Cat Bucyrus 39HR Blast Hole Drill Electrical Operation & Troubleshooting Manual BI617156 – PDF DOWNL by www.heydownloads.com

Technical Manual

BI617156

BUCYRUS

• 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.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL

Instructions For 39HR

Electrical Operation and Troubleshooting

X-4134

Thisdocumentisprotectedunderapplicablecopyrightlawstotheextentavailable. Anyunauthorized andunlawfulreproduction,distributionorotheruseshallbesubjecttoliability.

X-4134

Jack Rupert

Approved Date: August, 2003

Revised Date: September, 2007

Page 1 of 117

Issued August, 2003

Re-issued September, 2007

X-4134

Approved By: Jack Rupert____

BI617156

X-4134 Page 2 of 117 Issued August, 2003 Jack Rupert Re-issued September, 2007 X-4134

OVERVIEW.................................................................................................................................................................5 GENERAL MACHINE DESCRIPTION..................................................................................................................6 DRILL OVERVIEW.......................................................................................................................................................6 AUXILIARY FUNCTIONS..............................................................................................................................................6 GENERAL CONTROLS AND POWER .............................................................................................................................7 OPERATOR INTERFACE......................................................................................................................................10 OVERVIEW ...............................................................................................................................................................10 OPERATOR CHAIR CONTROLS ..................................................................................................................................10 Left Propel Track / Winch – Joystick – PLMS.....................................................................................................11 Right Propel Track / Pipe Arm / Mast – Joystick – PRPAMS.............................................................................11 Pulldown Force – Masterswitch – PFLP............................................................................................................11 Pulldown/Hoist Rate – Masterswitch - HPMS....................................................................................................11 Rotary Speed Rate – Masterswitch – RMS..........................................................................................................11 Foam Injection – Pushbutton – FIS (Option)......................................................................................................11 Depth Indicator Reset – Pushbutton – DIRS.......................................................................................................11 Auto Index Pipe Carousel – Spring Return Selector Switch – AICS-L/U (Option).............................................12 Pulldown/Hoist Speed Range – Selector Switch – HPS-H..................................................................................12 Operating Mode – Selector Switch – DPMS.......................................................................................................12 Rotary Drive Speed Range – Selector Switch – RDSRS......................................................................................13 Hoist Brake – Selector Switch – HBS..................................................................................................................13 Drill Air Valve – Selector Switch – DAVS...........................................................................................................13 Water Injection – Selector Switch – WIS (Option).............................................................................................13 Water Injection – Control – WIC (Option)..........................................................................................................14 Emergency Stop / Engine Kill – Maintained Pushbutton – EMS01.....................................................................14 Auto Pipe Arm Lower – Pushbutton – APALS.....................................................................................................14 Pipe Thread Lubricator – Pushbutton - PTLS (Option)......................................................................................14 Pipe Arm Clamp/Gate – Selector Switch – PACGS.............................................................................................14 Horn – Pushbutton – ESHRS01...........................................................................................................................15 Tool Wrench – Selector Switch – TWS................................................................................................................15 Breakout Wrench – Selector Switch – ABOWS....................................................................................................15 Propel Brake – Selector Switch – PBS................................................................................................................15 Propel Speed Range – Selector Switch – PSRS...................................................................................................16 Leveling Jacks – Control Switches – LJS, FJS, RJS............................................................................................16 CONSOLE CONTROLS................................................................................................................................................17 Thermostat – Control – ACTP.............................................................................................................................17 Fan – Selector Switch – HVACSS........................................................................................................................17 HVAC Mode – Selector Switch – HVACS............................................................................................................17 Boarding Stairs – Selector Switch – BSS2...........................................................................................................17 Mainframe Lights – Selector Switch – EXLS1.....................................................................................................18 Ground / Mast Lights – Selector Switch – EXLS2...............................................................................................18 Cab Light – Pushbutton/Control – CLDCP.........................................................................................................18 Diesel / Gauge Panel...........................................................................................................................................18 OPERATOR DISPLAY.................................................................................................................................................18 MACHINE OPERATION........................................................................................................................................19 OVERVIEW ...............................................................................................................................................................19 MACHINE STARTUP..................................................................................................................................................19 MACHINE SHUTDOWN..............................................................................................................................................19 CONTROL ENABLE....................................................................................................................................................19 MACHINE SETUP AND CALIBRATION........................................................................................................................20 Overview..............................................................................................................................................................20 BI617156

