DOWNLOAD PDF : Cat Super Simpson Control System Fault Codes Troubleshooting Guide Manual A6474X472

BI016801 A6474X472 February 2013

Troubleshooting Guide Super Simpson Control System Fault Codes A6474X472 (1565916)

SAFETY.CAT.COM

BI016801

__________________________________________________________ This manual is intended to provide troubleshooting information for the Super Simpson Control System . The illustrations, descriptions and procedures contained in this publication apply only to THIS system.

Caterpillar reserves the right to revise models and designs without prior notice.

This Super Simpson Control System was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of the manufacturing process, this unit was issued any required approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar’ s instructions, may invalidate these approvals and render this unit unsafe to operate.

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

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

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

© CATERPILLAR 2013 ALL RIGHTS RESERVED

BI016801

_________________________________________________Table of contents

Table of contents Message conventions........................................................................ 2 Error Messages ................................................................................. 3 Fault Messages ................................................................................. 43

________________________________________________________________ A6474X472

Rev 0

BI016801

Operation _______________________________________________________ The Super Simpson control system is a radio remote control and monitoring system for continuous miners. The system allows the operator to remotely control machine operation from a safe distance using a radio remote control console.

This manual provides troubleshooting information for the system. For actual controller operation, please see the Super Simpson Operation Manual, document number A6474X364 and the Super Simpson Display Manual, document A6474X362.

Message convention The control system will issue system halt, warning, and fault messages.

System halt message A system halt message appears when a condition occurs that prevents continued operation of the machine in a safe manner. The message will be displayed in the middle of the screen and cannot be cleared. The power to the control system must be recycled before the machine can be operated.

Error message An error message indicates a warning condition that is currently active but does not necessarily shut down the machine. These messages are set and cleared by the control system in real time but are logged in the control system fault log.

During normal operations, error messages are normally only displayed on the main page of the graphics display screen. Error messages are number less than 300. Error messages are listed in Table 1.

Fault message A fault message indicates a condition that either causes a motor or function to shut down or prevents a motor or function from starting. Fault messages occur in a pop-up window over the active screen and must be cleared by the operator.

Fault messages are listed in Table 2.

There is an Auto Fault Clear option in the menu that is set to YES or NO (default is YES). When set to YES, the next key stroke on the radio remote clears the fault message. When set to NO, the operator must use the SHIFT and RESUME keys on the radio remote to clear the fault.

The last fault of the power up session, even if cleared, is displayed in red text in the status box on the main screen. Fault messages are logged in the control system fault log and are number greater than 300.

________________________________________________________________ 2 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1: Error messages Fault number 0001 SOLENOID BOARD COMMS FAIL Either an internal or a communications failure of the solenoid board 0002 RELAY BOARD COMMS FAILURE Either an internal or a communications failure of the relay board 0003 THERMISTOR MODULE COMMS FAILURE Either an internal or a communications failure of the thermistor module (L0H9)

Possible cause

Checks to carry out

 Failure of 485 bus wiring to the board

 Replace the machine controller(L0Q6)

 Internal failure of the solenoid board  Failure of 485 bus wiring to the board  Internal failure of the solenoid board

 Replace the machine controller (L0Q6)

 Loss of 12VAC power to the A16 con-  Check the 12VAC supply to the nector on the module

 Failure of CAN bus wiring to module  Short circuit or open circuit of daisy chain cable that connects to A2 socket on the module

 Internal failure of the thermistor mod-

A6 connector module

 Check all modules are properly connected to the daisy chain module

 Check that there are no short circuits of the CAN bus wiring

 Replace the module (L0LH09)

ule 0004 REMOTE CONSOLE LOW BATTERY WARNING

 Remote has not been charged  Battery needs replaced

The remote console has reported a low battery.

 Charge the remote for at least 5 hours.

 Check voltage level of the remote battery.

0005 VOLTAGE TRANSDUCER FAILURE

 Supply to transducer (24VDC) is not

Signal from the voltage transducer not healthy (healthy level is between 4mA and 20mA).

 Broken or short-circuit signal wire

present

from transducer to the Super Simpson

 Check 24VDC is present at the transducer

 Check signal line from transducer to the Super Simpson

 Internal transducer failure

 Replace the transducer

 Internal failure of the Super Simpson

 Replace the Super Simpson (if signal > 4mA from transducer

0006 PUMP MOTOR MATE FAILURE (A)

 Loss of 24VDC supply to the motor

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal lines have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate)

_______________________________________________________________ A6474X472 Rev 0 3

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

0007 PUMP MOTOR MATE FAILURE (B)

 Loss of 24VDC supply to the motor

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal line have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the Motor Mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate) 0008 PUMP MOTOR MATE FAILURE (C)

 Loss of 24VDC supply to the motor

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal line have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the Motor Mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0009 LEFT CUTTER MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate) 0010 LEFT CUTTER MOTOR MATE FAILURE (B) Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate) ________________________________________________________________ 4 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0011 LEFT CUTTER MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Possible cause

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate) 0012 RIGHT CUTTER MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate)

0013 RIGHT CUTTER MOTOR MATE FAILURE (B) Phase B from motor mate not healthy (between 4 and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to the Motor Mate)

_______________________________________________________________ A6474X472 Rev 0 5

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0014 RIGHT CUTTER MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Possible cause

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0015 LEFT CONVEYOR MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0016 LEFT CONVEYOR MOTOR MATE FAILURE (B) Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0017 LEFT CONVEYOR MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to

________________________________________________________________ 6 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0018 RIGHT CONVEYOR MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

Possible cause

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0019 RIGHT CONVEYOR MOTOR MATE FAILURE (B) Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0020 RIGHT CONVEYOR MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0021 FAN MOTOR MATE FAILURE (A)

 Loss of 24VDC supply to the motor

Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal lines have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to

_______________________________________________________________ A6474X472 Rev 0 7

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

0022 FAN MOTOR MATE FAILURE (B)

 Loss of 24VDC supply to the motor

Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal lines have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0023 FAN MOTOR MATE FAILURE (C)

 Loss of 24VDC supply to the motor

Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

 One or more signal lines have gone

mate

open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0024 LEFT TRAM MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0025 LEFT TRAM MOTOR MATE FAILURE (B) Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to

________________________________________________________________ 8 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0026 LEFT TRAM MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

Possible cause

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

Checks to carry out

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0027 RIGHT TRAM MOTOR MATE FAILURE (A) Phase A from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0028 RIGHT TRAM MOTOR MATE FAILURE (B) Phase B from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to 0029 RIGHT TRAM MOTOR MATE FAILURE (C) Phase C from motor mate is not healthy (healthy is between 4 mA and 20mA)

 Loss of 24VDC supply to the motor mate

 One or more signal lines have gone open circuit

 One or more signal lines have been shorted

 Motor mate is faulty

 Check 24 VDC supply wiring is OK (+24 VDC line is provided by output pin X4-DD)

 Check that each signal line is not open or short circuit

 Replace the motor mate  Replace the Super Simpson

 Super Simpson is faulty (interface to

_______________________________________________________________ A6474X472 Rev 0 9

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0030 LOW MACHINE VOLTAGE LEVEL Machine voltage reading has fallen below operational level

Possible cause

Checks to carry out

 Transducer failure

 Check transducer wiring

 Bad connection between machine

 Verify voltage supply to transducer

and power center

input

 Check connection with power center 0031 HIGH MACHINE VOLTAGE LEVEL Machine voltage is above acceptable level

 Transducer failure

 Check transducer wiring

 Bad connection between machine

 Verify voltage supply to transducer

and power center

input

 Check connection with power center 0032 SOLENOID BOARD SUPPLY VOLTAGE LEVEL LOW

 Broken wire for 110VDC input  Internal failure on solenoid board

Solenoid board is reporting loss of voltage

 Check 110VDC supply to solenoid board

 Check 110VDC being generated from power supply

 Replace the Super Simpson 0033 SOLENOID BOARD SUPPLY VOLTAGE LEVEL HIGH Solenoid board is reporting dangerously high voltage level 0034 PUMP THERMAL OVERLOAD The motor has been operated at a current level above the recommended FLA.

 Supply voltage to the power supply is very high

 Verify input voltage level to power supply is very high

 Internal failure on solenoid board

 Replace Super Simpson

 The motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

 Super Simpson is faulty

actual operating current

 Replace pump motor, motor mate or Super Simpson

0035 PUMP MOTOR RTD THERMAL TRIP Motor thermistor is reading over allowed operating temperature

 Motor is damaged

 Check thermistor circuit resistance

 Motor thermistor is faulty

and verify that thermistor module is correctly reporting that value

 Thermistor module is faulty

 Check if thermistor reading is rapidly fluctuating, if so thermistor is damaged or there is noise in the circuit

 Replace thermistor module 0036  The motor is faulty LEFT CUTTER THERMAL OVERLOAD The motor has been operated at a current level above the recommended FLA.

 Motor mate is faulty  Super Simpson is faulty

 Verify actual operating current  Check that motor mate is reporting actual operating current

 Replace pump motor, motor mate or Super Simpson

________________________________________________________________ 10 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0037 LEFT CUTTER MOTOR RTD THERMAL TRIP

Possible cause

 Motor is damaged  Motor thermistor is faulty

Motor thermistor is reading over allowed  Thermistor module is faulty operating temperature

Checks to carry out

 Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

 Check if thermistor reading is rapidly fluctuating, if so thermistor is damaged or there is noise in the circuit

0038 RIGHT CUTTER THERMAL OVERLOAD

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

Motor has been operated at a current level above the recommended FLA

 Super Simpson is faulty

actual operating current

 Replace pump motor, motor mate, or controller

0039 RIGHT CUTTER MOTOR RTD THERMAL TRIP

 Motor is damaged  Motor thermistor is faulty

Motor thermistor is reading over allowed  Thermistor module if faulty operating temperature

 Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

 Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

 Replace thermistor module 0040 LEFT CONVEYOR THERMAL OVERLOAD

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

Motor has been operated at a current level above the recommended FLA

 Super Simpson is faulty

actual operating current

 Replace pump motor, motor mate, or controller

0041 LEFT CONVEYOR MOTOR RTD THERMAL TRIP

Motor thermistor is reading over allowed operating temperature

 Motor is damaged

 Check thermistor circuit resistance

 Motor thermistor is faulty

and verify that thermistor module is correctly reporting that value

 Thermistor module if faulty

 Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

 Replace thermistor module 0042 RIGHT CONVEYOR THERMAL OVERLOAD

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

Motor has been operated at a current level above the recommended FLA

 Super Simpson is faulty

actual operating current

 Replace pump motor, motor mate, or controller

_______________________________________________________________ A6474X472 Rev 0 11

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0043 RIGHT CONVEYOR MOTOR RTD THERMAL TRIP

Possible cause

 Motor is damaged  Motor thermistor is faulty

Motor thermistor is reading over allowed  Thermistor module if faulty operating temperature

Checks to carry out

 Check thermistor circuit resistance and verify that thermistor module is correctly reporting that value

 Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

 Replace thermistor module 0044 FAN THERMAL OVERLOAD Motor has been operated at a current level above the recommended FLA

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

 Super Simpson is faulty

actual operating current

 Replace motor, motor mate, or Super Simpson

0045 FAN MOTOR OVER TEMPERATURE Motor thermistor is reading over allowed operating temperature

 Motor is damaged

 Check thermistor circuit resistance

 Motor thermistor is faulty

and verify that thermistor module is correctly reporting that value

 Thermistor module if faulty

 Check for rapidly fluctuating thermistor reading - if so, thermistor is damaged or there is noise in the circuit.

 Replace thermistor module 0046 LEFT TRAM MOTOR OVERLOAD Motor has been operated at a current level above the recommended FLA

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

 Super Simpson is faulty

actual operating current

 Replace motor, motor mate, or Super Simpson

0047 RIGHT TRAM MOTOR OVERLOAD Motor has been operated at a current level above the recommended FLA

 Motor is faulty

 Verify actual operating current

 Motor mate is faulty

 Check that motor mate is reporting

 Super Simpson is faulty

actual operating current

 Replace motor, motor mate, or Super Simpson

0048 METHANE SENSOR FAULT S800 methane sensor is reporting an internal fault

 Sensor is faulty

 Verify fault report on methane sensor display

 Replace methane sensor

0049 ILLEGAL PUMP CURRENT FEEDBACK

________________________________________________________________ 12 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0050 RIGHT SIDE STOP BUTTON PRESSED Operator Side E-Stop detected as being pressed

0051 LEFT SIDE STOP BUTTON PRESSED Left side E-Stop detected as being pressed

Possible cause

 Operator Side E-Stop button was pressed

The main AC supply input is detected as low

 Verify the E-Stop button is not being pressed

 Input wire to machine controller is broken

 Measure for 110VAC at machine controller input

 Super Simpson is faulty

 Replace Super Simpson

 Operator Side E-Stop button was

 Verify the E-Stop button is not being

pressed

pressed

 Input wire to machine controller is broken

 Measure for 110VAC at machine controller input

 Super Simpson is faulty 0052 MAIN AC SUPPLY VOLTAGE LEVEL LOST

Checks to carry out

 Replace Super Simpson

 110VAC control voltage has been lost  Verify that 110VAC is being supplied on machine

 Machine controller digital Input is faulty

from transformer

 Verify that high voltage is being supplied from power center

 Verify X1-a input to machine controller is reading 110VAC

 Replace Super Simpson 0053 METHANE MONITOR RELAY CONTACTS OPEN The MMR has been detected as open

 Methane Gas Level is above trip percentage

 Check methane gas level and verify sensor is correctly reporting

 MMR is faulty

 Replace MMR

 Digital input on machine controller is

 Replace Super Simpson

faulty

 X1-D wire is broken

 Check X1-D wire and voltage reading

 Digital input is faulty

 Replace Super Simpson

0055 RIGHT SIDE E-STOP STATUS WIRE BROKEN

 E-stop switch is faulty

 Verify E-stop wiring on left and right

E-stop detected as pressed but other digital inputs still reporting 110VAC levels

 Digital input is faulty

0056 LEFT SIDE E-STOP STATUS WIRE BROKEN

 E-stop switch is faulty

0054 MMR STATUS WIRE BROKEN MMR input is detected as open but other digital inputs are still reporting 110VAC levels

 Wire is broken

 Wire is broken

sides

 Replace Super Simpson

 Verify E-stop wiring on left and right sides

 Replace Super Simpson E-stop detected as pressed but other  Digital input is faulty digital inputs still reporting 110VAC levels _______________________________________________________________ A6474X472

Rev 0

13

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

0057 TRACTION COMMS FAILURE

 485 communications bus wiring is

Communications with the traction module have failed

 Traction Module has lost input voltage

damaged

 Super Simpson is faulty

Checks to carry out

 Verify 485 bus wiring  Verify that tractions module is receiving control power

 Replace Traction module  Replace pine box  Replace Super Simpson

0058 PUMP PT100 SHORT CIRCUIT PT100 resistance detected as less than 100 ohms

 PT100 wiring has been short circuited  Check motor  Thermistor Module Failure (LOLH09)  Motor failure

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0059 LEFT CUTTER PT100 SHORT CIRCUIT

 PT100 wiring has been short circuited  Check motor

PT100 resistance detected as less than 100 ohms

 Motor failure

 Thermistor Module Failure (LOLH09)

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0060 RIGHT CUTTER PT100 SHORT CIRCUIT

 PT100 wiring has been short circuited  Check motor

PT100 resistance detected as less than 100 ohms

 Motor failure

 Thermistor Module Failure (LOLH09)

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0061  PT100 wiring has been short circuited  Check motor LEFT CONVEYOR PT100 SHORT CIRCUIT  Thermistor Module Failure (LOLH09)  Check condition of wiring to RTD circuit and measure RTD resistance PT100 resistance detected as less than  Motor failure 100 ohms  Replace Thermistor Module (LOLH09)

