CAT PMC™ Evo-S Control System EL1000 Operating & Maintenance Manual - PDF DOWNLOAD

Media-ID: EM028767-00-EN Doc.-No.: 1999 001 044 TB 01-10 Apr. 2018

Operating and Maintenance Manual PMC™ Evo-S Control System EL1000

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© 2018 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of content

Table of content 1 PMC-S Control System ............................................................................... 5

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1.1 General Features.................................................................................. 5 1.2 System Overview.................................................................................. 6 1.2.1 PLC ............................................................................................ 6 1.2.2 Automation IPC.......................................................................... 7 1.2.3 Keypad....................................................................................... 8 1.2.4 Electrical Systems and Equipment .......................................... 11 1.2.5 Contactors................................................................................ 12 1.2.6 Motors ...................................................................................... 12 1.2.7 Haulage.................................................................................... 14 1.2.8 Encoder.................................................................................... 16 1.2.9 Pre Start Warning Alarm .......................................................... 17 1.2.10 Door Push Buttons................................................................... 17 1.2.11 Solenoid Controls..................................................................... 17 1.2.12 Pilot Circuit............................................................................... 17 1.2.13 Earth Leakage Monitoring........................................................ 19 1.2.14 Methane Monitoring ................................................................. 20 1.3 Operating Procedure .......................................................................... 21 1.3.1 Visible Disconnect.................................................................... 21 1.3.2 Operator Control Modes .......................................................... 22 1.3.3 Motor Start / Stop Operation ..................................................... 29 1.3.4 Hydraulic Function Operation .................................................. 33 1.3.5 Haulage Operation................................................................... 37 1.4 Man Machine Interface ....................................................................... 42 1.4.1 Display Page Formats.............................................................. 42 1.4.2 Page Navigation....................................................................... 44 1.4.3 Status Indication by Colour ...................................................... 50 1.4.4 Page Descriptions.................................................................... 51 1.4.5 Device Module Set up.............................................................. 87 1.4.6 Setting up MAC Table.............................................................. 97 1.4.7 Software Installation MMC ..................................................... 100 1.4.8 Web browser Installation........................................................ 111 1.4.9 Software Revision Check....................................................... 113 1.4.10 Parameter Management ........................................................ 116 2 Control System: Automation.................................................................. 124 2.1 Introduction and Purpose of Auto Steering....................................... 124 2.1.1 Machine Automation Information ........................................... 124 2.2 Machine Dimensions ........................................................................ 124 2.2.1 Device Positions .................................................................... 126 2.2.2 Machine and Drum Positions ................................................. 127 2.3 Machine Position Encoders .............................................................. 128 2.3.1 Overview and Commissioning ............................................... 128 2.3.2 Machine Angle Measurement ................................................ 130 2.3.3 Ranging Arm Potentiometers................................................. 132 2.4 General Operation Overview ............................................................ 134 2.4.1 Communication Layout .......................................................... 135 2.4.2 Shearer Radio Transmitter Operation Overview.................... 135 2.4.3 Haulage Overview.................................................................. 137 2.4.4 Status Beacons...................................................................... 137 2.4.5 Drum Modes and Automation Methods ................................. 138 PMC™ Evo-S Control System EL1000

Table of content

2.5 Automation Zones............................................................................. 145 2.5.1 Face Settings Zones .............................................................. 146 2.5.2 Drum Automation Zones ........................................................ 146 2.5.3 Cowl Automation Zones......................................................... 148 2.6 State based Automation ................................................................... 148 2.6.1 State Automation Overview ................................................... 149 2.6.2 Automation State Table Description ...................................... 150 2.6.3 Automation State Quick Guide............................................... 152 2.7 Automation Configuration Options.................................................... 155 2.7.1 Ranging Arm Control Set Up ................................................. 155 2.7.2 Gain Definitions...................................................................... 159 2.7.3 Limit Definitions...................................................................... 163 2.8 Anti-Collision Drum Raise Inhibit ...................................................... 168 2.9 LongwallFusion Face Alignment....................................................... 169 2.11 Extended Functions .......................................................................... 178 2.11.1 Encoder Fail Detect ............................................................... 178 2.11.2 Ranging Arm Gear Mesh Enhancement ................................ 179 2.11.3 Ranging Arm Levelling........................................................... 183 2.11.4 Thermal Inclinometer Enhancement ...................................... 185 2.11.5 Water Exclusion Zone Enhancement..................................... 190 3 Faults and Alarms ................................................................................... 192 3.1 Introduction ....................................................................................... 192 3.2 Keypad Overview.............................................................................. 193 3.3 Display Pages Overview................................................................... 194 3.4 Display Pages Menu Overview......................................................... 195 3.5 Faults, Alarm and Event Handling .................................................... 196 3.5.1 Faults Overview ..................................................................... 199 3.5.2 Fault Actions .......................................................................... 203 3.5.3 Fault Descriptions .................................................................. 206 3.6 Inactive Functions / Transducers....................................................... 207 3.7 Logged Faults, Alarms and Events................................................... 209 3.8 MMC Fault Management .................................................................. 211 3.8.1 Fault List ................................................................................ 211 3.8.2 Fault Description Window ...................................................... 212 3.8.3 Navigation .............................................................................. 213 3.8.4 Flow Chart.............................................................................. 213 4 Appendix .................................................................................................. 214 4.1 PMC™ Evo-S Commissioning Menu Pages..................................... 214 4.2 PMC™ Evo-S Commissioning Automation Pages ........................... 215 4.3 Faults, Alarms and Events................................................................ 225 4.3.1 Machine Event Messages...................................................... 226 4.3.2 Machine Fault Messages ....................................................... 227 4.3.3 Machine Alarm Messages...................................................... 241 4.3.4 State Automation Faults......................................................... 245 4.3.5 State Automation Alarms ....................................................... 247

