TripRite Commissioning and Setup

TripRite Commissioning and Setup Centurion AC Commissioning
TripRite Commissioning and Setup

Determining Firmware Version and Upgrading if Necessary
Step 1: With 24V power to the drive controller shut off, find the CF card slot at the front of the CU320-DP controller
and remove the memory card.
NOTICE
Do not re-format the card. The card has proprietary formatting to allow it to work with the drive. Formatting will erase
this.
Figure 62: CU320-DP Controller Module
Review copy for reference only 4/21/14

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01 - LEDs 04 - T0, T1, T2 Measurement 06 - Protective Conductor

Sockets Connection M5 / 2.2 ft-lb (3
02 - LED Reserved N·m)
05 - X140 Serial Interface
03 - Type Plate
© 2014 Joy Global Inc. or one of its affiliates. -133- Version 0001
Centurion AC Commissioning TripRite Commissioning and Setup
07 - Diag Pushbutton 11 - Slot for CompactFlash Card 16 - X124 Electronic Power Supply
08 - Equipotential Bonding 12 - X127 LAN (Ethernet) 17 - Digital Inputs / Outputs
Connection, e.g. for Profibus
13 - Type Plate 18 - Lug for Connecting the Cable
M5 / 2.2 ft-lb (3 N·m)
Shielding
14 - X126 Profibus
09 - Profibus Address Switch
19 - X100-X103 DRIVE-CLiQ
15 - Option Slot
10 - Reset Button Interfaces
Step 2: Insert the card into your CF card reader and open to view the files.
The files and folders should look like the following figure.
Figure 63: CF Card Contents

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Step 3: Open the CONTENT.TXT file. At the top of the file, verify the version shown in the header.
If you do not have V04.06, proceed to Step 4. If you do have V04.06, proceed to Establishing Communication with
the Drive on page 136.
Version 0001 -134- © 2014 Joy Global Inc. or one of its affiliates.
Figure 64: CONTENT.TXT File

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Step 4: Retrieve the 4.6 Firmware with 4.3 technology package.zip file from Dimensions.
Extract the contents to a folder in a location of your choice on your computer.
Step 5: Select and delete all of the firmware files on the compact flash card.
Step 6: With all of the firmware files deleted, select and copy in all of the files and folders you extracted from the
4.6 Firmware with 4.3 technology package.zip file.
Figure 65: Copy In New Firmware Files

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Step 7: Re-insert the CF card into the CU-320 drive controller and restore the 24V power to the drive.
The status LEDs on the front of all of the drive modules will flash red while the drive controller is upgrading its own
and its subordinate components’ firmware. When finished, the status LEDs on the infeed and motor (Servo) module
will be orange, while the RDY status light on the front of the CU-320 controller will flash green, indicating you are
ready to load parameters onto the drive.
Establishing Communication with the Drive

Step 1: Verify that your laptop’s network IP is set to an unused address on the 192.168.1.XXX subnet and that you
can communicate with various devices on the shovel network.
Step 2: If your drive controller is part of a complete TripRite drive lineup supplied by the P&H factory,
communications will have already been set up and tested as part of the factory’s commissioning/test
procedures. Verify this is the case by pinging the 192.168.1.12 IP address of the CU-320 drive controller.
If you are able to communicate with the drive as shown in the following figure, skip to Opening STARTER and De-
Archiving / Opening Drive Parameter Set on page 146.
Figure 66: Pinging the IP Address: Communicating with the Drive

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If you have a previously unconfigured drive controller, such as a replacement for a failed unit, you will need to set the
IP address of the controller as described in the following steps before moving on to Opening STARTER and De-
Archiving / Opening Drive Parameter Set on page 146.
Step 3: In order to use the Primary Setup Tool software, first disable the McAfee network security protocols on your
computer as shown in the following figure.
Make sure the Host IPS, Network IPS, and Firewall are all de-selected and turned off. These services prevent the
PST Tool from seeking out Siemens devices with factory default IP settings across subnets. Access these settings
through the icon bar at the bottom right of your Windows desktop by clicking on the McAfee shield symbol (Windows
7).
Figure 67: Disabling McAfee
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Step 4: Once the McAfee security features are disabled, run the Siemens Primary Setup Tool.
Figure 68: Siemens Primary Setup Tool

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Step 5: Under the Settings drop-down menu, select Set PG/PC Interface....
Figure 69: Set PG/PC Interface
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Step 6: In the Set PG/PC Interface dialog box, select S7ONLINE (STEP 7) for the access point of the application,
and your built-in wired Ethernet adapter card for the Interface Parameter Assignment Used.
The correct selection with be similar to the Intel(R) 82577LM Gigabit Network Connection.TCPIP.1 shown in the
following figure.
Figure 70: Set PG/PC Interface Settings

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Once the PG/PC interface is set, you can search the shovel network for Siemens devices.
NOTICE
Once the PG/PC interface is set the first time, you will not need to reset it for future uses of the PST Tool.
Step 7: Under the Network drop-down menu, select Browse.