 Replace motor 0062 RIGHT CONVEYOR PT100 SHORT CIRCUIT

 PT100 wiring has been short circuited  Check motor

PT100 resistance detected as less than 100 ohms

 Motor failure

 Thermistor Module Failure (LOLH09)

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

________________________________________________________________ 14 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

0063 PUMP PT100 OPEN CIRCUIT

 PT100 wiring has been shorted cir-

PT100 resistance detected as greater than 166 ohms

 Thermistor Module Failure (LOLH09)

cuited

 Motor failure

Checks to carry out

 Check motor  Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0064 LEFT CUTTER PT100 OPEN CIRCUIT PT100 resistance detected as greater than 166 ohms

 PT100 wiring has been shorted circuited

 Thermistor Module Failure (LOLH09)  Motor failure

 Check motor  Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0065 RIGHT CUTTER PT100 OPEN CIRCUIT

 PT100 wiring has been damaged

 Check motor

 Thermistor module failure (LOLH09)

 Check condition of wiring to RTD cir-

PT100 resistance detected as greater than 166 ohms

 Motor failure

cuit and measure RTD resistance

 Replace thermistor module (LOLH09)  Replace motor

0066 LEFT CONVEYOR PT100 OPEN CIRCUIT

 PT100 wiring has been short circuited  Check motor

PT100 resistance detected as greater than 166 ohms

 Motor Failure

 Thermistor module failure (l0LH09)

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace thermistor module (L0LH09)  Replace motor

0067  PT100 wiring has been short circuited  Check motor RIGHT CONVEYOR PT100 OPEN CIRCUIT  Thermistor module failure (l0LH09)  Check condition of wiring to RTD circuit and measure RTD resistance PT100 resistance detected as greater  Motor Failure than 166 ohms  Replace thermistor module (L0LH09)

 Replace motor 0068 FAN PT100 SHORT CIRCUIT Fan PT100 resistance detected at 100 ohms or less

 Short circuit in PT100 wiring  Thermistor module internal failure

 Check that actual circuit resistance is same as reported by thermistor module

 Replace thermistor module

_______________________________________________________________ A6474X472 Rev 0 15

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0069 FAN PT100 OPEN CIRCUIT Fan PT100 has been detected at 168 ohms or more 0070 FAN MOTOR RTD THERMAL WARNING The motor temperature has been above 140C but less than 150C

Possible cause

 Short circuit in PT100 wiring  Thermistor module internal failure

Checks to carry out

 Check that actual circuit resistance is same as reported by thermistor module

 Replace thermistor module  Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

0071 FAN MOTOR RTD THERMAL TRIP Thermistor module reported motor temperature is above 150C but less than 175C

 Motor temperature is above 150C  Measure RTD resistance and compare to chart

 Cable damage

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

0072 LEFT TRAM PT100 SHORT CIRCUIT PT100 resistance detected as less than 100 ohms

 PT100 wiring has been short circuited  Check motor  Thermistor Module Failure (LOLH09)  Motor failure

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0073 LEFT TRAM PT100 OPEN CIRCUIT PT100 resistance detected as greater than 168 ohms

 PT100 wiring has been damaged

 Check motor

 Thermistor module failure (l0LH09)

 Check condition of wiring to RTD cir-

 Motor Failure

cuit and measure RTD resistance

 Replace thermistor module (L0LH09)  Replace motor

________________________________________________________________ 16 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0074 LEFT TRAM MOTOR RTD THERMAL WARNING The motor temperature has been above 140C but less than 150C

Possible cause

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage

Checks to carry out

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

0075 LEFT TRAM MOTOR RTD THERMAL TRIP The motor temperature has been above 140C but less than 150C

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

0076 RIGHT TRAM PT100 SHORT CIRCUIT PT100 resistance detected as less than 100 ohms

 PT100 wiring has been short circuited  Check motor  Thermistor Module Failure (LOLH09)  Motor failure

 Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

0077 RIGHT TRAM PT100 OPEN CIRCUIT PT100 resistance detected as greater than 168 ohms

 PT100 wiring has been damaged

 Check motor

 Thermistor module failure (LOLH09)

 Check condition of wiring to RTD cir-

 Motor failure

cuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

_______________________________________________________________ A6474X472 Rev 0 17

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

0078 RIGHT TRAM MOTOR RTD THERMAL WARNING

 Measure RTD resistance and com-

 Check condition of wiring to RTD circuit

The motor temperature has been above 140C but less than 150C

pare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage

and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable.

If pilot cores are damaged, replace cable

0079 RIGHT TRAM MOTOR RTD THERMAL TRIP The motor temperature has been above 140C but less than 150C

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Thermistor module failure (LOLH09)  Motor failure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable.

If pilot cores are damaged, replace cable

0080 TRANSFORMER PT100 SHORT CIRCUIT PT100 resistance detected as less than 100 ohms

 PT100 wiring has been short circuited

 Thermistor Module Failure (LOLH09)

 Motor failure 0081 TRANSFORMER PT100 OPEN CIRCUIT

 PT100 wiring has been damaged

PT100 resistance detected as greater than 166 ohms

 Motor failure

 Check motor  Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor  Check motor

 Thermistor module failure (LOLH09)  Check condition of wiring to RTD circuit and measure RTD resistance

 Replace Thermistor Module (LOLH09)  Replace motor

________________________________________________________________ 18 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0082 TRANSFORMER RTD THERMAL TRIP Thermistor module reported motor temperature is above 150C but less than 175C

Possible cause

 Motor temperature is above 150C  Measure RTD resistance and compare to chart

 Cable damage  Thermistor module failure (LOLH09)  Motor failure

Checks to carry out

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Replace thermistor module (LOLH09)  Replace motor  Check pilot cores in motor supply cable.

If pilot cores are damaged, replace cable

0083 PUMP MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C but less than 150C

 Motor temperature is as reported by system

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

0084 LEFT CUTTER MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C/165C but less than 150C/175C

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable.

 Motor temperature is as reported by

 Check condition of wiring to RTD circuit

system

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

If pilot cores are damaged, replace cable and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable.

If pilot cores are damaged, replace cable

_______________________________________________________________ A6474X472 Rev 0 19

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0085 RIGHT CUTTER MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C/165C but less than 150C/175C

Possible cause

Checks to carry out

 Motor temperature is as reported by system  Check condition of wiring to RTD  Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage  Thermistor module failure (LOLH09)  Motor failure

circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Replace thermistor module (LOLH09)

 Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged,

0086 LEFT CONV MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C but less than 150C

 Motor temperature is as reported by system  Check condition of wiring to RTD  Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage  Thermistor module failure (LOLH09)  Motor failure

circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Replace thermistor module (LOLH09)

 Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged,

0087 RIGHT CONV MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C but less than 150C

 Motor temperature is as reported by system  Check condition of wiring to RTD  Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)  Cable damage  Thermistor module failure (LOLH09)  Motor failure

circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Replace thermistor module (LOLH09)

 Replace motor  Check pilot cores in motor supply cable. If pilot cores are damaged,

________________________________________________________________ 20 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0088 SCRUBBER MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C but less than 150C

Possible cause

 Motor temperature is as reported by system

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

0089 LEFT TRAM MOTOR RTD THERMAL WARNING Thermistor reported temperature is above 140C but less than 150C

Checks to carry out

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable.

 Motor temperature is as reported by

 Check condition of wiring to RTD cir-

system

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

If pilot cores are damaged, replace cable

cuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

0090  Motor temperature is as reported by RIGHT TRAM MOTOR RTD THERMAL system WARNING Thermistor reported temperature is above 140C but less than 150C

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

 Check condition of wiring to RTD circuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable. If pilot cores are damaged, replace cable

_______________________________________________________________ A6474X472 Rev 0 21

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0091 TRANSFORMER RTD THERMAL WARNING VFD has reported a short circuit fault

Possible cause

Checks to carry out

 Motor temperature is as reported by

 Check condition of wiring to RTD cir-

system

 Measure RTD resistance and compare to chart

 RTD failure (DO NOT MEGGAR)

cuit and measure RTD resistance and compare to chart. Note: Check connections in motor cable junction boxes

 Connect spare RTD circuit in motor terminal enclosure

 Cable damage

 Replace thermistor module (LOLH09)

 Thermistor module failure (LOLH09)

 Replace motor

 Motor failure

 Check pilot cores in motor supply cable. If pilot cores are damaged,

0092 CUTTER BREAKER OPEN Circuit breaker was detected as open.

 Jumper wire is broken

 At this time no cutter breaker is in-

 Digital input is faulty

stalled so check jumper wire to breaker input

 Replace Super Simpson 0093 INTERMEDIATE BREAKER OPEN

 Auxiliary contact wire from breaker is

CB2 or intermediate breaker is detected as open

 Auxiliary contact on breaker is faulty,

broken

 Check to verify 110VAC from auxiliary contact to machine controller input

 Replace Super Simpson

check UV

 Digital input is faulty 0094 TRAM BREAKER OPEN

 Auxiliary contact wire from breaker is

Tram breaker is detected as open

 Auxiliary contact on breaker is faulty,

broken

 Check to verify 110VAC from auxiliary contact to machine controller input

 Replace Super Simpson

check UV

 Digital input is faulty 0095 PUMP OVERLOAD RELAY OPEN Pump circuit overload relay detected as open

 Pump motor current is too high

 Check motor current, replace motor

 Relay is faulty

 Check relay current, replace relay

 Digital input failure

 Check 110VAC signal to machine controller, replace machine controller

0096 LEFT TRAM MOTOR OVERLOAD RELAY OPEN

 Left tram motor current is too high

 Check motor current, replace motor

 Relay is faulty

 Check relay current, replace relay

Left tram circuit overload relay detected as open

 Digital input failure

 Check 110VAC signal to machine controller, replace machine controller

________________________________________________________________ 22 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

0097 RIGHT TRAM MOTOR OVERLOAD RELAY OPEN

 Left tram motor current is too high

 Check motor current, replace motor

 Relay is faulty

 Check relay current, replace relay

Right tram circuit overload relay detected as open

 Digital input failure

 Check 110VAC signal to machine

0098 LH VFD COMMS FAILURE

 CAN bus wire break between rectifier

The Super Simpson is reporting a CAN bus communications failure

 Internal drive failure

controller, replace machine controller and VFD

 Check conductivity of CAN bus wiring and fuses

 Check CAN bus termination resistance

 Replace drive  Replace Super Simpson 0099 RH VFD COMMS FAILURE

 CAN bus wire break between rectifier

The Super Simpson is reporting a CAN bus communications failure

 Internal drive failure

and VFD

 Check conductivity of CAN bus wiring and fuses

 Check CAN bus termination resistance

 Replace drive  Replace Super Simpson 0100 LEFT INVERTER ENCODERLESS OPERATION

 Drive was set to operate in this mode

 Check drive settings

 Drive has malfunctioned

 Replace drive

 Drive was set to operate in this mode

 Check drive settings

 Drive has malfunctioned

 Replace drive

 Low coolant flow

 Check coolant flow and level

 Poor thermal contact with rectifier

 Check proper installation of rectifier

The drive is reporting that it is operating in encoderless mode 0101 RIGHT INVERTER ENCODERLESS OPERATION The drive is reporting that it is operating in encoderless mode 0102 RECTIFIER HEATSINK TEMPERATURE WARNING Rectifier has reported heatsink temperature warning 0103 RECTIFIER INPUT UNDERVOLTAGE The rectifier has reported low input voltage

base and enclosure

 Voltage below 750V  Rectifier has faulty DC bus voltage circuit

 Verify machine voltage and rectifier unit output

 Replace rectifier

_______________________________________________________________ A6474X472 Rev 0 23

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0104 BRAKE RESISTOR THERMAL TRIP The rectifier has reported a brake resistor thermal trip code 0105 RECTIFIER PHASE SYNC LOSS

Possible cause

Checks to carry out

 Operating voltage is too high

 Check drive settings

 Machine is tramming too fast

 Slow machine down

 TBA

 TBA

 Rectifier has detected a phase loss

 TBD

The rectifier has reported a phase loss code after the pump started 0106 RECTIFIER PHASE LOSS

for more than 10 seconds after pump start

Rectifier is reporting a phase loss fault code 0107 RECTIFIER COMMS FAILURE

 The rectifier does not have 120VAC

Super Simpson is not recognizing or receiving packets from the rectifier

 The CAN bus wiring is not intact

control power applied

 A fuse on the CAN bus has blown  The rectifier is not sending packets or the Super Simpson has failed.

 Check that 120VAC is being applied to the rectifier

 Check CAN bus connections and fuses

 Use CAN analyzer to verify any packets on the bus.

 Replace the Super Simpson or the rectifier

0108 EMERGENCY STOP RELAY CONTACT OPEN

 ESR auxiliary contact is open

The emergency stop relay has been detected as open

 Digital input failure

0109 ILLEGAL VOLTAGE ON PILOT CIRCUIT

 110VAC short circuit external to relay

 Wire is broken

board or internal to relay board

 Verify 110VAC input to machine controller from ESR contact

 Replace Super Simpson  Verify 110VAC on pilot trip circuit  Replace Super Simpson

Voltage has been detected on the pilot output relay circuit 0110 CONTROL EARTH LEAKAGE TRIP

 Ground fault relay auxiliary contact is

The ground fault relay has been detected as open

 Wire is broken

open

 Verify 110VAC input to machine controller from GFR contact

 Replace Super Simpson

 Digital input failure 0111 LEFT RMS DRIVE COMMS FAILURE RMS drive is reporting an internal CAN communications loss

 The drive has an internal failure

 Check CAN bus connections  Replace drive

________________________________________________________________ 24 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0112 RIGHT RMS DRIVE COMMS LOSS

Possible cause

 The drive has an internal failure

 Check CAN bus connections  Replace drive

RMS drive is reporting an internal CAN communications loss 0113 LEFT DRIVE HANDSHAKE FAILURE

Checks to carry out

 Drive is not responding to enabled

 Replace the drive

command due to internal fault

RMS drive enable handshaking sequence failed 0114 RIGHT DRIVE HANDSHAKE FAILURE

 Drive is not responding to enabled

 Replace the drive

command due to internal fault

RMS drive enable handshaking sequence failed 0115 SOLENOID OPEN CIRCUIT

 Wiring has been short circuited, sole-

A solenoid circuit has been detected as Open Circuit

 Solenoid board failure

0116 SOLENOID SHORT CIRCUIT

 Wiring has been short circuited, sole-

A solenoid circuit has been detected as Open Circuit

 Solenoid board failure

0117 SOLENOID OVER CURRENT

 Wiring has been short circuited, sole-

A solenoid has been detected as drawing too much current

 Solenoid board failure

noid coil is damaged.

noid coil is damaged.

noid coil is damaged.

0118  Pump contactor is frozen shut PUMP CONTACTOR STUCK CLOSED The smart contactor has reported an illegally closed condition. The control system assumed that the pump contactor had illegally become active and turned off power to the machine by tripping the out-by e-stop relay.

