CAT BUCYRUS 49HX 49HR (L111 & Later) Operator Display Instructions Manual BI619458 - PDF DOWNLOAD

BI619458

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI619458

Instructions For 49HX/49HR (L111 & Later) Operator Display X-4137

This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 2010 Bucyrus International, Inc. All rights reserved.

Approved By: _______________

Approved Date: Revised Date: February, 2010 Page 1 of 74

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TABLE OF CONTENTS OVERVIEW......................................................................................................................................................... 7 HARDWARE ....................................................................................................................................................... 8 OVERVIEW .......................................................................................................................................................... 8 Touch Screen and Keyboard ........................................................................................................................... 8 File Storage.................................................................................................................................................... 8 Ethernet Communication ................................................................................................................................ 9 Power............................................................................................................................................................. 9 Display Configuration and Setup .................................................................................................................... 9 Opening the Display ....................................................................................................................................... 9 SOFTWARE OVERVIEW ................................................................................................................................ 10 BOOTUP (POWER UP) ........................................................................................................................................ 10 NAVIGATION, PROGRAM CONTROL, AND DATA ENTRY ....................................................................................... 10 ICON AND NAVIGATION HELP SCREENS .............................................................................................................. 10 SECURITY ......................................................................................................................................................... 11 DRILL OPERATION SCREENS...................................................................................................................... 13 SCREEN LAYOUT ............................................................................................................................................... 13 Active Alarm Indicator (Screen Item 1) ......................................................................................................... 13 Main Menu Buttons (Screen Item 2) .............................................................................................................. 14 Languages Button (Screen Item 3)................................................................................................................. 14 Configuration Button (Screen Item 4)............................................................................................................ 14 Active Alarm Banner (Screen Item 5) ............................................................................................................ 14 Clock (Screen Item 6).................................................................................................................................... 14 Title Screen Button (Screen Item 7) ............................................................................................................... 14 Help Button (Screen Item 8).......................................................................................................................... 14 Display Name and Revision Date (Screen Item 9).......................................................................................... 14 MAIN MENU ..................................................................................................................................................... 15 Status Screen Button ..................................................................................................................................... 15 Calibration Screen Button............................................................................................................................. 15 Active Logic Screen Button ........................................................................................................................... 15 PLC I/O Screen Button ................................................................................................................................. 15 Alarms History Screen Button ....................................................................................................................... 15 Hour Meters and Fault Counters Screen Button ............................................................................................ 15 Test Analog I/O Screen Button ...................................................................................................................... 15 Field Test Screen Button ............................................................................................................................... 15 Timers and Counters Screen Button .............................................................................................................. 16 Programmed Drill Control (PDC) Screen Button .......................................................................................... 16 STATUS SCREEN ................................................................................................................................................ 16 Limits ........................................................................................................................................................... 17 Rotary Current Bar Graph............................................................................................................................ 18 Rotary Speed Bar Graph............................................................................................................................... 18 Bailing Air Pressure Bar Graph.................................................................................................................... 18 Page 2 of 74

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Hoist/PD Current Bar Graph........................................................................................................................ 18 Hoist/PD Speed Bar Graph........................................................................................................................... 18 Hoist/PD Force Bar Graph........................................................................................................................... 18 Level Indicator ............................................................................................................................................. 19 Operating Mode / Brake Released Indicator Box ........................................................................................... 19 Control Enable Button .................................................................................................................................. 19 Torque Control ............................................................................................................................................. 19 Main Motor Button ....................................................................................................................................... 19 Hoist Mode Indicators .................................................................................................................................. 19 Rotary Mode Indicators ................................................................................................................................ 20 Master Switch Neutral Indicator ................................................................................................................... 20 Jacks Retracted Indicator.............................................................................................................................. 20 Lube System Fault Indicator ......................................................................................................................... 20 Boarding Stairs Down Indicator.................................................................................................................... 21 PDC On Indicator (Option) .......................................................................................................................... 21 PDC Limit Indicator (Option) ....................................................................................................................... 21 Hole Clogged Indicator (Option) .................................................................................................................. 21 Low Water Indicator (Option)....................................................................................................................... 21 Remote Transmitter On Indicator (Option).................................................................................................... 21 Remote Propel Active Indicator (Option)....................................................................................................... 22 Hole Depth Numeric Display ........................................................................................................................ 22 Bit Position Numeric Display........................................................................................................................ 22 Head Position Numeric Display .................................................................................................................... 22 Water Flow Numeric Display (Option).......................................................................................................... 22 Mast Angle Numeric Display (Option)........................................................................................................... 22 Leveling Screen Button ................................................................................................................................. 23 Maintenance Screen Button........................................................................................................................... 23 Mast Operations Screen Button..................................................................................................................... 23 LEVELING SCREEN ............................................................................................................................................ 24 Front to Rear Level Graph............................................................................................................................ 24 Side to Side Level Graph............................................................................................................................... 25 Front to Rear Level Numeric Display............................................................................................................ 25 Side to Side Level Numeric Display............................................................................................................... 25 Level Indicators............................................................................................................................................ 25 Tilt Numeric Display..................................................................................................................................... 25 Tilt Warning Indicator .................................................................................................................................. 25 Jack Ground Pressure Indicators .................................................................................................................. 26 Jacks Retracted Indicators ............................................................................................................................ 26 Status Indicators........................................................................................................................................... 26 Mode Indicators ........................................................................................................................................... 26 Cable Reel In/Out Buttons (Option)............................................................................................................... 26 MAINTENANCE SCREEN ..................................................................................................................................... 27 Hydraulic Oil Indicators............................................................................................................................... 27 Compressor Oil Temperature........................................................................................................................ 27 Page 3 of 74

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Compressor Air Temperature........................................................................................................................ 28 Lubrication System ....................................................................................................................................... 28 Window Guard (Option) ............................................................................................................................... 28 Thread Lubrication (Option)......................................................................................................................... 28 House Pressurizing Fan................................................................................................................................ 28 MAST OPERATIONS SCREEN .............................................................................................................................. 29 Pin Status Indicators..................................................................................................................................... 29 Pin Lock/Unlock Buttons............................................................................................................................... 29 Mast Operation Conditions........................................................................................................................... 29 Remote Winch Control (Option).................................................................................................................... 30 TITLE SCREEN ................................................................................................................................................... 30 HEAD CALIBRATION AND LIMITS SCREEN .......................................................................................................... 31 Head Calibration.......................................................................................................................................... 32 Setting Limits................................................................................................................................................ 32 Head Data Numeric Display ......................................................................................................................... 32 Machine Settings Button ............................................................................................................................... 32 Lubrication Button........................................................................................................................................ 32 MACHINE SETTINGS SCREEN ............................................................................................................................. 33 LUBRICATION SCREEN ....................................................................................................................................... 34 Timer Setting ................................................................................................................................................ 34 Lubrication Setup Button .............................................................................................................................. 35 HOUR METERS AND FAULT COUNTERS SCREEN .................................................................................................. 35 Total Operating Hours Section...................................................................................................................... 35 Operating Hours Since Last Reset Section..................................................................................................... 36 Fault Counts................................................................................................................................................. 36 Counter Reset Buttons................................................................................................................................... 36 Lubrication System Faulted Operation.......................................................................................................... 36 PROGRAMMED DRILL CONTROL SCREENS (OPTION).......................................................................... 37 OVERVIEW ........................................................................................................................................................ 37 PDC OPERATOR SETTINGS ................................................................................................................................ 37 Changing Hole Parameters........................................................................................................................... 37 Changing Parameter Presets ........................................................................................................................ 38 PDC PARAMETERS ............................................................................................................................................ 38 Changing Parameters Within a Preset........................................................................................................... 39 Changing Individual Parameters................................................................................................................... 39 Bit Specification Pulldown Force Limit ......................................................................................................... 39 PDC OPERATORS SCREEN 1............................................................................................................................... 40 Performance Parameter Data ....................................................................................................................... 40 PDC Regulator Status Indicators .................................................................................................................. 41 Drilling Status Indicators.............................................................................................................................. 41 PDC OPERATORS SCREEN 2............................................................................................................................... 42 Performance Parameter Data ....................................................................................................................... 42 PDC Regulator Status Indicators .................................................................................................................. 42 Drilling Status Indicators.............................................................................................................................. 43 Page 4 of 74

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TEST AND CONTROL SYSTEM STATUS SCREENS................................................................................... 44 OVERVIEW ........................................................................................................................................................ 44 FIELD TESTS ..................................................................................................................................................... 44 Test 1 ........................................................................................................................................................... 45 Test 2 ........................................................................................................................................................... 45 Test 3 ........................................................................................................................................................... 45 Test 4 ........................................................................................................................................................... 45 Test 5 ........................................................................................................................................................... 45 Test 6 ........................................................................................................................................................... 45 Test 7 ........................................................................................................................................................... 46 Test 8 ........................................................................................................................................................... 46 HYDRAULIC CARDS SETUP ................................................................................................................................ 46 Valve Output Buttons .................................................................................................................................... 46 TEST SCREENS (TEST – ANALOG I/O)................................................................................................................. 47 View Voltage/Current ................................................................................................................................... 48 Test Screen Buttons....................................................................................................................................... 48 Drive Test Button.......................................................................................................................................... 48 DRIVE TEST SCREEN ......................................................................................................................................... 49 Numeric Displays ......................................................................................................................................... 49 Rotary Mode Indicators ................................................................................................................................ 49 Hoist Mode Indicators .................................................................................................................................. 50 Motion Drive Diagnostics ............................................................................................................................. 50 Motion Drive Test Functions......................................................................................................................... 50 Setup Test ..................................................................................................................................................... 51 Stall Test ...................................................................................................................................................... 52 Bypass Test................................................................................................................................................... 53 PLC/PROFIBUS MENU ....................................................................................................................................... 54 DATA BLOCK VALUES SCREEN .......................................................................................................................... 55 Entering Addresses ....................................................................................................................................... 55 PLC DIAGNOSTICS SCREEN ............................................................................................................................... 56 Profibus Node Data ...................................................................................................................................... 56 Processor Scan Data .................................................................................................................................... 57 Processor LED Status................................................................................................................................... 57 PLC Diagnostic Buffer.................................................................................................................................. 57 RACK DISPLAY SCREENS ................................................................................................................................... 58 Navigation.................................................................................................................................................... 58 Digital I/O Cards.......................................................................................................................................... 58 Analog I/O Cards ......................................................................................................................................... 58 View Voltage/Current – View Integer Button................................................................................................. 59 TIMERS/COUNTERS SCREEN............................................................................................................................... 59 Entering Addresses ....................................................................................................................................... 59 ACTIVE LOGIC .................................................................................................................................................. 60 Active Logic Menu........................................................................................................................................ 60 ALARMS, FAULTS, AND MESSAGES ........................................................................................................... 61 Page 5 of 74

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OVERVIEW ........................................................................................................................................................ 61 Latched Faults.............................................................................................................................................. 61 Audible Alarm .............................................................................................................................................. 61 Alarm History Button.................................................................................................................................... 61 Active Alarms Button .................................................................................................................................... 61 ALARM HISTORY SCREEN .................................................................................................................................. 62 Alarm History List ........................................................................................................................................ 62 ACTIVE ALARMS SCREEN .................................................................................................................................. 63 Active Alarms List......................................................................................................................................... 63 Alarm History Button.................................................................................................................................... 63 Export Alarm History Button......................................................................................................................... 64 Latched Fault Reset Button ........................................................................................................................... 64 EXPORT ALARM HISTORY SCREEN ..................................................................................................................... 64 DISPLAY SETUP AND MANAGEMENT........................................................................................................ 66 OVERVIEW ........................................................................................................................................................ 66 CONFIGURATION SCREEN .................................................................................................................................. 66 Option Setup................................................................................................................................................. 67 Option 1 ....................................................................................................................................................... 67 Option 2 ....................................................................................................................................................... 67 Option 3 ....................................................................................................................................................... 67 Option 4 ....................................................................................................................................................... 67 Option 5 ....................................................................................................................................................... 67 Option 6 ....................................................................................................................................................... 67 Option 7 ....................................................................................................................................................... 67 Option 8 ....................................................................................................................................................... 67 Password Setup ............................................................................................................................................ 68 LANGUAGE ....................................................................................................................................................... 69 TOUCH SCREEN CALIBRATION ........................................................................................................................... 69 What do I do if I see a yellow banner with the words “PLC COMMUNICATION LOST”?............................. 70 How do I change the time and date?.............................................................................................................. 70 When I touch the screen nothing happens or a button is activated that doesn’t line up with where I touched.

