(Bucyrus 25M Miner Version)
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This document is intended as an operator’s reference to the Super Simpson Remote Control System (Bucyrus 25M Miner Version). This version of the Super Simpson RCS (Remote Control System) is integrated into the electrical system of Bucyrus 25M Continuous Miners and is used to provide radio remote control and monitoring of the machine.
Forced Potato Incorporated
640 Bizzell Drive
Lexington KY 40510
Telephone: +1 859 252 4439
Fax: +1 859 252 4641
Web: www.forcedpotato.com
© Forced Potato Inc.
Other than is permitted by law, no part of this document may be reproduced, stored in a retrieval system or transmitted in any form or process without prior written consent of Forced Potato Incorporated.
Every effort has been made to ensure the accuracy and correctness of the information presented within this document. However, Forced Potato does not provide guarantee of its correctness or accuracy. Other than is required by law, no warranty of any kind is expressed or implied.
Copies of this manual, and other documentation pertaining to Forced Potato control system products, may be obtained by contacting Forced Potato directly.
For all matters involving servicing or purchase of Super Simpson RCS (Bucyrus 25M Miner Version) control system components, please contact your Bucyrus representative or local Bucyrus service center.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 5 of 145 Issue: SY0101.B
The Super Simpson Remote Control System (Bucyrus 25M Miner Version) is a dependable and high-speed radio remote control and monitoring system developed for Bucyrus 25M series continuous miners.
The system is installed in the electrical system of a 25M continuous miner and allows an operator to remotely control machine operation from a safe distance using a radio remote control console.
This manual provides basic information and user instructions for the system. Since that time the system has undergone a number of software revisions to improve performance and to provide additional automation features. Each new revision of software is accompanied by a different part number of receiver control unit.
This manual only pertains to the following model of receiver control unit:
Bucyrus Receiver Part Number: 377873 Forced Potato Part Number: L0Q60101
If this manual does not correspond to your model of receiver control unit, please contact Forced Potato immediately to obtain a copy of the correct publication.
Please contact your local Bucyrus America representative or service center to obtain service or replacement parts for the control system.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 6 of 145 Issue: SY0101.B
The advent of remote control has afforded the operator a notable improvement in personal safety. However, the potential for injury or fatality still exists when operating heavy machinery remotely.
Thus, it is expressly important that the operator observe safe work practice when operating a remote control mining machine. This will be defined by mine and company management and should encompass any relevant state and federal regulations and/or guidelines where applicable.
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Forced Potato Mining Electronics
System Name Super Simpson RCS (Bucyrus 25M Miner Version)
Last S/W Rev.* December 2008
Receiver Part Number
Forced Potato P/N: L0Q60101
Bucyrus P/N: 377873
For exact details on machine wiring configuration please consult the electrical schematic that pertains to your particular miner.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 8 of 145 Issue: SY0101.B
Super Simpson RCS (Bucyrus 25M Miner Version)
Receiver Control Unit
Name given to the remote control system and all its components.
Main control unit of the control system that includes the radio data receiver used to receive and decode commands from the remote control handset
Remote Control Handset Handheld controller that an operator would typically use to control the machine at a distance. Also known as the “Remote Control Console”, “Remote Box” or “Transmitter”
Remote Mode
Manual Mode
Mode of operation where the control system is in control of the machine and can be operated at a distance using the remote control handset.
Mode of operation where “hardwired” switches, buttons and hydraulic levers on the miner are used to control the machine. In this mode all power is usually removed from the Super Simpson control system.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 9 of 145 Issue: SY0101.B
Forced Potato Mining Electronics
“TITO”
(Remote Control Console)
“BRICK”
(Remote Control Console)
“LARGE BRICK”
(Remote Control Console)
Forced
Electronics
“Receiver”
(Integrated radio control receiver and machine control unit)
Part No. 377873
“Standard Power Supply” (no battery backup)
Part No. 295496
“Battery Backup Power Supply”
(automatic battery backup)
Part No. 295275
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“Thermistor Module”
(Measures motor temperatures)
Part No. 388867
“Motor Mate”
(Monitors Motor Amperage at 200A Saturation)
Part No. 385184
“Motor Mate”
(Monitors Motor Amperage at 500A Saturation)
Part No. 385185
Forced Potato Mining Electronics Super Simpson RCS (Bucyrus 25M Miner)
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Forced Potato Mining Electronics
“Traction Unit”
(controls machine tramming)
Part No. 295269
“Miner Display”
(Miner Diagnostic Display)
Part No. 317084
“Antenna”
(Standard Radio Data Antenna)
Part No. 275522
The Super Simpson RCS (Bucyrus 25M Miner Version) is designed to operate in one of two modes:
(1) Machine-based Manual Control Mode (Manual Mode)
(2) Radio Remote Control Mode (Remote Mode)
Typically, the 25M continuous miner features a pair of remote/manual selector switches that the operator may use to switch between the two control modes at any time.