0119 PUMP COTACTOR STUCK OPEN

 The contactor (or auxiliary contact) is faulty

 Replace solenoid  Replace Super Simpson  Run system solenoid test  Replace solenoid  Replace Super Simpson  Run system solenoid test  Replace solenoid  Replace Super Simpson  Check the state of the contactor  Replace the contactor  Replace the Super Simpson

 Pump contactor has suffered an inter-  Check the state of the contactor nal failure

The smart contactor has reported an inability to close the contacts 0120 PUMP CONTACTOR PHASE IMBALANCE

 Run system solenoid test

 Replace the contactor  Replace the Super Simpson

TBD

TBD

_______________________________________________________________ A6474X472 Rev 0 25

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

0121 PUMP CONTACTOR NO LOAD

TBD

TBD

0122 PUMP CONTACTOR CALIBRATION REQUIRED

TBD

TBD

0123 TBD PUMP CONTACTOR CURRENT WITHOUT COMMAND

TBD

0124 TBD PUMP CONTACTOR SUPPLY BELOW LIMIT

TBD

0125 PUMP CONTACTOR ATD ERROR

TBD

TBD

0126 PUMP CONTACTOR TEMPERATURE ERROR

TBD

TBD

0127 PUMP CONTACTOR POWER RESTORED

TBD

TBD

0128 PUMP CONTACTOR CONFIGURATION SET

TBD

TBD

0129 TBD PUMP CONTACTOR REPORTED CAN FAULT

TBD

0130 PUMP CONTACTOR THERMAL OVERLOAD

TBD

TBD

________________________________________________________________ 26 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

0131 PUMP CONTACTOR INSTANT OVERLOAD

TBD

TBD

0132 PUMP CONTACTOR NOT COMMUNICATING

TBD

TBD

0133 SHEAR: SLICE ADC ERROR

 Initialization error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Initialization error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire broken inside slice

 Replace the coils

The internal analog to digital converter is malfunctioning 0134 SHEAR: SLICE SAFETY POWER SWITCH FAIL The power switch and watchdog are unable to cut power to the driver circuitry 0135 SHEAR: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0136 SHEAR: SLICE SOL A RESISTANCE LOW

Solenoid resistance measured below 14  Internal component failure ohms 0137 SHEAR: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms 0138 SHEAR: SLICE SOL B RESISTANCE LOW

 Replace the slice

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

_______________________________________________________________ A6474X472 Rev 0 27

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0139 SHEAR: SLICE SOL B RESISTANCE HIGH

Possible cause

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms 0140 SHEAR: SLICE SUPPLY UNDER VOLTAGE

 Power supply failure

Supply voltage has dipped below 10VDC

 System running heavy load on

0141 SHEAR: SLICE SUPPLY OVER VOLTAGE

 Power supply failure

Slice voltage has risen above 35VDC

Checks to carry out

 Blown fuse on 24VDC bus

 Replace the slice  Check primary supply and connections

 Check fuses on 24VDC bus

backup supply output

 Short circuit/bad connection onto 24VDC bus

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0142 SHEAR: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature below -40C 0143 SHEAR: SLICE OVER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature above +85C 0144 SHEAR: SLICE COMMUNICATION TIMEOUT

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables

The slice has not received a command packet for 250ms 0145 STAB: SLICE ADC ERROR The internal analog to digital converter is malfunctioning

 Replace the unit  Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

________________________________________________________________ 28 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

 Initialization error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0146 STAB: SLICE SAFETY POWER SWITCH FAIL The fail safe power switch is dysfunctional and unable to cut power to the driver circuitry 0147 STAB: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0148 STAB: SLICE SOL A RESISTANCE LOW

0149 STAB: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0150 STAB: SLICE SOL B RESISTANCE LOW

0151 STAB: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid measured above 37 ohms

 Internal component failure

 Replace the slice

0152  Power supply failure STAB: SLICE SUPPLY UNDER VOLTAGE  Blown fuse on 24VDC bus Supply voltage has dipped below 10VDC

 System running heavy load on

0153 STAB: SLICE SUPPLY OVERVOLTAGE

 Power supply failure

Slice voltage has risen above 35VDC

 Check primary supply and connections

 Check fuses on 24VDC bus

backup supply output

 Short circuit/bad connection to 24VDC bus

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter

_______________________________________________________________ A6474X472 Rev 0 29

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0154 STAB: SLICE UNDER TEMPERATURE

Possible cause

 Internal component failure

Checks to carry out

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature below -40C 0155 STAB: SLICE OVER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature above +85C 0156  Rectifier has detected a phase loss STAB: SLICE COMMUICATION TIMEfor more than 10 seconds after pump OUT start

 Cycle 24VDC to unit

The slice has not received a command packet for 250 ohms

 Replace the unit

 Check CAN bus connections/cables

 Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0157 CONV: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0158 CONV: SLICE SAFETY POWER SWITCH FAIL The fail-safe power switch is dysfunctional and unable to cut power to the driver circuitry 0159 CONV: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0160 CONV: SLICE SOL A RESISTANCE LOW

0161 CONV: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

________________________________________________________________ 30 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

 Coil is faulty

 Cycle 24VDC to unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0162 CONV: SLICE SOL B RESISTANCE LOW

0163 CONV: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

0164  Power supply failure CONV: SLICE SUPPLY UNDERVOLTAGE  Blown fuse on 24VDC bus

 Check primary supply and connec-

Supply voltage has dipped below 10VDC

 System running heavy load on

0165 CONV: SLICE SUPPLY OVERVOLTAGE

 Power supply failure

Slice voltage has risen above 35VDC

tions

 Check fuses on 24VDC bus

backup supply output

 Short circuit/bad connection onto 24VDC bus

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0166 CONV: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature below -40C 0167  Internal component failure CONV: SLICE OVER TEMPERATURE

 Replace the unit

Slice has reported a temperature above +85C 0168 CONV: SLICE COMMUNICATION TIMEOUT The slice has not received a command packet for 250 ohms

 Cycle 24VDC to unit

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables  Replace the unit

_______________________________________________________________ A6474X472 Rev 0 31

BI016801

Operation _______________________________________________________

Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

 Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0169 CONV: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0170 CONV: SLICE SAFETY POWER SWITCH FAIL The fail-safe power switch is dysfunctional and unable to cut power to the driver circuitry 0171 CONV: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0172 CONV: SLICE SOL A RESISTANCE LOW

0173 CONV: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0174 CONV: SLICE SOL B RESISTANCE LOW

0175 CONV: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms 0176 CONV: SLICE SUPPLY UNDERVOLTAGE

 Power supply failure

Supply voltage has dipped below 10VDC

 System running heavy load on

 Blown fuse on 24VDC bus

 Replace the slice  Check primary supply and connections

 Check fuses on 24VDC bus

________________________________________________________________ 32 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0177 CONV: SLICE SUPPLY OVERVOLTAGE Slice voltage has risen above 35VDC

Possible cause

 Power supply failure  Short circuit/bad connection onto 24VDC bus

Checks to carry out

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0178 CONV: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature below -40C 0179  Internal component failure CONV: SLICE OVER TEMPERATURE

 Replace the unit

Slice has reported a temperature above +85C 0180 CONV: SLICE COMMUNICATION TIMEOUT

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables

The slice has not received a command packet for 250ohms 0181 GATH: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0182 GATH: SLICE SAFETY POWER SWITCH FAIL

 Cycle 24VDC to unit

 Replace the unit  Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Initialization error

 Cycle 24VDC to unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

The fail-safe power switch is dysfunctional and unable to cut power to the driver circuitry 0183 GATH: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range

_______________________________________________________________ A6474X472 Rev 0 33

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0184 GATH: SLICE SOL A RESISTANCE LOW

0185 GATH: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0186 GATH: SLICE SOL B RESISTANCE LOW

0187 GATH: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

0188  Power supply failure GATH: SLICE SUPPLY UNDERVOLTAGE  Blown fuse on 24VDC bus

 Check primary supply and connec-

Supply voltage has dipped below 10VDC

 System running heavy load on

0189 GATH: SLICE SUPPLY OVERVOLTAGE

 Power supply failure

Slice voltage has risen above 35VDC

tions

 Check fuses on 24VDC bus

backup supply output

 Short circuit/bad connection onto 24VDC bus

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0190 GATH: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

Slice has reported a temperature below -40C 0191 GATH: SLICE OVER TEMPERATURE Slice has reported a temperature above +85C

 Internal component failure

 Cycle 24VDC to unit  Replace the unit

________________________________________________________________ 34 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0192 GATH: SLICE COMMUNICATION TIMEOUT

Possible cause

Checks to carry out

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables

The slice has not received a command packet for 250ms

 Replace the unit  Initializing error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Initializing error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coil

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0193 BREAK: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0194 BREAK: SLICE SAFETY POWER SWITCH FAIL The fail-safe power switch is not functional and is unable to remove power to the driver circuitry 0195 BREAK: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0196 BREAK: SLICE SOL A RESISTANCE LOW

0197 BREAK: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coil

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coil

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0198 BREAK: SLICE SOL B RESISTANCE LOW

0199 BREAK: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coil

Solenoid resistance measured above 37  Internal component failure ohms 0200 BREAK: SLICE SUPPLY UNDER VOLTAGE

 Power supply failure

Supply voltage has dipped below 10VDC

 System running heavy load on

 Blown fuse on 24VDC bus

 Replace the slice  Check primary supply and connections

 Check fuses on 24VDC bus

backup supply output _______________________________________________________________ A6474X472 Rev 0 35

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

0201  Power supply failure BREAK: SLICE SUPPLY OVERVOLTAGE  Short circuit/bad connection onto 24VDC bus Slice voltage has risen above 35VDC

Checks to carry out

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0202 BREAK: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace unit

Slice has reported a temperature below -40C 0203 BREAK: SLICE OVER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace unit

Slice has reported a temperature above +85C 0204 BREAK: SLICE COMMUNICATION TIMEOUT

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables

The slice has not received a command packet for 250 msec

 Replace the unit  Initializing error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0205 DUST: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0206 DUST: SLICE SAFETY POWER SWITCH FAIL The fail-safe power switch is not functional and is unable to remove power to the driver circuitry 0207 DUST: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0208 DUST: SLICE SOL A RESISTANCE LOW

________________________________________________________________ 36 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0209 DUST: SLICE SOL A RESISTANCE HIGH

Possible cause

Checks to carry out

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coil

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coils

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0210 DUST: SICE SOL B RESISTANCE LOW

0211 DUST: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coils

Solenoid resistance measured above 37  Internal component failure ohms 0212 DUST: SLICE SUPPLY UNDERVOLTAGE

 Power supply failure

Supply voltage has fallen below 10VDC

 System running heavy load on

 Blown fuse on 24VDC bus

 Replace the slice  Check primary supply and connections

 Check fuses on 24VDC bus

backup supply output 0213 DUST: SLICE SUPPLY OVERVOLTAGE Slice voltage has risen above 35VDC

 Power supply failure  Short circuit/bad connection onto 24VDC bus

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand held meter 0214 DUST: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace unit

Slice has reported a temperature below -40C 0215 DUST: SLICE OVER TEMPERATURE

 Internal component failure

 Replace unit

Slice has reported a temperature above +85C 0216 DUST: SLICE COMMUNICATION TIMEOUT The slice has not received a command packet for 250 msec

 Cycle 24VDC to unit

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables  Replace the unit

_______________________________________________________________ A6474X472 Rev 0 37

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number

Possible cause

Checks to carry out

 Initializing error

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Broken wire inside the slice top

 Cycle 24VDC to the unit

 Internal component failure

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coil

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0217 SCRUB: SLICE ADC ERROR The internal analog to digital converter is malfunctioning 0218 SCRUB: SLICE SAFETY POWER SWITCH FAIL The fail-safe power switch is not functional and is unable to remove power to the driver circuitry 0219 SCRUB: SLICE SPOOL POSITION SENSOR FAIL The output from the hall effect sensor is outside of the expected range 0220 SCRUB: SLICE SOL A RESISTANCE LOW

0221 SCRUB: SLICE SOL A RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coil

Solenoid resistance measured above 37  Internal component failure ohms

 Replace the slice

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is broken inside slice

 Replace the coil

Solenoid resistance measured below 14  Internal component failure ohms

 Replace the slice

0222 SCRUB: SLICE SOL B RESISTANCE LOW

0223 SCRUB: SLICE SOL B RESISTANCE HIGH

 Coil is faulty

 Cycle 24VDC to the unit

 Wire is making poor contact to coil

 Replace the coil

Solenoid resistance measured above 37  Internal component failure ohms 0224 SCRUB: SLICE SUPPLY UNDERVOLTAGE

 Power supply failure

Supply voltage has fallen below 10VDC

 System running heavy load on

 Blown fuse on 24VDC bus

 Replace the slice  Check primary supply and connections

 Check fuses on 24VDC bus

________________________________________________________________ 38 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number

Possible cause

0225  Power supply failure SCRUB: SLICE SUPPLY OVER VOLTAGE  Short circuit/bad connection onto 24VDC bus slice voltage has risen above 35VDC

Checks to carry out

 Check primary supply and connections

 Check secondary supply output and connections

 Verify high voltage reading with hand 0226 SCRUB: SLICE UNDER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace unit

Slice has reported a temperature below -40C 0227 SCRUB: SLICE OVER TEMPERATURE

 Internal component failure

 Cycle 24VDC to unit  Replace unit

Slice has reported a temperature above +85C 0228 SCRUB: SLICE COMMUNICATION TIMEOUT

 Internal component failure

 Cycle 24VDC to unit

 Broken connection to CAN bus

 Check CAN bus connections/cables

The slice has not received a command packet for 250 msec 0229 24VDC BUS UNDER 20VDC L0GP power supply reports that bus voltage dropped below 20VDC

 Replace the unit  Primary supply failed  Blown fuse or diode on 24VDC bus  Machine under heavy load with low input voltage

0230 24VDC BUS ABOVE 28VDC L0GP power supply reports that bus voltage rose above 28VDC

0231 RADIO SWITCH TIMEOUT A radio remote switch has been held for at least 15 seconds. 30 seconds for shearing

 Primary supply failed  Short circuit on 24VDC bus  Machine input voltage level is high  Operator is holding lever  A switch has become stuck

 Check primary supply and connections

 Test fuses and diode on 24VDC bus  Verify machine input voltage level  Check primary supply and connections

 Test fuses and diode on 24VDC bus

 Verify that operator releases switches within 15 seconds

 Check for obstructions that would hold switch in active position

 Replace the radio remote 0232 SHEAR: SLICE SPOOL NOT CENTERED No hydraulic command is active and the spool has not returned to center position

 Internal component failure

 Check the pilot and system pressure

 Valve has remained open due to

 Cycle the 24VDC to the unit

pressure from the valve bank

 Replace the unit

_______________________________________________________________ A6474X472 Rev 0 39

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0233 GATH: SLICE SPOOL NOT CENTERED No hydraulic command is active and the spool has not returned to center position 0234 CONV: SLICE SPOOL NOT CENTERED No hydraulic command is active and the spool has not returned to center position 0235 CONV: SLICE SPOOL NOT CENTERED No hydraulic command is active and the spool has not returned to center position 0236 STAB: SLICE SPOOL NOT CENTERED No hydraulic command is active and the spool has not returned to center position 0237 SHEAR: SLICE TEMPERATURE RAPID INCREASE

Possible cause

 Internal component failure

 Check the pilot and system pressure

 Valve has remained open due to

 Cycle the 24VDC to the unit

pressure from the valve bank

 Check the pilot and system pressure

 Valve has remained open due to

 Cycle the 24VDC to the unit

pressure from the valve bank

 Check the pilot and system pressure

 Valve has remained open due to

 Cycle the 24VDC to the unit

pressure from the valve bank

 Replace the unit

 Internal component failure

 Check the pilot and system pressure

 Valve has remained open due to

 Cycle the 24VDC to the unit

pressure from the valve bank

 Replace the unit

 Ambient temperature much cooler

 Cycle 24VDC to the unit than working temperature of the valve bank  Replace the slice  Verify valve bank pressure and spool position

 Ambient temperature much cooler

 Cycle 24VDC to the unit than working temperature of the valve bank  Replace the slice  Verify valve bank pressure and spool position

 Ambient temperature much cooler

 Cycle 24VDC to the unit than working temperature of the valve bank  Replace the slice

Slice temperature has increased several  Heavy hydraulic load degrees above the average temperature

0240 CONV:SLICE TEMPERATURE RAPID INCREASE

 Replace the unit

 Internal component failure

Slice temperature has increased several  Heavy hydraulic load degrees above the average temperature

