Traction electric drive for dump trucks with

payload capacity from 120 to 220 tonnes

Setup Manual
 CONTENTS

1 Introduction ...................................................................................................................................... 3
2 Safety requirements......................................................................................................................... 3
3 Control of completing products of the traction electric drive prior to the assembly of the dump
truck ................................................................................................................................................. 3
3.1 Each product which is a part of the traction electric drive should meet the requirements of
specification and complete set of the design documentation for this product. ................................ 3
3.2 Traction motors and alternator ........................................................................................................ 3
3.3 Installation of ventilated brake resistors .......................................................................................... 4
3.4 Cabinet with start-controlling equipment ......................................................................................... 4
4 Description of adjustment process .................................................................................................. 4
4.1 Preparatory operations .................................................................................................................... 4
4.2 Editing of protection set points and logic signals in function of rotational speed of the traction
motor................................................................................................................................................ 4
4.3 Editing of external (traction and brake) characteristics of system «traction alternator – rectifier».. 7
5 Control of the traction electric drive after assembly of the dump truck before start-up of the diesel
engine ............................................................................................................................................ 12
6 Control of the traction electric drive of the dump truck after start-up of the diesel engine at the
hung out driving wheels ................................................................................................................. 15
7 Check of parameters of the traction electric drive ......................................................................... 16
7.1 Check of functioning of the protection device at imitation of short circuit of power circuit on the
case of the dump truck .................................................................................................................. 16
7.2 Check of the protection device at excess of legitimate value of armature chain current of traction
motors M1 and М2 in traction mode .............................................................................................. 16
7.3 Check of functioning of the protection device at excess of legitimate value of output voltage of
rectifiers UZ1 or UZ2 in traction mode........................................................................................... 17
7.4 Check of functioning of the protection device at excess of admissible current of loading of
rectifiers UZ1 and UZ2 in traction mode on the limiting characteristic .......................................... 18
7.5 Check of functioning of the protection device at imitation of the electromotor-wheels skidding ... 18
7.6 Check of functioning of the protection device at excess legitimate value of voltage on armature
chain of traction motors М1 and М2 in a traction mode ................................................................ 18
7.7 Check of functioning of the protection device at imitation of short circuit on entry (exit) of power
rectifier UZ1 or UZ2, or puncture of the valve in one of branches of rectifier bridges................... 19
7.8 Check of functioning of the device forming logic control signals by the traction electric drive in
function of rotational speed of traction motors .............................................................................. 19
7.9 Check of the device of smooth field reduction (smooth exciting current control) of traction electric
motors in traction mode ................................................................................................................. 20
7.10 Check of the device for restriction of the electromotor-wheels skidding ....................................... 20
7.11 Check of the channel of restriction of output voltage of rectifier UZ1 or UZ2 in traction mode..... 21
7.12 Check of the maximum loading current of rectifiers UZ1 and UZ2 in traction mode..................... 21
7.13 Check of the channel of restriction of power on exit of rectifiers UZ1 and UZ2 in traction mode . 21
7.14 Check of the max exciting current of traction motors in electronic braking mode ......................... 21
7.15 Check of restriction of voltage (current) of brake resistor RB1.1 or RB1.2 in electro-dynamic
retardation mode............................................................................................................................ 22
7.16 Check of restriction of voltage (current) of traction motors in electro-dynamic retardation mode on
conditions of their commutation..................................................................................................... 22
APPENDIX A .............................................................................................................................................. 23
APPENDIX B .............................................................................................................................................. 24
APPENDIX B .............................................................................................................................................. 25

2
 1 Introduction

This Manual specifies procedures for setup of AC/DC traction electric drive for BELAZ dump
trucks with control system СУТЭП-01. The Manual is designed for carrying-out tasks for setup of traction
electric drive prior to the assembly, and verification (if necessary) of traction electric drive setup
parameters after the assembly of dump truck.
In addition, procedures specified in this Manual can be carried out during operation of dump truck
in case due to any reason the values of one or more parameters do not meet the requirements specified
in this Manual.

2 Safety requirements

2.1 Setup of traction electric drive can be carried out only by personnel familiarized with this
Manual, appropriately trained and familiar with the operational and safety regulations.
2.2 Operations on check of parameters of adjustment of the traction electric drive should be
carried out according to demands of acting “User Rules for Operating Electrical Equipment» (М.:
Energoatomizdat, 1987 – 648 p.) and «User Safety Rules for Operating Electrical Equipment» (М.:
Energoatomizdat, 1986 – 424 p.) by team of not less than two persons, knowing an arrangement of
electric equipment on dump truck, its device and circuit diagrams. One of them should have IV qualifying
group on electric security, others — not below III.
Dump truck operator participating in process on regulating of the traction electric drive should
have II qualifying group on electric security.
2.3 At accomplishment of works during regulating on motionless dump truck at its ladder the
poster “Warning! Dangerous!” should be hung out. On dump truck there should be only set-up men
(electricians) and operator. Dump truck should be braked by parking brake system, and under its wheels
from both sides there should be supports.
2.4 Dump truck operator on command of the head of team of set-up men (electricians) should
make start-up of the diesel engine, turning on and shut down of the traction electric drive. At the working
diesel engine the operator should stay in operator’s cab of the dump truck.
2.5 At accomplishment of operations outside of cab of the dump truck on the dash panel in
the cab the prohibiting poster “Do not turn on! Men in work!” should be present.
2.6 Operations which are carried out on electric equipment of the traction electric drive which
can appear energized, should be made with switches SA1 and SA2 in a neutral position on the dash
panel, and also disconnected switch QF1 in the control cabinet. On the handle of the switch the
prohibiting poster “Do not turn on! Men in work!” should be present.
2.7 Wires detached from leading-outs and crimped locks of electric equipment should be
reliably isolated.
2.8 Before extraction and the subsequent installation of sliding blocks in meshes it is
necessary to disconnect switches SF2 and SF3 in the control cabinet.
2.9 At work on motionless dump truck before turning on of voltage at its ladder the warning
poster poster “Warning! Dangerous!” should be hung out.
2.10 It is necessary to remember that at turning on of switches SA1 and SA2 of the electric
drive the body is automatically hauled down. Therefore, if adjusting works are carried out with the lifted
body the latter should be fixed by safety wire ropes.

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

3 Control of completing products of the traction electric drive prior to

the assembly of the dump truck

3.1 Each product which is a part of the traction electric drive should meet the
requirements of specification and complete set of the design documentation for this product.
3.2 Traction motors and alternator
Traction motors and the alternator should pass incoming inspection according to process of
incoming inspection.
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 3.3 Installation of ventilated brake resistors
Installation of ventilated brake resistors should be tested according to the program and method
7512-2126004 ПМ.
3.4 Cabinet with start-controlling equipment
3.4.1 Examine the cabinet with start-controlling equipment. On the equipment there should not be
mechanical injuries and fasteners that are not torqued.
3.4.2 Check fastening and a condition of locks, sealing of doors. Locks should be reliably fixed
and at closing doors there should not be grooves between door and the case of the cabinet.
3.4.3 Check completeness of the spare parts set according to the accompanying documents.

