PDF Systems Operation Manual Cat MD6640 Blast Hole Drill - 6 MB
This manual provides detailed information on the systems operation, testing, and adjusting for the Cat MD6640 Blast Hole Drill (S/N: 2U70T57).
It is a technical document intended for service personnel to understand how the machine's systems function.
Use this guide for advanced troubleshooting and precise adjustments to keep your drill performing at its best.
This is a critical resource for maintaining the complex hydraulic and electrical systems of the MD6640.
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В!012589
JUNE 2013
VOLUME I of II
System Operation,
Testing & Adjusting
Manual
MD6640 Blast Hole Drill
Serial Number DR612159
SAFETY.CAT.COM
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
Caterpillar Global Mining, LLC.
Electrical Adjustments For MD6640 Drill
I 9.3
I 9.4
I 9.5
I 9.6
I 9.7
I 10 0
I 10.1
I 10 2
I 10 3
I 10.4
I 10 5
I 10 6
I 10.7
I 11 0
I 11.1
I 11 2
I 11 3
I 11.4
I 11 5
I 11 6
I 11.7
SLOT 7
I 12 0
I 12.1
I 12 2
I 12 3
I 12.4
I 12 5
I 12 6
I 12.7
I 13 0
I 13.1
I 13 2
I 13 3
I 13.4
I 13 5
I 13 6
I 13.7
I 14 0
I 14.1
I 14 2
I 14 3
I 14.4
I 14 5
I 14 6
I 14.7
I 15 0
I 15.1
I 15 2
I 15 3
I 15.4
I 15 5
I 15 6
I 15.7
SLOT 8
I 16 0
I 16.1
I 16 2
I 16 3
I 16.4
I 16 5
I 16 6
I 16.7
I 17 0
I 17.1
I 17 2
I 17 3
I 17.4
I 17 5
I 17 6
I 17.7
I 18 0
I 18.1
I 18 2
I 18 3
I 18.4
I 18 5
I 18 6
I 18.7
I 19 0
I 19.1
CSDR612159.xls 7 of 25 5/15/2013
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
CATERPILLAR GLOBAL MINING, LLC.
ELECTRICAL ADJUSTMENTS FOR BLAST HOLE DRILLS
USING SIEMENS DC MOTION CONTROL DRIVES
ROTARY DRIVE START UP ADJUSTMENTS WITH POWER ON
PARAM. INDEX PARAM DEFAULT MDV810 ROTARY
NO. NO. DESC. VALUE STD. VALUE ACTUAL VALUE
P456 2 CONNECTOR SELECTOR SWITCH 1 CONTROL 0 20
P457 1 INPUT FOR CONNECTOR SELECTOR SWITCH 2 0 230
P458 1 CONNECTOR SELECTOR SWITCH 2 CONTROL 0 24
P611 1 FIELD CURRENT REFERENCE SELECTION 277 231
P664 1 SOURCE FOR CONTROL WORD 1, BIT 6 1 16
P665 1 1ST SOURCE FOR CONTROL WORD 1, BIT 7 0 10
P750 0 OUTPUT VALUE SOURCE, ANALOG OUTPUT 1 0 292
P752 0 ANALOG OUTPUT 1 FILTER TIME 0 100
P753 0 NORMALIZATION OF ANALOG OUTPUT 1 10 10.38
P755 0 OUTPUT VALUE SOURCE, ANALOG OUTPUT 2 0 266
P757 0 ANALOG OUTPUT 2 FILTER TIME 0 100
P758 0 NORMALIZATION OF ANALOG OUTPUT 2 10 15
P760 0 OUTPUT VALUE SOURCE, ANALOG OUTPUT 3 0 117
P762 0 ANALOG OUTPUT 3 FILTER TIME 0 100
P763 0 NORMALIZATION OF ANALOG OUTPUT 3 10 6.8
P771 0 OUTPUT VALUE SOURCE, BINARY OUTPUT 1 0 107
P820 7 DISABLE FAULT MONITORING 0 38
P820 8 DISABLE FAULT MONITORING 0 42
P820 9 DISABLE FAULT MONITORING 0 48
P820 10 DISABLE FAULT MONITORING 0 40
P825 1 FIELD FEEDBACK ANALOG OFFSET 19139 *
P825 2 FIELD FEEDBACK ANALOG OFFSET 19139 *
P825 3 FIELD FEEDBACK ANALOG OFFSET 19139 *
P826 1 AC LINE ZERO CROSSING CORRECTION 0 **
P826 2 AC LINE ZERO CROSSING CORRECTION 0 **
P826 3 AC LINE ZERO CROSSING CORRECTION 0 **
P826 4 AC LINE ZERO CROSSING CORRECTION 0 **
P826 5 AC LINE ZERO CROSSING CORRECTION 0 **
P826 6 AC LINE ZERO CROSSING CORRECTION 0 **
U580 0 CONTROL WORD FOR COMMUATION MONITORING 7 4
U962 99 FUNCTION BLOCK PROCESSING SEQUENCE 299 0
U962 100 FUNCTION BLOCK PROCESSING SEQUENCE 300 299
* AUTOMATICALLY DETERMINED BY THE DRIVE DURING THE PARAMETER DEFAULT PROCEDURE.
