CAT Armored Face Conveyor PCM-D- Drive Control SystemConveyor with CST gearbox Operation & Maintenan

Media-ID: EM010401 Doc. no.: 1999 001 009 BA 00-08 Jan. 2016

Operating and Maintenance Manual PMC®-D – Drive Control System Conveyor with CST gearbox

SAFETY.CAT.COM

© 2016 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. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4 1.4 1.4

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2. Your safety General information for avoiding accidents . . . . .

2.3

Additional operating manuals . . . . . . . . . . . . . . . . .

2.3

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . .

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

2.4 2.4 2.4 2.4 2.5

Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Installation and startup . . . . . . . . . . . . . . . . . . . . . . .

2.6

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport containers, dimensions and weights . . . . . . . . .

3.3 3.3

3.4 3.4

4. Installation General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing control units . . . . . . . . . . . . . . . . . . . . . . . .

PMC data stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the sensor/actuator terminal box . . . . . . . . . . . . .

Installing the connection line . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Profibus connections . . . . . . . . . . . . . . . . . . . . . . .

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4.3 4.3

4.4 4.5 4.5 4.8 4.9

Table of content 5. Operation Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

PMC-Vkeypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

PMC-VLEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

Password input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defined key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Profibus diagnostics (internal) . . . . . . . . . . . . . . . . . . . . . . .

Device information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the date/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Global menu level of the CST drive system . . . . .

5.13 5.13 5.17 5.18 5.20 5.20 5.21

5.22

Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process overv. cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor current overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load sharing controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu level for CST drive unit . . . . . . . . . . . . . . . . . .

5.24 5.27 5.27 5.29 5.30 5.33 5.36 5.38

5.39

Display process data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process data cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Semiautomatic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor/gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear oil monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox type setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User-defined gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process configuration . . . . . . . . . . . . . . . . . . . . . . . .

5.41 5.42 5.42 5.43 5.44 5.44 5.45 5.46 5.48 5.50 5.51 5.52 5.52 5.53 5.54

5.56

Process functions on/off Process functions (contd.) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor startup recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch prefill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerating the conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heavy load startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conveyor shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overload settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.57 5.60 5.61 5.63 5.65 5.65 5.67

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5.11

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Global menu level, PMC Drive control . . . . . . . . . .

5.6 5.7

Table of content Pressure/slip controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.68

6. Technical data Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buffer battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Pin assignment, PMC®-V . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor/actuator terminal box pin assignments . . . . . . . . .

Electric specification of the connections of the sensor/actuator terminal box . . . . . . . . . . . . . . . . . . . . . . . .

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6.3 6.4

6.4 6.4 6.7 6.8

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Table of content

PMC-D CST

1

About this manual

Before starting work

About this manual This chapter contains important information that will make it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols and characters used in it.

Before starting work applicable operating manual

application

This operating manual is for the PMC®-D Drive Control System conveyor with CST gearbox

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Take care to ensure that the operating manual available to you is applicable to the aforementioned case of operation. You will otherwise endanger yourself and others and may damage items of equipment.

Make sure the information on the system components' housings designates them as part of the PMC® system.

The designation PMC® is legally protected and property of Caterpillar Global Mining Europe GmbH, Lünen, Germany. For the purpose of improved legibility, the registered trademark symbol ® will henceforth not be used in this manual. category acc. to ATEX directive

new operating manual

The system components of the PMC system meet the European directive 94/9/EC in Group I, Category M2 - Device in compliance with EN 50014-1997 + Revisions 1 and 2 Intrinsic safety “i” EN 50020-2002.

Operating manuals for the support in question must always be available at the place of operation.

Order copies of the respective operating manuals immediately if the existing ones are no longer complete or legible.

Persons for whom the operating manual is intended The operating manual is intended for those persons who set up the PMC system, work with it, make settings and do troubleshooting.

All persons working on the face, at the edge of the face or at the entry must read this operating manual.

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

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

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Before starting work Purpose of this operating manual efficiency

This operating manual is intended to help you work economically and safely with our product. It provides you with important information on all the activities related to the PMC system.

Read this operating manual completely and at your leisure. Pay special attention to the respective safety instructions. Try to memorize the appearance and meaning of the safety and instruction symbols.

safety

Read the Chapter “Your safety” closely. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Danger!

Points in the text marked with this symbol point out immediately impending danger. Possible consequences are very serious injury or even death.

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

Notice!

Sections indicated with this symbol draw attention to harmful situations. Possible consequences: the gearbox, motor, couplings, drive frame, conveyor or surrounding equipment could become damaged.

Important!

Useful tips and information intended to facilitate work are provided here. They do not warn about harmful or hazardous situations.

Tips!

In order to make it easier to find your way around in the menu structure, thumbnail images of higher-ordered menus are placed in front of the corresponding menu item description.