4 Description of adjustment process

4.1 Preparatory operations

4.1.1 Adjustment is made after acceptance of the cabinet with start-controlling equipment by
Quality Department.
4.1.2 For realization of adjustment before mounting of the power cabinet on dump truck it is
necessary to connect the power supply 24 V (table А1, appendix A) – plus terminal on carrier socket ХТ3,
minus terminal – on ХТ4.
4.1.3 Preparatory operations listed in 4.1.4, should be performed prior to each operation or
group of operations that are carried out according to several subsections of the present instruction.
4.1.4 Prior to each adjustment operation, carried out with open doors of the control cabinet it is
necessary to block make contacts of cabinet door interlock switches SA5, SA6 and SA7. After completion
of operations unblock switches SA5, SA6 and SA7.
4.1.5 Measure by voltage meter PV3 (table А1, appendix A) voltage serially in the places
specified in table 4.1.

Table 4.1 — ХТ1 Voltages

Desired voltage
Parameter Place of measurement
value, V
+6
Supply voltage ХТ1: 301, 0 24
–4

Supply voltage 15±0.2

ХТ1: 303, 0

4.1.6 During adjustment disconnect switch QF1 on dump truck. Put switches SA1 and SA2 in
positions «ВКЛ» (ON) and «Вперед» (Forward) accordingly.

4.2 Editing of protection set points and logic signals in function of rotational speed of
the traction motor
For editing of protection set points and logic signals in function of rotational speed of the traction
motor it is necessary:
- to connect special cable through COM port of the portable computer to connector XS5 on the
control cabinet or RS232 on the dash panel in the driver’s cab;
- to start the program «Визуализация для обслуживающего персонала (AUTO VISUAL2)»
(Visualization for maintenance staff - AUTO VISUAL2) (see figure 1);

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 Figure 1 – Program «Визуализация для обслуживающего персонала (AUTO VISUAL2)»
(Visualization for maintenance staff - AUTO VISUAL2)
- section «Редактирование параметров» (Editing of parameters) in the field «Текущее
значение параметра» (Current parameter value) shows the value of the chosen factor in the controller
see figure 2;

Figure 2 – Section «Редактирование параметров» (Editing of parameters)

5
 - in order to choose a parameter for editing it is necessary to bring the mouse pointer to matching
white field and to push the left mouse button. After change of parameter press ENTER. If value of the
entered parameter is beyond the necessary range a dialog box with the message about incorrect input
and necessary range will appear (see figure 3). Click OK;

Figure 3 – «Неверный диапазон»

(Incorrect range) dialog box

- if value is true a dialog box with confirmation of the parameter change will appear – for
continuation it is necessary to move the mouse pointer to the necessary button: «Да» (Yes) – to enter the
value, «Нет» (No) – to exit, see figure 4;

Figure 4 – «Изменение параметра»

(Parameter Change) dialog box

- if the change is confirmed the value of parameter in the control unit will be rewritten;
- values of the entered parameters are specified in table 4.2 (in special cases change of
parameters for not more than ±10 % is permitted), designations of abbreviation are specified in table 4.3.

Table 4.2 – Values of the entered parameters

Parameters for Parameters for Parameters for
dump trucks with dump trucks with dump trucks with
Designation Units
payload capacity payload capacity payload capacity
120-125 tons 130-136 tons 200-220 tons
Уст.I 1450 1450 1870 A
Уст.Ud1 1100 1200 1200 V
Уст.Ud2 1100 1200 1200 V
Uyстrb1 1100 1200 1200 V
Uyстrb2 1100 1200 1200 V
Uyстm1 1100 1200 1200 V
Uyстm2 1100 1200 1200 V
Uopk1 650 650 650 V
Uopk2 650 650 650 V
Уст.301 18 18 18 V
Uyстd 325 325 325 V
Uyстdm 530 530 530 V
Uyст 400 400 400 V
Uycтdrb 325 325 325 V
OCON 95 78 62 Hz
OCOFF 92 72 56 Hz
Vmin1ON 50 33 22 Hz
Vmin1OFF 40 25 20 Hz
Vmin2ON 51 51 29 Hz
Vmin2OFF 49 49 27 Hz

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 Table 4.3 – Abbreviations
Abbreviation Definition
Уст.I Protection at excess of a legitimate value of a current of power circuit
Уст.Ud1 Protection at excess of a legitimate value of a pressure on exit of power
rectifier UZ1
Уст.Ud2 Protection at excess of a legitimate value of a pressure on exit of power
rectifier UZ2
Uyстrb1 Protection at excess of a legitimate value of a pressure on brake resistor
RB1.1 (in electric retardation mode)
Uyстrb2 Protection at excess of a legitimate value of a pressure on brake resistor
RB1.2 (in electric retardation mode)
Uyстm1 Protection at excess of a legitimate value of a pressure on anchor chain of
electric motor M1
Uyстm2 Protection at excess of a legitimate value of a pressure on anchor chain of
electric motor M2
Uopk1 Protection at excess of a legitimate value of a pressure of earth fault of power
rectifier UZ1
Uopk2 Protection at excess of a legitimate value of a pressure of earth fault of power
rectifier UZ2
Уст.301 Protection at reduction of a pressure of onboard network below a legitimate
value
Uyстd Protection at excess of a legitimate value of a difference of pressure on exit of
power rectifiers
Uyстdm Protection at excess of a legitimate value of a difference of pressure on anchor
chains of electric motors
Uyст Protection at skidding of wheels
Uycтdrb Protection at excess of a legitimate value of a difference of pressure on brake
resistors
OCON Restriction of speed at starting of the dump truck
OCOFF Restriction of speed at dump truck shutdown
Vmin1ON Frequency of turning on of field reduction ОП
Vmin1OFF Frequency of switching-off of field reduction ОП
Vmin2ON Frequency of turning on of contactor KM3 of electro-dynamic braking
Vmin2OFF Frequency of switching-off of contactor KM3 of electro-dynamic braking

4.3 Editing of external (traction and brake) characteristics of system «traction

alternator – rectifier»

4.3.1 Do not reinstall control program.

4.3.2 For editing of characteristics it is necessary to connect portable computer through
converter CAN-USB with special cable to SAN network (in the break of CAN bus, having disconnected
the connector on front panel БУВГ-02).
4.3.3 To start program StrimShell it is necessary to run start.bat (see figure 5).

7
 Figure 5 – Start of program StrimShell

4.3.4 At correct connection a dialog box «Сбор информации о контроллерах» (Controllers

data acquisition) should appear (see figure 6).

Figure 6 – «Сбор информации о контроллерах» (Controllers data acquisition) dialog

box

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

- control console for opening/saving of working area file, start/stop of the system;
- set of indicators that represent the information that is transferred at present status via CAN.
Each indicator has the name, according to its purpose. On indicators there are initial and final values of
the scale, and also on some indicators there is a red zone which represents a zone of cut-off of the given
parameter;
- block of БУВГ-02 controller;
- indicators of СУТЭП status;
- two blocks of МВС controllers.

