E- LYNK MANUAL
PART ONE
OPERATIONS DESCRIPTION AND OVERVIEW
1
SECTION ONE
Contents
Description
Page
System Overview
Features
System Components
Machine Unit
Machine Unit Components
Indicator Lights for Machine Unit
Operators Unit
Operators Unit Components
Indicator Lights for Operators Unit
2.4Ghz Radio Information
Hydraulic Interface Components
Electrical Interface Components
Machine Unit and Operators Unit Enclosures
Operating Procedures
Manual to Remote Mode
Remote to Manual Mode
Guidelines To Follow for Remote Control Safety
Guidelines To Follow For Remote Control Component Care
Remote Control Brake Systems
Second Brake Valve
Service Brake Valve
Park Brake Valve
Operator Training
Warranty
SECTION TWO
E – Lynx Training Test
Part - A
Part – B
SECTION THREE
Safety considerations when commissioning or troubleshooting
Terminology
Description of remote control interlocks and timeouts
2
SYSTEM OVERVIEW
Certain modern mining methods may rely extensively on radio remote control systems. Radio remote
controlled mobile equipment can provide options in the choice and design of a mining method where large
amounts of ore can be mined in a safe, cost effective and productive manner. The E-Lynx radio
remote control systems were designed for mining applications and consist of two main electronic
components. The first main component is the module attached to the machine being controlled,
(Machine Unit).
Figure 1. E – Lynk Machine Unit
Figure 2. Operator Unit
The second main component is the module used by an operator to control the machine, (Operator Unit)
The radio remote control system is compact, sturdy and easy to use. More importantly the same unit
can be used and interchanged with any other machine using an E-Lynk radio remote control system.
FEATURES
The E-Lynx 2.4Ghz wireless radio remote control system was specifically designed and engineered
for usage in harsh underground and industrial environments. It Incorporates spread spectrum
technology for safer and more stable wireless link. The system can be used in a basic “line of site”
application or as a fully TELE-OPERATED system complete with video and audio where a suitable
communication structure has been installed in the mine. The output control functions can be
customized On/Off or proportional to suit the end users requirements. The same custom designed
radio board is used in the machine and operator units.
The two way link between the operator unit and the machine unit is programmed such that the
operator is forced to follow a specific set of procedures when changing from manual to remote
operation or remote to manual operation. Failure to follow these simple and safe procedures will cause the
machine to “shutdown”.
SYSTEM COMPONENTS
This system is made of four basic components.
1.
Machine Unit
2.
Operator Unit
3.
Electric Interface Components
4.
Hydraulic Interface Components
1. Machine Unit Components
1. One Fiberglass Reinforced Plastic Enclosure
2. One 2.4Ghz. Radio Board
3. One Output Driver Board
4. One Radio Status LED Board
5. One Mounting Plate c/w Shock Mounts
6. One 2.4Ghz. Antenna
7. One 10 Socket Connector Wiring Harness
8. One 19 Socket Connector Wiring Harness
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Indicator Lights for Machine Unit
1. Power - Indicates that the power is on and the voltage is sufficient.
2. Link - Indicates that Vehicle Unit and Joystick Unit are communicating
3. Ready - Indicates that the LHD park brake is applied, that the transmission is in neutral and
the selector switch is selected remote
4. Diagnostic – Light will turn on when:
1) The LHD Park Brake has not been applied.
2) The LHD transmission is not in Neutral before switching from Manual to Remote
3) The Manual/Remote switch is defective.
Figure 3. Indicator Lights for Machine Unit
2. Operators Unit Components
1.
2.
3.
4.
5.
6.
7.
8.
9.
One Fiberglass Reinforced Plastic Enclosure
One Microprocessor
Two Joysticks
One 2.4Ghz. Radio Board
One Switch Function interface Board
Multiple On/Off Switches
Three Momentary off/On Switches
One Mushroom Switch
One Skid Plate
INDICATOR LIGHTS FOR THE OPERATOR UNIT
1. Power on Indicates that voltage is applied. Green indicates adequate voltage; a red light
indicates insufficient supplied voltage.
