S3 - TRM - 001 Standard Dragline Technical Reference

Technical Reference Manual For 9000 Series 3 Dragline Monitor
Leica Geosystems Pty. Ltd.
Technical Reference Manual
For
9000 Series 3 Dragline Monitor
Internal Document
Not to be shown to Non-Leica employees
Document Status
In Use – Subject to change
Document No: S3_TRM_003 DragNav Technical Reference.doc
Source: VSS :$/DOCUMENATION/Serie3/S3_TRM_003 DragNav Technical

Reference.doc.doc
Revision Issue Date Author Checked Authorised
09 16/7/2009 I Worlock
08 22/4/2009 R Gullickson
S3_TRM_003 DragNav Technical Reference.doc – 08

Copyright Leica Geosystems Pty Ltd 2009
Leica Geosystems Pty Ltd

270 Gladstone Rd
Dutton Park
Australia
4102
Tel +61 7 3891 9772
Fax +61 7 3891 9336
LIMITATIONS
This document is copyright and is provided solely for the use of the recipient. It is not to be copied in
any way, nor its contents divulged to any third party, nor to be used as the basis of a tender or
specification without the express written permission of Leica Geosystems Pty Ltd. This document
discloses confidential intellectual property that belongs to Leica Geosystems. This document does not
invest any rights to Leica Geosystems intellectual property in the recipient. Moreover the recipient is
required not to disclose any of the intellectual property contained in this document to any other party
unless authorised in writing by Leica Geosystems Pty Ltd.
ii

REVISION HISTORY
Revision Issue Date Author Comment
00 14/9/2005 R Gullickson Initial Version
01 24/10/2005 R Gullickson Removed a lot of sensitive info about the weighing –

added section for programming the Display Module
02 30/12/2005 R Gullickson Added description of encoder faults and methods of

fixing and clearing them.
03 22/2/2006 R Gullickson Added a section describing in simple terms all the

possible states a dragline can be in.
Added a section on manually downloading files to the

Display Module.
04 14/6/2006 R Gullickson Added a section on SIMS and Dutymeter diagnostics.

Added a brief description of KPI’s.
05 19/7/2006 R Gullickson Added extra information on troubleshooting strain

gauges for SIMS and Dutymeter. Format change –
organised the document in sections to allow easier
upgrade of paper copies.
06 27/7/2006 R Gullickson Improved strain gauge troubleshooting and added a

DragNav section
07 22/3/2007 R Gullickson New weight calibration procedure. Updated the RDC

collection procedure.
08 22/4/2009 R Gullickson Updated for build 28xx
09 16/7/2009 I Worlock Added information on PLC input filtering to Weighing

System Overview
iii

TABLE OF CONTENTS
1 Introduction and Overview ..............................................................................................................1-1
1.1 Dragline Monitor Overview..................................................................................................1-1
1.2 Hardware ............................................................................................................................1-1
2 Weighing System ............................................................................................................................2-1
2.1 Overview .............................................................................................................................2-1
2.2 Weighing.............................................................................................................................2-1
2.2.1 Weighing Notes..............................................................................................................2-1
2.3 Weight Calibration...............................................................................................................2-2
2.3.1 Background ....................................................................................................................2-2
2.3.2 Calibration Overview and Notes.....................................................................................2-2
2.3.3 Combined Hoisting and Lowering Calibration ................................................................2-3
2.3.4 Separate Hoisting and Lowering Calibration ..................................................................2-3

2.3.4.1 Hoisting Calibration ...................................................................................................2-3
2.3.4.2 Lowering Calibration..................................................................................................2-3
3 Radio System .................................................................................................................................3-1
3.1 Tait Radio Systems.............................................................................................................3-1
3.2 Spread Spectrum Systems .................................................................................................3-1
3.2.1 Data Radio .....................................................................................................................3-1
3.2.2 RTK Radio......................................................................................................................3-1
3.3 IP Radio Systems ...............................................................................................................3-1
4 Cycle Logic and Operation..............................................................................................................4-1
4.1 Dragline Cycle Detection.....................................................................................................4-1
4.2 Dragline Dumping ...............................................................................................................4-2
5 Faults within Series 3......................................................................................................................5-1
5.1 Dragline Faults....................................................................................................................5-1
5.2 Drag Stall ............................................................................................................................5-1
5.3 Hoist Stall (Not Implemented) .............................................................................................5-1
5.4 Motor Volts Failure..............................................................................................................5-1
5.5 Encoder Faults....................................................................................................................5-2
6 Debug Commands ..........................................................................................................................6-1
6.1 Setup ..................................................................................................................................6-1
6.2 PMC and IOP......................................................................................................................6-1
6.3 Display Module ...................................................................................................................6-1
iv

7 Serial Debug Screens .....................................................................................................................7-1
7.1 Debug Screen General Description ....................................................................................7-1
7.2 PMC Debug Screens ..........................................................................................................7-2
7.2.1 Bucket Debug Screen ....................................................................................................7-2
7.2.2 Main debug screen.........................................................................................................7-3
7.2.3 Display debug screen.....................................................................................................7-4
7.2.4 Electrical Parameter Screen...........................................................................................7-5
7.2.5 Cycle Debug Screen ......................................................................................................7-6
7.2.6 Summary Stats Screen ..................................................................................................7-7
7.2.7 Tuneable Variables (TV’s)..............................................................................................7-8
7.2.8 Radio Debug Screen......................................................................................................7-8
7.2.9 Input Test Screen...........................................................................................................7-9
7.2.10 Board Test Screen .......................................................................................................7-10
7.2.11 DragNav Screen...........................................................................................................7-11
7.2.12 Task Accounting Screen ..............................................................................................7-11
7.2.13 PLC Registers Input Screen.........................................................................................7-12
7.3 IOP Debug Screens ..........................................................................................................7-13
7.3.1 IOP General Information ..............................................................................................7-13
7.3.2 Interface Board.............................................................................................................7-13
7.3.3 Motor Parameters ........................................................................................................7-14
7.3.4 Geometry Parameters ..................................................................................................7-14
7.3.5 Diagnostic Screen ........................................................................................................7-15
7.3.6 Bucket Calibration ........................................................................................................7-15
7.3.7 Serial Protocol Debug ..................................................................................................7-16
7.3.8 Serial Protocol Debug – Screen 2 ................................................................................7-16
7.3.11 Board Testing...............................................................................................................7-18
7.3.12 SIMS / Dutymeter.........................................................................................................7-18
7.3.13 Tightline Information.....................................................................................................7-19
7.3.14 Task Accounting Screen ..............................................................................................7-20
8 Debugging the Display Module .......................................................................................................8-1
8.1 Network and Communications Issues.................................................................................8-1
8.2 For suspected Build Issues .................................................................................................8-1

9 Programming Onboard Firmware....................................................................................................9-1
9.1 Programming the PMC and IOP .........................................................................................9-1
9.1.1 Manual Programming.....................................................................................................9-1
9.2 Programming the Display Module .......................................................................................9-5
9.2.1 Programming New Application .......................................................................................9-5
9.2.2 Using Tech Cable...........................................................................................................9-5
9.2.3 Using Telemetry .............................................................................................................9-5
9.2.4 Using FTP ......................................................................................................................9-7
10 Dragline Configurations and Personalities ................................................................................10-1
10.1 Main Configuration (Personality).......................................................................................10-1
10.1.1 Normal Operation.........................................................................................................10-1
10.1.2 Debugging....................................................................................................................10-1
10.1.3 Editing the Configuration ..............................................................................................10-1
10.2 DragNav Configuration .....................................................................................................10-2
10.2.1 Getting the DragNav configuration off the Display Module...........................................10-2
10.2.2 Sending DragNav configuration files to the Display Module.........................................10-2
11 DragNav Maps ..........................................................................................................................11-1
11.1 Downloading Maps Manually ............................................................................................11-1
11.1.1 Using Tech Cable.........................................................................................................11-2
11.1.2 Using FTP (IP networks only).......................................................................................11-2
11.2 Deleting Maps Manually....................................................................................................11-3
11.2.1 Using Tech Cable.........................................................................................................11-3
11.2.2 Using FTP (IP networks only).......................................................................................11-4
12 KPI’s..........................................................................................................................................12-1
13 Raw Data Collection..................................................................................................................13-1
13.1 Introduction .......................................................................................................................13-1
13.2 Method 1 – With no access to the network .......................................................................13-1
13.2.1 Tools Required.............................................................................................................13-1
13.2.2 Preparation...................................................................................................................13-1
13.2.3 To check if nc is installed: ............................................................................................13-1
13.2.4 Installing nc ..................................................................................................................13-2
13.2.5 Procedure for collecting Raw Data...............................................................................13-2
13.3 Method 2 – With access to the network ............................................................................13-3
13.3.1 Tools Required.............................................................................................................13-3
vi

13.3.2 Preparation...................................................................................................................13-3
13.3.3 To check if nc.exe is installed:......................................................................................13-3
13.3.4 Installing nc.exe ...........................................................................................................13-3
13.3.5 Procedure for collecting Raw Data...............................................................................13-4
13.4 Network Configuration Scripts...........................................................................................13-4
13.4.1 DHCP Script (Home/Office)..........................................................................................13-4
13.4.2 Static IP Script (Standard Dragline) .............................................................................13-5
13.4.3 Creating a Custom Static IP Script...............................................................................13-5
13.5 Method 3 – RDC via Telemetry.........................................................................................13-5
14 Collecting Data from Data Logger .............................................................................................14-1
14.1 Data structure ...................................................................................................................14-1
14.2 Data Size ..........................................................................................................................14-1
14.3 Data Retrieval ...................................................................................................................14-1
14.4 Automatic Retrieval - New Data Only................................................................................14-2
14.5 Manual Retrieval - All Data ...............................................................................................14-2
14.5.1 FTP ..............................................................................................................................14-2
14.5.2 Remote Desktop ..........................................................................................................14-3
14.5.3 Network Configuration Scripts......................................................................................14-3

14.5.3.1 office-network-config.bat .........................................................................................14-3
14.5.3.2 datalogger-network-config.bat .................................................................................14-3
15 UDD – Universal Dig and Dump................................................................................................15-4
vii

1 Introduction and Overview

This document describes the operation of the Leica 9000 Series 3 Dragline Monitor and provides
support procedures and tips.
1.1 Dragline Monitor Overview

