IGBT Standard Training Course Outline

SIEMENS Energy & Automation, Inc.

IGBT Standard Training Course Outline

Revised JAN 2009

of 6

IGBT Standard Training Course Schedule

Class Length 5 Days

Scope of Class: This class is being given for IGBT Standard Shovel customers. It is assumed that the

people in class will be familiar with electrical shovels and basic electrical fundamentals. This class will

introduce the student to the technology as applied on the standard IGBT shovels.

I Documentation and Software furnished to the students:

A. Class Schedule

B. IGBT Shovel Systems Class Manual

C. General electrical schematics for shovels (SIEMENS & BUCYRUS)

D. General Information and Procedures for the SiBas control system

E. Shovel electronic devices manual

F. CDA / ANF Fault Manual

G. SIB Fault Manual

H. SIRAS remote logon information

I. SiBas Monitor software for connecting to SiBas32 program

Basic Outline:

I. System Overview (3 hours)

A. OBJECTIVES: Upon completion of this section, the student will be able to :

• Introduce the major technologies used in the standard IGBT System

• List the power connections and lock-out safety points for the cabinet

• Explain the operation of components used on the shovel “skid”

• List the three classes of faults that annunciate on the shovel

• Read schematics and locate components based on device name

• Maneuver through the various HMI screens found on the skid

• Research faults in both the HMI and the troubleshooting manuals

• Locate devices and characteristic in the Device Manual

B. MATERIALS:

• Class Manual

• Siemens Schematics

• Bucyrus Schematics

• Device Manuals

• Troubleshooting Manuals

C. INTRODUCTION: Provides an overview of the technologies used in the Siemens IGBT shovel

family. The instructor introduces the major black boxes used in controlling the system. Discusses

the functions and responsibilities of each, as well as the interfaces between them.

D. SIEMENS SCHEMATICS: Introduction to the schematic style used for the IGBT system. Covers

Print Sections, Cross-Referencing, Tracing. Exercises include tracing control loops, component

locations, Cable Detail Identification, etc.

E. BUCYRUS SCHEMATICS: Explanation of the different style of drawing used in the Bucyrus

schematics. Identifying components and identifying interface points between the BI and SE&A

schematics.



Revised JAN 2009

of 6

F. SYSTEM COMPONENTS: Describes some of the important system devices, their operation and

their specifications. Comparison of device specifications from the vendors vs. those in the

application. Use of the Device Manual.

G. TYPES OF FAULT MESSAGES:

• ANF – PLC

• CDA – PLC

• SIB – SiBas

II. Component Identification – Practical (1 hour)

A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Locate any component in the Siemens cabinet based upon information from the Siemens

schematic.

• Locate any component in the Siemens schematic based upon its markings in the drive cabinet.

• Locate and Identify all connections points for field wiring to the drive cabinet

B. MATERIALS:

• Class Manual


• Bucyrus Schematics

• Device Manuals

• Troubleshooting Manuals

• Shovel drive cabinet – Power Disconnected

III. HMI Operation (2 hours)


• Monitor feedback values from the PLC and drive systems.

• Locate the various screens for Active Logic for monitoring and troubleshooting.

• Read faults from the Active Alarms screen.

• Read and Save faults from the Fault History screen.

• Follow faults to the on-line Troubleshooting Manual.

B. MATERIALS:

• Maintenance Station Owner’s Manual

IV. HMI Operation – Practical (2 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Monitor feedback values from the PLC and drive systems.

• Locate the various screens for Active Logic for monitoring and troubleshooting.

• Read faults from the Active Alarms screen.

• Read and Save faults from the Fault History screen.

• Follow faults to the on-line Troubleshooting Manual.

• Use Footprints screen to locate system components.

• Locate and view Synchronizing voltages ULRT & ULST

B. MATERIALS:

• Maintenance Station Owner’s Manual

• Shovel drive cabinet – Power ON



Revised JAN 2009

of 6

V. SiBas 32 (6 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Explain the functions of the ZR and SIP processors

• Explain the difference between the PLC and SiBas scan logic

• Explain different block types, connector types, and scan times in the SiBas program.

• Trace the signal flow through the speed regulator function package.

• Explain the functions of each card in the SiBas rack.

• Explain the different protection levels in the UWS cards.

• Start the Monitor program.

• Start the Monitor program to load the ZR and SIP programs.

• Start the Monitor program to read faults and clear faults.

• Start the Monitor program to read and record values.

• Start the Monitor program to change connectors and edit changes in the buffer

• Explain the functions of the SIP Traco and how to set up and trigger record on fault

conditions.

• Set the system to Manual mode (for hoist & crowd).

B. MATERIALS:

• SiBas Rack

• Laptop with SiBas Monitor program installed

• Interface cable

• Class Manual

• Microsoft Excel

• Manual General Information and Procedures for SiBas 32 Control System

C. SiBas OVERVIEW:

• SiBas as a motion control system, the differences between SiBas and earlier control systems.

