.4 Check functioning of rotational speed sensors of traction motors.

On the operators panel press button F8 to enter in the mode of monitoring. With the help ofbutton F9 choose the necessary dialog box (see figure 13).

* * * * * 1 0 : 4 4F b r 1 = 2 0 *F b r 2 = 2 0 N = 1 2 0 0 /


Install switch SA1 in position (ON) and switch SA2 in position (FORWARD). Press movement pedal and achieve rotational speed of the crankshaft of the diesel engine

of not more than 1200 RPM. Indications Fbr1 and Fbr2 should change.It is possible to make the check by other method. Connect voltage meter PV3 (appendix A) to

crimped locks (362 plus wire and 0 minus wire) on connecting panel XT1. Press movementpedal and achieve rotational speed of the crankshaft of the diesel engine (120050) RPM. The voltage


16/25

16

measured by voltage meter PV3 should be (12+3) V. Release movement pedal. Disconnect positivecrimped lock of voltage meter PV3 from a crimped lock 362 on connecting panel XT1 and connect it tocrimped lock 364. Press movement pedal and achieve rotational speed of the crankshaft of the dieselengine (120050) RPM. The voltage measured by voltage meter PV3 should be (12+3) V. Releasemovement pedal. Disconnect voltage meter PV3 from crimped locks 364 and 0.

Install switches SA1 and SA2 in a neutral position. Switch on switch QF1. Close doors of thepower cabinet. Shut down diesel engine.

Remove driving wheels of the dump truck from jambs.

7 Check of parameters of the traction electric drive

Over-all demands:

- check on sections of the given paragraph is to be carried out at origination of faults revealedduring running-in or maintenance of the dump truck;

- check of parameters of adjustment is to be carried out on braked dump truck at the workingdiesel engine if other is not stipulated separately;

- rotation frequency monitoring is performed with the help of tachometer installed on the dashpanel in cab;

- if hereinafter on any subitems of the given paragraph it is not possible to gain demanded valuesof parameters it is necessary to find fault, eliminate it and repeat check procedure;

- the operating time of the traction electric drive with currents above 1000 A should be no morethan 30 s, reclosing not less than through 10 minutes;

- for dump trucks with payload capacity of 220 tonnes accomplishment of item 7.2 is obligatory asvalue of an operating current differs from factory adjustment of the relay.

7.1 Check of functioning of the protection device at imitation of short circuit of powercircuit on the case of the dump truck

7.1.1. Open doors of the control cabinet. Install axis of resistor Assignment -02 in position

against the stop counter-clockwise, the switch on front panel of -02 in position (MANUAL), switch SA9 of block in position (ON).

Disconnect switch QF1. Connect one end of the jumper with cross-section from 0.35 to 0.5 mm2to the case, the second end to a wire 135 on relay KA1 in power cabinet. Switch on switch QF1.

7.1.2 Press movement pedal against the stop. Rotate an axis of resistor Assignment -02clockwise before reception of voltage UV8 controlled by means of the operators panel, matching valueUopK1 = UopK2 from table 4.2. Indicator (CASE) on the dash panel in operators cabshould switch on and on the operators panel should appear the message about the active protection.Check magnitude of voltage at which protection has operated is possible in the crash log. Viewing of thecrash log on the operators panel is carried out by means of button F6. Codes of protection are presentedin table 1 (Appendix B).

Install axis of resistor Assignment -02 in position against the stop counter-clockwise.

Release movement pedal. Press and release button F5 on the operators panel; indicator (CASE) should be disconnected.

7.1.3 Disconnect switch QF1. Disconnect jumper from a wire 135 and connect it to wire 149on contactor KM1. Switch on switch QF1. Repeat operations described in step 7.1.2. Controlled bymeans of the operators panel, voltage of power circuit UV7. Turning on of the protection device is to bedefined by turning on of indicator (CASE).

7.1.4 After process of regulating disconnect switch QF1, disconnect jumper from a wire 149and case. Install the switch on front panel -02 in position (AUTOMATIC), switch SA9 inposition (OFF). Switch on switch QF1. Close doors of the power cabinet.

