CAT 49RII 49RIII 59R (Lot 4 & LATER) Blast Hole Drill Operation Manual BI616928 - PDF DOWNLOAD

BI616928

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI616928

49RII/49RIII/59R (Lot 4 & LATER) DRILLS

XYCOM (COLOR) DISPLAY MANUAL

This X-Instruction Replaces Section 1, Parts B-3 and C of X-4064 For 49RII’s/49RIII’s That Incorporate The XYCOM (Color) Display And Is A Stand-Alone Document For 59R’s (Lot 4 and Later).

Approved By: Jack Rupert JCV:XI4:96:669

Revised July, 1999 Revised November, 1998 Revised February, 1998 Issued April, 1996 X-4093

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INTRODUCTION This operator's display is designed to assist a drill operator in efficient operation of the blast hole drill. It gives the user machine data, indicators, and alarms. Some machine setup parameters are also entered through the display. An external data logger unit also allows all alarms and faults to be recorded and removed from the drill for office analysis.

All servicing and most calibration of the system are to be done only by qualified service personnel.

This manual is written to help the drill operator understand the working of the display information system as it pertains to the operator during drill operation. Headings throughout this manual which state “option” apply only to those machines that have the specified option installed.

The first section of this manual deals with the hardware, including a description of it, how it works and maintenance. The second section covers the software, including a description of each screen.

This PC display unit is the primary means of displaying machine status information for the operator, production supervisors and maintenance personnel. The display contains a series of screens, or windows, that provide operational details on all PLC controlled machine functions. Among the types of information displayed, the following categories are very important: 1.

2.

3.

4.

General machine operating status (normal operation and leveling) Alarm status Fault messages Programmed Drill Control operational status (option)

The display also provides the means to modify, control, and/or monitor the following areas: 1.

2.

3.

4.

5.

6.

7.

Lubrication system timing Head position limit set-up Accumulated fault history and motion operating hours PLC input/output operation PLC word, bit, and timer status Programmed Drill Control (option) parameter manipulation Drive test functions

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Approved By: Jack Rupert JCV:XI4:96:669

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TABLE OF CONTENTS SECTION 1 - HARDWARE (12 Pages)................................................................................. 1-1 1.1 Hardware Overview .............................................................................................. 1-1 1.2 Power ................................................................................................................... 1-4 1.3 Hardware Key....................................................................................................... 1-4 1.4 Fan ....................................................................................................................... 1-5 1.5 Battery.................................................................................................................. 1-6 1.6 Opening the PC..................................................................................................... 1-7 1.7 Fuse...................................................................................................................... 1-8 1.8 Hot Cathode TFT Bulb Replacement (Display P/N 12330801) .............................. 1-9 1.9 Cold Cathode TFT Bulb Replacement (Display P/N 12330802)............................1-10 1.10 Data Logger Drive and Card ..............................................................................1-11 SECTION 2 - SOFTWARE (91 Pages) ................................................................................... 2-1 2.1 Software Overview ............................................................................................... 2-1 2.2 Bootup (Power Up) ............................................................................................. 2-1 2.3 Program Control ................................................................................................... 2-2 2.4 Normal Operational Screens.................................................................................. 2-4 2.4.1 Title Screen ............................................................................................ 2-4 2.4.2 Main Menu............................................................................................. 2-5 2.4.3 Operator's Screen ................................................................................... 2-6 2.4.4 Leveling/Propel Window .......................................................................2-17 2.4.5 Head Calibration Screen (Security: User 6)............................................2-22 2.4.6 Head & Rack Limits Screen (Security: User 2) ......................................2-25 2.4.7 Mast Pins Status Screen ........................................................................2-30 2.4.8 Lubrication Screen (Security: User 3) ....................................................2-33 2.4.9 Fault Counters / Operating Hours Screen...............................................2-36 2.4.10 PDC Operating Parameters-1 Screen (option) .....................................2-38 2.4.11 PDC Operating Parameters-2 Screen (option) (Security:User 4) ..........2-40 2.4.12 PDC Operating Display - 1 Screen (option) .........................................2-42 2.4.13 PDC Operating Display - 2 Screen (option) .........................................2-45 2.5 Test and Status Screens........................................................................................2-48 2.5.1 Introduction...........................................................................................2-48 2.5.2 PLC Bit Display Screen .........................................................................2-49 2.5.3 PLC Word/Bit Display Screen ...............................................................2-51 2.5.4 PLC Timer/Counter Display Screen .......................................................2-53 2.5.5 Test Display - 1 Screen..........................................................................2-55 2.5.6 Test Display - 2 Screen (Security: User 5) .............................................2-57 2.5.7 Hydraulic/Electrical Field Tests Screen (Security: User 7)......................2-65 2.6 Alarms and Logging.............................................................................................2-68 2.6.1 Introduction...........................................................................................2-68 2.6.2 New Alarms Window ............................................................................2-69 2.6.3 Active Alarms Screen ............................................................................2-71 2.6.4 Alarm History Screen ............................................................................2-73 - ii -

Approved By: Jack Rupert JCV:XI4:96:669

Revised July, 1999 Revised November, 1998 Revised February, 1998 Issued April, 1996 X-4093

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2.6.5 All Alarms Screen..................................................................................2-76 2.6.6 Fault Logging ........................................................................................2-78 2.7 Setup and Disk Management......................................................................................................................2-80

2.7.1 Introduction...........................................................................................2-80 2.7.2

Setup Menu ……………………...……………………………………………….………2-81

2.7.3 Time/Date Window ...............................................................................2-83 2.7.4 Password Window.................................................................................2-85 2.7.5 Option Setup .........................................................................................2-87 2.7.6 System/Disk Utilities .............................................................................2-90 2.8 Screen Security....................................................................................................2-93 APPENDIX A (3 Pages) .........................................................................................................A-1 A.1 Alarm Window Messages .....................................................................................A-1 APPENDIX B (1 Page) ...........................................................................................................B-1 B.1 Screen Security ....................................................................................................B-1 APPENDIX C (2 Pages) .........................................................................................................C-1 C.1 CMOS Setup........................................................................................................C-1

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Approved By: Jack Rupert JCV:XI4:96:669

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HARDWARE

1.1 Hardware Overview The Operator's Display Terminal (fig. 1-1) consists of a complete industrial computer (PC). It includes at least a 486DX2-66 microprocessor, 16MB of RAM, and a color TFT active matrix display.

Figure 1-1 Display Terminal There are two serial ports and one parallel port located on the right side of the PC (fig. 1-2).

COM1 is used for communication between the PC and the drill's PLC processor. COM2 is used for communication with the external data logger drive. The parallel port is used for the hardware key that allows operation of the application software.

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Figure 1-2 Right Side Due to the shock and vibration of the mining environment, there is no conventional hard drive in the system. Instead, a 40MB (or greater) flash drive is included. This emulates the operation of a conventional hard drive, but since there are no rotating parts it is not as vulnerable to shock, vibration, or cold temperatures.

While the industrial computer has a floppy drive located under the front access door, this drive is subject to the same problems a conventional hard drive would have. The floppy drive is not required for machine operation and is included only for software installation at the factory.

Therefore, no warranties apply to this peripheral.

Data logger drive, which is mounted in the cabinet under the display, is a PCMCIA flash drive, which acts like a floppy drive without moving parts. The flash card that is included stores up to 1.8MB of data. If necessary, cards with more memory are available. The data can be accessed with any computer that will accept ATA flash cards. (Most laptops fall into this category).

Additionally, another drive unit like the one used for data logging can be purchased for use with a desktop computer.

The keyboard contains 20 function keys and 32 keypad keys. These have been programmed to allow all required operations without the use of an external keyboard. Besides the function keys, the <+> key has been programmed to emulate the <TAB> key on a conventional keyboard. The <=> key will print a colon (:) for use in entering PLC addresses, as will be described in the Software section of this manual.

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There are six status LEDs on the front of the unit under the keypad. The POWER LED is green whenever power is applied to the unit. The DISK LED never comes on since there is no rotating hard disk in the system. The COM LED blinks green whenever the system is attempting to communicate with either the PLC processor or the data logger drive. The other three LEDs do not have any function and will not be on except possibly during initial boot-up.

The front access door under the keypad conceals a keyboard port and the floppy drive discussed above. Since neither of these have any function in the operation or use of the drill or display, this door must be kept shut at all times to prevent dirt and dust from entering the PC and causing failures.

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1.2 Power The PC requires 90 to 250VAC and is connected to machine power through a receptacle on the floor of its cabinet. A power switch is located on the left side (fig. 1-3) of the unit and is shipped in the “ON” position. There is no need to shut this switch off, as the power can be controlled by the circuit breakers in the PLC cabinet door. It is recommended, however, that the application software be exited before any power is removed (see System/Disk Utilities screen in Software section). The data logger drive requires 15VDC that it gets through one of the drill's power supplies.

Figure 1-3 Left Side

1.3 Hardware Key On some units, a hardware key is fastened to the parallel port of the computer. This key enables the functionality of the display software. If the key is not present, the software will display a message informing the operator that the access to the program is denied. Additionally, no other hardware (except a printer) is to be connected through this key. Doing so will cause the key to be ruined. DO NOT LOSE OR DESTROY THIS KEY!

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1.4 Fan The PC has a small cooling fan located on the left side (fig. 1-3). The filter should be cleaned on a regular basis (depending on the environment) to ensure that the air circulating in the unit is clean. To get to the filter, remove snap off the grill and remove the filter (fig. 1-4). Wash the filter with warm water and dish soap and let it air dry. Do not scrub the filter, and do not reinstall it into the unit until it is completely dry. Replace the filter and snap the grill back into position.

Figure 1-4 Fan Filter Replacement

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1.5 Battery An external battery is located in the back of the PC (fig. 1-5). To replace the battery, use a screw driver and turn the battery cap to the left until it pops off. When replacing the battery, slide it into the battery compartment, negative (-) side first with the positive side touching the cap.

CAUTION: There is the danger of an explosion if the battery is incorrectly replaced. Replace the battery only with the same or equivalent type. The life of the battery depends upon machine usage including how long power is on the machine versus how long it is off.

Figure 1-5 Back of Display Unit

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1.6 Opening the PC Opening the PC should only be done by qualified personnel. In order to change the fuse or the display bulbs, it is necessary to open the PC up. First, remove power to the unit. The unit consists of two sections, a slide out the module (the back of the unit) and the front panel that is fastened to the cabinet. To remove the slide out module, first remove the six screws which hold it in (fig. 1-6). These are marked ACCESS on the back of the unit. Grasp the handles that protrude from the back panel on the left and right sides, above the I/O inserts. Pull straight back, easily sliding the module out. While inside the unit, make sure it is clean and any dirt is carefully remove.

Figure 1-6 Opening Computer When finished, match the top and bottom guides on the module with the slider indentations on the inside of the front panel (fig. 1-6). Push forward firmly until the top and bottom of the module are flush with the top and bottom of the front panel. Reinsert the six screws that were removed in the beginning.

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1.7 Fuse The PC display uses a standard 5 amp 3AG 250 volt fuse. The fuse holder is located on the power supply in the slide out module (fig. 1-7). To replace the fuse, first open the PC as described above, making sure the power is disconnected before starting. Grasp the fuse and pull it out. It should snap out of its holder. Replace the fuse by inserting the new fuse sideways against the holder and pushing it away from you until it snaps into place. Finally, replace the slide out module.

SIMM DRAM SITES

LED CONNECTOR

HARD DRIVE CABLE CONNECTOR

FLOPPY DRIVE CABLE CONNEC

COM1 & COM2 SERIAL (OR TOUCH) PORTS

FLAT PANEL CONNECTOR

ON/OFF POWER SWITCH

POWER RECEPTACLE

Figure 1-7 Slide Out Module

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1.8 Hot Cathode TFT Bulb Replacement (Display P/N 12330801) The display is lit up by florescent bulbs. When these go out, the bulbs are replaced together.

Bulb replacement should only be performed by qualified personnel. (Note: Due to the rapid rate of change in flat panel technology, these procedures may differ for the flat panel installed in your system. If so, the monitor’s manufacturer can supply the proper instructions.)

Figure 1-8 Hot Cathode Bulb Replacement To replace the bulbs, make sure the power is disconnected and open the PC as describe above.

The bulbs are located in the front panel (fig. 1-8). On the right side of the flat panel display, push the plastic tab down while inserting a screw driver in the hole in the metal bulb cover and pulling up. Once the tab is disengaged, lift up the edge of the bulb cover and slide it out to the right.

Repeat this procedure for the second bulb. Remove the tape holding down the connecting wires on the right side of the flat panel, then lift off the four black rubber shock absorbers on the ends of the bulbs. Gently pop the wires out of the wire guides running through the middle of the flat panel. Pull out the tabs holding the bulb connectors in place and pop them out of their slots, then gently lift the bulbs out.

Replace the bulbs locating the connecting wires on the right-hand side. Snap the wires into the wire guides then snap the bulb connectors back in place. Replace the four black rubber shock absorbers on the ends of the bulbs, then slide the bulb covers under the guides and snap them under the plastic tabs to secure them. Finally, replace the slide out module into the front panel.

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1.9 Cold Cathode TFT Bulb Replacement (Display P/N 12330802) The display is lit up by florescent bulbs. When these go out, the bulbs are replaced together.

Bulb replacement should only be performed by qualified personnel. (Note: Due to the rapid rate of change in flat panel technology, these procedures may differ for the flat panel installed in your system. If so, the monitor’s manufacturer can supply the proper instructions.) To replace the bulbs, make sure the power is disconnected and open the PC as describe above. The bulbs are located in the front panel. Remove the slide out module. Locate the bulb covers (fig. 1-9) on the outside edges of the flat panel (each bulb cover has two screws and a cable). Disconnect the bulb cables and remove the screws using a small Phillips screw driver. Lift up the bulb covers on the same side as the screws and pull them out. The bulbs are attached to these covers.

Figure 1-9 Cold Cathode Bulb Replacement Replace the bulbs and reinsert the bulb covers in the flat panel. Reconnect the bulb cables and replace the slide out module into the front panel.

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1.10 Data Logger Drive and Card The data logger drive (located inside the lower portion of the display’s cabinet on the left wall) is a PCMCIA flash card drive that is configured to act like a floppy drive. It is given the designation as the D: drive. The drive requires very little maintenance, other than making sure no dirt enters the card slot. There are two LEDs on the front panel, immediately next to the card slot. The BUSY LED is red whenever data is being written to the card. The BATT LED is never on except when power is first applied to the unit. On power-up this LED blinks GREEN-REDGREEN-RED if everything is working properly. The drive is connected to the PC's serial port with an RS-232 cable.

A card is inserted into the front slot of the unit with the manufacturer's name up. Make sure the card is inserted all the way until the eject button comes out. The eject button is located immediately to the right of the slot. When pressed, the card will be ejected and can then be easily removed. It is strongly recommended that the card be removed before power is shut off.

WARNING: NEVER remove a card from the drive or shut off power while the LED is on.

This will corrupt the data and possibly destroy the card!

The flash disk cards that are used are 1.8MB SunDisk ATA cards (SDP5A-1.8). If more capacity is required, SunDisk makes other cards of the same style. (Note: “SunDisk Corp.” may become known as “SanDisk Corp.”) Most standard DOS commands work on the card, however, formatting MUST be done using the option on the System/Disk Utilities screen, as described in the Software section of this manual. The card can be read using most PCMCIA drives configured to accept ATA flash cards. It has been successfully tested in a Toshiba T2100 laptop computer.

If no flash drives are available, an additional drive identical to the one used in the drill can be purchased through Bucyrus for use with a desktop computer.

If problems occur and the unit will not write to the flash card, first make sure that the card has been inserted all the way into the unit. Also check that the power connector is energized and in place in the back of the drive. If this checks out, verify that the card is not full or, if it is a new card, that it has been properly formatted. These steps can be done in the office or laptop computer. Finally, flash disks have a finite life-cycle of around 500,000 writes per sector. If the card is getting old or there does not appear to be the full available space on the card, try a new formatted card.

The system creates two types of files, one for alarms and one for data. Each of these is described in the Software section of the manual under the appropriate headings. The files are stored in standard ASCII format. With ATA flash, a card emulates a floppy drive, so the data can easily be copied to another computer. On machines with a foreign language option, some characters (with accents, tildes, or based on different alphabets) may not appear properly if the file is viewed with a DOS editor. To view these files properly, read them into a Windows

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program such as Write. If using Write, do not allow the program to convert the file into Write format while it is opening. Most Windows based word processors should allow the user to convert these files from ANSI Windows format. A fixed distance font (such as Courier) will allow for proper column widths. If the characters of the alternate language are significantly different from English, it may be necessary to use the same font that Bucyrus-Erie used to create the display application.