0239 CONV:SLICE TEMPERATURE RAPID INCREASE

 Replace the unit

 Internal component failure

Slice temperature has increased several  Heavy hydraulic load degrees above the average temperature

0238 GATH: SLICE TEMPERATURE RAPID INCREASE

Checks to carry out

 Verify valve bank pressure and spool position

 Ambient temperature much cooler

 Cycle 24VDC to the unit than working temperature of the valve bank  Replace the slice

Slice temperature has increased several  Heavy hydraulic load degrees above the average temperature

 Verify valve bank pressure and spool position

 Valve bank failure ________________________________________________________________ 40 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 1, continued: Error messages Fault number 0241 STAB: SLICE TEMPERATURE RAPID INCREASE

Possible cause

Checks to carry out

 Ambient temperature much cooler

 Cycle 24VDC to the unit than working temperature of the valve bank  Replace the slice

Slice temperature has increased several  Heavy hydraulic load degrees above the average temperature

 Valve bank failure

 Verify valve bank pressure and spool position

0242 REMOTE CONSOLE ID FAILURE

 A secondary radio remote is operating  Check radio remote ID

The control system detected a radio remote with an illegal ID number setting such as zero

 ID of a radio remote was not properly

on the same frequency

set

 Radio remote is faulty 0243 SECOND REMOTE CONSOLE DETECTED The control system detected a second remote console ID on the same frequency as the primary remote

 Shift change when the miner was powered up

 Second remote is operating on the same section

 Miner was not powered down, possi-

 Check if other radio remotes are on the same frequency

 Replace the radio remote if problem persists

 Cycle 24VDC on the miner. Verify little blue display turns off

 Replace the Super Simpson  Make sure a second remote is not operating on the same frequency

bly battery backup system did not time out 0244 RELAY BOARD WRONG FIRMWARE

 Relay board was loaded with an old

 Replace Super Simpson

revision of firmware

The relay board is reporting an outdated version of firmware 0245 TRACTION EARTH LEAKAGE TRIP

 Earth leakage relay auxiliary contact

The earth leakage relay has been detected as open

 Wire is broken

is open

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson

 Digital input failure 0246 LIGHTS EARTH LEAKAGE TRIP

 Earth leakage relay auxiliary contact

The earth leakage relay has been detected as open

 Wire is broken

is open

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson

 Digital input failure 0247 LOW OIL LEVEL WARNING The oil level warning switch has been detected as open

 The oil level warning contact is open  Wire is broken  Digital input failure

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 41

BI016801

Operation _______________________________________________________ Table 1, continued: Error messages Fault number 0248 HIGH OIL TEMPERATURE TRIP The oil temperature trip switch has been detected as open

0249 LOW OIL LEVEL TRIP The oil level trip switch has been detected as open

0250 WATER FLOW TRIP The water relay has been detected as open 0251 WATER PRESSURE TRIP The water pressure relay has been detected as open

Possible cause

Checks to carry out

 The oil temperature contact is open

 Verify 110VAC input to machine con-

 Wire is broken  Digital input failure  The oil level trip contact is open  Wire is broken  Digital input failure  The auxiliary contact is open  Wire is broken  Digital input failure  The auxiliary contact is open  Wire is broken  Digital input failure

troller from contact

 Replace Super Simpson

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson  Verify 110VAC input to machine controller from contact

 Replace Super Simpson

0252 SUPPLY EARTH LEAKAGE TRIP

 The earth leakage relay auxiliary con-  Verify 110VAC input to machine con-

The earth leakage relay has been detected as open

 Wire is broken

tact is open

troller from contact

 Replace Super Simpson

 Digital input failure 0253 METHANE LEVEL WARNING The methane warning relay has been detected as open

 The auxiliary contact is open  Wire is broken  Digital input failure

0254  Damage to processor card REAL TIME CLOCK BATTERY LEVEL LOW

 Verify 110VAC input to machine controller from contact

 Replace Super Simpson  Replace Super Simpson

The Super Simpson processor is reporting that the battery level is low 0255 TRACTION DRIVE COMMUNICATIONS DETECTED Communications with the traction system were active when the pump motor was not running

 120 VAC supply to the traction drives is not interlocked with the pump auxiliary contact

 Check traction drive page for packet counts

 Verify traction drive 120VAC supply connections

 Check pump motor auxiliary contact

________________________________________________________________ 42 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2: Fault messages Fault number

Possible cause

Checks to carry out

0301  Internal failure of the machine control-  Replace the machine controller.

SOLENOID BOARD COMMS FAILURE ler There was a failure of communication between the internal processor and the internal solenoid drive board inside the machine controller. The pump motor was shut down. If the problem persists, the machine controller should be changed.

0302 RELAY BOARD COMMS FAILURE

 Internal failure of the machine control-  Replace the machine controller. ler

There was a failure of communication between the internal processor and the internal solenoid drive board inside the machine controller. The pump motor was shut down. If the problem persists, the machine controller should be changed.

0303 THERMISTOR MODULE COMMS FAILURE

 Communication wires between the machine controller and the thermistor module are broken or shorted

There was either an internal failure or a  There is no 12 VAC power supply to communications failure of the Thermisthe thermistor module tor Module (LOLH09). This fault only occurs if the thermistor module is fitted  The thermistor module is faulty and enabled in the system. Pump motor is shut down because it is not possible to measure the pump motor temperature  Machine controller is faulty when the module is not working.

 Check the integrity of the daisy chain cable and its internal wires

 Check that all modules are properly connected to the daisy chain cable

 Check the 12VAC supply to module  Replace the module

0304 RADIO SIGNAL LOST

 Distance between machine and hand-  Verify charge of remote battery

While the pump motor was running the radio control signal from the operator’ s handset was lost.

 Radio antenna or antenna cable is

set is too far

damaged

 The radio control handset is faulty or

 Check antenna connections  Replace radio remote  Replace the machine controller

battery is low

 Machine controller is faulty 0305 LOST PUMP CURRENT While pump was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the pump motor.

 Wire X1-J broken

 Check that contactor closes

 Contractor faulty

 Check motor mate feedback versus

 Motor mate faulty  Machine controller faulty

hand held meter

 Replace motor mate  Replace Super Simpson

0306 PUMP E-STOP PRESSED

_______________________________________________________________ A6474X472 Rev 0 43

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

0307 PUMP MOTOR MATE FAULT

 Wires to the motor mate are broken or  Check wiring between relay output

At least one of three signal lines from the motor mate is faulty, while the pump was running or an attempt was made to start the pump. Each signal line must read between 4mA and 20mA to be normal. If any of the lines is not in this range then this fault will occur. The pump motor was shut down.

 There is no 24VDC supply to the mo-

0308 PUMP NO LOAD CURRENT

 No load connected to motor shaft

While the pump was running, the currents detected in the pump motor were very small. It is possible that no load is connected to the pump motor or that there is a mechanical failure of the pump itself or the pump gearbox. The pump motor was shut down.

0309 PUMP PHASE LOSS While the pump was running, at least one of the phase currents went to 0 amperes for unknown reasons. It is possible that the motor lead is not connected from the motor. It is also possible that the motor itself has a serious internal failure. The pump motor was shut down.

0310 PUMP PHASE IMBALANCE While the pump motor was running a significant difference in the pump phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The pump motor was shut down.

0311 PUMP INSTANT OVERLOAD While the pump motor was running the current measured in the motor exceeded the instantaneous overload threshold. The pump motor was shut down.

shorted

tor mate

 The motor mate is faulty

and pump contactor

 Check that 120VAC is coming from the controller

 Replace the controller

 Machine controller (or inputs to machine controller) is faulty

 Mechanical failure of the pump  Mechanical failure of the pump gearbox (drive train from motor to pump)

 Motor mate failure

 Verify the state of the motor and proper functionality

 Check motor mate reading against hand held meter

 Replace motor mate  Replace Super Simpson

 Motor power conductor is broken

 Verify proper functionality of the motor

 Serious motor failure

 Check motor mate reading versus

 Pump motor mate is faulty  Machine controller is faulty (inputs from motor mate)

hand held meter

 Replace motor mate  Replace Super Simpson

 Motor power conductor is broken

 Verify proper functionality of the motor

 Serious motor failure

 Check motor mate reading versus

 Pump motor mate is faulty  Machine controller is faulty (inputs from motor mate)

hand held meter

 Replace motor mate  Replace Super Simpson

 Failure of pump gearbox that is over-

 Verify proper functionality of the motor loading or jamming the pump motor shaft overload of the hydraulic system  Check motor mate reading versus that is placing excessive mechanical hand held meter loading of the pump motor shaft  Replace motor mate  Serious failure of the pump motor  Replace Super Simpson

________________________________________________________________ 44 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0312 PUMP THERMAL OVERLOAD

Possible cause

 Hydraulic system was heavily used

Checks to carry out

 Verify proper functionality of the motor

and caused pump currents to be abnormally high for too long

 Check motor mate reading versus The pump motor current was too high hand held meter for too long of a period. The can cause  Failure of pump gearbox that is overoverheating and possible damage to the loading or jamming the pump motor  Replace motor mate motor. The pump motor was shut down shaft overload of the hydraulic system and is prevented from starting for sevthat is placing excessive mechanical  Replace Super Simpson eral minutes to prevent motor damage. loading of the pump motor shaft  Serious failure of the pump motor 0313 PUMP MOTOR RTD THERMAL TRIP

 Cooling system of the pump motor is impeded by debris or other factors, preventing adequate cooling

 Verify state of coolant flow and proper functionality of motor

The temperature of the motor windings  Check the resistance reported by in the pump motor is over the safe tem-  Internal failure of the motor is causing thermistor module versus a hand held perature threshold. Pump is shut down. the motor to become unusually hot meter This fault is only available if a thermistor module is installed in the system.  Failure of thermistor in pump motor or  Replace thermistor module in the wiring from the thermistor to the system thermistor module

 Thermistor module is faulty 0314 LOW OIL LEVEL - PUMP TRIP While the pump was running the low oil switch was detected by 120VAC signal for a continuous 20 second period. The pump motor was shut down.

0315 LOST LEFT CUTTER CURRENT While the cutter was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motors.

 Low hydraulic oil level

 Check switch

 Low oil switch (or the IS switch relay)

 Check that there is 120VAC active to

is faulty or short circuited

 Signal wire from the switch relay to

pin X3-JJ or 0VAC for normal operations

pin X3-JJ on the machine controller is  Replace the switch short circuited  Replace the Super Simpson  Machine controller is faulty

 Wire X1-L broken

 Check that contactor closes

 Contactor faulty

 Check motor mate feedback versus

 Motor mate faulty  Machine controller faulty

hand held meter

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 45

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0316 LOST RIGHT CUTTER CURRENT While the cutter was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motors.

0317 LEFT CUTTER MOTOR MATE FAULT

Possible cause

 Wire X1-S broken

 Check that contactor closes

 Contactor faulty

 Check motor mate feedback versus

 Motor mate faulty  Machine controller faulty

shorted

 No load connected to motor shaft  Mechanical failure of the cutter shaft

While the left cutter was running, the currents detected in the left cutter motor  Mechanical failure of the cutter gear were very small. It is possible that no box load is connected to the left cutter motor or that there is a mechanical failure of the left cutter itself or the left cutter gear box. The cutter motors were shut down.

0319 LEFT CUTTER PHASE LOSS While the left cutter was running, at last one of the phase currents went to 0 amperes for unknown reasons. It is possible that the motor lead is not connected from the motor. It is also possible that the motor itself has a serious internal failure. The cutter motors were shut down.

0320 LEFT CUTTER MOTOR PHASE IMBALANCE While the cutter motors were running, a significant difference in the left cutter phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The cutter motors were shut down.

hand held meter

 Replace motor mate  Replace Super Simpson

 Wires to the motor mate are broken or  Check 24VDC supply to motor mate

At least one of the three signal lines  There is no 24VDC supply to the moform the motor mate is faulty, while the tor mate left cutter was running, or an attempt was made to start the left cutter. Each  The motor mate is faulty signal line must read between 4mA and 20mA to be normal. If any of the lines in  Machine controller (or inputs to manot in this range then this fault will occhine controller) faulty cur. The cutter motors were shut down.

0318 LEFT CUTTER NO LOAD CURRENT

Checks to carry out

 Motor power conductor is broken  Serious motor failure  Left cutter motor mate is faulty  Machine controller is faulty* inputs from motor mate)

 Motor power conductor is broken  Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

 Check wire connection from motor mate to Super Simpson

 Replace motor mate  Replace Super Simpson

 Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

________________________________________________________________ 46 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0321 LEFT CUTTER MOTOR INSTANT OVERLOAD While the cutter motors were running, the current measured in the left cutter motor exceeded the instantaneous overload threshold. The left cutter motors were shut down.

Possible cause

Checks to carry out

 Failure of gear box that is overloading  Check proper functionality of cutter or jamming the motor shaft

motor

 Heavy cutting loads are causing over-  Verify motor mate feedback against loading of the motor

 Serious failure of the left cutter motor

hand held meter

 Replace motor mate  Replace Super Simpson

0322 LEFT CUTTER THERMAL OVERLOAD

 Heavy cutting loads are causing over-  Check proper functionality of cutter

The left cutter motor current was too high for too long of a period. This can cause overheating and possible damage to the motor. The cutter motors were shut down and are prevented from starting for several minutes to prevent left cutter motor damage.

 Failure of gear box that is overloading  Verify motor mate feedback against

0323 LEFT CUTTER MOTOR RTD THERMAL TRIP

 Cooling system of the left cutter motor  Check proper functionality of cutter

The temperature of the motor windings in the left cutter motor is over the sage temperature threshold. Cutters are shut down.

This fault is only available if a thermistor module is installed in the system.

 Internal failure of the motor causing

loading of the motor

or jamming of the motor shaft

 Serious failure of the left cutter motor

motor

hand held meter

 Replace motor mate  Replace Super Simpson

is impeded by debris or other factors, preventing adequate cooling

the motor to become unusually hot

 Failure of thermistor in left cutter mo-

motor

 Verify thermistor feedback resistance against hand held meter

 Replace thermistor module

tor or in the wiring from the thermistor to the system thermistor module

 Thermistor module is faulty 0324 RIGHT CUTTER MOTOR MATE FAULTY

 Wires to the motor mate are broken or  Check 24VDC supply to motor mate shorted

At least one of three signal lines from the  There is no 24VDC supply to the momotor mate is faulty, while the right cutter tor mate was running or an attempt was made to start the right cutter. Each signal line must  There motor mate is faulty read between4mA and 20mA to be normal.

If any of the lines is not in this range, then this fault will occur. The cutter motors were  Machine controller (or inputs to machine controller) faulty shut down.

0325 RIGHT CUTTER NO LOAD CURRENT

 No load connected to motor shaft  Mechanical failure of the cutter shaft

While the right cutter was running, the currents detected in the right cutter motor  Mechanical failure of the cutter gear were very small. It is possible that no load box is connected to the right cutter or that there is a mechanical failure of the right cutter itself or the right cutter gear box. The cutter motors were shut down.

 Check wire connection from motor mate to Super Simpson

 Replace motor mate  Replace Super Simpson

 Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 47

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0326 RIGHT CUTTER PHASE LOSS While the right cutter was running, at least one of the phase currents went to 0 amperes for unknown reasons. It is possible that the motor lead is not connected from the motor. It is also possible that the motor itself has a serious internal failure. The cutter motors were shut down.

0327 RIGHT CUTTER PHASE IMBALANCE While the cutter motors were running, a significant difference in the right cutter phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The cutter motors were shut down.

0328 RIGHT CUTTER INSTANT OVERLOAD While the cutter motors were running, the current measured in the right cutter motor exceeded the instantaneous overload threshold. The cutter motors were shut down.

