Miner AggreGate User manual

©Miner Enterprises 2019
Page 1of 28
Solar Powered Stand-Alone
Electric AggreGate™
Revision B
8/14/2020

©Miner Enterprises 2019
Page 2of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 1
Table of Contents
Table of Contents.................................................................................... Section 1
General Information................................................................................. Section 2
Safety Precautions.................................................................................. Section 3
Component Identification......................................................................... Section 4
Principle of Operation.............................................................................. Section 5
Operating Instructions............................................................................. Section 6
Installation Instructions............................................................................ Section 7
Inspection/Maintenance .......................................................................... Section 8
Troubleshooting ...................................................................................... Section 9

©Miner Enterprises 2019
Page 3of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 2
General Information
This manual consists of information, which will be useful in the operation and
maintenance of the Miner Solar Powered Stand-Alone Electric AggreGate™ equipped
ballast cars. The manual includes operating, maintenance and troubleshooting
procedures with illustrations to assist in identifying various components.
Before proceeding with operation or maintenance of the ballast cars, read and
understand the SAFETY PRECAUTIONS SECTION of this manual in addition to
precautions prescribed by the AAR, FRA and individual handling railroads.
It is expressly understood that issuance of these Miner instructions which were
prepared in good faith and are believed to be complete and accurate, shall not be
construed to mean that Miner Enterprises, Inc. assumes any liability on account of
accidents to persons or property involving the Miner Solar Powered Stand-Alone
Electric AggreGate™ .
Miner Enterprises is not responsible for car construction or design, including
modifications for gate application.

©Miner Enterprises 2019
Page 4of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 3
Safety Precautions
In addition to safety precautions prescribed by the car owner, loading site, unloading
site, repair shop and handling railroad, the following safety precautions must be
observed whenever a Miner Solar Powered Stand-Alone Electric AggreGate™ is
operated and whenever any maintenance is performed on it.
1. All maintenance, repair, or adjustment must be made on a shop or repair track
where the car will not be moved.
2. Protective eye and ear wear and gloves should be used when doors are
operated.
3. Read and follow Caution Notes, Remote Gate Operation, and the Emergency
Manual Operation decals which are posted on the side of the car.
4. Emergency Manual Operation is only to be used when the doors cannot be
operated by the Remote Gate Operation or the Manual Powered Operation. In
the event of Emergency Manual Operation, the car must be stopped.
5. If doors do not operate by the Remote Gate Operation or the Manual Powered
Operation refer to SECTION 9 Troubleshooting.
6. Never attempt to adjust or repair the system without disconnecting the power
using the main power shut-off located in the battery box.
7. After unloading, confirm that all doors are in the completely closed position with
no obstructions.
8. Always report an inoperable or damaged gate to a supervisor so that it may be
properly repaired or replaced.
9. Do not attempt to force the door system in any way.

©Miner Enterprises 2019
Page 5of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 4
Component Identification
General Description
The Miner Solar Powered Stand-Alone Electric AggreGate™ was designed and built for
twin hopper ballast rail cars. The system is actuated by electric drive units, is powered
by solar modules that charge special batteries, and is remote controlled by a hand-held
transmitter. There are two gates per hopper and each gate is independent of the others,
with two electric drive units to discharge inside and outside the rail.
Component Identification
For a complete list of components and descriptions and part numbers, refer to latest
revision of the following:
General Arrangement Drawing
Electrical Schematic Drawing
Customer Schedule
For a complete list of Miner part numbers and descriptions refer to the latest revision of
the Customer Schedule. Any of these documents can be obtained by contacting Miner
Customer Service at [phone].

