CAT Forced Potato Simpson Remote Control System (Bucyrus 25M Miner Version) Operator’s Manual
Simpson Remote Control System (Bucyrus 25M Miner Version)
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(1) Preface
This document is intended as an operator’s reference to the Simpson Remote Control System (Bucyrus 25M Miner Version). This version of the Simpson RCS (Remote Control System) is integrated into the electrical system of Bucyrus 25M Continuous Miners and is used to provide radio remote control and monitoring of the machine.
Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Incorporated.
Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy. Other than is required by law, no warranty of any kind is expressed or implied.
Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.
For all matters involving servicing or purchase of Simpson RCS (Bucyrus 25M Miner Version) control system components, please contact your Bucyrus representative or local Bucyrus service center.
The Simpson Remote Control System (Bucyrus 25M Miner Version) is a dependable and high-speed radio remote control and monitoring system developed for Bucyrus 25M series continuous miners.
The system is installed in the electrical system of a 25M continuous miner and allows an operator to remotely control machine operation from a safe distance using a radio remote control console.
This manual provides basic information and user instructions for the system. This control system was first fitted to 25M machines in 1998. Since that time the system has undergone a number of software revisions to improve performance and to provide additional automation features. Each new revision of software is accompanied by a different part number of receiver control unit.
This manual only pertains to the following model of receiver control unit:
Bucyrus Receiver Part Number: 372753
Forced Potato Part Number: L0FA2101
Software Revision: Bucyrus 25M Revision 4.28
If this manual does not correspond to your model of receiver control unit, please contact Forced Potato immediately to obtain a copy of the correct publication.
Please contact your local Bucyrus representative or service center to obtain service or replacement parts for the control system.
The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.
Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine and company management and should encompass any relevant state and federal regulations and/or guidelines where applicable.
Simpson RCS (Bucyrus 25M Miner
(4) System Information
System Name Simpson RCS (Bucyrus 25M Miner Version)
Software Name Bucyrus 25M Simpson
Last S/W Rev.* Bucyrus 25M Revision: 4.28
Receiver Part Number
Forced Potato P/N: L0FA2101
Bucyrus P/N: 372753
For exact details on machine wiring configuration please consult the electrical schematic that pertains to your particular miner.
(5) Explanation of Terms
Simpson RCS (Bucyrus 25M Miner Version)
Receiver Control Unit
Remote Control Handset
Name given to the remote control system and all its components.
Main control unit of the control system that includes the radio data receiver used to receive and decode commands from the remote control handset
Handheld controller that an operator would typically use to control the machine at a distance. Also known as the “Remote Control Console”, “Remote Box” or “Transmitter”
Remote Mode
Manual Mode
Mode of operation where the control system is in control of the machine and can be operated at a distance using the remote control handset.
Mode of operation where “hardwired” switches, buttons and hydraulic levers on the miner are used to control the machine. In this mode all power is usually removed from the Simpson control system.
(Integrated radio control receiver and machine control unit)
“Standard Power Supply” (no battery backup)
“Battery Backup Power Supply” (automatic battery backup)
Simpson RCS (Bucyrus 25M Miner Version) –
Forced Potato Mining Electronics
“Traction Unit” (controls machine tramming)
“Miner Display” (Miner Diagnostic Display)
“Antenna” (Standard Radio Data Antenna)
Simpson
(Bucyrus 25M
(7) System Control Modes
The Simpson RCS (Bucyrus 25M Miner Version) is designed to operate in one of two modes:
(1) Machined-based Manual Control Mode (Manual Mode)
(2) Radio Remote Control Mode (Remote Mode)
Typically, the 25M continuous miner features a pair of remote/manual selector switches that the operator may use to switch between the two control modes at any time.
Manual Mode
Normally, when the remote/manual selector switches on the miner are in the MANUAL position, all power is removed from the remote control system. In this case, the control system diagnostic display will be blank.
