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Electrotorque Plus®
TEST PROCEDURE
1. GENERAL
The following test procedure provides a guide for the
inspection and adjustment of the electrical systems
used on Harnischfeger ELECTROTORQUE-PLUS
mining excavators. This is the procedure to be followed
to obtain the required test data and to insure accurate
test documentation.
1.1 The test procedure is written in a step-by-
step sequence which should be followed dur-
ing the commissioning process.
1.2 The control tests for each machine motion
(hoist/propel, crowd/propel, or swing) are
usually sufficiently redundant to allow tests
to be made for troubleshooting purposes
without starting at the beginning of the
entire test procedure.
1.3 The test procedure with proper interpreta-
tion can be used for shop tests at the factory,
commissioning tests when the machine is
started at the customer's site, start-up after
troubleshooting or replacement of electrical
components, and testing of the control and
converter equipment when the entire elec-
trical system is not complete.
1.4 The proper schematic diagrams should be
utilized and consulted frequently for all
testing procedures.
Certain procedures require working on
live circuits. Proper CAUTION should
be observed at all times.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
2. TEST EQUIPMENT
2.1 A digital multimeter, oscilloscope, two-chan-
nel chart recorder, clamp-on ammeter, meg-
ger, and laptop PC are required to do the
electrical tests outlined in this test proce-
dure. This same equipment should also be
considered as essential for field testing or
troubleshooting.
2.2 The shop tests and start-up tests require
additional equipment to aid in performing
the necessary tests and to provide the nec-
essary test information.
2.2.1 A laptop PC with Rockwell PLC communica-
tions hardware and software is required to com-
municate with the on-board Programmable
Logic Controller.
2.2.2 A Push-button/Reference Unit is recommended
to simplify control of the individual motions dur-
ing testing. See Figure 2.2.2 in Appendix B.
2.2.3 A large resistor, 12.5 ohm 6000 watt, is
required to limit the armature current during
the start-up of each converter. See Figure 2.2.3
in Appendix B.
2.2.4 For testing the Reactive Power Compensation,
a capacitor unit, as shown in Figure 2.2.4, is
required as a test load. See Figure 2.2.4 in
Appendix B.
2.2.5 A voltage divider, such as the one shown in Fig-
ure 2.2.5, should be used to aid in making high
voltage measurements on the RPC. See Figure
2.2.5 in Appendix B.
2.2.6 A 15A, 600V, molded case circuit breaker with
#12 wire connected to 1 pole should be used as a
shorting switch for ground fault checks.
2.2.7 Miscellaneous test leads, probes, clips, cables,
auxiliary push-buttons, switches, sealing lac-
quer, etc. should be available.
1 TEST PROCEDURE
Return to Index
Electrotorque Plus®
2.3 See Appendix A showing a list of recom-
mended test equipment.
3. VISUAL INSPECTION
3.1 Check that all electrical connections are
tight and that the wiring is properly bun-
dled and secured.
3.1.1 Check that the proper leads are connected to
the respective coil terminals on the main, auxil-
iary, field, lighting etc. transformers and that
the primaries are connected for the correct oper-
ating and test voltage.
3.1.2 Check that the connections to the dc buswork
on the bottom of the thyristor cabinet are tight
and do not rub against any sharp edges.
3.1.3 Check that all overhead bus bar connections
are tight and that the proper joint compound,
such as Alcoa No. 2 Electrical Joint Compound
has been used.
3.1.4 Check that the connections to all dc motors are
properly made and that all motor brushes are in
place with the brush springs properly secured.
3.2 Check the electrical cabinets to assure that
all components are properly mounted and
secure.
3.2.1 Plug-in relays should be secured with a hold
down spring or clamp.
3.2.2 Check that the thermal overload elements on
the auxiliaries circuits are of the specified size
and that the trip adjustments are set at the
specified setting, on the motor starters.
3.2.3 Check the thermal overload relays on the dc
motor circuits, and that the overload elements
are of the specified size.
3.2.4 Check all major components of feedback and
metering circuits for proper components.
3.2.5 Check the oil level in the lubrication system.
3.2.6 Check that all dc motor brakes are properly
adjusted and operable.
TEST PROCEDURE
3.2.7 Check that all plug type connectors are
installed and locked in position. A loose locking
feel on the quarter turn connectors may indicate
the absence of the sealing o-ring.
4. CONTINUITY TESTS
4.1 When checking circuits containing
semiconductors, devices such as bells or buzzers
should not be used because of possible voltage
surges developed by these devices. Instead, a
DVM, continuity tester, ohmmeter, or lamp should
be used.
4.2 The entire system wiring must be checked
and compared to the schematic diagrams
for that particular system.
4.3 Polarities on all dc circuits should be care-
fully noted.
5. GROUND CHECKS
5.1 The power transformers have a resistance ground
system connected from the secondary neutrals to
the shovel frame. Any circuit connected to the
transformers secondaries will have a resistance to
ground of approximately 250-500 ohms, therefore,
it is necessary to isolate the transformer neutrals
to make ground checks.
NOTICE
When checking connections on the trans-
former secondaries, two leads must be dis-
connected from the transformer to avoid
reading from phase to phase through the low
resistance transformer windings.
This check may also be made before the transformer
secondaries are wired.
All transformers with high voltage primaries should
be “Megger” checked before high voltage is applied.
The check should be performed immediately prior to
placing the transformer into service.
Before using the Megger, the primary and secondary
must be completely disconnected from all external con-
nections. A 1000V Megger with a 2000 megohm scale
is recommended. Readings should be taken between
Copyright © 1999 Harnischfeger Corporation
2 CAT312.fm
Return to Index
the low voltage winding and ground, low voltage and
high voltage windings, and high voltage winding and
ground.
A value of 1000 megohms or one half the factory test
values, as posted on the interior of the transformer,
should be considered as the minimum obtained levels
before the unit is energized. If a Megger test card is
not available, all transformers, in general, must test to
a minimum level of 500 Megohms.
A reading of less than 500 megohms indicates mois-
ture or contamination. A proper clean-up procedure
and dry out procedure must be initiated to bring the
resistance levels above 500 megohms. Refer to P&H
Service Bulletins for proper procedures.
NOTICE
If over potential tests are made, they must be
limited to 75% of the factory test, for a dura-
tion not to exceed 1 minute. Leakage must be
controlled or monitored to prevent complete
breakover, tracking, etc., which will destroy
the transformer. Megger checks must always
be done prior to any over potential testing.
5.2 Circuits separated from the secondaries will
have normal readings to the frame.
5.2.1 500,000 ohms is considered as a low isolation
resistance for average climatic conditions on the
low voltage circuits.
5.2.2 Extreme CAUTION should be observed in the
use of the Megger.
5.3 Proceed now with a systematic ground
check of all voltage systems and electrical
equipment.
5.4 All dc motor armatures should be checked
using a 500V Megger. Readings should be
in excess of 2 megohms. All leads directly
connected to the motor must be discon-
nected prior to the Megger check.
A reading of less than 2 megohms indicates
moisture or contamination. A proper clean-
up procedure and dry-out procedure must
be initiated to bring the resistance level
above 2 megohms.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
6. TRANSFORMER VOLTAGE AND PHASE
SEQUENCE CHECKS
The tail cable must be disconnected
from the machine during the following
low voltage tests.
6.1 The phase sequence relationship between
the main transformer, auxiliaries and field
secondary windings must be correct. For ini-
tial start-ups, a preliminary check-out of
voltages, phasing and possible ground
faults should be done by applying low volt-
age to the transformer primaries according
to the following procedure.
6.1.1 Open all circuit breakers on the main trans-
former, auxiliaries and field secondaries to iso-
late the secondaries from any loads.
6.1.2 Short across the open power contacts on the
high voltage vacuum contactor.
6.1.3 Short the neutral terminals on the ground fault
circuits together for the main, auxiliaries and
field transformer secondaries.
6.2 TRANSFORMER VOLTAGES.
6.2.1 Apply a 3 phase test voltage to the main pri-
mary transformer and the auxiliaries and field
primaries. The test voltage should not exceed
600V.
6.2.2 Measure the secondary voltages and record the
voltage readings on the test data sheet for the
indicated test points.
6.2.3 The following formula is used to determine the
voltages to be measured on the transformer sec-
ondaries when a low test voltage is applied to
the primary:
VSEC = (VS rated / VP rated ) x VPRI
3 TEST PROCEDURE
Electrotorque Plus®

Where: 6.3.5 Compare the measured readings to the values

determined using the calculation of step 6.3.4
VS rated = nameplate rated secondary volts These values should not vary more than +/–5%.

VP rated = nameplate rated primary voltage (OPTIONAL TEST)

VSEC = voltage measured at the secondary terminals
6.3.6 (OPTIONAL TEST) A more extensive test to
VPRI = voltage applied to the primary terminals determine the transformer phase relationship
can be made using a two channel oscilloscope.
Example:
VP rated = transformer connected for 4160VAC • 6.3.6.1 Set the trigger mode to LINE.

VS rated = 600VAC • 6.3.6.2 Make sure that the chassis of the

oscilloscope is isolated from the frame of the
VPRI = 460VAC machine, and that the AC line connection to the
VSEC = (VS rated / VP rated ) x VPRI oscilloscope is not grounded.

= 600 / 4160 x 460 = 66VAC • 6.3.6.3 Measure the phase displacement of two
secondary voltages; say A1 - B1 to C1 - B1 by
connecting the ground leads to B1, Channel A to
6.3 TRANSFORMER PHASE RELATION.
A1, and Channel B to C1. See the transformer
connections of Figure 6.3.6.3.
6.3.1 The phase relationship between the main
transformer, auxiliaries and field secondaries is
checked by measuring the voltage difference
between corresponding phases of each trans-
former.

6.3.2 Check that the transformer neutrals are

shorted together for this test.

6.3.3 Record the voltage readings on the test data

sheet for the indicated test points.

6.3.4 To determine the correct voltage difference

between transformer phases, use the formula
found in step 6.2.3 to find the secondary volt-
ages with the test voltage on the primary, then
use this formula:
Vdiff = (Vsec1 - Vsec2) / 1.732
Example:
Figure 6.3.6.3 Transformer Connections
• 6.3.6.4 Compare the pattern of the waveforms
from one transformer secondary to that of the
other taking care to connect the oscilloscope the
same on comparable terminals, i.e. probe on A1,
ground on B1, probe on A2, ground on B2, etc.

Vsec1 (main xfmr) = 66V • 6.3.6.5 Voltages of like phases should give a trace
of the same position on the screen. See waveforms
Vsec2 (aux. xfmr) = 51V of Figure 6.3.6.5.

Vdiff = (66 - 51) / 1.732 = 8.7V

This is the voltage that should be measured between

the corresponding phases of the auxiliaries and main
transformer secondaries.

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 4 CAT312.fm
Return to Index
Figure 6.3.6.5 Waveforms
6.3.7 Remove shorting leads from high voltage con-
tactor and from the transformer neutral termi-
nals and reconnect the neutrals to the ground
fault circuits.
7. HIGH VOLTAGE TO TRANSFORMER
PRIMARIES
Double check Step 6.3.7. Notify and
warn personnel, and observe all safety
precautions prior to applying high volt-
age.
7.1 Check that all circuit breakers on the auxil-
iaries and field secondaries are open to iso-
late the loads. Open the main transformer
disconnect switch.
7.2 Set the test selector switch to CONTROL
TEST position.
7.3 Check that the main air disconnect switch
in the high voltage cabinet is closed.
7.4 Apply rated high voltage power to the
machine and check that the auxiliaries and
field transformer is energized.
7.5 Measure the following voltages on the line
side of the respective circuit breakers:
(Refer to the schematics for all supplies.)
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
1. All Auxiliary Supplies
2. Control Supply
3. Relay Supply
4. Field Supplies
5. Lower Control Supply
6. Lighting Supply
7. Heater Supplies, etc.
Record these readings on the test data sheet.
NOTICE
When the capacitors on the main trans-
former secondaries are energized, the supply
voltage will tend to rise, causing the above
voltages to read proportionately higher.
8. CONTROL SUPPLY VOLTAGES
8.1 Verify that the disconnect switch connected
to the primary of the main transformer is
open.
8.1.1 Check that the test selector switch is set to
CONTROL TEST.
8.1.2 Open the relay and control supply circuit
breakers (RSCB, CSB), and the breaker supply-
ing 120VAC to the PLC power supply.
8.1.3 Open the circuit to each capacitor charging
relay coil at the diverter circuit terminal board
for each motion.
8.1.4 Use an ohmmeter to check each PLC input and
each PLC output for shorts to machinery house
ground (01021G). If any input or output is
grounded, troubleshoot and remove the ground
before applying power to any of the I/O circuits.
8.2 120V Main Supply: 120V (60Hz) - 110V
(50Hz)
8.2.1 If a separate lighting supply transformer is
used, close its primary supply circuit breaker.
8.2.2 Close the lighting supply breakers. Check for
proper operation of the various lighting circuits.
8.2.3 Close the 120V (110V) main circuit breaker
(MB). Measure the 120V main supply.
5 TEST PROCEDURE
Electrotorque Plus®

8.2.4 Verify that the PLC is properly wired for a ify proper communication between the PLC
120V supply. Close the branch circuit breaker and operator touch screens.
supplying the PLC constant voltage supply
(CVSB). Measure the PLC CVS supply and ver- 8.7 PLC INPUTS VERIFICATION.
ify that the power on indicator is lit on the PLC
power supplies. Confirm that power is being
Use the PLC I/O screen on the GUI to access the PLC
supplied to the control cabinet touch screen com-
input screens.
puter and the operator’s cab touch screen panel.
8.7.1 Refer to the schematics and data sheets as a
8.2.5 Close the 120V lower control cabinet supply cir-
guide to verifying the various PLC inputs. Actu-
cuit breaker (LSB). Measure the 120V lower
ate each input switch, push- button, etc., or sim-
supply.
ulate actuation of the input component or
device. Check for proper status indication on the
8.2.6 Close the dc contactor supply circuit breaker
touchscreen GUI.
(DCSB). Measure the dc contactor supply.
8.7.2 Verify each of the inputs on the first PLC input
8.2.7 Verify the level of all the ac and dc circuits sup- module. Repeat this procedure for each PLC
plied by the 120V branches. (Use your machine input module.
schematics as a guide).

