MT2200

System knowledge and troubleshooting

4. Control System

Mining and Rock Excavation Services

FOR INTERNAL USE ONLY

Control system
Course agenda
1. Introduction
2. Safety Questions you should be able
to answer after this chapter:
3. Application and operating ü What are the main
components?
4. Electric system
ü Where are the main
5. Control system components located on the
machine?
6. Hydraulic system ü What is the function of the
main components?
7. Brake system ü How does the control system
work?
8. Engine and fuel system
ü How to use the navigation
screens?
9. Powertrain
ü How to adjust speeds of
10. Maintenance different functions?
ü What are the troubleshooting
11. Analytical troubleshooting methods?
ü What are the typical problems
and ways to manage them?
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Control system
Micro RCS/PLC
Introduction of RCS User levels
System description Menu description
Component locations Troubleshooting and fault finding
Modules

3
Control System
Introduction of RCS

What is RCS?
• RCS (Rig Control System) is a control system for Epiroc equipment
• Designed for monitoring and controlling the equipment
• Built utilizing the CAN 2.0 architecture
• Developed and maintained by Epiroc

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Control System
Introduction of RCS

What is CAN?
• CAN is short for Controller Area Network
• Serial network technology for embedded solutions
• Originally designed by Bosch for automotive industry
• Designed for maximum performance and reliability
• Operates at data rates up to 1 Mbit/sec
• Is an international standard: ISO 11898

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Control System
Introduction of RCS

Why did Bosch invent CAN?

The original electrics used in vehicles (cars, buses…), called point-to-point or dedicated wiring,
started to get very complex due to higher demands of electrical components in vehicles which lead
to expensive and bulky harnesses that were very heavy and very troublesome to work with design
wise
I/O

ECU Device

Overview of a conventional dedicated wiring system without CAN

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Control System
Introduction of RCS

What are the benefits with CAN?

CAN provides an inexpensive, durable network that helps multiple CAN devices communicate with
one another. This gives large advantages such as that electronic control units (ECUs) can have a
single CAN interface rather than multiple analog and digital inputs to every device in the system.
This decreases overall costs and weights but also adds intelligence to each and every device.
I/O

ECU Device

Overview of a Controller Area Network (CAN) wiring system

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Control System
Introduction of RCS

Where is CAN used today?

• Wherever two or more microprocessor units need to communicate with each other
• In passenger cars (often multiple separate CAN networks)
• In robotics (motion control applications)
• In passenger/cargo trains (for brake control, wagon communication)
• In aircrafts
• In elevators
• In building technologies (light and door control systems, sensors, etc.)
• In medical equipment (X-rays, CAT scanners, etc.)
• In Aerospace technology (satellites, etc.)
• In trucks, buses, and UNDERGROUND LOADERS
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Control System
Introduction of RCS

What is digital communication? IF pin 1 has power

THEN send power out on pin 5
AND consider light in state On
ELSE consider light in state Off

User presses button to Computer receives a

turn on the lights input to turn on the lights

+24V is sent from button to input +24V is sent from output on computer
on the computer to the light, which illuminates it

101110010111100100101110101100010110110001 01001001010001100011001110110001011011000
001010101110111001010110001111000100… 1111000100010111001010110001111000100…
Computer sends back the requested data Display sends a digital message to computer
as a digital message (binary code), and
ON
to receive the information it requests by use
the information is shown on the display. of binary code.

The display requests to find out

if the light is turned On or Off

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Control System
System description

CAN signals

Connections
Pin 1: Ground CAN High
Pin 2: + (blue)
Pin 3: -
Pin 4: High
Pin 5: Low
Negative (-)
(black)
+21 Volts
+21 Volt
CAN Low (red)
(white)

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Control System
System description

CAN signals

5V

CAN High (2.6V)

2.5V

CAN Low (2.4V)

0V
This is how the CAN-Bus signal looks like in idle state
In reality the signal never looks like this because all the modules constantly communicates with each other
However when we measure the signal with the tools from the service bag, these are the levels that we are measuring

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Control System
System description

CAN signals
5V Dominant bit (0)

3.5V

2.5V Idle

1.5V
Parts of a message
Recessive bit (1)

Time
250 bit/second
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Control System
System description

External power from batteries

24 Volt main power from battery

D501
Display

D100
PLC

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Control System
The address- and end plugs

How to know the difference

The address- and end plugs are visually almost the same, but the difference is there…

M12 round male connector

M12
round female connector

9106 1324 38 1-9106 1324 91

End plug (120 Ohm) Address plugs

End plugs only has a part number written on it Address plugs has a leading number followed by its part number
9106 1324 38 1-9106 1324 91

