PDF Electrical Technical Manual Cat Bucyrus 30MB3 - 2 MB
This specialized technical manual focuses on the electrical systems of the Cat Bucyrus 30MB3 mining machine.
It provides detailed wiring diagrams, component locations, and troubleshooting procedures.
Electricians and technicians will find this guide indispensable for diagnosing and resolving electrical issues efficiently.
Ensure the safety and reliability of your equipment's complex electrical systems with this factory manual.
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BI620101
Β© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI620101
Bucyrus Australia
Delta SBD 30MB3 Electrical Manual
Main Chassis
CONVEYOR
PIVOT POINT
GATHERING HEAD PIVOT POINT
CUTTING HEAD PIVOT POINT
GATHERING HEAD PIVOT POINT
HYDRAULIC TANK
GATHERING HEAD
PIVOT POINT
The main chassis of the machine is a robust box-type structure of high-strength steel construction that
provides the following:
Mounting of the RH and LH crawler tracks and their independent drive systems and take-up
provisions.
β’ Independent pivots for mounting the cutting head and gathering head and conveyor components
and their associated hydraulic cylinders for articulation.
β’ An integral hydraulic oil tank along with two electric motor/hydraulic pump assemblyβs and
associated valves and piping.
β’ A rear stabiliser and its articulating hydraulic cylinder for improving leverage forces during shear-
down in the cutting sequence.
β’ Mounting provisions for all major electrical system components and their associated wiring.
December 2009 Page 8 of 22 Manual No. M01342
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Bucyrus Australia
Delta SBD 30MB3 Electrical Manual
Bolting, Mining and Maintenance Modes
Bolting, Mining and maintenance modes have been fitted to the 30MB3 Miner and can be selected by
operating a diversion valve as per its tagging, this valve is mounted upon the Right Hand side of the
Miner beside the rib drilling rig.
The selections for the diversion valve are as follows:
Mining Mode - Raise the handle to the top position
Maintenance Mode - Move the handle to the centre position
Bolting Mode - Lower the handle to the lowest position
December 2009 Page 18 of 22 Manual No. M01342
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Bucyrus Australia
Delta SBD 30MB3 Electrical Manual
3. Isolate and secure energy sources
β’ Isolate primary isolator in an approved manner or using site procedures and/or
manufacturers recommended instructions e.g., operate whole current isolator, remove plug,
close valve etc. Shedding of loads prior to operating primary isolator may need to be
considered in some instances.
β’ Isolate or secure/control all secondary energy sources. For example:
- bleed off stored hydraulic or pneumatic pressure from pressure vessels, accumulators
etc,
- Release stored energy such as springs, conveyor belt tension, etc.
- secure/barricade/chock elevated equipment or material hang-up in chutes, truck bodies
etc
- Chock machinery and equipment to prevent unplanned movement.
β’ Do not use auxiliary devices for isolation e.g., push buttons, control circuit devices,
emergency stop buttons, key-switches, conveyor lanyards, etc. except where these remote
isolator devices control an approved (to relevant Australian Standard) whole of current
isolation device e.g. Motorised lanyard controls on conveyors to AS1755.
4. Apply Personal Danger Tags / Locks, or Permit Danger Tags / Locks
β’ A Personal Danger Tag or lock is to be placed on the appropriate isolation point/s by a
competent person.
β’ In the case of a permit:
- a Permit Danger Tag / Lock is to be placed on the relevant isolation point/s by the
Authorised Isolator after the Permit Holder has raised the appropriate permit
- All members of the work party shall sign onto, or attach their Personal Danger Tag or
lock to the appropriate permit after checking the work they are performing is covered by
the Permit.
β’ Any visitor requiring to place a Personal Danger Tag or lock or sign onto a permit can only
do so under direct supervision of a competent person or Permit Holder
NB Depending on the circumstances, it may be necessary to reverse steps 4 and 5 e.g. When
access to switchboards is necessary for verification purposes and a tag or lock will prevent
entry.
5. Verify the effectiveness of the isolation
All isolations must be checked to verify the isolation has been effective by:
β’ Testing the test equipment is in good operating condition and is set to correct scale eg.
Pressure gauges, non-contact voltage detector, multi-meters etc
β’ Checking the operation of test equipment before and after isolation
β’ Test the isolation has been effective by:
- Checking for the presence of voltage for electrical isolations
- Attempting to start the equipment e.g. mobile equipment/machinery
- Opening valves in pipelines
- Confirming secondary energies are secured e.g. Chocks etc.
Check for test methods that may have been developed and approved for use for various
isolations.