8.2.8 Check the functions of each of the 120V devices 8.8 PLC OUTPUTS VERIFICATION.
supplied by the individual branch circuit break-
ers. (heaters, dc contactors, etc.)

8.3 120V RELAY SUPPLY When outputs are forced on, the con-
nected device will energize. Double
8.3.1 Close the relay supply circuit breaker (RSCB). check that the test selector switch is set
Measure the 120VAC supply. to the CONTROL TEST position, and the
high voltage disconnect switch is open.
Check that the master control relay (MCR) picks up The machine and motions should be at
when all of the emergency stop push-buttons are rest and not loaded i.e., no hoist ropes,
pulled out, and that MCR drops out when any one no handles, machine on level ground. If
emergency stop push-button is pressed. an output cannot be energized safely,
disconnect the output device and check
for actuation with a 120V test lamp.
8.4 230V CONTROL SUPPLY
Make sure the ground checks called for in Step 8.1.4
8.4.1 Close the 230V supply breaker (SB), and the
have been completed.
control supply breaker. (CSB)
8.8.1 Refer to the schematics and data sheets as a
Measure the 230V control supply.
guide to verifying the various PLC outputs.
Output verification is done by forcing an indi-
8.4.2 Measure the 28VDC diverter power supply.
vidual PLC output address using a laptop PC
and checking for the proper hardware response.
8.4.3 Measure both 120V kVAR transducer supplies.
8.8.2 Verify each of the outputs on the first PLC out-
8.4.4 Close the 120V constant voltage supply breaker
put module, by forcing each of the individual
(CVMSB). Measure the 120V C.V.S. supply.
PLC output addresses either on or off as
required. Repeat this procedure for each PLC
8.5 Check the schematics for all optional equip- output module.
ment and verify their operation.
8.8.3 When finished with PLC outputs verification
8.6 With the 120V main supply breaker (MB), remove all forces!
and PLC supply breaker (CVSB) closed, ver-

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 6 CAT312.fm
Return to Index
Electrotorque Plus®

8.9 If a complete machine commissioning is to 8.12.10 Increase the swing reference to full positive
be performed, install a Reference/ Push-but- (+). Check that the swing operator’s reference
ton Unit at this time. Reference Figure 2.2.2 analog input and output respond correctly as
in Appendix B. seen on the GUI screens.

8.12.11 Repeat with the swing reference set to full

8.10 Close the suppression circuit breakers on
negative (–).
the suppression/capacitor monitor cabinet.
Close the RPC, auxiliary, and lower control 8.12.12 Set the swing brake. Press the STOP push-
cabinet breakers. button.

8.11 Check the crowd/propel transfer circuits.
8.11.1 Press the START push-button.
8.11.2 Alternately press the PROPEL and HOIST/
CROWD push-buttons and check that the arma-
ture and field contactors in transfer cabinet
operate.
8.11.3 Press the STOP push-button.
8.12.13 Again, using the analog I/O screens on the
GUI, check the dc motor and bearing tempera-
ture monitoring. These RTD measurements
should read ambient temperatures at this time.
8.13 Check that the trip settings on the following
circuit breakers are adjusted to indicated
settings (if adjustable):
Circuit Breaker Setting

8.12 PLC ANALOG I/O CHECKS. RPC Time Delay = 300mS

Current = 3X
Monitor the Analog I/O using the GUI Analog I/O
screens.
9. AUXILIARIES
8.12.1 Press the START push-button. Press the
HOIST BRAKE RELEASE push-button. 9.1 Set test selector switch to AUXILIARY
TEST.
8.12.2 Increase the hoist reference to full positive (+).
Check that the hoist operator’s reference analog 9.2 Open all auxiliary load breakers and all
input and output respond correctly as seen on motor starter breakers.
the GUI screens.

8.12.3 Repeat with the hoist reference set to full neg-

9.3 Close the main auxiliary breaker.
ative (–).
9.4 Check the auxiliary cabinet voltmeter for
8.12.4 Set the hoist brake. proper readings.

8.12.5 Release the crowd brake. 9.5 AUXILIARY LOADS BREAKER CHECK.

8.12.6 Increase the crowd reference to full positive 9.5.1 Individually close each auxiliary branch circuit
(+). Check that the crowd operator’s reference breaker. Refer to schematic.
analog input and output respond correctly as
seen on the GUI screens. 9.5.2 Check for proper voltage or operation of the
load.
8.12.7 Repeat with the crowd reference set to full neg-
ative (–). 9.5.3 Check the air compressor system.

8.12.8 Set the crowd brake. 9.5.4 Check for proper operation of the pressure
switches.
8.12.9 Release the swing brake.

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 7 TEST PROCEDURE
Return to Index
Electrotorque Plus®
9.6 AUXILIARY SYSTEM CHECKS.
9.6.1 Set the test selector switch to AUXILIARIES
TEST.
9.6.2 Close all relay supply, control and 230V supply
circuit breakers.
9.6.3 Close each of the auxiliary motor starter circuit
breakers individually:
9.6.4 Press the START button. Check that the
motors on the closed breaker operate properly
and that the direction of rotation is correct.
Transfer to propel. Verify propel blower opera-
tion.
9.6.5 The instantaneous trip adjustment on the
motor starters is set to nominal the factory. If
tripping occurs due to starting inrush current,
adjust the instantaneous trip setting. Refer to
drawing R31892 for factory settings.
9.6.6 Press the STOP push-button. Open the
breaker on the starter just tested, and close the
next.
9.6.7 Close the dipper trip motor starter circuit
breaker(s). Check that the dipper trip circuit
operates properly, and that motor rotation is cor-
rect.
9.6.8 It may be necessary to make the final adjust-
ments on the dipper trip resistors after the
machine is operational to obtain the proper
slack take up and tripping torque on the motor.
All resistor adjustments must be made
with the power off.
9.7 Check the ground fault circuits by pressing
the ground fault test push-buttons. Check
for appropriate fault indication.
9.7.1 The fault indication will remain after the test
short is removed. The ground fault reset button
must be used to extinguish the light. See sche-
matics.
TEST PROCEDURE
9.7.2 Some machines may be equipped with a 30 sec-
ond ground fault shutdown system. See sche-
matics. Repeat 9.7 in control test and observe
30 second shutdown routine.
9.8 Check schematics for other auxiliary func-
tions and supplies; verify for correct opera-
tion.
10. SWING FIELD CONTROL
10.1 TEST PREPARATION
10.1.1 Check that all field circuit breakers are open.
10.1.2 Check that the field cables are connected to the
motors.
10.1.3 Set the test selector switch to FIELD TEST.
10.1.4 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
agree with the shovel documentation.
10.2 SUPPLY VOLTAGES
10.2.1 Close the following circuit breakers:
• 120V Main Breaker (MB)
• Constant Voltage Supply Breaker (CVSB)
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB)
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
(CVMSB)
• Synchronizing Supply Breaker (SSB)
10.2.2 Using a DVM, check that the following voltages
are present at the fields drive module (field
AFM):
120VAC control power at TB1-1 to TB1-2.
230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3.
42VDC (approx. 50VDC no load) gate voltage at P11-
13 (+) to P11-14 (–).
Copyright © 1999 Harnischfeger Corporation
8 CAT312.fm

10.3 AFM SOFTWARE
10.3.1 When the field AFM is properly powered, its
LCD display should read:
P&H Electrotorque-Plus
Field Control
This indicates that this AFM most likely has the cor-
rect firmware installed.
10.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using
the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
number agrees with the shovel documentation.
10.4 AFM TESTING
10.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board (A1) on your
right side.
Attach a digital voltmeter across test points TP1
(ACOM) and TP2 (VREF) which are located on the bot-
tom left side of the microprocessor board. Record the
measured voltage (approx. –7.000 VDC) as a negative
number.
10.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
the right arrow key and set the following param-
eter:
X000: I/O V-REF = – VDC (Value measured in
10.4.1 )
Press the S key twice to save the value and exit the
edit mode.
10.4.3 Reset the drive by cycling the drive power.
10.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
10.4.5 Calculate the expected dc voltage across the
feedback resistor at normal current levels:
Vfb = Ifld / CT Ratio x Rfb
Example:
80A / 150 x 5 ohm = 2.7 VDC
10.4.6 Verify that the test selector switch is set to
FIELD TEST, and that the meter selector switch
is set to SWING. Close the swing field circuit
breaker.
10.4.7 Check that the swing field current remains at 0
amps.
10.4.8 Press the START push-button.
10.4.9 Check that the swing field current increases to
the specified level, using the meter panel.
10.5 PERFORMANCE CHECKS
10.5.1 Check the accuracy of the field current level by
measuring the dc voltage across the test jacks
for the swing field current on the test panel.
The voltage measured should equal that calculated in
10.4.5.
10.5.2 Swing field control should be documented by
connecting a chart recorder across the swing
field test jacks. Alternately START and STOP
the machine while recording. Compare the
recordings to Figure 10.5.2.
10.5.3 Press the STOP push-button.
10.5.4 Check the swing field voltage waveform by con-
necting an oscilloscope across the dc terminals
of the swing field converter. Press the START
push-button. Compare to Figure 10.5.4.
10.5.5 Press the STOP push-button. Open the swing
field circuit breaker.
9 TEST PROCEDURE
Electrotorque Plus®

Figure 10.5.2 Swing Field Waveform Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 10 CAT312.fm
 Electrotorque Plus®

Figure 10.5.4 Swing Field Waveform Oscilloscope Display

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 11 TEST PROCEDURE
Return to Index
Electrotorque Plus®
11. CROWD / PROPEL FIELD CONTROL
11.1 Test Preparation
11.1.1 Check that all field circuit breakers are open.
11.1.2 Check that the field cables are connected to the
motors.
11.1.3 Set the test selector switch to FIELD TEST.
NOTE: If you have just commissioned the swing field,
you can skip to step 11.4.4.
11.1.4 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
agree with the shovel documentation.
11.2 SUPPLY VOLTAGES
11.2.1 Close the following circuit breakers:
• 120V Main Breaker (MB)
• Constant Voltage Supply Breaker (CVSB)
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB)
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
(CVMSB)
• Synchronizing Supply Breaker (SSB)
11.2.2 Using a DVM, check that the following voltages
are present at the fields AFM:
120VAC control power at TB1-1 to TB1-2.
230VAC, 3ph, synchronizing voltage at P11-1 to P11-
16 to P11-3.
42VDC (approx. 50VDC no load) gate voltage at P11-
13 (+) to P11-14 (–).
TEST PROCEDURE
11.3 AFM SOFTWARE
11.3.1 When the field AFM is properly powered, its
LCD Display should read:
P&H Electrotorque-Plus
Field Control
This indicates that this AFM most likely has the cor-
rect firmware installed.
11.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using
the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
number agrees with the shovel documentation.
11.4 AFM TESTING
11.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board (A1) on your
right side. Attach a digital voltmeter across TP1
(ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
Record the measured voltage (approx. –7.000
VDC) as a negative number.
11.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
the right arrow key and set the following param-
eter:
X000: I/O V-REF = – VDC (Value measured in
11.4.1 )
Press the S key twice to save the value and exit the
edit mode.
11.4.3 Reset the drive by cycling the drive power.
11.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
11.4.5 Calculate the expected dc voltage across the
feedback resistor at normal current levels:
Vfb = Ifld / CT Ratio x Rfb
Examples:
70A / 150 x 5ohm = 2.3 VDC
150A / 150 x 5ohm = 5.0 VDC
Copyright © 1999 Harnischfeger Corporation
12 CAT312.fm