** AUTOMATICALLY DETERMINED BY THE DRIVE IF ARMATURE CURRENT CONTROLLER SELF
TUNING IS PERFORMED.
CSDR612159.xls Page 19 of 25 5/15/2013
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
TABLE OF CONTENTS
OVERVIEW......................................................................................................................................................... 5
GENERAL MACHINE DESCRIPTION ............................................................................................................ 5
GENERAL MACHINE DESCRIPTION ............................................................................................................ 6
DRILL OVERVIEW ............................................................................................................................................... 6
AUXILIARY FUNCTIONS ....................................................................................................................................... 6
GENERAL CONTROLS AND POWER ....................................................................................................................... 7
OPERATOR INTERFACE ................................................................................................................................. 9
OVERVIEW.......................................................................................................................................................... 9
OPERATOR CHAIR CONTROLS .............................................................................................................................. 9
Left Propel Track / Winch – Joystick – POLMS............................................................................................. 10
Right Propel Track / Pipe Rack / Mast – Joystick – PORMS .......................................................................... 10
Hoist/Pulldown Master Switch - HPMS......................................................................................................... 10
Rotary Master Switch – RMS ........................................................................................................................ 10
Programmed Drill Control Pushbutton – PDCPB (Option) ........................................................................... 10
Depth Indicator Reset Pushbutton – DIRPB .................................................................................................. 10
Drill Deck Hatch Selector Switch – DDHSS.................................................................................................. 11
Hoist/Pulldown Selector Switch – HPSS........................................................................................................ 11
Drill/Propel/Mast Selector Switch – DPMSS................................................................................................. 11
Rotary Speed Control Selector Switch – RSCSS............................................................................................. 12
Hoist/Pulldown Brake Selector Switch – HPBSS ........................................................................................... 12
Air Compressor Unload Selector Switch – ACUSS ........................................................................................ 12
Water Injection Selector Switch – WISS (Option) .......................................................................................... 13
Water Injection Rheostat – WIR (Option) ...................................................................................................... 13
Dust Curtain Selector Switch – DCSS (Option) ............................................................................................. 13
Emergency Stop Maintained Pushbutton – ESPB1......................................................................................... 14
Drill Pipe Position Selector Switch (STORE/OVER HOLE) – DPPSS (Option).............................................. 14
Dust Seal Slider Selector Switch (FRONT/REAR) - DSSSS (Option) .............................................................. 14
Propel Speed Range Selector Switch – POSRSS ............................................................................................ 14
Horn Pushbutton – SHNPB1......................................................................................................................... 14
Tool Wrench Selector Switch – TWSS............................................................................................................ 14
Breakout Wrench Selector Switch – BOWSS.................................................................................................. 15
Pipe Rack Selector Switch – PRSS (Option) .................................................................................................. 15
Manual Leveling Jack Control Switches – JRRSS, JFLRSS, JRLSS ................................................................ 15
Automatic Leveling Jack Control Switch – JACSS ......................................................................................... 15
CONSOLE CONTROLS......................................................................................................................................... 16
Ground Test Pushbutton – GTPB .................................................................................................................. 16
Exterior Lights Selector Switch – ELSS......................................................................................................... 16
Thermostat Control – HVACTC .................................................................................................................... 16
HVAC Fan Selector Switch – HVACFSS ....................................................................................................... 16
HVAC Mode Selector Switch – HVACMSS.................................................................................................... 16
Boarding Stairs Cab Selector Switch – BSCSS .............................................................................................. 17
MACHINERY HOUSE CONTROLS ......................................................................................................................... 17
Air Compressor Start Pushbutton - ACSTARTPB .......................................................................................... 17
Air Compressor Stop Pushbutton - ACSTOPPB............................................................................................. 17
Emergency Stop Pushbutton – ESPB2........................................................................................................... 17
OPERATOR DISPLAY .......................................................................................................................................... 17
MACHINE OPERATION ................................................................................................................................. 19
OVERVIEW........................................................................................................................................................ 19
MACHINE STARTUP ........................................................................................................................................... 19
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
Automatic Leveling
In addition to manual leveling switches, the 49HR incorporates logic for the automatic leveling of the drill.