Manual No. M01342 Page 5 of 9 December 2009
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Bucyrus Australia
Delta SBD 30MB3 Electrical Technical Manual
Control and Light Circuit Breakers
The control and lights breaker handle is a thin lever located on the top right hand side of the
flameproof Main Control Case, which is on the left hand side of the machine.
The lever is pushed in to turn both circuit breakers ON and pulled out to turn circuit breakers OFF.
If the machine is powered and these circuit breakers are ON, the green 110V Control LED indication
light should be indicating healthy, behind the viewing window on the Main Control Case.
Traction AC Circuit Breakers
The Traction AC Circuit Breakers are located in the flameproof Main Control Case and operated via
the operating handle located on the front right hand side on the Main Control Case.
These isolate the AC power to the SCR Traction Drive Units. The circuit breakers are switched on by
moving the handle to the left. If a circuit breaker has tripped it must be reset by turning the handle
fully to the OFF position before it can be turned back on.
Whenever working on the traction, setting conveyor stops or head stops ensure both circuit breakers
are opened and operator handle tagged.
NOTE: This circuit breaker must be open to operate in
maintenance mode
Control & Lights Circuit
Breaker Lever
Traction Circuit
Breakers Handle
December 2009 Page 5 of 14 Manual No. M01342
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BI620101
30MB3 ELECTRICAL
TECHNICAL MANUAL
SECTION 4
GENERAL ELECTRICAL
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BI620101
30MB3 ELECTRICAL
TECHNICAL MANUAL
SECTION 5
ELECTRICAL COMPONENT
LAYOUTS
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Bucyrus Australia
Delta SBD 30MB3 Electrical Technical Manual
Swing Panel Front Components
No. Component Labelled Qty
1 MTL Zener Barrier for Siren Z1 1
2 24V dc Power Supply PS1 1
3 50mA Control Fuses F4 & F5 2
4 Banshee Siren Auxiliary Relay BS 1
5 Side Lights Auxiliary Relay (Area Lights) SLR 1
6 Rear Lights Auxiliary Relay (Not Used) RLR 1
7 Traction Earth Leakage Auxiliary Relay TELR 1
8 Front Lights Auxiliary Relay (Headlights) FLR 1
9 Lights Dimmer Auxiliary Relay (Headlights) LDR 1
10 Machine Voltage Analogue Converters C1, C2 & C3 3
11 110V 3 Phase Control Circuit Breaker CB6 1
12 LED Indication Panel 1
13 Relay I/O Module A LAP00391 1
14 Relay I/O Module B LAP00522 1
15 Control System Power Supply Module LAP00395 1
16 Processor Control Hub LAP00418 1
17 Traction Fibre Optic Interface Module LAP00565 1
18 Thermistor Module LAP00394 1
19 RS422/RS232 Data Converter for CH4 TX9042 Dwg 509021 1
20 MTL Zener Barrier for Methane Cct Dwg 509020 1
December 2009 Page 11 of 16 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
Power Supply Module
The 110/24 V DC Power supply module supplies 24V dc to all radio modules excluding the I.S. Solenoid
Driver. It is complete with (2) relay outputs which are used to interrupt the pilot (earth continuity) circuit from
the DCB to the miner when an inadvertent operation is detected by the control system or a Pilot Trip function
is activated by the operator on the remote control transmitter.
Inclinometer
The inclinometer is mounting within its own flameproof enclosure and is mounted under a small cover behind
the headlights on the cutter boom.
The inclinometer is used to indicate the cutting head height. The top and bottom cutting heights are
referenced to the horizontal zero position. You will not be able to shear beyond these limits unless boom
override mode is enabled.
To override the Inclinometer with the pumps running, using the transmitter operate the [SHIFT] then TRAM 3
and TRAM 4.
Override will stay on until the pumps are turned off.
Traction Module
The traction module is mounted on the front of the swing panel in the main control case.
The traction module communicates with the hub via a fibre optic CAN link and then interfaces to the SCR
traction drives via a RS 484 link that loops two the two drives. The power supply is 24V from the control
system.
Graphics Display Screen
This graphics display screen is located behind the viewing window on the display enclosure and provides the
operator/tradesman with fault information, machine modes and performance information.
The graphics display screen is connected directly to the processor control hub via a display communications
port. This is connected via a designated screen cable between the main control case and the display
enclosure.
The intrinsically safe hardware consists of:
I.S. Solenoid Module
The module is located in the stainless steel solenoid junction box mounted beside the main solenoid valve
bank.
The I.S. Solenoid Module is complete with:
a) (18) I.S. digital inputs
b) (14) I.S. proximity inputs
c) (22) I.S. solenoid outputs
The solenoid module is supplied by a Forced Potato 12V 2A I.S. power supplied which is mounted inside the
top compartment of the display enclosure.
