REPAIR/SPARE PARTS WARRANTY :1:
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for a period of six (6) months from the date of delivery, F.G.B. point of shipment, will meet ap-
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• Should any failure of the Dresser products to conform to this warranty appear within the limited
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• time period set forth above, Dresser shall, upon Buyer's submission of a claim as provided
'"' above, either
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• Dresser's products which have been returned to it for examination, transportation prepaid, or
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SECTION 1
GENERAL DESCRIPTION
This section provides a general description of the overall operation of the Motion Limit Control for the 204-M mining shovel.
Refer to Figures 1.0 and 1.1. These illustrations show the general layout of the 204M SuperFront shovel and the motion limits desired to achieve optimum digging from the machine. Because of the unique front end geometry of the SuperFront shovel, the shovel is able to move its dipper in a flat trajectory across the surface to be dug, achieving high digging efficiency and breakout forces.
The 204M Motion limit Controller modifies the reference commands given to the shovel by the operator from his master control switches, when required to provide the optimum digging trajectory for the shovel dipper. In the digging region, this optimum path can be broken up into two areas: the "Flat Pass" region, and the "Dig Range limit" region. These are shown in Figure 1.1
In the FLAT PASS region the requested automatic Motion limit Control should enable the operator to move his bucket horizontally across the digging surface. In the DIG RANGE LIMIT region the motion limit control should prevent the dipper from undercutting the bank of material being dug, and instead, give a vertical wall by limiting the radius of digging to a certain fixed value.
In addition to the automation-assisted digging described above, the Motion Limit Control provides limits to the motion of the hoist and crowd to avoid equipment damage due to over-travel of the dipper, hoist or crowd mechanisms. Additional protection is provided to keep the dipper under control by avoiding high velocity while lowering the dipper near the end of travel.
Refer to Figure 1.2. This illustration shows the system block diagram of the Motion limit Control package as it is implemented into the basic 204M crowd and hoist motion drive system. Note that the Motion Limit Control package for the 204M is a command reference modifier to the basic crowd and hoist motion drive system. That is, the motions requested by the operator by means of his master switches are modified as a function of hoist and crowd position, when required.
Refer to Figure 1.3. This figure shows the Motion Limit Control panel as a rectangular block in the center. Shown also are the various inputs and outputs from the system. System inputs are:
Crowd master switch signal (analog, + /-)
- Hoist master switch signal (analog, + /-)
1.1 BI005708
- Crowd mast angle encoder (Binary Coded Decimal (BCD), 3- % decade)
- Hoist drum revolutions encoder (Binary Coded Decimal (BCD), 4 decade)
- Motion limit bypass contacts
- DC panel inputs
AC power to system
The outputs are as follows:
- Modified crowd reference.
- Modified hoist reference.
- Binary Coded Decimal (BCD) display.
- Relay contacts for control diagnostics relay.
- Relay contacts for crowd retract and hoist limit relays.
- Relay contacts for crowd motor field control.
The processing of these inputs and outputs will be described in detail in later pages.
Refer to Figure 1.4 which shows the processing of the hoist and crowd reference to produce the modified hoist and crowd references to the hoist and crowd drives. This figure shows the reference modification done and the logic used to perform this modification. Within the central reference modification blocks are the reference numbers of figures which show the actual function implemented. All the reference modification is performed by a General Electric Series 6 Programmable Logic Controller as described in the next paragraph.
Again referring to Figures 1.3 and 1.4" note that the Motion Limit Control panel uses a GE Series 6 Programmable Logic Control as its main processing unit for both analog and digital inputs and outputs. Referring specifically to Figure 1.4 note that the Series 6 unit is provided with Analog to Digital Converters to receive the master switch inputs from the operator and Digital to Analog Converters to provide the modified crowd and hoist signals to the motion drive itself.
Reference modification is done by the extended instruction set provided within the Series 6 unit. Additionally, crowd speed feedback, the Binary Coded Decimal (BCD) shaft encoder inputs, relay inputs and outputs, display outputs, calibration settings, and operator cab inputs and outputs are all handled by the Series 6 Control.
