CAT Bucyrus 49HX 49HR (24 VDC Control Systems)Electrical Operation & Troubleshooting Manual BI619460

Technical Manual

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Instructions For 49HX/49HR (24 VDC Control Systems)

Electrical Operation and Troubleshooting

X-4138

This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability. © 2010 Bucyrus International, Inc. All rights reserved.

OVERVIEW

The 49HR is an electric 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 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 49HR 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 at 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 and set all PLC outputs to zero.

GENERAL MACHINE DESCRIPTION

Drill Overview

The 49HR rotary blast hole drill incorporates DC motor drives, 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 and hoist/pulldown motions are powered by specially built blower cooled excavator grade DC mill motors. Each of the motors is controlled by its own independent static (electronic) DC drive that provides complete control over motor speed, direction and torque (motoring and regenerating). The drives incorporate advanced digital controls which aid troubleshooting and minimize downtime. Motor speed control is achieved by variable armature voltage control with fixed (but range selectable) shunt field current levels. Both the rotary and hoist/pulldown motors are physically mounted on the head assembly and move up and down with the drill stems during the drilling operation. The rotary motion incorporates multiple gear reductions which are housed in a head mounted gearbox. The hoist/pulldown motion also incorporates multiple gear reductions in a head mounted gearbox, but its final drive mechanism is a rack and pinion. The rack teeth are located on the vertical structure of the mast assembly. No chains are used as part of the drive mechanism.

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 hydraulic pumps are powered by direct coupling to one of the output shafts of a dual shafted squirrel cage induction motor. The other output shaft of this motor is coupled to a screw compressor which is used during the drilling operation to clear chips and dust from the hole being drilled. The screw compressor incorporates a special unload system that reduces the horsepower demanded from the compressor during idle and propel operation. This, in turn, allows more power to be available to the propel pumps when propelling and minimizes power consumption during other non-drilling periods of time on the drill.

Auxiliary Functions

In addition to the main motion controls, the 49HR incorporates several auxiliary functions that support overall operation of the drill. Compressor oil cooling is provided by a large radiator that uses a motor driven fan unit. Machinery house pressurization and cooling is provided by means of a large blower and dust filter 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, a hydraulically operated pump is used in the lubrication system, an electric release – spring set brake is used in the head assembly, and an electric horn is provided. In addition, brakes for the propel system are hydraulic release – spring set.

Various options that may be installed to improve and enhance the drill’s operation and performance include:

Water Injection Dust Control System

Dry Dust Collector

Static or Hydraulically Actuated Dust Curtain

Multiple Drill Pipe Racks (Up to 4)

Remote Propel Control (Radio or Pendant Units)

Compressor Variable Volume

Bit Lubricator

Thread Lubricator

Fire Suppression

Welding Outlets

Protective Upper Window Hatch

Angle Hole Drilling Package

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 (including drive sequencing) is provided by a programmable logic controller (PLC). This device is mounted in a cabinet located in the machinery house along with other input/output control devices, power supplies, relays, electronic-hydraulic control boards, and other miscellaneous control devices. The PLC communicates with all machine functions via various input and output nodes located in the programmable controller cabinet (ZPCA) and operator’s cab. Communication between the PLC processor and these remote I/O nodes 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 processor over Ethernet.

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

On standard configuration machines, a load center is incorporated to provide for lighting control. In addition, the load center provides circuit breakers for various cabinet heat exchangers, cabinet air conditioners (optional), cabinet heaters (optional), water injection control (optional) and general machine control power requirements.

In general, the entire PLC control system and operator display are powered from a DC power supply located within the ZPCA cabinet. This power supply receives its 220/240 VAC power from a transformer (LCT) located inside of the left hand extention of the machine. All auxiliary device starters are housed in a motor control center (ZLV) located in the machinery house. Normally, phase sequence and ground fault protection devices are located in the same cabinet. Starting equipment for the compressor motor is mounted in another motor control center (ZSC) which is also located in the machinery house. The compressor motor can either incorporate a vacuum contactor or standard air contactor, depending upon application horsepower and source voltage. Ground fault protection components for the compressor motor are located in the ZSC cabinet.