In MANUAL MODE machine control is achieved using hard-wired control buttons and hydraulic levers. Control buttons mounted on the front panel of the operator’s electrical enclosure are used to start and stop all machine motors. When the pump is running, manual levers mounted on the main hydraulic valve bank are used to operate hydraulic functions on the machine.
The Simpson RCS (Bucyrus 25M Miner Version) is isolated in Manual Mode and normally has no control or effect on manual control functions or operations.
When the remote/manual selector switches on the 25M miner are in the REMOTE position, the system will assume the REMOTE MODE of operation.
In REMOTE MODE, the Simpson RCS (Bucyrus 25M Miner Version) is in control of machine motors and hydraulic functions. The operator uses a remote control handset to operate the machine at a distance. This is the typical mode of operation and is normally used when the machine is used in a production situation.
Currently, there are several different models of remote control handset that can be used to operate the system in REMOTE MODE. The TITO model handset (Bucyrus P/N: 312982) is the latest model of remote control console. The machine can be operated in the same fashion with earlier model handsets also.
In REMOTE MODE, the diagnostic display will be active and should appear as follows:
A remote control console (or handset) is used by the operator to remotely control the miner at a distance in REMOTE MODE.
The Simpson RCS (Bucyrus 25M Miner Version) can be controlled with several different models of remote control handset. Forced Potato recommends use of the latest model handsets – known as TITO. The TITO model handsets offer improved battery life, additional safety features and enhanced diagnostics. TITO handsets also comply with the latest MSHA recommendations for continuous miner remote control safety (as outlined in MSHA Program Information Bulletin PIB P03-3).
Available handsets that can be used with the Simpson RCS (Bucyrus 25M Miner Version) include:
L0KN5602 TITO Remote Handset
L0KN5301 TITO Remote Handset (Reversed Function Version)
L06K0602 BRICK Remote Handset 313808
L06K0701 BRICK Remote Handset (Reversed Function Version)
Control switches on each model of remote are generally identical (except for reverse function versions where hydraulic function directions are reversed). This manual will explain machine operation based on the TITO L0KN56 model handset. Please contact Forced Potato or Bucyrus if you require more information on an earlier model of handset.
TITO model handset feature a built-in diagnostic screen on the radio remote console that provides the operator with useful diagnostic messages. Note that these messages are only available on TITO model remote handsets. Earlier model handsets do not feature a built-in diagnostic display.
Message Meaning
UHF1, UHF2, UHF3, UHF4, UHF5, UHF6, UHF7, UHF8
Operating on Frequency 1,2,3,4,5,6,7 and 8
ON Power is ON
ON (Flashing) Power is ON and a switch on the console is currently pressed.
OFF Powering down whilst issuing PUMP OFF command.
STOP Radio Stop Activated
TILT The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted. (Must be enabled using setup mode)
LOW (Flashing) The internal battery is low with and expected remaining operating time of approximately 30 minutes.
SERV Indicating possible service requirements, a fault condition has been detected.
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Charging the Remote Control Console (TITO)
The TITO remote console contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be recharged using the Battery Charger. Recharge times for the unit are typically 1-4 hours; depending on the remaining charge in the battery.
(1) Plug one of the 4 Charging Cables into the Transmitter.
(2) Red and Green Lights will flash for a few moments.
(3) Charger will begin charging.
(4) While charging is in progress, the red light will be on
(5) When charging is complete the green light will come on
(6) During charging, the screen shows how long each transmitter has been on charge.
(1) Look at the socket on the transmitter and the charging plug
(2) Ensure that the socket and plug are free from dirt and coal.
(3) Line up the plug so that it slides gently into the socket
(4) Push gently until you feel or hear the plug “click” into the socket.
Simpson
(Bucyrus 25M
Be Careful Unplugging the Remote Console
(1) Hold the outside tube of the plug firmly.
(2) The tube should be slightly loose.
(3) Pull backwards on the tube so it slides outwards from the transmitter.
(4) The Plug should release itself from the transmitter.
