CAT Continuous Haulage Control System (8 Unit) MCU-930 Pocket Guide BI016956 - PDF DOWNLOAD

BI016956 A6474X276 May 2013

Pocket Guide Continuous Haulage Control System (8 Unit) Model – MCU-930

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PUBLICATION DISCLAIMER AND COPYRIGHT This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations nor to provide for every possible contingency in connection with troubleshooting and maintenance. Features may be described herein which are not present in all systems. Caterpillar assumes no obligation of notice to holders of this document with respect to changes subsequently made.

Caterpillar makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein.

No warranties of merchantability of fitness for purpose shall apply.

© CATERPILLAR 2012 ALL RIGHTS RESERVED

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______________ Manual contents Table of contents 1. Safety General safety notices ....................................... 1.3 Safety recommendations ................................... 1.4

2. Components 3. Schematics 4. Troubleshooting How to troubleshoot the system ....................... 4.3

5. System status indicators Status LED functional categories ...................... 5.3 Status LED descriptions .................................... 5.9

6. Fault code information Fault codes ......................................................... 6.3

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______________ Manual contents List of tables Table Table 5.1: LED functional categories.................5.8 Table 5.2a: LED description (R1 & R2) ................5.9 Table 5.2b: LED description (R3 & R4) .............. 5.10 Table 5.2c: LED description (R5 & R6) .............. 5.11 Table 5.2d: LED description (R7 & R8) .............. 5.12 Table 5.2e: LED description (R9, R10, & R11) ... 5.13 Table 5.2f: LED description (R12 & R13) .......... 5.14 Table 5.2g: LED description (other) ................... 5.15 Table 6.1: Normal operation fault codes ...........6.4 Table 6.2: Fault codes ........................................6.5

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______________ Manual contents List of figures Figure Fig. 1: CST .............................................................. 2.3 Fig. 2: Display ........................................................ 2.4 Fig. 3: MCU ............................................................. 2.5 Fig. 4: Communication diagram............................ 3.3 Fig. 5: MCU-930 faceplate LED legend (left) ........ 5.5 Fig. 6: MCU-930 faceplate LED legend (middle) .. 5.6 Fig. 7: MCU-930 faceplate LED legend (right) ...... 5.7

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______________ Manual contents

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Safety

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______________________ Safety General safety notices This section addresses some general safety guidelines involved with Caterpillar products. These guidelines are intended to promote safe usage of equipment.

This section is not intended to replace present safety practices at your site.

It is the responsibility of the contractor, installer, purchaser, owner, and user to install, maintain, and operate the parts or components manufactured and supplied by Caterpillar in such a manner as to comply with the MSHA Safety Standards and all state and local laws, ordinances, regulations.

WARNING: If malfunctions occur in any aspect to the CST (control station) or the MCU (machine control unit) do not continue to operate; power down the system, fill out the service tag, and return it to the factory for inspection and repair. When the system is in use and if any part of the unit is damaged physically, discontinue operation and return it to the factory for inspection and repair.

At anytime during usage of the system any damage is found physically or electronically, it is crucial for the safety of the operator and others in the operating area that the system is not allowed to continue in operation.

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______________________ Safety Safety recommendations Ghosting (gosting), v., 1: Unplanned movement by machines that use Computer Control Technology.

The Mine Safety and Health Administration has recognized a problem involving malfunctions of electro-hydraulic shield advance systems at various longwall installations. This has lead MSHA to issue the following recommendations for the safe operation of all computer controlled mining equipment to prevent the condition known as ‘ghosting’.

The recommendations are as follows: 1. Mine personnel who operate this equipment should be trained to insure the proper operational procedures and sequences are used to recognize improper system operation, alarms, and displays.

2. Maintenance of the system is critical for safe operation.

Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3. Mine personnel should be made aware that the entry of moisture or water into the transmitter or umbilical enclosure could cause undesired machine movements.

Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure Control Unit Troubleshooting Guide

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______________________ Safety sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field. When signs of moisture or water are observed in the control unit enclosure, the units must be immediately replaced.

4. Any abnormal operational sequences of the system, alarm displays, or unintended machine movement which might be due to a software programming error should be noted, reported to the manufacturer, and corrected immediately.