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SOFTWARE

2.1 Software Overview The application software used for the displays was created by Bucyrus-Erie using Wonderware Intouch. This software runs under Microsoft Windows. Some functions call Windows applications, but no knowledge of Windows is required to operate this system. It is suggested that the application software be closed before power is removed. (See “Exit to DOS” under System/Disk Utilities.)

Some of the screens have security attached to them, meaning that only people who enter the proper password may access that screen. These passwords are setup in the Password Window, accessed under the Setup Menu (see Setup and Disk Management). The Security section of this manual discusses the operation of these passwords, and Appendix B shows a matrix of the secure screens and the users who have access. NOTE: The Administrator has access to all screens.

User 1 has access to all screens except the Setup screens. The title of each secure screen shows the other User who may access it.

The screens shown in this manual are typical configurations and have all indicators active for ease of location. The layouts and/or color associated with the screens may change as the application requires.

2.2 Bootup (Power Up) The display terminal will automatically bootup (power up) whenever power is applied to the unit.

The entire bootup process, from power-on until the system is ready for use, takes less than three minutes. During this time NO KEYS ARE TO BE PRESSED. When power is first applied to the PC, the manufacturer's name will appear as well as the BIOS version. The system then does a complete test of its internal memory and starts communication with the external data logger drive.

Messages are displayed on the screen, documenting the progress of this. During this time, the system also cleans up any temporary files that may have been left over from the previous session.

If none exist, it displays “File not found” twice. This is the usual, expected behavior. A background screen of the Bucyrus logo is shown and box indicating the progress of the Wonderware software is displayed. Since various checks are made while the Wonderware software is loading, this generally takes the longest amount of time. Once the loading is finished, communication between the PC and the PLC processor is established and the title screen appears.

The system is ready for use as soon as the “PLC Communications Lost” indication disappears from the top of the screen.

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2.3 Program Control The user can get around the program using the function keys (fig. 2-1), located below the screen, and the keypad (fig. 2-2), located to the right of the screen.

Figure 2-1 Function Keys

Figure 2-2 Keypad When a function key can be used, there will be some indication on the screen. In most cases, an indicator will appear immediately above the function key with a description of what that key does.

For example, on most screens the indicator above the F1 key says “Main Menu - F1”. This means that if the F1 key is pressed the screen will change to the Main Menu screen. The function of each of these keys will be discussed with the screen on which they appear. On some screens, where an explanation is necessary or the function is too long to fit in the button picture, the text on the screen will tell which function key to press.

The arrow keys (found to the left of the number keys) and the plus key, <+> (found above the number keys), control the cursor. All objects that have a user function, including those tied to a function key, can be moved to by pressing these keys. A box will surround the current object. To pick this object, press the <ENTER> key. The arrow keys move the cursor in a straight line in the direction of that arrow key. If there is no other user object in that line, the cursor will not move. The <+> key will move the cursor through all the user objects on the screen in a predetermined order. When finished, it will repeat the cycle. Each of the user objects and how to 17 SECTION 2 JCV:XI4:96:660

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get to them will be described with the screen on which they appear.

When changing values on those screens that allow it, move the cursor to the desired object as described above and press the <ENTER> key. Type in the new value in the small box that appears and press the <ENTER> key. If the new value is out of the predetermined range one of two things will happen. If the value is outside the variable limits allowed for that particular parameter, the text on the screen will turn red and the appropriate range will appear next to the entry. Press <ENTER> again and re-enter a value within the range. If the value is extremely large, outside the range allowed for that object on the screen, a box will appear in the center of the screen with the appropriate range.

Clear the box by pressing either <ENTER> or <ESC> and repeat the procedure to enter a value within the range. Note: The actual limits may be different, depending on the status of the machine

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.2.4 Normal Operational Screens

2.4.1 Title Screen When power is first applied to the drill, or if control power for the system has been off and turns back on, the display will show the Title Window (fig. 2-3) immediately after the bootup (power up) is through. If an alarm condition exists on power-up, the New Alarms window will pop up on the bottom half of the screen. This is described in the section on alarms.

Figure 2-3 Title Screen

The Title Window shows the drill's model number and serial number, along with the name of the specific customer. A separate box below the customer's name lists the drill's schematic number, the PLC program documentation, the display's manual, and the software version number. As on most screens, the current time and date are shown in the upper right corner. See the Setup section for information on changing these values.

To leave the screen, press either function key F1 or F2. Pressing F1 changes the screen to the Main Menu, which allows the user to pick other screens. Pressing F2 changes the screen to the Operator's Screen. This is the main functional screen during drilling operations.

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2.4.2 Main Menu The Main Menu (fig. 2-4) is the primary area from which other screens are selected. When an arrow key or the <+> key is pressed, the cursor will appear as a white frame around one of the selections.

Move the cursor using either the arrow keys or the <+> until the cursor surrounds the desired screen name. Press <ENTER> to change to that screen. The Menu consists of a list of other screens.

Figure 2-4 Main Menu If there are multiple screens with the same function (e.g., Test Display - 1 and Test Display - 2) only the first one is shown on the Main Menu. The second screen can be accessed with a button on the first screen of the set. Likewise, all Setup screens can be reached through another menu after choosing "Setup” from this list. Screens that pertain to options that are not on a particular machine are not shown on the Menu.

The “Oper.” key, <F2>, will make the Operator's Screen come on immediately without the need for moving the cursor. It is just a shortcut to allow easy access to the most commonly used screen.

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2.4.3 Operator's Screen The Operator's Screen (fig. 2-5) is representative of the screen that will normally be used by an operator during the drilling process. The screen displays information on machine status including rotary motor operation, hoist/ pulldown motor operation, air pressure, head position, hole depth, function statuses of all systems, and numerous other operational parameters. The information is presented in several forms: 1.

2.

3.

4.

Bar graph indicators Numeric displays Function keys Multi-state message indicators

Each element on the Operator's Screen will be discussed in detail in the following sections. Refer to figure 2-5 for specific location reference details.

Figure 2-5 Operator’s Screen Rotary Current Bar Graph This bar graph shows the DC current in the armature loop in amps. A numeric display below the graph provides the exact value while the graph itself provides relative scaling. The maximum scale level is printed at the top of the scale to the right of the graph. The bar graph is normally green in color. If the operating current rises above 105% of the motor rating, but stays less than 140%, the color changes to yellow. This indicates that the motor current is in an overload warning range. In the yellow region, an operator can safely finish his operation before taking corrective action with no damage to the system. If the operating current rises to 140% or more of the motor rating, the bar graph changes to red to indicate that the motor current is in a major 21 SECTION 2 JCV:XI4:96:659

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overload range. After a short time delay in the red region, an audible alarm will energize for a 2 second period. Sustained operation in an overload range will result in an automatic system shutdown. If the display gets into the red area, the operator should stop immediately to avoid damage to the motor.

Rotary Speed Bar Graph This bar graph shows the speed of the bit in revolutions per minute (rpm). A numeric display below the graph provides the exact value, while the graph itself provides relative scaling. The maximum scale level is printed at the top or the scale to the right or the graph. This is not necessarily the maximum rotary speed.

Hoist/Pulldown Force Bar Graph This bar graph shows the force at the bit in units of kilopounds (klbs) or kilonewtons (kN), depending on the selected unit setting (see Setup screens). The maximum scale level is printed at the top of the scale to the right of the graph. The bar graph is normally green in color. If the operating current rises above 105% of the motor rating, but stays less than 140%, the color changes to yellow. This indicates that the motor current is in an overload warning range. If the operating current rises to 140% or more of the motor rating, the bar graph changes to red to indicate that the motor current is in a major overload range. In addition, after a short time delay, an audible alarm will energize for a two second period. Sustained operation in an overload range will result in an automatic system.

Hoist/Pulldown Current Bar Graph This bar graph shows the DC current in the armature loop in amps. A numeric display below the graph provides the exact value while the graph itself provides relative scaling. The maximum scale level is printed at the top of the scale to the right of the graph. The bar graph is normally green in color. If the operating current rises above 105% of the motor rating, but stays less than 140%, the color changes to yellow. This indicates that the motor current is in an overload warning range. If the operating current rises to 140% or more of the motor rating, the bar graph changes to red to indicate that the motor current is in a major overload range. In addition, after a short time delay, an audible alarm will energize for a two second period. Sustained operation in an overload range will result in an automatic system shutdown.

Hoist/Pulldown Speed Bar Graph This bar graph shows the head speed in units of feet per minute (fpm) or meters per minute (mpm), depending on the selected unit setting (see Setup screens). A numeric display below the graph provides the exact value while the graph itself provides relative scaling. The maximum scale level is printed at the top or the scale to the right or the graph. This is not necessarily the maximum head speed.

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Air Pressure Bar Graph This bar graph shows the bailing air pressure in units of pounds per square inch (psi) or bars, depending on the selected unit setting (see Setup screens). A numeric display below the graph provides the exact value while the graph itself provides relative scaling. The maximum scale level is printed at the top or the scale to the right or the graph. This is not necessarily the maximum system pressure capability.

Head Position Animation This picture show the relative position of the head between the top and bottom extreme travel limits.

A numeric display below the graph provides the exact position in relation to the top stop. This is shown in feet or meters, depending on the selected unit setting (see Setup screens).

Water Injection Numeric Display (option) The rate of water flow on drills that are equipped with the optional water injection dust suppression system is found in the numeric display box, found under the bar graphs. The value is displayed in units of gallons per minute (gpm) or liters per minute (lpm), depending on the selected unit setting (see Setup screens). On machines that do not have the water injection system installed, a message will be displayed in the box stating that the option is not there.

Hole Depth Numeric Display The actual drilled hole depth is shown in the numeric display box, found under the bar graphs. The value is displayed in units of feet or meters, depending on the selected unit setting (see Setup screens). On multiple pass drilling operations, the readout represents the accumulated multiple pass hole depth. At the beginning of each NEW hole, the console mounted DEPTH INDICATOR RESET push-button must be pressed to reset the hole depth readout to zero.

NOTE: On multiple pass drilling cycles, operation of the tool wrench switch is used to keep track of multiple pipe drilling operations in calculating the accumulated hole depth. The operator should refrain from manipulating the tool wrench switch when the machine is drilling. The switch should be operated only when use of the tool wrench is necessary to make or break a drill pipe joint. If the operation intended is to unclamp the pipe, the last operation on the switch must be “Retract” before moving the head assembly. If these guidelines are followed, the accumulated hole depth calculations and displayed value will be correct.

Bit Depth Numeric Display The actual position of the drill bit relative to ground level (where the drilling operation began) is shown in the numeric display box, found under the bar graphs. The value is displayed in units of feet or meters, depending on the selected unit setting (see Setup screens). At the beginning of each NEW hole, the console mounted DEPTH INDICATOR RESET push-button must be pressed to reset the bit depth readout to zero.

NOTE: On multiple pass drilling cycles, operation of the tool wrench switch is used to keep track of multiple pipe drilling operations in calculating bit depth and to prevent drill propel when the pipe is in the hole. The operator should refrain from manipulating the tool wrench switch when the machine is drilling. The switch should be operated only when use of the tool wrench is necessary to make or break a drill pipe joint. If the operation intended is to unclamp the pipe, the last operation on the switch must be “Retract” before moving the head assembly. If these guidelines are followed, 23 SECTION 2 JCV:XI4:96:659

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the bit depth calculations, displayed value, and Pipe In Hole warning will be correct.

Active Alarms F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Active Alarms screen. An operator would use this key to check which alarms are currently active or have not been reset. See the screen description in a different section.

Alarm History F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Alarm History screen. An operator or maintenance supervisor would use this key to check on recent machine problems by inspecting the most recent alarms. See the screen description in another section Fault Rest F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key forces the reset of several latched fault indications and auxiliary control circuits if the problem causing the fault has been corrected.

The following, WARNING ONLY, faults require reset from F3 to be cleared as active fault indications. Even if the problem has been corrected, F3 must be pressed in order to clear the indication. NOTE: This list does not include all possible machine warning messages, only those requiring a reset with F3: ANF006 ANF007 ANF011 ANF037 ANF038 ANF045 ANF059 ANF060 ANF065 ANF066 ANF084 ANF094 ANF104 (1)

Hydraulic Oil Overtemperature Hydraulic Oil Filter Clogged Auxiliary System Ground Fault Air Compressor Low Oil Level (1) Air Compressor Motor Ground Fault (2) Low Water Level (option) Air Pressure Transducer Fault Head Brake Sensor Switch Fault (3) Horizontal Vibration Transducer Fault (option) Vertical Vibration Transducer Fault (option) Compressor Oil Temperature Transducer Fault (option) Compressor Air Temperature Transducer Fault Auxiliary Transformer Overtemperature (option)

This fault indication will also be reset when the main compressor is started via the AIR COMPRESSOR START push-button.

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(2)

On standard machines, clearing this fault may require a manual reset to be made at the sensing device located in one of the machinery house cabinets. On machines that incorporate shunt trip circuit breakers in the ground fault circuit, this indication may no exist on the display. Instead, a red light in the machinery house would be ON and hardware resets would be required as well.

(3)

This fault indication will also be reset when the DRILL/PROPEL CONTROL ON push-button is pressed to activate the DRILL mode on the machine.

The following Shutdown Level faults require a reset from F3 before the circuit latched off will be allowed to operate. Unless otherwise stated, even if the problem has been corrected, F3 must be pressed before the latched off circuit will be allowed to restart. These circuits are configured as manual resets for safety reasons to insure that a fan or motor cannot automatically restart while maintenance personnel are present. NOTE: This list does not include all possible machine warning messages, only those requiring a reset with F3: ANF008 ANF026 ANF057 ANF058 ANF069 ANF070

Compressor Air Overtemperature (1) House Fan Control Fault Hydraulic Oil Cooler Fault Cable Reel Control Fault (option) Compressor Radiator Fan Control Fault (1), (2) Air Compressor Control Fault

(1)

Unless otherwise stated, this fault will normally result in a shutdown of the main compressor. The fault indication/circuit will also be reset when the main compressor started via the AIR COMPRESSOR START push-button, but only if the problem has been corrected.

(2)

On machines that incorporate temperature controlled louvers and temperature controlled ON/OFF control for the compressor radiator fan, this fault will not result in a shutdown of the main compressor motor. Either reset function will still work for the fault indicator.

Leveling F4 Function Key Above the F4 key is an indicator indicating the action of the key. Pressing the F4 key causes the display to change to the Leveling/Propel screen. An operator or maintenance supervisor would press this key to check on leveling, propelling, and towing related parameters. This key is provided to eliminate the need of going through the Main Menu. See the screen description, elsewhere. Note: The Leveling/Propel Window appears whenever the machine enters either propel or autolevel mode.

PDC Settings F5 Function Key (option) Above the F5 key is an indicator indicating the action of the key. Pressing the F5 key causes the display to change to the PDC Operating Parameters - 1 screen. An operator would use this key to set basic parameters when Programmed Drill Control is being used. This key is provided to eliminate the need of going through the Main Menu. See the screen description, elsewhere.

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Above the F6 key is an indicator indicating the action of the key. Pressing the F6 key causes the display to change to the Mast Pin Status screen. An operator would press this key whenever he is going to reposition the mast. This key is provided to eliminate the need of going through the Main Menu. See the screen description, elsewhere.

Manual Lube F7 Function Key Above the F7 key is an indicator indicating the action of the key. Pressing the F7 key activates a manual lube cycle. It is functional whenever the compressor motor is operating, control power is available, and the lube system is not in an active cycle or faulted.

Thread Lube F8 Function Key (option) Above the F8 key is an indicator indicating the action of the key. Pressing the F8 key activates one cycle of the pipe thread lubricator, provided the drill is in pipe rack mode and it is not in the middle of a cycle.

Main Menu F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to the Main Menu, from which all available screens may be chosen. Note that keys F1, F2, F4, F5, and F6 (previously described) all the operator and maintenance personnel to jump directly to the more commonly used screens without the need for going through the Main Menu. See the screen description elsewhere.

Rotary Mode Indicator The rotary mode indicator is a five-state indicator located in the left most position of the indicator row above the function keys. Its states are as follows: ROTARY OFF (blue background) - This message indicates that the rotary drive is not energized.

The machine is in PROPEL mode or the machine power is OFF. ROTARY LOW (yellow background) - This message indicates that the rotary drive is active in the LOW speed range.

ROTARY MEDIUM (yellow background) - This message indicates that the rotary drive is active in the MEDIUM speed range.

ROTARY HIGH (yellow background) - This message indicates that the rotary drive is active in the HIGH speed range.

ROTARY POWER ON (flashing) - This message indicates that the rotary drive is in a condition whereby the input power contactor has closed during the startup sequence but the armature controls have not been released. This is normal in a drive SETUP mode of operation. This indication will also occur in conjunction with an ANF067 Rotary Incomplete Sequence Fault.

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Hoist/Pulldown Mode Indicator The hoist/pulldown mode indicator is a six-state indicator located in the second position from the left of the indicator row above the function keys. Its states are as follows: HOIST PULLDOWN OFF (blue background) - This message indicates that the hoist/pulldown drive is not energized. The machine is in the PROPEL mode or the machine power is off.