2. Link 3. Ready -
Indicates that Machine Unit and Operator Unit are communicating
Indicates unit is ready for operation without any faults.
4
Figure 4. Indicator Lights For Operators Unit
4
Diagnostics –
Light will turn on when:
1. The Delayed Shutdown feature is activated.
2. The Joystick unit is tilted over for more than one-quarter of a second while in Link.
3. The switch closure test is being performed.
4. The Operator Unit is powered up before switching from manual to remote.
5. The LHD Park Brake is not applied and or the transmission is not in the Neutral
position before switching from Manual to Remote.
6. The switches on the Operator Unit are not in their safe power up positions when
turning Operator Unit power on.
To correct any fault as indicated by the Diagnostic light being lit check and correct anything not right on the
above six items. Once the fault has been corrected reapply power to the Operator Unit.
Programming in the Operators unit allows for quick diagnostics on the machine and internal
components of the unit. Trained operators and service personnel can quickly diagnose and isolate
radio or machine related problems thus reducing any downtimes and increasing productivity.
3. Hydraulic Interface Components
1.
2.
3.
4.
Custom Built Hydraulic Manifold(s)
On/Off Cartridges As Required
Proportional Cartridges (Min. 3 Required)
Slave Cylinders If Required
Figure 5. Typical Valve Body
And Cartridge assembly
Figure 6. On/Off And Proportional
Hydraulic Cartridges
4. Electric Interface Components
1.
2.
3.
4.
One Manual Remote Selector Switch c/w contact blocks
Relay(s) 12Vdc or 24Vdc
Throttle interface 12 or 24Vdc PW M input to 5Vdc output or 10Vdc output (optical isolation)
Wiring Harness to connect to machine and control cartridges
The hydraulic and electrical interface systems are designed for ease of installation and to provide
conformity and simplicity to customers with multiple machine installations. The components can be
used interchangeably with other machines and reduces the inventory and warehousing cost
Machine and Operator Enclosures
1. Manufactured with corrosion resistant glass reinforced plastic (GRP).
2. Captive stainless steel lid screws
3. The enclosure lid is tongue and groove construction and fitted with an oil and petroleum resistant
neoprene gasket which provides excellent protection against the infiltration of dust, oil and water.
4. Temperature range of material in continuous use: -40°C to +80°C
5. The machine unit comes complete with a mounting plate and shock absorbers.
6. DIN 40050 Standards
7. ISO 9001 Specifications
5
OPERATING PROCEDURES
In order to operate the LHD machine in a safe and productive manner the following steps listed
must be adhered to, failure to do so will cause the LHD machine to be shut down.
MANUAL TO REMOTE MODE
On LHD Machine
1. Drive to and bring the LHD machine to a complete stop at the designated transfer point.
2. Apply the LHD “Park Brake”
3. Put the LHD manual gear selector into the “NEUTRAL” position.
4 . Switch the “MANUAL / REMOTE” selector switch on the LHD to “REMOTE.” The LHD will
continue to run for 60 seconds.
5. Leave the LHD and proceed to remote operator’s unit.
On Operators Unit
1. Check the remote operators unit and ensure the E-Stop switch is in the up position and the
Park Brake Switch is in the applied position
2. Turn the “POWER” switch to the “ON” position.
3. The LHD is now in radio remote control mode. Release the park brake to begin operating
The LHD Will Shut Down If Any Of The Following Conditions Exist.
1. The LHD manual gear selector is not in the “NEUTRAL” position before the MANUAL /
REMOTE SELECTOR is switched to the “REMOTE” position.
2. The LHD park brake is not applied before the MANUAL / REMOTE SELECTOR switch is
switched to the “REMOTE” position.
3. The Operators Unit “POWER” switch is in the “ON” position when the MANUAL / REMOTE
SELECTOR is switched to the “REMOTE” position.
4. The Operators Unit “POWER” switch is NOT turned to the “ON” position within 60 seconds
after the MANUAL / REMOTE SELECTOR is switched to the “REMOTE” position.
5. The Operators Unit PARK BRAKE switch is in the “OFF” (released) position.
RADIO CONTROL TO MANUAL MODE
On the Operator’s Unit.