8
 Figure 7 - Main dialog box of StrimShell

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

Figure 8 – Choosing «Параметры» (Parameters) option in StrimShell

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

Figure 9 – Section «Параметры” (Parameters) in StrimShell

Figure 10 – Choosing of a file with parameters depending on payload capacity of the dump
truck

4.3.8 Then click “Принять значения” (Accept Values) button (see figure 9).
4.3.9 Repeat steps 4.3.6 - 4.3.8 for МВС-01.2.

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

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 Table 4.4 – Parameters for dump trucks with payload capacity of 120-125 tonnes
Name, designation and units Values
Rotational speed of diesel engine
700 900 1100 1300 1500 1700 1900
N, RPM
Power circuit current I, A 50 250 550 750 850 980 1200
Power rectifiers exit voltage U, V 140 260 380 500 640 810 950
Power take-off P, kW 50 170 270 370 460 640 760
Restriction of exciting current in
dynamic braking mode 800
Ib, A
Restriction of brake resistors
910
voltage Ub, V
Restriction of field reduction current
420
Iop, A
Restriction of the maximum power
1200
circuit current Iотс., A
Restriction of the maximum power
950
rectifiers exit voltage Uотс, V
Voltage in dynamic braking mode
910 910 910 910 910 910 910 765 660 580
U, V
Rotational speed of wheels N, Hz 20 25 30 40 50 60 70 80 90 100

Table 4.5 – Parameters for dump trucks with payload capacity of 130-136 tonnes with ТЭД-6
Name, designation and units Values
Rotational speed of diesel
700 900 1100 1300 1500 1700 1900
engine N, RPM
Power circuit current I, A 50 250 550 750 850 980 1200
Power rectifiers exit voltage U,
140 260 380 500 640 810 1000
V
Power take-off P, kW 50 170 270 370 460 640 1000
Restriction of exciting current in
dynamic braking mode 800
Ib, A
Restriction of brake resistors
840
voltage Ub, V
Restriction of field reduction
580
current Iop, A
Restriction of the maximum
1200
power circuit current Iотс., A
Restriction of the maximum
power rectifiers exit voltage 1000
Uм, V
Voltage in dynamic braking
840 840 840 840 840 840 840 840 840 840
mode U, V
Rotational speed of wheels N,
20 25 30 40 50 60 70 80 90 100
Hz

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 Table 4.6 – Parameters for dump trucks with payload capacity of 130-136 tonnes with ЭК-420
Name, designation and units Values
Rotational speed of diesel engine N,
700 900 1100 1300 1500 1700 1900
RPM
Power circuit current I, A 50 250 550 750 850 980 1200
Power rectifiers exit voltage U, V 140 260 380 500 640 810 1000
Power take-off P, kW 50 170 270 370 460 640 1000
Restriction of exciting current in
dynamic braking mode 800
Ib, A
Restriction of brake resistors voltage
840
Ub, V
Restriction of field reduction current
580
Iop, A
Restriction of the maximum power
1200
circuit current Iотс., A
Restriction of the maximum power
1000
rectifiers exit voltage Uотс, V
Voltage in dynamic braking mode U,
840 840 840 840 840 840 840 765 660 580
V
Rotational speed of wheels N, Hz 20 25 30 40 50 60 70 80 90 100

Table 4.7 – Parameters for dump trucks with payload capacity of 200-220 tonnes
Name, designation and units Values
Rotational speed of diesel engine N,
700 900 1100 1300 1500 1700 1900
RPM
Power circuit current I, A 70 355 780 1060 1200 1390 1700
Power rectifiers exit voltage U, V 150 650 700 770 900 950 1000
Power take-off P, kW 50 230 420 750 1000 1330 1510
Restriction of exciting current in
dynamic braking mode 1250
Ib, A
Restriction of brake resistors voltage
880
Ub, V
Restriction of field reduction current
725
Iop, A
Restriction of the maximum power
1700
circuit current Iотс., A
Restriction of the maximum power
1000
rectifiers exit voltage Uм, V
Voltage in dynamic braking mode U,
880 880 880 860 820 800 790 765 660 580
V
Rotational speed of wheels N, Hz 20 25 30 40 50 60 70 80 90 100

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

5.1 Before check of the condition of the traction electric drive install accumulator batteries on
dump truck. Make sure that connection of power wires to electric machines and apparatuses is executed
according to basic and assembly circuit diagrams.
5.2 Check absence of ectogenic subjects in the cabinet with electro apparatuses and make sure
that switches SA8 and SA9 are in position «Выкл» (OFF), switch QF2 is in position «ОТКЛ» (OFF), and
switches SF1-SF3 are in position «ВКЛ» (ON). Block make contacts of door switches SA5, SA6 and SA7.
5.3 Turn the ground on and check sequence of actuation of the control equipment at turning on of
a traction and brake modes.

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

5.3.1 At installation of switches SA1 and SA2 in the position «ВКЛ» (ON) and «ВПЕРЕД»
(FORWARD) contactors KM4, КМ5 should switch on accordingly.
5.3.2 After pressing of movement pedal the following should switch on: contactors KM8, КМ9,
then (with time limit from 0.5 up to 2 s) contactors KM1, КМ2. The indicator U-БУВГ-02 (Appendix B) on
front panel should switch on.
Release movement pedal. Contactors KM8, КМ9 and (with time limit from 0.5 up to 2 s)
contactors KM1, КМ2 should be disconnected. Indicator U- БУВГ -02 should be disconnected.
5.3.3 Press electric retardation pedal. Contactors KM4 and КМ5 should be switched off, and
contactors KM6-KM9, contactor KM3, solenoid valve YB1 (installed only on the dump trucks with diesel
engine KTA-38) should switch on. Press movement pedal. Contactor KM3 should be disconnected.

Release both pedals. Contactors KM8, КМ9, solenoid valve YB1 should be disconnected. With
time limit from 0.5 up to 2 s contactors KM6 and КМ7 should be disconnected, and contactors KM4, КМ5
should switch on.

5.3.4 Install switches SA1, SA2 in a neutral position. Contactors KM4, КМ5 should be
disconnected.
5.3.5 Install switches SA1 and SA2 in positions «ВКЛ» (ON) and «НАЗАД» (REVERSE)
accordingly. Contactors KM6, КМ7 should switch on.
5.3.6 Install switches SA1, SA2 in neutral position. Contactors KM6, КМ7 should be
disconnected.
5.3.7 Control of actuation of the equipment in the cabinet can be carried out from the panel of the
operator in diagnostic mode of code tables. To perform it press button F3 for programmed logic matrix 1
(ПЛМ1) and button F4 for programmed logic matrix 2 (ПЛМ2) according to the tables 5.1 and 5.2.

