CAT Shearer MMC control for mobile machines System Operation Manual – PDF DOWNLOAD

Media-ID: EM027782-01-EN Doc.-No.: 1999 001 047 BA 00 Sep. 2018

System Operations MMC control for mobile machines

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AMENDMENTS AND ALTERATIONS TO THIS PUBLICATION ARE NOT SUBJECT TO NOTIFICATION. CATERPILLAR RESERVES ALL RIGHTS TO THIS PUBLICATION. ITS CONTENT IS PROTECTED BY COPYRIGHT LAWS. NO PART OF THIS PUBLICATION MAY BE REPRODUCED OR TRANSFERRED IN ANY WAY OR FORM WITHOUT THE PRIOR WRITTEN APPROVAL OF CATERPILLAR. CATERPILLAR DECLINES ANY LIABILITY FOR DIRECT OR INDIRECT CONSEQUENCES OF PRINTING ERRORS. WE RESERVE THE RIGHT TO INTRDUCE MODIFICATIONS AS A RESULT OF TECHNICAL DEVELOPMENTS WITHOUT PREVIOUS NOTICE. © 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 Contents

Table of Contents 1 About this manual ....................................................................................... 6 1.1 Signs and symbols................................................................................ 7 1.2 Terms and representations................................................................... 8 2 Safety............................................................................................................ 9 2.1 General safety instructions ................................................................... 9 2.2 Operating conditions........................................................................... 10 2.2.1 Intended use ............................................................................ 10 2.2.2 Unauthorized use..................................................................... 10 2.2.3 Ambient conditions................................................................... 10 2.2.4 Prerequisites for operation....................................................... 11 2.3 Personnel............................................................................................ 11 Media-ID: EM027782-01-EN / Caterpillar Global Mining Europe GmbH 2018 ©

2.4 Operator requirements........................................................................ 12 2.5 Work on and with the machines.......................................................... 12 3 Storage ....................................................................................................... 14 4 Transport.................................................................................................... 15 5 Installation.................................................................................................. 16 5.1 Drawing number system ..................................................................... 16 5.2 Tools required..................................................................................... 16 5.3 Maintenance of the control units......................................................... 16 5.3.1 Replacing control components................................................. 17 5.3.2 Tightening torques ................................................................... 17 5.3.3 Changing batteries and charging rechargeable batteries ........ 18 5.3.4 Repair of fiber-optic cables ...................................................... 19 5.3.5 Cleaning the machine .............................................................. 19 6 MMC system description .......................................................................... 20 6.1 System Overview................................................................................ 20 6.1.1 MMC component communication ............................................ 21 6.1.2 Operational environments........................................................ 23 6.1.3 Network structure..................................................................... 25 6.1.4 HMI .......................................................................................... 25 6.1.5 Node abbreviations .................................................................. 25 6.1.6 Addressing the nodes .............................................................. 26 6.2 The CIOS system ............................................................................... 27 6.2.1 Designations of CIOS components.......................................... 27 6.2.2 Components of a CIOS device ................................................ 28 6.2.3 Status displays of the various CIOS module types .................. 29 6.2.4 Fieldbus coupler CIOS FBC EIP OS4 IS/NIS .......................... 32 6.2.5 Digital output module CIOS DOUT4 OS4 IS............................ 34 6.2.6 Analog input module CIOS AIN6 E1 OS4 I.............................. 35 6.2.7 Digital input module CIOS DIN4 E1 OS4 IS ............................ 36 6.2.8 Analog input module CIOS RTD4 OS4 IS ............................... 37 6.2.9 Digital input module CIOS DIN10 E1 PH ................................. 38 6.2.10 Analog input module CIOS AIN8 E1 PH .................................. 40 6.2.11 Analog input module CIOS RTD12 PH .................................... 41 6.2.12 Motor management module CIOS MM PH .............................. 42 6.2.13 Motor data transmitter MDT for CIOS MM PH ......................... 43 MMC control for mobile machines