Items in lists are indicated by bullets.

– Items of sub-lists are indicated by a long dash at the start of the line.

. Text passages indicated in this way describe individual work

steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

Service If you should require spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.mining.cat.com).

1.4

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Memorize the symbols and their meanings.

2

Your safety

General information for avoiding accidents

Your safety This chapter provides you with important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.

General information for avoiding accidents state-of-the-art technology

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

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

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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

use outside the EU

accident prevention regulations

The European guidelines/standards which appear in this operating manual must be applied if the PMC system components are used within the European Union (EU).

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

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 mine, of the mines inspectorate and of mining supervisory authorities.

Additional 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 apparatus. Clarify any issues which arise before starting work.

Personnel Installation and repairs As a fundamental rule, installation work may only be carried out by personnel who have been adequately trained to meet these particular requirements. Repair work on the PMC system components may be performed by service personnel of the manufacturer only.

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2.3

Operating conditions Operating conditions Intended use The PMC system was developed and manufactured to control support frames. The PMC system components may be used for other control tasks only in agreement with the manufacturer.

Use the PMC system components only as intended.

Unauthorized use Use which is not explicitly specified as intended use and/or has not been approved by the manufacturer is unauthorized and may not be performed with the PMC system.

Caterpillar Global Mining Europe GmbH does not accept any liability for any damage resulting from any such unauthorized use.

Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust. (see DIN EN 1710) These include: adequate and consistent ventilation plow water curtain / water spraying system etc.

The M2 equipment must be switched off if the firedamp concentration in the free cross section of the consistently ventilated areas of the face exceeds a percentage of the lower explosion limit (LEL) as defined by national legislation.

Important!

The voltage of the supply cable and the cable of the control system must be switched off when the local gas concentration in the areas around the mining system exceeds the parameters permitted in accordance with the safety regulations in 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 (locked out) if firedamp protection facilities are found to be damaged.

The PMC components have no effect on the safety regulations and the regulations concerning firedamp protection at the mining company.

The control and peripheral equipment of the PMC system are intrinsically safe and have been manufactured according to approved technical regulations.

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Ambient conditions

Basic principles Prerequisites for operation Commissioning of the complete PMC system is not permitted until it has been determined by appropriately trained and authorized persons that the machine, which is controlled by the system, satisfies the European directive 94/9/EC and the standard DIN EN 1710.

Since the control system supplied is only part of an overall system, the operator must meet the safety requirements or install the required safety systems for the devices/components not included in the scope of supply of this system and/or other devices/components required for operation. These shall be identified according to the legal provisions applicable at the time they are placed on the market. safety requirements according to DIN EN 1552

The M2 device may only be operated once the safety requirements according to DIN EN 1552 have been met. These include, among other things:

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equipment for preventing unauthorized starting, startup warning systems, safe shutdown command systems, emergency stop equipment, vacuum-cleaning equipment, noise protection, warning notices etc.

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.

Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

Always wear personal protective equipment. This includes wearing ear protectors since the noise produced by the conveyor exceeds 85 dB(A).

Inform your colleagues about: your exact location, the work you are carrying out how much time you will probably need.

Keep the signaling and lighting systems in proper working order.

Pay attention to the acoustic and optical startup warning systems.

emergency stop

Press 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.

Press the emergency stop switch also if safety equipment, such as firedamp protection systems, fails.

Never allow parts of your body to come between components which could move towards each other, such as conveyors and supports etc.

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2.5

Storage and transport support lock-out switch

While working at the shield support, driving at points with limited clearance or when encountering two or more persons, the support lock-out switch for the corresponding shield support should be actuated for your own safety and the safety of others.

Storage and transport storage temperature

Do not store electrical components containing batteries at a temperature below 15C. The control units of the PMC system can be stored for a maximum of 5 years without an electrical connection. The installed buffer battery is discharged after this time. This battery must then be replaced.

Inform the persons concerned about the intended transport route and the probable duration of transport. transport safety devices

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

use system brackets

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

Installation and startup inclined face

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.

environmental protection

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

Secure your working area over a wide range, in order to avoid endangering other persons.

Secure the conveyor against unauthorized and unintentional restarting before all operations.

replacing components

Before replacing any defective components, you must shut down the conveyor and mining equipment and secure them against being switched back on again.

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

Pass on these components for servicing without delay.

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

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

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Maintain the prescribed storage periods and temperatures and observe the instructions for storage.

Installation and startup Only use spare parts which meet the technical requirements. This can only be ensured by using original Caterpillar Global Mining Europe GmbH spare parts. 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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original parts

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Installation and startup

2.8

PMC-D CST

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and safe transport of the PMC components. Observance of the instructions and manuals will increase the service life and reliability of the system components. Reading this chapter thoroughly will also help you to make your day-to-day work easier.