©Miner Enterprises 2019
Page 6of 28
Part Identification
Hand Held Transmitter
and Battery with Charger

©Miner Enterprises 2019
Page 7of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 5
Principle of Operation
General Description
The Miner Solar Powered Stand-Alone Electric AggreGate™ was designed for twin
hopper ballast rail cars. The purpose of the gate is to rapidly discharge ballast from the
car to the rail-bed. The primary mode of operation is remote gate operation with hand-
held transmitter. In the event remote operation cannot be completed, manual powered
operation can be achieved using manual override toggles located in the box assembly
on the side of the car. If primary and secondary modes of operation cannot be
achieved; the car must be stopped, power cut off in the battery box, and emergency
manual door operation can be completed using the provided wrench on the hex nut
mounted on the gate shafts.
Carefully read and understand the SAFETY PRECAUTIONS SECTION of this manual.
Principle of Operation Electric Aggregate Gate System
Principle of Operation - Gate
Ballast can be unloaded inside or outside of the rail. Power supplied to the drive units
results in rotation of the operating shafts which act through linkages to open and close
the inner and outer door.

©Miner Enterprises 2019
Page 8of 28
Electricity from two deep cell batteries provides the power to activate the electric
drive units on each gate. The electricity is directed to the proper gate by solid state
circuitry.
The system is designed for primary operation through digital signal from a radio
receiver controlled by an operator using a hand-held radio transmitter. In the event
the primary operation cannot be completed, a secondary manual powered operation
of the gates can be achieved using toggles located in the gate control box located on
the side of the car.

©Miner Enterprises 2019
Page 9of 28
Principle of Operation –Radio Receiver
The receiver can be controlled by two separate transmitters that operate on opposite
sides of the car without interfering with each other. Data is transmitted by the radio
signal. Up to four transmitters can operate on the same frequency while in proximity.
The operating range outdoors is -22°F to 140°F (-30°C to 60°C), RH 0 to 95%
The hand-held transmitter transmits signals to the receiver/decoder using a UHF radio
link. The signal is picked up by the antenna and passed on to the receiver. If the signal
is the correct frequency and passes all required data tests, the signal is passed on to
the decoder.
The decoder compares the base address code of the signal to its own address code. If
the signal's base address code does not match the decoder's base address code, it is
ignored. If the base address and sub address (ballast car I.D. number) codes are
correct, the decoder processes the message and energizes and de-energizes the
appropriate output relays.

©Miner Enterprises 2019
Page 10 of 28
A 20 Amp control fuse is mounted in the common input line of each relay group to
provide over-current protection. During operation, the microprocessor on the decoder
board resets a watchdog timer circuit whenever valid messages are received and
decoded.
The system operates in the specific band, does not require an FCC license, and has a
range of 200 feet. The transmitter can operate up to 1000 cars (000-999) individually by
using preprogrammed radio receivers mounted on each car which is set up with a
unique address. The receiver is turned on by depressing one of the two power toggle
switches located in the aggregate control boxes mounted on either side of the car above
the side sill.
Note: The receiver will not operate unless both the lids on the aggregate control
boxes are latched closed.

©Miner Enterprises 2019
Page 11 of 28
The hand-held transmitter has been customized specifically for Ballast Car Operation and
contains a highly advanced encoder circuit board using micro-computer digital circuitry.
The hand-held transmitter uses a rechargeable Battery Pack and Charger. The (LED)
indicator changes from green to orange when the batteries need replacing.
Note: Transmitters should be maintained at six feet separation from each other
during operation.
POWER ON SELF TEST (P.O.S.T.) DIAGNOSTICS - When the operator first turns the
power switch on, a sophisticated self-test routine tests the microcomputer and all critical
switch inputs to detect unwanted commands in the system. A small speaker beeps twice
when the test has been completed satisfactorily.