HOIST LOW (yellow background) - This message indicates that the hoist/pulldown drive is active in the HOIST LOW speed range for pipe handling or hoisting operation.

HOIST HIGH (yellow background) - This message indicates that the hoist/pulldown drive is active in the HOIST HIGH speed range for pipe handling or hoisting operation.

PIPE JOINTS (yellow background) - This message indicates that the hoist/pulldown drive is active in the PULLDOWN operating mode for normal drilling operation.

HOIST/PD POWER ON (flashing) - This message indicates that the hoist/pulldown drive is in a condition whereby the input power contactor has closed during the startup sequence but the armature controls have not been released. This is normal in a drive SETUP mode of operation. This indication will also occur in conjunction with an ANF068 Hoist/Pulldown Incomplete Sequence Fault indication.

Head Brake Indicator The head brake indicator is a two-state indicator located in the third position from the left of the indicator row above the function keys. Its states are as follows: HEAD BRAKE SET (blue background) - This message indicates that the electric head brake is not released. The spring-set mechanism should be holding the head assembly stationary.

HEAD BRAKE RELEASED (yellow background) - This message indicates that the hoist/pulldown drive is active, the hoist brake control switch is in the RELEASE position, the electric brake has been energized, and that any two of the three feedback switches inside the brake assembly indicate brake release.

NOTE: The hoist/pulldown drive can be active without the head brake being released. Under this circumstance, the drive will not be allowed to produce current in the hoist/pulldown motor.

Air Compressor Indicator The air compressor indicator is a two-state indicator located in the fourth position from the left of the indicator row above the function keys. Its states are as follows: AIR COMP. OFF (blue background) - This message indicates that the main compressor motor is not energized.

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AIR COMP. ON (yellow background) - This message indicates that the main compressor motor is operating.

PDC Mode Indicator (option) The PDC mode indicator is a two-state indicator located in the fifth position from the left of the indicator row above the function keys. Its states are as follows: PDC OFF (blue background) - This message indicates that the Programmed Drill Control system is not energized.

PDC ON (yellow background) - This message indicates that the Programmed drill Control system is functional and controlling machine drilling operations.

Level Indicator The level indicator is a five-state indicator located in the sixth position from the left of the indicator row above the function keys. Its states are as follows: NOT LEVEL (blue background) - This message indicates that the drill is out of level in the front-rear or side-side axis by greater than two (2) degrees. This indication is functional in all machine operating modes.

COARSE LEVEL (yellow background) - This message indicates that both the front-rear and sideside drill axes are out of level by less than two (2) degrees, but at least one of those axes is out of level by more than 0.5 degree. This indicator is functional in all machine operating modes.

FINE LEVEL (yellow background) - This message indicates that both the front-rear and side-side drill axes are level within 0.5 degrees. This indicator is functional in all machine operating modes.

LEVEL LIMIT (flashing) - This indicator, which is functional only in the DRILL operating mode, advises that the drill tilt angle is beyond the point where the automatic leveling system is allowed to operate, typically seven (7) degrees. In conjunction with this indication, an ANF079 Automatic Level Limit Fault will be displayed. Dual indications are provided for this circumstance because an operator can clear the fault indication from the screen and lose knowledge of the status information. The level limit indicator cannot be removed until the condition changes or the machine is taken out of the DRILL operating mode.

TIP WARNING (flashing) - This indicator, which is functional in all machine operating modes, advises that the drill tilt angle is at a point where machine stability may be a concern. In conjunction with this indication, an ANF078 Machine Tip Warning Fault will be displayed. Dual indications are provided for this circumstance because an operator can clear the fault indication from the screen and lose knowledge of the status information. The tip warning indicator cannot be removed until the tilt condition is removed.

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Limit Indicator The limit indicator is a five-state indicator located in the seventh position from the left of the indicator row above the function keys. Its states are as follows: No Text - For non-limit positions of the head, this area remains blank.

UPPER LIMIT (flashing) - This message indicates that the head assembly has reached the upper limit position as set by operations personnel. Further upward movement is not allowed unless the limit function is bypassed by operating with the Head and Rack Limits screen active. A security access code is required for access to that screen. See the screen description, elsewhere. Downward movement of the head assembly (away from the limit) is allowed regardless of which screen is active.

It should be noted that if the hoist/pulldown rate master switch is calling for upward movement when the upper limit is reached, head upper movement will cease but the head will drift slowly downward due to drive regulator gain limitations. When the head moves downward enough for the limit to be released, the head assembly will again go in an upward direction until the upper limit is reached. This up/down cycle will continue until the head brake is set or the speed reference is removed via the master switch. Without the head brake being set, downward drifting of the head assembly will always take place while the hoist/pulldown drive is active unless enough upward reference is provided to offset the effect of gravity in pulling the head down.

RACK LIMIT (flashing) - This message indicates that the head assembly has reached the elevation level that allows pipe rack operation without mechanical interference wit the head assembly. This level, as set by operations personnel on the Head and Rack Limits screen, would include a reasonable amount of physical clearance to ensure safe rack operation. In NORMAL operation, upon reaching this level an audible annunciator will beep three times. If pipe rack operation is desired, the operator should put the hoist brake selector switch in the SET position to stop the downward drift of the head assembly. Pipe rack operations will now be allowed if the operating mode selector switch is in the DRILL position and the hoist/pulldown rate selector switch is in the PIPE RACK/JOINT position.

PROPEL LIMIT (flashing) - This message indicates that the head assembly has reached the elevation necessary to allow the bit to clear ground obstructions during machine propel operations. This level, as set by operations personnel on the Head and Rack Limits screen, should be indicated before the machine propel system is energized. In NORMAL operation, upon reaching this level, an audible annunciator will beep two times. At this point, if propel operation is desired, the operator should put the hoist brake selector switch in the SET position to stop the downward drift of the head assembly.

If this indicator is not on when the machine operation mode is switched from DRILL to PROPEL or REMOTE (and the PLC logic senses that a pipe is still connected to the head assembly), an ANF074 Propel With Pipe in Hole Fault indication will be displayed. Note: It is important to realize that the ANF074 indication will not prevent propel operation. It is only intended as a status warning message.

LOWER LIMIT (flashing) - This message indicates that the head assembly has reached the lower limit position as set by operation personnel. Further “powered” downward movement is not allowed unless the limit function is bypassed by operating with the Head and Rack Limits screen active. A security access code is required for access to that screen. See the screen description, elsewhere.

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downward, past the lower limit set point, due to drive regulator gain limitations. Eventually, the head will come to a complete stop by reaching the bottom mechanical stop or by the bit bottoming out of the hole. If the downward drifting is not desired, the head brake should be set. If desired, it is possible to adjust the pulldown/hoist rate master switch to provide a small upward reference to offset the effect of gravity in pulling the head down and achieve a “zero speed” condition on the head.

PDC Limit Indicator (option) The PDC LIMIT INDICATOR is located in the eighth position from the left of the indicator row above the function keys. This message flashes to indicate that the PDC system is controlling the drilling operation and one or more of the parameters monitored and controlled by the system is being actively reduced to ensure that the predefined limits are not exceeded. The operating parameters that can be controlled include the following: 1.

2.

3.

4.

5.

6.

Pulldown force Bailing air pressure Vertical vibration Horizontal vibration Rotary motor armature current Hoist/pulldown motor armature current

The PDC LIMIT indicator will generally come on and off periodically during the drilling sequence but should not remain on for extended periods of time.

Low Water Indicator (option) The LOW WATER indicator is located in the ninth position from the left of the indicator row above the function keys. This message appears with a yellow background to indicate that the water level in the tank for water injection is low and the tank needs refilling.

Not in Neutral Indicator The NOT IN NEUTRAL indicator is located in the tenth position from the left of the indicator row above the function keys. This message flashes to indicate that the hoist/pulldown rate master switch and/or the rotary rate master switch is not in the NEUTRAL positions. In a drive startup sequence, if either of the master switches is not in NEUTRAL, the drive associated with that master switch will not be allowed to energize completely until the switch is first placed in the NEUTRAL position.

Additionally, an audio annunciator will beep continuously in the operator's cab until both master switches are placed in NEUTRAL or the drive controls are turned OFF by pressing the DRILL/PROPEL CONTROL OFF push-button.

Hole Clogged Indicator (option) The HOLE CLOGGED indicator is located in the right most position of the indicator row above the function keys. This indicator flashes on drills with Programmed Drill Control to

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indicate that the PDC system is controlling drill operation and the bailing air pressure has exceeded its predefined limit point. This situation implies that the hole is clogged. In conjunction with this indicator, the PDC Limit indicator is active, the pulldown rate will be reduced, and the pipe may actually be lifted in an effort to clear the clogged hole condition. Concurrently, if the water injection system (option) is being used, water flow is momentarily turned off to facilitate dropping the bailing air pressure to a value within limits.

Compressor Preheat Activated Indicator (option) The COMPRESSOR PREHEAT ACTIVATED indicator is located to the left of the numeric display box, immediately under the bar graphs. This message displays whenever the air compressor tank heating option is active.

Active Alarms Indicator The ACTIVE ALARMS indicator is located to the right of the numeric display box, immediately under the bar graphs. This “light bulb” will flash red to indicate that one or more alarm conditions presently exist on the drill and/or one or more latching faults had been sensed previously but not cleared with the FAULT RESET KEY, F3. Details on the active alarms can be displayed by pressing the ACTIVE ALARMS key, F1. See the screen description, elsewhere.

Washdown Disabled Indicator (option) The washdown disabled indicator is a two-state indicator located to the right of the Active Alarms indicator. Its states are as follows: COMP. MOTOR NOT ON (flashing) - The washdown option is not available, since the air compressor motor needs to be on.

WASHDOWN DISABLED DURING DRILLING (flashing) - Since water injection can be used during drilling, the washdown option is not available.

Air Compressor Volume F20 Key/Indicator (option) The AIR COMPRESSOR VOLUME indicator is located to the right of the Active Alarms indicator.

This shows the current volume percent on drills with the variable volume control option. By pressing the F20 function key, below the screen, the operator can scroll through the various settings allowed.

As each setting becomes active, the indicator will be updated.

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2.4.4 Leveling/Propel Window The Leveling/Propel window (fig. 2-6) will come on automatically from the Operator's Screen whenever the drill is in an active PROPEL mode of operation or a manual/automatic leveling sequence is active. The screen shows a top view of the drill with information presented on jack operation, tilt status, and machine operational status. The information is presented in several forms: 1.

2.

3.

4.

Graphical indicators Numeric displays Function keys Multi-state message indicators

Each element on the Leveling/Propel Window will be discussed in detail in the following sections.

Refer to figure 2-6 for specific location reference details.

Figure 2-6 Leveling/Propel Window Front/Rear Level Indicator The Front/Rear Level indicator is located immediately below the deck plan of the drill. This gives a relative indication of the machine's front/rear tilt angle. The range of the graph is ±10 degrees. When the arrow indicator is on a given side, it indicates that the machine is tilted in that direction (i.e., that side is low). When the drill is level, the arrow will point to zero. In a fine level condition, the machine can be between -0.5 degrees and +0.5 degrees.

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Therefore, the pointer may be slightly away from the zero marker after an automatic leveling operation has been completed.

The numeric display underneath the pointer indicates the actual tilt of the machine in the front-rear axis. A positive value indicates that the machine is tilted to the rear (i.e., the rear of the drill is low).

Conversely, a negative reading indicates that the machine is tilted to the front (i.e., the front of the drill is low).

Side/Side Level Indicator The Side/Side Level indicator is located immediately to the left of the deck plan of the drill. This gives a relative indication of the machine's front/rear tilt angle. The range of the graph is ±10 degrees.

When the arrow indicator is on a given side, it indicates that the machine is tilted in that direction (i.e., that side is low). When the drill is level, the arrow will point to zero. In a fine level condition, the machine can be between -0.5 degrees and +0.5 degrees. Therefore, the pointer may be slightly away from the zero marker after an automatic leveling operation has been completed.

The numeric display above the graph the graph indicates the actual tilt of the machine in the side-side axis. A positive value indicates that the machine is tilted to the left (i.e., the left side of the drill is low). Conversely, a negative reading indicates that the machine is tilted to the right (i.e., the right side of the drill is low).

Side to Side Numeric Display The Side to Side numeric display is located in the numeric display box, under the front/rear level graph. It summarizes the same information as in the indicator described above.

Front to Rear Numeric Display The Front to Rear numeric display is located in the numeric display box, under the front/rear level graph. It summarizes the same information as in the indicator described above.

Tilt Numeric Display The Tilt numeric display is located in the numeric display box, under the front/rear level graph. It shows the effective combined front/rear and side/side tilt vector.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. However, if the motion drive controls had still been off, due to propel or remote propel operation, the Operator's screen will appear automatically when the motion drives are energized in the DRILL mode of operation. See the screen description, elsewhere.

Cable Reel In F9 Function Key (option) Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key will manually turn the cable reel in.

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Cable Reel Out F10 Function Key (option) Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key will manually turn the cable reel out.

Propel Mode Indicator The propel mode indicator is a two-state indicator located in the left most position of the indicator row above the function keys. Its states are as follows: PROPEL OFF (blue background) - This message indicates that the propel controls have not been energized.

PROPEL NORMAL (yellow background) - This message indicates that the propel motion controls are active in either the normal or remote propel mode and that the propel speed selector switch is set to the NORMAL SPEED RANGE position. If operating the REMOTE PROPEL mode, the readout indicates that the remote mounted propel selector switch is set to the NORMAL position.

Propel Brake Indicator The propel brake indicator is a two-state indicator located in the second position from the left of the indicator row above the function keys. Its states are as follows: PROPEL BRAKE SET (blue background) - This message indicates one of two conditions. Either the propel motion controls are not active, which automatically sets the brakes, or the propel motion controls are active in either NORMAL or REMOTE PROPEL mode but one of the controlling joystick neutral switches has not been energized to call for brake release and subsequent motion operation.

PROPEL BRAKE RELEASE (yellow background) - This message indicates that the propel motion controls are active and at least one of the console joysticks or remote propel joysticks has been activated by disengaging the neutral detent (either by lifting up or by pressing the button), thereby releasing the brakes.

Level Indicator The level indicator is a five-state indicator located in the third position from the left of the indicator row above the function keys. Its states are as follows: NOT LEVEL (blue background) - This message indicates that the drill is out of level in the front-rear or side-side axis by greater than two (2) degrees. This indication is functional in all machine operating modes.

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COARSE LEVEL (yellow background) - This message indicates that both the front-rear and sideside drill axes are out of level by less than two (2) degrees, but at least one of those axes is out of level by more than 0.5 degree. This indicator is functional in all machine operating modes.

FINE LEVEL (yellow background) - This message indicates that both the front-rear and side-side drill axes are level within 0.5 degrees. This indicator is functional in all machine operating modes.

LEVEL LIMIT (flashing) - This indicator, which is functional only in the DRILL operating mode, advises that the drill tilt angle is beyond the point where the automatic leveling system is allowed to operate, typically seven (7) degrees. In conjunction with this indication, an ANF079 Automatic Level Limit Fault will be displayed. Dual indications are provided for this circumstance because an operator can clear the fault indication from the screen and lose knowledge of the status information. The level limit indicator cannot be removed until the condition changes or the machine is taken out of the DRILL operating mode.

TIP WARNING (flashing) - This indicator, which is functional in all machine operating modes, advises that the drill tilt angle is at a point where machine stability may be a concern. In conjunction with this indication, an ANF078 Machine Tip Warning Fault will be displayed. Dual indications are provided for this circumstance because an operator can clear the fault indication from the screen and lose knowledge of the status information. The tip warning indicator cannot be removed until the tilt condition is removed.

Not in Neutral Indicator The NOT IN NEUTRAL indicator is located in the fourth position from the left of the indicator row above the function keys. This message flashes to indicate that the hoist/pulldown rate master switch and/or the rotary rate master switch is not in the NEUTRAL positions. In a drive startup sequence, if either of the master switches is not in NEUTRAL, the drive associated with that master switch will not be allowed to energize completely until the switch is first placed in the NEUTRAL position.

Additionally, an audio annunciator will beep continuously in the operator's cab until both master switches are placed in NEUTRAL or the drive controls are turned OFF by pressing the DRILL/PROPEL CONTROL OFF push-button.

Jack Operation Indicators On the drill's deck plan, a diagram is shown at the location of each of the four jacks. These change in appearance to indicate the current state of that jack. These states are as follows: LIGHT BLUE - This indicates that the specific jack assembly is not operating.

FLASHING RED - This indicates that the specific jack assembly is operating in an extend direction either manually or by means of the automatic leveling controls. The drill must be in the DRILL operating mode with the main motor operating to allow this action to occur.