Normally, when the remote/manual selector switches on the miner are in the MANUAL position, all power is removed from the remote control system. In this case, the control system diagnostic display will be blank.
In MANUAL MODE machine control is achieved using hard-wired control buttons and hydraulic levers. Control buttons mounted on the front panel of the operator’s electrical enclosure are used to start and stop all machine motors. When the pump is running, manual levers mounted on the main hydraulic valve bank are used to operate hydraulic functions on the machine.
The Super Simpson RCS (Bucyrus 25M Miner Version) is isolated in Manual Mode and normally has no control or effect on manual control functions or operations.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 14 of 145 Issue: SY0101.B
When the remote/manual selector switches on the 25M miner are in the REMOTE position, the system will assume the REMOTE MODE of operation.
In REMOTE MODE, the Super Simpson RCS (Bucyrus 25M Miner Version) is in control of machine motors and hydraulic functions. The operator uses a remote control handset to operate the machine at a distance. This is the typical mode of operation and is normally used when the machine is used in a production situation.
Currently, there are several different models of remote control handset that can be used to operate the system in REMOTE MODE. The TITO model handset (Bucyrus P/N: 323307) is the latest model of remote control console. The machine can be operated in the same fashion with earlier model handsets also.
In REMOTE MODE, the diagnostic display will be active and should appear as follows:
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 15 of 145 Issue: SY0101.B
A remote control console (or handset) is used by the operator to remotely control the miner at a distance in REMOTE MODE.
The Super Simpson RCS (Bucyrus 25M Miner Version) can be controlled with several different models of remote control handset. Forced Potato recommends use of the latest model handsets – known as TITO. The TITO model handsets offer improved battery life, additional safety features and enhanced diagnostics. TITO handsets also comply with the latest MSHA recommendations for continuous miner remote control safety (as outlined in MSHA Program Information Bulletin PIB P03-3).
Available handsets that can be used with the Super Simpson RCS (Bucyrus 25M Miner Version) include:
(Reversed Function Version)
Remote Handset* (Caplamp Battery Version)
* Not approved for use in underground coal mines
Control switches on each model of remote are generally identical (except for reverse function versions where hydraulic function directions are reversed). This manual will explain machine operation based on the TITO L0KN56 model handset. Please contact Forced Potato or Bucyrus if you require more information on an earlier model of handset.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 16 of 145 Issue: SY0101.B
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TITO model handset feature a built-in diagnostic screen on the radio remote console that provides the operator with useful diagnostic messages. Note that these messages are only available on TITO model remote handsets. Earlier model handsets do not feature a built-in diagnostic display.
Message Meaning
UHF1, UHF2, UHF3, UHF4, UHF5, UHF6
UHF7, UHF8
Operating on Frequency 1-8 ON Power is ON
ON (Flashing) Power is ON and a switch on the console is currently pressed.
OFF
STOP
TILT
Powering down whilst issuing PUMP OFF command.
The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted. (Must be enabled using setup mode)
LOW (Flashing) The internal battery is low with and expected remaining operating time of approximately 30 minutes.
SERV Indicating possible service requirements, a fault condition has been detected.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 17 of 145 Issue: SY0101.B
The TITO remote console contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be recharged using the Battery Charger. Recharge times for the unit are typically 1-4 hours; depending on the remaining charge in the battery.
(1) Plug one of the 4 Charging Cables into the Transmitter.
(2) Red and Green Lights will flash for a few moments.
(3) Charger will begin charging.
(4) While charging is in progress, the red light will be on
(5) When charging is complete the green light will come on
(6) During charging, the screen shows how long each transmitter has been on charge.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 18 of 145 Issue: SY0101.B
(1) Look at the socket on the transmitter and the charging plug
(2) Ensure that the socket and plug are free from dirt and coal.
