Forced Potato TITO Remote Console (Bucyrus 25M Miner Version) Operator’s Manual KN5602.C - PDF DOWNL

Forced Potato TITO Remote Console (Bucyrus 25M Miner Version)

Operator’s Manual Issue: KN5602.C

Forced Potato Mining Electronics

Contents Contents ............................................................................................... 2 Preface ................................................................................................. 3 Introduction ........................................................................................... 4 Notice ............................................................................................ 4 Safety Notice ........................................................................................ 5 What’s New........................................................................................... 6 Remote Control Battery Charger .......................................................... 8 Remote Control Diagnostics ............................................................... 11 Notice .......................................................................................... 12 User Setup .......................................................................................... 13 Password Entry ........................................................................... 13 Options ........................................................................................ 14 1. Radio Channel ....................................................................... 15 2. Radio Timeout ....................................................................... 15 3. Tilt Switch .............................................................................. 16 4. ID Number ............................................................................. 16 5. Saving Changes .................................................................... 17 Maintenance ....................................................................................... 18 Inspection Frequency .................................................................. 18 Factory Service Frequency ......................................................... 18 Tools ............................................................................................ 19 Disassembly ................................................................................ 20 Cleaning ...................................................................................... 21 Reassembly ................................................................................. 22

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Forced Potato Mining Electronics

Preface This document is intended to provide reference to the Type KN Remote Console. This version of the TITO remote console has been developed for operation of Bucyrus continuous miners.

Forced Potato Inc. 640 Bizzell Drive Lexington, KY 40510 Telephone: +859 252 4439 Fax: +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 Inc. 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 Forced Potato control system components used with machinery manufactured by Bucyrus, please contact your Bucyrus representative or local Bucyrus service center.

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Forced Potato Mining Electronics

Introduction The Type L0KN Remote Console (RC) is a self-contained battery powered remote control that has been specifically designed to provide a safer, more efficient means of operating mining machinery.

Notice This manual includes information specific to the following part: Part# L0KN5602

Description Bucyrus UHF

If this manual does not correspond to your equipment’s part number, please contact Forced Potato Inc. immediately to obtain a copy of the correct publication.

To obtain service of your TITO L0KN56 model remote control handset please contact your local Bucyrus representative or service center.

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Forced Potato Mining Electronics

Safety Notice 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 management and should encompass MSHA recommendations where applicable.

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Forced Potato Mining Electronics

What’s New The Type KN Remote Console has been designed to meet the requirements of AS4240 / MDG5001. These requirements compel a number of design variations over existing equipment manufactured by Forced Potato Inc.

•

Size Whilst a similar physical layout has been retained to support transparent integration, the overall size has grown to support control spacing standards as specified by AS4240.

•

Visual Diagnostics A highly efficient LED display has been integrated to facilitate operating diagnostics. Information such as operating frequency, power and general operating status is available at all times.

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Forced Potato Mining Electronics •

Battery To improve operational readiness, a larger battery pack has been incorporated which affords a minimum 20 hours of continuous remote control operation.

•

Tilt Monitoring Dual tilt switches have been installed to allow detection of the angle of inclination relative to the horizontal plane. This feature can be enabled or disabled via the User Setup Options on the Remote Control Battery Charger. By default, this option is disabled.

•

Safety The most important design addition is single electrical fault tolerance. By incorporating dual-pole switch architecture and a new approach to switch sampling, a high level of fault tolerance has been achieved.

The KN56 TITO remote console also features a push-button stop button. This push-button makes the device compliant with MSHA P03-3 recommendations.

•

Ergonomics In an effort to improve operator comfort, stylish comfort knobs have been added to the most commonly used functions – traction and shear. These are entirely optional and can be removed if required.

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Forced Potato Mining Electronics

Remote Control Battery Charger Connect the Remote Control Battery Charger to your mains power outlet. During initial power-up, the firmware release information is displayed for 10 seconds.

After this period, the charger will then display the main screen which details the charge status.

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Forced Potato Mining Electronics Diagnostics The Remote Control Battery Charger permits the operator to verify that all switches are operating as expected. Similarly, it provides a secondary means of determining the operating frequency.

Power Up Turn the RC on by asserting and holding the ON [SHIFT] key for twoseconds. This startup requirement has been introduced to reduce the likelihood of incidental activation.

After the two-second period has expired, the RC will show the operating frequency via the LED display. The available operating frequencies for the L0KN5602 (Bucyrus UHF) are as follows: Indicated Frequency UHF1 UHF2 UHF3 UHF4 UHF5 UHF6 UHF7 UHF8

Actual Frequency 458.500MHz 458.525MHz 458.550MHz 458.575MHz 458.600MHz 458.625MHz 458.650MHz 458.675MHz

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Forced Potato Mining Electronics The Remote Control Battery Charger continually scans all 8 channels in an attempt to recognize a supported RC. On average, the Remote Control Battery Charger requires approximately 4 seconds to acquire a signal.

Upon detecting a valid signal, an identification screen is displayed for three seconds to allow classification of the type and frequency of the operating RC.

After this period has expired, the diagnostic screen is displayed.

Operators should be satisfied that all key functions operate as expected prior to taking the equipment underground. Similarly, operators should verify that the operating frequency corresponds to that displayed on the RC – See the Frequency Table on the previous page.

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Forced Potato Mining Electronics

Remote Control Diagnostics The RC supports a number of inbuilt diagnostics to aid operation. The following table details each of these messages and their implication.

