Cat Continuous Miner Cervis Control System Operation Manual - PDF DOWNLOAD

BI001580 A6474X446 December 2012

Operation Manual

Cervis Control System

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information.

The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your service representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© CATERPILLAR 2012.

ALL RIGHTS RESERVED

________________________________________________ Table of Contents

Table of contents Safety Precautions........................................................................................... 4 Machine Control System.................................................................................. 5 Components .............................................................................................. 5 Radio Remote ........................................................................................... 6 IR Remote ................................................................................................. 7 Graphics Display ....................................................................................... 9 Remote Status........................................................................................... 9 Fault and Error Messages ........................................................................12 Miner Overview Display............................................................................13 Motor Monitoring Display..........................................................................13 I/O Status..................................................................................................15 Protective Devices....................................................................................16

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Safety Instructions _______________________________________________ Safety Precautions

!

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations, must be followed at all times.

WARNING The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

IMPORTANT

The following information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the Continuous Miner, training must be completed. For a detailed description of component locations, please see the parts book for your machine.

IMPORTANT

Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

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__________________________________________ Machine Control System Introduction

An multi-component system is used to control various aspects of the machine and consists of the following main components: 

MCU (Motor Control Unit)



Radio Receiver



Radio Remote



Backup Power Supply



Infrared (IR) Remote



Emergency Tram Pendant



DC Tram Drive



Display Screen

MCU

The MCU is a custom PLC used to automate control, protection, and monitoring of the machine. It automatically controls tram motor voltage, provides protection by stopping motors when preset conditions are met, and provides information transfer between inputs to the display.

Radio Receiver

The radio receiver receives the signal from the radio remote (remote control) and communicates that signal to the MCU.

Radio Remote

The radio remote (Fig. 1) allows the operator to control the continuous miner from a remote location. The remote sends a signal to the machine controller via the radio receiver, which is mounted on the machine.

The remote is powered by two 9V, non-rechargeable batteries or can be operated via a cable connected to the machine.

Machine operations are hand operated using the eight (8) push buttons, thirteen (13) toggle switches, two (2) tram levers, and a machine stop button.

There are also six LEDs on the remote to provide operator feedback.

For complete radio remote operation, see the Remote Control Operation Manual, A6474X447 (BI001581).

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Machine Control System___________________________________________ Fig. 1: Radio remote (typical)

Backup Power Supply

The backup power supply provides emergency power to the radio receiver and the MCU, as well as for actuation of the 12VDC fire contact output, the 12VDC breaker ON contact output, and the 12VDC breaker Reset contact output.

It is supplied by the 120VAC power circuit and provides both 5VDC and 12VDC output. It provides up to 15 minutes of standby operation and has a short recharge time of 5 minutes. It has an infinite number of charge/discharge cycles and can be recharged at any temperature.

Infrared (IR) Remote

The handheld IR remote (Fig.2) is used to interface with the view screen from a remote location. The remote allows navigation through the screens and provides parameter modification capabilities.

The remote will automatically power down after 30 seconds of inactivity. It consists of six functions and one LED indicator: LINK LED The “LINK”LED flashes red when the remote is active (turned on). The remote will automatically power down after thirty (30) seconds of inactivity to conserve power. Any button press enables (powers on) the remote when it is inactive.

PAGE UP The PAGE UP button moves to the preceding menu from the current menu.

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__________________________________________ Machine Control System PAGE DOWN The PAGE DOWN button moves to the following menu from the current menu.

UP The UP button increments the selected menu attribute value. The “SET”button must be pressed immediately after adjusting the attribute value for the system to store the change in memory.

DOWN The DOWN button decreases the selected menu attribute value. The “SET” button must be pressed immediately after adjusting the attribute value for the system to store the change in memory.

SET The SET button sets the new value shown on the display.

MENU The MENU button is used to access the default menu on the view screen.

Fig. 2: IR remote “MENU” “PAGE UP” “UP”

“SET”

“LINK”

“PAGE DOWN”

“DOWN”

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Machine Control System___________________________________________ Emergency Tram (E-Tram) Pendant

The emergency tram (e-tram) pendant (Fig. 3) is a handheld controller that connects to the machine via an umbilical cord. Its primary purpose is to be used as an end station controller when it becomes necessary to move the machine and radio remote operation is not possible. It is normally stored on the miner in a safe/protected location, disconnected until needed. The e-tram pendant works independent of the MCU and has the ability to start the pump motor, raise and lower the cutter head, and tram the miner.

It is important to note that the following: 

The e-tram pendant cannot be used unless the MCU is disabled.



12VDC power to the pendant is provided by the tram pendant interface (TPI) when the pendant is connected.



The e-tram pendant is active when connected to the machine and the Miner Mode of Operation switch is in the E-Tram position.



The MODE LED on the pendant will be lit green when the pendant is active.

For e-tram pendant operating procedures, please see the Remote Control Operation Manual, A6474X447 (BI001581).

IMPORTANT

The pendant controller and its umbilical cord should be stored in a protected location on the working section, away from the miner, to prevent damage.

Fig. 3: Emergency tram pendant

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__________________________________________ Machine Control System DC Tram Drives

The tram drives convert the incoming 3-phase AC power to a variable DC output voltage based on either a serial or command reference. The also provide internal current limit in the event of a stalled traction motor and provide diagnostic data back to the MCU. The drives feature 3-phase AC input (220VAC to 460 VAC) and 120VAC control voltage input, local diagnostic LED’ s for serial operation, manual operation, and error conditions, and internal measurement of bus voltage, armature current, armature voltage, base plate temperature, and internal ambient temperature.

Display Screen IMPORTANT

The display screen (Fig. 4), located in the operator’ s case, is used to modify parameter and to display miner operating information and error messages.

Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

Fig. 4: Display screen location

Graphics display

The operator navigates through the menus using the yellow “SHIFT”button on the remote in conjunction with the switches marked with yellow labels or by using the IR remote.

Features of the display: 

Parameters entered are stored in the MCU.



Monitoring 

Voltages, currents, temperatures



Transmitter



Hydraulic functions



Trending: one minute graphs of motor currents



Alarming 

Current alarm



Last alarm



Alarm history

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Machine Control System___________________________________________ The default menu is the “REMOTE RUNTIME STATUS”menu (Fig. 5). This menu graphically displays all motor currents and temperatures using color changing bar graphs that indicate whether the values are high or low.

Fig. 5: Default menu (typical)

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__________________________________________ Machine Control System Remote Status

The remote status area (Fig. 5) is located in the upper right corner of all menus.

The remote ID is the identification number of the remote from which the system is receiving messages. The green LED indicates when a valid command is being transmitted.

“BATTERY”

“BATTERY”indicates the voltage of the remote battery. Low battery voltage is indicated by red battery text. The battery should be changed if the text is red.

“RF SIGNAL”

IMPORTANT

“MSG/SEC”

The “RF SIGNAL”indicator shows the relative strength of the signal. A low value indicates that the miner is approaching a point where signal loss can occur.

A low signal indications does not mean there is a loss of information transmitted to the miner; as a digital signal, it will either work or not work. The “RF SIGNAL”indicator shows a potential problem and that remote troubleshooting is required. If a low signal is shown when the remote is held near the antenna, check the antenna cabling and then check the remote for low power output.