Table 5.1 – Identification of entries of a programmed logic matrix 1 (ПЛМ1) and logic signals
А1 Status of the movement controller
А2 Status of the retardation controller
А3 Status of speed restriction signal. 1 – off, 0 – on
А5 Assignment of movement direction. 1 – forward, 0 – neutral, 2 – reverse
А6 Status of signal matching to turning on of any protection device. 1 – off
А8 Status of feedback signal of contactor KM8
А9 Status of feedback signal of contactor KM5
А10 Status of feedback signal of contactor KM9
А11 Status of feedback signal of contactor KM7
А12 Status of feedback signal of contactor KM1
А13 Status of feedback signal of contactor KM2
А14 Memory (programmed)
А15 Delay №1 (programmed)
А16 Delay №2 (programmed)
В1 Signal on turning on of contactor KM8
В2 Signal on turning on of contactors KM1, КМ2
В3 Signal on turning on of contactors KM4, КМ5
В4 Signal on turning on of contactors KM6, КМ7
В6 Memory
В7 Delay №1
В8 Delay №2

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 Table 5.2 – Identification of entries of ПЛМ2 and logic signals
А1 Status of speed restriction signal. 1 – off, 0 – on
А2 Status of signal on formation of operating modes of field reduction
А3 Status of feedback signal of contactor KM1
А4 Status of feedback signal of contactor KM2
А5 Status of feedback signal of contactor KM3
А6 Status of feedback signal of contactor KM8
А7 Status of signal matching to turning on of any protection device. 1 – off
А8 Status of the retardation controller
А9 Status of the movement controller 2 position
А10 Feedback signal of contactor KM9
А12 Movement direction
А13 Memory
А14 Control signal on turning on of contactor KM8
А15 Control signal on turning on of contactor KM1
А16 Delay №3
В2 Signal on turning on of contactor KM3
В3 Status of traction mode or forced electric retardation mode signal
В4 Status of signal of running-out mode (РВ)
В5 Status of separate excitation signal
В6 Status of reverse protection signal
В7 Status of field reduction signal
В8 Delay №3

5.4 On the operator’s panel enter into diagnostic mode of code tables. Check status of logic
levels according to table 5.3

Table 5.3 – Controlled logic levels

Operation which is
Parameter necessary for execution Place of the control Logic level
before measurement
Control signal
“RUNNING-OUT
ПЛМ2: В4 1
MODE”
РВ
Control signal
“MOVEMENT MODE” ПЛМ1: В2 1
РХ
Control signal Press movement pedal against
“RUNNING-OUT the stop
ПЛМ2: В4 0
MODE”
РВ
Control signal of scaling ПЛМ2: В3 1
____ ____ ____
Release movement pedal
Control signal
“RUNNING-OUT
ПЛМ2: В4 0
MODE” Press electric retardation pedal
РВ
Control signal ПЛМ2: В5 1
“SEPARATE
EXCITATION”
Press movement pedal ПЛМ2: В5 0
HB
Control signal
Release pedals of an electric
“MOVEMENT MODE” ПЛМ1: В2 0
retardation and a course
РХ

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

Д И А Г Н О С Т . П Л М 1 * * 1 0 : 4 4
* 1 * 2 * 3 * 4 * 5 * 6 * 7 * 8 *
А * 0 * 1 * 1 * * 2 * 0 * * 1 *
В * 0 * 0 * 0 * 0 * * 1 * 0 * 0 * ↓
Figure 11 – Dialog box of programmed logic matrix (ПЛМ) diagnostic

5.5 Adjust the sensor of electro-dynamic braking pedal. On the operator’s panel enter into
monitoring mode by pressing button F8, with the help of transition buttons (F9 – next, F12 – previous)
open dialog box №4 (see figure 12).

* * М О Н И Т О Р И Н Г * * * 1 0 : 4 7
U b c = х х г р д . *
U z = х . х B ↑
U r s = х х . х B ↓
Figure 12 – Dialog box of monitoring №4

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

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

6.1 Disconnect excitation circuit of the traction alternator by switch QF1. Install switch SA1 in
position «ВКЛ» (ON), and switch SA2 — in position «ВПЕРЕД» (FORWARD). Press movement pedal
and achieve rotational speed of the crankshaft of the diesel engine of not more than 1200 RPM.
Make sure that wheels of the dump truck rotate in the same direction, providing movement of the
dump truck forward. Release movement pedal. After a dead stop of wheels install switch SA2 in position
«НАЗАД» (REVERSE). Press movement pedal and achieve rotational speed of the crankshaft of the
diesel engine of not more than 1200 RPM. Make sure that wheels of the dump truck rotate in the same
direction, providing reverse movement of the dump truck. Release movement pedal.
6.2 Changing length of a tie-rod of the movement controller achieve turning on of circuits of the
traction electric drive at a rotational speed of the crankshaft of the diesel engine (900+100) RPM.
6.3 Press electric retardation pedal. The rotational speed of the crankshaft of the diesel engine
should increase up to (1300±10) RPM. For diesel engines with a mechanical regulator, at misfit of a
rotational speed adjust it changing length of a tie-rod of the executive pneumatic cylinder under a cab.
Release electric retardation pedal, install switches SA1 and SA2 in neutral position.
6.4 Check functioning of rotational speed sensors of traction motors.
On the operator’s panel press button F8 to enter in the mode of monitoring. With the help of
button F9 choose the necessary dialog box (see figure 13).

* * М О Н И Т О Р И Н Г * * * 1 0 : 4 4
F b r 1 = 2 0 Г ц *
F b r 2 = 2 0 Г ц ↑
N д и з = 1 2 0 0 о б / м и н ↓
Figure 13 – Dialog box of monitoring №5

Install switch SA1 in position «ВКЛ» (ON) and switch SA2 — in position «ВПЕРЕД»
(FORWARD). Press movement pedal and achieve rotational speed of the crankshaft of the diesel engine
of not more than 1200 RPM. Indications Fbr1 and Fbr2 should change.
It is possible to make the check by other method. Connect voltage meter PV3 (appendix A) to
crimped locks («362» – plus wire and «0» – minus wire) on connecting panel XT1. Press movement
pedal and achieve rotational speed of the crankshaft of the diesel engine (1200±50) RPM. The voltage

15
measured by voltage meter PV3 should be (12+3) V. Release movement pedal. Disconnect positive
crimped lock of voltage meter PV3 from a crimped lock «362» on connecting panel XT1 and connect it to
crimped lock «364». Press movement pedal and achieve rotational speed of the crankshaft of the diesel
engine (1200±50) RPM. The voltage measured by voltage meter PV3 should be (12+3) V. Release
movement pedal. Disconnect voltage meter PV3 from crimped locks «364» and «0».
Install switches SA1 and SA2 in a neutral position. Switch on switch QF1. Close doors of the
power cabinet. Shut down diesel engine.
Remove driving wheels of the dump truck from jambs.

