DOWNLOAD PDF : CAT BUCYRUS CONTINUOUS MINER TX-944 OPERATION MANUAL (1)

BUCYRUS CONTINUOUS MINER TX-944 OPERATION MANUAL

AS PROVIDED BY: Cervis Inc. 330 Perry Highway Harmony, PA 16037 Phone (724) 452-3775 Fax(724) 452-3779

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INTRODUCTION This manual describes the operation and maintenance of the radio control system using the model TX-944 transmitter/endstation. Specific sections of this manual are used to explain each major component of the complete remote control system, their general operation, and a general trouble shooting section. Please read this manual in its entirety and become familiar with the systems operation before controlling energized equipment. Understanding the operational features of the system is REQUIRED for safe operation.

System Warning IF MALFUNCTIONS OCCUR IN ANY ASPECT OF THE TRANSMITTER OR RECEIVERS OPERATION DO NOT CONTINUE TO OPERATE; POWER DOWN THE SYSTEM AND RETURN IT TO THE FACTORY FOR INSPECTION AND REPAIR. WHEN THE SYSTEM IS IN USE IF ANY PART OF THE UNIT IS DAMAGED PHYSICALLY DISCONTINUE OPERATION AND RETURN IT TO THE FACTORY FOR INPECTION AND REPAIR. AT ANY TIME DURING USAGE OF THE TX-9XX / RX9XX SYSTEM ANY DAMAGE IS FOUND PHYSICALLY OR ELECTRONICALLY IT IS CRUCIAL FOR THE SAFETY OF THE OPERATOR AND OTHERS IN THE OPERATING AREA THAT THE SYSTEM IS NOT ALLOWED TO CONTINUE IN OPERATION.

SAFETY RECOMMENDATIONS Ghosting (gosting), v., 1. Unplanned movement, machines that use Computer Control Technology.

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

The recommendations are as follows: 1.

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

2.

2. Maintenance of the system is critical for safe operation. Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3.

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

Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field. When signs of moisture or water are observed in the control unit enclosure, the units must be immediately replaced.

4.

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

5.

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

6.

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

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

System Components The system consists of a transmitter/endstation and a receiver. The OEM completes the entire machine by adding electro/hydraulic interface components as well as relay/contactor hardware for the motor stop/start and/or machine shutdown.

Transmitter (TX-944) The TX-944 is a mobile hand operated transmitter for the radio control system. The enclosure is black polycarbonate and is rated to the specifications of a NEMA 4 enclosure. Inside the transmitter enclosure is the RF, CPU - Switch PCB, and an internal antenna. The radio frequency is modulated around a center frequency of 466.2500Mhz. Output power is approximately 20mW used in a pulsed operation.

Machine operations are hand operated via the 8 pushbuttons, 13 toggle switches, 2 tram

levers and a big red machine stop button. All functions on the transmitter are labeled clearly; at any time during operation if a label comes off or is covered with dust it is recommended for safe operation that it be replaced or cleaned before continuing operation. For operator feedback there are six LEDs are used to show BATTERY LIFE, ERROR, LINK REQUEST/SHUTDOWN, SWITCH ACTIVE/LOW BATTERY, TRAM ENABLE/INACTIVITY, and LINK ACKNOWLEDGE/COMMANDED POWER DOWN. Batteries are removable. Replacement batteries are removed and replaced via a compartment on the side of the transmitter. Only batteries that are approved by MSHA for use with this transmitter should be used.

ENDSTATION The endstation operation is accomplished by connecting the endstation cable to the bottom of the transmitter. The operation of the endstation will be exactly the same as the operation of the handheld in the transmitter mode. As soon as the transmitter is connected to the machine by using the endstation cable the system will use the endstation as the only source to control the machine. The endstation will now have full control of the receiver. If a transmitter and endstation are on at the same time the endstation will be in control because the MCU will have sensed a connection with an endstation. It will also exchange serial numbers with the endstation and will only respond with that transmitter.

RECEIVER/DECODER (RX-944) The RX-944 is a compact receiver for the remote control system. Inside the extruded shell are the PCBs used to receive the transmitted signal, decode and validate it, and repackage the data stream for transmission to the MCU via a rs232 serial link. There is a reference decal on the top of the unit that corresponds with drawing # 03115500 to aid in installation.. The receiver features 4 leds on the front to aid in the operation of the system. The antenna attachment is located on the face of the receiver and is for Structured Mining Systems P.N. # ANT-100.

OPERATIONAL SAFETY FEATURES

TRANSMITTER FEATURES:

1.) Switch Scan PWR Up- Each time the transmitter is switched on, all switches are scanned to ensure they are in an inactive state. The transmitter will send an error code to the MCU specifying which switch is not working In the event that more than one switch is stuck the MCU will display only one until it is corrected then it will display the next one affected. This will repeat until all switches are cleared. The transmitter can be shut down with the TX POWER OFF button or the MACHINE STOP BUTTON. 2.) Low Voltage Shutdown- Battery voltage is continuously monitored by an analog input channel of the micro-controller and the transmitter will shut itself down before the voltage decays to a value which could possibly affect proper microcontroller operation. The transmitter will display the cause of the shutdown by lighting the “low battery” led while shutting down and transmit low voltage

shutdown commands..

