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AutoMine / AutoMine-Lite and MPM

Onboard Service & Repair Manual

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Table of Contents

1. INTRODUCTION ............................................................................................................................ 9
1.1. Foreward ............................................................................................................................................................. 9
1.2. Abbreviations and definitions used in AutoMine system ..................................................................... 10
1.3. Warning and information symbols used in this manual ........................................................................ 12
1.3.1. Safety Symbols Pertaining to the Machine ................................................................................................ 12

2. SAFETY INSTRUCTIONS ............................................................................................................. 18

2.1. General Safety Instructions ........................................................................................................................... 18
2.2. General safety precautions during operation ........................................................................................... 19
2.3. Important safety notes .................................................................................................................................... 21
2.4. General Repair Instructions ........................................................................................................................... 22
2.5. Incident reporting ............................................................................................................................................. 22

3. VCM SYSTEM AUTOMATION FUNCTIONS ................................................................................ 23

3.1. Graphical user interface (GUI) ...................................................................................................................... 23
3.1.1. AutoMine main window ................................................................................................................................. 24
3.1.2. Start-up status window ................................................................................................................................. 25
3.1.3. Comms status window .................................................................................................................................. 27
3.1.4. AutoMine gauges window ............................................................................................................................ 28
3.1.5. System specialist window ............................................................................................................................. 30
3.1.6. Reset InfraFREE ............................................................................................................................................ 40
3.2. Engine control ................................................................................................................................................... 40
3.2.1. Starting and shutting down ........................................................................................................................... 41
3.2.2. Lockings .......................................................................................................................................................... 41
3.2.3. Inputs ............................................................................................................................................................... 42
3.2.4. Outputs ............................................................................................................................................................ 42
3.2.5. Diagnostics ..................................................................................................................................................... 42
3.3. Engine revolution control ............................................................................................................................... 43
3.3.1. Lockings .......................................................................................................................................................... 43
3.3.2. Inputs ............................................................................................................................................................... 43
3.3.3. Outputs ............................................................................................................................................................ 44
3.3.4. Diagnostics ..................................................................................................................................................... 44
3.4. Gear control ....................................................................................................................................................... 44
3.4.1. Lockings .......................................................................................................................................................... 44
3.4.2. Inputs ............................................................................................................................................................... 45
3.4.3. Outputs ............................................................................................................................................................ 45
3.4.4. Sensor calibration window ........................................................................................................................... 46
3.5. Brake control ..................................................................................................................................................... 46
3.5.1. Service brake .................................................................................................................................................. 46
3.5.2. Parking brake ................................................................................................................................................. 47
3.5.3. Emergency brake ........................................................................................................................................... 47
3.5.4. Brake release in case the machine breaks down (option) ...................................................................... 47
3.5.5. Inputs ............................................................................................................................................................... 48
3.5.6. Outputs ............................................................................................................................................................ 48
3.5.7. Diagnostics ..................................................................................................................................................... 48

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 3.6. Steering control ................................................................................................................................................ 49
3.6.1. Lockings .......................................................................................................................................................... 49
3.6.2. Emergency steering (option) ........................................................................................................................ 49
3.6.3. Inputs ............................................................................................................................................................... 50
3.6.4. Outputs ............................................................................................................................................................ 50
3.6.5. Diagnostics ..................................................................................................................................................... 50
3.7. Boom control ..................................................................................................................................................... 51
3.7.1. Lockings .......................................................................................................................................................... 51
3.7.2. Inputs ............................................................................................................................................................... 52
3.7.3. Outputs ............................................................................................................................................................ 52
3.7.4. Diagnostics ..................................................................................................................................................... 52
3.8. Bucket control (loader only) .......................................................................................................................... 52
3.8.1. Lockings .......................................................................................................................................................... 53
3.8.2. Inputs ............................................................................................................................................................... 53
3.8.3. Outputs ............................................................................................................................................................ 53
3.8.4. Diagnostics ..................................................................................................................................................... 53
3.9. Weighing control (option) .............................................................................................................................. 54
3.9.1. Inputs ............................................................................................................................................................... 54
3.9.2. Outputs ............................................................................................................................................................ 54
3.10. Light control ....................................................................................................................................................... 55
3.10.1. Mode lights ...................................................................................................................................................... 55
3.10.2. Driving lights ................................................................................................................................................... 55
3.10.3. Working lights ................................................................................................................................................. 55
3.10.4. Parking lights .................................................................................................................................................. 55
3.10.5. Brake lights ..................................................................................................................................................... 56
3.10.6. Reverse light and buzzer .............................................................................................................................. 56
3.10.7. Driving direction lights (option) .................................................................................................................... 56
3.10.8. Inputs ............................................................................................................................................................... 56
3.10.9. Outputs ............................................................................................................................................................ 57
3.10.10. Parameters ..................................................................................................................................................... 58
3.10.11. Diagnostics ..................................................................................................................................................... 59
3.11. Machine mode selection ................................................................................................................................. 62
3.11.1. Mode lights ...................................................................................................................................................... 63
3.11.2. Start-up test .................................................................................................................................................... 64
3.11.3. Force to safe mode (option) ......................................................................................................................... 64
3.11.4. Inputs ............................................................................................................................................................... 65
3.11.5. Outputs ............................................................................................................................................................ 65
3.11.6. Parameters ..................................................................................................................................................... 65
3.11.7. Diagnostics ..................................................................................................................................................... 66
3.12. Camera control .................................................................................................................................................. 68
3.12.1. Inputs ............................................................................................................................................................... 68
3.12.2. Outputs ............................................................................................................................................................ 68
3.12.3. Diagnostics ..................................................................................................................................................... 69
3.13. Powersave mode .............................................................................................................................................. 71
3.13.1. Communication power control ..................................................................................................................... 71
3.13.2. InfraFREE communication power control .................................................................................................. 72
3.13.3. Emergency functions ..................................................................................................................................... 72
3.13.4. Inputs ............................................................................................................................................................... 72
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 3.13.5. Outputs ............................................................................................................................................................ 73
3.13.6. Parameters ..................................................................................................................................................... 73
3.13.7. Diagnostics ..................................................................................................................................................... 74
3.14. Fire suppression system ................................................................................................................................ 77
3.14.1. Inputs ............................................................................................................................................................... 78
3.14.2. Outputs ............................................................................................................................................................ 78
3.14.3. Diagnostics ..................................................................................................................................................... 78
3.15. Emergency stop circuit and safety message ............................................................................................ 79
3.15.1. Inputs ............................................................................................................................................................... 80
3.15.2. Outputs ............................................................................................................................................................ 80
3.15.3. Parameters ..................................................................................................................................................... 80
3.15.4. Diagnostics ..................................................................................................................................................... 81
3.16. AutoMine option parameter control ............................................................................................................ 83
3.16.1. Activating or deactivating an optional function .......................................................................................... 84
3.16.2. Optional parameters ...................................................................................................................................... 85
3.17. Manual Production Monitoring (MPM) VCM system ............................................................................... 87
3.17.1. Logging in ....................................................................................................................................................... 88
3.17.2. Machine status ............................................................................................................................................... 89
3.17.3. Production order ............................................................................................................................................ 90
3.17.4. MPM maintenance windows ........................................................................................................................ 92

4. ONBOARD COMPONENTS .......................................................................................................... 98

4.1. Communication ................................................................................................................................................. 101
4.1.1. MineLAN client ............................................................................................................................................... 102
4.1.2. Antenna ........................................................................................................................................................... 105
4.1.3. Cabling (Mobile Terminal version) .............................................................................................................. 108
4.1.4. Cabling (WLAN client version) ..................................................................................................................... 109
4.1.5. Communication troubleshooting (if equipped with Mobile Terminal) ..................................................... 109
4.1.6. Communication troubleshooting (if equipped with WLAN client) ........................................................... 119
4.2. InfraFREE ............................................................................................................................................................ 130
4.2.1. InfraFREE Navigation Module ..................................................................................................................... 130
4.2.2. InfraFREE connections ................................................................................................................................. 131
4.2.3. InfraFREE power supply ............................................................................................................................... 134
4.2.4. InfraFREE cabling .......................................................................................................................................... 136
4.2.5. InfraFREE humidity absorber ...................................................................................................................... 140
4.2.6. Common troubleshooting instructions ........................................................................................................ 140
4.2.7. Connection failure to the navigation module ............................................................................................. 142
4.2.8. Testing the hardware and sensors ............................................................................................................. 144
4.2.9. InfraFREE error codes .................................................................................................................................. 154
4.3. Front/Rear Scanner .......................................................................................................................................... 190
4.3.1. Technical data ................................................................................................................................................ 190
4.3.2. Scanner lens cleaning ................................................................................................................................... 191
4.3.3. Scanner humidity absorber .......................................................................................................................... 191
4.4. Sensor Module .................................................................................................................................................. 192
4.4.1. Technical data ................................................................................................................................................ 193
4.4.2. Gyroscope ....................................................................................................................................................... 193
4.4.3. Accelerometers .............................................................................................................................................. 194

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 4.5. Bucket Sensor ................................................................................................................................................... 194
4.5.1. Technical data ................................................................................................................................................ 195
4.5.2. Testing the bucket sensor ............................................................................................................................ 195
4.6. Boom/Box Sensor ............................................................................................................................................ 195
4.6.1. Technical data ................................................................................................................................................ 196
4.6.2. Testing the boom/box sensor ...................................................................................................................... 196
4.7. Odometer ............................................................................................................................................................ 197
4.7.1. Technical data ................................................................................................................................................ 198
4.7.2. Installing odometer (drive line version) ...................................................................................................... 198
4.7.3. Installing odometer (gear box version) ....................................................................................................... 198
4.7.4. Testing the odometer sensor ....................................................................................................................... 199
4.7.5. Checking the odometer signal ..................................................................................................................... 199
4.8. Articulation Sensor .......................................................................................................................................... 199
4.8.1. Technical data ................................................................................................................................................ 200
4.8.2. Testing the articulation sensor ..................................................................................................................... 200
4.9. Audio/video ........................................................................................................................................................ 201
4.9.1. Onboard Video Box ....................................................................................................................................... 202
4.9.2. Cameras .......................................................................................................................................................... 202
4.9.3. Camera installation ........................................................................................................................................ 204
4.9.4. Video switch .................................................................................................................................................... 205
4.9.5. Ethernet switch ............................................................................................................................................... 206
4.9.6. Video server .................................................................................................................................................... 207
4.9.7. Audio/video cabling ....................................................................................................................................... 216
4.9.8. Audio/video troubleshooting ......................................................................................................................... 218
4.10. Machine Mode Switch ..................................................................................................................................... 219
4.11. Monitoring .......................................................................................................................................................... 220
4.11.1. VCM ................................................................................................................................................................. 221
4.11.2. Portbox ............................................................................................................................................................ 222
4.11.3. Weighing interface ......................................................................................................................................... 225
4.12. ACS onboard unit ............................................................................................................................................. 226
4.12.1. Display of system leds .................................................................................................................................. 227
4.13. RFID tag reader ................................................................................................................................................. 228
4.14. Manual Production Monitoring (MPM) error codes ................................................................................. 229

5. CHECKING AND ADJUSTING ...................................................................................................... 239

5.1. Malfunctions ...................................................................................................................................................... 239
5.2. Order of sensor calibration ............................................................................................................................ 239
5.3. Sensor calibration ............................................................................................................................................ 240
5.3.1. Interrupting the calibration ............................................................................................................................ 240
5.3.2. Saving the calibration .................................................................................................................................... 241
5.3.3. Malfunctions .................................................................................................................................................... 242
5.4. Scanner position calibration ......................................................................................................................... 242
5.5. Scanner heading calibration ......................................................................................................................... 243
5.6. Calibrate the Odometer ................................................................................................................................... 244
5.7. Accelerometer calibration .............................................................................................................................. 245
5.8. Gyro calibration ................................................................................................................................................ 246
5.9. Articulation angle sensor calibration .......................................................................................................... 247
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5.10. Boom/box angle sensor calibration ............................................................................................................ 249
5.11. Bucket angle sensor calibration ................................................................................................................... 250
5.12. Automine gauges calibration ........................................................................................................................ 251
5.12.1. Steering sensor gauge calibration .............................................................................................................. 251
5.12.2. Boom sensor gauge calibration ................................................................................................................... 252
5.12.3. Bucket sensor gauge calibration ................................................................................................................. 252
5.13. Common rules for checking cables ............................................................................................................. 252
5.14. WLAN client configuration ............................................................................................................................. 253
5.14.1. Client ................................................................................................................................................................ 253
5.14.2. Client and access point ................................................................................................................................. 256

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 AutoMine / AutoMine-Lite and MPM
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1. INTRODUCTION

1.1. Foreward

The purpose of this manual is to guide mine personnel in observing correct and safe working
procedures during operation and maintenance of the AutoMine / AutoMine-Lite / Manual Production
Monitoring (MPM) system. The standard maintenance procedures are described in the AutoMine /
AutoMine-Lite / MPM maintenance manuals.
AutoMine or AutoMine-Lite systems are intended for automated and efficient loading, hauling and
dumping operations in tunnels and mines.
The AutoMine, AutoMine-Lite and MPM instructions are
intended to supplement machine-specific operation and
maintenance manuals with respect to the system. Reading and
understanding the machine-specific instructions is mandatory
for safe operation and maintenance of the machinery as a
whole.

Only personnel with the appropriate training and authorization may perform the procedures described
in this manual. Each operator and maintenance engineer must become familiar with the machine and
understand the operating and maintenance instructions as well as the general safe working
procedures prior to operating, maintaining or repairing AutoMine / AutoMine-Lite / MPM system. This
manual contains information about the safe use of components, instruments and working procedures.
The AutoMine / AutoMine-Lite / MPM system must be operated only by personnel with proper training
in the use of the system.
This warning symbol is used to identify important safety
messages in this manual. Pay close attention whenever the
warning symbol is shown. Read the safety message carefully
and clearly inform other operators of the warning as necessary.

All personnel operating the AutoMine / AutoMine-Lite / MPM

system or carrying out maintenance or repair work on it must
read and understand the operating and safety instructions prior
to starting work.

Always observe the required legislation and local safety regulations concerning the prevention of
accidents and environmental protection. Observing generally recognized technical regulations
ensures professional and safe use of the system.
If demanding or complex maintenance and repair work is required, contact your nearest Sandvik
Mining and Construction service centre. Sandvik Mining and Construction’s trained maintenance
personnel and special tools guarantee a successful repair result.
Continuous product development of the AutoMine / AutoMine-Lite / MPM system may have resulted
in changes to the system that are not included in this manual. Always consult the Sandvik equipment
support bulletins.

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1.2. Abbreviations and definitions used in AutoMine system

Abbreviation Definition
AB Access Barrier, a gateless safety device used to restrict access to the
automated production area and to prevent unauthorized personnel from
entering the area during production.
AG Access Gate, used to restrict access to the automated production area and to
prevent unauthorized personnel from entering the area during production.
ACS Access Control System
ADT Area Definition Tool
AP Access Point
AutoMine An automated mining system for loader and dump-truck automation, developed
by Sandvik Mining and Construction.
AutoMine-Lite An automated mining system for loader automation, developed by Sandvik
Mining and Construction.
Calibration The term "calibration" is used mainly to refer to the scaling or setting of sensors,
or saving of them into the system memory.
CAN Controller Area Network, the internal data communication bus used in vehicles
and machines.
Comms Short for ”Communication Systems”. In this manual, mainly used to refer to the
machine’s communication and video equipment.
Control room The location of the remote control and supervision site of the automated
machine. This can be, for example, a van near the production area, or a fixed
building or space in a mine or on the surface.
CS Refers to the machine control system. An abbreviation used on the display in
order to save space. A system consisting of modules and related software and
wiring. Included in the machine’s electrical system.
DLB Dual Light Barrier
DT window DIO test window.
(G)UI (Graphical) User Interface
Gyro Gyroscope, or ”gyrocompass”. A sensor that keeps track of the machine's
direction of travel.
I/O Input/Output
IG Isolation Gate
InfraFree A navigation system for mining machines, developed by Sandvik Mining and
Construction.
IP Internet Protocol
LHD Load Haul Dump machine
MCS Mission Control System, AutoMine control system software.
MG Man Gate
MineLAN Mine Local Area Network; the wireless communication system used in the mine.

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Monitoring One of several data communication ”pipelines” between the machine and the
channel control room. A data communication channel used to transfer the machine’s
status monitoring and alarm information. The monitoring channel is set up
between the machine’s display and the control room. Different channels use
the same physical data communication link (MineLAN).
MPM Manual Production Monitoring
MT Mobile Terminal
MTS Mobile Terminal System
NMS Network Management System
Operator A person using the automated system, for example the operator or a
maintenance person.A person with a basic training in the use of the system.
Has permission to adjust the operator level settings of the machine’s
automation system and to perform maintenance operations on it.
Option A feature not necessarily found in all machines and systems. Can also be used
to refer to a feature to be made available in the future.
Parameter In this manual, used to refer to a set software value that can be changed via
the machine’s display without reprogramming. Using the parameters, you can
change the machine’s features and, for example, introduce new features.
PCS Production Control System
PDA Personal Digital Assistant. A configuration tool for the AutoMine-Lite ACS.
PE Protective Earth (electrical units safety measure)
PLC Programmable Logic Controller
RDT Route Definition Tool, a tool for teaching and defining routes for the automated
machine.
RFID Radio Frequency IDentification
RFID tag RFID tag is a microchip combined with antenna. Microchip is for storing
information and other special functions. Antenna picks up signals from an RFID
tag reader and then returns the signal.
RFID tag reader RFID tag reader is used to detect and identify RFID tags.
SCADA Supervisor Control And Data Acquisition
Scanner A sensor that ”sweeps” the environment horizontally with a laser beam and
measures the distance to objects that reflect the beam back.
Segment A section of a path along which an automated machine moves. It has a direction
of movement with a start and an end point.
SRCF Safety-Related Control Function
SRECS Safety-Related Electrical Control System
SS Supervisory System, AutoMine-Lite control system software.
SSID Service Set Identifier
System specialist A person specially trained in the use of the automated system. He or she has
permission to adjust all of the settings of the machine’s automation system, and
to perform maintenance operations on it.
TE Terminal Earth
UPS Uninterruptible Power Supply

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VCM (CS) Vehicle Control and Management. Refers to the machine control system. An
abbreviation used on the display in order to save space. A system consisting
of modules and related software and wiring. Included in the machine’s electrical
system.
WLAN Wireless Local Area Network
WPA Wi-Fi Protected Access

1.3. Warning and information symbols used in this manual

The warnings in this manual have been divided into the following three categories.

The term "DANGER" Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

The term “WARNING” Indicates a hazardous situation which, if not avoided,

could result in death or injury.

The term "NOTICE" Indicates a situation which, if not avoided, could result
in damage to property.

1.3.1. Safety Symbols Pertaining to the Machine

The safety symbols found in this manual may also be posted on

the machine. All personnel who operate, repair, or service the
machine MUST be familiar with and observe all safety symbols,
labels, and instructions!

• Keep safety instructions and safety labels clean and visible at all times.
• Replace any illegible or missing safety instructions and safety labels before operating the machine.

Hazard
The black symbol inside a yellow triangle with a black border describes the
hazard.

Prohibition
The black symbol inside a red ring with a diagonal red bar describes the
action that should not be taken.

Mandatory action
The white symbol inside a blue circle describes the action that must be taken
to avoid a hazardous situation.

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Hazard symbols

These symbols are used in warnings to indicate a hazardous situation or action.

Hazard symbols are divided into seven categories according to their nature:
• Mechanical hazards
• Electrical hazards
• Noise hazards
• Radiation hazards
• Material/substance hazards
• Ergonomic hazards
• General hazard

The hazard symbols related to each hazardous situation are presented below.

Mechanical Hazard Symbols

Falling load hazard Squashing hazard Flying material hazard

Crushing hazard - feet Crushing hazard - hands Cutting hazard

Entanglement hazard Entanglement hazard Entanglement hazard

Entanglement hazard - rotating Falling hazard Trip hazard

drill

Skin injection hazard High pressure injection hazard Hanging load hazard

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Run over hazard Slipping hazard Sideways tipping hazard

Forward/backward tipping haz- Sideways tipping hazard Forward/backward tipping haz-

ard ard

Electrical Hazard Symbols

Electrical hazard Dangerous electrical voltage Electrical shock/

Electrocution hazard

Noise Hazard Symbols

Noise hazard

Radiation Hazard Symbols

Radioactive hazard Laser hazard

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Material / Substance Hazard Symbols

Hot surface hazard Explosion hazard Flammable hazard

Hazardous/poisonous material Chemical burn hazard Silica/dust hazard

hazard

Hot coolant splashing hazard Environment pollution hazard

Ergonomic Hazard Symbols

Lifting hazard

General Hazard Symbol

General hazard

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Prohibited action symbols

These symbols are used in warnings and notifications to indicate a the action that should not be taken.
The prohibition symbols are presented in the following table.

No climbing No smoking No open flames

Do not touch Limit or restrict access Do not weld

Do not remove safety guard Do not modify General symbol for prohibited
action

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Mandatory action symbols

These symbols are used in warnings and notifications to indicate the action that must be taken to
avoid a hazardous situation.
The mandatory action symbols are presented in the following table.

Wear safety gloves Wear eye protection Wear safety helmet

Wear safety harness Wear ear protection Wear steel toed safety boots

Wear close fitting overalls Wear high visibility vest Wear respirator

Disconnect from power source Switch off and lockout equip- Read the manual or instructions
ment

Use cardboard for locating leaks Use lap belt General symbol for mandatory
in hoses action

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2. SAFETY INSTRUCTIONS

2.1. General Safety Instructions

DANGER
PERSONAL INJURY HAZARD!
Operating or servicing the machine in a dangerous or incorrect
manner or without adequate safety procedures will result in
serious injury or death.
Operating, service and adjustment procedures must be carried
out by personnel with specialized operation and service
training.
All personnel operating or driving the machine/system or
carrying out maintenance or repair work must read and
understand the operating and safety instructions prior to
starting work.
Carefully plan your work beforehand to minimise risk of damage
or injury.

WARNING!
Always obey local laws and safety regulations.

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2.2. General safety precautions during operation

DANGER
RUNOVER HAZARD!
Danger of death or serious injury.
The secured production area must be strictly free of all
personnel when the area is set to automatic mode.

WARNING
GENERAL HAZARD!
Failure to adhere to the instructions could result in death,
serious injury, or damage to property.
All mine safety measures, labels and rules are effective at all
times regardless of AutoMine/AutoMine-Lite system functions.

WARNING
NOISE HAZARD!
Continuous exposure to noise could cause hearing impairment.
Using approved hearing protection is recommended near field
cabinets and near the component box due to potentially high
sound pressure levels.Adjust noise levels as necessary.

Machines intended for automation use must be compatible with

the AutoMine/AutoMine-Lite system.

Operating, service and adjustment procedures must be carried

out only by personnel with specialized operation and service
training.
All personnel operating the system or carrying out maintenance
or repair work on it must read and fully understand the
operating, maintenance and safety instructions prior to starting
work.

Due caution must be observed at all times when operating the system. Failure to do so can seriously
endanger the safety of the operators and other personnel. All persons involved in operation or
maintenance work must be aware of potential hazards and must use safe working methods. Before
starting any maintenance or repair work, read the manufacturer’s instructions and follow them.
Operators must understand how to use the system and must also understand the consequences of
using the system contrary to the instructions.

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All production personnel with access to the automated production area must be trained to recognize
safety risks and to learn how to gain access to the area safely if needed. Sufficient signs to instruct
people must also be in place at each access area.
Mine personnel must be trained to understand the meaning of the area status indicator lights and
sound alarms. Personnel must be trained to perform appropriate emergency procedures in the event
that the area they are in switches to automated operation mode.
It is recommended that additional fire suppression equipment and rescue packs are provided in the
vicinity of the operating station.
ACS activation authorization shall only be given to persons who have received sufficient training in
the use of the ACS and understand the potential safety hazards resulting from using the system
contrary to instructions.
When the machine is outside the production area, the machine mode switch must always be in manual
mode and the machine must be disconnected from every remotely controlled sub-system. The mode
switch must be locked in the manual position with a padlock.
Any maintenance or repair work on the system must be performed by trained or instructed personnel
only. Work performed on electric appliances must be done by electricians, and work on hydraulic
appliances by mechanical technicians with specific knowledge and experience.
We recommend that records be kept on repairs and wearing part replacements. Regular maintenance
at correct intervals increases the productivity, reliability, economy, and safety of the equipment.
Spare parts must correspond to the manufacturer’s technical specifications. Conformity is guaranteed
only with genuine parts.
Do not perform any equipment modifications, extensions or rebuilds which may affect safety. Consult
the supplier or the manufacturer. This also includes the addition and adjustment of safety devices
and valves, as well as the welding of frame structures. Modifications shall not be performed without
prior written authorization from Sandvik Mining Automation Systems. Modifications to the system shall
be documented and performed by competent and authorized personnel.
Clean and wash the equipment regularly, and always before and after maintenance and repair work.
Before cleaning the machine with water or by steam jet or other cleaners, protect the alternator,
connection boxes, onboard components and major connections against dirt and moisture. Remove
the protection after cleaning.
All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean of oil, dirt, snow
and ice to prevent accidents.
Never attempt to clean, adjust, repair or lubricate the equipment while it is in operation. Notify
personnel on the location and use of fire extinguishers.
If the machine or a part of it has been stopped for maintenance or repair, make sure that it cannot be
started accidentally.
• Turn the main switch off
• Remove the ignition key
• Put a “DANGER DO NOT START” or a corresponding warning sign on the main switch. Lock the
main switch with a padlock. The sign and padlock must not be removed without authorization from
the maintenance person who is/was working on the machine and who is fully aware of the situation.

After preventive maintenance and repairs, ensure that all safety systems are tested before the unit
is returned to work.

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2.3. Important safety notes

Only authorized and trained personnel are allowed to operate,

maintain, repair, or modify the system and related components.
Improper or unauthorized operation, maintenance, or repairs
may lead to serious injury or death. When operating,
maintaining or repairing the system, always adhere to the
mandatory rules relating to accident prevention and
environmental protection, as well as the safe working
instructions.

Continuous research and development of the system and its related products may lead to changes
that are not covered in this manual. For the latest manual updates, contact Sandvik Mining and
Construction.
• Work on electrical equipment or materials may only be carried out by qualified electricians or other
professionals, or assistants under their supervision and control, observing electrotechnical
regulations.
• The local electrotechnical and electric safety regulations must always be observed.
• Use only original electrical components.
• Electrical power must be disconnected from all equipment parts or devices to be checked, serviced
or repaired, as required by electrical safety regulations. Check that the disconnected parts are de-
energized and then lock the main switch or install temporary earthing as necessary.
• Connections and connectors must be de-energized before plugging or unplugging cables.
• Check electrical equipment regularly. Faults such as loose wires and damaged insulation must be
repaired at once.
• When handling high-voltage components, remember that capacitors may have an electric charge
even when the power is cut off. Short the capacitors with an earthing rod.
• Do not make any changes to electrical equipment. Sandvik Mining and Construction is not
responsible for alterations to electrical equipment. Contact Sandvik Mining and Construction's
electrical engineering department if necessary.

Working on energized components

• If a component must be live, one employee must be ready on-hand at all times to switch the power
off via the emergency stop or main switch. Follow the electrical safety regulations.
• Use a safety chain and warning signs to encircle the working area.
• Use only insulated tools.
• Observe special caution.

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2.4. General Repair Instructions

Define the person responsible for maintenance and repair procedures clearly.
• Do not perform any work that you are not authorized to do.
• Read and ensure you understand corresponding instructions before servicing equipment.
• To avoid potential damage and injuries, carefully plan your work beforehand.
• Secure extensively the area of maintenance works as needed.
• Inform the users of the equipment about any maintenance work.
• If the equipment or a part of it has been stopped for maintenance or repair, make sure that it cannot
be started accidentally:
- turn the main switch off
- remove the ignition key
- place a “DANGER DO NOT START” or corresponding warning sign on the main switch. Lock
the main switch with a padlock. The sign and padlock must not be removed without authorization
from the maintenance person who is/was working on the machine and is fully aware of the
situation.
• If required, ensure that suitable and safe ladders or working platforms are available for repair and
maintenance work.
• Do not use parts of the equipment as steps. If maintenance work must be done high up, or in an
otherwise dangerous place or position, use necessary safety devices to prevent falling.
• All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean of oil, dirt, snow,
and ice to prevent accidents.
• It is absolutely necessary to have suitable specialized workshop equipment for high maintenance
performance.
• Always use the appropriate tools for the task and be sure you understand how to use them before
performing any maintenance work.
• Before commencing maintenance or repair work, ensure that the system is not operational.
• Replace or repair faulty tools and equipment before performing any maintenance work.
• When replacing heavy parts, use correct lifting devices and techniques.
• After preventive maintenance and repairs, always tighten unscrewed fasteners. Reassemble all
dismantled safety appliances immediately after the work is done. Ensure that all safety systems are
tested before the system is returned to operation.
• Ensure safe and environmentally protective disposal of process materials and exchange parts.

2.5. Incident reporting

Product safety issues to be reported are events where a product manufactured by Sandvik Mining
and Construction has been involved in an accident or near-miss incident. Safety-related feedback,
such as unauthorized modifications, missing manuals and safety labels, negligence of maintenance
or misuse shall be reported to your local Sandvik representative as well.
Reporting is mandatory to ensure safe working conditions for employees, to provide information for
the risk assessment process, and to initiate product improvements.
Contact your local Sandvik representative to report safety issues, such as those mentioned above.

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3. VCM SYSTEM AUTOMATION FUNCTIONS

If you can not find the issue you are looking for from this
manual, refer to machine workshop manual’s corresponding
section.

3.1. Graphical user interface (GUI)

Following sections describe the machine user interface of the various parts of the system where
AutoMine and Manual Production Monitoring (MPM) is concerned. The first section introduces the
AutoMine display window in general, while the others introduce the hierarchy and navigation between
the AutoMine display windows. The last section introduces the MPM VCM system.
General use of the display module and the display window symbols are described in the manual
machine’s operating instructions. This manual is designed for a person with basic knowledge of the
display.

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3.1.1. AutoMine main window

2 3

1 Main window
2 AutoMine main window
3 Info window for AutoMine main view
In the system’s main window, press "AutoMine" (button 2) to go to the AutoMine main window.
The AutoMine main window contains following windows:
• Start-up status
• Comms status
• AutoMine gauges
• Operator
• Specialist
• Reset InfraFREE (restarting)

There is no ”AutoMine” button in the main display if the option

NOTE!
is not installed for the machine or if it is not activated.

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3.1.2. Start-up status window

1 2

5 4

1 AutoMine main window 2 Start-up status dispaly

3 Info window for start-up status 4 Start-up details
5 Info window for start-up details
The start-up status display window informs the operator of whether the machine is ready to operate
in automatic mode. The window shows relevant, continuously updating status information, and the
result of the previous start-up test on the last row.
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The start-up status display window shows the following status information:
• InfraFREE power: ON / OFF
• Comms power: ON / OFF
• InfraFREE heartbeat (existence of the message): OK / FAIL
• CS emergency stop: ON / OFF
• InfraFREE emergency stop: ON / OFF
• Parking brake: ON / OFF
• CS status: OK / FAIL
• Start-up test result: OK / FAIL

The status required in automatic drive is in bold (statuses with

NOTE!
the person still at the machine).

If you want to perform a new start-up test, press the ”New test” button.
To view the start-up test details and to find out which item is causing an error, press the ”Details”
button.
In the start-up test, InfraFREE tests the following statuses and sensors (the mode switch status is
provided by the VCM System):
• Mode switch: AUTO / MAN
• Emergency stop: OK / FAIL
• Steering sensor: OK / FAIL
• Boom and bucket / box sensors: OK / FAIL
• Front and rear scanners: OK / FAIL
• Gyro: OK / FAIL
• Accelerometer: OK (future option)
• CS error status: OK (future option)
• Control room (connection to): OK / FAIL (not included in test result)
• Weighting system: OK (future option)

The status required in automatic drive is in bold (statuses with

NOTE!
the person still at the machine).

With the exception of connection to the control room, if the status of any item in the start-up test is
FAIL, the test fails (FAIL). The machine is not ready to be operated in automatic mode. Note that at
the beginning of a new test the status of all items is FAIL, and that during the test the status of the
mode switch should change to Auto and the other statuses should change to OK. The test takes about
30 seconds.

If an error is found during the test, the test will be aborted and
NOTE! the status of several items, not just the one causing the error,
may be FAIL.

