CAT Super Simpson Control System Fault Codes Troubleshooting Guide Manual BI016958 – PDF DOWNLOAD

BI016958

A6474X408

February 2012

Troubleshooting Guide

Super Simpson Control System Fault Codes

A6474X408 (Revision D)

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This manual is intended to provide troubleshooting information for the Super Simpson Control System . The illustrations, descriptions and procedures contained in this publication apply only to THIS system. Caterpillar reserves the right to revise models and designs without prior notice.

This Super Simpson Control System was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of the manufacturing process, this unit was issued any required approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Caterpillar Service Representative immediately

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

The Super Simpson control system is a radio remote control and monitoring system for continuous miners. The system allows the operator to remotely control machine operation from a safe distance using a radio remote control console.

This manual provides troubleshooting information for the system. For actual controller operation, please see the Super Simpson Operation Manual, document number A6474X364 and the Super Simpson Display Manual, document A6474X362.

Message convention

The control system will issue system halt, warning, and fault messages.

System halt message

A system halt message appears when a condition occurs that prevents continued operation of the machine in a safe manner. The message will be displayed in the middle of the screen and cannot be cleared. The power to the control system must be recycled before the machine can be operated.

Error message

An error message indicates a warning condition that is currently active but does not necessarily shut down the machine. These messages are set and cleared by the control system in real time but are logged in the control system fault log. During normal operations, error messages are normally only displayed on the main page of the graphics display screen. Error messages are number less than 300. Error messages are listed in Table 2.

Fault message

A fault message indicates a condition that either causes a motor or function to shut down or prevents a motor or function from starting. Fault messages occur in a pop-up window over the active screen and must be cleared by the operator. Fault messages are listed in Table 3.

There is an Auto Fault Clear option in the menu that is set to YES or NO (default is YES). When set to YES, the next key stroke on the radio remote clears the fault message. When set to NO, the operator must use the SHIFT and RESUME keys on the radio remote to clear the fault.

The last fault of the power up session, even if cleared, is displayed in red text in the status box on the main screen. Fault messages are logged in the control system fault log and are number greater than 300.

Table 2: Error messages

0001

SOL BOARD COMMS FAIL

Either an internal or a communications failure of the solenoid board

0002

RELAY BOARD COMMS FAIL

Either an internal or a communications failure of the relay board

0003

THERMISTOR MODULE FAILURE

Either an internal or a communications failure of the thermistor module (L0H9)

Failure of 485 bus wiring to the board

Internal failure of the solenoid board

Failure of 485 bus wiring to the board

Internal failure of the solenoid board

Loss of 12VAC power to the A16 connector on the module

Failure of CAN bus wiring to module

Short circuit or open circuit of daisy chain cable that connects to A2 socket on the module

Internal failure of the thermistor module

Replace the machine controller(L0Q6)

Replace the machine controller (L0Q6)

Check the 12VAC supply to the A6 connector module

Check all modules are properly connected to the daisy chain module

Check that there are no short circuits of the CAN bus wiring

Replace the module (L0LH09)

0004 RC HANDSET LOW BATTERY

The remote console has reported a low battery.

0005 VOLTAGE TRANSDUCER FAILURE

Signal from the voltage transducer not healthy (healthy level is between 4mA and 20mA).

Remote has not been charged

Battery needs replaced

Charge the remote for at least 5 hours.

Check voltage level of the remote battery.

0006

PUMP MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Supply to transducer (24VDC) is not present

Broken or short-circuit signal wire from transducer to the Super Simpson

Internal transducer failure

Internal failure of the Super Simpson

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24VDC is present at the transducer

Check signal line from transducer to the Super Simpson

Replace the transducer

Replace the Super Simpson (if signal > 4mA from transducer

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0007

PUMP MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal line have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the Motor Mate

Replace the Super Simpson

0008

PUMP MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal line have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the Motor Mate

Replace the Super Simpson

0009

LEFT CUTTER MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0010

LEFT CUTTER MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0011

LEFT CUTTER MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0012

RIGHT CUTTER MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0013

RIGHT CUTTER MOTOR MATE FAILURE PHASE B

Phase B from motor mate not healthy (between 4 and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to the Motor Mate)