The following page shows the single line schematic for the primary distribution and control systems for the 49HR. This diagram is for a typical configuration. Refer to the machine schematics supplied with your drill for the details of your particular setup.

Distribution Single Line

OPERATOR INTERFACE

Overview

There are three main components to the 49HR operator interface. The primary component is the collection 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 Control Console, which is located on top of the operator’s cab cabinet labeled ZCCA. This console includes less frequently accessed controls, and indicators. 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.

NOTE: There may also be a Remote Propel unit if that option was purchased for the drill.

Most of the controls mentioned above feed directly into the PLC system, which will be 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 the operation of each of the primary controls. The schematic/PLC symbol code is specified in the heading for each control.

NOTE: There may be additional controls not discussed in this document. These may be part of certain enhancements, special options packages, or customer requests.

Operator Chair Controls

In this section, each of the primary controls on the operator’s chair is discussed (see Figure 2). Master switches are listed first, and then each of the selector switches and pushbuttons in the order in which they occur on the operator chair pods.

Figure 2 – Operator’s Chair

Left

Propel Track / Winch – Joystick – POLMS

This joystick is located in the left pod of the operator’s chair. It is used to control the left crawler track and the winch. In PROPEL mode, this joystick controls the speed and direction of the left crawler track. In DRILL mode, this joystick controls the speed and direction of the mast winch.

The joystick incorporates a neutral detent which must be lifted up to release the handle. A micro-switch, linked to operation of the neutral detent, is used by the PLC logic to sequence functions. In the WINCH operating sequence, proportional hydraulic control is allowed to operate after lifting the neutral detent.

Right

Propel Track / Pipe Rack / Mast – Joystick – PORMS

This joystick is located in the right pod of the operator’s chair. It is used to control the right crawler track, the pipe rack, and the mast. In PROPEL mode, this joystick controls the speed and direction of the right crawler track. In DRILL mode, this joystick controls the movement or the pipe racks, which are used to bring additional pipes to the head or remove them from the head during drilling. In MAST mode, this joystick controls are used for raising of the mast for drilling, lowering for propelling, or setting the angle for angle-hole drilling.

The joystick incorporates a neutral detent which must be lifted up to release the handle. A micro-switch, linked to operation of the neutral detent, is used by the PLC logic to sequence functions. In the MAST operating sequence, proportional hydraulic control is allowed to operate after lifting the neutral detent.

Hoist/Pulldown Master Switch - HPMS

The Hoist/Pulldown Master Switch is located in the left pod of the operator’s chair. It controls the speed and direction of the drill head along the mast structure. 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 head limits, the current screen on the operator display, and the speed selector switches. The neutral position is located in the top-center position. Note that control of the drill head is only allowed in DRILL mode and if the hoist/pulldown DC drive has been enabled.

Rotary Master Switch – RMS

The Rotary Master Switch is located in the right pod of the operator’s chair. It controls the drill bit’s rate of rotation. The neutral position is located in the top-center position. From the neutral position, turning the master switch clockwise will rotate the drill bit in the clockwise direction. Turning it counterclockwise will rotate the drill bit in the counterclockwise direction. Note that control of the drill bit is only allowed in DRILL mode and if the rotary DC drive has been enabled.

Programmed Drill Control Pushbutton

– PDCPB (Option)

This momentary pushbutton is the operator input to enable or disable the programmed drill control system from having control of the machine’s drilling operations. In order to start a programmed drill control hole, the drill must be in DRILL mode with both DC drives enabled and all master switches in the neutral position. Pressing the Programmed Drill Control Pushbutton will hand over all drilling control to the PDC system until the hole is completed, a critical fault is detected, or the Programmed Drill Control Pushbutton is pressed again.

Depth Indicator Reset Pushbutton – DIRPB

This pushbutton resets the hole depth count value for the operator 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.

Drill Deck Hatch Selector Switch – DDHSS

This two-position maintained selector switch controls operation of the hydraulically actuated drill deck bit view hatch. It is functional whenever the hydraulic pump motor is on (ACM is running). In the OPEN position, the hatch is powered against hydraulic pressure. In the CLOSE position, the hatch is held closed by hydraulic pilot pressure. When the machine hydraulic system is off, the hatch drops to the open position as a result of pilot pressure loss.