The sensors are checked in the following order:

1. Gyro
2. Rear scanner
3. Front scanner
4. Boom/box and steering sensors simultaneously
5. Other sensors simultaneously
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One reason for a FAIL result in the control room connection test could be that the control station is
not ready. In other cases, check that ”Comms” (communication systems) power is on (see the section
"Comms (communication systems) status window").

3.1.3. Comms status window

1 2

1 AutoMine main window

2 Comms status
3 Info window for comms status
The "Comms" (communication systems) status window shows the operator the following information:
• Power: ON / OFF
• Communication system's temperature (option)
• Incoming and outgoing monitoring channel messages (counter value)
• Incoming and outgoing weighing messages (counter value)

If the machine has both the monitoring and the weighing option, all incoming and outgoing message
counter values must change. If options do not exists, only the weighing outgoing message counter
value increases.

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3.1.4. AutoMine gauges window

1 2

3 4

1 AutoMine main window

2 AutoMine gauges
3 Info window for AutoMine gauges
4 Info window for AutoMine gauges
The AutoMine gauges window shows the operator the position of the steering (center articulation),
boom, and bucket as percentages. This window can be used to check the operation of the sensors
in question during service, for instance. The gauges do not require an InfraFREE computer in order
to operate. In the "Info" window, the operator can check the meaning of the symbols. There are also
fields for sensor warning and alarm limits, but the limits are not set (these alarms are not used).
With calibrated gauges, the boom display range is 0-100% and the steering display range is -100%
to +100%. If the sensor reacts to actual movement - even if the scale is incorrect due to, e.g., the
sensor being replaced - this proves that the sensor is working. This is the only purpose of this display
window.

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If the sensor has been, e.g., replaced, it must be calibrated using option parameters in order to ensure
that the scaling works in the aforesaid manner and to avoid "jumps" in the sensor operating range.
For general instructions on changing the option parameters, refer to the basic machine manual. Using
the option parameters, set the limit values for the boom and steering sensor operating range - e.g.,
the boom’s uppermost and lowermost position. In the InfraFREE "Sensor calibration" window, you
can record the necessary "raw values" from the bottom of the calibration window of the sensors
concerned.
It is not necessary to calibrate these gauges in order for the
automatic drive to operate, but if a sensor is replaced or
removed, the InfraFREE sensor calibration must always be
performed. For instructions, refer to the "Sensor calibration"
section of this manual.

Parameter control window can be used for controlling certain

parameters which might be needed to adjust when operating in
autonomous mode (for example sensor calibration values).

For further information about option parameter control see

machine workshop manual section “Controlling additional
functions”.

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3.1.5. System specialist window

Operator window

1 2

4 3 6

5 9 7

1 AutoMine main window 2 Operator password

3 AutoMine operator menu 4 Sensor calibration
5 Power settings 6 InfraFREE status
7 Parameter save 8 Parameter save confirmation
9 Info window for AutoMine operator menu
To access the AutoMine operator window, you need to enter the operator password. In the operator
menu, you can choose from the following windows:
• sensor calibration
• power settings
• InfraFREE status
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• save (parameters)

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System specialist window

1 2

4 3 7

5 8

1 AutoMine main window 2 System specialist password

3 AutoMine system specialist menu 4 Parameter control
5 Restore factory parameters 6 Restore factory parameter confirmation
7 Power settings 8 Info window for AutoMine system
specialist menu

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10 3 12

11 14 13

15

10 InfraFREE parameter backup 11 Sensor calibration

12 Configure CAN sensor 13 InfraFREE status
14 Parameter save 15 Parameter save confirmation
To access the AutoMine system specialist menu, you need to enter the system specialist password.
In the system specialist menu, you can select from among the following function:
• parameter control (InfraFREE)
• restore factory parameters
• parameter backup
• sensor calibration
• power settings
• configure CAN sensor
• InfraFREE status
• save (parameters)

Parameter control window

In the parameter control window, the operator can choose the desired InfraFREE function or feature
and change it's parameter values. The operator can see the minimum and maximum values. If the
operator wishes to change the parameter values permanently, they must be saved from the system
specialist main menu’s "Save (parameters)" window. If not saved, the old parameters will be taken
into use following power-off.

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Restore factory parameters window

From this window, the operator can restore InfraFREE factory settings. This is an extreme measure,
to be used if the parameters, for some reason, are incorrect or if they have disappeared - e.g., in
replacing the computer. You should always try to restore the parameters by means of the parameter
backup window before proceeding with restoring factory parameters. Note that this action restores
the values in the InfraFREE computer’s own memory. Therefore, the values are not ideal for every
machine (e.g., spare machine), and the parameters often need to be adjusted via, e.g., the parameter
control window.
The system prompts the operator to confirm the correctness of the parameter file. After confirmation,
the operator is presented with "Save" window containing an "OK" button, pressing of which will restore
the InfraFREE factory settings. After this, the operator should save the parameters in the system
specialist main menu’s "Save (parameters)" window.

Parameter backup window

In the "Parameter backup" window, the operator can save the parameters from InfraFREE to the
display by loading them via the "Save" command, and transfer the parameters from the display to
InfraFREE via the "Load" command. If the parameters are changed, the "Save" function should be
used regularly. This way, if the InfraFREE computer should break down, the correct parameters saved
via the machine’s display can be restored easily to a spare machine.
Saving the parameters to the display takes only minutes, but to load them back into InfraFREE may
take approximately half an hour. During transfer, the following text appears on the display:
• Uploading / Downloading Param 0 Index 200200 Node 64

The "Index" value goes through the values 200200, 200300, 200400, and 200500, and the "Param"
values range over 0 to 255 for each. The "Node" value is constantly 64 (or in special cases, such as
with MPM, 65).
A notification similar to the following may appear on the display at the end of both the saving and the
loading procedure: "Uploading Param 0 Index 0 Node 0", followed by "ERROR". This is normal,
provided that the transfer procedure has progressed in the above manner.

Sensor calibration window

All items (names of the sensors) in the "Sensor calibration" window will appear in gray if the sensors
have not been initialized or if the initialization process is not complete. After initialization, the names
will appear in dark (enabled). When necessary, InfraFREE performs the initialization automatically
when entering the calibration window (if the internal status of InfraFREE is "Emergency stop" or "Fast
stop", initialization will not work; check the InfraFREE status window). The names are followed by a
date indicating the last successful calibration of the sensor. For more information, refer to the section
"Sensor calibration".
Initialization is possible in idle and standby modes. To ensure that InfraFREE is in a mode allowing
initialization, switch the machine’s power off for a while and then back on again. If there is a problem
with one of the sensors, initialization and sensor calibration cannot be performed successfully. To
determine the cause, go to the "Details" window via the "Start-up status display" window.

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Power settings window

In the "Power settings" window, the control station operator can change the default power setting
value of the communication devices (MineLAN, etc.) and InfraFREE temporarily. The temporary
setting is valid only up to the next power-off or setting change. There are three possible settings: ON,
OFF, and MODE, the last being mode-specific: OFF in manual mode, ON in automatic mode. In the
settings window, the control station operator can see the power-off delay also. The delay is used only
when the machine mode changes from automatic to manual with the MODE setting selected. For
more information, refer to the section "Power save".

Configure CAN sensor window

This window is needed in exceptional cases only, since the manufacturer already has set the spare
sensor settings according to Sandvik’s specifications. With this function, you can adjust certain boom
sensor and steering sensor settings to values required by the system. The settings are communication
speed (250 kbit/s), measurement result transmission interval (20 ms), reading of address from the
sensor connector address pins, and resolution (12-bit). Work with these settings requires a special
cable used to connect the sensor to the VCM System’s "New module" connector - i.e., programming
connector - and cutting off of the sensor voltage. The programming connector is normally located in
the cabin, inside the instrument panel.
During the procedure, the operator receives instructions on the display. The first task is to determine
the communication speed of the sensor. The system sends the sensor a message, then waits for a
reply. If no reply is received, the operator is instructed to cut off the sensor power for a moment, after
which the next speed out of approximately 10 possible speeds will be tried. Once the correct speed
is determined, it is possible to set the other settings and change the speed setting as required (250
kbit/s).
You can familiarize yourself with the function by pressing the "Start" button, even if the sensor is not
connected.
Pressing the "Start" button sends a start command to the sensor. If the sensor settings are correct,
the CAN sensor value (sensor’s raw value) at the bottom of the window is updated; i.e., it starts to
follow the measurement of the sensor. The value of the sensor can be from 0 to 4095 (or 0 to 8191).

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InfraFREE status window

The InfraFREE status window shows the following information:

Header Explanation
Mode Internal mode of the InfraFREE system (possible
values: idle, standby, auto, auto-view, semi-auto,
IniPos, remote, teach, emergency stop,
teach_seg, forced remote). If the display does not
receive an answer to the inquiry, the mode can
be unknown.
Accuracy The accuracy of the InfraFREE positioning. If the
the tunnel is well-defined and the positioning is
"reliable", the value can be close to 100%. If the
shape of the tunnel prevents reliable positioning,
the value starts to decrease towards 0%. In prac-
tice, the value should be approximately 80% or
more during driving.
Start-up test The result of the start-up test (possible values:
OK, FAIL).
Distance difference The horizontal control accuracy of the machine’s
route. Indicates the distance between the loca-
tion given by the positioning and that of the de-
sired location. Values above normal may indicate
e.g. problems in the machine’s hydraulics.
Path The path used when driving - i.e., the numbers of
the route segments. The number of the route
segment in progress is highlighted.
Heading The direction of movement of the machine - i.e.,
the measurement result of the gyro or the value
calculated from it.
X, Y The location coordinates of the machine on the
taught route according to the system’s own coor-
dinates (normally different from the mine coordi-
nates).
Heading difference The difference between the measured direction
of movement (heading) and the direction of
movement required to stay on the route. Used as
a basis in forming the machine’s control com-
mands.
Speed The speed measured by InfraFREE (m/s).
Gear The number of the gear selected by InfraFREE,
-4...0...4 (Negative number refers to a reverse
gear).

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Save (parameters) window

After InfraFREE sensor calibration, parameter changes, and restoring of factory settings, always
remember to save the new parameter values by using the "Save" option in the operator window. This
will open a prompt asking whether the new values should be saved. Pressing the "Yes" button opens
the parameter save window. To save the parameters, press the "OK" button.

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Verification and Updating parameter files

Both InfraFREE and the VCM contain parameter

version files, and these files are automatically
checked every time parameter control is ac-
cessed. When entering the parameter control
window from the display, if the files do not match,
a warning appears to update the file in VCM. If the
files do match, the parameter control window
opens automatically.

After the warning, the parameter file can be downloaded from InfraFREE by answering ”YES” to the
question or you can return to the system specialist menu by answering ”NO”.
If ”YES” is selected, the VCM downloads the parameter files from InfraFREE.
If there is a problem downloading files, one of the following messages will appear:

Possible reasons for downloading to fail are:

• Ethernet connection loast during download
• InfraFREE sofware is not running
• There are no parameter files inside the InfraFREE
• Parameter files are corrupted

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If InfaREE is not responding, a message will in-

form you of this.
• Check that InfraFREE is up and running.
• Check also the CANbus connection.

In some cases, verification of the InfraFREE IP

address may be required. In this case, the follow-
ing windows will appear.

The IP address must be either verified by select-

ing ”YES”, or if it is incorrect selecting ”NO”, which
will open the second IP address window, which
requires you to enter the IP address.

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3.1.6. Reset InfraFREE

2 3

1 AutoMine main window

2 Reset InfraFREE
3 Info window for reset InfraFREE
With this function, the InfraFREE restarting can be triggered via the machine’s display. Restarting is
required, e.g., after parameter changes or if sensor calibration is unsuccessful because of an incorrect
InfraFREE software mode (e.g., always after completion of automatic drive). Alternatively, you can
switch the machine’s power off for a moment from the main switch.
The operator can shut down and restart the InfraFREE via forced power-off by selecting the "Hard
boot" button and keeping the "OK" button pressed for approximately two seconds. This function
switches InfraFREE power off for five seconds. Before using this function, ensure that the machine
is not moving.
With the "Cancel" button, you can return to the AutoMine main window without restarting.

3.2. Engine control

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3.2.1. Starting and shutting down

In the automatic mode, the control station operator controls the engine start and shutdown signals.
When starting and shutting down functions are controlled in the automatic mode, the ignition key in
the cabin must be in the ON position.
A horn signal, lasting the time set in the parameters, will always be sounded before the engine is
started. When the engine is being started, the lights go off, and they come on again when the engine
has started (for more information, refer to the section "Light control").
When the engine speed and oil pressure exceed the values set in the parameters, the system
determines that the engine is running. Correspondingly, when the engine speed or engine oil pressure
is below the set parameter values, the engine is determined to be stopped. The engine control module
(ECM) shuts down the engine when the oil pressure drops. The engine is also shut down if the
machine enters to emergency stop mode.
If starting takes longer than the value set via the parameters, starter motor control is aborted. The
function is designed to protect the starter motor from overheating. When the maximum time has
elapsed, the start and shutdown signals must be switched off briefly before a new starting attempt.
The system is equipped with the engine protection shutdown option (SEO / Engine Bypass) also in
automatic mode. Thisway, the control station operator can send amachine SEO / Engine Bypass
control request to the engine VCM Systemto keep the engine running for the duration determined by
the engine control system, during which time the machine can be moved. Use of this function will be
recorded in the alarm log.
If the machine is equipped with emergency control function (option), the emergency steering pump
is controlled by the system if the engine shuts down in an abnormal manner - i.e., without a shutdown
command from the control station operator.

3.2.2. Lockings

Conditions that prevent engine starting:

• Emergency stop mode is active
• Engine is running
• Engine has stopped in an unusual way
• Engine start-up is attempted via InfraFREE without the ignition key in the cabin set to ON position
• Door is open

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3.2.3. Inputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
Ignition switch Engine mode 24 V / Float Chair XC3.21
InfraFREE Engine start CAN
InfraFREE Engine shut-down CAN
InfraFREE Stop engine over- CAN
ride (SEO / Engine
bypass)
Fire alarm infor- Fire alarm infor- 24 V / Float Dashboard XD2.18
mation mation
Engine control Engine speed, oil Chair CAN
module (ECM) pressure and other
measurements on
display

3.2.4. Outputs

Actuator Name Signal level Module Connector pin

Ignition switch Ignition switch op- 24 V / 0 V Chair XC2.23
erating voltage
Engine control Engine start 24 V / 0 V Middle XM1.16
module (ECM)
Engine control Engine shut-down 24 V / 0 V Dashboard XD2.7
module (ECM)
Engine Stop engine over- 24 V / Float Dashboard XD3.19
ride (SEO / Engine
bypass
Horn Acoustic signal 24 V / Float Chair XC2.18
Emergency steer- Emergency steer- 24 V / 0 V Middle XM1.17
ing pump ing pump control
Display Engine speed, oil
pressure and other
measurements to
control station

3.2.5. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

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3.3. Engine revolution control

The control station operator controls the engine rpm request only in remote control, otherwise the
rpm request is controlled by InfraFREE. The engine rpm request cannot be lower than the idle rpm
request value.
In the event of an overspeed alarm the engine is forced to brake, i.e. the rpm request is limited
regardless of the InfraFREE request.

3.3.1. Lockings

Conditions that prevent throttle control:

• Engine is not running
• Engine control bus is not working properly (SAE J1939)
• Emergency stop mode is active

3.3.2. Inputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
Ignition switch Engine mode 24 V / Float Chair XC3.21
InfraFREE Engine start CAN
InfraFREE Engine shutdown CAN
InfraFREE Stop engine over- CAN
ride (SEO / Engine
bypass)
InfraFREE or con- Throttle control CAN
trol station
Fire alarm infor- Fire alarm infor- 24 V / Float Dashboard XD2.18
mation mation
Engine control Engine speed, oil Chair CAN
module (ECM) pressure and other
measurements on
display
Emergency stop Emergency stop 24 V / 0 V Middle XM3.16
circuit mode
Engine Engine over-rev CAN
information

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3.3.3. Outputs

Actuator Name Signal level Module Connector pin

Ignition switch Ignition switch op- 24 V / 0 V Chair XC2.23
erating voltage
Engine control Engine start 24 V / 0 V Middle XM1.16
module (ECM)
Engine control Engine shut-down 24 V / 0 V Dashboard XD2.7
module (ECM)
Engine Stop engine over- 24 V / Float Dashboard XD3.19
ride (SEO / Engine
bypass
Horn Acoustic signal 24 V / Float Chair XC2.18
Emergency steer- Emergency steer- 24 V / 0 V Middle XM1.17
ing pump ing pump control
Display Engine speed, oil
pressure and other
measurements to
control station

3.3.4. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

3.4. Gear control

The control station operator controls the gears and driving direction from the control station only in
remote control, otherwise the gears are controlled by InfraFREE.
The machine is equipped with an emergency reverse function which enables extra fast direction
change. If the control station operator puts the emergency reverse on, the first reverse gear is
engaged regardless of any other conditions (e.g. gear protection). Emergency reversing can be used,
for example, in cave-in situations where falling rocks must be avoided to prevent burying of the
machine. An alarm of the event is added to the display’s alarm log.

3.4.1. Lockings

Conditions that prevent transmission control:

• Modules are not working properly
• Emergency mode is active
• Parking brake is on
• Engine is not running
• The door is open

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3.4.2. Inputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
Emergency stop Emegency stop 24 V / Float Middle XM3.16
circuit mode
Parking brake Parking brake 24 V / Float Middle XM2.19
mode
Door Door mode 24 V / Float Chair XC3.19
Door Door mode 24 V / Float Chair XC3.20
InfraFREE or con- Gear request 24 V / Float CAN
trol station
InfraFREE Emergency re- 24 V / Float CAN
verse
Inductive sensor Converter rotation 24 V / Float Middle XM3.18
speed sensor
Inductive sensor Cardan rotation 24 V / Float Front XF3.16
speed sensor 1
Inductive sensor Cardan rotation 24 V / Float Front XF3.17
speed sensor 2

3.4.3. Outputs

Actuator Name Signal level Module Connector pin

Valve Forward direction 24 V / 0 V Middle XM2.5
valve
Valve Reverse direction 24 V / 0 V Middle XM2.6
valve
Valve 1st gear valve 24 V / 0 V Middle XM2.17
Valve 2nd gear valve 24 V / 0 V Middle XM2.7
Valve 3rd gear valve 24 V / 0 V Middle XM2.8
Valve 4th gear valve 24 V / 0 V Middle XM2.9

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3.4.4. Sensor calibration window

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Middle 183 Converter pulse input missing signal X
Middle 184 Converter and cardan RPM signals not equal X

Alarms middle 183-184

Description 1: Fault in the converter revolution speed sensor

Action 1: Coupling
• Check the current supply for converter revolution speed sensor.
• Check the cable between the revolution speed sensor and the module’s XM3.18 pin.

Action 2: Sensor
• Measure the operation of the revolution speed sensor.

Description 2: Fault in the converter or the revolution speed sensor

Action 1: Sensor
• Check the operation of the converter revolution speed sensor.
• Check the operation of the cardan revolution speed sensor.

3.5. Brake control

3.5.1. Service brake

In automatic mode the control station operator controls the service brake only in remote control,
otherwise the brake is controlled by InfraFREE. Due to common valves, the service brake follows the
control station operator’s command in automatic mode only if the parking and emergency brake
conditions also allow the release. The brakes are engaged if there is no current in the valves.

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3.5.2. Parking brake

In automatic mode, the parking brake control requests are transmitted from the control station
operator only in remote control, otherwise the brake is controlled by InfraFREE. The brakes are
engaged if there is no current in the valves.
The parking brake is always engaged, if
• InfraFREE requests it
• Machine enters emergency stop mode
• Engine stops
• The level of hydraulic oil or brake hydraulic oil falls below the permitted limit
• Door is opened
• Transmission pressure falls below the alarm limit
• Brake charging pressure falls below the alarm limit

In the last three cases the parking brake is activated with a ramp defined by a parameter value. The
ramp allows stable braking.

3.5.3. Emergency brake

The emergency brake functions with the same valves as the parking brake and the service brake of
the automatic mode. Activating the emergency stop disconnects the control signals between the
module’s outputs and the valves with the help of safety relays.

3.5.4. Brake release in case the machine breaks down (option)

If the machine breaks down, it is possible to produce the pressure needed to release the brakes with
a special brake release pump. In automatic mode, the brake release pump is controlled via the
emergency radio.

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3.5.5. Inputs

Actuator Name Signal level Module Connector pin

Emergency stop Emergency stop 24 V / Float Middle XM3.16
mode
Parking brake Parking brake 24 V / Float Middle XM2.19
mode
Door Door mode 24 V / Float Chair XC3.19
Door Door mode 24 V / Float Chair XC3.20
Brake circuit Brake circuit 1 4-20 mA Middle XM3.5
pressure
Brake circuit Brake circuit 2 4-20 mA Middle XM3.6
pressure
Valve Brake valve feed- Middle XM1.6
back current 1
Valve Brake valve feed- Middle XM1.5
back current 2
Transmission Transmission oil 4-20 mA Middle XM3.7
pressure
Brake circuit 4-20 mA Middle XM3.13
charging pressure
Brake hydraulic oil Float / 24 V Middle XM3.22
alarm
Hydraulic oil alarm Float / 24 V Middle XM3.23

3.5.6. Outputs

Actuator Name Signal level Module Connector pin

InfraFREE Brake light control CAN
Brake release Brake release 24 V / 0 V Middle XM2.22
pump pump control
Valve Brake valve 1 24 V / 0 V Middle XM1.7
Valve Brake valve 2 Rear XR1.2

3.5.7. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

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3.6. Steering control

In automatic mode the control station operator controls the steering only in remote control, otherwise
the steering is controlled by InfraFREE.
If an abnormal situation stops the steering control (see "Lockings"), the control room operator must
release the locking and return the steering to the centre positions before the control can be
reactivated.
Movement end damping (option) is realized at both ends of the control. The centre articulation has
an inductive sensor that, when activated, activates the end deceleration function. When the control
station operator or InfraFREE controls the machine to turn again towards the end limit, after the
manoeuvre has stopped, the turn is controlled without end deceleration.
If the feedback signal of the proportional valves of the steering control is not received or disappears,
the control is disengaged. The control station operator can reactivate the control only after the control
request has reached zero.

3.6.1. Lockings

The system prevents steering control in the following circumstances:

• Parking brake is not released
• Door is open
• Emergency stop is active
• Engine is not running

When an operation condition prevents the centre articulation control, the control is reactivated only
after the control station operator’s or InfraFREE’s control request has reached zero.

3.6.2. Emergency steering (option)

The machine can have an emergency steering function. Pressure is produced for the steering with
an electric pump, e.g. after engine shutdown during driving.
The emergency steering pump is engaged in automatic mode when the engine shuts down in an
unusual way, i.e. due to reason other than a shutdown request from the control station operator or
InfraFREE.
Emergency steering is allowed when the door is shut and the emergency stop is reset.

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3.6.3. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Steering control CAN
command
Emergency stop Emergency stop 24 V / Float Middle XM3.16
mode
Parking brake Parking brake 24 V / Float Middle XM2.19
mode
Door Door mode 24 V / Float Chair XC3.19
Door Door mode 24 V / Float Chair XC3.20
Steering valve Steering propor- 24 V / Float Middle XM1.5
tional valves' feed-
back current
Centre articulation End damping 24 V / Float Front XF3.18
end damping sen-
sor

3.6.4. Outputs

Actuator Name Signal level Module Connector pin

Steering valve Steering left 0-100 % Middle XM1.2
Steering valve Steering right 0-100 % Middle XM1.3

3.6.5. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

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3.7. Boom control

In automatic mode the control station operator controls the boom only in remote control, otherwise
the boom is controlled by InfraFREE.
The movement’s end damping is realized only at the lower end of the boom. At the end of the
movement there is an inductive sensor that, when activated by downward movement, activates the
end deceleration function. When the control station operator or InfraFREE controls the boom to move
again towards the end limit, after the manoeuvre has stopped the movement is controlled without end
deceleration.
In the automatic machine, an angle sensor is used to detect the boom position. The angle sensor
gives the boom’s absolute angle.
If the feedback signal of the proportional valves of the boom is not received or it disappears, the
control is disengaged. The control station operator can reactivate the control only after the control
request has been to zero.

Ride control (option)

The ride control is not used in automatic mode because the boom or bucket may hinder the scanner
view.

3.7.1. Lockings

The system prevents boom control in the following circumstances:

• Parking brake is not released
• Door is open
• Emergency stop is active
• Engine is not running

When an operation condition prevents the boom control, the control is reactivated only after the control
station operator’s or InfraFREE’s control request has been to zero.

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3.7.2. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Boom control CAN
InfraFREE Ride control CAN
Boom / bucket Boom proportional 0 - 1 A Front XF1.5
valve valves' feedback
current
Boom lower limit Limit sensor for 24 V / Float Front XF1.19
sensor ride control and
lower end damp-
ening
Emergency stop Emergency stop 24 V / Float Middle XM3.16
mode
Parking brake Parking brake 24 V / Float Middle XM2.19
mode
Door Door mode 24 V / Float Chair XC3.19
Door Door mode 24 V / Float Chair XC3.20

3.7.3. Outputs

Actuator Name Signal level Module Connector pin

Boom / bucket Boom control UP 0-100 % Front XF1.3
valve
Boom / bucket Boom control 0-100 % Front XF1.4
valve DOWN

3.7.4. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

3.8. Bucket control (loader only)

In automatic mode the control station operator controls the bucket only in remote control, otherwise
the bucket is controlled by the InfraFREE.
The operating principle of the bucket is the same as for the boom. The bucket cylinder of the automatic
machine has an analogue sensor that shows the bucket position.
If the feedback signal of the proportional valves of the bucket is not received or disappears, the control
is disengaged. The control is reactivated only after the control request has been to zero.

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3.8.1. Lockings

Conditions that prevent bucket control:

• Parking brake is not released
• Door is open
• Emergency stop mode is active
• Engine is not running

If an operation condition prevents the bucket control, the control is reactivated only after the control
station operator’s or InfraFREE’s control request has been to zero.

3.8.2. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Bucket control CAN
Boom / bucket Bucket proportion- 0 - 1 A Front XF1.6
valve al valves' feed-
back current
Boom / bucket Bucket end damp- 24 V / Float Front XF1.20
valve ening limit sensor
Emergency stop Emergency stop 24 V / Float Middle XM3.16
mode
Parking brake Parking brake 24 V / Float Middle XM2.19
mode
Door Door mode 24 V / Float Chair XC3.19
Door Door mode 24 V / Float Chair XC3.20

3.8.3. Outputs

Actuator Name Signal level Module Connector pin

Boom / bucket Bucket control UP 0-100 % Front XF1.7
valve
Boom / bucket Bucket control 0-100 % Front XF1.8
valve DOWN

3.8.4. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

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3.9. Weighing control (option)

The bucket is weighed with each bucketful, and the control station operator can view the weighing
result in the user interface.

Weighing system

The control station operator can reset the weighing system, after which the weighing needs to be
zero weighed. The control station operator receives zeroing instructions requiring lifting and lowering
of the boom.

Pause mode

In the pause mode, weighing stops. To return from pause mode, the weighing appliance needs to be
reset (see above).

3.9.1. Inputs

Actuator Name Signal level Module Connector pin

Display Weighing result RS-232
from the weighing
appliance
Display Boom lift request RS-232
from the weighing
appliance
Display Boom lower re- RS-232
quest from the
weighing appli-
ance
Display Weighing appli- RS-232
ance reseting from
the control station

3.9.2. Outputs

Actuator Name Signal level Module Connector pin

Control station Boom lift request RS-232
from the display
Control station Boom lower re- RS-232
quest from the dis-
play
Weighing appli- Weighing appli- RS-232
ance ance resetting
from the display
Control station Weighing result RS-232
from the display

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3.10. Light control

The following lights are controlled in automatic mode: mode lights, driving lights, working lights, driving
direction lights and brake lights. In addition, the reversing alarm light and signal are controlled.

3.10.1. Mode lights

The red and orange mode lights and orange beacon light are used in automatic mode. The green
indicator light indicates manual mode.
Red mode light:
• Machine in automatic mode
• Main current is switched on
• Emergency stop is reset

Orange mode light:

• Machine is in emergency stop mode
• When light flashes, the delayed reset of the emergency stop circuit is unfinished

Orange beacon light:

• Flashes for a set time, as defined by the parameter, before the emergency stop circuit is reset. The
purpose is to provide warning when the machine enters a mode in which automatic start is possible.
• Does not flash in automatic drive as Sandvik default setting.

Mine can have exceptional rules for beacon. Function can be

NOTE!
freely selected for each machine mode with option parameter.

3.10.2. Driving lights

Low and high beam lights are controlled at both the front and rear. The driving direction does not
influence the control of high beam lights in automatic mode; the lights are switched according to the
InfraFREE request. The driving lights always switch off during engine start and when the machine
enters powersave mode.

3.10.3. Working lights

When the low beam front lights are on, the front working lights are switched on. The rear working
lights are switched on when the high beam rear lights are on. The working lights are always switched
off during engine start-up and when the machine enters powersave mode.When the machine mode
changes to automatic mode, the working lights flash to indicate the success of start test and start up
status.

3.10.4. Parking lights

The driving direction is indicated with the parking lights by switching them on only at one end of the
machine at a time. The rear parking lights are lit when the machine is driven forward (in bucket
direction). The front parking lights are lit when the machine is driven backwards.
Both the front and rear parking lights are lit when the gear is in neutral, the parking brake is engaged,
or the ignition switch is in the parking position.

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3.10.5. Brake lights

The rear brake lights are switched on when driving forward and braking. Accordingly, the front brake
lights are switched on when driving backwards and when braking. The brake lights are also switched
on when the parking brake is engaged. The brake lights are not controlled when the engine is stopped.
The brake lights are always switched off during engine start-up and when the machine enters
powersave mode.

3.10.6. Reverse light and buzzer

The reversing alarm light and signal are switched on when the reverse gear is engaged.

3.10.7. Driving direction lights (option)

The driving direction lights function in automatic mode when the machine is running as follows:
• When the gear is in the forward position, a red driving direction light switches on at the front of the
machine and a green driving direction light switches on at the rear of the machine.
• When the gear is in the reverse position, a red driving direction light switches on at the rear of the
machine and a green driving direction light switches on at the front of the machine.
• If the gear is in neutral, neither of the driving direction lights is on.

3.10.8. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Mode light CAN
InfraFREE Beacon light con- CAN
trol
InfraFREE Front low beam CAN
light control
InfraFREE Front high beam CAN
light control
InfraFREE Rear low beam CAN
light control
InfraFREE Rear high beam CAN
light control
InfraFREE Working light con- CAN
trol
InfraFREE Driving direction CAN
light control
InfraFREE Brake light CAN

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3.10.9. Outputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
Mode light Mode light red 24 V / 0 V Dashboard XD2.5
Mode light Mode light green 24 V / 0 V Dashboard XD2.1
Mode light Mode light orange 24 V / 0 V Dashboard XD2.2
Beacon Beacon light 24 V / 0 V Dashboard XD1.23
Relay Front high/low 24 V / 0 V Front XR2.6
beam lights
Relay Rear low beam 24 V / 0 V Rear XR2.5
lights
Relay Rear high beam 24 V / 0 V Middle XM1.14
lights
Relay Rear working 24 V / 0 V Dashboard XD1.15
lights
Relay Front working 24 V / 0 V Front XF2.5
lights
Relay Front cabin corner 24 V / 0 V Dashboard XD1.7
lights
Relay Rear cabin corner 24 V / 0 V Dashboard XD1.8
lights
LED-light Rear parking light 24 V / 0 V Front XF2.8
(E209, E201)
LED-light Rear parking light GND Front XF2.14
ground
LED-light Front parking light 24 V / 0 V Middle XM1.8
LED-light Front parking light GND Middle XM1.11
ground
Driving direction Driving direction 24 V / 0 V Front XF2.8
light light backward
Driving direction Driving direction 24 V / 0 V Middle XM1.8
light light forward
Driving direction Customer option 24 V / 0 V Front XF1.22
light (driving direction
light forward, red)
Driving direction Customer option 24 V / 0 V Front XF1.23
light (driving direction
light forward,
green)
Driving direction Customer option 24 V / 0 V Rear XR2.2
light (driving direction
light reverse, red)

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Actuator Name Signal level Module Connector pin

Driving direction Customer option 24 V / 0 V Rear XR2.6
light (driving direction
light reverse,
green)
LED-light Brake light forward 24 V / 0 V Front XF2.10
LED-light Brake light forward 24 V / 0 V Front XF2.9
LED-light Brake light back- 24 V / 0 V Middle XM1.23
ward
LED-light Brake light back- 24 V / 0 V Middle XM1.22
ward

3.10.10. Parameters

Parameter name Explanation Unit Default Max. val- Min. value

value ue
BeaconTimeWhenChan- Time beacon is lit during s 5
geToAuto mode change.
WorkingLightMode- Number of working light Count of 4
ChangeBlinkAmount blinks when the mode is blinks
changed.
WorkingLightMode- Time between working s 2
ChangeBlinkInterval light blinks

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3.10.11. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Dashboard 50 Orange mode light signal short to ground X
Dashboard 51 Orange mode light signal short to external voltage X
Dashboard 52 Red mode light signal short to ground X
Dashboard 53 Red mode light signal short to external voltage X
Dashboard 64 More than one mode light controlled together X
Front 48 Customer options control 2 signal short to ground X
(green driving direction light forward)
Front 49 Customer options control 2 signal short to ext. voltage X
(green driving direction light forward)
Front 72 Customer options control 1 signal short to ground (red X
driving direction light forward)
Front 73 Customer options control 1 signal short to ext. voltage X
(red driving direction light forward)
Rear 48 Switch output 2 short to ground, customer option (green X
driving direction light backwards)
Rear 49 Switch output 2 short to ext. voltage, customer option X
(green driving direction light backwards)

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Alarms dashboard 50-53

Description 1: Output short-circuit in the lights connected to the dashboard module.