D. READING SiBas PROGRAM LISTING:

• Reading Function Packages; block types, scan rates, scan sequence, connector and data types.

E. SiBas RACK CARDS:

• Functionality and interchangeability of SiBas rack cards. Different levels of protection in the

UWS cards and their reset routine.

F. SiBas HARDWARE LIST:

• Guide to reading the SiBas Hardware List; information contained.

G. SiBas MONITOR:

• Installation, startup and configuration. Observing connectors and changing values.

• Creating, opening and saving files and data

• Loading programs into the ZR and SIP cards. SIP Traco functions.

A. SiBas MONITOR PRACTICE

• Exercises for the installation, startup and configuration of the software on the laptop.

• Creating, opening and saving files and data.

VI. SiBas 32 – Practical (2 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Creating, opening and saving files and data.

• Trapping signal values in the Monitor program.

• Graphing signal values in Excel

• Practice in troubleshooting SiBas faults

B. MATERIALS:

• SiBas Monitor Software with Interface cable and Microsoft Excel programs




Revised JAN 2009

of 6

VII. Step 7 PLC and ET200 Stations (6 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Understand the topology of the S7 network and its stations

• Understand and Edit the S7 Hardware Configuration

• Understand basics of Profibus communication

• Work between the ON line / OFF Line windows

• Use the Simatic Manager to check system information

• Use the Simatic Manager to observe and change PLC values

• Use the Simatic Manager to search for variables and I/O

• Download & Upload programs

• Archive & Retrieve projects

• Configure individual ET200 stations

• Understand PLC program structure

B. MATERIALS:

• Class Manual

• Laptop with Simatic Manager installed

C. PLC HARDWARE: Explanation of PLC network configuration. Differences between earlier

network with Host PC / Slot PLC and the new system with Rocky. Explanation of ET200 cards

and setup. Setting network addresses at stations and terminating resistors.

D. PROFIBUS: Basic steps in setting up Profibus networks.

E. STEP 7 INTRODUCTION

F. STEP 7 SIMATIC MANAGER

• Using the Simatic Manager to open PLC projects

• Viewing and setting up the Hardware Configuration

• Object properties of the hardware components

• Searching for I/O and variables in the Step 7 program

• Comparing I/O addresses in the PLC program and the Siemens schematics

• Troubleshooting from the HMI – System Ready screen and the Simatic Manger

G. SETTING IP ADDRESS IN STEP 7

• Setting the internal Ethernet address for the PLC

VIII. Step 7 PLC - Practical (2 hours)


• Troubleshoot problems via the System Ready screen, the Simatic Manager and around the

network.

B. MATERIALS:


• HMI screens and the preinstalled Simatic Manager



Revised JAN 2009

of 6

IX. Shovel Command / Control Structure (2 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• List the steps in the DC Buss ON/OFF sequence

• List the steps in the Motion ON/OFF sequence

B. MATERIALS:

• Class Manual

• PLC Listing

X. AC Motors & Controls (2 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• Explain the motor nameplate information

• Understand the difference between real power and reactive power and describe power factor

• Explain the three basic methods of motor speed control

B. MATERIALS:

• Class Manual

• Step 2000 series guide

C. BASICS OF AC MOTORS

• Nameplate data and slip

• Real power, reactive power and power factor

• Volts per Hertz relationship

D. BASIC DRIVE OPERATION

• Modes of open-loop and closed-loop control for variable speed motors

• The SiBas implementation of control

• Torque and flux generation

• Functions of the SIP’s and ZR

XI. AFE Operation & State Vector Control (2 hours) A. OBJECTIVES: Upon completion of this section, the student will be able to:

• List the advantages of the AFE’s compared to other rectification systems

• Describe the purpose of the choppers

• Describe the difference between chopper firing and AFE firing

• Describe the operation of Ground Fault detection in the IGBT system

B. MATERIALS

• Class Manuals and Overheads

C. BASICS OF AFE POWER SECTION OPERATION

• AFE Block Diagram

• State Vector Modulation (SVM)

D. BASIC AFE MONITORING

• Monitoring through the SiBas and the test points.

• Observation of the chopper operation

E. GROUND FAULT DETECTION

• Explanation of Ground Fault protection

XII. AFE Operation & Control – Practical (2 hours) A. OBJECTIVES

• Troubleshoot faults initiated in SiBas

B. MATERIALS


• Voltmeter



Revised JAN 2009

of 6

XIII. Midas and Siras (3 hours) A. OBJECTIVES

• Understand the differences between MIDAS and SIRAS and how they work together

• Understand Maintenance tools vs. Operations tools

• Become familiar with the various screens and information presented in the MIDAS DesktopR

B. MATERIALS

• Class Manual

• Laptop with MIDAS files stored for viewing

XIV. Review (1 hour) A. OBJECTIVES

• Summary of presented material

• Open question and answer period

IGBT Standard Training Course Outline

Documents

Transcript of IGBT Standard Training Course Outline