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FLASHING GREEN - This indicates that the specific jack assembly is operation in a retrace direction either manually or by means of the automatic leveling controls. The drill must be in the DRILL operating mode with the main motor operating to allow this action to occur.

Jack Status Indicators On the drill's deck plan, a message indicator may be displayed next to the jack diagrams. They can show the following four states: BLANK - During a propel operation, no message will be displayed. Additionally, if the specific jack is neither on the ground nor fully retracted, no text will be shown.

JACK GROUND PRESSURE (brown background) - When a specific jack pad has contacted the ground and sufficient pressure has been applied to push the jack downward, this indicator will turn on. The indication should remain on after the drill has been leveled and the drilling operation has commenced.

JACK FULLY RETRACTED (green background) - When a specific jack cylinder has bottomed out in the retract direction, this indication will come on and remain on only as long as either the automatic level switch is held in the RETRACT position or the specific jack manual level joystick is held in the RETRACT direction. The indicator will turn off when the jack is not actively being powered in the retract direction. It should be noted that the fully retracted indication is not retained because it is derived from a hydraulic pressure condition that may not be constant after the jack has stopped operation for a while even though the jack may still physically be fully retracted. A permanent indication requires the addition of the jack retract limit switch (option).

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2.4.5 Head Calibration Screen (Security: User 6) The Head Calibration screen (fig. 2-7) is used to calibrate the head position encoder. The screen can be accessed from either the Main Menu or the Head & Rack Limits screen, described elsewhere. General notes are included on this screen to aid in properly making changes.

Figure 2-7 Head Calibration Screen Access to this screen is controlled by a security code, set for User 6. This number should be retained by operating personnel supervision to assure that changes are made consistent with mine operation practices and that limits are retained at levels sufficient to protect the machine. Refer to the section on Security for information on changing the password.

Encoder Calibration This procedure is normally performed at the initial erection of the machine and should not need to be performed again unless the head position encoder has been changed or the encoder mechanical linkage has been disturbed.

WARNING: No safety limits of any kind exist while this screen is active. Extreme care must be taken to prevent mechanical damage to the machine.

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The procedures involve moving the head to both the top and bottom travel limits and having the PLD read the encoder value at both points. The actual procedure is as follows: 1.

Carefully move the head assembly to the top mechanical stop and set the head brake.

2.

Make sure that the encoder count is within the desired range (between zero and 200).

Adjust if necessary.

3.

Press the arrow keys or the <+> key to move the cursor to the “Head Top Calibrate” position and press <ENTER.

4.

Press the <F10> Calibrate Head function key. The “Accepted” message should appear below the head encoder information.

5.

Release the head brake, lower the head assembly to the bottom mechanical stop and set the head brake.

6.

Press the arrow keys or the <+> key to move the cursor to the “Head Bottom Calibrate” position and press <ENTER>.

7.

Press the <F10> Calibrate Head function key. The “Accepted” message should appear below the head encoder information.

At this point, the encoder calibration procedure is done. All head position limits should now be reset/rechecked to verify proper limit point positions.

Encoder Numeric Displays The Head Encoder Count is the number sent back from the encoder and will display the largest value when the head is on the bottom stop position. It will not read zero at the top. The Head Encoder Top Calibrate Point and the Head Encoder Bottom Calibrate Point are values sent back from the encoder when each of the calibrations was performed. The Hoist/Pulldown Motor Armature Current is shown to assist in locating the limits.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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Limits Screen F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to the Head & Rack Limits screen. See the screen description, elsewhere.

Calibrate Head F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the encoder to be calibrated as described above.

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2.4.6 Head & Rack Limits Screen (Security: User 2) The Head & Rack Limits screen (fig. 2-8) is used to calibrate the head position to the hoist/pulldown force bar graphs and numeric displays used on the Operator's Screen.

Additionally, this screen is used to set all head position related points and input data used to determine if there is a pipe in the hole before propel operations are started. The screen can be accessed from either the Main Menu or the Head Calibration screen, described elsewhere.

Figure 2- 8 Head & Rack Limits Screen Access to this screen is controlled by a security code, set for User 2. This number should be retained by operating personnel supervision to assure that changes are made consistent with mine operation practices and that limits are retained at levels sufficient to protect the machine. Refer to the section on Security for information on changing the password.

General notes are included on this screen to aid in properly making changes. Once this screen is active, head speed is limited to about 35% of the normal maximum rate, as determined by the position of the hoist/pulldown rate selector switch. To obtain the maximum speed capability, the HOIST HIGH setting should be used. When practical, the head assembly should be moved close to the final desired position before accessing this screen in order to reduce the time needed to perform the various calibration procedures.

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WARNING: When this screen is active, the head position lower safety limit is bypassed.

Despite the fact that head speed capability is reduced, extreme care should be exercised to insure that mechanical damage is not done to the head assembly or mast related structures in the event of impacts. A software enforced upper limit is used to assure that the top stop cannot be impacted.

Limit Calibration If limit calibration is being performed as a continuation of the encoder calibration procedure, follow the suggested sequence for setting the limits. If only selected limits are being changed to accommodate changes in machine production needs, change only the limits that require changing.

NOTE: The F10 Set Limits key only has an effect on the limits when a yellow pointer is to the left of the desired limit.

The following sequence is suggested when setting all head limits.

1.

Press the arrow keys or the <+> key to move the cursor to the ΑHead Lower Limit Calibration≅ position. Press <ENTER> to cause the yellow pointer to appear to the left of the limit text. Move the head assembly to the desired lower limit position, which should be a reasonable distance above the bottom mechanical stop. Set the brake.

2.

Press the <F10> Set Limits function key. The ΑAccepted≅ message should appear below the head encoder information.

3.

Press the arrow keys or the <+> key to move the cursor to the “Head Propel Limit Calibration” position. Press <ENTER> to cause the yellow pointer to appear to the left of the limit text. Move the head assembly to the desired position that allows the drill bit to clear the hole cuttings and debris. Set the brake.

4.

Press the <F10> Set Limits function key. The “Accepted” message should appear below the head encoder information.

5.

Press the arrow keys or the <+> key to move the cursor to the “Pipe Rack Limit Calibration” position. Press <ENTER> to cause the yellow pointer to appear to the left of the limit text. Move the head assembly to the position that allows the bottom of the pipe (single pipe length) comfortably to clear the pipe pod during pipe rack operation. About four to 5 inches would be a good clearance value to use. Set the brake.

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6.

Press the <F10> Set Limits function key. The “Accepted” message should appear below the head encoder information.

7.

Press the arrow keys or the <+> key to move the cursor to the “Head Upper Limit Calibration” position. Press <ENTER> to cause the yellow pointer to appear to the left of the limit text. Move the head assembly to the desired upper limit position, which should be a reasonable distance below the top mechanical stop. Set the brake.

8.

Press the <F10> Set Limits function key. The “Accepted” message should appear below the head encoder information.

This completes the head limit calibration procedure. If no further settings are to be changed, leave the screen with either F1 Main Menu or F2 Oper. Screen.

NOTE: On most drills it is customary for the Head Propel Limit setting to be lower than the Pipe Rack Limit setting as a result of using single pipe lengths in single pass drilling and/or performing a racking operation when multi-pass drilling is used.

If shorter than typical pipes are used and connected for a single pass operation, the Pipe Rack Limit will need to be lower than the Head Propel Limit in order to facilitate racking the pipe when it is eventually stored.

During limit setup the “Out of Range” message may be displayed for a few seconds. This indicates that the head position at that point is not in the proper travel range to accept the particular limit being attempted. In addition, the limit text will turn red.

The head assembly must be in the upper 50% of its travel range to allow the Head Upper Limit, Pipe Rack Limit, and Head Propel Limit to be set. If this screen is left with out of range data remaining, an ANF033 Head Limit/Data Out of Range fault will be displayed and recorded.

Drill Pipe and Head Data Numeric Input The numeric data provided under this category is used to determine if a pipe may still be in the hole before propel is started. The data is also used to calibrate the Hoist/Pulldown Force Bar Graph on the Operator’s Screen properly.

To change any of the values, use the arrow keys or the <+> key to move the cursor to the desired object and press <ENTER>. Then, enter the new setting. If the value is not accepted, the text will change to red and the value's limits will be displayed to the right. The value must be readjusted accordingly. If this screen is left with out of range data remaining, an ANF033 Head Limit/Data Out of Range fault will be displayed and recorded.

The number used for drill pipes typically reflects the quantity of pipes being actively used, racked, or handled on a hole by hole basis. If short pipes are being coupled and not disassembled on a hole by hole basis, the assembled pipes should be considered as a single

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pipe for the purpose of this numeric input. HOWEVER, WHEN THE PIPES ARE EVENTUALLY DISASSEMBLED AND RACKED (I.E., FOR LOWERING THE MAST, ETC.), IT SHOULD BE REALIZED THAT THE LOGIC THAT SENSES A PIPE IN THE HOLE WILL NOT FUNCTION PROPERLY UNLESS THE VALUES FOR THE NUMBER OF DRILL PIPES IS CHANGED TO REFLECT THE ACTUAL QUANTITY OF PIPES ACTIVELY BEING HANDLED. The value used for pipe weight should reflect either the actual measured weight or vendor estimated weight based upon the type and length of pipe being used. The value used for head weight should include the head weight plus all variables other than pipe weight (stabilizers, etc.)

Pulldown Force Limit The Pulldown Force Limit determines the maximum pulldown force available. This value should be set based on the bit manufacturer's recommendation or mine experience with bit life. To change the Pulldown Force Limit, use the arrow keys or the <+> key to move the cursor to the desired object and press <ENTER>. Then, enter the new setting. If the value is not accepted (greater than 105% of the machine rating), the text will change to red and the value's limits will be displayed to the right.

The value must be readjusted accordingly. If this screen is left with out of range data remaining, an ANF033 Head Limit/Data Out of Range fault will be displayed and recorded.

Encoder Numeric Displays The Head Position numeric display shows the head position relative to the top of the mast (i.e., the readout is zero at the top and maximum at the bottom). The total distance between the top and bottom calibration points is displayed in the Head Total Travel numeric display. The current head encoder count is also shown.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be save to an ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called LIMITS.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 550 bytes.

Calibrate Screen F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to the Head Calibration screen. See the screen description, elsewhere.

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Set Limits F10 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F10 key causes the limits to be set as described above.

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2.4.7 Mast Pins Status Screen The Mast Pins Status screen (fig. 2-9) provides the operator with a visual display of the mast pin configuration. This screen is automatically activated when mast pin functions are active. It can also be accessed with the Pin Status <F6> function key on the Operator's screen or through the Main Menu. There are a number of indicators on this screen to assist the operator in placing console switches in their proper position during mast operations.

Figure 2-9 Mast Pin Status Screen Pins' Status Indicators The center of this screen lists the pin types for the individual machine. These are mast brace pins, A-frame lock pins (angle hole option only), and mast lock pins. When the corresponding pin (left or right) is fully locked or unlocked, a yellow indicator displaying “Locked” or “Unlocked” will illuminate to display the condition. No message for any given pin indicates that the pin is in midtravel or a switch has failed.

Mast Mode Indicator The Mast Mode Indicator is a two-state indicator located in the left most position of the indicator row above the function keys. Its states are as follows: MAST MODE (yellow background) -This indicator must be ON before any mast operations are allowed. The Mast-Off-Winch selector switch (WMS) must be in the MAST position.

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NOT IN MAST MODE (yellow background) - This indicator comes on when mast functions are attempted and the mast-off-winch selector switch (WMS) is not in the MAST position. With this indicator on, the mast functions are disabled.

Drill Mode Indicator The Drill Mode Indicator is a two-state indicator located in the second position from the left of the indicator row above the function keys. Its states are as follows: DRILL MODE (yellow background) - This indicator must be ON before any mast operations are allowed. The operating mode selector switch (DPMS) must be in the DRILL position.

NOT IN DRILL MODE (yellow background) - This indicator comes on when mast functions are attempted and the operating mode selector switch (DPMS) is not in the DRILL position. With this indicator on, the mast functions are disabled.

Head Limit Indicator The Head Limit Indicator is a two-state indicator located in the third position from the left of the indicator row above the function keys. Its states are as follows: HEAD AT LOWER LIMIT (yellow background) - This indicator must be ON before any functions related to the pins or operating mast hydraulic functions are allowed. On selected machines, the head is allowed to be above the lower limit by a controlled distance to let the operator lower the mast with stabilizers, shock subs, etc. attached to the drill head.

HEAD NOT AT LOWER LIMIT (yellow background) - This indicator comes on when mast functions are attempted and the head is not at the lower limit. With this indicator on, the mast functions are disabled.

Mast Vertical Switch Indicator (option) The Mast Vertical Switch is a two-state indicator located in the fourth position from the left of the indicator row above the function keys on machines with the angle hole drilling option. Its states are as follows: MAST VERTICAL SWITCH CLOSED (yellow background) - This message indicates that the mast vertical lock switch is in the closed position.

MAST VERTICAL SWITCH NOT CLOSED (yellow background) - This message indicates that the mast lock switch is NOT closed.

A-Frame Pins Indicator (with angle hole option) The A-Frame Pins Indicator is a two-state indicator located in the fifth position from the left of the indicator row above the function keys on machines with the angle hole drilling option. Its states are as follows:

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BOTH A-FRAME LOCK PINS LOCKED (yellow background) - This message indicates that both A-frame lock pins are in the locked position.

BOTH A-FRAME LOCK PINS NOT LOCKED (yellow background) - This message indicates that at least one of the A-frame lock pins is NOT in the locked position.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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2.4.8 Lubrication Screen (Security: User 3) The Lubrication screen (fig. 2-10) is used to set the field adjustable lubrication system parameters.

Access to this screen is controled by a security code, set for User 3. This number should be retained by operating personnel supervision to assure that changes are made consistent with mine operation practices and that lubrication system operation is sufficient for machine operational needs. Refer to the section on Security for information on changing the password.

Figure 2-10 Lubrication Screen Timer Setting To set a timer, use the arrow keys or the <+> key to move the cursor to the desired timer and press <ENTER>. Enter the new setting in the box that pops up. If the new value is not within the acceptable range, a message box will pop up in the middle of the screen with the appropriate range.

If this occurs press the <ENTER> key to clear the box and then enter a new value. The settings are as follows: DRILL MODE INTERVAL TIME - This value controls the time between drill mode lubrication cycles.

PROPEL MODE INTERVAL TIME - This value controls the time between propel mode lubrication cycles.

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VENT PRESSURE FAULT TIME - This value controls the amount of time to wait for pressure to vent after a lubrication cycle has not been completed, before a fault is indicated and recorded.

LOW PRESSURE FAULT TIME - This value controls the amount of time to wait for pressure to build up after a lubrication cycle has started, before a fault is indicated and recorded.

MAST LUBE DIVERTER DROPOUT DELAY - This value controls the amount of time the diverter valve is allowed to remain open after a cycle has finished. This is to accommodate the relieving of pressure in the injector area. This is more of a factor with thick grease or when the pressure switch reset is at a level above that of the injectors.

PIPE THREAD LUBE TIME (option) - This value controls the amount of time lubrication is applied to the pipe thread, whenever a cycle is activated.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be save to an ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called LUBE.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data adds approximately 350 bytes.

Thread Lube Test F7 Function Key (option) Above the F7 key is an indicator indicating the action of the key. Pressing the F7 key toggles the pipe thread lubes test mode. When this test mode is active, the pipe thread lube valve will be energized continuously whenever the drill is in Pipe Rack / Joints mode, bypassing the timer. When active, the text of this indicator is red.

Thread Lube F8 Function Key (option) Above the F8 key is an indicator indicating the action of the key. Pressing the F8 key activates a pipe thread lube cycle for the amount of time specified on this screen. When active, the text of this indicator is red.

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Manual Lube F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key activates a manual lube cycle. It is functional whenever the compressor motor is operating, control power is available, and the lube system is not in an active cycle or faulted. When active, the text of this indicator is red.

Lube Setup F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key toggles the lube setup mode. This mode does two things. First, it performs the same function as holding the manual lube on continuously. Also, this mode disables the lube system low pressure and vent pressure faults. When active, the text of this indicator is red.

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2.4.9 Fault Counters / Operating Hours Screen The Fault Counters / Operating Hours screen (fig. 2-11) shows the accumulated operating hours in various modes of operating, provides running totals for a variety of machine faults, and records a recent history of holes drilled and accumulated drilled depth. This screen can be accessed on from the Main Menu.

Figure 2-11 Fault Counters/Operating Hours Screen Fault Counts As shown in figure 2-11, various fault types are listed which provide maintenance and service personnel with a cumulative fault log of problem areas that may need attention. The time span associated with the accumulated fault counts is displayed in the lower right corner in a box entitled “Drill Operating Hours Since Last Reset.” The accumulation interval can be controlled by resetting the counters to zero at pre-established intervals and keeping records of faults within the established intervals. Pressing F10 Counter Reset resets all fault counters and the “Drill Operating Hours Since Last Reset” to zero. It should be noted that not all faults are mutually exclusive. There will be instances in which a fault may be recorded in more than one fault category.