The primary purpose of a dragline/shovel monitor is to provide production statistics to mining personnel
to facilitate mine planning, machine operation, equipment downtime scheduling and related activities.
On draglines, the monitor can also provide tightline/boom collision protection as well as endlimit
protection to guard against costly damage and downtime. The existing Dragline Monitor provides a
variety of production related statistics including:
• Bucket weights.
• Cycle detection.
• Cycle time, broken down into fill, swing, return and spot time.
• Start/End Delay.
• Start/End Idle.
• Start/End walk.
• Power down detection.
• Operator Identification.
Operator feedback is provided via a touch panel.
Other functionality that is standard includes:
• Auto-Calibration – there are procedures to allow mine personnel to calibrate the dragline after
minor work, eg rope replacement / modification and bucket changes.
• Fault detection – Input faults are detected and reported to the operator and to the office.
rd
Faults from 3 party systems can also be logged, eg from a separate PLC unit.
• For Shovels, it will be integrated with the fleet system.
The following optional systems are currently available for the Leica Dragline Monitor:
1. DragNav – high precision GPS navigation
2. Dutymeter – Fatigue monitoring of the boom structure, including real time feedback to the
operator
3. SIMS – Structural and Fatigue monitoring of the boom structure, including real time
feedback to the operator
4. Tightline – Protection of the boom from bucket strikes and rope drum run off.
5. UDD – the Universal Dig and Dump dragline rigging system is supported.
1.2 Hardware
A number of pieces of hardware are required for operation of a Leica Dragline Monitor.
Draglines are driven from AC Power, which is used to drive AC Motors. These motors are mechanically
coupled to DC Generators, which in turn electrically drive DC Motors. There are generally 4 separate
DC generator / motor sets within a dragline. These are:
1-1

• Hoist
• Drag
• Swing and,
• Propel - Often these motors are driven from one of the sets of Drag generators, but all
draglines are individual. The Leica Dragline monitor does not monitor the Propel motors.
These DC motors are mechanically connected to the hoist and drag drums which control the length of
the hoist and drag ropes. The Swing motors are connected to the swing gear to enable rotation, and the
Propel motors are connected to the shoes of the dragline.
The generators and motors are normally arranged with two motors and two generators per loop, with
multiple loops present on the machine, depending on it’s size.
The parameters that can be input to the Leica Dragline monitor are:
1. Motor inputs – the following parameters from the motors driving the Hoist, Swing and Drag
motors are measured and input into the system:
a. Motor Armature Amps – measurements are made from a shunt positioned in the
motor-generator loop. There is support for 8 armature amps measurements.
b. Motor Volts – measurements are made of the voltage across one of the motors within
the DC Generator / Motor loop. There is support for 7 volts inputs.
c. Motor Field Amps – The fields around the stator of the DC Motors are varied to
maximise the efficiency at different loads. Generally all the field windings for all
motors (across all loops) are connected. Hence, the Dragline Monitor only supports
three Hoist field amp inputs.
2. Operator References – the current output of the reference controls used by the operator is
monitored to detect what is happening to the dragline. It is used primarily for cycle logic.
There is one channel for each of the three motions
3. Rope Lengths and Swing Angle – these need to be monitored to determine the position of
the Hoist and Drag ropes, the swing angle per cycle and the current activity within the
cycle. One of three different systems are used:
a. Encoders – Encoders are fitted to one of the Hoist Motors, Drag Motors and Swing
Motors. These can be powered from the Dragline Monitor or externally powered,
depending on the setup.
b. Resolvers are occasionally used. Resolvers require an extra interface module to

convert the resolver output to encoder type output suitable for the Dragline monitor.
c. Encoder inputs can also be sent from a PLC unit. In this case the PLC unit monitors
it’s encoders or resolvers and outputs an encoder signal for the Dragline Monitor’s
use.
4. Switch inputs – a number of switches are available, and are connected to the following
items:
a. Dipper – Shovel only, it is connected to the dump control of the shovel bucket
b. Propel – this is activated when the operator switches into Propel mode.
c. Step – this is wired to a switch on the step gear so that it triggers once for every step
that is taken by the dragline
d. Cal – activated when the calibration switch on the front of the Computer Module is in
the Calibrate position.
1-2

e. Cntrl – activated when the calibration switch on the front of the Computer Module is in
the Diagnostic position. This is required for anti-tightline modifications. A special key
is necessary to move to the Diagnostic position.
f. Hfld 1 – not normally connected.
g. Hfld 1 – not normally connected.
h. Excit – Excitation is active when the main dragline excitation is up. This is used to
determine if the dragline is Idle or not.
1-3

2 Weighing System
2.1 Overview
The channels are sampled at 260Hz and down-sampled to 20Hz by an FIR decimating filter
The analogue channels are scaled using calibration values stored in the interface board – these
calibrations take care of inaccuracies in the op-amps on the interface board and are set up in the
workshop before the board is sent out.
The encoders are sampled differently at 20Hz. Sometimes, the encoders are really a PLC output – this
is the case with BCD input encoders.
As of July 2009, a configuration option has been added allowing filtering of the 20Hz sampled channel
data. This is achieved by smoothing out sharp ‘steps’ seen in the sample values. The configuration
option allows this extra filtering layer to be enabled/disabled dynamically from the Configuration Editor.
The option is set via the radio button found at IO->Modbus->PLC Options->Filter Modbus
Inputs 10Hz.
2.2 Weighing
Very simply, the weighing algorithm uses the current geometry and motor parameters to determine the
suspended load of the bucket for every sample (ie 20Hz). This weight already has the rope weights
removed.
At the end of the swing, a selection process analyses the samples and uses the best samples to get a
weight. The number of samples used depends on the number available – shorter or rougher swings will
result in less samples etc. The items analysed are:
1. Geometry must be valid, ie the bucket is within boom point and there is not some gross
error
2. the hoist motor must be in strong fields
3. some further motor and geometry rules are applied to weight the samples to allow the
better ones to be used.
All the good samples are then averaged to arrive at a final weight.
The known bucket weights and jewellery weights are then removed to arrive at a net weight.
The weight result is sent to the PMC along with the number of samples used and the lowest goodness
of the samples used – calculated in step 3 above - (called the rule in the cycle debug packet).
2.2.1 Weighing Notes

The Boom Point Offset value affects the weighing since the weighing relies on detecting dump or return
to know when to stop sampling. Hence if the Boom Point Offset for a bucket is set incorrectly, then the
system can incorrectly weigh.
See the following section on how to calibrate the Boom Point Offset.
2-1

2.3 Weight Calibration

2.3.1 Background
The Series 3 weighing calibration calculates calibration factors by weighing an empty bucket with a
known weight. The calibration is completed via the Display Panel.
The way the weighing calibration algorithm works is as follows:
After the start button is pressed on the weighting calibration screen, the system waits until it detects a
fill. It starts collecting samples at the beginning of swing and keeps collecting until the system detects
dump.
There are two calibration factors Q1 (hoisting) and Q4 (lowering) which is why both hoisting and
lowering are needed for the calibration. Once the data for the cycle is collected, it processes it to find
the quality of hoisting and lowering samples, and then if the quality is sufficient it processes it further to
find values for Q1 and/or Q4.
The calibration algorithm has been modified to support UDD For UDD draglines, both front and rear
rope calibration factors are calculated at the same time.
UDD machines will take longer to calculate the calibration factors due to the extra calculations required
to get the calibration factors for both front and rear ropes at once.
2.3.2 Calibration Overview and Notes

Some important notes for calibration:
1. Make sure the system is in Calibrate mode by switching to calibrate on the Computer
Module.
2. Enter the new bucket or select the existing bucket from the screen. If this bucket has been
on another machine, make sure the bucket is assigned to the correct machine in IMS prior
to doing the calibration. If a bucket is added via the Display Panel and it already exists in
IMS, then copies of this bucket will exist in the database and the bucket history reports will
not work.
3. Boom Point Offset – this must be set for each bucket, and can only be set via the
Configuration Editor. To test, the Beyond Boom Point Flag on the Cycle Debug screen
needs to go true when dirt begins to fall from the bucket during dumping. Adjust the value
of the Boom Point Offset to ensure this happens. Zero angle means the hoist rope is
vertical, a positive angle is towards the boom and negative away from the boom
4. Switch the Hoist Motor Fields to the maximum setting after the rope and depth calibration
is completed but before the Swing Calibration is started.
5. The calibration only uses one swing at a time. After pressing Start Calibration, ensure the
operator does a gentle phantom cycle. Once the return has been finished, the operator
can stop the machine while the calculations take place.
6. Ideally, a phantom cycle would contain both hoisting and lowering, however this is often
difficult to achieve. Instead, carry out the final weight calibration step twice – do one cycle
where the operator hoists, and when complete, start again and do a cycle with lowering.
The system only calibrates and updates the calibration factor for which there is valid data.
7. If the operator is erratic, or it is difficult to get a good cycle, the calibration can be
conducted numerous times, and after each one the calibration factor can be recorded. At
the end, average the calibration factors recorded and update the factors in the bucket
2-2

debug screen. (In a future upgrade to the system we hope to add this feature
automatically, so that multiple cycles can be done at once and then averaged)
8. Always watch the operation of the dragline for a number of cycles after the calibration. Try
and get the operator to do some small loads and some large loads to determine if the
calibration is correct.
2.3.3 Combined Hoisting and Lowering Calibration

If the number of hoisting and lowering samples captured during the empty bucket cycle is high enough,
then both hoisting and lowering calibration factors can be calculated from one cycle.
There are a few things that should help getting a better lowering status when performing the combined
calibration.
1. Lowering before the start of the cycle (ie before starting to dragging in) doesn't count, the
system doesn't record calibration samples before it has detected fill. So you can still do this,
but it will have no effect on the calibration.
2. Make sure that the operation is smooth and that the bucket is not jolted. An empty bucket will
bounce around much more than a full one, so the operators do need to take extra care. When
the bucket is jolted it creates spikes in the motor torque and the data where the spikes occur
don't produce as accurate weights.
3. The best results are achieved when the operator is asked to pretend they are hoisting over a
spoil pile and then dumping into a hole on the other side. The operator needs to make sure that
they pay-in drag as they are lowering to keep the bucket inside boom point and to stop
triggering the dump detection too early. Once the bucket is almost back down to tub level the
operator can pay out to trigger the dump.
2.3.4 Separate Hoisting and Lowering Calibration

If it is not possible to perform a combined calibration, the hoisting and lowering calibrations can be
performed separately. Smooth operation of the machine is important for both hoisting and lowering
calibrations.
2.3.4.1 Hoisting Calibration

To calibrate hoisting separately, get the operator to drag in just above the ground, hoist and swing, and
then dump. The system will calibrate the hoisting calibration factor and will leave the lowering factor
unchanged.
2.3.4.2 Lowering Calibration