“MSG/SEC”is a diagnostic tool. There should be eight (8) to twelve (12) messaged displayed per second (MSG/SEC) when there is an active command. If the radio remote is idle for one (1) second, the number decreases to four (4) to seven (7) message per second. If there is interference from another remote, the number of messages decrease and the displayed value will be smaller.

Fig. 5: Remote status area (typical) Remote ID

LED

“RF SIGNAL” indicator

“BATTERY”

“MSG/SEC”

Fault message

Transmitter not active

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Machine Control System___________________________________________ Fault and Error Messages

The machine displays faults and errors that occur during operation. Only faults that cause a motor to shutdown are logged to memory.

Error messages are displayed on a red background on the main display (Fig. 6).

The radio remote cannot be used until the condition that generated the error message is corrected.

Fault messages are stored and are available for later viewing on the “FAULT LOG”menu (Fig. 7).

IMPORTANT

It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

Fig. 6: Error message (typical) Error message

Fig. 7: Fault log (typical)

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__________________________________________ Machine Control System “MINER OVERVIEW” Display

The “MINER OVERVIEW”screen (Fig. 8) gives a graphical overview of motor currents and temperatures, machine voltage, tram transformer temperature, and MCU temperature.

Fig. 8: “MINER OVERVIEW”(typical)

Motor Monitoring Displays

There are separate monitoring screens for the pump motor, fan motor, cutter motors, CLA motors, and the tram motors (Fig. 9).

The individual screens provide motor history in one minute intervals. Color bars display current and temperature for each motor (except for the pump and fan motors, where there is only one each). The current and temperature are also displayed in numerical values on the bottom The graph at the bottom of the screen displays %FLA (Full Load Amps) reading in one minute intervals from left to right.

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Machine Control System___________________________________________ Fig. 9: Motor monitoring displays (typical)

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__________________________________________ Machine Control System “I/O STATUS PAGE”

There are four (4) input/output (I/O) status monitoring pages (Fig. 10). Items will be marked in green if a response has been provided to that situation.

Fig. 10: “I/O STATUS PAGE”

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Machine Control System___________________________________________ Protective Devices

The control system is equipped with various input devices that monitor the operating components and trigger protective actions is certain conditions are met.

Note: Values listed are typical but may differ from the values used to optimize your machine’s performance.

RTD Over-temperature The RTD over-temperature sensors protect the motors. Information from the sensors is used to stop the motors or prevent them from starting. The sensors have three monitored inputs: 

If the temperature is greater than 150° C (302° F) for 10 seconds, a fault occurs. There are two possible actions: Contact specific to that motor will open or will not close.



If temperature is 140° C (284° F) or less for 10 seconds, operation can resume.



If temperature is 180° C (356° F) or more, the motor is disabled. No message is displayed but value is 0.

Motor Amplitude Imbalance The motor amplitude imbalance sensors protect the cutter and conveyor motors.

Input from the sensors is used to stop motors, if the following conditions are met: If the current on either cutter motor is greater than 50% FLA or greater than 44% FLA on either conveyor motors AND the current difference between the motors is greater than 50% FLA AND both conditions persist for at least 5 seconds, then a fault occurs. There is a 10 second delay before the motors can be restarted.

Machine Voltage Monitoring Machine voltage monitoring protect the motors from either an under voltage or an over voltage condition. If the following conditions are met, the pump motor will be shut down: If machine voltage is less than 80% of nominal OR greater than 117% of nominal AND the pump motor is running AND the condition persists for more than 20 seconds, then a fault occurs. There is a 10 second delay before the pump motor can be restarted.

Motor Phase Loss Motor phase loss monitoring protects the motors. If any one of the three AC input phases is lost (as indicated by the following monitoring parameters), the motor will be shut down: If input current is greater than 30% FLA AND ripple amplitude becomes sever for that current load AND both conditions persist for more than 5 seconds, then a fault occurs. There is a 10 second delay before the motor can be restarted.

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______________________________________________________ Red Zones Motor Low Current Detection The motor low current detection sensors detect loss of feedback necessary when monitoring AC motors. Information is used to stop the motor when the following conditions are met: If the motor contact is commanded to close AND the input current is less than 5% FLA AND both conditions persist for more than 1 second, then a fault occurs. There is an 11 second delay before the motor can be restarted.

Motor Jam Current Detection The motor jam current sensors are used to detect excessive levels of current occurring quickly with the cutter, fan, and conveyor motors (does not monitor the pump motor). Information is used to stop the motor when the following conditions are met: If the motor contact is commanded to close AND the following amount of operation time has elapsed (start-up time): Cutter motors - 2 seconds Fan motor - 3 seconds Conveyor motors - 2 seconds AND if input current is greater than a preset amp value AND both conditions persist for more than a preset number of milliseconds, then a fault occurs. there is a 5 second delay before the motor can be restarted.

Motor Instantaneous Current Detection These sensors detect an excessive level of current occurring quickly at startup longer than normal in-rush current. Information is used to stop the motor if the following conditions are met: If the motor contact is commanded to close AND if input current is greater than a preset amp value AND both conditions persist for 2 - 3 seconds (3 seconds for the fan), then a fault occurs. there is an 11 second delay before the motor can be restarted.

Current without Command Detection The current without command sensors are used to detect current when no command has been sent. For AC motors, information is used to trip the power center and for tram motors, information is used to stop the pump motor when the following conditions are met: If motor the motor contact is NOT commanded to close (AC motor) or move (tram motor) AND the input current is greater than 5% FLA AND both conditions persist for more than 1 second, then a fault occurs.

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Machine Control System___________________________________________ Data Link Loss Data link loss monitoring is used to prevent unsafe movement of the machine due to loss of command link. 

If, after 1 second, no valid message is received, the following occur:  

Hydraulic actuation is stopped Tram command is set to STOP

No fault log entry or error message will be displayed. 

If, after 2 seconds, no valid message is received, the following occur:  

Pump motor contact opens and Fault log message is displayed

Motor Current Overload Detection The motor current overload sensors detect an excessive level of current over time to protect the motor from overheating. Information is used to stop the motor when the following conditions are met: The motor contact is commanded to close AND input current is greater than 125% FLA (150% FLA for tram motors) AND both conditions persist for a preset number of seconds, then a fault occurs. There is a 30 second delay before motors can be restarted if the RTD measured temperature is less than 140° C (284° F) or a 3 to 10 minute delay (depending on parameter) before the motor can be restarted if the RTD temperature values is greater than 140° C (284° F) (does not apply to tram motors).

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__________________________________________ Machine Control System Contact Interlocks

There are also interlocks to allow or stop/prevent motor operation.

