SIEMENS

Energy & Automation, Inc.

IGBT Standard Training Course Schedule

Class Length 5 Days
Scope of Class: This class is being given for IGBT Standard Shovel customers. It is assumed that the
people in class will be familiar with electrical shovels and basic electrical fundamentals. This class will
introduce the student to the technology as applied on the standard IGBT shovels.
I

Documentation and Software furnished to the students:

A. Class Schedule
B. IGBT Shovel Systems Class Manual
C. General electrical schematics for shovels (SIEMENS & BUCYRUS)
D. General Information and Procedures for the SiBas control system
E. Shovel electronic devices manual
F. CDA / ANF Fault Manual
G. SIB Fault Manual
H. SIRAS remote logon information
I. SiBas Monitor software for connecting to SiBas32 program

Basic Outline:
I.

System Overview (3 hours)

A. OBJECTIVES: Upon completion of this section, the student will be able to :
Introduce the major technologies used in the standard IGBT System
List the power connections and lock-out safety points for the cabinet
Explain the operation of components used on the shovel skid
List the three classes of faults that annunciate on the shovel
Read schematics and locate components based on device name
Maneuver through the various HMI screens found on the skid
Research faults in both the HMI and the troubleshooting manuals
Locate devices and characteristic in the Device Manual
B. MATERIALS:
Class Manual
Siemens Schematics
Bucyrus Schematics
Device Manuals
Troubleshooting Manuals
C. INTRODUCTION: Provides an overview of the technologies used in the Siemens IGBT shovel
family. The instructor introduces the major black boxes used in controlling the system. Discusses
the functions and responsibilities of each, as well as the interfaces between them.
D. SIEMENS SCHEMATICS: Introduction to the schematic style used for the IGBT system. Covers
Print Sections, Cross-Referencing, Tracing. Exercises include tracing control loops, component
locations, Cable Detail Identification, etc.
E. BUCYRUS SCHEMATICS: Explanation of the different style of drawing used in the Bucyrus
schematics. Identifying components and identifying interface points between the BI and SE&A
schematics.

IGBT Standard Training Course Outline

Revised JAN 2009

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SIEMENS

Energy & Automation, Inc.

F. SYSTEM COMPONENTS: Describes some of the important system devices, their operation and
their specifications. Comparison of device specifications from the vendors vs. those in the
application. Use of the Device Manual.
G. TYPES OF FAULT MESSAGES:
ANF PLC
CDA PLC
SIB SiBas
II. Component Identification Practical (1 hour)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Locate any component in the Siemens cabinet based upon information from the Siemens
schematic.
Locate any component in the Siemens schematic based upon its markings in the drive cabinet.
Locate and Identify all connections points for field wiring to the drive cabinet
B. MATERIALS:
Class Manual
Siemens Schematics
Bucyrus Schematics
Device Manuals
Troubleshooting Manuals
Shovel drive cabinet Power Disconnected
III. HMI Operation (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Monitor feedback values from the PLC and drive systems.
Locate the various screens for Active Logic for monitoring and troubleshooting.
Read faults from the Active Alarms screen.
Read and Save faults from the Fault History screen.
Follow faults to the on-line Troubleshooting Manual.
B. MATERIALS:
Maintenance Station Owners Manual
IV. HMI Operation Practical (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Monitor feedback values from the PLC and drive systems.
Locate the various screens for Active Logic for monitoring and troubleshooting.
Read faults from the Active Alarms screen.
Read and Save faults from the Fault History screen.
Follow faults to the on-line Troubleshooting Manual.
Use Footprints screen to locate system components.
Locate and view Synchronizing voltages ULRT & ULST
B. MATERIALS:
Maintenance Station Owners Manual
Shovel drive cabinet Power ON

IGBT Standard Training Course Outline

Revised JAN 2009

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SIEMENS

Energy & Automation, Inc.

V. SiBas 32 (6 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Explain the functions of the ZR and SIP processors
Explain the difference between the PLC and SiBas scan logic
Explain different block types, connector types, and scan times in the SiBas program.
Trace the signal flow through the speed regulator function package.
Explain the functions of each card in the SiBas rack.
Explain the different protection levels in the UWS cards.
Start the Monitor program.
Start the Monitor program to load the ZR and SIP programs.
Start the Monitor program to read faults and clear faults.
Start the Monitor program to read and record values.
Start the Monitor program to change connectors and edit changes in the buffer
Explain the functions of the SIP Traco and how to set up and trigger record on fault
conditions.
Set the system to Manual mode (for hoist & crowd).
B. MATERIALS:
SiBas Rack
Laptop with SiBas Monitor program installed
Interface cable
Class Manual
Microsoft Excel
Manual General Information and Procedures for SiBas 32 Control System
C. SiBas OVERVIEW:
SiBas as a motion control system, the differences between SiBas and earlier control systems.
D. READING SiBas PROGRAM LISTING:
Reading Function Packages; block types, scan rates, scan sequence, connector and data types.
E. SiBas RACK CARDS:
Functionality and interchangeability of SiBas rack cards. Different levels of protection in the
UWS cards and their reset routine.
F. SiBas HARDWARE LIST:
Guide to reading the SiBas Hardware List; information contained.
G. SiBas MONITOR:
Installation, startup and configuration. Observing connectors and changing values.
Creating, opening and saving files and data
Loading programs into the ZR and SIP cards. SIP Traco functions.
A. SiBas MONITOR PRACTICE
Exercises for the installation, startup and configuration of the software on the laptop.
Creating, opening and saving files and data.
VI. SiBas 32 Practical (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Creating, opening and saving files and data.
Trapping signal values in the Monitor program.
Graphing signal values in Excel
Practice in troubleshooting SiBas faults
B. MATERIALS:
SiBas Monitor Software with Interface cable and Microsoft Excel programs
Shovel drive cabinet Power ON
IGBT Standard Training Course Outline
Revised JAN 2009

