TripRite Drive Setup and Testing Procedure

1. Setup Windows 7 environment Network settings. **Note: This only needs to be performed once the first time
the computer is set up or after there has been a change to network settings. Skip to Step 2 if this has already
been completed ** Open Start Menu/Control Panel and double click on Network and Sharing Center.
a. In the Network and Sharing Center dialog box, select “Change adaptor settings”.
b. Double click on Local Area Connection.
c. Select “Properties” in the Local Area Connection Status dialog box.
d. In the Local Area Connection Properties dialog box, select “Internet Protocol Version 4 (TCP/IPv4)” and
click Properties.

e.
f. In the Internet Protocol Version 4 Properties dialog box, enter 192.168.1.253 in the IP Address field. Click
on the Default Gateway field and it will auto populate with 255.255.255.0. Click OK to close the dialog
box. Click Close in the Local Area Connection Properties dialog box to close it. Click Close in the Local
Area Connection Status dialog box to save the settings and put the computer on the shovel network.
2. To verify communication with the shovel network, open the Start menu, select All
Programs/Accessories/Command Prompt. In the Command Prompt window, enter the command “ping
192.168.1.2”. This will attempt to establish communication with the AC800 processor. The result should look as
shown below, with pings being returned quickly. If all four pings time out, you likely have an incorrect
communication setting. Some, but not all, of the pings timing out or excessively long ping times (greater than 20
ms) may indicate a faulty cable that is improperly terminated.

3. Next, open up the Windows XP virtual machine environment by selecting Start Menu/All Programs/Windows
Virtual PC/Windows XP Mode.
4. The next step is to set up network communications in the XP Environment. ** Note: This step should only need
to be performed once, the first time this procedure is performed, and is not necessary unless the settings have
been changed or lost.** Proceed to step 5 if this step is not required.
a. From within the XP environment, open the Control Panel from within the Start Menu. Select Network
and Sharing Center.
b. With the Network and Sharing Center opened, select “Change adapter settings” at the upper left of the
dialog box.
c. In the Network Connections window that opens up, double click on Local Area Connection.
d. In the Local Area Connection Status dialog box that opens, select Properties.
e. The Local Area Connection Properties box will then open. Select “Internet Protocol (TCP/IP)” then select
Properties.

f. In the Internet Protocol Properties dialog box that opens, select “Use the following IP address” and enter
192.168.1.252 for the IP address and 192.168.1.253 as the default gateway as shown. Clicking in the
subnet mask field will auto-populate the field with 255.255.255.0. What this step is accomplishing is to
establish a unique IP address for the XP virtual environment, then directing it to first look to the Win 7
environment for routing information to outside devices. This insures the most consistent and stable
 communications path to the TripRite drive and other devices.

g. To verify correct communications from within the Windows XP environment, open the Start Menu/All
Programs/Accessories/Commend Prompt. In the Commend Prompt window, again enter the “ping
192.168.1.2” command to check communication to the PLC processor. Again, you should have 0% signal
loss (all four pings successful) and sub-20ms ping times.
5. Open the Siemens Primary Setup Tool (PST Tool). From within the PST window, select Network Adapter from the
Settings drop-down menu and set the adapter to Local Area Connection.
6. Next, select Browse from the Network drop-down menu.
7. After the PST Tool has completed browsing the network, you will see two Siemens devices, the Scalance X-200
Ethernet switch and the3 Sinamics S drive, as shown. Click the + simbols to the left of these devices to expand
them, as shown. The Sinamics S drive may require you to select the root device (as shown) after clicking the +
symbol in order to fully expand the device tree.
8. Select the “Ind. Ethernet interface” under the Scalance switch (as shown) and select “Assign IP parameters”.
Enter 192.168.1.20 as the IP address and 255.255.255.0 for the subnet mask as shown.
9. Similarly, enter 192.168.1.12 as the IP address for the drive and 255.255.255.0 as the subnet mask as shown.
10. For the Ethernet switch, select the root device (as shown) and then select Download from the Module drop-
down menu. The software will ask you to confirm that you want to download the setting, erasing the existing
settings. Answer “Yes”. Repeat the steps for the Sinamics S drive as well. This sets the IP addresses of the two
devices, making communication to the drive possible and allowing the use of the built-in diagnostics of the
switch from a web browser.
a.
b.
11. Re-open the Command Prompt window and ping the Ethernet switch (192.168.1.20) and the drive
(192.168.1.12) as shown to verify the correct settings have been downloaded.

12. Close the Comment Prompt and PST Tool windows.

13. Open Siemens Starter. Close out and tips or reminders that pop open when the program is first started. Select
Open from the Project drop-down menu.
14. In the Open Project dialog box that opens, select Browse and navigate to the drive parameter set downloaded
from the machine’s PVCS folder.
15. With the correct parameter set selected, click OK to close the Browse dialog box, then click OK in the Open
Project box as well.
16. While opening the parameter set, a dialog box may open indicating you do not have Step 7 or the CFC add-on
package installed. Simply select OK to clear the box as you do not need these.