RCS
Miner Version) – Operator’s Manual Page 18 of 76
Simpson
(Bucyrus 25M
Cleaning the Remote Control Console (TITO)
The TITO remote console is designed for long-term use in harsh underground mining environments. As such, the unit is totally selfcontained and requires very little routine maintenance. To extend the service life of the control switches and ensure that switches remain free of mud and debris, regular cleaning of the switch plate is recommended.
Typically the cleaning procedure should be observed once every 2 weeks or as often as required.
Step (1) – TITO Disassembly
• Remove the M3 bolts.
• Remove the switch guard.
• Remove the switch caps.
• Remove the comfort knobs by loosening the grub screw.
• Remove the engraved plate.
Simpson
(Bucyrus 25M
Step (2) – TITO Cleaning
• Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.
• Wash the transmitter with warm soapy water.
• Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service. Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.
• Dry the transmitter with light compressed air or cloth.
Important
Do not use caustic solvents or displacement solutions as this may cause premature seal failure.
Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.
Step (3) – TITO Reassembly
• Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm.
• Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.
• Install the engraved plate.
• Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm.
• Install the switch caps
• Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.
• After reassembly, test the unit on the Remote Control Battery Charger
(9) Using the Remote Control
Single Key Functions
Functions activated by a single key press.
Two Key Functions
Functions marked in “[]” brackets require the [SHIFT] key also be used to operate that function. Motor starts are generally Two Key Functions for added safety.
Pump Motor Start
Two Key Function. Pump Motor must be started before other motors, tramming or hydraulics can be controlled.
Hydraulics
Single Key Functions control hydraulic cylinders on the Miner.
Tramming
Transmitter provides 3 tram speeds. Speed selected by pressing [TRAM 2-3] whilst tramming levers are engaged and the machine is tramming.
Simpson
Remote Console – Power On
(1) Press and hold the ON key forward for 1 second.
(2) The console display should read HOLD.
(3) Release the key and the display should show ON.
Remote Console – Power Off
(1) Move the ON/OFF key to the OFF position.
(2) The console display will show the OFF message for a moment.
(3) The console will then turn itself off.
Remote Console – Emergency Stop
(1) The Radio Emergency Stop will quickly shutdown all motors and functions on the miner.
(2) At any time, press the STOP key down towards the top of the console panel.
(3) The console will send the stop command and then turn itself off.
(4) The STOP key must be reset – by rotating the button clockwise – before the handset can be turned on again.
The control system uses a solenoid output to drive a fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of power supply, the fire suppression can also be activated in BATTERY STANDY MODE. The system remains in BATTERY STANDBY MODE at least 10 minutes after the loss of mains power to the machine.
(1) The Fire Suppression System can be engaged at any time.
(2) Press the [SHIFT] key and the [FIRE] key together.
(3) Continue to assert the [SHIFT] key and the [FIRE] key for a full 2 seconds.
(4) After 2 seconds, the fire suppression system will activate. At this time, the [SHIFT] and [FIRE] keys can be released.
Simpson
Remote Console – Pump Motor Control
Starting the Pump Motor
(1) Ensure that the console is on.
(2) Press [SHIFT] and wait ¼ second.
(3) Press PUMP [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the pump motor will start.
(7) Release PUMP [ON] first. This is important. If [SHIFT] is released first the pump is shutdown.
(8) Then release [SHIFT].
(9) Pump should continue to run normally.
Stopping the Pump Motor
(1) Pump is running normally.
(2) Press and hold PUMP OFF.
(3) The Pump Motor should shut down immediately.
(4) Release PUMP OFF.
Simpson
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Remote Console – Cutter Motors Control
Starting the Cutter Motors
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press CUTTER [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the cutter motors will start.
(7) Release CUTTER [ON] first. This is important. If [SHIFT] is released first the cutters are shutdown.
(8) Then release [SHIFT].
(9) Cutter motors should continue to run normally.
&Stopping the Cutter Motors
(1) Cutters are running normally.
(2) Press and hold CUTTER OFF.
(3) The Cutter Motors should shut down immediately.
(4) Release CUTTER OFF.