Table 1: Pump motor contact interlocks

Stop or Prevent Start (any one true will open contact)

Start or Maintain (all must be true)

Emergency mode active

All stop conditions false

Methane monitor (if equipped) not OK

If methane monitor NOT OK but Methane Monitor Override enabled (S800 only)

Tram current without command for 1 sec

If Machine or Left Stop active but Machine Stop Override enabled

CB2 breaker open (CM200 series)

Enable first, then PUMP START for 1 second (start only)

Tilt switch active (if enabled)

No other motor start buttons active on radio remote (start only)

Low oil alarm or lockout (if enabled)

No tram command active at time of start (joysticks on radio remote must be in neutral position

Outside machine voltage range

Start switch not active at time of radio remote activation

RTD over-temperature

Enable switch not active at time of radio remote activation

Low current Instantaneous current Loss of phase Machine stop active Left stop active Data link loss for 2 seconds Stale pump start button radio remote Enable button stale on radio remote Internal MCU error Pump Stop active

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Machine Control System___________________________________________ Table 2: Fan motor contact interlocks Stop or Prevent Start (any one true will open contact)

Start or Maintain (all must be true)

Emergency mode active

All stop conditions false

Methane monitor (if equipped) not OK

If methane monitor NOT OK but Methane Monitor Override enabled (S800 only)

Pump not active

If Machine or Left Stop active but Machine Stop Override enabled

RTD over-temperature

Enable first, then FAN START for 1 second (start only)

Low current

No other motor start buttons active on radio remote (start only)

Instantaneous current

Start switch not active at time of radio remote activation

Jam current

Enable switch not active at time of radio remote activation

Overload current

Must follow configuration settings (i.e. fan after cutter, fan before cutter, etc.)

Loss of phase Machine stop active Stale fan start button on radio remote Internal MCU error Fan Stop active

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__________________________________________ Machine Control System Table 3: Cutter motor contact interlocks (left or right) Stop or Prevent Start (any one true will open contact)

Start or Maintain (all must be true)

Emergency mode active

All stop conditions false

Methane monitor (if equipped) not OK

Enable first, then CUTTER START for 1 second (start only)

CB2 breaker open (CM300 series)

No other motor start buttons active on radio remote (start only)

Cutter lockout active

Start switch not active at time of radio remote activation

Pump not active

Enable switch not active at time of radio remote activation

Low oil alarm or lockout (if enabled)

Must follow configuration settings (i.e. fan after cutter, fan before cutter, etc.)

RTD over-temperature Low current Instantaneous current Overload current Loss of phase Amplitude imbalance Machine stop active Left stop active Stale cutter start button on radio remote Enable button stale on radio remote Internal MCU error Cutter Stop active

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Machine Control System___________________________________________ Table 4: Conveyor motor contact interlocks (left or right) Stop or Prevent Start (any one true will open contact)

Start or Maintain (all must be true)

Emergency mode active

All stop conditions false

Methane monitor (if equipped) not OK

If FWD, Enable first, then CONVEYOR START for 1 second (start only)

Pump not active

If REV, Enable first, then CONVEYOR START, then CONVEYOR REVERSE (must be maintained)

RTD over-temperature

No other motor start buttons active on radio remote (start only)

Low current

Start switch not active at time of radio remote activation

Instantaneous current

Enable switch not active at time of radio remote activation

Overload current

Conveyor movement requested 8 seconds after opposite movement request

Loss of phase Amplitude imbalance Machine stop active Left stop active Stale conveyor start button on radio remote Enable button stale on radio remote Internal MCU error Conveyor Stop active Opposite movement (FWD, REV) attempted

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__________________________________________ Machine Control System Table 5: Tram motor contact interlocks (left or right) Stop or Prevent Start (any one true will open contact)

Start or Maintain (all must be true)

Emergency mode active

All stop conditions false

Methane monitor (if equipped) not OK

Tram Enable active before joystick movement

Pump not active

If methane monitor NOT OK but Methane Monitor Override enabled (S800 only)

Motor current overload

If machine or left stop active but machine stop override enabled

Drive communication error Drive over-temperature Drive Phase A over current Drive Phase B over current Drive Bus over voltage Drive loss of voltage feedback Tram command without enable Data link loss after 1 second (no message) Internal MCU error Stale Tram Enable Tram Enable active for more than 5 minutes

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Machine Control System___________________________________________ Sump Parameter Set Up

Sump Speed Parameters 1. Max Sump This parameter will give a maximum threshold for voltage applied to the Tram Motors. (Fastest Speed while Cutting)  

170 is a typical set point for this parameter Tram Motor Voltage is directly proportional to motor speed.

The setting of this parameter is dependent on the following conditions: 

Traction planetary type. Adjust “Max Speed”for how hard you will be contacting the face. For example:  



High Speed Planetary = Lower Max Sump High Torque Planetary = Higher Max Sump

Coal/Material Hardness:  

Harder Material being cut = Lower Max Sump Softer Material being cut = Higher Max Sump

2. Min Sump This parameter will give a minimum threshold for voltage applied to the Tram Motors. (Slowest Speed while Cutting)  

70 is a typical set point for this parameter Tram Motor Voltage is directly proportional to motor speed.

Cutter Motor Feedback Setpoint 3. Cutter Motor Feedback Setpoint (CMFS) This parameter is the maximum current that you want the Cutter Motors to pull.   

This parameter will be set at the FLA of the Cutter Motors.

The CMFS will act as the upper threshold for the Cutter Motor Current.

This setting will tell the control system when to vary tram speeds to keep the cutter current under the CMFS. Once established this parameter should not need changed, typically.

4. Differential Rate of change for the Tram Motor Voltage upon the initial surpassing of the CMFS 

 

This parameter will determine how quickly or slowly the initial reaction to surpassing the CMFS setting will be. Once the CMFS setting has been surpassed the Tram motors will revert to the Min Sump setting at a speed based on the Differential setpoint.

A typical setpoint for this parameter will be between 8 and 12 The lower the setpoint value will equal slower reaction and higher value will equal faster reaction.

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__________________________________________ Machine Control System 5. Proportional Once the initial reaction (which is determined by the Differential setting) of surpassing the CMFS setting has occurred and the machine has reverted to Min Sump the Proportional setting will determine the rate of change for the Tram Motor Voltage during the rest of the cut sequence. 

The Proportional setting is variable by increments of 32 per 2 Volts per second.  



For Ex. If setting is at 64 then the rate of change will be 4 volts/ second For Ex. If setting is at 128 then the rate of change will be 8 volts/ second

For example: If the machine has the following parameters. Proportional = 64 / Max Sump = 100/ Min Sump = 60 Then as the machine sumps in and reaches the “Cutter Motor Feedback Setpoint”the speed will start to drop at a rate of: At 0 sec. Sump Speed = 100 At 1 sec. Sump Speed = 96 At 2 sec. Sump Speed = 92..........

Thus it will take 10 seconds to reach 60 Volts on the Tram Motors



A typical set point for the Proportional parameter is 32-64  

When the Proportional setting is too high, the miner will typically start to surge back and forth When Proportional setting is set too low, the speed will drop too slowly and cause the Cutter Motor Current to stay above the CMFS setting for too long.

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Machine Control System___________________________________________ Fig. 11 is a graphical representation of a properly setup sump algorithm.

NOTE: These graphs are for demonstration purposes only. Individual results will vary depending on mining conditions.

Fig. 11: Sump algorithm

At time T1, Cutter Current will be greater than CMFS therefore speed begins to ramp down at a rate equal to the Differential setpoint.

Between time T1 and T2 is the time it takes the Tram voltage to change from the Max Sump setting to the Min Sump setting. This time can be changed by adjusting the Differential parameter.

Between time T2 and T3 the Tram motor voltage will increase at a rate equal to the setting of the Proportional parameter until the CMFS is reached. In this example the Proportional setpoint is 64 which equal 4 volts/second.

At time T3, The CMFS parameter has been reached and the Tram Motor Voltage will raise and lower at a rate equal to the Proportional setpoint to maintain the Cutter Current close to the CMFS parameter.

