Cat Super Simpson Control System Display Operation and Maintenance Manual A6474X362

A6474X362 February 2012

Operation and Maintenance Manual Super Simpson Control System Display A6474X362 (Super Simpson Control System Display)

SAFETY.CAT.COM

__________________________________________________________ This manual is intended to provide GENERAL product information.

The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine 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 the appropriate 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 the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all 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 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 2012.

ALL RIGHTS RESERVED

________________________________________________ Table of Contents

Table of contents Safety Precautions........................................................................................... 4 Machine Control System.................................................................................. 5 Components .............................................................................................. 5 Radio Remote ........................................................................................... 6 Displays ..................................................................................................... 8 Main Screen........................................................................................ 8 System Menu .....................................................................................10 Diagnostics ........................................................................................12 Fault Log ............................................................................................17 Hour Meters .......................................................................................20 Setup Menu........................................................................................21

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Safety Instructions _______________________________________________ Safety Precautions

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The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations, must be followed at all times.

WARNING Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

IMPORTANT

Refer to the radio remote control operation manual supplied with your machine for information regarding the operation of your specific remote control.

IMPORTANT

Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

IMPORTANT

All functions and motors are shut down and disable when the system menu is selected.

IMPORTANT

It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

IMPORTANT

The hours meters should only be cleared when a motor is replaced or when the machine controller is installed. To keep an accurate log of a motor’s total hours, the information should be recorded anytime data is cleared.

IMPORTANT

The pendant controller and its umbilical cord should be stored in a protected location on the working section, away from the miner, to prevent damage.

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__________________________________________ Machine Control System Introduction

A multi-component system is used to control and monitor the functions of the machine. This system consists of the following main components: 1. Machine controller 2. Power supply 3. Input/output (I/O) modules 4. Radio remote 5. Graphics display This information is presented as a general guide to the capabilities and functions of the control system. Before attempting to operate, service, or troubleshoot the continuous miner, training must be completed.

Machine Controller

The machine controller is the main control unit of the system. It includes the radio data receiver which is used to receive and decode commands from the radio remote.

Power Supply

The control system has its own power supply, with the option of having battery backup for the power supply, which provides power to the machine controller and I/O modules.

Input/Output Modules

Input/output modules may be used to read data from and/or send commands to the following machine functions: 1. Cutter motors (left and right) 2. Gathering head motors (left and right) 3. Traction motors (left and right) 4. Pump motor 5. Hydraulic oil level 6. Methane monitoring (if applicable) 7. Fan motor (if applicable) Based on the parameter settings and the input received from different components, the control system has the ability to issue error messages, fault messages, and/or shutdown the machine.

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Machine Control System___________________________________________ Radio Remote

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The radio remote (Fig. 1) is a battery powered remote used to control the continuous miner during normal operations.

WARNING Radio remote control systems are dangerous. The continuous miner operator cannot operate a remote system until he is properly trained in the operation of the system. Remote control systems sometimes have automatic features of which untrained operators and workers may not be aware.

Fig. 1: Radio remote (typical)

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__________________________________________ Machine Control System Radio Remote Charging

The radio remote contains an internal battery that allows up to 20 hours of continuous operation. The internal battery can be re-charged using the battery charger (Fig. 2). Recharge times for the unit are typically 1-4 hours, depending on the remaining charge in the battery.

Fig. 2: Radio remote battery charger (typical)

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Machine Control System___________________________________________ Displays

There are two displays located on the machine: a graphics display located at the operator’s case and a text display located near the back right hand side of the machine (Fig. 3). Both screens are used to display diagnostic information on the miner.

Fig. 3: Control system display locations (typical)

Text display

Graphics display

IMPORTANT

Information priority is given to the graphics display unless the graphics display becomes unhealthy. The two monitors will not necessarily display the same information at the same time.

The graphics display, located on the operator’s case, is used to monitor machine operating parameters, for diagnosing error and fault codes, and for input of operating parameters.

The text display, located above the operator’s case, has the same functions as the graphics display. If the control system loses power, the text display will remain powered through the battery back up.

Displays

There are different screens that can be displayed: production monitoring, function monitoring, diagnostic, motor hours, and fault pages. A system halt message can appear as a pop-up dialog box in the middle of any screen. A message will appear when a critical conditions has occurred that prevents continued operation of the machine in a safe manner.

The main screen (Fig. 4) is displayed during normal remote control operation of the machine. The screen presents real time diagnostic and performance information.

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__________________________________________ Machine Control System Fig. 4: Main page, example

Graphics display

Text display

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Machine Control System___________________________________________ System Menu

The control system provides information, diagnostic, and setup screens that are grouped together in the system menu (Fig. 5). The system menu is accessed by using either display and a remote control handset.