To calibrate lowering separately, get the operator to drag in just above the pad, then swing out over the
low wall while lowering the bucket into the pit, then dump. The system will calibrate the lowering
calibration factor and will leave the hoisting factor unchanged.
2-3

3 Radio System
The Dragline monitor supports the following radio systems:
1. 450 MHz Tait radios – only at the 2400 baud system. These are not common and are only
being installed as a short term measure at new sites.
2. 900MHz Freewave Spread Spectrum radios – this is the standard radio system at the
moment.
3. 2.4GHz Freewave Spread Spectrum radios – these are supported and to the Dragline
Monitor appear to be the same as the 900MHz version.
4. IP over 802.11 wireless networks. The S3 can be connected to a LAN and be given the
telemetry servers address to allow communications. GPS corrections can also be
acquired in a similar fashion – the GPS system needs to transmit the corrections to the
dragline via the wireless network.
3.1 Tait Radio Systems

The radio is located in the Power Module. It is a data radio and it needs to be on the same channel as
master and repeaters.
3.2 Spread Spectrum Systems

This is the most common installation to date. These systems have two completely separate radio
systems, each with a master, repeaters and slaves.
3.2.1 Data Radio

The slave data radio is situated in the computer module. It handles all communications between the
PMC and the Telemetry service, receiving configuration data from Telemetry and sending back data.
Due to the data requirements, 3 repeaters are normally supported. If the site is larger than can be
covered from 1 master and 3 repeaters, then an extra link is required to cover the other part of the mine.
Up to 6 (8?) links are supported.
3.2.2 RTK Radio

The RTK radio is situated in the Display Module and receives the RTK corrections put out by the GPS
Base station. This system is optimised to send data to the slaves, as it requires no data transfer from
the slave to the master. Hence up to 15 repeaters can be used, covering the majority of sites
completely.
The RTK radio outputs the corrections directly to the GPS receivers in the Display Module, so no further
settings are required.
3.3 IP Radio Systems

IP Radio systems are becoming popular. They are much quicker than Spread Spectrum links, although
2.4GHz has less penetration and range than the 900MHz systems.
With the IP Radio system, only one radio is required on the machine. This radio accepts both a data
connection to the Telemetry server (via UDP port 4001), and a RTK correction signal via UDP 6000.
On systems where the dragline has it’s own private network behind the radio network id (ie the radio has
an address on the main network, eg 10.94.150.254 and the computer module and display module are
3-1

192.168.0.1 and 192.168.0.2 respectively, then the Telemetry port is forwarded from the radio to the
computer module, while the correction port is forwarded to the Display Module.
A task in the Display Module reads the corrections and outputs them to the radio serial port. A header is
then required instead of a Spread Spectrum Radio. This header connects pins 5 and 7 together on the
10 pin Molex connector. (Pin 1 is closest to the fuse). This is done due to the limited number of serial
ports available in the system.
The command srn=t on the Display Module debug prompt turns on debug which outputs a message
each time a correction is received. The debug indicates the size of the correction, for 8 satellites, it
should be around 130 to 140.
3-2

4 Cycle Logic and Operation

4.1 Dragline Cycle Detection
The dragline uses a number of inputs to determine what the dragline is currently doing.
The possible events logged by the dragline are:
1. Cycling – this event is entered when the dragline detects a fill. The dragline will then be in
one of the following sub-events. Within IMS the event will always be cycling.
a. Look / Spot – time spent lining up the bucket for the next fill.
b. Fill – filling the bucket.
c. Swing – dragline swinging. Some or all of the dump time can may be included in the
dump time – see note below in Dump description.
d. Dump – bucket dumping is occurring. The dump time is recorded in the database but
is not included as a separate part of the total cycle time. This is due to the highly
variable timing of dump – dump can occur totally within swing (ie operator dumps
before the dragline stops swinging, or does a 360 degree swing), partly in swing and
return (operator reverses swing during dump) or totally in return (operator has
reversed swing before dumping). Hence dump is detected and timed, however it’s
time is independent of the swing and return times.
e. Return – the dragline is swinging back to the fill position. For 360 degree swings,
there will be no return time. Some or all of the dump time may be included in the
return – see note above in Dump description.
Cycling ends when one of the other main states is detected.
2. Face Preparation – if the dragline stays in fill for too long (default is 90 seconds), the
system switches to face preparation. This is designed to cater for clean up work that is not
generally productive.
3. Propel - Positioning or Relocating – When the propel input is activated, the dragline will go
to either Positioning or Relocating. This depends on the digmode chosen – if a digmode
of deadheading is chosen, then the system goes to Relocating, else it Is Positioning.
Relocating is designed for when the dragline does major movements, eg from one pit to
another pit, while Positioning accounts for all the movement associated with movement
within an area.
4. Idle – this event occurs after there is no significant change in inputs for a period of time
(default is 90 seconds). This event automatically ends when cycling or movement is
detected.
5. Delay – logged when the machine would otherwise be in an idle event, and the operator
chooses a specific delay. Delays can also be set automatically based on time. For a time
based delay, the time period of each delay is set up in IMS. If the machine goes idle
during that time period, it will automatically log the pre-determined delay. This event
automatically ends when cycling or movement is detected.
6. Calibration – When the system is put into the calibration mode, the event of Calibration is
logged.
4-1

4.2 Dragline Dumping

The system has 2 ways of detecting dump:
1. When the bucket goes beyond the boom point,
2. When a ‘short dump’ is detected – this is a special sequence of bucket movements that
experienced operators carry out.
Draglines dumps when the ByBmPt flag goes TRUE.
Questions to ask when getting zero dump times and dump heights.
1. Is it dumping?
2. Is the geometry correct?
a. Are the rope calibrations correct?
b. Is the rope scaling correct? Check the rope length at 10metres and then at
100metres. Can use a PLC system to check if that is known to be correct.
3. Is the bucket setup correctly? It has a boom point offset which determines at what angle the
logic decides the bucket is beyond boom point and hence dumps.
Use the flags on the Cycle Debug screen on the PMC.
bdump (before dump)
ddump (during dump)
adump(after dump) and
hdump (has dumped) which indicate the dump progress,
as well as a
Dump (dump time)
dhgt (dump height )
GeoVld (Geometry Valid)
ByBmPt (Beyond Boom Point).
4-2

5 Faults within Series 3

A number of faults are logged within the Series 3 software. Some of these detail dragline faults and
warnings, such as Drag Stall, some warn of calibration issues, eg un-calibrated ropes and others detail
faults with the monitoring equipment.
The following headings describe each of the faults that the Series 3 monitor can log, what causes it and
how it can be fixed.
The current state of faults can be seen in the Diagnostic Debug Screen on the PMC. This is also
available on the Dragline Display – select Setup -> Debug -> Computer Module -> DIAG.
5.1 Dragline Faults

If a fault appears, a fault message to the office and the operator will be logged every 30 minutes while
the fault exists. If the fault is cleared and then detected again, another fault will be logged, both to the
office and the display.
5.2 Drag Stall

A drag stall is triggered if the following conditions exist for more than 3 seconds:
• Drag reference is > 60%
• Drag Amps > the setting in TV59 (default value is 70%)
• Drag velocity is < the setting in TV58 (default 15%)
exist for more than 3 seconds.
The Drag reference needs to drop to zero or below to clear this fault
5.3 Hoist Stall (Not Implemented)

A hoist stall is triggered if the following conditions:
• Hoist reference is > 60%
• Hoist Amps > the setting in TV60 (default value is 70%)
• Hoist velocity is < the setting in TV51 (default 15%)
The Hoist reference needs to drop to zero or below to clear this fault.
5.4 Motor Volts Failure

Drag and Hoist motions are monitored in exactly the same way. If the velocity of the motion (derived via
the encoder input) indicates movement but the voltage of that motion indicates no movement, a voltage
error occurs. A Motor Voltage Failure error is logged if the following conditions exist for 2 seconds:
• Motion Reference > 50%
• Motion Velocity > 50%
• Motion Volts <15%
5-1

Ie if operator is requesting motion(reference), there is movement (velocity) but the volts are still very low
for more than 2 seconds, a fault is logged.
5.5 Encoder Faults

Drag, Hoist and Swing encoders report faults if it is detected that the motors are moving but the
encoders aren’t. The following conditions will cause an encoder fault if present for more than two
seconds:
• Motion Volts > 15%
• Encoder moves less than 25 counts.
Encoder faults can be caused by:
• Shaft slippage – the encoder shaft, the gearbox shaft, the coupling device or the motor
shaft may be experiencing slippage, which causes the encoder to not show movement.
• Bits stuck high / low – the encoder output could be incorrect due to internal or cabling
errors. If a bit is stuck high or low, it will be evident in jumps and flat spots in the
encoder count. This can be monitored on the Input Test Screen on the PMC.
To clear an encoder fault, movement must be detected – once the encoder has been repaired, the
motion needs to be operated for more than 2 seconds with the following conditions for the fault to be
cleared:
• Motion Volts > 15%
• Encoder moves more than 25 counts within the 2 seconds.
N.B. For systems that utilise a Leica Geosystems fitted Anti-Tightline system, extra steps are needed
than detailed above. Please refer to the specific Anti-Tightline Reference document for full details of the
procedure.
5-2

6 Debug Commands
All three processors, PMC, IOP and Display, contain a serial port interface. This allows configuration
settings to be checked and modified, faults and errors to be diagnosed and calibration to be carried out.
6.1 Setup
All serial ports have the following setup:
Baud Rate: 57600
Bits: 8
Parity: None
Stop Bits: 1
Hardware Control: None
6.2 PMC and IOP

The currently selected processor is shown with a special prompt each time Enter is pressed
PMC: PMC#
IOP: IOP#
The following commands can be used in the PMC and IOP debug:
Help Display the following list
? Display all categories
?? Display all commands with default help
command ? Display command help
?command Display command help
command ! Show source file name
#command Execute command on the other processor
?CATEGORY List commands for the given category
help list List all commands
xyzTAB cycle through all matches for xyzTAB*
UpArrow recall most recent successful command, rotate history buffer
DownArrow recall least recent successful command, rotate history buffer
6.3 Display Module

When initially connecting to the Display Module, the following prompt is shown:
6-1

Tritronics Display Module
Login:
Type debug <Enter>
And the following prompt will be shown: 9020 Panel >>
The following commands are used:
? Display list of categories
?CATEGORY List commands for the given category.
6-2