11.4.6 Verify that the test selector switch is set to
FIELD TEST, and that the meter selector switch
is set to CROWD. Close the crowd field circuit
breaker.
11.4.7 Check that the crowd field current remains at 0
amps.
11.4.8 Press the START push-button.
11.4.9 Check that the crowd field current increases to
the specified level, using the meter panel.
11.5 PERFORMANCE CHECKS
11.5.1 Check the accuracy of the field current level by
measuring the dc voltage across the test jacks
for the crowd field current on the test panel.
The voltage measured should equal that calculated in
11.4.5.
11.5.2 Press the PROPEL push-button.
11.5.3 Check that the propel field current increases to
the specified level, using the meter panel.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
11.5.4 Force a strong propel field level from the GUI
screen called AFM TEST SCREEN. Check that
the propel field current increases to the speci-
fied level, using the meter panel.
11.5.5 The crowd/propel field control should be docu-
mented by connecting a chart recorder across
the crowd/propel field test jacks. While record-
ing, start the machine, then after a few seconds,
transfer to the propel mode, then force a strong
propel field
Transfer back to crowd, press the STOP push-button.
Compare the recordings to Figures 11.5.5a, 11.5.5b,
and 11.5.5c.
11.5.6 Press the STOP push-button.
11.5.7 Check the crowd/propel field Voltage waveform
by connecting an oscilloscope across the dc ter-
minals of the crowd/propel field converter. Press
the START push-button. Compare to Figure
11.5.7.
11.5.8 Press the STOP push-button. Open the crowd/
propel field circuit breaker.
13 TEST PROCEDURE
Electrotorque Plus®

Figure 11.5.5a Crowd Field Current Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 14 CAT312.fm
 Electrotorque Plus®

Figure 11.5.5b Propel Field Current Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 15 TEST PROCEDURE
Electrotorque Plus®

Figure 11.5.5c Crowd/Propel Transfer Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 16 CAT312.fm
 Electrotorque Plus®

Figure 11.5.7 Crowd/Propel Field Voltage Oscilloscope Display

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 17 TEST PROCEDURE
Return to Index
Electrotorque Plus®
12. HOIST FIELD CONTROL
12.1 TEST PREPARATION
12.1.1 Check that all field circuit breakers are open.
12.1.2 Check that the field cables are connected to the
motors.
12.1.3 Set the test selector switch to FIELD TEST.
NOTE: If you have just commissioned the swing or
crowd/propel field, you can skip to step 12.4.4.
12.1.4 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
agree with the shovel documentation.
12.2 SUPPLY VOLTAGES
12.2.1 Close the following circuit breakers:
• 120V Main Breaker (MB)
• Constant Voltage Supply Breaker (CVSB)
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB)
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
(CVMSB)
• Synchronizing Supply Breaker (SSB)
12.2.2 Using a DVM, check that the following voltages
are present at the fields AFM:
120VAC Control Power at TB1-1 to TB1-2.
230VAC, 3ph, Synchronizing Voltage at P11-1 to
P11-16 to P11-3.
42VDC (approx. 50VDC no load) gate voltage at
P11-13 (+) to P11-14 (–).
TEST PROCEDURE
12.3 AFM SOFTWARE
12.3.1 When the field AFM is properly powered, its
LCD Display should read:
P&H Electrotorque-Plus
Field Control
This indicates that this AFM most likely has the cor-
rect firmware installed.
12.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using
the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
number agrees with the shovel documentation.
12.4 AFM TESTING
12.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board (A1) on your
right side. Attach a digital voltmeter across TP1
(ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
Record the measured voltage (approx. –7.000
VDC) as a negative number.
12.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
the right arrow key and set the following
parameter:
X000: I/O V-REF = – VDC (Value measured in
12.4.1 )
Press the S key twice to save the value and exit the
edit mode.
12.4.3 Reset the drive by cycling the drive power.
12.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
12.4.5 Calculate the expected dc voltage across the
feedback resistor at normal current levels:
Vfb = Ifld / CT Ratio x Rfb
Examples:
50A / 150 x 5ohm = 1.7 VDC
140A / 150 x 5ohm = 4.7 VDC
Copyright © 1999 Harnischfeger Corporation
18 CAT312.fm
Return to Index
Electrotorque Plus®

12.4.6 Verify that the test selector switch is set to 13. HOIST ARMATURE CONTROL
FIELD TEST, and that the meter selector switch
is set to HOIST. Close the hoist field circuit
breaker.
13.1 TEST PREPARATION

12.4.7 Check that the hoist field current remains 13.1.1 Set the test selector switch to CONTROL TEST.
at 0 amps.
13.1.2 Open the circuit breakers on the RPC cabinet.
12.4.8 Press the START push-button. Open the constant voltage module supply circuit
breaker (CVMSB), and the control supply
12.4.9 Check that the hoist field current increases to breaker (CSB).
the specified level, using the meter panel.
13.1.3 Connect a 12.5 ohm current limiting resistor in
series with hoist motor armature, H2.
12.5 PERFORMANCE CHECKS
13.1.4 Install a reference/push-button unit.
12.5.1 Check the accuracy of the field current level by Reference: Figure 2.2.2 in Appendix B.
measuring the dc voltage across the test jacks
for the hoist field current on the test panel. 13.1.5 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
The voltage measured should equal that calculated in agree with the shovel documentation.
12.4.5.
13.1.6 Check for open or shorted thyristor firing pulse
12.5.2 Force a weak hoist field level from the GUI cables by measuring between the bridge inter-
screen called AFM TEST SCREEN. Check that face connector pins. A reading of 50 ohms is to
the hoist field current increases to the specified be expected between the following pins:
level, using the meter panel.
P9-1 to P9-2, P9-3 to P9-4,
12.5.3 The hoist field control should be documented by
connecting a chart recorder across the hoist field P9-5 to P9-6, P9-9 to P9-10,
test jacks. While recording, start the machine, P9-11 to P9-12, P9-13 to P9-14,
then after a few seconds force a strong hoist
P9-15 to P9-16, P9-17 to P9-18,
field, then a weak hoist field When completed
press the STOP push-button. Compare the P9-19 to P9-20, P9-23 to P9-24,
recordings to Figure 12.5.3. P9-25 to P9-26, P9-27 to P9-28
P10-1 to P10-2, P10-3 to P10-4,
12.5.4 Press the STOP push-button.
P10-5 to P10-6, P10-9 to P10-10,
12.5.5 Check the hoist field voltage waveform by con- P10-11 to P10-12, P10-13 to P10-14,
necting an oscilloscope across the dc terminals
P10-15 to P10-16, P10-17 to P10-18,
of the hoist field converter. Press the START
push-button. Compare to Figure 12.5.5. P10-19 to P10-20, P10-23 to P10-24,
P10-25 to P10-26, P10-27 to P10-28
12.5.6 Press the STOP push-button. Open the hoist
field circuit breaker.

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 19 TEST PROCEDURE
Electrotorque Plus®

Figure 12.5.3 Hoist Field Current Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 20 CAT312.fm
 Electrotorque Plus®

Figure 12.5.5 Hoist Field Voltage Waveform Display

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 21 TEST PROCEDURE
Electrotorque Plus®
13.2 SUPPLY VOLTAGES
13.2.1 Close the following circuit breakers:
• 120V Main Breaker (MB)
• Constant Voltage Supply Breaker (CVSB)
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB)
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB)
• Constant Voltage Module Supply Breaker
(CVMSB)
• Synchronizing Supply Breaker (SSB)
13.2.2 Using a DVM, check that the following voltages
are present at the hoist AFM:
120VAC Control Power at TB1-1 to TB1-2.
230VAC, 3ph, Synchronizing Voltage at P11-1 to
P11-16 to P11-3.
42VDC (approx. 50VDC no load) gate voltage at
P11-13 (+) to P11-14 (–).
13.3 AFM SOFTWARE
13.3.1 When the hoist AFM is properly powered, its
LCD Display should read:
P&H Electrotorque-Plus
Armature Control
This indicates that this AFM most likely has the cor-
rect firmware installed.
13.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using
the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
number agrees with the shovel documentation.
TEST PROCEDURE
13.4 13.4 AFM TESTING
13.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board (A1) on your
right side. Attach a digital voltmeter across TP1
(ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
Record the measured voltage (approx. –7.000
VDC) as a negative number.
13.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
the right arrow key and set the following
parameter:
X000: I/O V-REF = – VDC (Value measured in
13.4.1 )
Press the S key twice to save the value and exit the
edit mode.
13.4.3 Reset the drive by cycling the drive power.
13.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
13.5 AUTOCAL PROCEDURE (Operator’s Ref-
erence Calibration)
13.5.1 On the GUI, go to the AFM TEST SCREEN.
13.5.2 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the HOIST BRAKE RELEASE push-
button.
13.5.3 Turn the hoist reference potentiometer to full
positive (+). At the AFM TEST SCREEN, press
the HOIST AUTOCAL ON touch button.
13.5.4 After the GUI touch button turns green, press
the HOIST AUTOCAL OFF touch button.
13.5.5 When the touch button turns red, turn the hoist
reference potentiometer to full negative (–).
13.5.6 Press the HOIST AUTOCAL ON touch button.
After the GUI touch button turns green, press
the HOIST AUTOCAL OFF touch button.
13.5.7 Confirm that the reference signals are properly
calibrated by checking that the adjusted refer-
ence at A066 is +100% with the reference full
Copyright © 1999 Harnischfeger Corporation
22 CAT312.fm

positive, and –100% with the reference full neg-
ative. Use the drive keypad to go to the OPER-
ATE sub-menu. Enter the sub-menu using the
right arrow key. Arrow up to reach the
BLOCKS ANALOG sub-menu, and enter it with
the right arrow key. Arrow up to A066.
13.5.8 The hoist AUTOCAL procedure is complete.
Press the STOP push-button. Press the drive S
key twice to exit the sub-menus.
13.6 THYRISTOR PULSE SEQUENCE
13.6.1 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the HOIST BRAKE RELEASE button.
13.6.2 With the reference in the full negative (lower)
position, use an oscilloscope to check the firing
pulse sequence of both hoist lower converters,
Figure 13.6.
13.6.3 Place the reference in the full positive (hoist)
position, and check the firing pulse sequence of
both hoist Converters, Figure 13.6.
13.6.4 Press the PROPEL push-button. Check that
the firing pulses to the H1 converter remains
present while the firing pulses to the H2 con-
verter are blocked.
13.6.5 Press the HOIST/CROWD push-button, and
the HOIST BRAKE RELEASE push-button.
Firing pulses should again be present on both
the H1 and H2 converters.
13.6.6 Press the STOP push-button.
13.7 VOLTAGE CONTROL, HOIST
13.7.1 Disable OPEN SCR TEST. At the Hoist AFM
keypad, change Y058 from D149 TEST ARM to
D087 ZERO BIT. Reset drive.
13.7.2 Connect a digital voltmeter (1kV range) across
the series armature resistor.
13.7.3 Remove the relay from the differential voltage
module (DVAH) to prevent a shutdown due to
unbalanced armature voltages.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
13.7.4 Set the test selector switch to ARMATURE
TEST, and close the high voltage disconnect
switch.
13.7.5 Set the reference to 0V.
NOTICE
With a series armature resistor installed, a
nuisance ground fault indication may occur
after the firing pulses are phased advanced
in armature test. The series resistor is the
cause of this indication, and the indication
can be ignored until the resistor is removed,
if:
1. The ground fault only occurs after the brake has been
released.
2. The MSN to ground voltage is less than 60VAC.
(A true line-to-ground fault would be approximately
350VAC)
3. Prior ground checks have proved negative.
13.7.6 Press the START push-button.
13.7.7 Check that the dc voltage across the series
armature resistor is approximately 0VDC. (A
higher voltage would indicate the possibility of a
phasing error on the main transformer second-
ary or on the synchronizing supply voltage.)
Reference: Figure 13.7.7 in Appendix B.
13.7.8 Press the HOIST BRAKE RELEASE push-but-
ton. Slowly increase the reference in the posi-
tive (+) direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference.
13.7.9 Slowly increase the reference in the negative
(–) direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference and
should have changed polarity.
NOTICE
The P1 propel armature circuit must be
intact for proper operation of the voltage
feedback circuit. See Figure 13.7.7 in Appen-
dix B.
23 TEST PROCEDURE
Electrotorque Plus®