Pressing and holding the JACSS (Jack Automatic Control Selector Switch) in the EXTEND position will
activate the automatic leveling logic as long as the button is held. The logic extends the leveling jacks
until ground pressure is sensed in each jack before leveling the machine first in the side-to-side axis, and
then in the front-to-rear axis. When the machine reaches “Fine Level”, all jacks are extended
simultaneously until the operator releases the Jack Automatic Control Selector Switch.
A customer selectable option is available through the Configuration Screen of the operator display to
toggle One Touch Automatic Leveling. With this option enabled, the leveling process is carried out with
one touch of the Jack Automatic Control Selector Switch rather than having to hold the switch down. The
machine is automatically leveled and then all jacks are raised for 5 seconds after “Fine Level” has been
achieved.
In both modes of automatic leveling, the machine must be within 7 of level before automatic functions
can take place. If in a position where the drill has a tilt reading of greater than 7 the drill must be
manually leveled to within this limit before pressing the Jack Automatic Control Selector Switch. An
indicator on the Leveling Screen of the operator display will indicate when automatic leveling operations
are allowed.
Retract Switches
The drill is also equipped with Jack Retract Switches. This will tell the operator, via the operator display if
each of the jacks has been fully retracted. These switches are also integrated with the control logic to
prevent certain operations, such as propel, if the jacks are down.
Mast
Operation
The raising and lowering of the mast is controlled with the same joystick used to control the right propel
crawler track. This joystick is located in the right pod of the operator’s chair. The mast can only be
moved when the drill is in MAST/WINCH mode, as set by the DPMSS on the operator’s chair.
In order for the mast to be raised or lowered with the joystick, the following conditions must be met.
NOTE: Other conditions may also be required due to customer requests or system enhancements.
Control must be enabled (see above).
The drill must be set in MAST mode.
The head machinery must be lowered to the mast lower limit.
Mast Lock Pins
These hydraulically actuated pins are used to lock the mast in a vertical position and are controlled
through buttons located on the Mast Operations Screen of the operator display. To function, the
hydraulic pump motor must be on (ACM running) and the DPMSS (Drill/Propel/Mast Selector Switch) must
be in the MAST/WINCH position. At this point, the mast lock pins can operate in the LOCK direction. To
function in the UNLOCK direction the rotary head assembly must be at the lower limit point. On
machines that incorporate the angle hole drilling option, the additional restriction of having the A-frame
pins in place is included. When controlling these pins through the operator display, pressing the Lock or
Unlock Button will move both pins in the appropriate direction for 10 seconds, or until limit switches
within the mast lock pin cylinders indicate that the pins are fully in the desired position.
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
b. The JACSS (Jack Automatic Control Selector Switch) must be in its center off position.
c. Put the DPMSS (Drill/Propel/Mast Selector Switch) in the DRILL position.
d. Each jack manual selector switch controls a jack extend valve and a jack retract valve.