A display on the front of the solenoid drive indicates if the I.S. supply is on and communicating with the hub.
December 2009 Page 5 of 21 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
I.S. Solenoid Module
12V dc I.S Solenoid Board
A18 - V35 Female 34 Pin
Wire
Pin Schematic Name Type
Number
A18-A SOL_5 Plow Out 605 12V I.S. Solenoid +
A18-B SOL_11 Conveyor Raise 611 12V I.S. Solenoid +
A18-C SOL_2 Cutter Head Lower 602 12V I.S. Solenoid +
A18-D SOL_8 Spare
A18-E SOL_4 Cutter Head Retract 604 12V I.S. Solenoid +
A18-F SOL_10 Stab Jack Lower 610 12V I.S. Solenoid +
A18-H SOL_1 Cutter Head Raise 601 12V I.S. Solenoid +
A18-J SOL_7 Spare
A18-K SOL_3 Cutter Head Extend 603 12V I.S. Solenoid +
A18-L SOL_9 Stab Jack Raise 609 12V I.S. Solenoid +
A18-M NC
A18-N SOL_6 Plow In 606 12V I.S. Solenoid +
A18-P SOL_ 12 Conveyor Lower 612 12V I.S. Solenoid +
A18-R SOL_13 Conveyor Swing Right 613 12V I.S. Solenoid +
A18-S NC
A18-T SOL_14 Conveyor Swing Left 614 12V I.S. Solenoid +
A18-U SOL_15 Apron Raise 615 12V I.S. Solenoid +
A18-V SOL_16 Apron Float 616 12V I.S. Solenoid +
A18-W NC
A18-X SOL_17 Water Sprays 617 12V I.S. Solenoid +
A18-Y SOL_18 Traction Brake 618 12V I.S. Solenoid +
A18-Z SOL_19 Left East / West 619 12V I.S. Solenoid +
Conveyor Fwd
A18-AA NC
A18-BB SOL_20 Right East / West 620 12V I.S. Solenoid +
Conveyor Fwd
A18-CC NC
A18-DD SOL_21 Left East / West 621 12V I.S. Solenoid +
Conveyor Rev
A18-EE NC
A18-FF SOL_22 Right East / West 622 12V I.S. Solenoid +
Conveyor Rev
A18-HH NC
A18-JJ SOL_23 Spare 12V I.S. Solenoid +
A18-KK NC
A18-LL SOL_24 Spare 12V I.S. Solenoid +
A18-MM OV 12V dc I.S. Negative 0VIS Power Supply
A18-NN 12V 12V dc I.S. Positive 401 Power Supply
December 2009 Page 15 of 21 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
Graphic Display Screens
The display screen is located on the right hand side of the machine in the flameproof display enclosure. This
provides the operator and tradesmen with fault information, machine modes and performance information.
Navigation Functions on Transmitter
The main machine display can be changed using the new Navigation System. To enter the radio system
Navigation mode the following steps must be followed.
1. Press [SHIFT] and [MENU] (WATER switch) and hold for approx 2 seconds until screen heading
flashes.
2. Press [SHIFT] and [NAV] (CON left or right) to move through consecutive screens until the desired
page is reached. A password is required for pages above page 99.
3. Alternatively you can access the desired page by using the Blue numbers on the transmitter. To
access page 201 press switches 2 (STAB DOWN), then 0 (FAN OFF), then 1 (TRAM 2-3), then #
(CON UP). This will then open page 201 Remote Console.
4. Screens can also be accessed by pushing the screen scroll button on the front of the display
enclosure. This provides access to screens 1 to 20 and 99 only, all other screens require password to
access. Optional β not fitted to all machines.
December 2009 Page 3 of 45 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
I/O Monitor β Inputs 1 of 5 (110V Inputs)
This I/O Monitor β Inputs 1 of 5 screen is Page 10 on the display screen menu. It displays the status of the
110V inputs connected to the I/O Modules A and B.
If a device input is closed (asserted/active), then it is displayed with a yellow button next to it on the screen.
If a device is open (non asserted or de-active), then no colour is shown next to it.
December 2009 Page 13 of 45 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
SCR Drive Monitor
This SCR Drive Monitor screen is Page 20 on the display screen menu. It displays the following information
from both the left and right SCR traction drive power modules:
β’ DC Motor Voltages
β’ DC Motor Currents
β’ DC Current Limits
β’ Motor Armature No Volts
β’ Motor Reversed Polarity
β’ Motor Armature No Current
β’ Drive Internal Error
β’ Drive Forward Rev Error
β’ Drive Reverse Rev Error
β’ Drive Over Temperature
The voltage and current will give an actual voltage and current readout.