Message UHF1, UHF2, UHF3, UHF4, UHF5, UHF6, UHF7, UHF8 ON

Meaning Operating on Frequency 1, 2, 3, 4, 5, 6, 7 or 8

ON

Power is ON and a command is being sent to the machine.

(Flashing)

Power is ON

OFF

Powering down whilst issuing PUMP OFF command.

STOP

Radio Stop Activated

TILT

The RC’s angle of inclination is beyond 45° relative to horizontal. The STOP command is issued continuously until the unit is righted.

The internal battery is low with and expected remaining operating time of approximately 30 minutes.

Indicating possible service requirements, a fault condition has been detected.

LOW (Flashing) SERV

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Forced Potato Mining Electronics

Notice The SERV message is displayed when a fault condition has been detected. There are a number of problems that can generate this fault and most of these would typically require the unit to be submitted for factory service.

However, this condition can be triggered if the operator asserts switches prior to turning the unit ON. If switches other than those allocated to User Setup are asserted prior to power up, it is assumed that these switches are faulty, consequently resulting in automatic power down.

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Forced Potato Mining Electronics

User Setup The RC supports a number of user programmable options that can be adjusted via the Remote Control Battery Charger. To engage User Setup and with the RC turned off, assert the following keys, in sequence, for two seconds: Assert Assert Assert

CONVEYOR ► SHEAR UP ON [SHIFT]

The RC will display SET on its LED display to indicate that User Setup has been selected.

Password Entry When the Remote Control Battery Charger has acquired the signal, the following password entry screen is displayed:

The password FORCED must be entered before access to User Setup is granted.

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Forced Potato Mining Electronics To enter characters, use the following keys: To change a character: Assert CONVEYOR UP or CONVEYOR DOWN To change cursor position: Assert CONVEYOR ► or CONVEYOR ◄ To check the password: Assert ON [SHIFT] After entering the password, assert ON [SHIFT] to gain access to the System Menu.

Options There are five menu options available to the end user. To navigate the system menu, see the following:

To change the menu option: Assert CONVEYOR ► or CONVEYOR◄ To engage or leave the menu option: Assert ON [SHIFT] To change the option value: Assert CONVEYOR UP or CONVEYOR DOWN

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Forced Potato Mining Electronics

1. Radio Channel

There are 8 selectable channels available to the end-user. This allows the mine to support multiple machines.

2. Radio Timeout

The RC supports a timeout that automatically powers the unit down if there is no switch activity after a defined period of time. A selectable range of between 2 and 60 minutes can be chosen.

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Forced Potato Mining Electronics

3. Tilt Switch

To support AS4240 requirements, dual tilt switches which detect the angle of inclination have been installed. If this option is enabled, the RC will automatically issue the Radio Stop command until the unit is righted upon detecting tilt motion beyond 45° relative to horizontal. (The LED display will show TILT as a diagnostic response.) After being righted, power is automatically removed.

Importantly, a 250ms timer acts to filter our mild impacts to compensate for the effects of inertia. This is an essential requirement when Tilt Monitoring is enabled.

4. ID Number

Each Remote Console is programmed with its respective serial number upon leaving the factory. This feature is not accessible to the end user and is password protected.

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Forced Potato Mining Electronics

5. Saving Changes

To save changes to the setup, you must select the EXIT & SAVE option and assert ON [SHIFT]. To abort changes to the setup, you can simply turn the RC OFF.

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Forced Potato Mining Electronics

Maintenance The maintenance required for Remote Consoles is basically limited to assembly, cleaning & inspection. Coal dust and other particulate deposits foul switch operation and can eventually lead to premature seal failure if not regularly expunged.

Inspection Frequency The following routines should be undertaken daily.

•

Determine if cleaning and disassembly is necessary. Onsite conditions should be used to determine the regularity of this procedure. If cleaning is required, see the following pages.

Typically, cleaning on a weekly basis is sufficient.

•

Perform a functional test on the Remote Control Battery Charger.

Factory Service Frequency Factory Service of this equipment is required 12-months from the date of dispatch with an allowance of 1-month for logistics.

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Forced Potato Mining Electronics

Tools Forced Potato Inc. recommends that the Maintenance Accessory Kit be acquired (or similar) to aid systematic maintenance. A maintenance kit is available which includes the following parts: Allen Hex Set

Allen ⅝″ Socket

Multi-Bit Precision Torque Driver

Field Part Replacements

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Forced Potato Mining Electronics

Disassembly • • • • •

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.

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Forced Potato Mining Electronics

Cleaning • • •

•

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.

Important 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.

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Forced Potato Mining Electronics

Reassembly • •

• • • •

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 to verify operation.

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Forced Potato Mining Electronics

B

O

Battery · 7

Options · 14

C

P

Cleaning · 21

Password Entry · 13 Power Up · 9 Preface · 3

D Diagnostics · 9 Disassembly · 20

E Ergonomics · 7

I Introduction · 4

R Radio Channel · 15 Radio Timeout · 15 Reassembly · 22 Remote Control Battery Charger · 8 Remote Control Diagnostics · 11

S Safety · 7 Safety Notice · 5 Size · 6

M Maintenance · 18

N

T Tilt Monitoring · 7 Tilt Switch · 16, 17 Tools · 19

Notes on “SERV” · 12 Notice · 4

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Forced Potato Mining Electronics

U

W

User Setup · 13

What’s New · 6

V Visual Diagnostics · 6

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