Figure 13.6 Thyristor Pulse Sequence

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 24 CAT312.fm

13.8 CURRENT FEEDBACK, HOIST
13.8.1 With the reference close to fully positive, check
that the current feedback signal at the AFM
connector P11 - terminal 10 to terminal 8
(08351 to 01021C) is positive. This signal will
be very small, 0.1V or less, so use care in read-
ing the meter. Use of a strip chart recorder will
insure that the feedback polarity is correct.
13.8.2 With the reference close to fully negative, check
that the current feedback signal at the AFM
connector P11 - terminal 10 to terminal 8
(08351 to 01021C) remains positive.
13.8.3 Reduce the REFERENCE to 0V. Press the
STOP push-button.
13.8.4 Remove the series armature resistor.
13.9 ARMATURE CURRENT RESPONSE,
HOIST
13.9.1 Connect a strip chart or memory recorder
(Ch. 1) across the hoist current feedback (IAFB)
test jacks.
13.9.2 Press the START push-button. Press the
HOIST BRAKE RELEASE push-button.
Increase the hoist operators reference until the
armature current ammeter reads 500A.
13.9.3 On the GUI, at the AFM TEST SCREEN, press
the HOIST CURRENT REGULATOR MODE
touch button then press the START HOIST
STEP REFERENCE touch button. The PLC
will cause the AFM to pulse the output current
for a 10 Sec. period. During this period, record
the IAFB output, and compare the recording to
Figure 13.9. Overshoots or undershoots should
not be present.
13.9.4 Press the HOIST CURRENT REGULATOR
MODE touch button to disable.
13.9.5 Press the STOP push-button.
13.10 STALL CURRENT, HOIST
13.10.1 Use the drive keypad to go to the DRIVE
ANALOG sub-menu. Enter the sub-menu using
the right arrow key , then go to parameter A004:
I ARM AMP.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
13.10.2 Connect a digital voltmeter across the hoist
current feedback (IAFB) test jacks.
13.10.3 Calculate the dc voltage to be expected across
the IAFB test jack resistor:
Istall / 300 = Vtest jack
Example:
2625A / 300 = 8.75 VDC
13.10.4 Set the meter selector switches to monitor the
hoist motion parameters.
13.10.5 Set the hoist reference potentiometer to 0
VDC. Press the START push-button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
13.10.6 Press the HOIST BRAKE RELEASE push-
button.
13.10.7 Increase the hoist reference to full positive
(hoist). Check the current value shown on the
drive LCD display. Record the voltage seen
across the IAFB test jacks.
13.10.8 Press the HOIST BRAKE SET push-button.
13.10.9 Verify that values recorded in 13.10.7, agree
with the I-A2 level shown In the Specified Elec-
trical Data sheet.
13.10.10 After the commutators have been allowed to
cool for at least one full minute, again, Press the
HOIST BRAKE RELEASE push-button and
increase the hoist reference to full negative
(lower).
13.10.11 Verify that values recorded in 13.10.10, agree
with the I-A3 level shown in the Specified Elec-
trical Data sheet. Press the HOIST BRAKE SET
push-button.
13.10.12 After the commutators have been allowed to
cool for at least one full minute, again, Press the
HOIST BRAKE RELEASE push-button and
25 TEST PROCEDURE
Electrotorque Plus®

Figure 13.9 IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 26 CAT312.fm

increase the hoist reference to full positive
(hoist).
13.10.13 Check that the analog armature current
panel meter also reads the stall level +/– 50A.
13.10.14 Press the HOIST BRAKE SET push-button.
13.11 STALL CURRENT, PROPEL (Hoist)
13.11.1 Calculate the dc voltage to be expected across
the hoist IAFB test jack resistor when in the
propel mode:
Istall / 300 = Vtest jack
Example:
1450A / 300 = 4.8 VDC
13.11.2 Press the PROPEL push-button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
13.11.3 Increase the hoist reference to full positive
(forward). Check the current value shown on
the drive LCD display. Record the voltage seen
across the IAFB test jacks.
13.11.4 Press the HOIST/CROWD push-button.
13.11.5 Verify that values recorded in 13.11.3, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
13.11.6 After the commutators have been allowed to
cool for at least one full minute, again, press the
PROPEL push-button and increase the hoist
reference to full negative (reverse). Check the
current value shown on the drive LCD display.
Record the voltage seen across the IAFB test
jacks.
13.11.7 Press the HOIST/CROWD push-button.
13.11.8 Verify that values recorded in 13.11.6, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
13.11.9 Press the STOP push-button. Reduce the
hoist reference to 0 VDC.
13.12 VOLTAGE CONTROL - RUN MODE,
HOIST
13.12.1 Set the test selector switch to RUN.
13.12.2 Deactivate the RPC shutdown by forcing off
the RPC circuit breaker inputs.
(Alternative: Disconnect the RPC circuit
breaker interlock input to the PLC.)
13.12.3 Close the hoist field circuit breaker.
13.12.4 With the reference set to 0 VDC, press the
START push-button.
13.12.5 Press the HOIST BRAKE RELEASE
push-button and check that the armature
current is approximately 0 A.
13.12.6 Check that the motors can be controlled with
the reference by accelerating, decelerating and
changing direction. Do not exceed 50% of full
speed.
13.12.7 Set the hoist brakes. Press the STOP push-
button.
13.13 FUSE FAULT DETECTION, HOIST
13.13.1 Remove a fuse monitor lead from the hoist
armature converter.
13.13.2 Press the START button.
13.13.3 Check that the machine shuts down and that
a hoist fuse fault is indicated.
13.13.4 Replace the fuse lead.
13.13.5 Repeat the test for the opposite hoist con-
verter.
27 TEST PROCEDURE
Electrotorque Plus®
13.14 DIVERTER CIRCUIT CHECKS.
13.14.1 Check that the relay and control supply cir-
cuit breakers are closed.
13.14.2 Set the test selector switch to CONTROL
TEST.
13.14.3 Connect a voltmeter to (TB1-1) on the hoist
diverter control module and check that the sup-
ply voltage is +28VDC.
13.14.4 Press the START button.
13.14.5 Check that the READY light on the diverter
module is on.
13.14.6 Check that the DE-BLOCK LED on the AFM
is on.
13.14.7 Check the gate block circuit by shorting TB2-
10 to TB2-9 on the diverter module.
13.14.8 The DE-BLOCK LED on the AFM should not
be illuminated.
13.14.9 Press STOP button. Remove the short on the
diverter module.
13.15 DIVERTER CURRENT SENSOR
CHECKS, HOIST
13.15.1 Connect a digital voltmeter to TP2 (–) and
TP3 (+) on the hoist diverter control module.
13.15.2 Set the test selector switch to ARMATURE
TEST.
13.15.3 Press START button, press HOIST BRAKE
RELEASE button and check that the meter
reads at full hoist:
Volts = Iarmstall/300 (+/–0.5VDC)
13.15.4 Record this in the test data sheet.
13.15.5 Press STOP button. Disconnect the meter.
TEST PROCEDURE
13.16 DIVERTER CAPACITOR CHECKS, HOIST
13.16.1 Reconnect the wire to the capacitor charging
relay at the terminal board on the hoist diverter
circuit panels in the converter cabinet to acti-
vate the capacitor charging power supply.
Use extreme caution when making volt-
age measurements in this section of the
test procedure. Voltages of approxi-
mately 1300V will be measured.
13.16.2 Connect a digital voltmeter (1kV range) across
the H1 hoist diverter capacitor.
13.16.3 Manually depress the hoist capacitor charging
relay armature to close its contacts.
13.16.4 The voltage across the diverter capacitor
should begin to climb at the capacitor charges.
Ultimately this voltage should be about 1300
VDC, but to avoid overvoltage on the DVM, we
will stop charging (release the relay armature)
at about 900 VDC. Check schematics for polar-
ity, and verify that the charging polarity is cor-
rect.
13.16.5 When you release the charging relay, the volt-
age across the diverter capacitor must decay to
less than 50 VDC in less than 30 Sec.
13.16.6 Repeat these tests for the H2 diverter capaci-
tor.
13.17 CHECK DIVERTER CIRCUIT OPERA-
TION, HOIST
13.17.1 Connect a digital voltmeter to TP1(+) and
TP2(–) on the diverter control module.
13.17.2 Adjust the current trip adjust potentiometer
so that the meter reads +2.1VDC.
13.17.3 Set the test selector switch to ARMATURE
TEST.
13.17.4 Reconnect the meter to TP3(+) and TP2(–) on
the diverter control module.
13.17.5 Press the START button. Press the HOIST
BRAKE RELEASE button.
Copyright © 1999 Harnischfeger Corporation
28 CAT312.fm

13.17.6 Slowly increase the hoist reference to the full
hoist position.
13.17.7 Check that the machine shuts down when the
meter reads about 3.5VDC.
13.17.8 Check that the capacitor voltage on the hoist
converter bridge drops instantly to approxi-
mately 0 volts.
13.17.9 Press the STOP button.
13.17.10 Adjust the current trip for normal operation.
13.17.11 Reconnect the meter to TP1(+) and TP2(–) on
the control module.
13.17.12 Readjust the current trip adjust potentiome-
ter to its maximum clockwise position.
13.17.13 Press the START push-button. Press the
HOIST BRAKE RELEASE push-button.
13.17.14 Stall the hoist and turn down the current
trip potentiometer until the module trips. Do
not stall motor for more than 5 seconds.
13.17.15 Check and read voltage at TP1-TP2.
13.17.16 Readjust level as follows.
Volts = (VTP1-VTP2) x 1.4
Where:
VTP1 to VTP2 is from 13.17.15
13.18 OPERATE FROM THE OPERATOR’S
COOP, HOIST
13.18.1 Remove the reference/push-button unit.
Reconnect the PLC/coop cables.
13.18.2 REPEAT THE AUTOCAL PROCEDURE
(Operator’s Reference Calibration)
13.18.3 On the GUI, go to AFM TEST SCREEN.
13.18.4 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the HOIST BRAKE RELEASE button.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
13.18.5 Move the hoist controller potentiometer to full
positive (+). On the GUI, press the AUTOCAL
HOIST ON touch button.
13.18.6 After the GUI touch button turns green for a
few moments, press the AUTOCAL HOIST OFF
touch button.
13.18.7 When the touch button turns red, move the
hoist controller potentiometer to full negative
(–).
13.18.8 On the GUI, press the AUTOCAL HOIST ON
touch button. After the GUI touch button turns
green for a few moments, press the AUTOCAL
HOIST OFF touch button.
13.18.9 Confirm that the reference signals are prop-
erly calibrated by checking that the ADJUSTED
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
13.18.10 The hoist AUTOCAL procedure is complete.
Press the STOP push-button. Press the drive S
key twice to exit the sub-menus.
13.18.11 Set the test selector switch to RUN. Start
the machine and release the hoist brakes.
13.18.12 Check that full control of the hoist motion is
obtained by the operator's controller.
13.18.13 Check that the hoist motion runs in the
proper direction in relation to the controller
position.
If the motor rotation is wrong, check that the reference
is of the proper polarity.
The motor rotation may be reversed by reversing the
motor field connections.
29 TEST PROCEDURE
Electrotorque Plus®
13.19 VOLTAGE RESPONSE, HOIST. (With
Hoist Ropes and Dipper attached)
13.19.1 Connect a chart recorder to record across the
hoist armature voltage feedback (VAFB) test
jacks (Ch. 1), and the hoist armature current
feedback (IAFB) test jacks (Ch. 2).
13.19.2 Press the START push-button. Press the
HOIST BRAKE RELEASE button.
13.19.3 Check that the armature voltage of each
motor is correct for both full hoist and full lower
directions as spelled out in the Specified Electri-
cal Data sheet.
• 13.19.3.1 If the terminal voltage is significantly
lower than the voltage read at the AFM (A012
ARM VOLTS) then change the X003 parameter
from 100 to something less. For example: If the
measured terminal voltage is 500V and A012
reads 550V then change X003 from 100 to 91
(500/550 x 100 = 91). Changes made to X
parameters are activated immediately after
pressing the S key. Note: X004 is used for right
propel.
13.19.4 Operate the hoist by alternately applying full
positive and full negative reference and compare
the recordings of VAFB and IAFB with Figure
13.19.4.
13.19.5 Voltage response recordings will require two
participants; an operator in the operator’s coop,
and a technician in the control room. Have the
operator slowly raise the empty dipper at a con-
stant speed.
13.19.6 As the dipper is slowly rising, press the
HOIST STEP REFERENCE touch button on the
GUI. The PLC will pulse the output voltage for
a 10 second time period. During this period,
record the VAFB and IAFB signals and compare
with Figure 13.19.6. The VAFB signal should
have minimum response time without over-
shoot. At any time during this procedure, the
operator has the ability to override the step ref-
erence, should safety require it. In case satisfac-
tory recordings are not obtained on the first run,
you can instruct the operator to quickly lower
the dipper before it reaches the upper limit, and
then begin raising it again at a slow and steady
rate.
TEST PROCEDURE
13.19.7 Set the dipper on the ground and press the
STOP push-button.
13.20 FIELD WEAKENING, HOIST
13.20.1 Connect channel 2 of the recorder to the
HOIST FIELD FEEDBACK (IFFB) test jacks
and check that field weakening occurs when
lowering with an empty dipper at full speed.
Compare with Figure 13.20.1.
13.20.2 Set the dipper on the ground and press the
STOP push-button.
13.21 DIVERTER VAFB SIGNAL CHECKS,
HOIST
13.21.1 Connect a digital voltmeter from TB1-4 to
TB1-5 on the hoist diverter control module.
13.21.2 With the test selector switch set to RUN, press
the START push-button and HOIST BRAKE
RELEASE push-button.
13.21.3 Operate the hoist motion, and check that the
voltage is –9.7V +/–1V at full speed in the hoist
direction and +8.9V +/–1V at full speed in the
lower direction.
13.21.4 Set the dipper on the ground and press STOP
button.
13.22 DIVERTER CIRCUIT OPERATION
13.22.1 If nuisance tripping occurs during normal
operation, use the procedure of 13.17.11 and
increase the trip setting by increments of 0.1V
until nuisance tripping does not occur. (It should
not be necessary to increase this setting more
than 0.5VDC. )
13.23 THIS COMPLETES TESTING OF THE
HOIST ARMATURE CONTROL
13.23.1 Press the STOP push-button.
13.23.2 Remove all PLC forces.
13.23.3 Open the field circuit breakers.
13.23.4 Enable OPEN SCR TEST. At the hoist AFM
keypad, change Y058 from D087 ZERO BIT to
D149 TEST ARM. Reset the drive.
Copyright © 1999 Harnischfeger Corporation
30 CAT312.fm
 Electrotorque Plus®

Figure 13.19.4 VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 31 TEST PROCEDURE
Electrotorque Plus®