PMC™ Evo-S Control System EL1000

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2.10 Enhanced Horizon Control................................................................ 178

PMC-S Control System General Features

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1 PMC-S Control System This section explains the relevant aspects of the on-board machine control system. The information in this section covers typical arrangements. There may be changes depending on the site application.

1.1 General Features PMC-S is a new generation control system platform for the Caterpillar range of Longwall Shearers. Specifically designed for ease of installation, commissioning and maintenance, PMC-S combines a flexible distributed field bus system with easily accessible equipment, utilising state of the art hardware and software technology. The main components that make up the shearer control system are shown below:

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Fig. 1: Shearer main components

PLM

Code Plug

PLC

Ethernet Switch

N Tron

N Tron N Tron

CIOS Modules Keypad

Main Display

Left Cutter Motor Inclinometer

Drive A

N Tron

PMC ASI

Encoder

PMC ASI

Encoder

Drive B

Right Cutter Motor Inclinometer Left End Display

CIOS Modules

Right End Display

IPC Left Radio A

Left Radio B

CIOS Modules

CIOS Modules

CIOS Modules

PLC

Programmable Logic Controller (PLC)

Ethernet network switch

Automation Controller (IPC)

N-Tron switches

Display and keypad

AC Inverter

Radio Controls

CIOS Modules (“Configurable Input Output System”)

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PMC-S Control System System Overview

1.2 System Overview 1.2.1 PLC The system core is the Rockwell PLC which oversees basic operation and safety. The PLC communicates exclusively using Ethernet to all peripheral equipment, including sensors, actuators, high level automation, and other On and Off-board systems. The majority of control data is routed internally on the shearer through a network of CIOS assemblies. CIOS comprises of a flexible arrangement of plugable units, allows wiring to sensor and actuator wiring to be routed efficiently in localised groups. The CIOS modules may be used both externally as intrinsically safe (IS) devices, or used within the control compartments in an explosion protected environment (FLP).

The PLC is responsible for the monitoring of all machine health and safety transducers. PMC-S monitors numerous intrinsically safe pressure, flow, level, temperature, angle and strain transducers. These sensors are used to monitor properties such as gearbox / reservoir fluid levels, oil temperatures and surface temperatures. The data from these transducers provides warning and protection against abnormal operating conditions hazardous to operators, and the longwall environment.

Actuators are controlled by the PLC logic and depend on exhaustive interlocking requirements of machine functions and sensors. The main areas of interest being Motor start / stop, Hydraulic actuators, Haulage Drive signals, and water circuit controls.

All on-board sensors, actuators, systems and components are monitored exclusively by the PLC application.

All motors are monitored for over temperature timed and instantaneous over current All fluids are monitored for pressure, flow, temperature, or level where necessary All heat sources are monitored for temperature: Motor Windings Motor Bearings Ranging Arm gears / oil Haulage gears / oil Haulage Parking brake Powerpack oil Control and Haulage compartments Abnormal conditions sensed by PMC-S will result in either the display of an ‘Alarm’, or (if necessary) cause electrical power to be removed from the area, otherwise known as a ‘Trip’.

Should the previously mentioned monitoring facility detect any irregularity, the visual display unit will provide an appropriate time stamped message and log that event into its memory as a record. Please refer to the fault manual for more information.