7.2 Check of the protection device at excess of legitimate value of armature chaincurrent of traction motors M1 and 2 in traction mode

7.2.1 Disconnect switch QF1. Install the switch on front panel -02 in position (MANUAL). Connect by jumpers with cross-sections not less than 120 mm2 wires 103 and 104,106 and 135.


17/25

17

Disconnect protection on excess of admissible current of power circuit. To do that start theprogram (AUTO VISUAL2) (Visualization formaintenance staff - AUTO VISUAL2) (see paragraph 4.2) and in section (Editing of parameters) switch off I (see figure 2).

Switch on switch QF1.

7.2.2 Press movement pedal against the stop. Rotate an axis of resistor Assignment - -02clockwise.

At values of current specified in table 7.1 blinker of relay KA1 should operate and disconnectexcitation circuit of the traction alternator and power circuit.

Install axis of resistor Assignment - -02 in position against the stop counter-clockwise.Release movement pedal. Return blinker of relay KA1 in an initial point.

If operation of relay 1 has occurred at values of a current of power circuit mismatchingspecified in table 7.1, adjust the relay by change of tension of the return spring.

7.2.3 Disconnect switch QF1. Disconnect the first jumper from wire 135 and connect it to wire107. Disconnect the second jumper from wire 104 and connect it to wire 147. Switch on switchQF1.

Repeat operations described in step 7.2.2. Relay KA2 should switch on. Adjust if necessary.

Table 7.1Payload capacity of dumptrucks, tonnes

120-125 130-136 200-220

Value of operating current ofrelay 1, 2, A

1500+50 1500+50 1900+50

7.2.4 Disconnect switch QF1. Disconnect jumpers from wires 106 and 107, 103 and147. Install switch -02 in position (AUTOMATIC).

Switch on protection .I (figure 2).

Switch on switch QF1.

7.3 Check of functioning of the protection device at excess of legitimate value ofoutput voltage of rectifiers UZ1 or UZ2 in traction mode

7.3.1 Open doors of the power cabinet, disconnect switch QF1. In break of wire 149 oncontactor KM1 and wire 146 on contactor KM2 connect resistors R1 and R2 (appendix A) withresistance (10+5) kOhm and power not less than 100 W. At presence bus isolators QS1, QS3 installresistors instead of buses.

Switch on switch QF1. Install the switch -02 on the front panel in position (MANUAL), and resistor Assignment -02 in position against the stop counter-clockwise.Disconnect protection Urb1, Urb2, Um1, Um2 in section (Editing of parameters) of program (AUTO VISUAL2) (Visualization for maintenance staff - AUTO VISUAL2) (see figure 2).

7.3.2 Press movement pedal against the stop. Rotate resistor Assignment -02 clockwise.At a voltage .Ud1 = .Ud2 (see table 4.2) controlled by means of the operators panel

UV1 and UV2, protection should turn on and indicator (PROTECTION) should also switchon, message on the operators panel confirming this protection should appear, excitation circuit of thetraction alternator and power circuit should break.

After disconnection of excitation circuit of the traction alternator and power circuit the voltageshould become equal to null.

Install resistor Assignment -02 in position against the stop counter-clockwise. Releasemovement pedal.

Press and release button F5 on the operators panel for reset of protection and indication on theoperators panel.

7.3.3 After check activate the disconnected protections. Install the switch on front panel -02

in position (AUTOMATIC). Disconnect switch QF1. Disconnect resistors R1 and R2 and reconnectwires 146 and 149. Switch on switch QF1. Close doors of the control cabinet.


18/25

18

7.4 Check of functioning of the protection device at excess of admissible current ofloading of rectifiers UZ1 and UZ2 in traction mode on the limiting characteristic

7.4.1 Install the toggle switch on front panel -02 in position (MANUAL), and resistorAssignment -02 in position against the stop counter-clockwise. Disconnect switch QF1. Connectby jumpers with cross-section of not less than 120 mm2 wires 103 and 104, 106 and 107.Switch on switch QF1.