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SIEMENS

Energy & Automation, Inc.

VII. Step 7 PLC and ET200 Stations (6 hours)

A. OBJECTIVES: Upon completion of this section, the student will be able to:
Understand the topology of the S7 network and its stations
Understand and Edit the S7 Hardware Configuration
Understand basics of Profibus communication
Work between the ON line / OFF Line windows
Use the Simatic Manager to check system information
Use the Simatic Manager to observe and change PLC values
Use the Simatic Manager to search for variables and I/O
Download & Upload programs
Archive & Retrieve projects
Configure individual ET200 stations
Understand PLC program structure
B. MATERIALS:
Class Manual
Laptop with Simatic Manager installed
C. PLC HARDWARE: Explanation of PLC network configuration. Differences between earlier
network with Host PC / Slot PLC and the new system with Rocky. Explanation of ET200 cards
and setup. Setting network addresses at stations and terminating resistors.
D. PROFIBUS: Basic steps in setting up Profibus networks.
E. STEP 7 INTRODUCTION
F. STEP 7 SIMATIC MANAGER
Using the Simatic Manager to open PLC projects
Viewing and setting up the Hardware Configuration
Object properties of the hardware components
Searching for I/O and variables in the Step 7 program
Comparing I/O addresses in the PLC program and the Siemens schematics
Troubleshooting from the HMI System Ready screen and the Simatic Manger
G. SETTING IP ADDRESS IN STEP 7
Setting the internal Ethernet address for the PLC
VIII. Step 7 PLC - Practical (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Troubleshoot problems via the System Ready screen, the Simatic Manager and around the
network.
B. MATERIALS:
Shovel drive cabinet Power ON
HMI screens and the preinstalled Simatic Manager

IGBT Standard Training Course Outline

Revised JAN 2009

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SIEMENS

Energy & Automation, Inc.

IX. Shovel Command / Control Structure (2 hours)

A. OBJECTIVES: Upon completion of this section, the student will be able to:
List the steps in the DC Buss ON/OFF sequence
List the steps in the Motion ON/OFF sequence
B. MATERIALS:
Class Manual
PLC Listing
X. AC Motors & Controls (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
Explain the motor nameplate information
Understand the difference between real power and reactive power and describe power factor
Explain the three basic methods of motor speed control
B. MATERIALS:
Class Manual
Step 2000 series guide
C. BASICS OF AC MOTORS
Nameplate data and slip
Real power, reactive power and power factor
Volts per Hertz relationship
D. BASIC DRIVE OPERATION
Modes of open-loop and closed-loop control for variable speed motors
The SiBas implementation of control
Torque and flux generation
Functions of the SIPs and ZR
XI. AFE Operation & State Vector Control (2 hours)
A. OBJECTIVES: Upon completion of this section, the student will be able to:
List the advantages of the AFEs compared to other rectification systems
Describe the purpose of the choppers
Describe the difference between chopper firing and AFE firing
Describe the operation of Ground Fault detection in the IGBT system
B. MATERIALS
Class Manuals and Overheads
C. BASICS OF AFE POWER SECTION OPERATION
AFE Block Diagram
State Vector Modulation (SVM)
D. BASIC AFE MONITORING
Monitoring through the SiBas and the test points.
Observation of the chopper operation
E. GROUND FAULT DETECTION
Explanation of Ground Fault protection
XII. AFE Operation & Control Practical (2 hours)
A. OBJECTIVES
Troubleshoot faults initiated in SiBas
B. MATERIALS
Siemens Schematics
Voltmeter
IGBT Standard Training Course Outline
Revised JAN 2009

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SIEMENS

Energy & Automation, Inc.

XIII. Midas and Siras (3 hours)

A. OBJECTIVES
Understand the differences between MIDAS and SIRAS and how they work together
Understand Maintenance tools vs. Operations tools
Become familiar with the various screens and information presented in the MIDAS DesktopR
B. MATERIALS
Class Manual
Laptop with MIDAS files stored for viewing
XIV. Review (1 hour)
A. OBJECTIVES
Summary of presented material
Open question and answer period

IGBT Standard Training Course Outline

Revised JAN 2009

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