0329 RIGHT CUTTER THERMAL OVERLOAD

Possible cause

 Motor power conductor is broken  Serious motor failure  Cutter motor mate is faulty  Machine controller is faulty (inputs from motor mate)

 Motor power conductor is broken  Serious motor failure  Cutter motor mate is faulty  Machine controller is faulty (inputs from motor mate)

 Right traction drive is faulty  CAN bus wiring is disconnected or broken

Checks to carry out

 Check the integrity of the daisy chain cable and its internal wires

 Check all modules are properly connected to the daisy chain cable

 Check the 24VDC supply to module  Replace the module  Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of cutter motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Heavy cutting loads are causing over-  Check proper functionality of cutter loading of the motor

motor

 Failure of gear box that is overloading  Verify motor mate feedback against The right cutter motor current was too or jamming the motor shaft hand held meter high for too long a period. This can cause overheating and possible damage  Serious failure of the left cutter motor  Replace motor mate to the motor. The cutter motors were shut down and are prevented from start Replace Super Simpson ing for several minutes to prevent cutter motor damage.

0330 RIGHT CUTTER MOTOR RTD THERMAL TRIP

 Cooling system of the right cutter mo-  Check proper functionality of cutter tor is impeded by debris or other factors, preventing adequate cooling

motor

 Verify thermistor feedback resistance The temperature of the motor windings  Internal failure of the motor is causing against hand held meter in the right cutter motor is over the safe the motor to become unusually hot temperature threshold. Cutter are shut  Replace thermistor module down. This fault is only available if a  Failure of thermistor in left cutter mothermistor module is installed in the systor or in the wiring from the thermistor tem. to the system thermistor module  Thermistor module is faulty

________________________________________________________________ 48 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0331 LOST CONVEYOR FWD CURRENT

Possible cause

 Wire X1-N broken

 Contactor faulty While the conveyor was running, current feedback was lost. The control system  Motor mate faulty assumed that the contactor had opened and shut down the conveyor motors.  Machine controller faulty 0332 LOST CONVEYOR REV CURRENT

 Wire X1-P broken

 Contactor faulty While the conveyor was running, current feedback was lost. The control system  Motor mate faulty assumed that the contactor had opened and shut down the conveyor motors.  Machine controller faulty

0333 LEFT CONVEYOR MOTOR MATE FAULTY

 Check that contactor closes  Check motor mate feedback versus hand held meter

 Replace motor mate

 Check that contactor closes  Check motor mate feedback versus hand held meter

 Replace motor mate  Replace Super Simpson

 Wires to the motor mate are broken or  Check 24VDC supply to motor mate shorted

 There is no 24VDC supply to the mo-

At least one of the three signal lines tor mate from the motor mate is faulty, while the conveyor was running or an attempt was  Motor mate faulty made to start the conveyor. Each signal line must read between 4mA and 20mA to be normal. If any of the lines is not in  Machine controller (or inputs to machine controller) faulty this range then this fault will occur. The conveyor motors were shut down.

0334 LEFT CONVEYOR NO LOAD CURRENT

Checks to carry out

 No load connected to motor shaft  Mechanical failure of the conveyor

shaft While the conveyor was running, the currents detected in the conveyor motor  Mechanical failure of the conveyor were very small. It is possible that no gear box load is connected to the left conveyor motor or that there is a mechanical failure of the motor itself or motor gear box.

The conveyor motors were shut down.

0335 LEFT CONVEYOR MOTOR PHASE LOSS

 Motor power conductor is broken

While the conveyor was running, at last one of the phase currents went to 0 amperes for unknown reasons. It is possible that the motor lead is not connected from the motor. It is also possible that the motor itself has a serious internal failure. The conveyor motors were shut down.

 Motor mate is faulty

 Serious motor failure

 Machine controller is faulty (inputs from motor mate)

 Check wire connection from motor mate to Super Simpson

 Replace motor mate  Replace Super Simpson

 Check proper functionality of conveyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of conveyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 49

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

0336 LEFT CONVEYOR PHASE IMBALANCE

 Motor power conductor is broken

While the conveyors were running a significant difference in the motor phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The conveyor motors were shut down.

 Motor mate is faulty

0337 LEFT CONVEYOR INSTANT OVERLOAD

 Failure of gear box that is overloading  Check proper functionality of motor

 Serious motor failure

 Machine controller is faulty

or jamming the motor shaft

While the conveyor motors were running of the motor the current measured in the motor exceeded the instantaneous overload  Serious failure of the conveyor motor threshold. The conveyor motors were shut down.

The motor current was too high for too long of a period. This can cause overheating and possible damage to the motor. The conveyor motors were shut down and are prevented from starting for several minutes to prevent motor damage.

0339 LEFT CONVEYOR MOTOR RTD THERMAL TRIP

veyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

 Heavy loads are causing overloading

0338 LEFT CONVEYOR THERMAL OVERLOAD

 Check proper functionality of con-

 Heavy loads are causing overloading of the motor

 Failure of gearbox that is overloading or jamming the motor shaft

 Serious failure of the conveyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of motor  Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Replace Super Simpson

 Cooling system of the motor is impeded by debris or other factors, preventing adequate cooling

 Check proper functionality of motor  Verify thermistor feedback resistance

against hand held meter The temperature of the motor windings  Internal failure of the motor is causing in the motor is over the safe temperathe motor to become unusually hot  Replace thermistor module ture threshold. Conveyors are shut down. This fault is only available if a  Failure of thermistor in motor or in the thermistor module is installed in the syswiring from the thermistor to the system. tem thermistor module

 Thermistor module is faulty 0340 RIGHT CONVEYOR MOTOR MATE FAULTY

 Wires to the motor mate are broken or  Check 24VDC supply to motor mate shorted

 There is no 24VDC supply to the mo-

At least one of the three signal lines tor mate from the motor mate is faulty, while the conveyor was running or an attempt was  The motor mate is faulty made to start the conveyor. Each signal line must read between 4mA and 20mA to be normal. If any of the lines is not in  Machine controller (or inputs to machine controller) faulty this range then the fault will occur. The conveyor motors were shut down.

 Check wire connection from motor mate to Super Simpson

 Replace motor mate  Replace Super Simpson

________________________________________________________________ 50 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0341 RIGHT CONVEYOR NO LOAD CURRENT

Possible cause

 No load connected to motor shaft  Mechanical failure of the conveyor

shaft While the conveyor was running, the currents detected in the conveyor motor  Mechanical failure of the conveyor were very small. It is possible that no gearbox load is connected to the left conveyor motor or that there is a mechanical failure of the motor itself or motor gear box.

The conveyor motors were shut down.

0342 RIGHT CONVEYOR PHASE LOSS

 Motor power conductor is broken  Serious motor failure

While the conveyor was running, at least one of the phase currents went to 0 am Motor mate is faulty peres for unknown reasons. It is possible that the motor lead is not connected  Machine controller is faulty (inputs from the motor. It is also possible that from motor mate) the motor itself has a serious internal failure. The conveyor motors were shut down.

Checks to carry out

 Check proper functionality of conveyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check proper functionality of conveyor motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

0343 RIGHT CONVEYOR PHASE IMBALANCE

 Motor power conductor broken

 Verify proper functionality of the motor

 Serious motor failure

 Check motor mate reading against a

While the conveyors were running a significant difference in the motor phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The conveyor motors were shut down.

 Pump motor mate faulty

0344 RIGHT CONVEYOR INSTANT OVERLOAD

 Failure of gear box that is overloading  Verify proper functionality of the motor

 Machine controller is faulty (inputs from motor mate)

or jamming the motor shaft

 Heavy loads are causing overloading

While the conveyor motors were running of the motor the current measured in the motor exceeded the instantaneous overload  Serious failure of the conveyor motor threshold. The conveyor motors were shut down.

0345 RIGHT CONVEYOR THERMAL OVERLOAD The motor current was too high for too long of a period. This can cause overheating and possible damage to the motor. The conveyor motors were shut down and are prevented from starting for several minutes to prevent motor damage.

 Heavy loads are causing overloading of the motor

 Failure of gear box that is overloading or jamming the motor shaft

 Serious failure of the motor

hand held meter

 Replace motor mate  Replace Super Simpson

 Check motor mate reading against a hand held meter

 Replace motor mate  Replace Super Simpson  Verify proper functionality of the motor  Check motor mate reading against a hand held meter

 Replace motor mate  Replace controller

_______________________________________________________________ A6474X472 Rev 0 51

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

0346 RIGHT CONVEYOR MOTOR RTD THERMAL TRIP

 Cooling system of the motor is im-

 Verify proper functionality of motor

peded by debris (or other factors) preventing adequate cooling

 Check the resistance reported by

The temperature of the motor windings in the pump motor is over the safe temperature threshold. Pump is shut down.

Fault is only available if a thermistor module is installed in the system.

 Internal failure of the motor is causing

thermistor module against a hand held meter

the motor to become unusually hot

 Failure of thermistor in motor or in the

 Replace thermistor module

wiring from the thermistor to the system thermistor module

 Thermistor module is faulty 0347 LOST FAN CURRENT

 Wire X1-M broken

 Contactor faulty While the fan was running, current feedback was lost. The control system as Motor mate faulty sumed that the contactor had opened and shut down the fan motor.  Machine controller faulty

 Check that contactor closes  Check motor mate feedback versus hand held meter

 Replace motor mate  Replace Super Simpson

0348 FAN MOTOR MATE FAULTY

 Wires to the motor mate are broken or  Check 24VDC supply to motor mate

At least one of the three signal lines from the motor mate is faulty, while the fan was running or an attempt was made to start the fan. Each signal line must read between 4mA and 20mA to be normal. If any of the lines is not in this range then this fault will occur. The fan motor was shut down.

 There is no 24VDC supply to the mo-

0349 FAN NO LOAD CURRENT

 No load connected to motor shaft

 Check for proper functionality of motor

 Mechanical failure of the motor shaft

 Verify motor mate feedback against

While the fan was running, the currents detected in the motor were very small.

It is possible that no load is connected to the motor or that there is a mechanical failure of the motor itself or motor gear box. The fan motor was shut down.

0350 FAN PHASE LOSS

shorted

tor mate

 The motor mate is faulty  Machine controller (or inputs to ma-

 Check wire connection from motor mate to Super Simpson

 Replace motor mate  Replace Super Simpson

chine controller) faulty

 Mechanical failure of the motor gear box

hand held meter

 Replace motor mate  Replace Super Simpson

 Motor power conductor is broken

 Serious motor failure While the fan was running, at least one of the phase currents went to 0 amperes  Motor mate is faulty for unknown reasons. It is also possible that the motor lead is not connected  Machine controller is faulty (inputs from the motor. It is also possible that from motor mate) the motor itself has a serious internal failure. The fan motor was shut down.

 Check for proper functionality of motor  Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

________________________________________________________________ 52 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0351 FAN PHASE IMBALANCE While the fan was running, a significant difference in the motor phase currents was detected. Normally all three phase currents for a motor should be approximately equal. The fan was shut down.

Possible cause

Checks to carry out

 Motor power conductor is broken

 Check for proper functionality of motor

 Serious motor failure

 Verify motor mate feedback against

 Motor mate is faulty  Machine controller is faulty (inputs from motor mate)

hand held meter

 Replace motor mate  Replace Super Simpson

0352 FAN INSTANT OVERLOAD

 Failure of gear box that is overloading  Check for proper functionality of motor

While the fan was running the current measured in the motor exceeded the instantaneous overload threshold. The motor was shut down.

 Heavy loads are causing overloading

0353 FAN THERMAL OVERLOAD

or jamming the motor shaft

of the motor

 Serious failure of the motor  Heavy loads are causing overloading

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check for proper functionality of motor

of the motor

 Verify motor mate feedback against The motor current was too high for too  Failure of gear box that is overloading hand held meter long of a period. This can cause overor jamming the motor shaft heating and possible damage to the  Replace motor mate motor. The motor was shut down and is  Serious failure of the motor prevented from staring for several min Replace Super Simpson utes to prevent motor damage.

0354 FAN MOTOR RTD THERMAL TRIP The temperature of the motor windings in the motor is over the safe temperature threshold. Fan is shut down. This fault is only available if a thermistor module is installed in the system.

 Cooling system of the motor is impeded by debris or other factors, preventing adequate cooling

 Internal failure of the motor is causing the motor to become unusually hot

 Check proper functionality of motor  Verify thermistor feedback resistance against hand held meter

 Replace thermistor module

 Failure of thermistor in motor or in the wiring from the thermistor to the system thermistor module

 Thermistor module is faulty 0355 REMOTE STOP KEY TRIP When the STOP key on the remote console is pressed, the pilot circuit is immediately opened. The power center supplying the machine then responds by removing main power from the machine.

 STOP key on the remote console

 Verify that STOP key is pulled out on remote

 Replace remote

_______________________________________________________________ A6474X472 Rev 0 53

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0356 PUMP MULTI-INST OL While the pump was running the current measured in the motor exceeded the instantaneous overload threshold. The pump motor was shut down. This has happened multiple times and the motor now requires a longer cool down period before restart.

Possible cause

Checks to carry out

 Failure of the pump gear box that is

 Verify proper functionality of motor

overloading or jamming the pump motor shaft

 Check motor mate reading against

 Overload of the hydraulic system that

hand held meter

is placing excessive mechanical load-  Replace motor mate ing of the pump motor shaft  Replace Super Simpson  Serious failure of the pump motor

0357 L CONV MULTI-INSTANT OL

 Failure of gear box that is overloading  Verify proper functionality of the motor

While the conveyor motor was running the current measured in the motor exceeded the instantaneous overload threshold. The conveyor was shut down. This has happened multiple times and the motor now requires a longer cool down period before restart.

 Overload of the hydraulic system that

0358 R CONV MULTI-INST OL

 Failure of gear box that is overloading  Verify proper functionality of the motor

While the conveyor was running the current measured in the motor exceeded the instantaneous overload threshold. The conveyor motor was shut down. This has happened multiple times and the motor now requires a longer cool down period before restart.

 Overload of the hydraulic system that

 Serious failure of the motor

 Replace controller

0359 L CUTT MULTI-INST OL

 Failure of gearbox that is overloading

 Verify proper functionality of the motor

or jamming the motor shaft

hand held meter is placing excessive mechanical loading of the motor shaft  Replace motor mate

 Serious failure of the motor

or jamming the pump motor shaft

 Replace controller

 Check motor mate reading against a

hand held meter is placing excessive mechanical loading of the motor shaft  Replace motor mate

or jamming the motor shaft

While the motor was running the current  Overload of the hydraulic is placing measured in the motor exceeded the excessive mechanical loading of the instantaneous overload threshold. The motor shaft cutter was shut down. This has happened multiple times and the motor now  Serious failure of the motor requires a longer cool down period before restart.

0360 R CUTT MULTI-INST OL

 Check motor mate reading against a

 Failure of gearbox that is overloading or jamming the motor shaft

While the motor was running the current  Overload of the hydraulic is placing measured in the motor exceeded the excessive mechanical loading of the instantaneous overload threshold. The motor shaft cutter was shut down. This has happened multiple times and the motor now  Serious failure of the motor requires a longer cool down period before restart.

 Check motor mate reading against a hand held meter

 Replace motor mate  Replace controller  Verify proper functionality of the motor  Check motor mate reading against a hand held meter

 Replace motor mate  Replace controller

________________________________________________________________ 54 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0361 FAN MULTI-INST OL

Possible cause

Checks to carry out

 Failure of gear box that is overloading  Verify proper functionality of the motor or jamming the motor shaft

 Check motor mate reading against a While the motor was running the current  Overload of the hydraulic system that hand held meter measured in the motor exceeded the is placing excessive mechanical loadinstantaneous overload threshold. The ing of the motor shaft  Replace motor mate fan was shut down. This has happened multiple times and the motor now re Serious failure of the motor  Replace controller quires a longer cool down period before restart.