Machine Operating Hours The hours recorded under this heading represent the total lifetime accumulated machine hours under each of the listed categories. These displays do not reset to zero when the Counter Reset key (F10) is pressed. The values should be retained as long as the processor's battery is intact or this display is functional.

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Lube System Faulted Operation The hours recorded under this heading are the total lifetime accumulated operating hours for drill and propel modes in which the lubrication system was not functioning. Like the Machine Operating Hours, these displays are not reset to zero when the Counter Reset key (F10) is pressed. The values should be retained as long as the processor's battery is intact or this display is functional.

Hole Data The value shown in the Number of Holes Drilled field is the quantity of holes drilled during the interval shown as Drill Operating Hours Since Last Reset. Similarly, the value of Total Feet Drilled (or meters depending on current setting) is the total accumulated drilled depth associated with the Number of Holes Drilled display. Both displays will reset to zero when the Counter Reset key (F10) is pressed. If desired, these values can be reset periodically (e.g., once per shift, once per day, etc.) and used as a comparison to manual records for verification of actual machine performance.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be save to an ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called CNTR_HRS.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 1150 bytes.

Counter Reset F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key resets the Fault Counts and Hole Data to zero as described above. It has no effect on Machine Operating Hours or Lube System Faulted Operation.

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2.4.10 PDC Operating Parameters - 1 Screen (option) The PDC Operating Parameters - 1 (fig. 2-12) screen is only available on drills with the Programmed Drill Control option. This screen is used to set PDC parameters that may vary from hole to hole.

These parameters include Hole Collaring Depth, Hole Total Depth, and Hole Depth with Water Injection. The desired depths are set directly in units of feet or meters, depending on the selected unit setting (see Setup screens). This screen can be accessed be accessed with the PDC Settings <F5> function key on the Operator's screen or through the Main Menu.

Figure 2-12 PDC Operating Parameters - 1 Changing Parameters To change the values, use the arrow keys or the <+> key to move the cursor box to the desired parameter and press the <ENTER> key. Enter the new value in the small box that pops up. If the number is outside the predefined limits, the text will turn red and the appropriate range will appear to the right of the value. A “Setting Out of Range” message may also occur if this is the only setting currently out of range. If a different screen is accessed while out of range data remains, an ANF034 PDC Setting Out of Range fault will be displayed and logged. All parameter values must be within the acceptable range before the PDC controls will be allowed to function. NOTE: The acceptable range of some settings is determined by the current setting of others. Changing one value may result in another value getting out of range.

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Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be saved to an ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called PDC1.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 200 bytes.

PDC Display F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to PDC Operating Display - 1. This display, described elsewhere, can be used to monitor basic machine performance parameters during PDC operation.

Screen 2 F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to PDC Operating Parameters - 2. This screen is described next.

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2.4.11 PDC Operating Parameters - 2 Screen (option) (Security: User 4) The PDC Operating Parameters - 2 (fig. 2-13) screen is only available on drills with the Programmed Drill Control option. This screen allows operations personnel to set the allowable limits on machine performance that are used by the PDC controls during operation. This screen can only be accessed with the F10 key on the PDC Operating Parameters - 1 screen. The units displayed on this screen on contingent upon the current Metric/English setting (see Setup screens). Note that the last parameter on this screen, Bit Spec Pulldown Force Limit, is for reference only and cannot be changed on this screen.

Access to this screen is controlled by a security code, set for User 4. This number should be retained by operating personnel supervision to assure that changes are made consistent with mine operation practices and maintenance practices with regard to bit life, vibration levels, force levels, and established drilling practices. Refer to the section on Security for information on changing the password.

Figure 2-13 PDC Operating Parameters - 2 Changing Parameters To change the values, use the arrow keys or the <+> key to move the cursor box to the desired parameter and press the <ENTER> key. Enter the new value in the small box that pops up. If the number is outside the predefined limits, the text will turn red and the appropriate range will appear to the right of the value. A ”Setting Out of Range” message may also occur if this is the only setting currently out of range. If a different screen is accessed while out of range data remains, an ANF034 PDC Setting Out of Range fault will be displayed and logged. All parameter values must be within the acceptable range before the PDC controls will be allowed to function. NOTE: The acceptable range of some settings is determined by the current setting of others. Changing one value may result 55 SECTION 2 JCV:XI4:96:659

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in another value getting out of range.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be save to a ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called PDC2.DAT. NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 900 bytes.

PDC Display F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to PDC Operating Display - 1. This display, described elsewhere, can be used to monitor basic machine performance parameters during PDC operation.

Screen 1 F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change back to PDC Operating Parameters - 2. This screen was described previously.

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2.4.12 PDC Operating Display - 1 Screen (option) The PDC Operating Display - 1 (fig. 2-14) is used to monitor basic machine performance parameters on machines that include the Programmed Drill Control option.

Figure 2-14 PDC Operating Display - 1 This screen can be accessed with the F9 key on either of the PDC Operating Parameters screens or from the Main Menu. The units displayed on this screen are contingent upon the current Metric/English setting (see Setup screens).

Performance Parameter Data The data listed on this screen includes actual performance data on the following: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Rotary motor current and speed Hoist/Pulldown motor current and speed Hoist/Pulldown force and rate Bailing air pressure Horizontal and vertical vibration Water injection (grayed out on machines without this option) Hole depth Head position Rotary motor I2T ratio Hoist/Pulldown motor I2T ratio

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This data is useful for checking machine performance during PDC operation and provides reference figures when determining where to set control parameters.

PDC Regulator Status Indicators During machine operation with the PDC system functional, a variety of regulators may operate to keep the machine performance within the pre-established boundaries. As each regulator comes on, a message will appear on the screen in the PDC Regulator Status column. These are from top to bottom: 1.

2.

3.

4.

5.

6.

7.

Bit specification limiter (Bit Spec) Pulldown force limiter (Pulldown Force) Horizontal vibration Vertical vibration Bailing air pressure (Air Pressure) Rotary motor heating ratio (Rotary I Sq. T) Hoist/Pulldown motor heating ratio (Hoist/PD I Sq. T)

The phrase in parentheses is the actual text that appears on the screen. During normal operation, there will be no indication.

Drilling Status Indicators While drilling under PDC control, the system may be in one of the several operating conditions. As each condition occurs, a message will appear on the screen in the Drilling Status column. These are from top to bottom: 1.

2.

3.

4.

5.

PDC operating (PDC On) Bit at bottom of hole position (Bit on Bottom) System at end of hole condition (End of Hole) Head assembly raising (Hoisting) System in collaring operation (Collaring)

The phrase in parentheses is the actual text that appears on the screen. These messages will only appear when the PDC system is in control. Otherwise, there will be no indications.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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PDC Settings F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to PDC Operating Parameters - 1. This display, described elsewhere, can be used to set PDC operation parameters.

Screen 2 F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to PDC Operating Display - 2. This screen is described next.

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2.4.13 PDC Operating Display - 2 Screen (option) The PDC Operating Display - 2 (fig. 2-15) is used to monitor internal details of the PDC regulators on machines that include the Programmed Drill Control option. Usually, the various values on this screen will only be used in advanced troubleshooting and/or in system check by Bucyrus-Erie service personnel. This screen can only be accessed with the F10 key on the PDC Operating Display - 1 screen. The units displayed on this screen on contingent upon the current Metric/English setting (see Setup screens).

Figure 2-15 PDC Operating Display - 2 Performance Parameter Data The data listed on this screen includes actual performance data on the following: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Rotary motor current error Bailing air pressure error Horizontal vibration error for rotary Horizontal vibration error for pulldown Vertical vibration error Pulldown motor current error Total error for rotary Total error for pulldown Rotary bit speed reference Pulldown rate reference

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11.

12.

Rotary control value Pulldown control value.

PDC Regulator Status Indicators During machine operation with the PDC system functional, a variety of regulators may operate to keep the machine performance within the pre-established boundaries. As each regulator comes on, a message will appear on the screen in the PDC Regulator Status column. These are from top to bottom: 1.

2.

3.

4.

5.

6.

7.

Bit specification limiter (Bit Spec) Pulldown force limiter (Pulldown Force) Horizontal vibration Vertical vibration Bailing air pressure (Air Pressure) Rotary motor heating ratio (Rotary I Sq. T) Hoist/Pulldown motor heating ration (Hoist/PD I Sq. T)

The phrase in parentheses is the actual text that appears on the screen. During normal operation, there will be no indication.

Drilling Status Indicators While drilling under PDC control, the system may be in one of the several operating conditions. As each condition occurs, a message will appear on the screen in the Drilling Status column. These are from top to bottom: 1.

2.

3.

4.

5.

PDC operating (PDC On) Bit at bottom of hole position (Bit on Bottom) System at end of hole condition (End of Hole) Head assembly raising (Hoisting) System in collaring operation (Collaring)

The phrase in parentheses is the actual text that appears on the screen. These messages will only appear when the PDC system is in control. Otherwise, there will be no indications.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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PDC Settings F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to PDC Operating Parameters - 1. This display, described elsewhere, can be used to set PDC operation parameters.

Screen 1 F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change back to PDC Operating Display - 1. This screen was described previously.

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2.5 Test and Status Screens 2.5.1 Introduction The screens discussed in this section are used in troubleshooting, machine setup (field and factory levels) and maintenance procedures. Machine operators will not normally access these screens unless assisting in one of the aforementioned procedures.

Collectively, these screens allow access to a significant amount of information pertaining to input/output status, internal setting values, PLC operation status, predefined test modes, and machine operational status. The screens are used in conjunction with the “Troubleshooting and Setup” section of the electrical X-instructions.

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2.5.2 PLC Bit Display Screen The PLC Bit Display screen (fig. 2-16) is used to observe PLC bit level data for inputs, outputs, and selected internal processor operations.

Figure 2-16 PLC Bit Display Screen This screen is accessible from the Main Menu or by pressing the F10 key on the PLC Word/Bit Display screen or the PLC Timer/Counter Display screen. Up to eight sixteen-bit words can be observed on this screen for a total of 128 simultaneous status indicators. Above the first row of bits are column labels from 0 through 15 for internal word bits. Below the last row of bits are column labels from 0 to 7 and 10 to 17 for input/output address references, which are indicated in octal. Alternate rows have different color backgrounds to assist in keeping track of the bit patterns of different words.

Data Entry To display a bit string, first determine the address of the word that is desired. This can come from the schematic page, software printout, C-sheet, etc. The address is in the form “Xff:ww/bb”, where “X” is a letter indicating the file type, “ff” is the file number, “ww” is the word number, and “bb” is the bit number (this bit reference may or may not be shown). Since the industrial PC does not contain a full keyboard, the file type letter is dropped when entering addresses. Once the desired address is determined, use the following steps to display the word bit string on the screen: 64 SECTION 2 JCV:XI4:96:658

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1.

Use the arrow keys or the <+> key to move the cursor to the address entry point on the desired line.

2.

Press the <ENTER> key.

3.

Enter the file number and the word number separated by a colon, as in “ff:ww”.

(The colon is made with the <=> key). Press the <ENTER> key.

4.

The entire bit string is now displayed with the most significant bit to the left. Note: On this screen the bit is not entered, since the entire bit string is displayed. An individual bit on an individual I/O point can be found by referencing the appropriate column as labeled either on the top or the bottom (described above).

5.

If additional words need to be observed, follow the above step for a different input line.

NOTE: Bit data in the format “Bff/bb" (e.g., B3/245) must be converted to a file and word format (B3:15/5) before it can be observed properly on the PLC Bit Display Screen. This screen can only display an entire word worth of data bits and not an individual bit. Entering data in the wrong format will give erroneous readings. Refer the electrical X-instruction PLC Theory Section for information on the format conversion process. It is suggested that if individual bits of a “B” file are desired, the PLC Word/Bit Display screen can be used to display the individual bits without format conversion.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Word Value F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to the PLC Word/Bit Display screen. See the screen description, elsewhere.

Timer/Counter F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to the PLC Timer/Counter Display screen. See the screen description, elsewhere.

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2.5.3 PLC Word/Bit Display Screen The PLC Word/Bit Display screen (fig. 2-17) is used to observe PLC word data in an integer format or in 0/1 format for bit data. This screen is accessible from the Main Menu or by pressing the F9 key on the PLC Bit Display screen or the PLC Timer/Counter Display screen. Up to eight words can be displayed simultaneously.

Figure 2-17 PLC Word/Bit Display Screen Data Entry To display a word value or individual bit, first determine the address of the word that is desired.

This can come from the schematic page, software printout, C-sheet, etc. For a full word, the address is in the form “Xff:ww”, where “X” is a letter indicating the file type, “ff” is the file number, “ww” is the word number. For an individual bit of a word, the form is “Xff:ww/bb” where “bb” is the bit number. In the case of bit files the format will be “Bff/bb”. Since the industrial PC does not contain a full keyboard, the file type letter is dropped when entering addresses. Once the desired address is determined, use the following steps to display the word bit string on the screen.

1.

Use the arrow keys or the <+> key to move the cursor to the address entry point on the desired line.

2.

Press the <ENTER> key.

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3.

To display an entire word value, enter the file number and the word number separated by a colon, as in “ff:ww”. (The colon is made with the <=> key). To display an individual bit, use a dot as the separator for the bit, as in "ff:ww.bb" for an individual bit of a word or “ff.bb” for “B” files. Press the <ENTER> key.

4.

The word or bit value is now displayed.

5.

If additional words need to be observed, follow the above step for a different input line.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen, elsewhere.

Timer/Counter F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to the PLC Timer/Counter Display screen. See the screen description, elsewhere.

Bit Display F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to the PLC Bit Display screen, described elsewhere.

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2.5.4 PLC Timer/Counter Display Screen The PLC Word/Bit Display screen (fig. 2-18) is used to observe PLC preset and accumulated values for timers and counters. This screen is accessible from the Main Menu or by pressing the F9 key on the PLC Word/Bit Display screen or the F10 key on the PLC Bit Display screen. Up to eight timer’s and/or counters can be displayed simultaneously.

Figure 2-18 PLC Timer/Counter Display Screen Data Entry To display the timer or counter's data, first determine the address of the timer or counter that is desired. This can come from the software printout, C-sheet, etc. The address is in the form “Xff:ww”, where “X” is a letter indicating the file type (either “T” or “C”), “ff” is the file number, and “ww” is the word number. Since the industrial PC does not contain a full keyboard, the file type letter is dropped when entering addresses. Once the desired address is determined, use the following steps to display the word bit string on the screen.

1.

Use the arrow keys or the <+> key to move the cursor to the address entry point on the desired line.

2.

Press the <ENTER> key.

3.

Enter the file number and the word number separated by a colon, as in “ff:ww”.

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(The colon is made with the <=> key). Press the <ENTER> key.

4.

The data for the timer or counter is now displayed in the Preset and Accumulator columns.

5.

If additional timers or counters need to be observed, follow the above step for a different input line.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Word Value F9 Function Key Above the F9 key is an indicator indicating the action of the key. Pressing the F9 key causes the display to change to the PLC Word/Bit Display screen, described elsewhere.

Bit Display F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to the PLC Bit Display screen, described elsewhere.

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2.5.5 Test Display - 1 Screen The Test Display - 1 screen (fig. 2-19) is used to observe the integer numbers that are used internal to the PLC to represent analog input and output signals. This screen is accessible either from the Main Menu or by pressing <F10> on Test Display - 2.

Figure 2-19 Test Display - 1 This screen is split into two sections. The top section, labeled “Analog Input Signals”, contains all the active analog input signals that are used on the machine. A value of ±4095 represents the maximum signal received by the particular analog input channel. The external input that corresponds to the ±4095 number can be ±10VDC, ±5VDC, or 4-20mA. The bottom section of the screen, labeled “Analog Output Signals”, contains all the active analog output signals that are used on the machine. A digital value of ±4095 represents the maximum signal that can be generated by the analog output card. In all cases, the maximum output voltage that corresponds to ±4095 is ±10VDC. Details on specific scaling for both inputs and outputs can be found in the software documentation, C-sheets, and/or machine schematics.

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Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Test Display - 2 F10 Function Key Above the F10 key is an indicator indicating the action of the key. Pressing the F10 key causes the display to change to the Test Display - 2 screen, described next.

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2.5.6 Test Display - 2 Screen (Security: User 5) The Test Display - 2 screen (fig. 2-20) is used for shop and field drive setup, test and troubleshooting. This screen is accessible only by pressing <F10> on Test Display - 1.

Access to this screen is controlled by a security code, set for User 4. This number should be retained by maintenance supervision and screen access restricted to qualified electrical personnel only. Refer to the section on Security for information on changing the password.

Figure 2-20 Test Display - 2 Numeric Displays This screen contains a series of numeric displays that are calibrated and labeled in engineering units. The following data is provided by the display for both the rotary and hoist/pulldown motors: 1.