Do I need to buy a new unit?......................................................................................................................... 70 I forgot the Administrator password. How can I get it back?......................................................................... 70 Can I make the display brighter? .................................................................................................................. 70 APPENDIX A – ANF MESSAGES.................................................................................................................... 71 APPENDIX B – ANW MESSAGES................................................................................................................... 73 REVISIONS ....................................................................................................................................................... 74

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OVERVIEW The 49HR operator display is designed by Bucyrus International Inc. ® to assist the drill operator in efficient operation of the blasthole drill. It gives the user machine data, indicators, and alarms as well as providing a means of entering setup parameters and user options.

All servicing of this display system is to be done only by qualified service personnel.

This manual is written to help the user understand the workings of the display information system as it pertains to the operation of the drill and troubleshooting the control system. Some objects referred to as “options” in this manual are only enabled on drills where that particular feature has been purchased. On other systems those options will either be non-functioning “grayed out” screen objects or inaccessible.

Notes on Screen Graphics: 1) The graphics and descriptions in this manual are for reference only. 2) Actual screens may differ depending upon software version and purchased options. 3) Actual screen colors may be different due to differences in printing and display technologies. 4) The values shown are examples and may not exactly match those on your display. 5) The current time is shown in the upper right corner of most screens.

Figure 1 – Operator Display

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HARDWARE Overview The operator display terminal consists of an industrial hardened computer running a Microsoft Windows operating system. The color touch screen was specifically chosen to provide optimum viewing in bright sunlight.

Touch Screen and Keyboard This display has a touch screen. This means that for normal operation it is designed to be used exclusively by simply choosing objects on the screen and touching them with your finger. Do not use anything other than your finger for selecting screen objects. Items such as pens, pencils, screwdrivers, etc. will damage the screen and should never be used.

Certain functions for troubleshooting the display or for initial setup may require the use of a keyboard (not supplied by Bucyrus). Any standard USB keyboard from a desktop computer may be used. The USB port is located on the left side of the operator’s seat. It is mounted below the display stand on the back of the left console. There are two ports here for a mouse and a keyboard.

Figure 2 shows the ports on the display. These are inaccessible except for the remote USB and ethernet ports on the operator’s seat.

Figure 2 – Operator Display (Bottom View) File Storage The complete operating system and application files are stored on solid state media (either a Compact Flash card in a PC card adapter, or a solid state hard drive) accessible on the top of the unit under the right-hand panel. If required, program updates may be delivered by exchanging the old flash drive for a new one. If this is done, please remember to return the old flash card to Bucyrus as soon as possible.

To remove the card, first remove power from the display. This is done by turning off the appropriate switch or circuit breaker. Then press the small button located immediately left of the card to eject it. Put Page 8 of 74

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the new card in, making sure it faces the same way that the old card did. Normally, the front of the card (identifiable by its label) goes toward the back of the display. Make sure the card is pushed all the way in, but do not force it.

Ethernet Communication Communication is established to the PLC through Ethernet. An Ethernet port exists on the bottom of the operator display. See Figure 2. This can also be used for programming the unit. It is also setup to allow data exchange over an Ethernet network and for remote monitoring.

Power Power is supplied to a three pin connector on the bottom rear of the display. See Figure 2. Only 24VDC is allowed, regardless of the configuration of the drill.

Figure 3 – Operator Display (Side View) Display Configuration and Setup All configuration and setup functions are done through software. Please refer to the Software section of this manual for a summary of these features.

Opening the Display The internal components of the operator display are not user-serviceable. It is not recommended that the user open the display for any reason, unless directed to by Bucyrus. If problems are serious enough to open the unit, it should be replaced or repaired by trained personnel.

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SOFTWARE OVERVIEW The application program for the operator display was created using proprietary development software.

The screens have been designed to resemble the layout of Bucyrus’ other PC based operator displays, but some differences are necessary due to machine specific requirements.

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 defined in the Setup Screen. The Security section of this manual discusses the operation of these passwords and the Appendix shows a table 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 screen.

Note: The screen pictures and descriptions in this manual are typical configurations for reference only.

Actual screen may differ depending upon software version and purchased options.

Bootup (Power Up) The operator display will automatically boot (power up) whenever power is applied to the unit. The entire bootup process, from power-on until the unit is ready for use usually takes less than five minutes.

DO NOT TOUCH THE TOUCH SCREEN DURING THIS TIME. Once the boot process is finished, communication between the display and the PLC is established and the Status Screen appears. The display is now ready for use. If a yellow banner appears at the top of the display stating “PLC COMMUNICATION LOST,” this is an indication that communication with the PLC has failed. Refer to the Troubleshooting section of this manual for help.

Navigation, Program Control, and Data Entry For normal operation, the operator display is controlled exclusively with the touch screen. To change screens or choose an object, simply touch it with your finger. Do not use anything other than your finger for selecting screen objects. Items such as pens, pencils, screwdrivers, etc. will damage the screen and should never be used.

Screens are changed by touching the on-screen button associated with the desired screen. Most screens or sections can be accessed from the Main Menu. Almost all screens have direct access to the Status Screen, and the Main Menu is located at the bottom of almost every screen.

When it is necessary to enter a number, a pop-up keypad will appear on the screen. Simply touch the keys on the keypad as you would with an actual keypad. Press <ENTER> when finished or <X> to abort the entry. With the keypad, errors are corrected with the delete key <del>.

Icon and Navigation Help Screens Many of the screens have a “HELP!” button in the upper right corner which is indicated with a <?>.

Pressing this key will bring up a separate screen that displays and describes all the different icons and navigation buttons that may be encountered throughout the program. When finished, press a button from the Main Menu at the bottom of the screen that corresponds to the desired function. Figure 4 shows an example of the Icon Help Screen.

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Figure 4 – Icon Help Screen Sample

Security Since some of the screens contain setup parameters that may impact performance of the drill, it is not always desirable for all users to have access to all screens. Therefore, the parameter screens that are not required for day to day operation are protected by a three to five digit security code. The Administrator password has access to all screens. User 1 has access to all screens except the Setup screen. Each of the other users has access to one screen as shown in the Password Setup section.

When a user attempts to access a secure screen, the Password Entry window will pop up. Figure 5 shows a typical Password Entry window.

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Figure 5 – Password Screen In order for the secure screen to open up, a specific code must be entered using this keypad. The user enters the password with the pop-up keypad. If the code is correct, the desired screen will appear. If the code is not correct, the Password Entry window will remain with a message indicating an invalid password. If the user decides not to enter the correct password, he can return to the previous screen by pressing the <X> button in the upper right corner.

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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DRILL OPERATION SCREENS

Screen Layout There are a few areas of the display application that will be visible on most screens for information and navigation. These include the alarm banner, current time, icon help button, configuration button, language change button, active alarms indicator and main menu.

Figure 6 - Screen Layout Active Alarm Indicator (Screen Item 1) The Active Alarm indicator is a three-state icon indicator that is a triangle shape with an exclamation point in the middle, located in the lower left corner of the screen. It displays the current status of any alarms, faults, or messages on the drill. Its states are as follows: NO ACTIVE ALARMS – When there are no alarms, faults, or messages currently active on the drill, a green light indicator appears in place of the triangle.

NEW ALARM (Illuminated/Flashing) – One or more alarm, fault, or message conditions on the drill have been detected but not yet acknowledged by the operator. Touching this button will acknowledge any new alarms, silence the audio alarm, and navigate to the Active Alarms Screen. See the Alarms section of this manual for more information.

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ACTIVE ALARMS (Illuminated) – There are one or more alarm, fault, or message conditions on the drill.

This could also be triggered by one or more latched faults being sensed but not yet reset with the LATCHED FAULT RESET button. Touch the button to view the active alarms and silence the audio alarm.

See the Alarms section of this manual for more information.

Main Menu Buttons (Screen Item 2) The buttons which are located across the bottom of the screen are the Main Menu selections. The icon descriptions can be found on the help screen.

Languages Button (Screen Item 3) This button is located on the top of the screen to the left of the configuration button. It is used to select the language of the text used throughout the display.

Configuration Button (Screen Item 4) This button is located on the top of the screen second from the left. The configuration screen allows the operator to select display units, time format, and set available drill operation options.

Active Alarm Banner (Screen Item 5) The Active Alarm Banner becomes visible when a new alarm becomes active. It will continue to display the most recent alarm until the Active Alarm Screen is visited or the <X> button is pressed to suppress it.

Clock (Screen Item 6) The Clock is displayed in the upper right corner of the display. It can be set to display in 12-Hour or 24Hour format from the Configuration Screen.

Title Screen Button (Screen Item 7) The Title Screen Button is located in the upper right corner of the display, to the left of the Icon Help button. It is used to view the screen that displays machine information such as model number, serial number, and X-Instruction numbers.

Help Button (Screen Item 8) This Help Button is located in the top right corner of the screen with a <?> symbol. It provides access to the Help-Icons and Help-Navigation screens which give descriptions of the many graphical symbols used throughout the display software.

Display Name and Revision Date (Screen Item 9) In order to aid in troubleshooting if problems occur with the HMI, the file name of the current screen, as well as the last revision date of that screen, are displayed in the lower right corner of the display.

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Main Menu The Main Menu is the primary means of navigating between commonly used display screens (See Figure 7 for location). The Main Menu is located across the bottom of almost every screen. Simply press the icon button for the screen that you wish to display.

Figure 7 – Main Menu If there are multiple screens with the same general functions (e.g., Test – Analog I/O screens or PLC/Profibus), pressing the button on the Main Menu will take you to the first screen of the group.

Another menu will appear along the left side of the display for choosing the remainder of the screens in that group.

Status Screen Button This is the first button from the left in the Main Menu and is used to navigate to the main Status Screen.

Calibration Screen Button This is the second button from the left in the Main Menu and will navigate to the Calibration/Limits Screen.

Active Logic Screen Button This is the third button from the left in the Main Menu and will navigate to the Active Logic Screens.

PLC I/O Screen Button This is the fourth button from the left in the Main Menu and will navigate to the PLC I/O Screen.

Alarms History Screen Button This is the fifth button from the left in the Main Menu and will display the Alarm History Screen.

Hour Meters and Fault Counters Screen Button This is the sixth button from the left in the Main Menu and will navigate to the Hour Meters and Fault Counters Screen.

Test Analog I/O Screen Button This is the seventh button from the left in the Main Menu and will navigate to the Test Analog I/O Screens.