5. Any equipment removed to correct “ghosting” problems should be sent to the manufacturer to determine the exact cause of the problem. Corrective action will then be taken by either the manufacturer or the operator to prevent similar occurrences.

6. Whenever an unplanned machine movement is observed, the hardwired emergency stop system should be activated, not the stop button on the electronic control unit.

7. These recommendations, though originally made in response to the unplanned movement of longwall shield advance systems utilizing computer control technology, are equally applicable to all equipment with machine control circuits utilizing computer control technology. The recommendations above should be followed on a continuing basis on all machines utilizing computer control technology.

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______________________ Safety

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Components

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_________________ Components Component identification This section describes the components that make up this control system.

I.S. Umbilical Station (CST) The CST (Fig. 1) is located in the operator’s compartment on each MBC. Each CST is connected via a barrier to the MCU’s Serial Port No. 3 (R13). The CST is a stainless steel enclosure that houses the control switches, push buttons, and tram handles that are necessary to control the operation of one MBC and one outby PIG. Display Unit The display unit (Fig. 2) is located in the operator’s compartment on each MBC. Each display unit is connected to the MCU’s Serial Port No. 2 (R10). The display unit provides the operator with machine status and fault/trip information from the control system. The display is a vacuum fluorescent, four line, twenty character display. The display is equipped with an infrared receiver to allow changes to be made to the set up parameters. The display is also used to access the fault log (a log of the last 256 faults).

Machine Control Unit (MCU) The MCU (Fig. 3) is located on the center panel board of each starter enclosure. The MCU receives and processes control information from the CST and the control and monitoring of the electrical components of the haulage system.

The flow of information is bi-directional: the most outby MCU is the lead MCU and the other MCUs receive and send information to the lead MCU. A6474X276

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_________________ Components Fig. 1: CST

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_________________ Components Fig. 2: Display

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_________________ Components Fig. 3: MCU

MCU

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_________________ Components Infrared Programming Adaptor (HDU-100) An infrared programming adaptor (one per system) is provided to allow changes to be made to the set-up parameters, to access faults stored in memory, and to operate a single MBC for testing and maintenance.

Power Up Upon power up, the HDU-100 displays as shown in Fig. 4. The display show the system name and the date of the operating software. This display show for approximately five seconds and then switches to a display similar to that shown in Fig. 5 Fig. 4: Initial display

The follow-up display (Fig. 5) shows the current time and date as the day of the week, the date (in mm dd yyyy format), and the time ( in hh:mm:ss format).

Fig. 5: Time and date display

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_________________ Components After approximately ten seconds, the display changes to show Outby MBC Mode (dependent on mode selected), Outby Conveyors On (dependent on mode selected), and the current status (dependent on mode selected and the condition of other attached units) (Fig. 6).

Fig. 6: Outby information and status (mode dependent)

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_________________ Components Menu (1) Programming mode PROGRAMMING MODE menus allow you to set Delay settings for the PSW, AUX Contact Delay, CONV. MOTOR stagger, and whether or not you are in manual mode.

These menus sequence by using the Page Up and Page Down buttons. Figure 7 show the display sequencing using the Page Up. X MSG/SEC is the number of messages per second for each screen.

The UP button is used to increase the numeric value by 0.1 increments per press to a maximum value of 5.0.

The DOWN button is used to decrease the value by 0.1 decrements per press to a minimum value of 2.0.

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_________________ Components Fig. 7: Program mode menu sequence (Page Up)

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_________________ Components Menu (2) Modify Time/Date MODIFY TIME/DATE menus allow you to modify the time and date. These menus sequence using the Page Up and Page Down buttons. Figure 8 shows the display sequencing using the Page Up button.

The UP and DOWN keys of the remote allow you to change the two digit numbers and the week day.

Fig. 8: Modify time/date menu sequence (Page UP)

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_________________ Components Menu (3x) ERR Log--Rec# The Error Log Date is laid out in the DMM/DD/YY format, where D is for date, MM is the month, DD is the day of the month, and YY is the year.

The Error Log Time is laid out in THH:MM:SS format, where T is for time, HH is for hour, MM is for minute, and SS if for second.

Information displayed refers to unit(s) involved.

The UP and DOWN buttons change REC# (record number) one per button press.