0362 HEAD METH COMM FAIL

 The sensor has suffered an internal

The methane sensor failed to send a message to the machine controller for more than a half second.

 A communication wire has broken

failure

between the sensor and the machine controller

 The sensor has lost power  The machine controller has failed 0363 HEAD METH SENS FAIL

 The sensor has suffered an internal

 Verify sensor is not reporting an internal error

 Check communications twisted pair to methane sensor

 Check that sensor has power  Replace Super Simpson  Replace sensor

failure

The methane sensor is reporting that it has suffered an internal failure that is not listed in the official documentation but it is still communicating with the machine controller.

0364 REAR METH COMM FAIL

 The sensor has suffered an internal

The methane sensor failed to send a message to the machine controller for more than a half second.

 A communication wire has broken

failure

between the sensor and the machine controller

 The sensor has lost power  The machine controller has failed 0365 REAR METH SENS FAIL

 The sensor has suffered an internal

 Verify sensor is not reporting an internal error

 Check communications twisted pair to methane sensor

 Check that sensor has power  Replace Super Simpson  Replace sensor

failure

The methane sensor is reporting that it has suffered an internal failure that is not listed in the official documentation but it is still communicating with the machine controller

_______________________________________________________________ A6474X472 Rev 0 55

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

0366 METHANE MONITOR RELAY OPEN PUMP SHUTDOWN

 The sensor has suffered an internal

The methane monitor relay has opened which removes power from the machine.

failure

 X3-LL wire has broken causing an open circuit

 The relay contact has failed causing an open circuit

Checks to carry out

 Check for internal methane sensor fault

 Check for 120VAC to X3-LL  Check MMR  Replace Super Simpson

 The machine controller has failed 0367 H. METH SENS FAULT F2

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor failed to successfully complete calibration.

0368 H. METH SENS FAULT F3

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an EEPROM checksum error.

0369 H. METH SENS FAULT F4

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an open or short circuit connection.

0370 H. METH SENS FAULT F6

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting a low supply voltage level.

0371 H. METH SENS FAULT F7

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an EEPROM verification error.

0372 H. METH SENS FAULT F8

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting that it was unable to complete setup.

0373 H. METH SENS FAULT F9

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting that it has serial communication errors.

0374 R. METH SENS FAULT F2

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor failed to successfully complete calibration.

________________________________________________________________ 56 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0375 R. METH SENS FAULT F3

Possible cause

Checks to carry out

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an EEPROM checksum error.

0376 R. METH SENS FAULT F4

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an open or short circuit connection.

0377 R. METH SENS FAULT F6

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting a low supply voltage level.

0378 R. METH SENS FAULT F7

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting an EEPROM verification error.

0379 R. METH SENS FAULT F8

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting that it was unable to complete setup.

0380 R. METH SENS FAULT F9

 The sensor suffered an internal failure  Replace methane sensor

The methane sensor is reporting that it has serial communication errors.

0381 CONVEYOR MOTOR IMBALANCE The conveyor motor torque shaft has broken.

 The torque shaft has broken

 Check motor

 There is no load on the motor

 Compare left and right motor readings

 There is a serious failure on the motor  Replace torque shaft  The motor gear box has failed

 Replace motor mate  Replace Super Simpson

0382 CUTTER MOTOR IMBALANCE The motor torque shaft has broken.

 The torque shaft has broken

 Check motor

 There is no load on the motor

 Compare left and right motor readings

 There is a serious failure on the motor  Replace torque shaft  The motor gear box has failed

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 57

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0383 PUMP RUN CURRENT LOST While the pump was running current feedback was lost. The control system assumed that the contactor had opened and shut down the pump motor.

0384 ILLEGAL PUMP CURRENT

Possible cause

Checks to carry out

 Wire X1-J broken

 Check that contactor closes

 Contactor faulty

 Check motor mate feedback versus

 Motor mate faulty  Machine controller faulty  A short on the contactor wiring

hand held meter

 Replace motor mate  Replace Super Simpson  Check contactor wiring

 The motor mate is faulty While the pump motor should have been off, current feedback was detected. The  The machine controller is faulty control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

 Check motor mate feedback versus

 Pump run output X1-J broken

 Check 120VAC from pump run relay

 The motor cables are not connected

 Verify that contactor is closing

0385 NO PUMP CURRENT DETECTED AT STARTUP When the pump motor should have started, no current was detected on the motor mate. The control system assumed that the contactor had remained open and issued a system fault.

0386 RIGHT SIDE E-STOP BUTTON PRESSED While the machine was running, the right hand e-stop button was pressed.

0387 LEFT SIDE E-STOP BUTTON PRESSED While the machine was running, the left hand e-stop button was pressed.

to the contactor

 The motor mate is faulty

 The right hand e-stop has been pressed

 There is no 110VAC on E-STOP input  The machine controller is faulty  The left hand e-stop has been pressed

 There is no 110VAC on E-STOP input  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

 Replace motor mate  Replace Super Simpson  Check that E-stop is pulled out  Check 120VAC to E-STOP input  Replace Super Simpson

 Check that E-stop is pulled out  Check 120VAC to E-STOP input  Replace Super Simpson

________________________________________________________________ 58 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0388 MAIN AC SUPPLY LOST

Possible cause

 There is no 110VAC on pin X1-a  Circuit breaker has opened

Checks to carry out

 Check that high voltage is arriving to transformer

While the machine was running, the main AC power supply was lost. All  The transformer is faulty machine functions have been shut down and machine is now in battery back-up.  The machine controller is faulty

 Check that 120VAC is arriving to X1-a

0389  There is no 120VAC on pin X1-D MMR STATUS WIRE BROKEN - PUMP SHUTDOWN  Machine controller is faulty

 Check 120VAC supply to X1-D

 Replace Super Simpson

 Replace Super Simpson

While the machine was running, the methane monitor status wire (X1-D) has broken.

0390 RIGHT E-STOP WIRE BROKEN While the machine was running, the right e-stop status wire (X1-V) broke.

0391 ILLEGAL LEFT CUTTER CURRENT

 There is no 110VAC on pin X1-V

 Check 110VAC to X1-V

 The machine controller is faulty

 Replace Super Simpson

 Contactor was unable to open

 Check that contactor is closed

 Motor mate is faulty While the cutter motor should have been off, current feedback was detected. The  The machine controller is faulty control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

0392 ILLEGAL RIGHT CUTTER CURRENT

 Contactor was unable to open

 Motor mate is faulty While the cutter motor should have been off, current feedback was detected. The  The machine controller is faulty control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

0393 LOST LEFT CUTTER CURRENT While cutter was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motor.

 Check wiring to contactor for 120VAC  Verify motor mate feedback  Replace motor mate  Replace Super Simpson  Check that contactor is closed  Check wiring to contactor for 120VAC  Verify motor mate feedback  Replace motor mate  Replace Super Simpson

 Wire X1-L has broken

 Check 120VAC on X1-L and X1-R

 The contactor is faulty

 Check motor mate feedback with

 The motor mate is faulty  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 59

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0394 LOST RIGHT CUTTER CURRENT While the cutter was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motor.

Possible cause

Checks to carry out

 Wire X1-S has broken

 Check 120VAC on X1-S and X1-R

 The contactor is faulty

 Check motor mate feedback with

 The motor mate is faulty  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

0395 ILLEGAL LEFT CONVEYOR CURRENT

 Left conveyor contact short

 Check that contactor is closed

 Motor mate faulty

 Check wiring to contactor for 120VAC

While the motor should have been off, current feedback was detected. The control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

 Machine controller faulty

 Verify motor mate feedback

0396 ILLEGAL RIGHT CONVEYOR CURRENT

 Right conveyor contact short

 Check that contactor is closed

 Motor mate faulty

 Check wiring to contactor for 120VAC

While the motor should have been off, current feedback was detected. The control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

 Machine controller faulty

 Verify motor mate feedback

0397 LOST LEFT CONVEYOR CURRENT

 Wire X1-P has broken

 Check 120VAC on X1-P and X1-R

 The contactor is faulty

 Check motor mate feedback with

While the motor was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motor.

0398 LOST RIGHT CONVEYOR CURRENT While the motor was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the cutter motor.

 Replace motor mate  Replace Super Simpson

 Replace motor mate  Replace Super Simpson

 The motor mate is faulty  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

 Wire X1-P has broken

 Check 120VAC on X1-P and X1-R

 The contactor is faulty

 Check motor mate feedback with

 The motor mate is faulty  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

________________________________________________________________ 60 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 399 ILLEGAL FAN CURRENT While the motor should have been off, current feedback was detected. The control system assumed the contactor had closed illegally and removed power from the machine by activating the outby e-stop relay.

0400 LOST FAN CURRENT While motor was running, current feedback was lost. The control system assumed that the contactor had opened and shut down the motor.

0401 LCAT - FROZEN INT. The traction module has detected an internal error.

0402 LCAT - FROZEN EXT. The traction module has detected an external error.

0403 LCAT - OPEN INT. The traction module has detected an internal error.

0404 LCAT - OPEN EXT. The traction module has detected an external error.

Possible cause

Checks to carry out

 Fan contact short

 Check that contactor is closed

 Motor mate is faulty

 Check wiring to contactor for 120VAC

 The machine controller is faulty

 Verify motor mate feedback  Replace motor mate  Replace Super Simpson

 Wire X1-M has broken

 Check 120VAC on X1-M and X1-R

 The contactor is faulty

 Check motor mate feedback with

 The motor mate is faulty  The machine controller is faulty

hand held meter

 Replace motor mate  Replace Super Simpson

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

_______________________________________________________________ A6474X472 Rev 0 61

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Replace the traction module

 The traction interface is faulty

 Replace the interface box

 The left drive is faulty

 Replace the drive

 The traction module is faulty

 Check deadman switch wiring

 Deadman switch is shorted

 Replace tractions module

 The traction module is faulty

 Check deadman switch wiring

 Deadman switch is shorted

 Replace tractions module

0411 TRACTION COMMS FAIL

 The communication wires are broken

 Check 485 communications wires

 No 24VDC to traction module

 Verify 24VDC supply to module

A communications error has occurred between the machine controller and the traction module.

 The traction module is faulty

 Replace module

 The machine controller is faulty

 Replace Super Simpson

0412 ILLEGAL LEFT TRAM CURRENT

 Drive is not responsive to tram com-

 Verify motor mate feedback with hand

Motor current was detected when no tram command had been issued.

 Motor mate is faulty

0405 RCAT - FROZEN INT. The traction module has detected an internal error.

0406 RCAT - FROZEN EXT. The traction module has detected an external error.

0407 RCAT - OPEN INT. The traction module has detected an internal error.

0408 RCAT - OPEN EXT The traction module has detected an external error.

0409 DEADMAN SW. OPEN The traction module has detected a deadman switch open condition.

0410 DEADMAN SW. FROZEN The traction module has detected a deadman switch frozen condition.

mands

held meter

 Replace drive or motor mate

________________________________________________________________ 62 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

0413 ILLEGAL RIGHT TRAM CURRENT

 Drive is not responsive to tram com-

 Verify motor mate feedback with hand

Motor current was detected when no tram command had been issued

 Motor mate is faulty

 Replace drive or motor mate

0414 LEFT TRAM MOTOR MATE FAULT

 24VDC supply to motor mate phase

 Verify 24VDC input to motor mate

Feedback from at least motor mate phase has been lost.

 Feedback wire is broken

0415 RIGHT TRAM MOTOR MATE FAULT Feedback from at least motor mate phase has been lost

0416 LOST LEFT TRAM CURRENT Current fell below expected minimum level during tram operation

0417 LOST RIGHT TRAM CURRENT Current fell below expected minimum level during tram operation

mands

was lost

held meter

 Check continuity on wiring back to machine controller

 Motor mate is faulty

 Replace motor mate

 Machine controller faulty

 Replace Super Simpson

 24VDC supply to motor mate phase

 Verify 24VDC input to motor mate

was lost

 Feedback wire is broken

 Check continuity on wiring back to machine controller

 Motor mate is faulty

 Replace motor mate

 Machine controller faulty

 Replace Super Simpson

 Three phase supply lost

 Verify three phase supply to drives

 Internal motor failure

 Verify motor mate feedback with hand

 Faulty motor mate reading

held meter

 Replace motor mate

 Three phase supply lost

 Verify three phase supply to drives

 Internal motor failure

 Verify motor mate feedback with hand

 Faulty motor mate reading

held meter

 Replace motor mate

0418 LEFT TRAM INSTANT OVERLOAD

 Failure of gear box that is overloading  Verify proper functionality of motor

While the traction motors were running the current measured in the motor exceeded the instantaneous overload threshold. The traction motors were shut down.

 Heavy loads are causing overloading

or jamming the motor shaft

of the motor

 Serious failure of the traction motor

 Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 63

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

0419 LEFT TRAM THERMAL OVERLOAD

 Heavy loads are causing overloading

The motor current was too high for too long of a period. This can cause overheating and possible damage to the motor. The traction motors were shut down and are prevented from starting for several minutes to prevent motor damage.

 Failure of gear box that is overloading

0420 RIGHT TRAM INSTANT OVERLOAD

 Failure of gear box that is overloading  Verify proper functionality of motor

While the traction motors were running the current measured in the motor exceeded the instantaneous overload threshold. The traction motors were shut down.

 Heavy loads are causing overloading

0421 RIGHT TRAM THERMAL OVERLOAD

 Heavy loads are causing overloading

The motor current was too high for too long of a period. This can cause overheating and possible damage to the motor. The traction motors were shut down and are prevented from starting for several minutes to prevent motor damage.

 Failure of gear box that is overloading

0422 IMMEDIATE BREAKER OPEN

 Breaker tripped

110VAC auxiliary contact voltage from circuit breaker was lost.

of the motor

or jamming the motor shaft

 Serious failure of the motor

or jamming the motor shaft

of the motor

 Serious failure of the traction motor

of the motor

or jamming the motor shaft

 Serious failure of the motor

 Auxiliary contact failure  Broken wire

Checks to carry out

 Verify proper functionality of motor  Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson

 Verify motor mate feedback against hand held meter

 Replace motor mate

 Verify proper functionality of motor  Verify motor mate feedback against hand held meter

 Replace motor mate  Replace Super Simpson  Check 110VAC from contactor auxiliary contact

 Check continuity from contactor to machine controller

 Replace Super Simpson 0423 CUTTER BREAKER OPEN 110VAC auxiliary contact voltage from circuit breaker was lost.

 Breaker tripped  Auxiliary contact failure  Broken wire

 Check 110VAC from contactor auxiliary contact

 Check continuity from contactor to machine controller

 Replace Super Simpson 0424 TRAM BREAKER OPEN 110VAC auxiliary contact voltage from circuit breaker was lost.