Figure 13.19.6 VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 32 CAT312.fm
 Electrotorque Plus®

Figure 13.20.1 Hoist Field Weakening Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 33 TEST PROCEDURE
Return to Index
Electrotorque Plus®

14. CROWD ARMATURE CONTROL 14.2.2 Using a DVM, check that the following voltages
are present at the crowd armature AFM:
14.1 TEST PREPARATION A) 120VAC control power at TB1-1 to TB1-2.
14.1.1 Set the test selector switch to CONTROL TEST. B) 230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3.
14.1.2 Open the circuit breakers on the RPC cabinet. C) 42VDC (approx. 50VDC no load) gate voltage at
Open the constant voltage module supply circuit P11-13 (+) to P11-14 (–).
breaker (CVMSB), and the control supply
breaker (CSB).
14.3 AFM SOFTWARE
14.1.3 Connect a 12.5 ohm current limiting resistor in
series with crowd motor armature. 14.3.1 When the crowd AFM is properly powered, its
LCD display should read:
14.1.4 Install a reference/push-button unit. See Fig-
ure 2.2.2 in Appendix B. P&H Electrotorque-Plus
Armature Control
14.1.5 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
agree with the shovel documentation. This indicates that this AFM most likely has the cor-
rect firmware installed.
14.1.6 Check for open or shorted thyristor firing pulse
cables by measuring between the bridge inter- 14.3.2 Use the drive keypad to go to the ACCESS
face connector pins. A reading of 50 ohms is to CODES sub-menu. Enter the sub-menu using
be expected between the following pins: the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
P9-1 to P9-2, P9-3 to P9-4, number agrees with the shovel documentation.
P9-5 to P9-6, P9-9 to P9-10,
14.4 AFM TESTING
P9-11 to P9-12, P9-13 to P9-14,
P9-15 to P9-16, P9-17 to P9-18, 14.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board A1 on your
P9-19 to P9-20, P9-23 to P9-24, right side. Attach a digital voltmeter across TP1
P9-25 to P9-26, P9-27 to P9-28 (ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
14.2 SUPPLY VOLTAGES Record the measured voltage (approx. –7.000
VDC) as a negative number.
14.2.1 Close the following circuit breakers:
14.4.2 Use the drive keypad to go to the DRIVE CALI-
• 120V Main Breaker (MB) BRATE sub-menu. Enter the sub-menu using
• Constant Voltage Supply Breaker (CVSB) the right arrow key and set the following
parameter:
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB) X000: I/O V-REF = – VDC (value measured in
14.4.1 )
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB) Press the S key twice to save the value and exit the
• Constant Voltage Module Supply Breaker edit mode.
(CVMSB)
14.4.3 Reset the drive by cycling the drive power.
• Synchronizing Supply Breaker (SSB)
14.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 34 CAT312.fm

14.5 AUTOCAL PROCEDURE
(Operator’s Reference Calibration)
14.5.1 On the GUI, go to the AFM TEST SCREEN.
14.5.2 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the CROWD BRAKE RELEASE but-
ton.
14.5.3 Turn the crowd reference potentiometer to full
positive (+). On the GUI, press the AUTOCAL
CROWD ON touch button.
14.5.4 After the touch button turns green for a few
moments, press the AUTOCAL CROWD OFF
touch button.
14.5.5 When the touch button turns red, turn the
crowd reference potentiometer to full negative
(–).
14.5.6 On the GUI, press the AUTOCAL CROWD ON
touch button. After the touch button turns
green for a few moments, press the AUTOCAL
CROWD OFF touch button.
14.5.7 Confirm that the reference signals are properly
calibrated by checking that the ADJUSTED
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
14.5.8 The crowd AUTOCAL procedure is complete.
Press the STOP push-button. Press the drive S
key twice to exit the sub-menus.
14.6 THYRISTOR PULSE SEQUENCE
14.6.1 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the CROWD BRAKE RELEASE but-
ton.
14.6.2 With the reference in the full negative (–)
(retract) position, use an oscilloscope to check
the firing pulse sequence of the retract con-
verter, Figure 14.6.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
14.6.3 Place the reference in the full positive (+)
(crowd) position, and check the firing pulse
sequence of the crowd converter, Figure 14.6
14.6.4 Press the STOP push-button.
14.7 VOLTAGE CONTROL, CROWD
14.7.1 Disable OPEN SCR TEST. At the crowd AFM
keypad, change Y058 from D149 TEST ARM to
D087 ZERO BIT. Reset drive.
14.7.2 Connect a digital voltmeter (1kV range) across
the series armature resistor.
14.7.3 Set the test selector switch to ARMATURE
TEST, and close the high voltage disconnect
switch.
14.7.4 Set the reference to 0V.
14.7.5 Press the START push-button.
14.7.6 Check that the dc voltage across the series
armature resistor is approximately 0VDC. (A
higher voltage would indicate the possibility of a
phasing error on the main transformer second-
ary, or on the synchronizing supply voltage.)
14.7.7 Press the CROWD BRAKE RELEASE push-
button. Slowly, increase the crowd reference in
the positive direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference.
14.7.8 Slowly, increase the crowd reference in the neg-
ative direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference, and
should have changed polarity.
35 TEST PROCEDURE
Electrotorque Plus®

Figure 14.6 Firing Pulse Sequence Oscilloscope Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 36 CAT312.fm

14.8 CURRENT FEEDBACK, CROWD
14.8.1 With the reference close to fully positive, check
that the current feedback signal at the AFM
connector P11- terminal 10 to terminal 8 (12251
to 01021C) is positive. This signal will be very
small, 0.1V or less so use care in reading the
meter, or better still, use a strip chart recorder
to assure that the feedback polarity is correct.
14.8.2 With the reference close to fully negative,
check that the current feedback signal at the
AFM connector P11- terminal 10 to terminal 8
(12251 to 01021C) remains positive.
14.8.3 Reduce the reference to 0V. Press the STOP
push-button.
14.8.4 Remove the series armature resistor.
Figure 14.9 Crowd IAFB Chart Recording
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
14.9 ARMATURE CURRENT RESPONSE,
CROWD
14.9.1 Connect a strip chart or memory recorder (Ch.
1 ) across the crowd current feedback (IAFB)
test jacks.
14.9.2 Press the START push-button. Press the
CROWD BRAKE RELEASE push-button.
Increase the crowd Operators Reference until
the armature current ammeter reads 500A.
14.9.3 On the GUI, press the CROWD CURRENT
REGULATOR MODE touch button then press
the CROWD STEP REFERENCE touch but-
ton. The PLC will cause the AFM to pulse the
output current for a 10 sec. period. During this
period, record the IAFB output, and compare
the recording to Figure 14.9. Overshoots or
undershoots should not be present.
14.9.4 Press the CROWD CURRENT REGULATOR
MODE touch button to disable.
14.9.5 Press the STOP push-button.
37 TEST PROCEDURE
Electrotorque Plus®
14.10 STALL CURRENT, CROWD
14.10.1 Use the drive keypad to go to the DRIVE
ANALOG sub-menu. Enter the sub-menu using
the right arrow key , then go to parameter
A004: I ARM AMP.
14.10.2 Connect a digital voltmeter across the crowd
current feedback (IAFB) test jacks.
14.10.3 Calculate the dc voltage to be expected across
the IAFB test jack resistor:
Istall / 300 = Vtest jack
Example:
1650A / 300 = 5.5 VDC
14.10.4 Set the meter selector switch to monitor the
crowd motion parameters.
14.10.5 Set the crowd reference potentiometer to 0
VDC. Press the START push-button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
14.10.6 Press the CROWD BRAKE RELEASE push-
button.
14.10.7 Increase the crowd reference to full positive
(crowd). Check the current value shown on the
drive LCD Display. Record the voltage seen
across the IAFB test jacks.
14.10.8 Press the CROWD BRAKE SET push-button.
14.10.9 Verify that values recorded in 14.10.7, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
14.10.10 After the commutators have been allowed to
cool for at least one full minute, again, Press the
CROWD BRAKE RELEASE push-button and
increase the crowd reference to full negative
(retract).
TEST PROCEDURE
14.10.11 Verify that values recorded in 14.10.7, agree
with the I-A3 level shown in the Specified Elec-
trical Data sheet. Press the CROWD BRAKE
SET push-button.
14.10.12 After the commutators have been allowed to
cool for at least one full minute, again, Press the
CROWD BRAKE RELEASE push-button and
increase the crowd reference to full positive
(crowd).
14.10.13 Check that the analog armature current
panel meter also reads the stall level +/–50A.
14.10.14 Press the CROWD BRAKE SET push-but-
ton. Reduce the crowd reference to 0 VDC.
14.11 STALL CURRENT, PROPEL (CROWD)
14.11.1 Calculate the dc voltage to be expected across
the crowd IAFB test jack resistor when in the
propel mode:
Istall / 300 = Vtest jack
Example:
1450A / 300 = 4.8 VDC
14.11.2 Press the PROPEL button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
14.11.3 Increase the crowd reference to full positive
(forward). Check the current value shown on
the drive LCD display. Record the voltage seen
across the IAFB test jacks.
14.11.4 Press the HOIST/CROWD button.
14.11.5 Verify that values recorded in 14.11.3, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
14.11.6 After the commutators have been allowed to
cool for at least one full minute, again, press the
PROPEL push-button and increase the crowd
reference to full negative (reverse). Check the
Copyright © 1999 Harnischfeger Corporation
38 CAT312.fm

current value shown on the drive LCD Display.
Record the voltage seen across the IAFB test
jacks.
14.11.7 Press the HOIST/CROWD button.
14.11.8 Verify that values recorded in 14.11.6, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
14.11.9 Press the STOP push-button. Reduce the
crowd reference to 0 VDC.
14.12 VOLTAGE CONTROL - RUN MODE,
CROWD
14.12.1 Set the test selector switch to RUN.
14.12.2 Deactivate the RPC shutdown by forcing the
RPC circuit breaker inputs, off. (Alternative:
Disconnect the RPC circuit breaker interlock
input to the PLC.)
14.12.3 Close the crowd field circuit breaker.
14.12.4 With the reference set to 0 VDC, press the
START button.
14.12.5 Press the CROWD BRAKE RELEASE push-
button and check that the armature current is
approximately 0 A.
14.12.6 Check that the motors can be controlled with
the reference by accelerating, decelerating and
changing direction. Do not exceed 50% of full
speed.
14.12.7 Set the crowd brakes. Press the STOP push-
button.
14.13 FUSE FAULT DETECTION, CROWD
14.13.1 Remove a fuse monitor lead from the crowd
armature converter.
14.13.2 Press the START button.
14.13.3 Check that the machine shuts down and that
a crowd fuse fault is indicated.
14.13.4 Replace the fuse lead.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
14.14 DIVERTER CIRCUIT CHECKS.
14.14.1 Check that the relay and control supply cir-
cuit breakers are closed.
14.14.2 Set the test selector switch to CONTROL
TEST.
14.14.3 Connect a voltmeter to (TB1-1) on the crowd
diverter control module and check that the sup-
ply voltage is +28VDC.
14.14.4 Press the START button.
14.14.5 Check that the READY light on the diverter
module is ON.
14.14.6 Check that the DE-BLOCK LED on the AFM
is on.
14.14.7 Check the gate Block Circuit by shorting TB2-
10 to TB2-9 on the diverter module.
14.14.8 The DE-BLOCK LED on the AFM should not
be illuminated.
14.14.9 Press STOP button. Remove the short on the
diverter module.
14.15 DIVERTER CURRENT SENSOR
CHECKS, CROWD
14.15.1 Connect a digital voltmeter to TP2 (–) and
TP3 (+) on the crowd diverter control module.
14.15.2 Set the test selector switch to ARMATURE
TEST.
14.15.3 Press START button, press CROWD BRAKE
RELEASE button and check that the meter
reads at full crowd:
Volts = Iarmstall/300 (+/–0.5VDC)
14.15.4 Record this in the test data sheet.
14.15.5 Press STOP button. Disconnect the DVM.
39 TEST PROCEDURE
Electrotorque Plus®

14.16 DIVERTER CAPACITOR CHECKS, 14.17.5 Press the START button. Press the CROWD
CROWD BRAKE RELEASE button.

14.16.1 Reconnect the wire to the capacitor charging
relay at the terminal board on the crowd
diverter circuit panels in the converter cabinet
to activate the capacitor charging power supply.
14.17.6 Slowly increase the crowd reference to the full
crowd position.
14.17.7 Check that the machine shuts down when the
meter reads about 3.5VDC.