7 Check of parameters of the traction electric drive

Over-all demands:
- check on sections of the given paragraph is to be carried out at origination of faults revealed
during running-in or maintenance of the dump truck;
- check of parameters of adjustment is to be carried out on braked dump truck at the working
diesel engine if other is not stipulated separately;
- rotation frequency monitoring is performed with the help of tachometer installed on the dash
panel in cab;
- if hereinafter on any subitems of the given paragraph it is not possible to gain demanded values
of parameters it is necessary to find fault, eliminate it and repeat check procedure;
- the operating time of the traction electric drive with currents above 1000 A should be no more
than 30 s, reclosing –not less than through 10 minutes;
- for dump trucks with payload capacity of 220 tonnes accomplishment of item 7.2 is obligatory as
value of an operating current differs from factory adjustment of the relay.

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

7.1.1. Open doors of the control cabinet. Install axis of resistor “Assignment” БУВГ-02 in position
against the stop counter-clockwise, the switch on front panel of БУВГ-02 — in position «РУЧН»
(MANUAL), switch SA9 of БПРР block – in position «ВКЛ» (ON).
Disconnect switch QF1. Connect one end of the jumper with cross-section from 0.35 to 0.5 mm2
to the case, the second end — to a wire «135» on relay KA1 in power cabinet. Switch on switch QF1.
7.1.2 Press movement pedal against the stop. Rotate an axis of resistor “Assignment” БУВГ-02
clockwise before reception of voltage UV8 controlled by means of the operator’s panel, matching value
«UopK1» = «UopK2» from table 4.2. Indicator «КОРПУС» (CASE) on the dash panel in operator’s cab
should switch on and on the operator’s panel should appear the message about the active protection.
Check magnitude of voltage at which protection has operated is possible in the crash log. Viewing of the
crash log on the operator’s panel is carried out by means of button F6. Codes of protection are presented
in table В1 (Appendix B).
Install axis of resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise.
Release movement pedal. Press and release button F5 on the operator’s panel; indicator «КОРПУС»
(CASE) should be disconnected.
7.1.3 Disconnect switch QF1. Disconnect jumper from a wire «135» and connect it to wire «149»
on contactor KM1. Switch on switch QF1. Repeat operations described in step 7.1.2. Controlled by
means of the operator’s panel, voltage of power circuit – UV7. Turning on of the protection device is to be
defined by turning on of indicator «КОРПУС» (CASE).
7.1.4 After process of regulating disconnect switch QF1, disconnect jumper from a wire «149»
and case. Install the switch on front panel БУВГ-02 in position «АВТ» (AUTOMATIC), switch SA9 in
position «Выкл» (OFF). Switch on switch QF1. Close doors of the power cabinet.

7.2 Check of the protection device at excess of legitimate value of armature chain
current of traction motors M1 and М2 in traction mode

7.2.1 Disconnect switch QF1. Install the switch on front panel БУВГ-02 in position «РУЧН»
(MANUAL). Connect by jumpers with cross-sections not less than 120 mm2 wires «103» and «104»,
«106» and «135».
16
 Disconnect protection on excess of admissible current of power circuit. To do that start the
program «Визуализация для обслуживающего персонала (AUTO VISUAL2)» (Visualization for
maintenance staff - AUTO VISUAL2) (see paragraph 4.2) and in section «Редактирование параметров»
(Editing of parameters) switch off «УстI» (see figure 2).
Switch on switch QF1.
7.2.2 Press movement pedal against the stop. Rotate an axis of resistor «Assignment” - БУВГ-02
clockwise.
At values of current specified in table 7.1 blinker of relay KA1 should operate and disconnect
excitation circuit of the traction alternator and power circuit.
Install axis of resistor “Assignment” - БУВГ-02 in position against the stop counter-clockwise.
Release movement pedal. Return blinker of relay KA1 in an initial point.
If operation of relay КА1 has occurred at values of a current of power circuit mismatching
specified in table 7.1, adjust the relay by change of tension of the return spring.
7.2.3 Disconnect switch QF1. Disconnect the first jumper from wire 135 and connect it to wire
«107». Disconnect the second jumper from wire «104» and connect it to wire «147». Switch on switch
QF1.
Repeat operations described in step 7.2.2. Relay KA2 should switch on. Adjust if necessary.

Table 7.1
Payload capacity of dump
120-125 130-136 200-220
trucks, tonnes
Value of operating current of
1500+50 1500+50 1900+50
relay КА1, КА2, A

7.2.4 Disconnect switch QF1. Disconnect jumpers from wires «106» and «107», «103» and
«147». Install switch БУВГ-02 in position «АВТ» (AUTOMATIC).
Switch on protection “Уст.I” (figure 2).
Switch on switch QF1.

7.3 Check of functioning of the protection device at excess of legitimate value of

output voltage of rectifiers UZ1 or UZ2 in traction mode

7.3.1 Open doors of the power cabinet, disconnect switch QF1. In break of wire «149» on
contactor KM1 and wire «146» on contactor KM2 connect resistors R1 and R2 (appendix A) with
resistance (10+5) kOhm and power not less than 100 W. At presence bus isolators QS1, QS3 install
resistors instead of buses.
Switch on switch QF1. Install the switch БУВГ-02 on the front panel in position «РУЧН»
(MANUAL), and resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise.
Disconnect protection «Uустrb1», «Uустrb2», «Uустm1», «Uустm2» in section «Редактирование
параметров» (Editing of parameters) of program «Визуализация для обслуживающего персонала
(AUTO VISUAL2)» (Visualization for maintenance staff - AUTO VISUAL2) (see figure 2).
7.3.2 Press movement pedal against the stop. Rotate resistor ”Assignment” БУВГ-02 clockwise.
At a voltage “Уст.Ud1” = “Уст.Ud2” (see table 4.2) controlled by means of the operator’s panel
UV1 and UV2, protection should turn on and indicator «ЗАЩИТА» (PROTECTION) should also switch
on, message on the operator’s panel confirming this protection should appear, excitation circuit of the
traction alternator and power circuit should break.
After disconnection of excitation circuit of the traction alternator and power circuit the voltage
should become equal to null.
Install resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise. Release
movement pedal.
Press and release button F5 on the operator’s panel for reset of protection and indication on the
operator’s panel.
7.3.3 After check activate the disconnected protections. Install the switch on front panel БУВГ-02
in position «АВТ» (AUTOMATIC). Disconnect switch QF1. Disconnect resistors R1 and R2 and reconnect
wires «146» and «149». Switch on switch QF1. Close doors of the control cabinet.