7 Serial Debug Screens
NOTE: As of version 2800, no modifications can be done via the Serial

Debug Screens.
Use the Configuration Editor instead. (see 10.1.3 Editing the
Configuration)
7.1 Debug Screen General Description

The debug screens show a number of useful parameters from the entire system. All three systems
(PMC, IOP and Display Module) all contain debug prompts and debug screens.
To use the debug screens on either the IOP, PMC or Display, type 'pp' at the debug prompt.
The following commands can be used in the debug screens.
t Forwards one screen
b Backwards one screen
r Refresh the current screen
x Exit the debug screens
7-1

7.2 PMC Debug Screens

7.2.1 Bucket Debug Screen
The bucket screen shows details of the buckets currently on the dragline.
On the right hand side is a list of buckets that currently exist on the machine. The machine must
communicate to the office and synchronise bucket lists before a new bucket can be saved. This is to
prevent buckets defined onboard from overwriting existing buckets when new modules are placed onto
the machine.
On the left is details of the currently selected bucket.
Bucket details shown are:
• Name
• Calibration, modification and usage dates,
• Bucket Weight,
• Jewellery Weight (if known as part of total bucket weight, put it all into the Bucket Weight and
leave the Jewellery as zero),
• Hoist and Drag offsets – from the end of the chain socket to the hitch on the bucket
• Capacity, in cubic metres,
• Bmpt Offset- Boom Point Offset –the hoist rope angle from vertical must be less than this
before a dump is detected. Zero angle means the hoist rope is vertical, a positive angle is
towards the boom and negative away from the boom.
• Depth offset – calibrated value to determine the depth shown to the operator. Calibrated via
the Display Auto-Calibration procedure.
• Q1, Q4 and Swing Cal – these are the calibration constants that are used in weighing the
bucket and payload. Originally these were thought to be bucket dependant, however it has
been found that they are machine dependant. Hence with the new bucket zeroing calibration
procedure, these values don’t change on every calibration.
7-2

7.2.2 Main debug screen

The main debug screen shows a variety of system information.
• Machine Name, type, radio id
• Build info – current build running build for the PMC and IOP
• Build being downloaded – this is for the PMC build only.
• Shift info – this can only be set from within IMS
• Memory left (DRAM), in bytes
• KPI downloads, including the current state
• The section headed RESETS indicates the number and type of resets seen since midnight
GMT.
• The stats are the total stats for the current shift.
7-3

7.2.3 Display debug screen

This shows information about the Display Module.
• The current build of the Display Module, and number of resets since midnight (UTC).
• State of the communication links to the Display Module. There are 4 sockets, and each one
connects separately. The System, List and Stats sockets are for normal use, and the Debug
socket is for the PMC debug screens that are available via the Setup button.
• Locn Entry Enabled – There is a feature that allows the entry of locations by the operator to
be turned off (set in the database) This field indicates whether the operator can enter a
location.
7-4

7.2.4 Electrical Parameter Screen

This screen is only for viewing. It shows the current value of most of the inputs to the system, as well as
some calculated values (the velocity and acceleration of each motion.) Lengths are in centimetres.
• Drive: Drive type of the motors. Will always be DC-WL (Direct Current – Ward-Leonard
configuration)
• Ref: Operator Reference values
• Amps: Motor Armature Amps – for machines with multiple loops connected, this is the
average value per loop
• Volts: Motor Armature Volts
• FAmps: Motor Field Amps – this needs to be at a maximum when doing a weight calibration
• Trqe: The torque calculated by the system
• RefPC: Operator Reference as a percentage
• AmpPC: Motor Armature Amps as a percentage
• FA PC: Motor Field Amps as a percentage
• VltPC: Motor Armature Volts as a percentage
• TrqePC: The torque calculated by the system
• TrqeSq: Value of any additional torque signal being input. Currently only used on UDD
machines.
• Vel: Velocity of the motor, determined from the voltage
• VelPC: Velocity of the motor, as a percentage
• Acc: Acceleration of the motor.
• Quad: Which quadrant the motor is currently in.
• Qlty: Indication of the current quality of the system as calculated by the weighing. Must
be zero when in weak fields.
7-5

7.2.5 Cycle Debug Screen

This is the main cycle debug screen and includes information on all parts of the cycle
It includes a lot of information, some of which is repeated elsewhere, for ease of viewing.
The important items are:
• Along the top, the current high level and low level state is shown.
o The high level state (on the left) will be one of:
ST_IDLE – machine is idle – excitation is off and references are zero
ST_UNKOWN – machine is not idle, but in an unknown state. Occurs when

excitation is raised but cycling hasn’t been detected yet.
ST_CYCLE – a start of cycle has been detected – initially this is when a fill to
swing transition occurs.
ST_POSTION – set when the system goes to Propel
ST_POWERDOWN - set when the AC power is off.
ST_DELAY – set when a delay has been entered via the Display Module.
ST_FACEPREP – any preparation work that isn’t cycling (dragline).
ST_CALIBRATING – set when the calibration screen is entered on the

Display Panel
o The low level state shows the current cycling or loading state
LOOK – special state where the operator is looking at what to dig next
FILL - filling the bucket
SWING – swinging
DUMP - dumping
RETURN – have dumped, am returning to fill point
• The Timers show the elapsed time in each state in the current cycle.
7-6

• The Last column (bottom row, centre screen), shows the cycle time breakdown for the last
cycle.
• The bottom left shows the percentage amounts for all the motor currents and voltages.
• Dump flags – these are used to see what is happening during a dump. The flags are:
o Bdump – Before dump
o Ddump – During dump
o Adump – After dump
o Hdump – Has dumped
In a normal cycle, each of these comes on and goes off in turn. This is useful when there
are problems detecting dump. Refer to the BoomPtOffset in the bucket screen and the
TV’s for more dump fields.
• The weight for the current cycle is shown on the lower right of the screen. At the start of each
cycle, the Start and End fields are cleared. They are set when the start and end of swing are
detected and it is between these times that the system weighs. Use this to monitor if the
system is detecting the start and end of the swing correctly.
7.2.6 Summary Stats Screen

This screen shows the summary stats that are recorded for the currently logged in operator. No values
are modifiable on this screen.
7-7

7.2.7 Tuneable Variables (TV’s)

These values control various pieces of logic, thresholds, features and other items within the Dragline
Monitor. They are only shown here for ease of use, as they are represented in the Configuration Editor
as values with meaningful names.
For a complete list of these variables, their meaning and use, see the commissioning document.
7.2.8 Radio Debug Screen

The radio debug screen changes depending on the type of radio installed.
Common details are:
• Radio statistics – top left hand corner, including CTS Fail and Ok, Replies, Fifo size
• Modem information - Modem type, current baud rate
• Personality information - top right hand corner, including current state and time of last upload,
download and onboard change.
• Link swapping logic – bottom right hand corner – shows current link, which other links will be
searched and the type of frame table current running.
7-8

The Tait radio screen (above) shows the temperature of the radio and it’s duty ratio – the duty ratio goes
down the hotter the radio gets.
The freewave radio provides a lot more information, including signal strength to repeaters, network id’s,
and whether any dynamic frames are allocated.
The system normally gets one frame every 6 seconds that it can transmit on. If it gets more than 30
packets in the fifo, or it is downloading a program or a file, it will request more frames from telemetry, up
to a maximum of 11 frames. Telemetry decides how many frames are available and tells the machine.
The machine must ‘hand back’ the frames every 10 minutes and re-request them if still needed. This
prevents one machine from hogging the bandwidth.
For IP Radios, most of the screen is blank. It only shows the Main column down to Fifo, then shows the
IP Port that it is configured for, and the Personality information in the top right. The rest of the screen is
blank.
7.2.9 Input Test Screen

This screen shows all the data inputs from the IOP.
7-9

It can be used to :
• detect stuck bits in encoders
• Check for faulty analogue channels
• Detect power supplies that are not holding up
• Check temperatures of the Mainboard and Power Module
• Check switch inputs
• Check the radio id
7.2.10 Board Test Screen

This screen is mostly used when initially testing the hardware after initial manufacture of the board. It is
not normally needed – any information needed here is also present on the previous screen, The Input
Test Screen.
7-10

7.2.11 DragNav Screen

This shows all the GPS related information from the high precision GPS’s in the Display Module. It will
only work when communications with the Display Module are working correctly. No values can be
modified on this screen.
7.2.12 Task Accounting Screen

This screen shows how much processor time each task is consuming. If one task takes too long, or
gets stuck in an infinite loop, it will stop the system from working and cause the watchdog to trigger,
which will reset the system. This screen is present in the PMC and IOP. No values can be modified on
this screen.
7-11

7.2.13 PLC Registers Input Screen
This screen shows all the inputs that can be sent via the PLC MODBUS interface. See the
commissioning document for the details of what the expected inputs are.
7-12

7.3 IOP Debug Screens

The IOP has a series of Debug Screens that also simplifies setup and troubleshooting. These are
described here:
7.3.1 IOP General Information

This screen provides current and downloading build information.
7.3.2 Interface Board

This screen shows miscellaneous inputs, the encoder inputs and the scale and offset that is read from
the EEPROM on the interface board.
7-13

7.3.3 Motor Parameters

This screen shows the calibrated inputs as raw volts and amps and as percentages of full scale.
7.3.4 Geometry Parameters

This screen shows a number of geometry parameters, including the current angles and length of the
ropes, the x and y positions of important points etc.
7-14

7.3.5 Diagnostic Screen

The Diagnostic screen provides details of the current faults that are active and what state the PMC is in.
For each fault, the PMC maintains a state, so that it can track what happens to a particular channel. For
instance, an encoder will be working ok, which is State 1, then it stops but the motor volts are still high,
which prompts the PMC to go to State 2, then after a timeout of 2 seconds, it enters State 3, which is the
fault state.
7.3.6 Bucket Calibration

Designed to assist with Bucket Calibration, it is not currently used.
7-15

7.3.7 Serial Protocol Debug

This screen shows what device is connected which external port and provides some debugging info for
that connection.
7.3.8 Serial Protocol Debug – Screen 2

This shows the data from a SIMS system. Each Boom Stress Module is displayed on this screen, along
with diagnostic information.
7-16


This shows the data from a SIMS system. Each Boom Stress Module is displayed on this screen, along
with diagnostic information.

th
Regardless of the title on this screen, it is actually the 4 Serial Protocol debug screen
The hoist Sheave encoder values are shown on this screen. The top angle is the raw value from the
encoder. The lowest value shows the value after it has had the clipping threshold applied
7-17