Page UP and Page DOWN do nothing.

SET pressed five (5) times when REC#0 is displayed will clear all ERR LOGs. Fig. 9: ERR Log---REC#

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_________________ Components Menu (4) System Comm Stat The SYSTEM COMM STAT Menu shows the communication status. This is a static, read only screen where UP/ DOWN and Page UP/Page DOWN do nothing.

Pressing the Menu button on the remote returns you to (1) Programming Mode.

Fig. 10: System communication status

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_________________ Components

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Schematics

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__________________ Schematics

  

  

Fig. 11: Communication diagram

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__________________ Schematics

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Troubleshooting

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______________ Troubleshooting How to troubleshoot the system This system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults. These troubleshooting aids consist of: WARNING! Before troubleshooting beyond the level of observing the fault code, read this entire manual and contact your supervisor.

Display - Four line, twenty character display.

Fault Message - A machine local display message that appears on every display in the system. The fault is displayed until it is resolved and each CST in the system is reset.

Fault Log - A permanent, machine-local, displayed timestamped record of the fault. The fault log can be accessed via the display or the infrared programming adapter. The last 256 faults are stored.

LED Indicators - Light emitting diode (LED) indicators are located on the MCU in the starter box for aid in troubleshooting.

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System Status Indicators

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________ System status indicators System status indicators Introduction Status LED functional categorization The LEDs used in troubleshooting this control system are located on the MCU-930 which is located in the starter box.

Each LED has a one-to-one correspondence with its connector pin. The layout of the connectors on the face plate is such that pins, and thus the LEDs, are grouped in functional categories as described in Table 5.1 and shown in Figures 12, 13, and 14.

NOTICE! LED locations on the MCU-930 are with reference to their associated connector. The LEDs are located to the right of their connector.

WARNING! Only qualified personnel with approved training on this equipment and knowledgeable of MSHA safety requirements should perform troubleshooting of this system.

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________ System status indicators Fig.12: MCU-930 faceplate LED legend (left side)

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________ System status indicators Fig. 13: MCU-930 faceplate LED legend (middle)

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________ System status indicators Fig. 14: MCU-930 faceplate LED legend (right side)

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________ System status indicators Generally, an abnormal status indication can be quickly attributed to either a fault in a component of the remote control system or controlled machine.

Table 5.1: MCU-930 LED functional categories LED Loc.

Functional Categories

R1-R4

A contact output. Either a solenoid output or a relay output. When ON, contact should be closed.

R5-R6

Not used.

R7-R8

120VAC inputs. When ON, 120VAC is present.

R9

Serial Port 1: COMM link

R10

Serial Port 2: Display

R11

Attached system link

R12 R13

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________ System status indicators MCU-930 Status LED Descriptions Use Table 5.2 to troubleshoot the system using the status LEDs. Table 5.2 has been divided into several sub-tables to allow quick access to specific status LED analysis.

Table 5.2a: Status LED description (R1 & R2) LED Function

Loc.

Description

Inby down

R1-1

Inby boom down solenoid (12V).

Inby up

R1-2

Inby boom up solenoid (12V).

Left tram reverse

R1-3

Left tram reverse solenoid (PWM).

Left tram forward

R1-4

Left tram forward solenoid (PWM).

Right tram reverse

R1-5

Right tram reverse solenoid (PWM).

Right tram forward

R1-6

Right tram forward solenoid (PWM).

Not used

R2-3/4

Cab down

R2-5

Cab down solenoid (12V).

Cab up

R2-6

Cab up solenoid (12V)

Canopy down

R2-7

Canopy down solenoid (12V)

Canopy up

R2-8

Canopy up solenoid (12V)

Outby down

R2-9

Outby boom down solenoid (12V)

Outby up

R2-10

Outby boom up solenoid (12V)

Note: R1 and R2 LEDs are on when the contact is closed.

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________ System status indicators Table 5.2b: Status LED description (R3 & R4) LED Function

Loc.

Description

Stop maintained

R3-1/2

Normally closed. Not connected.

Machine stop

R3-3/4

Normally closed. I.S. circuit - shut down.