Example Set Points CMFS = 138 Max Sump = 170 Min Sump = 70 Differential = 20 Proportional = 64

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_________________________________________________ Troubleshooting System Status Indicators The majority of status LED’ s of interest in troubleshooting the control system are located on the MCU. 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 LED’ s, are grouped in functional categories. The LED locations on the MCU are located to the right of their associated connector.

Note: Always use the LED directory for the MCU for your machine, located in your machine’s parts book.

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Troubleshooting _________________________________________________ Fig. 12: MCU944 LED directory

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_________________________________________________ Troubleshooting Troubleshooting The control system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults. !

WARNING Before troubleshooting beyond the level of observing the fault log, you must be trained on the control, electrical, and hydraulic systems on this machine and must be authorized to perform troubleshooting.

The troubleshooting aids consist of: Display: Graphics and/or text device that shows run time data and the fault log.

Fault Message: A machine local display message that appears for 10 seconds when the system detects a fault.

Fault Log: A permanent, machine local, displayed, time-stamped record of faults. It can be paged through via the IR transmitter.

Operational Error Messages: A machine local graphics display message that appears whenever an action is prevented from execution due to a fault condition.

LED Indicators: Lights placed strategically on most system sub-assemblies to indicated certain conditions.

If a fault occurs, try to recreate the fault by repeating the operation that resulted in the fault. Watch for the fault message on the display. If the fault reoccurs, note the message from the display or log, then consult the troubleshooting information in this document.

When troubleshooting the system, it is important to note the following: 

The control system does not recognize hydraulic system problems unrelated to the pump motor.



Most faults only affect one machine function. However, if dependent faults should occur, the most significant fault message appears first, then the next, and so on.



The system will not recognize power lost to the machine unless initiated by the machine control unit. If the MCU initiated the power loss, the system will indicate that once power is restored to the machine.

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Troubleshooting _________________________________________________ Table 6: MCU944 LED functional categories (reference Fig. 12) LED Location R1 - R6

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

R11

120VAC inputs. When ON, 120VAC is present. For normal operation of the miner, MACHINE STOP (R11-1) and LEFT STOP (R11-2) LED’ s should be ON.

R12

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

R13

12VDC inputs (top three) and outputs (bottom three).

R14

Future use.

R15

Top LED: Flashes when the MCU is transmitting (only occurs during Teach/Learn). Will flash a minimum of 3 times for a successful teach/learn cycle.

Bottom LED: flashes whenever the MCU has received valid messages from the radio remote.

This can only occur if the mode is not local, checksum is valid, and proper radio remote is communicating with the MCU.

R16

Top LED: Indicates when the display is transmitting.

Bottom LED: Indicates when the display responds to the MCU.

R17

Top LED: Flashes whenever there is activity between the MCU and the IR receiver.

R18

Top LED: Flashes quickly (looks steady) whenever the MCU is transmitting.

Bottom LED: Flashes quickly (looks steady) whenever a valid message has been received from either the right or left drive.

R19

Not used.

R20

Indicates activity with respect o the download/debug cable connection.

R21

Not used.

R22

Indicates voltage levels inside the MCU. Top LED Indicates +5V is present.

Middle LED: Indicates +12V is present.

Bottom LED: Flashes whenever the MCU is in umbilical mode with the radio remote.

Rotary Switch Top LED: Located to the left of the rotary switch - flashes whenever there have been multiple internal backplane communication errors inside the MCU. Other three LED’s: Engineering use.

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_________________________________________________ Troubleshooting Table 7: MCU944 Status LED descriptions (R1 and R2) (reference Fig. 12) LED Location

LED Function

Description

R1-1

Not used

R1-2

Fan water spray solenoid

R1-3

Aux solenoid output # 6 (momentary)

R1-4

Dust suppression

R1-5

Cutter raise solenoid

R1-6

Gathering head float solenoid

R2-3

Cutter lower solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-4

Conveyor raise solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-5

Conveyor lower solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-6

Conveyor swing left solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-7

Conveyor swing right solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-8

Stab up solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-9

Stab down solenoid

Active when contact is closed. Action is controlled by radio remote.

R2-10

Gathering head raise solenoid

Active when contact is closed. Action is controlled by radio remote.

Not used.

On when fan water spray solenoid is energized. Action is slaved to fan operation.

Active when contact is closed. Action is momentary and controlled from the radio remote.

Active when dust suppression is closed. Action is controlled from radio remote.

Active when cutter raise contact is closed. Action is controlled from radio remote.

Active when gathering head float contact is closed. This action will latch and is deactivated only when gathering head raise solenoid is active or pump is inactive Requires pump active prior to use.

_____________________________________________________________ A6474X446 REV 0 31

Troubleshooting _________________________________________________ Table 8: MCU944 Status LED descriptions (R3 and R4) (reference Fig. 12) LED Location

LED Function

R3-1

Aux output #7 (latched)

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

R3-2

Aux output #8 (latched)

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

R3-3

Conveyor REV contactor

R3-4

Fan contactor

R4-3

Aux output #5 (momentary)

R4-4

Low oil alarm output

R4-5

Description

Active when reverse conveyor contact is closed.

Active when fan contact is closed.

Active when contact is closed. Action is momentary.

Active when contact is closed. Action is predicated upon configuration.

Control ground fault alarm output Active when contact is closed.

R4-6

Headlights

Active when contact is closed. Action is controlled by radio remote.

R4-7

Pump contactor

Active when contact is closed.

R4-8

Left cutter contactor

Active when contact is closed.

R4-9

Right cutter contactor

Active when contact is closed.

R4-10

Conveyor FWD contactor

Active when contact is closed.

________________________________________________________________ 32 Cervis Control System

_________________________________________________ Troubleshooting Table 9: MCU944 Status LED descriptions (R5 and R6) (reference Fig. 12) LED Location

LED Function

Description

R5-1/2

Redundant right cutter

Active when contact is closed.

R5-3/4

Redundant left cutter

Active when contact is closed.

R6-3

Breaker on (alt)

Active when Breaker ON contact is closed. Action is controlled from the radio remote.

R6-4

Breaker off (alt)

Active when Breaker OFF contact is closed. Action is controlled from the radio remote.

R6-5

Brake release

R6-6

Spare #1

Active when spare contact is closed.

R6-7

Spare #2

Active when spare contact is closed.

R6-8

Spare #3

Active when spare contact is closed.

R6-9

Aux solenoid out #3 (momentary)

R6-10

Aux output #4 (latched/pump)

Active when Brake Release contact is closed. Brake Release contact will activate when tram is authorized.

Active when contact is closed. Action is momentary.

Active when contact is closed. this contact requires that the pump be operating prior to use. Action is momentary and is controlled from the radio remote.

_____________________________________________________________ A6474X446 REV 0 33

Troubleshooting _________________________________________________ Table 10: MCU944 Status LED descriptions (R11 and R12) (reference Fig. 12) LED Location

LED Function

Description

R11-1

Machine stop

R11-2

Left stop

Active when 120VAC is present. When not present, indicates that left stop is pressed. Operation is prevented unless machine stop override on radio remote is utilized.

R11-3

Cutter run

Active when 120VAC is present. When present, cutter motor operation is desired. When not present, this input will deactivate the cutter motors only in Local mode.

R11-4

Pump run

Active when 120VAC is present. When present, pump motor operation is desired. When not present, this input will deactivate the pump motor only in Local mode.