Action 1: Connection
• Detach the connector pin that caused the alarm from the dashboard module:

Alarm number Connector pin Function

50 XD2.2 Orange mode light
52 XD2.1 Red mode light

• After removing the connector, switch off the output from the digital outputs’ forcing window in the
digital outputs’ module and then switch it back on. Check whether the alarm stops (see "Forcing
the module digital outputs" under "Forced functions").
• If the alarm stops, the fault is in the wire harness. The problem causes a short to ground.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the dashboard module is broken. Change the
module.

Description 2: Voltage in the uncontrolled output for lights connected to the dashboard module
Action 1: Connection
• Detach the connector pin that caused the alarm from the dashboard module:

Alarm number Connector pin Function

51 XD2.2 Orange mode light
53 XD2.1 Red mode light

• Check whether the alarm stops when switching off the output in question from the forcing window
of the module digital outputs (see "Forcing the module digital outputs" under "Forced functions").
• If the alarm stops, the problem lies with the wire harness. The problem causes a short to the
operating voltage.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the dashboard module is broken. Change the
module.

Alarms dashboard 64

Description 1: More than one mode light controlled together.

Action 1: System error
• Contact the Sandvik Mining and Construction service. This alarm should appear only when function
is forced.

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Alarms front 48-49 and 72-73

Description 1: Output short-circuit of lights connected to the front module.

Action 1: Connection
• Remove the connector pin that caused the alarm from the front module:

Alarm number Connector pin Function

48 XF1.23 Customer option (green driving
direction light forward)
72 XF1.22 Customer option (red driving di-
rection light forward)

• After removing the connector, switch off the output via the digital outputs forcing window in the digital
outputs module and then switch it back on. Check whether the alarm stops.
• If the alarm stops, the fault is in wire harness. The problem causes a short to ground.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the front module is broken. Change the module.

Description 2: Voltage in the uncontrolled output for lights connected to the front module.
Action 1: Connection
• Remove the connector pin that caused the alarm from the front module:

Alarm number Connector pin Function

49 XF1.23 Customer option (green driving
direction light forward)
73 XF1.22 Customer option (red driving di-
rection light forward)

• Check whether the alarm stops when you switch off the output in question from the forcing window
of the module digital outputs (see "Forcing the module digital outputs" under "Forced functions").
• If the alarm stops, the fault is in wire harness. The problem causes a short to the operating voltage.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the front module is broken. Change the module.

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Alarms rear 48-49

Description 1: Short circuit in the output of the lights connected to rear module.
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

48 XR2.6 Customer option (green direc-
tion light backwards)

• After removing the connector, switch off the output from the digital outputs forcing window in the
digital outputsmodule and then switch it back on. Check whether the alarm stops (see "Forcing the
module digital outputs" under "Forced functions" in the manual machine’s operating instructions).
• If the alarm stops, the fault is in wire harness, short circuit to ground.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the rear module is broken. Change the module.

Description 2: Voltage in the uncontrolled output of the lights connected to rear module.
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

49 XR2.6 Customer option (green direc-
tion light backwards)

• Check whether the alarm stops when you force the output in question on the I/O Forcing window
(see section "Forced functions", section "Forcing the digital outputs of the modules").
• If the alarm stops, the fault is in wire harness, short circuit to operating voltage.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the rear module is broken. Change the module.

3.11. Machine mode selection

The operator can select manual or automatic mode via the mode selector switch on the rear frame.
InfraFREE checks the machine mode by reading the position of the mode selector switch when the
main current is switched on. The machine does not remember the last mode used before turning off
the power. The mode cannot be changed while the machine is moving (speed over 0.5 km/h).
When the system mode changes to automatic mode, the engine is stopped and a start-up test request
is sent to InfraFREE.

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3.11.1. Mode lights

Green:
• Machine in manual mode, emergency stop reset

Orange:
• Machine is in emergency stop mode
• When the light flashes, the delayed reset of the emergency stop circuit is unfinished in the automatic
mode

Red:
• Machine is in automatic mode
• Main current is switched on
• Emergency stop is reset

Orange beacon light:

• Flashes for the set time defined by the parameter value before the emergency stop circuit is reset.
The purpose is to give warning of when the machine enters a mode in which automatic start is
possible.
• Does not flash in automatic drive as Sandvik default setting.

Mine can have exceptional rules for beacon. Function can be

NOTE!
freely selected for each machine mode with option parameter.

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3.11.2. Start-up test

When the machine mode changes from manual to automatic, a start-up test is performed for the
sensors etc. This test can also be initiated by the operator from the machine’s display. The machine
VCM Systemdisplay shows the latest test result sent to the control station operator by InfraFREE
after completing the test.
The results of the start-up test must comply with the table below in order to be approved. Information
X means that the mode does not matter.

Bit Meaning / tested item

1=X General result
2=1 Mode switch
3=X Emergency stop active
4=1 Steering sensor
5=1 Boom / Box sensor
6=1 Bucket / Tail gate sensor
7=1 Front laser
8=1 Rear laser
9=1 Gyro
10 = 1 Accelerometers
11 = 1 CS error status
12 = X Control station
13 = X Weighing system

The result is considered approved if:

• Start-up test result is as in the above table (the ones marked with X don’t matter)
• Cabin door is closed
• Comms power is on

3.11.3. Force to safe mode (option)

The control station operator can force the machine from the AutoMine control station to a safe mode
for approaching, even though the machine is in automatic mode. The control station operator can
send a forcing command from the control station to cause the machine to enter powersave mode.
The forcing is only possible after the engine has been stopped. See section "power save mode".
In powersave mode, it is safe to approach the machine because InfraFREE is not activated. In this
status, the safety message is absent and the machine is in emergency stop mode. The orange mode
light visible from outside the machine indicates that the safe mode is on.

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3.11.4. Inputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
InfraFREE Start-up test mode CAN
InfraFREE Start-up test result CAN
InfraFREE Forcing the ma- CAN
chine to the pow-
ersave mode
InfraFREE Beacon light con- CAN
trol
Parking brake con- Parking brake 24 V / 0 V Middle XM1.7
trol mode

3.11.5. Outputs

Actuator Name Signal level Module Connector pin

InfraFREE Start-up test CAN
Lights etc. Forcing the ma- 24 V / 0 V Rear XR1.17
chine to the pow-
ersave mode
Mode light Mode light, red 24 V / 0 V Dashboard XD2.5
Mode light Mode light, green 24 V / 0 V Dashboard XD2.1
Mode light Mode light, orange 24 V / 0 V Dashboard XD2.2
Beacon Beacon light con- 24 V / 0 V Dashboard XD1.23
trol

3.11.6. Parameters

Parameter name Explanation Unit Default Max. val- Min. value

value ue
TestResultWaitTime Waiting time for start-up s 20
test result.
BeaconTimeWhenChan- Time beacon is lit during s 5
geToAuto mode change.

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3.11.7. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Dashboard 48 Green mode light signal short to ground X
Dashboard 49 Green mode light signal short to external voltage X
Dashboard 50 Orange mode light signal short to ground X
Dashboard 51 Orange mode light signal short to external voltage X
Dashboard 52 Red mode light signal short to ground X
Dashboard 53 Red mode light signal short to external voltage X
Dashboard 64 More than one mode light controlled together X

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Alarms dashboard 48-53

Description 1: Output short-circuit in the lights connected to the dashboard module.

Action 1: Connection
• Detach the connector pin that caused the alarm from the dashboard module:

Alarm number Connector pin Function

48 XD2.5 Green mode light
50 XD2.2 Orange mode light
52 XD2.1 Red mode light

• After removing the connector, switch off the output from the digital outputs’ forcing window in the
digital outputs’ module and then switch it back on. Check whether the alarm stops (see "Forcing
the module digital outputs" under "Forced functions").
• If the alarm stops, the fault is in the wire harness. The problem causes a short to ground.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the dashboard module is broken. Change the
module.

Description 2: Voltage in the uncontrolled output for lights connected to the dashboard module
Action 1: Connection
• Detach the connector pin that caused the alarm from the dashboard module:

Alarm number Connector pin Function

49 XD2.5 Green mode light
51 XD2.2 Orange mode light
53 XD2.1 Red mode light

• Check whether the alarm stops when switching off the output in question from the forcing window
of the module digital outputs (see "Forcing the module digital outputs" under "Forced functions").
• If the alarm stops, the problem lies with the wire harness. The problem causes a short to the
operating voltage.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the dashboard module is broken. Change the
module.

Alarms dashboard 64

Description 1: More than one mode light controlled together.

Action 1: System error
• Contact the Sandvik Mining and Construction service. This alarm should appear only when function
is forced.

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3.12. Camera control

The machine has a maximum of four cameras: three in front and one at the rear. The front cameras
are usually located in the cabin in front of the machine centre articulation and on the right side of the
machine.
The control station operator chooses the camera from the control station, after which InfraFREE
transmits the chosen camera’s data to the machine VCM System. If InfraFREE does not designate
a mode for the cameras in automatic mode, the machine VCM System shows the central front camera
image as default.

3.12.1. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Camera 1 control CAN
InfraFREE Camera 2 control CAN
InfraFREE Camera 3 control CAN
InfraFREE Camera 4 control CAN

3.12.2. Outputs

Actuator Name Signal level Module Connector pin

Camera control Camera 1 control, 24 V / 0 V Rear XR2.9
front center
Camera control Camera 2 control, 24 V / 0 V Rear XR2.10
front right
Camera control Camera 3 control, 24 V / 0 V Rear XR2.16
front left
Camera control Camera 4 control, 24 V / 0 V Rear XR2.17
rear

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3.12.3. Diagnostics

Camera test (service password needed)

NOTICE
It is very important, that the service password is not given to
any unauthorized persons. Any unauthorized use of the service
menus may result in serious malfunctions. The service
password may only be given to a service person sufficiently
trained by Sandvik Mining and Construction.

In the camera test window the operator can force the chosen camera (1-4) on by setting the field
value to "ON". The camera test overrides other camera control commands when the "SEND" button
is pressed and switches the chosen camera on.
The camera test does the same operation as the forcing of the camera digital output (see "Forcing
functions").

The measurement data of the modules (requires service password)

The measurement data windows show the values and statuses of the connector pins. The windows
are used as help in trouble shooting. Select the connector of the module you want on the
measurements menu window and press the "Ok" button. The measurement data window of the
connector opens.

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Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Rear 64 Camera control 1 signal short to ground X
Rear 66 Camera control 1 signal short to external voltage X
Rear 71 Camera control 2 short cut X
Rear 72 Camera control 2 voltage in pin X
Rear 87 Camera control 3 signal short to ground X
Rear 88 Camera control 3 signal short to external voltage X
Rear 107 Camera control 4 signal short to ground X
Rear 108 Camera control 4 signal short to external voltage X

Alarms rear 64, 66, 71-72, 87-88 and 107-108

Description 1: Short circuit in the output of the cameras connected to rear module.
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

64 XR2.9 Camera 1 control
71 XR2.10 Camera 2 control
87 XR2.16 Camera 3 control
107 XR2.17 Camera 4 control

• After removing the connector, switch off the output from the digital outputs’ forcing window in the
digital outputs’ module and then switch it back on. Check whether the alarm stops (see "Forcing
the module digital outputs" under "Forcing functions").
• If the alarm stops, the function needs to be controlled again. If the alarm does not reappear, the
problem lies with the wire harness. The problem causes a short to ground.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the rear module is broken. Change the module.

Description 2: Voltage in the uncontrolled output for cameras connected to the rear module
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

66 XR2.9 Camera 1 control
72 XR2.10 Camera 2 control

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Alarm number Connector pin Function

88 XR2.16 Camera 3 control
108 XR2.17 Camera 4 control

• Check whether the alarm stops when switching off the output in question from the forcing window
of the module digital outputs (see "Forcing the module digital outputs" under "Forced functions").
• If the alarm stops, the function needs to be controlled again. If the alarm does not reappear, the
problem lies with the wire harness. The problem causes a short to the operating voltage.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the rear module is broken. Change the module.

3.13. Powersave mode

The control station operator can transmit the command to enter powersave mode from the AutoMine
control station.
The purpose of the powersave mode is to reduce the drain on the batteries during a known or
estimated period of interrupted use. The duration of the machine’s "sleep time" is entered in
conjunction with the enter powersave command.
The powersave function has two levels.
Level 1:
• Machine VCM System shuts off the machine’s driving lights, working lights and loading lights
regardless of InfraFREE control
• Machine VCM System switches off comms power

NOTE! Both parking lights and mode lights are left on.

Level 2: (Includes level 1)

• InfraFREE and sensors are switched off

The closed systems are restarted after the sleep time. The driving and working lights are lit according
to the control station operator’s or InfraFREE command.

3.13.1. Communication power control

The communication power control mode setting can be one of the following:
• ON mode. The communication system is on.
• OFF mode. The communication system is off.
• MODE mode. Whether the communication system is on or off depends on the machine mode. The
communication system is ON in automatic mode and OFF in manual mode.

After switching on the power, the communication power control mode setting is at the factory setting.
Changing the default value requires a factory password. The standard factory setting is MODE.
The operator can change the communication power control mode setting from the default value via
the machine’s display. Changing the setting requires an AutoMine / AutoMine-Lite system specialist
or an AutoMine / AutoMine-Lite operator password. The setting made by the operator is valid for as
long as the power is switched off from the machine’s main switch.
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3.13.2. InfraFREE communication power control

The communication power control mode setting can be one of the following:
• ON mode. InfraFREE is on.
• OFF mode. InfraFREE is off.
• MODE mode. Whether InfraFREE is on or off depends on the machine mode. InfraFREE is ON in
automatic mode and OFF in manual mode.

After switching on the power, the current control mode setting is at the factory setting. Changing the
default value requires a factory password. The standard factory setting is MODE.
The operator can change the communication power control mode setting to differ from the default
value via the machine’s display. Changing the setting requires an AutoMine / AutoMine-Lite system
specialist or an AutoMine operator password. The setting made by the operator is valid for as long
as the power is switched off from the machine’s main switch.
When transferring from automatic mode to manual mode, if the communication power control mode
is set as MODE, the InfraFREE system is not switched off immediately but after a delay set by a
parameter value. The purpose of the delay is to prevent power switch-off if the machine is set to
manual mode for a short period of time.

3.13.3. Emergency functions

The control station operator can switch quickly to normal mode from powersave mode by turning off
the main current (the switch on the rear frame) and turning it back on.
The systems are started as at the end of the powersave mode if:
• The operating voltage of the batteries drops below the battery voltage alarm limit
• The fire alarm system detects a fire

In both of the above-mentioned cases, an alarm message is sent via the monitoring channel when
the system starts.

3.13.4. Inputs

Actuator Name Signal level Module Connector pin

Control station Entering power- CAN
save mode
Control station Sleep time in sec- CAN
onds
Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
Module Batteries operat- Chair Internal module
ing voltage measurement
Check fire Fire detected 24 V / 0 V Dashboard XD2.18

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3.13.5. Outputs

Actuator Name Signal level Module Connector pin

Relay Current supply 0 V / 24 V Rear XR1.14
control (comms)
Relay Current supply 0 V / 24 V Rear XR1.15
control (InfraFREE
etc.)

3.13.6. Parameters

Parameter name Explanation Unit Default Max. val- Min. value

value ue
InfraFREEControlState 2 2 0
InfraFREEDelayWhen- s 300 65535 0
ManualMode
CommsControlState 2 2 0
CommsDelayWhenMa- s 300 65535 0
nualMode

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3.13.7. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Rear 79 Power enable 2 (InfraFREE etc.) short to ground X
Rear 80 Power enable 2 (InfraFREE etc.) voltage in pin X
Rear 85 Power enable 1 (Comms) short to ground X
Rear 86 Power enable 1 (Comms) short to external voltage X
Rear (power ena- 77 Power enable 2 (InfraFREE etc.) short to ground X
ble 2)
Rear (power ena- 78 Power enable 2 (InfraFREE etc.) voltage in pin X
ble 2)
Rear (power ena- 81 Power enable 1 (Comms) short to ground X
ble 1)
Rear (power ena- 82 Power enable 1 (Comms) short to external voltage X
ble 1)
Rear (power ena- 131 Power enable 1 (Comms) switched off X
ble 1)
Rear (power ena- 78 Power enable 1 (Comms) switching off after delay X
ble 1)
Rear (power ena- 81 Power enable 2 (InfraFREE etc.) switched off X
ble 2)
Rear (power ena- 82 Power enable 2 (InfraFREE etc. switching off after de- X
ble 2) lay

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Alarms rear 79-80 and 85-86

Description 1: Short in the output for current supply connected to rear module.
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

79 XR1.15 InfraFREE current supply
85 XR1.14 Comms current supply

• After removing the connector, switch off the output from the digital outputs’ forcing window in the
digital outputs’ module and then switch it back on. Check whether the alarm stops (see "Forcing
the module digital outputs" under "Forced functions").
• If the alarm stops, the fault is in the wire harness. The problem causes a short to ground.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the rear module is broken. Change the module.

Description 2: Voltage in the uncontrolled output for current supply controls connected to the rear
module
Action 1: Connection
• Detach the connector pin that caused the alarm from the rear module:

Alarm number Connector pin Function

80 XR1.15 InfraFREE current supply
86 XR1.14 Comms current supply

• Check whether the alarm stops when you force the output in question on in the I/O Forcing window
(see section "Forced functions", section "Forcing the digital outputs of the modules").
• If the alarm stops, the fault is in wire harness, short circuit to operating voltage.
• Repair the wire harness.

Action 2: Module
• If the problem cannot be corrected with action 1, the rear module is broken. Change the module.

Alarms rear (power enable 2) 77-78 and rear (power enable 1) 81-82

Description 1: Alarm for high InfraFREE supply current.

Description 2: Warning for high InfraFREE supply current.
Description 3: The signal level of the InfraFREE supply current is high.
Description 4: The signal level of the InfraFREE supply current is low.
Action 1: No action
• No actions required. The operator is informed of the alarm.

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Alarms rear (power enable 1) 131, 78 and rear (power enable 2) 81-82

Description 1: Power enable 1 (Comms) switched off.

Description 2: Power enable 1 (Comms) switching off after delay.
Description 3: Power enable 2 (InfraFREE etc.) switched off.
Description 4: Power enable 2 (InfraFREE etc.) switching off after delay.
Action 1: No action
• No actions required. The operator is informed of the alarm.

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3.14. Fire suppression system

A fire detection wire runs around the inflammable points of the machine and is connected to the
CheckFire accessory that automates the fire suppression system. When a fire is detected, the device
gives an alarm signal and, within a set delay time, triggers an electric sprinkler device that sprinkles
extinguishing medium around the machine. The machine VCM System records the alarm in a log
before triggering and transmits the information to the monitoring channel.
In automatic mode, the control station operator can activate the fire suppression system from the
control panel if a fire is detected before the automatic fire extinguisher is activated. When fire
suppression system is triggered, InfraFREE simultaneously sends the machine a fire extinguisher
trigger request and a check-up message. The alarm is saved in the log before triggering, as triggering
normally cuts off the power from the machine.

Testing the fire suppression system

You must disconnect the cable going to fire suppression before

you press the test button. If the cable is still connected when
the test buttons are pressed, the fire suppression system will
actuate. Both buttons must be pressed simultaneously.

Use the forced functions window to test the fire suppression system. Disconnect the cable going to
cartridges. The cable must be disconnected before testing. If the cable is still connected when the
test buttons are pressed, the fire suppression system will actuate.
Test the fire extinguisher by pressing both "TEST" buttons simultaneously and measure voltage (+24
V) from the connector. With this procedure the fire suppression system can be tested till cartridges.
When testing the fire suppression system, it will be recorded in the alarm log.
The digital outputs of the fire suppression system:

Function Module Connector pin

Activating fire suppression Dashboard XD1.14
(K153)

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3.14.1. Inputs

Actuator Name Signal level Module Connector pin

InfraFREE Fire extinguishing CAN
launch request
InfraFREE Check-up mes- CAN
sage
CheckFire Fire alarm detec- 24 V / 0 V Dashboard XD2.18
ted

3.14.2. Outputs

Actuator Name Signal level Module Connector pin

Display Fire alarm infor-
mation to the con-
trol station
CheckFire Activating fire sup- 24 V / 0 V Dashboard XD1.14
pression

3.14.3. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Dashboard 61 Fire suppression system activated from display X
Dashboard 62 Fire suppression system activated from InfraFREE X

Alarms dashboard 61-62

Description 1: Fire extinguisher released from InfraFREE

Action 1: Fire extinguishing system
• No action needed.

Description 2: Fire extinguisher released from the display module

Action 1: Fire extinguishing system
• No action needed.

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3.15. Emergency stop circuit and safety message

In the automatic mode, the emergency stop circuit supply XC 2.2 becomes active when:
• Machine VCM System has started
• All modules are operational (i.e. communicating on the bus)
• InfraFREE heartbeat message is OK
• Safety message information is OK
• InfraFREE’s emergency brake release is active. This signal controls both circuit supply and relay
K3024 (this must be requested by control station system or by temporary test means by system
specialist).

If one of the above-mentioned conditions prevents the emergency stop circuit supply, the supply is
switched off for at least the time specified by the parameter (500 ms). The purpose of this is to ensure
that the machine stops.
The heartbeat message informing of the InfraFREE module operation changes every 100 ms. If the
InfraFREE heartbeat disappears, the emergency stop circuit supply is cut off.
The safety message is sent from the control station to the machine where both the InfraFREE and
machine VCM System check the message. If the safety message is not approved, the emergency
stop circuit supply is cut off. The safety message is approved if the message value changes
sufficiently often but not excessively at any one time. The required change interval of the message
and the allowed maximum change are factory parameters.
The emergency brake release command is sent from the control station to the machine. InfraFREE
forwards the command to the machine VCM System if InfraFREE is operational.
The emergency stop circuit is equipped with ACS safety unit. ACS is an independent unit from other
systems and it's purpose is to stop the machine if the set safety requirements are not met. ACS safety
unit does not affect to circuit supply. The function is same as in emergency stop buttons (emergency
circuit is cut off).
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To release the emergency stop in the automatic mode following additional functions must be met:
• InfraFREE’s emergency brake release is active
• ACS safety unit is OK

3.15.1. Inputs

Actuator Name Signal level Module Connector pin

Auto / Manual Function mode Float / 24 V Rear XR1.19
switch (auto/manual)
Auto / Manual Function mode Float / 24 V Rear XR1.20
switch (auto/manual)
InfraFREE InfraFREE heart- Chair CAN
beat
InfraFREE Safety message Chair CAN
InfraFREE Emergency brake Chair CAN
release
Emergency stop Emergency stop 24 V / 0 V Middle XM3.16
circuit state

3.15.2. Outputs

Actuator Name Signal level Module Connector pin

Emergency stop Emergency stop 24 V / 0 V Chair XC2.2
circuit enable
Emergency stop Emergency brake 5 V / 0 V InfraFREE X359 (emergency
circuit release stop)
Beacon Beacon control 24 V / 0 V Dashboard XD1.23

3.15.3. Parameters

Parameter name Explanation Unit Default Max. val- Min. value

value ue
EStopReleaseSupplyMi- Minimum time for which ms 500
nOffTime the emergency stop cir-
cuit supply is off.

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3.15.4. Diagnostics

To see all VCM System alarms and troubleshooting, refer to

machine workshop manual's corresponding section.

Additional AutoMine related alarms and troubleshooting

Module No Alarm text Alarm log

Chair 27 E-stop activated. InfraFREE safety object not OK. X
Chair 28 E-stop activated X
Chair 29 Automode, e-stop will be released X

Alarms chair 27

Description 1: E-stop activated. InfraFREE safety object not OK.

Action 1: Communication between control station and InfraFREE (Ethernets and MineLAN)
• Communication problem, too long delays between consecutive safety messages sent by VCM
System.
• Fault find according to communication system trouble shooting instructions.
• Check onboard ethernet connection InfraFREE - Ethernet switch - MineLAN for example using
"ping"-tool.

Action 2: Communication between InfraFREE and machine VCM System (CANbus connection of
InfraFREE)
• Check if InfraFREE heartbeat signal changes to OK on the machine display latest 1 minute from
power on. See section "Start-up status window".
• If heart beat fails, check that InfraFREE program is running.
• Check the InfraFREE CANbus connectors and CANbus wiring between InfraFREE and machine
VCM System.

Action 3: Machine serial number

• Check that machine serial number in safety message correspond to the value set onboard machine.
Value must be configured to be same and unique per each machine. The parameter can be found
under options onboard the machine: AutoMine - CS - safety message - serial number.

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Alarms chair 28

Description 1: Emergency stop activated according to status feedback input (XM3.16)

Action 1: Emergency stop was intended function
• No actions needed. This is event type of info and confirmation to operator

Action 2: Set machine to manual mode

• Try to release emergency stop
• If not released - fault find in manual mode, see machine workshop manual and actions 3-4 below
• If released - The failure has been isolated to "Auto-mode additional E-stop circuit" or circuit supply
(XC2.2). Fault find in automatic mode. See action 5 below.

Action 3: Emergency stop button

• Release Emergency stop button

Action 4: Wire harness

• Measure the voltage in chair module XC3.16 connector pin with the emergency stop button in it's
posterior position
• If the voltage is below the machine’s operating voltage (approx. 24-27 V), check the emergency
stop buttons and the wire harness

Action 5: Circuit supply (enable) (XC2.2)

• Check the supply pin status using cabin display
• Check the preconditions:
- Machine VCM System has started
- All modules are operational (i.e. communicating on the bus)
- InfraFREE heartbeat message is OK
- Safety message information is OK
- InfraFREE’s emergency brake release is active

Action 6: Manual / Auto mode switch

• Check if one of the Relays K3167 or K3166 has tripped (green led light on relay not illuminating)
- If K3167 is tripped, follow action 7
- If K3166 is tripped, follow action 8

Action 7: InfraFREE emergency brake release

• Check that relay (K3024 ) gets the control signal (5 V) from InfraFREE. The light on the relay is on,
if control signal is OK
• Check that the emergency stop release signal (24 V) is present on the relay input contact
• Check that the relay contacts are ok i.e. 24 V signal can be measured on the relay output
• Change the relay

Action 8: ACS system

• Check that input signals (24 V on pins 20, 21 and 22) are present on the ACS module
• Switch the ACS teach button (S1105) to position 2. If emergency stop circuit releases (mode light
changes from orange to red and led on K3166 is illuminating), there is problem on the ACS system.
• Fault find according to ACS system instructions. Note that problem can be outside the machine also
like open safety gate somewhere.

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Action 9: Connection
• If emergency stop release signal (24 V) is not present on middle module input side (XM3:16) when
all safety relays are active, fault is in wire harness or in line supply voltage.

Alarms chair 29

Description 1: Delayed Emergency stop resetting of automode state

Action 1: No action
• No actions. Info that E-stop supply (XC2.2) is activated after set delay time. Delay time is normally
set to 5-30 seconds. Orange mode light is blinking while in this phase.

3.16. AutoMine option parameter control

NOTICE
It is very important, that the service password is not given to
any unauthorized persons. Any unauthorized use of the service
menus may result in serious malfunctions. The service
password may only be given to a service person sufficiently
trained by Sandvik Mining and Construction.

Open the options control window of the service window with the "Options" button on the parameters
menu. The installed options and their parameters can be browsed in this window. The "option in
machine" parameter tells whether the optional function is activated or not. When the value in the set
field of the "Option in machine" parameter is "1" the optional function is activated, and when the value
is "0" the optional function is not activated.

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3.16.1. Activating or deactivating an optional function

1. Select an optional function and press ok.

2. A window opens in which the user is asked to enter a password that corresponds to the code on
the window. Sandvik Mining and Construction supplies the password.
3. Enter the password and press ok. The setting window of the optional function you selected opens.
Activate the optional function by setting the value "1" in the set field of the "Option in machine"
parameter. Set the value "0" to deactivate the optional function.
4. Choose the modules whose parameters you want to save (On = module chosen, Off = module
not chosen). Choosing "Save all modules" saves the parameters of all modules.
5. Activate the optional function by pressing the save button.

The code and password of the password window can be used

NOTE!
only once.

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3.16.2. Optional parameters

Search level 1 Search level 2 Search level 3 Parameter name Explanation

Gearing Initialization Speed measure- Max pulse differ- Value of the al-
ment ence lowed pulse differ-
ence between
speed sensors.
Needed for sensor
diagnostics.
Default = 100 (in
auto mode)
Brakes Rexroth valves Front Brake valve max. Set front brake
current in auto valve max current
mode in mA. Effective in
auto mode.
Default = 425
Brakes Rexroth valves Rear Brake valve max. Set rear brake
current in auto valve max current
mode in mA. Effective in
auto mode.
Default = 425
Brakes Parker valves Front Brake valve max. Set max current in
current in auto mA. Effective in
mode automode. Goal to
have max pres-
sure of 110 bar.
Default = 425
Brakes Parker valves Rear Brake valve max. Set max current in
current in auto mA. Effective in
mode automode. Goal to
have max pres-
sure of 110 bar.
Default = 425
Engine Protection Running limits Brake or Hydr. oil Do you want en-
level low auto gine to be stopped
mode to protect pumps if
oil level is too low.
0 = No, 1 = Yes.
Effective in Auto
mode only.
Default = 1
AutoMine Display Display Display AutoMine Configuration of
button visible button 2 in main
window. 0 = Auto-
Mine, 1 = MPM
Manual Produc-
tion Monitoring, 2
= No button
Default = 2

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Search level 1 Search level 2 Search level 3 Parameter name Explanation

AutoMine InfraFREE InfraFREE InfraFREE control InfraFREE (+ oth-
state er automation)
power enable con-
trol (XR1/15): Al-
ways ON = 0, Al-
ways OFF = 1
Control by mode
(in manual OFF, in
auto ON) = 2
Default = 2
AutoMine Comms Comms COMMS control Communication
state system (MineLAN)
power enable con-
trol (XR1/14): Al-
ways ON = 0, Al-
ways OFF = 1
Control by mode
(in manual OFF, in
auto ON) = 2
Default = 2
AutoMine CS Safety message Serial number 5 last digits of ma-
chine serial num-
ber or mine own
rule to give value.
Safety message
checking require
correct value of
this to keep on au-
tomatic driving.
Default = 1
Lights Mode lights Mode lights Rotating beacon Activates rotating
active in auto- beacon in auto
mode mode 0 = OFF, 1 =
ON
Default = 1
CAN sensor CAN sensor Boom angle Boom low value Feed in boom an-
gle sensor raw val-
ue 0 - 4095 when
boom is in lowest
position.
Default = 1
CAN sensor CAN sensor Boom angle Boom high value Feed in boom an-
gle sensor raw val-
ue 0 - 4095 when
boom is in highest
position.
Default = 1

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Search level 1 Search level 2 Search level 3 Parameter name Explanation

CAN sensor CAN sensor Steering angle Steering left value Feed in Steering
angle sensor raw
value 0 - 4095
when steering an-
gle is in most left
position.
Default = 1
CAN sensor CAN sensor Steering angle Steering right val- Feed in Steering
ue angle sensor raw
value 0 - 4095
when steering an-
gle is in most right
position.
Default = 1

3.17. Manual Production Monitoring (MPM) VCM system

The AutoMine and MPM user interface are implemented as a part of standard VCM user interface. It is possible
to activate AutoMine and MPM related windows with an option parameter. In the VCM main window, there is
an access to the AutoMine main menu, and the window access is marked with text “AutoMine”. If the MPM
option is activated, “Order” button replaces the “AutoMine” button in the VCM main window. If neither option is
activated, the button is “i”.