©Miner Enterprises 2019
Page 12 of 28
BATTERY SAVER –If the controller has not been operated for 15 minutes, a battery
management system detects this inactivity and puts the controller into a deep sleep' mode.
To reset the controller, the ON/OFF SWITCH must be set to 'OFF', and then set to 'ON'
again.
CHANNEL SELECTOR –This switch is used to select which side of the ballast car the two
operators will be stationed. For example: Operator No. 1 selects controller "CHANNEL 1'
and stands trackside with a commanding view of the left hand side of the targeted ballast
car. Conversely, Operator No. 2 selects controller 'CHANNEL 2' and stands trackside to
view the right hand side of the same ballast car.
CAR ID. TOGGLE SWITCH –These 3-position, spring return-to-center switches are used
to set the targeted ballast car identification (I.D.) number. It should be noted that all three
toggle switches may only be operated in conjunction with the CAR I.D.
CAR I.D. DISPLAY - This digital display shows the current 3-digit ballast car I.D. number
selected on the controller. It may also be used to view the last ballast car I.D. number
selected by the operator.
SIDE SELECTOR –This 2-position selector switch is used to select either the INSIDE or
OUTSIDE doors.
DOOR OPEN/CLOSE TOGGLE SWITCHES –Four toggle switches are provided, one for
each door. The ballast car has four doors denoted A, B, C, and D, with three sides each
that allow ballast to be released to inside or outside of the rail as the train moves. These 3-
position, spring return-to-center switches are used to OPEN and CLOSE the selected door.
Charging System
The two deep cell batteries producing 24 Volts are kept properly charged by a current
from regulated solar panels. The batteries provide power for the radio receiver and the
electric drive units. A fully charged system alone has enough storage capacity to
provide service for one week of overcast days. When storing the railcar for an extended
period, the batteries should be fully charged. The useful service life of the batteries
when properly charged and fully functioning charging system should be 3-5 years.
Caution: The electric drive units can be back driven and must be safely secured up and
away from anything that may cause them damage when not fully attached to the gate. It
is unsafe to use the wrench on the gate when the car is moving.

©Miner Enterprises 2019
Page 13 of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 6
Operating Instructions
General Description
The Miner Solar Powered Stand-Alone Electric AggreGate™ is designed and built for
twin hopper ballast rail cars. Read and understand the SAFETY PRECAUTIONS
SECTION of this manual in addition to precautions prescribed by the AAR, FRA and
individual handling railroads.
The system must be turned on by depressing the power toggle switches located in the
gate toggle boxes mounted on either side of the car.
The green LED light will stay on while power is applied to the gate system. Either
power toggle switch on the right or left side of the car can be used.

©Miner Enterprises 2019
Page 14 of 28
Primary Of Operation –Remote Gate Operation
1.) Power up the system inside the gate toggle box.
2.) Close and secure the gate toggle box for the hand-held transmitter to function.
3.) Power up the hand-held transmitter.
4.) When two transmitters are used, set one at channel one and the other at
channel two.
5.) Dial the last three digits of the car number into the transmitter. Starting with the
HUNDREDS switch, pushing upwards increments the first (hundred's) digit of
the CAR I.D. DISPLAY. Conversely, pushing the same switch down
decrements the first (hundred's) digit of the CAR I.D. DISPLAY. Operation of
the TENS and UNITS toggle switches in the same manner will increment or
decrement the second and third digits of the CAR I.D. DISPLAY respectively.
6.) Set “Inside” or “Outside” of the rail for discharge.
7.) Push the toggle to “Open” position for the desired gate (1,2,3,4). The door will
continue to open if the toggle is held in the open position and will stop and hold
position when the switch is released or when the door is fully open.
8.) Close the doors when unloading is complete.
9.) Repeat the procedure for each car.
10.) Power off the transmitter when unloading is complete.

©Miner Enterprises 2019
Page 15 of 28
Secondary Mode Of Operation –Manual Powered Operation
1.) Manual powered operation of the gates can be achieved using the manual
override toggles located in the box assembly on each side of the car. This
procedure is to be used for ballasting only when the remote operation does not
function.
2.) Use toggle switches to open and close the desired gate.
3.) The Toggle Box on the right side of the car can only operate the gates on the
right side of the car, and the left only operate the left side. Gates operate while
switches are toggled, allowing precision control.