17. With Starter open, the PG/PC interface needs to be set. **Note, this only needs to be set once, if this has already
been completed, move to step 18. ** **Also note: depending on what tabs were open when the particular
parameter set you are working with was last saved, the exact tabs you see in the example picture below may not
match what you are seeing. This is expected and no cause for concern.**
a. From the Options drop-down menu, select “Set PG/PC interface”.
b. In the Set PG/PC Interface dialog box, select “S7ONLINE (STEP 7)” under Access Point of the Application.
Under Interface Parameter Assignment Used, Select the TCP/IP set connected with the hardwired
Ethernet card in your computer. Select OK to close the dialog box and set the interface.
18. From the Project drop-down menu, select “Connect to selected target devices”.
19. The Online/offline comparison dialog box will them appear, pointing out the differences between the drive
(which is blank) and the project. It will also ask if you want to download to the device or load from the device to
the project. Select Download.

20. A warning dialog box will then appear asking you to confirm your choice and letting you know that all data on the
drive will be lost. By default, the radio button next to “After loading, copy RAM to ROM” is selected. Leave it
selected, as this will copy the parameter set to the compact flash card in the controller after loading it into the
drive’s RAM memory. Select Yes to begin the download.
21. The Online/offline comparison box will again appear, but will show no differences this time. Select Close.
22. The drive controller will now need to transfer firmware to the other drive components and check the topography
of the system. Allow the drive system a minute or so to do this, then disconnect from the drive, using either
“Disconnect from target system” under the Project drop-down menu or with the button at the top of the screen.
Once disconnected, cycle control power to the drive, allowing 10 seconds for the drive to completely power
down before restoring power. Once power is restored, observe the status lights on the line module, motor
module, control unit, and resolver interface. After 30 seconds or so, the drive will have re-stared and loaded the
program from the compact flash card. The RDY status lights on the four drive components will now be solid
green.
23. With the drive up-and-running again, reconnect to it with either “Connect to selected target devices” from the
Project drop-down menu or with the button at the top of the screen. Starter should reconnect without any
issues or warnings. This indicates the parameter set was properly stored on the compact flash.
24. Set the drive’s expected three-phase voltage to 480VAC. **Note: This step is only required if the parameter set
you have loaded is for a voltage other than the 480 VAC used in North America. If the drive was loaded with a
460/480VAC parameter set, skip to step 25. ** This step will temporarily change the drives expected line voltage
to 480V for the purposes of testing. These changes will not be saved and will be overwritten by the parameters
stored on the compact flash card during the next power cycle.
a. If it is not already open, open the Expert List of parameters. This can be found under
S120_CU320_2_DP/B_INF_02/Expert List.
b. Find p10 in the list and set to “[1] Quick commissioning”.
c. Find p210 and set to 480. Restore p10 back to “[0] Ready”.
25. Navigate to the controller selection (configurator) tool in the “03 DC Control Cabinet Test” ControlBuilder project
folder. Run the controller selection tool.
26. In the Controller Selection tool, select Test_Controller under Machine Model Configuration Selection. Select
Sinamics S120 in the TripRite drop-down menu. Select PM864 / TP830 under Controller type. Leave the Close
After Successful Load option selected. Press Load Configuration.
27. Once the configuration is successfully loaded into ControlBuilder, select OK to close the controller selection tool,
leaving the ControlBuilder window open.
28. Under the Tools drop-down menu, select Download Project and Go Online.
29. The Online Analysis dialog box will appear. Select Cold Restart All, then select Continue.
30. During compilation of the program, ControlBuilder will find two loops in the code. Ignore these and select
Continue.
31. ControlBuilder will also then note a variety of warnings for remote IO racks and devices that are not present.
Ignore these as well and select Comntinue.
32. With the controller loaded with the test program and online with ControlBuilder, right click on TripRite_Test1 and
select Interaction Window.
33. This will bring up the TripRite_Test1 control module window.

34. With 480V power connected to the drive, go to the interaction window and set the slack take-up torque
reference to 5.0%. Next, select the Brake Release, and turn the infeed module on. Last, press Start Dipper Trip
Drive. With the motor running, change the RPM to 700, which concludes the test. Stop the drive, turn off the
infeed module, re-set the brake, and close the interaction window.
35. Take ControlBuilder Offline.
36. Close the project.
37. Exit out of ControlBuilder, return to Starter, and disconnect from the target devices, either from the Project drop-
down menu or the button at the top of the screen. If you performed step 24 and made changes to the expect
line voltage setting, perform the following steps. If no changes were made, go to step 38. cycle power to the
drive, then re-connect to the drive (“Connect to selected target devices” from Project drop-down). With the
drive re-connected, navigate to p210 again and verify that it is set to its original value (380 or 415V) rather than
480V. This verifies that the original parameter set was freshly loaded during the power cycle. Disconnect from
the drive again.
38. From the Project menu, close the parameter set.
39. If changes were made in step 24, you will be prompted to save changes. Select No, then close Starter. The setup
and test procedure is now complete.