17
 7.4 Check of functioning of the protection device at excess of admissible current of
loading of rectifiers UZ1 and UZ2 in traction mode on the limiting characteristic

7.4.1 Install the toggle switch on front panel БУВГ-02 in position «РУЧН» (MANUAL), and resistor
“Assignment” БУВГ-02 in position against the stop counter-clockwise. Disconnect switch QF1. Connect
by jumpers with cross-section of not less than 120 mm2 wires «103» and «104», «106» and «107».
Switch on switch QF1.
7.4.2 Press movement pedal against the stop. Rotate axis of resistor “Assignment” БУВГ-02
clockwise. At value of current “Уст.I” (see table 4.2), controlled by means of the operator’s panel UА1,
should switch on indicator «ЗАЩИТА» (PROTECTION) and message on the operator’s panel, excitation
circuit of the traction alternator and power circuit should open.
Install axis of resistor “Assignment” БУВГ-02 in an initial point. Release movement pedal. Press
and release button F5 on the operator’s panel. Indicator «ЗАЩИТА» (PROTECTION) and message on
the operator’s panel should be switched off.
7.4.3 Install the toggle switch on front panel БУВГ-02 in position «АВТ» (AUTOMATIC).
Disconnect switch QF1. Disconnect jumpers «103» and «104», « 106 and «107». Switch on switch QF1.
Close doors of the control cabinet.

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

wheels skidding

7.5.1 Disconnect switch QF1. In break of circuit «135» connect technological resistor with
resistance (10+5) kOhm and power of not less than 100 W. Switch on switch QF1.
Disconnect protection «Uустd» in section «Редактирование параметров» (Editing of
parameters) of program «Визуализация для обслуживающего персонала (AUTO VISUAL2)»
(Visualization for maintenance staff - AUTO VISUAL2) (see figure 2).
Install the switch on front panel БУВГ-02 in position «РУЧН» (MANUAL), and resistor
“Assignment” БУВГ-02 — in position against the stop counter-clockwise.
7.5.2 Press movement pedal against the stop. Rotate an axis of resistor “Assignment” БУВГ-02
clockwise.
At value of voltage «Uустdm» (see table 4.2), controlled on the operator’s panel UV5, indicator
«ЗАЩИТА» (PROTECTION) and the message on the operator’s panel should switch on, excitation circuit
and power circuit should open.
Install axis of resistor “Assignment” БУВГ-02 against the stop counter-clockwise. Release
movement pedal. Press and release button F5. Indicator «ЗАЩИТА» (PROTECTION) and the message
on the operator’s panel should be switched off.
7.5.3 Disconnect switch QF1. Rebuild circuit «135».
In break of circuit «147» connect the technological resistor with resistance (10+5) kOhm and
power of not less than 100 W. Switch on switch QF1.
Repeat operations described in step 7.5.2. The voltage of power circuit is controlled by UV6 on
the operator’s panel.
7.5.4 Activate protection «Uустd». Install the switch on front panel БУВГ-02 in position «АВТ»
(AUTOMATIC). Disconnect switch QF1. Rebuild circuit «147». Switch on switch QF1. Close doors of the
power cabinet.

7.6 Check of functioning of the protection device at excess legitimate value of voltage
on armature chain of traction motors М1 and М2 in a traction mode

7.6.1. Disconnect switch QF1. Disconnect wire 149 from contactor KM1. Switch on switch QF1.
Disconnect protection “Уст.Ud1”, «Уст.Ud2”, «Устrb1», «Устrb2» in section «Редактирование
параметров» (Editing of parameters) of program «Визуализация для обслуживающего персонала
(AUTO VISUAL2)» (Visualization for maintenance staff - AUTO VISUAL2).
Install the switch on front panel БУВГ-02 in position «РУЧН» (MANUAL), and resistor
“Assignment” БУВГ-02 in position against the stop counter-clockwise.
7.6.2. Press movement pedal against the stop. Rotate axis of resistor «Assignment” БУВГ-02
clockwise.

18
 At value of voltage «Uустm1» = «Uустm2» (see table 4.2), controlled by means of the operator’s
panel UV5, indicator «ЗАЩИТА» (PROTECTION) and the message on the operator’s panel should
switch on, excitation circuit of the traction alternator and power circuit should open.
Install axis of resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise.
Release movement pedal. Press and release button F5. Indicator «ЗАЩИТА» (PROTECTION) should
switch off.
7.6.3 Disconnect switch QF1. Install wire «149» in its place. Disconnect wire «146» from
contactor KM2. Switch on switch QF1.
Repeat operations described in step 7.6.2. Controlled voltage of power circuit – UV6.
7.6.4 Activate protection “Уст.Ud1”, «Уст.Ud2”, «Устrb1», «Устrb2».
Install the switch on front panel БУВГ-02 in position «АВТ» (AUTOMATIC). Disconnect switch
QF1. Install wire «146» in its place. Switch on switch QF1. Close doors of the control cabinet.

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

7.7.1 Install switch SA9 of БПРР block in position «ВКЛ» (ON), switch on front panel БУВГ-02 in
position «РУЧН» (MANUAL), and resistor “Assignment” БУВГ-02 in position against the stop counter-
clockwise. Disconnect switch QF1. Disconnect «107» wire on terminal block XT5 and isolate it. Switch on
switch QF1.
7.7.2 Press movement pedal and install nominal rotational speed of the diesel engine. Rotate axis
of resistor “Assignment” БУВГ-02 clockwise. At value of voltage «Uустd» (see paragraph 5.3.7),
controlled by means of the operator’s panel UV2, indicator «ЗАЩИТА» (PROTECTION) and message on
the operator’s panel should switch on, excitation circuit of the traction alternator and power circuit should
open.
Install axis of resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise.
Release movement pedal. Press and release button F5. Indicator «ЗАЩИТА» (PROTECTION) should
switch off.
7.7.3 Disconnect switch QF1. Rebuild circuit «107». Disconnect «104» wire on terminal block
XT5 and isolate it. Switch on switch QF1. Repeat operations described in step 7.7.2.
7.7.4 Disconnect switch QF1. Rebuild circuit of wire «104». Switch on switch QF1. Install the
switch on front panel БУВГ-02 in position «АВТ» (AUTOMATIC), switch SA9 in position «Выкл» (OFF).
Close doors of the power cabinet.

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

7.8.1 Disconnect from crimped locks ХТ2 of the power cabinet wires «362» and «364» going on
sensors of rotational speed of traction motors M1 and М2 accordingly.
Connect to crimped locks «XT2:362» and «XT2:0» the signal generator (appendix A). Install on
exit of the signal generator the minimal value of frequency.
7.8.2 Press movement pedal against the stop.
Increase frequency of the signal generator. At frequency «Vmin1ON» according to table 4.2, the
signal of field reduction (ОП) =1 (see table 5.2) should be generated. It corresponds to formation of the
logic signal allowing switching of the traction electric drive from operating mode with full field of traction
motors into the mode of smooth field reduction.
7.8.3 Continue to increase frequency of the signal generator. At frequency «OCON» according to
table 4.2 the indicator for restriction of speed (OC) should switch on. There should be switching of the
traction electric drive from traction mode in brake mode. It corresponds to automatic transition of the
traction electric drive in the mode of electro-dynamic braking in case of excess of admissible speed of
movement of the dump truck.
7.8.4 Reduce frequency of the signal generator. At frequency «OCOFF» according to table 4.2,
the OC indicator should be switched off. Thus there should be an automatic switching from mode of
electro-dynamic braking in running-out mode. Release movement pedal.
7.8.5 Press against the stop electro-dynamic braking pedal. Reduce frequency of the signal
generator. At frequency «Vmin2ON» according to table 4.2, contactor KM3 should switch on. It
corresponds to switching of the traction electric drive in mode of separate excitation of traction motors at

19
electro-dynamic braking in zone of low speeds. Reduce frequency of the signal generator up to null.
Release electro-dynamic braking pedal.
7.8.6 Disconnect the signal generator and frequency meter from crimped locks «ХТ2:362»,
«ХТ2:0» and connect them to crimped locks «ХТ2:364», «ХТ2:0».
Repeat checks described in steps 7.8.2-7.8.5.
7.8.7 Disconnect the signal generator and frequency meter from crimped locks «ХТ2:364»,
«ХТ2:0». Reconnect wires «362», «364» to crimped locks ХТ2. Close doors of the power cabinet.