Figure 71: Browse the Network
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Step 8: An error message may appear before it begins to browse the network. If it does, ignore it by selecting OK.
Figure 72: Primary Setup Tool Error Message
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You should see the status bar while the software is searching the network for Siemens Ethernet devices.

Figure 73: Browsing the Network
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Step 9: If you see the error in the following figure: No station was detected on the network, verify that the McAfee
security protocols have not re-enabled automatically.
Per corporate IT settings, they will do so after 10 – 15 min. Select OK to acknowledge the error and repeat Step 3 to
disable the protocols again before repeating Step 7 and Step 8.
Figure 74: No Station Detected Error
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Step 10: Upon successfully browsing the network, you should see various Siemens devices show up in the PST
Tool window similar to those shown in the following figure.
NOTICE
The Sinamics S device is the CU-320 TripRite drive controller, and any Scalance devices are Ethernet network
switches.
Figure 75: Successful Network Browsing

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Step 11: Expand the Sinamics S device and select Ind. Ethernet interface.
Figure 76: Setting the IP Address

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Step 12: Set the IP address for the drive controller as shown in the previous figure.
Step 13: To download the new settings to the drive controller, select the main device, then select Download from the
Module drop-down menu.
Figure 77: Select the Main Device

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Figure 78: Download the New Settings
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Step 14: The software will first prompt you to confirm that IP settings on the controller will be lost and that you wish
to continue; select Yes.
Figure 79: Continue Downloading Message
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After selecting Yes, you should see the following two progress bars as the PST Tool downloads the new IP settings to
the drive controller.
Figure 80: Combination of Ethernet Parameters Progress
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Figure 81: Download Station Progress
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Step 15: If this does not happen, and you see the following error, acknowledge it by selecting OK.
Figure 82: Could Not Reach Node Error
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Step 16: You will then see the second error; acknowledge it as well by selecting OK.
Figure 83: Unknown Error
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What has occurred is that the McAfee security protocols have reset automatically.

Step 17: Repeat Step 3 to disable the McAffee security protocols, then repeat Step 13 and Step 14.
Step 18: Once the new IP addressing information has successfully downloaded, the IP address next to the main
device listing should read 192.168.1.12, as shown.
Figure 84: New IP Address
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Step 19: Close the PST Tool window.
Opening STARTER and De-Archiving / Opening Drive Parameter Set

Step 1: Open the Siemens STARTER drive interface software.
You should see something similar to the following screen.
Figure 85: STARTER Getting Started

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Step 2: Close the Getting Started window if it has appeared.
NOTICE
You can prevent the Getting Started screen from opening every time at start-up by selecting Settings from the
Options pull-down menu and de-selecting the Display “Getting Started” at start check box.
Figure 86: STARTER Settings

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At this point, you should have also downloaded the appropriate TripRite drive parameter set from Dimensions and
have the .zip file stored somewhere on your computer.
NOTICE
Do not unzip or extract the files; the STARTER software will do this itself as described in the following steps.
NOTICE
If you have previously de-archived the parameter set you will be using, complete Step 3.
If you have not previously de-archived the parameter set you will be using, complete Step 4.
Step 3: To use an already existing parameter set:

a. Select Open... from the Project drop-down menu.
Figure 87: Open Existing Parameter Set
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b. The Open Project dialog box will open. Select the parameter set you wish to open and select OK.
Figure 88: Select Parameter to Open

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c. Proceed to Step 5.
Step 4: If you have not previously de-archived the parameter set:
a. From the Project drop-down menu, select Retrieve from archive....