14.17.8 Check that the capacitor voltage on the crowd

converter bridge drops instantly to approxi-
Use extreme caution when making volt-
mately 0 volts.
age measurements in this section of the
test procedure. Voltages of approxi-
14.17.9 Press the STOP button.
mately 1300V will be measured.
14.17.10 Adjust the current trip for normal operation.
14.16.2 Connect a digital voltmeter (1kV range) across
the crowd diverter capacitor for the forward
14.17.11 Reconnect the meter to TP1(+) and TP2(–) on
bridge.
the control module.
14.16.3 Manually depress the crowd capacitor charg-
14.17.12 Readjust the current trip adjust potentiome-
ing relay armature to close its contacts.
ter to its maximum clockwise position.
14.16.4 The voltage across the diverter capacitor
14.17.13 Press the START push-button. Press the
should begin to climb at the capacitor charges.
CROWD BRAKE RELEASE button.
Ultimately this voltage should be about 1300
VDC, but to avoid overvoltage on the DVM, we
14.17.14 Stall the crowd and turn down the current
will stop charging (release the relay armature)
trip potentiometer until the module trips. Do
at about 900 VDC. Check schematics for polar-
not stall motor for more than 5 seconds.
ity, and verify that the charging polarity is cor-
rect.
14.17.15 Check and read voltage at TP1-TP2.
14.16.5 When you release the charging relay, the volt-
14.17.16 Readjust level as follows.
age across the diverter capacitor must decay to
less than 50 VDC in less than 30 Sec.
Volts = (VTP1-VTP2) x 1.4
14.16.6 Repeat these tests for the reverse bridge
crowd diverter capacitor. Where:

14.17 CHECK DIVERTER CIRCUIT OPERA- VTP1 to VTP2 is from 14.17.15

TION, CROWD
14.17.1 Connect a digital voltmeter to TP1(+) and
TP2(–) on the diverter control module.
14.17.2 Adjust the current trip adjust potentiometer
so that the meter reads +2.1VDC.
14.17.3 Set the test selector switch to ARMATURE
TEST.
14.17.4 Reconnect the meter to TP3(+) and TP2(–) on
the diverter control module.
14.18 OPERATE FROM THE OPERATOR’S
COOP, CROWD
14.18.1 Remove the reference/push-button unit.
Reconnect the PLC/coop cables.
14.18.2 REPEAT THE AUTOCAL PROCEDURE
(Operator’s reference Calibration)
14.18.3 On the GUI, go to the AFM TEST SCREEN.
14.18.4 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 40 CAT312.fm

ton, and the CROWD BRAKE RELEASE but-
ton.
14.18.5 Move the crowd controller potentiometer to
full positive (+). On the GUI, press the AUTO-
CAL CROWD ON touch button.
14.18.6 After the GUI touch button turns green for a
few moments, press the AUTOCAL CROWD
OFF touch button.
14.18.7 When the touch button turns red, move the
crowd controller potentiometer to full negative
(–).
14.18.8 On the GUI, press the AUTOCAL CROWD
ON touch button. After the GUI touch button
turns green for a few moments, press the AUTO-
CAL CROWD OFF touch button.
14.18.9 Confirm that the reference signals are prop-
erly calibrated by checking that the ADJUSTED
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
14.18.10 The crowd AUTOCAL procedure is complete.
Press the STOP push-button.
Press the drive S key twice to exit the sub-menus.
14.18.11 Set the test selector switch to RUN. Start
the machine and release the crowd brakes.
14.18.12 Check that full control of the crowd motion is
obtained by the operator’s controller.
14.18.13 Check that the crowd motion runs in the
proper direction in relation to the controller
position. If the motor rotation is wrong, check
that the reference is of the proper polarity.
The motor rotation may be reversed by reversing the
motor field connections.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
14.19 VOLTAGE RESPONSE, CROWD. (With
crowd Ropes and Dipper attached)
14.19.1 Connect a chart recorder to record across the
crowd armature voltage feedback (VAFB) test
jacks (Ch. 1), and the crowd armature current
feedback (IAFB) test jacks (Ch. 2).
14.19.2 Press the START push-button. Press the
CROWD BRAKE RELEASE button.
14.19.3 Check that the armature voltage of each
motor is correct for both full crowd and full
lower directions as spelled out in the Specified
Electrical Data sheet.
• 14.19.3.1 If the terminal voltage is significantly
lower than the voltage read at the AFM (A012
ARM VOLTS) then change the X003 parameter
from 100 to something less. For example: If the
measured terminal voltage is 500V and A012
reads 550V then change X003 from 100 to 91 (500/
550 x 100 = 91). Changes made to X parameters
are activated immediately after pressing the S key.
Note: X003 is used for left propel.
14.19.4 Operate the crowd by alternately applying full
positive and full negative reference and compare
the recordings of VAFB and IAFB with Figure
14.19.4.
14.19.5 Voltage response recordings will require two
participants; an operator in the operator’s coop,
and a technician in the control room. Have the
operator place the dipper handle (sticks) at a
position that is about 90 degrees to the boom
with the handle fully extended. The operator
should then very slowly retract the empty dip-
per at a constant speed.
14.19.6 As the dipper is slowly retracting, press the
CROWD STEP REFERENCE touch button on
the GUI. The PLC will pulse the output voltage
for a 10 second time period. During this period,
record crowd VAFB and IAFB signals and com-
pare them with Figure 14.19.6. The VAFB sig-
nal should have minimum response time
without overshoot. At any time during this pro-
cedure, the operator has the ability to override
the step reference, should safety require it. In
case satisfactory recordings are not obtained on
the first run, you can instruct the operator to
quickly crowd the dipper before it reaches the
41 TEST PROCEDURE
Electrotorque Plus®

Figure 14.19.4 Crowd VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 42 CAT312.fm
 Electrotorque Plus®

Figure 14.19.6 Crowd VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 43 TEST PROCEDURE
Electrotorque Plus®

retract limit, and then begin retracting it again
at a slow and steady rate.
14.19.7 Set the dipper on the ground and press the
STOP push-button.
14.20 VOLTAGE RESPONSE, PROPEL.
14.20.1 Connect channel 1 of the chart recorder across
Propel #1 armature voltage feedback (Hoist
VAFB) test jacks, and channel 2 to Propel #2
(Crowd VAFB).
Operate the machine from the operator’s seat.
14.20.2 Press the START push-button. Press the
PROPEL transfer button.
14.22 DIVERTER CIRCUIT OPERATION
14.22.1 If nuisance tripping occurs during normal
operation, use the procedure of 14.17.11 and
increase the trip setting by increments of 0.1V
until nuisance tripping does not occur. (It should
not be necessary to increase this setting more
than 0.5VDC. )
14.23 THIS COMPLETES TESTING OF THE
CROWD ARMATURE CONTROL
14.23.1 Press the STOP push-button.
14.23.2 Remove all PLC forces.
14.23.3 Open the field circuit breakers.

14.20.3 Record VAFB while alternately applying full 14.23.4 Enable OPEN SCR TEST. At the crowd AFM
positive and full negative reference and compare keypad, change Y058 from D087 ZERO BIT to
the recordings with Figure 14.20.3. D149 TEST ARM. Reset drive.

14.20.4 Press the STOP push-button.

14.21 DIVERTER VAFB SIGNAL CHECKS,

CROWD

14.21.1 Connect a digital voltmeter from TB1-4 to

TB1-5 on the crowd diverter control module.

14.21.2 With the test selector switch set to RUN, press

START button and CROWD BRAKE RELEASE
button.

14.21.3 Operate the crowd motion, and check that the

voltage is –8.9V"1V at full speed in the crowd
direction and +8.9V"1V at full speed in the lower
direction.

14.21.4 Set the dipper on the ground and press STOP

button.

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 44 CAT312.fm
 Electrotorque Plus®

Figure 14.20.3 Propel VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 45 TEST PROCEDURE
Return to Index
Electrotorque Plus®

15. SWING ARMATURE CONTROL 15.2.2 Using a DVM, check that the following voltages
are present at the swing armature AFM:
15.1 TEST PREPARATION A) 120VAC Control Power at TB1-1 to TB1-2.
15.1.1 Set the test selector switch to CONTROL TEST. B) 230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3.
15.1.2 Open the circuit breakers on the RPC cabinet. C) 42VDC (approx. 50VDC no load) gate voltage at
Open the constant voltage module supply circuit P11-13 (+) to P11-14 (–).
breaker (CVMSB), and the control supply
breaker (CSB).
15.3 15.3 AFM SOFTWARE
15.1.3 Connect a 12.5 ohm current limiting resistor in
series with the swing motor armature. 15.3.1 When the swing AFM is properly powered, its
LCD Display should read:
15.1.4 Install a reference/push-button unit. See Fig-
ure 2.2.2 in Appendix B. P&H Electrotorque-Plus
Armature Control
15.1.5 Check the ID on the flash PROM (U8), and on
the EEPROM (U10) to make sure that they
agree with the shovel documentation. This indicates that this AFM most likely has the cor-
rect firmware installed.
15.1.6 Check for open or shorted thyristor firing pulse
cables by measuring between the bridge inter- 15.3.2 Use the drive keypad to go to the ACCESS
face connector pins. A reading of 50 ohms is to CODES sub-menu. Enter the sub-menu using
be expected between the following pins: the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
P9-1 to P9-2, P9-3 to P9-4, number agrees with the shovel documentation.
P9-5 to P9-6, P9-9 to P9-10,
15.4 AFM TESTING
P9-11 to P9-12, P9-13 to P9-14,
P9-15 to P9-16, P9-17 to P9-18, 15.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board A1 on your
P9-19 to P9-20, P9-23 to P9-24, right side. Attach a digital voltmeter across TP1
P9-25 to P9-26, P9-27 to P9-28 (ACOM) and TP2 (VREF) which are located on
the bottom left side of the microprocessor board.
15.2 SUPPLY VOLTAGES Record the measured voltage (approx. –7.000
VDC) as a negative number.
15.2.1 Close the following circuit breakers:
15.4.2 Use the drive keypad to go to the DRIVE CALI-
• 120V Main Breaker (MB) BRATE sub-menu. Enter the sub-menu using
• Constant Voltage Supply Breaker (CVSB) the right arrow key and set the following
parameter:
• DC Contactor Supply (DCSB)
• 230V Supply Breaker (SB) X000: I/O V-REF = – VDC (value measured in
15.4.1 )
• Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB) Press the S key twice to save the value and exit the
• Constant Voltage Module Supply Breaker edit mode.
(CVMSB)
15.4.3 Reset the drive by cycling the drive power.
• Synchronizing Supply Breaker (SSB)
15.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 46 CAT312.fm

15.5 AUTOCAL PROCEDURE (Operator’s refer-
ence Calibration)
15.5.1 On the GUI, go to the AFM TEST SCREEN.
15.5.2 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the SWING BRAKE RELEASE button.
15.5.3 Turn the swing reference potentiometer to full
positive (+). On the GUI, press the AUTOCAL
SWING ON touch button.
15.5.4 After the GUI touch button turns green for a
few moments, press the AUTOCAL SWING OFF
touch button.
15.5.5 When the touch button turns red, turn the
swing reference potentiometer to full negative
(–).
15.5.6 On the GUI, press the AUTOCAL SWING ON
touch button. After the GUI touch button turns
green for a few moments, press the AUTOCAL
SWING OFF touch button.
15.5.7 Confirm that the reference signals are properly
calibrated by checking that the ADJUSTED
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
15.5.8 The swing AUTOCAL procedure is complete.
Press the STOP push-button.
Press the drive S key twice to exit the sub-menus.
15.6 THYRISTOR PULSE SEQUENCE
15.6.1 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the SWING BRAKE RELEASE button.
15.6.2 With the reference in the full negative (–)
(swing left) position, use an oscilloscope to check
the firing pulse sequence of the swing left con-
verter, Figure 15.6.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
15.6.3 Place the reference in the full positive (+)
(swing right) position, and check the firing pulse
sequence of the swing right converter, Figure
15.6.
15.6.4 Press the STOP push-button.
15.7 VOLTAGE CONTROL, SWING
15.7.1 Disable OPEN SCR TEST. At the Swing AFM
keypad, change Y058 from D149 TEST ARM to
D087 ZERO BIT. Reset drive.
15.7.2 Connect a digital voltmeter (1kV range) across
the series armature resistor.
15.7.3 Remove the relay from the differential voltage
module (DVAS) to prevent shutdown due to
unbalanced armature voltage.
15.7.4 Set the test selector switch to ARMATURE
TEST, and close the high voltage disconnect
switch.
15.7.5 Set the reference to 0V.
15.7.6 Press the START push-button.
15.7.7 Check that the dc voltage across the series
armature resistor is approximately 0VDC. (A
higher voltage would indicate the possibility of a
phasing error on the main transformer second-
ary, or on the synchronizing supply voltage.)
15.7.8 Press the SWING BRAKE RELEASE push-but-
ton. Slowly, increase the swing reference in the
positive direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference.
15.7.9 Slowly, Increase the swing reference in the neg-
ative direction.
The voltage across the feedback resistor should
increase directly in proportion to the reference, and
should have changed polarity.
47 TEST PROCEDURE
Electrotorque Plus®

Figure 15.6 Firing Pulse Sequence Oscilloscope Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 48 CAT312.fm