Not used

R3-5

Light

R3-6

Light relay LCR

PIG #1 forward

R4-3

PIG #1 conveyor forward contactor

PIG #1 reverse

R4-4

PIG #1 conveyor reverse contactor

Pump

R4-5

Hydraulic pump contactor

MBC forward

R4-6

MBC conveyor forward contactor

MBC reverse

R4-7

MBC conveyor reverse contactor

PIG #2 forward

R4-8

PIG #2 conveyor forward contactor

PIG #2 reverse

R4-9

PIG #2 conveyor reverse contactor

Horn

R4-10

Horn relay (HLR)

Note: R3 and R4 LEDs are on when the contact is closed.

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________ System status indicators Table 5.2c: Status LED description (R5 & R6) LED Function

Loc.

Not used

R5-1/4

Not used

R6-1/8

Description

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________ System status indicators Table 5.2d: Status LED description (R7 & R8) LED Function

Loc.

Description

PIG #1 conveyor overload

R7-1

PIG 1 overload OK

Pump motor overload

R7-2

Pump motor overload OK

MBC conveyor overload

R7-3

MBC conveyor overload OK

PIG #2 conveyor overload

R7-4

PIG 2 overload OK

Belt sequence switch

R7-5

Outby MBC only sequence input

Footswitch/panic bar

R7-6

CRSS input safety circuit

Miner shutdown

R7-7

MP-130 relay input inby only on attached systems

Not used

R7-8

PIG #1 forward

R8-1

Auxiliary contact input.

PIG #1 reverse

R8-2

Auxiliary contact input.

Pump

R8-3

Auxiliary contact input.

MBC forward

R8-4

Auxiliary contact input.

MBC reverse

R8-5

Auxiliary contact input.

PIGs #2 forward

R8-6

Auxiliary contact input.

PIG #2 reverse

R8-7

Auxiliary contact input.

Note: R7 and R8 LEDs are on when 120 VAC is present.

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________ System status indicators Table 5.2d: Status LED description (R9, R10, & R11) LED Function

Loc.

Description

MCU RX

R9-1

On when RS-485 data received from other MCUs.

MCU TX

R9-2

On when RS-485 data transmitted to other MCUs.

Display RX

R10-1

On when RS-485 data received from display.

Display TX

R10-2

On when RS-485 data transmitted to display.

ATCH/DTCH

R11-1

Attached/detached signal. On for attached, Off for detached.

Not used

R11-2

Manual

R11-3

Not used

R11-4

Manual control for MCU.

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________ System status indicators Table 5.2d: Status LED description (R12 & R13) LED Function

Loc.

CST link

R12-1/2

On when the control station is recognized.

Power

R12-3/4

On when 120 VAC is applied to MCU.

CST activity

R13-1

On when data is present on CST line.

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________ System status indicators Table 5.2d: Status LED description (Other) LED Function Watchdog

Loc.

Description On when the internal MCU processor is operational.

Not used CST valid msg

Blinks for control station valid message (10 msg/sec).

Not used

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Fault Code Information

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__________________ Fault codes Fault codes The purpose of this section is to provide service personnel with the fault codes that are designed into the system for troubleshooting purposes. There are two basic types of fault codes: fault log codes and real time codes.

Fault log codes are sequentially numbered and are stored in the fault log only when they result in a system shutdown.

They normally DO NOT appear on the display. The infrared transmitter is used to access the fault error log.

Real time codes appear on the Display immediately. They are almost always displayed on the fourth line of the display, replacing the “STATUS OK” message. They are numbered and transferred to the fault log if a motor shutdown resulted when they occurred.

Note, almost all fault codes are common between the fault log and real time codes.

The fault log and real time codes given in this document are for an eight unit system. All faults may not be applicable to your system.

Regardless of which unit the fault occurs on, each reset button on each CST in the system must be activated before the system is reset.

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__________________ Fault codes Normal operation (real time) unnumbered codes The following codes are not numbered and will appear during normal operation (real time), usually on the fourth line of the display.

Table 6.1: Normal operation fault codes Displayed

Description

OUTBY CST COMM ERROR (MBC NO.1)

Outby control station communication fault (fault log, fault #1)

INBY 1 CST COMM ERROR (MBC NO.2)

Inby 1 control station communication fault (fault log, fault #2)

INBY 2 CST COMM ERROR (MBC NO.3)

Inby 2 control station communication fault (fault log, fault #3)

INBY 3 CST COMM ERROR (MBC NO.4)

Inby 3 control station communication fault (fault log, fault #4)

These codes indicate an actual communication fault or an initialization error on the part of the control station (CST).