The other outputs will be either β0β or β1β. With a β1β indicating that that output function is on and the β0β
being off.
The voltages should be equal when observing both motor trends but the current can vary depending on the
load required for each track.
December 2009 Page 23 of 45 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
Setup 5 of 10 β Inclinometer
The Setup 5 of 10 β Inclinometer is Page 108 on the display screen menu and this screen includes:
β’ Roof Limit β Is the height of heading that is required to be cut.
β’ Floor Limit β Is the lower height that the Shear Down function is inhibited.
β’ Boom Horizontal Radians β This is the raw data received from the Inclinometer.
β’ Top Cutting Overshoot β Is the distance the solenoid is de-energised from the roof to ensure the cutter
stops at the required height while cutting coal.
β’ Top Air Overshoot β Is the distance the solenoid is de-energised from the roof to ensure the cutter
stops at the required height while not cutting coal.
β’ Bottom Cutting Overshoot β Is the distance the solenoid is de-energised from the floor to ensure the
cutter stops at the required height while cutting coal.
β’ Bottom Air Overshoot β Is the distance the solenoid is de-energised from the roof to ensure the cutter
stops at the required height while not cutting coal.
β’ Inclinometer Filter β provides a filter on the readings coming from the inclinometer to ensure the
readings do not jump around too much.
December 2009 Page 33 of 45 Manual No. M01342
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Delta SBD 30MB3 Electrical Technical Manual
Parameters β Commissioning January 2010
Parameters in Red Wonβt Change at commissioning. Black parameters may change.
Setup β Left Traction Page 102
SPEED 1: 35% RAMP DELTA: 0.2s
SPEED 2: 65% SUMP DELTA 0.2s
SPEED 3: 100% MIN SUMP: 10%
MAX SUMP: 30%
Setup β Right Traction Page 103
SPEED 1: 35% RAMP DELTA: 0.2s
SPEED 2: 65% SUMP DELTA 0.2s
SPEED 3: 100% MIN SUMP: 10%
MAX SUMP: 30%
Setup β Timers Page 104
PUMP PRE START 3 Sec BRAKE PRESSURE DELAY 6 Sec
CUTTER PRE START 1 Sec BRAKE DELAY TO APPLYING 200 ms
CONV.FWD PRE START 1 Sec CONV E/W PRE START TIMER 3 Sec
INSTANTANEOUS OVERLOAD
CONV REV PRE START 4 Sec 1200ms
TIMER
MODE CHANGE PRE START 2 Sec UNDER VOLTAGE COIL FITTED YES
December 2009 Page 43 of 45 Manual No. M01342
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BI620101
30MB3 MINER FAULT DISPLAY GUIDE DELTA SBD
MESSAGE DISPLAY EXPLANATION POSSIBLE SYMPTOM CHECKS TO CARRY OUT
LEFT CUTTER RTD OPEN Motors have been stopped due to No water supply. 1. Ensure sufficient mine water supply.
excessive heat in the windings. Blocked bag filter. 2. Check operation of bag filter
RIGHT CUTTER RTD OPEN
An open circuit RTD circuit will result in Blocked sprays. 3. Check sprays
LEFT PUMP RTD OPEN a reading of greater than 160 deg C. If
Faulty motor cooling circuit. 4. Check motor cooling circuit for:
this occurs a message will be displayed
RIGHT PUMP RTD OPEN and the fault logged. Faulty water solenoid c) Sufficient flow (no blockages).
LEFT GATHERER RTD OPEN As there is a normally closed back up Faulty pilot operated water valves d) Damaged or broken hosing
RIGHT GATHERER RTD OPEN thermostat in series with the RTD a Open circuit fault in the motor 5. Check continuity of motor RTD circuit.
temperature trip will result in an open RTD circuit. 6. Check operation of water solenoid and pilot operated
LEFT CONVEYOR RTD OPEN circuit. water valves.
Cable damage
RIGHT CONVEYOR RTD TRIP NOTE: The RTD over temperature 7. Check pilot cores in motor supply cable. If pilot cores
protection will trip the motor circuit when are damaged replace cable. Motor cables have one
LEFT TRACTION RTD OPEN a temperature of 130oC is reached. spare core.
RIGHT TRACTION RTD OPEN The trip point of the motor thermostat is
TRANSFORMER RTD OPEN set at 145oC.