1. Bring the LHD to a complete stop at the designated transfer point..
2. Release both joysticks and allow them to return to the “NEAUTRAL” position.
3. Switch the Operators Unit” PARK BRAKE” switch to the applied or “ON” position.
4. Toggle the Operators Unit “DELAYED SHUTDOWN” switch.
5. Switch the Operators Unit “POWER” switch to the “OFF” position. The LHD will continue to
run for 60 seconds.
6. Leave remote operators station and proceed to the LHD.
On the LHD Machine Unit.
1. Switch the MANUAL / REMOTE SELECTOR to “MANUAL” position.
2. The LHD is now in manual control mode. Proceed with load haul dump operation.
The LHD Will Shut Down If the Following Conditions Exist
1. The Operators Unit “EMERGENCY STOP” mushroom switch is depressed.
2. The Operators Unit “POWER” switch is turned “OFF” without toggling the
3. “DELAYED SHUTDOWN” switch.
4. The Operators Unit “PARK BRAKE” is not applied or in the “ON” position before toggling the
“DELAYED SHUTDOWN” switch.
5. The Operators Unit “FIRE SUPPRESSION” switch is activated.
6. The “MANUAL / REMOTE SELECTOR” switch on the LHD is not turned to the “MANUAL”
position within 60 seconds.
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REMOTE CONTROL MODE FUNCTIONS
The following list the standard functions which can be activated from the Operators Unit on an ELynx radio remote control system on an LHD application.
1. Remote Start - This function includes a park brake interlock - The park brake toggle
on the Operators Unit must be in the “ON” position to start the engine.
2. E-Stop Function – Shuts down the engine, stops the machine and applies the
brakes immediately when activated.
3. Delayed shutdown - Allows the machine to run for a predetermined time (60
seconds) before the engine is shutdown. This feature is part of the procedure when
changing from remote to manual or manual to remote mode.
4. Service brake application - They can be applied as required using the toggle switch
on top of the right hand joystick.
5. Service Brake application – The machine service brakes are applied automatically
after half a second delay when the left hand joystick is released or brought to the
“NEUTRAL” position.
6. Forward/Reverse Park Brake Interlock - The system programming will NOT allow
the transmission to go into forward or reverse with the park brake switch on the
Operators Unit in the applied or “ON” position.
7. The Front and Rear lights on the LHD can be turned on or off from the light
switches on the Operators Unit.
8. Engine throttle - The engine speed can be controlled proportionally from the
Operators Unit. The engine speed increases as the left-hand joystick is moved from
the “NEUTRAL” position. Activating the “Park Brake” switch and moving the lefthand joystick in the north-south axis activates the engine speed proportionally while
maintaining a stationary LHD.
9. Forward/Reverse - The directions are obtained by moving the left-hand joystick in
the direction as indicated after the park brakes switch is in the “OFF” position.
10. Steering - The steering functions are activated by moving the left-hand joystick in
an east to west axis.
11. Boom and Bucket Functions” are activated using the right hand joystick as
indicated.
12. Fire suppression” - The fire suppression is activated by closing and holding the
Fire Suppression” switch for three seconds on the Operators Unit. When the fire
suppression is activated the LHD engine is shut off, the park brake and service
brakes are applied, and the transmission is shifted into neutral.
13. Tilt Switch Shutdown- When the Operators Unit is tilted at an angle greater than
forty five degrees for more the 3 seconds the LHD engine will be shut down, the
park brakes will be applied and the transmission will be shifted into neutral.
14. Power Switch Shutdown”- By toggling the “POWER” switch to the “OFF” position
on the Operators Unit will cause the LHD engine to be shutdown, the park and
service brakes will be activated and the transmission will be shifted into “NEUTRAL”.
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REMOTE CONTROL BRAKE SYSTEMS
Dual Valve System
A complete installation of a E-Lynx LHD Radio Remote Control System may include the installation of
a second brake valve. This means that there are two brake valves that work independently of each
other. In the event that one valve fails, the other brake valve can be used to safely stop the LHD.