Notes – This check is to be carried out at not working diesel engine.

7.9 Check of the device of smooth field reduction (smooth exciting current control) of
traction electric motors in traction mode

7.9.1 Disconnect switch QF1. Perform operations described in step 7.8.1.

Switch on switch QF1.
Install frequency of the alternator allowing work of field reduction.
Install axis of resistor “Assignment” БУВГ-02 in position against the stop counter-clockwise.
Install the switch on front panel БУВГ-02 in position «РУЧН» (MANUAL), switch SA9 of БПРР block – in
position «ВКЛ» (ON).
7.9.2 Press movement pedal against the stop. Rotating axis of resistor “Assignment” БУВГ-02
clockwise install value of the current controlled by means of the operator’s panel UА1 equal to (400±20) A
(at Р = 1000 kW — (490±30) A, at Р = 1400 kW — (600±20) A).
Value of current «Ioп» on operator’s panel should increase, that testifies to full opening thyristors
of regulator of field reduction of traction motors.
Install value of the current controlled by means of the operator’s panel UА1, equal to (460±20) A
(or (520±30) A at Р=1000 kW, at Р=1400 kW — (700±35) A). Value of current «Ioп» on the operator’s
panel should become close to 0, that testifies to closing thyristors of regulator of field reduction. Release
movement pedal.
7.9.3 Disconnect switch QF1. Disconnect the signal generator and frequency meter from crimped
locks «ХТ2:364», «ХТ2:0». Reconnect wires «362», «364» to crimped lock ХТ2. Install the switch on
front panel БУВГ-02 in position «АВТ» (AUTOMATIC), switch SA9 – in position «ОТКЛ» (OFF). Switch
on switch QF1. Close doors of the control cabinet.

7.10 Check of the device for restriction of the electromotor-wheels skidding

7.10.1 Disconnect switch QF1. Disconnect from current relay KA2 wire «147» going to traction
motor M2. Switch on switch QF1.
Install axis of resistor «Assignment” БУВГ-02 in position against the stop counter-clockwise.
Install the switch on front panel БУВГ-02 in position «РУЧН» (MANUAL).
7.10.2 Press movement pedal. Achieve rotational speed of the crankshaft of the engine from
1400 to 1500 RPM (for diesel engines with a nominal rotational speed of 1900 RPM).
Rotate axis of resistor “Assignment” БУВГ-02 clockwise.
7.10.3 At value of voltage «Uуст» (see table 4.2), controlled by means of the operator’s panel
UV2, the device for restriction of wheels skidding should switch on. Thus the voltage should decrease up
to value of (200±50) V, value of the current controlled by means of the operator’s panel UА1 should be
(65±20) A.
Install axis of resistor «Assignment” БУВГ-02 in position against the stop counter-clockwise.
Disconnect switch QF1. Connect a wire «147» to current relay KA2.
7.10.4 Disconnect from relay KA1 wire «135» going to traction motor M1.
Switch on switch QF1. Repeat operations described in steps 7.10.2 and 7.10.3. Voltage
controlled by means of the operator’s panel – UV1. Value of the current controlled by means of the
operator’s panel UA1 should be (45±15) A.
7.10.5 Disconnect switch QF1. Install axis of resistor “Assignment” БУВГ-02 in position against
the stop counter-clockwise, the switch on front panel БУВГ-02 in position «АВТ» (AUTOMATIC), connect
wire «135» to relay KA1. Switch on switch QF1.

20
 7.11 Check of the channel of restriction of output voltage of rectifier UZ1 or UZ2 in
traction mode

7.11.1 Open doors of the power cabinet, disconnect switch QF1. In break of wire «149» on
contactor KM1 and wire «146» on contactor KM2 connect resistors R1 and R2 (Appendix A) with
resistance of (10+5) kOhm and power of not less than 100 W. At presence bus isolators QS1 and QS3
install resistors instead of buses. Switch on switch QF1.
7.11.2 Press movement pedal and achieve nominal rotational speed of the diesel engine.
Values of the voltage controlled by means of the operator’s panel UV1 and UV2, should be
«Uотс.» (Restriction of the maximum voltage on exit of the power rectifier) (see tables 4.4 – 4.7).
7.11.3 Disconnect switch QF1. Disconnect resistors R1 and R2 and rebuild circuits «149» and
«146». At presence of disconnectors QS1 and QS3 disconnect resistors and install bus isolators QS1 and
QS3 in position «1-2». Switch on switch QF1. Close doors of the control cabinet.

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

7.12.1 Disconnect switch QF1. Connect by jumpers with cross-section not less than 120 mm2
wires «103» and «104», «106» and «107». Switch on switch QF1.
7.12.2 Press movement pedal and achieve nominal rotational speed of the diesel engine.
Value of the current controlled by means of the operator’s panel UА1, should be equal «Iотс.»
(restriction of the maximum current in power circuit) (see tables 4.4 – 4.7).
Release movement pedal.
7.12.3 Disconnect switch QF1. Disconnect the jumpers connecting wires «103» and «104»,
«106» and «107». Switch on switch QF1.
Close doors of the control cabinet.

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

7.13.1. Install switch SA9 of БПРР block in position «ВКЛ» (ON). On the operator’s panel press
button F8 to enter into monitoring mode, with the help of transition buttons (F9 – next, F12 – previous)
open dialog box №2 (see figure 14).

* * М О Н И Т О Р И Н Г * * * 1 0 : 4 7
U V 5 = x x x x B = U V 6 = x x x x B *
U A 1 = x х x х A ↑
P = х х x х B т ↓
Figure 14 – Dialog box of monitoring №2

Press movement pedal and achieve rotational speed of the crankshaft of the diesel engine equal
to nominal.
Value of power on exit of power rectifiers UZ1 and UZ2 is controlled by value P in the open dialog
box of the operator’s panel.
Release movement pedal.
Install switch SA9 in position «Откл.» (OFF). Close doors of the control cabinet.
Notes – in order to prevent falling out of installation of ventilated brake resistors УВТР2х600 the
operating time of the traction electric drive in the given mode should be no more than 30 s, a reclosing –
not less than through 10 minutes For longer time of measurement it is recommended connect the same
installation (wires «149», «106» and «146», «102») in parallel to installation УВТР.