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Scope of Control

PMC-S Control System System Overview

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1.2.2 Automation IPC The IPC is an embedded computer running high level communication and control applications. A summary of the shearer applications is given in the following section.

PMC Network Integration This application is responsible for interfacing the shearer to off-board systems in the Longwall. This includes Caterpillar Roof Supports PMC-R, AFC Drives PMC-D, and 3rd Party Gate End control interfaces.

The PMC-R interface provides the following functions: Shield Anti-collision Shearer position to the shields (for SRB) Auto State integration Media-ID: EM028767-00-EN / Caterpillar Global Mining Europe GmbH 2018 ©

Shearer automation sequence status Shearer speed limiting The PMC-D interface provides the following functions: Advanced CST load control through Shearer speed limiting Conveyor Run Status Chain Tension Position (extended tail gate stop) The 3rd Party Gate End PLC interface allows the customer to control many machine functions using their own plant, or machine interface. The following functions are available: Gate End Water Pump Control Remote Motor Start Operator on-screen message display AutoState state change Machine Commands (stop all motors, power down etc)

Shearer Navigator The Shearer Steering functions are provided by the “Shearer Navigator” package. This set of functions performs the following functions: Zone Based Automation (Navigator 1) Method Zones Extraction Zones Undercut Zones State Based Automation (Navigator 2) State Machine implementation extending the Navigator 1 automation features with a highly customisable and flexible programming and control interface Enhanced Horizon Control (Navigator 3) Accurate Pan / Floor Profiling Control and monitoring of longwall face advance horizon

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PMC-S Control System System Overview

Target Line correction of floor cut Navigator 3 uses the services of the “longwall Navigator” package for precision machine position tracking in 3D space.

Longwall Navigator This is the Caterpillar implementation of a fully 3-Dimensional Face profiling package. Longwall Navigator is fully self contained on board the shearer, requiring no offboard servers or databases to perform the primary task of face profiling for both floor profile, and also face straightening with roof supports.

Display Module

This module not only provides information relating to the machine operation, status and commissioning, but only oversees the operation and setup of CIOS and all other Ethernet peripherals. The main functions are given below: Fault and alarm viewing and archiving Shearer parameter management (loading / saving, changing) Unauthorized parameter modification detection Network addressing and configuration (DHCP) Software update management

1.2.3 Keypad The tethered keypad is used by the operator to communicate with the PMC-S system main display. The keypad has 21 keys (capable of 28 functions) laid out in a PC numeric keypad style, except that the row numerical keys are laid out similar to a telephone (123 is at the top). The keypad can be easily removed via an OS8 connector for maintenance and machine cleaning.

It is recommended that the keypad be removed when the machine is being cleaned.

The keys comprise of the following functions: Numeric data entry 0 to 9.

Function Keys (F1, F2, F3) Menu Keys (Home, Tab, Backspace) Page Up, Page down (alternate minus, and decimal point) Navigation mode Key (direction arrows).

Alarm Key (Quick access Faults menu) Return Key (implement commands).

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PMC™ Evo-S Control System EL1000

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This display is visible through a window on the control box flameproof door, and provides a tethered USB keypad.

PMC-S Control System

1

System Overview Fig. 2: Keypad

Function Keys

Menu Keys

Numeric Keys

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Direction Keys

Page Keys

Navigation Alarm and Return Keys

Display Quick Start To change pages enter a page number after F3 pressed or use the page menu hot keys identified at the bottom of the current Display screen.

To enter commissioning press F3 and enter page number or press number 8 from Main default start up Display page.

To view the faults screen press the Alarm key (bell icon).

Press tab to set the focus on modifiable items and use the arrow keys to navigate when an item is in focus.

Tab. 1: Keys Key

Description Quick Menu Change Control mode Reset Radio Handset Reset Drive Faults or Automation State number entry Note: F2 key not used with current issue

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PMC-S Control System System Overview

Page Numbering Navigation

Home key - Step back to previous pages

Tab key - Navigate around current Set up page or highlight an instruction item

Backspace key - Toggle between Current display page and Last previous page viewed Used as a Delete key in Set up pages

To navigate through menus and pages To edit numbers in Set up pages Arrow keys up, down, left, right To navigate around Set up pages and move up or down page listings

Navigation key - Toggles between Numbers and direction arrow keys

Page key - Steps forward through menu pages, both Run and Set up menus and decimal point used in Set up pages when editing numbers

Page key - Steps back through menu pages, both Run and Set up menus and minus sign used in Set up pages when editing numbers

Note: The Navigation Toggle key is used to allow Page up and down keys Fault key - Always steps to Current Faults page from any Run or Set up screens

Return key - Used to initiate Instructions and commands

Note: Log into Setup pages to Edit Values.