(3) Line up the plug so that it slides gently into the socket
(4) Push gently until you feel or hear the plug “click” into the socket.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 19 of 145 Issue: SY0101.B
(1) Hold the outside tube of the plug firmly.
(2) The tube should be slightly loose.
(3) Pull backwards on the tube so it slides outwards from the transmitter.
(4) The Plug should release itself from the transmitter.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 20 of 145 Issue: SY0101.B
The TITO remote console is designed for long-term use in harsh underground mining environments. As such, the unit is totally selfcontained and requires very little routine maintenance. To extend the service life of the control switches and ensure that switches remain free of mud and debris, regular cleaning of the switch plate is recommended.
Typically the cleaning procedure should be observed once every 2 weeks or as often as required.
• Remove the M3 bolts.
• Remove the switch guard.
• Remove the switch caps.
• Remove the comfort knobs by loosening the grub screw.
• Remove the engraved plate.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 21 of 145 Issue: SY0101.B
• Expunge heavy debris from the switch assembly with a Soft Bristle Cleaning Brush.
• Wash the transmitter with warm soapy water.
• Inspect the switch seals for signs of deterioration. Seals exhibiting wear require the equipment to be scheduled for factory service. Note: these seals are the primary seal, a secondary seal within the switch itself and an internal neoprene seal operate as a barrier to moisture ingress.
• Dry the transmitter with light compressed air or cloth.
Do not use caustic solvents or displacement solutions as this may cause premature seal failure.
Do not use metal implements to dig out coal, mud or soapstone that may be found in the charge receptacle.
• Ensure all switch seals are tight. If a seal appears loose, tighten the seal to the recommended torque of 2.5Nm.
• Ensure all switch plate M2 bolts are tight. If an M2 bolt appears loose, tighten the bolt to the recommended torque of 1.5Nm. Do NOT over tighten these bolts as this may break the enclosure seal.
• Install the engraved plate.
• Install the comfort knobs as depicted. Tighten the grub screw to the recommended torque of 2.5Nm.
• Install the switch caps
• Install the switch guard. Tighten the switch guard M3 bolts to the recommended torque of 2.5Nm.
• After reassembly, test the unit on the Remote Control Battery Charger
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual
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Single Key Functions
Functions activated by a single key press.
Two Key Functions
Functions marked in “[ ]” brackets require the [SHIFT] key also be used to operate that function. Motor starts are generally Two Key Functions for added safety.
Two Key Function. Pump Motor must be started before other motors, tramming or hydraulics can be controlled.
Single Key Functions control hydraulic cylinders on the Miner.
Transmitter provides 3 tram speeds. Speed selected by pressing [TRAM 2-3] whilst tramming levers are engaged and the machine is tramming.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 23 of 145 Issue: SY0101.B
(1) Press and hold the ON key forward for 1 second.
(2) The console display should read HOLD.
(3) Release the key and the display should show ON.
(1) Move the ON/OFF key to the OFF position.
(2) The console display will show the OFF message for a moment.
(3) The console will then turn itself off.
(1) The Radio Emergency Stop will quickly shutdown all motors and functions on the STOP miner.
(2) At any time, press the STOP key down towards the top of the console panel.
(3) The console will send the stop command and then turn itself off.
(4) To turn the console back on, the STOP key must be returned to its original position.
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 24 of 145
The control system uses a solenoid output to drive a fire suppression system on the continuous miner. The fire suppression can be activated at any time from the remote control console. If the machine is fitted with the battery backup version of power supply, the fire suppression can also be activated in BATTERY STANDY MODE. The system remains in BATTERY STANDBY MODE at least 10 minutes after the loss of mains power to the machine.
(1) The Fire Suppression System can be engaged at any time.
(2) Press the [SHIFT] key and the [FIRE] key together.
(3) Continue to assert the [SHIFT] key and the [FIRE] key for a full 2 seconds.
(4) After 2 seconds, the fire suppression system will activate. At this time, the [SHIFT] and [FIRE] keys can be released.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 25 of 145 Issue: SY0101.B
Starting the Pump Motor
(1) Ensure that the console is on.
(2) Press [SHIFT] and wait ¼ second.
(3) Press PUMP [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the pump motor will start.