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

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

21
 Smoothly press electric retardation pedal against the stop. The rotational speed of the crankshaft
of the diesel engine should increase up to (1300+10) RPM.
The exciting current of traction motors measured on the operator’s panel UА1 should change
from the initial value which should not exceed 100-200 А to limiting value that is equal to «Ib» (see tables
4.4-4.7.)
Release electric retardation pedal.

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

7.15.1 Disconnect switch QF1. Connect by jumper with cross-section of not less than 120 mm2
wires «102» and «147», «106» and «135». Switch on switch QF1.
7.15.2 Press against the stop electric retardation pedal and movement pedal. Value of the voltage
controlled by means of the operator’s panel UV3 and value of the current controlled by means of the
operator’s panel UА1 should match to the values specified in table 7.2. The voltage controlled by means
of the operator’s panel UV4 should be equal to null.

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

retardation mode
Resistance of the brake resistor, The voltage measured by The current measured by
Ohm voltage meter UV3, V ammeter UA1, A
1.4 910±35 650±25
1.05 840±35 800±25
0.7 880±35 1250±25

Release movement pedal and electric retardation pedal.

7.15.3 Disconnect выключательQF1. Disconnect the jumpers connecting wires «102» and
«147», «106» and «135». Switch on switch QF1. Close doors of the control cabinet.

7.16 Check of restriction of voltage (current) of traction motors in electro-dynamic

retardation mode on conditions of their commutation

7.16.1. Disconnect from terminal block ХТ1 wire «362» going to sensor BR1 of rotational speed
of electric motor M1. Connect to crimped lock «ХТ1:362» and «XT1:0» plus and minus terminals of the
signal generator (Appendix A) accordingly. Install on exit of the signal generator the minimal value of
frequency.
7.16.2 Disconnect switch QF1. Connect by jumpers with cross-section of not less than 120 mm2
wires «102» and «147», «106» and «135». Switch on switch QF1.
7.16.3 Press against the stop electric retardation pedal and movement pedal. Smoothly changing
frequency of the signal generator make sure that value of the voltage controlled by means of the
operator’s panel UV3 matches the value specified in tables 4.4-4.7 (voltage of brake installation in
electro-dynamic braking mode).
The voltage controlled by means of the operator’s panel UV4 should be equal to null.
Release movement pedal and electric retardation pedal. Reduce frequency of the signal
generator to null.
7.16.5 Disconnect the signal generator and frequency meter from a crimped lock «ХТ1:362» and
connect them to a crimped lock «ХТ1:364». Repeat check on described in step7.16.3.
7.16.6 Disconnect switch QF1. Disconnect the jumpers connecting wires «102» and «147»,
«106» and «135». Switch on switch QF1.
Disconnect the signal generator and frequency meter from crimped locks «ХТ1:364» and
«ХТ1:0». Connect wires «362», «364» on matching places to crimped locks ХТ1. Close doors of the
control cabinet.

22
 APPENDIX A
(obligatory)

Table А.1 – List of the equipment necessary for adjustment of the traction electric drive
Identificatio Accuracy Designation of the
Name Type
n code rating standard
DC multilimiting voltage meter
PV3 0.5 GOST8711-93 М1106
0,015 … 600 V
Low-frequency signal generator 10
— 2.5 ЕХ3.268.039 ТУ Г3-112/1
… 100 Hz
DC ammeter 0 — 1 kА PA2 1.5 ТУ 25-04.ЭД1.4058 М42300
Megaohmmeter — 15 ТУ25-7534.014-90 ЭС0202
С5-35В-100-10
Resistor R1, R2 — ОЖО.467.551 ТУ
kOhm
ДСР3033,
Additional resistance — — ТУ25-04.4041
1 kV, 5 mА
МКИЯ.318572.002
Power supply — 2.5 БЗ – 786,4
ТУ
Notes:

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

2 Instead of resistor С5-35В-100-10 kOhm application of the resistor of other type with resistance from
10 to 15 kOhm and power of not less than 100 W is permitted.

23
 APPENDIX B
(obligatory)

Table B.1 – List of indicators and diagnostic connectors

Designation
The name of controlled signal (parameter)
Block Point
CAN Indication of CAN work
+5 V Presence of voltage +5 V
U Indication of control pulse UTRB
БУВГ-02
V Field reduction
Work
+15 V Presence of supply voltage +15 V
0U Over-all
БУМ –3.2 +15 V Voltage control +15 V
OUT1 Control pulses (galvanically not untied) VS6
ХТ3 OUT2 Control pulses (galvanically not untied) VS7
OUT3 Control pulses (galvanically not untied) VS8
0U Over-all
VCС0
OUT1 Control pulses (galvanically not untied) VS4
БУТ-1.2
OUT2 Control pulses (galvanically not untied) VS5
UPR1 Permission VS4
UPR2 Permission VS5
1 Input assignment
2 Synchronization of exit
3 Exit ОП
4 Exit UTRB
БУВГ-02 5 Manual control
6
7 Over-all
8 +5 V
9

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 APPENDIX B
(recommended)

Тable B.1 – Codes of protection

Crash
Designation Explanation
code
Protection on excess of admissible current of loading of
001 Urs1_z
rectifiers Uz1, Uz2
Protection on excess of legitimate value of output voltage on
002 Ud1_z
rectifier Uz1
Protection on excess of legitimate value of output voltage on
003 Ud2_z
rectifier Uz2
Protection on excess of difference of voltage on traction
004 dUm_z
motors
Protection on excess of difference of voltage on power
005 dUd_z
rectifiers
006 Urs_zh Protection on current on the partial characteristic
Protection on excess of legitimate value of voltage on brake
007 Urb1_z
resistor Rb1
Protection on excess of legitimate value of voltage on brake
008 Urb2_z
resistor Rb2
Protection on excess of legitimate value of voltage on traction
009 Um1_z
motor M1
Protection on excess of legitimate value of voltage on traction
010 Um2_z
motor M2
011 Uzr_z Protection at the forced retardation
012 Thermal protection Rk1
013 Breakage of circuit of thermal sensor Rk1
014 КЗ in circuit of thermal sensor Rk1
015 Thermal protection Rk2
016 Breakage of circuit of thermal sensor Rk2
017 КЗ in circuit of thermal sensor Rk2
018 Thermal protection Rk3
019 Breakage of circuit of thermal sensor Rk3
020 КЗ in circuit of thermal sensor Rk3
021 Thermal protection Rk4
022 Breakage of circuit of thermal sensor Rk4
023 КЗ in circuit of thermal sensor Rk4
024 Uk1_z Protection on the case
025 Uk2_z Protection on the case
026 dUrb_z Excess of admissible difference of voltage on brake resistors
027 Us Restriction of speed
028 Уст.301 Reduction of supply to the cabinet up to 18V

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