Storage Storing the equipment Components coated with anticorrosion protection are protected for about six months.

no direct exposure to sunlight

Protect the equipment from direct exposure to sunlight. Store the electrical equipment, electronic components and spare parts made of rubber or plastic, such as seals, cables and hose cables, only in closed rooms at temperatures between 15C and 25C.

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anticorrosion protection

dirt and moisture

storage

Protect all equipment parts from dirt and moisture. In particular, do not remove any dummy plugs or temporary covers. Use the dummy plugs and canopies if you wish to put the equipment into storage after using it. Avoid any damage to the plug-type connections.

Never store electronic equipment outdoors.

The computers should be checked after a storage period of five years, since the installed battery is discharged after this amount of time. It must then be replaced. The inspection and the battery replacement should be performed by service personnel.

If the PMC component is used, the battery has a longer service life.

A battery failure does not have any safety-relevant consequences.

After a storage period of approx. two years, the system components must be checked for any resulting damage.

Seals, hose lines and lines are subject to natural aging, even if they are stored properly. Do not continue to use these components, since malfunctions and ghost functions cannot be ruled out.

Important!

Make sure that incoming stock is stored separately from the old stock, notably in such a manner that computer components of the same age are stored together, to avoid conflicts between different types of programming versions.

Make sure that display covers, keyboard protective covers and plug-type connections are not damaged during storage.

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Transport Transport Transport containers, dimensions and weights Make sure you observe the technical data sheet. It provides you with information about: dimensions and weights The computers and interfaces of the PMC system which belong to the same operating point can be transported in the same transport container. You must make sure, however, that they are not packed together with heavy and/or sharp-edged materials to avoid damage to displays, keyboards, cables and plug-type connections.

Caution!

Load and transport the components carefully with concentration. Protect yourself from injury due to falling parts by wearing gloves and safety work shoes.

No sudden loads may be initiated during transport at low temperatures.

Electronic equipment should be transported very carefully at low temperatures (below -10C) since all materials become brittle and fragile at low temperatures. For this reason, cables may not be installed at temperatures below +4C. If cold cables and lines are transported underground in this way, they should be allowed to warm up to the ambient temperatures before being installed on site.

Line and cable connections must be protected carefully for sea transport. The equipment must be packed carefully so that it is seaproof.

When transporting the controls via air freight, the vent screws on the devices must be opened so that large differences in pressure don't damage the displays and keyboard protective covers. This is usually done by Caterpillar personnel before dispatch via air freight.

Caution!

Make sure that the vent screws are closed before starting up the control devices so that the electronic components are protected from dirt, moisture and firedamp.

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Equipment that could be damaged by strong magnetic fields may not be transported using magnet cranes. That applies e.g. to electronic units and cylinders with reed rods for stroke measurement.

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The corresponding lines and hose cables must also be packed and transported carefully to avoid damage to the plug-type and screw connections.

4

Installation

General notes

Installation General notes Important!

Control units, peripheral devices and the machines to be controlled can be damaged seriously due to incorrect installation.

Install the PMC system initially only under supervision of expert personnel of Caterpillar Global Mining Europe GmbH.

Required tools The following tools are required to install system components underground: Installation of the brass retaining strip and the PMC-D on the brass retaining strip: EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Allen key, size 10 mm Installation of SKK24 connectors: All further installations in the PMC system can be performed with a sturdy screwdriver and water pump pliers.

System components are installed on carrier plates etc. with customary tools for mechanical engineering/mining.

The PMC Drive Control System consists of the following system components.

PMC-D control unit with 7-segment display V visualization device with monitor and keyboard Sensor/actuator connection box Holding strip Line for the connection between the control unit PMC-D and the sensor/actuator connection box Fig. 1:

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PMC-D control unit

4.3

Installing control units PMC-V visualization device

Installing control units holding strip

The control units are delivered with a holding strip made of brass.

On this holding strip, the connected hose lines (SKK24) are secured by appropriate clamps to prevent them from slipping from the plug-in contacts of the control units. The holding strip is equipped for fastening to the control units with two captive mounted screws (M10 thread). The screws are constructed so that when they are screwed into the control unit, the hose lines held on the holding strip are pressed into the plug-in contacts. When they are screwed out, the lines are released from the plug-in contacts, accordingly.

Caution!

After dismantling a control unit, the contacts of the hose lines fastened on the holding strip and those of the control unit must be protected from contamination.

fastening via the holding strip

The holding strip has two bores for Allen screws (M12 thread).

Using these screws and the corresponding spacer sleeves, the holding strip can be fastened to a mounting plate, for example. The advantage of this installation variant is the easy exchangeability of the control units and the secure fastening of the hose lines.

Caution!

Installation exclusively via the holding strip is only recommended when the control unit is not subject to constant vibrations.