Field Test Screen Button This is the eighth button from the left in the Main Menu and will navigate to the Field Test Screen.

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Timers and Counters Screen Button This is the ninth button from the left in the Main Menu and will navigate to the Timers and Counters Screen.

Programmed Drill Control (PDC) Screen Button This is the tenth button from the left in the Main Menu and will navigate to the PDC Operator’s Screen.

This button will only be visible if the PDC option has been purchased.

Status Screen The Status Screen is most commonly used by the drill operator during the drilling process (see Figure 8).

Because of its importance, it is accessible with a button in the lower left corner of all other screens. This screen displays information on machine status including drill head operation, air pressure, head position, hole depth, system status, and numerous other operation parameters. The information is presented in the form of analog bar graphs, numeric displays, and multi-state indicators.

Each element on the Status Screen will be discussed in detail in the following subsections. The current time is shown in the upper right corner of this screen. Refer to the Setup section of this manual for information on changing the time format.

Figure 8 – Status Screen

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Limits This limit box is located at the top left of the Status Screen. These two state indicator lights show when the position of the head is at the top and bottom extreme travel limits, when the head is above the Pipe Rack Limit, and when the head is above the Propel Limit. The head can not be powered beyond the upper or lower limits unless the limit function is bypassed by operating with the Calibration/Limits Screen active, which requires a security code to access. A numeric display located under Drilling Data provides the current head position. Units are either feet or meters.

NOTE: The head must be properly calibrated for this feature to work. See the Calibration/Limits Screen section for the procedure.

UPPER LIMIT - 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 Calibration/Limits Screen 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.

PIPE RACK LIMIT - 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 Calibration/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 Drill/Propel/Mast Selector Switch is in the DRILL position and the Hoist/Pulldown Selector Switch is in the PIPE RACK/JOINT position.

PROPEL LIMIT - 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 Calibration/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), a Propel With Pipe in Hole Fault indication will be displayed. This fault indication will not prevent propel operation. It is only intended as a status warning message.

LOWER LIMIT - 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 Calibration/Limits Screen active. It should be noted that even if the lower limit function is active, the head will drift slowly 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.

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Rotary Current Bar Graph The Rotary Current Bar Graph shows the electrical current being supplied from the DC drive to the rotary motor in units of amps. A numeric display below the graph shows the actual value, while the graph itself provides relative scaling. The maximum level on the bar graph is not necessarily the maximum current capability. The bar graph is normally green in color but will change to yellow if the operating current rises above 105% of the motor rating, indicating 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 the motor current is in a major overload range. Sustained operation in an overload range will result in an automatic system shutdown. If the bar graph enters the red area, the operator should stop immediately to avoid damage to the motor.

Rotary Speed Bar Graph The Rotary Speed Bar Graph shows the actual rotary 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 level on the bar graph is not necessarily the maximum rotary speed capability.

Bailing Air Pressure Bar Graph The Bailing Air Pressure Bar Graph shows the air pressure in units of pounds per square inch (PSI) or bars, depending on the selected unit setting (see Configuration Screen). A numeric display below the graph shows the actual value, while the graph itself provides relative scaling. The maximum level on the bar graph is not necessarily the maximum system pressure capability.

Hoist/PD Current Bar Graph The Hoist/PD Current Bar Graph shows the electrical current being supplied from the DC drive to the hoist/pulldown motor in units of amps. A numeric display below the graph shows the actual value, while the graph itself provides relative scaling. The maximum level on the bar graph is not necessarily the maximum current capability. The bar graph is normally green in color but will change to yellow if the operating current rises above 105% of the motor rating, indicating 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 the motor current is in a major overload range.

Sustained operation in an overload range will result in an automatic system shutdown. If the bar graph enters the red area, the operator should stop immediately to avoid damage to the motor.

Hoist/PD Speed Bar Graph The Hoist/PD Speed 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 Configuration Screen). A numeric display below the graph shows the actual value, while the graph itself provides relative scaling. The maximum level on the bar graph is not necessarily the maximum head speed.

Hoist/PD Force Bar Graph The Hoist/PD Force Bar Graph shows the force at the bit in units of kilo-pounds (klbs) or kilo-Newtons (kN) depending on the selected unit setting (see Configuration Screen). A numeric display below the graph shows the actual value, while the graph itself provides relative scaling. The maximum level on the bar graph is not necessarily the maximum force.

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NOTE: The head and pipe weight must be properly entered to get a meaningful display. See Machine Settings (accessible from the Calibration/Limits Screen) for more information.

Level Indicator The Level Indicator is located above the Drilling Data box. It displays the level status of the drill as follows: COARSE – This light indicates that the tilt of the machine is less than 2° but greater than 0.5°. Tilt is determined from a mathematical function that looks at both front-to-rear and side-to-side levels. This indication is functional for all machine operating modes.

FINE – This light indicates that the tilt of the machine is less than 0.5°. Tilt is determined from a mathematical function that looks at both front-to-rear and side-to-side levels. This indication is functional for all machine operating modes.

Operating Mode / Brake Released Indicator Box The Operating Mode / Brake Released Indicator Box is located in the bottom left of the Status Screen.

The indicators at the top of the box indicate whether the machine is in drill mode or propel mode. The indicators at the bottom of the box indicate if the head or propel brakes are released, respectively.

Control Enable Button The Control Enable Pushbutton enables control power for the DC drives to allow operation of the head machinery, as well as control of all hydraulic operations. When all conditions are met for operator control the button will blink yellow indicating the ready state. Pressing the button will enable control and turn the Control Enable button green. If at any point the operator wishes to disable control, pressing this button while it is green will put control back into the ready state. If a critical fault or other machine shutdown condition is present on the drill, this button will appear grey and in the off state.

Torque Control The Torque Control Pushbutton toggles the operating mode of the hoist/pulldown master switch operator input. If this button is in the off state the hoist/pulldown drive receives a speed reference signal that is proportional to the position of the hoist/pulldown master switch. If this button is green and in the on state, logic is enabled to send a speed reference to the hoist/pulldown drive that will produce a torque proportional to the position of the hoist/pulldown master switch.

Main Motor Button The Main Motor Button provides indication as to the state of the main motor, as well as a means of turning off the main motor from the HMI. When all conditions are met for starting the main motor the button will blink yellow indicating the ready state. After the main motor is started from the machinery house, the button will turn green indicating that the motor has started and is running successfully. If at any point the operator wishes to shut down the main motor, pressing and holding this button for two seconds while it is green will stop the motor and place the button in the off state.

Hoist Mode Indicators The Hoist Mode Indicators are located in the upper right hand corner of the Status Screen, to the left of the Rotary Mode Indicators. It displays the status of the Hoist speed mode. Its states are as follows: Page 19 of 74

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ENABLE - This light indicates that the hoist mode is active and the hoist/pulldown drive is energized. The indicator is off when the machine is not in the DRILL mode or is prevented from going into the drill mode.

HOIST JOINT MODE - This indicator shows that the hoist/pulldown function is active in the pipe joint mode to allow the head to drift downward for joining pipes together.

HOIST LOW SPEED (turtle) - This icon indicates that the hoist/pulldown function is active in the Hoist Low Speed range for pipe handling, hoisting, or pulldown operations. Both Hoist Low and Pulldown selections share this indicator since both use the same DC field current setting.

HOIST HIGH SPEED (rabbit) - This icon indicates that the hoist/pulldown function is active in the Hoist High Speed range for pipe handling or hoisting operation.

Rotary Mode Indicators The Rotary Mode Indicators are located in the upper right hand corner of the Status Screen. It displays the status of the rotary speed mode. Its states are as follows: ENABLE - This light indicates that the rotary mode is active and the rotary drive is energized. The indicator is off when the machine is not in the DRILL mode or is prevented from going into the drill mode.

ROTARY LOW SPEED (turtle) - This icon indicates that the rotary function is active in the Rotary Low Speed range.

ROTARY MEDIUM SPEED (vertical arrow) - This icon indicates that the rotary function is active in the Rotary Medium Speed range.

ROTARY HIGH SPEED (rabbit) - This icon indicates that the rotary function is active in the Rotary High Speed range.

Master Switch Neutral Indicator The Master Switch Neutral Indicator is a two state indicator located first in the Status box on the right hand side of the Status Screen. It indicates whether the hoist/pulldown, rotary, and propel master switches are in the neutral position. If any of these switches are not in the neutral position, the operator is prevented from changing the operating mode of the drill (propel, drill, mast/winch modes).

Jacks Retracted Indicator The Jacks Retracted Indicator is a two state indicator located second in the Status box on the right hand side of the Status Screen. If all leveling jacks are fully retracted, the indicator turns green. When this indicator is grey, it indicates that all jacks have not been fully retracted, so propel should not be performed.

Lube System Fault Indicator The Lube System Fault Indicator is a two state indicator located third in the Status box on the right hand side of the Status Screen. It indicates that a fault has occurred with the lubrication system.

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Boarding Stairs Down Indicator The Boarding Stairs Indicator is a two state indicator located fourth in the Status box on the right hand side of the Status Screen. If this indicator is green the boarding stairs are currently in the down position.

PDC On Indicator (Option) The PDC On Indicator is a two state indicator located fifth in the Status box on the right hand side of the Status Screen. If this indicator is green, Programmed Drill Control is functional and controlling machine drilling operations. This indicator is only visible if the PDC option has been purchased.

PDC Limit Indicator (Option) The PDC Limit Indicator is a two state indicator located sixth in the Status box on the right hand side of the Status Screen. If this indicator is green, the PDC system is controlling the drilling operation and one or more of the parameters controlled by the system are 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. This indicator is only visible if the PDC option has been purchased.

Hole Clogged Indicator (Option) The Hole Clogged Indicator is a two state indicator located seventh in the Status box on the right hand side of the Status Screen. This indicator will turn red to 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.

Low Water Indicator (Option) The Low Water Indicator is a two state indicator located eighth in the Status box on the right hand side of the Status Screen. If this indicator is red, the water level in the tank for water injection is low and the tank needs refilling. This indicator is only visible if the water injection dust control option has been purchased.

Remote Transmitter On Indicator (Option) The Remote Transmitter On Indicator is a two state indicator located ninth in the Status box on the right hand side of the Status Screen. It indicates when the radio remote transmitter is powered on and within operating range. This indicator is only visible if the radio remote propel option has been purchased.

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Remote Propel Active Indicator (Option) The Remote Propel Active indicator is a single state indicator located last in the Status box on the right hand side of the Status Screen. It indicates when the radio remote propel mode has been selected and control has been turned over to the remote transmitter. The operator cab controls should not be used in this mode. This indicator is only visible if the radio remote option has been purchased.

Hole Depth Numeric Display The actual drilled hole depth is shown in the Drilling Data box located at the bottom of the Status Screen.

The value is displayed in feet or meters. On multi-pass drilling operations, this readout represents the total depth of the hole by summing the depth drilled by each pipe. At the beginning of each NEW hole, the operator must press the Depth Indicator Reset Pushbutton (mounted on the operator’s chair). This will reset the hole depth readout to zero.

Note: On multi-pass drilling cycles, operation of the tool wrench is used to keep track of the pipes for calculating accumulated hole depth and to prevent propelling when the pipe is in the hole. The operator should refrain from manipulating the tool wrench when the machine is drilling. The wrench should only be operated when it is necessary to make or break a drill pipe joint. If these guidelines are followed, the hole depth will be displayed correctly.