The model of the Series 6 selected is model 60. More details on the Series 6 with its capabilities, programs, and specifications will be given on subsequent pages.
Note that the entire Motion Limit Control system can be bypassed by means of the Motion Limit Bypass Relay (MLBR).
1.2 BI005708
50 CL Rotation I / / I I 30 20 10 o I 0.L -+-_':::""_-+- l- ......::::""" 70 10" •• 50 .• •• - 30 20 10 5 .--FIGURE 1.0 CL Rotation I----'UT_---"ASS AANGE----!---START 'L-'T 'ASS o 70 30 20 10 0 I 10 t Do [ Ig :l0J. Range t Limit f 20 f FIGURE 1.1 204-M MOTION LIMITS 1.3 BI005708
CROWD VOLTAGE FEEDBACK OPERATOR REF. REQUEST OVERRIDE MOTION LIMIT CONTROL PACKAGE MO IFI D REFERENCES (ANALOG) MOTION LIMITS (ON-OFF) 204M CROWD B HOI ST MO T ION DRIVE SYSTEM 8 8 DIGITAL
(BCD) POS I TION ENCODERS
FIGURE 1.2
1.4 BI005708
SYSTEM BLOCK DIAGRAM
MLBR MLBR * ....
eMS HMS (-) CROWD VFB
SIGNALS B 12VDC C
CROWD MAST IISVAC ANGLE
SIGNALS B 12VDC
H
HOIST DRUM IISVAC REVS
BCD POSITION ENCODERS
*NOTE: MOTION LIMIT BYPASS
MLBR
SERIES 6 LOGIC CONTROL H MLBR MONITOR PANEL WITH TEST POINTS FIG. 5.0 12IJDC
(j 'd 'cf / , / , / , FAULT RUN BYPASS
NORM BYP oe 0 EN1ER CALlS.SELECTOR
MODIFIED REFERENCE FOR CROWD (C) 8 HOIST (HI
n'1 AUDIBLE '-'J ALARM AUDIBLE t DEFEAT 'cf / , (21 IISVAC L...C-AS -M":-:O":"':U-:'":"NT==E=-=D MOTION
liMIT LIGHT B AUDIBLE WARNING
MOTION LIMIT CONTROL PANEL (MLCP)
(+)
C
ENCODER P.S. 12V. 6A AUXIL. P.S. SV. SA RELAY CONTACTS: CLeo RLC. HLC RUN MLRR DC -' DIG
RELAY -hJlJlJ1Jlt SPACE HEATER 20A (----r72-POLE ! !
50/60 HZ 20A
IISVAC
FIGURE 1.3
1.5 BI005708
SERIES 6 PLCS
r----I NO I I
MASTER SWI TCH (HOIST) I
(+) I r-A-N-AL""'O-G-' TO DIGITAL CONY CHAN I
CROWD VFB
BCD HOIST POS.
MASTER I SWITCH (CROWD) I (+ )
I0 AND HOIST I YES·, / LIMIT- I .J FIG 5.1
o HOiST pas.
HOIST LOWER TAPER AND LOWER LIMIT o
NO I\ FIG 5.2 CROWD O/SPEED
DIGI TAL TO ANALOG CONY CHAN I H.
MODIFIED HOIST REF.
HO IS T 1\ ."t--1.0_-1-_-+ -11 pas 0 I NO +. ::r: CVFB LO,c.o VOL1S HOIST VELOC. CALC.
VELOCITY
H. POSITION
H. POS. ANALOG TO DIGITAL CONY CHAN 2
MODIFIED I CROWD I ,--...L.-.-:,R EF.
DIG RAN GEl DI Gi JAL
Ll MIT 1---'----'-' AN ALOG I CONY
(FIG 5.3A. B. Cl I CHAN 2
I r---+- +- ----l ANGLE '----...,r---J - '---y-----/ I ANALOG v,....------......J/ ANALOG
CROWD I INPUTS DIGITAL LOGIC OUTPUTS
MAST ANGLE
FIGURE 1.4
INPUT AND OUTPUT PROCESS
1.6 BI005708
SECTION 2 SYSTEM FEATURES
This section includes a general discussion of the features provided by the Motion Limit Control, the major components used and defines the environment in which the Motion Limit Control is designed to operate.