2.

3.

4.

5.

Motor Armature Voltage (DC volts) Motor Armature Current (DC amps) Motor Field Current (DC amps) Motor Speed (rpm) Motor Torque (ft-lbs or N-m)

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Additionally, the air compressor's oil and air temperatures are displayed in degrees F or C. There may also be special displays included on a customized basis.

Rotary Mode Indicator The rotary mode indicator is a five-state indicator located in the left most position of the indicator row above the setup/test function keys. Its states are as follows: ROTARY OFF (blue background) - This message indicates that the rotary drive is not energized.

The machine is in PROPEL mode or the machine power is OFF. ROTARY LOW (yellow background) - This message indicates that the rotary drive is active in the LOW speed range.

ROTARY MEDIUM (yellow background) - This message indicates that the rotary drive is active in the MEDIUM speed range.

ROTARY HIGH (yellow background) - This message indicates that the rotary drive is active in the HIGH speed range.

ROTARY POWER ON (flashing) - This message indicates that the rotary drive is in a condition whereby the input power contactor has closed during the startup sequence by the armature controls have not been released. This is normal in a drive SETUP mode of operation. This indication will also occur in conjunction with an ANF067 Rotary Incomplete Sequence Fault.

Hoist/Pulldown Mode Indicator The hoist/pulldown mode indicator is a six-state indicator located in the second position from the left of the indicator row above the setup/test function keys. Its states are as follows: HOIST PULLDOWN OFF (blue background) - This message indicates that the hoist/pulldown drive is not energized. The machine is in the PROPEL mode or the machine power is off.

HOIST LOW (yellow background) - This message indicates that the hoist/pulldown drive is active in the HOIST LOW speed range for pipe handling or hoisting operation.

HOIST HIGH (yellow background) - This message indicates that the hoist/pulldown drive is active in the HOIST HIGH speed range for pipe handling or hoisting operation.

PIPE JOINTS (yellow background) - This message indicates that the hoist/pulldown drive is active in the PULLDOWN operating mode for normal drilling operation.

HOIST/PD POWER OFF (flashing) - This message indicates that the hoist/pulldown drive is in a condition whereby the input power contactor has closed during the startup sequence but the 73 SECTION 2 JCV:XI4:96:658

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armature controls have not been released. This is normal in a drive SETUP mode of operation This indication will also occur in conjunction with an ANF068 Hoist/Pulldown Incomplete Sequence Fault indication.

Head Brake Indicator The head brake indicator is a two-state indicator located in the third position from the left of the indicator row above the setup/test function keys. Its states are as follows: HEAD BRAKE SET (blue background) - This message indicates that the electric head brake is not active. The spring-set mechanism should be holding the head assembly stationary.

HEAD BRAKE RELEASED (yellow background) - This message indicates that the hoist/pulldown drive is active, the hoist brake control switch is in the RELEASE position, the electric brake has been energized, and that any two of the three feedback switches inside the brake assembly indicate brake release.

NOTE: The hoist/pulldown drive can be active without the head brake being released. Under this circumstance, the drive will not be allowed to produce current in the hoist/pulldown motor.

Air Compressor Indicator The air compressor indicator is a two-state indicator located in the right most of the indicator row above the function keys. Its states are as follows: AIR COMP. OFF (blue background) - This message indicates that the main compressor motor is not energized.

AIR COMP. ON (yellow background) - This message indicates that the main compressor motor is operating.

Motion Drive Test Functions In normal operation, pressing the console DRILL/PROPEL CONTROL ON push-button initiates a PLC controlled sequence that applies power to the drives, waits for field current to build, releases drive controls, and eventually releases drive speed references. This action is automatic and cannot be altered unless a problem is sensed or a manually initiated stop sequence is activated by the operator. In order to set drive parameters, calibrate certain signals, and perform some troubleshooting steps, it is necessary to place the drives in a condition where input power is applied but the controls are no released. Furthermore, it is necessary to be able to stall the drives in a controlled manner (i.e., operate without field current) in order to verify proper operation and setup. It may also be necessary to keep control logic active in case signal tracing needs to be completed. Test functions Setup F7, Stall F8, and Bypass F9 provide these capabilities. Refer to the Setup and Troubleshooting sections of the electrical X-instructions for further details on using the test modes. If field current levels are being adjusted, the Field Economizing circuit of the drive under test should be disabled.

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PRETEST REQUIREMENTS - In order to be allowed to activate any of the test modes, several conditions must first be met. These include the following: 1.

2.

3.

4.

5.

6.

7.

No PLC rack I/O fault conditions may exist.

No latched fault condition can exist that would prevent the drive from restarting.

The console operating mode selector switch must be in the DRILL position.

The compressor motor must be OFF. The emergency stop contactor must be CLOSED (i.e., no emergency stop). There cannot be an active ANF042 Emergency Stop Activated Fault displayed.

No system level stop sequences can be active and control/power inputs must be normal.

Both the hoist/pulldown and the rotary drive input power contactors must initially be OFF.

The following section describes the operation of each of the three tests.

Setup F7 Function Key If all the pretest requirements have been satisfied and the Test Display - 2 screen is active, pressing the F7 function key will activate the drive setup test logic.

NOTE: Only one test mode can be active at a time. If either of the other modes is active, the drive setup test will not be allowed to release.

When the setup mode is active, the indicator light above the function key button will come on. At this point, the compressor start logic is disabled to prevent startup of the compressor motor.

WARNING: To minimize potential test problems, the input power disconnect switch for the drive not under test should be left open.

To actually start the test, press the DRILL/PROPEL CONTROL ON push-button, located on the operator's console. This will energize the input power contactors for the drives. The drive with its input power disconnect switch open will indicate an input power fault. This is normal and expected under these test conditions. When the New Alarm screen (described elsewhere) pops up, press the Exit Alarms F8 key and continue with the test.

When power is put onto the drive under test, the respective “Power On” indicator will be flashing.

Under this operating condition, the drive under test has input power applied, the respective DC motor blower is operating, the motor field power circuit is functional, and the speed control is released. The motor field level will respond to the console switch and the speed reference will track the master switch setting directly without any other logic related restrictions.

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NOTE: The hoist/pulldown drive speed reference range will be a function of the hoist/pulldown rate selector switch setting. Leave the switch in the HOIST LOW or the HOIST HIGH position to obtain maximum speed reference range.

The armature circuit for the drive is disabled by not allowing the respective drives' Αrun≅ relay to energize. Under these operating conditions, the following procedures can be carried out: 1.

2.

3.

4.

5.

6.

Drive parameters can be set or changed.

The drive field current sensor can be calibrated.

Drive speed references can be verified and the input isolator calibrated.

Drive motor field operating values can be adjusted or checked.

Drive motor field overcurrent/undercurrent sensing circuitry can be checked.

Steady state voltage levels can be verified in the drive controls.

Upon completion of testing, reset any drive parameters that may have been disabled and then press the console DRILL/PROPEL CONTROL OFF push-button. This automatically stops the drive under test and unlatches the Setup F7 test mode. In addition, leaving the Test Display - 2 screen during an active test condition will stop the drive and unlatch the test mode. If no further testing is to be done, close the non-tested drive's input disconnect switch before resuming machine operation.

Stall F8 Function Key If all the pretest requirements have been satisfied and the Test Display - 2 screen is active, pressing the F8 function key will activate the drive stall test logic.

NOTE: Only one test mode can be active at a time. If either of the other modes are active, the drive setup test will not be allowed to release.

When the stall mode is active, the indicator light above the function key button will come on. At this point, the compressor start logic is disabled to prevent startup of the compressor motor.

WARNING: To minimize the potential for motor damage, the input power disconnect switch for the drive not under test should be left open. This will eliminate the chance of inadvertently running stall current in one motor while performing tests on the other motor/drive system.

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WARNING: Keep the time in actual stall operation at a minimum to reduce the chance of causing damage to the motor. Refer to the Setup and Troubleshooting sections of the electrical X-instructions.

To actually start the test, press the DRILL/PROPEL CONTROL ON push-button, located on the operator's console. This will energize the input power contactors for the drives. The drive with its input power disconnect switch open will indicate an input power fault. This is normal and expected under these test conditions. When the New Alarm screen (described elsewhere) pops up, press the Exit Alarms F8 key and continue with the test.

When the drive under test in energized, one of the operating status message indicators will be displayed. If the rotary drive is under test, either the “Rotary Low”, “Rotary Medium”, or “Rotary High” message will activate, depending on the setting of the rotary speed selector switch.

If the hoist/pulldown drive is under test, either the “Hoist Low”, “Hoist Height”, “Pipe Joints”, or “Pulldown” message will activate, depending on the setting of the hoist pulldown rate selector switch. One second after the respective drives' status indicator comes on, the corresponding master switch can be moved out of NEUTRAL to generate armature current. Regardless of what the drive status indicator states, no field current will actually be generated because the field reference has been automatically set to zero as part of the test mode. Concurrently, the appropriated field loss sense circuitry has been defeated.

NOTE: If the hoist/pulldown drive is being tested, the hoist brake switch must be placed in the RELEASE position in order to allow the armature current to be generated. The head brake will not release in the test mode and the brake fault logic will not indicate a fault.

Upon completion of testing, press the console DRILL/PROPEL CONTROL OFF push-button.

This action automatically stops the drive under test and unlatches the Stall F8 test mode. In addition, leaving the Test Display - 2 screen during an active test condition will stop the drive and unlatch the test mode. Before resuming normal machine operation, make sure that any drive parameters that were changed and/or disabled for test purposes are reset to their normal running values. This may necessitate going back to the Setup F7 test mode. Also, make sure that the input disconnect on the non-tested drive is placed in the closed position.

Bypass F9 Function Key If all the pretest requirements have been satisfied and the Test Display - 2 screen is active, pressing the F9 function key will activate the drive bypass test logic.

NOTE: Only one test mode can be active at a time. If either of the other modes is active, the drive setup test will not be allowed to release.

When the bypass mode is active, the indicator light above the function key button will come on.

At this point, the compressor start logic is disabled to prevent startup of the compressor motor.

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NOTE: The input power disconnect switch for the drive not under test can be left open if desired. However, it is not necessary to do so for this test sequence.

Before starting the actual bypass test, the master switch for the drive being tested must be in NEUTRAL. To activate the test, press the console DRILL/PROPEL CONTROL ON pushbutton. This energizes the input power contactors for the drive.

The drive with its input power disconnect switch open will indicate an input power fault. This is normal and expected under these test conditions. When the New Alarm screen (described elsewhere) pops up, press the Exit Alarms F8 key and continue with the test.

When the drive under test in energized, one of the operating status message indicators will be displayed. If the rotary drive is under test, either the “Rotary Low”, “Rotary Medium”, or “Rotary High” message will activate, depending on the setting of the rotary speed selector switch.

If the hoist/pulldown drive is under test, either the “Hoist Low”, “Hoist Height”, “Pipe Joints”, or “Pulldown” message will activate, depending on the setting of the hoist pulldown rate selector switch.

For the drive under test, the field current is set to zero and the drive speed reference is held to zero to insure that no powered movement can take place. In the case of the hoist/pulldown drive, the head brake is not allowed to release.

Under these operating conditions, the following drive fault will be indicated but the drive shutdown logic will be bypassed to allow checking signals and interfaces that may be contributing to the fault such as: 1.

2.

3.

Input power fault Blower control fault Incomplete sequence

The logic is designed to hold the starting sequence at the point of the actual fault. Logic conditions that occur after the fault will not be satisfied until the fault is eliminated.

Upon completion of testing, press the console DRILL/PROPEL CONTROL OFF push-button.

This action automatically stops the drive under test and unlatches the Bypass F9 test mode. In addition, leaving the Test Display - 2 screen during an active test condition will stop the drive and unlatch the test mode. Before resuming normal machine operation, make sure that any drive parameters that were changed and/or disabled for test purposes are reset to their normal running values. This may necessitate going back to the Setup F7 test mode. Also, make sure that the input disconnect on the non-tested drive is placed in the closed position.

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Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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2.5.7 Hydraulic/Electrical Field Tests Screen (Security: User 7) The Hydraulic/Electrical Field Tests Screen (fig. 2-21) is used for field testing of electrical and hydraulic functions. This screen can only be accessed from the Main Menu.

Figure 2-21 Hydraulic/Electrical Field Tests Screen Access to this screen is controlled by a security code, set for User 4. This number should be retained by maintenance supervision and screen access restricted to qualified electrical personnel only. Refer to the section on Security for information on changing the password.

Any given test can be activated by pressing the associated function key. If desired, multiple tests can occur simultaneously; however, all tests terminate by pressing the Test Off F20 function key or by leaving the screen.

Each test is defined on the screen. In each case, the respective function is energized and actual system operation will depend on the status of the support systems (i.e., hydraulic pumps ON, control power ON, etc.). The following describes each of the tests: Test 1 F11 Function Key Pressing the F11 function key initiates Test 1 which energizes the Main Flow Valve.

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Test 2 F12 Function Key Pressing the F12 function key initiates Test 2 which energizes the Jack Loader Valve.

Test 3 F13 Function Key Pressing the F13 function key initiates Test 3 which energizes the Propel Active Valve.

Test 4 F14 Function Key Pressing the F14 function key initiates Test 4 which performs the following: 1.

Output O:12/10 is energized to turn on RLY-1 on EHTCM if the mode switch is in the DRILL position.

2.

The Jack Loader Valve (JLV) is disabled.

This test is used to verify certain hydraulic interactions that are normally not allowed as part or regular machine operation. Refer to the mechanical maintenance documentation to determine the details of when to perform this test.

Test 5 F15 Function Key Pressing the F15 function key initiates Test 5 which is used to setup the proportional hydraulic control cards or test pipe rack valve controls. The following actions take place during this test: 1.

Output O:12/13 is energized to turn on relay MRVR if in the MAST mode or output O:12/12 is energized to turn on relay WCVR if in the WINCH mode. (The drill must be in the DRILL mode and RLY-1 on EHTCM must be energized for either action to occur.)

2.

Output O:12/11 is energized to turn on relay PRPVR if RLY-1 on EHTCM is energized.

3.

The head is simulated as being at the rack limit point to allow testing of pipe rack logic.

4.

The air compressor motor is disabled to insure that only circuit logic will be tested.

Test 6 F16 Function Key Pressing the F16 function key initiates Test 6 which activates the self test feature of the hydraulic oil tank level sensor on machines with this feature.

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Test 7 F17 Function Key Pressing the F17 function key initiates Test 7 which disables the underspeed/overspeed sense circuits on machines with the water injection option. It also removes some of the interlocks so the water injection system can be tested independent the air compressor. This facilitates water injection setup.

2.6 Alarms and Logging 2.6.1 Introduction This display serves as a means of informing its users when various alarm or fault conditions appear. It also records these alarms, faults, and events to a removable PC card, so that mine supervision can keep a record of machine operation. Whenever a new alarm occurs, a number of things happen. First, a pop up window overwrites the bottom half of the screen and an audible warning sounds. This New Alarms window, described below, lists up to five new alarms. At the same time, the alarm text is written to an ASCII file on the PC's internal drive and copied to the removable card. When the operator acknowledges the fault by leaving closing the pop up window, this time and date are also recorded. Other screens allow a user to see currently active alarms, the alarm history, and a list of all possible alarms along with their current state. These features are described below. Disk management is described in the Setup section of this manual.

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2.6.2 New Alarms Window Whenever a new alarm condition occurs, the New Alarms window (fig. 2-22) pops up and covers the lower portion of the active window. This display shows up to five new alarms.

Figure 2-22 New Alarms Window If there are less than five, only the new alarms are displayed. If there are more than five new alarms, the Active Alarms screen (F9) can be used to display all. An audible alarm will also occur when this window opens, unless that function has been disabled (see the Setup section).

Alarm List The alarm box, which takes up most of this window, lists the faults in reverse chronological order (i.e., most recent on bottom). For each entry, the date and time of the alarm's occurrence are shown in the first two fields in the formats specified in the Setup screens. The third field shows the event, which is this case will always by ALM or “alarm”. The next field gives a verbal description of the alarm and the right field gives its name or ANF number. This ANF number is an index which can be used to identify a fault to Bucyrus-Erie personnel absolutely.

When this window is shown, the user can press any of the following function keys: Silence Alarm F7 Function Key If a user wishes to read the contents of this screen without the alarm sounding, the F7 key can be pressed to silence the alarm. Leaving this window (with F8, F9, or F10) also silences the audible alarm.

Exit Alarms F8 Function Key Pressing the F8 function key closes the New Alarms Window, silences the audible alarm, and returns the display to the same screen that was shown when the alarm occurred. When this key is pressed, all of the new alarms are simultaneously acknowledged with a message in the log file.

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Active Alarms F9 Function Key Pressing the F9 function key changes the display to the Active Alarms screen, described below, and silences the audible alarm. When this key is pressed, all of the new alarms are simultaneously acknowledged with a message in the log file. The Active Alarms screen can be used to view all the alarms that are currently active or latched.