Bit Position Numeric Display The actual position of the bit relative to ground level (where the drilling operation begins) is shown in the Drilling Data box located at the bottom of the Status Screen. The value is displayed in feet or meters. At the beginning of each NEW hole, the operator must press the Depth Indicator Reset Pushbutton (mounted on the operator’s chair). This will reset the bit position readout to zero.

Note: On multi-pass drilling cycles, operation of the tool wrench is used to keep track of the pipes for calculating accumulated bit position and to prevent propelling when the pipe is in the hole. The operator should refrain from manipulating the tool wrench when the machine is drilling. The wrench should only be operated when it is necessary to make or break a drill pipe joint. If these guidelines are followed, the bit position will be displayed correctly.

Head Position Numeric Display The current head position is shown in the Drilling Data box located at the bottom of the Status Screen.

The value is displayed in either feet or meters from the top calibration point of the mast.

Water Flow 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 Drilling Data box located at the bottom of the Status Screen. The value is displayed in units of gallons per minute (gpm) or liters per minute (lpm), depending on the selected unit setting (see Configuration Screen).

Mast Angle Numeric Display (Option) The current angle of the mast is shown in the Drilling Data box located at the bottom of the Status Screen. The value is displayed in degrees and is relative to the drill deck (a completely vertical mast is 90°). Angle hole drilling is accomplished at the angles of 70°, 75°, 80°, 85° and 90°. The angle sensor is accurate for the entire range. This indicator is only visible if the mast angle monitor option has been purchased.

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Leveling Screen Button This button is located on the left side of the screen, the second of the four buttons in the submenu. It is used to change the screen to one that displays more detailed leveling and jack status information.

Maintenance Screen Button This button is located on the left side of the screen, the third of the four buttons in the submenu. It is used to change the screen to one that displays maintenance related information such as lubrication system settings, air and oil temperatures, and cooler status.

Mast Operations Screen Button This button is located on the left side of the screen, the fourth of the four buttons in the submenu. It is used to change the screen to one that displays mast pin locations, mast operating conditions, and winch settings.

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Leveling Screen The Leveling Screen is accessible from the Status Screen by pressing the button located in the left side submenu (see Figure 9). It provides more detail on the machine’s level and jack status. This screen shows the right and rear views of the drill with information presented on jack operation, tilt status, and machine operational status. The information is presented in the form of graphical indicators, numeric displays and multi-state indicators.

Each element on the Leveling Screen will be discussed in detail in the following subsections. As on most screens, the current time is shown in the upper right corner. Refer to the Setup section of this manual for information on changing the time format.

The Leveling screen will come on automatically from any other screen whenever the drill is in an active Propel mode of operation or a manual/automatic leveling sequence is active.

Figure 9 - Leveling Screen Front to Rear Level Graph The Front to Rear Level Graph is located on the bottom right of the screen. This gives a relative indication of the machine’s front/rear tilt angle. A moving indicator bar shows the approximate angle of the drill deck in the front/ rear axis. When the indicator is displaying a negative angle it means that the rear end of the machine is low. When the drill is level, the indicator will be centered. In Fine Level mode, the machine can be up to 0.5° off center. In Coarse Level mode, the machine can be up to 2° off center.

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Side to Side Level Graph The Side to Side Level Graph is located on the bottom left of the screen. This gives a relative indication of the machine’s side to side tilt angle. A moving indicator bar shows the approximate angle of the drill deck in the side to side axis. When the indicator is displaying a negative angle, it means that the left side of the machine is low. When the drill is level, the indicator will be centered. In Fine Level mode, the machine can be up to 0.5° off center. In Coarse Level mode, the machine can be up to 2° off center.

Front to Rear Level Numeric Display The Front-to-Rear Numeric Display is located in the numeric display box above the Front-to-Rear Graph.

It summarizes the same information as the indicator described above.

Side to Side Level Numeric Display The Side to Side Numeric Display is located in the numeric display box above the Side-to-Side Graph. It summarizes the same information as the indicator described above.

Level Indicators The Level Indicators are located on the top row in the middle of the screen. It displays the level status of the drill as well as the leveling functions that are available. Its indicators are as follows: FINE – This light indicates that the tilt of the machine is less than 0.5°. Tilt is determined from a mathematical function that looks at both front-to-rear and side-to-side levels. This indication is functional for all machine operating modes.

COARSE – This light indicates that the tilt of the machine is less than 2° but greater than 0.5°. Tilt is determined from a mathematical function that looks at both front-to-rear and side-to-side levels. This indication is functional for all machine operating modes.

AUTO LEVEL DISABLED – This light indicates that the tilt of the machine is greater than 7°, or current conditions will not allow automatic leveling operations. If all other operating conditions are met, the machine must be manually leveled to within the automatic leveling limits to turn off this indicator and allow automatic leveling.

AUTO LEVELING – This light indicates that the drill’s automatic leveling logic is currently functioning and controlling leveling jack operation.

Tilt Numeric Display The Tilt Numeric Display is located in the numeric display box between the Front-to-Rear Graph and Sideto-Side Graph. The tilt value is a combined calculation of both the front-to-rear and side-to-side level indications.

Tilt Warning Indicator The Tilt Warning Indicator is located underneath the numeric display box. It will only be illuminated when the calculated tilt of the drill exceeds 7.5°. An audible alarm will also sound in this condition, although the drill will not shut itself down.

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Jack Ground Pressure Indicators The Jack Ground Pressure Indicators are two state indicators located on the left top row of the screen.

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.

Jacks Retracted Indicators The Jacks Retracted Indicators are two state indicators located second to the left on the top row of the screen. 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 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).

Status Indicators The Status Indicators are located to the right of the Level Indicator panel. The Propel Brake Released indicator is illuminated green when the propel brake has been released and the drill is permitted to propel. The Propel Limit Indicator is illuminated green when the head machinery is raised above the propel limit (see Calibration/Limits Screen), and is in a position that will allow the drill to propel.

Mode Indicators The Mode Indicators are two state indicators located to the right of the Status Indicators. These indicators are illuminated green when the drill is successfully placed into drill or propel mode respectively.

Cable Reel In/Out Buttons (Option) The Cable Reel In and Cable Reel Out Buttons are located in the middle of the screen on the bottom edge, between the machine level graphical displays. They control the manual operation of the optional cable reel, if installed.

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Maintenance Screen The Maintenance Screen is accessible from the Status Screen by pressing the button located in the left side sub menu (see Figure 10). This screen displays useful information and functionality to the drill operator that may not be used as frequently as items on the main Status Screen. Several multi-state indicators and functional buttons make up the majority of this screen.

Figure 10 - Maintenance Screen Hydraulic Oil Indicators Three multi-state indicators are provided to show the condition of the hydraulic oil and hydraulic oil cooler. The High Temperature Fault Indicator turns red when the hydraulic oil reaches 140º F (60º C) and will be associated with a fault indication and a shutdown of the main motor. The Operating Temperature Indicator will turn yellow when the hydraulic oil reaches 100º F (38º C) which indicates normal operating temperature and the point at which the hydraulic oil cooler should be activated. The Hydraulic Oil Cooler On Indicator turns green when the contactor energizing the hydraulic oil cooler is active.

Compressor Oil Temperature The status of the compressor oil temperature is indicated by a numerical display, showing the actual temperature in ºF or ºC, and two multi-state indicators. The High Temperature Warning Indicator turns yellow when the compressor oil temperature reaches 190º F (88º C) as a warning that the oil temperature is approaching its shutdown limit of 200º F (93º C). In addition, the Compressor Oil Cooler On Indicator turns green when the contactor energizing the compressor oil cooler is active.

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Compressor Air Temperature The status of the compressor air temperature is indicated by a numerical display, showing the actual temperature in ºF or ºC, and one multi-state indicator. The High Temperature Warning Indicator turns yellow when the compressor air temperature reaches 212º F (100º C) as a warning that the air temperature is approaching its shutdown limit of 225º F (107º C).

Lubrication System The Lubrication System section provides the operator with the basic functions of the lubrication system.

From here automatic lubrication can be toggled on/off, a manual lubrication cycle can be initiated, and a two state indicator is provided to show when a lubrication cycle is in process.

Window Guard (Option) The Window Guard section provides two buttons for positioning the optional upper window guard.

Holding these buttons will open or close the window guard respectively into the operator’s desired position.

Thread Lubrication (Option) On machines with the thread lubrication option this section provides the button to start a thread lubrication cycle. In addition, a pipe thread lubrication test button is present to toggle the pipe thread lube 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.

House Pressurizing Fan The button in the House Pressurizing Fan section allows the operator to toggle between automatic and manual modes for running the house pressurizing fan. When in manual mode, the fan will run any time control is enabled. In automatic mode it will only run when the main motor is running.

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Mast Operations Screen The Leveling Screen is accessible from the Status Screen by pressing the button located in the left side submenu (see Figure 11). It provides indicators and controls for all mast locking pins as well as information that the operator may need while raising or lowering the mast.

Figure 11 – Mast Operations Screen Pin Status Indicators The center of this screen lists the pin types for the individual machine. These are mast lock pins, mast brace pins, and A-frame lock pins (angle hole option only). When the corresponding pin (left or right) is fully locked or unlocked an indicator will illuminate green to display the condition. No message for any given pin indicates that the pin is in mid-travel or a switch has failed.

Pin Lock/Unlock Buttons Along with the indicators, for all pins there are buttons to move the pins into the locked or unlocked positions. Each button controls both associated pins (left and right) at the same time when pressed.

Pressing any of these buttons will active the associated hydraulic valve for ten seconds or until the pin status indicators detect that both associated pins are in the complete locked/unlocked position. When a button is actively controlling a pair of pins it will turn green to indicate activity.

Mast Operation Conditions The Mast Operation Conditions section contains information that may be useful to the operator while raising/lowering the mast, or positioning the mast for angle hole drilling. All indicators are two state and turn green when the associated condition becomes true. The Mast Vertical Limit Switch Closed, Both Page 29 of 74

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Mast Lock Pins Locked, and Both A-Frame Lock Pins Locked Indicators are only visible if the angle hole option is purchased on the machine. A numeric indicator of the mast’s angle to the drill deck can also be present if the mast angle monitor option is purchased.

Remote Winch Control (Option) If the remote winch option is purchased for a machine this section provides a means of toggling between remote and local winch control. A slider is also provided to allow the operator to select the speed at which the winch will operate when using remote control.

Title Screen The Title Screen is accessible from the <i> button in the upper right corner of every screen (see Figure 12). This screen displays the drill’s model number, serial number, X-Instruction numbers and copyright notice relating to the control and display software. Version number for both the PLC and HMI are also displayed here for documentation, as well as to aid in troubleshooting.

Figure 12 - Title Screen

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Head Calibration and Limits Screen The Head Calibration and Limits Screen is accessible from the Main Menu (see Figure 13). It is used to calibrate the head position encoder and set the operational limits for the head. It is also used to access the Machine Settings and Lubrication Screens. Note: Top and bottom head encoder calibration must be performed before setting head limits.

Access to this screen is password controlled. See the Security section for more information on password protection.

Figure 13 - Calibration & Limits Screen

When this screen is active, speed reference to the hoist/pulldown drive is reduced to 35% of the master switch input and all head limits are disabled.

WARNING: When this screen is active, all limits are disabled. Extreme care must be taken to prevent mechanical damage to the drill.

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Head Calibration The following procedure outlines the calibration routine for the head encoder. This is normally performed at the initial machine erection and should not need to be performed again unless the encoder fails or the PLC/Display program data are lost.