 Breaker tripped  Auxiliary contact failure  Broken wire

 Check 110VAC from contactor auxiliary contact

 Check continuity from contactor to machine controller

 Replace Super Simpson

________________________________________________________________ 64 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0425 NO LEFT CUTTER CURRENT DETECTED AT STARTUP No current was detected by motor mate during start of motor (1 second time out)

Possible cause

Checks to carry out

 No 110VAC supplied from machine

 Check wiring from machine controller

controller to contactor

 Contactor failed to close  Motor mate is faulty

to contactor

 Verify that contactor is closing and three phase is supplied

 Verify motor mate feedback with hand held meter

 Replace motor mate 0426 NO RIGHT CUTTER CURRENT DETECTED AT STARTUP No current was detected by motor mate during start of motor (1 second time out)

 No 110VAC supplied from machine controller to contactor

 Connector failed to close  Motor mate is faulty

 Check wiring from machine controller to contactor

 Verify that contactor is closing and three phase is supplied

 Verify motor mate feedback with hand held meter

 Replace motor mate 0427 NO LEFT CONVEYOR CURRENT DETECTED AT STARTUP No current was detected by motor mate during start of motor (1 second time out)

 No 110VAC supplied from machine controller to contactor

 Connector failed to close  Motor mate is faulty

 Check wiring from machine controller to contactor

 Verify that contactor is closing and three phase is supplied

 Verify motor mate feedback with hand held meter

 Replace motor mate 0428 NO RIGHT CONVEYOR CURRENT DETECTED AT STARTUP No current was detected by motor mate during start of motor (1 second time out)

 No 110VAC supplied from machine controller to contactor

 Connector failed to close  Motor mate is faulty

 Check wiring from machine controller to contactor

 Verify that contactor is closing and three phase is supplied

 Verify motor mate feedback with hand held meter

 Replace motor mate 0429 NO FAN CURRENT DETECTED AT STARTUP No current was detected by motor mate during start of motor (1 second time out)

 No 110VAC supplied from machine controller to contactor

 Connector failed to close  Motor mate is faulty

 Check wiring from machine controller to contactor

 Verify that contactor is closing and three phase is supplied

 Verify motor mate feedback with hand held meter

 Replace motor mate

_______________________________________________________________ A6474X472 Rev 0 65

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0430 PUMP OVERLOAD RELAY OPEN

Possible cause

Checks to carry out

 Motor being run at high current level

 Verify relay is set correctly and motor

for long period of time

Thermal overload relay was detected as  Relay amperage setting is too low open.

 Relay is faulty  Broken wiring

is operating at normal levels

 Check 110VAC from relay to machine controller

 Check wire continuity from relay to machine controller

 Replace machine controller 0431 LEFT TRAM MOTOR OVERLOAD RELAY OPEN Thermal overload relay was detected as open.

 Motor being run at high current level for long period of time

 Relay amperage setting is too low  Relay is faulty  Broken wiring

 Verify relay is set correctly and motor is operating at normal levels

 Check 110VAC from relay to machine controller

 Check wire continuity from relay to machine controller

 Replace machine controller 0432 RIGHT TRAM MOTOR OVERLOAD RELAY OPEN Thermal overload relay was detected as open.

 Motor being run at high current level for long period of time

 Relay amperage setting is too low  Relay is faulty  Broken wiring

 Verify relay is set correctly and motor is operating at normal levels

 Check 110VAC from relay to machine controller

 Check wire continuity from relay to machine controller

 Replace machine controller 0433 CB2 OPEN DURING FAN START Circuit breaker was detected as open during fan motor start

 Breaker tripped  Auxiliary contact failure  Broken wire

 Check 110VAC from contactor auxiliary contact

 Check continuity from contactor to machine controller

 Replace Super Simpson 0434 FAN LOST AUX PUMP FB 110VAC from pump auxiliary contact not detected during motor operation

0435 CUTTER LOST AUX PUMP FB 110VAC from pump auxiliary contact not detected during motor operation

 Auxiliary contact is faulty  Broken wire  Machine controller is faulty

 Auxiliary contact is faulty  Broken wire  Machine controller is faulty

 Verify 110VAC from pump auxiliary contact

 Check wire continuity from contact to machine controller

 Verify 110VAC from pump auxiliary contact

 Check wire continuity from contact to machine controller

 Replace Super Simpson ________________________________________________________________ 66 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0436 CONVEYOR LOST AUX PUMP FB 110VAC from pump auxiliary contact not detected during motor operation

Possible cause

 Auxiliary contact is faulty  Broken wire  Machine controller is faulty

Checks to carry out

 Verify 110VAC from pump auxiliary contact

 Check wire continuity from contact to machine controller

 Replace Super Simpson 0437 CB2 OPEN AT LEFT CUTTER START Circuit breaker was detected as open during motor start

 Breaker tripped  Auxiliary contact failure  Broken wire

 Check 110VAC from contactor auxiliary contact

 Check continuity from contactor to machine controller

 Machine controller failure

 Replace Super Simpson

0438 CB2 OPEN AT RIGHT CUTTER START

 Breaker tripped

 Check 110VAC from contactor auxil-

Circuit breaker was detected as open during motor start

 Broken wire

0439 CB2 OPEN FWD CONVEYOR START Circuit breaker was detected as open during motor start

0440 CB2 OPEN REV CONVEYOR START Circuit breaker was detected as open during motor start

0441 CB2 OPEN DURING PUMP START Circuit breaker was detected as open during motor start

 Auxiliary contact failure

iary contact

 Check continuity from contactor to machine controller

 Machine controller failure

 Replace Super Simpson

 Breaker tripped

 Check 110VAC from contactor auxil-

 Auxiliary contact failure  Broken wire

iary contact

 Check continuity from contactor to machine controller

 Machine controller failure

 Replace Super Simpson

 Breaker tripped

 Check 110VAC from contactor auxil-

 Auxiliary contact failure  Broken wire

iary contact

 Check continuity from contactor to machine controller

 Machine controller failure

 Replace Super Simpson

 Breaker tripped

 Check 110VAC from contactor auxil-

 Auxiliary contact failure  Broken wire  Machine controller failure

iary contact

 Check continuity from contactor to machine controller

 Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 67

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0442 LEFT INVERTER COMMS FAILURE

Possible cause

 Communication wires between the machine controller and thermistor module are broken or shorted

While the pump was running the system lost communications with the inverter.  There is no 120VAC power supply or 24VDC power supply to the drive

 The traction drive unit is faulty  Machine controller is faulty 0443 LEFT VFD UNDERVOLTAGE While tram was enabled, the VFD reported an undervoltage condition (code 02).

0444 LEFT VFD HEATSINK TRIP While tram was enabled, the VFD reported heatsink temperature as above safe operating level (code 04).

0445 LEFT VFD SHORT CIRCUIT While tram was enabled, the VFD reported a short circuit condition (code 05).

0446 LEFT VFD OVERVOLTAGE While tram was enabled, the VFD reported an overvoltage condition (code 06).

0447 LEFT VFD MOTOR OVERLOAD While tram was enabled, the VFD reported an overload condition (code 13).

0448 LEFT VFD INSTANT OVERLOAD While tram was enabled, the VFD reported an instant overload condition (code 20).

Checks to carry out

 Check the integrity of the daisy chain and its internal wires

 Check that all modules are properly connected to the daisy chain cable

 Check the 24VDC supply to module  Replace the module

 Bus voltage below 750VDC

 Increase DC supply

 Rectifier voltage too low

 Check voltage bus connections

 Faulty DC Voltage Measurement Cir-

 Replace rectifier unit

cuit

 Replace drive

 Low coolant flow

 Restore water flow

 Poor drive base contact with enclo-

 Install drive with recommended layer

sure

of thermal paste

 Stall duration of 1 minute

 Remove the cause of the motor stall

 Motor winding failure

 Reset the fault

 Poor terminal contact

 Replace the drive

 Voltage over 1200VDC

 Reduce the supply voltage

 Brake are in thermal condition and

 Allow brake unit to cool

cutting out while braking

 Brake unit faulty

 Replace rectifier or brake module

 Tram load is too high

 Resume tramming at low speed

 Motor settings not properly set

 Check motor setup

 Motor has stalled

 Remove cause of motor stall

 Motor has stalled for 1 minute

 Remove cause of motor stall condition

 Failure in motor winding

 Check all motor terminals

 Poor connection at motor terminals

 Reduce load on the motor  Check IGBT

________________________________________________________________ 68 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0449 LEFT VFD MOTOR TSTAT TRIP While tram was enabled, the VFD reported a thermostat trip (code 35).

0450 LEFT VFD MOTOR OVERSPEED While tram was enabled, the VFD reported an overspeed condition (code 38).

0451 LEFT VFD PHASE LOSS While tram was enabled, the VFD reported a phase loss condition (code 43).

0452 LEFT VFD CAN FAILURE While tram was enabled, the VFD reported a CAN communications loss (code 44).

0453 RIGHT INVERTER COMMS FAILURE While the pump was running, the system lost communication with the inverter.

Possible cause

 Tram load is too high

 Resume tramming at low speed

 Low coolant flow

 Increase coolant flow

 Noise in the encoder

 Check motor connections

 Incorrect inverter settings

 Check motor setup

 Machine is being trammed downhill or dragged

 Motor phase disconnected

 Check all motor terminals

 Motor current is very low

 Reset the fault

 Inverter output phase is very low

 Replace the inverter

 CAN wire broken

 Check CAN link

 Noise on CAN line

 Check CAN link connections

 No control power to inverter

 Restore 120VAC control power

 Drive faulty

 Replace the inverter

 Communication wires between the

 Check the integrity of the daisy chain

machine controller and thermistor module are broken or shorted

 There is no 120VAC power supply or 24 VDC power supply to the drive

 The traction drive unit is faulty  Machine controller faulty 0454 RH VFD UNDERVOLTAGE While tram was enabled, the VFD reported an undervoltage condition (code 02).

0455 RH VFD HEATSINK TRIP While tram was enabled, the VFD reported heatsink temperature as above safe operating level (code 04).

Checks to carry out

cable and its internal wires

 Check that all modules are properly connected to the daisy chain cable

 Check the 24VDC supply to module  Replace the module

 Bus voltage below 750VDC

 Increase DC supply

 Rectifier voltage too low

 Check voltage bus connections

 Faulty DC voltage measurement cir-

 Replace rectifier unit

cuit

 Replace drive

 Low coolant flow

 Restore water flow

 Poor drive base contact with enclo-

 Install drive with recommended layer

sure

of thermal paste

_______________________________________________________________ A6474X472 Rev 0 69

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number

Possible cause

0456 RH VFD SHORT CIRCUIT

 Stall duration of 1 minute

 Remove the cause of motor stall

 Motor winding failure

 Reset the fault

 Poor terminal contact

 Replace the drive

 Voltage over 1200VDC

 Reduce the supply voltage

 Brakes are in thermal condition and

 Allow brake unit to cool

While tram was enabled, the VFD reported a short circuit condition (code 05).

0457 RH VFD OVERVOLTAGE While tram was enabled, the VFD reported an overvoltage condition (code 06).

0458 RIGHT VFD MOTOR OVERLOAD While tram was enabled, the VFD reported an overload condition (code 13).

0459 RH VFD INSTANT OLOAD While tram was enabled, the VFD reported an instant overload condition (code 20).

cutting out while braking

 Brake unit faulty

Checks to carry out

 Replace rectifier or brake module

 Tram load is too high

 Resume tramming at low speed

 Motor settings not properly set

 Check motor setup

 Motor has stalled

 Remove cause of motor stall

 Motor has stalled for 1 minute

 Remove cause of motor stall condition

 Failure in motor winding

 Check all motor terminals

 Poor connection at motor terminals

 Reduce load on the motor  Check IGBT

0460 RH VFD MOTOR TERMOSTAT TRIP While tram was enabled, the VFD reported a thermostat trip (code 35).

0461 RH VFD MOTOR OVERSPEED While tram was enabled, the VFD reported an overspeed condition (code 38).

0462 RH VFD PHASE LOSS While tram was enabled, the VFD reported a phase loss condition (code 43).

0463 RH VFD CAN FAILURE While tram was enabled, the VFD reported a CAN communications loss (code 44).

 Tram load is too high

 Resume tramming at low speed

 Low coolant flow

 Increase coolant flow

 Noise on the encoder

 Check motor connections

 Incorrect inverter settings

 Check motor setup

 Machine is being trammed downhill or dragged

 Motor phase disconnected

 Check all motor terminals

 Motor current is very low

 Reset the fault

 Inverter output phase is very low

 Replace the inverter

 CAN wire broken

 Check CAN link

 Noise on CAN line

 Check CAN link connections

 No control power to inverter

 Restore 120VAC control power

 Drive faulty

 Replace the inverter

________________________________________________________________ 70 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0464 RECTIFIER HEATSINK TRIP While tram was enabled, the rectifier reported a heatsink trip condition (code 04).

0465 RECTIFIER SHORT CIRCUIT While tram was enabled, the rectifier reported a short circuit condition (code 05).

0466 BRAKE IGBT OVER TEMP While tram was enabled, the rectifier reported a IGBT overtemperature condition (code 15).

0467 RECTIFIER INPUT INSTANT O/L While tram was enabled, the rectifier reported an instant overload condition (code 19).

0468 RECTIFIER COMMS FAILURE While tram was enabled, the rectifier reported a CAN communications loss (code 44).

0469 LH VFD MOTOR RTD TRIP While tram was enabled, the VFD reported an RTD trip condition (code 34).

0470 RH VFD MOTOR RTD TRIP While tram was enabled, the VFD reported and RTD trip condition (code 34).

Possible cause

Checks to carry out

 Low coolant flow

 Check coolant flow

 Poor drive base contact with enclo-

 Install drive with recommended layer

sure

of thermal paste

 Brake resistor unit is faulty

 Replace the brake unit

 Dynamic brake IGBT failure

 Replace the rectifier

 Insufficient coolant flow

 Check coolant flow

 Poor thermal contact between base

 Install unit with recommended layer of

and enclosure surface, too much or too little past applied

thermal paste

 DC contact swapped at terminals

 Swap line polarity

 Short on DC bus

 Remove short circuit from bus wiring

 Failed IGBT in an inverter

 Replace the inverter

 Brake IGBT failure

 Replace the rectifier

 Broken communications wiring

 Check CAN wiring in traction enclo-

 Rectifier faulty

 Traction motor load too high  Low coolant flow  Traction motor load too high  Low coolant flow

0471 EMERGENCY STOP RELAY CONTACT OPEN

 ESR tripped by e-stop button

ESR auxiliary contact detected as open.

 Broken wire

 ESR auxiliary contact faulty

 Machine controller digital input faulty

sure

 Replace rectifier unit

 Check resistance reported by RTD module with hand held meter

 Replace RTD module  Check resistance reported by RTD module with hand held meter

 Replace RTD module  Verify that machine e-stops are not asserted

 Verify 110VAC from auxiliary contact  Check wire continuity from contact to machine controller

 Replace Super Simpson

_______________________________________________________________ A6474X472 Rev 0 71

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0472 PILOT ILLEGAL VOLTAGE Voltage was detected on the pilot trip circuit when command was not given.

0473 LH VFD ENCODER LOSS While tram was enabled, the VFD reported an encoder loss condition (code 60).

Possible cause

 Wire short circuit  Machine controller faulty

Checks to carry out

 Check for short circuit condition in wiring

 Replace machine controller

 Encoder failure

 Restore encoder supply

 Encoder supply lost

 Replace encoder

 Encoder signal disconnected

 Replace encoder wiring

 Encoder is faulty 0474 RH VFD ENCODER LOSS While tram was enabled, the VFD reported an encoder loss condition (code 60).

 Encoder failure

 Restore encoder supply

 Encoder supply lost

 Replace encoder

 Encoder signal disconnected

 Replace encoder wiring

 Encoder is faulty 0475 LEFT DC DRIVE COMMS FAILURE While the pump was running the system lost communication with the drive.

 CAN wire is broken

 Replace or repair CAN wiring

 Noise on CAN line

 Restore power to the drive

 No control power to drive

 Replace the drive

 Drive is faulty 0476 LH RMS PHASE SYNC LOSS While tram was enabled, the drive reported a phase sync loss condition.

0477 LH RMS LOST THREE PHASE While tram was enabled, the drive reported a supply loss condition.

0478 LH RMS LOST CAN COMMS

 Motor phase is disconnected

 Restore motor phase connections

 Motor current is very low

 Restore drive input voltage level

 Drive output phase is very low

 Replace the drive

 Motor phase is disconnected

 Restore motor phase connections

 Motor current is very low

 Restore drive input voltage level

 Drive output phase is very low

 Replace the drive

 Noise on CAN lines

 Replace or repair CAN wiring

 Drive is faulty

 Replace the drive

While tram was enabled, the drive reported a CAN communications loss.