Main menu of machine with diesel engine Main menu of machine with electric motor

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3.17.1. Logging in

When the user pushes the Order button, and the

operator is not logged in, he/she must first log in
before he/she can enter to other MPM windows.

Button Function
1 Back to the main menu

2 Next name

3 Previous name

4
5 Selects the name and opens the next window

The operator must feed the own number code to

enter to the next window.

Button Function
1 Moves up in the figures case.

2 Moves down in the figures case.

3 Moves left in the figures case.

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4 Moves right in the figures case.

5 Sets selected number to the box and moves to the next box. If the last box is
selected, pressing the button sends the given code number to the MPM module.

After the code number has been given, the display sends the number to the MPM module and waits
for a reply. If the number is correct, the display opens the next window. If the number is incorrect, the
display shows a text “invalid password -- try again” and the buttons are changed to OK and Cancel.
OK button gives a change to the user to reselect the number. The Cancel button opens the select
operator window.

3.17.2. Machine status

User selects machine status. The status func-

tions e.g. manual production, development load-
ing, parkup, ready, etc. are read from MPM mod-
ule every time user pushes arrow up or arrow
down buttons.
After operator has selected status and reason
texts, the display sends information to the MPM
module.

Button Function
1
2 Next status or reason

3 Previous status or reason

4 Change focus from reason to status

5 Selects the name and opens the next window

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3.17.3. Production order

This is the main MPM window. If the operator has

already logged in, this window opens from the
main menu. MPM module gives order information
about a draw point, a dump point and a remaining
order. If the remaining order is < 0, the display
asks for a new order (object production order re-
quest).
When MPM module gives a new order to the dis-
play (object new production order), the display
reads the information (object’s draw point, dump
point and remaining order), scales remaining or-
der bar, sets the draw point, the dump point and
the remaining order information. After setting the
information, the display flashes few times.

Item Description
Time Current time
Remaining order bar Graphical view about the remaining order
Draw point
Dump point
Last bucket Weight of the last bucket
Remaining order Tonnage, which is left from the order
Shift total Total tonnage during a shift
Shift buckets Total number of buckets during a shift
Information box Information, which comes from the MPM module
is shown here e.g. Wrong dump point
Positioning On or off
Communication Wlan communication, on or off
Status Displays object’s MPM active status and MPM
active reason

Button Function
1 Dashboard Back to the main menu
2 Status Back to the machine status window
3 Cancel Enters to the Cancel Production order window
4 Log out The user logs out, and the display returns back to the main menu
5 Emergency Sends emergency message to the MPM module

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Cancel production order

With arrow buttons it is possible to scroll the rea-

sons, why it might be necessary to send “cancel
the production order”. Possible reasons might be
e.g. tunnel blocked, dump point blocked or foot
wall oversized. When the selection has been
made, pressing the OK button causes the display
to send the cancel order. Since the button is
pressed, the display returns to the production or-
der window.

Button Function
1 Back to the production order window

2 Next text

3 Previous text

4
5 Sends the “cancel production order”

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3.17.4. MPM maintenance windows

MPM Maintenance Menu

The MPM Service Menu can be entered by pressing the MPM Menu button in the main menu. The
MPM event log can be entered by pressing the MPM Log button.

Diesel version Electric version

Button Function
1 Moving to a higher (previous) display window level. For example, returning from
the gauge windows to the main window.
2 Moving to the previous item on the menu.

3 Moving to the next item on the menu.

4 Activating a menu function.

5 Moving from the main window to the service menu.

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Event log

The event log can be entered by pressing the

MPM Log button. Event log shows the MPM log-
ging information (8 events at a time). With arrow
buttons the user can scroll the previous and next
events.

Button Function
1 Moving to a higher (previous) display window level. For example, returning from
the gauge windows to the main window.
2 Previous

3 Next

4
5

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MPM Service Menu Password

Before the user can enter to the MPM Service

Menu, press MPM Menu button and enter the
MPM Service Password.
Pressing the OK button confirms the selection,
and the MPM Service Menu appears on the dis-
play.

Button Function
1 Moving to a higher (previous) display window level. For example, returning from
the gauge windows to the main window.
2 Previous selection

3 Next selection

4
5 Confirm selection

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MPM Service Menu

Sensor calibration, Save, Parameter Control, Re-

store Factory Params and Parameter Backup are
identical withInfraFREE window. For more infor-
mation see AutoMine / AutoMine-Lite and MPM
Onboard Service and Repair manual chapter
VCM System Automation Functions, section
Graphical user interface (GUI).

Button Function
1 Back to previous window

2 Previous selection

3 Next selection

4 Information window

5 Select target

Settings

Use positioning data selections: Use positioning

data, Use production order, Use default. If Use
default selection is selected user can adjust Draw
Point values.

Button Function
1 Back to previous window

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2 Previous selection

3 Next selection

4 Information window

5 Select target

General message

A window opens when a general message arrives

from the MPM module.

Button Function
1 ∆ Back to previous window
2 Yes Operator’s answer
3 No Operator’s answer
4 Wait Operator’s answer
5 Ok Operator’s answer

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Reset InfraFREE (MPM)

With this function, the InfraFREE restarting can be triggered via the machine’s display. Alternatively,
you can switch the machine’s power off for a moment from the main switch. Restarting is required,
e.g.
• always when machine is changed to automatic production (AutoMine) after use in Manual
Production Monitoring (MPM) system, change machine mode to Auto and then restart navigation
computer using Reset InfraFREE function.
always when machine is changed to Manual Production monitoring (MPM) after use in automatic
production (AutoMine), change machine mode to Manual and then restart navigation computer
using Reset InfraFREE function.
• after parameter changes.
• if sensor calibration is unsuccessful because of an incorrect InfraFREE software mode (e.g., always
after completion of automatic drive).

The operator can shut down and restart the InfraFREE via forced power-off by selecting the "Hard
boot" button and keeping the "OK" button pressed for approximately two seconds. This function
switches InfraFREE power off for five seconds. Before using this function, ensure that the machine
is not moving. Computer restart takes about 1 to 2 minute.
With the "Cancel" button, you can return to the MPM Service Menu window without restarting.

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4. ONBOARD COMPONENTS

The main onboard components are introduced in the figures below.

Component placement is only suggestive and varies based on
NOTE!
the machine type. For detailed structure, see Spare Part manual.

Loader

3 5 13 10 14
777
1

11

4
11

12

11

8
9

1 MineLAN client 2 Front antenna **

3 InfraFREE Navigation Module / 4 Front/Rear Scanner *
Navigation computer (MPM)
5 Sensor Module 6 Bucket Sensor *
7 Boom Sensor * 8 Odometer (speed sensors)
9 Articulation Sensor 10 Onboard Video Box
11 Camera * 12 Machine Mode Switch
13 ACS Onboard Unit * 14 Rear antenna ***
* not used in Manual Production Monitoring system (MPM)
** not in use if machine is equipped with WLAN client
*** with the WLAN client there are two omnidirectional antennas.

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Location of RFID Tag Reader

Manual Production Monitoring system is also equipped with RFID Tag Reader. The placement of the
RFID Tag reader is shown in the figures below. In diesel loader version the RFID reader is placed
near the cabin in front of the rear frame. In electric loader version the placement is more middle of
the frame behind the rear tire. In both machines the reader is on top of the back frame.

Diesel version Electric version

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Truck

13

2 11 4 7 9

11

2 4 1 10 12 777
11

1 MineLAN Mobile Terminal 2 Antenna

3 InfraFREE Navigation Module 4 Front/Rear Scanner
5 Sensor Module 6 Bucket Sensor
7 Box Sensor 8 Odometer (speed sensors)
9 Articulation Sensor 10 Onboard Video Box
11 Camera 12 Machine Mode Switch
13 ACS Onboard Unit

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4.1. Communication

A B

1 2 3 4 5 6 7 8 9

A Loader B Truck
1 MineLAN client 2 Antenna**
3 Video box 4 Camera *
5 InfraFREE and ACS * unit 6 Laser scanner *
7 Sensor module 8 Speed sensor *
9 CAN-bus
* not used in Manual Production Monitoring system (MPM)
** Front antennas not in use with WLAN client
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The MineLAN onboard configuration consists of either a Mobile Terminal or WLAN client. With the
Mobile Terminal there are four rugged antennas onboard, two pointing forwards and two pointing
backwards. The antennas are connected to MineLAN client using an antenna diversity function to
achieve optimal radio behavior. With the WLAN client there are two omnidirectional antennas at the
rear of the machine.
The MineLAN client is connected to a connection box, which contains the Ethernet switch, video-
audio encoders, video relays and power supply for the MineLAN client - and onboard cameras.
Basic numbering / naming of the cabling is the same in all machine types and cables connected to
InfraFREE navigation module. There are separate sparepart ID numbers for the cables due to
different cable lengths. The cable/connector naming is mainly the same.

4.1.1. MineLAN client

The MineLAN client is rugged industry class communication terminal installed onboard. The MineLAN
client provides a standard Ethernet connection to onboard devices, as well as antenna connectors
to onboard antennas.
The Mobile Terminal (MT) consists of a MineLAN Access Point unit (AP), power cabling, antenna
cabling, Ethernet cabling and special software (different from the software in the APs). The Mobile
Terminal is equipped with 90 degree antennas and the WLAN client is equipped with omnidirectional
antennas.
The MineLAN client uses a regulated 24 VDC power supply.

WLAN client version Mobile Terminal version

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Installing MineLAN Mobile Terminal

Vehicle installation:

1 Mobile Terminal
2 Antenna
The MineLAN onboard Communication System
consist of a MineLAN Mobile Terminal unit, power 2
cabling, antenna cabling, Ethernet cabling and
connectors for these different types of cables.
Adjacent figure presents the basic configuration
1
of the Mobile Terminal installation. RN jumper ca-
bles and male N (or 90° male N) connectors are
used for MT installations.

If any antenna or Ethernet connector is left unused, use

protective connector cover to protect it from dirt and moisture.

System specialist needs to configure new MT before the

machine is taken to operation.

1 Antenna connector (radio 1.1)

2 Antenna connector (radio 1.2)
3
3 Antenna connector (radio 2.1)
4 Antenna connector (radio 2.2) 4
5 Ethernet connector 1
6 Ethernet connector 2
7 Power connector
1

2
5 6 7

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Installing MineLAN WLAN client

Vehicle installation:

1 WLAN client
2 Antennas (MAIN and AUX)
3 Video switch 5
4 ACS I/0 1
5 Instrumental panel 6
6 VCM display
7 Cabin plug

MineLAN onboard Communication System consists of a MineLAN WLAN client, power cabling,
antenna cabling, Ethernet cabling and connectors for these different types of cables. The previous
figure presents the basic configuration of the MineLAN WLAN client installation. RN jumper cables
and male N (or 90° male N) connectors are used for MineLAN WLAN client installations.
If any antenna or Ethernet connector is left unused, use
protective connector cover to protect it from dirt and moisture.

System specialist needs to configure new MineLAN WLAN

client before the machine is taken to operation.

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1 Main antenna connector

1 2
2 AUX antenna connector
3 Ethernet connector
4 Power connector

4
3

Removing MineLAN

If the MineLAN is removed for manual operation, cover antenna

cable connectors and Ethernet connector.

4.1.2. Antenna

With the Mobile Terminal there are four rugged antennas onboard, two pointing forwards and two
pointing backwards, connected to the MinaLAN client using an antenna diversity function to achieve
optimal radio coverage and behavior in hand-over situations between access points.
With the WLAN client there are two omnidirectional antennas located at the rear of the machine.
Component placement is only suggestive and varies based on
NOTE!
the machine type. For detailed structure, see Spare Part manual.

WLAN client version Mobile Terminal version

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Details (Mobile Terminal version)

RN-HD-A-20 is heavy-duty industrial client antenna with 10 dBi gain and 90 degree beamwidth.

Property MT antenna
Frequency range (MHz) 2400-2483.5
Max. gain (dBi) 10
Polarization Vertical
Beamwidth, azimuth (°) 90
Beamwidth, elevation (°) 30
Cross Pol. discrimination (dB) >25
Front-to-back-ratio >25
Impedance (Ω) 50
VSWR 1.5:1
Connector N (jack)

N connectors should be sealed using seal tape. N connectors

that are not properly sealed permit moisture to enter the
connection, which leads to performance degradation or
coverage problems.

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Details (WLAN client version)

ANT-WSB-ANF-09 is heavy-duty industrial omni -directional antenna with 9 dBi gain.

Antenna Characteristics
Frequency (GHz) 2.4 to 2.5
Typical Antenna Gain (dBi) 9
Polarization Linear
HPBW/horizontal (°) 360
HPBW/vertical (°) 10
Impedance ((Ω) 50±5
Antenna Type Omni-directional
Power Handling (W) 15 max.
V.S.W.R. 1:1.3 max.
Connector N-type (female)

Physical Characteristics
Weight (g) 430
Dimensions (mm) diameter: 35, length: 420
IP Rating IP65
Radome Color white radome
Material fiberglass

Physical Characteristics
Operating Temperature -40 to 80°C (-40 to 176°F)
Storage Temperature -40 to 80°C (-40 to 176°F)
Ambient Relative Humidity 5 to 95% (30°C, non-condensing)

N connectors should be sealed using seal tape. N connectors

that are not properly sealed permit moisture to enter the
connection, which leads to performance degradation or
coverage problems.

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4.1.3. Cabling (Mobile Terminal version)

Basic numbering / naming of the cabling is the same in all machines. Mainly the cable length is causing
the different sparepart ID numbers, but the cable / connector naming is mainly the same.

Antenna cables W205, W303, W304 and W306

Same type of RFF ½” jumper cables and male N (or 90° male N) connectors are used also for MT
installations as AP installations. Use only specific cables for each machine type and antenna position.
Correct cable type can be found from the sparepart manual. Minimum bending radius of the cable is
80 mm on a single bending and 180 mm on a repeated bending. Do not pass under this radius when
mounting the cable.

Power cable X399

Pin Signal Wire Signal Pin

1 1 1
2 2 2
3 3
4 4
GND GND

Power cable is 2x1,5 mm² cable with Harting HAN 4A female insert type connector on other end and
Harting HAN 4A male insert connector on other end of the cable. Cable must be inside NW8,5 plastic
cable sleeve.

Ethernet cable X398

Ethernet cable between MineLAN MT and video box must fulfil CAT5 category FTP outdoor cable
specification. Cable is 4x2x0,5 mm² + scr cable with Harting HAN Brid RJ45 connectors on both ends.
E.g. BETAflam 90 C-flex cable. Cable must be inside NW8,5 plastic cable sleeve.

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4.1.4. Cabling (WLAN client version)

Basic numbering / naming of the cabling is the same in all machines. Mainly the cable length is causing
the different sparepart ID numbers, but the cable / connector naming is mainly the same.

Antenna cables W3003 and W3004

These cables with male N (or 90° male N) connectors are used also for MT installations as AP
installations. Use only specific cables for each machine type and antenna position. Correct cable type
can be found from the sparepart manual. Minimum bending radius of the cable is 80 mm on a single
bending and 180 mm on a repeated bending. Do not pass under this radius when mounting the cable.

Power cable X399

Power cable is with M12 female insert type connector and with Harting HAN 4A male insert type
connector on the other end. The M12 female insert should be connected to the MineLAN Client
(Power) and the Harting HAN 4A male should be connected to the video box (X4B). The cable must
be inside NW8,5 plastic cable sleeve.

Ethernet cable X398




Ethernet cable between MineLAN Client (LAN) and video box (X6B) must fulfil CAT5 category FTP
outdoor cable specification. Cable is with Harting HAN Brid RJ45 connectors on both ends. E.g.
BETAflam 90 C-flex cable. The MineLAN Client (LAN) head has a threaded plug housing (IP67). The
cable must be inside NW7,5 plastic cable sleeve.

4.1.5. Communication troubleshooting (if equipped with Mobile Terminal)

This section explains the most common fault finding techniques for the onboard MineLAN system.
Always take the logfile before performing any troubleshooting
actions. This is to assist in faultfinding and follow-up reports.
NOTE! Once a critical alarm occurs, a log files should be taken within
one minute. All machine information is lost if a log is not taken
within one minute of the alarm being displayed.

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Background information for troubleshooting

Communication to each machine is governed by a 500 ms timeout. This means that if you have a
communication break of longer than 500 ms to a machine, the machine will go to fast stop. If this
happens, the following error is displayed : "Master Channel comms broken".
There are some common reasons for communication breaks:
• Infrastructure network is at faulty state
• Onboard antenna network is faulty
• Onboard Ethernet cabling is faulty
• Mobile Terminal is faulty
• Radio parameters are incorrect

Deciding which one of the above points are the most likely cause, is easily checked with running the
poing utility on the MineLAN server.

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Infrastructure troubleshooting

Following figure shows a typical snapshot of poing when the infrastructure is at fault:

In previous figure the poing configuration is as follows:

• Line 1: InfraFREE IP address
• Line 2: Mobile Terminal bridge IP address
• Line 3: Mobile Terminal Radio 1 IP address
• Line 4: Mobile Terminal Radio 2 IP address

In the scenario above, Radio 2 of the Mobile Terminal looses communication in the same place each
time the machine passes APT11. Since the communication for Radio 2 of the Mobile Terminal was
OK in the rest of the automation area, it means that the infrastructure is most likely at fault (The
communication gap is longer than a normal handover, so there is a problem somewhere).
• If there is more than one automation machine in the area, the other machines should exhibit the
same behavior at the same place.
• If only one machine looses communication at a specific spot and the other machines behave normal,
the problems are onboard - consult the onboard faultfinding section on how to test antennas.

To find the faulty Access Point:

Radio 2 of the Mobile Terminal will only connect to Access Points with Radio channels 7-13. In the
radio map, the only access point configured for Channels 7-13 is APT-11. Looking at the layout, most
probably the downward pointing antenna , -cable, or -splitter is broken. For further instructions on
MineLAN infrastructure testing, see the AutoMine System Workshop Manual.
If Radio 1 looses communication in a specific area, look for AP’s configured for channels 1-6 with the
same method as above.

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Onboard antenna network troubleshooting

Figure below shows a typical snapshot of poing when the onboard antennas or antenna cables are
at fault:

In previous figure the poing configuration is as follows:

• Line 1: InfraFREE IP address
• Line 2: Mobile Terminal bridge IP address
• Line 3: Mobile Terminal Radio 1 IP address
• Line 4: Mobile Terminal Radio 2 IP address

In the above scenario, Radio 1 looses communication (extremely long handover) all over the
automation area. This means that the communication problem is onboard rather than in the
infrastructure. From the poing snapshot, it would seem that the front Radio of the Mobile Terminal is
at fault. The reasoning is as follows:
• As the machine goes around the curve from APT-25 in its current direction, the signal strength from
Access Point APT-25 will start to drop, until it is finally beneath the threshold of either the Mobile
Terminal or APT-25.
• When the signal gets cut from APT-25, the Mobile Terminal will try to connect Radio 1 to an access
point with Radio Channels 1-6.
• In the figure, the machine is so close to Access Point APT-1, that the Mobile Terminal should have
connected to it by this time.
• When the machine passed APT-25 and the APT-25 was to the rear of the machine, the machine
was still connected to APT-25. This means that most probably the front antenna on the machine is
not working due to a possible antenna or cable fault.

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Testing onboard antennas and cables

Vehicle installation:

1 Mobile Terminal
2 Antenna
The Mobile Terminal has two radio channels with
two antennas (rear and front) connected to each 2
channel. During normal driving, both radio chan-
nels should be connected to access points.
The Mobile Terminal is setup so that Radio Chan-
1
nel 1 will only communicate with WLAN channels
1-6 (IEEE 802.g standard) and Radio 2 will only
communicate with channels 7-13. This means
that to test both channels of the Mobile Terminal
two access points are needed.
Alternatively, one access point may be used, of
which the channels have to be changed to first be 2
in the region of channels 1-6 for MT Radio 1, and
then to channels 7-13 for MT Radio 2.

Before testing the antennas, measure the continuity of all four antenna cables. The reading should
be < 0.1 Ohm. If the antennas are a suspect, it is possible to test them by logging into the Mobile
Terminal and checking the signal strength. This can easily be done in the production area during a
production break.

Figure: Testing distance between the loader/truck and the access point

If the distance is closer than 20 m, the access point can be heard

NOTE!
even without an antenna causing false test result.

Testing procedure:
1. Ensure you have a working Access Point. This can be an installed AP in the production area.
2. Drive the machine in front of the Access Point.
3. Disconnect the rear antennas. This is to prevent the Mobile Terminal from picking up reflected
signals at the rear of the machine.
4. Set the Access Point channel to channel 5.
5. Measure the received signal strength of the front antenna on Channel 1 from the MT web GUI.
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6. Measure the received signal strength inside the access point from the AP web GUI.
7. Set the Access Point to channel 13.
8. Measure the received signal strength of the front antenna on Channel 2 from the MT web GUI.
9. Measure the received signal strength inside the access point from the AP web GUI.
10. Turn the machine around, reconnect the rear antennas and disconnect the front antennas.
11. Repeat the process above for the rear antennas.

Notes:
• When the machine is parked about 20m from a working Access Point, the received signal strengths
of all antennas should be over 85%. If the signal strength is lower than 85%, change the antennas
and see if the signal strength improves. If not, change the cable.
• If the exact antenna locations and channels are known , it may be faster to enable the antennas
one-by-one for testing purposes. If this approach is followed, you need to be sure that the right
antenna is being enabled!
• Received signal strength for both Mobile Terminals and Access Points can be checked by logging
into the AP or MT and checking the associations page. Next figure shows an example of an MT,
with two access points connected to it. If the test setup in previous figure is used, only one Radio
will show an association.

• The MAC address of the associated AP radio can be seen from above. This is useful to determine
to which AP a machine is connected during autonomous operation.
• The signal strengths are not updated in real time. Each time a change is made or the machine is
moved, the "OK" button needs to be clicked.

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Onboard Ethernet troubleshooting

1 Portbox
2 Video server
3 Ethernet switch
4 NaviPC
5 Mobile Terminal 1
6 Ethernet cabling
7 Onboard ACS I/O 5
2
Ethernet communication flows from surface
through the antennas, passes through the MT
and is copied via the MT bridge to the Ethernet
lines. All Ethernet lines are connected to a switch. 3 6

7
4

From time to time it happens that there is an Ethernet cabling problem onboard. This is easily
determined by running poing to the specific machine.
Figure below shows a poing snapshot of a machine with possible onboard Ethernet cabling problems:

In previous figure the poing configuration is as follows:

• Line 1: InfraFREE IP address
• Line 2: Mobile Terminal bridge IP address
• Line 3: Mobile Terminal Radio 1 IP address
• Line 4: Mobile Terminal Radio 2 IP address

The communication to the Radios and MT bridge is fine, but there is a break in communication to the
InfraFREE Navigation module. Since the InfraFREE navigation module is hardwired via Ethernet to
the MT bridge, it most probably means that there is an intermittent problem with the Ethernet cabling.
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The following test setup may be used to fault find the onboard Ethernet cabling:
The laptop is connected to Ethernet port nr.2 on the Mobile Terminal. Since all components are now
in "series", it is possible to test the cabling from the MT to the InfraFREE navigation module by
continuously pinging the navigation module address.
Testing procedure:
1. From the laptop command prompt, type: ping Navigation module_address -t -w 5, where
Navigation module_address is the IP address of the Navigation module. This command will
continuously ping the Navigation module, until "CTRL-C" is pressed on the laptop.
2. While ping is running, wiggle each Ethernet cable, starting from the MT-to-switch cable. If a
"Request Timed out" message is seen on the laptop, it means that some packets are lost due to
the faulty cable being moved causing a communication error. Change the cable and re-test.
3. Check all cables in this fashion. If it is unclear where the fault lies, take a long Ethernet cable and
connect the MT directly to the InfraFREE Navigation module. If the problem still does not go away,
the fault is with either the InfraFREE navigation module or the MT. To test the MT, connect the
laptop directly to the MT and ping the MT bridge address. To test the Navigation module, connect
the laptop directly to the Navigation module (a special cable is needed for this) and ping the
Navigation module (Note! When the Pilot is running, it may influence the ping response times, so
it is better to first kill the pilot before attempting the faultfinding procedure).
4. For a graphical result of pinging the InfraFREE navigation module, the Ping Plotter utility should
be used.

Faulty Mobile Terminal

If infrastructure, onboard antennas and onboard Ethernet have been tested, and the communication
is still not what on a good enough level, it most probably means that the Mobile Terminal is damaged
internally. The only way to check this is to swop it with a spare unit and run poing and associations
during production to monitor the communication.

Incorrect radio parameters

Determining whether incorrect radio parameters are at fault is a bit more involved, and cannot be
determined from a stationary machine. These parameters should never change if the infrastructure
remains unchanged.
For more information on radio parameter fine-tuning, see the AutoMine System Workshop Manual.

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MineLAN network troubleshooting in AutoMine-Lite

Diagnostics tools

The Diagnostic tools screen contain the MineLAN network analyzer (MT Trace). MT Trace gives real
time information on the delay between the MTS server and the MT, MT radio signal strengths and to
which AP the MT is currently associated. MT Trace also stores the information gathered during the
time MT Trace is enabled and can then plot that data.
MT Trace should not be used during normal operation as it
NOTE! requires some processing power from the MTS server and also
causes some traffic to the network.

When MT Trace is enabled, a "Show Trace" link will appear. This link opens a new window where
MT Trace is viewed.

MT Trace guideline

Analyzing MineLAN network performance with MT Trace:

1. The ping of the MT should not show an x (ping timeout) inside the network coverage area. When
the MT is reachable through both radios, one of the radios should always show something else
than x.
2. Radios should not been associated to the same AP at the same time.
3. Testing time should be as short as possible to facilitate the analysis. It is recommended that the
route is driven for example from end to end and the data is analysed immediately afterwards. The
route can be driven to the opposite direction after the first analysis.
4. It is recommended that the driving route is also tested with video traffic if video systems are going
to be used (video traffic affects network performance by for example increasing delays).

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Ping table

3
4

1 Ping table
2 Plot Trace
3 Trace graph
4 Return (to diagnostics tools page)
The ping table shows delays in milliseconds between the access point - Mobile Terminal bridge, radio
1 and radio 2.
x means a ping timeout, delay over 200 ms, shown as value -5 on the ping graph
o means a delay over 50 ms, shown as value -2 on the ping graph
The MT is reachable through both radios which means that if
NOTE!
one of the radios responds, the MT should also respond.

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Plot Trace

The Plot Trace graphs opens to the same window as the ping table. The trace’s time scale is
synchronised and presented in seconds according to time parameters.

1 2 5

3 4

1 Association AP (radio 1) Association between AP and radio 1.

2 Association AP (radio 2) Association between AP and radio 2.
3 Signal strength (radio 1) Signal quality between MT and radio 1.
4 Signal strength (radio 2) Signal quality between MT and radio 2.
5 Delay Delays between AP - MT, radio 1 and radio 2.

Trace graph

The Trace graph functions similarly to Plot Trace, but in its own window. If necessary, the page can
be saved and sent to the system specialist for analysing purposes.
NOTE! Use the browser return button to return to the previous view.

4.1.6. Communication troubleshooting (if equipped with WLAN client)

This section explains the most common fault finding techniques for the onboard MineLAN client
system.
Always take the logfile before performing any troubleshooting
actions. This is to assist in faultfinding and follow-up reports.
NOTE! Once a critical alarm occurs, a log files should be taken within
one minute. All machine information is lost if a log is not taken
within one minute of the alarm being displayed.

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Background information for troubleshooting (WLAN client version)

Communication to each machine is governed by a 500 ms timeout. This means that if you have a
communication break of longer than 500 ms to a machine, the machine will go to fast stop. If this
happens, the following error is displayed : "Master Channel comms broken".
There are some common reasons for communication breaks:
• Infrastructure network is at faulty state
• Onboard antenna network is faulty
• Onboard Ethernet cabling is faulty
• MineLAN WLAN client is faulty

Deciding which one of the above points are the most likely cause, is easily checked with running the
poing utility on the MineLAN server.

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Infrastructure troubleshooting (WLAN client version)

Machine always stops in the same place

1. Start the MineLAN.exe program.

2. After the program has started, drive the entire route manually with the LHD.
During this, the program will receive syslog - log files. With the help of these log files the diagnostic
program will automatically save the used access points and clients to the database.
3. To display the signal strength received by the client, open the Client - tab and enter the IP address
of the client to the IP address field.

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4. Once the IP address has been set, right-click the row and select Monitor from the menu to monitor
the signals received by the client.
The access points and clients can be saved by opening the File menu and selecting Save As....
The access points and clients will be stored in the database and the measurements can be started
immediately.

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5. Drive through the route several times manually and observe the signal strengths and hand-overs
from the Status tab.

The strength of the signal received by the client, along with the MAC-address, is shown at the
right. The signal strength value is 0... -100, where 0 is the best possible connection, and -100 is
a connection failure. If the signal is weaker than -66 and the client can see another access point
with a signal strength 7 dBm higher then the signal from the current access point, a hand-over
will occur.
The strength of the signal is also shown as a graph, in which the hand-overs of the access points
are indicated by changing the line color. The line color follows the pattern: red - green - blue -
yellow, then starts over again.
The syslog messages and their time stamps are displayed in the text field at the bottom. The client
hand-overs can also be checked from the text field.

There usually are two possible reasons for the machine stopping:
• The signal is not strong enough.
• The hand-overs happen too frequently.

If signal strength is the issue, check the placement and configuration of the access points and also
the condition of the access points (including cabling and antennas).
If the hand-overs happen too frequently (twice a second), check the placement of the access points
and their transmission power.

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Testing onboard antennas and cables (WLAN client version)

Vehicle installation:

1 WLAN client
2 Antennas (MAIN and AUX)
3 Video switch 5
4 ACS I/0 1
5 Instrumental panel 6
6 VCM display
7 Cabin plug

The MineLAN WLAN client is equipped with one radio that includes two antenna ports. MineLAN
WLAN client use only one channel and this channel must be configured for the base stations and
client
Before testing the antennas, measure the continuity of all two antenna cables. The reading should
be < 0.1 Ohm. If the antennas are a suspect, it is possible to test them by logging into the MineLAN
WLAN client and checking the signal strength. This can easily be done in the production area during
a production break.
RF1
RF2

Testing procedure:
1. Ensure you have a working Access Point. This can be an installed AP in the production area.
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2. Drive the machine in front of the Access Point.

3. Disconnect the other antenna cable from the WLAN client.
4. Check the signal strength from the WLAN client. See Infrastructure troubleshooting (WLAN client
version) for more details.
5. Remove a moment ago used antenna and connect the antenna back that was removed in the
step 3.
6. Check the received signal strength from the WLAN client.

Notes:
• When the machine is parked about 20 m from a working Access Point, the received signal strengths
of all antennas should be approximately -55 dBm. If the signal strength is approximately -60 dBm,
change the antennas and see if the signal strength improves. If not, change the cable.
• Received signal strength for both MineLAN WLAN client and Access Points can be checked by
logging into the AP or WLAN client and checking the main page.

• The MAC address of the associated AP radio can be seen from above. This is useful to determine
to which AP a machine is connected during autonomous operation.
• The signal strengths are not updated in real time. Each time a change is made or the machine is
moved, the "OK" button needs to be clicked.

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Onboard Ethernet troubleshooting (WLAN client version)

1 WLAN client
2 Antennas (MAIN and AUX)
3 Video switch 5
4 ACS I/0 1
5 Instrumental panel 6
6 VCM display
7 Cabin plug

It is possible to use MineLAN Client to ping onboard components of the machine. First log in to WLAN
client and then ping manually network components of the machine. IP -addresses of the network
components can be checked from Network Plan.

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No connection to an onboard component

The onboard components can be "pinged" with the MineLAN client diagnostics tool. The diagnostics
tool can be accessed using an ordinary web browser (Internet Explorer, Firefox). Other browsers may
also be acceptable, but have not been tested.

1. Enter the IP address (default value: 192.168.127.253) in your browser's address or location bar.
2. Enter username and password.

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3. When logged in, select Main menu, then Maintenance and Ping.

4. Enter the IP address of the onboard component you wish to check to the Destination field and
click Ping, e.g. in AutoMine Lite:.
• InfraFREE PC: 10.10.100.40
• Video transmitter 1: 10.10.100.41
• Video transmitter 1: 10.10.100.42
• Monitor channel (EPEC): 10.10.100.48
• Safety system I/O: 10.10.100.102

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5. If the "ping" is successful, the connection to the component is operational.