Address- and end plugs colors may vary

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Control System
Supply Voltage

Normal state when:

• Main supply voltage (grey cable)
24-28 V (MAIN POWER)
• CAN supply voltage (purple cable)
18-24 V (CAN POWER)

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Control System
CAN cables

General rules for CAN cable routing

• The weakest point on a cable is the connector < 200 mm
• Minimum bending diameter is 200 mm
• Make sure all contacts are relieved so they can’t
move if the cable moves
Correct Incorrect
• Put all CAN cables in a protection hose and make
sure they are covered all the way
• If the cable is in a position where it will move,
fix the protection hose in both ends
• Route the CAN cables separate from other cables
such as power cables or analog cables
• If you use cable ties, make sure that they do not cut
in to the cable jacket or even deform the cable
Correct Incorrect
• If the CAN cable is too long, make big bends and hide it
but make sure that the minimum bending diameter is 200 mm

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Control System
Component location Cabin
D501 Display
A12
A13

A11
A10

D604 Checkfire display

D100 PLC
Bulkhead connections

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Control System
Display

• Micro RCS/PLC
– Display to monitor values
– Standard log in with Password and USB key
– Touch screen
– Menus and Parameters to adjust settings
o Self explanatory text
o Troubleshooting
– Ethernet file transfer

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 Control System
Modules

D501 Display module

Connector legend

X1 X2 X3 X4 X8 X9
Power J1939 Adress CAN USB Camera/Eternet

Pin 1 +24V Not used Not used Not used Vbus +

Pin 2 +24V Not used Not used Not used D- +
Pin 3 Ground Not used Not used Not used D+ -
Pin 4 Ground CAN + CAN High CAN High Ground -

Pin 5 N/A CAN - CAN Low CAN Low Shield Not used
Pin 6 N/A N/A N/A N/A Not used Not used

Pin 7 N/A N/A N/A N/A Not used Not used

Pin 8 N/A N/A N/A N/A Not used Not used

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Control System
Modules
Display status LED
D501 Display module
LED Status Description

Status Green Display is working properly

Yellow Communication error
Red Display error
Ethernet Off Ethernet is inactive
Green Ethernet is linked
Flashing Ethernet is active

Ethernet status LED

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Control System
D100 - Inputs

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Control System
D100 - Inputs

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Control System
PLC – D100

• For complex control functions in vehicles and mobile machines

• Multifunctional configurable input and output channels
• CAN interface
• For use in safety applications
• E1 type approval by the Kraftfahrt-Bundesamt (German
Federal Office for Motor Traffic) for use under difficult
conditions

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Control System
D100 - Outputs

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Control System
D100 - Outputs

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Control System
D100 – LED indicators/operating states
Operating states PLC/Application Operating states of the system
LED Color Status Desc LED SYS0 LE SYS1 System state
SYS0 On No application Color Status Color Status
Green
2 Hz Standard PLC Run - Off - Off No operating viltage

Red 10 Hz Error application (Serious error) Green 5 Hz - Off No operating system loaded

Yellow 2 Hz Debug run Red On - Off Hardware error (Fatal error+)

On Debug stop Red On Red On System error (Fatal error)
SYS0 Green On No application Green/Yellow On 2 Hz 2 Hz Update
2 Hz Run
Safe PLC

Red 10 Hz Error application (Serious error)

Yellow 2 Hz Debug run
On Debug stop
ETH0 Green Flashing Data transmission Ethernet
On Ethernet connection ok
ETH1 Green Flashing Data transmission Ethernet
On Ethernet connection ok, no data transfer
APP0 Red On Status display of the application, freely programmable
Green On Status display of the application, freely programmable
Blue On Status display of the application, freely programmable

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Control System
D100 – connectors

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Control System
D100 – wiring connactor A

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Control System
D100 – wiring connector B

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Control System (Options)
Certiq Ethernet Switch D720
Protocol EterNet (IEEE 802.3)
Switch Functionality Unmanaged
Type N/A
UPC 887191685229
Woodhead Yes

Physical
Ethernet Connector 4-Pole Ultra-Lock (M12) Conn
Housing Width 60.00mm
Mechanical Shock 50G (Iec 68-2-29)
Mounting Style N/A
Packaging Type Carton
Ports 8
Power Input 5-pole Micro-Change (M12)
Temperature Range -40°C to +75°C
Uplink Connection 5-Pole Micro-Change (M12)
Vibration 7g (IEC 68-2-29)

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 Control System (Options)
Certic Wireless Bridge D771

Order code 021440-B

Range 400 meters

Antenna Built in

Operating temperature -30 to +65°C

Weight 120g

Housing Plastic (IP65)

Dimensions M12 (Ethernet/Power)

Connectors M12 (Ethernet/Power)

ELECTRICAL CHARACTERISTICS

Output power 20 dBm

RF power supply 9-30 VDC

Power consumption 47 mA @30V (min.)