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Number keys 1-9

PMC-S Control System System Overview

1

Radio Keypad Mode An optional means of keypad control is available on the radio handsets. Selected by a special sequence of buttons, this keypad mode can be activated allowing functions similar to the tethered keypad. Therefore the operator can use this radio transmitter without requiring access to the onboard controls. When active the operator cannot carry out the primary functions of those buttons, as such the machine will be placed into a safe state when radio keypad mode is activated. All motors and the haulage are stopped if running.

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Fig. 3: Radio keypad

Shift Function This sequence requires a two button press together HELD ON > 1 Secs Keypad Mode After this procedure then all buttons will simulate the USB keypad

1.2.4 Electrical Systems and Equipment In order to carry out its various functions, PMC-S is connected to a large number of peripheral equipment. Details of this are shown on the Machine Electrical diagrams. The following is a description of equipment that may be connected to PMC-S. PLC & Watchdog Timer Display & USB Keypad IPC Network Switches CIOS Modules Machine Position Encoder(s)

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PMC-S Control System

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System Overview

AC Inverters Contactors Fig. 4: Electrical systems

Pilot circuit

Watchdog

12V DC

ECB2 & HTB2 I.S 110 CIOS Modules VAC

Ethernet Comms Ethernet Switch NTRON

708FX2

IMU

Ethernet Switch NTRON

IPC RS485

708FX2

Motor controls Motor contactors

Ethernet Switch NTRON

Optional

Drive A

PMC ASCI

Ethernet Switch I.S

Pump Motor Haulage Motor management

CIOS Modules

CIOS Modules

Main Display

Keypad

PP01 Ethernet switch CIOS Modules

Optional

PLC

PLM

I.S 12 VDC

Drive B

I.S Solenoid Controls Health Monitoring

716FX2

Radio Encoder

Left Radio A

WLAN Video

Thermal Inclinometer

End Display

Thermal Inclinometer

End Display

Right Radio B Encoder Encoder

CIOS Modules

Cutter Motor FLC monitoring feedback

CIOS Modules Ethernet communiations Fibre optic communications Input / output controls Serial communications

Optional

CIOS Modules

Pre Start Audible Alarms Health Monitoring Ranging Arm Angles

1.2.5 Contactors The contactors start and stop motors and supply power to the haulage AC inverter drives, all are controlled directly from the PLC via CIOS. The contactors are a single 110VAC voltage close and economy type. Auxiliary contacts are monitored on all contactors to detect open / closed status in addition to current monitoring to satisfy requirements that the contactor is operating correctly.

All motors and Haulage system voltages and currents are monitored by PMC-S to provide a comprehensive display and over-current protection facility. On certain Shearer configurations there may also be optional current monitors for the main incoming machine current, the haulage system transformer.

1.2.6 Motors PMC-S monitors a number of intelligent Motor Data Transmitters (MDT) located inside each motor terminal enclosure. Each interface module is wired using a point-to-point serial link to a dedicated CIOS Motor Management Module. Individual motor RTD’s (up to 6 PT100’s) and thermostats (up to 4) can be wired into each MDT Module. The MDT module is intended for single motor cable designs, requiring only three auxiliary cores in the motor cable.

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PMC™ Evo-S Control System EL1000

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110 VAC

ECB2 & HTB2 NTRON Switches Pilot Relay CH4 Relay trips

24 VDC

PMC-S Control System System Overview

1

The data gathered from the MDT is used to provide protection to the windings and bearings, and in certain regions ensure critical temperatures are monitored.

Fig. 5: Motors

Ethernet Switch in the HTB3 Haulage Control Box

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Ethernet Switch in the ECB3 Low Voltage Control Box

Motor Management modules receive Motor temperature Data from Motor Data Transmitter Right Cutter Motor Communications

Haulage Motor Communication Left and Right

Left Cutter Motor Communications Haulage Transformer Communications Pump Motor Communications

Each Motor (except the Haulage Motors) has a dedicated Motor Management Module that provides the motor monitoring

Motor Data Transmitter Fig. 6: Motor data transmitter

6 RTDs, Winding Phases U, V, W Face side and Goaf side Bearings Water Jacket cooling

LED Status PWR - White, 12 VDC ACT - Green, MDT Activity ERR - Red, Fault TX - Yellow, Transmitting Data

4 Thermostats, Winding Phases U, V and W Water Jacket cooling

PMC™ Evo-S Control System EL1000

Power and Communications 1. 12 VDC 2. TX Serial 3. Ground

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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