R11-5

Conveyor run

Active when 120VAC is present. When present, conveyor motor operation is desired. When not present, this input will deactivate the conveyor motors only in Local mode.

R11-6

Miner type #1

Active when 120VAC is present. Used in conjunction with miner type #2 input to notify the MCU of the continuous miner model.

R11-7

Miner type #2

Active when 120VAC is present. Used in conjunction with miner type #2 input to notify the MCU of the continuous miner model.

R11-8

Methane monitor OK

Active when 120VAC is present. When present, indicates that the methane monitor is functioning correctly and methane levels are within acceptable limits.

R12-1

CB2 breaker

Active when 120VAC is present.

R12-2

Emergency tram

Active when 120VAC is present.

R12-3

Man scrubber (fan) run

Active when 120VAC is present.

R12-4

Cutter run with fan

Active when 120VAC is present.

R12-5

Cutter Lockout

Active when 120VAC is present.

R12-6

Motor start/Tram enable (local)

R12-7

Remote

R12-8

Any input on R9

Active when 120VAC is present. When not present, indicates that machine stop is pressed. Operation is prevented unless machine stop override on radio remote is utilized.

Active when 120VAC is present. This input must be present prior to any motor start in Local mode.

Active when 120VAC is present.

Active when 120VAC is present at any input on connector R9.

________________________________________________________________ 34 Cervis Control System

_________________________________________________ Troubleshooting Table 11: MCU944 Status LED descriptions (R13 and R14) (reference Fig. 12) LED Location

LED Function

Description

R13-1

Fire suppression

Active when fire suppression contact is closed. The fire suppression contact, when fire suppression is initiated, will stay active for 10 seconds. Controlled from radio remote.

R13-2

Breaker On

Active when Breaker ON contact is closed. Controlled from radio remote.

R13-3

Breaker Off

Active when Breaker OFF contact is closed. Controlled from radio remote.

R13-4

+12VDC Output

Indicates +12V I/O have power.

R13-6

Low oil lockout

Active when low oil lockout input sensor is active.

R13-7

Low oil alarm

R13-8

Spare DC input

R14-1

+5.0VDC to tram levers

R14-3

Right tram proportional signal

R14-4

Right tram FWD contact

Not used. Replaced with emergency tram pendant. Active when right forward command is given in Local mode.

R14-5

Right tram REV contact

Not used. Replaced with emergency tram pendant. Active when right reverse command is given in Local mode.

R14-6

Left tram proportional signal

R14-7

Left tram FWD contact

Not used. Replaced with emergency tram pendant. Active when left forward command is given in Local mode.

R14-8

Left tram REV contact

Not used. Replaced with emergency tram pendant. Active when left reverse command is given in Local mode.

Active when low oil alarm input sensor is active.

Unused.

Indicates +5.0V I/O have power.

Not used. Replaced with emergency tram pendant. Proportional LED output directly related to the tram command in Local mode.

Not used. Replaced with emergency tram pendant. Proportional LED output directly related to the tram command in Local mode.

_____________________________________________________________ A6474X446 REV 0 35

Troubleshooting _________________________________________________ Table 12: MCU944 Status LED descriptions (R15 through R20) (reference Fig. 12) LED Location

LED Function

Description

R15-1/2

Radio receiver TX

Active when MCU944 transmits out.

R15-3/4

Radio receiver RX

Active when MCU944 receives packets specific to its ID.

R16-1/2

Display TX

Active when MCU944 receives packets.

R16-3/4

Display RX

Active when MCU944 transmits out.

R17-1/2

IR pendant TX

Active when MCU944 receives valid packets.

R17-3/4

IR pendant TX received

Active when MCU944 receives valid packets.

R18-1

MCU944 TX to traction drive

R18-2

MCU944 RX from traction drive

R19

No LED’ s

R20-3

Download/debug TX

Active when MCU944 transmits out.

R20-2

Download/debut RX

Active when MCU944 receives bytes.

Active when MCU944 transmits out.

Active when MCU944 receives valid messages.

________________________________________________________________ 36 Cervis Control System

_________________________________________________ Troubleshooting Table 13: MCU944 Status LED descriptions (R21 and R22) (reference Fig. 12) LED Location

LED Function

Description

R21

GP10

R22-2/3

+5V

Indicates when +5V is active. This voltage is required to operate the MCU944.

R22-4/5

+12V

Indicates when +12V is active. This voltage is required to operate the MCU944 in normal modes. It is deliberately deactivated in battery mode until required.

R22-6

Umbilical (pendant activity)

Indicates when transmitter is connected to the MCU944 via umbilical cable and is active.

SW Hole Plug

Hardware failure (toggle)

Unused.

Flashes whenever there is a hardware failure internal to the MCU944.

Modbus comm error (toggle) IR pendant comm error (toggle) Write to eeprom (toggle)

_____________________________________________________________ A6474X446 REV 0 37

Troubleshooting _________________________________________________ Radio remote troubleshooting There are six LED’ s on the remote (Fig. 13). with functions as listed in Table 14.

Fig. 13: Radio remote LED’s

________________________________________________________________ 38 Cervis Control System

_________________________________________________ Troubleshooting Table 14: Radio remote LED functions (reference Fig. 13) LED BATTERY/ UMB MSG

Description Note: This LED has 2 functions.

BATTERY: Battery transmitter mode. A flashing LED indicates good battery strength.

A double blink-pause-double blink LED indicates that the batteries need to be changed (approximately 24 hours of battery life remain). The transmitter will operate until the batteries are dead but performance and range will diminish quickly and may be unsafe if trying to operate from a long range. A double blink LED indicates the batteries should be changed immediately.

UMB MSG: Umbilical message function - LED blinks, indicating that a message has been sent to the MCU. The blink rate should e steady at 10 times per hour.

ERROR LINK REQUEST/ SHUTDOWN

LED will illuminate briefly after power up. If the LED stays on after power up, the transmitter should be returned for repair.

Note: This LED has 2 functions.

LINK REQUEST: When the radio remote is connected via umbilical cord, the LED will illuminate as the radio remote attempts to link to the MCU. SHUTDOWN: Lit LED indicates that the radio remote shutdown is in progress and that power down messages are being sent to the MCU. A second LED, located to the right of this LED, will be lit at the same time to indicate the reason for the radio remote power down.

SWITCH ACTIVE/ LOW BATTERY

Note: This LED has 2 functions.

SWITCH ACTIVE: Indicates a stuck switch if, after radio remote power up, this LED remains lit. No other switches on the transmitter will be operational while this LED is lit..

The transmitter will send an error condition to the MCU and the system will display which switch is stuck. The stuck switch must be corrected before operation can resume.

This LED will illuminate whenever a switch is activate. This LED can be used to verify all switches via the radio remote.

Only one switch can be operated at any time and this LED is common to all switches.

Certain switches are timed to maintain safety features. If the ENABLE switch is active for more than 25 seconds, the radio remote will enter an error mode: an error message will be sent to the MCU and all commands will cease to operate. To resume operation, the enable switch must be released. Timed switches are: ENABLE, SHIFT, TRAM ENABLE, PUMP START, CONV START, CONV REV, and CUTTER START. Important: In normal operation, all of these switches are to be operated for only short periods of time. A constantly held switch is abnormal and defeats safety functions.

Therefore, these switches are monitored and timed.

LOW BATTERY: This LED will illuminate in conjunction with the SHUTDOWN LED to indicate the reason the radio remote powered down was a low battery condition.