4.)

MACHINE STOP- This transmitter incorporates a distinctive large red button labeled OFF. Upon depressing this button a string of Power Down commands will be sent to the receiver and the machine will commence operation.

Activating the MACHINE STOP BUTTON will also trip the power center relay if set in the menu screen of the MCU.

5.)

Two Hand Start- Outputs which mandate additional safety consideration such as motor starts which require two-handed initiations. They usually include an enable button. Additionally, a time delay is incorporated such that both buttons must be held for a period of time before the function is enabled. The pump start will require that the enable button be pressed first then the pump start toggle switch be thrown.

6.) Inactivity Shutdown-All transmitters utilize an internal timer which is reset by the operation of any switch. If this timer expires then the transmitter and machine will shut down. The inactivity time is for the TX-944 is 5 minutes.

GENERAL OPERATION Note: Upon power-up, all transmitter functions must be OFF. This includes all latched functions. If any transmitter functions are engaged upon receiver power-up, the receiver will regard that transmitter as faulty and it will begin to send error information to the MCU to be put on the main display. These stuck button error messages will not be entered into the error log. Resetting all transmitter/endstation functions to idle position will reset this safety feature.

Startup Procedures: To begin, there are two different start-up procedures. The first is if the transmitter having either never before operated the miner or another transmitter previously had operated the miner. The second is if the transmitter was the last one to operate the miner.

If this is the first time that the transmitter is going to be used with the miner then it will have to be logged in using the umbilical cord.

The first time a transmitter is used with the machine or the first time the transmitter is used after another transmitter is used you must go through a “Teach Learn” sequence. The transmitter will have to be turned upside down and the port for plugging the umbilical cord will be visible on the bottom. It is easily recognizable by the silver cap on the end. See FIG 1.

FIG 1.

Remove the plug by unscrewing the black ring and plug the umbilical into it (See FIG 2.) then press the ON button

FIG 2.

. The left top led, UMB MSG, (umbilical messages) and the left bottom led, LINK REQ, (link request) will flash and then the, LINK ACK, (link acknowledge) will flash once for verifying that the serial number provided by the MCU is the same one as in it memory or twice for logging in it in memory as a new machine that it is connected to.

The description of the LEDs are discussed in the next section.

Once this process is done the handheld can be used as an endstation or unplugged from the machine and used as a transmitter. Since the machine unit holds only one serial

number (transmitter’s ID ) and the handhelds only hold one serial number at a time (machine unit’s ID ) They will only communicate with each other. If there is another handheld in the area it will not communicate with the machine but it might cause some interference such as a lower number of messages per second that the system is capable of operating.

If the transmitter is the last one that had been used with the miner then there is no need to go through the “teach learn” sequence again. The transmitter can now be turned on and operated normally.

The transmitter will not work as a “radio transmitter” without the silver plug attached and screwed into the bottom of the unit.

TRANSMITTER MODEL TX-944 LED DESCRIPTIONS

FIG 3.

BATTERY/UMB MSG – In transmitter mode, this LED will blink at a rate to give a general indication of the battery condition. A rapid blink indicates a relatively

full battery and a slow blink indicates a relatively weak battery. When approximately 8 hours of battery life remains, this LED will enter a different blink pattern. There will be two blinks followed by a longer pause and then two blinks again. This pattern will continue indicating that fresh batteries are needed. When in umbilical mode, this LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at 10 times per second.

ERROR – This LED indicates an internal error within the transmitter and it should be replaced. Note that all LED’s come on briefly during power up to prove that they are working. The ERROR LED on briefly at power up is normal.

When this LED is on after power up, the transmitter should be returned for repair.

LINK REQUEST/SHUTDOWN – When the transmitter is connected as an umbilical, it will attempt to LINK to the MCU (refer to TEACH/LEARN discussion). This LED will blink for each link request sent to the MCU. When the transmitter switches off, this LED serves a second purpose in that it indicates that a shutdown is in progress and power down messages are being sent to the MCU. At the same time, one of three other LED’s will indicate why the transmitter is powering down: Commanded (Operator initiated), Inactivity or Low Battery (see following paragraphs).

SWITCH ACTIVE/LOW BATTERY – After power up this LED is used to indicate a “stuck switch”. ALL switches must be in their neutral or safe position before the transmitter is allowed to become operational. If after power up (i.e. TX PWR ON depressed), this LED illuminates and stays illuminated (solid) then there is a “stuck” switch. In this condition, no other switches on the transmitter will be operational. The transmitter will send the error condition to the MCU and the system will display which switch is “stuck”. This switch must be replaced before proper operation will resume. After power up, any switch that is operated will result in this LED being solidly on while the switch is operated. In this manner, all switches can be verified locally at the transmitter. To see if the transmitter switch is being properly read, operate the switch and observe the SW ACTIVE LED. Note that only one switch will be indicated at any time as this LED is common for all switches. Also while in normal operation, certain switches are timed to maintain safety features, primarily two handed starts. If for example the ENABLE button is held down for more than 15 seconds, then the transmitter will enter an error mode. If this occurs then all command will cease to operate and an error code will be sent to the machine. To resume normal operation, the ENABLE button must be released. Switches that are timed in this manner are: a) ENABLE b) SHIFT c) TRAM ENABLE d) PUMP START e) CONV START

f) CONV REV g) CUTTER START

Note that in normal operation, all of these switches are held operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and other enabled functions unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly on switch.

Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a low battery condition.

TRAM ENABLE/INACTIVITY – This LED indicates that the tram levers are armed (active) and that any operation of the tram levers will result in machine movement.

Conversely, if this LED is off, then the tram levers are dead. Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was inactivity (no switch operation for 5 minutes).

LINK ACK/COMMANDED POWER DOWN – During the TEACH/LEARN process, this LED indicates that a link response (acknowledgement) has been received back at the transmitter from the MCU. If the transmitter was re-linked back to the same MCU (machine), then this LED will flash once. If this is a new link to a different MCU (machine), then this LED will flash twice. Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a commanded power down (operated initiated) as a result of the operator pressing either the MACHINE STOP mushroom head or the TX PWR OFF pushbutton.

CONVEYOR STOP: Moving the conveyor lever to the stop position will send a signal to stop the conveyor. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR START: This action will start the conveyor. This action requires the enable button to be pressed concurrently. This lever is momentary and does not have to be held in this position. The toggle switch will be scanned upon startup. If the switch is held for more than 15 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen.

FIRE: This action will start the fire suppression on the miner. The lever is momentary and does not have to be held in this position. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

LIGHTS: This action will activate and deactivate the lights. This function is latched function. It will turn on the lights when the toggle switch is pushed and released. If it is pushed again the light will be turned out. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

DUST OFF: This function will turn off the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

DUST ON: This function will turn on the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

FAN OFF: This action will turn off the fan (scrubber). This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

FAN ON: This action will turn on the fan (scrubber). . This action requires the enable button to be pressed concurrently. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

PUMP STOP: This function will turn off the pump. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

PUMP START: This function will start the pump. This action requires the enable button to be pressed before the lever is activated. This lever is momentary but has to be held in this position for half a second before the transmitter will transfer the command. The toggle switch will be scanned upon startup. If the switch is held for more than 15 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen CUTTER HEAD LOWER: This function will lower the

cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CUTTER HEAD RAISE: This function will raise the cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

GATHERING HEAD FLOAT: This function will allow the Gathering head to float.

This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

GATHERING HEAD RAISE: This function will raise the Gathering head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR SWING LEFT: This function will swing the conveyor to the left. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR SWING RIGHT: This function will swing the conveyor to the right.

This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR LOWER: This function will lower the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR RAISE: This function will raise the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

BREAKER RESET: This function will reset the breaker. . This action requires the enable button to be pressed concurrently. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

BREAKER ON: This function will turn on the breaker. . This action requires the enable button to be pressed concurrently. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

STAB LOWER: This function will lower the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

STAB RAISE: This function will raise the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner. This

switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAM ENABLE: This toggle switch whether pushed left or right will activate the tram enable on the transmitter. It will be active for 3 seconds until a tram lever is activated. If at the end of 3 seconds the trams are not activated the enable will go out and all tram activity will be disabled. The function will not engage until the tram levers are in the center position. The tram enable will also be reset if the pump start is activated. The tram enable is checked upon start up and if active at startup will cause an error to be displayed on the view screen. This toggle switch will generate an error if held on for more than 15 seconds and will send shutdown codes.

SHIFT: This button is yellow on the transmitter and will be used in conjunction with the lower right 6 toggle switches. On these switches are the functions that they will command. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

MSTOP OVERIDE: This button will override the machine stop button on the left side of the miner. This button should be held down while the pump is started and during tramming. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

ENABLE: The enable button will be used in conjunction with other switches. These switches will be marked with their function in green. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen. This toggle switch will generate an error if held on for more than 15 seconds and will send shutdown codes.

TX POWER ON: This push button is the “ON” button for the transmitter. This is the only function of this button TX POWER OFF: This button will turn off the transmitter. It will initiate a shutdown sequence that will shut off all pumps and put the machine in a safe state. It will transmit these command 20 times and then shut off the transmitter.

TRAM HIGH: This button will put the miner in high tram. The button is a latch function. This button will only put the miner in high tram. While in high tram pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAM LOW: This button will put the miner in low tram. The button is a latch function.

This button will only put the miner in low tram. While in low tram pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAMMING There are two tram levers on the transmitter. They each control one of the trams. See Fig 5. FIG 5.

TRAMMING Cont…

Before tramming can occur the hydraulic pump must be started. See PUMP START. Once this has been done then the Tram Enable must be pressed either to the left or the right.

The enable switch lever is the first lever to the right of the tram levers. See Fig 5.

The tram lever must be operated within approximately 3 seconds after the enable is activated or the function will timeout and the enable will have to be pressed again to activate the trams.