7.4.2 Press movement pedal against the stop. Rotate axis of resistor Assignment -02clockwise. At value of current .I (see table 4.2), controlled by means of the operators panel U1,should switch on indicator (PROTECTION) and message on the operators panel, excitationcircuit of the traction alternator and power circuit should open.

Install axis of resistor Assignment -02 in an initial point. Release movement pedal. Pressand release button F5 on the operators panel. Indicator (PROTECTION) and message onthe operators panel should be switched off.

7.4.3 Install the toggle switch on front panel -02 in position (AUTOMATIC).Disconnect switch QF1. Disconnect jumpers 103 and 104, 106 and 107. Switch on switch QF1.Close doors of the control cabinet.

7.5 Check of functioning of the protection device at imitation of the electromotor-wheels skidding

7.5.1 Disconnect switch QF1. In break of circuit 135 connect technological resistor withresistance (10+5) kOhm and power of not less than 100 W. Switch on switch QF1.

Disconnect protection Ud in section (Editing ofparameters) of program (AUTO VISUAL2)(Visualization for maintenance staff - AUTO VISUAL2) (see figure 2).

Install the switch on front panel -02 in position (MANUAL), and resistorAssignment -02 in position against the stop counter-clockwise.

7.5.2 Press movement pedal against the stop. Rotate an axis of resistor Assignment -02clockwise.

At value of voltage Udm (see table 4.2), controlled on the operators panel UV5, indicator (PROTECTION) and the message on the operators panel should switch on, excitation circuitand power circuit should open.

Install axis of resistor Assignment -02 against the stop counter-clockwise. Releasemovement pedal. Press and release button F5. Indicator (PROTECTION) and the messageon the operators panel should be switched off.

7.5.3 Disconnect switch QF1. Rebuild circuit 135.

In break of circuit 147 connect the technological resistor with resistance (10+5) kOhm andpower of not less than 100 W. Switch on switch QF1.

Repeat operations described in step 7.5.2. The voltage of power circuit is controlled by UV6 onthe operators panel.

7.5.4 Activate protection Ud. Install the switch on front panel -02 in position (AUTOMATIC). Disconnect switch QF1. Rebuild circuit 147. Switch on switch QF1. Close doors of thepower cabinet.

7.6 Check of functioning of the protection device at excess legitimate value of voltageon armature chain of traction motors 1 and 2 in a traction mode

7.6.1. Disconnect switch QF1. Disconnect wire 149 from contactor KM1. Switch on switch QF1.

Disconnect protection .Ud1, .Ud2, rb1, rb2 in section (Editing of parameters) of program (AUTO VISUAL2) (Visualization for maintenance staff - AUTO VISUAL2).

Install the switch on front panel -02 in position (MANUAL), and resistor

Assignment -02 in position against the stop counter-clockwise.7.6.2. Press movement pedal against the stop. Rotate axis of resistor Assignment -02

clockwise.


19/25

19

At value of voltage Um1 = Um2 (see table 4.2), controlled by means of the operatorspanel UV5, indicator (PROTECTION) and the message on the operators panel shouldswitch on, excitation circuit of the traction alternator and power circuit should open.

Install axis of resistor Assignment -02 in position against the stop counter-clockwise.Release movement pedal. Press and release button F5. Indicator (PROTECTION) shouldswitch off.

7.6.3 Disconnect switch QF1. Install wire 149 in its place. Disconnect wire 146 from

contactor KM2. Switch on switch QF1.Repeat operations described in step 7.6.2. Controlled voltage of power circuit UV6.

7.6.4 Activate protection .Ud1, .Ud2, rb1, rb2.

Install the switch on front panel -02 in position (AUTOMATIC). Disconnect switchQF1. Install wire 146 in its place. Switch on switch QF1. Close doors of the control cabinet.