(7) Release PUMP [ON] first. This is important. If [SHIFT] is released first the pump is shutdown.
(8) Then release [SHIFT].
(9) Pump should continue to run normally.
Stopping the Pump Motor
(1) Pump is running normally.
(2) Press and hold PUMP OFF.
(3) The Pump Motor should shut down immediately.
(4) Release PUMP OFF.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 26 of 145
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press CUTTER [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the cutter motors will start.
(7) Release CUTTER [ON] first. This is important. If [SHIFT] is released first the cutters are shutdown.
(8) Then release [SHIFT].
(9) Cutter motors should continue to run normally.
(1) Cutters are running normally.
(2) Press and hold CUTTER OFF.
(3) The Cutter Motors should shut down immediately.
(4) Release CUTTER OFF.
Starting the Conveyor Motors in Forward
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press CONV [ON] while [SHIFT] is also pressed.
(4) After a few moments the conveyor will start in forward.
(5) Release CONV [ON] first. Then release [SHIFT].
(6) Cutter motors should continue to run normally.
(1) Conveyor is running in forward
(2) Press and hold CONV OFF.
(3) The Conveyor Motors should shut down immediately.
Running the Conveyor Motors in Reverse (Momentary Only)
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press [CONV REV] while [SHIFT] is also pressed.
(4) After a few moments the conveyor will start in reverse.
(5) The Conveyor will remain running in reverse until the [CONV REV] key or the [SHIFT] key is released.
(1) Ensure that the pump motor is first running normally.
(2) Press [SHIFT] and wait ¼ second.
(3) Press FAN [ON] while [SHIFT] is also pressed.
(4) Keep the keys asserted for a few moments.
(5) After a few moments the cutter motors will start.
(7) Release FAN [ON] first. This is important. If [SHIFT] is released first the fan is shutdown.
(8) Then release [SHIFT].
(9) Fan motor should continue to run normally.
(1) Cutters are running normally.
(2) Press and hold FAN OFF.
(3) The Fan Motor should shut down immediately.
(4) Release FAN OFF.
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The pump motor must be running in order to raise and lower the cutter boom.
Press SHEAR UP to move the Cutter Boom up. Shear Up Solenoid remains energized until key is released (unless height limiting is in force).
Press SHEAR DOWN to move the Cutter Boom down. Shear Down Solenoid remains energized until key is released.
The pump motor must be running to allow the gathering pan to be raised and lowered.
Press PAN UP to lift the gathering pan. The Pan Up Solenoid remains energized until key is released.
Press PAN FLOAT to “float” the pan down.
Page 30 of 145 Issue: SY0101.B
Remote control of the stabilizer jack requires that the pump motor be running.
Press STAB UP to lift the stabilizer jack. The stabilizer jack solenoid will remain energized until the key is released.
Press STAB DWN to lower the stabilizer jack. The down solenoid for the stabilizer remains on until the key is released.
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 31 of 145 Issue: SY0101.B
The conveyor raise, lower and swing can only be controlled once the pump motor is started and running.
Press the CONVEYOR LEFT/RIGHT to the left to swing the conveyor tail to the left. The solenoid controlling the left conveyor swing will remain energized until the key is released.
Press the CONVEYOR LEFT/RIGHT to the right to swing the conveyor tail to the right. The conveyor right solenoid will remain on until the key is released.
Press the CONVEYOR DWN key to lower the conveyor boom. The solenoid for the conveyor lower function remains on until the key is released.
Press the CONVEYOR UP key to raise the conveyor boom. The conveyor up solenoid will stay on until the key is released.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 32 of 145 Issue: SY0101.B
The control system has the possibility of turning cutter water sprays on and off from a key on the remote console. However, this function is normally not available due to the wiring configuration of most miner electrical systems. Check with Bucyrus or mine staff if remote control of water sprays is a necessary requirement for your particular mining operation.
Press and release the WATER key to turn on or off the water sprays. Water sprays are typically turned on automatically when cutter motors are started.
Head lights can be turned on and off from the remote console at any time that the system is in REMOTE MODE and the remote console is on,
Press the [SHIFT] and [LIGHTS] keys together. The lights will turn on.
To turn off the lights press the [SHIFT] and [LIGHTS] keys together again.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 33 of 145 Issue: SY0101.B
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Normally the pump motor must be running in order to control machine tramming.