Encoders. Details of the encoders and the encoder interfaces accommodated are described in Section 3. The sensors to be accommodated are digital, multiturn, BCD output, shaft encoders. Power for these encoders is provided by the Motion Limit Control.
A panel-mounted digital LED data readout is provided in the motion limit control cabinet to display encoder inputs, settings and diagnostic messages.
A travel limit set by digital thumbwheels is provided to prevent overtravel of the hoist, crowd and retract motions.
Hoist reference taper ("Flat Pass") control is provided during crowd operation while hoisting to provide a flat digging pass of the dipper while filling the dipper. The actual trajectory is adjustable.
To provide better control of the dipper motion while moving the dipper toward the lower frame of the shovel, the hoist motion reference is tapered. This is the Hoist Lower Taper Function.
To provide a lowering limit for the hoist motion while bringing the dipper close to the stiffleg, the hoist reference during lowering will be reduced to a low level at a point away from the frame dependent on the approach velocity of the dipper toward the frame. This is called the Hoist Motion Lower limit control function.
To prevent undercutting a bank of material, a Dig Range Limit is incorporated to limit the extension of the crowd motion while hoisting through the bank.
In the event that the Motion Limit Control is nonfunctional or needs to be bypassed for any other reason, a Motion Limit Bypass Relay is incorporated and interfaced with the Motion Limit Control to nullify any reference modification functions provided by the Motion Limit Control and reduces reference under fault conditions.
2.1 BI005708
The digital motion position limits can be bypassed by a cab switch to permit changing of ropes.
A Monitor Panel is provided to allow field adjustment of all of the motion limit control, motion limit, and motion reference modification functions, without reprogramming the basic logic of the PLC. The Monitor Panel includes a digital display.
As part of the Monitor Panel, a key operated switch is provided to prevent unauthorized tampering with the settings of the Motion Limit Control System.
Test Points are provided on the Monitor Panel from which analog measurements may be made to assure proper operation and calibration of the Motion Limit Control.
Calibration of encoder zero points requires the use of a key operated switch in order to prevent unauthorized tampering.
The Series 6 unit will perform a continual self-check of major functions and continually hold closed a motion limit "Run" relay. If this relay is not picked up, the motion limit control will be bypassed and the operator notified by means of a light indication in the cab.
The motion drives for hoist and crowd interface with the Motion Limit Control in such a way as to allow the functions requested, while not limiting the productive capability of the machine beyond the reference modifications described in this manual. Only hoist and crowd drives are affected, and no modification of the propel or swing motions is done by any of this equipment.
ENVIRONMENT
The Motion Limit Control Panel is designed to operate in the environment on board a Marion 204M Mining Shovel. All equipment within the panel will operate in the temperature range of -40 to + 50 C. Temperatures below O°C will be moderated by means of internal space heaters with thermostc":ic controls, when required.
POWER REQUIRED
Input power required is 115 volts AC, 50/60 Hz, 20 amperes. Included in this total is power to feed the internal heaters contained within the BCD shaft encoders, when these heaters are required. 2.2
BI005708
SECTION 3 POSITION SENSORS
Two optical shaft encoders will provide the hoist and crowd posItions. The details of these encoders and their interfaces to the Motion Limit Control system are described below.
Refer to Figure 3.0. This figure describes the digital shaft encoders to be used to measure hoist drum revolutions and crowd mast angle. Each of these encoders has the following general characteristics:
Input power 8-15 V DC at 1 amp maximum
Encoder output parallel BCD at DTlITTL compatible levels
- Logic 1 = 3.0-5.0 V DC
- Logic 0 = 0-0.5 V DC at 4.8 milliamps max
- Direction sense - electrically selectable
Encoding means - optical, using LED light source
- Temperature range - 0-50 0 C (internal built-in 115 V AC heater extends this range to -40 0 C to 50 0 C when required)
Environmental packaging - shaft seals, sealed connectors, terminal block with conduit termination and built-in heater, when required
HOIST ENCODER
The hoist encoder measures the number of revolutions of the hoist drum from a zero point. The hoist encoder itself, as indicated in Figure 3.0, is a1 O-turn full scale device. It can harmlessly rotate beyond the 10 turns. Each turn produces precisely 1000 counts, for a full scale range of from 0 to 9999 counts, or 10 turns.