TABLE OF CONTENTS

X-4134 Page 3 of 117 Issued August, 2003 Jack Rupert Re-issued September, 2007 X-4134 Head Calibration.................................................................................................................................................20 Setting Limits.......................................................................................................................................................21 Machine Settings.................................................................................................................................................22 OPERATIONAL MODE ...............................................................................................................................................23 AIR COMPRESSOR.....................................................................................................................................................23 Startup.................................................................................................................................................................23 Drill Air...............................................................................................................................................................23 Venting.................................................................................................................................................................23 BOARDING STAIRS....................................................................................................................................................24 Operation.............................................................................................................................................................24 Alarms..................................................................................................................................................................24 HOIST/PULLDOWN & ROTARY .................................................................................................................................24 Overview..............................................................................................................................................................24 Hoist/Pulldown – Speed, Direction, and Force...................................................................................................24 Hoist/Pulldown Brake..........................................................................................................................................25 Rotary..................................................................................................................................................................25 Rotary Speed Feedback.......................................................................................................................................26 JACKS & LEVELING..................................................................................................................................................26 Operation.............................................................................................................................................................26 Retract Switch......................................................................................................................................................27 MAST .......................................................................................................................................................................27 Operation.............................................................................................................................................................27 OIL COOLERS ...........................................................................................................................................................27 Overview..............................................................................................................................................................27 Hydraulic Oil Cooler...........................................................................................................................................27 Compressor Oil Cooler........................................................................................................................................27 PIPE HANDLING........................................................................................................................................................28 Overview..............................................................................................................................................................28 Raising/Lowering Pipe Arm................................................................................................................................28 Auto Lower..........................................................................................................................................................28 Clamp & Gate......................................................................................................................................................29 PROPEL.....................................................................................................................................................................29 Overview..............................................................................................................................................................29 Propel Brakes......................................................................................................................................................29 WINCH .....................................................................................................................................................................30 OPTIONS...................................................................................................................................................................30 Air Compressor Variable Volume Control (Option)............................................................................................30 Bit Lubricator (Option)........................................................................................................................................31 Cold Temperature (Option).................................................................................................................................31 Fire Suppression (Option)...................................................................................................................................31 Foam Injection (Option)......................................................................................................................................31 Multi-Pipe Carousel (Option)..............................................................................................................................31 Pipe Thread Lubricator (Option)........................................................................................................................32 Radio Remote Propel (Option)............................................................................................................................32 Water Injection (Option)......................................................................................................................................35 Windshield Wipers (Option)................................................................................................................................35 CONTROL SYSTEM (PLC)....................................................................................................................................36 OVERVIEW ...............................................................................................................................................................36 NETWORK.................................................................................................................................................................36 Overview..............................................................................................................................................................36 Connections.........................................................................................................................................................37 Node Settings.......................................................................................................................................................38 HARDWARE..............................................................................................................................................................39 Overview..............................................................................................................................................................39 Standard “Racks”................................................................................................................................................39 BI617156