To access and navigate the system menu using the radio remote: 1. Press the SHIFT and MENU key to access the system menu screen.

2. Press CONV UP or CONV DOWN to move the cursor up and down the list.

IMPORTANT

All functions and motors are shut down and disable when the system menu is selected.

3. Press SHIFT and MENU to select the highlighted item 4. To leave the menu and return to remote mode, press SHIFT and REMOTE. Fig. 5: System menu, example

Graphics display

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__________________________________________ Machine Control System Fig. 5: System menu, example, continued

Text display

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Machine Control System___________________________________________ Diagnostic Mode

Diagnostic mode allows a large number of monitoring screens to be selected and displayed while the machine is operating. Each screen 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, etc. Diagnostic mode is for informational purposes only. No configuration changes can be made within this mode.

To navigate through the screens, hold the SHIFT switch while pressing a conveyor switch. To return to the main menu, press SHIFT and MENU Graphics diagnostics may include the following pages: NOTE: Menu options may vary depending on machine configuration.

1. Main monitor 2. Production monitor 3. Pump monitor 4. Cutter monitor 5. Conveyor monitor 6. I/O monitor - relay outputs 7. I/O monitor - digital inputs 8. I/O monitor - analog outputs 9. Solenoids 10. Inverter right monitor 11. Inverter left monitor 12. Rectifier monitor 13. Thermistor monitor 14. Motor mate network monitor 15. CAN network monitor See Fig. 6 for example screen shots of various diagnostic pages.

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__________________________________________ Machine Control System Fig. 6: Graphics display diagnostic pages, examples

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Machine Control System___________________________________________ Fig. 6: Graphics display diagnostic pages, examples, continued

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__________________________________________ Machine Control System Text diagnostics includes the following pages: 1. Main monitor 2. Machine information 3. Pump diagnostics 4. Cutter diagnostics 5. Conveyor diagnostics 6. Fan diagnostics 7. Tram diagnostics 8. 24VDC digital input 9. I/O monitor - relay board 10. I/O monitor - solenoid board 11. I/O monitor - analog outputs 12. Solenoid board diagnostics 13. Relay board status 14. Power supply status 15. Thermistor module status To navigate the text display screens: 1. Enter menu - “SHIFT” + “MENU” 2. Exit menu - “SHIFT” + “REMOTE” 3. Move back one page - “SHIFT” + “CONV LEFT” 4. Move forward one page - “SHIFT” + “CONV RIGHT” 5. Move cursor down - “SHIFT” + “CONV UP” 6. Move cursor up - “SHIFT” + “CONV DOWN”

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Machine Control System___________________________________________ Fig. 7: Text display diagnostic pages, examples

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__________________________________________ Machine Control System Fault Log

The fault event log (Fig. 6) provides a list of recent faults. Individual faults (Fig. 6) can be selected from this screen to see more information regarding the fault.

To navigate through the screens: 1. Move browsing cursor up: “CONV UP” 2. Move down one page: “SHIFT” + “CONV DOWN” 3. Move up one page: “SHIFT” + “CONV UP” 4. Move browsing cursor down: “CONV DOWN” 5. Select a fault for more information: “SHIFT” + “MENU” 6. Go back up one level: “SHIFT” + “REMOTE”

IMPORTANT

It is not recommended that the fault log be cleared unless the machine controller has been replaced. Retaining the faults is very helpful in troubleshooting a problem when a machine controller is sent for service. Faults cannot be retrieved once they have been cleared. Use caution and only clear the log if it is absolutely necessary.

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Machine Control System___________________________________________ Fig 8: Fault log, example

Graphics display

Text display

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__________________________________________ Machine Control System Once a fault has been selected, the SHIFT and MENU keys can be used to access more information on the fault (Fig. 9).

Fig. 9: Fault detailed information, example

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Machine Control System___________________________________________ Hour Meters

Selecting hour meters (Fig. 10) 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 format. This runtime only reflects accumulated time since the machine controller has been installed or since the counter was last reset. The hour meters can be cleared under the Engineering Setup Menu, which is password protected.

IMPORTANT

The hours meters should only be cleared when a motor is replaced or when the machine controller is installed. To keep an accurate log of a motor’s total hours, the information should be recorded anytime data is cleared.

Fig. 10: Hour meters, examples

Graphics display

Text display

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__________________________________________ Machine Control System Setup Menu

There are three password protected setup menus available: Tradesman, Engineering, and OEM. Information regarding the adjustable parameters accessed on each screen is given in the machine specific training.

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Machine Control System___________________________________________

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