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0014

RIGHT CUTTER MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0015

LEFT CONVEYOR MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0016

LEFT CONVEYOR MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0017

LEFT CONVEYOR MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0018

RIGHT CONVEYOR MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0019

RIGHT CONVEYOR MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0020

RIGHT CONVEYOR MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0021

FAN MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0022

FAN MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0023

FAN MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0024

LEFT TRAM MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0025

LEFT TRAM MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

Table 2, continued: Error messages

0026

LEFT TRAM MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0027

RIGHT TRAM MOTOR MATE FAILURE PHASE A

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0028

RIGHT TRAM MOTOR MATE FAILURE PHASE B

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

0029

RIGHT TRAM MOTOR MATE FAILURE PHASE C

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Loss of 24VDC supply to the motor mate

One or more signal lines have gone open circuit

One or more signal lines have been shorted

Motor mate is faulty

Super Simpson is faulty (interface to

Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

Check that each signal line is not open or short circuit

Replace the motor mate

Replace the Super Simpson

BI016958 Table 2, continued: Error messages

0030

LOW MACHINE VOLTAGE

Machine voltage reading has fallen below operational level

0031

HIGH MACHINE VOLTAGE

Machine voltage is above acceptable level

0032

SOLENOID BOARD SUPPLY VOLTAGE LEVEL LOW

Solenoid board is reporting loss of voltage

0033

SOLENOID BOARD SUPPLY VOLTAGE LEVEL HIGH

Solenoid board is reporting dangerously high voltage level

0034

PUMP THERMAL OVERLOAD

The motor has been operated at a current level above the recommended FLA.

Transducer failure

Bad connection between machine and power center

Transducer failure

Bad connection between machine and power center

Broken wire for 110VDC input

Internal failure on solenoid board

Check transducer wiring

Verify voltage supply to transducer input

Check connection with power center

Check transducer wiring

Verify voltage supply to transducer input

Check connection with power center

Check 110VDC supply to solenoid board

Check 110VDC being generated from power supply

Replace the Super Simpson

Supply voltage to the power supply is very high

Internal failure on solenoid board

Verify input voltage level to power supply is very high

Replace Super Simpson

0035

PUMP MOTOR RTD THERMAL TRIP

Motor thermistor is reading over allowed operating temperature

The motor is faulty

Motor mate is faulty

Super Simpson is faulty

Motor is damaged

Motor thermistor is faulty

Thermistor module is faulty

Verify actual operating current

Check that motor mate is reporting actual operating current

Replace pump motor, motor mate or Super Simpson

Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

Check if thermistor reading is rapidly fluctuating, if so thermistor is damaged or there is noise in the circuit

Replace thermistor module

0036

LEFT CUTTER THERMAL OVERLOAD

The motor has been operated at a current level above the recommended FLA.

The motor is faulty

Motor mate is faulty

Super Simpson is faulty

Verify actual operating current

Check that motor mate is reporting actual operating current

Replace pump motor, motor mate or Super Simpson

BI016958 Table 2, continued: Error messages

0037

LEFT CUTTER MOTOR RTD THERMAL TRIP

Motor thermistor is reading over allowed operating temperature

Motor is damaged

Motor thermistor is faulty

Thermistor module is faulty

Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

Check if thermistor reading is rapidly fluctuating, if so thermistor is damaged or there is noise in the circuit

0038

RIGHT CUTTER THERMAL OVERLOAD

Motor has been operated at a current level above the recommended FLA

0039

RIGHT CUTTER MOTOR RTD THERMAL TRIP

Motor thermistor is reading over allowed operating temperature

Motor is faulty

Motor mate is faulty

Super Simpson is faulty

Motor is damaged

Motor thermistor is faulty

Thermistor module if faulty

Verify actual operating current

Check that motor mate is reporting actual operating current

Replace pump motor, motor mate, or controller

Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

Replace thermistor module

0040

LEFT CONVEYOR THERMAL OVERLOAD

Motor has been operated at a current level above the recommended FLA

0041

LEFT CONVEYOR MOTOR RTD THERMAL TRIP

Motor thermistor is reading over allowed operating temperature

Motor is faulty

Motor mate is faulty

Super Simpson is faulty

Verify actual operating current

Check that motor mate is reporting actual operating current

Replace pump motor, motor mate, or controller

0042

RIGHT CONVEYOR THERMAL OVERLOAD

Motor has been operated at a current level above the recommended FLA

Motor is damaged

Motor thermistor is faulty

Thermistor module if faulty

Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

Replace thermistor module

Motor is faulty

Motor mate is faulty

Super Simpson is faulty

Verify actual operating current

Check that motor mate is reporting actual operating current

Replace pump motor, motor mate, or controller

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.