Each full drum revolution represents 13.09 feet of rope travel. Each count on the hoist drum revolution encoder then represents 1/1 OOOth of this drum circumference, or .01309 feet of rope.
CROWD MAST ANGLE ENCODER
The crowd position information is gathered by a digital BCD shaft encoder identical in physical characteristics and electrical characteristics to the hoist encoder, except that one full rotation represents full scale output. One full rotation produces 3599 counts. This provides resolution of .1 angular degrees per count. Full travel of the crowd mast is approximately 44.2°. Thus only a fraction of the encoder full scale range will be used in the crowd motion.
3.1 BI005708
INTERFACE TO LOGIC CONTROL
The BCD shaft encoders interface to the logic control by means of a high density TTL level input card.
POWER
The Motion Limit Control provides 12 volts DC to the hoist and crowd encoders at up to one ampere each. When required, 115 VAC power at approximately 25 VA is provided to each encoder to energize the built-in environmental heaters.
DISPLAY OF POSITION
The Motion Limit Control provides for displaying of the encoder readings on the LED readout, described in section 2, by selecting the appropriate display code number.
SETTING HOIST AND CROWD ZERO POSITIONS
The procedure used to establish the encoder readings, which correspond to zero hoist and crowd position, is called Zero Position Calibration. The procedure is described in detail in section 4, which includes placing the machine in the calibrate position and operating the calibrate key switch.
NOTE: The encoders do not need to be in any particular position for calibration. The encoder readings obtained when calibrating are used thereafter to calculate the travels from zero position.
The conditions where calibration may be necessary are as follows:
(a) If at any time during operation of the machine, the calculated postion exceeds that which is mechanically possible, an encoder out-of-range alarm is generated, indicating that an encoder coupling has slipped.
(b) When ropes are changed.
(c) when motion limit controller CPU memory fails, or a new program is loaded.
3.2 BI005708
NOTE:
Position information (Le. calibration) and set points are stored in "register memory", and are not affected by power loss to the motion limit control. Movement of the drums while the Motion Limit Control is turned off will not affect calibration, although some alarms may be tripped with a reset becoming necessary. Reset is accomplished by momentarily pressing the CLEAR FAULT push button on the monitor panel (see section 4).
ENCODER DIRECTIONS
Increasing counts of the crowd encoder represents the retract direction from the zero point, which is with the crowd mast vertical. Increasing counts of the hoist drum encoder represents the hoisting direction from the zero point, which is with the dipper fully lowered.
WIRING
Outputs from the encoders are supplied to the Motion Limit Control in shielded cable. The sheid should be grounded at the cabinet and isolated elsewhere.
3.3 BI005708
Input Power: 5 VDC :::5% at 1.0 A maximum.
Encoder Range: 0-999. 0-9999. 0-99999. 0-999999. 0-;)59. 0-3599, 0-35999
Accuracy: == 1 least significant digil.
Encoder Output: Parallel BCD at DTL/TTL compatible level.
Logic ·1· = 3.0 to 5.0 VDC.
·0· = 0 to 0.5 VDC @ 4.8 MA (max.)
Direction Sense: Electrically selectable for linear encoders. Specify CW or CCW for angular encoders.
Light Source: Long-life LED.
Speed: 3000 RPM maximum.'
Operating Temperature: 0 to 50'C.
PHYSICAL CHARACTERISTICS
NOTE: ADD 2.0 IN-Ol rOR SHAFT SEAL , Applies to units of 200 counts/ rev or less. For units of more than 200 counts/rev. maximum speed must be reduced proportionately.
ORDERING
OPTIONS
Where environments demand it, units are available with Shaft seals. Sealed connectors, Terminal Block with Conduit Terminations and built-in heaters.