59mA @30V (average)

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Control system (Options)
Wireless bridge II – LED’s

LED Status Description

Off No power
PWR
Green Normal operation
Off No link
Access Point mode: Connected to at least one client. Client mode: Connected to
Blue
access point
WLAN Blue flickering WLAN data activity (when connected)
Purple blinking Client mode: Scanning for access points
Purple Client mode: Connecting to a detected access point
Red Unrecoverable error
Off No Ethernet connection
LAN Yellow Ethernet link present
Yellow flickering Ethernet data activity (When connected)
Off Bluetooth adapter disabled or no power
Blue NAP mode: Connected to at least one PANU client / PANU mode: Connected to NAP
BT Blue flickering Bluetooth data activity (when connected)
Purple PANU mode: Trying to connect to NAP
Red Unrecoverable error
A-B-C-D Green RSSI (received signal strength) or Link Quality

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Control System
Block diagram E10 cabin

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Control System
Block diagram E10 canopy

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Control System
Block diagram E20

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Control System
User levels

User levels have different authority to adjust machine settings, in some

cases different authority is needed to view information
OP No access to settings
SE Adjust basic settings
AC Limited machine settings
ACP Full access to settings

OP Default no authorization to log on needed

SE Code required to log in,
AC,ACP needs additional USB key

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Control System
Menus in Start Page

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Control System
User Menu

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 Control System
User Menu

Under User menu, the operator

can change service level here.

Under User menu, the operator

can change language here.

To exit a submenu and return to the

start menu, press the Home button.

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Control System
System Menu

The Following can be found in the System menu:

• Module information
• Personal settings
• Event log
• IP configuration

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Control System
System- Module View

• If a module is green, it is working. If a

symbol is red, the module is not working.
• For more information about each module,
press the symbol.

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Control System
Module information

• Pressing a module symbol will provide the

user with more information.

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Control System
System

• Access more submenus by pressing this

button if it is available.

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Control System
System

• Machine information.

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Control System
System

• Personnel settings, brightness, imperial or

metric, save and load parameters.

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Control System
System

• Event log.

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Control System
System

• IP configuration.

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Control System
System

• Options, need AC log in or higher to make

changes.

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Control System
Settings Menu
The following can be made in the
Settings menu:
• PLC Settings
• Engine ECU
• External sensor information
• Service Interval

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Control System
Settings

In the IFM PLC menu, the converter stall test to check the performance of the machine can be done. If there is
fire suppression actuation, the warning can be unchecked (If you have SE login or higher).

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Control System
Settings

• Engine sensors
• If a symbol has two or more white dots
( ) you can switch pages by pressing
the symbol

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Control System
Settings

Under menu , the service symbol can be

reset. SE login or higher to reset.

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 Control System
Settings

• Input to PLC
• If a symbol has two or more white dots you
can switch pages by pressing the symbol.

In the Sensors menu, the operator can

troubleshoot the input and output signals to
PLC.

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 Control System
Settings

• Output from PLC

• If a symbol has two or more white dots you
can switch pages by pressing the symbol.

In the Sensors menu, the operator can

troubleshoot the input and output signals to
PLC.

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Control System
Settings

External sensors give information about:

• Hydraulic information
• Transmission oil pressure
• Vehicle information

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Control System
Settings

Settings-engine-diagnostic
• Active fault codes engine
• Non active fault codes engine, log

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Control System
Settings

The corresponding information can be

found in the transmission.

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Control System
Data Menu

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Control System
Data Menu

Under Data menu, the operator can find

information about:
• Maintenance log, statistics log and save
all logs
• Fault codes
• Synchronize Certiq data

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Control System
Statistics Menu

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Control System
Statistics Menu

Under Statistics menu, the operator can

see the accumulating engine data for
example, engine hours and fuel
consumption.

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Control System
Dashboard Menu

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Control System
Dashboard Menu

Under Dashboard menu, the operator can find information

about the following functions:
• Diesel engine temperature • Engine hours
• Fuel level • Active functions
• Speed • Warnings
• Engine RPM • Alarms

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Control System
Dashboard Menu

Information on conditions monitored by the

control system
presented with different symbols in the
status bar. Different colors indicate different
information levels:
• Red = Fault
• Yellow = Warning
• White = Function is active

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Control System
Dashboard Menu

• Parking brake activated

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Control System
Dashboard Menu

• Lock up engaged

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Control System
Dashboard Menu

• Dump box up

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Control System
Dashboard Menu

• Tailgate open (option, only teletram)

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Control System
Dashboard Menu

• Converter stall test

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Control System
Dashboard Menu

• ADES

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Control System
Dashboard Menu

• Cab door open, door interlock, DOBA

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Control System
Dashboard Menu

• Cab door interlock override

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Control System
Dashboard Menu

• Gear indicator

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Control System
Dashboard Menu

Bottom status bar of the Dashboard

menu contains fields that can be
pressed. If the number of faults are
more than viewable in the field, they
appear in a list when touching the
status bar.