When the CST is powered up, it scans it’s switches for the “OFF” position. If a switch is found “ON” (including tram joysticks), the CST will not transmit to the machine control unit (MCU). The MCU will indicate “CST COMM ERROR”.

The Est Msg’s LED on the CST will NOT be blinking and the switch active LED will be illuminated. The Est Msg LED MUST be blinking for transmission back to the MCU. KEEP THE CONNECTIONS TIGHT between the CST and the MCU. There may also be trouble with the barrier but the most likely cause is a cable problem.

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__________________ Fault codes Numbered fault codes A communication error between MCUs (RS-485) is most likely a cable or MCU fault. Since communication is bidirectional (the same cable carries information both ways), the codes help to narrow down the cause. A cable problem will most often result in Error 5, 6, or 7. Error codes 9 thru 16 indicate a return message problem and will usually indicate a problem internal to an MCU as the wiring must have been intact for the outgoing message to have been received.

Table 6.2: Fault codes #

Fault

5

Comm fault Outby to Inby 1

COMM ERR OUTBY-INBY1

6

Comm fault Outby to Inby 2

COMM ERR OUTBY-INBY2

7

Comm fault Outby to Inby 3

COMM ERR OUTBY-INBY3

8

Comm fault Inby 1 to Outby

COMM ERR INBY1-OUTBY

9

Comm fault Inby 1 to Inby 2

COMM ERR INBY1-INBY2

10 Comm fault Inby 1 to Inby 3

COMM ERR INBY1-INBY3

11 Comm fault Inby 2 to Outby

COMM ERR INBY2-OUTBY

12 Comm fault Inby 2 to Inby 1

COMM ERR INBY2-INBY1

13 Comm fault Inby 2 to Inby 3

COMM ERR INBY2-INBY3

14 Comm fault Inby 3 to Outby

COMM ERR INBY3-OUTBY

15 Comm fault Inby 3 to Inby 1

COMM ERR INBY3-INBY1

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__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

16 Comm fault Inby 3 to Inby 2

COMM ERR INBY3-INBY2

17 Outby footswitch tripped

OUTBY FOOTSWITCH OPEN

18 Inby 1 footswitch tripped

INBY1 FOOTSWITCH OPEN

19 Inby 2 footswitch tripped

INBY2 FOOTSWITCH OPEN

20 Inby 3 footswitch tripped

INBY3 FOOTSWITCH OPEN

21 Outby pump motor overload

OUTBY PMP MTR OVLOAD

22 Inby 1 pump motor overload

INBY1 PMP MTR OVLOAD

23 Inby 2 pump motor overload

INBY2 PMP MTR OVLOAD

24 Inby 3 pump motor overload

INBY3 PMP MTR OVLOAD

25 Outby PIG 1 overload

OUTBY PG1 MTR OVLOAD

26 Inby 1 PIG 1 overload

INBY1 PG1 MTR OVLOAD

27 Inby 2 PIG 1 overload

INBY2 PG1 MTR OVLOAD

28 Inby 3 PIG 1 overload

INBY3 PG1 MTR OVLOAD

29 Outby MBC overload

OUTBY MBC OVLOAD

30 Inby 1 MBC overload

INBY1 MBC MTR OVLOAD

31 Inby 2 MBC overload

INBY2 MBC MTR OVLOAD

32 Inby 3 MBC overload

INBY3 MBC MTR OVLOAD

33 Outby PIG 2 overload

OUTBY PG2 MTR OVLOAD

34 Inby 1 PIG 2 overload

INBY1 PG2 MTR OVLOAD

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__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