To enable machine tramming the TRAM 2-3 key must be pressed and released. This enables the tram function. Once enabled, the tram levers can be used to drive left and right tramming tracks forwards and backwards. If the tram levers are released for a continuous period of 5 seconds, the tram becomes disabled again. To re-enable the tram function, the TRAM 2-3 key must be pressed and released again.
Tram tracks on the machine can be moved forwards and backwards using the tram levers on the remote control console. Control of machine tramming is only possible once the pump motor is running and the tramming has been enabled (see above).
Press the LEFT FWD tram key to turn the left tramming track forwards.
Press the LEFT REV tram key to turn the left tramming track backwards.
Press the RIGHT FWD tram key to turn the right tramming track forwards.
Press the RIGHT REV tram key to turn the right tramming track backwards.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 34 of 145 Issue: SY0101.B
The system allows the tramming to be driven in three discrete speeds (SPEED 1, SPEED 2 and SPEED 3).
SPEED 1 is the default tramming speed and is the slowest tramming speed.
By pressing the TRAM LEVERS and [TRAM 2-3] keys together the operator may move to SPEED 2 from SPEED 1. Once in SPEED 2, the operator can toggle between SPEED 2 and SPEED 3 using the TRAM LEVERS and [TRAM 2-3] keys together.
The following tramming configurations are enforced by the control system for safety reasons:
• Split Track Tramming is limited to SPEED 1
• Single Track Tramming is normally limited to SPEED 1
• It is possible to speed up a single track from SPEED 1 to SPEED2 providing that tramming is started in SPEED1
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 35 of 145 Issue: SY0101.B
A typical Bucyrus 25M continuous miner is fitted with a “mushroomstyle” emergency stop button on the left side of the machine. This button is normally used to shut down the machine in an emergency. In difficult mining conditions, it is possible for the left side of the machine to become jammed against the wall (rib) of the mine roadway. In these cases, the emergency stop button can be jammed in the “on” position by the wall, preventing the pump motor to be started on the machine.
To allow the machine to be started and moved away from the wall in such a scenario, the control system provides a special emergency stop bypass feature that can be activated from the remote control console. When activated, the bypass function affords the operator a 30-second window where the emergency stop button is bypassed and the pump motor can be started. During this window the operator is able to tram the machine away from the wall, allowing the emergency stop button on the machine to reset.
To activate the E-stop Bypass, press and hold the [SHIFT] and [BYPASS] keys together for a continuous 5 seconds.
While the keys are held, the diagnostic display on the miner will show a “countdown timer”. The timer counts the 5-second period that the keys must be held in order for the bypass function to become enabled.
Once the 5-second delay has passed; the system will enter the ESTOP BYPASS mode. The [SHIFT] and [BYPASS] keys can then be released. The screen will then show that the bypass is active and feature another countdown timer. In this case the timer counts down the 30 second window for which the bypass will remain active.
Once the 30-second window has expired, the bypass will again be disabled. The bypass mode can be activated again by pressing and holding the [SHIFT] and [BYPASS] keys again for 5 seconds.
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 37 of 145 Issue: SY0101.B
The control system allows the main circuit breaker on the miner to be turned on and off using the radio remote control console. This normally requires that a battery backup version of power supply be installed on the machine.
Press and hold the [SHIFT] and [C.B. OFF] keys together for a 2 seconds.
&After 2 seconds, the breaker off solenoid will energize (turning off the machine circuit breaker).
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 38 of 145 Issue: SY0101.B
To turn on the breaker:
It is essential that a battery backup version of the control system power supply be installed for this function to be available.
Typically, a hydraulic valve provides the mechanical force for the breaker mechanism. To allow this valve to be operated after loss of power a hydraulic accumulator is charged by the pump motor during normal “powered” operation of the machine. If the hydraulic accumulator is discharged then it will not be possible for the breaker to be turned on from the remote control transmitter.
Press and hold the [SHIFT] and [C.B. ON] keys together for a 2 seconds.
After 2 seconds, the breaker on solenoid will energize (turning on the machine circuit breaker).
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 39 of 145 Issue: SY0101.B
The control system provides two independent auxiliary outputs that can be controlled from the remote control console and used for a number of different applications.
The outputs are controlled as a 2-key function on the remote console:
[SHIFT] and [AUX-1] Or
[SHIFT] and [AUX-2]
These outputs can be configured to operate with or without interlocking from the pump motor. The outputs can also be configured to be latching or non-latching (momentary).