Move the head to the top most part of its range at the mechanical stop. It is recommended that the brake be set before continuing. While not absolutely necessary, any head drift while the button is being pressed in the next step will cause the calibration to be invalidated.

Press the "Top Calibrate" button. The calibrated encoder value below the button will be set to the current Head Encoder Count.

While moving the head down, make sure the Head Encoder Count starts incrementing immediately. If the head makes significant movement with no change in count, it is likely that the calibration did not take. Repeat from step one, making sure the brake is set.

Repeat the process at the lower mechanical stop and press the "Bottom Calibrate". Its value will change to the current encoder count.

Setting Limits Make sure that the head has been calibrated.

Move the head to the location where the limit will be set. The top and bottom limits should be set at the desired extents of the drill head travel during normal drilling operations, which should be a reasonable distance from the mechanical stops. The propel limit should be set to a position that allows the drill bit to clear hole cutting and debris before propelling with a drill pipe in the drill string. The pipe rack limits should be set to a position that allows the bottom of a single pipe to comfortably clear the pipe rack pod during pipe rack operation.

Press the desired limit button. If the location is accepted, the limit value to the right of the button will be updated. If the limit is out of range, the limit indication will not update. In this case move the head to a position within the range of the limit you wish to set and press the desired limit button again.

Head Data Numeric Display The box labeled Drilling Data on the screen shows the current encoder count, head position, hole depth, bit position, mast angle (mast angle option only), and water flow (water injection option only) values. It also shows the hoist/pulldown motor armature current. Total travel is the calculated distance between the top and bottom calibration points. Head data is shown either in feet or meters.

Machine Settings Button This button is located on the left side of the screen, the second of the three buttons in the submenu.

This button navigates to a screen that allows the user to enter machine setting data such as number of pipes and pipe/head weight. See the Machine Settings section of this manual.

Lubrication Button This button is located on the left side of the screen, the third of the three buttons in the submenu. This button navigates to the Lubrication Screen where lubrication timing setting and setup functions can be reached. See the Lubrication section of this manual.

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Machine Settings Screen This screen is used to enter drill setup data needed to properly make various calculations for the display and control system (see Figure 14). It is accessible only from the Calibration and Limits submenu.

Figure 14 - Machine Settings Screen

On the Machine Settings screen enter the total number of pipes the drill is using (in the head and pipe rack), the weight of each pipe, the diameter of each pipe, the total weight of the head including any aftermarket hardware that has been installed, and the pulldown force limit. Weights are entered in kilopounds (klbs) or kilo-Newtons (kN).

Each entry has two values. The lower value is the actual setting in the control system. The upper white value is the input from the user. The input is only transferred to the control system when the user presses the Accept button.

To change the current data, touch the entry box and enter the new setting using the keypad that appears. Once this is done, the upper white box will reflect your entry. After verifying your entry press the Accept button to transfer the new entry to the control system. Refer to the Navigation, Program Control, and Data Entry section of this manual for more information about the pop-up keypad.

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Lubrication Screen The Lubrication Screen is used to set field adjustable lubrication system parameters. It can be accessed by pressing the Lubrication Button on the left side submenu of the Calibration/Limits Screen (see Figure 15).

Figure 15 – Lubrication Screen Timer Setting In order to change timers within the lubrication system logic, values must be entered through this screen.

Typical settings as well as the range of acceptable values are provided for ease in setting up the system.

Pressing the white input field for an associated timer will bring up a keypad where a new timer value can be entered. Pressing the enter button on the keypad will automatically change the timer setting to the entered value. Refer to the Navigation, Program Control, and Data Entry section of this manual for more information about the pop-up keypad. The available 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.

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.

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Lubrication Setup Button Below the lubrication timer table is the Lubrication Setup Button. Pressing this button toggles the lubrication setup mode which performs two functions. First, it performs the same function as holding the manual lube button down continuously. Second, this mode disables the lube system low pressure and vent pressure faults. When active, the background of this button will turn green.

Hour Meters and Fault Counters Screen The Operating Hours & Fault Counters screen shows the length of time certain machine functions have been operating, as well as some cumulative hole and fault data (see Figure 16). This data can provide the maintenance and service personnel with a cumulative fault count of areas that may be experiencing problems. The accumulation interval can be controlled by manually resetting the counters at preestablished intervals and keeping records of machine performance during those intervals.

Figure 16 - Hour Meters & Fault Counters Screen

Total Operating Hours Section The top middle section of the screen shows the total number of hours the drill has been powered on, the total number of hours spent operating the hoist and rotary motors, total hours propelling and the total number of hours the PLC has been turned on. The total number of holes drilled and total distance drilled is also displayed. It is not possible for the user to reset these values, however, they may be lost if the PLC program is reloaded.

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Operating Hours Since Last Reset Section This section displays the same data as described above. However, the user can reset these meters with the Hours and Hole Data reset buttons at the bottom left of the screen.

Fault Counts This section lists the total number of faults in each of several categories since the last user reset. These faults are a compilation of the ANF faults that pertain to the given category. These can be cleared with the Faults Counter Reset Button at the bottom left of the screen.

Counter Reset Buttons The counter reset buttons are located at the bottom left of the display. The three buttons are labeled Hours, Hole Data and Faults. Pressing any of the three buttons will reset the labeled counters (except those in the Total box) to zero.

Lubrication 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 any of the Counter Reset Buttons are pressed. The values should be retained unless the PLC program is reloaded.

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PROGRAMMED DRILL CONTROL SCREENS (OPTION) Overview Programmed Drill Control (PDC) is an automated system that controls all aspects of drilling after a machine has been positioned and leveled correctly. The display screens discussed in this section are used to configure the PDC system and monitor its status while it has control of the machine’s drilling operations. See the machine’s Operator’s Manual for additional information on the procedures for performing PDC drilling.

PDC Operator Settings The PDC Operator Settings Screen is used to set PDC parameters that may very 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. This screen can be accessed by pressing the Programmed Drill Control Button on the Main Menu (see Figure 17).

Figure 17 – PDC Hole Settings Screen

Changing Hole Parameters From this screen the operator has the option of changing the three hole depth parameters. To change the current data, touch the white entry box near the desired parameter and enter the new setting using the keypad that appears. Once this is done, the upper white box will reflect your entry. After verifying your entry press the Accept button to transfer the new entry to the control system (represented by the Page 37 of 74

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black box). Refer to the Navigation, Program Control, and Data Entry section of this manual for more information about the pop-up keypad.

Changing Parameter Presets When this screen is first displayed the Preset Parameters section will be filled with the parameter values that are currently being used by the PDC control system. In addition, the Current Preset section will display the preset that these parameters represent if one has been used. Although the operator does not have the ability to change these parameters individually from this screen, a different preset drilling configuration can be selected. In the Select Preset section touch the white input field to enter a desired preset. Pressing the View button will show the preset values in the Preset Parameters section for review.

Pressing the Accept button will move the Selected Preset into the Current Preset and become the new working parameters for the PDC control system.

PDC Parameters The PDC Parameters Screen is used to set up PDC parameter presets, as well as change individual parameters that cannot be accessed from the PDC Operator Settings Screen. It can be accessed through a button on the left side submenu from any other PDC screen (see Figure 18).

Access to this screen is password controlled. See the Security section for more information on password protection.

Figure 18 – PDC Parameters Screen

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Changing Parameters Within a Preset This screen allows qualified mine personnel to change parameter preset values that can later be selected by the drill operators. In order to view an existing preset touch the white input box in the Select Preset section to select a desired preset, and then press the Load Button. The list of parameters on the left side of the screen will be updated to show the selected preset. From here each parameter value can be manipulated to different values within the parameter’s limits. Once the parameters have been set to the desired values, pressing the Save Button will store the preset values to the PLC processor memory to be accessed later.

NOTE: All values on this screen are temporary values and will not be associated with a preset unless the Save Button is pressed.

Changing Individual Parameters When this screen is first opened, the parameter list will be compiled with the parameters currently being used by the PDC control system. This screen allows for manipulation of individual parameters in the event that a preset is not available for desired parameters. In order to change an individual parameter, manipulate the parameter list to the desired values and then press the Accept Parameter Changes Button. This will set the working PDC parameters to the values entered on this screen without manipulating a preset. This also sets the Current Preset indication on the PDC Operator Settings Screen to 0 to indicate that the current parameter settings do not exist as a preset.

NOTE: All values on this screen are temporary values and will not be set to the working parameter list unless the Accept Parameter Changes Button is pressed.

Bit Specification Pulldown Force Limit This numerical indicator displays the calculated bit pulldown force limit based on manufacture specifications entered in the existing working parameters. This is for reference only and can only be manipulated by entering new data into the Bit Specification parameters.

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PDC Operators Screen 1 The PDC Operating Screen 1 is used to monitor basic machine performance parameters on machines that include the Programmed Drill Control option. The screen can be accessed from the left side submenu from any of the other PDC screens (see Figure 19).

Figure 19 – PDC Operators Screen 1 Performance Parameter Data The data listed on this screen includes actual performance data on the following: 1. Rotary Motor Current and Speed 2. Hoist/Pulldown Motor Current 3. Hoist/Pulldown Force and Rate 4. Bailing Air Pressure 5. Horizontal and Vertical Vibration 6. Water Injection Flow Rate (Water Injection Option Only) 7. Hole Depth 8. Head Position 9. Rotary Motor I Squared T Ratio 10. Hoist/Pulldown Motor I Squared T Ratio This data is useful for checking machine performance during PDC operation and provides reference figures when determining where to set control parameters.

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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, an indicator will appear on the screen in the PDC Regulator Status section. These are from top to bottom: 1.

2.

3.

4.

5.

6.

7.

Bit Specification Limiter (Bit Spec Active) Pulldown Force Limiter Horizontal Vibration Limiter Vertical Vibration Limiter Bailing Air Pressure Limiter Rotary Motor Heating Ratio (Rotary I Squared T Limit) Hoist/Pulldown Motor Heating Ratio (Hoist I Squared T Limit)

Drilling Status Indicators While drilling under PDC control, the system may be in one of several operating stages. As each stage occurs, an indicator will appear on the screen in the Drilling Status section. These are from top to bottom: 1.

2.

3.

4.

5.

PDC Operating Bit at Bottom of Hole System has completed hole (End of Hole) Head Assembly Raising (Hoisting) System in Collaring Stage (Collaring)

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PDC Operators Screen 2 The PDC Operating Screen 2 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 service personnel. The screen can be accessed from the left side submenu from any of the other PDC screens (see Figure 20).

Figure 20 – PDC Operators Screen 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.

Rotary Motor Current Error Bailing Air Pressure Error Horizontal Vibration Error Vertical Vibration Error Pulldown Motor Current Error Total Error for Rotary Total Error for Pulldown Rotary Bit Speed Reference Pulldown Rate Reference

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, an indicator will appear on the screen in the PDC Regulator Status section. These are from top to bottom: Page 42 of 74

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1.

2.

3.

4.

5.

6.

7.

Bit Specification Limiter (Bit Spec Active) Pulldown Force Limiter Horizontal Vibration Limiter Vertical Vibration Limiter Bailing Air Pressure Limiter Rotary Motor Heating Ratio (Rotary I Squared T Limit) Hoist/Pulldown Motor Heating Ratio (Hoist I Squared T Limit)

Drilling Status Indicators While drilling under PDC control, the system may be in one of several operating stages. As each stage occurs, an indicator will appear on the screen in the Drilling Status section. These are from top to bottom: 1.

2.

3.

4.

5.