15.8 CURRENT FEEDBACK, SWING
15.8.1 With the reference close to fully positive, check
that the current feedback signal at the AFM
connector P11 - terminal 10 to terminal 8 (10251
to 01021C) is positive. This signal will be very
small, 0.1V or less so use care in reading the
meter, or better still, use a strip chart recorder
to assure that the feedback polarity is correct.
15.8.2 With the reference close to fully negative, check
that the current feedback signal at the AFM
connector P11 - terminal 10 to terminal 8 (10251
to 01021C) remains positive.
15.8.3 Reduce the reference to 0V. Press the STOP
push-button.
15.8.4 Remove the series armature resistor.
15.9 ARMATURE CURRENT RESPONSE,
SWING
15.9.1 Connect a strip chart or memory recorder
(Ch. 1 ) across the Swing current feedback
(IAFB) test jacks.
15.9.2 Press the START push-button. Press the
SWING BRAKE RELEASE push-button.
Increase the swing operator’s reference until the
armature current ammeter reads 500A.
15.9.3 On the GUI, press the SWING STEP REFER-
ENCE touch button. The PLC will cause the
AFM to pulse the output current for a 10 sec.
period. During this period, record the IAFB out-
put, and compare the recording to Figure 15.9.
Overshoots or undershoots should not be
present.
15.9.4 Press the STOP push-button.
15.10 STALL CURRENT, SWING
15.10.1 Use the drive keypad to go to the DRIVE
ANALOG sub-menu. Enter the sub-menu using
the right arrow key, then go to parameter A004:
I ARM AMP.
15.10.2 Connect a digital voltmeter across the swing
current feedback (IAFB) test jacks.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
15.10.3 Calculate the dc voltage to be expected across
the IAFB test jack resistor:
Istall / 300 = Vtest jack
Example:
2250A / 300 = 7.5 VDC
15.10.4 Set the meter selector switch to monitor the
swing motion parameters.
15.10.5 Set the swing reference potentiometer to 0
VDC. Press the START push-button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. Longer periods will
cause localized commutator heating.
15.10.6 Press the SWING BRAKE RELEASE push-
button.
15.10.7 Increase the swing reference to full positive
(swing right). Check the current value shown
on the drive LCD Display. Record the voltage
seen across the IAFB test jacks.
15.10.8 Press the SWING BRAKE SET push-button.
15.10.9 Verify that values recorded in 15.10.7, agree
with the I-A2 level shown in the Specified Elec-
trical Data sheet.
15.10.10 After the commutators have been allowed to
cool for at least one full minute, again, Press the
SWING BRAKE RELEASE push-button and
increase the swing reference to full negative
(SW. LEFT).
15.10.11 Verify that values recorded in 15.10.7, agree
with the I-A3 level shown in the Specified Elec-
trical Data sheet. Press the SWING BRAKE
SET push-button.
15.10.12 After the commutators have been allowed to
cool for at least one full minute, again, press the
SWING BRAKE RELEASE push-button and
increase the swing reference to full positive
(swing right).
49 TEST PROCEDURE
Electrotorque Plus®

Figure 15.9 Swing VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 50 CAT312.fm

15.10.13 Check that the analog armature current
panel meter also reads the stall level +/–50A.
15.10.14 Press the SWING BRAKE SET push-button.
Reduce the swing reference to 0 VDC.
15.11 VOLTAGE CONTROL - RUN MODE,
SWING
15.11.1 Set the test selector switch to RUN.
15.11.2 Deactivate the RPC shutdown by forcing off
the RPC circuit breaker inputs.
(Alternative: Disconnect the RPC circuit breaker inter-
lock input to the PLC.)
15.11.3 Close the swing field circuit breaker.
15.11.4 With the reference set to 0 VDC, press the
START button.
15.11.5 Press the SWING BRAKE RELEASE push-
button and check that the armature current is
approximately 0.
15.11.6 Check that the motors can be controlled with
the reference by accelerating, decelerating and
changing direction. Do not exceed 50% of full
speed.
15.11.7 Set the swing brakes. Press the STOP push-
button.
15.12 FUSE FAULT DETECTION, SWING
15.12.1 Remove a fuse monitor lead from the swing
armature converter.
15.12.2 Press the START button.
15.12.3 Check that the machine shuts down and that
a swing fuse fault is indicated.
15.12.4 Replace the fuse lead.
15.13 DIVERTER CIRCUIT CHECKS.
15.13.1 Check that the relay and control supply cir-
cuit breakers are closed.
15.13.2 Set the test selector switch to CONTROL
TEST.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
15.13.3 Connect a voltmeter to (TB1-1) on the swing
diverter control module and check that the sup-
ply voltage is +28VDC.
15.13.4 Press the START button.
15.13.5 Check that the READY light on the diverter
module is on.
15.13.6 Check that the DE-BLOCK LED on the AFM
is on.
15.13.7 Check the gate block circuit by shorting TB2-
10 to TB2-9 on the diverter module.
15.13.8 The DE-BLOCK LED on the AFM should not
be illuminated.
15.13.9 Press STOP button. Remove the short on the
diverter module.
15.14 DIVERTER CURRENT SENSOR
CHECKS, SWING
15.14.1 Connect a digital voltmeter to TP2 (–) and
TP3 (+) on the swing diverter control module.
15.14.2 Set the test selector switch to ARMATURE
TEST.
15.14.3 Press START button, press SWING BRAKE
RELEASE button and check that the meter
reads at full swing:
Volts = Iarmstall/300 (+/–0.5VDC)
15.14.4 Record this in the test data sheet.
15.14.5 Press the STOP button. Disconnect the DVM.
15.15 DIVERTER CAPACITOR CHECKS,
SWING
15.15.1 Reconnect the wire to the capacitor charging
relay at the terminal board on the swing
diverter circuit panels in the converter cabinet
to activate the capacitor charging power supply.
Use extreme caution when making volt-
age measurements in this section of the
51 TEST PROCEDURE
Electrotorque Plus®
test procedure. Voltages of approxi-
mately 1300V will be measured.
15.15.2 Connect a digital voltmeter (1kV range)
across the swing diverter capacitor for the for-
ward bridge.
15.15.3 Manually depress the swing capacitor charg-
ing relay armature to close its contacts.
15.15.4 The voltage across the diverter capacitor
should begin to climb at the capacitor charges.
Ultimately this voltage should be about 1300
VDC, but to avoid overvoltage on the DVM, we
will stop charging (release the relay armature)
at about 900 VDC. Check schematics for polar-
ity, and verify that the charging polarity is cor-
rect.
15.15.5 When you release the charging relay, the volt-
age across the diverter capacitor must decay to
less than 50 VDC in less than 30 sec.
15.15.6 Repeat these tests for the reverse bridge
swing diverter capacitor.
15.16 CHECK DIVERTER CIRCUIT OPERA-
TION, SWING
15.16.1 Connect a digital voltmeter to TP1(+) and
TP2(–) on the diverter control module.
15.16.2 Adjust the current trip adjust potentiometer
so that the meter reads +2.1VDC.
15.16.3 Set the test selector switch to ARMATURE
TEST.
15.16.4 Reconnect the meter to TP3(+) and TP2(–) on
the diverter control module.
15.16.5 Press the START button. Press the SWING
BRAKE RELEASE button.
15.16.6 Slowly increase the swing reference to the full
swing right position.
15.16.7 Check that the machine shuts down when the
meter reads about 3.5VDC.
15.16.8 Check that the capacitor voltage on the swing
converter bridge drops instantly to approxi-
mately 0 volts.
TEST PROCEDURE
15.16.9 Press the STOP button.
15.16.10 Adjust the current trip for normal operation.
15.16.11 Reconnect the meter to TP1(+) and TP2(–) on
the control module.
15.16.12 Readjust the current trip adjust potentiome-
ter to its maximum clockwise position.
15.16.13 Press the START push-button. Press the
SWING BRAKE RELEASE button.
15.16.14 Stall the swing and turn down the current
trip potentiometer until the module trips. Do
not stall motor for more than 5 seconds.
15.16.15 Check and read voltage at TP1-TP2.
15.16.16 Readjust level as follows.
Volts = (VTP1-VTP2) x 1.4
Where:
VTP1 to VTP2 is from 15.16.15
15.17 OPERATE FROM THE OPERATOR’S
COOP, SWING
15.17.1 Remove the reference/push-button unit.
Reconnect the PLC/coop cables.
15.17.2 REPEAT THE AUTOCAL PROCEDURE
(Operator’s Reference Calibration)
15.17.3 On the GUI, go to the AFM TEST SCREEN.
15.17.4 Verify that the test selector switch is set to
CONTROL TEST. Press the START push-but-
ton, and the SWING BRAKE RELEASE button.
15.17.5 Move the swing controller potentiometer to
full positive (+). On the GUI, press the AUTO-
CAL SWING ON touch button.
15.17.6 After the GUI touch button turns green for a
few moments, press the AUTOCAL SWING OFF
touch button.
15.17.7 When the touch button turns red, move the
swing controller potentiometer to full negative
(–).
Copyright © 1999 Harnischfeger Corporation
52 CAT312.fm

15.17.8 On the GUI, press the AUTOCAL SWING ON
touch button. After the GUI touch button turns
green for a few moments, press the AUTOCAL
SWING OFF touch button.
15.17.9 Confirm that the reference signals are prop-
erly calibrated by checking that the ADJUSTED
REFERENCE at A066 is +100% with the refer-
ence full positive, and –100% with the reference
full negative. Use the drive keypad to go to the
OPERATE sub-menu. Enter the sub-menu
using the right arrow key. Arrow up to reach
the BLOCKS ANALOG sub-menu, and enter it
with the right arrow key. Arrow up to A066.
15.17.10 The swing AUTOCAL procedure is complete.
Press the STOP push-button. Press the drive S
key twice to exit the sub-menus.
15.17.11 Set the test selector switch to RUN. START
the machine and RELEASE the Swing brakes.
15.17.12 Check that full control of the swing motion is
obtained by the operator’s controller.
15.17.13 Check that the swing motion runs in the
proper direction in relation to the controller
position.
If the motor rotation is wrong, check that the reference
is of the proper polarity.
The motor rotation may be reversed by reversing the
motor field connections.
15.18 VOLTAGE RESPONSE, SWING
15.18.1 Connect a chart recorder to record across the
swing armature voltage feedback (VAFB) test
jacks (Ch. 1), and the swing armature current
feedback (IAFB) test jacks (Ch. 2).
15.18.2 Press the START push-button. Press the
SWING BRAKE RELEASE button.
15.18.3 Check that the armature voltage of each
motor is correct for both full swing right and full
swing left directions as spelled out in the Speci-
fied Electrical Data sheet.
• 15.18.3.1 If the terminal voltage is significantly
lower than the voltage read at the AFM (A012
ARM VOLTS) then change the X003 parameter
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
from 100 to something less. For example: If the
measured terminal voltage is 500V and A012
reads 550V then change X003 from 100 to 91 (500/
550 x 100 = 91). Changes made to X parameters
are activated immediately after pressing the S key.
15.18.4 Operate the swing by alternately applying full
positive and full negative reference and compare
the recordings of VAFB and IAFB with 15.18.4.
15.18.5 Set the dipper on the ground and press the
STOP push-button.
15.19 DIVERTER VAFB SIGNAL CHECKS,
SWING
15.19.1 Connect a digital voltmeter from TB1-4 to
TB1-5 on the swing diverter control module.
15.19.2 With the test selector switch set to RUN, press
START button and SWING BRAKE RELEASE
button.
15.19.3 Operate the swing motion, and check that the
voltage is –9.7V+/–1V at full speed in the swing
direction and +9.7V+/–1V at full speed in the
lower direction.
15.19.4 Set the dipper on the ground and press STOP
button.
15.20 DIVERTER CIRCUIT OPERATION
15.20.1 If nuisance tripping occurs during normal
operation, use the procedure of 15.16.11 and
increase the trip setting by increments of 0.1V
until nuisance tripping does not occur. (It should
not be necessary to increase this setting more
than 0.5VDC. )
15.21 THIS COMPLETES TESTING OF THE
SWING ARMATURE CONTROL
15.21.1 Press the STOP push-button.
15.21.2 Remove all PLC forces.
15.21.3 Open the field circuit breakers.
15.21.4 Enable OPEN SCR TEST. At the Swing AFM
keypad, change Y058 from D087 ZERO BIT to
D149 TEST ARM. Reset drive.
53 TEST PROCEDURE
Electrotorque Plus®

Figure 15.18.4 Swing VAFB and IAFB Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 54 CAT312.fm
Return to Index
Electrotorque Plus®

16. REACTIVE POWER COMPENSATOR, 16.1.6 Check for open or shorted thyristor firing pulse
cables by measuring between the bridge inter-
(RPC). face connector pins. A reading of 50 ohms is to
be expected between the following pins:
The RPC utilizes banks of tuned capacitors/reactors,
which are automatically switched in and out of the P9-1 to P9-2, P9-3 to P9-4,
600V power circuit. The number of banks used,
depends on the individual shovel model served. A P9-5 to P9-6, P9-9 to P9-10,
combination of 1/2 and full banks are used for compen- P9-11 to P9-12, P9-13 to P9-14,
sation. As can be seen in the following chart, the 1/2
bank is brought in to add compensation of smaller P9-15 to P9-16, P9-17 to P9-18,
increments between the full banks. P9-19 to P9-20, P9-23 to P9-24,
P9-25 to P9-26, P9-27 to P9-28

16.2 SUPPLY VOLTAGES

STEP # 1 2 3 4 5 6 7

1/2 BANK | O | O | O | 16.2.1 Close the following circuit breakers:

BANK 1 O | | | | | | • 120V Main Breaker (MB)

• Constant Voltage Supply Breaker (CVSB)
BANK 2 O O O | | | |
• DC Contactor Supply (DCSB)
BANK 3 O O O O O | |
• 230V Supply Breaker (SB)
TOTAL # OF 1/2 1 1 1/2 2 2 1/2 3 3 1/2
BANKS ON • Control Supply Breaker (CSB)
• Relay Supply Circuit Breaker (RSCB)
| = Bank is ON O = Bank is OFF • Constant Voltage Module Supply Breaker
(CVMSB)
16.1 TEST PREPARATION • Synchronizing Supply Breaker (SSB)

16.1.1 Set the test selector switch to CONTROL TEST.
16.1.2 Open the constant voltage module supply cir-
cuit breaker (CVMSB), and the control supply
breaker (CSB).
16.1.3 Open the circuit breakers on the cabinet for the
Reactive Power Compensator.
16.1.4 Install a reference/push-button unit. See Figure
2.2.2 in Appendix B.
16.2.2 Using a DVM, check that the following voltages
are present at the RPC AFM:
A) 120VAC control power at TB1-1 to TB1-2.
B) 230VAC, 3ph, synchronizing voltage at P11-1 to
P11-16 to P11-3.
C) 42VDC (approx. 50VDC no load) gate voltage at
P11-13 (+) to P11-14 (–).