Simpson
(Bucyrus 25M
Remote Console – Conveyor Motors Control
Starting the Conveyor Motors in Forward
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press CONV [ON] while [SHIFT] is also pressed.
(4) After a few moments the conveyor will start in forward.
(5) Release CONV [ON] first. Then release [SHIFT].
(6) Cutter motors should continue to run normally.
Stopping the Conveyor Motors
(1) Conveyor is running in forward
(2) Press and hold CONV OFF.
(3) The Conveyor Motors should shut down immediately.
Running the Conveyor Motors in Reverse (Momentary Only)
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press [CONV REV] while [SHIFT] is also pressed.
(4) After a few moments the conveyor will start in reverse.
(5) The Conveyor will remain running in reverse until the [CONV REV] key or the [SHIFT] key is released.
Remote Console – Fan Motor Control
Starting the Fan Motor
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press FAN [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the cutter motors will start.
(7) Release FAN [ON] first. This is important. If [SHIFT] is released first the fan is shutdown.
The conveyor raise and lower and swing can only be controlled once the pump motor is started and running.
Press the CONVEYOR LEFT/RIGHT to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.
Press the CONVEYOR LEFT/RIGHT to the right to swing the conveyor tail to the right. The conveyor right solenoid will remain on until the key is released.
Press the CONVEYOR DWN key to lower the conveyor boom. The solenoid for the conveyor lower function remains on until the key is released.
Press the CONVEYOR UP key to raise the conveyor boom. The conveyor up solenoid will stay on until the key is released.
The control system has the possibility of turning cutter water sprays on and off from a key on the remote console. However, this function is normally not available due to the wiring configuration of most miner electrical systems. Check with Bucyrus or mine staff if remote control of water sprays is a necessary requirement for your particular mining operation.
Press and release the WATER key to turn on or off the water sprays. Water sprays are typically turned on automatically when cutter motors are started.
Remote Console – Head Lights Control
Head lights can be turned on and off from the remote console at any time that the system is in REMOTE MODE and the remote console is on,
Press the [SHIFT] and [LIGHTS] keys together. The lights will turn on.
To turn off the lights press the [SHIFT] and [LIGHTS] keys together again.
Remote Console – Tram Enable
Normally the pump motor must be running in order to control machine tramming.
To enable machine tramming the TRAM 2-3 key must be pressed and released. This enables the tram function. Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of 5 seconds, the tram becomes disabled again. To re-enable the tram function, the TRAM 2-3 key must be pressed and released again.
Remote Console – Tram Track Control
Tram tracks on the machine can be moved forwards and backwards using the tram levers on the remote control console. Control of machine tramming is only possible once the pump motor is running and the tramming has been enabled (see above).
Press the LEFT FWD tram key to turn the left tramming track forwards.
Press the LEFT REV tram key to turn the left tramming track backwards.
Press the RIGHT FWD tram key to turn the right tramming track forwards.
Press the RIGHT REV tram key to turn the right tramming track backwards.
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Remote Console – Tram Speed Control
The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2 and SPEED 3).
SPEED 1 is the default tramming speed and is the slowest tramming speed.
By pressing the TRAM LEVERS and [TRAM 2-3] keys together the operator may move to SPEED 2 from SPEED 1. Once in SPEED 2, the operator can toggle between SPEED 2 and SPEED 3 using the TRAM LEVERS and [TRAM 2-3] keys together.
The following tramming configurations are enforced by the control system for safety reasons:
• Split Track Tramming is limited to SPEED 1
• Single Track Tramming is normally limited to SPEED 1
• It is possible to speed up a single track from SPEED 1 to SPEED2 providing that tramming is started in SPEED1
• Tramming is limited to SPEED 1 while cutters are on
• While the cutters are running reverse speed can be incremented even while the forward tram keys are being pressed
A typical Bucyrus 25M continuous miner is fitted with a “mushroomstyle” emergency stop button on the left side of the machine. This button is normally used to shut down the machine in an emergency. In difficult mining conditions, it is possible for the left side of the machine to become jammed against the wall (rib) of the mine roadway. In these cases, the emergency stop button can be jammed in the “on” position by the wall, preventing the pump motor to be started on the machine.