Alarm History F10 Function Key Pressing the F10 function key changes the display to the Alarm History screen, described below and silences the audible alarm. When this key is pressed, all of the new alarms are simultaneously acknowledged with a message in the log file. The Alarm History screen can be used to view all recent alarms and events or extract certain ones for group viewing.

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2.6.3 Active Alarms Screen The Active Alarm screen (fig. 2-23) is used to display all currently active fault conditions and fault indications that have previously taken place but have not been reset by pressing the Fault Reset key (F3) on the Operator's Display.

The Active Alarms screen can be accessed from the Main Menu, the Operator's Display (F1), the New Alarms window (F9), the Alarm History screen (F10), and the All Alarms screen (F9). Up to 14 active alarms can be displayed at one time. If more alarms are active, pressing the PAGE DOWN key on the keypad to the right of the screen can be used to scroll to the next page of alarms. The PAGE UP key can be used to scroll back.

Figure 2-23 Active Alarms Screen Alarm List The alarm box, which takes up most of this window, lists the faults in reverse chronological order (i.e., most recent on bottom). For each entry, the date and time of the alarm's occurrence are shown in the first two fields in the formats specified in the Setup screens. The third field shows the event, which is this case will always by ALM or Αalarm≅. The next field gives a verbal description of the alarm and the right field gives its name or ANF number. This ANF number is an index which can be used to identify a fault to Bucyrus-Erie personnel absolutely.

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impending problems, and actual component/system failures. If the fault messages are not resettable and/or repeat often, appropriate maintenance personnel need to be advised. As much information as possible on machine symptoms and fault codes should be recorded to aid the troubleshooting process.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

All Alarms F9 Function Key Pressing the F9 function key changes the display to the All Alarms screen, described below. The All Alarms screen can be used to the text and state of all alarms that may occur.

Alarm History F10 Function Key Pressing the F10 function key changes the display to the Alarm History screen, described below.

The Alarm History screen can be used to view all recent alarms and events or extract certain ones for group viewing.

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2.6.4 Alarm History Screen The Alarm History screen (fig. 2-24) is used to display the history of recent (last 30 days) fault.

This screen can be accessed from the Main Menu, the Operator's Display (F2), the New Alarms window (F10), the Active Alarms screen (F10), and the All Alarms screen (F10). When this screen is first accessed, the alarm history is compiled by combining all existing log files on the internal drive. This takes a few seconds or longer depending on the number and size of files. The screen blanks for a moment as the screen reports the name of each file that it is adding. When the screen comes back, the “Please Wait” message will disappear and the history can be viewed.

Figure 2-24 Alarm History Screen Message List The message box, which takes up most of this window, lists the events in reverse chronological order (i.e., most recent on bottom). For each entry, the date and time of the alarm's occurrence are shown in the first two fields in the formats specified in the Setup screens. The third field shows the event. ALM (alarm) implies that the line shows the time that the alarm became active.

This line would be in red. RTN (return to normal) implies that the line shows the time that the fault quit being active. This line would be in green. ACK (acknowledge) implies that the line shows the time that the operator saw the alarm and left the New Alarms screen. This line would be in blue. The fourth field gives a verbal description of the alarm and the right field gives its name or ANF number. This ANF number is an index which can be used to identify a fault to Bucyrus-Erie personnel absolutely.

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Seven messages are displayed per page. Pressing the PAGE DOWN key on the keypad to the right of the screen can be used to scroll to the next page of alarms. The PAGE UP key can be used to scroll back. The most recent messages are at the bottom of the list. Either move the cursor to the Bottom of List indicator and press <ENTER>, or press the <END> key on the keypad to see the latest entries. To return to the top (oldest entries), either move the cursor to the Top of List indicator and press <ENTER>, or press the <HOME> key on the keypad.

Extract String The Extract String indicator allows a user to perform a search of the entire history file for all occurrences of a particular word or phase. This option is designed for advance searches and troubleshooting only. In most instances, it is much easier to use the Extract ANF indicator, described next. To use Extract String, use the arrow keys or the <+> key to the Extract ANF indicator and press <ENTER>. In the entry window that pops up, enter the string for which to search. This can be done by activating the cursor with the <+> key and then using either the arrow keys or the <+> key to move to a given letter and press the <ENTER> key to put that letter into the string. Repeat the process by again activating the cursor with the <+>, until the entire word or phase has been spelled out. Then, move the cursor to “OK” and press <ENTER> to initiate the search.

NOTE: Depending on the size and quantity of the fault files, this search can take quite a while.

Make sure you have the time, since there is no way to stop the search once it has begun.

While the search is being performed, the status is reported in the information box that appears on top of the display. On the bottom, it lists the number of lines that have currently been searched and the number of lines that have been found matching the desired fault.

Once the search is complete, the list of all lines involving the selected fault is displayed. To see other pages, use the same keys that were described for the full list.

Extract ANF The Extract ANF indicator allows a user to perform a search of the entire history file for all instances of a particular fault. To use this indicator, use the arrow keys or the <+> key to the Extract ANF indicator and press <ENTER>. In the entry window that pops up, enter the number porting of the fault index. For example, to see all occurrence of ANF045, enter “045” and press the <ENTER> key to initiate the search.

NOTE: Depending on the size and quantity of the fault files, this search can take quite a while.

Make sure you have the time, since there is no way to stop the search once it has begun.

While the search is being performed, the status is reported in the information box that appears on top of the display. On the bottom, it lists the number of lines that have currently been searched and the number of lines that have been found matching the desired fault.

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Once the search is complete, the list of all lines involving the selected fault is displayed. To see other pages, use the same keys that were described for the full list.

View All Once a search has been performed, using the View All indicator will return to the initial display showing the entire history. This will show immediately without the need to recompile. To use this option, move the cursor with the arrow keys or the <+> key to View All and press the <ENTER> key.

Last Search The most recent search is stored in memory. If a search has been performed and then the screen is closed or either the View All or Refresh indicators have been pushed, this indicator will redisplay the information from that search. This eliminates the need to wait for the search to be performed again. Note that any new alarms that have occurred since the search will not be included in this display. To use this option, move the cursor with the arrow keys or the <+> key to Last Search and press the <ENTER> key.

Refresh Because the history function combines existing files for display, alarms which occur while this screen is active are not added to the displayed history. To display these alarms, use the Refresh key. This will perform the same operation that happens when the screen is first activated. To use this option, move the cursor with the arrow keys or the <+> key to Refresh and press the <ENTER> key.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

All Alarms F9 Function Key Pressing the F9 function key changes the display to the All Alarms screen, described below. The All Alarms screen can be used to the text and state of all alarms that may occur.

Active Alarms F10 Function Key Pressing the F10 function key changes the display to the Active Alarms screen, described above.

The Active Alarms screen can be used to view all the alarms that are currently active or latched.

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2.6.5 All Alarms Screen The All Alarms screen (fig. 2-25) is used to display a listing of all available fault messages and their current state. It is important to realize that not all messages shown are active on any given machine. Certain options may not be included on each drill, but their alarm message and state (always OFF) will be displayed on this screen.

Figure 2-25 All Alarms Screen The Active Alarms screen can be accessed from the Main Menu, the Alarm History screen (F9), and the Active Alarms screen (F9). Twenty messages are displayed at once. To see other messages, scroll to other pages by pressing the PAGE DOWN key or the PAGE UP key on the keypad to the right of the screen. The messages are in numerical order of their ANF number and an indicator in the bottom right corner of the list displays the current page.

Each message listing starts with the alarms ANF number, which is an index to be used to identify a fault to Bucyrus-Erie personnel absolutely. Next comes the current state of that alarm. If the alarm is active or not reset, this will say ON and the entire line will be displayed in red.

Otherwise, the status will say OFF and the entire line will be in blue. The rest of the line shows the text of the actual alarm message.

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Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be save to an ASCII text file on the removable flash card. The time and date will be saved immediately before the data. This data will be stored in a file called ALMSTAT.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 5400 bytes.

Active Alarms F9 Function Key Pressing the F9 function key changes the display to the Active Alarms screen, described above.

The Active Alarms screen can be used to view all the alarms that are currently active or latched.

Alarm History F10 Function Key Pressing the F10 function key changes the display to the Alarm History screen, described below.

The Alarm History screen can be used to view all recent alarms and events or extract certain ones for group viewing.

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2.6.6 Fault Logging File Naming Whenever a fault or alarm occurs, the text of that fault is immediately saved to a file on the internal disk emulator and copied to the removable flash card. This file is in the form: YYMMDD00.ALG Where: YY MM DD

The last two digits of the current year The month The day

For example, faults occurring on April 2, 1996 would be stored in the file “96040200.ALG”, and December 19, 1996 would be stored in the file “96121900.ALG”. This file is created once a day or when the PC records its first event of the day.

File Storage and Disk Space The files are saved for 30 days on the internal disk and indefinitely on the removable flash. To manage these files, see the section on the System/Disk Utilities in Setup. When an alarm returns to normal (RTN) or when a user leaves the New Alarms window (ACK) the event is immediately logged to the internal drive and copied to the removable flash within the hour.

The standard flash card has 1.8MB of space, which corresponds to approximately 23,500 entries.

Remember that each time data files are saved (as in the case of the F3 key on the Lubrication screen, the Fault Counters screen, etc.) some additional space is used up. When the disk has less than 20% free space a message will pop up in the middle of the screen, suggesting that the card be changed soon (fig. 2-26).

Figure 2-26

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This will occur once a day and on each power up until either the card has been replaced with a blank one, or the data on it has been deleted (see the section on the System/Disk Utilities in Setup). When there is less than 5% free an ANF107 alarm will occur, stating that the space is extremely low. If space runs out, the system will stop copying the faults to the removable drive, although they will still be recorded internally.

The standard machine has approximately 5 times the amount of space that the flash drive has, so it is extremely unlikely that the disk would fill in 30 days. (This would require 120,000 lines or about 1300 faults each day!) If this does happen, though, logging will stop and need to be restarted (see the section on the System/Disk Utilities in Setup).

Reading Card Data The card drive is located inside the lower portion of the display’s cabinet on the left wall. The eject button is located immediately to the right of the drive's slot. When pressed, the card will be ejected and can then be easily removed. If the machine is operated without a card in the drive, data will still be logged for 30 days to the internal drive, but not externally. Additionally, the system will see that no space is available (as there is no card) so the warning and fault discussed previously will be active.

WARNING: NEVER remove a card from the drive or shut off power while the LED is on.

This will corrupt the data and possibly destroy the card!

The card can then be taken to another computer with a PCMCIA drive set up to read ATA flash.

The data is stored in ASCII format and ATA flash act just like any other disk drive, so the data can be copied to an office computer and deleted for the flash so it can be used again.

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2.7 Setup and Disk Management 2.7.1 Introduction This section deals with the setup of user selectable options, security codes, and system and disk utilities. In order to perform any of these functions, the user must know the security code for the Administrator (shipped as “888”).

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2.7.2 Setup Menu (Security: Administrator) The Setup Menu (fig. 2-27) is used to access the various setup and utility screens. This screen can only be accessed from the Main Menu.

Figure 2-27 Setup Menu Access to this screen is controlled by a security code, set ONLY for the Administrator. This number should be retained by only by trusted supervisory personnel, as it allows the changing of machine operating options as well as setting user passwords. Refer to the section on Security for information on changing the password. The choices on this menu are as follows: F11 Time and Date Format and Setup Pressing the F11 function key changes the display to a screen that will allow the user to change the time and date that appear in the upper right corner and is used for logging. This screen also allows the user to toggle between different display formats.

F12 Password Setup Pressing the F12 function key changes the display to a screen that will allow the user to change all of the passwords for access to the various screens.

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F13 User Selectable Options Pressing the F13 function key changes the display to a screen that will allow the user to select various machine performance options. This screen can also be used to set the display units to either Metric or English.

F14 System/Disk Utilities Pressing the F14 function key changes the display to a screen that will allow the user to copy and setup the files on the flash and internal disk. It also allows the user to exit to DOS. Disk Information The middle of this screen contains an information box that lists amount of space left free on both the removable flash and the internal disk emulator.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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2.7.3 Time/Date Window The Time/Date Window (fig. 2-28) allows the user to set the current time and date and change the format in which the date is displayed. The settings made here will affect the way these values are displayed at the top of the screen, as well as how they are displayed in the log and data files.

When these functions are used, the Microsoft Setup screens will be momentarily displayed. While this is happening, do not press any key. The system will then return to this screen.

This screen can only be accessed from the Setup Menu.

Figure 2-28 Time/Date Window Set Time F4 Function Key Pressing the F4 function key allows the user to set the current time. After pressing the key, a small box will appear in the vicinity of the key on the screen. Enter the current time in 24 hour format in the form HH:MM, where HH is the two digit hour and MM is the two digit minute. To create the “:”, press the <=> key. When one of the numbers is a single digit, enter a leading zero.

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If the format is entered incorrectly, a message will appear with the correct format. Re-enter the value properly.

Set Date F5 Function Key Pressing the F5 function key allows the user to set the current time. After pressing the key, a small box will appear in the vicinity of the key on the screen. Enter the time in the current format with a dot as the separator. This would be either MM.DD.YY or DD.MM.YY where MM is the two digit month, DD is the two digit day, and YY is the two digit year. When one of the numbers is a single digit, enter a leadin zero. For example: January 27, 1996 is entered as either: 01.27.96 or 27.01.96 October 2, 1996 is entered as either: 10.02.96 or 02.10.96 If the format is entered incorrectly, a message will appear with the correct format. Reenter the value properly.

Date Format F6 Function Key Pressing the F6 function key will toggle the date format between the forms month-day-year and day-month-year. Remember that pressing this key changes the way the data is stored in the log files.

Setup Menu F10 Function Key Pressing the F10 function key returns the display to the Setup Menu, described earlier. This key exists, so the user can go directly back without needing to reenter the password.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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2.7.4 Password Window The Password Window (fig. 2-29) is used to set all passwords for the predetermined security windows. The screen lists the screens to which each user has access. User 1 has access to all screens except the Setup Menu and the screens accessed through it. The Administrator has access to all screens.

Figure 2-29 Password Window Pressing the designated function key (F11 - F18) opens an input box near that password display.

Enter any combination of numbers for the new password. A maximum of eight characters can be used. When the <ENTER> key is pressed, the password is updated and shown on the screen.

WARNING: Remember the password for “ADMINISTRATOR”. Without it you will not be able to see or change the passwords. Access to all other Setup menu screens will also be prohibited. THERE IS NO WAY FOR for a CUSTOMER TO RECOVER THE ADMINISTRATOR PASSWORD!

If security is not desired, press the backspace key to clear the current word and then press <ENTER>. A user will then just press the <ENTER> key when asked for the password.

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WARNING: Since all machines are shipped with the same set of default passwords mine supervision should change these passwords as soon as possible to prevent unauthorized screen accesses or updates.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

Save to File F3 Function Key Above the F3 key is an indicator indicating the action of the key. Pressing the F3 key causes all the data displayed on this screen to be saved to an ASCII text file on the removable flash card.

The time and date will be saved immediately before the data. This data will be stored in a file called PASSWORD.DAT NOTE: Each time this key is pressed the current data will be appended to the end of the existing file. Each set of data takes up approximately 250 bytes.

Remember to secure this file after it is saved to the removable flash card. Anyone with access to the PCMCIA card drive will be able to read the card and find the password!

Setup Menu F10 Function Key Pressing the F10 function key returns the display to the Setup Menu described earlier. This key exists so the user can go directly back without needing to re-enter the password.

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2.7.5 Option Setup The Option Setup screen (fig. 2-30) is used to select the User Settable options. These options should generally be set only once, at machine commissioning; however, they are included here so they can be updated as required. Some additional option may be added according to certain customer situations.

Figure 2-30 Option Setup To activate a function, press the associated function key. The column to the right, in red, shows the current status of each option. This screen is only accessible from the Setup Menu. The options are as follows: F11 - Unit Select Pressing the F11 function key toggles the displayed units between Metric and English. This settings control how various parameters are displayed on the screen, how inputs are interpreted, and how the values are written to the data files. Since toggling this key requires the system to recalculate all the display values, it may take a few seconds for the status indicator to change.

NOTE: For customers who request customized unit configurations (e.g., pressure displayed in PSI, and everything else in metric), pressing this key will only toggle those units that are not specially defined. (In the above example, pressure would always be shown in PSI regardless of the setting of this option.)

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F12 - Main Air Valve Auto Open Pressing the F12 function key toggles the Auto Open option on the main air valve. When this option is enabled, the main air valve will automatically open when the air compressor is started.

F13 - Hydraulic Tank Level Self Test Disable Pressing the F13 function key toggles the Hydraulic Tank Oil Level Self Test Disable option.

When this option is enabled, the hydraulic tank oil level self test circuit will not function.