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Control System
Warning/alarm symbols
Image Description Image Description
Gear indicator Diesel engine coolant temperature high
• White - Information • Amber – Warning
Transmission oil pressure low <11 bar • Red – Alarm
• Red – Alarm Clogged air filter, diesel engine
Transmission oil temperature high >120°C • Amber – Warning
• Red – Alarm Engine, wait to start
Parking brake activated Amber – Warning
• Red – Alarm Engine, stop
Hydraulic oil level low • Red – Alarm
• Red – Alarm
Low fuel level. The icon is activated when
Hydraulic oil temperature high >90°C the fuel level is <20%
• Red – Alarm • Amber – Warning
Fault in brake system <104 bar Battery potential low
• Amber – Warning • Amber – Warning
Fault in brake system <96 bar Grease level low
• Red – Alarm • Amber – Warning
Steering pressure low <4.0 bar No time zone selected
• Red – Alarm • Amber – Warning
Engine failure. Unknown error from ECM. PLC CAN failure
• Amber – Warning • Red – Alarm
Low coolant level
• Amber – Warning
• Red – Alarm
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Control System
Warning/alarm symbols

Image Description
Emergency stop. The symbol lights up red when
any of the emergency stops has been activated.
The diesel engine is switched off automatically.
• Red - Alarm
Fire suppression off
• Red - Alarm
Service interval 250 hours
• Amber – Warning
Converter stall test
• White – Information
Box up
• White – Information
Cab door open
• Amber – Warning
Cab door interlock override
• Amber – Warning

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Control System
User Levels

OP SE AC ACP DEV

Converter stall test Service interval reset Red and green lights,
AC IFM PLC
steady/directional

Fire suppression reset Joystick settings

Main power switch alarm

Start-up alarm

Horn in joystick

Tractive effort test

Block 3 and 4

Block 4

Certiq

Camera

Logs

NBA

Teletram

ADES
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Service interval
Control System
Adaptive Delayed Engine Shutdown

ADES (Adaptive Delayed Engine Shutdown) is a

delayed shutdown function for the engine to protect
and increase the life time of the turbo.

ADES is activated automatically when the machine is in

following mode:
• The parking brake is applied.
• No throttle pedal.
• The engine start and stop button is pressed.
The system calculates the needed engine cooling time
due to the historical engine load, up to 3 minutes.
The ADES-symbol will flashes in the display. To
override this press the engine override button twice.
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Control System
Exhaust brake

The exhaust brake is a three-position switch: off,

low, and high.

Off = 0%
Low = 50%
High =100%

The switch light illuminates when the function is

active. The system is also equipped with a speed-
sensing switch that automatically activates the
Jake brake upon engine overspeed.

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Control System
Fault finding and troubleshooting – Service toolbox

• Service toolbox 9106 2241 80 for CAN (CANopen)

– Contains all necessary tools for conducting fault finding and troubleshooting on the CAN network
– Multimeter, CAN tester, I/O tester, test cables and more…

A CAN tester Main- and CAN power, traffic, cable test…

B Resolve tester Only for TME products
C Multimeter Standard multimeter
D Encoder tester Only for TME products
E Test cables For breaking in to existing CAN cables etc…
F I/O tester For testing I/O modules (M12 tester)
G Test box Only for TME products
H Connectors End plugs, address plugs, connectors…

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Control System
Fault finding and troubleshooting – CAN Tester

• Main power to I/O modules from batteries (+24V)

• CAN power distribution (+21V)
• CAN traffic (CAN High and CAN Low) activity
• Cable resistance test (CAN line resistance)

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Control System
Fault finding and troubleshooting – Multimeter

• Fluke multimeter
• For measuring alternating (AC) and direct (DC) current
• Resistance and diode measuring capabilities
• Use together with CAN tester to read data from CAN tester

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Control System
Fault finding and troubleshooting – Test cable

• Use test cables to break in to existing CAN cables

• Do not use as replacement cables on the machine
• M12 connectors in both ends
• Comes in various lengths

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United. Inspired.
Performance unites us, innovation inspires us,
and commitment drives us to keep moving forward.
Count on Epiroc to deliver the solutions you need
to succeed today and the technology to lead tomorrow.
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