7.7 Check of functioning of the protection device at imitation of short circuit on entry(exit) of power rectifier UZ1 or UZ2, or puncture of the valve in one of branches of rectifier bridges

7.7.1 Install switch SA9 of block in position (ON), switch on front panel -02 inposition (MANUAL), and resistor Assignment -02 in position against the stop counter-

clockwise. Disconnect switch QF1. Disconnect 107 wire on terminal block XT5 and isolate it. Switch onswitch QF1.

7.7.2 Press movement pedal and install nominal rotational speed of the diesel engine. Rotate axisof resistor Assignment -02 clockwise. At value of voltage Ud (see paragraph 5.3.7),controlled by means of the operators panel UV2, indicator (PROTECTION) and message onthe operators panel should switch on, excitation circuit of the traction alternator and power circuit shouldopen.

Install axis of resistor Assignment -02 in position against the stop counter-clockwise.Release movement pedal. Press and release button F5. Indicator (PROTECTION) shouldswitch off.

7.7.3 Disconnect switch QF1. Rebuild circuit 107. Disconnect 104 wire on terminal blockXT5 and isolate it. Switch on switch QF1. Repeat operations described in step 7.7.2.

7.7.4 Disconnect switch QF1. Rebuild circuit of wire 104. Switch on switch QF1. Install theswitch on front panel -02 in position (AUTOMATIC), switch SA9 in position (OFF).Close doors of the power cabinet.

7.8 Check of functioning of the device forming logic control signals by the tractionelectric drive in function of rotational speed of traction motors

7.8.1 Disconnect from crimped locks 2 of the power cabinet wires 362 and 364 going onsensors of rotational speed of traction motors M1 and 2 accordingly.

Connect to crimped locks XT2:362 and XT2:0 the signal generator (appendix A). Install onexit of the signal generator the minimal value of frequency.

7.8.2 Press movement pedal against the stop.Increase frequency of the signal generator. At frequency Vmin1ON according to table 4.2, the

signal of field reduction () =1 (see table 5.2) should be generated. It corresponds to formation of thelogic signal allowing switching of the traction electric drive from operating mode with full field of tractionmotors into the mode of smooth field reduction.

7.8.3 Continue to increase frequency of the signal generator. At frequency OCON according totable 4.2 the indicator for restriction of speed (OC) should switch on. There should be switching of thetraction electric drive from traction mode in brake mode. It corresponds to automatic transition of thetraction electric drive in the mode of electro-dynamic braking in case of excess of admissible speed ofmovement of the dump truck.

7.8.4 Reduce frequency of the signal generator. At frequency OCOFF according to table 4.2,the OC indicator should be switched off. Thus there should be an automatic switching from mode of

electro-dynamic braking in running-out mode. Release movement pedal.7.8.5 Press against the stop electro-dynamic braking pedal. Reduce frequency of the signal

generator. At frequency Vmin2ON according to table 4.2, contactor KM3 should switch on. Itcorresponds to switching of the traction electric drive in mode of separate excitation of traction motors at


20/25


21/25

21

7.11 Check of the channel of restriction of output voltage of rectifier UZ1 or UZ2 intraction mode

7.11.1 Open doors of the power cabinet, disconnect switch QF1. In break of wire 149 oncontactor KM1 and wire 146 on contactor KM2 connect resistors R1 and R2 (Appendix A) withresistance of (10+5) kOhm and power of not less than 100 W. At presence bus isolators QS1 and QS3install resistors instead of buses. Switch on switch QF1.

7.11.2 Press movement pedal and achieve nominal rotational speed of the diesel engine.

Values of the voltage controlled by means of the operators panel UV1 and UV2, should beU. (Restriction of the maximum voltage on exit of the power rectifier) (see tables 4.4 4.7).

7.11.3 Disconnect switch QF1. Disconnect resistors R1 and R2 and rebuild circuits 149 and146. At presence of disconnectors QS1 and QS3 disconnect resistors and install bus isolators QS1 andQS3 in position 1-2. Switch on switch QF1. Close doors of the control cabinet.