7.3.11 Board Testing

This shows each analogue channel and the corresponding counts and volts on that channel. This
screen is mainly used during production.
7.3.12 SIMS / Dutymeter

This screen shows processed data from the strain gauges.
7-18

The fields are:
• Strain – strain value of each sensor, in MPa.
• Current and Last Fatigue – this is the fatigue value for the last full cycle and the fatigue for the
current cycle.
• Fatigue Alarm, Strain Alarm, Bucket eng., Fly Dump, Sw. Too Fast – each of this is an
indication of an alarm. If the alarm has gone off in the current cycle, this will show as T against
the sensor that triggered the alarm.
• Quality % - The system calculates a quality of the input sensor at all times. If the quality drops
below 50%, the sensor will be flagged as faulty
• Faulty- Shows whether each sensor is faulty or not.
7.3.13 Tightline Information

This shows real time information about the tightline system. It is very useful in determining where the
system believes the bucket is and what it is doing to control it.
7-19

7.3.14 Task Accounting Screen

This screen shows how much processor time each task is consuming. If one task takes too long, or
gets stuck in an infinite loop, it will stop the system from working and cause the watchdog to trigger,
which will reset the system. This screen is present in the PMC and IOP. No values can be modified on
this screen.
7-20

8 Debugging the Display Module

8.1 Network and Communications Issues
If the connection between the PMC and Display module will not work, collect the following information
via the serial debug port and send to Leica Mining Support.
This assumes that all the hardware is correctly setup and working, all cables are connected etc.
1. Start hyperterminal (or equivalent) and begin a text capture ( Go to Transfer menu -> Capture
Text and enter a unique filename)
2. Login to the Display Module as debug <Enter>
3. Switch to Ethernet comms: Type comms=e <Enter>
4. Power cycle the Display Module
6. Type shell <Enter>
7. Type ps <Enter>
8. Type cat /etc/config/sysinit.1 <Enter>
9. Type cat /etc/netstart <Enter>
10. Type cat /etc/hosts <Enter>
11. Type netstat –an <Enter>
12. Type netstat –rn <Enter>
13. Type ifconfig en1 <Enter>
14. Type ls -l /9020/backups <Enter>
15. type ls –l /9020/nav
16. type ls –l /9020/config
17. Exit by typing Exit <Enter>
18. Connect to the PMC debug port.
19. Check that the PMC is correctly setup – record the Ethernet information on the Network
configuration screen. Record both the left and the right columns
20. Type nsd <Enter>
21. Stop the text capture: ( Go to Transfer menu -> Capture Text-> Stop)
Send the text file to Leica Mining Support so that they can examine any problems and suggest a course
of action.
8.2 For suspected Build Issues

24. Type cd /9020/backups <Enter>
25. Type sz backup.tgz <Enter> This should load the file backup.tgz from the display module to
your computer.
Send the backup.tgz file to Leica Mining Support so that they can examine any problems and suggest a
course of action.
8-1

9 Programming Onboard Firmware

When manually updating the Series 3 Firmware on the Dragline the following procedure needs to be
followed:
1. Ensure that the current build is suitable for upgrading to the planned build. Check the Release
Notes if unsure.
2. Get the current configuration off the machine. This is used if the configuration is either
corrupted or lost while upgrading, or if the system needs to be put back to the original build due
to unforeseen problems. The configuration undergoes a number of changes from build 26xx
through to build 28xx and they are not compatible.
3. Use the Config Editor program to capture the configuration.
4. If the display needs to be upgraded, it is suggested that this is done first.
5. Upgrade the IOP and the PMC. The order is not important. Note that no production will be
logged while these are being upgraded.
6. Ensure normal operation recommences with the new builds. Make sure that all the systems
are fully operational before leaving the dragline.
9.1 Programming the PMC and IOP

The PMC and IOP can be programmed remotely via Telemetry, or manually via a programming cable
via a laptop.
9.1.1 Manual Programming

To program manually, you require:
• A laptop with a parallel port
• A Series 3 programming lead
• The pmc.dwn and/or iop.dwn file of the build that you want to program.
• The special loader files, flash860.dwn (for PMC) and flash505.dwn (for IOP)
• The batch files that actually do the programming, progpmc.bat (for PMC) and progiop.bat (for
IOP)
• The program ppcbdm.exe, which is available in SourceSafe, under $/Series3/Tools/bin
Procedure for programming:
(Note – this procedure shows an IOP being programmed, but the procedure is identical for the PMC)
1. It has been observed that when programming the Series 3 the radio configuration is
occasionally corrupted. This results in the loss of communication and the need to reprogram
the radio configuration. Before programming the Series 3 the radio must be physically
disconnected. After the successful software change on IOP / PMC the radio must be
reconnected again
2. Put the correct build, the flash505.dwn / flash860.dwn file and the progiop.bat or progpmc.bat
batch file into a directory, as shown in Figure 1.
9-1

Figure 1 - Folder containing IOP builds

3. Connect the programming lead from the laptop to the IOP port on the Series 3 mainboard. The
programming ports for the IOP and PMC are P21 and P22 respectively, named IOP Prog and
PMC Prog on the Series 3 mainboard, within the Computer Module.
4. Double click on the progiop.bat file as shown in Figure 1.
5. A DOS window should appear as shown in Figure 2.
The batch file does the following:
• checks that the build that is being downloaded is not corrupt and reports the build
that is being downloaded (see Figure 2) – use this to make sure you are
downloading the build you think you are
• runs the correct command which resets and then sets up the processor,
• checks that we are talking to the correct processor – the IOP is shown as an
MPC505, while the PMC is a MPC860.
• Erases the flash segments ready to load the new program. Once all the segments
are erased, the previous build will no longer run. This is the point of no return!
• The flash loader (flash505.dwn or flash860.dwn) is then downloaded. This piece of

code is programmed to RAM and allows the flash to be programmed.
• The actual program is then downloaded and the flash loader stores it to flash
• Another check is then done that the build number in the flash is correct
• Finally a verification of the flash storage is then done. This is necessary to make
sure that the program was successfully stored to flash
• The batch file will pause at the end of it’s operation so that any errors can be seen.
9-2

Figure 2 - Successfully programming the IOP

6. Remove the programming lead and reset the module, using the reset button mounted in the
centre of the mainboard.
9-3

7. Using the appropriate debug cable, check that the processor that was programmed is running
the new build. Carry out any verification necessary to prove that the monitor is operating
correctly before leaving the dragline.
Points of Failure
The programming of the IOP and PMC can fail in a number of ways. Use the following table to
troubleshoot any problems. If it still won’t work, call the Leica Support Line.
Error Description Solution
If the batch file can’t find a Make sure the build you want to
Error opening file : iop.dwn xxx.dwn file, it will exit with program is in the correct
this error. directory.
Invalid S Record file - aborting. If the xxx.dwn file is corrupt,

invalid or just wrong, the Get another copy of the xxx.dwn
File appears corrupt
system will exit with one of file and try again.
Can't find build in file these errors
This is most likely that the

The program can’t read
programming cable is not
Reading processor type…Unknown what processor it is
connected or faulty – connect or
connected to
replace and try again.
The correct flashxxx.dwn file

may not be in the directory.
Check that it is there and try
The program can’t find the again
Error: flashld file not good or at EOF flash loader (flashxxx.dwn) If the programming cable is
file it expects connected to the wrong
processor, this error also
appears. Connect to the correct
processor and try again.
This shouldn’t happen now as

Error: programming file not good or There was a problem with
there is the check of the file
at EOF the xxx.dwn file.
before erasing the flash
Error programming flash : Flash not These errors are all internal Try to reprogram one or two
erased. to the processor. Many times.
factors influence these
There is often noise in a dragline
errors
which can cause problems. If
Error programming flash :
there is any slack in the
Programming timed out
programming cable, try coiling it
Error programming flash : Verify in a loose roll to minimise noise.
failed Remember that the
programming cable acts like an
Error programming flash : Unknown
antenna and can pick up any
error code
stray noise.
Error programming flash : No data
Also try holding the reset button
supplied
9-4

down, start the programming

Error programming flash : Bad
and release the reset button just
checksum
before the flash is erased. This
Error programming flash : Did not may take you a few tries as you
finish want to release the reset button
just before the S record file
Error programming flash : Did not
finishes checking – see line
run loader
Checking S Record File in
Figure 2 - Successfully
programming the IOP.
To verify your cable, try to

program a different module. If
the same errors occur, replace
Verify ERROR at address There was an error while
your programming cable.
0x12345678 PPC=> 0x87654321 verifying the program in
File=> 0x56781234 flash If these errors keep happening
for this module only, especially
at the same location (ie always
at line 11340), there may be a
problem with the onboard flash.
Replace the computer module.
9.2 Programming the Display Module

9.2.1 Programming New Application
General Firmware can be sent over Telemetry, HyperTerminal or using FTP if IP network.
9.2.2 Using Tech Cable

• Using Hyperterminal, login as debug.
Using the Tech
Cable • From the menu in Hyperterminal, choose Transfer -> Send File and browse to the
app.tgz file and press Send.
• It will take about 10 minutes to download the file and the machine can continue to
work normally while this is occurring.
• Once downloaded, type shutdown at the prompt and the application will restart,
detect the new application, test it to make sure its checksum is ok (integrity) and
reprogram over the top.
9.2.3 Using Telemetry

• Place *.PRG file (e.g. DM02844.PRG) in /IMS/Distrib folder on IMS server.
Using Telemetry
• Open IMS > Configuration > Machines.
• (Need to be Tritro Admin or Tritro Super.)
• Highlight the machine of interest.
• Click on the Hardware tab on the bottom half of the Machines menu.
• Click on the Assign button next to List of Software Components section.
9-5

• Note the following screen shots are for a DrillNav product, however it is the same for a
Display Module.
• This opens Software Components menu

• Within Software Components highlight S3 Panel Components and click on Add
button next to a Component Build section.
• Enter the Build number of the application which you just placed on the server’s
/IMS/Distrib folder and entre 0 for Blocks field.
• Click Save to finish adding a new build to the list.
9-6

• Highlight both Display ModuleComponent and the correct application build under
Component Build.
• Click Select to finish the assignment.
• Check that Desired field changed to the new application you just assigned.
Transferring application file over the Telemetry takes up to three days for the download to
complete. Please plan around accordingly.
9.2.4 Using FTP

Using FTP over Display Module application upgrade over the IP network connection is done by placing
an IP network app.tgz (instead of DM0xxxx.PRG ) file on the /9020/downloads directory of the Display
Module then restart the system.
(Assuming IP network is working correctly.)
Following steps show how to copy files using command line FTP then restart the system
using Telnet connection:
• Open Command line by typing CMD on Start > Run.
• Change directory to where app.tgz is located on the local terminal.
• Type ftp 10.76.11.225 (replace IP address with the display module you need to
access.)
Use following user name and password to login:
User Name: leica
Password: leica
Note: Login in as leica allows user to browse file system structure.
C:\NavigateToFolderWhereApp.tgzLocated>ftp 10.76.11.225
Connected to 10.76.11.225.
9-7

220 display FTP server (Version 5.60) ready.