Please consult with mine management as to the application and control configuration of the outputs on your machine.
Note: The AUX-2 output may not be available on machines where the methane monitor override is supported. On these machines, the [AUX-2] function is used to activate the methane override system (See Section 11).
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 40 of 145 Issue: SY0101.B
The Super Simpson RCS (Bucyrus 25M Miner Version) is fitted with a number of special and automatic functions. These special features either improve machine productivity or provide for compliance with special safety or statutory requirements.
The control system provides for user configuration of different functions. It is important that operators are aware of which features are setup on the machine that they are using. Please contact mine management for more details as to the exact configuration of the machine you are using.
When enabled (See Section 13), the automatic scrubber fan option turns on the scrubber fan 3 seconds after the start of the cutter motors and turns the fan off 10 seconds after the cutters have been shut down.
Even if the automatic scrubber fan is enabled, the operator may still start and stop the fan at any time using the remote control console.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 41 of 145 Issue: SY0101.B
In certain cases, local statutory authorities or difficult mining conditions may require that the scrubber fan be started before the cutter motors are started.
To support these mining situations, the control system has a “Fan Before Cutter” option that can be enabled.
When this option is YES (See Section 13), the control system will not allow the cutter motors to be started until the fan motor has been running for a full 3 seconds.
In the state of Pennsylvania, it is typically a statutory requirement that the scrubber fan feature the following automatic operations:
(1) Scrubber fan is started at least 3 seconds prior to cutter motors are started.
(2) Scrubber fan remains on at least 10 seconds after cutter motors are shut down.
To satisfy these automatic control requirements, two different setup options must be enabled in the Super Simpson RCS (Bucyrus 25M Miner Version) setup. These options should be configured as follows:
Recommended Scrubber Fan
for State of Pennsylvania Statutory Requirements
See Section 13 for instructions on how to access and modify these setup options.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 42 of 145 Issue: SY0101.B
Normally, the methane monitor system on the miner will disable the pump, tramming and all other electrical circuits if the methane sensor is faulty. This can pose a problem for mine staff if the machine is inaccessible or under a section of roof that has not be properly secured and supported.
The Methane Monitor Override Option has been designed to allow the operator to start the pump motor and tram the machine if the methane monitor is reporting a fault condition.
This option is only available on machines that feature the General Monitors S800 Methane Monitor and have been fitted with additional wiring. Please contact mine management or Bucyrus for information about the availability of this feature on your continuous miner.
This option can be turned on and off in the Main Menu (See Section 13).
The override must be activated by the operator using the radio remote control handset.
To activate the methane monitor override:
Ensure that the methane monitor is in fault condition. This will be reported by the control system diagnostic display.
Press and hold the [SHIFT] and [AUX-2] keys together for 5 seconds.
After holding the keys for 5 seconds, the system should enter the methane override mode for 120 seconds. During this time, the pump may be started and the machine can be trammed in SPEED 1 only. Hydraulic functions can also be controlled whilst the override mode is active. It is not possible to start any other motors – including the cutter – in this mode.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 43 of 145 Issue: SY0101.B
The main diagnostic screen is displayed during normal remote control operation of the continuous miner. The screen presents real-time diagnostic and performance information.
ACTIVE MODE ACTIVE CHANNEL
ACTIVE MODE
ACTIVE CHANNEL
CARRIER STATUS
CARRIER STATUS
EVENT MESSAGE
Current operating mode either REMOTE or MANUAL. In MANUAL machine will not respond to the transmitter
Radio channel used by the miner. Up to 8 channels are available: UHF01, UHF02, UHF03, UHF04, UHF05, UHF06, UHF07 and UHF08
Tells you how the radio transmitter is performing. First White DOT – Remote is Communicating OK. Second White DOT - A key on the remote is pressed.
EVENT MESSAGE Any warning or fault messages.
MOTOR STATUS
Current operating status of machine motors. Displays real-time current information and error status.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 44 of 145 Issue: SY0101.B
The control system provides a number of information, diagnostic and setup screens that are grouped together in the System Menu. The System Menu is accessed by using the diagnostic display module and a remote control handset. Different keys on the remote handset are used to select, view and navigate between different screens in the menu.