7.12 Check of the maximum loading current of rectifiers UZ1 and UZ2 in traction mode

7.12.1 Disconnect switch QF1. Connect by jumpers with cross-section not less than 120 mm2wires 103 and 104, 106 and 107. Switch on switch QF1.

7.12.2 Press movement pedal and achieve nominal rotational speed of the diesel engine.

Value of the current controlled by means of the operators panel U1, should be equal I.(restriction of the maximum current in power circuit) (see tables 4.4 4.7).

Release movement pedal.

7.12.3 Disconnect switch QF1. Disconnect the jumpers connecting wires 103 and 104,106 and 107. Switch on switch QF1.

Close doors of the control cabinet.

7.13 Check of the channel of restriction of power on exit of rectifiers UZ1 and UZ2 intraction mode

7.13.1. Install switch SA9 of block in position (ON). On the operators panel pressbutton F8 to enter into monitoring mode, with the help of transition buttons (F9 next, F12 previous)open dialog box 2 (see figure 14).

* * * * * 1 0 : 4 7U V 5 = x x x x B = U V 6 = x x x x B *

U A 1 = x x A P = x B


Press movement pedal and achieve rotational speed of the crankshaft of the diesel engine equal

to nominal.Value of power on exit of power rectifiers UZ1 and UZ2 is controlled by value P in the open dialog

box of the operators panel.

Release movement pedal.

Install switch SA9 in position . (OFF). Close doors of the control cabinet.

Notes in order to prevent falling out of installation of ventilated brake resistors 2600 theoperating time of the traction electric drive in the given mode should be no more than 30 s, a reclosing not less than through 10 minutes For longer time of measurement it is recommended connect the sameinstallation (wires 149, 106 and 146, 102) in parallel to installation .

7.14 Check of the max exciting current of traction motors in electronic braking mode

Before the beginning of check it is necessary to make sure that works on adjustment of theposition angle sensor of electro-dynamic brake pedal according to paragraph 5.5 were carried out.


22/25

22

Smoothly press electric retardation pedal against the stop. The rotational speed of the crankshaftof the diesel engine should increase up to (1300+10) RPM.

The exciting current of traction motors measured on the operators panel U1 should changefrom the initial value which should not exceed 100-200 to limiting value that is equal to Ib (see tables4.4-4.7.)

Release electric retardation pedal.

7.15 Check of restriction of voltage (current) of brake resistor RB1.1 or RB1.2 in electro-dynamic retardation mode

7.15.1 Disconnect switch QF1. Connect by jumper with cross-section of not less than 120 mm2wires 102 and 147, 106 and 135. Switch on switch QF1.

7.15.2 Press against the stop electric retardation pedal and movement pedal. Value of the voltagecontrolled by means of the operators panel UV3 and value of the current controlled by means of theoperators panel U1 should match to the values specified in table 7.2. The voltage controlled by meansof the operators panel UV4 should be equal to null.

able 7.2 Values of voltage and current on brake resistors in electro-dynamic

retardation modeResistance of the brake resistor,

OhmThe voltage measured by

voltage meter UV3, VThe current measured by

ammeter UA1, A

1.4 91035 65025

1.05 84035 80025

0.7 88035 125025

Release movement pedal and electric retardation pedal.

7.15.3 Disconnect QF1. Disconnect the jumpers connecting wires 102 and147, 106 and 135. Switch on switch QF1. Close doors of the control cabinet.

7.16 Check of restriction of voltage (current) of traction motors in electro-dynamicretardation mode on conditions of their commutation

7.16.1. Disconnect from terminal block 1 wire 362 going to sensor BR1 of rotational speedof electric motor M1. Connect to crimped lock 1:362 and XT1:0 plus and minus terminals of thesignal generator (Appendix A) accordingly. Install on exit of the signal generator the minimal value offrequency.

7.16.2 Disconnect switch QF1. Connect by jumpers with cross-section of not less than 120 mm2wires 102 and 147, 106 and 135. Switch on switch QF1.