PDC Operating Bit at Bottom of Hole System has completed hole (End of Hole) Head Assembly Raising (Hoisting) System in Collaring Stage (Collaring)

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TEST AND CONTROL SYSTEM STATUS SCREENS Overview The topics discussed in this section are used for machine testing, troubleshooting, and maintenance.

Operators will not normally access these screens unless assisting in one of these procedures.

Collectively, these screens allow access to a significant amount of machine information pertaining to input/output status, internal setting values, PLC operational status, predefined test modes, and machine status.

Field Tests The Field Tests Screen is accessible from the Main Menu (see Figure 21). It is used for field testing of the electrical, hydraulic, and mechanical subsystems. The tests on this screen allow certain protective circuits to be bypassed for test purposes.

Figure 21 - Field Tests Screen

Access to this screen is password controlled. See the Security section for more information on password protection.

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WARNING: These tests disable certain protections. To prevent serious injury or damage to the drill, make sure you completely understand the consequences of a test before enabling it.

Any given test can be activated by pressing the associated function key. When a test is activated, its button will turn green. Press it again to turn the test off. If desired, multiple tests can occur simultaneously. When any test is active, the buttons that allow you to change screens are hidden.

DISABLE ALL TESTS BEFORE ATTEMPTING TO SHUT THE DRILL DOWN OR LEAVE THIS SCREEN. Note: Your system may have additional tests not described below due to configuration differences.

Test 1 This test energizes Valve Bank 1 Load Control Valve Solenoid (VB1LCS).

Test 2 This test energizes the Jack Loader Valve Solenoid (JLVS).

Test 3 This test energizes the Propel Active Valve Solenoid (POEVS).

Test 4 This test disables the Jack Loader Valve Solenoid to enable Mast/Winch/Pipe Rack operation during jack operation. This test is used to verify certain hydraulic interactions that are normally not allowed as part of regular machine operation. Refer to the mechanical maintenance documentation to determine the details of when to perform this test.

Test 5 This test is used to setup the proportional hydraulic control cards or test the pipe rack valve controls.

The following actions take place during this test: 1. Output Q 6.3 is energized to turn on relay MRLVCR if in the Mast mode or output Q 6.2 is energized to turn on relay WCVCR if in the Winch mode. The drill must be in Drill mode for either action to occur.

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

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

Test 6 This test activates the self test feature of the hydraulic oil tank level sensor on machines with this feature.

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Test 7 This test disables the under speed and over speed sense circuits on machines with the water injection option. It also removes some of the interlocks so the water injection can be tested independent of the air compressor. This test is primarily used during water injection setup.

Test 8 This test will allow the drill to propel without the jacks retracted.

Hydraulic Cards Setup The Hydraulic Cards Setup Screen allows service personnel to force outputs to the proportional hydraulic cards in the initial setup of these cards (see Figure 22). Refer to the “Electrical Operation and Troubleshooting Manual” for the complete procedure. This screen should only be accessed by qualified Bucyrus personnel, but is discussed in this manual for completeness.

Figure 22 - Hydraulic Card Setup Valve Output Buttons Refer to the “Electrical Operation and Troubleshooting Manual” and machine C-Sheets for the complete procedure for setting up the proportional hydraulic cards as well as the most recent settings. Each button on this display forces an output value on proportional hydraulic card EHPC1 or EHPC2 that is necessary in setting the correct current ramp for each signal. The optimum threshold voltage for each signal, as well as all necessary ramp voltages for setting up these devices, are provided on this screen.

After pressing a button to produce one of the ramp setting voltages, the ideal current output for that setting will be displayed under the target output label. Consult C-Sheets to verify these values as they represent the setup of a typical machine and are for reference only.

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NOTE: Only one button for each signal can be active at any given time. In addition, leaving the Hydraulic Card Setup Screen will disable all active signals being forced by these buttons.

Test Screens (Test – Analog I/O) The Test Screens are accessible from the Test – Analog I/O Button on the Main Menu. These screens display all of the analog input and output values as they are read by the PLC. Two screens are available to display analog inputs (see Figure 23) while another screen displays analog outputs (see Figure 24).

These screens are useful for testing the drills control system to determine where problems may exist.

Figure 23 - Test Screen Analog Inputs 1 (Units View)

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Figure 24 - Test Screen Analog Outputs

In addition to the actual value, these screens show the PLC address, symbol, and description of each analog signal.

The display can show values in either voltage/current mode or in units mode. This can be changed by the last button on the left side submenu. In voltage/current mode, the PLC converts its integer signal to the voltage or current that would be measured at the card's terminals. In units mode, the PLC calculates the engineering units (ex. percent, degrees, PSI, etc.) that the raw signal represents.

View Voltage/Current This button is located on the bottom of the left side submenu. It toggles the display between showing the voltage or current measured at the card’s terminals and the engineering units that the integer signal represents. Changing the view on one screen will change it on all screens that use this feature.

Test Screen Buttons These buttons are located on the left side submenu. They have PLC icons with arrows either coming in or out of them. These buttons toggle between the analog input and analog output displays.

Drive Test Button This button is the fourth button on the sub-menu located at the left side of the screen. This button will navigate to the screen used for shop and field drive setup, test and troubleshooting.

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Drive Test Screen The Drive Test Screen is used for shop and field drive setup, test and troubleshooting (see Figure 25).

Access to this screen is password controlled. See the Security section for more information on password protection.

Figure 25 – Drive Test Screen 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)

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 Indicators The Rotary Mode indicator is located in the lower right hand corner of the Drive Test Screen. It displays the status of the rotary speed mode. Its states are as follows: ENABLE - This light indicates that the rotary mode is active and the rotary drive is energized. The indicator is off when the machine is not in the DRILL mode or is prevented from going into the drill mode.

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ROTARY LOW SPEED (turtle) - This icon indicates that the rotary function is active in the Rotary Low Speed range.

ROTARY MEDIUM SPEED (vertical arrow) - This icon indicates that the rotary function is active in the Rotary Medium Speed range.

Rotary HIGH SPEED (rabbit) - This icon indicates that the rotary function is active in the Rotary High Speed range.

Hoist Mode Indicators The Hoist Mode indicators are located in the lower right hand corner of the Drive Test Screen, to the left of the Rotary Mode Indicators. It displays the status of the Hoist speed mode. Its states are as follows: ENABLE - This light indicates that the hoist mode is active and the hoist/pulldown drive is energized. The indicator is off when the machine is not in the DRILL mode or is prevented from going into the drill mode.

HOIST JOINT MODE - This indicator shows that the hoist/pulldown function is active in the pipe joint mode to allow the head to drift downward for joining pipes together.

HOIST LOW SPEED (turtle) - This icon indicates that the hoist/pulldown function is active in the Hoist Low Speed range for pipe handling, hoisting, or pulldown operations. Both Hoist Low and Pulldown selections share this indicator since both use the same DC field current setting.

HOIST HIGH SPEED (rabbit) - This icon indicates that the hoist/pulldown function is active in the Hoist High Speed range for pipe handling or hoisting operation.

Motion Drive Diagnostics The motion drive diagnostics section provides multi-state indicators to track the status of the operator master switches, electric head brake, and air compressor.

Motion Drive Test Functions In normal operation, pressing the Control Enable Button on the Status Screen 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 not 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, Stall, and Bypass provide these capabilities. Refer to the Setup and Troubleshooting sections of the electrical X-instructions for further details on using the test modes.

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.

No PLC rack I/O fault conditions may exist.

2.

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

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3.

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

4.

The compressor motor must be OFF.

5.

The Control Enable Button on the Status Screen must be in the Ready (yellow/flashing) state.

6.

The emergency stop contactor must be CLOSED (i.e., no emergency stop). There cannot be an active ANF000 Emergency Stop Activated Fault displayed.

7.

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

8.

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 Test If all the pretest requirements have been satisfied and the Drive Test Screen is active, pressing the Setup button 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 Setup button will turn green. 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.

Pressing the Setup test button will both initiate test logic and give the control enable signal to the drives.

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 Active Alarm Indicator (see Screen Layout) pops up, press the “X” button and continue with the test.

When power is put onto the drive under test, the Enable indicator will not be illuminated but the drive will be energized. 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 control switch and the speed reference will track the master switch setting directly without any other logic related restrictions.

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.

Drive parameters can be set or changed.

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2.

The drive field current sensor can be calibrated.

3.

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

4.

Drive motor field operating values can be adjusted or checked.

5.

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

6.

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 Setup test button again. This automatically stops the drive under test and unlatches the Setup test mode. In addition, leaving the Drive Test 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 Test If all the pretest requirements have been satisfied and the Drive Test Screen is active, pressing the Stall button will activate the drive stall 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 stall mode is active, the Stall button will turn green. 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.

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

Pressing the Stall test button will both initiate test logic and give the control enable signal to the drives.

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 Active Alarm Indicator (see Screen Layout) pops up, press the “X” button and continue with the test.

When the drive under test in energized, one of the operating status 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 High”, or “Pipe Joints”, indicator will activate, depending on the setting of the hoist pulldown rate selector switch. One second after the respective drives' status indicator Page 52 of 74

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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 Stall test button again. This action automatically stops the drive under test and unlatches the Stall test mode. In addition, leaving the Drive Test 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 test mode. Also, make sure that the input disconnect on the non-tested drive is placed in the closed position.

Bypass Test If all the pretest requirements have been satisfied and the Drive Test Screen is active, pressing the Bypass button 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 Bypass button will turn green. At this point, the compressor start logic is disabled to prevent startup of the compressor motor.

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 bypass test, the master switch for the drive being tested must be in NEUTRAL. To activate the test, press the Bypass button on the Drive Test Screen. This initiates test logic and 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 Active Alarm Indicator (see Screen Layout) pops up, press the “X” button and continue with the test.

When the drive under test in energized, one of the operating status 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 High”, or “Pipe Joints”, indicator 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.

Input power fault Blower control fault Page 53 of 74

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3.

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 Bypass button again. This action automatically stops the drive under test and unlatches the Bypass test mode. In addition, leaving the Drive Test 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 test mode. Also, make sure that the input disconnect on the non-tested drive is placed in the closed position.

PLC/Profibus Menu This submenu is used to access PLC troubleshooting data screens described below (see Figure 26). It is accessible from the Main Menu selection row.

Figure 26 - PLC/Profibus Menu Features accessible through this submenu include PLC data block values and PLC/Profibus status information. Additionally, the status of all inputs and outputs on each of the I/O racks can be viewed. As with the Main Menu, simply pressing the appropriate button will change the screen.

Refer to the section on the individual screens for more information.

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Data Block Values Screen This screen is accessible from the PLC/Profibus submenu (see Figure 27). It allows the user to view the contents of data bocks in the PLC. The value of any valid address can be displayed. The addresses can be found by looking at the PLC software documentation.

Figure 27 - Data Block Values Screen Entering Addresses Once the address is known, perform the following steps to display the values. In the PLC, the address format is as follows, where the values in brackets are numbers or choices that refer to the actual DB: DB[number].DB[X,B,W,D][byte].[bit] Touch the DB box in the desired row and enter the Data Block number. In the address above, this is show as [number].

Touch the Type box repeatedly until the desired type is shown. Types are as follows: Bit - DBX, Byte DBB, Word - DBW, Double Word – DBD, and Real Number - REAL NOTE: The data type real number has a DBD address, but has a different structure than normal double words. If attempting to view an address containing a real number, make sure that REAL is selected in the Type field, despite the address being DBD. Touch the Byte box and enter the starting byte of the desired address. In the address above, this is shown as [byte].