X-4134 Page 4 of 117 Issued August, 2003 Jack Rupert Re-issued September, 2007 X-4134 Processor.............................................................................................................................................................40 Communication Cards.........................................................................................................................................41 Digital Inputs.......................................................................................................................................................41 Digital Outputs....................................................................................................................................................42 Analog Inputs.......................................................................................................................................................43 Analog Outputs....................................................................................................................................................43 Additional Components.......................................................................................................................................44 PLC RESET ..............................................................................................................................................................44 STARTUP, TESTS, ADJUSMENTS, & TROUBLESHOOTING........................................................................45 PRELIMINARY COMMISSIONING CABLING CHECKS ..................................................................................................45 MAIN POWER SYSTEM CHECKS................................................................................................................................45 DC POWER SUPPLY CHECKS....................................................................................................................................45 CONTROL SYSTEM TROUBLESHOOTING....................................................................................................................46 DIGITAL HYDRAULIC VALVES ELECTRICAL CHECKS...............................................................................................47 PROPORTIONAL HYDRAULIC VALVES ELECTRICAL CHECKS....................................................................................47 Overview..............................................................................................................................................................47 Integrated Valves.................................................................................................................................................47 Non-Integrated Valves.........................................................................................................................................48 HEAD ENCODER CHECKS AND REPLACEMENT .........................................................................................................52 APPENDIX A – CAB DISPLAY ALARMS (CDA MESSAGES).........................................................................55 APPENDIX B – PLC LED DIAGNOSTICS...........................................................................................................85 PROCESSOR LED’S...................................................................................................................................................85 REMOTE I/O LED’S..................................................................................................................................................88 ANALOG INPUT / OUTPUT CARDS.............................................................................................................................89 HEAD ENCODER LED’S............................................................................................................................................90 APPENDIX C – PLC DIAGNOSTIC BUFFER EVENTS....................................................................................91 APPENDIX D – PROFIBUS NODE DIAGNOSTICS.........................................................................................111 NODE STATE ..........................................................................................................................................................111 ERROR TYPE...........................................................................................................................................................111 MODULE STATE......................................................................................................................................................111 CHANNEL TYPE......................................................................................................................................................111 CHANNEL ERROR ...................................................................................................................................................111 APPENDIX E – CAB RACK ANALOG DIAGNOSTICS...................................................................................116 REVISIONS.............................................................................................................................................................117 BI617156

OVERVIEW

The 39HR is a diesel-hydraulic drill designed by Bucyrus International Inc.® This instruction discusses its electrical control system. A separate instruction covers the operation of the operator display. Please refer to the hydraulic, diesel, and mechanical documentation for help with other features of the drill.

This manual is written to help the user understand the workings and general operation of the 39HR electrical control system. Certain objects referred to in this manual and in the schematics as “options” are only present on drills where that particular feature has been purchased. On other systems, those items are either not wired or not functioning.

It is important to read this manual with respect to the actual schematics supplied with your drill. Certain design enhancements may have been made to your machine, which improve the operation of various systems. Therefore, there may be some differences between the operation described in this manual and the actual operation of the drill.

NOTICE: If an anytime the machine is operating in an unexpected and unsafe manner, pressing any of the EMERGENCY STOP pushbuttons located throughout the machine will interrupt control to the diesel engine and set all PLC outputs to zero.

August, 2003

X-4134 Page 5 of 117 Issued

September, 2007

Jack Rupert Re-issued

X-4134

BI617156

GENERAL MACHINE DESCRIPTION

Drill Overview

The 39HR rotary blast hole drill incorporates 24VDC batteries, proportional hydraulics, a programmable logic controller (PLC), and other technically advanced devices in a form that promotes high performance and production, low operating costs, and operator comfort. All operator functions are electronically controlled and the ergonomically designed operator interface provides improved efficiency.

The rotary, hoist/pulldown, and propel motions are controlled by hydraulic valves. Each of these four valves has two distinct functions:

• Hoist and Left Track Propel Forward

• Pulldown and Left Track Propel Reverse

• Rotary Clockwise and Right Track Propel Forward

• Rotary Counterclockwise and Right Track Propel Reverse

The selected motion is controlled by the PLC. This control system determines which valve will be energized depending upon the function required (e.g., mast raise, pipe arm lower) and the mode of the drill (i.e., Propel, Drill, Mast/Winch). The head’s actual drive mechanism is rack and pinion, so no chains are used as part of the drive mechanism. In fact, the drill was designed to minimize all cabling attached to the head.

The propel motion consists of dual independent crawler mechanisms that are hydraulically powered. Each hydraulic drive motor is connected to its respective drive tumbler by means of a heavy-duty gearbox. No chains are used in the propel drive train. Control of the hydraulic drive system is provided by electronically controlled proportional valves, as described in this manual.

The hydraulics pumps are powered by direct coupling to the diesel engine. The output shafts of these are directly coupled to the compressor, which is used during the drilling operation to clear the chips out of the hole. The diesel/compressor startup sequence includes an electrically powered “easy start” system, which reduces initial load during startup.