User (10.76.11.225:(none)): leica
331 Password required for leica.
Password: leica
230 User leica logged in.
ftp> cd /9020/downloads …..change to downloads directory
250 CWD command successful.
ftp> pwd …..checking presently working directory
257 “/9020/downloads” is current directory.
ftp> bin …..change to binary transfer mode
200 Type set to I.
ftp> put app.tgz …..send application file to the drill
200 PORT command successful.
150 Opening BINARY mode data connection for app.tgz.
226 Transfer complete. …..success!
ftp: 3976524 bytes sent in 52.33Seconds 75.99Kbytes/sec.
ftp> by …..closing FTP connection
221 Goodbye.
• Open Telnet session by typing Telnet 10.76.11.225. (replace IP address with the
display module you need to access.)
• Login to Debug Terminal as Debug.
• Type shutdown at the 9020 PANEL>> prompt to restart the application.
Using Windows Windows Explorer can be used to transfer files.

Explorer FTP • Type ‘ftp://username:password@Display.Module.IP.Address’
ie. ftp://leica:leica@10.76.11.225/
• Navigate to 9020/download directory.
9-8

• Drag and drop app.tgx file in /9020/downloads directory.

• Open Telnet session by typing Telnet 10.76.11.225. (replace IP address with the drill
you need to access.)
• Login to Debug Terminal as Debug.
• Type shutdown at the 9020 PANEL>> prompt to restart the application.
When application is loaded successfully, app.tgz file will be removed automatically up on

restart of the system.
Check that the correct build is loaded. Type pp<Enter> at the debug prompt and check that
the build number for all of the files on the left hand side is correct. In the following picture, the
build is 2601.
Power cycle the unit to make sure that it will start automatically after a power loss.
9-9

10 Dragline Configurations and Personalities

10.1 Main Configuration (Personality)
The main configuration (personality) for the dragline is stored in EEPROM via the PMC. It is also
backed up onto the mine site server as protection against corruption and module failure.
10.1.1 Normal Operation

Every hour, the dragline monitor compares the timestamp of the local configuration to the timestamp of
the version of the server. If there is a difference, the version on the server is downloaded to the dragline
monitor. This allows changes to be made remotely and placed on the server. This can also let the
system recover itself if the onboard version is corrupt.
If a change is made onboard the dragline, the configuration is flagged as updated, preventing any
download. 30 minutes after the last change, the configuration is uploaded to the server, where it
replaces the current configuration (Located in IMS\OnboardFiles\Backup\S3Prs.xxx where xxx is the
radio id of the machine.) A copy of this file is also saved as
IMS\OnboardFiles\Backup\YYYYMMDD_HHMMSS_S3Prs.xxx. This allows all the changes made to the
machine to be tracked if needed, or an old configuration can be reinstated if problems are found with a
newer version.
10.1.2 Debugging
There is a number of debug commands available:
Command Description
dbgprs Turns on basic debugging for the dragnav configuration.
prsfu Forces the dragnav configuration to be uploaded to the server
prsfd Forces a download check of the dragnav configuration file.
prs Shows the current state of the configuration logic for the main configuration file
prs info Shows detailed information about the configuration logic for the main
configuration file
prs verbose Turns on debug that outputs as the logic changes state for the main configuration
file.
prs fu Forces the configuration to be uploaded to the server. Always uploads. Main
configuration file only.
prs fd Forces the timestamp comparison of the configuration which may cause a
download of the main configuration if a change is detected
prs pause Pauses any upload or download currently in progress. Main configuration file
only
10.1.3 Editing the Configuration

Editing of the configuration can only be done with the Dragline Config Editor program which runs on a
Windows OS. The Configuration Editor has commands to get the configuration from the dragline, either
10-1

via the serial port or via TCP/IP. See the S3_CMP_004 Standard Commissioning Procedure.pdf for
details on how to use the Configuration Editor.
10.2 DragNav Configuration

The DragNav system has a secondary configuration to the main Series 3 Dragline configuration file.
This DragNav configuration is stored on the Display Module and is saved on the server for backup
purposes. The current configuration can be saved to disk and applied to a new module in the case
where Telemetry isn’t running.
10.2.1 Getting the DragNav configuration off the Display

Module
1. Log in as debug <Enter>.
3. Type cd /9020/nav <Enter>
4. Type ls <Enter> A list of files will appear. The important files are all the .dat files. The
.ini files are for the GPS and can be copied for completeness.
5. Set up hyperterminal to receive files – Go to Transfer->Receive File then enter the folder
where you want to place the DragNav files and check that the protocol is Zmodem with
Crash Recovery. Press Receive. The receive screen appears – Press Cancel. This will
take 5-10 seconds to close.
6. Type sz *.dat <Enter> then sz *.ini <Enter>. Each of the files should be uploaded to the
computer. Note: The Display Module is case sensitive, so *.dat is different to *.DAT.
Check the file listing from Step 4 for the correct form.
7. Once all the files are confirmed to be on the laptop, the module can be shut down.
10.2.2 Sending DragNav configuration files to the Display

Module
1. Log in as debug <Enter>.
2. Type prsdn <Enter>. This will print a few lines saying that checking is suspended for 10
minutes.
4. Type cd /9020/nav <Enter>
5. Go to Transfer->Send Files and send each of the files that was collected previously.
Note that the system is case sensitive, and all the files need to be in lower case (eg
settings.dat). These can be changed on the PC before downloading.
6. Type ls –l <Enter>. Verify that the files are correct on the Display Module – the
timestamps and sizes should be the same as on the laptop. Also check the file names are
all in lower case. Some terminal programs change the case of files to be all positive. To
change the file on the Display Module:
a. Make sure there is no existing file of the same name. If so, delete it by typing
rm filename <Enter>
b. Type mv original_filename new_filename <Enter>.
10-2

c. Repeat steps a. and b. for each incorrect file.
d. Type ls –l <Enter> and check that the names are now correct.
7. Type exit <Enter>
8. Type prsend <Enter>. The system will output some debug while it is checking and
updating the personality. Ensure that the output indicates that it updated. The personality
will now be sent automatically to the server for backup.
9. That’s it folks.
10-3

11 DragNav
11.1 GPS Receiver Issues
11.1.1 Novatel Receiver Fix – MCS Dragline
If the MCS is fitted with Novatel Receivers, follow the following procedure to set the correct baud rate on
the Novatel Receivers:
• Login to the debug terminal as debug.

• At the 9020 Panel >> prompt type prsdn [enter]
• Type shell [enter]
• Make sure the NOVATEL.INI files exist. Need to be:
o NOVATEL.INI
o NOVATEL.INI.cmr
o NOVATEL.INI.rtcm2
o NOVATEL.INI.rtcm3
To check, type ls –l /9020/nav [enter]
If they don’t exist, but DNOVATEL.INI files do copy the DNOVATEL.INI file to NOVATEL.INI
files.
Type cp /9020/nav/DNOVATEL.INI /9020/nav/NOVATEL.INI [enter]
Do this for each of the 4 files, putting the correct name in for each one.
• Now setup the Novatel receivers. Run the following command to get a list of processes:
ps | grep gps [enter]
• Write down the pid’s of the following 2 processes (the pid is the first LHS column in the list of
numbers)
gpstasks G /dev/ser10 1 pid ______________
gpstasks G /dev/ser11 2 pid ______________
• Kill the 2 processes using the command
Run: kill [pid] [enter]
Run: kill [pid] [enter]
• Use the qtalk application to open the serial port the first GPS receiver:
Run: qtalk –m /dev/ser10 –b 9600 [enter]
Type Ctrl-A then ? then e to turn on local echo so you can see what you type
Type: +++, wait 2 seconds and then press +++ again then [enter]
Type a [enter] and confirm that a [com1] prompt appears. You are now talking to the
gps
Type the follow command to change the baud rate: COM COM1 57600 [enter]
The system will show ^. overwriting the COM command. This means it has already
changed to the new baud rate.
Exit qtalk by pressing: Ctrl-A followed by x
Run: qtalk –m /dev/ser10 –b 57600 [enter] Note the changed baud rate.
11-1

Type Ctrl-A then ? then e to turn on local echo so you can see what you type
Type a [enter] and confirm that a [com1] prompt appears. You are now talking to the
gps at the new baud rate of 57600.
Type saveconfig [enter] and confirm that the system shows OK
Exit qtalk by pressing: Ctrl-A followed by x
• Do the previous step but use ser11 instead to change the second receiver.
ie: qtalk –m /dev/ser11 –b 9600 [enter]
• Once done, type exit [enter]

• At the 9020 Panel >> prompt, type prsend [enter]
• Wait 30 seconds then type shutdown [enter] and confirm that the GPS’s work as expected via
the Dragnav GPS Status screen.
• Do a full power cycle and confirm that the GPS’s work.
11.2 Downloading Maps Manually

General Map files can be downloaded manually to the DrillNav system using either the Technician
debug cable or FTP on IP networks.
NOTE If files are downloaded manually, they are not displayed in Pit Ops and will need to be
manually deleted (see next section).
Instructions Manually downloading files is normally performed because there is a problem downloading
using IMS or Pit Ops and is not considered normal practice.
Prep
• Browse to the file in Windows and make sure that the .MAP extension is in capital
letters otherwise it will not be visible in the application.

• Onboard the drill, connect up your Debug Cable to the debug terminal port of the
Using Tech Cable module and run Hyperterminal on your laptop as described in Section Error!
Reference source not found..
• Login as root
• Change to the Maps directory cd /9020/maps
• Then transfer the map file the same way as sending a program. Transfer -> Send File
then select the file and pres Send.
• In order for the Map to be visible in the application, it needs to be in capital letters. To
check this once the file send is complete, type ls –l and make sure that the file you
send is listed and in capitals.
11.2.2 Using FTP (IP networks only)

• Again make sure that the filename you are transferring has the .MAP extension in
Using FTP (IP capitals.
11-2

networks only) • Start My Computer on the PC that you want to transfer the file from. Not your laptop,
the mine site PC that has access to the MAP file and the wireless network the DrillNav
is on.
• Type in ftp://10.76.8.123/maps/ where the IP address is the address of the drill.
• You will be able to see all the maps all files used by the system.
• Simply drag and drop the MAP file into the FTP window or Copy and Paste the file
(whichever suits you).
NOTE: This is not being used by customers as it does not go through Pit Ops and you lose
the pattern progress functionality doing it.
11.3 Deleting Maps Manually
General Maps can be deleted manually from the DragNav system using either the Technician debug
cable or FTP on IP networks.