FIGURE 3.0 DIGITAL SHAFT ENCODERS - SPECIFICATIONS
BREAKAWAY TORQUE: CONNECTOR J1 MSJ102A28·21P MATES WITH MSJ106A28-21 D -----'--;. ; , "---" -1 I 5.50MAX.---j _2.91--j I COUNTS PER DIM "l·l HOLE : QIA REVOLUTION I - 0000 PA.TTERN -0002 100 l.ca I 8 I 249') 200 , 2.1a " 360 2.18 " I .3749 500 148 B i 2499 1000 1.48 B I 2499 3600 2.1' A J7C9 .. .. r I ...J 88 I" u .. .. In .( Q ..20 MAX. .175 L 1 ....-+-:----r1 , -r .8·32
HOIST REVS
Encoder
100 Counts/Turns 0.2IN-Ol 200 0.2IN-<Jl 500 0.5IN-Ol 1000 1.0IN·Ol -
TAP_ .19 DEEP J HOLES EOUALLlI SPACEO ON A 3.000 BOl.TCIRCl.E
INFORMATION
Resolution Breakaway Torque
Model Linear Input Turns For Number Ranges Full Range TO-Q3-100 0-999 10 TO-03-200 0-999 5 TO-Q3-500 0-999 2 TO-Q3-1000 0-999 1 TO-Q4-100 0-9999 100 TO-04-200 0-9999 50 T(,)-<l4-'iOO 0-999g ?n Tn_:1J..1nnl1 11_0000 111 TO-QS-100 0-99999 1.000 TO-OS-200 0-99999 500 TO-Q5-500 0-99999 200 TO-DS-1000 0-99999 100 TO-Q6-100 0-999999 10,000 TO-Q6-200 0-999999 5.000 TO-Q6-500 0-999999 2.000 TO-06-1000 0-999999 1,000 Angular Model Number Ranges Input Tn-53-360' 0-359 , f(,)-'i4- 1h(1()' , TO-54-360' 0-3599 10 TO-55-3600' 0-35999 10 TO-55-360' 0-35999 100 'Indicate CW for clockwise rotation or CCW for counterclockwise rotation. CROWD ANGLE
3.4 BI005708
SECTION 4 MONITOR PANEL
The Monitor Panel is used to make adjustments to the 204-M Motion Limit Control functions. Additionally, this panel displays the following: any adjustments to the system, the encoder readings, the hoist and crowd positions and diagnostic codes. The Monitor Panel also provides:
- Data display.
- Set Point Entry.
- Zero Position calibration.
- Normal - Bypass.
- Fault indication.
Each of these provisions will be discussed separately. Refer to Figure 4.0.
DATA DISPLAY
The Monitor Panel includes a 4-digit display, with decimal points, and a 2-digit Display Selector thumbswitch.
A chart of Display Select Codes is provided (See Figure 4.1). When the Display Selector thumbswitch is set to one of these Display Code numbers, the present value of the corresponding data will be displayed.
Display codes 1, 2, 3, and 6 thru 20 apply to the Set Points, which are the settings of limits and other parameters. These numbers correspond to the adjustments shown in Figures 4.3, 4.4 and 4.5. These values can be displayed at any time, but they can be changed only as described in SET POINT ENTRY, this section.
Display Codes 21 and 22 are used to display the present crowd and hoist encoder readings, and Display Codes 23 and 24 are used to display the present crowd and hoist position.
Display Code 30 is used to display the Diagnostic Codes, which are defined on the chart.
If the Display Selector thumbswitch is set to an unused Display Code number, the display will be blank (or dark).
The data is displayed in the following units: Crowd position and the related SET POINTS are displayed in degrees of mast angle, with zero being with the mast vertical. Hoist position and the related SET POINTS are displayed in number of drum revolutions, with zero being near the fully lowered position. (Refer to Section 3 of this manual ifit is necessary to determine rope length.) Reference and tapers are displayed per unit, and the speed factor in displayed in seconds.
-----------------_._------------------------
4.1 BI005708
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