7.16.3 Press against the stop electric retardation pedal and movement pedal. Smoothly changingfrequency of the signal generator make sure that value of the voltage controlled by means of theoperators panel UV3 matches the value specified in tables 4.4-4.7 (voltage of brake installation in

electro-dynamic braking mode).The voltage controlled by means of the operators panel UV4 should be equal to null.

Release movement pedal and electric retardation pedal. Reduce frequency of the signalgenerator to null.

7.16.5 Disconnect the signal generator and frequency meter from a crimped lock 1:362 andconnect them to a crimped lock 1:364. Repeat check on described in step7.16.3.

7.16.6 Disconnect switch QF1. Disconnect the jumpers connecting wires 102 and 147,106 and 135. Switch on switch QF1.

Disconnect the signal generator and frequency meter from crimped locks 1:364 and1:0. Connect wires 362, 364 on matching places to crimped locks 1. Close doors of thecontrol cabinet.


23/25

23

APPENDIX A(obligatory)

Table.1 List of the equipment necessary for adjustment of the traction electric drive

NameIdentificatio

n code

Accuracy

rating

Designation of the

standard

Type

DC multilimiting voltage meter0,015 600 V

PV3 0.5 GOST8711-93 1106

Low-frequency signal generator 10 100 Hz

2.5 3.268.039 3-112/1

DC ammeter 0 1 k PA2 1.5 25-04.1.4058 42300

Megaohmmeter 15 25-7534.014-90 0202

Resistor R1, R2 .467.551 5-35-100-10

kOhm

Additional resistance 25-04.40413033,1 kV, 5 m

Power supply 2.5.318572.002

786,4

Notes:

1 Replacement of measuring devices under is admitted only if demanded measuring range and accuracyrating is observed.

2 Instead of resistor5-35-100-10 kOhm application of the resistor of other type with resistance from10 to 15 kOhm and power of not less than 100 W is permitted.


24/25

24

APPENDIX B(obligatory)

Table B.1 List of indicators and diagnostic connectors

Designation

Block Point

The name of controlled signal (parameter)

CAN Indication of CAN work

+5 V Presence of voltage +5 V

U Indication of control pulse UTRB

V Field reduction

Work

-02

+15 V Presence of supply voltage +15 V

0U Over-all

+15 V Voltage control +15 V

OUT1 Control pulses (galvanically not untied) VS6


3.2

3


0U Over-all

VC0



UPR1 Permission VS4

-1.2

UPR2 Permission VS5

1 Input assignment

2 Synchronization of exit

3 Exit

4 Exit UTRB

5 Manual control

6

7 Over-all

8 +5 V

-02

9


25/25

APPENDIX B(recommended)

able B.1 Codes of protection

Crash

code

Designation Explanation

001 Urs1_zProtection on excess of admissible current of loading ofrectifiers Uz1, Uz2

002 Ud1_zProtection on excess of legitimate value of output voltage onrectifier Uz1

003 Ud2_zProtection on excess of legitimate value of output voltage onrectifier Uz2

004 dUm_zProtection on excess of difference of voltage on tractionmotors

005 dUd_zProtection on excess of difference of voltage on powerrectifiers

006 Urs_zh Protection on current on the partial characteristic

007 Urb1_z

Protection on excess of legitimate value of voltage on brake

resistor Rb1

008 Urb2_zProtection on excess of legitimate value of voltage on brakeresistor Rb2

009 Um1_zProtection on excess of legitimate value of voltage on tractionmotor M1

010 Um2_zProtection on excess of legitimate value of voltage on tractionmotor M2

011 Uzr_z Protection at the forced retardation

012 Thermal protection Rk1

013 Breakage of circuit of thermal sensor Rk1

014 in circuit of thermal sensor Rk1


016 Breakage of circuit of thermal sensor Rk2017 in circuit of thermal sensor Rk2







024 Uk1_z Protection on the case

025 Uk2_z Protection on the case

026 dUrb_z Excess of admissible difference of voltage on brake resistors

027 Us Restriction of speed

028 .301 Reduction of supply to the cabinet up to 18V

Documents

Traction Electric Drive-Eng