©Miner Enterprises 2019
Page 16 of 28
Emergency Manual Gate Operation
Emergency manual operation should be used only when the doors can not be opened
or closed using power. Cars must be stopped, and the system should be powered
down before using this procedure.
1.) Turn Power Off inside the battery box.
2.) Disconnect the cable from the electric drive motor on the non-functioning door
position.
C-0957

©Miner Enterprises 2019
Page 17 of 28
3.) Open or close door using box wrench. The wrench is provided and can be found
in a secure location under the ballast car. Use wrench to open and close the
doors to be operated by placing the head of the wrench on the hex nuts attached
to shaft at the end of the gates.
4.) Close all the gate doors to complete the process.

©Miner Enterprises 2019
Page 18 of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 7
Installation Instructions
General Description
The Miner Solar Powered Stand-Alone Electric AggreGate™ was designed and built for
twin hopper ballast rail cars. The purpose of the system is to rapidly discharge ballast
from the ballast car to the rail-bed. There are two gates per hopper, and each gate is
independent of the others.
Carefully read and understand the SAFETY PRECAUTIONS SECTION of this manual.
Required Drawings
For a complete list of components and descriptions and part numbers, refer to latest
revision of the following:
General Arrangement Drawing
Electrical Schematic Drawing
Customer Schedule
For a complete list of Miner part numbers and descriptions refer to the latest revision of
the Customer Schedule. Any of these documents can be obtained by contacting Miner
Customer Service at [phone].
Gate Installation Instructions
The Miner Enterprises General Arrangement Drawing and all drawings referenced by
said drawings will be necessary to perform gate installation.
.
Electrical Installation Instructions
The Miner Enterprises General Arrangement Drawing and Electric Schematic Drawing
will be necessary to perform electrical installation.

©Miner Enterprises 2019
Page 19 of 28
Solar Powered Stand-Alone Electric AggreGate™
Section 8
Inspection Procedures
General Description
The system has three areas that require Inspection:
Mechanical System
Electrical System
Charging System
Use the general arrangement drawing, the electrical schematic drawing, and the
customer schedule to identify damaged or missing components. Contact Miner
Enterprises for assistance in replacing damaged or missing components.
Mechanical System Inspection
Check for damaged welds and components. (Inspect before each loading and after
each unloading.)
Check for missing or damaged pins, washers or cotter pins. (Inspect once per year.)
Check for damaged or missing bolts. (Inspect once per year.)
Check for damaged or missing Cable Ties and Cable Tie Brackets. (Inspect once per
year.)
Check for damaged or missing Cables. (Inspect once per year.)
Check for damaged or missing Decals. (Inspect once per year.)
Contact Miner Enterprises for assistance in replacing damaged or missing components.

©Miner Enterprises 2019
Page 20 of 28
Electrical System Inspection
Check for damaged welds and components. (Inspect before each loading and after
each unloading.)
Check for damaged or missing or bolts. (Inspect once per year.) Replace and repair
with like components.
Check Toggle Box Assembly for damage inside or outside and ensure box is functioning
properly. If box is not functioning properly, attempt to repair using SECTION 9
TROUBLESHOOTING. (Inspect once per year.)
Check Controller Box Assembly for outside damage and ensure box is functioning
properly. If box is not functioning properly, attempt to repair using SECTION 9
TROUBLESHOOTING. (Inspect once per year.)
Check Radio Receiver Box Assembly for outside damage and ensure box is functioning
properly. If box is not functioning properly, attempt to repair using SECTION 9
TROUBLESHOOTING. (Inspect once per year.)
Check Radio Receiver Interface Assembly for outside damage and ensure box is
functioning properly. If box is not functioning properly the attempt to repair using
SECTION 9 TROUBLESHOOTING. (Inspect once per year.)
Check Electric Drive Units for outside damage and ensure unit is functioning properly. If
unit is not functioning properly, contact Miner Enterprises for assistance in replacing
damaged or missing components.