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If you are looking for a bit, touch the Bit box and enter the desired bit (0-7). Note that this box is not visible with anything other than DBX. In the address above, this is shown as [bit].

These steps will return the desired value from the PLC. Note that in some cases the resulting value will be too large to display on the screen. In that case, the Value field will be filled with asterisks. Also note that the display will always show the values in decimal format. Sometime the PLC program is using hexadecimal, so the numbers displayed here may need to be converted.

PLC Diagnostics Screen The PLC Diagnostics Screen is accessible from the PLC/Profibus submenu (see Figure 28). It displays certain diagnostic information about the PLC without the need of a laptop computer. This screen is primarily used for troubleshooting PLC and data communication faults. It is expected that users of this screen are extremely familiar with the data communication network and hardware used on this drill.

Refer to the manufacturer of the specific hardware component for more information on the codes supplied. Many of these codes can be found in the appendices of the “49HR Electrical Operation and Troubleshooting Manual”.

Figure 28 - PLC Diagnostics Screen

Profibus Node Data The top part of the screen shows the status of the Profibus nodes (Remote I/O). The "Nodes" indicators are green if the associated node is OK, red if there is a fault (i.e., the node is offline), or yellow if the node has some other problem. The box below these indicators shows the fault information for the currently selected node. Nodes and errors can be cycled through with the two buttons in the center of Page 56 of 74

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the information box. Refer to Appendix D of the “49HR Electrical Operation and Troubleshooting Manual” for an explanation of these codes.

Processor Scan Data To the right of the Profibus information box is the scan time information. This shows the current amount of time it takes the PLC to execute the program once. It also shows the maximum and minimum times.

Note that the maximum time usually occurs during the power-up cycle when system tests are performed.

A high number here does not necessarily indicate a problem.

Processor LED Status To the right of the screen, is a box that shows the LED status on the front of the PLC processor. Refer to Appendix B of the “49HR Electrical Operation and Troubleshooting Manual” for the meaning of these LED’s. Note that in many error cases, it will be necessary to view the processor directly, since the display is not operational if the processor is not running.

PLC Diagnostic Buffer The bottom right section of the screen shows the most recent codes in the PLC's diagnostic buffer.

These codes sometimes refer to errors and other times are acknowledgements of certain functions. Note that these codes are shown in decimal format. It may be necessary to convert them to hexadecimal when checking their meaning. Refer to Appendix C of the “49HR Electrical Operation and Troubleshooting Manual”.

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Rack Display Screens From the PLC/Profibus submenu, there are links to each of the PLC racks. A sample screen from the Main Processor Rack is shown in Figure 29. These screens show the current status of all analog and digital I/O in their actual locations on the drill. Each set of screens refers to one of the remote I/O racks and shows all of the cards assigned to that rack.

Figure 29 - Sample Rack Display Screen

Navigation Each screen has set of buttons along the left side that allow the user to move directly from one remote I/O node to another by simply choosing the appropriate button.

Digital I/O Cards Digital input and output cards are shown similar to how they appear in real life. When an I/O point is active, the associated LED turns green. The I/O address is shown next to the groups of LED's (ex. I2.1).

The bit address is also the number (0-7) next to the LED. This helps in cross-referencing the displayed values to the machine schematics or to the PLC program.

Analog I/O Cards Analog input and output signals are shown on their associated card, below the corresponding address.

These can be displayed either as integer values (as interpreted by the PLC) or as voltages and currents measured at the card’s terminals. A toggle button on the left side of the screen allows the representation Page 58 of 74

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to be changed. In the raw mode, signals normally have a range of ±32767 including over-range values.

This range is reduced to ±27648 for the full range.

View Voltage/Current – View Integer Button This button is located on the left side of the screen at the bottom of the sub-menu, and toggles the display between showing the voltage or current measured at the card’s terminals and the integer signal in the PLC. Changing the view on one screen will change it on all screens that use this feature.

Timers/Counters Screen This screen is accessible from the Main Menu (see Figure 30). It allows the user to view the preset and time values of the timers and the current count of the counters in the PLC. In order to use this screen, it is necessary to know the timer or counter address, which can be found in the PLC software documentation.

Figure 30 - Timers/Counters Screen Entering Addresses Once the address is known, perform the following steps to display the values.

Touch the Timer/Counter box in the first column to select either "T" for Timer or "C" for Counter. These values toggle back and forth.

Enter the address number in the second box. This will completely specify the desired timer or counter.

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For timers, the Value is the current count of the timer in the same units. It will be 0 if the timer is done or has not yet started. For counters, only the Value is returned. This is the current count of the counter.

Active Logic The Active Logic Screens are a troubleshooting feature first used on Bucyrus AC shovels. A simplified version of this feature is included with the 49HR drill. Active Logic is a form of ladder logic diagram that gives an overview of certain control related functions, without needing to connect to the PLC and actually read the program. For each major control, the permissives are represented by blocks, with their labels below them. When the box is red, that implies that the particular function is in the wrong state to allow control to pass through. When the box is green, that implies that the particular function is in the proper state for control to occur. When a complete path of green boxes exists from the start of the line all the way through to the control function (represented by a circle), the necessary permissives have been set and the control is enabled. Note that there may be parallel paths through the logic. Only one of these needs to be active for the control to be enabled (see Figure 31).

Figure 31 – Active Logic

Active Logic Menu This menu, which is located on the left side of the screen, provides access to all the other Active Logic screens.

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ALARMS, FAULTS, AND MESSAGES Overview The operator display serves as a means of informing its users when various alarm or fault conditions occur on the drill. It also records these conditions in a short-term history so the user can see problems that may have occurred during the current operating session.

Whenever a new alarm, fault, or message occurs, the triangle shaped Alarm Icon will flash and an audible alarm sounds. A yellow message banner will also appear at the top of the screen below the Bucyrus name that displays the alarm number and description of the most recent alarm. Other screens allow the user to see all currently active alarms/faults, as well as the short-term history.

Alarms, faults, and messages are always referred to by their ANF (Annunciated Fault), or ANW (Annunciated Warning) number. If you are contacting Bucyrus about a specific message, make sure that you know its exact ANF or ANW number.

The features of each of the alarm screens are described below.

Latched Faults All ANF faults are “Latched Faults”. These remain active until the operator clears them, even if the situation that caused the fault has been corrected. The primary purpose of these is to have the operator acknowledge faults that have disabled control of the machine or a particular function. Control will not be re-enabled until the latched fault is reset, even if the condition that caused the fault is no longer present.

To clear a latched fault, the operator needs to press the Latched Fault Reset Button on the Active Alarms screen. The button is indicated by a “hand pointing a finger” icon. In order for the reset button to take effect, all master switches must be in the neutral position.

Audible Alarm Whenever a new alarm, fault, or message occurs, an audible beeper will sound for a preset period of time. The beeper will automatically shut itself off after the time has elapsed or as soon as the flashing Alarm icon has been pressed. The alarm beeper can also be permanently disabled with an option setting on the Configuration screen. Refer to the Configuration section of this manual for more information.

Alarm History Button This button appears at the bottom of the screen. It is used to bring up the short-term history window, which lists all alarms, faults, or messages that have recently occurred.

Active Alarms Button This button appears at the bottom of the screen and is a triangle shaped icon with an exclamation point inside. It is used to bring up the list of all currently active or currently latched alarms, faults, and messages. Pressing this button will silence the audible alarm. This button is not visible while on the Field Test screen.

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Alarm History Screen The Alarm History screen can be accessed from the Main Menu or from one of the other Alarm screens.

This screen is used to display a brief history of alarm, fault, and message activity (see Figure 32).

Figure 32 - Alarm History Screen

Alarm History List The Alarm History List takes up the majority of the screen and lists all of the alarms, faults, and messages currently recorded since the display was powered up. The most recent event is shown on top.

The first two columns list the date and time that the event occurred. The third column lists the alarm number (ANF/ANW) which is the primary key to identifying the message. The fourth column lists a brief description of the alarm. If the number of events is large enough, the Page Up and Page Down buttons to the left of the list can be used to scroll through the list one page at a time. It is also possible to sort the ANF list by any of the columns by touching the column header. Double tapping a row or highlighting it and selecting the open book icon will bring up a page describing the alarm.

Note, it is possible that the list may contain a number of messages identified as “Spare”. This generally occurs at power-up or when the PLC and display programs are changed. The existence of these messages do not pose any problem. They can be safely ignored.

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Active Alarms Screen The Active Alarms Screen can be accessed from the Main Menu or from one of the other Alarm screens (see Figure 33). This screen lists all of the alarms, faults, and messages that are currently in the active or latched states. Pressing the button to reach this screen will silence the Audible Alarm. The screen also allows latched faults to be reset.

Figure 33 - Active Alarms Screen

Active Alarms List The Active Alarms List takes up the majority of the screen and lists all of the alarms, faults, and messages currently active or latched. The first two columns list the date and time that the event occurred. The third column lists the alarm number (ANF/ANW) which is the primary key to identifying the message. The fourth column lists a brief description of the alarm. If the number of events is large enough, the Page Up and Page Down buttons to the left of the list can be used to scroll through the list one page at a time. Like the Alarm History List, it is also possible to sort the ANF list by any of the columns by touching the column header. Double tapping an ANF row or highlighting it and selecting the open book icon will bring up a page describing the alarm.

Alarm History Button This button appears in the bottom row exactly in the middle of the screen. It is used to bring up the short-term history window, which lists all alarms, faults, or messages that have recently occurred.

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Export Alarm History Button This button is located on the bottom of the left hand submenu and navigates to a screen by which the operator or service technician can export the alarm history list to an external memory device in the form of a CSV spreadsheet.

Latched Fault Reset Button This button is located toward the left bottom of the screen and has a “hand pointing a finger” icon surrounded by a red rectangle. It is only visible when there are active faults that can be reset with this button. Pressing this button resets all of the currently latched faults if the problem that caused the fault has been eliminated and all master switches are in neutral when the button is pressed.

Export Alarm History Screen The Export Alarm History Screen can be accessed from the left hand sub-menu found on either of the alarm screens (see Figure 34). This screen allows the operator or service technician to export the alarm history list to an external memory device in the form of a CSV spreadsheet.

Figure 34 – Export Alarm History Screen

In order to successfully export alarm history data, navigate to the Export Alarm History screen as seen above. Press the Find Local Drives or Find Network Drives button depending on the intended location for the resulting CSV file. Under the Destination Drives Available heading, select the drive where the CSV file is to be stored and then press the Export CSV Alarm Data button located in the middle of the display. At this point, the CSVPath and Enter File Name fields will be filled in (if a keyboard is available the user has the option of entering a unique file name under the Enter File Name Field), and the user is shown option Page 64 of 74

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buttons to either Cancel or Save CSV Alarm Data. Pressing the Save CSV Alarm Data will create the CSV alarm file in the specified directory, and then return the display to its original state. If any errors occur during the exporting of the data, troubleshooting information will be displayed in the bottom Status window.

NOTE: This utility does not have the ability to overwrite directory paths when creating an alarm data CSV file. Ensure that the directory shown in the CSVPath field does not exist before attempting to export data.

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DISPLAY SETUP AND MANAGEMENT Overview This section discusses the setup of user selectable options, and security codes as well as date and time formats. It also discusses the procedures necessary to setup display hardware.

Configuration Screen The Configurations Screen is accessible from all screens except the Field Test Screen. It is used to set passwords, enable user-selectable options, and enter certain machine settings. The button for this screen is located in the top menu and is represented by a gear icon (see Figure 35). Access to this screen is password controlled so that only the Administrator password can access it. See the Security section for more information on password protection.