If the connection is not operational, the "ping" will fail.

Faulty MineLAN WLAN client

Check the following things if the network components and cabling are noticed to work, and connection
still do not work:
1. Settings of the MineLAN WLAN client, especially IP -address, SSID, scanned channel and radio
parameters.
2. Condition and settings of the base station.
3. MineLAN WLAN client has to be changed to new one.
4. MineLAN Acces Point has to be changed to new one.
5. Contact technical support of Sandvik for further information.
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4.2. InfraFREE

InfraFREE main functions are described in the following list:

• Enables autonomous operation of the machine
- Determines the position and heading of the machine equipped with InfraFREE.
- Calculates required control signals for the machine in order to drive the machine to the
destination.
- Calculates required control signals to move the machine actuators in order to load and dump it.
• Enables remote control of the machine
- Provides means to receive remote control commands and controls the machine accordingly.
InfraFREE forwards all steering, brake, etc. commands to CS using CAN.
• Provides means to teach the new production areas to the machine
- Records new segments or environment models when teaching a new area.
• Conducts self-diagnostics
• Provides integrated safety functionality
- Multilevel component, software, communication and machine safety functionality.
- Commands the machine to emergency stop state in case of failure or external (operator) request.

InfraFREE system includes following components:

• InfraFREE navigation module
• Scanners
• Gyroscope
• Accelerometers
• Odometers

4.2.1. InfraFREE Navigation Module

The InfraFREE navigation module handles Infra-

FREE system data processing, interfaces to ex-
ternal systems and machine control signal gen-
eration when the machine is in automatic mode
(AUTO).
The InfraFREE navigation module consists of a
number of interfaces to InfraFREE internal and
external components.
The construction of the InfraFREE navigation
module is modular. The mechanical structure
consists of frames where standard PC/104 cards
are attached. Each frame is also equipped with
connectors that are required to provide interfaces
to other InfraFREE internal or external compo-
nents.

Change new seals when assembling navigation module layers.

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4.2.2. InfraFREE connections

Figure: InfraFREE navigation module circuit diagram

1 CPU frame
2 Serial connection frame 1
3 I/O frame
4 Power frame 2

1 2 3 4 9 10 11 12

5 6 7 8 13 14

1 Debug port 2 Rear scanner

3 Front scanner 4 Ethernet
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5 Power 6 DI / DO (optional)
7 Emergency stop 8 Accelerometer
9 Master 10 Speed
11 Gyro 12 Remote
13 CAN bus 14 CAN bus

InfraFREE frames

Power frame powers up the InfraFREE navigation module and all sensors wired straight to it.
Power is supplied to InfraFREE from regulating power supply using 3-pin connection:
• pin A = "delayed" power-up
• pin B = GND
• pin C = "immediate" power-up

Power frame gives all needed voltages (+5V, GND, +24V) using powerbus to the frames above the
power frame.

I/O frame

I/O frame is utilized to connect following sensors or I/O to InfraFREE navigation module:
• CAN bus (X391)
• InfraFREE E-STOP relay (X359)
• Sensor module acceleration sensors signal (X395)

Serial frame

Serial frame is utilized to connect following sensors to InfraFREE navigation module:

• Front scanner (X21002)
• Rear scanner (X31004)
• Odometer (X373)
• Sensor module power supply and GYRO signal (X394)

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CPU frame

CPU frame is utilized to have following connections to InfraFREE navigation module:

• Ethernet cable from video box (X3107)
• One serial port "debug" wired to CPU frame
• In manual production monitoring machines also RF Tag Reader is connected to CPU frame "debug"
serial port (X3134)

CPU frame includes also:

• Mother board (CPU)
- Display and keyboard connectors (internal only)
- Other PC connections (internal only)
- RAM memory
• Flash memory card
- To store and run operating system
- InfraFREE application
- InfraFREE log storage

CPU uses top cover to emit the heat generated at CPU to

surrounding air or machine chassis, DO NOT OPERATE
InfraFREE PC with out top cover secured in place. Keep the top
plate and InfraFREE navigation module frames clean to be able
to emit heat.

In order to avoid internal humidity problems in InfraFREE PC,

humidity absorber has to be changed when it's color has
changed from light-blue to white.

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4.2.3. InfraFREE power supply

InfraFREE is fed by regulated 24-volt supply voltage. Power to this power supply can be disabled or
enabled using relays on machine commanded by CS. From this power supply InfraFREE is supplied
with two power supply wires (one physical cable).
• Straight up to 24 V power
- Scanners, etc. high current start-up sensors
• Delayed power for the InfraFREE
- Sensor module 24 V supply from InfraFREE
- Supply 24 V to powercard in power frame
- Power card gives 5 V supply to InfraFREE navigation module and all circuit boards inside the
InfraFREE computer

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Supply voltage relay (K3164) delay time adjustment

1 Mode of operation (delay on operate), de-

fault = OP
2 Time multiplier (scale 1 to 10), default = 3
1
3 Time range (scale 1 to 60 s), default = 1
Supply voltage relay delay time can be adjusted
by turning the time multiplier knob on the relay.
Default time is 3-10 seconds.
2

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4.2.4. InfraFREE cabling

Basic numbering / naming of the cabling is the same in all

machines. Mainly the cable length is causing the different in
sparepart ID numbering, but the cable / connector naming is the
same.

Power cable X360

Wire Signal Pin

1 + 24 V A
2 GND B
3 + 24 V C
4 NC

InfraFREE power cable is 4 x 1,5mm² cable with 3 pin MIL female connector on other end. Cable
must be inside NW10 plastic cable sleeve.

Ethernet cable X3107

Pin Signal Wire Signal Pin

A IN- 5 / grey IN- A
B IN+ 4 / yellow IN+ B
C 3 / green C
D OUT- 2 / brown OUT- D
E OUT+ 1 / white OUT+ E

InfraFREE Ethernet cable is 2 x 2 x 0,5 mm² twisted pair cable (e.g. BETAflam 90 Cflex cable) with
5 pin MIL male connectors on both ends. Cable must be inside NW8,5 plastic cable sleeve.

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Laser scanner cable X21002 and X31004

Pin Signal Wire Signal Pin

9 TXD- 1 RXD- A
10 TXD+ 2 RXD+ B
16 Sen 24 V 3 Sen 24 V D
8 Sen GND 4 Sen GND E
1 RXD- 5 TXD- F
2 RXD+ 6 TXD+ G
5 NC 7 NC C
6
3 RS232 / 422
4 *Heater GND
7
11 RS232 / 422
12 *Heater 24 V

InfraFREE scanner cable is 7 x 0,5 mm² (e.g. SAB PET/PUR cable) cable with 10 pin MIL male
connector on other end and SICK 16 pin female connector on other end. Cable must be inside NW10
plastic cable sleeve.
Pins 3 and 11 must be connected to ensure proper function.

Gyro cable X394

Pin Signal Wire Signal Pin

A RX / TX + 5 / grey RX / TX + A
B RX / TX - 4 / yellow RX / TX - B
C GND 3 / green GND C
D GND 2 / brown GND D
E 5V 1 / white 5V E

InfraFREE Gyro cable is 5 x 0,5 mm² cable (e.g. SAB S 366 C cable) with 5 pin MIL female connectors
on both ends. Cable must be inside NW8,5 plastic cable sleeve.

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Acceleration sensor cable X395

Pin Signal Wire Signal Pin

A 24 V 1 24 V A
B Ref 1 2 Ref 1 B
C Ref 2 3 Ref 2 C
D GND 4 GND D
E Input 2 5 Input 2 E
F Input 1 6 Input 1 F
NC 7 NC

InfraFREE acceleration sensor cable is 7 x 0,5 mm² cable (e.g. SAB PET/PUR 12YC11YZ-0 cable)
with 6 pin MIL male connector on other end and 6 pin MIL female connector on other end. Cable must
be inside NW10 plastic cable sleeve.

Emergency stop cable X359

Wire Signal Pin

2 5V A
1 GND B
NC C

InfraFREE E-stop cable is 2 x 1,5 mm² cable (e.g. SAB 760 cable) with 3 pin MIL male connector on
other end. Cable must be inside NW8,5 plastic cable sleeve.

CAN bus cable X391

Wire Signal Pin

1 NC A
2 / yellow GND B

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Wire Signal Pin

3 / green CAN H C
4 / brown CAN L D
5 NC E

InfraFREE CAN bus cable is 5 x 0,5 mm² cable (e.g. SAB S 366 C cable) with 5 pin MIL male connector
on other end. Cable must be inside NW8,5 plastic cable sleeve.

Odometer sensor cable X373

Wire Signal Pin

5 / grey + 12 V A
4 / yellow GND B
3 / green + 12 V C
2 NC
1 NC

InfraFREE odometer sensor cable is 5 x 0,5 mm² cable (e.g. SAB S 366 C cable) with 3 pin MIL male
connector on other end. Cable must be inside NW8,5 plastic cable sleeve.

Articulation angle sensor cable B330 and boom/box angle sensor cable B232

Wire Signal Pin

1 ADR 0 A
2 ADR 1 B
3 ADR 2 C
4 ADR 3 D
5 + 24 V E
6 GND F
7 CAN H G
8 CAN L H

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4.2.5. InfraFREE humidity absorber

In order to avoid internal humidity problems in the

InfraFREE module, the absorber needs to be
changed, when the color has changed from light-
blue to white.

1 Wet absorber
2 Dry absorber
Wet absorber can be refurbished by keeping it in
dry environment until the color is light-blue again.
Dry it in an electric oven several hours or in weld-
ing-electrode dryer (beware of melting!) or keep 1 2
it e.g. in hot sun during daytimes and seal it in
plastic bag for the night-times.

Absorber patron and color indicator ("parer label") are separate

units. It can take much longer for absorber to dry than color
indicator to change back to light-blue.

DO NOT expose the indicator- window to the sun, otherwise it

may lose the indicating ability.

Keep always good stock of dry absorbers. Store absorbers in

individual sealed bags.

4.2.6. Common troubleshooting instructions

When there is a doubt, that there may be fault in InfraFREE, the following working order shall be
followed:
1. Isolate the fault into small area:
• one machine versus all the machines
• InfraFREE versus other subsystems
• sensors versus InfraFREE computer
• sensor versus cable or connectors
2. Continue isolation into faulty unit by changing components. Start from cheap components, as
cables, then sensors or InfraFREE computer interface boards and last the whole InfraFREE
computer.

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Fault isolation

This section gives some clues for isolating the fault into smaller area.
• Is the problem in more than one machine and does it happen always in the same place? If so,
probably the error is in changed tunnel environment or incorrect environment- or route definition
file.
• When the problem started? In middle of production or after special action like machine service or
repair, machine washing, road cleaning, infrastructure (electrics, communication...) maintenance,
software update etc. The later one is quite frequent in practice. In that case check what was done
and think what it might have caused.
• Does the machine stop in "speed controller error" in turning points. If so, possibly the problem is in
the brakes. They do not release quickly enough. Another possibility is a boulder or other obstacle
on the road, that prevents the machine slow movement.
• Is there strange behavior in machine control functions or sensor values? Be sure that supply voltage
for all InfraFREE components is stable +24 V and all the return wires are connected and really in
0 V potential. Also make sure, that the CANbus is working properly. Read the CAN error counters
on the CS display.

Do not connect or disconnect any InfraFREE connectors, when

powered on. Breaking the return wire occasionally before +24 V
supply wire may cause return current flowing through signal
wires and thus damage equipment.

• Does this machine stop often in errors 6 and 224 ("wall too close" and "position lost - correlation
error")? This is very probably caused by scanner problems: Scanner may be dirty outside or wet
inside. Clean the lens and check the humidity absorber. Check that there are no obstacles in front
of the scanner beam (view area 180 degrees). Also it is possible, that the scanner position has
changed since the calibration. Take log by driving machine in auto in straight tunnel. Send the logfile
to the remote support center for analyze. According to analyze you may have to re-calibrate a
scanner. (See section checking and adjusting, sensor calibration instructions). The position
confidence of navigation can be also followed in IF-MCS logfile. Look for row e.g. "Pos-Conf.: 31".
In this case the confidence is certainly too low. Normally should be over 90%, but can temporarily
drop down to 50%.
• Does the position of the machine suddenly "jump" far away, typically "inside the rock" or "slide"
forward or backward even though the machine has already stopped. This may be caused by
odometer errors. It has been noticed, that sometimes the odometer generates false readings, that
cause this kind of behavior. In these cases the direction of "jump" or "sliding" is always the current
machine direction, forward or backward. This kind of odometer error can be traced from IF-MCS
logfile. Look for row e.g. "Distance: 72.7568" showing the odometer value in meters. Compare it
with position values, e.g. "XposFront: 399.7790 and YposFront: 485.0020". Position should change
about the same amount than distance. The odometer sensor faults can be also traced from the CS
display module logfile. CS has an alarm for false (lack off) odometer pulses.

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4.2.7. Connection failure to the navigation module

If connection to the navigation module is not possible to be created, it means that either:
1. The Ethernet cable to the navigation module is damaged.
2. There is no power to the navigation module or video box in which the Ethernet switch is located.
3. The navigation module power supply card is damaged.
4. The navigation module CPU card is damaged.
5. The navigation module flash is corrupted.
6. The pilot has crashed.

Damaged Ethernet cable

When connection is not possible to establish to the navigation module, cable X3107, the navigation
module Ethernet cable, might be damaged. A quick way of determining this, is to check the switch
located in the onboard video box - check if the connection lights on the switch are lit when the power
to the navigation module is turned on.

If the connection light is not on, take a direct nav-

igation module connection with a special Ethernet
cable. This cable has a RJ-45 connector on one
end, and a mil-connector on the other end. The
figure provides the pin-out for such a cable.

If the laptop Ethernet cards’ connection light does not lit up, then there is a problem with either the
power supply to the navigation module, or a hardware problem. Make sure that the laptop's Ethernet
card is working, as well as the test Ethernet cable.

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Power test

Disconnect the power cable from the navigation module. Switch the machine on and wait for the
power-on delay to time out. Test the cable for:
• Pins A-B : 24 V (Delayed power).

Delay should be AT MINIMUM around 3-5 sec. It can be set by

adjusting the power supply delay relay at machine’s main
electrical box. If delay is too short there is a risk of hardware
damage for InfraFREE upon power up due the scanners and
other sensors take a lot current and InfraFREE CPU / FLASH
card might suffer supply power brownout.

• Pins C-B : 24V (Immediate power)

If the power is OK, the pilot might have crashed.

Make sure that the debug port loopback is not installed. This
will cause the navigation module to go to a default IP address.

PS-, CPU board damaged or flash corrupt

The only way to check whether the PS-board, CPU board or flash are faulty, is to open the navigation
module.
This should be done by trained personnel in a laboratory environment only with a spare sealing set
and proper tools, so the only remedy is to change to navigation module. Refer to the "Configuring a
new navigation module" section to setup a new navigation module.

Pilot has crashed

If changes to the parameter file or system files were made, it is possible that the pilot crashed. A
corrupted flash might also cause the pilot to crash.
To recover from a software crash, it is possible to boot the navigation module without starting the
pilot. To boot the navigation module without starting the pilot:
1. Switch off the power to the navigation module.
2. Put a loopback connector on the debug serial port (alternatively bridge pins A-B on the debug
serial port).
3. Turn on the power to the navigation module with the loopback connector connected to the debug
port. This causes the navigation module to boot with an alternative host file, thereby not starting
the pilot software.
4. Try to get a connection now to IP 10.10.14.100. If no connection is possible, the PSU, CPU of
flash might be damaged.

When bridging serial port pins make sure not to bridge the
wrong pins. Connecting the wrong pins to GND or 5V will
damage the port.

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4.2.8. Testing the hardware and sensors

Once a telnet connection has been established to the navigation module, it is now possible to test all
the sensors connected to the navigation module.

Navigation module E-stop and accelerometers

The Navigation module E-stop is tested in conjunction with the accelerometers. The E-stop output is
connected with a special test cable to the accelerometer input on the navigation module.
Connect the acceleration sensor cable pin F (input 1) to emergency stop cable pin A (5 V).
The hwtest will then activate the E-stop output, which will cause 5V to be input on the analogue input
card (accelerometer input), which will then be read by the hwtest program. Once this input is read on
the accelerometer input, the test passes.
If the test fails, either the E-stop output is blown, or the analogue input card which reads the
accelerometers is blown. The E-stop may be forced by starting the pilot and forcing the pilot from fast
stop to standby.

Odometer

The odometer consists of two proximity switches that count the "holes" in the driveshaft speed-cardan.
These pulses are counted and converted to distance. The proximity sensors are connected in parallel
to both the InfraFREE navigation unit and the machine VCM System.

Machine VCM System

The machine CS uses only one of the proximity

signals to determine speed. The other signal is
not used. The CS does however display the in-
puts for both, and is useful for faultfinding:
The frequencies should be within 2% of each oth-
er (inputs XF3/16 and XF3/17).
Even though the frequencies are displayed cor-
rectly on the CS display, there might still be prob-
lems with the signals read by InfraFREE due to
incorrect phasing or cabling to InfraFREE.

InfraFREE

The odometer is cardinal to the correct working of the InfraFREE software. The navigation system
obtains distance travelled and direction from the odometer.

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Missing proxy signal and incorrect phasing

The quickest way to check if there are missing pulses from one of the proxy’s is to connect a two-
channel oscilloscope to the proxy’s:
Connect the oscilloscope between the odometer sensor cable pin A (+ 12 V) and pin C (+ 12 V). Use
the pin B (GND) for ground.

From the scope recording, it can quickly be de-

termined whether a proxy signal is missing or
whether the phasing is out. Signal goes up when
sensor sees metal on the plate installed around
cardan axle.

Notes:
• The odometer proximity signals are checked using oscilloscope with 2 channels.
• The two signals need to be 90 degrees out of phase.
• Especially the point when A signal goes down, how much after the B goes down is important.
• If signal A and B go up/down too fast after each other, InfraFREE can fail to measure any speed,
distance or direction.
• This case shown in oscilloscope screen capture is quite optimum when there is clear phase
difference between signals A and B.
• The phase difference can be adjusted by physically moving the proxy’s left-or-right in the slots at
the cardan
• If not enough left-right movement can be achieved, the same result can be achieved by moving the
proxy’s in-or-out.
• If the air-gaps between the two proxy’s and the cardan are different, it will effect the switching of
the proxy. It may take longer for one proxy to turn on than for the other. This might have adverse
effects at high speeds.

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Testing the navigation module counter board

The pulses are read into the navigation module by a counter board. If one signal is missing from the
counter board, the resultant speed read by InfraFREE will be zero. Similar, if the phasing is out, some
pulses will be missed or the resultant speed read by InfraFREE will be zero.

To test the counter board, use the following

hwtest command:
hwtest -c O
This option will continuously display the cumula-
tive odo-counters.

Test sequence:
1. Start the ODO test. The cumulative pulse counter will be zero.
2. Drive forward for at least 15 m without using steering (longer distaces prefered if possible).
3. Check the printout whilst driving: the counter should increase uniformly as the machine moves
forward.
4. Stop after 15 m, and reverse to the starting point, also without using the steering. As the machine
reverses, the counter should decrement uniformly.
5. Stop exactly on the starting point. The cumulative counter should be now close to zero again. If
there is more than 50 counts difference, there is a problem with the ODO.

These problems are crucial for autonomous operations since positioning is based mostly on distance
and only secondary to laser scanners.
Notes:
• If at any time during the test the cumulative counter jumps excessively, the counter board is
damaged (provided the proxy phasing is correct).
• If at any time during the test the cumulative counter jumps to 65536 (max counts), the counter board
is faulty.
• If one speed signal is missing (e.g broken proxy), the cumulative counter will not change.
• If the proxy phasing is out, some pulses will be missed. This will be seen as an excessive difference
in the cumulative counter when the machine has been reversed to the starting position.

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Steering- and Boom/Box sensor

The navigation module reads these sensor values form the CANbus. To test the steering or boom/
bucket sensor from the navigation module, use the following hwtest command line options:
To test the middle joint sensor: hwtest -c MJ
To test the boom/box sensor: hwtest -c BO

These commands will continuously print the sen-

sor values, until CNTRL-C is pressed.

This hwtest option is different from the other tests, in that it will
not detect an intermittent cable problem - if the connection to
the sensor falls away during the test, the same reading will be
displayed. This option is thus not helpful for finding cable
problems.

1 Navigation module
1 2 5 6
2 Navigation module CAN interface
3 Navigation module CAN cable (X391)
4 CANbus network
5 Sensor cable (B330)
6 CAN sensor

3 4

If the printed sensor reading is zero, it means one of the following may be faulty:
• Navigation module CAN cable (cable X391)
• Sensor cable (cable B330)
• Navigation module CAN interface
• Sensor is broken

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Navigation module CAN cable

If there are no readings at all, it might mean that the navigation module CAN cable or CAN interface
is broken. First run the other CAN sensor checks to see whether any other CAN data is received. If
no CAN data is received at all, either the CAN cable or navigation module CAN interface is damaged.

There is not a hwtest available to test these cables. The only way
to check the cable is to measure with a multimeter.

3.75 V
CAN high

2.5 V

CAN low
1.25 V
0 0 1 0 1 0 1 0 0 1 1 0 1 0 1

1 4

3 6

1 Chair module 2 Front module

3 Middle module 4 Rear module
5 Display 6 Node id connector
When measuring, while power from CAN is off, there should be a 60 ohm reading between CAN high
and CAN low wires (120 ohm at each end of bus equates to 60 ohm in the middle at any point).
When power is on in both CAN high and CAN low voltages will be constantly changing according to
CAN state.
If no readings are obtained from other CAN devices or the spare CAN navigation module port, first
change the CAN cable, then the navigation module.

Sensor cable

If sensor readings were obtained from other CAN devices, but the current sensor gives no readings,
either the sensor cable or the sensor itself is broken.

There is not a hwtest option to test the cable, so the cable has
to be tested with a multimeter for continuity and insulation.
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Broken sensor

1. Change the sensor with a spare unit.

2. Run the hwtest again.
If the sensor was changed, or if the sensor shaft was
disconnected at any stage, the sensor must be recalibrated
using the machine VCM System interface. Calibrations are
crucial for correct autonomous operations.

Tilt sensor

The bucket tilt sensor is a bit different from the other CAN sensors in that it is a 4-20 mA sensor,
whose reading is then converted and copied to the CANbus.
When testing and faultfinding the tilt sensor, first check that the 4-20 mA signal is received by the
mA/CAN converter, and then follow the same steps as with the other CAN sensors, while using the
following command line option:
hwtest BU

Front and rear laser scanners

Testing the laser scanner connection to the navigation module involves 3 steps:
1. Test the navigation module serial port that connects to the scanner.
2. Test the cable that connects the scanner to the navigation module.
3. Test the laser scanner.

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Testing the navigation module port

The front and rear laser scanners are connected via two RS-422 to the navigation module.
The ports are easily tested by using loopback connectors and the hwtest program. The loopback
connector basically connects the TX+ to RX+ and TX- to RX- on the serial port. This means that any
data sent to the port is immediately received back. When the hwtest is running, it sends a test string
to the port and expects exactly the same string back. If the string is successfully received, it means
that both the RX and TX part of the port are fine.
The loopback connects the following on the navigation module itself:
• Connect the laser scanner cable pin A (RXD-) to the laser scanner cable pin F (TXD-).
• Connect the laser scanner cable pin B (RXD+) to the laser scanner cable pin G (TXD+).

To test the navigation module scanner serial

ports, use the following hwtest command line op-
tion:
hwtest 3 or hwtest 4
Port number three is the front scanner and port
number four is the rear scanner. A successful re-
sult is presented on right.
If the test fails, the port is damaged and the nav-
igation module needs to be changed.

A quick way to check a scanner port is to swop the front and

rear scanner cables. Just remember to put the cables back in
NOTE!
their correct positions, since swopped rear- and front scanner
cables will cause problems during auto driving.

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Testing the scanner cable

Before using the hwtest to check the scanner cable, test the cable for continuity and insulation:
• Continuity: All readings < 0.2 Ohm.
• Insulation between cores : Infinite
• Insulation between cores and earth: Infinite

Never use a test device on the scanner cables while the cable
is still connected to the navigation module or laser scanner.

After the cable has been tested OK, connect the special loop-back connector to the phoenix-laser
scanner connector:
• Connect the laser scanner cable pin 9 (TXD-) to the laser scanner cable pin 1 (RXD-).
• Connect the laser scanner cable pin 10 (TXD+) to the laser scanner cable pin 2 (RXD+).

To test the scanner cables with the hwtest utility, use the following command line option: hwtest -c 3
for the front scanner port or hwtest -c 4 for the rear scanner port. This will continuously send test data
to the port, and expect the same data back.
Since the loopback is now at the end of the cable, the cable is also tested in this fashion. Whilst the
test is running, wiggle the cable at each bend and connector. As soon as one test string is missed
(due to a bad cable), the test will stop and fail. This is an indication that the cable is faulty and needs
to be replaced.

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Testing the laser scanner

After the navigation module port and cable have been tested, the laser scanner itself may be tested.
To test the laser scanner, use the following command line option: hwtest -d SF for the front scanner
or hwtest -d SR for the rear scanner.

This will run the detailed scanner test. Sequence

sends a full initialisation string to the scanner and
also checks all the status bits inside the scanner.
A successful test is as shown on right:
If the test fails, the scanner is damaged and
needs to be changed.

When an intermittent problem is suspected with the laser

scanner or cables, it might be useful to run the continuous laser
scanner tests. This test will abort as soon as any error is
received. To run the continuous scanner test, type: hwtest -c SF
for the front scanner testor hwtest -c SR for the rear scanner
test.

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Gyro

Communication from the navigationmodule to the gyro is via a RS-485 serial port, using a two wire
configuration.
Since the gyro communication is half-duplex, no loopback
connector can be used to test the gyro serial port on the
navigation module.

The only way of determining whether the port is broken is by method of elimination - if the cable or
gyro is not broken, it has to be the navigation module serial port. The gyro communication is tested
by the following hwtest command line options:
Normal detailed test: hwtest -d G
Continuous detailed test useful for checking the gyro cable: hwtest -cd G

The first test reads the gyro for a predefined time

and then calculates the gyro drift. This is useful
for determining whether the gyro has excessive
drift, in which case the gyro needs to be changed.
If there is no response form the gyro, the cable
needs to be tested.

The second test is useful for finding faulty cables.

While the test is running, "wiggle" the cable at
each bend and connector and check whether the
comms to the gyro falls away.
In the screenshot on right, the comms fell away
while the cable was being moved around. This
points to a cable with a bad connection.

The sensor module (gyro) is extremely sensitive for supply

power brownouts while booting and supply voltage varying too
much upon gyro start-up can cause malfunctions.

Check that the power-on delay to InfraFREE is at least 3

seconds. This is to give all the sensors a chance to boot before
InfraFREE boots up. When the boot period is too small, the gyro
might get damaged.

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4.2.9. InfraFREE error codes

Always take the logfile before performing any troubleshooting

actions. This is to assist in faultfinding and follow-up reports.
Once a critical alarm occurs, a log files should be taken within
one minute. All machine information is lost if a log is not taken
within one minute of the alarm being displayed.

InfraFREE generates several type of errors that are shown to the control station operator with RDT
or MCS / SS. Following list contains all errors that InfraFREE can generate and some instructions
how to deal with errors. Whenever the MCS / SS user is unsure of further actions, stop ALL
autonomous production and contact the system specialist.

Error number 1

Error name: SC_MEAS_R

Description: The rear scanner works but there are too many incorrect (too short or
long) measurements. The limit is defined by parameter
SCAN_D_ERR_LIM.

Possible reasons Checking Recovery

The scanner is dirty. Visual inspection. Cleaning the scanner.
There is an object very close to Visual inspection. Removing the extra object.
the scanner limiting visibility.
The machine is in such open If this case is suspected, take a Changing parameter
area that the scanners do not log and send to remote support. SCAN_D_ERR_LIM to a higher
see enough wall. value, if the reason is not dirty
scanner or extra object.

Error number 2

Error name: SC_INI_R

Description: The rear scanner does not reply properly or at all when initialized.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection. Cable fixing or change.
Serial port problem. Changing navigation unit or se-
rial board frame.
Scanner problem. Changing scanner.

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Error number 3

Error name: SC_COMM_R

Description: The rear scanner has stopped to communicate properly.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection. Cable fixing or change.
Serial port problem. Changing navigation unit or se-
rial board frame.
Scanner problem. Changing scanner.

Error number 4

Error name: SC_CRC_R

Description: Rear scanner communication CRC error in five consecutive distance
messages.

Possible reasons Checking Recovery

CPU overload. This should be a temporary Generating fast stop and initial-
problem. izing sensors.

Error number 5

Error name: SC_LENS_R

Description: The internal diagnostics of the rear scanner indicates that the lens is
too dirty to drive safely. Before this error there should be a warning
about dirty scanner.

Possible reasons Checking Recovery

Dirt on the scanner lens. Visual inspection. Cleaning the lens gently.

Error number 6

Error name: SC_WALL_R

Description: There is an obstacle seen by the rear scanner in the safety area of the
machine.

Possible reasons Checking Recovery

The machine is too near the Visual inspection, taking a log to Depends on the log analysis.
wall. remote support.
There is something hanging Visual inspection. Removing extra objects.
from the ceiling.
There is dust in the air. Visual inspection. Retrying automatic driving.

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Error number 7

Error name: SC_INT_R

Description: Unspecified error from the rear scanner internal diagnostics.

Possible reasons Checking Recovery

Taking a log file to remote sup- Generating fast stop and initial-
port if error repeats. izing sensors. If the error is fre-
quent, changing the scanner.

Error number 8

Error name: SC_MEAS_F

Description: The front scanner works but there are too many incorrect (too short or
long) measurements. The limit is defined by parameter
SCAN_D_ERR_LIM.

Possible reasons Checking Recovery

The scanner is dirty. Visual inspection. Cleaning the scanner.
There is an object very close to Visual inspection. Removing the extra object.
the scanner limiting visibility.
The machine is in such open If this case is suspected, take a Changing parameter
area that the scanners do not log and send to remote support. SCAN_D_ERR_LIM to a higher
see enough wall. value, if the reason is not dirty
scanner or extra object.

Error number 9

Error name: SC_INI_F

Description: The front scanner does not reply properly or at all when initialized.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection. Cable fixing or change.
Serial port problem. Changing navigation unit or se-
rial board frame.
Scanner problem. Changing scanner.

Error number 10

Error name: SC_COMM_F

Description: The front scanner has stopped to communicate properly.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection. Cable fixing or change.
Serial port problem. Changing navigation unit or se-
rial board frame.
Scanner problem. Changing scanner.
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Error number 11

Error name: SC_CRC_F

Description: Front scanner communication CRC error in five consecutive distance
messages.

Possible reasons Checking Recovery

CPU overload. This should be a temporary Generating fast stop and initial-
problem. izing sensors.

Error number 12

Error name: SC_LENS_F

Description: The internal diagnostics of front scanner indicates that the lens is too
dirty to drive safely. Before this error there should be a warning about
dirty scanner.

Possible reasons Checking Recovery

Dirt on the scanner lens. Visual inspection. Cleaning the lens gently.

Error number 13

Error name: SC_WALL_F

Description: There is an obstacle seen by the front scanner in the safety area of
the machine.

Possible reasons Checking Recovery

The machine is too near the Visual inspection, taking a log to Depends on the log analysis.
wall. remote support.
There is something hanging Visual inspection. Removing extra objects.
from the ceiling.
There is dust in the air. Visual inspection. Retrying automatic driving.

Error number 14

Error name: SC_INT_F

Description: Unspecified error from the front scanner internal diagnostics.

Possible reasons Checking Recovery

Taking a log file to remote sup- Generating fast stop and initial-
port if error repeats. izing sensors. If the error is fre-
quent, changing the scanner.

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Error number 15

Error name: GY_COMM

Description: Gyro does not start to send anything through serial port or stops to
send.

Possible reasons Checking Recovery

Cable problem. Visual inspection, cable change, Cable fixing or change.
hwtest.
Serial port problem. Navigation unit or frame change, Navigation unit or serial board
hwtest. frame changing.
Gyro problem. Gyro change, hwtest. Changing gyro.

Error number 16

Error name: GY_POWER

Description: Not in use with Litef gyro.

Error number 17

Error name: GY_INT

Description: Gyro interface error.

Possible reasons Checking Recovery

CPU overload. Take a log file to remote support Reinitializing the sensor.
Serial port problem. Take a log file to remote support Changing gyro or cable.
Gyro problem. Take a log file to remote support Changing gyro or cable.