Table of Contents

6.2.14 PWM module CIOS PSO OS4 NIS.......................................... 45 6.2.15 Analog output module CIOS AOUT4 OS4 NIS ........................ 46 6.2.16 Supply module CIOS PWR OS4 NIS ...................................... 47 6.3 DMS UI Interface OS4 IS.................................................................... 48 6.4 POT UI Interface SKK24 IS ................................................................ 49 6.5 PowerSwitch (IS/NIS) ......................................................................... 49 6.6 IS Switch............................................................................................. 50 6.7 PowerLine modem.............................................................................. 51 6.8 PLC..................................................................................................... 54 6.9 USB stick OS4 IS................................................................................ 58 6.10 Power supply PSU 12.8.2................................................................... 58 6.11 Power Indicator 28.............................................................................. 60 6.13 IPC 4................................................................................................... 63 6.14 HMIs ................................................................................................... 64 6.15 IS remote controls............................................................................... 66 6.15.1 IS USB remote control ............................................................. 66 6.15.2 IS wireless remote control and receiver................................... 68 6.15.3 Charging station for the wireless remote control...................... 70 7 Technical data............................................................................................ 77 7.1 MMC system....................................................................................... 77 7.2 Name plates........................................................................................ 77 7.3 CIOS BP6 NIS/IS, BP11 NIS/IS.......................................................... 78 7.4 CIOS FBC EIP OS4 IS/NIS ................................................................ 83 7.5 CIOS AIN4 E2 OS4 IS ........................................................................ 87 7.6 CIOS AIN6 E1 OS4 IS ........................................................................ 91 7.7 CIOS AIN8 E1 PH NIS........................................................................ 94 7.8 CIOS AOUT4 OS4 IS ......................................................................... 97 7.9 CIOS DIN4 E1 OS4 IS...................................................................... 100 7.10 CIOS DIN10 E1 PH NIS ................................................................... 102 7.11 CIOS DOUT4 OS4 IS ....................................................................... 105 7.12 CIOS RTD4 OS4 IS .......................................................................... 108 7.13 CIOS RTD12 PH NIS........................................................................ 111 7.14 CIOS MM PH NIS ............................................................................. 114 7.15 CIOS MDT NIS ................................................................................. 119 7.16 CIOS PSO OS4 NIS ......................................................................... 122 7.17 CIOS PWR OS4 NIS ........................................................................ 126 7.18 DMS UI Interface OS4 IS.................................................................. 129 7.19 POT UI Interface SKK24 IS .............................................................. 130 7.20 PowerSwitch (IS/NIS) ....................................................................... 131 7.21 IS Switch........................................................................................... 135 7.22 PowerLine modem (NIS), PLM coupler ............................................ 136 7.22.1 PowerLine modem ................................................................. 136

MMC control for mobile machines

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6.12 Power Indicator 10.............................................................................. 61

Table of Contents

7.22.2 PLM coupler........................................................................... 139 7.23 PLC controls 1768-L43, -L43S, 1756-L63S, L-73S .......................... 140 7.23.1 1768-L43, -L43S .................................................................... 140 7.23.2 1756-L63S, -L73S.................................................................. 143 7.24 Power Indicator 28............................................................................ 146 7.25 Power Indicator 10............................................................................ 149 7.26 USB stick OS4 IS.............................................................................. 151 7.27 Power supply PSU 12.8.2................................................................. 152 7.28 IPC 4................................................................................................. 155 7.29 External battery module OS4 IS ....................................................... 158 7.30 HMI 5 ................................................................................................ 159 7.31 HMI 10 .............................................................................................. 161 7.32 USB remote control (IS).................................................................... 164 Media-ID: EM027782-01-EN / Caterpillar Global Mining Europe GmbH 2018 ©

7.33 IS wireless remote control, receiver and charging station................ 166 7.33.1 IS wireless remote control...................................................... 167 7.33.2 IS wireless receiver................................................................ 168 7.33.3 Charging station..................................................................... 169

MMC control for mobile machines

About this manual

1

1 About this manual This chapter contains important information that makes it easier for you to use this manual. You will also get information about the structure of the manual and the symbols, characters and abbreviations used and frequently used terms. applicable operating manual

application

If you use an operating manual that is not intended for your hardware or software, you are endangering yourself, other people and items of equipment.