When the selector switch is moved out of its center off position, the JLVS (Jack Loader
Valve Solenoid) and a jack extend or retract valve are simultaneously energized. When
the selector switch is returned to its center off position, the JLVS will turn off
immediately. The jack extend or retract valve that was energized will turn off two
seconds later. Verify that the correct jack valves are energized when the joysticks are
operated as shown in the table below.
Switch Position PLC Input PLC Output Valve
JRLSS Extend I40.6 Q12.5 JRLLVS
JRLSS Retract I40.7 Q12.4 JRLRVS
JFLRSS Extend I41.0 Q12.1 JFLLVS
JFLRSS Retract I41.1 Q12.0 JFLRVS
JFLRSS Extend I41.0 Q12.3 JFRLVS
JFLRSS Retract I41.1 Q12.2 JFRRVS
JRRSS Extend I41.2 Q12.7 JRRLVS
JRRSS Retract I41.3 Q12.6 JRRRVS
8. The lubrication system hydraulic valves can be electrically tested using the procedure that
follows.
a. Use the Maintenance Screen of the operator display to ensure that automatic lubrication
is not enabled.
b. Display the Lubrication Screen on the operator display, and note the setting for the low
pressure fault time.
c. Press the Manual Lube Pushbutton on the Maintenance Screen of the operator display.
The LDVS (Lube Direction Valve Solenoid) connected to output Q2.5 should energize
immediately. After a delay of approximately one second, the LEVS (Lube Enable Valve
Solenoid) connected to output Q2.6 should energize. When the low pressure fault time is
exceeded, the operator display should annunciate a low pressure fault alarm. The lube
system fault indicator on the Status Screen of the operator display should come on, and
all of the lube valves should turn off.
Proportional Hydraulic Valves Electrical Setup
This section covers the adjustment of the proportional hydraulic valve control cards EHPC1, and EHPC2.
Further adjustments should not be required unless a card is replaced. The following procedure can be
used to check card operation and to make card adjustments should this be necessary. Refer to the
C-sheets and electrical schematics.
1. Open and lockout the ACD air compressor disconnect. This will prevent operation of the air
compressor motor during any of the testing that follows.
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
Drill Leveling System
The leveling system was adjusted and tested at the factory. It will be functionally checked in this section
to verify that field wiring and piping are correct. Do not make adjustments unless absolutely certain that
they are necessary.
The level sensors are precision inclinometers mounted to detect tilt in the front-to-rear and side-to-side
axes of the drill. The inclinometer analog signals are sent to the PLC which controls the jacks in the
automatic leveling mode and scales the signals for the operator display.
1. Navigate to the Leveling/Propel Screen on the operator display. This provides complete
information on the status of the leveling system. Indicators in the upper right corner of the
display show when a jack is on the ground or fully retracted. Illuminated bars show the amount
of front-to-rear and side-to-side tilt. In addition to the bar indication, the actual degrees of tilt
are shown numerically at the bottom of the screen.
2. Put the DPMSS (Drill/Propel/Mast Selector Switch) in its DRILL position.
3. Make certain that all personnel are clear of the main air compressor. Put the ACUSS (Air
Compressor Unload Selector Switch) in the CLOSE position, and start the compressor.
4. Make certain that all personnel and equipment are clear of the jacks.
5. Using the manual jack control switches, extend each jack until it touches the ground. The
associated ground pressure indicator should illuminate on the operator display.
6. Using the manual jack control switches, fully retract each jack. The associated fully retracted
indicator should illuminate on the operator display.
7. Manually level the drill with the jack control switches. Use the most accurate means available on
site to determine when the drill is level. Surveying instruments or laser leveling devices can be
used and provide good results. The level sensors will be checked using this manually obtained
level condition as a reference.