Figure 89: Retrieve from Archive

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b. In the Select an archive dialog box that opens, find the zipped parameter file that you downloaded from
Dimensions and select Open.
Figure 90: Select an Archive
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c. Another dialog box will open, asking you to select a destination directory for the new project. Allow it to
save the new project in the default location (shown in the following figure) and select OK.
Figure 91: Default Project Location

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d. If a previous parameter set save on your machine has used the same project directory name, a dialog
box will appear asking if you want to rename the new folder or replace the existing one. If this is the
latest update to a parameter set you have used before, select Replace; otherwise, select Rename.
Figure 92: Directory Already Exists
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e. After the de-archiving process is complete, the software will ask you if you would like to open the
project. Select Yes.
Figure 93: Open the Project?

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f. Proceed to Step 5.
Step 5: A dialog box may appear warning you of missing software packages. These may have been present on the
computer used to develop the parameter set, but are not necessary to download the project or interface
with the drive. Select OK to ignore the missing software packages.
Figure 94: Missing Software Packages
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Downloading Parameter Set to Drive

Step 1: With the parameter set open, select the Connect to selected target devices button from the tool bar at the
top of the screen.
Alternatively, you can select Connect to selected target devices from the Project drop-down menu.
Figure 95: Connect to Selected Target Devices

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Step 2: You should see a dialog box similar to the following figure open. This dialog box details the major
differences between what is in the drive controller’s memory (if anything) and what you are about to
download. Select <== Download.
Figure 96: Online / Offline Comparison

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Step 3: Once you have selected Download, you will see the following dialog box open. Leave After loading, copy
RAM to ROM selected as shown and select Yes.
Figure 97: Downloading Options

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During the downloading process, you should see the following progress display:
Figure 98: Downloading Progress
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You should then see the Copy RAM to ROM status display:
NOTICE
If the load progress bar does not advance to 100%, and if the Copy RAM to ROM window does not appear and close
successfully, proceed to Step 4.
Figure 99: Copy RAM to ROM Status
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If the Copy RAM to ROM window appears and closes successfully, proceed to Step 5.
Step 4: If you see a dialog box that looks like the following, with the only difference between projects in the custom
DCC chart programming, you are likely to see the error illustrated in Step 4a.
Figure 100: DCC Chart Programming Differences

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NOTICE
This is a known and expected error.
If this error occurs, complete the following substeps. If you do not see this error, follow the procedures in Step 3.
a. Acknowledge this message by selecting Close.

Figure 101: Downloading Error

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b. Acknowledging the previous error will take you back to the download dialog box shown in Step 4. You
will notice errors in red text (similar to the following) in the Target system output tab behind the
download dialog box.
Figure 102: Target System Output
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c. To reload the parameter set (which usually corrects any errors encountered on the first attempt), select
<== Download again in the dialog box. If you have closed the dialog box, select the Load project to
target system button from the tool bar at the top of the screen.
Figure 103: Load Project to Target System

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d. Proceed to Step 5.
Step 5: When the project has finished downloading, you should see a blank download dialog box similar to the
following, indicating that there are no longer any differences between the drive controller’s memory and the
project. Close the window.
Figure 104: No Differences

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Drive Project Structure

Once the project has been successfully loaded into the drive and you are online, expand the project tree at the left of
the screen shown in the following figure. The object labeled S120_CU320_2_DP is the main drive set. Under it, there
are all of the sub-components of the drive system. The three components we are concerned with are the drive
controller (CU_S_012), the infeed module (B_INF_02), and the motor module (sometimes referred to as the Servo
module) (SERVO_03).
Figure 105: Project Tree

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Under each of the components previously named, there are a number of sub-areas. The area we are concerned with
in each of these components is the Expert list. Double-clicking the Expert list under each component will open a tab
on the right-hand side of the STARTER window with a complete list of all of the parameters available for that module.
Open the Expert list for the infeed and Servo modules.
Figure 106: Expert List

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Confirming / Setting Relevant Parameters

Step 1: Referencing the appropriate guide for finding and changing tag values in the Centurion AC800 code with
ControlBuilder, verify the following values are set:
• In the OptionSelect control module, be sure that the TripRite system is selected, along with the correct
transmission ratio (12:1 or 17:1), and the Sinamics S120 drive system.
• In the ShovelCFG/OptionSel data type, the TripRite_Speed_Ref_RPM tag should be one of the following values,
depending on shovel type:
– 12:1 transmission: 440 rpm
• In the TripRite function block, the cTripSpdRef tag should be set at one of the following values, depending on
shovel type:
• In the TripRite function block, the cTripTorqRef tag should be set to 70.0%.
Step 2: Referencing the Touch Panel manual in the Operator suite, navigate to the TripRite monitoring and
adjustment screen on the operator interface screen and verify that the slack take-up torque is set to the
factory default 4%, and the reduced slack take-up torque is set to 1.5%.
Step 3: In the Expert list tab for the line (infeed) module, find parameter 210 (line supply voltage) as shown. Set this
value to the nominal three-phase auxiliary voltage appropriate for your machine: 380, 415, or 460VAC.
Figure 107: Parameter 210: Drive Unit Line Supply Voltage