Error number 18

Error name: GY_ZERO

Description: Gyro heading zeroing command does not affect.

Possible reasons Checking Recovery

CPU overload. Take a log file to remote support Reinitializing the sensor.
Serial port problem. Take a log file to remote support Changing gyro or cable.
Gyro problem. Take a log file to remote support Changing gyro or cable.

Error number 19

Error name: GY_TEMP

Description: Not in use with Litef gyro.

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Error number 20

Error name: GY_MEAS

Description: Gyro heading out of range.

Possible reasons Checking Recovery

Gyro error. Log to remote support. Changing gyro.

Description: Too high heading rate from gyro (parameter GYRO_MAX_H_RATE)

Possible reasons Checking Recovery

Sensor box loosened, gyro er- Sensor box inspection, log to re- Changing gyro.
ror. mote support.

Error number 21

Error name: GY_INI

Description: Gyro drift out of range (defined by parameter GYRO_MAX_DRIFT)

Possible reasons Checking Recovery

Gyro loosened. Visual inspection. Fixing the gyro.
Machine is moving during sen- Visual inspection. Reinitializing the sensor and
sor initialization. making sure the machine does
not move.
Gyro is broken. Log to remote support. Changing gyro.

Error number 22

Error name: STE_COMM

Description: Steering angle sensor communication error. No angle measurement
from CAN bus.

Possible reasons Checking Recovery

Sensor or cable broken, CAN Visual inspection, hwtest. Changing the cable, steering
bus interface card broken. sensor or CAN bus interface
board.

Error number 23

Error name: STE_MEAS

Description: Steering angle measurement rate out of range (parameter AN-
GLE_MAX_RATE).

Possible reasons Checking Recovery

Sensor fastening broken. Visual inspection. Repairing sensor fastening.
Sensor broken (jumping read- Log to remote support. Changing steering sensor.
ing).

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Error number 24

Error name: BO_COMM

Description: Boom angle communication error. No angle measurement from CAN
bus.

Possible reasons Checking Recovery

Sensor or cable broken, CAN Visual inspection, hwtest. Repairing or changing the cable,
bus interface card broken. boom sensor or CAN bus inter-
face board.

Description: Boom angle communication error. No box sensor reading from CAN
bus.

Possible reasons Checking Recovery

Sensor or cable broken, CAN Visual inspection, hwtest. Repairing or changing the cable,
bus interface card broken. boom sensor or CAN bus inter-
face board.

Error number 25

Error name: BO_MEAS

Description: Boom angle communication error. Boom measurement out of range
(parameter BO_SCALE).

Possible reasons Checking Recovery

Calibration problem. Check parameter BO_SCALE. Correction of parameter.

Description: Boom or box measurement rate out of range (parameter

BO_MAX_MOVEMENT).

Possible reasons Checking Recovery

Sensor fastening or sensor bro- Visual inspection, hwtest. Sensor fastening or repair.
ken.

Error number 26

Error name: BU_COMM

Description: Bucket angle sensor communication error. No angle measurement
from CAN bus.

Possible reasons Checking Recovery

Sensor or cable broken, CS Visual inspection, hwtest. Changing the cable, CS module
problem, CAN bus interface or CAN bus interface board.
card broken.

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Error number 27

Error name: BU_MEAS

Description: Bucket measurement out of range (parameter BU_SCALE).

Possible reasons Checking Recovery

Calibration problem. Check parameter BU_SCALE. Correction of parameter.

Description: Bucket measurement rate out of range (parameter BU_MAX_MOVE-

MENT).

Possible reasons Checking Recovery

Sensor fastening or sensor bro- Visual inspection, hwtest. Sensor fastening or repair.
ken.

Error number 28

Description: Odometer measurement error. Odometer reading out of range (pa-

rameter SPEED_MAX).

Possible reasons Checking Recovery

Odometer measurement prob- A log to system remote support. Fix the odometer related hard-
lem (missing or extra pulses, Odometer calibration. Calibrate ware, if the reason is there. Cal-
pulse sensor attachment) or cal- at least three times and check ibration of odometer.
ibration problem, counter board that parameter ODO_SCALE
problem. gets the same value each time.

Error number 29

Error name: MASTER_COMM

Description: Master channel communication break.

Possible reasons Checking Recovery

MineLAN problem (most proba- Restart communication. If it Retry operation.
bly local radio coverage prob- does not help, try to ping differ-
lem). ent parts onboard the machine.
Cabling problem. Try to ping the navigation mod- Locate the broken cable or con-
ule. nector and fix it.
Socket configuration problem in Check the file. Edit and save the file sock-
sockets.xml (if communication ets.xml, reboot the navigation
has worked and then breaks, module.
this is not a reason).

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Error number 30

Error name: REMOTE_COMM

Description: Remote channel communication break or fast stop commanded from
PLC.

Possible reasons Checking Recovery

MineLAN or PLC problem (most Restart communication. If it Retry operation.
probably local radio coverage does not help, try to ping differ-
problem). ent parts onboard the machine
and make sure the PLC gets
messages from InfraFREE.
Cabling problem. Try to ping the navigation mod- Locate the broken cable or con-
ule. nector and fix it.
Socket configuration problem in Check the file. Edit and save the file sock-
sockets.xml (if communication ets.xml, reboot the navigation
has worked and then breaks, module.
this is not a reason).

Error number 31

Error name: CAN_COMM

Description: CAN bus communication error (CS gives an error status to InfraFREE).

Possible reasons Checking Recovery

An error detected by CS. Check CS error log. Depending on the error.
An error detected by InfraFREE Check CS error log. Depending on the error.
CAN interface.

Error number 32

Error name: GY_TEMP_WARN

Description: Litef gyro has informed about too high internal temperature.

Possible reasons Checking Recovery

Gyro problem. Check the outside temperature Improve gyro cooling or chang-
of the gyro. ing the gyro.

Error number 33

Error name: GY_CONT_LOOP

Description: Gyro internal error.

Possible reasons Checking Recovery

Gyro failure or too low polling Gyro change or a log to remote Changing the gyro.
rate by InfraFREE. support.

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Error number 34

Error name: GY_HARDWARE

Description: Gyro internal diagnostics indicates a hardware error.

Possible reasons Checking Recovery

Gyro broken. Gyro change. Retrying or gyro change.

Error number 35

Error name: GY_MEAS_RANGE

Description: Gyro internal diagnostics indicates that the turning rate of gyro has
been too high.

Possible reasons Checking Recovery

Gyro attachment loosened. Visual inspection. Fixing the gyro attachment.

Error number 36

Error name: GY_UNKNOWN

Description: Gyro internal diagnostics indicates that the gyro has received an un-
known command.

Possible reasons Checking Recovery

Occasional communication Retry driving. Retry driving.
problem.

Error number 37

Error name: AD_CONV

Description: AD conversion of acceleration measurement has failed.

Possible reasons Checking Recovery

Measurement board problem. Change the board. Retry and if necessary, change
the board.

Error number 38

Error name: ACC_FW

Description: Filtered value of measured forward acceleration is out of range (pa-
rameter ACC_FW_MAX_VAL).

Possible reasons Checking Recovery

I/O board problem. Board change. Changing I/O board or sensor
box.
Sensor or sensor attachment Sensor box change or visual Fixing the attachment of sensor
problem. checking of attachment of accel- or sensor box.
erometer sensor or sensor box.
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Error number 39

Error name: ACC_UP

Description: Filtered value of measured upwards acceleration is out of range (pa-
rameter ACC_UP_MAX_VAL).

Possible reasons Checking Recovery

I/O board problem. Board change. Changing I/O board or sensor
box.
Sensor or sensor attachment Sensor box change or visual Fixing the attachment of sensor
problem. checking of attachment of accel- or sensor box.
erometer sensor or sensor box.

Error number 40

Error name: SC_BUCKET_F

Description: An obstacle seen by the front scanner very close to the bucket.

Possible reasons Checking Recovery

A rock hanging out from the Visual checking. Take a log to Moving the rock hanging out
bucket or the bucket is near the remote support. from the bucket or moving the
wall. machine further away from the
wall and then retry to drive.

Error number 41

Error name: SAFETY_CHANNEL

Description: Not currently in use.

Error number 42

Error name: PLC_ID

Description: Different PLC ID in MCS / SS ConnectRemote message and remote
channel message.

Possible reasons Checking Recovery

MCS / SS configuration error. Take a log to remote support. Fixing the MCS / SS configura-
tion.

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Error number 43

Error name: GY_DIAG_RATE

Description: Gyro measurement rate does not comply with rate calculated from
steering angle and speed measurement.

Possible reasons Checking Recovery

Gyro error. Hwtest. Take a log to remote Changing gyro.
support.
Steering angle measurement er- Checking steering angle meas- Fixing steering angle measure-
ror. urement (hwtest/visual). Take a ment.
log to remote support.
Speed measurement error. Checking speed measurement Fixing speed measurement.
(hwtest/visual). Take a log to re-
mote support.

Error number 44

Error name: GY_DIAG_CORR

Description: Transversal position correction exceeds a given parameter
(LOC_MAX_CUM_CORR).

Possible reasons Checking Recovery

Gyro error. Hwtest. Take a log to remote Changing gyro.
support.
Steering angle calibration error. Checking steering angle meas- Fixing steering angle calibration.
urement (hwtest/visual). Take a
log to remote support.
Scanner orientation calibration Checking speed measurement Fixing scanner calibration.
error. (hwtest/visual). Take a log to re-
mote support.

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Error number 45

Error name: ODO_DIAG_CORR

Description: Odometer measurement does not comply with scanner based position
correction in the direction of motion (parameter
LOC_MAX_ODO_DRIFT).

Possible reasons Checking Recovery

Scanner problem. Checking odometer calibration. Fix the odometer related hard-
Calibrate at least three times ware, if the reason is there. Cal-
and check that parameter ibration of odometer, steering
ODO_SCALE gets the same and scanner orientation.
value each time. Steering angle
and scanner calibration, if od-
ometer calibration is ok. Take a
log to remote support.
Odometer measurement prob- Checking odometer calibration. Fix the odometer related hard-
lem (missing or extra pulses, Calibrate at least three times ware, if the reason is there. Cal-
pulse sensor attachment) or cal- and check that parameter ibration of odometer, steering
ibration problem, counter board ODO_SCALE gets the same and scanner orientation.
problem. value each time. Steering angle
and scanner calibration, if od-
ometer calibration is ok. Take a
log to remote support.
A deep hill or badly taught envi- Checking odometer calibration. Fix the odometer related hard-
ronment may also cause this er- Calibrate at least three times ware, if the reason is there. Cal-
ror. and check that parameter ibration of odometer, steering
ODO_SCALE gets the same and scanner orientation.
value each time. Steering angle
and scanner calibration, if od-
ometer calibration is ok. Take a
log to remote support.

Error number 46

Error name: REMOTE_STOP

Description: Remote faststop commanded from PLC.

Possible reasons Checking Recovery

Not a system error.

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Error number 51

Error name: STE_CONT

Description: Steering response does not comply with the steering command (pa-
rameters ANGLE_FAIL_LIMIT, ANGLE_MIN_RATE and AN-
GLE_CMD_LIM).

Possible reasons Checking Recovery

Steering angle error, sensor fas- Visual inspection, testing the Fixing the sensor, sensor fas-
tening broken or hydraulic ac- steering response in remote. tening or hydraulic error.
tuator error. Take a log to remote support.

Error number 52

Error name: PO_CONT

Description: Postion controller error:
1. Too large heading error.
2. Too large position.
3. Unable to create a shortcut path to the original path (currently not
active).

Possible reasons Checking Recovery

Machine too far away from the Visual inspection of machine po- Initialize position and if neces-
path or heading error is too high sition relative to the path. In- sary, drive the machine close to
after loading. spection of speed profile, route the path. If the problem is fre-
curvature and environment quently at the same location, ed-
model at a problematic location. it the route or the speed or re-
teach the environment.
Driving speed is too high or cur- Visual inspection of machine po- Initialize position and if neces-
vature of path is too high relative sition relative to the path. In- sary, drive the machine close to
to speed. spection of speed profile, route the path. If the problem is fre-
curvature and environment quently at the same location, ed-
model at a problematic location. it the route or the speed or re-
teach the environment.
Bad environment model causes Visual inspection of machine po- Initialize position and if neces-
fast localization correction dis- sition relative to the path. In- sary, drive the machine close to
turbing the position controller. spection of speed profile, route the path. If the problem is fre-
curvature and environment quently at the same location, ed-
model at a problematic location. it the route or the speed or re-
teach the environment.

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Error number 53

Error name: SP_CONT

Description: Speed controller error. Machine does not start to move in automatic
mode.

Possible reasons Checking Recovery

Machine pushing against a bar- Visual checking of possible bar- Removing the barricade, fixing
ricade or speed measurement ricade or odometer testing the odometer.
does not work. (hwtest).

Description: Speed controller error. Too high speed error (reference speed relative
to measured speed) too long time (parameters SPEED_FAIL_LIMIT
and SPEED_ERR_CNT_LIM).

Possible reasons Checking Recovery

Brake problem (brakes on dur- Brake pressure checking during Repairing the brake system.
ing driving), too high reference automatic driving using CS.
speed.

Description: Speed controller error. Machine does not stop in 4 s after reaching the
end of the drive order.

Possible reasons Checking Recovery

Brake problem. Testing brakes in remote. Repairing the brake system.

Error number 54

Error name: BR_CONT

Description: Brake controller error:
1. Braking takes too long time.
2. Too high speed error during braking too long time (parameters
BR_SPEED_DROP, BR_MIN_CMD, BR_TIME).

Possible reasons Checking Recovery

Brake problem. Testing brakes in remote. A log Repairing the brake system.
to remote support.

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Error number 55

Error name: BO_CONT

Description: Boom controller error. Too high boom or box error value too long time
(parameters BO_ERR_LIM, BO_WAIT_TIME, BOX_WAIT_TIME).

Possible reasons Checking Recovery

Sensor problem, actuator prob- Check the sensor and the actua- Repairing the hardware prob-
lem, bucket pushing against an tor in remote mode, take a log to lem, if any; remove the possible
object. remote support. barricade.

Description: Boom controller error. Sensor reading does not change according to
controller commands (parameters BO_CMD_LIM and BO_NO_MO-
TION_ERR_CNT).

Possible reasons Checking Recovery

Sensor fastening broken or Visual inspection, testing the Repairing the sensor fastening.
boom actuator problem. boom response in remote, take
a log to remote support.

Description: Boom controller error. Box sensor reading does not change according
to controller commands (parameter BO_LIM)

Possible reasons Checking Recovery

Sensor fastening broken or box Testing in manual mode and Repairing either sensor or box
actuator problem. printing the box sensor reading. actuator.
Take a log to remote support.

Description: Boom controller error. In autotramming, the measured boom value is

too far away from the last reference value (parameters BB_MONITOR,
BO_LIM).

Possible reasons Checking Recovery

Hydraulic problem (leakage). A log to remote support. Fix the possible hydraulic leak-
age.

Description: Boom controller error. Dumping of the bucket does not take place in
20 seconds.

Possible reasons Checking Recovery

Sensor problem, actuator prob- Check the sensor and the actua- Repairing the hardware prob-
lem, bucket pushing against an tor in remote mode, take a log to lem, if any; remove the possible
object. remote support, visual checking object.
of an object e.g. under the buck-
et.

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Error number 56

Error name: BU_CONT

Description: Bucket controller error. Too high bucket error value too long time (pa-
rameters BU_ERR_LIM, BU_WAIT_TIME).

Possible reasons Checking Recovery

Sensor problem, actuator prob- Check the sensor and the actua- Repairing the hardware prob-
lem, bucket pushing against an tor in remote mode, take a log to lem, if any; remove the possible
object. remote support. barricade.

Description: Bucket controller error. In autotramming, the measured bucket value

is too far away from the last reference value (parameters BB_MONI-
TOR, BU_LIM).

Possible reasons Checking Recovery

Hydraulic problem (leakage). Take a log to remote support. Fix the possible hydraulic leak-
age.

Description: Bucket controller error. Sensor reading does not change according to
controller commands (parameters BU_CMD_LIM and BU_NO_MO-
TION_ERR_CNT).

Possible reasons Checking Recovery

Sensor fastening broken or Visual inspection, testing the Repairing sensor fastening.
bucket actuator problem. steering response in remote.
Take a log to remote support.

Error number 57

Error name: WALL_FOLL

Description: Not currently in use.

Error number 58

Error name: BB_BUSY

Description: Not currently in use.

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Error number 59

Error name: ENGINE

Description: Engine error:
1. Engine RPM is too low (engine has stopped without InfraFREE
stopping it).
2. Engine does not start in time (parameter
ENG_MAX_START_TIME).
3. Engine not running while starting autotramming.

Possible reasons Checking Recovery

No safety signal or CAN heart Check the safety signal and Find out the reason for missing
beat to TCS, emergency button heart beat and the emergency safety signal or heart beat and
down, machine related reasons. buttons. Check other machine fix it.
Or human error. related reasons.

Error number 60

Error name: CABLE_REEL

Description: Cable reel error in electrical machines.

Possible reasons Checking Recovery

This error is based on CS error Use CS to check this error. Depends on error.
indication.

Error number 61

Error name: PO_CONT_HEAD

Description: Too large heading error.

Possible reasons Checking Recovery

Machine too far away from the Visual inspection of the machine Initialize position and if neces-
path or heading error is too high position relative to the path. In- sary, drive the machine close to
after loading. spection of the speed profile, the the path. If the problem is fre-
Driving speed is too high or cur- route curvature and the environ- quently at the same location, ed-
vature of the path is too high rel- ment model at the problematic it the route or the speed or re-
ative to speed. location. teach the environment.
Bad environment model causes
fast localization correction dis-
turbing the position controller.

Error number 62

Error name: PO_CONT_SHORT

Description: Unable to create a shortcut path to the original path (currently not ac-
tive)

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Error number 63

Error name: PARK_BRAKE

Description: Parking brake problem. Parking brake does not release.

Possible reasons Checking Recovery

Parking brake is engaged when Check if parking brake is engag- Remove the problem indicated
machine is about to start driving. ed. Take alog to remote support. by CS.
The reason may be checked
from CS alarm list.

Error number 64

Error name: BB_TRAJ

Description: Amount of boom and bucket reference trajectories in the given seg-
ment too low (must be at least 1).

Possible reasons Checking Recovery

Human error. Check the route segment using Fix the faulty segment using
RDT. RDT or text editor.

Error number 100

Error name: NBR_SEG_CORR

Description: Maximum number of points for correlation exceeded.

Possible reasons Checking Recovery

Too long route selected to be Select shorter route. Retry.
driven using RDT.

Error number 101

Error name: MEM_ALLOC

Description: Not enough memory to allocate for InfraFREE.

Possible reasons Checking Recovery

Hardware problem of navigation QNX command sin info gives If the memory amount seen by
module. the amount of memory availa- QNX is less than 128 MB the
ble. It should be around 128 MB. CPU board or RAM memory
module must be changed.
Too large environment model. The size of environment model The environment model must be
file should not exceed 15 MB. limited to around 15 MB using
RDT.

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Error number 102

Error name: TASK_BLOCK

Description: One of the InfraFREE tasks blocked or killed.

Possible reasons Checking Recovery

Software bug or QNX overload- Take a log to remote support. Software correction. Retrying.
ing (e.g. taking or transferring a
log while InfraFREE is running).

Error number 103

Error name: FILE_SAVE

Description: Saving a file to flash or RAM disk failed.

Possible reasons Checking Recovery

Not enough disk space. Use df command to check that Free disk space.
there is enough free space in file
system.

Error number 104

Error name: FILE_READ

Description: Opening or reading environment, segment or parameter file failed.

Possible reasons Checking Recovery

File does not exist. Take a log file to remote support. Missing or corrupted files must
be replaced.
File contents is not what was ex- Take a log file to remote support. Missing or corrupted files must
pected (e.g. XML structure in- be replaced.
complete).
Log config file Take a log file to remote support. Missing or corrupted files must
be replaced.

Error number 105

Error name: BM_POSTURE

Description: InfraFREE internal error, task localize does not get position correction
from task beac_man.

Possible reasons Checking Recovery

CPU overload or software error. A log file to remote support. Restart, possible software up-
date.

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Error number 106

Error name: BM_SC_R

Description: Rear scanner task (read_di1) ceased to provide distance data to task
beac_man. Error SC_COMM_R should appear before this error.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

Error number 107

Error name: BM_SC_F

Description: Front scanner task (read_di1) ceased to provide distance data to task
beac_man. Error SC_COMM_F should appear before this error.

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

Error number 108

Error name: LO_GYRO

Description: Gyro task (read_gyr) ceased to provide distance data to task localize.
Error GY_COMM should appear before this error.

Possible reasons Checking Recovery

Cable problem. Visual inspection, cable change, Cable fixing or change.
hwtest.
Serial port problem. Navigation unit or frame change, Navigation unit or serial board
hwtest. frame changing.
Gyro problem. Gyro change, hwtest. Gyro change.
CPU overload. Take a log file to remote support. Restarting operation.

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Error number 109

Error name: LO_ODO

Description: Localization task (localize) ceased to get odometer data from task
speed_c.

Possible reasons Checking Recovery

This could be a chain reaction Take a log file to remote support. Restarting operation.
from a gyro problem or a soft-
ware error.

Error number 110

Error name: CU_REF

Description: Steering controller task (cur_c) ceased to get curvature reference from
the position controller (task pos_cont).

Possible reasons Checking Recovery

Software or parameter error. Take a log file to remote support. Software update or parameter
configuration.

Error number 111

Error name: CU_MEAS

Description: Steering controller task (cur_c) ceased to get steering angle meas-
urement from the CAN interface task.

Possible reasons Checking Recovery

Software or parameter error. Take a log file to remote support. Software update or parameter
configuration.

Error number 112

Error name: ST_BB

Description: Task bb_cont (boom and bucket controller) has not informed task state
about state change.

Possible reasons Checking Recovery

Software error. Take a log file to remote support. Software update.

Error number 113

Error name: ST_PC

Description: Task pos_cont (position controller) has not informed task state about
state change.

Possible reasons Checking Recovery

Software error. Take a log file to remote support. Software update.
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Error number 114

Error name: ST_BM

Description: Task beac_man has not informed task state about state change.

Possible reasons Checking Recovery

Software error. Take a log file to remote support. Software update.

Error number 115

Error name: ST_SP

Description: Task speed_c (speed controller) has not informed task state about
state change.

Possible reasons Checking Recovery

Software error. Take a log file to remote support. Software update.

Error number 116

Error name: WM_SC_R

Description: No distance data from the rear scanner interface task (read_di1) to
task wall_mon (obstacle avoidance).

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

Error number 117

Error name: WM_SC_F

Description: No distance data from the front scanner interface task (read_di2) to
task wall_mon (obstacle avoidance).

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

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Error number 118

Error name: SP_REF_TOUT

Description: Speed controller task (speed_c) ceased to get speed reference from
the position controller (task pos_cont).

Possible reasons Checking Recovery

Software or parameter error. Take a log file to remote support. Software update or parameter
configuration.

Error number 119

Error name: SP_REF_VAL

Description: The value of speed reference is out of limits (parameter
SPEED_MAX).

Possible reasons Checking Recovery

Problem in segment file. Use RDT. Editing the segment with RDT.

Error number 120

Error name: BE_SC_R

Description: No distance data from the rear scanner interface task (read_di1) to
task teach (active only when teaching environment).

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

Error number 121

Error name: BE_SC_F

Description: No distance data from the front scanner interface task (read_di1) to
task teach (active only when teaching environment).

Possible reasons Checking Recovery

Scanner cable problem. Visual inspection, cable change. Cable fixing or change.
Serial port problem. Navigation unit or serial board Changing navigation unit or se-
frame change. rial board frame.
Scanner problem. Scanner change. Changing scanner.
CPU overload. Take a log file to remote support. Restarting operation.

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Error number 122

Error name: PC_POSTURE

Description: No position data from task localize to the task pos_cont (position con-
troller).

Possible reasons Checking Recovery

Software error. Take a log file to remote support. Software update.

Error number 123

Error name: FILE_SAVE_RAM

Description: File save error to RAM disk.

Possible reasons Checking Recovery

RAM disk is full. Use df command to check that Free disk space.
there is enough free space in the
file system.

Error number 124

Error name: FILE_READ_ENV

Description: File read error, environment file

Possible reasons Checking Recovery

File does not exist. Take a log file to remote support. Missing or corrupted files must
be replaced. Corrective actions
may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.
File contents is not what was ex- Take a log file to remote support. Missing or corrupted files must
pected (e.g. XML structure in- be replaced. Corrective actions
complete). may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.

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Error number 125

Error name: FILE_READ_SEG

Description: File read error, segment file

Possible reasons Checking Recovery

File does not exist. Take a log file to remote support. Missing or corrupted files must
be replaced. Corrective actions
may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.
File contents is not what was ex- Take a log file to remote support. Missing or corrupted files must
pected (e.g. XML structure in- be replaced. Corrective actions
complete). may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.

Error number 126

Error name: SEG_DATA

Description: Segment data mismatch

Possible reasons Checking Recovery

In drive order message the re- Take a log file to remote support. Missing or corrupted files must
quested number of segments be replaced. Corrective actions
exceeds a given limit (50). may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.
In XmeterMovement command Take a log file to remote support. Missing or corrupted files must
the driving direction does not be replaced. Corrective actions
comply with the sign of refer- may include MCS / SS or Infra-
ence speed of the given seg- FREE software update or pa-
ment. rameter configuration.
A segment received in the drive Take a log file to remote support. Missing or corrupted files must
order does not exist. be replaced. Corrective actions
may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.
A commanded segment does Take a log file to remote support. Missing or corrupted files must
not include enough segment be replaced. Corrective actions
points (must be >2). may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.

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Possible reasons Checking Recovery

Consecutive points of a seg- Take a log file to remote support. Missing or corrupted files must
ment too far from each other be replaced. Corrective actions
(parameter may include MCS / SS or Infra-
PC_MAX_POINT_DIST). FREE software update or pa-
rameter configuration.
Start or end point given in the Take a log file to remote support. Missing or corrupted files must
drive order too far from the be replaced. Corrective actions
points of a given segment. may include MCS / SS or Infra-
FREE software update or pa-
rameter configuration.

Error number 127

Error name: EXTENSION_FAR

Description: Drive extension too far

Possible reasons Checking Recovery

Start point of a drive extension is Take a log file to remote support. Corrective actions include
too far from the last point of the MCS / SS or InfraFREE soft-
current drive order. ware update or parameter con-
figuration.

Error number 128

Error name: PROD_LEVEL

Description: Production level error

Possible reasons Checking Recovery

Incorrect level in command Star- Take a log file to remote support. Corrective actions include
Init (position initialization) MCS / SS or InfraFREE soft-
ware update or parameter con-
figuration.

Error number 200

Error name: SHORT_CUT_ERR

Description: Currently not in use.

Error number 201

Error name: TEACH_DRIFT

Description: Currently not in use.

Error number 202

Error name: TEACH_PATH

Description: Currently not in use.
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Error number 203

Error name: ST_CHANGE

Description: Currently not in use.

Error number 204

Error name: AUTO_HEADING

Description: Heading of the machine differs from the reference path when starting
autotramming.

Possible reasons Checking Recovery

Operator has placed the ma- Visual inspection (camera im- Correcting the heading in re-
chine in unfavorable orientation age). mote control.
after loading.

Error number 205

Error name: AUTO_POS

Description: Position of the machine differs from that of the reference path when
starting autotramming.

Possible reasons Checking Recovery

Operator has placed the ma- Visual inspection (camera im- Driving the machine into better
chine in unfavorable position af- age). position in remote control.
ter loading.

Error number 206

Error name: REM_ST_CHANGE

Description: Currently not in use.

Error number 221

Error name: INI_POS_FAR

Description: The start position in the position initialization message is too far away
from a given segment.

Possible reasons Checking Recovery

MCS / SS configuration error. InfraFREE and MCS / SS log Fixing MCS / SS configuration.
files to remote support.

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Error number 222

Error name: BOOM_HIGH

Description: Boom is too high when starting position is initialized. This can disturb
the front scanner.

Possible reasons Checking Recovery

Operator has left the boom too Visual inspection (possibly cam- Lowering the boom in remote
high. era image), trying to lower the control.
boom in remote control.

Error number 223

Error name: INI_CORR

Description: Currently not in use.

Error number 224

Error name: CORR

Description: Correlation error. The scanner measurements do not comply with the
environment well enough.

Possible reasons Checking Recovery

Scanner calibration or measure- A log file to remote support. Cal- Calibration. Re-teaching the
ment problem. ibration procedures (first odom- problematic area of the environ-
eter, then steering, then scanner ment model. New position initi-
orientations). alization and re-trying.
Steering angle calibration prob- A log file to remote support. Cal- Calibration. Re-teaching the
lem. ibration procedures (first odom- problematic area of the environ-
eter, then steering, then scanner ment model. New position initi-
orientations). alization and re-trying.
Odometer scaling error. A log file to remote support. Cal- Calibration. Re-teaching the
ibration procedures (first odom- problematic area of the environ-
eter, then steering, then scanner ment model. New position initi-
orientations). alization and re-trying.
Problems in environment model. A log file to remote support. Cal- Calibration. Re-teaching the
ibration procedures (first odom- problematic area of the environ-
eter, then steering, then scanner ment model. New position initi-
orientations). alization and re-trying.
Position of the machine initial- A log file to remote support. Cal- Calibration. Re-teaching the
ized in incorrect location. ibration procedures (first odom- problematic area of the environ-
eter, then steering, then scanner ment model. New position initi-
orientations). alization and re-trying.

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Error number 225

Error name: UNKNOWN_SEG

Description: Unknown segment in segment list of position initialization command
from MCS / SS.

Possible reasons Checking Recovery

MCS / SS configuration error. InfraFREE and MCS / SS log Fixing MCS / SS configuration.
files to remote support.

Error number 226

Error name: SEG_GAP

Description: In drive extension, segments are too far from each other (parameter
PC_MAX_POINT_DIST) or the given start point of new segment is too
far from the segment.

Possible reasons Checking Recovery

MCS / SS configuration error. InfraFREE and MCS / SS log Fixing MCS / SS configuration.
files to remote support.

Error number 227

Error name: PO_CUR_LARGE

Description: Curvature of the interpolated reference path calculated by InfraFREE
is too high (parameter CUR_MAX).

Possible reasons Checking Recovery

Most probably MCS / SS config- InfraFREE and MCS / SS log Fixing MCS / SS configuration or
uration error related to logical files to remote support. removing extra segment point.
segment connections. Another
possibility is that two points in
the beginning or end of a seg-
ment just taught are too near
each other.

Error number 228

Error name: SHORT_PATH

Description: A given drive order or drive extension contains less than 3 points.

Possible reasons Checking Recovery

Operator gives the target point InfraFREE and MCS / SS log Retrying the GoToPosition com-
of GoToPosition command too files to remote support. mand or fixing MCS / SS config-
near the machine. Also error in uration.
logical segment connections
could result this error.

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Error number 229

Error name: POS_NOT_INI

Description: Position not initialized when starting autotramming.

Possible reasons Checking Recovery

Operator error. Initialize position and retry. Initialize position and retry.

Description: Automatic position initialization after fast stop failed.

Possible reasons Checking Recovery

Position confidence is not high Quite obvious if this error comes Move the machine and initialize
enough (parameter by itself after releasing fast stop. position manually.
INI_POS_FSTOP_LIMIT).

Description: Over 3 min standing without position initialization.

Possible reasons Checking Recovery

Machine has been standing for Initialize position and retry. Initialize position and retry.
a long time.

Error number 230

Error name: SENSOR_INI_DISTURB

Description: Currently not in use.

Error number 231

Error name: EXTENSION_LATE

Description: Drive extension comes so late that the machine is already stopping.

Possible reasons Checking Recovery

The value of parameter Decrease the value of parame- Decresing parameter value.
SPEED_AHEAD_DIST is too ter SPEED_AHEAD_DIST by
high meaning a too long slow 20% and retry.
down ramp at the end of a drive
order.

Error number 232

Error name: HIGH_ACC

Description: Currently not in use.

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Error number 233

Error name: POS_LOW_CONF

Description: Current position confidence is too low when starting a drive order (pa-
rameter LOC_MIN_POS_CONF).

Possible reasons Checking Recovery

The machine has got lost before Initialize position and retry.
the drive order, for example
when loading.

Error number 234

Error name: PAR_READ_FAIL

Description: Parameter files internal error detected when reading it.