This operating manual belongs to the Control for mobile machines (Mobile Machine Control, MMC) For the locally different requirements, there are two series of the MMC components: Non-intrinsically safe components (NIS) for locations without a danger of explosion.

This manual describes how to service and/or repair the unit.

A central component of the MMC system is the CIOS® system (CIOS = Configurable Input Output System) with I/O modules (I/O = Input / Output). The designation CIOS® is legally protected and is the property of Caterpillar Global Mining Europe GmbH, Lünen. For the purpose of improved legibility, the registered trademark symbol® will henceforth not be used in this manual. category acc. to ATEX Directive

The system components of the intrinsically safe series meet the European directive 94/9/EC, device group I, category M2.

new operating manual

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

target group

The operating manual is intended for those persons who set up the control system, work with it, make settings and perform troubleshooting.

This includes persons who: are in charge of transport, perform installation/removal work, correct malfunctions, perform daily routine work on the face, carry out maintenance work, carry out repair work.

Supervisory personnel who: initiate the activities mentioned above and/or supervise them.

efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all activities relating to the product.

Take the time to read this operating manual in its entirety. Pay particular attention to the respective safety instructions. Familiarize yourself well with the appearance and meaning of the safety and information symbols.

safety

Carefully read through the chapter "Safety". This chapter contains important information indicating possible hazards.

Observe the information given and follow the instructions.

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Intrinsically safe components (IS) for locations with a danger of explosion.

About this manual

1

Signs and symbols

liability exclusion

Caterpillar Global Mining Europe GmbH assumes no liability for damage or operating malfunctions resulting from non-compliance with this operating manual.

The warranty provided by Caterpillar Global Mining Europe GmbH becomes void in the event of non-compliance with this operating manual.

service partner

Please contact your service partner for spare part requests or for the clarification of technical questions.

1.1 Signs and symbols DANGER The combination of the signal word DANGER and a corresponding symbol warns you of an immediate danger with a high personal risk!

Media-ID: EM027782-01-EN / Caterpillar Global Mining Europe GmbH 2018 ©

If not observed, you or your coworkers will be seriously injured or killed.

Follow the described instructions!

WARNING The combination of the signal word WARNING and a corresponding symbol warns you of a potential danger with a moderate personal risk!

If not observed, you or your co-workers might be seriously injured or killed.

Follow the described instructions!

CAUTION The combination of the signal word CAUTION and a corresponding symbol indicates a potential personal risk!

If not observed, you or your co-workers could suffer minor to moderate injuries.

Follow the described instructions!

NOTICE The combination of the signal word NOTICE and the adjacent symbol indicates a potential risk of damage to the machine!

If not observed, material damage might occur on the machine.

Follow the described instructions!

Tip The signal word TIP indicates useful tips and information!

This information will help you become more familiar with the machine and allow you to prepare your work more exactly.

Observe the provided tips and information!

Important information The combination of the signal words IMPORTANT INFORMATION and the adjacent symbol indicates important information or other operating manuals which must be observed at this place.

Observe the information and read the specified operating manuals.

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1

About this manual Terms and representations

1.2 Terms and representations lists

Lists are marked by triangular, yellow eye-catching symbols at the beginning of the line. Sublists are marked with gray eye-catching symbols.

Example: Columns with error messages follow for each value: Sensor not configured!

instructions

Instructions begin with the prerequisites. The prerequisites must be met prior to proceeding with the instruction. Prerequisites are identified by a checkmark.

The individual instruction steps then follow as a numbered list. Intermediate results (if specified) are marked within the individual steps as non-numbered lists with an arrow (⇨). At the end of an instruction is the result of the action. Results are indicated by checkmarks on a gray circle. Follow the instructions step by step. Proceed with the instructions steps only if the required prerequisites are met.

Structure: Prerequisite that must be met prior to the instruction 1. First step 2. Second step ð Intermediate result 3. Last step Result after completing instructions Example: A PC is to be switched off.

No external application has access to the PC. 1. Save all files you worked on last.