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Step 4: In the Expert list tab for the motor (Servo) module, find the following variables and verify or change their
values as appropriate:
• p210 – Drive unit line supply voltage: 510, 584, or 678VDC ([p210 Infeed * 2.1] - 288)
• p1244 – DC Link Voltage Threshold Upper: 576, 659, or 765VDC (p210 Servo * 1.129)
• p1248 – DC Link Voltage Threshold Lower: 328, 376, or 437VDC (p210 Servo * 0.644)
• p1821 – Direction of rotation:
– 0 (clockwise) – TripRite mounting orientations with the motor facing to the shovel’s right, away from the crowd
motor. These TripRite assemblies will have right-hand orientation cable drums and guards.
– 1 (counterclockwise) – TripRite mounting orientations with the motor facing to the shovel’s left, toward the
crowd motor. These TripRite assemblies will have left-hand orientation cable drums and guards.
Adjusting Resolver Offset

Step 1: Referencing the Operator Procedures manual in the Operator suite, start the shovel.
This should cause the TripRite brake/heater relay to pull in, releasing the TripRite motor brake and starting the drive
in slack take-up mode. At this point, the system should begin reeling in slack cable. Generally, the factory indexing of
the motor’s built-in resolver is close enough to the preset angular commutation offset angle to allow for normal
operation. However, it is possible that the resolver indexing is off from the factory or as a result of a motor rebuild.
This will cause either a failure to rotate or a significant reduction in available torque. It is not necessary to physically
alter the resolver orientation (in fact this practice is strongly discouraged). Standard practice, when commissioning a
new system, is to allow the drive system to automatically adjust the resolver commutation offset.
Step 2: Allow the drive system to automatically adjust the resolver commutation offset:
a. With the drive running, set p1990 in the Expert list of the Servo module to 1.
The parameter will perform the recalculation, then automatically reset to 0.
b. Verify that this has completed by looking at p431 in the Servo module to see if it has changed from its
factory default of 62.95°.
To preserve the newly calculated resolver offset and any parameter values changed during commissioning, it is
necessary to save the current values in the drive controller’s RAM memory to ROM (the firmware compact flash
card).
Step 3: Highlight the drive set’s main component and select the Copy RAM to ROM button in the tool bar.
Figure 108: Copy RAM to ROM

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Disconnecting and Closing

Step 1: Disconnect from the drive system.
Figure 109: Disconnect from Target System

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Step 2: Close the project.

Do not save the new values to your project, as they are shovel-specific
Figure 110: Closing the Project
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TripRite Commissioning and Setup Centurion AC Commissioning

Review copy for reference only 4/21/14

01 - LEDs 04 - T0, T1, T2 Measurement 06 - Protective Conductor

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Figure 64: CONTENT.TXT File

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Establishing Communication with the Drive

Figure 66: Pinging the IP Address: Communicating with the Drive

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Figure 70: Set PG/PC Interface Settings

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Step 7: Under the Network drop-down menu, select Browse.

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Figure 75: Successful Network Browsing

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Figure 78: Download the New Settings

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Figure 81: Download Station Progress

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Step 19: Close the PST Tool window.

Opening STARTER and De-Archiving / Opening Drive Parameter Set

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Step 2: Close the Getting Started window if it has appeared.

Figure 86: STARTER Settings

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Step 3: To use an already existing parameter set:

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Step 4: If you have not previously de-archived the parameter set:

a. From the Project drop-down menu, select Retrieve from archive....

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Downloading Parameter Set to Drive

Figure 95: Connect to Selected Target Devices

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a. Acknowledge this message by selecting Close.

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Drive Project Structure

Figure 105: Project Tree

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Figure 106: Expert List

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Confirming / Setting Relevant Parameters

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Adjusting Resolver Offset

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Disconnecting and Closing

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Step 2: Close the project.

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