Auxiliary Functions

In addition to the main motion controls, the 39HR incorporates several auxiliary functions that support overall operation of the drill. Compressor oil cooling is provided by a separate cooling unit. Operator comfort is handled by an HVAC (heating, ventilation, and air conditioning) system that is mounted on the cab roof.

Since this drill does not incorporate an auxiliary compressor as part of its inherent design, pneumatic devices do not exist. Instead, an electric horn and hydraulically operated brakes with spring setting are supplied.

The standard drill can maintain two pipes. One is stored in the head and the other is stored in the pipe arm on the drill deck. This pipe arm will lift the spare pipe to the head at any normal drilling angle. If more pipes are required, an optional carousel unit can be incorporated with this pipe arm.

Various options may also be purchased to enhance the drill’s operation and performance. These include:

Jack Rupert Re-issued

X-4134

Page 6 of 117 Issued August, 2003

September,

2007 X-4134

BI617156

• Water Injection

• Multi-Pipe Carousel

• Radio Remote Control

• Compressor Variable Volume

• Jacks Fully Retracted Indicators

• Bit Lubricator

• Thread Lubricator

• Foam Injection

• Fire Suppression

• AM/FM Radio

• Jump Start Receptacle

• Washdown (with Water Injection)

• Windshield Wipers.

If other auxiliary functions such as special lighting, customer options, and additional features are incorporated into the machine, the schematics should be referenced for the latest information on these additional features.

General Controls and Power

All machine logic control is provided by a programmable logic controller (PLC). The processor is located in the Control Console cabinet in the operator’s cab. Remote I/O boxes are located throughout the drill to minimize the wiring and ease troubleshooting. Communication takes place through the industry standard Profibus protocol.

Operator information, data, and machine parameter adjustments are handled through the operator display, mounted to the chair in the cab. This display incorporates a touch-screen interface for operator inputs and communicates directly with the PLC over ethernet.

The operator’s seat has two pods on either side. These independent control systems contain the external buttons, switches, and joysticks that the operator will use to control the drill.

Electric power comes from a bank of six (or more) 12VDC batteries and an alternator during engine operation. The batteries are wired in a manner to provide 24VDC to the drill. Because this arrangement is subject to minor fluctuations in the voltage level supplied, DC-DC converters are used on electrically sensitive components. These provide a steady voltage over the peaks and valleys that the battery/alternator system may provide. All circuits are isolated with their own circuit breakers, with the exception of the two high powered units (HVAC and Easy Start) which are protected with fuses.

The following few pages show the single line schematic for the primary distribution and startup systems for the 39HR. These schematics are for a typical configuration. Refer to the machine schematics supplied with your drill for the details of your particular setup. Figure 1 shows the overview of the power distribution system. Figure 2 shows the startup routine for the diesel engine.

X-4134

Jack Rupert Re-issued

Page 7 of 117 Issued August, 2003

September,

2007 X-4134

BI617156

12V Batteries

X-4134 Page 8 of 117 Issued August, 2003 Jack Rupert Re-issued September, 2007 X-4134 BATDIS A CB12 Compressor Easy Start HVAC Horn & Limit Switches CB24 Light Plant CB25 Light Plant CB26 Light Plant CB17 Proportional Valves DIRR02 EMSR01 PUTR CB13 Angle Sensors & Masterswitches DIRR01 D/DC01 CB18 Operator Display DIRR01 D/DC02 CB14 Head Encoder and Transducers CB15 CB19 PLC Control / Inputs DIRR02 D/DC0\3 CB16 Proportional Valve Control CB20 CB21 Cab Lights DIRR03 D/DC04 CB31 Radio Option CB23 PLC - Cab Outputs EMSF02 DIRR03 CB27 PLC - Main Frame Outputs CB28 PLC - Power Unit Outputs EMSF03 DIRR03\4 CB29 PLC - Mast Outputs CB30 CB32 Diesel Control CB11 Diesel Keyswitch Diesel Engine Alternator