Figure 35 - Configuration Screen

This screen allows the administrator to select how the time, date, and engineering units will be displayed on all other HMI screens. The date can be toggled between Day-Month-Year and Month-Day-Year format by touching the corresponding radio button. The time can be toggled between 24-hour and 12-hour format by touching the corresponding radio button. Engineering units can be selected on an individual basis, by pressing the displayed radio buttons, or categorically, by pressing the buttons located to the right of the unit selection boxes.

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Option Setup The Option Setup area of the Configuration Screen is where various machine setup options, not necessarily related to purchased options, can be turned on and off based on user preferences.

Note: Your system may have additional options not described below due to configuration differences.

Option 1 This option disables the self test circuit for the Hydraulic Tank Oil Low Level Switch (HTOLLS).

Option 2 On machines with a hydraulic dust curtain, this option enables the dust curtain to raise automatically when the drill is switched to propel mode. This button is only visible if the Hydraulic Dust Curtain option has been purchased.

Option 3 On machines with Programmed Drill Control (PDC), this option will stop the hoist operation at the end of the hole at the propel limit, instead of the start of hole position. This button is only visible if the PDC option has been purchased.

Option 4 On machines with PDC, this option controls the pulldown reference to limit the rotary current to a predefined setting. This button is only visible if the PDC option has been purchased.

Option 5 On machines with PDC, this option enables the horn to sound when a hole is finished. To silence the alarm horn at the end of the hole, press the Control Enable Button on the Status Screen. This button is only visible if the PDC option has been purchased.

Option 6 This option allows the head machinery to slowly drift downward while the hoist/pulldown master switch is in the neutral position no matter what hoist mode is selected (Normally this functionality is reserved for Pipe Joints Mode).

Option 7 On machines with cable reels installed, this option disables cable reel operation unless the drill is placed into propel mode.

Option 8 This option enables the operator to level the drill, or retract leveling jacks, with one touch of the automatic leveling switch on the operator’s chair. If this option is disabled, the operator must hold down the automatic leveling switch to enable automatic leveling logic.

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Password Setup Each password is listed in the Password section on the screen, along with the screens that can be accessed by each user. The Password Screen can be accessed through the left side submenu when on the Configuration Screen (see Figure 36).

To change a password, touch the desired entry box and enter the new password using the keypad that appears. Once this is done, the white box will change to reflect your entry. Passwords are numbers only, in the range of 100 to 32000. The following table shows each of the screens with security attached and the users that may access each screen.

Configuration Calibration PDC Parameters Drive Tests Field Tests Operating Hours

Admin X X X X X X

User 1

User 2

X X X X X

X

User 3

User 4

User 5

User 6

X X X X

Figure 36 - Password Configuration Screen

WARNING: Do not forget the Administrator password.

Without it, this screen cannot be accessed. It cannot be recovered without a service call from Bucyrus.

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Language There is a Change Language Button that is accessible from most screens located in the upper left corner of the display. Simply press this button to view the language options (see Figure 37). Note, however, that the Change Language Button is disabled if the air compressor motor is running. This is because system control needs to be off. It usually takes a few seconds for the screen to change to the new language and if control was running during the change, unspecified faults may occur. The languages that are available to each machine may depend on region and software version.

Figure 37 - Language Screen

Touch Screen Calibration It may happen that the touch screen requires calibration. This will be needed if you find that the screen is not being activated in the exact location that it is being touched. To recalibrate the screen, contact Bucyrus for the procedure, as it requires exiting the application into the Windows environment where great harm could be inflicted. Note that you will need a mouse to properly calibrate the screen. Refer to the Hardware section of this manual for details. Note: These instructions may be slightly different depending upon your version of the display hardware.

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TROUBLESHOOTING AND FREQUENTLY ASKED QUESTIONS What do I do if I see a yellow banner with the words “PLC COMMUNICATION LOST”?

This means that there is a communication problem between the display and the PLC. Check the following items.

Make sure the LED labeled RUN on the PLC is green.

Check to see if any of the other remote I/O stations are faulted or offline.

Make sure the Ethernet cable is properly attached to the display and processor.

Make sure the Profibus cable (purple hose) is properly attached to the processor and all other remote I/O stations.

Make sure the Ethernet cable has not been damaged.

Make sure the Profibus cable (purple hose) has not been damaged.

Check the termination resistor switch in the connector to the processor and all other remote I/O stations.

It should be set as shown in the schematic. Normally, this means that if there is one cable going in, the switch is set to ON. If there are two cables, the switch is set to OFF. Check that the correct program is running in both the PLC and the display.

How do I change the time and date?

Time and date can be changed directly from the standard screens. Touch the clock in the upper right corner of most screens to bring up the Microsoft Windows “Date and Time Properties” window. If the window goes away either the display needs to be restarted, or you have to exit the application into Windows. Refer to the manual section on Display Setup and Management for the procedure on setting the time and date format.

When I touch the screen nothing happens or a button is activated that doesn’t line up with where I touched. Do I need to buy a new unit?

Normally, this generally means that the touch screen is not properly calibrated. This is especially the case if the unit is new and was not setup properly. Refer to the manual section on Display Setup and Management for the procedure on Touch Screen Calibration.

I forgot the Administrator password. How can I get it back?

The Administrator password is the key to the display security. As such, there is no documented way for the user to extract it. If you need to retrieve the password, it will be necessary to contact the Bucyrus service organization for help.

Can I make the display brighter?

The brightness of the display can be adjusted using the “+” and “-” buttons on the right side edge of the display, above the power button. See Figure 3.

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Appendix A – ANF Messages The following table is a representative list of the fault and alarm conditions along with their ANF numbers. These faults will appear on the Active Alarms Screen when the associated condition is present and will stay active until the condition is corrected and the Fault Reset Button is pressed by the operator (see Alarms, Faults, and Messages section). Note that the actual list may differ due to options or version.

Alarm

Message

ANF000 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 ANF037 ANF038 ANF039 ANF040 ANF041

Emergency Stop Active Emergency Stop Circuit Fault Operator Control Screen Communication Fault Spare Spare Spare Hydraulic Oil Overtemperature Hydraulic Oil Filter Clogged Hydraulic Oil Cooler Control Fault Hydraulic Tank Oil Level Sensor Fault Phase Sequence Line Fault Auxiliary Ground Fault Rotary Motor Blower Control Fault Rotary Input Power Fault Rotary Stall Fault Rotary Drive Incomplete Sequence Rotary Drive Internal Fault Rotary Field Loss Rotary Field Overcurrent Hoist/Pulldown Drive Internal Fault Hoist/Pulldown Field Loss Hoist/Pulldown Field Overcurrent Hoist/Pulldown Motor Blower Control Fault Hoist/Pulldown Input Power Fault Hoist/Pulldown Stall Fault Hoist/Pulldown Drive Incomplete Sequence House Fan Fault Water Injection Drive Fault Water Injection Low Water Level Drill Mode Low Lube Pressure Propel Mode Low Lube Pressure Lubrication System Vent Fault Drill Bit Lubrication Level Low Jacks Not Retracted in Propel Mode Air Compressor Oil Pump Start Failure Air Compressor Failure Air Compressor Oil Cooling Failure Air Compressor High Air Temperature Fault Air Compressor Oil Pressure Switch Fault Air Compressor High Oil Temperature Fault Air Compressor Oil Cooler Fan Control Fault Air Compressor Control Fault Page 71 of 74

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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 ANF080 ANF081 ANF082 ANF083 ANF084 ANF085 ANF086 ANF087 ANF088 ANF089 ANF090 ANF091 ANF092 ANF093 ANF094 ANF095 ANF096 ANF097 ANF098 ANF099 ANF100 ANF101 ANF102

Air Compressor Oil Pressure Low Head Brake Release Fault Head Brake Setting Fault Head Brake Forcing Circuit Fault Head Brake Sensor Switch Fault Head Encoder Fault Head Overspeed Fault Cable Reel Control Fault Radio Remote Tilt Shutdown Radio Remote Fault 24VDC Control Power Fault 24VDC Input Power Fault 24VDC Node 2 Output Power Fault 24VDC Node 3 Output Power Fault 24VDC Node 4 Output Power Fault 24VDC Node 5 Output Power Fault 24VDC Utility Power Fault Main Processor Rack 1 Card Fault Profibus Node 1 Main Processor Rack Fault Profibus Node 2 Fault Profibus Node 3 Fault Profibus Node 4 Fault Profibus Node 5 Fault Master Switches Not In Neutral Rotary Motor Overtemperature Fault Hoist/Pulldown Motor Overtemperature Fault Hydraulic Tank Low Oil Level PIW256 (RCPAV) Input Out of Range PIW258 (RCPAC) Input Out of Range PIW260 (RCPFC) Input Out of Range PIW262 (HCPAV) Input Out of Range PIW264 (HCPAC) Input Out of Range PIW266 (HCPFC) Input Out of Range PIW268 (RRRRMS) Input Out of Range PIW270 (RRRLMS) Input Out of Range PIW272 (ACPT) Input Out of Range PIW274 (ACOTT) Input Out of Range PIW276 (ACATT) Input Out of Range PIW278 (WIMS) Input Out of Range PIW280 (VVM) Input Out of Range PIW282 (HVM) Input Out of Range PIW284 Input Out of Range PIW286 (MAM) Input Out of Range PIW288 (RMS) Input Out of Range PIW290 (HPMS) Input Out of Range PIW292 (SSLM) Input Out of Range PIW294 (FRLM) Input Out of Range PIW296 (WIDFC) Input Out of Range PIW298 (POLMS) Input Out of Range PIW300 (PORMS) Input Out of Range

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Appendix B – ANW Messages The following table is a representative list of the warning conditions along with their ANW numbers.

These warnings will appear on the Active Alarms Screen when the associated condition is present, but will automatically be removed from the list if the condition is corrected. Note that the actual list may differ due to options or version.

Warning

Message

ANW000 ANW001 ANW002 ANW003 ANW004 ANW005 ANW006 ANW007 ANW008 ANW009 ANW010 ANW011 ANW012 ANW013 ANW014 ANW015 ANW016 ANW017 ANW018 ANW019 ANW020 ANW021 ANW022 ANW023 ANW024 ANW025 ANW026 ANW027 ANW028

Air Compressor Starts Per Hour Exceeded Hoist/Pulldown Drive Ground Fault Rotary Drive Ground Fault Hoist/Pulldown Motor Overload Rotary Motor Overload Automatic Lubrication Not Enabled Head Limit Data Out of Range Air Compressor Air Over Temperature Hydraulic Tank Valve Closed Propel Brakes Released For Towing Rotary Motor Over Temperature Hoist/Pulldown Motor Over Temperature Rotary Master Switch Mis-Aligned Hoist/Pulldown Master Switch Mis-Aligned Pipe In Hole Warning For Propel Propel With Stairs Down Tip Warning (Deck Angle Greater Than 7.5 Degrees) Automatic Level Limit (Deck Angle Greater Than 7 Degrees) Leveling Jack Stud Air Compressor Oil Filter Clogged Communication Module Link Fault Spare HMI Running On UPS UPS Alarm UPS Battery Low Spare Spare Programming Forces Active Air Compressor Oil Pressure Switch Failure To Reset

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REVISIONS Revision

Date

Description

0

February, 2010

Original Release. Adapted from X-4133 (39HR) for the 24VDC 49HR/HX.

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