16.1.5 Check the ID on the flash PROM (U8), and on

the EEPROM (U10) to make sure that they
agree with the shovel documentation.

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 55 TEST PROCEDURE
Electrotorque Plus®
16.3 AFM SOFTWARE
16.3.1 When the RPC AFM is properly powered, its
LCD Display should read:
P&H Electrotorque-Plus
RPC Control
This indicates that this AFM most likely has the cor-
rect firmware installed.
16.3.2 Use the drive keypad to go to the ACCESS
CODES sub-menu. Enter the sub-menu using
the right arrow key and go to E007 SWR VER-
SION. Confirm that the displayed software part
number agrees with the shovel documentation.
16.4 AFM TESTING
16.4.1 Open the Electrotorque-Plus top door to
expose the microprocessor board A1 on your
right side. Attach a digital voltmeter across TP1
(ACOM) to TP2 (VREF) which are located on the
bottom left side of the microprocessor board.
Record the measured voltage (approx. –7.000
VDC) as a negative number.
16.4.2 Use the drive keypad to go to the DRIVE CALI-
BRATE sub-menu. Enter the sub-menu using
the right arrow key and set the following param-
eter:
X000: I/O V-REF = – VDC (value measured in
16.4.1 )
Press the S key twice to save the value and exit the
edit mode.
16.4.3 Reset the drive by cycling the drive power.
16.4.4 Verify that the EMERG STOP OK and DRIVE
READY LED’s are illuminated.
16.5 LEVEL DETECTOR CHECKS
16.5.1 Connect a digital voltmeter to the manual
kVAR reference input to the RPC AFM at con-
nector P9-16 (+) to P9-17 (–). Set the Manual
kVAR potentiometer to 0.00.
TEST PROCEDURE
16.5.2 Set the test selector switch to CONTROL TEST.
Press the START push-button. On the GUI,
press the RPC MANUAL MODE touch button.
16.5.3 Slowly increase the manual kVAR reference
until the first green LED (STEP 1) on the AFM
illuminates. The voltmeter reading the kVAR
reference should now read V-LEV1 as docu-
mented in the Specified Electrical Data sheet.
16.5.4 Increase the manual kVAR reference until each
successive LED on the AFM illuminates. As
each LED first turns on, the kVAR reference
should read the appropriate V-LEV as docu-
mented in the Specified Electrical Data sheet.
16.5.5 Reduce the manual kVAR reference to 0VDC.
16.6 RPC FIRING CHECKS
16.6.1 Slowly increase the manual kVAR reference
until the first green LED (STEP 1) on the AFM
illuminates. Verify that the red LED’s for the
1/2 BANK pulse transformers are illuminated
(dimly).
16.6.2 Connect an oscilloscope to the gate (G) and
cathode (K) of each pulse transformer. Firing
pulses should be similar to that shown in Figure
16.6.2.
Figure 16.6.2 Thyristor Pulse Waveform
16.6.3 As required, continue increasing the manual
kVAR reference until STEP 2 LED on the AFM
illuminates. Verify that the red LED’s for the
BANK 1 pulse transformers are illuminated.
Check firing pulses.
Continue to the next bank by increasing the reference
to STEP 4 for BANK 2, and to STEP 6 for BANK 3.
Check firing pulses after each bank.
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16.6.4 Reduce the manual kVAR reference to 0VDC.
On the GUI, press the RPC MANUAL MODE
OFF touch button.
16.7 RPC OPERATION WITH CAPACITOR
TEST UNIT.
16.7.1 Verify that the manual kVAR reference is set to
0VDC. Verify that all of the RPC circuit break-
ers are open on the RPC cabinets.
Figure 16.7.2 Capacitor Test Typical Connections
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
16.7.2 Connect each leg of the capacitor test unit (Fig-
ure 2.2.5 in Appendix B) across the open con-
tacts of the breaker on the 1/2 bank. Figure
16.7.2 shows the typical connections.
16.7.3 Short circuit each capacitor bank on this step
with jumper wires. (The reactors need not be
shorted for this test.)
57 TEST PROCEDURE
Electrotorque Plus®
16.7.4 Set the test selector switch to ARMATURE
TEST.
16.7.5 Connect a digital (dc setting) voltmeter (1kV
range) between terminals MS1 and RBC of the
capacitor unit to measure approximately
800VDC.
The recorder or oscilloscope being used
should be isolated from its power sup-
ply through an isolation transformer
because of the high voltage to ground
(approximately 1000V).
DO NOT TOUCH the instrument frames when power
is on the RPC.
DO NOT TOUCH live parts when obtaining measure-
ments on the RPC equipment when power is on the
RPC.
16.7.6 Press the START button.
16.7.7 Check that the voltmeter indicates approxi-
mately 800V with reference set at 0.
16.7.8 Connect voltmeter between terminals MS2 and
RCC and check that voltage is approximately
800V.
16.7.9 Connect the voltmeter to MS3 and RAC, repeat
the above tests.
16.7.10 Press the STOP push-button.
16.7.11 Connect a stripchart recorder across one of the
10 ohm resistors on the capacitor unit. The
recorder should be isolated from its power sup-
ply through an isolation transformer, or be bat-
tery operated, because of the high voltage to
ground (approximately 1000V).
DO NOT TOUCH the frame of the recorder while
power is on the RPC.
16.7.12 Press the START push-button.
16.7.13 Record the voltage across the resistor when
the output voltage from the manual kVAR refer-
ence is changed rapidly from a setting just below
the switching setpoint to a setting just above the
TEST PROCEDURE
setpoint, and back with the kVAR reference
potentiometer. Compare the recording to Figure
16.7.13.
Check that the first half cycle has the same amplitude
as the subsequent cycles.
16.7.14 These tests should be performed on all three
resistors of the capacitor unit. The recorder
must be run at high speed for these tests. Chart
paper can be saved by rapidly changing the ref-
erence signal before starting the recorder.
16.7.15 Press the STOP button.
16.7.16 Connect each leg of the capacitor test unit
across the open contacts of the breaker on
BANK 1. Repeat the tests of 16.7.1 through
16.7.15.
16.7.17 Connect the capacitor unit across the open
contacts of the breaker on BANK 2. Repeat the
tests of 16.7.1 through 16.7.15.
16.7.18 Connect the capacitor unit across the open
contacts of the breaker on BANK 3. Repeat the
tests of 16.7.1 through 16.7.15.
16.7.19 Remove the capacitor unit, jumper wires, and
all test instruments.
16.8 TESTING RPC POWER CIRCUITS
16.8.1 Check that the test selector switch is set to
ARMATURE TEST.
16.8.2 Connect a recorder, using a voltage divider,
across phase A of the 1/2 BANK to measure the
capacitor voltage (approximately 850V).
The recorder or oscilloscope being used
should be battery powered or isolated
from its ac power supply through an iso-
lation transformer because of the high
voltage to ground (approximately
1000V).
DO NOT TOUCH the instrument frames when power
is on the RPC.
Copyright © 1999 Harnischfeger Corporation
58 CAT312.fm
 Electrotorque Plus®

Figure 16.7.13 RPC Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 59 TEST PROCEDURE
Electrotorque Plus®
DO NOT TOUCH live parts when obtaining measure-
ments on the RPC equipment when power is on the
RPC.
16.8.3 Close the RPC circuit breaker for the 1/2 BANK
only.
16.8.4 Start the recorder (5 sec/div). Press the
START push-button.
16.8.5 Check that the voltage across the capacitors
corresponds to the recording of Figure 16.8.5.
Check the schematics for polarity. Check that
overshoots at the start, do not exceed those
shown in Figure 16.8.5.
16.8.6 Using the following procedure, check the RPC
capacitor switching.
16.8.7 Increase the recorder speed to 100ms/div and
record the voltage across the capacitors when
the output voltage from the kVAR reference
potentiometer is changed rapidly from a setting
just below the switching setpoint to a setting
just above the setpoint, and back with the RPC
reference potentiometer.
16.8.8 Check that the capacitors have been switched
on by noting if an ac voltage appears across the
terminals as shown in Figure 16.8.8.
16.8.9 Check that no overshoots occur when the capac-
itors are switched on or off.
16.8.10 Press the STOP push-button.
16.8.11 Connect the recorder across the capacitors of
phase B of the 1/2 BANK, and repeat the tests of
16.8.5 through 16.8.10.
!! OBSERVE WARNINGS !!
16.8.12 Connect the recorder across the capacitors of
phase C of the 1/2 BANK, and repeat the tests of
16.8.5 through 16.8.10.
!! OBSERVE WARNINGS !!
16.8.13 Open the circuit breaker for the 1/2 BANK,
and close the breaker for BANK 1.
16.8.14 Repeat the tests of 16.8.5 through 16.8.12 for
BANK 1.
TEST PROCEDURE
!! OBSERVE WARNINGS !!
16.8.15 As required, close the circuit breaker succes-
sively for BANK 2, and BANK 3, and open the
breaker for the previous bank.
Repeat the tests of 16.8.5 through 16.8.12 for each
phase of each bank.
NOTICE
Do not energize more than one bank at a
time.
16.8.16 Press the STOP Push-button.
16.9 REACTIVE POWER MEASUREMENT
These tests are made to check operation of the reactive
power measurement circuits.
16.9.1 Open all RPC Circuit Breakers. Check that the
test selector switch is set to ARMATURE TEST.
Connect two digital voltmeters. One between
terminals 1 and 2 on the kVAR transducer to
measure its output voltage, VQ, and another to
measure the ac voltage (115V) between termi-
nals 3 and 4, or 5 and 6 on the kVAR transducer.
16.9.2 Press the START push-button. Press the
HOIST BRAKE RELEASE push-button.
The motors should not be run at maxi-
mum stall current for more than 5 sec-
onds at a time. If repeated stall tests are
required the motors should be operated
in the RUN position occasionally to
eliminate the possibility of localized
heating on the commutators.
16.9.3 Set the hoist reference to the full positive (+)
position to give the specified stall armature cur-
rent I-A2.
16.9.4 Using two digital voltmeters, measure the out-
put voltage, VQ, of the kVAR transducer at ter-
minals 1 and 2, and simultaneously, the ac
voltage (115V) between terminals 3 and 4, or 5
and 6.
Copyright © 1999 Harnischfeger Corporation
60 CAT312.fm
 Electrotorque Plus®

Figure 16.8.5 RPC Switching Chart Recording

Copyright © 1999 Harnischfeger Corporation

CAT312.fm 61 TEST PROCEDURE
Electrotorque Plus®

Figure 16.8.8 RPC Capacitor Chart Recording

Copyright © 1999 Harnischfeger Corporation

TEST PROCEDURE 62 CAT312.fm

16.9.5 Return the hoist reference voltage to 0V. Set
the hoist brake, and press the STOP push-but-
ton.
16.9.6 Verify that the output voltage, V Q, measured is:
VQ = (0.00000141 x VAC x Iarmstall) +/–0.02VDC
Where: VAC is the AC voltage measured in step
16.10.3.
Example:
VQ = (0.00000141 x 105 x 2650A) +/– 0.02VDC
= 0.392 VDC +/– 0.02 VDC
16.10 CHECK THE RPC UNDER FULL POWER
CONDITIONS
16.10.1 Set the test selector switch to ARMATURE
TEST. Close all RPC circuit breakers.
16.10.2 Press the START push-button. Press the
HOIST and CROWD BRAKE RELEASE push-
buttons.
Copyright © 1999 Harnischfeger Corporation
CAT312.fm
Electrotorque Plus®
16.10.3 While someone is monitoring the RPC indica-
tors, the RPC steps can be successively brought
in slowly by stalling the hoist and then adding
the crowd.
Stall test must not exceed 10 seconds.
16.10.4 Reduce both the hoist and crowd reference
voltages to 0V. Set both brakes. Press the
STOP push-button.
16.10.5 Refer to the RPC indicator decals to verify
proper operation.
16.11 Remove test equipment.
16.11.1 Remove all PLC forces if any exist. Discon-
nect and remove the PLC terminal.
16.11.2 Remove the reference/push-button unit and
reconnect the appropriate PLC cables. Remove
any and all external connections made to the
control circuits.
63 TEST PROCEDURE