Hoist/Pulldown Selector Switch – HPSS

This four-position selector switch controls the operating characteristics and speed rate range of the hoist/pulldown drive when in a drilling mode of operation. It is located in the left pod of the operator’s chair. The drill operation mode must be in DRILL for this speed selector switch to function. The settings are as follows:

PULLDOWN – The PULLDOWN position should be selected for all drilling operations. In this position, full pulldown force is allowed but the speed range for both the pulldown (lowering) and hoisting directions is limited to about 25 FPM (7.6 MPM).

HOIST LOW – In this mode, full hoisting and lowering force is allowed but the speed is allowed to reach a higher level.

HOIST HIGH – The HOIST HIGH position allows maximum head speed capability in both the lower and hoisting direction. However, force capability in the lowering direction is limited to that associated with the weight of the drill head and drill string combination. No significant contribution of additional down force is allowed from the drive, which reduces the chance of equipment damage during lowering operation. In addition, as a result of obtaining a higher speed, the hoisting force capability at full speed is not as large as that obtainable in the HOIST LOW position. Stall capability, however, is the same.

PIPE RACK / JOINT – This position allows the same hoisting and lowering force capabilities as those allowed in the HOIST HIGH position. However, the speed limit is reduced to about 25 FPM (7.6MPM). This switch position is required for any pipe rack operations since is enables both the mast related lock/selection hydraulic controls and the proportional electronic hydraulic controls. In addition, while the Hoist/Pulldown Master Switch is in the neutral position, this mode allows the drill head to slowly drift down the mast to aid in the jointing of drill pipes.

NOTE: Pipe rack operation also requires the head assembly to be above the pipe racks before operations are allowed.

Drill/Propel/Mast Selector Switch – DPMSS

This 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 master switches to control the propel function of the drill. It also disables both DC drives and therefore all drilling 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 master switches 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 master switches to control the hoist, pulldown, and rotary functions of the drill. This mode will also disable all 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 master switches 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 master switches to control the mast position and the winch. This mode will also disable 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 master switches must be in neutral before the mode transition can occur.

REMOTE PROPEL (OPTION) – This mode allows the propel function to be controlled by an optional radio remote or pendant remote unit. It operates the same as the Propel setting defined above, except that motion is controlled by the remote unit, rather than the main master switches. In the case of the radio remote propel option, both the base receiver unit and transmitter unit must be powered before selecting this mode to prevent unwanted faults.

Rotary Speed Control Selector Switch – RSCSS

This three-position selector switch controls the operating speed and torque capability range of the rotary motor. 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:

LOW – In this mode, the motor has the highest torque capability but is limited in speed to about 85-100 RPM at the bit (the exact value depends upon the specific motor/gear ratio being used).

HIGH – In this mode, the motor has a higher speed capability, (typically between 110-140 RPM at the bit) but motor torque capability is less than that obtainable in the LOW position (typically 68% - 74% of low speed torque).

MEDIUM – The MEDIUM position provide for operation between the other two range settings.

Hoist/Pulldown Brake Selector Switch – HPBSS

This two-position switch controls the relay that sends electrical power to the hoist brake solenoid valve (which in turn releases the electric head brake). This switch must be in the RELEASE position before the hoist/pulldown drive is allowed to move the rotary head assembly. With the switch in the SET position during machine operation, the hoist/pulldown motion will not be allowed to generate a down force for the drilling operation. The rotary motion will continue operating, however.

Air Compressor Unload Selector Switch – ACUSS

During normal drilling operations with the proper controls energized and the main compressor running, this selector switch allows the operator to open or close the electrically actuated valves that allow air to go down the hole. In the OPEN position air is allowed to pass through the main air hose (i.e. load the compressor). This is not an exclusive operator controlled function since several other conditions can override the selected OPEN mode of operation. The following conditions will NOT allow air to exit the main air hose even if the selector switch is in the OPEN position:

1. If either of the electric drive controls are de-energized.

2. If the machine is in the PROPEL or REMOTE PROPEL operating modes.

3. If the main compressor is not energized (i.e. ACM not ON). In addition, if the main compressor if OFF, system air pressure is allowed to bleed down to zero via a normally open valve that is kept closed during normal operation.

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