• Onboard the drill, connect up your Debug Cable to the debug terminal port of the
Using Tech Cable module and run Hyperterminal on your laptop as described in Section Error!
Reference source not found..
• Login as root
• Change to the Maps directory cd /9020/maps
• Type ls –l and make sure the file name you need to delete.
• Type rm FILENAME.MAP
• Type ls –l again to make sure the file is removed.
11-3

11.3.2 Using FTP (IP networks only)

• Start My Computer on the PC that you want to transfer the file from. Not your laptop,
Using FTP (IP the mine site PC that has access to the MAP file and the wireless network the DrillNav
networks only) is on.
• Type in ftp://10.76.8.123/maps/ where the IP address is the address of the drill.
• You will be able to see all the maps all files used by the system.
• Right click on the file to be deleted. Select delete option to delete the file.
NOTE: This is not being used by customers as it does not go through Pit Ops and you lose
the pattern progress functionality doing it.
11-4

12 KPI’s
KPI's compare the production efficiency of the current cycle (or part thereof) to a historic
statistical model of all cycles that had the same parameters.
For instance, each cycle is categorised according to dragline, bucket and digmode, and then
each part of the cycle (fill, swing, return) is divided into segments.
Take swing as an example:

The swing is divided into multiple swing segments - 0 to 20 degrees,20 to 40 degrees etc
(these can be set on a per mine basis). On the server, the stored proc gathers all the data for
a particular dragline, bucket and digmode combination over the last set time period (default is
90 days), then it works out the production for each swing (weight divided by time - production
rate), and then allocates each rate to the correct segment. From this a statistical model of
each segment is made and an upper and lower threshold is calculated. These upper and
lower thresholds are then downloaded to the dragline. Hence for each combination of
dragline, bucket, digmode and swing angle, there are 2 numbers - an upper and lower
threshold. eg, DRE1, BKT1, Bridge to Spoil operation, 0-20 angle has 2 numbers, DRE1,
BKT1, Bridge to Spoil operation, 20-40 degrees has 2 numbers, etc.
Onboard, when a cycle is performed on the dragline, it calculates the production rate, then
looks up the upper and lower threshold in the correct segment (for that particular machine,
bucket, digmode and swing angle), and works out where the current production value lies with
regards to the upper and lower thresholds. This is then represented as a percentage and
shown to the operator. Values are truncated at 0 and 100%.
In this way 100 degree swings are not compared to 20 degree swings, because the
production rate would be much better for the smaller angle. A similar calculation is done for
return, and fill uses the start and end fill heights and reaches to define the segments.
Times where the system won't work:

1. An equivalent cycle has never been done on that machine, bucket, digmode
combination - if there is no data in the db that is included in the latest processing, then there
won't be any upper or lower thresholds. In this case the system reports 10. (100%). This
most often comes about from a bucket or digmode change. The stored proc is meant to run
each night, so that the next day there should be some information available for the dragline
after such a change.
2. stored proc not running - new data isn't added to the system, so the dragline
continues to report 10's
12-1

13 Raw Data Collection

13.1 Introduction
Raw data often needs to be collected from the Series 3 system for diagnostic purposes.
There are two methods for collecting the data based on the availability of access to the
Ethernet network connecting the Computer Module to the Display Module.
13.2 Method 1 – With no access to the network

13.2.1 Tools Required
• nc for qnx
• HyperTerminal
• Display Module serial debug lead.
13.2.2 Preparation
The program nc needs to be installed on the display. This only needs to be done once on
each display module, but on any particular module it may or may not have been done already.
13.2.3 To check if nc is installed:

a. Connect to the display module using HyperTerminal with the following settings:
Bit per second: 57600
Data bits: 8
Parity: None
Stop bits: 1
Flow control: None
b. Log into the Display as “debug”.
c. At the “9020 PANEL >>” prompt type: “!nc<Enter>“
If the display responds with “Cmd line:”, press the enter key to exit nc and skip down to
Procedure. It is safe to disregard the message “no port[s] to connect to” in this instance.
If the system responds with “nc: not found”, continue on with Installing nc
13-1

13.2.4 Installing nc
a. Type: “shell<Enter>”. This takes you to the qnx prompt, “#”.
b. Type: “cd /bin<Enter>”
c. From the menu select Transfer→Send File…
d. Browse to find the “nc” file
e. Select “Zmodem with Crash Recovery” from the dropdown box.
f. Press the Send button. A progress window will be displayed.
g. Once the file has been downloaded, type: “chmod +x nc<Enter>”.
h. Type: exit<Enter> to go back to the debug prompt.
13.2.5 Procedure for collecting Raw Data

a. Log into the display module as debug<Enter>
b. Type: “shell<Enter>”
c. Type: “cd /9020/backup<Enter>”
d. Type: “nc cm01 PORT | gzip > YYYYMMDD-HHMM-Site-Dragline.txt.gz &<Enter>”
Where PORT is 3000 for 26xx builds and earlier, or 3006 for 28xx builds and later,
and where YYYYMMDD-HHMM is a timestamp. A description can also be added to
the file name to help identify what phenomenon the data is capturing.
Hint: The ‘|’ character is called the pipe character and is typed with <Shift>-
<Backslash> (above the enter key on HP notebooks.)
Hint: The ‘&’ character is called the ampersand character and must be typed in as a
part of the above command. It makes the command run in the background, which is
important in this case for ending the capture without loosing any data.
e. To end the capture type: “slay nc”
f. To set the directory where the file will be saved on your notebook, from the menu
select Transfer→Receive File…
g. Click the Browse button and find the directory where you want to save the file. Click
OK to close the dialog.
h. Click Close on the Receive File dialog. Do not click Receive. HyperTerminal will
automatically start receiving the file and will save it in the selected directory in the
next step.
i. Type: “sz YYYYMMDD-HHMM-Site-Dragline.txt.gz<Enter>”
A progress window will be displayed and the file will be downloaded into the
previously selected directory, be aware that the download will take approximately 1
minute for every 4 minutes of captured data.
Note: You must be using HyperTerminal for this to work. HyperTerminal will detect
that the sz command is trying to send a file, some other terminal programs might do
this too but they will not have been tested.
Hint: In QNX, typing the first few letters of a filename and hitting <esc> twice will
automatically complete the filename, if the completion fails type more of the name
13-2

and try again. This makes life much easier especially when using long descriptive file
names.
j. Type: “rm YYYYMMDD-HHMM-Site-Dragline.txt.gz<Enter>”
k. Type: “exit<Enter>” to get back to the debug prompt.
Note: If the Computer Module or the Display Module resets during the procedure the data
collection will stop at that point. If a continuous data set is required the collection must be
restarted.
13.3 Method 2 – With access to the network

13.3.1 Tools Required
• nc.exe for windows
• HyperTerminal
• Computer Module serial debug lead.
• Cat-5 network cable
13.3.2 Preparation
The program nc.exe needs to be installed on your laptop. This only needs to be done once.
13.3.3 To check if nc.exe is installed:

a. Open a command prompt.
b. At the prompt type: “nc<Enter>”
If the computer responds with “Cmd line:”, press the enter key to exit nc and skip down to
Procedure. It is safe to disregard the message “invalid port: NO_DATA” in this instance.
If the system responds with “'nc' is not recognized as an internal or external command,
operable program or batch file.”, continue on with Installing nc.exe
13.3.4 Installing nc.exe

a. Make a new directory/folder in C:\ called Projects.
b. Copy “nc.exe” into c:\Projects
c. Right click on My Computer and select Properties
d. Select the advanced tab
e. Click on the “Environment Variables” button
f. In System Variables pane, selected the Path entry and click edit
g. Press the end key, to take you to then end of the selection. Note that the text in this
text box is likely to be very long.
h. Type: “;c:\Projects”, quotations excluded.
Note: the semicolon at the beginning is not a typo and must be entered.
i. Click OK to close of all the system properties forms, and close any command
windows that are open.
13-3

13.3.5 Procedure for collecting Raw Data

a. Determine the IP address of the computer module – It is available on the PMC pp
debug screens. The standard address is 192.168.0.1. The default used to be
203.29.180.75 so many systems continue to use this.
b. Set the computers IP address to a static address on the Dragline monitor’s sub net,
see the Network Configuration Scripts below.
c. Connect the laptop to the Ethernet switch that the Computer Module and Display
Module are connected to. The connection can be tested by trying to ping the
computer module (At the command prompt type ping ip_address).
d. Type: “nc ip_address PORT > YYYYMMDD-HHMM-Site-Dragline.txt<Enter>”
Where PORT is 3000 for 26xx builds and earlier, or 3006 for 28xx builds and later,
and where YYYYMMDD-HHMM is a timestamp. A description can also be added to
the file name to help identify what phenomenon the data is capturing.
Hint: The ‘|’ character is called the pipe character and is typed with <Shift>-
<Backslash> (above the enter key on HP notebooks.)
e. To end the capture type “<Ctrl>-C”
Note: If the Computer Module resets during the procedure the data collection will stop at that
point. If a continuous data set is required the collection must be restarted.
13.4 Network Configuration Scripts

The following scripts can be cut and paste into notepad, saved as batch file, and executed
when required to change the network settings of the “Local Area Connection” on a laptop or
PC.
13.4.1 DHCP Script (Home/Office)

netdhcp.bat
@echo off
echo Setting IP address for office or home network (DHCP). Please wait...
netsh interface ip set address name="Local Area Connection" source=dhcp
netsh interface ip show config "Local Area Connection"
pause
13-4

13.4.2 Static IP Script (Standard Dragline)

net-dragline-standard.bat
@echo off
echo Setting IP address for Datalogger. Please wait...
netsh interface ip set address name="Local Area Connection" source=static
addr=192.168.0.10 mask=255.255.255.0 gateway=none
pause
13.4.3 Creating a Custom Static IP Script