L0LE1 RELAY OUTPUT Each I/O module relay output has two Loss of control voltage or open 1. Check I/O monitor page 15 to confirm faulty output
ACTIVATION FAULT relays in series. circuit wiring to output relay(s) relay and check continuity of supply wiring to I/O
L0LE2 RELAY OUTPUT Relay 1 is to be energised and feedback whilst activated. module output relays.
ACTIVATION FAULT checked 100mS before relay 2 is closed. Open circuit wiring between 2. Check wiring from I/O output plug (A9 or B9) to
If a feedback from either relay is output relay and contactor coil. contactor coils.
o
detected when not required, the pumps Open circuit wiring from contactor 3. Check wiring of contactor coil neutrals (wire N 110)
will shut down. coil to control neutral supply. 4. Check continuity of wire No 110 to neutral reference
If a feedback from either relay is not Open circuit control neutral for output relay groups.
detected when required the pumps will reference to I/O module output 5. Check continuity of contactor coils.
be shut down. relay groups.
6. If the only the right pump will start in mining mode
Note: LOLE1 is I/O module A, and Open circuit contactor coil. and both pumps will start in bolting mode check the
LOLE2 is I/O module B. Faulty auxiliary contact block on auxiliary contact block on the right pump contactor
right pump contactor. (wire No116 and 125). This ensures that the other
Internal I/O module fault motors will not start until the right pump motor has
started.
7. Replace I/O module if no other faults can be found.
Manual No. M01342 Page 9 of 34 December 2009
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30MB3 MINER FAULT DISPLAY GUIDE DELTA SBD
MESSAGE DISPLAY EXPLANATION POSSIBLE SYMPTOM CHECKS TO CARRY OUT
module with function not operated: 600 to
650mVDC. Measured from Proximity return to 0 V
I.S.
Return supply from proximity switch to Solenoid I/O
module with function operated: 2.0 to 2.55 V I.S.
Measured from Proximity return to 0 V I.S.
Remove proximity switch wiring from the terminal
and test continuity between the supply leads with a
meter on diode range. A reading of approx 1.3 V
from the positive to negative leads.
If a proximity function is not working correctly
perform the tests as above.
A readjustment may be necessary. Unscrew the
proximity until the reading goes above 2.0 V. Screw
the proximity switch back in until the measured
voltage reads between 600 to 650 mV. Test function
for correct operation.
6. Replace Solenoid I/O module if no other faults can
be found.
PROXIMITY FROZEN - SHEAR Intrinsically Safe Proximity switches are Incorrect main spool adjustment. 1. Operate the Miner and observe the pressure gauges
UP/DOWN SOLENOIDS fitted to the hydraulic valve bank to Hydraulic spool jammed on to ensure that the hydraulic system is operating
PROXIMITY FROZEN - monitor for stuck spools, incorrect (Hydraulic oil contamination). correctly. Pilot pressure should be set at 35 bar.
STABILIZER UP/DOWN operation of solenoids and valves. Check valve banks if hydraulic function operates in
Hydraulic pilot pressure
SOLENOIDS The radio system monitors the status of blockage. pendant mode. The brake solenoid is the only
PROXIMITY FROZEN - the 12V I.S. Solenoid Proximity switches solenoid function operated in pendant mode. All
Solenoid valve not operating
CONVEYOR UP/DOWN via inputs into the I.S. Solenoid Driver other solenoid functions should not operate. If any
correctly (stuck on).
SOLENOIDS Module. other function operates inspect valve banks for
Solenoid valve being operated mechanical malfunction.
PROXIMITY FROZEN - The pump motor operation will be
inhibited if the status of the spools is not Manually. 2. Access the Solenoid I/O monitor page 202 and
CONVEYOR LEFT/RIGHT
SOLENOIDS in accordance to the hydraulic operation. perform a solenoid test to confirm a faulty solenoid
The hydraulic spool for the selected or wiring.
PROXIMITY FROZEN - PLOW
function has not returned to the OFF or 3. If the fault occurs on individual solenoids check both
IN/OUT SOLENOIDS
neutral position (stuck on) after active and common wiring from Solenoid output plug
PROXIMITY FROZEN - DRUM operation when required by the control (A18) to the individual solenoids.
IN/OUT SOLENOIDS system for the βPROXIMITY FROZENβ
4. Check operation of solenoid coils. A red LED should
PROXIMITY FROZEN - APRON fault to occur.
Manual No. M01342 Page 19 of 34 December 2009
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Delta SBD 30MB3 Electrical Technical Manual
Proximity Switch Install/Adjust Procedure
Installation of New Proximity - For adjustment only go to Step 5
Step 1 β Preparation
Before screwing proximity switch into the valve bank position locknut up towards the flattened section of the
thread. This will keep it out the way when screwing in. See Figure 1