_____________________________________________________________ A6474X446 REV 0 39

Troubleshooting _________________________________________________ Table 14 (continued): Radio remote LED functions (reference Fig. 13) LED TRAM ENABLE/ INACTIVITY

Description Note: This LED has 2 functions.

TRAM ENABLE: Illuminated LED indicates that the tram levers are active and that any movement of the levers will result in machine movement. If the LED is not lit, the tram levers are not enabled.

INACTIVITY: If the radio remote has shutdown and this LED is illuminated, it indicates the remote shutdown due to inactivity (no switch operation in a 5 minute period).

LINK ACK/ COMMANDED POWER DOWN

Note: This LED has 2 functions.

LINK ACK: During the teach/learn process, an illuminated LED indicates that a link response has been received by the radio remote from the MCU. If the radio remote is relinked to the same MCU, the LED will flash once. If the radio remote is linked to a different MCU, the LED will flash twice.

COMMANDED POWER DOWN: If the radio remote has shutdown and this LED is illuminated, it indicates the remote shutdown via the MACHINE STOP or TX PWR OFF switch.

________________________________________________________________ 40 Cervis Control System

_________________________________________________ Troubleshooting Receiver troubleshooting The receiver is located on the swing panel of the main control case of the 200 series miners and in the radio receiver case of the 300 series miners. It runs on 12V power supply via R1-1 and R1-2. There are eight LED’ s on the receiver (Fig. 14). with functions as listed in Table 15.

Fig. 14: Receiver LED’s

Table 15: Receiver LED functions

LED

LED Function

Description

1

Watchdog

One flash per second: Indicates power has been applied and that the internal processor is alive and working.

2

Pre-amble detected

Ten flashes per second: Indicates that the radio remote is on the correct frequency and has been detected. Should blink as soon as the transmitter is powered up and is in the vicinity of the machine.

3

Valid message

4

Link received

5-8

Not used

Blinks: Indicates that valid messages from a radio remote on the correct frequency are being received. Note: This does not necessarily indicate that the correct remote is sending the message. Verify the correct radio remote is communicating by checking the serial number in the top right corner of the graphics display against the radio remote serial number.

Steady on: Indicates that a sufficient number of messages are being received from the radio remote to operate and that the system should not drop out.

Reserved for future use.

_____________________________________________________________ A6474X446 REV 0 41

Troubleshooting _________________________________________________ Capacitor backup status LED’s The capacitor backup is located on the swing panel of the main control case of the 200 series miners and in the radio receiver case of the 300 series miners.

It runs on 120V power supply via R2-2 and R2-3. There are three LED’ s on the backup (Fig. 15). with functions as listed in Table 16.

Fig. 15: Capacitor backup LED’s

Table 16: Capacitor backup LED functions LED

LED Function

Description

1

+12VDC Output active Active in battery mode.

2

+5VDC Output active

3

120VAC Input present Active when not in battery mode.

Active in battery mode.

________________________________________________________________ 42 Cervis Control System

_________________________________________________ Troubleshooting DC Tram drive LED’s The DC tram drive is located in the tram case of the 200 series miners and in the control case of the 300 series miners. It runs on 120V power supply via D11 and D1-2. There are eleven LED’ s on the backup (Fig. 16). with functions as listed in Table 17.

Fig. 16: DC Tram drive LED’s

Table 17: DC Tram drive LED functions LED

LED Function

Description

1

Local FWD

Indicates forward direction command while in local control.

2

Local REV

Indicates reverse direction command while in local control.

3

Unused

Not used.

4

Unused

Not used.

AC

AC Present

Indicates when 120VAC power is available.

TX

Transmit out

Indicates transmission by the unit over a serial COM port.

RX

Received in

Indicates reception by the unit over a serial COM port.

WDG

Watchdog

OUT

Proportional output

RT (FWD)

Forward direction

Indicates when commanded output direction is forward.

LT (REV)

Reverse direction

Indicates when commanded output direction is reverse.

Indicates unit is active and operating code.

Blinks when active. Rate of blinking is directly related to the magnitude of the command.

_____________________________________________________________ A6474X446 REV 0 43

Troubleshooting _________________________________________________ Emergency tram pendant LED’s The emergency tram pendant is a handheld controller that connects to the machine via an umbilical cord. The pendant is normally stored on the machine, disconnected from the MCU until needed. It is an alternate to MCU control and works independent of the MCU. It cannot be sued unless the MCU is disabled and the machine selector is in E-TRAM mode. There are four LED’ s on the pendant (Fig. 17). with functions as listed in Table 18.

Fig. 17: Emergency tram pendant LED’s

________________________________________________________________ 44 Cervis Control System

_________________________________________________ Troubleshooting Table 18: Emergency tram pendant LED functions LED

LED Function

MODE

Mode

TRME

Tram enable

TRML

Tram left

TRMR

Tram right

Description Green: LED blinks green when the unit has power and is on.

Yellow: Solid yellow LED indicates that the tram function is active and tram button activation will result in machine movement.

Red: Solid red LED indicates a left tram command has been issued. Note that the TRME LED must be yellow before the tram left command is issued. When the LED is red, the operator can select TRAM FWD or TRAM REV. Red: Solid red LED indicates a right tram command has been issued. Note that the TRME LED must be yellow before the tram right command is issued.

When the LED is red, the operator can select TRAM FWD or TRAM REV.

_____________________________________________________________ A6474X446 REV 0 45

Troubleshooting _________________________________________________ Troubleshooting with the graphics display The top banner of the graphics display (Fig. 18) will provide troubleshooting information. Tables 19 and 20 list alarm and warning codes that may be displayed.

Fig. 18: Graphics display top banner

1

2

7

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

4

3

8

5

9

6

10

Miner model MCU mode RF signal intensity Radio remote (transmitter) ID Alarm message Active input indicator Fault log message, warning message block Battery voltage Commanded input message indication Messages per second from the radio remote

________________________________________________________________ 46 Cervis Control System

_________________________________________________ Troubleshooting Table 19: Alarm Codes Code

Description

A001

120VAC loss MMR

A002

Pump shutdown - left stop activated

A003

Pump shutdown - machine stop activated

A004

Transmitter shutdown - maximum switch/button active time exceeded

A005

Error - internal backplane communications

A009

Error - control ground fault

A010

Enable pushbutton stuck

A011

Transmitter shutdown - low battery

A012

Transmitter shutdown - inactivity period expired

A013

Transmitter shutdown - data link loss

A014

Methane monitor link loss

A015

Methane monitor override time expired

A016

Methane monitor sensor failure

A017

Pump shutdown - Low oil lockout for 5 seconds

A018

Pump shutdown - tilt switch active

A019

Pump shutdown - over-temperature (RTD) above 150 C

A020

Pump shutdown - pump motor overload

A021

Pump shutdown - right drive current without tram command

A022

Pump shutdown - left drive current without tram command

A023

Pump shutdown - pump instantaneous current trip - 5 seconds to reset

A024

Pump shutdown - pump phase imbalance trip

A025

Pump shutdown - - pump low current - 11 seconds to reset

A026

Pump shutdown - pump start switch held too long

A027

Pump start toggle switch stuck

A028

Conveyor reverse pushbutton stuck

A029

Conveyor start toggle switch stuck

A030

Conveyor shutdown - right motor jam current - 5 seconds to reset

A031

Conveyor shutdown - left motor jam current - 5 seconds to reset

A032

Conveyor shutdown - right motor over-temperature

A033

Conveyor shutdown - left motor over-temperature

A034

Conveyor shutdown - right motor overload

A035

Conveyor shutdown - left motor overload

_____________________________________________________________ A6474X446 REV 0 47

Troubleshooting _________________________________________________ Table 19: Alarm Codes (continued) Code