35 Inby 2 PIG 2 overload

INBY2 PG2 MTR OVLOAD

36 Inby 3 PIG 2 overload

INBY3 PG2 MTR OVLOAD

37 Outby pump contactor frozen open

OUTBY PUMP FZ OPEN

38 Inby 1 pump contactor frozen open

INBY1 PUMP FZ OPEN

39 Inby 2 pump contactor frozen open

INBY2 PUMP FZ OPEN

40 Inby 3 pump contactor frozen open

INBY3 PUMP FZ OPEN

41 Outby pump contactor frozen closed

OUTBY PUMP FZ CLOSED

42 Inby 1 pump contactor frozen closed

INBY1 PUMP FZ CLOSED

43 Inby 2 pump contactor frozen closed

INBY2 PUMP FZ CLOSED

44 Inby 3 pump contactor frozen closed

INBY3 PUMP FZ CLOSED

45 Outby PIG 1 forward contactor frozen open

OUTBY PIG1 FZ OPEN

46 Inby 1 PIG 1 forward contactor frozen open

INBY1 PIG1 FZ OPEN

47 Inby 2 PIG 1 forward contactor frozen open

INBY2 PIG1 FZ OPEN

48 Inby 3 PIG 1 forward contactor frozen open

INBY3 PIG1 FZ OPEN

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__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

49 Outby PIG 1 forward contactor frozen closed

OUTBY PIG1 FZ CLOSED

50 Inby 1 PIG 1 forward contractor frozen closed

INBY1 PIG1 FZ CLOSED

51 Inby 2 PIG 1 forward contactor frozen closed

INBY2 PIG1 FZ CLOSED

52 Inby 3 PIG 1 forward contactor frozen closed

INBY3 PIG1 FZ CLOSED

53 Outby PIG 1 reverse contactor frozen open

OUTBY PG1 RV FZ OPN

54 Inby 1 PIG 1 reverse contactor frozen open

INBY1 PG1 REV FZ OPN

55 Inby 2 PIG 1 reverse contactor frozen open

INBY2 PG1 REV FZ OPN

56 Inby 3 PIG 1 reverse contactor frozen open

INBY3 PG1 REV FZ OPN

57 Outby PIG 1 reverse contactor frozen closed

OUTBY PG1 REV FZ CLO

58 Inby 1 PIG 1 reverse contactor frozen closed

INBY1 PG1 REV FZ CLO

59 Inby 2 PIG 1 reverse contactor frozen closed

INBY2 PG1 REV FZ CLO

60 Inby 3 PIG 1 reverse contactor frozen closed

INBY3 PG1 REV FZ CLO

61 Outby MBC forward contactor frozen open

OUTBY MBC FZ OPEN

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__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

62 Inby 1 MBC forward contactor frozen open

INBY1 MBC FZ OPEN

63 Inby 2 MBC forward contactor frozen open

INBY2 MBC FZ OPEN

64 Inby 3 MBC forward contactor frozen open

INBY3 MBC FZ OPEN

65 Outby MBC forward contactor frozen closed

OUTBY MBC FZ CLOSED

66 Inby 1 MBC forward contactor frozen closed

INBY1 MBC FZ CLOSED

67 Inby 2 MBC forward contactor frozen closed

INBY2 MBC FZ CLOSED

68 Inby 3 MBC forward contactor frozen closed

INBY3 MBC FZ CLOSED

69 Outby MBC reverse contactor frozen open

OUTBY MBC REV FZ OPEN

70 Inby 1 MBC reverse contactor frozen open

INBY1 MBC REV FZ OPEN

71 Inby 2 MBC reverse contactor frozen open

INBY2 MBC REV FZ OPEN

72 Inby 3 MBC reverse contactor frozen open

INBY3 MBC REV FZ OPEN

73 Outby MBC reverse contactor frozen closed

OUTBY MBC REV FZ CLO

74 Inby 1 MBC reverse contactor frozen closed

INBY1 MBC REV FZ CLO

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__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