F14 - PDC Propel Limit Stop (option) On machines with PDC, pressing the F14 function key toggles the PDC Propel Limit Stop option.

When this option is enabled, Programmed Drill Control will stop the hoist at end of hole lifting operation at the propel limit, instead of the start of hole position.

F15 - PDC Rotary Current Limiter (option) On machines with PDC, pressing the F15 function key toggles the PDC Rotary Current Limiter option. When this option is enabled, the pulldown reference is controlled to limit rotary current to a predefined setting.

F16 - PDC Hole End Alarm (option) On machines with PDC, pressing the F14 function key toggles the PDC End of Hole Alarm.

When this option is enabled, a horn will sound when Programmed Drill Control finishes a hole.

To silence the alarm horn at the end of the hole, press the DRILL/PROPEL CONTROL ON push-button.

F17 - Audible Alarm Control Pressing the F17 function key toggles the audible alarm sound when new faults or alarms occur.

When this option is ENABLED, the alarm will NOT sound.

F20 - Language (option) On machines designed for an alternate language, pressing the F20 function key will toggle between the selected language and English. All screens, fault messages, and files will be in the currently selected language.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu, from which all available screens may be chosen. See the screen description, elsewhere.

Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen description, elsewhere.

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Setup Menu F10 Function Key Pressing the F10 function key returns the display to the Setup Menu described earlier. This key exists so the user can go directly back without needing to re-enter the password.

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2.7.6 System/Disk Utilities The System/Disk Utilities (fig. 2-31) screen is used to exit the application software, and perform disk management operation. This screen is only accessible from the Setup Menu.

Figure 2-31 System/Disk Utilities F11 - Exit to DOS Pressing the F11 function key leaves the application software and returns the screen to the DOS prompt. It is recommended that this action be done whenever power is to be removed from the unit. To start the display software again, press the <CTRL - ALT - DEL> keys simultaneously.

F12 - Delete All Alarm Files From Removable Flash Pressing the F12 function key deletes all the alarm files (*.ALG) from the removable flash drive.

While this is occurring, the screen may blank momentarily, which is expected. This function is used when the card is becoming full and maintenance supervision does not wish to save the data.

The alarm files can also be removed with the “DEL” command on other computer hardware.

F13 - Delete All Screen Data Files From Removable Flash Pressing the F13 function key deletes all screen data files (*.DAT) from the removable flash drive.

These files were created by pressing the F3 key on certain screens. While this is occurring, the screen may blank momentarily, which is expected. This function is used when the card is becoming full and maintenance supervision does not wish to save the data. The data files can also be removed with the “DEL” command on other computer hardware.

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F14 - Format SunDisk ATA Flash Disk Pressing the F14 function key formats thr removable SunDisk ATA flash disk in the drive. Disks are generally pre-formatted when they are shipped, so this functions primary use is for deleting all files from a disk, or attempting to reset a corrupted disk. When this function is selected, a text screen will appear with some disk information. This will end by asking for a confirmation. Press the <F19> key to continue or the <ESC> key to quit without formatting the flash.

NOTE: This command will only work with ATA flash disks, manufactured by Sundisk Corporation.

NOTE: “SunDisk Corp.” may become known as “SanDisk Corp.”

F15 - Delete All Alarm Files From Internal Disk As mentioned in the section on data logging, it is extremely unlikely that the internal hard disk emulator will fill with alarm files in the 30 days they are kept. If this occurs, however, data logging to the drive will be suspended until space is made and logging is manually restarted (see F16 on this screen). The amount of space left on the internal drive is shown in an information box on the Setup Menu. Pressing the F15 function key will remove all alarm files from the internal disk. While this is occurring, the screen may blank momentarily, which is expected. Note that these are the same file used to build the Alarm History display.

F16 - Restart Logging to Internal Disk As mentioned in the section on data logging, it is extremely unlikely that the internal hard disk emulator will fill with alarm files in the 30 days they are kept. If this occurs, however, data logging to the drive will be suspended until space is made and logging is manually restarted.

Pressing the F16 function key manually restarts the data logging, once disk space has been freed up.

F17 - Copy All Alarm Files from the Internal Disk to the Removable Flash Pressing the F17 function key copies all the alarm files from the internal disk to the removable flash. While this is occurring, the screen may blank momentarily, which is expected. Since the alarm files are generally logged to both disks simultaneously, this function will probably only be used when a removable flash has become corrupted, or the system has been allowed to operate without a removable flash card installed. Note that the internal disk has about five times as much free space as the 1.8MB flash that is generally included with the machine. If there is not enough room on the card, not all the files will be copied. SunDisk (or SanDisk) does make ATA flash card of the same style with greater capacities.

Main Menu F1 Function Key Above the F1 key is an indicator indicating the action of the key. Pressing the F1 key causes the display to change to the Main Menu from which all available screens may be chosen. See the screen description, elsewhere.

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Operator's Screen F2 Function Key Above the F2 key is an indicator indicating the action of the key. Pressing the F2 key causes the display to change to the Operator's screen. See the screen elsewhere.

Setup Menu F10 Function Key Pressing the F10 function key returns the display to the Setup Menu, described earlier. This key exists so the user can go directly back without needing to re-enter the password.

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2.8 Screen Security Since many screens contain setup parameters, it is not always desirable to allow all users to access all screens. Therefore, the parameter screens that are not required for day to day machine operation are protected by a one to eight digit security code. There are eight different securities assigned. The administrator password has access to all screens. User 1 has access to all screens except the Setup Menu and the screens accessible through that. Each of the other six users has access to one screen as shown in Appendix B. When a user attempts to access a secure screen, the Password Entry window (fig. 2-32) pops up in the middle of the screen. This window lists the users (other than the administrator) who have access to this screen. The user can immediately type in the security code and press <ENTER> (or, if mine supervision chose not to use security, just press <ENTER>). If the security code is correct, the desired screen will appear. If it is not correct, the Password Error box (fig. 2-33) will appear in the center of the screen. Pressing the <ENTER> key will clear this box and return the display to the original screen. There is no way for any user other than the administrator to see or change any of the passwords.

Figure 2-32 Password Entry

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Figure 2-33 Password Error NOTE: In some cases (i.e., when communication to the PLC is lost), the input box will disappear from the Password Entry screen. To get it back, press the <+> key until the cursor is on the Password Entry screen and press <ENTER>. The password can now be entered.

WARNING: Since all machines are shipped with the same set of default passwords mine supervision should change these passwords as soon as possible to prevent unauthorized screen accesses or updates.

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APPENDIX A A.1 Alarm Window Messages The following table lists all the possible fault and alarm conditions, along with their ANF numbers that may be displayed on any drill. Some of these messages relate directly to options. While these option faults are included in this list and can be viewed on the All Alarms screen, they will never be active if their associated option is not installed on a particular drill.

Alarm ANF001 ANF002 ANF003 ANF004 ANF005 ANF006 ANF007 ANF008 ANF009 ANF010 ANF011 ANF012 ANF013 ANF014 ANF015 ANF016 ANF017 ANF018 ANF019 ANF020 ANF021 ANF022 ANF023 ANF024 ANF025 ANF026 ANF027 ANF028 ANF029 ANF030 ANF031 ANF032 ANF033 ANF034 ANF035 ANF036

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Message PLC Analog Input Block Transfer Fault PLC Analog Output Block Transfer Fault Replace PLC Battery PLC EEPROM Memory Transfer at Power Up PLC Rack 2 I/O Fault Hydraulic Oil Overtemperature Hydraulic Oil Filter Clogged Compressor Air Overtemperature (Shutdown) Hoist/Pulldown Drive Ground Fault Rotary Drive Ground Fault Auxiliary System Ground Fault Hoist/Pulldown Drive Fault Hoist/Pulldown Motor Field Loss Hoist/Pulldown Motor Field Overcurrent Hoist/Pulldown Motor Overload Rotary Drive Fault Rotary Motor Field Loss Rotary Motor Field Overcurrent Rotary Motor Field Overload PLC Rack 0 I/O Fault PLC Rack 1 I/O Fault PLC Rack 3 I/O Fault Water Injection Pump Overspeed Fault Water Injection Pump Underspeed Fault Head Brake Release Fault House Fan Control Fault Lube Timer Set Out of Range Lube System Power Off Drill Lube Low Pressure Fault Propel Lube Low Pressure Fault Lube Vent Pressure Fault Head Encoder Fault Head Limit or Pipe Data Out of Range PDC Setting Out of Range Main Air Valve Opening Fault Main Air Valve Closing Fault

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ANF037 ANF038 ANF039 ANF040 ANF041 ANF042 ANF043 ANF044 ANF045 ANF046 ANF047 ANF048 ANF049 ANF050 ANF051 ANF052 ANF053 ANF054 ANF055 ANF056 ANF057 ANF058 ANF059 ANF060 ANF061 ANF062 ANF063 ANF064 ANF065 ANF066 ANF067 ANF068 ANF069 ANF070 ANF071 ANF072 ANF073 ANF074 ANF075 ANF076 ANF077 ANF078 ANF079 ANF080 ANF081 ANF082

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Air Compressor Low Oil Level Air Compressor Motor Ground Fault Spare Fault Spare Fault PLC Output Circuit Breaker Open Emergency Stop Activated PLC Input Circuit Breaker Open Spare Fault Water Injection Low Water Level Hydraulic Tank Maintenance Valve Closed Phase Sequence / Input Line Fault Propel Brakes Released For Towing Rotary Motor Overtemperature Hoist/Pulldown Motor Overtemperature Compressor Motor Shutdown Fault (MULTILIN) Compressor Motor Warning (MULTILIN) 24 VDC Control Voltage Low Head Overspeed Fault Rotary Motor Blower Control Fault Hoist/Pulldown Motor Blower Control Fault Hydraulic Oil Cooler Control Fault Cable Reel Control Fault Air Pressure Transduce Fault Head Brake Sensor Switch Fault Rotary Master Switch Misaligned Hoist/Pulldown Master Switch Misaligned Rotary Motor Stall Hoist/Pulldown Motor Stall Horizontal Vibration Transducer Fault Vertical Vibration Transducer Fault Rotary Drive Incomplete Sequence Hoist/Pulldown Drive Incomplete Sequence Air Compressor Radiator Fan Control Fault Air Compressor Control Fault Spare Fault Rotary Input Power Fault Hoist/Pulldown Input Power Fault Propel with Pipe in Hole Warning Propel with Stairs Down Warning Mast Lock Pin Removed Mast Brace Pin Removed Machine Tip Warning Automatic Level Limit MCC Control Fuse Fault Head Brake Setting Fault Head Brake Forcing Circuit Fault

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ANF083 ANF084 ANF085 ANF086 ANF087 ANF088 ANF089 ANF090 ANF091 ANF092 ANF093 ANF094 ANF095 ANF096 ANF097 ANF098 ANF099 ANF100 ANF101 ANF102 ANF103 ANF104 ANF105 ANF106 ANF107 ANF108 ANF109 ANF110 ANF111 ANF112 ANF113 ANF114 ANF115 ANF116 ANF117 ANF118 ANF119 ANF120

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A-Frame Pin(s) Not in Place Compressor Oil Temp. Transducer Fault Hydraulic Tank Low Oil Level (Shutdown) Hydraulic Tank Low Oil Level Sensor Fault Spare Fault Spare Fault Spare Fault Spare Fault PLC Cabinet Temp. Below Operating Range Air Compressor Oil Pressure Fault Compressor Air Overtemperature (Warning) Comp. Air Temperature Transducer Fault Centering Guide Not Fully Retracted Spare Fault Spare Fault Spare Fault Spare Fault Spare Fault Spare Fault Auxiliary Transformer Temperature Warning Main Transformer Temperature Warning Auxiliary Transformer Overtemperature Main Transformer Overtemperature Drill Bit Lube Level Low Removable Disk Space Extremely Low Spare Fault (Fire System) Spare Fault (Fire System) Spare Fault (Fire System) Spare Fault (Fire System) Spare Fault (Fire System) DB Module Fault Power Monitor Block Transfer Fault Spare Fault (Fire System) Spare Fault Spare Fault KE MODULE RS-232 Link Fault KE Module DH+ Link Fault Spare Fault

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APPENDIX B B.1 Screen Security The following table shows each of the screens with security attached and the users that may access that screen.

Admin.

User 1

User 2

Head & Rack Limits

X

X

X

Lubrication

X

X

PDC Parameters - 2

X

X

Test Display - 2

X

X

Head Calibration

X

X

Field Tests

X

X

Setup Menu

X

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User 3

User 4

User 5

User 6

User 7

X X X X X

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APPENDIX C C.1 CMOS Setup (for P/N 1233801, 12330802, and 12330803) As is the case for any 80x88-based computer, certain rare circumstances or failures cause the PC to lose its internal setups stored in CMOS. The following table shows the setup necessary for the computer to function properly. Only personnel trained in PC maintenance should try to reset these parameters.

To call up the setup menu use the <CTRL - ALT - F13> combination when not in the display application. Use the arrow keys to move to a particular field and <F5> or <F6> to change the data. <F10> saves all the parameters and <ESC> leaves the screen.

Setup Current Date: Current Time:

as required as required

System Memory: Extended Memory:

640K 15360K

Internal COM at a: Internal COM B: Internal LPT:

COM1, 3F8H COM2, 2F8H LPT1, 378H

Diskette Drive 0: Diskette Drive 1:

1.44 MB, 3 1/2 Not installed

Fixed Disk 0 (for 1233080l): Fixed Disk 0 (for 12330802): Fixed Disk 0 (for 12330803): Fixed Disk 1:

Type: NONE Type: NONE Type: USER CY:640 HD:6 ST:32 LZ:640 WP:0 Type: NONE

Video System

EGA / VGA

BIOS Shadow:

System in RAM Video in RAM

Internal Floppy: Internal IDE: Setup Prompt:

Enabled Enabled Enabled

System Memory Cache:

ON

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Extended BIOS Features Auto-park Disk: Quick Boot: Screen Saver Keyboard Click Keyboard Delay Keyboard Rate Numlock Boot State

NO YES Disabled NO 3/4 Sec. 22/Sec. OFF

Flat Panel Blanking Timeout:

Disabled

C.2 CMOS Setup (for P/N 12330804) As is the case for any 80x88-based computer, certain rare circumstances or failures cause the PC to lose its internal setups stored in CMOS. Only personnel trained in PC maintenance should try to reset these parameters.

To call up the setup menu, reboot the computer by cycling power and then press <F2> immediately after the memory test. To enter the setup screens, a password is required. Contact Bucyrus Engineering for this password. A keyboard will also be required to enter the password.

Use the arrow keys to move to a particular field and the <+> and <-> keys to change the data.

Pressing <ESC> and then <ENTER> will leave setup and store all of the changes.

Main System Time: System Date: Diskette A: Diskette B: IDE Adapter 0 Master Type: Cylinders: Heads: Sectors/Track: Write Precomp: Multi-Sector Transfers: LBA Mode Control: 32 Bit I/O: Transfer Mode: IDE Adapter 0 Slave Video System Memory Shadow System Shadow: Video Shadow:

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As required As required 1.44 MB, 32 " Not Installed (Press Enter for Setup) Auto 62MB 640 6 32 None Disabled Enabled Disabled Fast PIO 1 None EGA / VGA (Press Enter for Setup) Enabled Enabled

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Boot Sequence Previous boot: Boot sequence: Setup prompt: POST Errors: Floppy check: Summary screen: Num Lock Numlock: Key Click: Keyboard auto-repeat rate: Keyboard auto-repeat delay:

(Press Enter for Setup) Disabled C: then A: Disabled Enabled Disabled Enabled (Press Enter for Setup) Auto Disabled 30/sec 2 sec

System Memory Extended Memory

640 KB 15 MB

Advanced Integrated Peripherals COM port: COM port: LPT port: LPT Mode: Diskette Controller: Local Bus IDE adapter: PCI Devices PCI Device, Slot #1 Enable Master Default Latency Latency Timer PCI Device, Slot #2 Enable Master Default Latency Latency Timer PCI Device, Slot #3 Enable Master Default Latency Latency Timer Advanced Chipset Control DRAM read timing: DRAM write timing: I/O recovery time setting CPU to PCI write buffer PCI to DRAM buffer Plug & Play O/S Large Disk Access Mode:

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(Press Enter for Setup) 3F8, IRQ 4 2F8, IRQ 3 378, IRQ 7 Bi-Directional Enabled Enabled (Press Enter for Setup) Enabled Yes 0040 Enabled Yes 0040 Enabled Yes 0040 (Press Enter for Setup) Normal Normal 0 us Enabled Enabled No DOS

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Security Supervisor Password is User Password is Set Supervisor Password Set User Password Password on boot: Diskette access: Fixed disk boot sector: System backup reminder: Virus check reminder:

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Enabled Disabled (See Bucyrus Engineering) (None defined) Disabled User Normal Disabled Disabled

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