8. The operator display side-to-side level and front-to-rear level numeric display values should be
+/- 0.1 degrees or zero. If the values are greater than +/- 0.1 degrees, the level sensors can be
adjusted using the procedure that follows.
a. The inclinometers are located on the back panel of the ZCCA cabinet of the operator’s
cab. Both inclinometers are mounted as a single unit that sends two independent signals
to the PLC.
b. Open the cabinet and the cover of the inclinometer unit to check that there is incoming
24VDC to each of the inclinometer channels. 24VDC should be present on each of the
channels opposite the signal wire to the PLC.
c. Use the Test Analog Inputs Screen, or the PLC – Remote Rack 5 Screen to see the
incoming signals from the clinometers. The screen will indicate 12.0mA if viewing
voltage/current signal level, or 13824 if viewing PLC integer value, when the inclinometer
channel is correctly zeroed.
d. To adjust either inclinometer, turn the “Zero Pot” for the associated channel until the
above values are achieved. Two potentiometers are provided for the adjustment of each
channel. Channel 1 potentiometers (front-to-rear level indication) are located on the left
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Critical
Fault Message Description / Effect Recommended Action Fault
ANF048 Head Overspeed Fault This fault occurs when the head exceeds 1. Verify that the head is actually moving at a
the maximum speed (approximately 1.6 faulted speed.
ft/s). Further use of the hoist functions are 2. If the speed is verified, refer to the
inhibited until the fault is reset. hydraulic/mechanical documentation.
3. If the speed is NOT verified and the fault
repeats, test and/or replace the head
encoder.
ANF049 Cable Reel Control Fault This fault occurs when there is not feedback 1. Check the operation of the cable reel.
from the cable reel contactor. 2. Verify the operation and/or wiring of the
cable reel motor contactor.
System Testing and Adjusting
3. On the operator display, check for feedback
from the cable reel.
ANF050 Radio Remote Tilt Shutdown This fault occurs when the radio remote 1. Check the level monitors to assure the tilt
propel option is enabled and tilt becomes angle is greater than 14 degrees.
greater than 14 degree. This will disable 2. Propel the drill from the cab until tilt is less
radio remote control. than 14 degrees.
ANF051 Radio Remote Fault If the radio remote option is installed and 1. Assure the remote transmitter is within the
the operating mode switch is in the remote signal range.
propel position for more than 5 seconds, 2. Check the operations and/or wiring of the
outputs to power the receiver are turned transmitter and receiver.
on. After a delay to allow the receiver to
power up, the inputs from both the receiver
and transmitter must be present or this
fault is set and control is disabled.
MD6640 BLAST HOLE DRILL
Note: If the transmitter gets too far out of
range, the transmitter on signal will be lost
and control will be disabled.
ANF052 24VDC Control Power Fault This fault occurs if 24VDC control power 1. Check the connection and/or operation of X
supply is not available. The emergency the 24VDC control power supply.
shutdown sequence will occur.
ANF053 24VDC Input Power Fault This fault occurs if the input power (24V) is 1. Check the operation and/or connection of X
not available to the PLC Node 1. The the 24VDC power supply to PLC Node 1.
emergency shutdown sequence will occur.
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System Testing and Adjusting MD6640 BLAST HOLE DRILL BI012589
APPENDIX B – PLC LED DIAGNOSTICS
Processor LED’s
Figure 2 – Processor Status LED’s
This table shows the status of the LED’s on the PLC processor, located in the Console in the Operator’s
Cab. The description column shows some suggested procedures that might be able to fix the problem.
LED
SF BF DC5V FRCE RUN STOP Description
OFF OFF OFF OFF OFF OFF Processor power is missing. Check power
connections and breakers that feed the processor in
the operator cab.
OFF OFF ON OFF ON OFF Normal operation.
OFF X ON X OFF ON CPU is on STOP mode. Move keyswitch on
processor to RUN mode.
ON OFF ON X X X Processor or remote I/O node has an error. Possible
solutions are:
1. Check remote nodes (including the operator cab
display and the head encoder) to make sure a
non-critical node fault is not causing this
situation.
2. Move keyswitch on processor from STOP to
RUN.
3. Cycle keyswitch on processor from RUN to STOP
and then back to RUN.
4. Cycle power to the processor.
5. Reset the memory using the procedure outlined
in the PLC section of this manual.
6. If the error was not found to be in the remote
I/O or in the main rack’s I/O modules, record
what was happening when the error occurred.
X OFF ON X OFF Flash Processor requires a memory reset. Possible
0.5Hz solutions are:
1. Cycle power to the processor.
2. Reset the memory using the procedure outlined
in the PLC section of this manual
X X ON X OFF Flash Processor is executing a memory reset. This is