Possible reasons Checking Recovery

Parameter file has been man- Copy a backup up to /usr/Infra-
ually edited or the file has cor- FREE and take it into use. Re-
rupted. start InfraFREE. If this does not
help, take a log to remote sup-
port.

Error number 235

Error name: SPEED_LIM

Description: Command CancelSpeedLimit refers to non-existing speed limitation.

Possible reasons Checking Recovery

Not known in advance. InfraFREE and MCS / SS log Depends on the reason found in
files to remote support. the logs.

Error number 236

Error name: PAR_VAL_ERR

Description: Parameter value error.

Possible reasons Checking Recovery

Parameter value is below the Copy a backup parameter file
minimum limit, higher than the and take it into use or fix the val-
maximum limit or is totally miss- ue of incorrect parameter. Retry.
ing in parameter file.

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Error number 237

Error name: UNKNOWN_BB_TRAJ

Description: An error related to boom and bucket trajectory in DriveOrder or Driv-
eExtension command from MCS / SS.

Possible reasons Checking Recovery

The segment file including boom InfraFREE and MCS / SS log MCS / SS or segment file con-
and bucket movement does not files to remote support. figuration.
include as many different trajec-
tories for boom and bucket as
assumed by MCS / SS configu-
ration.

Error number 238

Error name: PAR_CHG_STATE_ERR

Description: An attempt to change parameter value in incorrect state of InfraFREE.

Possible reasons Checking Recovery

InfraFREE state must be fast Make sure the InfraFREE state
stop, idle or stand by when ad- is correct and retry.
justing parameters using MCS /
SS or CS.

Error number 239

Error name: TRANSITION_ERR

Description: Currently not in use.

Error number 240

Error name: SHORT_PATH_HEADING

Description: Machine heading too far from path direction for shortcut path calcula-
tion, currently not in use.

Error number 241

Error name: SHORT_PATH_POS

Description: Machine position too far from reference path for shortcut path calcu-
lation, currently not in use.

Error number 242

Error name: NO_SCUT

Description: Shortcut path calculation timeout, currently not in use.

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Error number 243

Error name: SHORT_PATH_CUR

Description: Shortcut path curvature error, currently not in use.

Error number 244

Error name: ERR_LL_RAM

Description: Problem with memory allocation.

Possible reasons Checking Recovery

RAM memory full/exhausted. InfraFREE log to remote sup- Restart InfraFREE. If this does
port. not help, software update may
be needed.

Error number 245

Error name: ERR_LL_NVM

Description: Storing long term log data into flash memory failed.

Possible reasons Checking Recovery

May be caused by exhausted If preceded by ERR_LL_RAM, If preceded by ERR_LL_RAM, it
RAM, if preceded by InfraFREE log to remote sup- must be dealt with first.
ERR_LL_RAM. port.
Flash hard disk full. If not preceded by If not preceded by
ERR_LL_RAM, then QNX com- ERR_LL_RAM, then free space
mand df tells the amount of free in Flash hard disk.
disk space.

Error number 246

Error name: ERR_NB_TIMEOUT

Description: No response from NaviBoard causes timeout.

Possible reasons Checking Recovery

Incorrect NaviBoard settings Check board settings. If settings Fix board settings. Restart Infra-
(HW switches). ok, send InfraFREE log to re- FREE. If problem arises repeat-
mote support. edly, change the NaviBoard and
retry.
Software bug. Check board settings. If settings Fix board settings. Restart Infra-
ok, send InfraFREE log to re- FREE. If problem arises repeat-
mote support. edly, change the NaviBoard and
retry.
NaviBoard hardware failure. Check board settings. If settings Fix board settings. Restart Infra-
ok, send InfraFREE log to re- FREE. If problem arises repeat-
mote support. edly, change the NaviBoard and
retry.

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Error number 247

Error name: ERR_NB_DATA

Description: NaviBoard internal error or NaviBoard read/write error.

Possible reasons Checking Recovery

NaviBoard internal diagnostics InfraFREE log to remote sup- Restart InfraFREE. If this does
gives an error status. port. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.
NaviBoard hardware failure. InfraFREE log to remote sup- Restart InfraFREE. If this does
port. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.
NaviBoard bus access error. InfraFREE log to remote sup- Restart InfraFREE. If this does
port. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.
Driver error. InfraFREE log to remote sup- Restart InfraFREE. If this does
port. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.

Error number 248

Error name: PART_CAL_STATE_ERR

Description: State change error in partial calibration.

Possible reasons Checking Recovery

Operator error during partial cal- InfraFREE log to remote sup- Restart InfraFREE and retry.
ibration. This error should not port.
occur without operator input.

Error number 249

Error name: ERR_NB_ODOFAILURE

Description: NaviBoard detects odometer error.

Possible reasons Checking Recovery

Phase difference of odometer Check that the proximity Repair the hw-problem or adjust
pulses is not correct or one of switches of odometer are prop- the switches so that the phase
the two odometer pulses is erly installed, the switches are difference of pulse trains is ok.
missing. operational, the cables are ok
and check the phase difference
of pulses.

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Error number 250

Error name: ERR_NB_DIAG

Description: Currently not in use.

Error number 251

Error name: ERR_LL_INT

Description: LongLog internal failure.

Possible reasons Checking Recovery

Software error. Take InfraFREE log to remote Restart InfraFREE. If this does
support. not help, software update may
be needed.

Error number 252

Error name: ERR_NB_CMD

Description: NaviBoard cmd interface error.

Possible reasons Checking Recovery

NaviBoard hardware failure. Take InfraFREE log to remote Restart InfraFREE. If this does
support. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.
NaviBoard bus access error. Take InfraFREE log to remote Restart InfraFREE. If this does
support. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.
Driver error. Take InfraFREE log to remote Restart InfraFREE. If this does
support. not help, software update may
be needed. If problem arises re-
peatedly, change the NaviBoard
and retry.

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4.3. Front/Rear Scanner

The InfraFREE system includes two laser scan-

ners, which are used to measure the environment
around the machine. This information is used to
calculate the machine’s position information and
to avoid collisions. One of the laser scanners
(front scanner) is mounted on the front part of the
machine, facing forwards. The other scanner
(rear scanner) is respectively mounted on the
rear part of the machine, and it is facing 180 de-
grees in the opposite direction compared to the
front scanner (when the machine articulation an-
gle is 0).

WARNING
LASER HAZARD!
Looking straight into the laser beam could cause permanent
damage to the eyes.
The sensor is using a Class 1 laser device. Do not stare directly
into the beam. Power off the machine before servicing the
scanners.

4.3.1. Technical data

Scanners interface to InfraFREE computer with serial line (RS-422) interface. Scanners are supplied
with 24 V supply from "straight up" power supply to InfraFREE.

Parameter Value
Scanning angle 180°
Laser protection class 1 (eye-safe)
Angular resolution 0.25° - 1°
Typical measurement range < 40 m (currently utilized with InfraFREE < 20 m)
Measurement resolution (< 20 m) 4 cm
Data interface RS422
Power consumption max. 37 W

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4.3.2. Scanner lens cleaning

Sensor is using class 1 laser device. Increased eye hazard. Do

not stare directly into the beam. Power off machine before
cleaning the scanners.

• Do not clean scanner lenses unnecessarily often. Navigation system reports when the scanner
requires cleaning.
• Use only special antistatic liquid and antistatic wipers for scanner lens cleaning.
• If lens is very muddy, use a lot of unpressurized water first to avoid scratches. One scratch can
destroy the scanner lens. Always use up and down movements when cleaning the scanner. Never
wipe horizontally (from left to right).

4.3.3. Scanner humidity absorber

In order to avoid internal humidity problems in

Sick scanners (mist on mirror or lens surfaces
etc.), humidity absorber inside the scanner needs
to be changed, when the color has changed from
light-blue to white.

1 Wet absorber
2 Dry absorber
Wet absorber can be refurbished by keeping it in
dry environment until the color is light-blue again.
Dry it in an electric oven several hours or in weld- 1 2
ing-electrode dryer (beware of melting!) or keep
it e.g. in hot sun during daytimes and seal it in
plastic bag for the night-times.

Absorber patron and color indicator ("parer label") are separate

units. It can take much longer for absorber to dry than color
indicator to change back to light-blue.

DO NOT expose the indicator- window to the sun, otherwise it

may lose the indicating ability.

Keep always good stock of dry absorbers. Store absorbers in

individual sealed bags.

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4.4. Sensor Module

The sensor module consists of a gyroscope and

an accelerometer.
• The gyroscope is used to measure the heading
of the machine.
• Harsh road conditions cause machine vibra-
tions. The measurement arrangement for these
vibrations includes a three-axis accelerometer
that is mounted on the machine. One axis
measures the vibration in the longitudinal direc-
tion of the machine, and the other measures the
vertical vibrations.

The gyroscope needs to be working properly before an

automated machine can operate safely.

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4.4.1. Technical data

The sensor module contains a power unit that

transforms the 24 V input to the 5 V for the gyro
and the accelerometer. The power also limits the
rise time of the voltage to be appropriate for the
gyro.
The gyro integrates the heading by itself but to
gain a better drift compensation the rate is calcu-
lated from the heading by the InfraFREE and In-
fraFREE calculates the drift by itself when the gy-
ro is initialized. During this process, which takes
about 10 s, the machine must stand still.
It is important that the sensor module is installed
to correct position. If sensor module is installed
upside down , the gyro measures the angle to
wrong direction.

4.4.2. Gyroscope

A gyroscope is used to measure the heading of the machine, i.e. the orientation of either the rear or
front part. The sensor is mounted at the rear part of a LHD and at the front part of a truck.
To avoid damage do not touch the gyro components under any
circumstances.

Parameter Value
Range ± 1000 °/s
Scale factor repeatability ≤ 0.2 %
Scale factor stability ≤ 0.05 %
Bias reatability ≤ 6 °/h
Power supply 5 V DC
Data interface RS485
Operating temperature - 40 °C....+ 65 °C

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4.4.3. Accelerometers

If road conditions change after operating area establishment and the machine vibrations grow too
large, the machine speed is reduced below the reference speed. A message is also sent to the MCS
and it can command InfraFREE to use a reduced speed every time the machine is approaching the
same place.
Harsh road condition causes machine vibrations. The measurement arrangement of these vibrations
includes a three-axis accelerometer that is mounted on the machine. One axis measures the vibration
in machine longitudinal direction and the other measures the vertical vibrations.
• Based on these vibrations the road condition is determined and the speed profile is adjusted
correspondingly.
• During the operating area establishment the road condition is measured and the reference speed
profile for each route segment is determined. The machines use this speed as reference speed in
autonomous operation each time they drive on this segment.

During autonomous operation, the accelerometers are also active.

Parameter Value
Data interface Analog voltage 0....5 V
Measurement range ± 2G (corresponding + 2.5 V ± 1 V)

4.5. Bucket Sensor

Only LHD machines are equipped with a sensor

that measures the bucket’s position. The sensor
is installed inside the bucket tilt cylinder, and in
effect measures the length of the cylinder (bucket
angle). The sensor can be accessed from the
downward side.

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4.5.1. Technical data

The sensor type differs from the boom sensor in terms of data interface. The sensor is not directly
connected to CAN-bus, but instead to CS front module and from there the sensor signal is forwarded
to CAN-bus. The reading of the sensor in CAN-bus is from 0 to 65535.

Parameter Value
Power supply + 13.5 to 26.4 V DC (± 0%) : Strokes = 1525 mm
+ 24 V DC (± 10%) : Strokes = 1525 mm
Data interface 4....20 mA
Operating temperature Head electronics: - 40 to + 85 °C
Sensing element: - 40 to + 105 °C

4.5.2. Testing the bucket sensor

Crushing hazard. Can cause severe injury or death. Make sure

that there are no unauthorized persons in the danger area.

1. Check the bucket sensor calibration by moving the bucket in extreme low and extreme high
positions.
2. Write down the respective values from CS calibrating display to machines follow up sheet. The
values shall not change more than ± 40 units from the last calibration.
If machine stops during autonomous drive and gives alarms which refer to bucket sensor or the
bucket stoppers have been changed, the sensor must be recalibrated.

4.6. Boom/Box Sensor

The LHD machine is equipped with a sensor that measures the boom’s position. The same sensor
type is used as a box position sensor in dump trucks.
On a loader, the boom sensor is mounted under the boom joint cover plate, or inside the joint pin for
protection.
On a truck, the box sensor is mounted on the box joint.

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4.6.1. Technical data

The sensor is of same type as steering sensor

and it's data interface is connected to Can-bus
with CANopen protocol as well. The measure-
ment is updated at the rate of 50 Hz to the Can-
bus but it is used by the InfraFREE controllers at
the rate of 10 Hz.
Fully up and fully down position calibrations are
crucial.

Parameter Value
Resolution 360°/4096 = 0.088°
Date interface CANopen

4.6.2. Testing the boom/box sensor

Crushing hazard. Can cause severe injury or death. Make sure

that there are no unauthorized persons in the danger area.

1. Check the box sensor calibration by moving the box in extreme low and extreme high positions.
2. Write down the respective values from CS calibrating display to machines follow up sheet. The
values shall not change more than ± 2 units from the last calibration.

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4.7. Odometer

The drive line version of the odometer (below)

consists of two inductive sensors which are in-
stalled to count the holes of an attached disk that
rotates with the drive line shaft of the machine.
The gearbox version (right) consists of one in-
ductive sensor (2 limits) which is installed directly
into the gearbox to count the toothing of the car-
dan axle.
Both sensors give a pulse train, and the phase
shift of these pulse trains determines the direction
of motion.

Odometer(s) need(s) to be calibrated and working properly

before an automated machine can operate safely.

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4.7.1. Technical data

The sensors are connected to the quadrate counter board of InfraFREE. This board automatically
increments or decrements the cumulative sum of the pulses corresponding the distance travelled of
the machine.
This is a critical sensor concerning the function of the
NOTE!
automation machine.

Parameter Value
Operating distance 5 mm
Min repeat accuracy ≤ 0.2%
Power supply 12....48 V DC
Data interface 3-wire, normally open, PNP
Operating temperature - 25 °C....+ 80 °C

4.7.2. Installing odometer (drive line version)

When installing the inductive sensors of odometer, it is very important to maintain the correct phase
between the two sensors and the plate holes.
1. Install sensor and adjust the gap between the sensor and the hole-plate to 3-4 mm.
2. Check that the hole-plate is not bent, i.e. the same 3-4 mm gap applies all around the hole-plate.
3. Check also, that the centers of both sensors are on the same line (± 2 mm) than the circle through
centers of the holes.
4. When the odometer is changed, the phase shift might change. Check phase shift or re-calibrate.

4.7.3. Installing odometer (gear box version)

1. Fit the new o-ring to the sensor thread and use thread sealing, for example Loctite 572.
2. Screw the sensor and wiring assembly carefully in as long as it touches the speed sensor gear.
3. Unscrew the sensor half a turn. If the sensor rotational mark points now upwards, go to step 5. If
not, continue to step 4. Rotational mark is shown by the arrow in the attached picture.
4. Unscrew the sensor more, maximum less than one turn, as long as the sensor rotational mark
points upwards. Rotational mark is shown by the arrow in the attached picture.
5. Tighten the lock nut. Check that the rotational mark still points upwards.
6. Heat the heat-shrinkable tubes on both ends of the wiring protective tube to be sure of joint
tightness.
7. Connect the sensor wiring.
8. Test functionality.

Maximum clearance between the sensor head and the sensor

speed gear is 2,25 mm. This is achieved by unscrewing the
sensor one and a half turn. Minimum clearance is 0,75 mm by
unscrewing the sensor half a turn.

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4.7.4. Testing the odometer sensor

You can test that the inductive sensor is working by putting metal near the front of the sensor when
the main power is on. If the sensor is OK, the lamp will lit in the back of the sensor.

4.7.5. Checking the odometer signal

The odometer signal can be checked using oscilloscope with two channels.
1. Measure the phase difference between signals from sensor A and sensor B.
If signal A and B go up and down too fast after each other, InfraFREE can fail to measure any
speed, distance or direction. This is specially the case if one sensor is missing or broken.
2. Monitor both signals for a while. Signals are
quite optimum when there is a clear phase
difference between signals A and B.

4.8. Articulation Sensor

The machine’s articulation is measured with an optical encoder type sensor. The articulation angle
sensor is located in the middle joint of the machine.

PROPERTY DAMAGE RISK!

Calibration of the middle (machine straight) reading and the full
right steering value are crucial for navigation.
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4.8.1. Technical data

Middle (machine straight) reading and full right steering value calibrations are crucial for navigation.

Parameter Value
Resolution 360°/4096 = 0.088°
Data interface CANopen

4.8.2. Testing the articulation sensor

Crushing hazard. Can cause severe injury or death. Make sure

that there are no unauthorized persons in the danger area.

1. Move the sensor lightly in both directions with your fingers: the value of "middle joint" in CS
calibration display shall not change more than ± 2 from the value last calibrated.
2. Turn steering to extreme left and extreme right.
3. Write down the values in the machines follow-up sheet.

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4.9. Audio/video

2 3

1 4

1 Front camera middle

2 Front camera cabin
3 Front camera left
4 Rear camera middle
Camera selection between rear and front cameras is done automatically when changing the direction
of travel. The front camera can also be selected manually by using the rocker switch on the joystick
in the operator station. The video signal of the selected camera is routed to the communications
system by a video switch in the video box. Optionally, two simultaneous video images can also be
transmitted to the control room. The machine is also equipped with a microphone that provides audio
feedback to the operator station.

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4.9.1. Onboard Video Box

The onboard video box contains a video switch

and video compression device(s). All video cam-
eras are connected to the video box, which com-
presses the video signal from the selected video
camera and transfers it via MineLAN client to the
control room video display.
The onboard video box contains the following
components: a video server, an Ethernet switch,
a DC/DC converter and a video switch board.
The video box uses a 24 VDC power supply.

4.9.2. Cameras

There are four (three in a truck) video cameras

onboard an automated machine - three (two in a
truck) cameras for the forward direction and one
camera for the reverse direction.

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Technical data

Cameras are located in rough environment and therefore the physical requirements to the camera
are high. Camera has to bear shaking, impacts and moisture. Due the cameras are packed in the
metal capsule, it is not possible to prevent all of the shaking and impacts from the camera.

Parameter Value
Camera module IP65 proof unit
Input voltage 12 V DC
Coax video output 75 Ω coax cable
Focus and brightness settings manual
Operating temperature - 10 to 40 °C
S/N ratio 50 dB
Effective pixels 752 (H) x 582 (V)
Resolution 450 TV lines (center)

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4.9.3. Camera installation

1 2

2-3 mm
3 4 5 6 7

1 Camera 2 Capsule
3 Cable lead-in 4 M4 nylock
5 M4x16 6 Plastic bracket
7 1/4" x n8
Capsule is mounted in the camera rack. Make sure that the tested sticker is readable (not upside-
down).
Remove the camera from the capsule in order to calibrate camera image. Image calibration can be
done by adjusting the lens focal length. After the adjustment is done the lenses position must be
locked with hot glue.
When cameras are installed, there should be ample space between the camera lense and the
protective cover. During normal operation, the camera might move forward, causing the camera lense
to scratch against the protective cover.

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Camera power cable

1 Deutsch connector (2-pin male)

1
2 BNC connector (female)
Power cable is 1,5 mm² two wired cable with DC-
plug on the camera end and 2-pin Deutsch con-
nector on the other end.

4.9.4. Video switch

The video switch board is located in the videobox. Video switch board provides following functions:
• Switches cameras according to gear information from CS.
• Changes cameras on command on remote channel from the operator station - InfraFREE - CS.
• Supplies all cameras with 12 V power supply.
• Receives video and connects one camera at a time to video server (video output 1).
• Provide optional functionality for another video output (video output 2).

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4.9.5. Ethernet switch

The Ethernet switch is located in the videobox.

Quick diagnostics of the onboard Ethernet net- 1
work can be performed by checking the Ethernet
led lights, also see section onboard Ethernet
faultfinding.
2

1 Power Lit: supply voltage present

2 Data rate Not lit: 10 Mbit/s link
Lit yellow: 100 Mbit/s link
3 Data link status Not lit: no valid link
Lit green: valid link
Flashing green: data traffic

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4.9.6. Video server

The video server is located inside the videobox.

1 Model 1 (Hirschmann)
1 2
2 Model 2 (Moxa)
Video server provides following functions:
• Utilizes 24 V power supply.
• Receives and compresses video to such a for-
mat that it can be transferred over MineLAN to
control station.
• The video server can handle multiple video ses-
sions at the same time.
• Possibility to connect several video receivers.
• Can be configured to send data to fixed receiver
or on-request to specific IP/ port.
• When machine is in REMOTE mode (connec-
ted to a operator station) there is a request to
video server to open video session to IP / port
of the video PC. The video PC is located at op-
erator station that requested video from ma-
chine.

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Video server configuration (Hirschmann)

Configuration for video server located inside videobox:

Service settings

• Setup IP
- according to IP address plan for the produc-
tion area
- Spare part default IP: Model 1: 192.168.0.1
and Model 2: 192.168.127.100
• Mask
- according to IP address plan for the produc-
tion area.
• Enable multilink
• Disable multicast steaming

Ensure the multicast is disabled, if not the unit will

start to send video to all IP addresses on the net-
work and block the traffic on MineLAN.

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Video settings

• Encoder configuration
- Contrast
- Saturation
- Brightness
- Picture quality
• Video standard
• Resolution
• MAX datarate
• Video termination
• Set ActiveX component in use

Interface settings

Serial port is only used to configure unit if web

browser GUI is not accessible for some reason.
Preferred setting will be:
• Serial Port Function: Terminal
• Baudrate: 9600
• Data bits: 8
• Stop bits: 1
• Parity Check: none
• Interface mode: RS232
• Half dublex mode: off

These settings only make it easy to access video

server when needed.

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Alarm configuration

• Alarm sources
• Connections on alarm

Test for power

1. Set your laptop serialport settings as follows:

• Bps: 9600
• Data bits: 8
• Parity: none
• Stop bits: 1
• Flow control: none
2. Open hyper terminal on corresponding
settings.
3. Connect the video server using cross over RS
232 cable (null modem cable).
4. Power up the video server.
5. A menu appears on terminal screen to give all
possible config options.

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Video server configuration (Moxa)

1. Set the computer IP address to 192.168.127.99.

2. Open the browser and establish a connection to Moxa video server. (Default: 192.168.127.100)
3. Check that Firmware version is up to date and upgrade if necessary. Select System configuration
- System - Firmware upgrade - Browse / Upgrade.

Before upgrading set the video server to factory settings. Select

NOTE!
System configuration - System - Factory default.

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4. Download configuration file sys_config.ini (file path: automation commissioning / communication /

Moxa). If the file does not change the settings, select System configuration - System - System
parameters - Import a system parameter file and retrieve the previously saved parameter file.
Press save.

Computer IP address changes and disconnects the

NOTE!
communication line.
5. Set the computer IP address to 10.10.2.110 and re-enter with IP 10.10.2.101.

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6. Check general, image and network settings.

Figure: General settings (System configuration - System - General)

Figure: Image settings (System configuration - Video - Image setting)

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Figure: Network settings (System configuration - Network - General)

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7. Test cameras. Open VCM System maintenance menu and Function test submenu. Select camera
test procedure. Force cameras 1-4 on in turns.
• Camera 1 = front middle
• Camera 2 = front right
• Camera 3 = cabin

Revise Active X component settings if video image does not

NOTE!
show.

Active X settings

Open internet options and local internet settings.

Select custom security level.

Settings to be adjusted Value

Allow previously unused ActiveX controls to run without promt Enable
Allow Scriptlets Enable
Automatic prompting for ActiveX controls Enable
Binary and script behaviours Enable
Display video and animation on a webpage that does not use... Disable
Download signed ActiveX controls Prompt
Download unsigned ActiveX controls Disable
Initialize and script ActiveX controls not marked as safe for... Disable
Run ActiveX controls and plug-ins Enable
Script ActiveX controls marked safe for scripting Enable
Automatic prompting for file downloads Enable
File download Enable
Font download Enable

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4.9.7. Audio/video cabling

Power cable x1128

Wire Signal Pin

1 24 V DC REG A
2 GND B
NC C

Video box power cable is 2 x 1,5 mm² cable (e.g. BETAflam 145 cable) with 3 pin MIL female
connector on other end. Cable must be inside NW8,5 plastic cable sleeve.

Audio signal cable a139

Pin Signal Wire Signal Pin

1 SPKR OUT 1 SPKR OUT 3
2 MIC IN 2 MIC IN 5
3 GND 3 GND 4
4 LINE IN 4 NC
5 LINE OUT 5 NC
6

Cable is BETAflam 90 C-flex 4 x 2 x 0,5 mm² + scr with 6 pin Deutz connector on other end and 5
pin Binder connector on other end.

Camera signal cables a141, a242, a343/a243 and a344

Video box camera signal cable is 75 Ω RG59 cable with BNC male connector on both ends. Cable
must be inside NW8,5 plastic cable sleeve.

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Camera power cables a141, a242, a343/a243 and a344

Pin Signal Wire Signal Pin

1 1 1
2 2 2

Video box camera power cable is 2 x 1,5 (e.q. BETAflam 145 FLEX) cable with Deutsch 2 pin
connectors on both ends. Cable must be inside NW8,5 plastic cable sleeve.

CS control signal cable a340

Wire Signal Pin

1 / white D208 A
2 / brown D209 B
3 / green D206 C
4 / yellow D213 D
5 / grey E
F
G
H
J
K

Video box control signal cable is 4 x 2 x 0,5 mm² + scr cable (e.g. BETAflam 90 C-flex cable) with 10
pin MIL connector on other end. Cable must be inside NW8,5 plastic cable sleeve.

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Video box - cabin Ethernet cable

Pin Signal Wire Signal Pin

A IN- 1 IN- A
B IN+ 2 IN+ B
C GND 5 GND C
D OUT- 3 OUT- D
E OUT+ 4 OUT+ E

Video box control signal cable is 2 x 2 x 0,5 mm² + scr cable (e.g. BETAflam 90 C-flex cable) with 5
pin MIL male connector on other end. Cable must be inside NW8,5 plastic cable sleeve.

MPM

• Power cable x1128

• Video box - cabin Ethernet cable

4.9.8. Audio/video troubleshooting

If the video is not connected to video display at control station:

• Ping the video server to test if the connection is accessible and OK (see IP from IP documentation).
• If video server has not been used before, check video server settings.
• Try to take connection to video server with your laptop web browser
- For IP of the unit use serial interface or see IP from IP documentation
- Remember to disable all possible proxy entries from your web browser. If proxies are used it
might make it impossible to connect video server.
- Open "live picture" page to see if there is video available from cameras.

If the video server responds, but on live picture the screen shows camera with red X on it:
• Try to select another camera.
• If the screen still shows the same icon, try to get opposite direction camera picture.
• If no change, check the video switcher and power supply to the video box and fuses inside the video
box.

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4.10. Machine Mode Switch

The machine mode switch is used to change the mode of the machine. Machine modes are indicated
as follows:
• The mode switch is in position 1: the machine is in manual mode.
• The mode switch is in position 2: the machine is in automated mode.

The machine mode switch is located on the machines as follows:

• On a truck: in front of the cabin on the left side of the machine
• On a loader: to the left side of the rear frame and near the main switch of the machine

Figure: Machine mode switch in trucks and reg- Figure: Machine mode switch in electrical load-
ular loaders. ers.

This switch is a “permission” for the VCM System to switch to

NOTE! automatic mode and start actuating commands from the
InfraFREE system.

COLLISION HAZARD!
When the machine is outside the production area, the machine
mode switch of the machine must always be in manual mode,
and the machine must be disconnected from each automatically
operated system. The machine mode switch must be locked to
manual position with a padlock.

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4.11. Monitoring

4
3

1 2

1 MineLAN Mobile Terminal 2 Video box

3 Portbox (Ethernet converter) 4 Tamtron weighing
5 RS232 6 Ethernet

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4.11.1. VCM

VCM Configuration

Make following settings to the VCM System interface.

1. Open AutoMine / Specialist / Monitoring
channel window.
2. Set the monitoring channel On.
3. Change local port and MCS port numbering to
17102.
4. Set MCS IP address to 10.10.2.110.
5. Save settings.

6. Restart the display.

7. Wait for the backdrop to appear (approx. 2-5 seconds). Press the number 5 button down and hold
it until the display switches off.
8. Release the number 5 button and the display
goes to setup mode.
9. Press Versions Setup button.

10. Press IP Setup button.

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11. Select Static IP setting with arrow keys and

confirm OK.
12. Enter following IP values to respective fields.
Activate text fields with arrow keys and confirm
OK. Numbers can be modified with arrow keys
and verified with OK.
13. Save settings.
14. Move back to setup menu with return arrow.

15. Switch the machine off and restart. New IP settings become valid.

4.11.2. Portbox

1 Portbox revision 1
2 Portbox revision 2
Portbox is Ethernet - RS232 converter for monitoring channel communication. Monitoring channel is
used to report machine health data (temperatures, pressures, etc.) to MCS / SS.
Connectors include normally at least RS 232 and Ethernet ports. Some models have also RS 422 or
RS 485.

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Portbox configuration

1. Set your laptop serialport settings as follows:

• Bps: 9600
• Data bits: 8
• Parity: none
• Stop bits: 1
• Flow control: none
2. Switch the portbox unit off.
3. Connect to the portbox RS 232 connector using cross over RS 232 cable (null modem cable).
4. Set DIP switch 1 to position ON.
5. Switch the portbox unit on and set it to setup mode.
6. Open Hyper terminal on corresponding settings. Recommended to use Hercules SETUP utility.

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7. Open the PortBoxMonitor test.TXT file. Configurate the portbox unit by adding three strings
located at the end of the file to terminal Send section. Press Send buttons.

8. Check whether settings were changed or not by pressing Enter.

9. All changes must be saved using D2 + Enter command.
10. Switch the portbox unit off and set DIP switch 1 to position OFF.
11. Reconnect the VCM System serial interface to the portbox unit.

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4.11.3. Weighing interface

Weighing system is an optional unit.

Weighing system reports tonnage to the machine
VCM System. Machine VCM System puts the
weight information to the monitoring channel.
MCS / SS takes weighing information from the
monitoring channel.

Weighing interface configuration

1. Set jumper connectors inside RS converter as

in clip from electrical drawing shows.
2. Make sure that terminals "A" and "B" are
looped together, also "D" and "E" as shown in
diagram beside.

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4.12. ACS onboard unit

The onboard ACS unit is wired to cut open the

“automation” loop in the machine safety circuit.
InfraFREE has a relay in series with the ACS on-
board I/O. If any of the safety relays in the auto-
mation circuit opens, the safety circuit is opened
and the machine goes into emergency STOP.
If the ACS unit can not communicate with the
master ACS, it cuts off the emergency stop circuit
and the machine cannot be operated in Automatic
mode.
If the ACS I/O overheats, the ACS unit cuts off the
emergency stop circuit.

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4.12.1. Display of system leds

ACS GUI test window can be used to troubleshoot onboard ACS I/O module.
NOTE! Testing window is only used in AutoMine.

ACS onboard unit can be override by pushing the ACS override

button in the cabin. This function shall only be used when
teaching the machine from the cabin. Never push the ACS
override button when starting autonomous operation. Pressing
the button causes the machine to ignore emergency stop
commands from master ACS.

LED Status Meaning

RUN (green) On Normal state of PES (RUN).
The CPU reads inputs, processes the logic and writes outputs;
communication and hardware/software tests are carried out.
Flash The CPU is in STOP and is not executing any application pro-
gram. All outputs are reset to a safe, de-energized state. STOP
can be triggered by setting the emergency stop system signal to
TRUE in the application program or by a direct command from
the PADT.
Off The CPU is in ERROR STOP (see ERROR below).
ERROR (red) On The CPU has discovered a hardware fault in the CPU and is
switching to ERROR STOP.
The CPU has discovered a software error in the operating sys-
tem.
The Watchdog has triggered ERROR STOP because the cycle
time has been exceeded.
The CPU has stopped the execution of the application program,
ended all hardware and software tests and all outputs have been
reset.
The CPU can only be started again through a command from
the PADT(Reboot).
Off No errors detected.
PROG (yellow) On The CPU is being loaded with a new configuration.