Description

A036

Conveyor shutdown - right motor instantaneous current trip - 5 seconds to reset

A037

Conveyor shutdown - left motor instantaneous current trip - 5 seconds to reset

A038

Conveyor shutdown - right motor phase imbalance trip

A039

Conveyor shutdown - left motor phase imbalance trip

A040

Conveyor shutdown - right motor low current - 11 seconds to reset

A041

Conveyor shutdown - left motor low current - 11 seconds to reset

A042

Conveyor shutdown - conveyor reverse switch operated

A043

Conveyor shutdown - conveyor motor current differential

A044

Conveyor circuit breaker is open

A045

Conveyor start switch held too long

A046

Conveyor reverse jog switch held too long

A051

Cutter shutdown - right motor over-temperature

A052

Conveyor shutdown - left motor over-temperature

A058

Conveyor shutdown - right motor overload

A059

Conveyor shutdown - left motor overload

A060

Conveyor shutdown - right motor instantaneous current trip - 5 seconds to reset

A061

Conveyor shutdown - left motor instantaneous current trip - 5 seconds to reset

A062

Conveyor shutdown - right motor phase imbalance trip

A063

Conveyor shutdown - left motor phase imbalance trip

A064

Conveyor shutdown - right motor low current - 11 seconds to reset

A065

Conveyor shutdown - left motor low current - 11 seconds to reset

A066

Conveyor shutdown - cutter lockout switch opens

A067

Conveyor shutdown - cutter motor current differential

A068

Conveyor shutdown - low oil alarm for 5 seconds

A069

Conveyor shutdown - cutter start switch held too long

A070

Cutter low oil lockout

A072

Conveyor shutdown - right motor jam current- 5 seconds to reset

A073

Conveyor shutdown - left motor jam current - 5 seconds to reset

A074

Cutter start toggle switch stuck

A075

Cutter circuit breaker is open

A080

Fan shutdown - instantaneous current trip - 5 seconds to reset

A081

Fan shutdown - overload trip

________________________________________________________________ 48 Cervis Control System

_________________________________________________ Troubleshooting Table 19: Alarm Codes (continued) Code

Description

A082

Fan shutdown - phase imbalance trip

A083

Fan shutdown - low current trip - 11 seconds to reset

A084

Fan shutdown - over-temperature

A085

Fan shutdown - jam current trip - 5 seconds to reset

A096

PLC to right drive COMM fault (all tram commands cleared)

A097

PLC to left drive COMM fault (all tram commands cleared)

A098

Machine voltage below allowable range (<80% V nominal)

A099

Machine voltage above allowable range (>117% V nominal)

A101

Right tram motor overload

A102

Left tram motor overload

A103

Tram enable switch held more than 3 seconds without tram

A104

Tram enable switch stuck

A112

Tram shutdown - left drive phase A overcurrent

A113

Tram shutdown - left drive phase b overcurrent

A114

Tram shutdown - left drive bus overvoltage

A115

Tram shutdown - left drive over-temperature

A116

Tram shutdown - right drive phase A overcurrent

A117

Tram shutdown - right drive phase b overcurrent

A118

Tram shutdown - right drive bus overvoltage

A119

Tram shutdown - right drive over-temperature

A120

Right drive - loss of voltage feedback: check tram breaker

A121

Left drive - loss of voltage feedback: check tram breaker

A128

Teach/Learn successful

A129

Teach/Learn failed

A335

Enable pushbutton stuck on radio remote

A336

Tram enable button stuck on radio remote

A337

Pump start pushbutton stuck on radio remote

A338

Conveyor start pushbutton stuck on radio remote

A339

Cutter start pushbutton stuck on radio remote

A348

Fan start button stuck on radio remote

A353

Transmitter shutdown - maximum switch/button active time exceeded

_____________________________________________________________ A6474X446 REV 0 49

Troubleshooting _________________________________________________ Table 20: Warning Codes Code

Description

W001

Conveyor reverse won’ t start - right conveyor jam

W002

Conveyor reverse won’ t start - left conveyor jam

W003

Conveyor reverse won’ t start - time period between forward/reverse not expired

W008

Conveyor reverse won’ t start - right conveyor instantaneous trip reset time not expired

W009

Conveyor reverse won’ t start - left conveyor instantaneous trip reset time not expired

W010

Conveyor reverse won’ t start - right conveyor low amp trip reset time not expired

W011

Conveyor reverse won’ t start - left conveyor low amp trip reset time not expired

W017

Conveyor reverse won’ t start - pump off

W018

Conveyor reverse won’ t start - conveyor breaker

W019

Conveyor reverse won’ t start - conveyor stop

W020

Conveyor reverse won’ t start - right conveyor over-temperature

W021

Conveyor reverse won’ t start - left conveyor over-temperature

W022

Conveyor reverse won’ t start - right conveyor overload

W023

Conveyor reverse won’ t start - left conveyor overload

W024

Conveyor reverse won’ t start - right conveyor instantaneous trip

W025

Conveyor reverse won’ t start - left conveyor instantaneous trip

W026

Conveyor reverse won’ t start - right conveyor low current

W027

Conveyor reverse won’ t start - left conveyor low current

W028

Conveyor reverse won’ t start - right motor single phase

W029

Conveyor reverse won’ t start - left motor single phase

W030

Conveyor reverse won’ t start - cutter

W031

Conveyor reverse won’ t start - current differential

W032

Conveyor reverse won’ t start - spare

W033

Pump won’ t start - low current

W034

Pump won’ t start - methane monitor link loss

W035

Pump won’ t start - machine voltage < 80% Vnominal

W036

Pump won’ t start - machine voltage > 117% Vnominal

W037

Pump won’ t start - conveyor jam

W038

Pump won’ t start - left drive current without command

W039

Pump won’ t start - right drive current without command

W049

Pump won’ t start - tilt switch active

________________________________________________________________ 50 Cervis Control System

_________________________________________________ Troubleshooting Table 20: Warning Codes (continued) Code

Description

W050

Pump won’ t start - left hand machine stop is open (R11-4)

W051

Pump won’ t start - machine stop is open (R12-7)

W052

Pump won’ t start - pump stop is operated

W053

Pump won’ t start - tram levers are not centered

W054

Pump won’ t start - low oil lockout active for 5 seconds (R14-4)

W055

Pump won’ t start - methane sensor failure

W056

Pump won’ t start - pump motor temperature above 150 C (140 C after trip)

W057

Pump won’ t start - overload trip reset time not expired

W058

Pump won’ t start - instantaneous trip reset time not expired

W059

Pump won’ t start - cutter

W060

Pump won’ t start - tram breaker is not set

W061

Pump won’ t start - conveyor breaker is not set

W062

Pump won’ t start - conveyor forward start is operated

W063

Pump won’ t start - conveyor reverse start is operated

W064

Pump won’ t start - pump phase

W065

Conveyor forward won’ t start - right conveyor jam trip reset time not expired

W066

Conveyor forward won’ t start - left conveyor jam trip reset time not expired

W067

Conveyor won’ t start - time period between forward/reverse not expired

W081

Conveyor won’ t start - pump off

W082

Conveyor won’ t start - conveyor breaker

W083

Conveyor won’ t start - conveyor stop

W084

Conveyor won’ t start - right conveyor over-temperature

W085

Conveyor won’ t start - left conveyor over-temperature

W086

Conveyor won’ t start - right conveyor overload

W087

Conveyor won’ t start - left conveyor overload

W088

Conveyor won’ t start - right conveyor instantaneous trip

W089

Conveyor won’ t start - left conveyor instantaneous trip

W090

Conveyor won’ t start - right conveyor low current

W091

Conveyor won’ t start - left conveyor low current

W092

Conveyor won’ t start - right phase

W093

Conveyor won’ t start - left phase

_____________________________________________________________ A6474X446 REV 0 51

Troubleshooting _________________________________________________ Table 20: Warning Codes (continued) Code

Description

W094

Conveyor won’ t start - cutter

W095

Conveyor won’ t start - current differential

W096

Conveyor won’ t start - conveyor reverse

W097

Cutter won’ t start - right cutter overload trip time not expired

W098

Cutter won’ t start - right cutter instantaneous trip reset time not expired

W099

Cutter won’ t start - right cutter low current

W100

Cutter won’ t start - left cutter overload trip time not expired

W101

Cutter won’ t start - left cutter instantaneous trip reset time not expired

W102

Cutter won’ t start - left cutter low current

W103

Cutter won’ t start - cutter start attempted without pump start

W104

Cutter won’ t start - low oil lockout

W105

Cutter won’ t start - circuit breaker active

W107

Cutter won’ t start - ground fault

W108

Cutter won’ t start - haulage transformer over-temperature

W109

Cutter won’ t start - right cutter jam

W110

Cutter won’ t start - left cutter jam

W111

Cutter won’ t start - cutter circuit breaker active

W113

Cutter won’ t start - pump not running

W117

Cutter won’ t start - right cutter over-temperature

W118

Cutter won’ t start - left cutter over-temperature

W124

Cutter won’ t start - current differential

W125

Cutter won’ t start - right phase

W126

Cutter won’ t start - left phase

W127

Cutter won’ t start - lockout switch open

W128

Cutter won’ t start - low oil

W129

Fan won’ t start - cutter must be started first

W130

Cutter won’ t start - fan must be started first

W131

Fan won’ t start - fan over-temperature

W132

Fan won’ t start - fan low current

W133

Fan won’ t start - fan overload

W134

Fan won’ t start - fan instantaneous trip

________________________________________________________________ 52 Cervis Control System

_________________________________________________ Troubleshooting Table 20: Warning Codes (continued) Code

Description

W135

Fan won’ t start - fan phase imbalance

W145

Tram - right tram analog reference without direction

W146

Tram - right tram direction without analog reference

W147

Tram - left tram analog reference without direction

W148

Tram - left tram direction without analog reference

W149

Tram - command without tram enable

W150

Tram - command without pump running

W151

Tram - command without tram circuit breaker closed

W152

Tram - reset high tram timeout via tram enable

W153

Tram - left tram overload

W154

Tram - right tram overload

W157

Tram won’ t start - left drive phase A overcurrent

W158

Tram won’ t start - right drive phase A overcurrent

W159

Tram won’ t start - left drive phase B overcurrent

W160

Tram won’ t start - right drive phase B overcurrent

W161

System shutdown due to power center trip

W162

Tram - left tram communication error

W163

Tram - right tram communication error

W172

MCU serial number out of range

W173

Cutter lower override due to right motor

W174

Cutter lower override due to left motor

W175

Cutter raise override due to right motor

W176

Cutter raise override due to left motor

W177

Tram won’ t start - left drive bus overvoltage

W178

Tram won’ t start - right drive bus overvoltage

W179

Tram won’ t start - left drive bus over-temperature

W193

Pump shutdown - pump stop operated

W194

Left hand stop operated

W195

Machine stop operated

W196

Conveyor shutdown - conveyor stop operated

W197

Cutter shutdown - cutter stop operated

_____________________________________________________________ A6474X446 REV 0 53

Troubleshooting _________________________________________________ Table 20: Warning Codes (continued) Code

Description

W210

Conveyor forward switch operated at start up

W211

Conveyor reverse switch operated at start up

W212

Cutter start switch operated at start up

W213

Ventilation only switch operated at start up

W214

Right tram reference present at start up

W215

Left tram reference present at start up

W216

Right tram forward contact closed at power up

W217

Right tram reverse contact closed at power up

W218

Left tram forward contact closed at power up

W219

Left tram reverse contact closed at power up

W220

Tram enable switch operated at start up

W221

Auxiliary relay 1 won’ t start - pump off

W222

Auxiliary relay 2 won’ t start - pump off

W225

Cutter won’ t start - machine stop override mode

W226

Conveyor won’ t start - machine stop override mode

W229

Conveyor won’ t start - machine stop override mode

W230

Conveyor won’ t start - machine stop override mode

W231

Conveyor won’ t start - machine stop override mode

W232

120VAC loss to the methane monitor relay

W301

Tram enable toggle switch stuck in position

W302

Tram enable toggle switch stuck in position

W303

Stab toggle switch stuck in lower position

W304

Stab toggle switch stuck in raise position

W305

Breaker toggle switch stuck in reset position

W306

Breaker toggle switch stuck in on position

W307

Conveyor toggle switch stuck in lower position

W308

Conveyor toggle switch stuck in raise position

W309

Conveyor swing toggle switch stuck in left position

W310

Conveyor swing toggle switch stuck in right position

W311

Gathering head toggle switch stuck in float position

W312

Gathering head toggle switch stuck in raise position

________________________________________________________________ 54 Cervis Control System

_________________________________________________ Troubleshooting Table 20: Warning Codes (continued) Code

Description

W313

Cutter head toggle switch stuck in lower position

W314

Cutter head toggle switch stuck in raise position

W315

Pump toggle switch stuck in stop position

W316

Pump toggle switch stuck in start position

W317

Fan toggle switch stuck in off position

W318

Fan toggle switch stuck in on position

W319

Dust toggle switch stuck in off position

W320

Dust toggle switch stuck in on position

W321

Fire/lights toggle switch stuck in fire position

W322

Fire/lights toggle switch stuck in lights position

W323

Conveyor toggle switch stuck in stop position

W324

Conveyor toggle switch stuck in tart position

W325

Conveyor reverse pushbutton stuck

W326

Cutter toggle switch stuck in stop position

W327

Cutter toggle switch stuck in start position

W328

Shift pushbutton stuck

W329

Machine stop override pushbutton stuck

W330

Enable pushbutton stuck

W331

Tram high pushbutton stuck

W332

Tram low pushbutton stuck

W333

Left tram lever stuck

W334

Right tram lever stuck

W344

Left tram command without enable

W345

Right tram command without enable.

W346

Tram enable and left tram pushed simultaneously

W347

Tram enable and right tram pushed simultaneously

W349

Function before enable

W351

Breaker on switch held too long

W352

Breaker reset switch held too long

_____________________________________________________________ A6474X446 REV 0 55

Troubleshooting _________________________________________________

________________________________________________________________ 56 Cervis Control System