At any time, press the [SHIFT] key and the [MENU] key together on the remote console. The system will then switch from REMOTE MODE to SYSTEM MENU MODE. Note that all functions and motors will be shut down and disabled when the system menu is selected.
You can leave the menu system and return to the REMOTE MODE at any time by pressing [SHIFT] and [REMOTE] keys together on the remote control handset.
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The remote control console is used to move around in the system menu and select different options and perform different diagnostic tasks.
Moving the Cursor:
Use CONV [UP] and CONV [DOWN] to move the cursor to the desired option.
Selecting an Option:
When the cursor is next to the desired option, press [SHIFT] and [MENU] to select that option.
To exit the System Menu:
Press [SHIFT] and [REMOTE] at any time.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 46 of 145 Issue: SY0101.B
The Main Menu is composed of 9 options. Options 7, 8 and 9 open password protected sub-menus as indicated below.
Selecting these options will require a password. Do not give the password to unauthorized personnel.
Option 7: Tradesman Setup
Using the CONV and SHEAR switches, enter the password and press the shift key to enter the sub-menus below.
Option 8: Engineering Setup (Contains options for Tradesman also)
Option 9: OEM Setup – Allows for advanced settings available only to factory personnel. This option will not be covered in this manual.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual
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The Main Menu consists of 6 options that are accessible without a password.
Diagnostics mode provides helpful troubleshooting information such as machine information, software revision and machine configuration. It also provides the status of the motors, digital and analog inputs, external modules, etc.
There are a total of 32 pages in diagnostics mode.
In order to navigate through the screens you must hold the [SHIFT] switch while pressing the conveyor switches.
To return to the Main Menu, press [SHIFT] and [MENU].
Diagnostics mode is for informational purposes only. No configuration changes can be made within this mode.
Here are some examples of the pages available in diagnostics mode:
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 48 of 145 Issue: SY0101.B
Tram Status
Current on all three phases for both left and right traction drives
24VDC Digital Inputs
Status of the monitored digital inputs.
Solenoid Board (Receiver)
Motor Mate (raw input)
4 to 20mA raw input from the motor mates
120VAC Digital Inputs
Status of the monitored digital inputs.
Relay Board (Receiver)
Temperature, fault status, software revision, and communication packets (Displayed as GOOD/BAD). When the boards are communicating properly the packet number on the GOOD side will be increasing constantly and the BAD side should be minimal.
Power Supply Status
Temperature, fault status, software revision and communication packets (as above).
Thermistor Module Status
Temperature, software revision, CAN Bus communication.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 49 of 145 Issue: SY0101.B
The Fault Log allows the user to review the last 100 faults that have occurred since the log was last cleared.
FAULT NUMBER
TOTAL FAULTS
FAULT CODE
FAULT DESCRIPTION
TIME OF FAULT
Sequential number of fault in order of occurrence from most recent (001) to oldest (100).
This is the total number of faults currently listed in the fault log.
Specific Code that identifies the fault displayed. Fault codes 0 to 199 are error codes; fault codes 200 and above are detected faults.
A brief description of the fault.
This is the time the fault occurred. It is expressed as Hour : Minute : Second – Day / Month
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 50 of 145 Issue: SY0101.B
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For a more detailed description of the fault(s), press and hold the TRAM [2] switch when the fault in question is displayed.
To bring up a list of possible causes for the fault(s), press and hold the TRAM [1] switch when the fault in question is displayed.
It is possible to clear the fault log under the Engineering Setup Menu, which is password protected.
NOTE: The Fault Log should not be cleared unless the receiver has been replaced. Retaining the faults in the fault log is very helpful in troubleshooting the problem when the receiver is sent in for service, but the faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.
Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 51 of 145
Selecting the Hour Meters from the Main Menu will display runtime for the following motors: PUMP, FAN, LEFT CUTTER, RIGHT CUTTER, and CONVEYOR.
Time is displayed in Hours : Minutes : Seconds
This runtime only reflects information since the receiver has been installed, or since the counter was last reset.
It is possible to clear the Hour Meters under the Engineering Setup Menu, which is password protected.
NOTE: The Hour Meters should only be cleared when a motor is replaced or when the receiver is installed. To keep an accurate log of a motor’s total hours for warranty purposes, the information should be recorded any time the data is cleared.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 52 of 145 Issue: SY0101.B
Selecting the Fan Before Cutter option from the Main Menu allows the user to review and change the settings for the Fan Before Cutter option discussed in Section 11.