FU11 CB33 DIRR05 CB33 Diesel Pump Motor

1 – Power Distribution Single Line BI617156

Figure

OFFRUNSTART

From CB32

DIS Diesel Key Switch

From CB11

DIRR04 Diesel Run EMSR01 Emergency Stop HSVCR Hydraulic Suction Valve Closed

HLOSS Hydraulic Oil Level Low

DICSR Diesel Cab Start Relay

DIRR## Diesel Run Relays

Diesel Engine RUN Command

From FU11

CB22 - 6A

CSHMO Compressor Start Hydraulic Motor Overload

DIRR06 Diesel Run

DASR Diesel Engine Shutdown

DPMO Diesel Pump Motor Overload

DICSR Diesel Cab Start Relay

DIEIR2 Diesel Engine Idle Relay

DICSR Diesel Cab Start Relay

CSHMC Compressor Start Hydraulic Motor Contactor

CIPS Compressor Inet Pressure Switch

EZSR Easy Start Relay

CSHMC Compressor Start Hydraulic Motor Contactor

CSHMO Compressor Start Hydraulic Motor Overload

CSHM Compressor Start Hydraulic Motor

From CB32

EZSR Easy Start Relay Diesel Starter

X-4134

Jack Rupert

Page 9 of 117

Issued August, 2003

Re-issued September, 2007

X-4134

BI617156

Figure 2 – Diesel Start Single Line

OPERATOR INTERFACE Overview

There are three main components to the 39HR operator interface. The primary component is the set of buttons and switches on the Operator’s Chair in the cab. These are the main controls used in the operation of the drill. The second set of controls exists in the Console, which is the cabinet housing the PLC processor located in the cab. This cabinet includes less frequently accessed controls as well as the control and feedback panel from the diesel engine. The third component of the operator interface system is the Operator Display, mounted on the Operator’s Chair. This displays machine data, indicators, and alarms. Machine setup parameters and user options are also entered through the display. Refer to the separate instruction that discusses the display in depth. NotethattheremayalsobeaRemote Propelunitifthatoptionwaspurchasedforthedrill

Most of the controls mentioned above feed directly into the PLC system, described in its own section. Others are “direct drive”, meaning that the controls are directly tied to their outputs and not modified by the computer control system.

The rest of this section discusses to the operation of each of the primary controls. The schematic/PLC symbol code is specified in the heading for each control. Notethattheremayalsobeothercontrolsnot discussedhere. Thesemaybepartofcertainenhancements,specialoptionspackages,orcustomer requests.

Operator Chair Controls

In this section, each of the primary controls on the operator’s chair are discussed. See Figure 3. The masterswitches are listed first, and then each of the selector switches and pushbuttons in the order in which they occur on the pods.

10 of 117 Issued August, 2003

X-4134 Page

Re-issued September, 2007 X-4134

Jack Rupert

BI617156

Figure 3 – Operator’s Chair

Left Propel Track / Winch – Joystick – PLMS

This joystick is located in the left pod of the operator’s chair. It is used to control the left track and the winch. In PROPEL mode, this joystick controls the speed and direction of the left track. In DRILL mode, this joystick controls the speed and direction of the winch. Note that the “lift-switch” must be picked up to enable operation.

Right Propel Track / Pipe Arm / Mast – Joystick – PRPAMS

This joystick is located in the right pod of the operator’s chair. It is used to control the right track, the pipe arm, and the mast. In PROPEL mode, this joystick controls the speed and direction of the right track. In DRILL mode, this joystick controls the raising and lowing of the pipe arm, which is used to bring additional pipes to the head or remove them from the head during drilling. In MAST mode, this joystick controls the raising of the mast for drilling, lowering for propelling, or setting the angle for anglehole drilling. Note that the “lift-switch” must be picked up to enable operation.

Pulldown Force – Masterswitch – PFLP

The Pulldown Force masterswitch is located in the left pod of the operator’s chair. It only operates in DRILL mode. This masterswitch limits the maximum pulldown force on the bit by controlling the output from the pulldown force valve. Refer to the hydraulic documentation.

Pulldown/Hoist Rate – Masterswitch - HPMS

The Hoist/Pulldown masterswitch is located in the left pod of the operator’s chair. It controls the speed and direction of the head. Turning it clockwise controls the hoist function, which raises the head. Turning it counterclockwise controls the pulldown function, which lowers the head. Note that head speed is also influenced by the limits, the current screen on the operator display, and the speed selector switches. Off is located in the up-center position.