If a particular dragline has a non-standard ip address (ie the computer module IP address is
not 192.168.0.1), the above static IP script can be modified and saved with a machine specific
name. To create an IP address on the computer modules subnet, simply change the first 3
numbers of the addr=203.29.180.10 setting to match the first 3 numbers of the computer
modules IP address (as shown on the pp screen) and leave the last number as 10.
13.5 Method 3 – RDC via Telemetry

Warning: Care needs to be taken with this command, as filling the Fifo to 80% limits the amount
of data that can be stored in the event of a telemetry stoppage. If the Fifo fills up, data will be
lost. Ensure that the Telemetry system is fully working before using this method.
Note: This raw data collection does not work for PLC input machines, and only collects the
first 12 channels of SIMS data.
For the above reasons, it is recommended that this method is not used
unless absolutely necessary.
Method 1:
a. Connect to the PMC debug screen and confirm you are at the PMC# prompt.
b. Type rdc<Enter> when you want to start the RDC. This makes the PMC put each raw data
sample into the Fifo as a separate packet. This continues until either the Fifo is 80% full, or
rdc<Enter> is entered again
Method 2:
a. Turn the Calibrate Keyswitch to Calibrate on the Computer Module
b. On the Display Screen, goto Setup -> Debug and press Turn RDC On.
c. When enough data has been collected, press Turn RDC Off.
d. If the Fifo gets to 80% full, it will automatically stop logging RDC.
e. Turn the Calibrate Keyswitch to Run on the Computer Module.
13-5

14 Collecting Data from Data Logger

This document outlines how to recover data from the Series 3 Data Logger. The data logger is
responsible for capturing data sent from the Series 3 over TCP/IP and saving the data for retrieval at a
later date.
The data logger is simply a collection of services that can run on any Windows XP platform, including
Windows XP Embedded
This document focuses on retrieving the data from an embedded PC mounted permanently on the
Dragline.
14.1 Data structure

During the setup of the Data Logger, a name is allocated to the machine. This name is used for
uniquely storing the raw data files. In the following example, the machine is called DL1.
The following directory structure is present on the embedded PC:
Figure 1 – Sample log directory structure.
Each log file is named indicating the time in which the log file was created. The format is
“YYYYMMDD_hhmm.log” where the date and time is in GMT. The log file is closed at the end of each
hour and a new one started.
Hence 20061112_0100.log is the data for 0100 to 0159 GMT on the 12 of November 2006.
Notes:
1. Log files are stamped based on the date and time configured on the embedded computer
and therefore may differ from the timestamp on the Series 3. This is because the Data
Logger does not assume a format of the data it receives and therefore cannot read
timestamp information that is embedded in the data.
2. The onboard timestamp is GMT. This time is updated periodically from GPS information
and is the correct time.
14.2 Data Size

The raw data files are stored in plain ASCII format for ease of use.
Each raw data file contains 1 hour of raw data.
Each 1 hour file is approximately 16Mb in size.
This equals approximately 380Mb of data per day.
14.3 Data Retrieval

There are two main methods of data retrieval:
1. Automatic Retrieval - For new data that has not previously been retrieved, a removable drive
can be plugged in and the data will be automatically transferred
2. Manual Retrieval - For data that has been retrieved previously and has been archived, ftp or
remote desktop can be used. The files of interest are then manually be copied via TCP/IP.
New data that has not been copied off can also be accessed via these methods.
14-1

14.4 Automatic Retrieval - New Data Only

A service on the embedded PC is responsible for monitoring for removable drives, copying log files to
these drives and archiving log files that have been copied.
A removable drive such as a flash stick or USB Hard Drive can be connected to the embedded
computer via the USB port. The internal service will detect the new removable drive and will start
copying any new log files to the device maintaining the same directory hierarchy as on the hard drive in
the embedded computer.
When no more files can be copied to the removable drive, either because the drive is full or there are no
more log files to copy, then the drive will be ejected using the “Safely Remove Hardware” functionality
under Windows XP. This ensures that the drive is not being used anymore.
The person retrieving data using the external storage can tell that the drive has been ejected by
checking that the LED light on the external storage casing has turned off. It is recommended that USB
devices with such an LED be used for data retrieval.
The “HDD” LED on the embedded computer will also indicate the status of data retrieval. As data is
being logged the LED will flash approximately once a second. When an external storage device is
connected and data is being transferred, this LED will start to flash more rapidly. Once the copy to the
external storage has finished and the drive has been ejected the LED will start flashing at the lower
speed again. This method can be used if the external device does not have an LED indicating the state.
The following directory structure is created on the external device.
Figure 2 –directory structure on attached device.
14.5 Manual Retrieval - All Data

Manual Retrieval can be completed by connecting to the dragline monitor network, which the data
logger is a part of.
Connecting to the dragline monitor network may require modifying the Windows XP network
configuration. Some scripts in section 14.5.3 allow this to be performed easily.
Ftp is the recommended access method; however remote desktop can also be used.
14.5.1 FTP
The address for ftp is simply the ip address of the machine. Most machines have default setups where
the address is:
ftp://192.168.0.3/
The standard login details are:
Username: datalogger
Password: datalogger
The following directory structure is available on the embedded PC:
Figure 3 – directory structure that can be copied from.
14-2

Note: The DL1 directory will be named according to the name of the machine, eg DRE26, DL104 etc.
All the new files are available in the LGSLOGS/DL1 directory and all the archives are in the
LGSLOGS/archives/DL1 directory.
Copy all files as needed.
Delete files from the system when they are no longer needed. This will maximise the space available on
the system to collect data.
14.5.2 Remote Desktop

Remote desktop can be used to access the system and copy off the files, however it does not provide
any more features than FTP. Contact Leica Geosystems if Remote Desktop access is required on any
machines.
14.5.3 Network Configuration Scripts

The following scripts can be copied into notepad.exe and saved with the appropriate names to allow
easy configuration of Windows XP network settings.
For sites that have non-standard addresses, site specific scripts can be created by modifying
“addr=xxx.xxx.xxx.xxx” and “mask=xxx.xxx.xxx.xxx”.
14.5.3.1office-network-config.bat
@echo off
netsh interface ip set address name="Local Area Connection" source=dhcp
pause
14.5.3.2datalogger-network-config.bat
@echo off
netsh interface ip set address name="Local Area Connection" source=static
addr=192.168.0.3 mask=255.255.255.0 gateway=none
pause
14-3

15 UDD – Universal Dig and Dump

The UDD system is a change in the bucket rigging and setup of the hoist ropes of the dragline. It
requires extra inputs and a more complex method of determining the geometry of the system.
The UDD capability is enabled using the feature flags in the Configuration Editor. This enables an extra
UDD configuration screen where the relevant options can be selected.
This also enables extra fields in the bucket fields, and extra fields in the electrical parameters.
Extra information for the front hoist motor is included in the relevant debug screens.
NOTE: Currently, the UDD system cannot be calibrated via the Display Module. It must be done via the
PMC debug and the Configuration Editor.
15-4

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9000 Series 3 Dragline Monitor

Document No: S3_TRM_003 DragNav Technical Reference.doc

Source: VSS :$/DOCUMENATION/Serie3/S3_TRM_003 DragNav Technical

S3_TRM_003 DragNav Technical Reference.doc – 08

Copyright Leica Geosystems Pty Ltd 2009

Leica Geosystems Pty Ltd

S3_TRM_003 DragNav Technical Reference.doc – 08

Revision Issue Date Author Comment

00 14/9/2005 R Gullickson Initial Version

01 24/10/2005 R Gullickson Removed a lot of sensitive info about the weighing –

02 30/12/2005 R Gullickson Added description of encoder faults and methods of

03 22/2/2006 R Gullickson Added a section describing in simple terms all the

Added a section on manually downloading files to the

04 14/6/2006 R Gullickson Added a section on SIMS and Dutymeter diagnostics.

05 19/7/2006 R Gullickson Added extra information on troubleshooting strain

06 27/7/2006 R Gullickson Improved strain gauge troubleshooting and added a

07 22/3/2007 R Gullickson New weight calibration procedure. Updated the RDC

08 22/4/2009 R Gullickson Updated for build 28xx

09 16/7/2009 I Worlock Added information on PLC input filtering to Weighing

S3_TRM_003 DragNav Technical Reference.doc – 08

1.1 Dragline Monitor Overview..................................................................................................1-1

1.2 Hardware ............................................................................................................................1-1

2 Weighing System ............................................................................................................................2-1

2.1 Overview .............................................................................................................................2-1

2.2.1 Weighing Notes..............................................................................................................2-1

2.3 Weight Calibration...............................................................................................................2-2

2.3.1 Background ....................................................................................................................2-2

2.3.2 Calibration Overview and Notes.....................................................................................2-2

2.3.3 Combined Hoisting and Lowering Calibration ................................................................2-3

2.3.4 Separate Hoisting and Lowering Calibration ..................................................................2-3

3 Radio System .................................................................................................................................3-1

3.1 Tait Radio Systems.............................................................................................................3-1

3.2 Spread Spectrum Systems .................................................................................................3-1

3.2.1 Data Radio .....................................................................................................................3-1

3.2.2 RTK Radio......................................................................................................................3-1

3.3 IP Radio Systems ...............................................................................................................3-1

4 Cycle Logic and Operation..............................................................................................................4-1

4.1 Dragline Cycle Detection.....................................................................................................4-1

4.2 Dragline Dumping ...............................................................................................................4-2

5 Faults within Series 3......................................................................................................................5-1

5.1 Dragline Faults....................................................................................................................5-1

5.2 Drag Stall ............................................................................................................................5-1

5.3 Hoist Stall (Not Implemented) .............................................................................................5-1

5.4 Motor Volts Failure..............................................................................................................5-1

5.5 Encoder Faults....................................................................................................................5-2

6 Debug Commands ..........................................................................................................................6-1

6.1 Setup ..................................................................................................................................6-1

6.2 PMC and IOP......................................................................................................................6-1

6.3 Display Module ...................................................................................................................6-1

S3_TRM_003 DragNav Technical Reference.doc – 08

7 Serial Debug Screens .....................................................................................................................7-1

7.1 Debug Screen General Description ....................................................................................7-1

7.2 PMC Debug Screens ..........................................................................................................7-2

7.2.1 Bucket Debug Screen ....................................................................................................7-2

7.2.2 Main debug screen.........................................................................................................7-3

7.2.3 Display debug screen.....................................................................................................7-4

7.2.4 Electrical Parameter Screen...........................................................................................7-5

7.2.5 Cycle Debug Screen ......................................................................................................7-6

7.2.6 Summary Stats Screen ..................................................................................................7-7

7.2.7 Tuneable Variables (TV’s)..............................................................................................7-8