75 Inby 2 MBC reverse contactor frozen closed

INBY2 MBC REV FZ CLO

76 Inby 3 MBC reverse contactor frozen closed

INBY3 MBC REV FZ CLO

77 Outby PIG 2 forward contactor frozen open

OUTBY PIG2 FZ OPEN

78 Inby 1 PIG 2 forward contactor frozen open

INBY1 PIG2 FZ OPEN

79 Inby 2 PIG 2 forward contactor frozen open

INBY2 PIG2 FZ OPEN

80 Inby 3 PIG 2 forward contactor frozen open

INBY3 PIG2 FZ OPEN

81 Outby PIG 2 forward contactor frozen closed

OUTBY PIG2 FZ CLOSED

82 Inby 1 PIG 2 forward contactor frozen closed

INBY1 PIG2 FZ CLOSED

83 Inby 2 PIG 2 forward contactor frozen closed

INBY2 PIG2 FZ CLOSED

84 Inby 3 PIG 2 forward contactor frozen closed

INBY3 PIG2 FZ CLOSED

85 Outby PIG 2 reverse contactor frozen open

OUTBY PG2 REV FZ OPN

86 Inby 1 PIG 2 reverse contactor frozen open

INBY1 PG2 REV FZ OPN

87 Inby 2 PIG 2 reverse contactor frozen open

INBY2 PG2 REV FZ OPN

Control Unit Troubleshooting Guide

6. 11

BI016956

__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

88 Inby 3 PIG 2 reverse contactor frozen open

INBY3 PG2 REV FZ OPN

89 Outby PIG 2 reverse contactor frozen closed

OUTBY PG2 REV FZ CLO

90 Inby 1 PIG 2 reverse contactor frozen closed

INBY1 PG2 REV FZ CLO

91 Inby 2 PIG 2 reverse contactor frozen closed

INBY2 PGS REV FZ CLO

92 Inby 3 PIG 2 reverse contactor frozen closed

INIBY3 PGS REV FZ CLO

Red “MACHINE STOP” button pushed on Outby CST.

OUTBY MACHINE STOP

Red “MACHINE STOP” button pushed on Inby 1 CST

INBY1 MACHINE STOP

Red “MACHINE STOP” button pushed on Inby 2 CST

INBY2 MACHINE STOP

Red “MACHINE STOP” button pushed on Inby 3 CST

INBY3 MACHINE STOP

“SYSTEM STOP” switch activated OUTBY SYSTEM STOP on Outby CST “SYSTEM STOP” switch activated INBY1 SYSTEM STOP on Inby 1 CST “SYSTEM STOP” switch activated INBY2 SYSTEM STOP on Inby 2 CST “SYSTEM STOP” switch activated INBY3 SYSTEM STOP on Inby 3 CST

A6474X276

REV 1

6. 12

BI016956

__________________ Fault codes Table 6.2: Fault codes #

Fault

Displayed

“MOTOR” switch on Outby CST switched to “STOP” position.

OUTBY PUMP MTR STOP

“MOTOR” switch on Inby 1 CST switched to “STOP” position.

INBY1 PUMP MTR STOP

“MOTOR” switch on Inby 2 CST switched to “STOP” position.

INBY2 PUMP MTR STOP

“MOTOR” switch on Inby 3 CST switched to “STOP” position.

INBY3 PUMP MTR STOP

“MBC” switch on Outby CST switched to “STOP” position.

“MBC” switch on Inby 1 CST switched to “STOP” position.

“MBC” switch on Inby 2 CST switched to “STOP” position.

“MBC” switch on Inby 3 CST switched to “STOP” position.

“PIG #1” switch on Outby CST switched to “STOP” position.

“PIG #2” switch on Outby CST switched to “STOP” position.

“PIG #1” switch on Inby 1 CST switched to “STOP” position.

“PIG #2” switch on Inby 1 CST switched to “STOP” position.

“PIG #1” switch on Inby 2 CST switched to “STOP” position.

“PIG #2” switch on Inby 2 CST switched to “STOP” position.

OUTBY MBC CONV STOP INBY1 MBC CONV STOP INBY2 MBC CONV STOP INBY3 MBC CONV STOP OUTBY PIG1 CONV STOP OUTBY PIG2 CONV STOP INBY1 PIG1 CONV STOP INBY1 PIG2 CONV STOP INBY2 PIG1 CONV STOP INBY2 PIG2 CONV STOP

Control Unit Troubleshooting Guide

6. 13

BI016956

7

For Your Information

BI016956

BI016956

__________________ Our service For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corp. Headquarters) 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

A6474X276

REV 1

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450 7. 3

BI016956

__________________ Our service Paonia, CO P.O. Box 566 Paonia, CO 81428 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Rebuild Facilities Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

Control Unit Troubleshooting Guide

7. 4