2. Close all running programs. ð All programs (applications) are closed.

3. Shut down the PC. The PC is off.

info LED

Statuses of info LEDs are shown using one- or two-colored symbols. Two-colored symbols indicate a flashing LED. Here, the LED can change from "on" to "off" or between "color 1" and "color 2". The following table shows a few examples of LED symbols: Tab. 1: Meaning of the symbols for info LEDs Symbol

Meaning The LED is not illuminated The LED lights up continuously in green The LED flashes green The LED flashes and changes its color (red / green)

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Short circuit!

Safety

2

General safety instructions

2 Safety This chapter provides you with important information about your safety. Pay special attention to this chapter. The safety instructions and rules of conduct are intended to help you avoid hazardous situations and perform the necessary work as safely as possible.

2.1 General safety instructions state of the art technology

The system components are state of the art and have been manufactured in accordance with approved safety regulations.

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You and others can nevertheless be exposed to dangerous situations, e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any modifications or changes. The devices may only be opened and worked on by the manufacturer or persons specially trained by the manufacturer. use within the EU

The European directives/standards which appear in this operating manual must be applied if the devices and system components are used within the European Union.

use outside the EU

If the device is used outside the EU, the directives and standards which apply in the respective countries must be observed.

accident prevention regulations

In addition to this operating manual, make sure you also observe the legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations of the: Mining company Mines inspectorate Employers' liability insurance association for mining.

other operating manuals

Also read the operating manuals of the components required to operate the face, such as electric motors, couplings, drive frames, chain tensioning devices, conveyors, drive advance devices and block anchorages as well as any other neighboring machines which may be affected by the control device. Clarify any questions which arise before starting work.

personal protective equipment

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by the system may at times exceed 85 dB(A), (e.g. when the conveyor is being emptied).

orderliness and cleanliness

Keep the machine as clean as possible. Make sure that the operating symbols and other information signs are clearly recognizable. Regularly clean the operating elements and control equipment.

Keep the signaling and lighting systems in proper working condition.

Pay special attention to the system's acoustic and optical start-up warnings.

Only start the machine if it is in a good and safe condition and all safety equipment, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Never reach into or enter areas between machine components which can move.

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2

Safety Operating conditions

2.2 Operating conditions 2.2.1 Intended use The MMC system was developed and manufactured for controlling mobile machines.

The MMC system components may only be used for other control tasks on agreement with the manufacturer.

Only use the MMC system components as intended!

2.2.2 Unauthorized use Use

that is not expressly listed as intended and/or that was not agreed upon with the manufacturer, constitutes unauthorized use and must not be performed with this control system.

In potentially explosive environments, you may only use control components which are marked with “IS” (Intrinsic Safety) (intrinsically safe components).

Caterpillar Global Mining Europe GmbH cannot be held liable for damage caused by unauthorized use.

2.2.3 Ambient conditions Suitable measures must be taken by the operator to mitigate explosion hazards due to firedamp and the ignition of dust which might occur in a mine (see DIN EN 1710).

That includes: adequate and consistent ventilation water spraying system If the firedamp concentration in the free cross-section of the parts of the face which are continuously ventilated reaches a percentage of the lower explosion limit (LEL) defined by applicable national legislation, the M2 device must be switched off. The limit values can be found in your national laws.

WARNING Explosion hazard The power to the supply cable and control system cable must be switched off if the local gas concentration in the mining equipment areas exceeds the permissible parameters given in the safety regulations for coal mines.

It may only be restarted by an authorized person.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except those which are relevant for safety and suitable for use in explosive atmospheres.

The M2 equipment must be stopped immediately and secured against restarting if the firedamp protection systems are found to be damaged.

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that is not described in this document,

Safety Personnel

2

The use of components marked with "IS" has no effect on the safety regulations and the regulations concerning firedamp protection at the mining company.

The control and peripheral equipment of the MMC system marked with “IS” are intrinsically safe and manufactured according to the approved technical regulations.

You may only open live control units in an environment which is not potentially explosive, even if there is no voltage. Observe the instructions on the device housings.

A few components contain batteries which you have to change occasionally.

CAUTION Danger of explosion during battery change

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Only open the control units in an environment which is not potentially explosive.

2.2.4 Prerequisites for operation Commissioning the entire PMC system is prohibited until an appropriately trained and authorized person has established that the machine controlled by the system is in accordance with European Directive 94/9/EC and the DIN EN 1710 standard.