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LED Status Meaning

Flash The flash ROM is being loaded with a new operating system.
LED flashes also during initialization of the device.
Off No loading of configuration or operating system.
FORCE (yellow) On The CPU is in RUN mode and force is active.
Flash The PES is in STOP, but force is prepared and is activated if the
PES is started.
Off Forcing is not activated.
FAULT (yellow) On Error display for Line Control.
The application program has caused an error.
The PES configuration is faulty.
The loading of a new operating system was faulty and the op-
erating system is corrupt.
Flash An error has occured during the write cycle for a Flash ROM
(during the operating system update).
One or more I/O errors have occured.
Off None of the above errors has occured.
OSL (yellow) Flash Emergency loader of the operating system is active.
BL (yellow) Flash COM in INIT_FAIL state.

4.13. RFID tag reader

RFID tag reader is used to detect and identify

RFID tags. Machine location in tunnel can be
identified based on tags. Tag reader is mounted
on rear frame of the machine. Reader is compat-
ible to read and write data to EPC Gen2 Tags that
are installed to the tunnel roof in mining applica-
tions. The reader isn’t polling automatically, but
requires commands from the host.
The reader supports the RS-232 interface.
When the reader is switched on, the buzzer
beeps and the (optional) red and yellow LED flash
during start-up. After initialization and during nor-
mal operation the green LED is on.

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4.14. Manual Production Monitoring (MPM) error codes

Always take the logfile before performing any troubleshooting

actions. This is to assist in faultfinding and follow-up reports.
Once a critical alarm occurs, a log files should be taken within
one minute. All machine information is lost if a log is not taken
within one minute of the alarm being displayed.

InfraFREE generates several type of errors that are shown to the control station operator with RDT
or MCS / SS. Following list contains all errors that InfraFREE can generate and some instructions
how to deal with errors. Whenever the MCS / SS user is unsure of further actions, stop ALL
autonomous production and contact the system specialist.

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InfraFREE and MPM common error codes

Error number 15

Error name: GY_COMM

Description: Gyro does not start to send anything through serial port or stops to
send.

Possible reasons Checking Recovery

Cable problem. Visual inspection, cable change, Cable fixing or change.
hwtest.
Serial port problem. Navigation unit or frame change, Navigation unit or serial board
hwtest. frame changing.
Gyro problem. Gyro change, hwtest. Changing gyro.

Error number 20

Error name: GY_MEAS

Description: Gyro heading out of range.

Possible reasons Checking Recovery

Gyro error. Log to remote support. Changing gyro.

Description: Too high heading rate from gyro (parameter GYRO_MAX_H_RATE)

Possible reasons Checking Recovery

Sensor box loosened, gyro er- Sensor box inspection, log to re- Changing gyro.
ror. mote support.

Error number 21

Error name: GY_INI

Description: Gyro drift out of range (defined by parameter GYRO_MAX_DRIFT)

Possible reasons Checking Recovery

Gyro loosened. Visual inspection. Fixing the gyro.
Machine is moving during sen- Visual inspection. Reinitializing the sensor and
sor initialization. making sure the machine does
not move.
Gyro is broken. Log to remote support. Changing gyro.

Error number 22

Error name: STE_COMM

Description: Steering angle sensor communication error. No angle measurement
from CAN bus.

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Possible reasons Checking Recovery

Sensor or cable broken, CAN Visual inspection, hwtest. Changing the cable, steering
bus interface card broken. sensor or CAN bus interface
board.

Error number 23

Error name: STE_MEAS

Description: Steering angle measurement rate out of range (parameter AN-
GLE_MAX_RATE).

Possible reasons Checking Recovery

Sensor fastening broken. Visual inspection. Repairing sensor fastening.
Sensor broken (jumping read- Log to remote support. Changing steering sensor.
ing).

Error number 31

Error name: CAN_COMM

Description: CAN bus communication error (CS gives an error status to InfraFREE).

Possible reasons Checking Recovery

An error detected by CS. Check CS error log. Depending on the error.
An error detected by InfraFREE Check CS error log. Depending on the error.
CAN interface.

Error number 32

Error name: GY_TEMP_WARN

Description: Litef gyro has informed about too high internal temperature.

Possible reasons Checking Recovery

Gyro problem. Check the outside temperature Improve gyro cooling or chang-
of the gyro. ing the gyro.

Error number 33

Error name: GY_CONT_LOOP

Description: Gyro internal error.

Possible reasons Checking Recovery

Gyro failure or too low polling Gyro change or a log to remote Changing the gyro.
rate by InfraFREE. support.

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Error number 34

Error name: GY_HARDWARE

Description: Gyro internal diagnostics indicates a hardware error.

Possible reasons Checking Recovery

Gyro broken. Gyro change. Retrying or gyro change.

Error number 35

Error name: GY_MEAS_RANGE

Description: Gyro internal diagnostics indicates that the turning rate of gyro has
been too high.

Possible reasons Checking Recovery

Gyro attachment loosened. Visual inspection. Fixing the gyro attachment.

Error number 36

Error name: GY_UNKNOWN

Description: Gyro internal diagnostics indicates that the gyro has received an un-
known command.

Possible reasons Checking Recovery

Occasional communication Retry driving. Retry driving.
problem.

Error number 102

Error name: TASK_BLOCK

Description: One of the InfraFREE tasks blocked or killed.

Possible reasons Checking Recovery

Software bug or QNX overload- Take a log to remote support. Software correction. Retrying.
ing (e.g. taking or transferring a
log while InfraFREE is running).

Error number 104

Error name: FILE_READ

Description: Opening or reading environment, segment or parameter file failed.

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Possible reasons Checking Recovery

File does not exist. Take a log file to remote support. Missing or corrupted files must
be replaced.
File contents is not what was ex- Take a log file to remote support. Missing or corrupted files must
pected (e.g. XML structure in- be replaced.
complete).
Log config file Take a log file to remote support. Missing or corrupted files must
be replaced.

Error number 108

Error name: LO_GYRO

Description: Gyro task (read_gyr) ceased to provide distance data to task localize.
Error GY_COMM should appear before this error.

Possible reasons Checking Recovery

Cable problem. Visual inspection, cable change, Cable fixing or change.
hwtest.
Serial port problem. Navigation unit or frame change, Navigation unit or serial board
hwtest. frame changing.
Gyro problem. Gyro change, hwtest. Gyro change.
CPU overload. Take a log file to remote support. Restarting operation.

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MPM specific error codes

Error number 1001

Error name: Not classified

Description: Shared memory allocation failed, fatal.

Instruction
Boot and restart. If this does not help, contact MPM specialist.

Error number 1002

Error name: Not classified

Description: Corrupted internal message.

Instruction
Single errors of this type can be neglected. If this error occurs often, system needs to be booted
and restarted. If this does not help, contact MPM specialist.

Error number 1003

Error name: Not classified

Description: More than 5 (current maximum) tag id’s detected at same area.

Instruction
If there are no several RFID tags near machine, some of the received tag id’s are corrupted. If this
error occurs often, contact MPM specialist.

Error number 1004

Error name: Not classified

Description: Currently not used (i.e. should never happen).

Error number 1005

Error name: Not classified

Description: RFID reader error.

Instruction
RFID reader is not responding to MPM system enquiries. 1. Check that RFID reader is properly
connected (DPU debug port) and powered. 2. Check that RFID reader is properly configured. 3.
Check that MPM system serial port is properly configured in operating system.

Error number 1006

Error name: Not classified

Description: Sensor calibration failed.
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Instruction
Retry. If calibration fails continuously, take a log and contact MPM specialist.

Error number 1007

Error name: Not classified

Description: Area definition file is corrupted.

Instruction
Check/replace corrupted file.

Error number 1008

Error name: Not classified

Description: Area definition file is corrupted.

Instruction
Check/replace corrupted file.

Error number 1009

Error name: Not classified

Description: Dynamic memory allocation failed.

Instruction
Boot and restart. If this does not help, contact MPM specialist.

Error number 1010

Error name: Not classified

Description: Area definition file is missing or corrupted.

Instruction
Check that file exists. Replace corrupted file.

Error number 1011

Error name: Not classified

Description: Currently not used (i.e. should never happen).

Error number 1012

Error name: Not classified

Description: Status file is missing or corrupted.

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Instruction
Check that file exists. Replace corrupted file.

Error number 1013

Error name: Not classified

Description: Status file is corrupted.

Instruction
Check/replace corrupted file.

Error number 1014

Error name: Not classified

Description: Status file is corrupted.

Instruction
Check/replace corrupted file.

Error number 1015

Error name: Not classified

Description: Status file is corrupted.

Instruction
Check/replace corrupted file.

Error number 1016

Error name: Not classified

Description: Event log write failure.

Instruction
Event writing to non-volatile memory has failed. Means that some events are lost. Not serious error.
If this error occurs often, contact MPM specialist.

Error number 1017

Error name: Not classified

Description: Event log buffer circulating failure.

Instruction
Event log buffer circulating failure means that chronological order of event log buffers is lost and
new events may be written over events that are not the oldest ones, as they should. Not serious
error. If this error occurs often, contact MPM specialist.

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Error number 1018

Error name: Not classified

Description: Event log buffer overflow.

Instruction
Event log write buffer overflow. This means that events are generated too fast for event log to really
store all of them into non-volatile memory. Not serious error. If this error occurs often, contact MPM
specialist.

Error number 1019

Error name: Not classified

Description: Articulation angle diagnostics problem.

Instruction
Either articulation angle measurement or gyro output failed. 1. Check articulation angle sensor as-
sembly, calibration and readings. 2. Check gyro output.

Error number 1020

Error name: Not classified

Description: Production cycle length exceeds limit.

Instruction
Travelled distance during production cycle length exceeds predefined limit. Check whether draw
and dump points are detected normally. If they are, parameter PRODMON_CYCLE_LEN_MAX
defining maximum cycle should be increased. Otherwise draw and/or dump point definitions and/or
detection criterias should be checked.Note: PRODMON_CYCLE_LEN_MAX value <= 0.0 disables
cycle length checking.

Error number 1021

Error name: Not classified

Description: Machine position distance to manual route is too large.

Instruction
Machine position distance can be exceptionally large to manual route if manual routes are incom-
pletely defined or machine is outside defined production area (there really is no manual routes
defined near machine). If neither of these is true MPM system may have positioning problems.
Contact MPM specialist.

Error number 1022

Error name: Not classified

Description: Weighing error, no weighing data detected.

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Instruction
Check that the weighing system works properly. If it does, boot and restart the system. If this does
not help, contact an MPM specialist.

Error number 1023

Error name: Not classified

Description: No RFID tag correction for a long time. Either maximum time or dis-
tance without RFID tag correction has been exceeded.

Instruction
Verify that the RFID tag reader functions properly, see instructions for error 1005.

Error number 1024

Error name: Not classified

Description: MCS message too long

Instruction
Single errors of this type are not serious. Boot and restart the system. If this does not help, contact
an MPM specialist.

Error number 1025

Error name: Not classified

Description: No room for new production areas

Instruction
Maximum number of production areas (i.e. area definition files) in the system has been exceeded.
Check that there are no old/unused area definition files in the onboard flash system (/nvm) If any
unused files are found, they can be removed. If this does not help, contact an MPM specialist.

Error number 1026

Error name: Not classified

Description: Reported RFID tag size is incorrect

Instruction
Internal error. The reported RFID tag size does not match the definition. Boot and restart the system.
If this does not help, contact an MPM specialist.

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5. CHECKING AND ADJUSTING

5.1. Malfunctions

The different malfunctions can be caused by problems in, for example, the sensor, wires, connectors,
supply voltage, InfraFREE computer or its settings (parameters).
Note that the most common problem cause is that the InfraFREE computer has not yet started when
entering the window. Always wait at least one minute, after switching the power on, before selecting
the sensor calibration function in the operator or system specialist window.
In addition to this, the sensors cannot be calibrated if the InfraFREE has an incorrect internal status.
You can check the status with the InfraFREE function of the operator or system specialist windows.
The machine mode must be Idle or Standby for sensor calibration to be possible. For example, after
automatic drive the internal status is always emergency stop mode and calibration is not possible. In
this case, switch the InfraFREE power off either with the main switch or with the reset InfraFREE
function in the main window. After start-up (approx. 1 minute) the mode will be Idle or Standby, as
required for calibration.
If sensor initialization is not successful, retry by switching the power off from the machine’s main
switch. If that does not help, find and repair the fault before continuing. The details sub-window of the
start-up status function in the main window can be useful in troubleshooting. For more information
see the relevant section of the manual.
If any of the sensors is broken, it cannot be initialized. This means that none of the sensors can be
calibrated. The program may use other sensors when calibrating a particular sensor. This is why
calibrating is prevented if all sensors are not operating properly, that is, are not initialized.

5.2. Order of sensor calibration

If you are calibrating more than one sensor, for example after replacing the InfraFREE navigation
module, take note of the correct calibration order. The reason for this is that other sensors are used
when calibrating sensors. The sensors must be calibrated in the order presented in the following list.
When calibrating several sensors, start with the one first in the list.
1. Odometer calibration
2. Articulation angle calibration
3. Accelerometers calibration
4. Gyro calibration
5. Scanner position calibration
6. Scanner heading calibration
7. Automine gauges calibration

You can calibrate the following sensors irrespective of other calibrations or calibration order because
they are not used in calibrating other sensors and other sensors are not used in their calibration:
• Boom/Box angle calibration
• Bucket angle calibration

Correct calibration order in MPM.

1. Odometer calibration
2. Articulation angle calibration
3. Gyro calibration

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5.3. Sensor calibration

Sensor initialization:
All items (names of sensors) in the sensor cali-
bration window appear grey if the sensors have
not been initialized. Initialization is the same as
that performed in automatic drive in connection
with system start-up and always in connection
with fast stop release. When necessary, initiali-
zation begins automatically and after about 30
seconds the text "wait, initializing sensors" disap-
pears and the sensor names turn black. Initiali-
zation has been successfully completed.

In the sensor calibration window, the sensor names are followed by a date indicating the last
successful calibration of the sensor.
Choose the sensor to be calibrated with the + and - buttons and approve the selection by pressing
the "OK" button.
Sensors in the calibration window in MPM are odometer, gyro and articulation angle.

5.3.1. Interrupting the calibration

The CANCEL button in the window can always be used to interrupt the calibration without causing
any changes to the system. The CANCEL buttons in the calibration windows are activated by
choosing them with the + and - buttons and pushing the OK button in the window.

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5.3.2. Saving the calibration

After calibration, always remember to save the new calibration values as follows:
1. Select Save in the service menu window.

2. Select YES, if you want to continue to save.

You can interrupt saving by pressing NO.

3. Select OK.

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5.3.3. Malfunctions

Malfunctions may be caused by problems in the sensors, cables, connectors, supply voltage,
navigation computer, etc. Try reinitializing the sensors by closing the calibration window and then
reopening it. If this does not help, search and repair the problem before continuing. As the program
may use other sensors to calibrate a specific sensor, the calibration of sensors other than the
malfunctioning sensor might be inaccurate if not all sensors are working.
When entering the sensor calibration window, and text does not turn from grey to black, there is a
connection problem to InfraFREE. All calibrations are managed by InfraFREE, CS only provides an
interface to this, so any sensor calibration related problem is related to InfraFREE.

5.4. Scanner position calibration

After calibration, InfraFREE can proportion the machine’s physical dimensions to the surroundings
seen by the scanner, i.e. the distance between the machine’s extremities and the tunnel walls. When
the scanner knows the physical locations of both scanners, InfraFREE can combine the two scanner
views, 180 + 180 degrees, to give a 360 degree view.
Calibration must be performed if the scanner pole has clearly
shifted / been moved from its original position. Calibration must
also be considered if the machine begins stopping
exceptionally often, giving the error message "wall too close"
without any good reason.

1. Determine from the machine’s dimensional

diagrams the original scanner position and
how much it differs from the current position.
2. Enter the rear scanner position in the rear
scanner calibration fields. Enter the front
scanner position in the front scanner
calibration fields.

3. The Y position refers to the scanner’s transverse positioning point with respect to the machine
frame. It is the perpendicular distance to the longitudinal axis via the centre articulation. It is
positive on the left side of the longitudinal axis of the machine, i.e. cabin side and negative on the
hydraulic reservoir side.
4. The X position means the scanner’s positioning point longitudinally with respect to the machine
frame. It is the distance to the perpendicular line of machine’s longitudinal axis via the centre
articulation’s centre point. It is positive in front of the centre articulation (bucket side) and negative
on the rear side.
5. The scanners’ measurement point is at the imaginary centre point of the circular arch formed by
the glass.
6. Enter the values as degrees.

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5.5. Scanner heading calibration

After calibration, InfraFREE knows the actual angle of both scanners with the machine’s longitudinal
axis. Optimally, the angle is exactly 90.0 degrees.
Only a half-degree calibration/angle error will cause the machine to travel approx. 5 cm off course.
Calibration must therefore be extreme accurate. Furthermore, never attempt to use this calibration
to compensate for errors made in scanner position calibration.
Calibration must always be performed whenever it is suspected
that the scanner has changed direction due to rock collision etc.
Otherwise the machine may begin excessively stopping and
displaying the error message "wall too close" without any good
reason.

Try not to use steering during calibration. Machine trajectory

has to be as straight as possible.

1. Ensure the machine is stopped at a location where there is sufficient continuous wall space on
both sides and the walls are not too far from the machine. This ensures that InfraFREE obtains
points of reference from the walls. The machine’s engine must be running.
2. Select START.
3. Drive forward and stop when the display
shows "Stop Machine Press OK When
Stopped".
4. Press the OK button and "Reverse Back Until
Stopping Is Requested" will be displayed.
5. Drive backwards and stop when the display
shows "Stop Machine Press OK When
Stopped".
6. Press OK.

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5.6. Calibrate the Odometer

Changes that occur gradually over time, such as tyre wear, ultimately result in distance measurement
errors. After odometer calibration, InfraFREE knows the actual distance driven forwards and
backwards by the machine.
The driven distance is measured with two odometers. The odometers calculate the number of holes
in a rotating plate on the cardan and calculate the distance based on their number. The driving
direction is determined by observing which odometer first detects a plate hole.
Calibration must be performed:
• When new tyres are installed on a machine on which calibration has been performed with worn
tyres.
• 3-4 times during tyre life cycle to reduce error margin caused by tyre wear.

Calibration is not needed when a malfunctioning odometer is

replaced with a new one.

Tyre pressures must be correct. Incorrect pressure causes

errors in odometer readings.

1. Stop the engine.

2. Check the proximity switches for the following:
• Mounting and tightening.
• The distance from the rotating plate on the cardan, which should be 3...4 mm.
• The positioning with regard to the plate’s holes. Accurate odometer positioning is essential to
ensure that pulses are emitted in the correct order. For this reason, do not move the odometer
panel if the measurement is in working order.
3. Start the engine.
4. Select START.
5. Drive the machine for about 15-20 meters
straight forward or backwards.
6. Stop, engage the parking brake, and press
OK.
7. Accurately measure the distance driven with a
tape measure.
8. Enter the measurement in the Actual distance
travelled field and press OK.
9. Select FINISH and press OK.

Calibration error messages:

”Calibration value not within limits”
• A calibrated item is not within its limits, the value concerned depends on the calibration. Most
probably there is a problem with odometer installation.

”Large measurement variance, uncertain calibration result”

• Steering was used when driving (steering sensor value changed too much).

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If an error occurs, calibration is interrupted and must be

restarted.

5.7. Accelerometer calibration

After calibration, InfraFREE detects e.g.

• During driving: machine bumping that hinders distance measurement and performs the necessary
corrective measures.
• When stationery: the machine’s upward and downward acceleration.
• During forward driving and braking: accelerometer’s longitudinal force.

The value must correspond to the acceleration caused by gravity. Respectively, the forces applied
longitudinally to the machine must be close to zero.
The calibration must always be performed before calibrating the
gyro. The calibration must also be performed whenever the
machine gives alarms concerning road quality without any good
reason.

1. Check that the accelerometer unit is securely fastened in its original position.
2. The machine must be stationary and the engine must be running.
3. Select START.
4. Wait until the display shows "UP & DOWN
sensor calibrated successfully. Press OK to
continue".
5. Press OK.
6. Drive the machine forwards about 5 meters.
7. Stop and engage the parking brake.
8. Wait until the display shows "BACK & FORTH
sensor calibrated successfully".

Calibration error messages:

Notification of calibration failure is given on the display with the following error messages:
• UP sensor value/orientation error
• BACK & FORTH sensor value/orientation error
• Insufficient motion in calibration driving

Upon receipt of a calibration error message, calibration must be performed again. If after several
attempts calibration is not successful, replace the accelerometer (includes the gyro, which must then
also be recalibrated).

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5.8. Gyro calibration

The gyro, i.e. gyrocompass, provides InfraFREE with information on changes in the machine’s
travelling direction. After calibrating the gyro, InfraFREE considers all direction changes made by the
gyro as correct default values.
InfraFREE calculates the "drift" of the gyro each time it is initialized. This takes about 10 seconds,
during which time the machine must be stationary (incl. no manoeuvres).
1. Check that the gyroscope unit is securely fastened in its original position. The gyro is located in
the same unit as the accelerometers.
2. The machine must be stationary and the engine must be running.
3. Select START.
4. Wait until the display shows "Gyro orientation
is correct. Press OK to continue".
5. Press OK.
6. Turn the steering to the extreme left position.
7. Wait until the display shows "Steering left OK.
Turn steering right".
8. Turn the steering to the extreme right position.
9. Wait until the display shows "Calibration
finished successfully. Engage parking brake.".

Calibration error messages:

• Gyro mounting orientation error.
• Gyro box mounted on side.
• Gyro mounting orientation error.
• Calibration steering error, wrong direction.

If the display shows an error message due to calibration failure, restart the calibration.

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5.9. Articulation angle sensor calibration

After calibration, InfraFREE knows which command given to the steering corresponds to driving in a
completely straight line or, respectively, which command corresponds to each turning angle, extreme
values included. After the calibration, InfraFREE can also decelerate the turning movement just
before the end limiters.
The calibration is done in two phases: while the machine is stationary and while driving forwards and
backwards.
Calibration is performed utilizing the gyro reading. The calibration takes into consideration the
possible gyro "drift" and the angle sensor scale’s "surpass", if it falls within the centre articulation
turning angle zone.

The gyro must be active while the centre articulation is

calibrated.

To test the centre articulation sensor move the sensor lightly in

both directions with your fingers. The value of "middle joint" in
CS calibration display shall not change more than ± 2 from the
value last calibrated.

The calibration must always be performed whenever the centre

articulation angle sensor is replaced or after repair work on the
connection (flexible coupling) between the sensor and centre
articulation. Sensor damage can be detected, for example, if
when turning the machine the display value does not change
steadily but jumps.

1. First, test the machine’s ability to drive straight (without manoeuvres) for about 20 meters. At the
same time, memorize the steering angle at which the machine travels more or less straight.
2. Stop the machine. Leave the engine running.
3. Select START.
4. Wait for completion of the gyro initialization
and for the display to show "Gyro initialized
successfully. Drive machine forward without
using steering".
5. Turn the steering completely to the right.

6. Wait until the display shows "STOP THE MACHINE and reverse to starting point. Drive machine
forward without using steering".
7. Straighten the steering, returning to the steering angle you memorized in step 1 of the calibration.
8. Drive the machine forward for about 20 meters without any manoeuvres.
9. Stop the machine and then drive the machine straight backwards without any manoeuvres until
the display shows "Calibration successful. STOP THE MACHINE and engage parking brake".

Calibration error messages:

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• Error, vehicle has moved during gyro initialization

• Not enough gyro measurements for drift calculation
• Too large gyro drift in initialization
• Not enough vehicle motion within calibration time
• Calibration value not within limits
• Steering has been touched during calibration drive

If the display shows an error message due to calibration failure, restart the calibration.

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5.10. Boom/box angle sensor calibration

After the calibration, InfraFREE knows the exact position of the boom/box in the entire movement
area, including extreme up and down positions. In the calibration, InfraFREE is taught which angle
sensor reading corresponds to which boom/box position.
When the boom/box is being moved, InfraFREE performs mean value calculations of the received
readings and checks that:
• The boom’s/boxes upper position value is greater than the lower position value or vice versa
depending on machine type i.e. sensor assembly.
• The upper and lower position values differ sufficiently from each other.

The boom angle sensor is located inside the articulation pin of the second boom/box articulation,
where it is protected from possible rock impacts etc. (in some loader models the sensor is located
between boom pins). The box angle sensor is located next to box pin.
The calibration must be performed:
• Always when the boom/box movement range has changed, e.g. limiters have been changed.
• When the sensor is replaced.
• When performing significant repairs to the sensor lever mechanics.
• If the levers have been disconnected from the sensor.
• If the dump movement has continuous problems.

The most common problems requiring sensor repair work are:

• Mounting or sensor lever mechanism that turns the sensor is bent or loose - the reading does not
start to change immediately upon changing direction.
• Due to boom repair or replacement the sensor or levers have had to be disconnected.
• Internal optics of the sensor are damaged - when the machine is turned the display value does not
change steadily but jumps.

1. The machine must be stationary and the engine must be running.

2. Select START.
3. Lift the boom to the extreme upper position and
press OK.
4. Wait until the display shows "Boom up
calibration successful. Move boom down and
press OK.".
5. Lower the boom to the extreme lower position
against the limiters and press OK.
6. Wait until the display shows "Boom calibration
successful.".

Calibration error messages:

• Large measurement variance, uncertain calibration result.
• Calibration value not within limits.
• Distance between boom/box positions is too small.

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5.11. Bucket angle sensor calibration

After the calibration, InfraFREE knows the position of the bucket in the entire movement area. In the
calibration, InfraFREE is taught which angle sensor reading (4 - 20 mA) corresponds to which bucket
position.
InfraFREE checks via the received readings that:
• When the bucket is up, the value is greater or the same as when the bucket is in the transport
position.
• When the bucket is in the transport position the value is greater than when the bucket is in the
cleaning position.
• When the bucket is in the cleaning position the value is greater than when the bucket is in the lower
position.
• The upper and lower position values differ sufficiently from each other.

The bucket position sensor is located entirely inside the bucket cylinder.
The calibration must be performed if:
• The bucket’s movement range changes, e.g. due to a mechanical limiter change.
• The bucket lowers so far that the front of the machine is lifted by it and the machine cannot be
controlled properly.

However, calibration is unnecessary in connection with cylinder

replacement if the cylinder type is the same.

1. The machine must be stationary and the engine must be running.

2. Select START.
3. Lift the bucket to the extreme upper position
and press OK.
4. Wait until the display shows "Bucket UP
calibration successful. Move bucket to
CLEANING position and press OK".
5. Lift the bucket to the tunnel ploughing position
and press OK.
6. Wait until the display shows "Bucket
CLEANING position calibrated successfully.
Move bucket to PARKING position and press
OK".
7. Lift the bucket to the parking position and press
OK.

8. Wait until the display shows "Bucket CLEANING calibration successful. Move bucket to DOWN
position and press OK".
9. Lower the bucket to the extreme lower position and press OK.
10. Wait until the display shows "Bucket calibration successful.".

Alarms and troubleshooting:

"Large measurement variance, uncertain calibration result"
• Excessive disturbance of the bucket position measurement signal. Check cabling between the
sensor and the front frame module. Change the sensor as necessary (i.e. cylinder).

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5.12. Automine gauges calibration

NOTICE
It is very important, that the service password is not given to
any unauthorized persons. Any unauthorized use of the service
menus may result in serious malfunctions. The service
password may only be given to a service person sufficiently
trained by Sandvik Mining and Construction.

When AutoMine gauges calibration is selected in

the calibration main window, the sensor selection
window appears.
In these sensor calibration windows, steering
sensor, boom sensor and bucket sensor can be
calibrated for gauge display use. Gauge display
can be used for sensor diagnostic purposes only
by service personnel. Note that this calibration
does not affect to AutoMine functions or Infra-
FREE! These same sensors MUST be calibrated
separately to InfraFREE navigation computer.
These calibrations are duplicates of the same
sensors calibration windows for InfraFREE. The
calibration for gauges window is simpler and the-
fore separate. Independent function makes it
possible to isolate fault on problem situations or
test sensor function without InfraFREE.

To perform calibration of these sensors, the machine must be

stationary and the engine must be running.

5.12.1. Steering sensor gauge calibration

1. Turn the machine completely to the right.

2. Select SET.
3. Turn the machine completely to the left.
4. Select SET.
5. Select CALIB to save these values.

If the values are accepted, CAN’T CALIBRATE WITH THESE VALUES disappears from this window.

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5.12.2. Boom sensor gauge calibration

1. Lift the boom to the extreme upper position.

2. Select SET.
3. Lower the boom to the extreme lower position
against the limiters.
4. Select SET.
5. Select CALIB to save these values.

If the values are accepted, CAN’T CALIBRATE WITH THESE VALUES disappears from this window.

5.12.3. Bucket sensor gauge calibration

1. Tilt the bucket completely down.

2. Roll the bucket completely back
3. Select CALIB to save these values.

If the values are accepted, CAN’T CALIBRATE WITH THESE VALUES disappears from this window.

5.13. Common rules for checking cables

• Especially check the cables which go over moving joints or are otherwise exposed to wearing. The
cables shall not rub to any sharp edges and they shall not be too tight in any machine position.
• Ensure that there are no self-made (=not documented) extensions or repairs in the cable.
• Repairs with electric tape are not allowed.
• Check that there are no bumps in the cable indicating possible internal wearing.
• Tie the loose cables with cable ties, if necessary.
• Check that there is a identification label installed in the both ends of the cable and they are clear to
read.

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5.14. WLAN client configuration

5.14.1. Client

The client is located on the LHD. The configuration tool can be accessed using an ordinary web
browser (Internet Explorer, or Firefox). Other web browsers may also be acceptable, but have not
been tested.

The adding of a device name and location, as well as defining

NOTE! the network settings, is done according to the instructions in
the previous "Access point" -chapter.

1. Enter the IP address (default value: 192.168.127.253) in your browser's address or location bar.
2. Enter username and password.
3. When logged in, select Main menu, then Basic settings and System info settings.
4. Add the device name and location.
5. Select Submit to finalize the settings.
6. To define the network settings, select Main menu, then Basic settings and Network settings.

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7. Add the following information:

• IP configuration: Static
• IP address: see the following table
• Subnet mask: see the following table
• Gateway: see the following table

End system IP address Network mask Default gateway

WLAN Client 1 10.10.100.181 255.255.255.0 10.10.100.1
WLAN Client 2 10.10.100.182 255.255.255.0 10.10.100.1
WLAN Client 3 10.10.100.183 255.255.255.0 10.10.100.1
WLAN Client 4 10.10.100.184 255.255.255.0 10.10.100.1
WLAN Client 5 10.10.100.185 255.255.255.0 10.10.100.1
WLAN Client 6 10.10.100.186 255.255.255.0 10.10.100.1
WLAN Client 7-30 10.10.100.187 - 210 255.255.255.0 10.10.100.1
8. Select Submit to finalize the settings.
9. Define the operation mode by going to the Main menu, then selecting Wireless settings and
Operation mode .
10. Add the following information:
• Wireless enable: Enable
• Operation mode: Client
11. To define the basic wireless settings go to the Main menu, and select Wireless settings, then
WLAN and Basic wireless settings.
12. Add the following information:
• RF type: G
• SSID: See the following table
Each access point and Mobile Terminal in the same system
should have the same SSID. Parallel MineLAN systems are
NOTE!
identified with letter codes such as system A, and the rest are
individualized in alphabetical order.

System SSID
A AutoMine-Lite-A
B AutoMine-Lite-B
C AutoMine-Lite-C
etc. etc.
13. To define the WLAN security settings go to the Main menu, and select Wireless settings, then
WLAN and WLAN security settings.
Enable security settings, if required.
14. To define the advanced wireless settings go to the Main menu, and select Wireless settings, then
WLAN and Advanced wireless settings.

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15. Add the following information:

• Transmission rate: Auto
• Fragmentation threshold: 2346
• Transmission power: Full
• Fragmentation threshold: 2346
• RTS threshold: 2346
• Transmission distance: 500
• Noise protection: Disabled
• Transmission enhancement: Disabled
• Antenna: Auto
• EAPOL version: 1
• WMM: Disabled
• Full 11a channel support: Disabled
• Turbo roaming: Enable
• AP alive check: Disable
• Scan channels: Select scanned channel (6)

The hand-over will not function properly, if the noise protection

NOTE!
is not disabled in all access points.

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5.14.2. Client and access point

1. To update the firmware, go to the Main menu, select Maintenance, then Firmware upgrade.

2. Click Browse to Select update image.

3. Click Firmware upgrade and Restart to finalize the selection.

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4. To import configurations, go to the Main menu, select Maintenance, then Config Import Export.

5. Click Browse to Select configuration file.

6. Config Import -button below Select configuration file.
7. To export configurations, go to the Main menu, select Maintenance, then Config Import Export.
8. Click the Config Export -button under the heading Config Export.

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