________________________________________________________________ 72 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number

Possible cause

0479 LH RMS UNPLANNED MOVE

 Drive detected output when not given

While tram was enabled, the drive reported an unplanned movement condition.

 Drive is faulty

0480 LH RMS E-TRAM MODE

 Power on e-tram pendant box

While tram was enabled, the drive reported that it was in E-TRAM mode.

0481 LH RMS NOT IN READY STATE Drive is not reporting ready state during operation 0482 RIGHT DC DRIVE COMMS FAILURE While the pump was running the system lost communications with the drive.

Checks to carry out

 Replace the drive

a command

 Noise on analog inputs  Drive is faulty

 Remove power from e-tram pendant box

 Repair E-TRAM connections  Replace the drive

 Replace or repair CAN wiring

 Replace or repair CAN wiring

 Replace the drive

 Replace the drive

 CAN wire is broken

 Replace or repair CAN wiring

 Noise on CAN line

 Restore power to the drives

 No control power to drive

 Replace the drive

 Drive is faulty 0483 RH RMS PHASE SYNC LOSS While tram was enabled, the drive reported a phase sync loss condition.

0484 RH RMS LOST THREE PHASE While tram was enabled, the drive reported a supply loss condition.

0485 RH RMS LOST CAN COMMS While tram was enabled, the drive reported a CAN communications loss.

 Motor phase is disconnected

 Restore motor phase connections

 Motor current is very low

 Restore drive input voltage level

 Drive output phase is very low

 Replace the drive

 Motor phase is disconnected

 Restore motor phase connections

 Motor current is very low

 Restore drive input voltage level

 Drive output phase is very low

 Replace the drive

 Noise on CAN lines

 Replace or repair CAN wiring

 Drive is faulty

 Replace the drive

_______________________________________________________________ A6474X472 Rev 0 73

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0486 RH RMS UNPLANNED MOVE While tram was enabled, the drive reported an unplanned movement condition.

0487 RH RMS E-TRAM MODE While tram was enabled, the drive reported that it was in E-TRAM mode.

0488 RH RMS NOT IN READY STATE Drive is not reporting operational state during operation.

0489 CONTROL EARTH LEAKAGE TRIP The machine controller has detected that the ground fault relay is open.

Possible cause

 Drive detected output when not given

Checks to carry out

 Replace the drive

a command

 Drive faulty

 Power on Cervis box

 Remove power from Cervis box

 Noise on analog inputs

 Repair E-TRAM connections

 Drive is faulty

 Replace the drive

 Noise on CAN lines

 Replace or repair CAN wiring

 Drive is faulty

 Replace the drive

 Ground fault has occurred

 Verify relay condition

 Relay is faulty

 Check conductivity between relay and

 Broken wire  Machine controller is faulty

0490 LEFT TRAM MOTOR RTD THERMAL TRIP

 Motor coolant problem

While ram was enabled, the PT100 feedback was above 166 ohms.

 PT100 is faulty

 Motor failure

machine controller

 Replace the machine controller

 Check resistance reported by RTD module with hand held meter

 Replace RTD module

 Thermistor module is faulty 0491 RIGHT TRAM MOTOR THERMAL TRIP

 Motor coolant problem

While tram was enabled, the PT 100 feedback was above 166 ohms.

 PT100 is faulty

 Motor failure

 Check resistance reported by RTD module with hand held meter

 Replace RTD module

 Thermistor module is faulty

________________________________________________________________ 74 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0492 LOW OIL LEVEL - CUTTER TRIP While the cutters were running, the low oil level input was detected as 120VAC continuously for 20 seconds.

Possible cause

Checks to carry out

 Oil level is low

 Add oil

 Oil level switch is faulty

 Verify with a meter 120VAC signal to

 Oil level wiring to X3-Y is short circuited

X3-Y

 Replace Super Simpson

 Digital input on Super Simpson is faulty 0493  Oil level is low LOW OIL LEVEL WARNING CUTTERS TRIP  Oil switch is faulty

 Add oil  Check 120VAC signal wire to Super Simpson

While cutters were running, the low oil level input was detected as 120VAC continuously for 20 seconds.

 Wire is short circuited

0494 PUMP SMART CONTACTOR: ATD FAULT

 Initialization error

 Cycle power

 Internal component failure

 Replace the unit

 Temperature of the unit exceeded

 Restore coolant flow

 Super Simpson is faulty

 Verify oil switch condition

The smart contactor has reported an ATD converter error.

0495 PUMP SMART CONTACTOR: TEMPERATURE FAULT The smart contactor has reported a temperature fault.

0496 PUMP SMART CONTACTOR: POWER RESTORED

85C.

 Contactor is faulty

 Replace the unit

 Power was restored after the unit was  Replace the unit. powered down.

The smart contactor reports power restored.

0497 PUMP SMART CONTACTOR: CONFIG SET The smart contactor reports configuration set.

 The contactor lost its CAN ID.

 Replace the unit

 Internal failure causing unit power to cycle off and on.

_______________________________________________________________ A6474X472 Rev 0 75

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0498 PUMP SMART CONTACTOR: CAN FAULT The smart contactor has reported a CAN communication failure.

Possible cause

 A CAN bus wire/pin has become loose or broken off

 Fuse is blown

Checks to carry out

 Replace or repair the CAN wiring  Replace the unit

 Termination link lost  Contactor lost supply  Super Simpson is faulty

0499 PUMP SHUT DOWN DUE TO RADIO SIGNAL LOSS While the pump was running, the RF signal from the remote console was lost for 1 second.

0500 SMART CONTACTOR - CAN FAULT

 Battery level is low

 Check remote console battery level

 Operator not in line of sight with ma-

 Verify operator position to machine

chine

when trips occur

 Antenna connections damaged

 Check antenna connections for quality

 Super Simpson is faulty

 Replace Super Simpson

 TBD

 Replace or repair the CAN wiring  Replace the unit

While the pump was running, the CAN communications with the contactor were lost.

0501 SMART CONTACTOR - PILOT TRIP

 Current was sensed when no com-

The smart contactor reported a pilot trip condition and the control system activated the out-by relay.

 Contactor failed to open after shut

 Replace the unit

mand was given

down command

 Contactor is faulty 0502 ORACLE - MODULE LINK LOST While the pump was running RS-422 communications with the oracle were lost.

0503 ORACLE - RADIO LINK LOST While the pump was running, the oracle reported that RF communications were lost.

 422 bus wire damaged/loose

 Replace or repair 422 bus wiring

 Noise on 422 bus wires

 Replace the oracle

 Oracle is faulty/Super Simpson is

 Replace the Super Simpson

faulty

 Remote console has low battery

 Replace the remote console

 Operator not in line of sight of ma-

 Repair or replace antenna connec-

chine

 Oracle damaged/loose/water

tions

 Replace the Super Simpson

________________________________________________________________ 76 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number

Possible cause

0504 RADIO SWITCH TIMEOUT

 Operator is holding lever

A radio remote switch has been held for at least 15 seconds.

 A switch has become stuck

Checks to carry out

 Verify that operator releases switches within 15 seconds

 Check for obstructions that would hold switch in active position

 Replace the radio remote 0505 RECTIFIER UNDEFINED FAULT CODE

 Rectifier malfunction  Super Simpson malfunction

 Verify communications between Super Simpson and rectifier

Super Simpson received a fault code form the rectifier unit that was not recognized.

0506 LH VFD UNDEFINED FAULT CODE Super Simpson received a fault code from the left inverter unit that was not recognized.

0507 RH VFD UNDEFINED FAULT CODE Super Simpson received a fault code from the right inverter unit that was not recognized.

0508 LH DRIVE UNDEFINED FAULT CODE Super Simpson received a fault code from the drive unit that was not recognized.

0509 RH DRIVE UNDEFINED FAULT CODE Super Simpson received a fault code from the drive unit that was not recognized.

 Left VFD malfunction  Super Simpson malfunction

 Left VFD malfunction  Super Simpson malfunction

per Simpson and rectifier

 Replace suspect units

 Verify communications between Super Simpson and rectifier

 Replace suspect units

 Drive firmware has changed.

 Cycle power to the drive

 Super Simpson firmware has

 Replace the drive

changed

 Drive faulty

 Report the code

 Drive firmware has changed.

 Cycle power to the drive

 Super Simpson firmware has

 Replace the drive

changed

 Drive faulty

0510  Transformer coolant problem TRANSFORMER RTD THERMAL TRIP While tram was enabled, the PT100 feedback was above 166 ohms.

 Verify communications between Su-

 Transformer problem  PT100 is faulty

 Report the code

 Check reported resistance with hand held meter

 Replace RTD module

 Thermistor module is faulty

_______________________________________________________________ A6474X472 Rev 0 77

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0511 MEMORY CRC CHECK FAILED The system memory check failed because the current memory space does not match the previously recorded value.

Possible cause

 A new program was just loaded  A sudden shut down interrupted a

0513 MACHINE TYPE CHANGED

 If problem persists over several power cycles, replace the Super Simpson

memory write

0512  A new program was just loaded PARAMETER RANGE CHECK FAILED A system parameter was found to be above or below the defined value range.

Checks to carry out

 A sudden shut down interrupted a

 If problem persists over several power cycles, replace the Super Simpson

memory write

 TBD

 TBD

 Oil level is low

 Verify 120VAC to Super Simpson

TBD 0514 OIL LEVEL WARNING CUTTER TRIP While the pump was running, the oil level input is inactive or 0V indicating that the oil level is low.

0515 OIL LEVEL WARNING PUMP TRIP While the pump was running, the oil level input is inactive or 0V indicating that the oil level is low.

0516 OIL TEMPERATURE PUMP TRIP While the pump was running, the oil level input is inactive or 0V indicating that the oil temperature is high.

0517 OIL TEMPERATURE CUTTER TRIP While the cutter was running, the oil temperature input is inactive or 0V indicating that the oil temperature is high.

0518 TRACTION EARTH LEAKAGE TRIP

 Wire is broken  Super Simpson malfunction  Oil level is low  Wire is broken  Super Simpson malfunction  Oil temperature is high  Wire is broken  Super Simpson malfunction  Oil temperature is high  Wire is broken  Super Simpson malfunction  Transformer is faulty  Wire is broken

While the traction was active, the earth leakage input is inactive or 0V indicating  Super Simpson malfunction that there is a ground fault on the transformer.

machine controller

 Fill the machine with oil  Replace the Super Simpson  Verify 120VAC to Super Simpson machine controller

 Fill the machine with oil  Replace the Super Simpson  Verify 120VAC to Super Simpson machine controller

 Allow the machine to cool  Replace the Super Simpson  Verify 120VAC to Super Simpson machine controller

 Allow the machine to cool

 Verify 120VAC to Super Simpson machine controller

 Examine the earth leakage relay and the radio remote connections

________________________________________________________________ 78 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number 0519 LIGHTS EARTH LEAKAGE TRIP

Possible cause

 Light circuit is faulty  Wire is broken

While a motor was running, the earth leakage input is inactive or 0V indicating  Super Simpson malfunction that there is a ground fault on the lighting circuit.

0520 WATER FLOW CUTTER TRIP While the cutter was running, the water flow input is inactive or 0V indicating that the water flow has decreased or stopped.

0521 WATER FLOW PUMP TRIP While the cutter was running, the water flow input is inactive or 0V indicating that the water flow has decreased or stopped.

 Water supply has been lost  Wire is broken  Super Simpson malfunction  Water supply has been lost  Wire is broken  Super Simpson malfunction

Checks to carry out

 Verify 120VAC to Super Simpson machine controller

 Examine the earth leakage relay and radio remote connections

 Verify 120VAC to Super Simpson machine controller

 Check water supply  Replace the Super Simpson  Verify 120VAC to Super Simpson machine controller

 Check water supply  Replace the Super Simpson

0522 WATER PRESSURE CUTTER TRIP

 Water supply has been lost or pump has failed

machine controller

While the cutter was running, the water flow input is inactive or 0V indicating that the water flow has decreased or stopped.

 Wire is broken

 Check water supply

 Super Simpson malfunction

 Replace the Super Simpson

0523 WATER PRESSURE PUMP TRIP

 Water supply has been lost or pump

 Verify 120VAC to Super Simpson

has failed

machine controller

While the cutter was running, the water flow input is inactive or 0V indicating that the water flow has decreased or stopped.

 Wire is broken

 Check water supply

 Super Simpson malfunction

 Replace the Super Simpson

0524 SUPPLY EARTH LEAKAGE TRIP

 Main transformer is faulty

 Verify 120VAC to Super Simpson

The supply leakage input is inactive or 0V indicating that there is a ground fault on the main transformer.

0525 MACHINE SHUT OFF DUE TO INACTIVITY

 Wire is broken  Super Simpson malfunction

 The machine was sitting idle

 Verify 120VAC to Super Simpson

machine controller

 Examine the earth leakage relay and the radio remote connections

 Verify the inactivity timer setting

The machine inactivity timeout expired and the pilot circuit was tripped.

_______________________________________________________________ A6474X472 Rev 0 79

BI016801

Operation _______________________________________________________ Table 2, continued: Fault messages Fault number 0526 LEFT BRAKE RELEASE NOT DETECTED After tramming was enabled, no feedback was received from the pressure switch.

0527 RIGHT BRAKE RELEASE NOT DETECTED After tramming was enabled, no feedback was received from the pressure switch.

Possible cause

 Switch is faulty  Brake did not release due to mechanical or hydraulic failure

 Wire is broken

 Switch is faulty  Brake did not release due to mechanical or hydraulic failure

 Wire is broken

0528  Methane level is increasing METHANE LEVEL WARNING CUTTER TRIP  Wire is broken

Checks to carry out

 Verify that the brake solenoid did activate

 Check 120VAC to machine controller from pressure switch

 Replace the Super Simpson  Verify that the brake solenoid did activate

 Check 120VAC to machine controller from pressure switch

 Replace Super Simpson  Verify 120VAC to Super Simpson machine controller

While the cutter was running, the methane level input is inactive or 0V indicating that the methane level is increasing.

 Super Simpson malfunction

0529 VOLTAGE TRANSDUCER FAILURE

 Wire is broken

 Check wiring to machine controller

 Transducer is faulty

 Verify transducer feedback value with

The transducer feedback level was below 4mA.

0530 LOW MACHINE VOLTAGE LEVEL PUMP TRIP Machine voltage level has dropped below the minimum voltage threshold long enough for the timeout to expire.

 Super Simpson is faulty  Machine voltage dipped due to load on the power center

 Machine voltage settings need to be adjusted

hand held meter

 Replace Super Simpson  Verify load on the power center with hand held meter

 Verify that machine voltage is being reported correctly

 Adjust machine voltage settings to

0531 HIGH MACHINE VOLTAGE LEVEL PUMP TRIP

 Machine voltage increased due to

Machine voltage level has increased above the maximum voltage threshold long enough for the timeout to expire.

 Machine voltage settings need to be

0532 MEMORY MIRROR CRC CHECK FAILED

TBD

reduced load on the power center or adjusted transformer tap settings

adjusted

 Verify load on the power center with hand held meter

 Verify that machine voltage is being reported correctly

 Adjust machine voltage settings to TBD

________________________________________________________________ 80 Super Simpson Control System Troubleshooting

BI016801

______________________________________________________ Operation Table 2, continued: Fault messages Fault number

Possible cause

Checks to carry out

0533 VFD DC BUS OVERVOLTAGE

TBD

TBD

0534 PUMP WITHOUT COOLING FAN TIMEOUT EXCEEDED

TBD

TBD

0535 HAULAGE NOT READY

TBD

TBD

0536 MOTOR SHUTDOWN IN TEST MODE

TBD

TBD

_______________________________________________________________ A6474X472 Rev 0 81

BI016801

Operation _______________________________________________________

________________________________________________________________ 82 Super Simpson Control System Troubleshooting