When the tram enable is active the tram enable light will be lit. See Fig 3 for location of this LED. There are 3 tramming speeds available to the operator. The first is SUMP. It is the lowest of speeds and is used while digging into the coal face. This speed will automatically be engaged when the miner comes into contact with the coal face. It will also be automatically selected when one tram is used alone or the trams are operated in different directions (“splitting the cats”). The miner will default on start up to the next speed, LOW TRAM speed. HIGH TRAM speed can be selected by pressing the high tram button on the transmitter.

The relationship between lever position and speed command can be seen on the view screen on the miner. The tram control signals from the transmitter can be seen in the lower left portion of the screen labeled TRACTION FT/MIN. See Fig below.

MACHINE DISPLAYS FOR VARIOUS ACTIONS On the miner itself there is a view screen that can be accessed by the operator of the transmitter. To navigate the menu system use the yellow shift button with the switches that have yellow labels. Refer to Fig 4 the Breaker Reset/on switch is also used to page up or page down in the menu system. Next to it, the Conveyor lower/raise switch is to change the value inside the menu. Up meaning to increase the value and down to decrease the value.

Following is a list of menus accessible by the operator of the transmitter in order that they occur on the miner. The default menu is Remote Runtime Status and is what the machine will display when started up.

This is the fault log screen. The machine will display faults and errors that occur during its operation. Only those faults that cause a motor to unintentionally shutdown will be logged into memory for later analysis. An example is if the miner is shut down when the MACHINE STOP Button is pressed it will be displayed here. If the miner stops because of an over temperature on the cutter motor then it will be displayed here and logged into flash memory.

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This menu is a graphical overview motor currents and motor temperatures. Also displayed is the temperature of the tram transformer. Also useful is the display of the machine voltage.

This menu is the default menu that is displayed when the miner is powered up. It will show currents and temperatures for all the motors graphically. In the upper right corner it will show the status of the transmitter. The green light is to show a valid command is being transmitted. The bar graph changes color depending whether they are high or low.

The battery voltage of the transmitter is shown. A Red battery text will indicate that the battery is very near empty. The battery should be changed if the battery text is red in color. The RF signal indicates the relative strength of the RF signal. A low signal does not mean that there is a loss of information transmitted to the miner. Remember, the signal is digital in nature and will either work or not work. So a low value for the strength will mean that the miner is approaching a point where signal loss can occur. This graphic can be used to tell if there is something wrong with the transmitter. If you hold the transmitter near the antenna and there is a low signal then you should investigate the antenna cabling first and then the transmitter should be checked for low power output.

Another diagnostic tool is messages/second. When there is an active command this number should be around 8 to 12. If the transmitter is idle for 1 second this will decrease to 4 to 7 messages/second to save battery life. If there is interference from another transmitter then this will decrease the number of valid packets (messages) from the transmitter and the number will be smaller.

This screen gives a detailed view of the pump motor and its history for one minute. The screen will display immediately the pump motor current and the temperature in the blue bars graphs. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This screen gives a detailed view of the fan motor and its history for one minute. The screen will display immediately the fan motor current in the blue bar graph. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

In this menu the left and the right cutting motors currents and temperatures will be displayed and the history for one minute.

The screen will display immediately the cutting motor currents and the temperatures in the blue bars graphs for each motor. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The right cutter motor will be colored green and the left motor will be colored blue.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This screen will display the CLA left and right motor status. The blue bar graphics will display the immediate values for the current and temperature. In the graphics area will be a one minute history of the motor currents. The current will be shown from right to left, the right most side of the screen will be the most recent measurements. The right CLA motor will be colored green and the left motor will be colored blue.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

In this menu the tram motor status will be displayed. The currents and the voltages for the left and right motors will be displayed as blue bars for the immediate values. A 1 minute history will be displayed for the voltage and the current for each motor. The left motor current will be blue. The left motor voltage will be red. The right current will be displayed in green. And the right voltage will be displayed in pink.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This is page one of four screens that display input/output status.

This is screen two of four status screens. As you can see the transmitter was communicating with the miner as the transmitter active status light was lit. Also note that in the upper right hand corner the battery voltage value was being sent. The receiver was measuring a moderate rf signal, no trams were active and no active command was being sent. The transmitter will always communicate with the miner even though there is no active command being sent.

This is page three of the status pages.

This is page four of four status pages. These status lights can be used to diagnose a fault in the machine if needed. If a status light is on because a command has been sent by the transmitter then you know that the transmitter is ok. You know the receiver is ok and the computer inside the miner is getting the command. Next look downstream from the computer for a fault in the wiring or a bad component.

This page will be for helpful hints in running the machine. It is not finished yet.

This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. When the operator presses the Machine Stop button on the transmitter the value that this screen contains will decide if the power center relay will trip or not. This screen is accessible by using the IR pendent.

This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. The tilt sensor always sends the signal to the MCU but is only acted upon if this menu item is set. This screen is accessible by using the IR pendent.

This menu shows what happens when the tram levers are not in the center position when the transmitter is turned on. The error in red states the first error the transmitter sees in itself. It is saying that the left tram lever is stuck . With all error conditions such as stuck buttons on power up and stuck motor function switches and enables the transmitter will only send these error codes and can not be used until all errors are cleared.

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This menu shows what happens when the pump start toggle is held in the start position.

The error is sent and visible on the screen.

Reading the Led Indicators Left to Right

POWER DOWN EVENTS There are currently four types of shut down modes for the RX-944 receiver. They are a “commanded power down”, “low battery shutdown.”, “inactivity shutdown”, and “loss of signal”. They are two separate and distinct ways of shutting down remote control operations.

Loss of Communication, Low Battery and Inactivity Power Down: A loss of communication power down is not initiated, but occurs due to a loss of communication between the transmitter and receiver for 2 sec. Typically, this occurs when a battery is weak, circuit malfunction occurs, the transmitter is out of range, or the antenna is being blocked or has a broken connection affecting the transmitter range.

When the receiver sees a loss of communication, a two-part power down occurs. After

one second the receiver will: 1.) Clear all non-latched outputs( Front/Rear Cylinders, and Tram commands) 2.) Set the power down bit in the Allen Bradley serial message (if a PLC is installed) 3.) Clear all outputs to OFF, Removing power from PUMP MOTOR. 4.) Wait for 2 sec. For power to be removed. If this does not occur, the receiver will return to a search condition and wait for a transmitter to turn ON. A low battery shutdown will display on the machine screen that the reason for shutting down was due to low battery voltage.

After 5 minutes the transmitter will auto shutoff. This will include shutdown messages sent to the MCU to turn off motor and hydraulic functions.

Commanded: A commanded power down is initiated by pressing the stop button on the handheld. It can also be shut down by pressing the machine stop button. The hand held will start and send 20 power down commands and then shut off. If in the menu system page “Machine Stop Shutdown Function”, the power center trip value is set then the command will be sent to trip the power center relay.

BATTERIES

One of the most beneficial features of the new transmitter style is its power design. The TX-9XX has a continuous operational life of approx. 120 hours. The power source is two 9 volt batteries. A BAT LED monitors battery life. A fast flashing LED means that battery strength is good. A slow flashing light means that the batteries are more than half used up. A double blink – pause- double blink LED means the batteries need to be changed (approx. 8 hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When the LED double blinks the batteries should be replaced. The battery compartment is polarized so the batteries can be inserted but the contact will only be made with the batteries in the correct orientation. Inside the compartment one contact is larger than the other corresponding to the larger contact on the battery. The battery compartment door should be closed with the screws finger tight.

RECEIVER FEATURES: 1.) Redundant Watchdog- The receiver incorporates the internal watchdog as described for the transmitter. In addition the receiver circuits include an external hardware based watchdog circuit to reset all outputs in the event of a microcontroller failure. This circuit is redundant to the internal watchdog and monitors the constant toggling of a dedicated I/O pin. Steady state values on the I/O pin, either low or high, will trip the external watchdog and reset

the receiver.

Note: Any time during operations that communications are lost between the transmitter and the receiver all outputs of the receiver will be cleared and it will begin scanning for the transmitter that contains the last serial number that was connected to it.

RADIO RECEIVER MODEL RX-944 LED DISCRIPTIONS

1 – Watchdog, blinks once per second to indicate that power has been applied and than internal processor is alive and working.

2 – Pre-Amble Detect, blinks to indicate that transmitter on the correct frequency has been detected. This LED should blink approximately 10 times per second as soon as a transmitter is switched on in the vicinity of the machine.

3 – Valid Message, blinks to indicate that valid messages from a transmitter on the correct frequency are being received. Note: This does NOT mean that the transmitter is the serial number that has been “TAUGHT” to the Machine Control Unit. All transmitter messages that pass the CRC tests are passed to the MCU for evaluation.

4 – Link LED, indicates that a sufficient number of messages are being received to qualify as a “link” and the system should not drop out.

Led’s 5 through 8 are for future use

WARNING! FAILURE TO READ THIS BEFORE INSTALLATION CAN RESULT IN INJURY OR DEATH. It is the responsibility of the installation technician to read and understand the following prior to installing and RX944. It is crucial that during installation of any RX-944 the mode be unique to any other receiver in the area. At the time of installation a definitive check on the modes of all receivers in the area must occur. Note the modes of each receiver and select a mode that is unique for the installation. Failure to do so may result in two receivers accepting signals from one transmitter. Two machines would be controlled by one transmitter resulting in unwanted movement. This is essential to ensure safe operation.

BELOW IS MSHA PROGRAM INFORMATION BULLETIN P03-03 RECOMMENDED DESIGN SAFEGUARDS FOR PERMISSIBLE REMOTE CONTROLLED MINING MACHINE U.S. Department of Labor

Mine Safety and Health Administration 1100 Wilson Boulevard Arlington, Virginia 22209-3939

ISSUE DATE: FEBRUARY 25, 2003

PROGRAM INFORMATION BULLETIN NO. P03-3

FROM:

MARK E. SKILES Director of Technical Support

RAY McKINNEY

Administrator for

Coal Mine Safety and Health

ROBERT M. FRIEND Administrator for

Metal and Nonmetal Mine Safety and Health SUBJECT: Recommended Design Safeguards for Permissible Remote Controlled Continuous Mining Machines Who needs to have this information?

Operators of underground coal or gassy metal and nonmetal mines, manufacturers of remote controllers and remote controlled continuous mining machines, Mine Safety and Health Administration (MSHA) enforcement personnel, miners' representatives, state mining agencies, and other interested parties need this information.

What equipment is affected by this bulletin?

This Program Information Bulletin (PIB) applies to new designs of permissible remote controlled continuous mining machines approved under Title 30 of the Code of Federal Regulations (30 CFR), Part 18 and to existing approved equipment in use in the mines as well. It applies to remote controllers that are portable and hand carried, or worn on the operator's body, to remotely control continuous mining machines from a location off the machine but in close proximity to and in visual and audible range of the machine being controlled. It is applicable to remote control systems using radio, infra-red or direct tethered electrical connection methods.

What is the purpose of this bulletin?

The purpose of this bulletin is to inform the mining industry of recommended safety design features for remote controlled continuous mining machines. These recommendations could help reduce the number of accidents resulting from the use of such equipment. This bulletin recommends safety design features for the following functions: .(1) Remote Emergency Stop Devices, located on remote controllers, that initiate an emergency shutdown function on remote controlled continuous mining machines; .(2) Prevention of accidental activation of machine tramming functions; and .(3) Reduction of the machine slew rate when the tram controls are split or singularly activated.

What is the background for this bulletin?

A review of thirteen fatal accidents involving the use of remote controlled continuous mining machines since 1988 reveals that two of these accidents were associated with the accessibility of the remote emergency stop device. Three accidents involved the bypassing of mechanical interlock safety devices on tram controls and eight accidents involved accidental activation of the tram controls.

Concerns With the Design of Remote Emergency Stop Devices In one accident, a remote controlled continuous mining machine operator was fatally injured when he was crushed between the continuous mining machine and coal rib. The remote controller did not have an emergency stop device that was readily accessible in the event of an emergency. In another accident, a maintenance helper sustained fatal crushing injuries when he became trapped between the conveyor boom and the mine roof. The chain conveyor became activated due to an electrical short inside the remote controller. The availability of a readily accessible emergency stop device may have saved the victim's life.

Good ergonomic design for a remote emergency stop device allows the device to be quickly and easily activated in an emergency. The device should be readily accessible, prominently located, and clearly differentiated from other controls. Existing emergency stop devices do not consistently utilize these design features, and as a result, confusion and delays in activating the device in an emergency situation can occur.

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Concerns With Bypassing Mechanical Interlock Safety Devices on Tram Controls There have been three fatal "caught-between" type accidents where the mechanical interlocks on the remote controller tram controls were defeated by the use of tape, thereby bypassing protection against accidental activation. Taping the interlocks was identified as a contributing factor to all three accidents.

PIBs P97-31, P98-19, and P00-14 were issued to emphasize the importance of the mechanical interlocks and warn of the safety hazards associated with bypassing this safety feature. The use of same-hand activated mechanical release devices on tram controls proved to be inconvenient and difficult to operate over a working shift and are often bypassed by machine operators. These devices have not proven to be an effective means for preventing accidental activation.

Concerns With Accidental Tram Control Activation A review of accident data identified eight reported accidents (fatal or nonfatal) involving accidental tram control activation on remote controlled continuous mining machines. Of these eight accidents, four (including one fatal) have been attributed to a cable falling across the remote controller while it was left unattended, causing the tram controls to be activated. The other four were attributed to unintentional body contact. The need to prevent accidental tram control activation is recognized and has been addressed in most designs. However, all designs should incorporate these safety features to prevent accidental activation of the tram controls.

Accident analysis has also identified the need for limiting the maximum slew rate of the machine under tram control settings that produce a pivoting action of the machine.

Limiting the slew rate under these conditions has the potential to reduce pinning hazards to operators unintentionally positioned at machine pinch points.

What is being recommended through this bulletin?

MSHA recommends certain design safeguards and training: I. Design SafeguardsEquipment manufacturers should implement the design safeguards in all new designs. MSHA also recommends that manufacturers of existing approved remote controllers and remote controlled continuous mining machines currently in use modify their equipment, to the extent possible, to include the recommended safeguards.

Design changes should be submitted for MSHA approval under 30 CFR, Part 18. Field testing of remote controlled equipment is recommended before a design is finalized and submitted for approval. MSHA's Experimental Permit Program may be used to allow field testing.

MSHA recommends that the following design features be addressed: Remote Emergency Stop Device The remote controller should be equipped with a remote emergency stop device that: (1) Overrides all other machine controls; (2) Removes power from machine movement actuators; and (3) Causes all moving parts to stop within the shortest possible time. Resetting of remote emergency stop devices requiring manual reset, or release of momentary action remote emergency stop devices, should not cause any function of the machine to operate.

In mines utilizing extended cuts, the emergency stop device should cause the

circuit breaker at the power center to trip rather than the onboard machine circuit breaker, if a circuit breaker is used for removing power from machine movement actuators.

The remote emergency stop device should be: .(1) Differentiated from other controls by size (larger) or shape; .(2) Located in a readily accessible, prominent location in the operator's direct field of vision on the remote controller's main control panel; .(3) Colored red; .(4) Activated by a pushing action perpendicular to the controller's main control panel surface. Note: For example, a red, mushroom-head shaped switch actuator, may be used for this purpose, but other designs meeting the general recommendation could be used.

The remote emergency stop device should be clearly labeled "Emergency Stop," and should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block its activation. Ready access to the remote emergency stop device should not be hindered by the proximity of other controls or by mechanical guards. The design should consider the need for additional spacing when gloves are worn.

Operation of the remote emergency stop device should be tested during the machine preoperational checks.

Accidental Tram Activation Protection All control devices, such as buttons, levers and joysticks, used for controlling the tramming function of remote controlled machinery, should be designed such that the tramming function stops when the device is released.

The remote controller actuating controls for the machine tram function should be designed to reduce the likelihood of unintentional activation. Tramming functions can be activated when cables or other material fall on the controls, or with unintentional hand or body contact. Recessed selector switches, shrouded selector switches, deadman control, two-hand control, or sequential two-switch operation such as use of a tram function enable switch should be used. These safety features should be ergonomically designed, tamper-resistant, and not interfere with the normal operation of the mining equipment.

When sequential two-switch operation (tram enable switch) is used, a tram function inactivity timer should be provided to disable the tram function if the tram controls are not activated within a pre-programmed time period. The tram function inactivity timer should be set as low as reasonably practicable, consistent with convenient machine operation. Five seconds is the recommended maximum inactivity timer setting.

The controls actuating the machine tramming function should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block their activation or movement. Note: The use of rubber boots or other effective means could be used for this purpose.

The use of same-hand activated mechanical release devices on tram controls, such as lift-to-operate mechanical interlocks on tram control levers, should be eliminated. Note: Safeguarding devices that impede convenient operation and that prove to be tiring over a working shift are often bypassed by operators.

The use of a "global" guarding method, such as a raised guard rail surrounding all the switches on the control panel, is not a recommended method for preventing accidental tram control activation when used as the only prevention method. Note: This guarding method does not provide adequate protection against accidental activation by cables of various sizes or other foreign objects and may result in accidental control activation when using the guardrail as a carrying handle. Attention must be paid in the design to ensure that the use of any mechanical guarding methods does not hinder activation of the remote emergency stop device.

Machine Slew Rate Control Remote controlled machinery utilizing a machine tramming function should be equipped with control circuits that reduce the machine rotational slew rate when the tram controls are set with one control forward and one control reverse (split cat) or a single control forward or reverse (hard turn) position. When the tram controls are split or set in a hard turn position, the tram speed of the activated drive(s) should be limited to no greater than the slowest operational tram speed provided on the machine, in order to minimize the slew rate (rotational speed) of the machine.

The slew rate of the machine needs to be minimized to obtain a pivoting action of the machine that reduces potential "caught-between" type hazards to machine operators inadvertently positioned at machine pinch points.

II. TrainingMSHA recommends that mine operators establish safe work practices and provide training for personnel addressing the safe operation and maintenance of remote controllers and remote controlled continuous mining machines. The training should address all danger areas applicable to specific machines and mining operations. Particular emphasis needs to be placed on the machine operator's and maintenance personnel's position when working near energized machines. Machine operators should be trained to check that safety features on remote controllers are operating properly and are not defeated. In addition, MSHA urges mine operators to regularly ensure that established safe work practices are being followed.

What is the authority for this bulletin?

Title 30 Code of Federal Regulations, Section 18.20(b), 57.12002, and 75.520.

Is this program information bulletin on the Internet?

This bulletin may be viewed on the World Wide Web by accessing the MSHA home page (http://www.msha.gov) and then choosing "Statutory and Regulatory Information" and "Compliance Assistance Information."

Who are the MSHA contact persons for this program information bulletin?

Coal Mine Safety and Health, Safety Division Erik Sherer, (202) 693-9523 E-mail: Sherer.Erik@dol.gov Metal and Nonmetal Mine Safety and Health, Safety Division Thomas Loyd, (202) 693-9645 E-mail: Loyd.Thomas@dol.gov

Technical Support, Approval and Certification Center David C. Chirdon, (304) 547-2026 E-mail: Chirdon.David@dol.gov Who will receive this program information bulletin?

MSHA Program Policy Manual Holders Underground Mine Operators Equipment Manufacturers Special Interest Groups Miners' Representatives Repair and Rebuild Facilities

Coal Mine Safety and Health The Red Zone

IT HURTS TO BE IN THE “RED ZONE” Entering the “RED ZONE” continues to result in mine fatalities and injuries. A recent non-fatal roof fall accident occurred that resulted in injuries to two miners who were working in the “RED ZONE”. The miners were loading supplies onto the roof bolting machine from a battery scoop. The roof bolting machine was positioned at the mouth of an unbolted right crosscut and the scoop was positioned to the right-rear of the bolting machine with the bucket extending into the “RED ZONE”. The miners were in front of the bucket, between the first and second row of roof bolts, moving supplies to the roof bolting machine when the roof material fell. Draw rock fell along the right rib of the

unsupported area and extended into where the men were working, striking and injuring both miners. Fortunately, the injuries were not life threatening.

Best practices to prevent such an accident from re-occurring include moving the roof bolting machine and the scoop to a safe area outby the newly developed crosscut. This would prevent the miners exposure to the hazards created by working close to the unsupported area or the need to perform work in the “RED ZONE”.

Please take time to re-instruct all miners as to the location of the “RED ZONE” as shown in your mine’s approved roof control plan. Working in the “RED ZONE” is not much different from working in an unsupported area. Roof material that begins to fall in the unbolted area doesn’t always stop at the first row of roof bolts. When that happens, it hurts to be in the “RED ZONE”.

Remote Control System for Continuous Miners

Troubleshooting Guide

Bucyrus America Inc. 2045 West Pike Street Houston PA 15342-1010

PUBLICATION DISCLAIMER AND COPYRIGHT

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

document with respect to changes subsequently made.

BUCYRUS makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability of fitness for purpose shall apply.

GENERAL SAFETY NOTICES

This section addresses some general safety guidelines involved with BUCYRUS products. These guidelines are intended to promote safe usage of equipment.

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

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

WARNING: If malfunctions occur in any aspect to the transmitter or receiver operation do not continue to operate; power down the system, fill out the service tag, and return it to the factory for inspection and repair. When the system is in use and if any part of the unit is damaged physically, discontinue operation and return it to the factory for inspection and repair. At anytime during usage of the system any damage is found physically or electronically, it is crucial for the safety of

the operator and others in the operating area that the system is not allowed to continue in operation.

SAFETY RECOMMENDATIONS Ghosting (gosting), v., 1: Unplanned movement by machines that use Computer Control Technology.

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

The recommendations are as follows: 1.

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

2.

2. Maintenance of the system is critical for safe operation. Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3.

3. Mine personnel should be made aware that the entry of moisture or water into the transmitter or umbilical enclosure could cause undesired machine movements. Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field.

When signs of moisture or water are observed in the control unit enclosure, the units must be immediately replaced.

4.

4. Any abnormal operational sequences of the system, alarm displays, or unintended machine movement which might be due to a software

programming error should be noted, reported to the manufacturer, and corrected immediately.

5.

5. Any equipment removed to correct “ghosting” problems should be sent to the manufacturer to determine the exact cause of the problem.

Corrective action will then be taken by either the manufacturer or the operator to prevent similar occurrences.

6.

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

These recommendations, though originally made in response to the unplanned movement of longwall shield advance systems utilizing computer control technology, are equally applicable to all equipment with machine control circuits utilizing computer control technology.

The recommendations above should be followed on a continuing basis on all machines utilizing computer control technology.

MANUAL

CONTENTS

Table of Contents Please read the important information contained in the previous section titled GENERAL SAFETY NOTICES. Section/Paragraph Page

SECTION 1. HOW ..........................1

TO

TROUBLESHOOT

SECTION 2.

SYSTEM ..............................................3

STATUS

THIS

SYSTEM

INDICATORS

2.1 Introduction.................................................................................................. .3

2.2 Status LED ......................................................3 2.3

Functional

Status

Categorization

LED

Response

Analysis....................................................................6 SECTION

3.

ALARMS,

WARNINGS,

AND

DISPLAY

INFORMATION..21

3.1

Coded

Alarms

and

Warnings

....................................................................22 3.1.1

Alarm

Codes

...........................................................................................22

3.1.2

Warning

Codes

.......................................................................................24 3.2

Informational

Messages

.............................................................................29 SECTION

4.

..........................................31

COMPONENT

IDENTIFICATION

4.1

Remote

Control

System

Components

.......................................................31

4.2

Remote

Control

System

Components

Tie-

in............................................31

List of Tables Table Page Table 2.1 MCU944 LED Functional Categories ......................................................5 Table 2.2a MCU944 Status LED Response Analysis (R1 & R2) ............................6 Table 2.2b MCU944 Status LED Response Analysis (R3 & R4) ............................7 Table 2.2c MCU944 Status LED Response Analysis (R5 & R6) ............................8 Table 2.2d MCU944 Status LED Response Analysis (R11 & R12) ........................9 Table 2.2e MCU944 Status LED Response Analysis (R13 & R14) ......................11 Table 2.2f MCU944 Status LED Response Analysis (R15 to R20).......................11 Table 2.2g MCU944 Status LED Response Analysis (R21 & R22) ......................12 Table 2.3 TX944 Status LED Response Analysis ..................................................13 Table 2.4 RX944 Status LED Response Analysis ..................................................17 Table 2.5 CPS944 Status LED Response Analysis ................................................18 Table 2.6 DCD100 Status LED Response Analysis ...............................................19 Table 3.1 Display Screen Top Banner General

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