Park Brake Valve
The Park Brake Switch activates the Park Brake Valve to release the Park Brakes when the switch is
in the OFF position. W hen the Park Brake switch is moved to the ON position, the Park Brake Valve
applies the brakes.
Service Brake Valve
The Service Brakes can be applied by using the Service Brake Switch on top of the right hand
joystick or by allowing the left hand joystick go to the neutral position. The brakes will apply after a
half second delay when the joystick is in the neutral position or immediately when pressing the switch
on top of the left hand joystick. This valve is the Service Brake Valve.
OPERATOR TRAINING
The operating procedures, as outlined by the manufacturers of the RRC and LHD control package,
must be completely understood by the operator. Training services are available from E-Lynx or their
agents. Machine downtimes can be minimized if both operator and service personnel have the
proper training on the complete remote control system.
GUIDELINES TO FOLLOW FOR REMOTE CONTROL SAFETY
1. These following listed items are general principles only. The use of this equipment must be
in accordance with the rules and procedures established at each customer’s worksite.
2. Always work using established company procedures and with SAFETY FIRST in mind at all
times.
3. Always do a pre-check of the LHD for proper operation in Manual mode first and then in
Remote. If a problem exists in Manual mode it will also exist in Remote mode. If any
problems exist in manual mode the machine must not be used before repairs are made before
operating in remote control.
4. Never turn away while in control of a remote operated machine unless it is stopped and the
brakes are applied
5. Never operate remote control equipment if you are not trained. Advise the training
department that you need training and this can be set up with E-Lynx or their agents.
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GUIDELINES TO FOLLOW FOR REMOTE CONTROL CARE
1. Never carry the Operators Unit by the joysticks. Use the carrying handle on the skid plate.
2. Do not power wash the Machine Unit or Operators unit when power washing the LHD.
Remove the Machine Unit before commencing to power wash the LHD.
3. Never boost or weld on the LHD without uncoupling both quick disconnect connectors on the
Machine Unit. Failure to do so can cause component failure inside the machine unit
4. Do not carry any radio remote control equipment in the bucket of an LHD.
5. Do not use a radio remote control system on an LHD if the LHD or the radio remote control
system is found to be malfunctioning in any way. Advise the appropriate maintenance staff to
have the equipment tested or repaired
6. Check to verify that all antenna connections are not damaged. Check to verify that the
center pin is not pulled back, and that the rest of the cables are in good order.
7. If using batteries to power the Operators Unit be sure to use a fully charged battery before
each shift. If using power adapters, make sure power cables are in good condition and have
not been damaged or modified in any way. The Operators Unit operates on 5vdc only.
9
WARRANTY
The E-Lynx Radio Remote Control System limits its warranty to the equipment only for a period of up
to six months on the original user’s installation. Replacement parts are warranted to be free from
defects in material and workmanship for six months from delivery to the customer. Repair or
replacements will be limited to the individual components proven defective.
Defective parts returned during the warranty period will be repaired or replaced at the discretion of the
manufacturer. This warranty does not include labour or shipping costs associated with repair or
replacement of replacement items.
Warranty does not apply to equipment or parts found by the manufacturer to have been damaged
through normal wear and tear, misuse, abuse, neglect, accident, or alterations not specifically
authorized by E-Lynx. W ear and tear constitutes normal deterioration of moving parts, seals, and
corrosion of metal components.
This warranty does not include preventative maintenance, operating services, adjustments, and
inspections, which are the responsibility of the user customer.
This warranty replaces all statutory and other warranties implied by law. Purchaser has conducted
its due diligence in the choice of this wireless equipment and does not rely on any representation of
merchantability or fitness for purpose.