Rotary Speed Rate – Masterswitch – RMS

The Rotary masterswitch is located in the right pod of the operator’s chair. It controls the rate of spin of the bit. Off is located in the up-center position. From the off position, turning the masterswitch to the right will yield clockwise control. Turning it to the left will yield counterclockwise control. Note that this only works in DRILL mode.

Foam Injection – Pushbutton – FIS (Option)

The Foam Injection pushbutton is only included on machines that have this option. Pressing this button will cause foam to be injected into the hole for as long as the button is pressed.

Depth Indicator Reset – Pushbutton – DIRS

This pushbutton resets the hole depth count value for the operator’s display. It is located in the left pod of the operator’s chair. It is to be pressed when the bit is at “zero depth”, or ground level. WARNING: THIS BUTTON MUST BE PRESSED AT GROUND LEVEL, IF IT IS PRESSED BELOW GROUND LEVEL, THE DRILL MAY THINK THE PIPE IS ABOVE THE HOLE WHEN IT IS ACTUALLY IN THE HOLE AND THE “PIPE IN HOLE” WARNING MAY NOT OCCUR.

Jack Rupert

11 of 117 Issued August, 2003

X-4134 Page

Re-issued September, 2007 X-4134

BI617156

Auto Index Pipe Carousel – Spring Return Selector Switch – AICS-L/U (Option)

This three-position (spring return to neutral) selector switch is only included with the multi-pipe carousel option. It is used to move the carousel to transfer pipes between the carousel and pipe arm. This switch is located in the left pod of the operator’s chair.

LOAD – In this position, the carousel will advance one index position to load a pipe into the pipe arm. Once the carousel begins to move beyond the current index point, it is no longer necessary to hold the switch in this position.

UNLOAD – In this position, the carousel will advance one index position to remove a pipe from the pipe arm. Once the carousel begins to move beyond the current index point, it is no longer necessary to hold the switch in this position.

Refer to the Options section of this manual for more information on carousel control.

Pulldown/Hoist Speed Range – Selector Switch – HPS-H

This two-position selector switch selects the speed range for the hoist/pulldown motion. It is located in the left pod of the operator’s chair. The drill operation mode must be in DRILL MODE for this speed selector switch to function. The settings are as follows:

DRILL – In this mode, the high-speed hoist valve is turned off. Refer to the hydraulic documentation.

HIGH – In this mode, the high-speed hoist valve is energized. Refer to the hydraulic documentation for a description of this valve’s function.

Operating Mode – Selector Switch – DPMS

This three- or four-position selector switch determines the operating mode of the drill. It is located in the left pod of the operator’s chair. The following modes are available:

PROPEL – This mode allows the masterswitches to control the propel function of the drill. It also disables the hoist/pulldown functions. Note that this switch only requests the mode. Refer to the operator display for the actual mode feedback. If certain conditions are not met, the drill will not immediately enter Propel mode when this setting is chosen. At a minimum, the following conditions must be met. 1) All masterswitches must be in neutral. 2) The pipe must be out of the hole. 3) This switch must be in the Propel setting. Also note that there will be a short delay when first going into Propel mode.

DRILL – This mode allows masterswitches to control the hoist, pulldown, and rotary functions of the drill. It also disables the propel function. Note that this switch only requests the mode. Refer to the operator display for the actual mode feedback. If certain conditions are not met, the drill will not immediately enter the Drill mode when this setting is chosen. At a minimum, the following conditions must be met. 1) All masterswitches must be in neutral. 2) This switch must be in the Drill setting. Also note that there will be a short delay when first going into Drill mode.

MAST/WINCH – This mode allows the masterswitches to control the mast position and the winch. It also disables the propel, hoist/pulldown, and rotary functions. Note that this switch only requests the mode. Refer to the operator display for the actual mode feedback. If certain conditions are not met, the drill will not immediately enter the Mast/Winch mode when this setting is chosen. At a minimum, all masterswitches must be in neutral. Hydraulically, this mode is defined as the absence of both the drill and propel modes.

August, 2003

X-4134 Page 12

117 Issued

September, 2007

Jack Rupert Re-issued

X-4134

BI617156

• 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.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL