CAT HRM220 Control for Hard Rock Miner Operating and Maintenance Manual - PDF DOWNLOAD

Media-ID: EM025821-01-EN Doc.-No.: 1999 001 043 BA 00 May. 2016

Operating and Maintenance Manual Control for Hard Rock Miner (HRM220)

SAFETY.CAT.COM

© 2016 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of content

Table of content 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4 1.4

2. Your safety General information for avoiding accidents . . . . .

2.3

Additional operating manuals . . . . . . . . . . . . . . . . .

2.3

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . .

Caterpillar Global Mining Europe GmbH, Lünen 2016

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

2.4 2.4 2.4 2.4 2.4

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Installation and commissioning . . . . . . . . . . . . . . . .

2.5

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport containers, dimensions and weights . . . . . . . . .

3.3 3.3

3.4 3.4

4. Installation General information . . . . . . . . . . . . . . . . . . . . . . . . . .

Drawing number system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control units of the MMC system . . . . . . . . . . . . . . . . . . . . .

Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of the control units . . . . . . . . . . . . . . .

Exchanging control components . . . . . . . . . . . . . . . . . . . . .

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing batteries and charging rechargeable batteries .

Repair of fiber-optic cables . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doc. no.: 1999 001 043 BA 00

VESL 09

4.3 4.3 4.3 4.3

4.4 4.4 4.4 4.4 4.4 4.5

Table of content 5. Operation Layout of the Pages on the Machine Display . . . . . . . . . . .

Navigation on the Machine Display . . . . . . . . . . . . . . . . . . .

Content of the Pages on the Machine Display . . . . . . . . . .

Control Console (Operator's Cab) . . . . . . . . . . . . . .

Layout of the Screen Pages at the Control Console . . . . .

Hierarchy of Screen Pages . . . . . . . . . . . . . . . . . . . . . . . . . .

Navigation Capabilities at the Control Console . . . . . . . . .

Example of Navigation with Parameterization . . . . . . . . . .

5.4 5.4 5.6 5.6

5.11 5.12 5.13 5.15 5.17

Starting Page - Overview/Diagnostics . . . . . . . . . .

5.21

Starting Page - Configuration/Parameterization .

5.24

Operation from the Control Console . . . . . . . . . . . . . . . . . .

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Observing Status Parameters . . . . . . . . . . . . . . . . . . . . . . .

Configuring the machine . . . . . . . . . . . . . . . . . . . . . .

Face Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature and Motor Current . . . . . . . . . . . . . . . . . . . . . .

Summary of Configuration Steps . . . . . . . . . . . . . . . . . . . . .

Operating Modes and Control Modes . . . . . . . . . . .

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Characteristics of the Operating Modes . . . . . . . .

Selection of Operating Mode and Control Mode . . . . . . . .

5.25 5.25 5.27

5.31 5.31 5.33 5.34 5.37 5.38

5.39 5.39 5.39

5.39 5.40

Radio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.41

"Automatic Mining" Operating Mode . . . . . . . . . . .

5.44

Machine Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intervening in Automatic Mining . . . . . . . . . . . . . . .

Intervention from the Control Center . . . . . . . . . . . . . . . . . .

Intervening with the Radio Controller . . . . . . . . . . . . . . . . . .

5.45

5.47 5.47 5.49

"Manual Mining" Operating Mode . . . . . . . . . . . . . .

5.54

"Maintenance" Operating Mode . . . . . . . . . . . . . . . .

5.62

Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pan Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controlling from the Panel at the Edge of the Face . . . . . .

Controlling from the Control Console . . . . . . . . . . . . . . . . . .

Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.70

5.71 5.71 5.72 5.73

Additional Diagnostic Pages on the Control Console . . . . . . . . . . . . . . . . . . . . . . .

5.74

Configuration Pages . . . . . . . . . . . . . . . . . . . . . . . . . .

5.105

Hard Rock Miner control

E

Machine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Caterpillar Global Mining Europe GmbH, Lünen 2016

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of content User Administration . . . . . . . . . . . . . . . . . . . . . . . . . .

5.129

Installing the software . . . . . . . . . . . . . . . . . . . . . . . .

5.132

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .

Types of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation On-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation via a Web Browser . . . . . . . . . . . . . . . . . . . . . . .

Parameter Administration . . . . . . . . . . . . . . . . . . . . .

Selecting, Saving and Deleting Parameters . . . . . . . . . . . .

Importing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.132 5.132 5.132 5.136 5.137

5.139 5.140 5.141 5.142

Configuring the Machine Network . . . . . . . . . . . . . .

5.143

List of Screen Pages . . . . . . . . . . . . . . . . . . . . . . . . . .

5.144

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.144 5.146

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

6. Technical data Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Limit stop MES 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Encoder 656995 cat . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

7. Tables Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.16

Suffix Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doc. no.: 1999 001 043 BA 00

VESL 09

7.36

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Table of content

Hard Rock Miner control

1

About this manual

Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It also provides you with information about the structure of the manual and the symbols and signs used in it.

Before starting work Applicable operating manual

Application

If you use an operating manual that is not intended for the application, you are endangering yourself, other people and items of equipment.

Make sure the information on the system components' housings identifies them as part of the MMC system.

This operating manual is for the Control for HRM 220

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Related documents

Document 1999 000 047 BA 00 (MMC control for mobile machines) as well as other supplier documents are part of this operating manual.

This machine is controlled by the MMC system. The CIOS® system with I/O modules (I/O = input/output) is an essential component.

The designation CIOS® is legally protected and is the property of Caterpillar Global Mining Europe GmbH. For better readability, the registered trademark symbol ® is not used further in this manual.

New operating manual

This operating manual must always be available at the place of operation.

Order the corresponding operating manuals immediately if the existing ones are no longer complete or legible.

Persons for whom the operating manual is intended The operating manual is intended for those persons who set up the control system, work with it, make settings and perform troubleshooting.

Every person who spends time in the entire working area of this machine must read this operating manual.

This includes persons who: are in charge of transport, set up the rise heading, perform installation/removal work, correct malfunctions, perform daily routine work on the face, carry out maintenance work, carry out repair work.

Doc. no.: 1999 001 043 BA 00

VESL 09

1.3

Before starting work Supervisory personnel who: initiate the activities mentioned above and/or supervise them.

Purpose of this operating manual Efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the control system.

Read this operating manual completely and at your leisure. Pay special attention to the respective safety instructions. Memorize the appearance and meaning of the safety and instruction symbols.

Safety

Carefully read through the chapter entitled "Your safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

Memorize the symbols and their meanings.

Danger!

Text passages indicated with this symbol draw your attention to imminent hazards. The possible consequences are very serious injury or even death.

Warning!

This symbol indicates hazardous situations. The possible consequences are very serious injury or even death.

Caution!

This symbol draws your attention to hazardous situations. The possible consequences are light to minor injuries and damage to machinery.

Notice!

Sections marked with this symbol draw your attention to harmful situations. The gearbox, motor, couplings, drive frame, conveyor or surrounding equipment could become damaged.

Important!

Useful tips and information intended to facilitate work are provided here. They do not warn about harmful or hazardous situations.

Items in lists are indicated by bullets.

– Items in sub-lists are indicated by a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

The following signs and symbols are used for safety instructions and important information in this operating manual.

E

Signs and symbols used

Before starting work [F1]

Keys on the computer keyboard are identified by brackets [ ].

{1234}

Numbers of screen pages are identified by curly brackets { }.

In this operating manual, if the directions LEFT and RIGHT are written in capital letters then the miner's understanding of direction is meant. For example, the LEFT shield is always the shield which is to the left when looking at the coal face, regardless of the direction in which you are currently looking.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

LEFT/RIGHT

Doc. no.: 1999 001 043 BA 00

VESL 09

1.5

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Before starting work

1.6

Hard Rock Miner control

2

Your safety

General information for avoiding accidents

Your safety This chapter provides important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure are intended to help you avoid hazardous situations and perform the necessary work as safely as possible.

General information for avoiding accidents State of the art technology

The control components have been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations, e.g. as a result of environmental influences, machine damage or operator errors.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Do not make any modifications or changes. Only personnel who have been trained and authorized by the manufacturer may open, modify and configure the devices.

Use within the EU

The European directives and standards referred to in this operating manual must be applied when using the control components within the European Union (EU).

Use outside the EU

If the device is used outside the EU, observe the directives and standards which apply in the respective countries.

Accident prevention regulations

In addition to this operating manual, make sure you also observe the legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations of the following parties: the mining company, the mines inspectorate and the mining supervisory authorities.

Additional operating manuals Also read the operating manuals of the components required to operate the face, such as electric motors, couplings, drive frames, conveyors, pushing devices and anchoring devices, as well as any other neighboring machines which may be affected by the control device. Clarify any questions before starting work.

Personnel Installation and repairs Installation and configuration work may only be performed by persons who have been adequately trained for these particular requirements. Repair work on the control components may only be carried out by service personnel from the manufacturer.

Doc. no.: 1999 001 043 BA 00

VESL 09

2.3

Operating Conditions Operating Conditions Intended use The control was developed and manufactured for the HRM 220.

The HRM 220 is used for underground mining of ore-containing rock in faces.

A machine equipped with this control may be used only in an area that does not contain a potentially explosive atmosphere.

The control system may only be used for other control tasks on agreement with the manufacturer.

Use this control system only as intended!

Unauthorized use

Ambient conditions The potential dust development in a mining operation must be combated by means of suitable measures. This includes using the water spraying system of the machine.

Prerequisites for operation The entire control system must not be put into service until an appropriately trained and authorized person has determined that the machine controlled by the system complies with European directive 94/9/EC and the DIN EN1710 standard.

If the control system delivered is only part of an overall system, the operator must meet the safety requirements required for the devices/components not included with this system or those necessary for operation or install the required safety equipment.

This must be labeled according to the legal provisions applicable at the time of its placement on the market.

Safety requirements to DIN EN 1552

Operation of the machine is only allowed once the safety requirements according to DIN EN 1552 have been met.

This includes: equipment for preventing unauthorized startup, startup warning systems, safe shutdown command systems, emergency-stop devices, dust extraction equipment, noise protection, Warnings All electrical equipment required to operate the face must be designated according to the legal provisions applicable at the time when it is placed on the market.

2.4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Caterpillar Global Mining Europe GmbH cannot be held liable for damage caused by unauthorized use.

E

Use which is not explicitly specified as intended use and/or has not been approved by the manufacturer is unauthorized and may not be performed with this control system.

Basic principles Basic principles General

Always remain focused when working.

Familiarize yourself with your working environment.

Protective clothing and equipment

Always wear your personal protective clothing and equipment.

This includes wearing ear protection since the noise emitted by the machine and neighboring equipment is louder than 85 dB(A).

In addition, it is necessary to wear suitable respiratory protection equipment and safety goggles to protect against the unavoidable development of dust.

Stay the greatest possible distance from the machine to avoid exposure to rock chips.

Always inform your coworkers about: where your exact site is. the work you are carrying out how much time you will probably need

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Keep the signaling and lighting systems in proper working order.

Pay attention to the acoustic and optical start-up warning systems.

Emergency stop

Actuate the emergency-stop switch immediately in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, so that necessary action can be taken immediately.

Actuate the emergency-stop switch also if safety equipment, such as firedamp protection systems, breaks down.

Never allow parts of your body to come between components which could move towards each other, such as conveyors and supports etc.

Support locking

For your own safety and that of other persons, the shield locking switch is to be actuated for the shield support in question when working in the shield support, driving through narrow passages or when two or more people meet.

Storage and transport Do not store any materials or components in the travel way or in your working area.

Inform the persons involved about the intended transport route and the probable duration of transport.

Transport safety devices

Use system holders

Make sure that the transport safety devices/packaging are attached correctly. Never walk or stay under unsecured components or suspended loads.

As brackets, only use retaining strips from the control system.

Do not damage any connector insertions or other fitting surfaces.

Installation and commissioning Inclined face

On inclined faces, secure all components by chains e.g. to the supports.

When working with oils, greases and other chemical substances, observe the safety regulations that apply to the product.

Doc. no.: 1999 001 043 BA 00

VESL 09

2.5

Installation and commissioning Environmental protection

Always dispose of materials contaminated with oil, grease or other chemical substances in an environmentally acceptable manner.

Inform the supervising personnel and the face crew about any maintenance and repair work required. Provide them with information on the intended work and its probable duration.

Securing the working area

Cordon off your working area over a wide range to avoid endangering other persons.

Secure the devices against unauthorized and unintentional restarting before all operations.

Replacing components

Stop and lock out the devices to secure them against restarting before replacing any defective components.

Remove any defective components from the face immediately to avoid hindering the face crew. This measure also helps to prevent the unintentional re-installation of these defective components elsewhere.

Original parts

Only use spare parts which meet the technical requirements. This is only guaranteed if using genuine spare parts from Caterpillar Global Mining Europe GmbH. Please refer to the spare parts lists for the order numbers.

Protective devices

Refit any removed protective devices immediately after completing work, and check that they are working properly.

Warning!

Dust concentrations hazardous to health can occur during operation of the machine. The equipment must not be started until the water spraying system is operating. Wear respiratory protection equipment.

Danger!

An audible start-up warning is generated before the machine starts. Immediately move to a safe area in response.

Danger!

The system is equipped with EMERGENCY STOP buttons at various locations to interrupt the supply of electrical power.

Never tamper with (e.g. tie down) these buttons or other safety devices. Keep the safety devices clean and check them regularly for proper operation.

Danger!

The operator must check all protection systems regularly and record the results.

The user must check all protection systems prior to starting work.

2.6

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

On inclined faces, secure the spare parts with chains or lifting tackle, for example.

E

Pass on these components for servicing without delay.

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and secure transport of the control components. Observing the instructions and manuals will increase the service life and reliability of the control components. Reading this chapter thoroughly will also help you make your day-to-day work easier.

Storage Storing the equipment Corrosion protection

Components with corrosion protection are protected for about six months.

No direct exposure to sunlight

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components and replacement parts made of rubber or plastic, such as seals, cables and hose cables, only in closed rooms at temperatures between 15°C and 25°C.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Dirt and moisture

Storage

Protect all equipment parts from dirt and moisture.

Do not remove, in particular, any plugs, temporary covers or protective caps. Use the plugs, temporary covers and protective caps if you wish to put the equipment into storage after using it.

Avoid any damage to the plug-type connections.

Never store electronic equipment outdoors!

Some devices contain batteries which undergo a natural loss in capacity during storage. Document "1999 001 043 BA 00 - MMC control for mobile machines" contains a table with information on the durability of the batteries.

Batteries (normal and rechargeable) are only allowed to be replaced above ground by personnel authorized to do so by Caterpillar Global Mining Europe GmbH. After a storage period of approx. two years, you must check all devices before using to see whether storage has led to damage.

Seals, hose lines and lines are subject to natural aging even if they are stored properly. Do not use these components anymore.

Important!

Make sure that incoming stock is stored separately from the old stock, notably in such a manner that computer components of the same age are stored together, to avoid conflicts between different program versions.

Make sure that display covers, keyboard protective covers and plug-type connections are not damaged when placing them in storage.

Doc. no.: 1999 001 043 BA 00

VESL 09

3.3

Transport Transport Transport containers, dimensions and weights Make sure you observe the technical data sheet. It provides you with information about: dimensions and weights The computers and interfaces belonging to the control system and which belong to the same operating point can be transported together in the same transport container. However, you must make sure that they are not packed together with heavy and/or sharp-edged materials so that displays, keyboards, cables and plug-type connections are not damaged.

Caution!

Load and transport the components carefully with concentration. Protect yourself from injury due to falling parts by wearing gloves and safety work shoes.

No sudden loads may be applied during transport at low temperatures.

Electronic equipment should be transported very carefully at low temperatures (below -10°C) since all materials become brittle and fragile at low temperatures. For this reason, cables may not be installed at temperatures below +4°C. If you transport such cold cables and lines underground, they should be left alone and warmed up to the ambient temperature before installing them on site.

When transporting by sea, you must carefully protect the line and cable connections and pack them so they are seaworthy.

3.4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Equipment which can be damaged by strong magnetic fields must not be transported by magnet cranes. This applies, for example, to electronic devices and cylinders with reed rods for stroke measurement.

E

This also applies to associated lines and hose cables. Avoid damage to plug-in and screw connections by using suitable packaging.

4

Installation

General information

Installation General information Important!

Control units, peripheral devices and the machines to be controlled could be damaged seriously by incorrect installation.

Install and configure the control system for the first time only under the instruction of skilled personnel from the manufacturer.

Drawing number system The control system is illustrated in drawings for the installation.

Fig. 1:

Example

4010 XXX 010 00 0X Components in the subproject

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Project drawing Subproject system overview Project number Drawing corresponding to the automation

The original drawings contain all parts numbers which refer to the part lists. The drawings shown here are only intended for a general understanding. They are not design drawings. Document numbering is based on the numbering system described above.

For the design-specific layout, the original drawings with part lists and parts numbers should be used for the precise assignment.

Help in finding the individual system components can be found in Chapter 6 of this operating manual, in which the main system components are illustrated by means of drawings and/or pictures. In addition, technical details and operating modes are explained.

Control units of the MMC system The control units of the MMC system are described in the operating manual "1999 001 043 BA 00 - MMC control for mobile machines".

You must refer to this operating manual during all work on the control system of the machine.

Tools required In order to install MMC system components underground, the following tools are required with standard torque settings: slot screwdriver ring or fork wrench for hex. head screws allen key

Doc. no.: 1999 001 043 BA 00

VESL 09

4.3

Maintenance of the control units Maintenance of the control units Only use suitable tools for maintenance work. In general, the devices in the MMC system are maintenance-free. The warning mechanisms (signal lamps, LEDs), keyboard protective covers of the radio controls and display covers must be cleaned regularly with suitable cleaning agents. If a keyboard protective cover is defective, put the radio controller out of operation immediately to avoid contaminating the switching contacts. Radio controllers can be repaired only by the manufacturer.

Notice!

Dirty contacts can lead to malfunctions!

Tightening torques The operating manual "1999 001 047 BA 00 - MMC control for mobile machines" contains a table with the required tightening torques.

It is absolutely essential that these be observed.

Notice!

Always tighten the mounting bolts to the required tightening torque!

Changing batteries and charging rechargeable batteries Some MMC system devices have (rechargeable) batteries.

Even with a constant power supply to the control system, the (rechargeable) battery's service life will be limited due to its self discharge.

For proper machine function, you must charge the rechargeable batteries in a timely manner and exchange dead batteries.

Depending on the device and how often the machine is used, the charging cycle or service life of the (rechargeable) batteries can vary. The document "1999 001 047 BA 00 - MMC control for mobile machines" contains a table that serves as a guide for scheduling charging and replacement cycles. Exchange dead batteries in a timely manner during planned shutdowns. This way, unwanted downtimes can be avoided.

Batteries (normal and rechargeable) are only allowed to be replaced above ground by personnel authorized to do so by Caterpillar Global Mining Europe GmbH.

Repair of fiber-optic cables For repair of fiber-optic cables underground, we recommend an installation and cleaning set from the cable manufacturer ODC (more detailed information can be found in the technical data in chapter 6).

4.4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

As a rule, the control components are already installed at the factory. However, it can occasionally happen that you have to exchange a defective device. All fastening elements of control components can be removed with standard tools (screwdriver, hexagon wrench, Allen key). For machines which are subject to vibrations and/or impacts, you must regularly check the screw connections for fastening the control components to make sure they are tight. The first check should be done a few hours after commissioning, at latest after the first shift.

E

Exchanging control components

Maintenance of the control units Cleaning the machine If your machine has external operating elements (e.g. hardwired remote control/keyboard), you should remove them prior to cleaning. Protect the socket and connector with corresponding protective plugs.

Danger!

The system is equipped with EMERGENCY STOP buttons at various locations to interrupt the supply of electrical power.

Never tamper with (e.g. tie down) these buttons or other safety devices. Keep the safety devices clean and check them regularly for proper operation.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Danger!

The operator must check all protection systems regularly and record the results.

The user must check all protection systems prior to starting work.

Doc. no.: 1999 001 043 BA 00

VESL 09

4.5

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Maintenance of the control units

4.6

Hard Rock Miner control

5

Operation

Operation Sections providing an overview of the following items precede the description of the control system of the HRM the machine display and the control console (control center) in the operator's cab.

In these sections you will find explanations of the screen page layouts, how to navigate between the pages and information on the content of the pages.

In the following, the HRM is designated as the machine.

Terms The following table lists some of the terms used here together with a brief description.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Tab. 1: Terms Term

Meaning

Advancing Speed

Speed of face removal in the direction of mining (face), perpendicular to the face conveyor.

Travel Speed

Speed of the mining machine parallel to the face conveyor.

Arm Infeed

Motion of the cutting arms in the direction of the face.

Approach Angle

Angle at which the bits cut into the rock.

Arm Height

Height of the cutting arms above the floor.

Overcut

Maximum cutting height of the overcutting arm.

Undercut

Lowest cutting height of the undercutting arm.

You can use a radio controller for mobile control and maintenance of the machine. It is called the radio controller in the following.

The screen pages of the control console are differentiated as pages of the diagnostics level and pages the configuration level (see Tab. 5 on page 5.13). Each page can be accessed by its number. To differentiate between diagnostics pages and configuration pages two different symbols are used. When pages are mentioned in the following text, the page number appears between braces {}. In addition, configuration pages are identified with the configuration symbol.

Example: {11} {11

Page 11 of the diagnostics level } Page 11 of the configuration level

The [F2] key allows you to switch between these levels.

The page numbers on the machine display always begin with the number 9. These are strictly display pages that reflect the status or your keyboard entry (e.g. {980}). They appear only on the machine display.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.3

Machine Display Machine Display Layout of the Pages on the Machine Display All screen pages on the machine display have the same layout (Fig. 2). The following information appears along the top edge of the screen: status of the machine (1) name of the page (2), or a fault message number of the page (3) Layout of the Pages on the Machine Display

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 2:

1 Overall machine status 2 Page header/fault status 3 Page number 4 Control status 5 Communication status 6 Input status

7 Machine status 8 Motor current, LH ranging arm motor 9 Motor current, RH ranging arm motor 10 Data area

The status of the overall machine is shown in the upper left corner (1). If a fault occurs, the message "Fault" appears there with a red background. The fault event is also displayed for 5 seconds in the header line (2) of the current page. Further information on the fault is provided on page {41}.

Tab. 2: Machine Status Symbol

Meaning

Ready

The machine is functioning normally

Fault

A fault has occurred. Please select {41} for additional information.

The name of the page appears in the header line (2). The page number (3) is shown at the right.

5.4

Hard Rock Miner control

Machine Display The left and right edges of the page are divided into two colored fields. These fields display a summary of the status. They can be displayed in three different colors, depending on the status. The colors are defined as follows: green: Everything OK yellow: Warning red: Critical machine status or fault The meaning of the different status messages can be found in the Table 3: Tab. 3: Meaning of the Colored Status Messages Color

Control Status

Communication Status (5)

Input Status

Operation via Radio Controller

No Communication Fault

Input from Radio Controller Accepted

Machine Status OK

Maintenance Mode

Communication Fault, No Impact on Function(s)

Input in Range of Limit Value

Occurrence of Minor Fault

Operation from Control Console

Serious Communication Fault

Input Ignored

Serious Fault

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

(4)

Machine Status (7)

(6)

In addition to these status fields, the motor current of the LH and RH ranging arm motors is displayed in the form of a bar diagram (Fig. 2 (8, 9)) in percent of the maximum permissible motor current.

The bar colors have the following meaning: green: Motor current in normal range (Fig. 2 (8, 9)).

Yellow: Warning. Motor current elevated, but not yet critical (Fig. 3 (1)).

Red: Motor current too high. Countermeasures are required.

Reduce the travel speed and/or the cut depth (Fig. 3 (2)).

Fig. 3:

Motor Current Elevated and Motor Current Too High

2 1

1 Motor current elevated 2 Motor current critical

The changing data area is displayed in between (Fig. 2 (10)).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.5

Machine Display Navigation on the Machine Display The machine display responds to commands from the radio controller. When you change the arm height, infeed, approach angle or speed with the radio controller, the display changes to the corresponding page. Once the entry is complete, i.e. there is no further interaction, the machine display switches back to the previously displayed page. The arrow keys next to the display on the radio controller (Fig. 4) also allow you to select pages without the intention of making a change.

Radio Controller Page Navigation

1 Selects a page with a higher number 2 Selects a page with a lower number

Content of the Pages on the Machine Display Page {980} shows the current travel speed of the machine in meters per minute, the requested travel speed and the direction of motion. When the machine is not moving, a rectangle appears instead of a direction arrow. A red rectangle indicates a fault.

Fig. 5:

5.6

Machine Display, Machine Position

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 4:

Machine Display Page {981} (Fig. 6) shows the machine position. The unit of measure is a meter.

Machine Display, Machine Position

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 6:

Page {984} (Fig. 7) shows both arm heights of the cutting arms together. The unit of measure is a millimeter.

Fig. 7:

Doc. no.: 1999 001 043 BA 00

VESL 09

Machine Display, Arm Height

5.7

Machine Display Page {985} (Fig. 8) is available only during manual cutting (manual mode). It is used to display arm positioning via the radio controller.

You can find additional information about this in the "Manual Mining" section, starting at page 5.55 Configuration

The behavior of the cutting arms, which arm is following which cutting line, is defined on page {986} (Fig. 9). As in the automatic mode, the response can be specified here for the leading and trailing cutting unit.

Fig. 9:

Configuration

The following combinations are possible for editing the individual fields with the radio controller:

5.8

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 8:

Machine Display Fig. 10:

Radio Controller Combinations

When the field is selected with the above combination, it is possible or . to select between the "top" or "bottom" values with Before you change the field, it is necessary to confirm the selection with ENT. ESC cancels the entry.

Page {987} (Fig. 11) shows both approach angles of the cutting arms together on one page. The angle is shown in degrees.

Machine Display, Approach Angles

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 11:

Doc. no.: 1999 001 043 BA 00

VESL 09

5.9

Machine Display Page {990} (Fig. 12) shows the infeed of both cutting arms. The unit of measure is a millimeter.

Machine Display, Infeed

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 12:

5.10

Hard Rock Miner control

Control Console (Operator's Cab) Control Console (Operator's Cab) The entire system is visualized on a 19" panel PC and a 19" flat-screen monitor at the operator console. A panel PC consists of a display and a computer unit installed in the same housing. These devices have been developed specifically for industrial applications in operator consoles or control cabinets.

This chapter describes only the visualization of the mining equipment and the face conveyor. Visualization of the shield control is described in a separate operating manual.

A bird's eye view of the operator console is shown schematically in Fig. 13. The panel PC (2) and the connected 2nd display (1) are mounted in an operator console into which the keyboard (3) is set.

The content of both monitors is controlled from this keyboard. The mining equipment (HRM) and the face conveyor (AFC) are visualized on the panel PC. Control Console

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 13:

1 LCD monitor 2 Panel PC

Doc. no.: 1999 001 043 BA 00

VESL 09

3 Keyboard 4 Operator's seat

5.11

Control Console (Operator's Cab) Layout of the Screen Pages at the Control Console All screen pages at the control console have the same layout (Fig. 14).

Page Layout at the Control Console

1 Machine status 2 Page header/fault message 3 Page number 4 Page mode

5 Page text 6 Language 7 Time 8 Navigation bar

The following information appears along the top and bottom edges of the screen: status of the machine (1) name of the page (2), or a fault message number of the page (3) associated level (4), diagnostic or configuration language selection (6) navigation buttons (8) time (7) The changing data area (5) is displayed in between.

The status of the overall machine is shown in the upper left corner (1). If a fault occurs, the message "Fault" appears there with a red background. The fault event is also displayed for 5 seconds in the header line (2) of the current page. Further information on the }. fault is provided on page {41 Tab. 4: Machine Status Symbol

5.12

Meaning

Ready

The machine is functioning normally

Fault

A fault has occurred. Please select {41} for additional information.

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 14:

Control Console (Operator's Cab) The name of the page appears in the header line (2). The page number (3) is shown at the right.

The symbol next to the page number identifies the type of page (see Table 5).

Tab. 5: Differentiation of Screen Pages between Diagnostics and Configuration Symbol

Type of Screen Page Information Level Overview and Diagnostics Configuration Level Parameterization and Configuration

On the parameterization and configuration pages, you are requested to enter your user ID and password before a change can be made (see page 5.129).

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Important!

Parameterization is possible only at the control console (master PC). On other installations, you are only allowed to reset counters and select the language at that location.

The content of different pages (data area) is shown in the center of the page (5).

A flag symbol (6) at the lower left shows the currently active language. Clicking on this symbol allows you to switch to a different language. If this is done at the control console, the language on the machine display simultaneously as well. On a client PC, the language change is only local.

Eight buttons for quick navigation (8) appear to the right. They provide links to other pages on the basis of the position of the page in the hierarchy tree and the function of the page. The numbers preceding the page names correspond to the numbers on the numeric keypad on the keyboard. You can click these buttons with the mouse or enter the corresponding number on the keyboard.

The time is shown at the right in the footer line (7).

Hierarchy of Screen Pages The screen pages are organized hierarchically. The deeper you navigate, the more detailed is the information available.

Level 1 contains the machine overview (pages {11} and {11 }.

From there you can navigate to level 2 via the navigation buttons.

It contains tables of contents that list the content at level 3. You access these contents via the buttons in the navigation bar. At level 3, the navigation bar once again contains buttons that allow you to access the next deeper level (if present). If no further level exists, you can access up to 8 diagnostic or configuration pages that belong to this branch. They are displayed in the navigation bar.

The number of digits in the page numbers increases with increasing level depth.

At the end of the branch, the navigation bar contains buttons to level 2. These allow you to select another category quickly in order to follow its branch.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.13

Control Console (Operator's Cab) Fig. 15 describes the path from a category at level 2, for instance, all the way to individual sensor values on level 5.

Fig. 15:

Detail of the Three-Dimensional Page Hierarchy (Schematic Illustration)

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Starting at page {11}, select the numeric string 51 for page {51} on level 3. This page is a table of contents with additional branching options. Numeral 1 takes you to page {511} on level 4. This page is once again a table of contents with the ability to select a page at level 5. Numeral 1 takes you from there to page {5111} at level 5.

If you wish to move within the branch at the level, you can use the keys [Page ] and [Page ] to scroll. Key [F6] takes you back to the previous level.

5.14

Hard Rock Miner control

Control Console (Operator's Cab) Navigation Capabilities at the Control Console Navigation in the hierarchy tree of the screen pages is possible by means of the numeric keypad on the keyboard and by means of special keys.

Navigation Keys The following keys are assigned navigation functions.

[F1] change the control unit (disable the radio controller).

[F2] change between the information and configuration levels [F3] select "Open page" window to enter a page number.

[F4] faults and events {41}. You can use [ ] to access additional fault pages.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

[F6] one level back (as far as {11} ).

Designated the "Home key" in some windows.

[Page ]/[Page down] scroll backwards to the first page in the hierarchy tree.

[Page ]/[Page up] scroll forwards to the last page in the hierarchy tree.

[Delete ] (“Backspace”) return to last page visited The following figure is intended to illustrate in graphical form the various navigation capabilities with the keyboard. The various levels are distinguished by color there. In addition, the number of digits corresponds to the level depth. Page {11} has a special status as the starting page. From there you can reach every other page by following the hierarchical structure.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.15

Control Console (Operator's Cab) Example of Navigating with the Keyboard

[Enter] / [Return] key [Delete] / [Backspace] key

[Page up] / [Page up] key [Page down] / [Page down] key

The origin page is the starting page {11}. In this example, the destination page is initially {5123}. Along the hierarchical structure you can use the entries 5, 12 and 3 to change between the levels until you reach the destination page {5123}. Since the corresponding digits appear on the navigation bars (Fig. 14 (8)) of the pages, you can also enter 5123 directly.

From there you can use the "Page down" key [ ] to navigate back in the hierarchy and access each preceding page each time you press the key.

If you wish to change from {5123} to {533}, select [F6] until you reach the starting page {11}, and then select the page by entering the numeric string 533 (this path is not shown). Alternatively, select [F3] and enter 533 in the window that appears, followed by [Enter ] . When using the path via [F3], you can now change between {5123} and {533} by pressing the [Delete ] key, since {5123} was the last page visited.

If you know the number of a desired page, the fastest way to reach it is via [F3]. You can always return to the starting page by pressing [F6].

This method of navigation applies to both the diagnostics branch and the configuration branch .

5.16

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 16:

Control Console (Operator's Cab) Example of Navigation with Parameterization Fig. 17 shows the origin page {11} of the navigation example.

In the navigation bar you can see buttons 1 to 8 with the possible branches in the hierarchy tree. Entering numeral 3 on the keyboard takes you to the overview page for the "Water/pressure" category.

Overview

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 17:

This overview of the content shows all subsequent pages that you can select in the "Water/Pressure" category.

The buttons of the navigation bar on this content page {3} correspond to the content information in the data area.

To select the " Cooling water" subcategory, now press 1.

Fig. 18:

Doc. no.: 1999 001 043 BA 00

VESL 09

Water / Pressure

5.17

Control Console (Operator's Cab) All measured values relevant to the cooling system are summarized here (Fig 19). You can read the temperatures and flow rates at the two cutting arms as well as at the pump.

Cooling water

Pressing [F2] takes you to the associated configuration page .

Here you can specify the individual alarm and fault limits for the measured values displayed previously (Fig. 20).

Fig. 20:

Cooling Water Parameters

To change the settings and values, you must log in to the system by pressing [Enter ] and then entering your user ID and password (Fig. 21, see also page 5.129).

5.18

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 19:

Control Console (Operator's Cab) Fig. 21:

Cooling Water Parameter Login

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

You can then bypass or activate individual sensors by means of selection lists or change limit values in input fields (Fig. 22).

Fig. 22:

Editing Cooling Water Parameters

Changed values or statuses that you have not yet saved are identified with an asterisk (*). As soon as you wish to leave the page by pressing [F 6], a window appears with a prompt asking how you wish to proceed (Fig. 23).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.19

Control Console (Operator's Cab) Fig. 23:

Saving Changed Parameters

1 2

3 4

2 - continue editing 3 - cancel without changes delete entry by pressing the "Delete backwards" key [ order to select another option.

] in

When you enter the corresponding digit, the selected instruction is executed without any further message. The asterisks preceding the statuses or values disappear.

Pressing [F2] takes you back to the previous diagnostics page.

5.20

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 - save changes

Starting Page - Overview/Diagnostics

Starting Page - Overview/Diagnostics The starting page {11} (Fig. 24) provides an overview of the most important machine data.

Starting Page - Overview of HRM

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 24:

1 Plan view of the HRM 2 LH approach angle 3 RH approach angle

10 Site of the machine

4 LH arm infeed 5 RH arm infeed 6 LH arm height 7 RH arm height 8 Travel speed 9 Distance of machine from end switch on drive unit

13 Actual speed

11 End switch on the drive unit 12 Requested speed 14 Max. travel speed 15 Symbol for direction of travel/stop 16 Pulling force on the hose and cable carrier 17 Overcurrent monitoring of the cutting arms

This page is divided into two areas. The upper area contains a representation of the machine with status displays for the motors (see Fig. 25) and the arm positions.

Arm Position The arm position includes the following displays: approach angle of the cutting arms in degrees (Fig. 24 (2, 3)) infeed of the cutting arms (4, 5) in millimeters. height of the cutting arms (6, 7) as the distance from the floor in millimeters.

Hose and Cable Carrier In addition, the pulling force on the hose and cable carrier (16) is shown in tons (1 ton corresponds approximately to a force of 9810 newtons).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.21

Starting Page - Overview/Diagnostics Motor Statuses Several machine statuses are shown graphically on page {11}.

Status Displays of the Motors on Page {11}

1 LH cutting arm 2 RH cutting arm 3 LH travel motor 4 RH travel motor

5 Hydraulic pump 6 Water spraying system, LH cutting arm 7 Water spraying system, RH cutting arm

The machine and its drive components can have any of four different operating statuses. These are displayed in color: Tab. 6: Examples of Symbol Colors and Drive Statuses Symbol Examples

Operating Statuses

The machine or the drive unit is idle (they are in active).

The machine for the drive unit is in the startup phase.

The machine or the drive unit is running normally.

5.22

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 25:

Starting Page - Overview/Diagnostics Symbol Examples

Operating Statuses

The machine or the drive unit did not start. The drive unit shown has a fault preventing it from starting.

On this screen page, the cutting arms change the approach angle to the clockwise or counterclockwise direction, depending on the direction of travel.

Travel Speed and Machine Position Information on the speed and position of the machine at the face as well as a warning about overcurrent in a cutting arm drive are shown in the lower area.

E

Travel speed of the machine in meters/minute (Fig. 24 (8)).

Caterpillar Global Mining Europe GmbH, Lünen 2016

Distance of machine from end switch on drive unit (9).

Graphical elements between the speed and position give information on the status of the machine's movement (15).

The meaning of the element colors is described in table 6.

– A square appears when the machine is not moving.

– An arrow pointing in the direction of travel appears when the machine is moving or a travel command has been issued.

Travel movement of the machine between drive unit and return unit (10). A unit consisting of a synchronization and an end switch (11) is located at the ends of the face. When one of the switches is actuated, it is displayed in green (synchronization switch) or red (end switch).

Speed control is displayed in the form of bar diagrams in percent of the theoretically possible speed.

– The top bar (12) shows the requested speed (target speed).

– The middle bar (13) shows the actual speed (current speed).

After the machine is started, they should quickly approach the requested speed. If this does not happen, you must check the corresponding parameter that is delaying or hindering the approach to these values.

– The bottom bar (14) shows the maximum possible speed indicated on screen page {62 }.

Overcurrent monitoring (17) of the LH and RH cutting arms indicates excessive motor current in the ranging arm motors by means of a red diode symbol.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.23

Starting Page - Configuration/Parameterization Starting Page Configuration/Parameterization Pressing [F 2] takes you from the starting page of the information and diagnostics level to the configuration level . The starting page also has page number {11} with the header "Control Center".

You use the functions on this page to control the machine from the control console.

"Control Center" Page

1 Selectable status displays 2 "Raise cut line" button, LH arm 3 "Raise cut line" button, RH arm 4 Cut line, LH arm 5 Cut line, RH arm 6 "Lower cut line" button, LH arm 7 "Lower cut line" button, RH arm 8 "AUTO START" button for starting the machine 9 "AFC AUTOSTART" button for starting the face conveyor

10 “Move left” button 11 Status of the machine 12 Movement and direction of travel of machine 13 "Login" button 14 Status of the conveyor 15 Position of the machine 16 Actual and requested speed of the machine 17 "Move right" button 18 "AFC AUTOSTOP" button for stopping the face conveyor 19 AUTO STOP" button for stopping the machine

Information on the travel speed and position of the machine is shown in the middle in the lower half.

5.24

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 26:

Starting Page - Configuration/Parameterization 51 Fig. 27:

Travel Speed and Position

1 Actual speed 2 Requested speed

3 Position as the distance from A in meters 4 Position as shield number

The machine accelerates to the requested travels the (Fig. 27 (2)).

The actual travel speed (1) approaches the requested travel speed during mining. "Position" (3) shows the distance of the machine from the drive unit in meters. The position as shield number (4) is shown to the side. It corresponds to the shield number displayed on the PMC-R of the shield.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

A yellow display field indicates a special situation or a special status. In this case, the special nature is the speed of the machine.

If temperature data is highlighted in yellow, this indicates a warning that you should heed. Warnings require your action to prevent a fault from occurring (for instance, shutdown of the motor because of excessive temperature).

Operation from the Control Console Important!

Login is required prior to starting operation (Fig. 26 (13) (see page 5.129).

Operating

This screen page is divided into two halves functionally. The lower half is used for operating the machine and the conveyor from the control console in a stationary mining mode (see also page 5.47).

Observing

The upper half contains various selectable panes with status parameters that are of special importance in the cutting mode.

The [Page ] and [Page ] keys changes the panes (see page 5.27) in a specific order in a loop.

Operating The lower half of the page is used for controlling the machine as well as for starting and stopping the face conveyor. Various buttons are provided for this purpose.

Before you can control the machine from here, you must log in to the system. First press the "Login" button (Fig. 26 (13)) or select the key [to the left ] in the direction key block of the keyboard . The window for entering your user ID and password then appears. After confirming by pressing [Enter ], the page elements for control are available.

Important!

The functions associated with the buttons "AUTO STOP" (19) and "AFC AUTOSTOP" (18) buttons can be executed without prior login.

You can adjust the dimensions for the overcut and undercut (4, 5) at the left and right. You do this by pressing one of the associated buttons "Arm up" (2, 3) or "Arm down" (6, 7). Each time you press a button, the arm height changes by 0.1 mm.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.25

Starting Page - Configuration/Parameterization Important!

You determine which arm performs the overcut or undercut on the configuration page {65 } (see page 5.34).

You use the "AUTO START" (8) and "AUTO STOP" (19) buttons to start and stop mining with the machine on the basis of the automatic sequences (see Fig. 51 on page 5.47).

A display field between these buttons shows the machine status (11). The following table lists the possible statuses and their meaning.

Meaning

RUNNING

The machine is in the mining mode and functioning normally.

STOPPED

The machine was stopped.

PRESTART

The machine is in the startup phase.

INHIBITED

A fault has prevented the machine from starting.

An arrow (12) above the machine status shows the machine's direction of travel. A colored square appears here when the machine is not moving (see also Fig. 24 on page 5.21 and Table 6 on page 5.22).

You can change the configured travel speed (16) between the direction arrows (10, 17).

The buttons with the direction arrows (10, 17) are used for accelerating the machine faster than the preconfigured value (arrow in direction of travel) or for braking (arrow opposite the direction of travel).

Tab. 8: Accelerating and Braking on Page {11

}

Direction of travel

Meaning

Button

The machine accelerates to the left (direction of travel).

The machine brakes.

The machine accelerates to the right (direction of travel).

The machine brakes.

You use the "AFC AUTOSTART" (9) and "AFC AUTOSTOP" (18) buttons for starting and stopping the face conveyor. The operating statuses of the face conveyor (14) are the same as those of the mining machine (Tab. 7). You can find further information on controlling the conveyor on page 5.71.

You can move from one control button to the next with the [Tab key. Each time you press the key, you move to the next button.

5.26

]

Hard Rock Miner control

E

Display

}

Caterpillar Global Mining Europe GmbH, Lünen 2016

Tab. 7: Machine Status on Page {11

Starting Page - Configuration/Parameterization Observing Status Parameters Various panes in the upper half of page {11 } are used for observing important status parameters while the machine is running.

Important!

All motors shut down automatically when you are logged in and leave page {11 }.

Motor Diagnostics Pane Status information on the motors is shown in the upper half of this pane (see also Fig. 26 (1)). See screen page {22}.

The [Page ] and [Page order in a loop.

Motor Check Pane

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 28:

] keys change the panes in a specific

1 Motors 2 Status 3 Temperature

4 Current consumption [%] 5 Current consumption, absolute

The first column lists the following motors: LH cutting arm, RH cutting arm Hydraulic pump and AFC (face conveyor) The following status information is shown for the motors: Status of the motor (2) Temperature of the motor in degrees Celsius (3) Bar diagram with current consumption in percent of the maximum value (4) Absolute current consumption in amps (5)

Doc. no.: 1999 001 043 BA 00

VESL 09

5.27

Starting Page - Configuration/Parameterization Cutting Units Pane (Angle and Infeed) The approach angles and infeed of both cutting arms are shown in this pane. See screen page {11}.

Cutting Units Pane

2 Infeed

Further information can be found in the description on page {65 on page 5.34.

}

Cooling Water Pane The most important status parameters for subsystem cooling are shown in this pane. See screen page {31}.

Fig. 30:

Cooling Water Pane

1 Cooling water, LH cutting unit: Temperature and volume flow 2 Cooling water, hydraulic pump: Temperature and volume flow 3 Oil cooler: Volume flow

5.28

4 Cooling water, RH cutting unit: Temperature and volume flow 5 Cooling water supply: Temperature and pressure 6 Cooling water, conveyor: Volume flow and temperature before and after the motor.

Hard Rock Miner control

E

1 Approach angle

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fig. 29:

Starting Page - Configuration/Parameterization Hydraulic System Pane The most important status parameters for the hydraulic system are shown in this pane. See screen page {36}.

Fig. 31:

Hydraulic System Pane

1 Travel drive: Pressure for forward and reverse 2 Oil tank: Fill level and temperature

3 Valve block: Inlet pressure

Additional explanations can be found under "Hydraulic System Overview" on page 5.83.

Chain Tensioner Pane Caterpillar Global Mining Europe GmbH, Lünen 2016

E

This pane shows the process parameters for the chain tensioner.

The content corresponds to screen page {13} on page 5.76.

Fig. 32:

Chain Tensioner Pane

Fault List Pane This pane displays a list of the fault messages.

See screen page {41}.

Fig. 33:

Fault List Pane

1 Fault number 2 Description

3 Date and time 4 Fault counter

Additional explanations can be found under "Faults and Alarms" starting at page 5.84.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.29

Starting Page - Configuration/Parameterization Event List Pane This pane displays a list of the event messages.

See screen page {45}.

Event List Pane

3 Date and time 4 Event counter

Additional explanations can be found under "Faults and Alarms" starting at page 5.84.

5.30

Hard Rock Miner control

E

1 Event number 2 Description

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fig. 34:

Configuring the machine Configuring the machine Prior to commissioning, you must provide the mining machine with some data on the surroundings. You access the corresponding screen pages via menu item "6 - Automation".

You can find the preset values in the parameter lists at the end of this document.

Caution!

Do not accept the preset values without examining them carefully. To prevent machine damage, you must check all parameters on site and adjust them to the actual conditions.

Important!

Backup the current parameters before changing the configuration of the machine. If the changes prove not to be beneficial, you can import the previously backed up parameters again. A description of the procedure for exporting and importing parameter blocks starts at page 5.139.

E

User Login Caterpillar Global Mining Europe GmbH, Lünen 2016

Prior to changing parameters, you must log in with your user ID (ID) and password. This procedure is described on page 5.129.

Saving changes To save the changes, leave the page by pressing [F 6].

A window with a prompt asking how you wish to proceed appears (see Fig. 23 on page 5.20).

Face Dimensions The following information is required under "Face" {61

} (Fig. 36):

length of the face in meters (distance between drive unit and return unit) width of the conveyor section (drive unit) in meters width of the maingate (return unit) in meters number of shields width of a shield in millimeters distance from the end switch in the conveyor section (A) to the shield support in meters Fig. 35 shows the face support schematically with the required dimensions for screen page {61 }.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.31

Configuring the machine Face Dimensions (Schematic Illustration)

6 Maingate 7 Face conveyor 8 Shield 9 Shield width 10 Working face 11 Machine (HRM)

E

1 Width of the return unit (position of the end switch) 2 Face length 3 Width of the drive unit (position of the end switch) 4 Conveyor section 5 Synchronization and end switches (red)

The distance from the. end switch to the inner entry wall (1, 3), also called "Width A" and "Width U", must be measured on-site.

The following figure (36) shows the screen page {61 enter the face parameters.

Fig. 36:

} where you

Face Configuration

2 3 1 9

1 Length of the face

4 Number of shields

2 Width of the conveyor section (drive unit)

5 Width of a shield

3 Width of the maingate (return unit)

5.32

6 Distance from the end switch A to the shield support

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fig. 35:

Configuring the machine In this way you establish the position of the end switch (distance and width of the drive units). The control system needs this information for starting and stopping the corresponding motors.

Machine Dimensions The following information is required on this screen page {62

}:

Length of the arm height cylinder in millimeters Length of the hydraulic cylinder used for adjusting the height of the cutting arms.

Length of the infeed cylinder in millimeters Length of the hydraulic cylinder used for cutting arm infeed.

Max. travel speed in meters per minute Limit on maximum speed of the mining machine, depends on the operating mode. The preset value protects the machine against excessive wear. You should not increase this value.

Undercut offset (zero point shift, offset) for the arm height.

ConFig. Arm Settings for Max. Travel Speed

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 37:

1 Length of the arm height cylinder 2 Length of the infeed cylinder

3 Max. travel speed 4 Armed height offset

Prior to commissioning and after replacement of cylinders, you must check these values and adjust them if necessary.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.33

Configuring the machine Arm Position You define values for the arm movements and the travel speed of the machine on this screen page {65 }. The following information is required: approach angle in degrees infeed in millimeters arm height in millimeters assignment of overcut and undercut to the cutting arms travel speed and automatic acceleration of the machine Arm Movements and Travel Speed

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 38:

1 2

3 4

1 Travel speed 2 Activate/deactivate autom. acceleration 3 Approach angle, leading arm 4 Approach angle, trailing arm 5 Infeed, leading arm 6 Infeed, trailing arm 7 Assignment of cut to leading arm at A

8 Assignment of cut to trailing arm at A 9 Assignment of cut to leading arm at the U 10 Assignment of cut to trailing arm at the U 11 Arm height for overcut 12 Arm height for undercut

Next, you define the values for the approach angle and infeed of the leading arm (Fig. 38 (3, 5)) at the left, and then the corresponding values for the trailing arm (4, 6) at the right. In between you set the target for the travel speed (1) and activate or deactivate automatic adjustment to the target speed. Below you set the heights for the overcut (11) and the undercut (12). At the left and right, you set the uppercut or undercut for the leading arm (7, 9) and the trailing arm (8, 10) for both drives sides (7, 8 and 9, 10) on the basis of the direction of travel (see Table 9, page 5.35).

5.34

Hard Rock Miner control

Configuring the machine Approach Angle The approach angle (3, 4) describes the position of the arms with respect to the working front. You should not change these values without consulting our service personnel.

Infeed You define the cut depth with the infeed (5, 6). The greater the cut depth, the more rock you can theoretically remove. The deeper the bits engage, the greater is the amount of power drawn from the ranging arm motors! To prevent overloading, it may be necessary to reduce the travel speed, since with increasing cut depth the "resistance" against which the travel drive must advance increases, Caution!

A higher load on the machine results in more frequent maintenance and repair, and reduces the service life.

Arm Height (Uppercut and Undercut) You enter the desired cut heights here (11, 12).

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

For the overcut (11), you define the height up to which the cutting arm assigned to overcutting should cut.

For the undercut (12), you define the depth down to which the cutting arm assigned to undercutting should cut.

You can also assign both arms simultaneously to overcutting or undercutting (see Table 9, page 5.35). In this case, the infeed of the trailing arm is increased by the value of the cut depth parameter, since the leading arm already has executed a cut depth.

For the undercut (12), you define at the same time whether the machine should maintain its horizon (undercut = 0), dip towards the floor (undercut < 0), or climb (undercut > 0). In this way you can follow the ore-containing rock.

Assignment of Overcut and Undercut You can assign the overcut or undercut to the leading and trailing arms for each drive side (Fig. 38 (7 - 10)). The possible combinations are shown in the following table.

Tab. 9: Possible Combinations of Overcut and Undercut Travel ANT > UMK Arm

Arm position ANT

FA NA

FA

Doc. no.: 1999 001 043 BA 00

Programmed

Programmed

top bottom

FA

bottom

NA

top

FA

bottom top

VESL 09

Infeed 0 mm

top

0 mm top

NA

NA

Arm position UMK

0 mm bottom

FA NA

Infeed

Travel UMK > ANT

Programmed 0 mm

bottom

Programmed

bottom 0 mm

top

Programmed

top 0 mm

bottom

Programmed

bottom 0 mm

top

Programmed

5.35

Configuring the machine Arm

Arm position ANT

FA

top

NA

Arm position UMK

Infeed

top 0 mm

bottom

FA NA

Infeed

bottom

0 mm bottom

Programmed 0 mm

Programmed

bottom (FR)

Programmed

Important!

Dipping and climbing are only possible within limits.

Please heed the recommended limit values for the undercut.

Travel Speed In the center of the window you can change the travel speed (1) and activate/deactivate the automatic acceleration (2).

If "Accelerate autom." (2) is active, the machine accelerates to the set final speed (1) on the basis of the specified parameters. You can change the desired final speed while traveling and in this way accelerate or brake the mining machine further.

If "Accelerate autom." (2) is deactivated, you can accelerate the machine in increments manually by means of screen page {11 } or via the radio controller. For this, use the button/keys shown in Figs. 39 and 40.

Fig. 39:

Increasing the Machine Speed while Traveling to the Left or Decreasing the Speed while Traveling to the Right.

1 2

5.36

+

1 Button on screen page {11 2 Key combination on the radio controller

}

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

If arms are configured to the same height, the infeed of the trailing arm is always greater by the amount of the infeed depth. This means that the leading arm operates with an infeed of "0" and the trailing arm with an infeed of 75 mm (If the corresponding parameter was so set). Depending on the configuration, the angle and position are interchanged at the return unit. The infeed is mirrored. For the machine to be positioned correctly at the face, the previously cut depth must be pushed out of the relay bar assembly of the shield column. This applies in particular when the arms follow the undercut when traveling in both directions and as a result do not cut more than one drum diameter.

E

FA = Leading arm NA = Trailing arm ANT = Drive unit UMK = Return unit FR = Advance conveyor

Configuring the machine Fig. 40:

Increasing the Machine Speed while Traveling to the Right or Decreasing the Speed while Traveling to the Left.

1 2

+

1 Button on screen page {11 2 Key combination on the radio controller

}

At the ends of the face, the control system limits the ability to change the speed and acceleration in the direction of travel. The machine switches to the "creep mode" at programmable positions so that it does not reach the end stop with excessive kinetic energy. You can change the parameters for this on screen page {23 }. Under "Haulage SlowDown" you can enter values for the "Distance" from the end switch and the reduced "speed". Upon reaching the set distance, the machine brakes to the creep speed.

Haulage Configuration

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 41:

1 2

3 4

Temperature and Motor Current On pages {211 } and {212 } you define the alarm and fault limit values as well as activation/deactivation of fault monitoring for the motors gearbox bearings coolant cooling counter motor current.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.37

Configuring the machine Handling of Cutting Unit Faults

E

Summary of Configuration Steps The following table summarizes the configuration steps required prior to (re)commissioning.

Tab. 10: Configuration Steps Configuration

Screen Page

Face Dimensions

{61}

, Content

Page 5.32

Length of Face Width of Drive Unit Width of Return Unit Number of Shields Width of a Shield Machine Dimensions

{62}

5.33

Length of Arm Height Cylinder Length of Infeed Cylinder Max. Travel Speed Undercut Offset Arm Position and Cutting Speed

{65}

Travel drive

{23}

Approach Angle Infeed Cut Height and Assignment of Overcut Undercut Speed Autom. Acceleration On/Off

5.34 ff

5.36

Alarm and Fault Limits Distance from End Switch Speed in Creep Mode Cutting Units

{212}, {212}

5.38

Fault Monitoring On/Off Warning Limits Fault Limits (Shutdown)

5.38

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fig. 42:

Operating Modes and Control Modes Operating Modes and Control Modes In the following, a distinction is drawn between operating modes and control modes.

Operating Modes Operating modes describe the behavior of the machine. Machine operation can be divided into three operating modes: automatic mining execution of an automated sequence for extracting ore. manual mining mobile control of the machine to extract ore maintenance manual operation for machine maintenance.

Control Modes

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Control modes describe the the possible ways of controlling the machine. There are two possibilities: control using a radio controller (mobile control), control using the panel PC at the control console (stationary control).

Radio Control You use the radio controller to control the machine in your immediate surroundings. You can see the status of the machine on the integrated display (see page 5.6).

In the "Manual Mining" and "Maintenance" modes, the machine can be operated only with the radio controller.

Control Console From the control console, the machine can be operated only in the "Automatic Mining" mode.

Characteristics of the Operating Modes The most important characteristics of the operating modes are summarized and differentiated in the following section. Details of the control possibilities are described further down.

Automatic Mining During automatic mining (page 5.44), operation follows a programmed sequence. In the simplest case, you need merely monitor the process. However, you can temporarily intervene in the process from the control center or the radio controller (page 5.41), for instance, to change the acceleration of the travel drive or the cutting lines.

Manual Mining During manual mining (page 5.55), You have greater flexibility to intervene in the process and considerably more parameters to change during operation. However, to protect personnel and the machine, the possibilities for setting the parameters are limited.

Maintenance In the maintenance mode (page 5.62), you are not allowed to cut any rock, since movement capabilities that could injure personnel and destroy the machine while cutting are available here. Special safety precautions are required in this operating mode.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.39

Characteristics of the Operating Modes Selection of Operating Mode and Control Mode Selection of the operating mode and the control mode is possible only from the control console upon pressing key [F1] on the keyboard.

In the window that appears, you select a combination of operating mode and control mode: The following window appears: Fig. 43:

Selecting the Control Mode

1

2 3 4

1 Registration of the radio controller 2 Maintenance (radio controller) 3 Automatic mining (radio controller)

4 Automatic mining (control center) 5 Manual mining (radio controller)

By selecting the first two options (Fig. 43 (2, 3)) and the last option (5), you operate the machine with the radio controller. By selecting a third option (4), you operate the machine from the panel PC on the control console.

Pressing the "Reset" button (1) registers the active radio controller with the machine (2, 3, 5) or unregisters it (4).

5.40

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

5

Radio Control Radio Control Important!

Before the machine can be operated with the radio controller for the first time, it is essential that it be located at the end switch on the drive unit.

You can see the keys on the radio controller in Fig. 44. You need the keys in the light blue area (7 to 17) for mining mode. You need the keys in the light green area (18 to 27) for maintenance mode.

Fig. 44:

Radio Controller 1 Display on the radio controller 2 Status displays 3 ESC (cancel) 4 ENT (confirm) 5 Scroll up 6 Scroll down 7 STOP (power off)

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

8 Move up 9 Move down 10 Move left 11 Move right 12 ON (power on) 13 AUTO START (start automatically) 14 HALT (stop) 15 Move machine 16 Overcut 17 Undercut 18 No function 19 LH cutting arm 20 RH cutting arm 21 Water spraying system 22 Move LH cutting arm 23 Move RH cutting arm 24 Hydraulic pump 25 Control valves manually 26 Approach angle LH cutting arm 27 Approach angle RH cutting arm

Danger!

Moving the machine can seriously or fatally injure you or other persons.

No one must be in the hazardous area when you switch on the machine. Always stay a safe distance from the machine.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.41

Radio Control Radio Controller Drop Detection The radio controller is equipped with an acceleration sensor. This sensor switches off the unit if you fall with the radio controller or the radio controller itself drops. For your safety, this causes the machine and all drive units stop. The following message appears on the display of the radio controller: Fig. 45:

Fault Message after Dropping

To acknowledge the fault, press the following key combination for more than 2 seconds: Acknowledging the Drop

>2s

Start-up Warning A start-up warning sounds for three seconds after a specific key combination is pressed. Following this, you can select the same key combination once again within two seconds. If the combination is not repeated within the specified time or there is a fault, the control system ignores the command. The start-up warning sounds again. You then you have a new time window to repeat the key combination.

Fig. 47:

Time Window for Keyboard Commands

1 First time keys pressed 2 Start-up warning (audible)

5.42

3 Time window for pressing keys the second time

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 46:

Radio Control Accelerating Movement The speed of movements depends on how long the key is pressed (Fig. 48).

Fig. 48:

Time-Dependent Speed of Movement

1 Slow movement within 3 seconds 2 Fast movement after 3 seconds

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

If the key combination for a movement command is pressed for up to three seconds, movement proceeds slowly. After this time, the movement is fast. The speed levels are freely configurable. You can set them on page {63 } (Fig. 177, page 5.122).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.43

"Automatic Mining" Operating Mode "Automatic Mining" Operating Mode In this operating mode, control of the machine is largely automatic.

After you have specified the direction of motion, the starting instructions and movements of the machine follow a programmed sequence.

Sequence in the "Mining" Operating Mode

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 49:

5.44

Hard Rock Miner control

"Automatic Mining" Operating Mode Machine Positions The automatic mode distinguishes seven machine positions (Fig. 50).

Fig. 50:

Machine Positions

UMK < ANT

ANT

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

UMK

UMK > ANT

ANT = Drive unit UMK = Return unit

Travel from drive unit to return unit Position 1 – The machine is standing at the synchronization switch on the drive unit, all actuators are off.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.45

"Automatic Mining" Operating Mode Position 2 – The machine moves towards the return unit.

Position 3.1 – At the face-entry junction, the cutting units of the LH arm star.

– The water spraying system starts.

Position 3.2 – The cutting units of the RH arm are timed to start before they reach the entry-face junction.

Position 4 – The machine approaches the return unit. At the fifth to last shield, a flashing light is actuated on the drive unit in the maingate to signal arrival of the machine.

Position 5 – The water spraying system on the cutting units switches off.

– The machine continues moving in the maingate until it reaches the synchronization switch on the return unit.

Position 7 – The machine is standing at synchronization switch UM. Travel from the return unit to the drive unit Position 7 – The cutting units swivel around in succession and reposition themselves (not in the manual mining mode).

– The conveyor advances by the amount of the cut depth.

Position 6 – The machine moves towards the drive unit.

Position 5 – The water spraying system starts.

Position 4 – The flashing light switches off.

Position 3 – The ranging arm motors switch off.

– The water spraying system switches off.

Position 1 – The machine stands still.

Important!

Before the machine can be operated with the radio controller for the first time, it must be located at the end switch on the drive unit.

5.46

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Position 6

Intervening in Automatic Mining Intervening in Automatic Mining Danger!

Life-threatening situation in the path of the machine. Suitable barriers must be used on the side of the return unit (maingate) to ensure that no one can enter the path of the machine while it is moving. A flashing light in the maingate signals travel towards the return unit.

Intervention from the Control Center You can intervene in the mining mode from the panel PC at the control center or the radio controller. The buttons that resemble the keys on the radio controller are shown on page {11 }.

Control Panel on "Control Center" Starting Page

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 51:

1 Configure the arm height of the LH cutting unit 2 Configure the arm height of the RH cutting unit 3 "Raise cut line" button, LH arm 4 "Raise cut line" button, RH arm 5 Cut line, LH arm 6 Cut line, RH arm 7 "Lower cut line" button, LH arm 8 "Lower cut line" button, RH arm 9 "AUTO START" button for starting the machine 10 "AUTO STOP" button for stopping the machine

11 "Move left" button 12 "Move right" button 13 Movement and direction of travel of machine 14 Status of the machine 15 "AFC AUTOSTART" button for starting the face conveyor 16 "AFC AUTOSTOP" button for stopping the face conveyor 17 Current speed of the machine 18 Requested speed of the machine 19 Position of the machine in meters 20 Position of the machine as shield number 21 "Login" button 22 Status of the conveyor

Important!

Please also heed the explanations starting at page 5.24 The cutting arms settings for the automatic mode are made on screen page {65 } (see page 5.34). You can adjust these values during operation on page {11 }.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.47

Intervening in Automatic Mining Cut Lines and Travel Speed The pump starts on initiation of the autostart sequence. Following this, you can adjust the arm heights from the control console. On the left side, you change the cut line of the LH arm (Fig. 51 (1)) by means of the "Arm up" (3) and "Arm down" (7) buttons. You proceed similarly with the corresponding buttons (4, 8) for the RH arm (2). Symbols (5, 6 ) between these buttons indicate whether the corresponding arm is working in the overcut or undercut. The dimensions of the cut lines in millimeters are shown next to the symbols.

Pressing the "AUTO STOP" button (Fig. 51 (10)) stops mining.

After the travel drive, the ranging arm motors also stop when the machine is at a standstill.

If the communication link to the machine is interrupted, the machine stops. If this occurs, you must correct the communication fault and disengage the machine by moving in the opposite direction in the automatic mode. The ranging arm motors now start operating again and you can accelerate the machine in the cutting direction.

5.48

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Increasing the travel speed (Fig. 51 (11 or 12)) at the control console or Fig. 56 (4 or 5) on the radio controller) starts the machine. As soon as the machine enters the face, the ranging arm motors and the water spraying system start. The actual travel speed (Fig. 51 (17)) approaches the requested speed (18) if this option was activated on {65 }.

E

Any change of the cut line is limited to a deviation of ± 25 mm from the parameter value (see {65 }). The deviation can be changed with the agreement of the manufacturer ("Action range of the arm height change" {64 }, requires access level 4).

Intervening in Automatic Mining Intervening with the Radio Controller You can also control the mining mode from the radio controller instead of the panel PC in the control console. At the same time, you can read essential machine data from the machine display (see page 5.6). You follow the machine down the face from an appropriate safe distance away, observe the machine and display, and intervene to make corrections by means of the radio controller.

Switching on the Radio Controller To switch on the radio controller, press and hold the "ON" button (Fig. 44 (12)) for longer than 2 seconds.

Switching on the Radio Controller

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 52:

>2s

Initiating the Autostart Sequence You start the mining mode from the radio controller with the following key combination:

. Press the key combination shown in Fig. 53. . Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Fig. 53:

Doc. no.: 1999 001 043 BA 00

VESL 09

Initiating the Autostart Sequence

5.49

Intervening in Automatic Mining Shutting Down the Machine Pressing the "STOP" key shuts off the radio link. The radio controller immediately sends a STOP signal to the control system.

This immediately shuts off all actuators and the machine switches to a safe status.

Fig. 54:

Shutting Down the Machine

. Press the key combination shown in Fig. 55.

Fig. 55:

Stopping the Machine

>2s

Setting the Overcut and Undercut When the radio controller is being used, adjustment of the arm position includes a time function. When you press the keys "Up" (Fig. 56 (2)) and "Down" (3) briefly, the cut line changes only slowly. Pressing the keys longer accelerates this movement (see also page 5.43).

5.50

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Pressing the key combination "HALT" and "AUTO START" stops the machine and all drives on the spot.

E

Stopping the Machine

Intervening in Automatic Mining Fig. 56:

Keys on the Radio Controller for the Mining Mode (Automatic)

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 STOP (power off) 7 AUTO START 2 Move up 8 HALT (stop) 3 Move down 9 Move machine 4 Move left 10 Overcut 5 Move right 11 Undercut 6 ON (power on) A complete description of the radio controller can be found on page 5.41.

The blue buttons are used to adjust the arm heights (setting the overcut and undercut).

With the following key combinations, you can change the cut height for the overcut (Fig. 57) and the undercut (Fig. 58):

. Press the key combinations shown in Figs. 57 and 58 for up to three seconds for slow movement or longer than three seconds for fast movement.

Fig. 57:

Overcut

Overcut (+)

Fig. 58:

Undercut

Undercut (+)

Doc. no.: 1999 001 043 BA 00

VESL 09

Overcut (-)

Undercut (-)

5.51

Intervening in Automatic Mining Affecting the Speed During Travel After the start-up warning, you can determine the travel speed by pressing the key combination for less than or more than than two seconds. The longer you hold the key combination beyond two seconds, the faster the speed of the machine increases. You can see the direction of motion and the speed on page {980} of the machine display (Fig. 5 on page 5.6).

. Press the key combinations shown in Figs. 59 (machine moves to the left) or 60 (machine moves to the right) for up to two seconds for slow movement or longer than two seconds for fast movement.

Increasing the Machine Speed while Traveling to the Left or Decreasing the Speed while Traveling to the Right.

Fig. 60:

Increasing the Machine Speed while Traveling to the Right or Decreasing the Speed while Traveling to the Left.

5.52

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 59:

Intervening in Automatic Mining The key combinations for affecting the speed on the basis of the direction of travel are summarized in Table 11.

Tab. 11: Key Combinations for Changing the Speed Increase Speed

Decrease Speed

Key Combination as in Fig. 59

Key Combination as in Fig. 60

Key Combination as in Fig. 60

Key Combination as in Fig. 59

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Direction of Motion of the Machine

Doc. no.: 1999 001 043 BA 00

VESL 09

5.53

"Manual Mining" Operating Mode "Manual Mining" Operating Mode If the automatic mining mode is temporarily not available, or automatic mining does not appear to be ideal at the moment, you can also cut the rock in a manual mode.

In this case, the following additional rules and sequences apply: You must be specially trained for this task.

Before the machine is switched on, the conveyor must be running in the forwards direction.

Use the following sequence to start the machine:

E

. Switch on the radio controller. . Switch on the hydraulic pump. . If necessary, reduce the infeed. . Start the water spraying system. . Start the ranging arm motors.

Important!

Starting the water spraying system and ranging arm motors is required only in special situations. They start automatically when the machine starts.

. Set the height of the cutting arms. . Set the infeed.

– Cut initially with minimal infeed of the cutting arms and carefully increase the infeed, if possible, when making the next cut. At the same time, watch the motor current display.

If the motor current continues to increase, you should reduce the infeed and/or the travel speed.

Notice!

The machine stops when the motor current reaches a critical level (motor current bar in Fig. 5 (page 5.6) is red). To prevent this, you should reduce the infeed and/or the speed of the machine before hand.

– The maximum infeed is 100 mm.

. Set the approach angle(s).

– During travel from the drive unit to the return unit, the approach angle of both arms must be +3°.

– During travel from the return unit to the drive unit, the approach angle of both arms must be -3°.

When the machine is started, the control system automatically sets the approach angles (direction of travel now known).

Caution!

Risk of machine damage: do not adjust the approach angles until the machine is clear of the face.

. Starting up the machine.

5.54

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Switching on

"Manual Mining" Operating Mode Switching off

The machine is shut down in reverse order.

The monitoring functions correspond to those for the "Automatic Mining" mode. All sensor values are evaluated, the conveyors must be running, limit value violations trigger fault messages and shutdown of the machine. These sequences described on page 5.45 apply.

In this operating mode, the control center is blocked until you select the STOP signal and change the operating mode.

In this operating mode, all target values are entered from the radio controller with the aid of page {985} on the machine display. When page {985} is active, some keys on the radio controller have a different meaning: Input of Numerical Values from the Radio Controller

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 61:

A Selected digit 1 Meter 2 Decimeter

Doc. no.: 1999 001 043 BA 00

VESL 09

3 Centimeter 4 Millimeter

5.55

"Manual Mining" Operating Mode Fig. 61 shows the key combinations for selecting the cutting height ( + ) and infeed ( + ) of the LH and RH drive units. After the parameter has been selected, you can select the decimal place of the value and change it by tapping. You then confirm the entries by pressing the ENT key (Fig. 62 (2)), or cancel by pressing the ESC (1) key.

Fig. 62:

ESC and ENTER Keys

1

Starting the Machine / Starting the Pump The hydraulic pump provides the required hydraulic pressure to position the cutter heads and move the machine along the face.

. Press the key combination shown in Fig. 63. . Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Fig. 63:

Starting the Pump

The temperature, cooling and current of the pump are monitored in the maintenance mode as well.

5.56

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

1 Cancel entry 2 Confirm entry

E

2

"Manual Mining" Operating Mode Switching Off the Pump

. Press the key combination shown in Fig. 64.

Fig. 64:

Switching Off the Pump

It is not necessary to press the combination several times or in a sequence. As soon as the pump has been switched off, there is no longer any hydraulically powered movement.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

If a fault occurs or you switch off the radio controller by pressing the "STOP" key, the pump is switched off automatically as well.

Special Aspects of Manual Mining There are a few special aspects of setting the cutting arms.

Cutting Height, Infeed and Swivel Position You can also enter the target values when the hydraulic pump is off. The target values are saved and activated when the hydraulic pump starts. As soon as you change the operating mode, however, these settings are no longer valid.

You enter the settings for the cutting height and infeed on the machine display on page {985} (see page 5.55).

Changing the cut lines during travel is limited to 25 mm up or down. There is no limit when the machine is at a standstill.

The swivel position of the cutter heads is limited to the positions -3°, +3° and 0° for both arms (no intermediate values).

You can only reduce the infeed during travel. There is a limit of 100 mm when the machine is at a standstill.

Caution!

The infeed limits set for the automatic mode do not apply in the manual mode. You can enter an infeed of up to 100 mm when the machine is at a standstill. However, please keep the load on the machine in mind; it results primarily from the infeed and travel speed.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.57

"Manual Mining" Operating Mode Approach Angle of the Cutter Heads The following key combination allows you to set the approach angle of both cutter heads. In the manual mining mode, both cutter heads are automatically swiveled in parallel (-3°, +3° or 0°) after you have specified the direction of travel by means of the travel command.

. Select one cutter head on the radio controller. . Press the key combination shown in Fig. 65 to swivel the cutter heads.

Fig. 65:

Changing the Approach Angle of the Cutter Heads Change approach angle in the clockwise direction

The set approach angle is shown on the machine display on page {987}.

Starting the Ranging Arm Motors When the machine is at a standstill, you can start the two ranging arm motors independently of one another. The combination with the LH key starts the LH motor, the combination with the RH key starts the RH motor.

. Press the key combination shown in Fig. 66 with the desired cutter head (LH or RH).

. Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Fig. 66:

5.58

Starting the Ranging Arm Motors

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Change approach angle in the counterclockwise direction

"Manual Mining" Operating Mode Shutting Down the Ranging Arm Motors Pressing the key combination "HALT" and "Ranging Arm Motor" stops the corresponding ranging arm motor.

. Press the key combination shown in Fig. 67.

Fig. 67:

Stopping the Ranging Arm Motors

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

The ranging arm motor that you selected on the radio controller is shut off. Pressing the combination with the LH key shuts off the LH ranging arm motor. This applies analogously to the RH ranging arm motor.

Moving the Machine A hydraulic motor is used to move the machine along the face.

Consequently, you must start the hydraulic pump before you can move the machine.

Starting Up the Machine:

. Press the key combination shown in Fig. 68 (start and move to the left) or 69 (start and move to the right).

. Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

The cutting arms are positioned automatically.

Fig. 68:

Doc. no.: 1999 001 043 BA 00

VESL 09

Starting the Machine and Moving to the Left

5.59

"Manual Mining" Operating Mode Fig. 69:

Starting the Machine and Moving to the Right

Affecting the Speed During Travel

to the left) or 71 (machine moves to the right) for up to two seconds for slow movement or longer than two seconds for fast movement.

Fig. 70:

Increasing the Machine Speed while Traveling to the Left or Decreasing the Speed while Traveling to the Right.

Fig. 71:

Increasing the Machine Speed while Traveling to the Right or Decreasing the Speed while Traveling to the Left.

The key combinations for affecting the speed on the basis of the direction of travel are summarized in Table 12.

5.60

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

. Press the key combinations shown in Figs. 70 (machine moves

E

After the start-up warning, you can determine the travel speed by pressing the key combination for less than or more than than two seconds. The longer you hold the key combination beyond two seconds, the faster the speed of the machine increases. You can see the direction of motion and the speed on page {980} of the machine display (Fig. 5 on page 5.6).

"Manual Mining" Operating Mode Tab. 12: Key Combinations for Changing the Speed Direction of Motion of the Machine

Increase Speed

Decrease Speed

Key Combination as in Fig. 70

Key Combination as in Fig. 71

Key Combination as in Fig. 71

Key Combination as in Fig. 70

Stopping the Machine

. Press the key combination shown in Fig. 89.

Stopping the Machine

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 72:

Doc. no.: 1999 001 043 BA 00

VESL 09

5.61

"Maintenance" Operating Mode "Maintenance" Operating Mode This operating mode is used solely for machine maintenance and commissioning.

In the "Maintenance" operating mode, the machine can be operated only with the radio controller (Fig. 44 on page 5.41).

Danger!

Moving the machine can seriously or fatally injure you or other persons.

No one must be in the hazardous area when you switch on the machine. Always stay a safe distance from the machine.

The "Maintenance" operating mode does not incorporate automatic starting. You must start all motors manually. If a fault occurs, for instance, the radio controller loses the connection to the receiver or the radio controller is switched off, the units are shut down.

The key combinations that you can use to start the individual components are explained in the following.

Fig. 73:

Switching on the Radio Controller

>2s

Start pump The hydraulic pump provides the required hydraulic pressure to position the cutter heads and move the machine along the face.

. Press the key combination shown in Fig. 74. . Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Fig. 74:

5.62

Starting the Pump

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

To switch on the radio controller, press and hold the "ON" button (Fig. (73)) for longer than 2 seconds.

E

Switching on the Radio Controller

"Maintenance" Operating Mode The temperature, cooling and current of the pump are monitored in the maintenance mode as well.

Switching Off the Pump

. Press the key combination shown in Fig. 75.

Fig. 75:

Switching Off the Pump

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

It is not necessary to press the combination several times or in a sequence. As soon as the pump has been switched off, there is no longer any hydraulically powered movement.

If a fault occurs or you switch off the radio controller by pressing the "STOP" key, the pump is switched off automatically as well.

Important!

Duplicate symbols on the radio controller Two symbols on the radio controller appear in duplicate (Fig. 76).

They are located in the lower part of the radio controller and mean the LH and RH functional unit, respectively.

Press the LH key to select the LH functional unit. Press the RH key to select the RH functional unit.

Fig. 76:

Duplicate Symbols

1 LH ranging arm motors/cutter head 2 RH ranging arm motor/cutter head

Starting the Ranging Arm Motors You can start the two ranging arm motors independently of one another. The combination with the LH key starts the LH motor, the combination with the RH key starts the RH motor.

Important!

You can only test this function in the "Maintenance" operating mode. The motors shut off again after five seconds.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.63

"Maintenance" Operating Mode . Press the key combination shown in Fig. 77 with the desired cutter head (LH or RH).

. Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Starting the Ranging Arm Motors

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 77:

5.64

Hard Rock Miner control

"Maintenance" Operating Mode Starting Other Devices In the manual mode, you can also start the water spraying system and cleaning brushes by means of key combinations. These are not started by pressing the "ON" key, but instead by means of the yellow direction arrows, which then indicate the rotational direction or water spraying direction.

Starting the Water Spraying System Pressing the following key combination starts the water spraying system for the LH and RH sides of both cutter heads:

. Press the key combination shown in Fig. 78 or 79. . Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

Starting the Water Spraying System

Fig. 79:

Alternative Starting Procedure for the Water Spraying System

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 78:

Doc. no.: 1999 001 043 BA 00

VESL 09

5.65

"Maintenance" Operating Mode Switching Off the Water Spraying system Pressing the key combination "HALT" and "Water spraying system" switches off the water spraying system.

. Press the key combination shown in Fig. 80.

Fig. 80:

Switching Off the Water Spraying System

The speed of the machine and cutting arm movements depends on how long the key is pressed (see Fig. 48 on page 5.43).

Height of the Cutting Arms Pressing the following key combination allows you to set the height of the LH and RH sides of both cutting arms:

. Press the key combinations shown in Fig. 81 for the desired cutter head (LH or RH) for up to three seconds for slow movement or longer than three seconds for fast movement.

Fig. 81:

Cutting Arm Height Adjustment

Cutting arm height (+)

Cutting arm height (-)

Infeed of the Cutting Arms In the "Maintenance" mode, you can select the infeed freely.

As soon as the hydraulic pump has started, you can select the individual arm infeeds by means of the radio controller.

Pressing the following key combination allows you to set the infeed of the LH and RH sides of both cutting arms:

. Press the key combinations shown in Fig. 82 for the desired cutter head (LH or RH) for up to three seconds for slow movement or longer than three seconds for fast movement.

5.66

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

You can move the cutting arms freely. You can change the height, infeed and approach angle of the cutter heads. However, it is first necessary to start the hydraulic pump.

E

Moving the Cutting Arms

"Maintenance" Operating Mode Notice!

The arrow keys refer to the hydraulic cylinders for the infeed of the cutting arms.

The arrow pointing to the right means reduce the cut depth (the cylinder retracts).

The arrow pointing to the left means increase the cut depth (the cylinder extends).

Fig. 82:

Cutting Arm Infeed

E

Cutting arm infeed (+)

Cutting arm infeed (-)

Caterpillar Global Mining Europe GmbH, Lünen 2016

Approach Angle of the Cutter Heads The following key combination allows you to set the approach angle for the LH and RH sides of both cutter heads: Approach Angle of the LH Cutter Head

. Select the LH cutter head on the radio controller. . Press the key combinations shown in Fig. 83 for up to three seconds for slow movement or longer than three seconds for fast movement.

Fig. 83:

Changing the Approach Angle of the LH Cutter Head in the Clockwise Direction

Change approach angle in the counterclockwise direction

Doc. no.: 1999 001 043 BA 00

VESL 09

Change approach angle in the clockwise direction

5.67

"Maintenance" Operating Mode Approach Angle of the RH Cutter Head

. Select the RH cutter head on the radio controller. . Press the key combinations shown in Fig. 84 for up to three seconds for slow movement or longer than three seconds for fast movement.

Changing the approach angle of the RH arm in the clockwise direction Change approach angle in the Change approach angle in counterclockwise direction the clockwise direction

Moving the Machine A hydraulic motor is used to move the machine along the face.

Consequently, you must start the hydraulic pump before you can move the machine.

Starting Up the Machine:

. Press the key combination shown in Fig. 85 (start and move to the left) or 86 (start and move to the right).

. Wait until the audible start-up warning ends. . Press the same key combination again within two seconds.

5.68

Fig. 85:

Starting the Machine and Moving to the Left

Fig. 86:

Starting the Machine and Moving to the Right

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 84:

"Maintenance" Operating Mode Affecting the Speed During Travel After the start-up warning, you can determine the travel speed by pressing the key combination for less than or more than than two seconds. The longer you hold the key combination beyond two seconds, the faster the speed of the machine increases. You can see the direction of motion and the speed on page {980} of the machine display (Fig. 5 on page 5.6).

. Press the key combinations shown in Figs. 87 (machine moves to the left) or 88 (machine moves to the right) for up to two seconds for slow movement or longer than two seconds for fast movement.

Increasing the Machine Speed while Traveling to the Left or Decreasing the Speed while Traveling to the Right.

Fig. 88:

Increasing the Machine Speed while Traveling to the Right or Decreasing the Speed while Traveling to the Left.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 87:

The key combinations for affecting the speed on the basis of the direction of travel are summarized in Table 13.

Tab. 13: Key Combinations for Changing the Speed Direction of Motion of the Machine

Doc. no.: 1999 001 043 BA 00

VESL 09

Increase Speed

Decrease Speed

Key Combination as in Fig. 87

Key Combination as in Fig. 88

Key Combination as in Fig. 88

Key Combination as in Fig. 87

5.69

"Maintenance" Operating Mode Stopping the Machine

. Press the key combination shown in Fig. 89.

Fig. 89:

Stopping the Machine

Special functions You can then control the valves manually for further maintenance functions.

In the "Maintenance" mode, you can control the valves directly after the pump is started. Monitoring of the position is disabled and no fault is generated when the arms move without the system having issued a request for a change.

5.70

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Controlling the Valves Manually

Pan Conveyor Pan Conveyor The pan conveyor delivers the cut rock to the beam stage loader.

You can start and stop it separately in both operating directions.

Controlling from the Panel at the Edge of the Face The panel at the edge of the face has 4 keys for controlling the pan conveyor (Fig. 90).

Keys for the AFC

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 90:

1 Enable 2 Stop 3 Forward 4 Reverse

Operation in the Forward Direction The forward direction of the AFC represents the normal operating state. It is used to remove the mind ore. This is a self-maintained machine status. The conveyor remains in operation until the "Stop" key is pressed.

To put the pan conveyor into operation in the forward direction, press the following key combination:

. Press the "Forward direction" (3) and "Enable" (1) keys until a start-up warning sounds.

. Wait until the start-up warning ends. . Press the same key combination again within 2 seconds.

Operation in the Reverse Direction The reverse direction of the pan conveyor represents a special operating status. It is used to move the pan conveyor opposite the normal operating direction in the event of a malfunction or for maintenance purposes. Accordingly, moving the pan conveyor opposite the normal conveying direction is allowed only in the "Maintenance" mode.

This is a momentary machine status. The conveyor moves in the reverse direction only while the "Reverse direction" key (4) is pressed and held. As soon as this key is released or a fault occurs, the conveyor shuts down.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.71

Pan Conveyor . Press the "Reverse direction" (4) and "Enable" (1) keys until a start-up warning sounds.

. Wait until the start-up warning ends. . Press the same key combination again within 2 seconds. . Press and hold the "Reverse direction" key (4) for as long as you wish to operate the conveyor in the reverse direction.

Controlling from the Control Console You can start operation only in the forward direction from the control console.

On the starting page {11}, press the [F2] key to open page {11 (Fig. 91).

Controlling the AFC from Page {11}

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 91:

}

1 AFC AUTO START

2 AFC AUTO STOP

Starting the Pan Conveyor Before you can start the conveyor from here, you must log in to the system. First select the key [to the left ] in the direction key block of the keyboard . The window for entering your user ID and password then appears. Following login, the page elements for control are available.

. Press the key shown in Fig. 92. . Wait until the audible start-up warning ends. . Press the same key again within two seconds.

5.72

Hard Rock Miner control

Pan Conveyor Fig. 92:

Starting the Pan Conveyor

Shutting Down the Pan Conveyor You do not need to login to the system to shut off the pan conveyor.

. Press the key shown in Fig. 93.

Shutting Down the Pan Conveyor

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 93:

Important!

Safety information The AFC is incorporated into the emergency-off and emergency-stop circuit, and in the event of an emergency is shut down by switching off the motor.

The control system is designed so that pressing the Stop button on the panel at the edge of the face and pressing the "AFC Auto Stop" button stops the conveyor in any operating state.

Chain Tensioner The automatic chain tensioning system tries to set the optimum chain pretension for all possible conveyor loading conditions, which ultimately leads to a recognizably longer service life or less wear and need for maintenance of the chain, chain wheel and drive components.

The chain tensioning system consists basically of pressure sensors and position sensors, both connected to the electrohydraulic control unit, that regulate the tension by means of hydraulic tensioner cylinders. The operating principle is designated as a maintained-pressure mode.

The diagnostics page for the chain tensioner can be found on page 5.76, the configuration page on page 5.107.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.73

Additional Diagnostic Pages on the Control Console Additional Diagnostic Pages on the Control Console {1}

Contents of the first subcategory: Fig. 94:

Overview

3 4

This takes you to the overview pages of the HRM and the pan conveyor (AFC). {11}

HRM overview page Fig. 95:

Hard Rock Miner

1 2

3 4

See also Fig. 24 on page 5.21.

5.74

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {12}

AFC overview (pan conveyor) Fig. 96:

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Pan conveyor

All relevant data for the pan conveyor (AFC) can be found on this page.

The data from the compact station are shown at the upper left.

These are digital fault evaluations and the current consumption.

The rotation of the AFC is shown underneath. Rotating green arrows indicate that the AFC is rotating clockwise. Red arrows indicate a counterclockwise rotational direction. If the conveyor is stationary, the arrows are gray.

The contacts of the AFC actuators on the panel at the edge of the face are shown to the left of the conveyor diagram. If a box is displayed in green, the corresponding button is pressed.

The cooling water values (temperatures upstream and downstream from the motor as well as the flow rate) are displayed on the right side in the upper block. The motors must be cooled for a defined period afterwards. This time is displayed in the after-cooling area.

The counter counts down.

The temperatures of the motor windings, the bearings and the cooling water are shown in the lower block.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.75

Additional Diagnostic Pages on the Control Console {13}

Chain Tensioner Chain tensioner

This page shows the position and pressure of the hydraulic cylinder of the chain tensioning system. {2}

Overview of motors installed on the HRM. Fig. 98:

1 2

Motors and drive units

3 4

The measured values for the individual motors on the HRM are shown on the following pages.

5.76

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 97:

Additional Diagnostic Pages on the Control Console {21}

Motor temperatures, motor current and recooling time Fig. 99:

Overview of HRM motors

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

The temperatures of the motors installed on the HRM are shown here. For the cutting units, the temperatures of the cooling water, the bearings and the gearbox are measured in addition to the winding temperatures. The motor current values are shown for all motors. To protect the motors, they are recooled. The recooling time is shown for each motor and counted down. {22}

Motor overview Fig. 100: Motor overview

1 2

3 4

The motors for the cutting units, the pump and the face conveyor are summarized on the second page. You can see at a glance which motors have been started. The highest temperature of the phases (U/V/W) is shown for temperature monitoring. In addition, the current is shown in percent and as an absolute value in amps.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.77

Additional Diagnostic Pages on the Control Console {23}

Travel drive Fig. 101: Travel drive

3 4

The pressure of the two travel drives is shown in the upper part of the page. The red region in the bar diagram indicates when a fault occurred.

The lower half of the page shows the position of the machine.

You can read the distance of the machine from the drive unit or the return unit. In addition, the direction of motion and speed are shown. So-called creep regions or braking zones are provided at each end of the face. The length of these regions and the maximum speed permitted there are shown. In the zones, the machine is decelerated to this speed to ensure controlled stopping in the end regions. {3}

Content page for the cooling water, pressure and hydraulic system.

Fig. 102: Water and hydraulic system

1 2

5.78

3 4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {31}

Overview of cooling water Fig. 103: Cooling water

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

The states of the HRM's cooling system are shown on this page.

Temperatures and flow rates are shown for the ranging arm motors and the hydraulic pump. The inlet pressure and inlet temperature in the cooling water supply are measured. The volume flow of cooling water is measured at the oil cooler. {32}

Hydraulic system, LH arm Fig. 104: LH hydraulic system

1 2

3 4

The pressures and the cylinder positions of the LH arm are shown on this page. The cylinders for positioning the cutter heads are shown at the upper left and right. The two cylinders for the arm height are shown in between. In addition, the actuators of the water spraying system are shown. Clockwise and counterclockwise rotation as well as LH or RH cutting drum are shown separately.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.79

Additional Diagnostic Pages on the Control Console {33}

Hydraulic system, RH arm Fig. 105: RH hydraulic system

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

As in Fig. 104, but for the RH arm.

5.80

Hard Rock Miner control

Additional Diagnostic Pages on the Control Console {34}

Cooling water system

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 106: Overview of cooling water

1 Heat exchanger 2 Reservoir 3 Pump 4 Volume flow and pressure in supply 5 Temperature and pressure in supply to machine 6 Temperature and volume flow upstream of the AFC drive

7 AFC drive and return temperature 8 Valve statuses 9 Volume flow upstream of the motors 10 Motor statuses 11 Temperatures of the returns from the motors 12 Return to the heat exchanger 13 Oil cooler

The cooling system for the entire complex is shown on this page.

The return temperature, status of the cooling fan and cooler outlet temperature in the feed (1) are shown. The reservoir (2) follows.

The volume flow and the pressure of the cooling water (4) are shown downstream from the reservoir and the pump (3).

The flow of cooling water then divides into two streams. One of these streams flows to the AFC (6). You can see the valve status, the temperature and the volume flow upstream from the AFC drive unit. The return temperature of the AFC drive unit (7) then follows.

The measured values of the cooling water's temperature and pressure (5) are shown for the supply stream to the machine.

The machine stream divides into four streams to the two motors of the cutting arms, the hydraulic motor and the oil cooler. The valve statuses (8), the volume flows and the motor as well as cooler statuses (10) are shown here. The return temperature (11) from the motors follows. The return streams then join and reach the heat exchanger (1) where the return temperature is indicated (above the heat exchanger).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.81

Additional Diagnostic Pages on the Control Console {35}

Overview of water spraying system Fig. 107: Water spraying system

3 4

The water spraying system is shown here schematically. You see the status of the valve for filling the reservoir, the temperature of the sprayed water, the fill level in the reservoir, the status of the spraying pump and the pressure of the sprayed water.

5.82

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {36}

Overview of hydraulic system

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 108: Hydraulic system

1 Oil tank 2 Dirt sensor (differential pressure) 3 Pump motor with 2 pressure systems 4 Hydraulic system branch for cutting arms 5 Hydraulic system branch for travel drive 6 Travel drive 7 Water spraying system 8 Brake 9 LH cutting arm up/down 10 RH cutting arm up/down 11 Positioning of LH cutting arm, RH cylinder

12 Positioning of RH cutting arm, RH cylinder 13 Cylinder strokes, LH cutting arm (signal from reed rod) 14 Positioning of LH cutting arm, LH cylinder 15 Column for LH cutting arm 16 Valve setting 17 Column for RH cutting arm 18 Positioning of RH cutting arm, LH cylinder 19 Cylinder strokes, RH cutting arm (signal from reed rod) 20 Cylinder stroke of RH cutting arm, LH cylinder

All components and measured values of the HRM's hydraulic system are shown on this page.

The fill level and oil temperature are shown for the hydraulic reservoir (Fig. 108 (1)). A differential pressure sensor (2) shows the degree of contamination of the hydraulic fluid. The hydraulic supply is divided by a motor with two pumps that feeds two streams (travel drive (5) and cutting arms with water spraying system and cleaning brushes (4)) at different pressures.

The status of the motor-pump unit is shown in color: green symbol: Motor running (active) gray symbol: Motor not running (inactive) red symbol: Motor not running because of a fault The pressures for counterclockwise rotation and clockwise rotation as well as the valve status are shown for the travel drive (6).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.83

Additional Diagnostic Pages on the Control Console The water spraying system (7) and the cleaning brushes (8) belong to the valve block for the cutting arms (gray background). Based on the symmetrical construction of the machine, the components above are always shown in duplicate for the arm movement for the LH (15) and the RH (17) cutting arms.

The cylinder strokes (20) are shown in percent of the maximum stroke to the left (13) and right (19) of the valve block. From bottom to top: the statuses of the proportional valves for the height adjustment (9, 10) as well as for the LH cylinders (14, 18) and RH cylinders (11, 12) for positioning of the cutting arms.

The valve statuses are shown in a bar diagram (16). When the display shows a half bar (50% green), the valves are in the neutral position. When the display shows a complete bar (100% green), the cylinders are extended, while at 0% green they are retracted.

Please keep in mind that the positioner for the angle consists of two cylinders which must have different values for an approach angle and for this reason are monitored separately. {4}

Content for faults, alarms and events.

Caterpillar Global Mining Europe GmbH, Lünen 2016

1 2

E

Fig. 109: Faults & alarms

3 4

From here you can reach all pages concerning faults, events and alarms.

5.84

Hard Rock Miner control

Additional Diagnostic Pages on the Control Console {41}

Faults Fig. 110: Faults

E

1 2

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

You can see a list with system faults on this page.

All faults are grayed out. You can clear them by pressing the "Acknowledge fault" button at the lower right.

Current faults are shown in red.

Faults are always shown with a fault number (ID) and description.

A timestamp is also saved for each fault.

A counter exists for each fault. This counter is incremented each time the fault occurs. You can reset the counter to zero by pressing the "Reset count" button.

Additional information about a fault can be displayed under "Data Snapshot" (lower left), for example: location of the sensor or CIOS module involved, or the configuration page on which you can bypass or deactivate the cause of the fault or display of the fault. {42}

Current Events Fig. 111: Current Events

1 2

Doc. no.: 1999 001 043 BA 00

VESL 09

3 4

5.85

Additional Diagnostic Pages on the Control Console This window shows the current events. You can remove the selected event from the list by pressing the "Acknowledge event" button. You can reset the fault counter for the selected event to zero by pressing the "Reset account" button. {43}

Alerts Fig. 112: Alarms

3 4

You can see a list with system alarms on this page.

All alarms are grayed out. You can clear them by pressing the "Acknowledge alarm" button at the lower right.

Current alarms are shown in red.

Alarms are always shown with a fault number (ID) and description.

A timestamp is also saved for each alarm.

A counter exists for each fault. This counter is incremented each time the alarm occurs.

Additional information about an alarm can be displayed under "Data Snapshot" (lower left), for example: location of the sensor or CIOS module involved, or the configuration page on which you can bypass or deactivate the cause of the alarm or display of the alarm.

5.86

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {44}

Fault Log Fig. 113: Fault Log

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

All fault entries and the event list (Fig. 110) are stored in the list shown here for subsequent analysis. {45}

Event Log Fig. 114: Event Log

1 2

3 4

All event entries (Fig. 111) are stored in the list shown here for subsequent analysis.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.87

Additional Diagnostic Pages on the Control Console {46}

Alarm Log Fig. 115: Stored alarms

3 4

All alarm entries (Fig. 112) are stored in the list shown here for subsequent analysis. {5}

Content page for the diagnosis categories Fig. 116: Diagnoses

1 2

3 4

This table of contents branches to subpages for diagnosis of the overall system. This allows you to examine the CIOS system in greater detail. In addition, you can diagnose the radio control, the motors and the compact station.

5.88

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {51}

CIOS I/O Fig. 117: CIOS I/O

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

The I/O area of the entire CIOS system installed is shown here.

Each individual module type is summarized on its own page. In addition, all inputs and outputs are shown regardless of whether they are actually assigned.

To avoid unnecessary repetitions in the description, each individual module page is described once in the following. Since the diagnoses are rudimentary in nature, the module types listed basically repeat, since only raw values are provided with no reference to physical quantities (pressure, flow rate etc.).

A description of the hierarchy showing how the individual modules are joined into blocks then follows.

An additional table of contents containing all backplanes of the CIOS system is shown on page {51}.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.89

Additional Diagnostic Pages on the Control Console {511}

Backplane Control Box (CB) Fig. 118: Backplane Control Box

This table of contents corresponds to how the slots of the CIOS backplane "CB" are populated. {5111}

MMPH Fig. 119: Slot 1: MM PH

1 2

3 4

This page describes all inputs and outputs of a motor management module.

AIN The information for an analog input can be found in the "AIN" block.

The measured value is displayed.

You can tell whether the value is a voltage or current from the "Range" field that follows.

The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

5.90

Hard Rock Miner control

E

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

1 2

Additional Diagnostic Pages on the Control Console The "MinB" and "MaxB" fields that follow contain the limit values that trigger a fault message by the module.

RTD The temperature input of the module is displayed in the "RTD" block. The current temperature is displayed in the "Value" field.

The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

The "Short" and "Broken" fields indicate whether there is a short circuit or broken wire in this module on this input. The "To ground" field indicates a short circuit to ground. The "Range" field indicates whether the value range of the sensor has been exceeded ("1") or not ("0").

Digital

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

The "Digital" block is divided into "Digital inputs" and "Digital outputs". The MMPH has four inputs. Whether a channel is closed ("0") or open ("1") is shown for all channels. In addition, whether a short circuit or broken wire exists is shown for each channel. The digital outputs are provided in duplicate. The "Value" field indicates whether the output is set ("1") or not ("0"). The "Off/On" field indicates whether a fault occurred when shutting down.

Analogously, "On/Off" indicates whether a fault occurred ("1") or not ("0") when starting up.

MDT 1 and MDT 2 Two motor data transmitters (MDT) are connected to the MMPH (“MDT 1” and “MDT 2”). These are shown on the lower part of the page. An MDT provides 4 digital ("DIN" row) and 6 analog temperature inputs ("Temp. row). The raw value is shown in the table for each individual channel. {5121}

AOUT4 Fig. 120: Slot 2: AOUT4

1 2

3 4

This page describes the CIOS module “AOUT4”. The output current and the output voltage are measured for each channel.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.91

Additional Diagnostic Pages on the Control Console The currents are listed in the first column.

The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

The "MinB" and "MaxB" fields that follow contain the limit values that trigger a fault message by the module. {5122}

AIN6 and AIN8

3 4

This page shows the raw values from the module's sensors in a table. It has 6 or 8 analog inputs (channels).

The "Value" line contains the currently measured raw values.

This can be a current (4 – 20 mA) or voltage (0 – 10 V).

The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

The "MinB" and "MaxB" and "Min. limit value" and "Max. limit value" (border) fields that follow contain the limit values that trigger a fault message by the module.

5.92

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

1 2

E

Fig. 121: Slot 3: AIN6

Additional Diagnostic Pages on the Control Console {5132}

PSO Fig. 122: Slot 1: PSO

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

This page shows the values measured by a PSO module in two tables.

Various values for the controller position are shown in the first table. "Actual Position" indicates the position read by the reed rod, while "Reference Position" shows the intended position. "Readback Mode" indicates whether the position controller is off ("0") or on ("1"). "0" in "PWM Swap" indicates the normal configuration while "1" indicates that the valve outputs were swapped.

The values of the two analog inputs (AIN1/2) are shown in the second table. Two columns with the currents at the valve outputs (OUT1/2) follow. The last two columns contain the 12 V from the secondary circuit (V12ISO) and the valve output voltage (V12Valve).

The "Value" line contains the currently measured raw values of each.

The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

The "MinB" and "MaxB" and "Min. limit value" and "Max. limit value" (border) fields that follow contain the limit values that trigger a fault message by the module.

The "Range" field indicates whether control involves current ("3" = 4-20 mA) or voltage ("2" = 0-10 V).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.93

Additional Diagnostic Pages on the Control Console {5143}

DOUT4 Fig. 123: Slot 3: DOUT4

3 4

This page shows the module's 4 digital outputs in a table.

The values of the output appear in the first line.

The remeasured current taken from the output is indicated in the 2nd line (output current).

Faults that occurred when starting up or shutting down are indicated in the "On/Off Fault" and "Off/On Fault" lines. {5151}

RTD4 Fig. 124: Slot 1: RTD4

1 2

3 4

This page shows the temperature measurement module's 4 digital input in a table.

The measured temperatures are shown in degrees Celsius in the first line.

5.94

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console The minimum and maximum values that occur at an input are saved in the "Min" and "Max" fields. You can clear these values by pressing the "Reset Min/Max" button.

The following lines show the fault status. A "Broken wire" is indicated in line 4, a "Short" in line 5. A short to ground is indicated in line 6 "ToGnd", and a measured value outside the measuring range is indicated in line 7 "Range". {5162}

DIN10

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 125: Slot 2: DIN10

1 2

3 4

This page shows the module's 10 digital inputs in a table.

In addition, a broken wire is indicated in the "Broken" line.

A short circuit is indicated in the "Short" line. {52}

Radio control Fig. 126: Radio control

1 2

Doc. no.: 1999 001 043 BA 00

VESL 09

3 4

5.95

Additional Diagnostic Pages on the Control Console You can check the status of the radio controller on the "Radio control" page. The radio controller is shown in a block on the left side. The keys actuated on the radio controller are shown there.

The current operating mode is indicated in the block at the upper right.

Information about the signal in dB and about the battery voltage in volts is shown in the block below. The radio controller number is shown in the last line. {53}

Content page for "Motor Diagnostics"

1 2

3 4

The summary of individual diagnostic data on the compact stations is contained in a separate subchapter. From here you can navigate to the individual motors. {531}

Hydraulic Pump Motor Diagnostics Fig. 128: Hydraulic Pump Motor Diagnostics

1 2

3 4

The digital statuses and current consumption of the pumps in amps are shown here.

5.96

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 127: Motor Diagnostics

Additional Diagnostic Pages on the Control Console {532}

Cutting Unit Motor Diagnostics Fig. 129: Cutting Unit Motor Diagnostics

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

The two ranging arm motors together with their digital fault statuses are shown on this page. The current consumption, the voltage, the power output and the frequency are measured and shown as analog values here. {533}

Blower Motor Diagnostics Fig. 130: Blower Motor Diagnostics

1 2

3 4

The digital statuses and current consumption of the fan motor in amps are shown here.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.97

Additional Diagnostic Pages on the Control Console {534}

Water Spraying System Pump Motor Diagnostics Fig. 131: Water Spraying System Pump Motor Diagnostics

3 4

The digital statuses and current consumption of the hydraulic motor in amps are shown here. {535}

Cooling Water Pump Motor Diagnostics Fig. 132: Cooling Water Pump Motor Diagnostics

1 2

3 4

The digital statuses and current consumption of the water motor in amps are shown here.

5.98

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {54}

Compact Station Fig. 133: Compact Station

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Information on the digital statuses of the following are found here in four blocks for the compact stations blower/cooling water pump hydraulic system/water spraying system cutting units LH & RH/AF low voltage Except for the low voltage at the compact station, all blocks are structured identically in terms of diagnostics. {55}

Low Voltage Fig. 134: Low Voltage

1 2

Doc. no.: 1999 001 043 BA 00

VESL 09

3 4

5.99

Additional Diagnostic Pages on the Control Console The individual lines of the low-voltage station are shown more exactly in three blocks on this page. For the lighting system shield support control panel (control console) the digital statuses and the actual current consumption are shown. {56}

CIOS Overview

1 2

3 4

An overview of the CIOS backplane is shown in table form on this page. Every box represents a CIOS module. If all are green, the system is running perfectly. Using this overview, if there is a CIOS fault, you can quickly identify on which backplane of which module a fault (red) exists. Gray boxes indicate that there is no fault monitoring for the module concerned. {57}

Point I/O Fig. 136: Point I/O

1 2

5.100

3 4

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fig. 135: CIOS Overview

Additional Diagnostic Pages on the Control Console The point I/O system of the compact station is shown on the next page in a manner similar to that used on the CIOS overview page {56}. There is one line in the table for each station. In the event of a fault, the faulty component is shown in red here; otherwise in green. {7}

General content page Fig. 137: General

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

This category contains pages with information about the control system (software), especially management of software and parameters. {71}

Software Version Fig. 138: Software Version

1 2

3 4

Every installed device of the MMC system is represented in a line in a table. In the columns Application Library Kernel

Doc. no.: 1999 001 043 BA 00

VESL 09

5.101

Additional Diagnostic Pages on the Control Console you can see the associated version number. If indications of problems emerge after a formal check of the software, an "Additional identifier" is appended to the version designation.

A key for the meaning of the identifier is given in the tables. {72}

Software Update Status Fig. 139: Software Update Status

3 4

You can follow the installation process for new software on this page. {73}

Software Installation Process Fig. 140: Software Update Log

1 2

3 4

This page contains a log of previous installations.

5.102

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Additional Diagnostic Pages on the Control Console {74}

Parameter Changes Fig. 141: Parameter Changes

3 4

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

This page contains a three-column table with altered parameters.

The first column contains the parameter name the second the altered value and the third the preset value (factory setting). {8}

Connections Fig. 142: Connections

1 2

3 4

Table of contents of the Connections category. It branches to subpages with connection information.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.103

Additional Diagnostic Pages on the Control Console {81}

Network Overview Fig. 143: Network Overview

3 4

The structure of the network can be seen from this diagram. The network status of devices shown in green can be interrogated using the CIP protocol. Devices in a gray have no CIP status. {82}

network status Fig. 144: network status

1 2

3 4

The table on this page contains all devices in the network. All devices are queried regularly with a "ping". If the device responds, the counter in the third column is incremented by one until the maximum value of 4 is reached. The characters in the line for the device are then displayed in green. As long as the count is less than four, the text is displayed in yellow. If the count is zero (unresponsive device), the background is red.

5.104

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

1 2

Configuration Pages Configuration Pages The pages at the configuration level follow in the next section ( The pages can be accessed from the diagnostics level ( ) by pressing the [F2] key. {1}

).

Contents Fig. 145: Overview

1 2

3 4

This page contains a table of contents. From here you can navigate to the control center (control console, for controlling the HRM), the armored face conveyor, the chain tensioner and the anti-coalition system. {11}

Control Center Fig. 146: Control Center

1 2

3 4

This page is described in detail on page 5.24.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.105

Configuration Pages {12}

Armored Face Conveyor Fig. 147: Pan conveyor

1 2

3 4

On this page, you can change the parameters for monitoring the temperature of the armored face conveyor and motor limit values.

The upper left block contains all faults and alarm limits for the temperatures in the motor or gearbox. The upper right block contains all values for the cooling circuit of the AFC. In the lower left block you can activate and deactivate fault monitoring and define the cooling time. The alarm and fault limits for the motor current can be changed in the lower right block.

You can set three statuses for the "Fault" parameters: INACTIVE Monitoring is off, a fault is ignored.

ACTIVE Monitoring is on, a fault results in the scheduled actions of the control system.

ALARMONLY A fault is displayed, but ignored by the control system.

5.106

Hard Rock Miner control

Configuration Pages {13}

Chain Tensioner Fig. 148: Chain tensioner

1 2

3 4

Fault monitoring for the cylinder stroke and the pressure of the chain tensioner can be activated and deactivated. In addition, it is possible to define limit values for the alarm and fault signals.

In the pressure maintenance mode, a target pressure (pressure set point) is specified by the user. The control system attempts to maintain this pressure – allowing for a programmable hysteresis.

Tab. 14: Chain Tensioning System Parameters

Doc. no.: 1999 001 043 BA 00

Parameters

Meaning

Controller Active

The controller is switched on or off

Max. Cylinder Stroke

Defines the maximum length of the cylinder

Min. Cylinder Stroke

Defines the minimum length of the cylinder

Pressure Set Point

The target pressure value is entered here

Pressure Hysteresis

Describes a pressure window around the specified value in which the pressure is allowed to vary

Max. Time

Specifies the time during which the controller can try to reach the target pressure

Max. Tries

Specifies the number of tries the controller may make

Extend Time

Defines the time during which the cylinder may be extended

Extend Wait Time

Specifies the wait time between extend tries

Retract Time

Defines the time during which the cylinder may be retracted

Retract Wait Time

Specifies the wait time between retract tries

Reverse Action Wait Time

Specifies the wait time between retract/extend tries

VESL 09

5.107

Configuration Pages {14}

Collision Warning Fig. 149: Anti-Collision

You can activate the anti-collision system when cantilevers are used at the face. Consequently, the PMC-R must first enable the travel drive of the machine. If the travel drive is not enabled, the machine stops. Further information can be found in the description of the PMC-R. {2}

Motors and Haulage Fig. 150: Motors and drive units

1 2

3 4

From this table of contents you can navigate to the configuration of motors and drive units.

5.108

Hard Rock Miner control

Configuration Pages {21}

HRM Motor Configuration Fig. 151: HRM Motor Configuration

1 2

3 4

From this table of contents you can navigate to the configuration of three motors on the mining equipment. {211}

LH Cutting Unit Motor Fig. 152: LH Cutting Unit Motor

1 2

3 4

This page allows you to configure the temperature & current of the LH ranging arm motor on the LH arm.

You can change the fault and alarm limits of the temperatures for the motor windings, the gearbox, the motor bearings and the cooling water. You configure the counter for the cooling time and maximum motor current in the lower part of the page. You can also adjust the individual upper limit values. In addition, you have the ability to set monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.109

Configuration Pages {212}

RH Cutting Unit Motor Fig. 153: RH Cutting Unit Motor

1 2

As page {211 {213}

3 4

} (see Fig. 152)

Hydraulic Pump Motor Fig. 154: Hydraulic Pump Motor

1 2

3 4

For the pump motor, you can deactivate monitoring of the winding temperatures of the individual windings. In addition, you can set alarm and fault limit values. If these limit values are exceeded, an entry is generated in the associated lists. In the event of a fault, the machine is shut down. You configure the counter for the cooling time and maximum permissible motor current in the lower part of the page.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

5.110

Hard Rock Miner control

Configuration Pages {22}

Motor Configuration Fig. 155: Motor Configuration

1 2

3 4

This page serves "only" as a directory to pages of another branch.

This prevents editing of the same parameters on different pages.

Selecting "1 - Temp. & Current LH Cutter Motor", for instance, takes you to page {211 } (see above). {23}

Haulage Configuration Fig. 156: Haulage Configuration

1 2

3 4

Parameters for the two travel drive motors are set on this page.

They can be specified separately for each direction of travel independently of the hydraulic pressure limits. You can deactivate each individual monitoring function with the aid of a selection list.

In addition, in the "Haulage SlowDown" block, you can set parameters for the so-called creep zones. These zones are located before the end switches in the direction of the face. A speed for the machine is specified there. The machine is braked to this maximum value to permit approach to the synchronization switch at a defined speed.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.111

Configuration Pages

{3}

In the "MotorStall" block, you specify the distance the machine must reverse if it stalls at the face during the cutting process. This is intended to prevent the motors becoming jammed in the rock.

Furthermore, after the machine has "reversed" the motor stall distance, it can accelerate without resistance in the direction of travel.

Water and Hydraulic System Fig. 157: Water and hydraulic system

1 2

{31}

3 4

On this content page you can navigate to the configuration of the cooling water and hydraulic system.

Cooling Water Fig. 158: Cooling Water

1 2

3 4

On this page you can set all parameter values for the temperature sensors in the cooling water circuit. You can set an alarm and fault limit for being over and under the value range for all sensors. If the limit values are violated, an entry is generated in the associated lists. If a fault is detected, the machine shuts down.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

5.112

Hard Rock Miner control

Configuration Pages {32}

LH Hydraulic System Fig. 159: LH Hydraulic System

1 2

3 4

On this page you define the possible motions of the LH cutting arm.

The "LH Infeed" and "RH Infeed" columns refer to the infeed cylinders. The "Height" column refers to the cylinder used for the arm height position. You can set alarm and fault limits for being over and under the value range.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106). {33}

RH Hydraulic System Fig. 160: RH hydraulic system

1 2

As page {32

Doc. no.: 1999 001 043 BA 00

VESL 09

3 4

} (see Fig. 159)

5.113

Configuration Pages {34}

Cooling System Configuration Fig. 161: Cooling System Configuration

1 2

3 4

From this content page you can navigate to the above-defined } and {12 }). This prevents setting of parameters pages ({31 on different pages. {35}

Water Spraying System Configuration Fig. 162: Water Spraying System Configuration

1 2

3 4

The inlet pressure for the water spraying system is monitored for faults. You can specify limit values for alarms and faults.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

5.114

Hard Rock Miner control

Configuration Pages {36}

Hydraulic System Configuration Fig. 163: Hydraulic System Configuration

1 2

3 4

From this content page you can navigate to the above-described pages ({32 }, {33 }, {23 }, {361 }). This prevents setting of parameters on different pages. {5}

Diagnostics Fig. 164: Diagnostics

1 2

3 4

From this content page you can navigate to the configuration of sensors, actuators and the radio controller.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.115

Configuration Pages {51}

Sensors Fig. 165: Sensors

1 2

3 4

From this content page you can navigate to the configuration of the sensors. {511}

Cable Carrier Pulling Force Fig. 166: Cable Carrier Pulling Force

1 2

3 4

On this page you can configure the pulling force sensor on the cable carrier. In addition to alarm and fault limits for the pulling force, you can establish switching delays and a fault delay.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

5.116

Hard Rock Miner control

Configuration Pages {512}

Encoder Fig. 167: Encoder

1 2

3 4

On this page you can configure the absolute encoder and the machine position. This is always necessary when the machine is placed on the conveyor again (commissioning).

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106). If fault monitoring is deactivated (INACTIVE), controlled movement of the machine is not possible, since the control system has no information about the position of the machine. Only limited maintenance without movement of the machine is possible. {513}

End Switch Fig. 168: End Switch

1 2

3 4

You set monitoring of the end and synchronization switches on this page. The "Head" is the return unit side of the conveyor. The "Belt" means the drive unit side of the conveyor.

You can set fault monitoring to INACTIVE, ACTIVE and ALARMONLY (see also Fig. 147 on page 5.106).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.117

Configuration Pages Important!

If one of the magnetic switches is deactivated, automatic mining is possible to only a limited extent. {515}

Loading Chute Fig. 169: Loading Chute

1 2

3 4

On this page you can deactivate the sensor on the loading chute.

Important!

When the loading chute is deactivated, you yourself must inspect it to ensure that it is in proper condition. {516}

Beam Stage Loader Overload Sensor Fig. 170: Beam Stage Loader Overload Sensor

1 2

3 4

On this page you can deactivate evaluation of the beam stage loader's digital overload sensors.

5.118

Hard Rock Miner control

Configuration Pages {517}

Motor data transmitter Fig. 171: Motor Data Transmitter

1 2

3 4

On this page you can deactivate the motor data transmitter used for monitoring the temperatures of the motors.

Caution!

Machine damage possible when motor data transmitter deactivated.

If a motor data transmitter is deactivated, the motor temperature is not monitored. You should correct the reason for the deactivation as quickly as possible and reactivate monitoring. {52}

Setting the Radio Controller Fig. 172: Radio Controller Settings

1 2

3 4

On this page you can switch the channel used for the radio connection in the event of a problem.

Important!

You must also switch the channel on the radio controller.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.119

Configuration Pages {53}

Actuators Fig. 173: Actuators

1 2

3 4

You can test the warning light for active ranging arm motors, the signal horns on the machine and the intercom system here.

Clicking on the corresponding button energizes the associated actuator for 20 seconds. This is displayed in the "Status" column. {6}

Automation Fig. 174: Automation

1 2

3 4

Table of contents with branching to configuration of the application software.

5.120

Hard Rock Miner control

Configuration Pages {61}

Longwall Fig. 175: Face

1 2

3 4

This page is already described on page 5.32. {62}

Machine Layout Fig. 176: Machine Layout

1 2

3 4

This page is already described on page 5.33.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.121

Configuration Pages {63}

Arm Movement Speeds Fig. 177: Arm Movement Speeds

1 2

3 4

On this page you can change the lower and upper limits for the speed of arm movements.

Under "Radio Mode" you can change the speed for infeed, angle positioning and height adjustment in the control system by means of the radio controller (see page 5.51 ff).

Under "Control Center" you can change the speed of height adjustment by means of the "Arm up" and "Arm down" buttons on page {11 } (see Fig. 26, page 5.24) in the control center. {64}

Movement Tolerances Fig. 178: Movement Tolerances

1 2

3 4

On this page you can change the allowed position tolerances and tracking delays for the arm movement and travel drive.

The maximum value by which the arm height can be changed in the automatic mode is established under "Automatic Sequence". The maximum deviation is ± 25.0 millimeters.

5.122

Hard Rock Miner control

Configuration Pages {65}

Arm Position and Cutting Speed Fig. 179:

1 2

3 4

Setting the assignment of cutting arms as well as infeed, angle positioning, arm height and travel speed.

This page is already described on page 5.34. {7}

General Fig. 180: General

1 2

3 4

This page contains a table of contents for general system management.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.123

Configuration Pages {71}

System Time Fig. 181: System Time

1 2

3 4

You set the system time on this page. The MMC system is synchronized to this time. Log files are given a timestamp based on this time. {72}

Copying the Software Package Fig. 182: Copying the Software Package

1 2

3 4

You copy the software package from the USB stick to the CIOS server on this page (see page 5.133).

5.124

Hard Rock Miner control

Configuration Pages {73}

Installing the Software Package Fig. 183: Installing the Software Package

1 2

3 4

You install or remove the software packages on this page (see page 5.134). {74}

Parameter Management Fig. 184: Parameter Management

1 2

3 4

You back up the parameter blocks on this page (see page 5.139).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.125

Configuration Pages {75}

Importing Parameters from a USB Stick Fig. 185: USB Stick Settings

1 2

3 4

On this page you import into the system the parameter blocks that were backed up on a USB stick (see page 5.139). {76}

User Administration Fig. 186: User Administration

1 2

3 4

You manage users and passwords on this page (see page 5.129).

5.126

Hard Rock Miner control

Configuration Pages {8}

Connections Fig. 187: Connections

1 2

3 4

You use this table of contents to navigate to other network configuration pages. {81}

Network Configuration Fig. 188: Network Configuration

1 2

3 4

On this page you assign the MAC addresses available in the network to a host name (see also page 5.143).

Doc. no.: 1999 001 043 BA 00

VESL 09

5.127

Configuration Pages {82}

Network Settings Fig. 189: Network Settings

1 2

3 4

Here you can activate/deactivate (manually) a DHCP server, IP addresses and the subnet mask.

5.128

Hard Rock Miner control

User Administration User Administration When changing the configuration of the mining machine, you must enter a user number (for your identification) and a password.

You can make changes only after successful entry of the above information.

Fig. 190: Entry of User Number and Password

1 Input field for your user number 2 Input field for your password

You can cancel the process by pressing [F6] key.

User administration can be found on page {76 users are listed in a table (Fig. 191)

}. All registered

Fig. 191: User Administration

1 List of registered users 2 User number column 3 Access level column 4 "Change password" button

5 "Add user" button 6 Current user 7 Information on access level

You must assign a user number (2) and an access level (3) to every user you add. In addition, every user requires a password.

You need the highest access level 4 for user administration.

The following table lists the access levels and their meanings.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.129

User Administration Tab. 15: Access levels No.

Meaning

0

The user receives read-only authorization; stop functions and monitoring counters can be reset (without a password).

1

Access to alarm values for temperatures, pressures and flow rates.

2

As in 1, additional access to all fault limits, alarm and sensor deactivation.

3

Full access to all system parameters for the mining process and machine setup.

4

As in 3, additional access to the network and user administration.

Creating a New User Pressing the "Add user" button (5) opens the following dialog window (Fig. 192).

Fig. 192: Creating a New User

1 2

3 4

If you have access level 4, you can enter the user number, password and access level for a new user here. At the end, you must reenter the password. You use the "Add user" button to register the user in the control system. Pressing "Cancel" closes the window without creating the user.

The newly created user can now change his password.

Changing the Password To change your password, you need the user number and password assigned to you by the administrator. Log in with this information on page {76 }. Pressing the "Change password" button (4) then opens the following dialog window (Fig. 193).

Fig. 193: Changing the Password

5.130

Hard Rock Miner control

User Administration You enter your existing password in the upper input field here.

Next, you enter your new password in the two other entry fields and confirm the entry by pressing "OK", or you close the window by pressing the "Cancel" button without making the change.

Deleting a User To delete a user, you must log in with access level 4 on page {76 }. Select the intended user in the list and press [Enter ].

In the window that now appears (Fig. 194), you can delete the intended user by pressing the "OK button.

Fig. 194: Deleting a User

Doc. no.: 1999 001 043 BA 00

VESL 09

5.131

Installing the software Installing the software You can update your MMC system with enhancements and corrections. The firmware (device software) is maintained for the following components: CIOS-FBC CIOS-CAN modules PowerSwitch CIOS-IPC CIOS HMI 10 The applications are also enhanced and can be updated. This applies to the above list and the device class of the Rockwell PLCs.

Installation Requirements The machine should be in the entry.

Important!

The system must not be disconnected from power during installation. Ensure that no other work that could trigger an emergency shutdown is being performed.

Types of Installation A distinction is drawn between the locations where the installation takes place: Installation on-site Installation over a network A distinction is also drawn regarding the number of installations: System-wide installation Installation for individual components.

Important!

Only the manufacturer's service personnel may perform an installation for individual components.

Installation On-site For this, you need a special USB stick with the software to be installed. Insert the USB stick into the FBC module on the control console.

Then navigate to the "Copy software package" configuration page {72 } and open the login dialog by pressing [Enter ]. Log in to the system there with your user number and your password.

Copying the Software Package Prior to installing, you must copy the desired software package to the device.

5.132

Hard Rock Miner control

Installing the software Fig. 195: Copying the Software Package

1

2 3 4

5 1 Table of packages 2 Enter package number 3 Package name

4 Copy status 5 Progress bar

All software packages contained on the USB stick are listed in the table (Fig. 195 (1)) on the page. The first column of the table contains a counter, the second column lists the name of the package. It always ends with ".tgz".

To select the package, enter the associated number in the "Select package number" field (2). The name of the selected package appears in the "Package" field (3). If you now press the "Copy" button, "Copy status" (4) changes from "Stopped" to "Copying".

A progress bar (5) at the lower right shows the progress of copying.

Once copying is complete, the "Copy status" field (4) reads "Copying completed".

If the package has been copied successfully, you can install the software.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.133

Installing the software Installing or Deleting Software To install the software, switch to page {73

}.

Fig. 196: Software Package

It has the same structure as page {72 button for deleting a file.

}, but has an additional

Enter the number of the package to be installed or deleted here as well and press the "Install file" or "Delete file" button. A progress bar shows the progress with time here also.

A software package can be very large and distributed over several devices. To observe this progress, press [F2] to switch to the diagnostics level of page {72} (Fig. 197).

Fig. 197: Software Update Status

1 2

5.134

3 4

Hard Rock Miner control

Installing the software Four counter fields show the progress of installation: Entire package Number of individual packages contained Installed packages Number of packages already installed Successful Number of packages successfully installed Failed Number of packages that could not be successfully installed.

With a successfully completed installation, the counters in the "Entire package" and "Successful" feels are identical.

Important!

After a successful installation, you must restart the machine so that the new software runs.

If an error occurs during installation, an error message appears in the "Installation error log".

Doc. no.: 1999 001 043 BA 00

VESL 09

5.135

Installing the software Version Overview You can find an overview of the installed versions on page {71} of the diagnostics level (Fig. 198).

Fig. 198: Software Version

1 2

3 4

Information on the version of the application, the library and the kernel (operating system) is provided for each device. This allows you to check the version level of the software and whether you might need to install additional software. Following an installation, you should go to this page to check the version level once again.

Uppercase letters may follow the file name. They indicate the level of the software. A key with level identifiers ("Additional identifiers") can be found below the table: C: Checksum error The checksum for the file does not match the checksum file in the package.

M: Revision level This is not software intended for general use! Use the device for development only.

N: No checksum file There is no checksum file in the system.

R: Revision incompatible The revision name saved in the image file does not match the entry in the file name.

X: Application does not match kernel or library The revision of the kernel or library does not match the expected revisions of the application.

Timeout: No communication The interrogated device has not communicated for at least 40 seconds.

Pending: Waiting for communication The system is waiting for a connection to be established in order to query the revisions.

None: No compatible version Querying the version is not supported by the device.

5.136

Hard Rock Miner control

Installing the software Installation via a Web Browser A classical web server is available for remote installation. To use it, you need a browser that provides access to the Internet (e.g.

Firefox or MS Internet Explorer). In addition, you need access to the machinery network or mine network with the IP address of the MMC system. If the PC is incorporated directly into the machinery network, the CIOS server with the IP address 192.168.46.2 is the device that offers this service for the ACT mining complex. If the IP address is entered into the address line of the browser, the page shown in the figure 199 appears.

Fig. 199: Start Page for Online Installation

1 2

3 4

There are three links below the company logo: Home Here, the current page (Fig. 199) Parameters Importing and exporting of parameters Package upload Uploading of packages to the MMC system Clicking "Package upload" takes you to the "MMC device upload" page.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.137

Installing the software Fig. 200: Uploading the Installation Package

1 2

3 4

Using the "Browse" button, you can search for and select the desired package in your directory structure here. The "OK" button starts uploading of the package and subsequent installation.

5.138

Hard Rock Miner control

Parameter Administration Parameter Administration In the MMC system, you can export parameter blocks from the machine, import them back to the machine or save them in the system. Export requires a special USB stick.

The parameters are saved as sets in lists. These lists are managed in up to six memory banks. Page {74 } contains a table with the available memory banks. The memory banks are numbered in the first column (Fig. 201 (1)).

Fig. 201: Parameter Management

1 Table with memory banks 2 Reset parameters

A more detailed explanation is provided in the following text

The content of the memory banks is listed in the 2nd column.

The 3rd column lists the save date with time.

In the 4th column, you enter the desired action: Export to USB Saves the parameters to a USB stick in the FBC module on the control console. You can use this to transfer the parameters to an identical machine.

Save All Saves all parameters. Since parameters for the network configuration are included here, you can use this set only on this machine. However, you can use this to create a backup of the parameters.

Save Machine Saves the machine parameters Save System Saves the system parameters Load Loads an existing parameter block onto the machine.

Delete Deletes an existing parameter block.

By pressing the "Reset" button (2), you can reset all machine parameters to the as-delivered status.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.139

Parameter Administration If the parameter list agrees with the parameter database, the diode symbol "Parameters synchronized" (4) appears in green, otherwise in gray. The diode symbol "USB status" (5) indicates that a USB stick has been detected (green). If no USB stick is detected, the diode symbol remains gray.

A progress bar under "USB upload progress" (6) shows the progress of the selected action.

Selecting, Saving and Deleting Parameters After logging in on this page, you press the [Enter ] key. You can now move from action to action in the context menu that appears in the 4th column by pressing the tab key [ ]. You select the desired action by pressing the [Enter ] key.

After making the selection, confirm it by pressing the [F6] key.

The following window appears: Fig. 202: Confirming a selection

1 2

3 4

With the first option, you save the changes. With the 2nd option, you return to the edited page for further editing (in this case, to page {74 }). With the 3rd option, you cancel the process. Confirm the selection by pressing [Enter ]. You can delete the entry and select another option with the "Delete backwards" key [ ].

5.140

Hard Rock Miner control

Parameter Administration Importing Parameters You can load parameter blocks from the USB stick to the system from page {75 } (Fig. 203).

Fig. 203: USB Stick Settings

1 Table with parameter blocks 2 Input field for set number 3 Display of selected set 4 Selection of the location where saved

5 Information about the location where saved 6 Progress bar 7 USB status

The parameter blocks on the USB stick are listed in the table (1).

To select a block, log into the system and enter the associated number from the first table column in the field "Select parameter block" (2) and then press [Enter ]. The file name then appears in the "Selected" field (3). Next, select an available memory bank (from 1 to 6) under "Copy to parameter memory bank" (4). If the memory bank is occupied, the message "Memory bank is occupied" appears under "Last event" (5), otherwise "OK".

Pressing the [F6] key opens the window for confirming the selection (see Fig. 202).

A green progress bar (6) shows the progress of the copying process.

Doc. no.: 1999 001 043 BA 00

VESL 09

5.141

Parameter Administration Changed Parameters On page {74} of the diagnostics level you can identify which parameters have been changed and which values have been assigned to you.

Fig. 204: Parameter Changes

1 2

3 4

The first column of the table lists the parameter name (Fig. 204).

The changed value and the preset value follow.

5.142

Hard Rock Miner control

Configuring the Machine Network Configuring the Machine Network The MMC system's communication is based on the Ethernet protocol. This means that all users must be identified unambiguously by their MAC address. Frequently, addressing takes place within the CIP protocol on multicast telegrams.

Nevertheless, standard addressing in the network is required.

This means that every network user in the system needs a distinct IP address. Usually, such IP addresses are assigned automatically and not saved in the device. For an IP address to be assigned to a device at an assigned installation location, address assignment by a DHCP server must be controlled. Accordingly, a mechanism that is intended to support this action has been provided for the MMC system.

Fig. 205: Network Status

1 2

3 4

When an MMC system is delivered, the host names and IP addresses are known and assigned to specific installation locations. The only thing missing for communication is the relationship between the MAC address and the IP address or host name. name. This cannot be established in advance, however, since the MAC addresses are hardware-dependent.

When a system is initialized for the first time, all DHCP-capable devices in the network request an IP address. The DHCP server is configured such that devices that are not known to the system receive an IP address <=200. It is thus possible to communicate with the device in the network, but the device is not incorporated into the automation. The device appears in the overview list as "unknown device".

Doc. no.: 1999 001 043 BA 00

VESL 09

5.143

List of Screen Pages List of Screen Pages Diagnostics IVZ = Table of contents Level

I

Screen Page

II

III

1

IV IVZ Overview

11

Hard Rock Miner (Overview)

12

Armored Face Conveyor (Overview)

13

Chain Tensioner

2

IVZ Motors & Haulage 21

Overview of HRM Motors

22

Motor overview

23

Travel drive

3

IVZ Water and Hydraulic System 31

Cooling Water

32

LH Hydraulic System

33

RH Hydraulic System

34

Cooling water system

35

Water Spraying System

36

Hydraulic System

4

IVZ Faults & Alarms 41

Faults

42

Alarms

43

Fault Log

44

Alarm Log

45

Current Events

46

Event Log

5

IVZ Diagnostics 51

IVZ CIOS I/O 511

IVZ Backplane Control Box (CB) 5111 MM PH 5112 MM PH

512

IVZ Backplane Haulage Box (HB) 5121 AOUT4 5122 AIN6 5123 AIN6 5124 AIN6 5125 AIN6

513

5.144

IVZ Backplane Power Pack (PP)

Hard Rock Miner control

List of Screen Pages Level

Screen Page

5131 PSO 5132 PSO 5133 PSO 5134 PSO 5135 PSO 5136 PSO 5137 PSO 5138 PSO 514

IVZ Backplane LH Cutter Box (LH) 5141 RTD4 5142 AIN6 5143 DOUT4

515

IVZ Backplane RH Cutter Box (RH) 5151 RTD4 5152 AIN6

516

IVZ Backplane CIOS AFC CONVEYOR (AFCC) 5161 MM PH 5162 DIN10 5163 DIN10 5164 DIN10 5165 DOUT4 5166 AIN8 5167 AIN8

517

IVZ Backplane CIOS AFC HEAD (AFCH) 5171 MM PH 5172 AIN6 5173 DOUT4 5174 DOUT4

Doc. no.: 1999 001 043 BA 00

VESL 09

52

Radio Control

53

IVZ Motor Diagnostics 531

Hydraulic Pump Motor Diagnostics

532

Cutting Unit Motor Diagnostics

533

Blower Motor Diagnostics

534

Water Spraying System Pump Motor Diagnostics

535

Cooling Water Pump Motor Diagnostics

54

Compact Station

55

Low Voltage

56

CIOS Overview

5.145

List of Screen Pages Level

Screen Page

57

Point I/O

7

IVZ General 71

Software Version

72

Software Update Status

73

Software Update Log

74

Parameter changes

8

IVZ Connections 81

Network Overview

82

Network status

Configuration IVZ = Table of contents Level

I

Screen Page

II

III

1

IV IVZ Overview

11

Control Center

12

Pan Conveyor

13

Chain Tensioner

14

Anti Collision

2

IVZ Motors & Haulage 21

IVZ HRM Motor Configuration 211

LH Cutting Unit Motor

212

RH Cutting Unit Motor

213

Hydraulic Pump Motor

22

Motor Configuration (cross‐reference to 211, 212,213,12)

23

Travel Drive Configuration

3

IVZ Water and Hydraulic System 31

Cooling Water

32

LH Hydraulic System

33

RH Hydraulic System

34

Cooling System Configuration

35

Water Spraying System Configuration

36

Hydraulic System Configuration (cross‐reference to 32, 33, 23)

5

IVZ Diagnostics 51

5.146

IVZ Sensors 511

Cable Carrier Pulling Force

512

Encoder

Hard Rock Miner control

List of Screen Pages Level

Screen Page

515

Loading Chute

516

Beam Stage Loader Overload Sensor

517

Motor Data Transmitter Radio Controller Settings

53

Actuators (signal devices) IVZ Automation

61

Face

62

Machine Layout

63

Arm Movement

64

Movement Tolerances

65

Arm Pos. & Cutting Speed

7

IVZ General 71

System Time

72

Copying the Software Package

73

Installing the Software Package

74

Parameter Management

75

USB Stick Settings

76

User Administration

8

VESL 09

Limit Switch

52 6

Doc. no.: 1999 001 043 BA 00

513

IVZ Connections 81

Network Configuration

82

Network Settings

5.147

List of Screen Pages

5.148

Hard Rock Miner control

6

Technical data

Related documents

Technical data Related documents Technical data for the MMC system can be found in document 1999 001 047 BA 00 "MMC control for mobile machines", which is part of this operating manual.

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

For the technical data of components from third parties, please refer to the datasheet of the respective manufacturer. This is supplied with the machine manual.

Doc. no.: 1999 001 043 BA 00

VESL 09

6.3

Limit stop MES 1-4 Limit stop MES 1-4 Fig. 206: Limit stop MES 1-4

The limit stop MES 1-4 is used to determine the position of the mining equipment (synchronization) and for shutdown when the mining equipment has reached its end position.

The MES 1-4 functions as a switch in intrinsically safe electrical circuits (max. two circuits).

Identification: Object: Limit stop Manufacturer: Caterpillar Global Mining Europe GmbH 44534 Lünen, Industriestr. 1 Description: MES 1-4 Purpose: Determine the position of the mining equipment There must be writing on the limit stop which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high: Name and address of the manufacturer Type: MES *-* Type of protection: I M2 EEx ib I Identification: 0158 Certificate number: IBExU 03 ATEX 1151 Serial number: XXXX XX XXXX Digits 5 and 6 indicate year of manufacture Type of protection: EEx ib I to: EN 50014: 1997 +A1 – A2 General regulations EN 50020: 2002 "Intrinsic safety" "i" Function The limit stop is used to sense a magnetic field and send a signal to higher-level, intrinsically safe control systems for switching processes. Each of the built-in NAMUR sensors can be incorporated in an intrinsically safe electrical circuit.

Structure The limit stop consists of a brass housing containing 2 potted NAMUR sensors. The 2 sensors are connected by means of a plug-in connector that is attached to a brass plate by an angle bracket and sealed to IP54.

The 2 wires from each of the 2 sensors are connected to the 4 wires of the connector and enclosed in shrink-on tubing. The materials used for the potting resin and shrink-on tubing have a comparative tracking index CTI = 100 (ICE 112).

6.4

Hard Rock Miner control

Limit stop MES 1-4 The insulation of the 2 intrinsically safe electrical circuit to one another and to grounded parts can withstand an alternating voltage of 500 V. Technical data Tab. 16: Technical data:

Doc. no.: 1999 001 043 BA 00

Designation

Technical data

Type

MES 1-4

Weight

6.6 kg

Dimensions

240 x 90 x 87 mm

Certificate number

IBExU 03 ATEX 1151

Type of protection

ATEX I M2 EEx [ib] I

Material number

4008 004 695 00 00

Temperature range

-20 °C to +70 °C

Output signal

Lt EN50227 Namur

Voltage, max.

14 V

Current, max.

30 mA

Capacitance Ci, max.

15 nF

Inductance Li; max.

25 µH

Intrinsically safe circuit 1

Connector pin 1 (-) and pin 2 (+)

Intrinsically safe circuit 2

Connector pin 3 (-) and pin 4 (+)

VESL 09

6.5

Encoder 656995 cat Encoder 656995 cat Fig. 207: Encoder

Tasks The encoder functions as an absolute linear motion transducer for determining the position of the mining equipment.

Name and address of the manufacturer: Object: Manufacturer: Description: Purpose: Identification: Type of protection: Identification: Certificate number:

6.6

Encoder Caterpillar Global Mining Europe GmbH 44534 Lünen, Industriestr. 1 EXMEHVA-656995 Determine the position of the mining equipment I M2 Ex d I/IIC T6 0539 Epsilon 07 ATEX 2317X -40°C < T.amb < 75°

Hard Rock Miner control

Encoder 656995 cat Major Characteristics – compact and heavy-duty industry version – EtherNet/IP interface – housing: 58 mm – shaft/quill – resolution: max. 30 bits = 1,073,741,824 – 16384 steps per revolution – coding: binary Mechanical Setup – flange and housing: Aluminum or brass – stainless steel shaft – precision ball bearings with rubber seal – encoder wheel made from high-strength and unbreakable plastic – rugged electrical entry (M12) Programmable Parameters – resolution – presets – rotational direction – speed – IP address Electrical Characteristics – integrated switch – status displays with 6 LEDs – temperature-insensitive – infrared opto-receiver (ASIC) – reverse polarity protection – surge protection

Doc. no.: 1999 001 043 BA 00

VESL 09

6.7

Encoder 656995 cat Connections Tab. 17: Ethernet - 4 pin female, D-coded Pin Number

Signal

1

Tx +

2

Rx +

3

Tx -

4

Rx -

Fig. 208:

Ethernet - 4 pin female, D-coded

Tab. 18: Power Supply - 4-Pin Male, A-coded Pin Number

Signal

1

US (15 - 30 V DC)

2

N.C.

3

GND (0 V)

4

N.C.

Fig. 209:

6.8

Power Supply - 4-Pin Male, A-code

Hard Rock Miner control

Encoder 656995 cat EtherNet/IP status displays Tab. 19: Power Supply - 4-Pin Male, A-coded

Doc. no.: 1999 001 043 BA 00

LED

Color

LED meaning = on

Active1

Yellow

Incoming and outgoing data traffic for port 1

Link1

Green

Connection to another Ethernet component for port 1

Aktive2

Yellow

Incoming and outgoing data traffic for port 2

Link2

Green

Connection to another Ethernet component for port 2

Stat1

Green

Status 1, Details in the user manual for the encoder

Stat2

Red

Status 2, Details in the user manual for the encoder

Fig. 210:

EtherNet/IP

VESL 09

6.9

Encoder 656995 cat

6.10

Hard Rock Miner control

7

Tables

Parameters

Tables Parameters Tab. 20: Pan Conveyor Page

Category

Measured Value

12

Bearing Temperature

Water Temperature

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Motor Temperature

Supply Water Temperature

Return Water Temperature

Water Flow Rate

Motor Current

Doc. no.: 1999 001 043 BA 00

Unit

Minimum

Maximum

Preset Value

Password Level

Face

0

2

1

1

Gob

0

2

1

1

Alarm Value

°C

60

100

80

0

Fault Value

°C

70

110

90

0

0

2

1

1

Fault Alarm Value

°C

30

60

40

0

Fault Value

°C

35

65

45

0

U Fault

0

2

1

1

V Fault

0

2

1

1

W Fault

0

2

1

1

Alarm Value

°C

70

110

90

0

Fault Value

°C

80

120

100

0

0

2

1

1

Fault Upper Alarm Limit

°C

0

60

35

0

Upper Fault Limit

°C

0

60

30

0

0

2

1

1

Fault Upper Alarm Limit

°C

0

60

45

0

Upper Fault Limit

°C

0

60

45

0

Fault

0

2

1

1

Upper Alarm Limit

l/min

15

20

20

0

Upper Fault Limit

l/min

15

20

20

0

0

2

1

2

Fault Alarm Value

A

0

200

60

1

Fault Value

A

0

200

60

1

VESL 09

7.3

Parameters Tab. 21: Chain Tensioner Page

Category

Measured Value

Unit

Minimum

Maximum

13

AFCChain Position

Trip

none

0

2

1

2

Upper Alarm Limit

mm

0

600

550

1

Lower Alarm Limit

mm

0

600

0

1

Upper Fault Limit

mm

0

600

550

2

Lower Fault Limit

mm

0

600

0

2

Power-on Delay

sec

0

60

5

2

Power-off Delay

sec

0

60

5

2

Delay Fault

sec

0

60

5

2

Trip

none

0

2

1

2

Upper Alarm Limit

bar

0

600

500

1

Lower Alarm Limit

bar

0

0

30

1

Upper Fault Limit

bar

0

600

550

2

Lower Fault Limit

bar

0

0

10

2

Power-on Delay

sec

0

60

5

2

Power-off Delay

sec

0

60

5

2

Delay Fault

sec

0

60

5

2

Activ_Switch

none

0

1

1

1

Extraction_Max

mm

0

10000

1000

3

Extraction_Min

mm

0

10000

0

3

Pressure_Hyst

Bar

0

100

9

1

Pressure_Setpoint

Bar

0

600

110

1

Max_Time

sec

0

360

60

3

Max_Try

none

0

100

8

3

Extract_push_time

none

0

30000

100

3

Extract_wait_time

none

0

30000

2000

3

Retract_pull_time

none

0

30000

100

3

Retract_wait_time

none

0

30000

2000

3

Reverse_action_time

none

0

30000

5000

3

Cylinder_length

mm

0

5000

1000

3

Chain Tensioner

7.4

Hard Rock Miner control

E

Password Level

Caterpillar Global Mining Europe GmbH, Lünen 2016

AFCChain Pressure

Preset Value

Parameters Tab. 22: Anti Collision Page

Category

Measured Value

Unit

Minimum

Maximum

14

Anti Collision

Active_Switch

none

0

1

1

4

MaintenanceMonitoring

none

0

1

1

3

Unit

Minimum

Maximum

Preset Value

Password Level

Preset Value

Password Level

Tab. 23: LH cutting unit motor Page

Category

Measured Value

211

Motor Temperature

U Fault

0

2

1

1

V Fault

0

2

1

1

W Fault

0

2

1

1

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Gear temperature

Bearing Temperature

Alarm Value

°C

70

110

90

0

Fault Value

°C

80

120

100

0

0

2

1

1

Fault Alarm Value

°C

70

110

90

0

Fault Value

°C

80

120

100

0

0

2

1

1

Face Gob

Water Temperature

Motor current

Doc. no.: 1999 001 043 BA 00

0

2

1

1

Alarm Value

°C

60

100

80

0

Fault Value

°C

70

110

90

0

0

2

1

1

Fault Alarm Value

°C

30

60

40

0

Fault Value

°C

35

65

45

0

0

2

1

2

Fault Alarm Value

A

0

200

140

1

Fault Value

A

0

200

140

1

VESL 09

7.5

Parameters

Category

Measured Value

212

Motor Temperature

Gear temperature

Bearing Temperature

Unit

Minimum

Maximum

Preset Value

Password Level

U Fault

0

2

1

1

V Fault

0

2

1

1

W Fault

0

2

1

1

Alarm Value

°C

70

110

90

0

Fault Value

°C

80

120

100

0

0

2

1

1

Fault Alarm Value

°C

70

110

90

0

Fault Value

°C

80

120

100

0

0

2

1

1

Face Gob

Water Temperature

Motor current

0

2

1

1

Alarm Value

°C

60

100

80

0

Fault Value

°C

70

110

90

0

0

2

1

1

Fault Alarm Value

°C

30

60

40

0

Fault Value

°C

35

65

45

0

Fault

0

2

1

2

Alarm Value

A

0

200

140

1

Fault Value

A

0

200

140

1

Tab. 25: Hydraulic Pump Motor Page

Category

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

213

Motor Temperature

U Fault

1

2

1

1

1

V Fault

1

2

1

1

1

W Fault

1

2

1

1

1

Alarm Value

10

110

90

0

0

Fault Value

10

120

100

0

0

0

2

1

2

Motor current

7.6

Fault Alarm Value

A

0

200

60

1

Alarm Value

A

0

200

60

1

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Page

E

Tab. 24: RH cutting unit motor

Parameters Tab. 26: Drive Configuration Page

Category

Measured Value

23

Drive pressure, forward

Fault

Drive pressure, reverse

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Drive, braking zone

Motor Stall

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Upper Alarm Limit

bar

0

380

380

0

Lower Alarm Limit

bar

0

380

380

0

Upper Fault Limit

bar

0

100

0

0

Lower Fault Limit

bar

0

80

0

0

0

2

1

1

Fault Upper Alarm Limit

bar

0

380

380

0

Lower Alarm Limit

bar

0

380

380

0

Upper Fault Limit

bar

0

100

0

0

Lower Fault Limit

bar

0

80

0

0

Distance

m

0

2

0.1

1

Speed

m/min

0

3

1

1

Distance

m

0.05

1

0.3

2

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Tab. 27: Cooling water Page

Category

Measured Value

31

LH cutter Temperature

Fault

LH cutter Flow

RH cutter Temperature

RH cutter Flow

Hydraulic pump Temperature

Doc. no.: 1999 001 043 BA 00

Upper Alarm Limit

°C

0

100

90

0

Lower Alarm Limit

°C

0

100

80

0

Upper Fault Limit

°C

0

10

0

0

Lower Fault Limit

°C

0

8

0

0

0

2

1

1

Fault Upper Alarm Limit

l/min

12

20

20

0

Lower Alarm Limit

l/min

12

20

18

0

Upper Fault Limit

l/min

10

18

12

0

Lower Fault Limit

l/min

10

18

10

0

0

2

1

1

Fault Upper Alarm Limit

°C

0

100

90

0

Lower Alarm Limit

°C

0

100

80

0

Upper Fault Limit

°C

0

10

0

0

Lower Fault Limit

°C

0

8

0

0

0

2

1

1

Fault Upper Alarm Limit

l/min

10

20

20

0

Lower Alarm Limit

l/min

10

20

18

0

Upper Fault Limit

l/min

10

15

12

0

Lower Fault Limit

l/min

10

15

10

0

0

2

1

1

Fault

VESL 09

7.7

Category

Hydraulic pump Flow

Supply Pressure

Supply Temperature

Oil Cooler Flow Rate

7.8

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

Upper Alarm Limit

°C

0

60

40

0

Lower Alarm Limit

°C

0

60

40

0

Upper Fault Limit

°C

0

10

0

0

Lower Fault Limit

°C

0

10

0

0

0

2

1

1

Fault Upper Alarm Limit

l/min

10

20

16

0

Lower Alarm Limit

l/min

10

20

14

0

Upper Fault Limit

l/min

5

10

8

0

Lower Fault Limit

l/min

5

10

6

0

0

2

1

1

Fault Upper Alarm Limit

bar

0

30

30

0

Lower Alarm Limit

bar

0

30

25

0

Upper Fault Limit

bar

0

10

12

0

Lower Fault Limit

bar

0

10

10

0

0

2

1

1

Fault Upper Alarm Limit

°C

0

60

35

0

Lower Alarm Limit

°C

0

60

35

0

Upper Fault Limit

°C

0

25

25

0

Lower Fault Limit

°C

0

25

20

0

0

2

1

1

Fault Upper Alarm Limit

l/min

10

20

14

0

Lower Alarm Limit

l/min

10

20

12

0

Upper Fault Limit

l/min

5

15

8

0

Lower Fault Limit

l/min

5

15

6

0

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Page

E

Parameters

Parameters Tab. 28: LH Hydraulic System Page

Category

Measured Value

32

LH Positioning

Reed Rod Fault

Unit

E Caterpillar Global Mining Europe GmbH, Lünen 2016

Password Level

0

2

1

1

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

0

2

1

1

Reed Rod Fault Upper Alarm Limit

mm

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

0

2

1

1

Reed Rod Fault Upper Alarm Limit

mm

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Positioning Fault

Doc. no.: 1999 001 043 BA 00

Preset Value

mm

Positioning Fault

Height

Maximum

Upper Alarm Limit

Positioning Fault

RH Positioning

Minimum

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

VESL 09

7.9

Parameters

Category

Measured Value

33

LH Positioning

Reed Rod Fault

Unit

Password Level

0

2

1

1

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

0

2

1

1

Reed Rod Fault Upper Alarm Limit

mm

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

0

2

1

1

Reed Rod Fault Upper Alarm Limit

mm

0

250

220

0

Lower Alarm Limit

mm

0

220

200

0

Upper Fault Limit

mm

0

100

0

0

Lower Fault Limit

mm

0

80

0

0

0

2

1

1

Positioning Fault

7.10

Preset Value

mm

Positioning Fault

Height

Maximum

Upper Alarm Limit

Positioning Fault

RH Positioning

Minimum

Power-on Delay

s

0

10

5

1

Power-down Delay

s

0

10

2

1

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Page

E

Tab. 29: RH Hydraulic System

Parameters Tab. 30: Water Spraying System Configuration Page

Category

Measured Value

35

Water Spraying System Pressure

Fault

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

bar

0

300

300

0

Upper Alarm Limit

bar

0

300

100

0

Lower Alarm Limit

bar

0

100

12

0

Lower Fault Limit

bar

0

80

10

0

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Upper Fault Limit

Doc. no.: 1999 001 043 BA 00

VESL 09

7.11

Parameters

Category

Measured Value

361

Valve Pressure

Fault

Oil Contamination Sensor

Tank Fill Level

Tank Temperature

7.12

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Upper Fault Limit

bar

0

400

250

0

Upper Alarm Limit

bar

0

400

250

0

Lower Alarm Limit

bar

0

100

0

0

Lower Fault Limit

bar

0

100

0

0

0

2

1

1

Fault Upper Fault Limit

bar

0

4

4

0

Upper Alarm Limit

bar

0

4

3

0

Lower Alarm Limit

bar

0

4

0

0

Lower Fault Limit

bar

0

4

0

0

0

2

1

1

Fault Upper Fault Limit

mm

0

300

300

0

Upper Alarm Limit

mm

0

300

300

0

Lower Alarm Limit

mm

0

200

200

0

Lower Fault Limit

mm

0

150

120

0

Fault

0

2

1

1

Upper Fault Limit

°C

0

125

75

0

Upper Alarm Limit

°C

0

125

70

0

Lower Alarm Limit

°C

0

100

0

0

Lower Fault Limit

°C

0

80

0

0

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Page

E

Tab. 31: Hydraulic System Configuration

Parameters Tab. 32: Hose Carrier Pulling Force (In Addition to Cable Carrier) Page

Category

Measured Value

511

Pulling Force

Fault

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Upper Alarm Limit

t

0

1

0.85

0

Lower Alarm Limit

t

0

1

0.75

0

Upper Fault Limit

t

-1

0

-0.75

0

Lower Fault Limit

t

-1

0

-0.85

0

Delay Fault

s

0

60

5

1

Power-on Delay

s

0

60

5

1

Power-down Delay

s

0

60

5

1

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Tab. 33: Cable Carrier Pulling Force Category

Measured Value

512

Pulling Force

Fault

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Page

Upper Alarm Limit

t

0

1

0.85

0

Lower Alarm Limit

t

0

1

0.75

0

Upper Fault Limit

t

-1

0

-0.75

0

Lower Fault Limit

t

-1

0

-0.85

0

Delay Fault

s

0

60

5

1

Power-on Delay

s

0

60

5

1

Power-down Delay

s

0

60

5

1

Unit

Minimum

Maximum

Preset Value

Password Level

0

1

0

3

Tab. 34: Encoder Page

Category

Measured Value

513

Encoder

Fault Machine Position

m

0

10000

0

1

Unit

Minimum

Maximum

Preset Value

Password Level

Tab. 35: Limit switch Page

Category

Measured Value

514

Limit Switch

Maingate

0

2

1

3

Belt Section

0

2

1

3

Maingate

0

2

1

3

Belt Section

0

2

1

3

Sync. Switch

Doc. no.: 1999 001 043 BA 00

VESL 09

7.13

Parameters Tab. 36: Warning Horn Page

Category

Measured Value

515

Warning Horn

Fault

Unit

Minimum

Maximum

Preset Value

Password Level

0

2

1

1

Minimum

Maximum

Preset Value

Password Level

0

2

1

2

Minimum

Maximum

Preset Value

Password Level

0

2

1

2

Minimum

Maximum

Preset Value

Password Level

Tab. 37: Loading Chute Page

Category

Measured Value

516

Loading Chute

Fault

Unit

Tab. 38: Beam Stage Loader Overload Sensor Page

Category

Measured Value

517

Beam Stage Loader Overload Sensor

Fault

Unit

Category

Measured Value

518

MDT

LH Cutting Unit

0

1

1

3

RH Cutting Unit

0

1

1

3

Pump

0

1

1

3

Conveyor

0

1

1

3

Minimum

Maximum

Preset Value

Password Level

0

20

1

3

Unit

Tab. 40: Radio Controller Settings Page

Category

Measured Value

52

Radio Controller

Radio Channel

Unit

Tab. 41: Face Page

Category

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

61

Face Configuration

Face Length

m

0

1000

0

1

Belt Section Width

m

0

1000

0

1

Maingate Width

m

0

1000

0

1

0

1000

0

1

Number of Shields Shield width

mm

0

10000

0

1

Tab. 42: Machine Layout Page

Category

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

62

Hydraulic Cylinder Arm Configuration

Height Cylinder Length

mm

0

10000

0

3

Positioning Cylinder Length

mm

0

10000

0

3

Max. Machine Speed

m/min

0

10

6

2

Traveled Drive Base Configuration

7.14

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Page

E

Tab. 39: Motor Data Transmitter

Parameters Tab. 43: Arm Movement Speeds Page

Category

Measured Value

63

Positioning

Angles

Height

Unit

Minimum

Maximum

Preset Value

Password Level

Slow

0

10000

10

2

Fast

0

10000

100

2

Slow

0

10000

10

2

Fast

0

10000

100

2

Slow

0

10000

10

2

Fast

0

10000

100

2

Tab. 44: Movement Tolerances Page

Category

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

64

Arm Movement

Tolerance

mm

0

10000

10

2

Delay

s

0

10000

1000

2

Tolerance

mm

0

10000

10

2

Delay

s

0

10000

1000

2

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Travel Drive Movement

Tab. 45: Arm Position and Cutting Speed Page

Category

Measured Value

Unit

Minimum

Maximum

Preset Value

Password Level

65

Trailing Arm

Angles

Degrees

-30

30

0

1

Positioning

mm

70

300

70

1

Height

mm

-10

900

800

1

Angles

Degrees

-30

30

0

1

Positioning

mm

70

300

70

1

Height

mm

110

2100

2000

1

Automatic Speed Adjustment

m/min

0

6

2.5

2

Leading Arm

Automatic Speed Adjustment

Doc. no.: 1999 001 043 BA 00

VESL 09

7.15

Error messages Error messages Tab. 46: LH Cutting Unit Fault Error Message

Meaning

Fault Treatment

F0101

LH_Cutter_Motor_Winding_U_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0102

LH_Cutter_Motor_Winding_V_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0103

LH_Cutter_Motor_Winding_W_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0104

LH_Cutter_Motor_Gear_RTD

Gearbox Overtemperature

Check cooling circuit, wait until temperature has dropped

F0105

LH_Cutter_Motor_CS_overcurrent

Overcurrent at Compact Station

Check the cutting parameters regarding undercut depth and travel speed

F0106

LH_Cutter_Motor_CS_short_circuit

Short Circuit at Compact Station

Check the motor connection cable

F0107

LH_Cutter_Motor_CS_earthleackage

Ground Fault at Compact Station

Check the motor connection cable

F0108

LH_Cutter_Motor_CS_Thermistor

Temperature Exceeded at Compact Station

Allow to cool

F0109

LH_Cutter_Motor_CS_phase

Phase Fault at Compact Station

Check the motor connection cable

F0110

LH_Cutter_Motor_CS_ground

Protective Conductor Fault at Compact Station

Check the motor connection cable

F0111

LH_Cutter_Motor_Readback_missing(RSS)

Readback signal missing after motor starts

Check Compact Station

F0112

LH_Cutter_Motor_Readback_missing

Readback Contact of Contactor not Following

If necessary, check signal path

F0113

LH_Cutter_Motor_start_without_request

Motors start without user interaction

Check compact station regarding contactor actuation. If necessary, contact manufacturer

F0114

LH_Cutter_Motor_RTD_Bearing_Face

Bearing Overtemperature, Face Side

Check cooling circuit, wait until temperature has dropped

F0115

LH_Cutter_Motor_RTD_Bearing_Goaf

Bearing Overtemperature, Shield Side

Check cooling circuit, wait until temperature has dropped

F0116

LH_Cutter_Motor_RTD_Motor

Motor Overtemperature

Check cooling circuit, wait until temperature has dropped

F0117

LH_Cutter_Motor_Overcurrent

Motor Overcurrent Detected

Check the cutting parameters regarding undercut depth and travel speed

7.16

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Error messages

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Tab. 47: RH Cutting Unit Fault Fault ID

Error Message

Meaning

Fault Treatment

F0201

RH_Cutter_Motor_Winding_U_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0202

RH_Cutter_Motor_Winding_V_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0203

RH_Cutter_Motor_Winding_W_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0204

RH_Cutter_Motor_Gear_RTD

Gearbox Overtemperature

Check cooling circuit, wait until temperature has dropped

F0205

RH_Cutter_Motor_CS_overcurrent

Overcurrent at Compact Station

Check the cutting parameters regarding undercut depth and travel speed

F0206

RH_Cutter_Motor_CS_short_circuit

Short Circuit at Compact Station

Check the motor connection cable

F0207

RH_Cutter_Motor_CS_earthleackage

Ground Fault at Compact Station

Check the motor connection cable

F0208

RH_Cutter_Motor_CS_Thermistor

Temperature Exceeded at Compact Station

Allow to cool

F0209

RH_Cutter_Motor_CS_phase

Phase Fault at Compact Station

Check the motor connection cable

F0210

RH_Cutter_Motor_CS_ground

Protective Conductor Fault at Compact Station

Check the motor connection cable

F0211

RH_Cutter_Motor_Readback_missing

Readback Contact of Contactor not Following

If necessary, check signal path

F0212

RH_Cutter_Motor_Readback_missing

Readback Contact of Contactor not Following

If necessary, check signal path

F0213

RH_Cutter_Motor_start_without_request

Motors start without user interaction

Check compact station regarding contactor actuation. If necessary, contact manufacturer

F0214

RH_Cutter_Motor_RTD_Bearing_Face

Bearing Overtemperature, Face Side

Check cooling circuit, wait until temperature has dropped

F0215

RH_Cutter_Motor_RTD_Bearing_Goaf

Bearing Overtemperature, Shield Side

Check cooling circuit, wait until temperature has dropped

F0216

RH_Cutter_Motor_RTD_Motor

Motor Overtemperature

Check cooling circuit, wait until temperature has dropped

F0217

RH_Cutter_Motor_Overcurrent

Motor Overcurrent Detected

Check the cutting parameters regarding undercut depth and travel speed

Doc. no.: 1999 001 043 BA 00

VESL 09

7.17

Error messages

Error Message

Meaning

Fault Treatment

F0301

Pump_Motor_Motor_Winding_U_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0302

Pump_Motor_Motor_Winding_V_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0303

Pump_Motor_Motor_Winding_W_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0305

Pump_Motor_Motor_CS_overcurrent

Overcurrent at Compact Station

Check the cutting parameters regarding undercut depth and travel speed

F0306

Pump_Motor_Motor_CS_short_circuit

Short Circuit at Compact Station

Check the motor connection cable

F0307

Pump_Motor_Motor_CS_earthleackage

Ground Fault at Compact Station

Check the motor connection cable

F0308

Pump_Motor_Motor_CS_Thermistor

Temperature Exceeded at Compact Station

Allow to cool

F0309

Pump_Motor_Motor_CS_phase

Phase Fault at Compact Station

Check the motor connection cable

F0310

Pump_Motor_Motor_CS_ground

Protective Conductor Fault at Compact Station

Check the motor connection cable

F0311

Pump_Motor_Motor_Readback_missing

Readback signal missing after motor starts

Check Compact Station

F0312

Pump_Motor_Motor_Readback_missing

Readback Contact of Contactor not Following

If necessary, check signal path

F0313

Pump_Motor_Motor_start_without_request

Pump starts without user interaction

Check compact station regarding contactor actuation. If necessary, contact manufacturer

F0314

Pump_Motor_Motor_Overcurrent

Pump Overcurrent Detected

Check the cutting parameters regarding undercut depth and travel speed

Tab. 49: AFC Fault Fault ID

Error Message

Meaning

Fault Treatment

F0401

AFC_Motor_Winding_U_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0402

AFC_Motor_Winding_V_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0403

AFC_Motor_Winding_W_RTD

Motor Winding Overtemperature

Check cooling circuit, wait until temperature has dropped

F0404

AFC_Motor_Overcurrent

Motor Overcurrent Detected

Check the cutting parameters regarding undercut depth and travel speed

F0405

AFC_Motor_CS_overcurrent

Overcurrent at Compact Station

Check the cutting parameters regarding undercut depth and travel speed

F0406

AFC_Motor_CS_short_circuit

Short Circuit at Compact Station

Check the motor connection cable

F0407

AFC_Motor_CS_earthleackage

Ground Fault at Compact Station

Check the motor connection cable

F0408

AFC_Motor_CS_Thermistor

Temperature Exceeded at Compact Station

Allow to cool

7.18

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fault ID

E

Tab. 48: Hydraulic Pump Fault

Error messages Error Message

Meaning

Fault Treatment

F0409

AFC_Motor_CS_phase

Phase Fault at Compact Station

Check the motor connection cable

F0410

AFC_Motor_CS_ground

Protective Conductor Fault at Compact Station

Check the motor connection cable

F0411

AFC_Motor_Readback_missing

Readback Contact of Contactor not Following

If necessary, check signal path

F0412

AFC_Motor_start_without_request

AFC starts without user interaction

Check compact station regarding contactor actuation. If necessary, contact manufacturer

F0413

AFC_Motor_RTD_Bearing_Face

Bearing Overtemperature, Face Side

Check cooling circuit, wait until temperature has dropped

F0414

AFC_Motor_RTD_Bearing_Goaf

Bearing Overtemperature, Shield Side

Check cooling circuit, wait until temperature has dropped

F0415

AFC_Motor_RTD_Motor

Motor Overtemperature

Check cooling circuit, wait until temperature has dropped

F0416

AFC_Chute_switch

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

Check wiring!

F0417

AFC_Button_approval_NC

The NC contact of the enabling button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0418

AFC_Button_approval_NO

The NO contact of the enabling button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0419

AFC_Button_Stop_NC

The NC contact of the stop button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0420

AFC_Button_Stop_NO

The NO contact of the stop button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0421

AFC_Button_Right_NC

The NC contact of the clockwise operation button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Doc. no.: 1999 001 043 BA 00

VESL 09

7.19

Error messages Error Message

Meaning

Fault Treatment

F0422

AFC_Button_Right_NO

The NO contact of the clockwise operation button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0423

AFC_Button_Left_NC

The NC contact of the counterclockwise operation button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0424

AFC_Button_left_NO

The NO contact of the counterclockwise operation button could not be read back correctly.

The exact fault specified can be seen in the suffix table

Check wiring!

F0425

AFC_Control_Panel_Switch_Malfunction

Fault in AFC control element in panel at edge of face

Check cables

F0426

AFC_Temperature_befor

Supply temperature of cooling water for the AFC motor is too high

Check cooling water volume Check cooling unit

F0427

AFC_Temperature_after

Return temperature of cooling water for the AFC motor is too high

Check cooling water volume Check cooling unit

F0428

AFC_Cooling_Flow

Cooling water volume for the AFC motor is insufficient

Check cooling water pump

F0429

AFC_AFC_Chain_Position

Chain tensioner position is outside the tolerance

Check sensor and cables

F0430

AFC_AFC_Chain_Pressure

Fault with chain tensioner pressure monitoring.

The exact fault specified can be seen in the suffix table

Check sensor and cables

F0431

AFC_Belt_Overload

Fault the with belt overload monitoring.

The exact fault specified can be seen in the suffix table

Check sensor and cables

7.20

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Error messages Tab. 50: Cooling Water System Fault Error Message

Meaning

Fault Treatment

F0501

Coolingwater_System_Motor_CS_overcurrent

Overcurrent detected in cooling water motor at compact station.

see Hansen operating manual!

F0502

Coolingwater_System_Motor_CS_short_circuit

Short circuit detected in cooling water motor at compact station.

see Hansen operating manual

F0503

Coolingwater_System_Motor_CS_earthleackage

Ground fault detected in cooling water motor at compact station.

see Hansen operating manual

F0504

Coolingwater_System_Motor_CS_Thermistor

Overheating detected at compact station

see Hansen operating manual

F0505

Coolingwater_System_Motor_CS_phase

Phase fault detected in cooling water motor at compact station.

see Hansen operating manual

F0506

Coolingwater_System_Motor_CS_ground

Protective conductor fault detected in cooling water motor at compact station.

see Hansen operating manual

F0507

Coolingwater_System_Motor_Readback_missing

The motor contactor should be energized, but the readback contact could not read back correctly.

The motor could not be started, another fault may possibly be preventing the motor's starting or the switching relay is not functioning correctly.

F0508

Coolingwater_System_Motor_start_without_request

The motor contactor is not energized, but a readback value has been read nevertheless

The motor started without a request, the switching relay may not be functioning correctly.

F0509

Coolingwater_System_Coolingwater_malfunction

Hauhinco control in fault status

Identify, correct and clear fault on Hauhinco control

F0510

Coolingwater_System_Water_KP1

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0511

Coolingwater_System_Feedback_KP1

Fault with readback contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0512

Coolingwater_System_Start_KP1

Fault with request contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0514

Coolingwater_System_LH_Overcooling

LH Cutter Motor Recool Time Exceeded

Please check the valve and flow monitoring

F0515

Coolingwater_System_RH_Overcooling

RH Cutter Motor Recool Time Exceeded

Please check the valve and flow monitoring

F0516

Coolingwater_System_Pump_Overcooling

Pump Motor Recool Time Exceeded

Please check the valve and flow monitoring

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Doc. no.: 1999 001 043 BA 00

VESL 09

7.21

Error messages Fault ID

Error Message

Meaning

Fault Treatment

F0517

Coolingwater_System_AFC_Overcooling

AFC Motor Recool Time Exceeded

Please check the valve and flow monitoring

F0518

Coolingwater_system_Tank_Overfill_Protection

Fault with water reservoir monitoring in cooling system.

The exact fault specified can be seen in the suffix table

see suffix table

Error Message

Meaning

Fault Treatment

F0601

Spraywater_System_Motor_CS_overcurrent

Overcurrent detected in water spraying system motor at compact station.

see Hansen operating manual

F0602

Spraywater_System_Motor_CS_short_circuit

Short circuit detected in water spraying system motor at compact station.

see Hansen operating manual

F0603

Spraywater_System_Motor_CS_earthleackage

Ground fault detected in water spraying system motor at compact station.

see Hansen operating manual

F0604

Spraywater_System_Motor_CS_Thermistor

Overheating detected at compact station

see Hansen operating manual

F0605

Spraywater_System_Motor_CS_phase

Phase fault detected in water spraying system motor at compact station.

see Hansen operating manual

F0606

Spraywater_System_Motor_CS_ground

Protective conductor fault detected in water spraying system motor at compact station.

see Hansen operating manual

F0607

Spraywater_System_Motor_Readback_missing

The motor contactor should be energized, but the readback contact could not read back correctly.

The motor could not be started, another fault may possibly be preventing the motor's starting or the switching relay is not functioning correctly.

F0608

Spraywater_System_Motor_start_without_request

The motor contactor is not energized, but a readback value has been read nevertheless

The motor started without a request, the switching relay may not be functioning correctly.

F0610

Spraywater_System_Water_BP1

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0611

Spraywater_System_Water_NV

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0612

Spraywater_System_Readback_BP1

Fault with readback contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

7.22

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fault ID

E

Tab. 51: Water Spraying System Fault

Error messages Fault ID

Error Message

Meaning

Fault Treatment

F0613

Spraywater_System_Start_BP1

Fault with request contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0614

Spraywater_System_Pressure_Spray_Bar

Fault with water spraying system pressure monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Tab. 52: Fan Fault Error Message

Meaning

Fault Treatment

F0701

Fan_Motor_CS_overcurrent

Overcurrent detected in fan motor at compact station.

see Hansen operating manual

F0702

Fan_Motor_CS_short_circuit

Short circuit detected in fan motor at compact station.

see Hansen operating manual

F0703

Fan_Motor_CS_earthleackage

Ground fault detected in fan motor at compact station.

see Hansen operating manual

F0704

Fan_Motor_CS_Thermistor

Overheating detected at compact station

see Hansen operating manual

F0705

Fan_Motor_CS_phase

Phase fault detected in fan motor at compact station.

see Hansen operating manual

F0706

Fan_Motor_CS_ground

Protective conductor fault detected in fan motor at compact station.

see Hansen operating manual

F0707

Fan_Motor_Readback_missing

The motor contactor should be energized, but the readback contact could not read back correctly.

The motor could not be started, another fault may possibly be preventing the motor's starting or the switching relay is not functioning correctly.

F0708

Fan_Motor_start_without_request

The motor contactor is not energized, but a readback value has been read nevertheless

The motor started without a request, the switching relay may not be functioning correctly.

F0710

Fan_Motor_Water_L1

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F0711

Fan_Motor_Readback_L1

Fault with readback contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Doc. no.: 1999 001 043 BA 00

VESL 09

7.23

Error messages

Error Message

Meaning

Fault Treatment

F0801

Low_Voltage_Lighting_short_circuit

Compact station has detected a short circuit in the lighting circuit.

see Hansen operating manual

F0802

Low_Voltage_Lighting_earth_leakage

Compact station has detected a ground fault in the lighting circuit.

see Hansen operating manual

F0803

Low_Voltage_Lighting_overload_PE

Compact station has detected a protective conductor overload in the lighting circuit.

see Hansen operating manual

F0804

Low_Voltage_Roof_Support_short_circuit

Compact station has detected a short circuit in the shield's electrical circuit.

see Hansen operating manual

F0805

Low_Voltage_Roof_Support_earth_leackage

Compact station has detected a ground fault in the shield's electrical circuit.

see Hansen operating manual

F0806

Low_Voltage_Roof_support_overload_PE

Compact station has detected a protective conductor overload in the shield's electrical circuit.

see Hansen operating manual

F0807

Low_Voltage_Control_Center_short_circuit

Compact station has detected a protective conductor overload in the control center's electrical circuit.

see Hansen operating manual

F0808

Low_Voltage_Control_Center_earth_leackage

Compact station has detected a short circuit in the control center's electrical circuit.

see Hansen operating manual

F0809

Low_Voltage_Control_Center_overload_PE

Compact station has detected a ground fault in the control center's electrical circuit.

see Hansen operating manual

Tab. 54: Compact Station Fault Fault ID

Error Message

Meaning

Fault Treatment

F0901

Compact_Station_CS1_42V_ESP

Compact Station 1 42V ESP

see Hansen operating manual

F0902

Compact_Station_CS1_Emergency_Stop

Compact Station 1 Emergency Stop Actuated

see Hansen operating manual

F0903

Compact_Station_CS2_42V_ESP

Compact Station 2 42V ESP

see Hansen operating manual

F0904

Compact_Station_CS2_Emergency_Stop

Compact Station 2 Emergency Stop Actuated

see Hansen operating manual

F0905

Compact_Station_CS3_42V_ESP

Compact Station 3 42V ESP

see Hansen operating manual

7.24

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fault ID

E

Tab. 53: Low Voltage Fault

Error messages Fault ID

Error Message

Meaning

Fault Treatment

F0906

Compact_Station_CS3_Emergency_Stop

Compact Station 3 Emergency Stop Actuated

see Hansen operating manual

F0907

Compact_Station_CS4_Overcurrent

Compact Station 4 Overvoltage

see Hansen operating manual

F0908

Compact_Station_CS4_Isolation_warnin

Compact Station 4 Insulation Test Warning

see Hansen operating manual

F0909

Compact_Station_Isolation_Fault

Compact Station 4 Insulation Test Fault

see Hansen operating manual

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Tab. 55: Chain Tensioner Fault Fault ID

Error Message

Meaning

Fault Treatment

F1001

Chain_Tensioner_DOUT_CH1_Fault

Monitoring of Valve Actuation Indicates a Fault

see suffix table

F1003

Chain_Tensioner_cylinder_over_max

Chain Tensioner Cylinder Stroke Over Maximum

Check the set parameters, check chain if necessary

F1004

Chain_Tensioner_cylinder_under_min

Chain Tensioner Cylinder Stroke Under Minimum.

Check the set parameters

F1005

Chain_Tensioner_out_of_try_limit

Chain Tensioner over Try Limit

Check the set parameters

F1006

Chain_Tensioner_out_of_time_limit

Specified time to reach required pressure on chain tensioner exceeded

Check the set parameters

Tab. 56: Anti Collision Fault ID

Error Message

Meaning

Fault Treatment

F1020

warning

Collision Warning.

Check canopies in travel path

F1021

one or more reed rods defect or other error

One or more reed rods faulty

Check PMC-R system

F1022

evaluation not possible

Calculation not possible

F1023

Communication CRC Fault

Checksum error in the PMC-R communication

Check cable, check interference

F1024

PMC-R Comms Fault

PMC-R Communication Fault

Check PMC-P, check PMC-R server

Doc. no.: 1999 001 043 BA 00

VESL 09

7.25

Error messages Tab. 57: LH Cutting Arm Fault Error Message

Meaning

Fault Treatment

F1101

LH_Arm_Movement_without_Request_Height

The cylinder responsible for the height setting of the LH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

F1102

LH_Arm_Movement_without_Request_infeed_left

The cylinder responsible for the LH positioning of the LH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

F1103

LH_Arm_Movement_without_Request_infeed_right

The cylinder responsible for the RH positioning of the LH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

Tab. 58: RH Cutting Arm Fault Fault ID

Error Message

Meaning

Fault Treatment

F1201

RH_Arm_Movement_without_Request_Height

The cylinder responsible for the height setting of the RH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

F1202

RH_Arm_Movement_without_Request_infeed_left

The cylinder responsible for the LH positioning of the RH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

F1203

RH_Arm_Movement_without_Request_infeed_right

The cylinder responsible for the RH positioning of the RH cutting arm was retracted or extended without the controller having sent a control command.

Please check the cylinder mechanically.

It was controlled directly at the valve Tolerance parameters were set too tight

7.26

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Error messages

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Tab. 59: Radio Controller Fault Fault ID

Error Message

Meaning

Fault Treatment

F1301

Radio_System_Radio_guard_lost

The Pempek radio controller is out of range or was switched off.

Reduce the distance to the receiver and eliminate any interference.

F1302

Radio_System_Radio_Comms_Fault

There is a communication problem between the radio controller's receiver and the Ethernet switch.

Check whether a connection exists.

Check whether the MAC address on the display is set correctly.

Check whether the switch functions correctly Restart the receiver

F1303

Radio_System_Radio_Config_Fault

Radio Controller Configured Incorrectly.

Using the documentation, check the configuration of the radio controller

F1304

Radio_System_Illegal_Handset

An unknown radio controller has communicated with the system. The serial number of the radio controller serves as a reference value

The Reset button in the Quick Access menu must be pressed.

The radio controller must be switched off.

F1305

Radio_System_Low_Battery

The battery level of the Pempek radio controller is too low.

Please recharge the battery or replace the radio controller

F1306

Radio_System_Deathman_Trip

The radio controller was subjected to excessive gravitation.

This indicates that the radio controller was dropped or that the operator fell together with the radio controller.

This is a safety function. If a machine operator falls or the radio controller is dropped, an emergency stop is triggered.

F1307

Radio_System_Stop_Pressed

The STOP button on the radio controller was pressed

The miner has been stopped. All miner functions have been stopped.

F1308

Radio_System_Receiver_Inactive

The radio link between the radio controller and receiver is interrupted.

Switch on the radio receiver

Doc. no.: 1999 001 043 BA 00

VESL 09

7.27

Error messages Tab. 60: Warning Device Fault Error Message

Meaning

Fault Treatment

F1321

Safety_PSW_HRM

Fault with the HRM siren actuator.

The exact fault specified can be seen in the suffix table

see suffix table

F1322

Safety_PSW_Head

Fault with the face siren actuator.

The exact fault specified can be seen in the suffix table

see suffix table

F1323

Safety_Emergency_Fast_Halt

Emergency Stop was Triggered

Fault disappears as soon as the cause of the emergency stop is eliminated.

F1324

Safety_Emergency_Stop_active

An Emergency Stop Switch at the Face Was Actuated

Identify and correct the cause of the emergency stop.

F1325

Safety_Signal_Light_Green

Fault with the signal light actuator.

The exact fault specified can be seen in the suffix table

see suffix table

F1326

Safety_Signal_Light_Yellow

Fault with the signal light actuator.

The exact fault specified can be seen in the suffix table

see suffix table

F1327

Safety_Signal_Light_Red

Fault with the signal light actuator.

The exact fault specified can be seen in the suffix table

see suffix table

F1328

Safety_Rotating_Beacon

Fault with the rotating beacon actuator.

The exact fault specified can be seen in the suffix table

Check the actuator and cables

7.28

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Error messages Tab. 61: Travel Drive Fault Error Message

Meaning

Fault Treatment

F1401

Haulage_System_Movment_without_Request

The machine moves at the face without the control system having issued an associated command.

Check the machine mechanically

F1402

Haulage_System_Haul_in_wrong_direction

Machine Moves in the Wrong Direction. For instance, movement to the right is requested, but the machine moves to the left instead.

Check the installation position of the encoder or the haulage motor

F1403

Haulage_System_Gateend_slow_down

The machine is at the end of the entry, the speed will be reduced there so that the machine comes to the end point slowly.

If the machine brakes prematurely, the face configuration is set incorrectly.

F1404

Haulage_System_Reference_Haul_necessary

Machine has lost its reference point to the entry and referencing is necessary

Specifying advance starts referencing, which then ends automatically at gate end.

F1405

Haulage_System_Encoder_incorrect_position

Encoder Value out of Tolerance Range.

Please check the set face length and reset the encoder position.

F1407

Haulage_System_Trailing_Cable_Over-tension

Fault with the trailing cable monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1408

Haulage_System_Axialpump_forward

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1409

Haulage_System_Axialpump_reverse

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1410

Haulage_System_PressureHaulage_forward

Fault with the oil pressure monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1411

Haulage_System_PressureHaulage_reverse

Fault with the oil pressure monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1412

Haulage_System_Tank_Temperature

Fault with the oil temperature monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1413

Haulage_System_Tank_Level

Fault with the oil level monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Doc. no.: 1999 001 043 BA 00

VESL 09

7.29

Error messages Error Message

Meaning

Fault Treatment

F1414

Haulage_System_Mud_Sensor

Fault with the oil contamination monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1415

Haulage_System_Endswitch_Conveyor2

Fault with the limit switch monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1416

Haulage_System_Endswitch_Conveyor1

Fault with the limit switch monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1417

Haulage_System_Endswitch_Head1

Fault with the limit switch monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1418

Haulage_System_Endswitch_Head2

Fault with the limit switch monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1419

Haulage_System_Endswitch_Missing

End switch was not actuated

Check that end switch functions properly.

F1420

Haulage_System_Chute_not_closed

Loading Chute on Drive Not Closed

Lower loading chute and check sensor.

F1421

Haulage_System_Parking_Brake_Valve

Fault with valve monitoring on hydraulic brake

see suffix table

F1422

Haulage_System_Parking_Brake_Pressure

Fault with pressure monitoring on hydraulic brake

see suffix table

F1423

Haulage_System_Parking_Brake_still_active

Fault in haulage system. Brake is active although a speed was requested

Check pressure value, check hydraulic system. Are there additional pressure monitoring faults?

7.30

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Error messages

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Tab. 62: Hydraulic System Fault Fault ID

Error Message

Meaning

Fault Treatment

F1501

Hydraulic_System_Spray_Bar

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1503

Hydraulic_System_LH_ArmInfeedLeft

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1504

Hydraulic_System_LH_ReedPosInfeedLeft

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1505

Hydraulic_System_LH_ArmInfeedRight

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1506

Hydraulic_System_LH_ReedPosInfeedRight

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1507

Hydraulic_System_LH_ArmHeight

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1508

Hydraulic_System_LH_ReedPosHeightLeft

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1509

Hydraulic_System_RH_ArmInfeedLeft

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1510

Hydraulic_System_RH_ReedPosInfeedLeft

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1511

Hydraulic_System_RH_ArmInfeedRight

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1512

Hydraulic_System_RH_ReedPosInfeedRight

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1513

Hydraulic_System_RH_ArmHeight

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Doc. no.: 1999 001 043 BA 00

VESL 09

7.31

Error messages Error Message

Meaning

Fault Treatment

F1514

Hydraulic_System_RH_ReedPosHeightLeft

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1516

Hydraulic_System_Valveblock_Pressure

Fault with valve block pressure monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1517

Hydraulic_System_Valve_direct_control_mode

Manual mode was activated for valve

Mode can be canceled by pressing the HAND button and the STOP button.

F1518

Hydraulic_System_LH_ReedPosHeightRight

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1519

Hydraulic_System_RH_ReedPosHeightRight

Fault with cylinder position monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Tab. 63: Water System Fault Fault ID

Error Message

Meaning

Fault Treatment

F1601

Water_System_LH_Drum_Water_Flow

Fault with the flow monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1602

Water_System_LH_Drum_Water_Temperature

Fault with the cooling water temperature monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1603

Water_System_RH_Drum_Water_Flow

Fault with the flow monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1604

Water_System_RH_Drum_Water_Temperature

Fault with the cooling water temperature monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1605

Water_System_Cooling_Water_Temperature

Fault with the flow monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1606

Water_System_Cooling_Water_Pressure

Fault with the cooling water pressure monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

7.32

Hard Rock Miner control

Error messages Error Message

Meaning

Fault Treatment

F1607

Water_System_Pump_Water_Flow

Fault with the flow monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1608

Water_System_Pump_Water_Temperature

Fault with the cooling water temperature monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1611

Water_System_OilCooler_Flow

Fault with the flow monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1612

Water_System_Hauhinco_Automode

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1613

Water_System_Hauhinco_Testmode

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1614

Water_System_Haunhinco_Fault

Fault with signal contact monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1620

Water_System_Valve_LH_Cutter

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1621

Water_System_Valve_RH_Cutter

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1622

Water_System_Valve_Hydraulics

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

F1623

Water_System_Valve_AFC

Fault with the valve control monitoring.

The exact fault specified can be seen in the suffix table

see suffix table

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Fault ID

Doc. no.: 1999 001 043 BA 00

VESL 09

7.33

Error messages

Error Message

Meaning

Fault Treatment

F1701

Control_System_Parameter_Plausibility

Error detected when checking the parameters. Setting a value of "0" for a parameter is not allowed. For instance, it is not possible to set the face length to "0".

Please check the parameters and set realistic values, note the parameter change log.

F1702

Control_System_Basis_PLC_Network

Connection to Network Card of Basis PLC Faulty

Check the network connection Check the basis PLC network card status

F1703

Control_System_COM_Basic_PLC

Connection to CPU of Basis PLC Faulty

Check the network connection Check the basis PLC status

F1704

Control_System_Cutter_Overload

Cutter Head Overcurrent. In the automatic mode, this situation reduces the feed rate

Feed rate has been reduced. Parameter for cut depth may need readjustment

F1705

Control_System_Reference_Fault

Fault with referencing. This fault can occur if the parameter for face length is incorrect.

Please check the face parameter, adjust if necessary and restart referencing.

Please check the encoder.

F1708

Control_System_Basic_PLC_not_in_run_mod e

The basis PLC is not ready for use or the connection is interrupted.

Check LED status of the basis PLC. Check the network connection. Restart basis PLC if necessary.

F1709

Control_System_Start_Points_without_position_set

Machine set to automatic mode without end switch on drive unit actuated.

Place machine in maintenance mode for drive unit

F1710

Control_System_Stalled_Motor_in_Face

Cutter heads are engaged and must be retracted from face before starting

Move the machine opposite the mining direction in accordance with set parameters (page 23).

F1711

Control_System_Control_Mode_Changed

Machine Mode was Changed

This fault disappears automatically after 5 seconds.

F1712

Control_System_Pump_not_started

A hydraulically powered machine function is being requested although the hydraulic pump is not active.

Start the pump

F1714

Control_System_wrong_arm_angle

Wrong positioning angle for the selected cutting direction.

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1715

Control_System_Arm_Movement_LH_Height

Arm Unable to Reach Set Height

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1716

Control_System_Arm_Movement_LH_Infeed

Arm Unable to Reach Set Infeed Position

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1717

Control_System_Arm_Movement_LH_Angle

Arm Unable to Reach Set Angle

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

7.34

Hard Rock Miner control

Caterpillar Global Mining Europe GmbH, Lünen 2016

Fault ID

E

Tab. 64: Control System Fault

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Error messages Fault ID

Error Message

Meaning

Fault Treatment

F1718

Control_System_Arm_Movement_RH_Height

Arm Unable to Reach Set Height

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1719

Control_System_Arm_Movement_RH_Infeed

Arm Unable to Reach Set Infeed Position

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1720

Control_System_Arm_Movement_RH_Angle

Arm Unable to Reach Set Angle

Check whether the end switch is actuated properly, no collision, arm is not moving in end region and reinitiate start sequence if necessary, check hydraulic system.

F1721

Control_System_AFC_start_without_Beltsystem

AFC start requested although belt system not running

Is the beam stage loader off? Switch it on.

Otherwise, check signal cables.

F1722

Control_System_AFC_stop_because_the_Beltsystem_stopped

AFC was stopped because belt system stopped

Start customer's belt system

F1723

Control_System_AFC_not_started_

AFC was not started

Start the AFC

F1724

Control_System_sppv_Manager_not_ready

Synchronization of parameters not completed

Restart system

F1725

Control_System_AFC_start_with_Chain_Tensioner_problem

Attempt was made to start the AFC although chain tensioner indicates a fault

Correct chain tensioner fault

Doc. no.: 1999 001 043 BA 00

VESL 09

7.35

Error messages Suffix Table Tab. 65: Suffix Table for Fault Description

Explanation

OK

no error

No-fault

PON

Power on delay

Power-on time delay

ROVR

Raw max limit check

Over raw maximum limit

RUVR

Raw min limit check

Under raw minimum limit

EOVR

Max over-range

Over maximum limit value as real quantity

UTRIP

HH level

Over fault upper limit

UALM

H level

Over alarm upper limit

EUDR

Min under-range

Under minimum limit value as real quantity

LTRIP

LL level

Under fault lower limit

LALM

L level

Under alarm lower limit

TO

CIOS comms timeout

Timeout in the CIOS communication

N/D

CIOS channel fault

CIOS channel fault

C/F

CIOS channel config

CIOS configuration error

S/C

Short Circuit

Short circuit

O/C

Open Circuit

Broken cable

E/F

Ground Fault (earthed)

Ground fault

DIS

Value inactive

Value inactive

TOFF

Fail to Turn Off

Power-off fault

TON

Fail to Turn On

Power-on fault

PERR

Dout Ext Supply Fail

External voltage supply fault

IOVR

Over Current

Overcurrent

N/F

Not fitted / used

Not installed

ROC

Raw over Current over limit

Check raw values

7.36

Caterpillar Global Mining Europe GmbH, Lünen 2016

E

Error Message

Hard Rock Miner control