Use the CONV [UP]/[DOWN] to toggle the value.
To save the updated setting and return to the menu, press [SHIFT] and [MENU].
When this option is set to YES, the control system will not allow the cutter motors to be started until the fan motor has been running for a full 3 seconds.
When the option is set to NO, the control system will not look for the fan motor condition before starting.
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Selecting the Meth O/Ride option from the Main Menu allows the user to review and change the settings for the Methane Monitor Override option discussed in Section 11.
Use the CONV [UP]/[DOWN] to toggle the value.
To save the updated setting and return to the menu, press [SHIFT] and [MENU].
When this option is set to YES, the control system will not allow the Methane Monitor to be overridden when activated by the operator as outlined in section 11.
When the option is set to NO, the control system will not allow the Methane Monitor to be overridden.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 54 of 145 Issue: SY0101.B
Selecting the Any Key Fault Clear option from the Main Menu allows the user to review and change the settings for the Any Key Fault Clear option.
Use the CONV [UP]/[DOWN] to toggle the value.
To save the updated setting and return to the menu, press [SHIFT] and [MENU].
When this option is set to YES, the control system will allow the operator to clear any fault alert screen by pressing any switch on the remote console.
When the option is set to NO, the operator must press [SHIFT] and [REMOTE] to clear the fault alert screen.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 55 of 145 Issue: SY0101.B
The Tradesman Setup Menu consists of 6 options that are accessible only with the tradesman, engineering, or OEM passwords.
This easy-to-use Solenoid Self Test function aids in troubleshooting faulty solenoid coils. When selected, the self-test begins automatically. The test analyzes each solenoid coil and determines if the coil is short circuit or open circuit.
The system looks at one solenoid at a time. First the solenoid is activated, and then the current is measured and displayed.
If the system finds that the coil is normal, it displays SOLENOID OK and then moves on to the next solenoid.
If the system believes that a solenoid coil is open circuit, it will pause the test at that solenoid and display SOLENOID OPEN. The number 3 key (LEFT TRAM REVERSE) must be pressed to continue the test.
If the system finds a solenoid coil that is short circuit, it pauses the test and displays the SOLENOID SHORT message for the solenoid. The number 3 key (LEFT TRAM REVERSE) must be pressed to continue the test.
The system will continue testing until all solenoids have been checked. Each time a fault is detected the system will pause until prompted to continue. After all solenoids have been checked the system will automatically return to the Menu.
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Another option for solenoid testing is the Solenoid User Test. This option allows for testing five solenoids at once. This test can be used to aid in troubleshooting a problem that only occurs when multiple solenoids are active. Once the option is selected the Solenoid User test screen is displayed.
Pressing [SHIFT] and SHEAR [UP] will activate odd numbered solenoids until the switches are released.
Pressing [SHIFT] and SHEAR [DOWN] will activate even numbered solenoids until the switches are released.
To return to the Menu press [SHIFT] and [MENU].
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 58 of 145 Issue: SY0101.B
The Console Test option allows for the operator to test the functionality of the Remote Control Transmitter at the machine without actually activating solenoids and starting any motors. This is useful if the Remote Console is suspected of being faulty.
While in this mode all key presses will display as they are received, with a maximum of three functions displayed at once.
To return to the Menu press [SHIFT] and [MENU].
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 59 of 145 Issue: SY0101.B
The control system features a real-time clock that keeps track of the time of day and the date, even when power is removed from the receiver control unit.
To review/change the DATE, select this option.
Once in the DATE SETUP screen, use the CONV [LEFT] and CONV [RIGHT] keys to move to the portion of the date that you wish to modify.
When the cursor is beneath the parameter you wish to change you may modify the value by using the CONV [UP] and CONV [DOWN] keys on the remote console.
Note that international date format is used by the control system:
DAY / MONTH / YEAR
For example, the date 23/06/08, indicates June 23rd, 2008.
Once the correct date is entered, press [SHIFT] and [MENU] to return to the system menu and save the date.
Super Simpson RCS (Bucyrus 25M Miner) Operator’s Manual Page 60 of 145 Issue: SY0101.B
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• You can download the complete manual from: www.heydownloads.com by clicking the link below
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