THE MANUFACTURER SHALL IN NO EVENT BE LIABLE FOR CONSEQUENTIAL OR
INCIDENTAL DAMAGES ARISING FROM THE USE OF ITS EQUIPMENT OR PRODUCTS
10
SECTION TWO
E-LYNX OPERATOR TRAINING TEST Part - A
1. As part of the required pre-operation check, the operator should always make sure that:
A) All remote control components are secure
B) There are no oil leaks at any hoses or hydraulic manifolds
C) All functions on Joystick Unit are operational
D) All the above
2. Guidelines for safe operation of the remote control unit are established by:
A) The safest way possible
B) The fastest way possible
C) The safety standards establish at the mine site
D) As the operator sees fit
3. Before leaving the machine to operate in remote, the operator should always:
A) Place wheel chocks under the wheel
B) Apply park brake; engage transmission in first gear and shutdown LHD
C) Apply park brake, place transmission in neutral, and turn the selector switch to the remote
position
D) Apply the park brakes, turn the LHD off and change the selector switch to the remote position
4. When the green indicating lights on the master unit and dash are illuminated this means
that.
A) The Joystick and Vehicle Units are operating correctly
B) The batteries in the Vehicle Unit need changing
C) The LHD is functioning properly
D) There is a fault with one of the components
5. The unattended Joystick unit feature means that: When the Operator unit is left on, and the
selector switch is turned from the manual to the remote position:
A) The Vehicle Unit will only shut off the engine
B) The Vehicle Unit will apply the brakes and then shut engine off
C) The Vehicle Unit will apply the brakes until the operator releases them with the Operator Unit
D) The Operator Unit is lost and a warning lamp will flash
6. The main purpose of the master unit is to:
A) Monitor the brakes
B) Verify that the LHD is running
C) Aid the troubleshooting process in case of remote breakdown
D) Control front and rear lights
7. The service brake is activated automatically by:
A) Moving the direction joystick back to the center position
B) Using the park brake switch on the slave unit
C) Pressing down the emergency stop button
D) Using the toggle switch on the top of the joystick.
11
8. When welding or boosting on the LHD, you should always:
A) Disconnect the battery
B) Turn the Joystick Unit off
C) Turn the remote switch to manual
D) Disconnect the dash cable (and DDEC if applies)
9. During a delayed shutdown how much time is the operator permitted to return the LHD to
switch the LHD to manual mode.
A) 10 seconds
B) 10 minutes
C) 60 seconds
D) 30 seconds
10. The LHD will start only in remote if:
A) The Operator Unit power is on, the emergency stop button is in the down position, the park brake
switch is in the on position, and the LHD is in neutral
B) The Operator Unit power is on, the emergency stop button is in the up position, the park brake
switch is in the on position, and the LHD is in neutral
C) The Operator unit's power is on, the emergency stop button is in the up position, the park brake
switch is in the off position, and the LHD is in neutral.
D) The Operator Unit power is off, the emergency stop button is in the up position, the park brake
switch is in the on position, and the LHD is in neutral
11. The fire suppression system can be activated remotely by:
A) Voice
B) Running to the machine and activating the manual actuator
C) Removing the fire suppression retaining pin and activating the toggle switch on the Operator Unit
for three (3) seconds
D) All the above
12. When remote mucking is performed the operator is allowed to:
A) W ork from the LHD’s bucket
B) Stand beside the LHD
C) Follow the LHD so you can see better
D) None of the above
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E-LYNX OPERATOR TRAINING TEST PART - B
1. The operator must be trained to understand the basic principles of the remote
control package.
TRUE
FALSE
2. The remote system has only one way to apply brakes.
TRUE
FALSE
3. When the selector switch is moved to the remote position, the operator has 60
seconds to turn the OPERATORS Unit on.
TRUE
FALSE
4. If the park brake switch on the Joystick Unit is in the on position (i.e. brakes applied),
the transmission will not engage in forward or reverse.
TRUE
FALSE
5. If the park brake switch on the Joystick Unit is in the off position (i.e. brakes
released) the LHD will not start in remote mode.
TRUE
FALSE
6. Remote mucking is done in the second gear.
TRUE
FALSE
7. The remote control unit has no distance limitations.
TRUE
FALSE
8. Before any welding or boosting is done on a machine, the dash cable must be
disconnected from the machine control unit (Vehicle unit).
TRUE
FALSE
9. The green light on the dash is used to verify proper communication between the
Operator Unit and Vehicle unit.