To allow the machine to be started and moved away from the wall in such a scenario, the control system provides a special emergency stop bypass feature that can be activated from the remote control console. When activated, the bypass function affords the operator a 30-second window where the emergency stop button is bypassed and the pump motor can be started. During this window the operator is able to tram the machine away from the wall, allowing the emergency stop button on the machine to reset.
To activate the E-stop Bypass, press and hold the [SHIFT] and [BYPASS] keys together for a continuous 5 seconds.
While the keys are held, the diagnostic display on the miner will show a “countdown timer”. The timer counts the 5-second period that the keys must be held in order for the bypass function to become enabled.
One the 5-second delay has passed, the system will enter the ESTOP BYPASS mode. The [SHIFT] and [BYPASS] keys can then be released. The screen will then show that the bypass is active and feature another countdown timer. In this case the timer counts down the 30 second window for which the bypass will remain active.
Once the 30-second window has expired, the bypass will again be disabled. The bypass mode can be activated again by pressing and holding the [SHIFT] and [BYPASS] keys again for 5 seconds.
The control system allows the main circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of power supply be installed on the machine.
To turn off the breaker:
Press and hold the [SHIFT] and [C.B. OFF] keys together for a 2 seconds.
After 2 seconds, the breaker off solenoid will energise (turning off the machine circuit breaker)
Simpson
To turn on the breaker:
It is essential that a battery backup version of the control system power supply be installed for this function to be available.
Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged then it will not be possible for the breaker to be turned on from the remote control transmitter.
Press and hold the [SHIFT] and [C.B. ON] keys together for a 2 seconds.
After 2 seconds, the breaker on solenoid will energise (turning on the machine circuit breaker)
The control system provides two independent auxiliary outputs that can be controlled from the remote control console and used for a number of different applications.
The outputs are controlled as a 2-key function on the remote console:
[SHIFT] and [AUX-1] Or [SHIFT] and [AUX-2]
These outputs can be configured to operate with or without interlocking from the pump motor. The outputs can also be configured to be latching or non-latching (momentary).
Please consult with mine management as to the application and control configuration of the outputs on your machine.
Note: The AUX-2 output may not be available on machines where the methane monitor override is supported. On these machines, the [AUX-2] function is used to activate the methane override system (See Section 11).
The Simpson RCS (Bucyrus 25M Miner Version) is fitted with a number of special and automatic functions. These special features either improve machine productivity or provide for compliance with special safety or statutory requirements.
The control system provides for user configuration of different functions. It is important that operators are aware of which features are setup on the machine that they are using. Please contact mine management for more details as to the exact configuration of the machine you are using.
Automatic Scrubber Fan Control
When enabled (See Section 18), the automatic scrubber fan option turns on the scrubber fan 3 seconds after the start of the cutter motors and turns the fan off 10 seconds after the cutters have been shut down.
Even if the automatic scrubber fan is enabled, the operator may still start and stop the fan at any time using the remote control console.
In certain cases, local statutory authorities or difficult mining conditions may require that the scrubber fan be started before the cutter motors are started.
To support these mining situations, the control system has a “Fan Before Cutter” option that can be enabled.
When this option is enabled (See Section 17), the control system will not allow the cutter motors to be started until the fan motor has been running for a full 3 seconds.
Pennsylvania Scrubber Fan Requirements
In the state of Pennsylvania, it is typically a statutory requirement that the scrubber fan feature the following automatic operations:
(1) Scrubber fan is started at least 3 seconds prior to cutter motors are started.
(2) Scrubber fan remains on at least 10 seconds after cutter motors are shut down.
To satisfy these automatic control requirements, two different setup options must be enabled in the Simpson RCS (Bucyrus 25M Miner Version) setup. These options should be configured as follows:
Recommended Scrubber Fan Setup for State of Pennsylvania Statutory Requirements Setup Option Recommended Setting
See Section 17 and Section 18 for instructions on how to access and modify these setup options.