Since the delivered control system is only part of an overall system, the operator must meet the safety requirements required for the devices/components not included with this system/those necessary for operation or install the required safety equipment. These must be labeled according to the legal provisions applicable at the time when they are placed on the market. safety requirements acc. to DIN EN 1552

Operation of an M2 equipment is only permitted if the safety requirements according to DIN EN 1552 are met. This includes: Devices which prevent unauthorized startup Startup warning systems Command systems for safe shutdown Emergency-stop devices Dust extraction equipment Noise protection Warnings All electrical equipment required to operate the face must be designated according to the legal provisions applicable at the time when it is placed on the market.

2.3 Personnel The machine may only be operated by skilled or trained personnel.

As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Repair work on the system components may be performed only by service personnel of the manufacturer, or a company authorized by the manufacturer.

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2

Safety Operator requirements

qualification

A skilled worker is someone who, based on his special training and experience, has sufficient knowledge and is familiar with the relevant regulations.

A skilled worker can carry out the work assigned to him. He can recognize potential hazards and take the necessary measures to eliminate them. He also has the required repair and installation knowledge.

An instructed person is someone who has been instructed with regard to the tasks assigned to him and the potential hazards which arise due to improper behavior, and, if applicable, has been trained/instructed concerning the necessary safety equipment and protective measures. The instructed person is able to work while looking ahead, recognize hazards and act accordingly.

2.4 Operator requirements Regularly maintenance and checking the machine in accordance with the provided schedule Ensuring sufficient supplies for operation such as electricity, water or hydraulic fluid Regularly checking all safety equipment (document the test results).

If any irregularities are noticed during operation, investigate them immediately and shut down the machine until any problems have been rectified Make sure that all of the signage on the machine is legible, and immediately replace any lost signs

2.5 Work on and with the machines Always work with great concentration and familiarize yourself with your working environment.

Inform your colleagues about: where your exact site is, the work you are carrying out, how much time you will probably need emergency stop

Make yourself familiar with the EMERGENCY STOP equipment on the face. Actuate the emergency-stop switch immediately in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, so that necessary action can be taken immediately.

Actuate the emergency-stop switch also if safety equipment, such as firedamp protection systems, breaks down.

support locking

For your own safety and that of other persons, the shield locking switch is to be actuated for the shield support in question when working in the shield support, driving through narrow passages or when two or more people meet.

Installation and commissioning storage/transport of parts

Do not store any materials or components in the travel way or in your working area.

inform involved persons

Inform the persons involved about the planned transport route and the expected duration of the transport.

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Operators are responsible for ensuring that the machine is always in a technically serviceable condition. This includes for example:

Safety Work on and with the machines

transport safety devices

Make sure the transport safety devices/packaging are fitted properly. Never walk or stay under unsecured components or suspended loads.

use system brackets

Only use retaining strips from the MMC system as brackets. Do not damage any connector insertions or other fitting surfaces.

inclined face environmental protection

2

On inclined faces, secure all components by chains e.g. to the supports.

When working with oils, greases and other chemical substances, observe the safety regulations that apply to the product.

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Always dispose of materials contaminated with oil, grease or other chemical substances in an environmentally acceptable manner. Inform the supervising personnel and the face crew about any maintenance and repair work required.

Provide them with information on the intended work and its probable duration. securing

Cordon off your working area over a wide range to avoid endangering other persons. Secure the devices against unauthorized and unintentional restarting before all operations.

replacing components

Stop and lock out the devices to secure them against restarting before replacing any defective components.

Remove any defective components from the face immediately to avoid hindering the face crew. This measure also helps to prevent the unintentional re-installation of these defective components elsewhere.

Pass on these components for servicing without delay.

On inclined faces, secure the spare parts with chains or lifting tackle, for example.

replacement parts

Only use spare parts which meet the technical requirements. This is only guaranteed if using genuine spare parts from Caterpillar Global Mining Europe GmbH. Please refer to the spare parts lists for the order numbers.

protective devices

Refit any removed protective devices immediately after completing work, and check that they are working properly.

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

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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