TRUE
FALSE
13
SECTION THREE
Safety considerations when commissioning and or troubleshooting
The following safety considerations are presented as a guide only. These considerations are in
addition to any government regulations and/or company policies regarding the safe operation of
radio controlled vehicles.
1.
2.
3.
4.
5.
6.
7.
8.
NEVER OPERATE A RADIO CONTROL VEHICLE WITHIN A SERVICE BAY OR
GARAGE.
Radio Control commissioning checks should be conducted in a reasonably level, open area.
No other Radio Control vehicles should be in operation near the LHD during
commissioning.
The operator conducting commissioning tests should be qualified to operate the LHD and
understand the principles & safety considerations regarding Radio Remote Control vehicle
operation.
The operator should conduct commissioning tests while in the operator’s cab in order to
take manual control in case of an emergency.
Observers should maintain a safe distance from the LHD.
Fire suppression squib should be disconnected to safely perform the fire suppression
commissioning tests.
Verify that wheel chocks are in place.
Terminology
LHD - Load Haul Dump other names include, Scooper, Scoop tram.
Vehicle Unit – The radio remote control box which plugs into the LHD via two quick disconnect
bayonet connectors.
Operator Unit – The radio control box with the two joysticks which the operator uses to control
the LHD when it is in radio remote control mode
Radio Control System – the Vehicle and Operator Unit pair.
Radio Control Link – The two-way communication link which is maintained between the Vehicle
and Operator Units.
HIGH Input - Any input voltage levels above 5 volts.
Low Input – Any input voltage under 2 volts.
CONTINUITY - Resistance measurement under 2 ohms.
Open Circuit – Any resistance measurement over one Mega ohms.
D/H – Indicates boom up, down and bucket roll, dump functions
2
Description of remote control interlocks and timeouts
Engine Start interlock
The engine start will only be processed when the Operators Unit controls are in their SAFE
RESTART positions, the E-Stop button is in the up position, the park brake is activated and the
joysticks are in the neutral position.
Delayed Shutdown interlock
Delayed shutdown switch will only be processed when the Operator Unit controls are in their SAFE
SHUTDOWN positions. When the Delayed shutdown switch is released, the operator has three (3)
seconds to turn off the power switch on the Operator Unit. When the Operator Unit is turned off within
this time, only the RUN output (19 pin E) is held high. If the Joystick Unit is still on after three (3)
seconds, the delayed shutdown request is cancelled. Turning off the Operator Unit after canceling
the delayed shutdown request will shut the LHD down as if the emergency stop was pressed.
Unattended Vehicle Timer
When the Delayed shutdown procedure is followed, the operator has 60 seconds to board the LHD
and switch from REMOTE to MANUAL control. The Vehicle Unit will hold the RUN output (19 pin E)
high for 60 seconds, when the 60 seconds has elapsed, the LHD will shut down.
Unattended Remote Timer
When the MANUAL/REMOTE switch is turned from the MANUAL to the REMOTE position, the
RUN output (19 pin E) is held HIGH to keep the engine running. The operator then has
60 seconds to turn on the Operators Unit and establish a control link. If a control link is not
established in this time, the engine will shut down. After this time, control can still be established,
but it will be necessary to restart the LHD.
Unattended Remote Standby Timer
When the radio control link is broken, the Vehicle Unit will stay in its ACTIVE STATE and attempt to
reestablish the control link for 90 seconds. After 90 seconds, the Vehicle Unit will enter a SLEEP
state. Turning on the Operator Unit will restore the Vehicle Unit to the ACTIVE STATE.
Forward/Reverse – Park Brake interlock
The LHD will only go into forward and reverse when the park brake is released.
Neutral – Service Brake interlock
The LHD service brake is only released when the left hand joystick moved from its neutral position to
forward or reverse. When the joystick is returned to neutral, the service brake will be applied after
one half second delay.
Manual to remote interlock
When the operator is ready to remotely operate the LHD, he must apply the vehicle parking brake
and place transmission to neutral position before selecting remote. If this procedure is not followed
the LHD will shutdown automatically. The operator will not be able to continue until these fault
conditions are cleared.
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