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Fig. 2:

Installing control units direct fastening

On the rear side of the control units, there are four tapped holes (M10 threads) which can be used to directly fasten the control unit to a mounting plate. The distance dimensions can be found on the attached data sheet. The holding strip is only connected to the control unit in this case. In order to disconnect the hose lines from the control unit, too, only the screws on the holding strip have to be released. The holding strip must be placed such that the contacts of the hose lines are protected from contamination and damage.

Caution!

For devices which are subject to constant vibrations, it is recommended to fasten via the holding strip and two points on the rear side of the control unit. In addition, the device should be mounted on vibration dampers.

The PMC-D unit is usually mounted to the drive motor in a special housing (see gearbox documentation). In this protective hprotective ousing, the device is fastened to the holding strip and to two points on the housing and is protected from vibrations by dampers.

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protective housing

PMC data stick The PMC data stick is for storing program data and the transmission of this to the PMC-D. It is connected to socket St2 (see chapter 6).

Fig. 3:

PMC data stick

Installing the sensor/actuator terminal box The sensor/actuator terminal box is installed inside the gearbox.

It allows a connection to be made between the internal sensors and actuators and the PMC-D control unit.

The entire subassembly mainly consists of three parts: the actual terminal box with the sockets for connecting the sensors and actuators, a cable (approx. 2.5 m long), and a housing feedthrough.

These three parts cannot be disconnected from one another and must therefore be considered as one subassembly.

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4.5

Installing control units Sensor/actuator terminal box with housing feedthrough

The sensor/actuator terminal box is already installed in the gearbox supply unit space protected by the left cover (as seen from the motor) when it is delivered and is connected to the internal sensors and actuators. From the outside, only the right feedthrough can be seen on the supply unit wall facing the motor. The thread and the contacts of the feedthrough must always be protected by the plastic cap included in delivery. If the feedthrough is damaged, the complete sensor/actuator terminal box must be exchanged. terminal box, cable

The sensor/actuator terminal box is fastened to a mounting plate inside the gearbox with four screws (M8x10). When installing the cable inside the gearbox, make sure that it is not bent/kinked.

Fig. 5:

4.6

Sensor/actuator terminal box installed in a CST gearbox

PMC-D CST

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Fig. 4:

Installing control units

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Fig. 6:

Caution!

If there is a defect in the feedthrough, the entire subassembly, consisting of terminal box, cable and feedthrough, must be exchanged. For this reason, the feedthrough must always be protected with the plastic cap included in delivery.

The feedthrough must not be damaged under any circumstances, since even the smallest flaw can lead to installation problems on the thread. When transporting the gearbox, the provided points of attachment must be fundamentally used. feedthrough

When installing the feedthrough, make sure that it is correctly inserted in the cutout on the inner wall of the gearbox (anti-twist safeguard). The nut (size 60) for fastening the feedthrough in the gearbox wall has an O-ring on each of its faces. Before the nut is mounted and tightened, the O-ring serving as a seal to the interior of the gearbox must be greased.

Fig. 7:

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Feedthrough

4.7

Installing control units Installing the connection line The sensor/actuator terminal box and the PMC-D unit are connected via a cable, which has a 90-degree angular plug on both ends.

These plugs can be swiveled within an angular range of 180 degrees about the axis in the longitudinal direction to the contacts so that the direction of the cable outlet can be adapted to the installation conditions.

Connection line on gearbox

O-rings are inserted in the faces of the fastening nuts, both on the line feedthrough in the gearbox as well as on the PMC-D unit connection. These must be greased before installing the connection line.

The cap nuts of the connection line must be tightened against these O-rings so that the connection threads are protected from moisture and a reliable connection of the contacts is ensured.

Important!

The connection line between the gearbox and the PMC-D control unit is not a hose line and must therefore be installed so that it is protected from mechanical stress, e.g. falling rock!

4.8

PMC-D CST

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Fig. 8:

Installing control units PMC-D control unit with connection line

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Fig. 9:

Installing Profibus connections The devices of the PMC Drive Control System communicate with each other via a bus system in accordance with the Profibus standard. In the connection line between the devices, two wires are required, which must be twisted together (twisted pair). This twisted pair must be maintained even in any intermediary distributors.

Important!

Only use twisted-pair lines for setting up Profibus connections.

Other lines will lead to communication failure.

To connect devices of the PMC Drive Control System to Profibus, special hose lines are supplied by Caterpillar, which are covered at both ends by a white shrink hose (about 10 cm long).

Important!

For connecting the devices to Profibus, only use the hose lines with white shrink hoses supplied by Caterpillar. Using other hose lines will lead to communication failure.

On all devices, the connections for Profibus are labeled ST6 and ST12. It does not matter to which plug the incoming line from the previous device and the outgoing line to the next device are plugged. It is just important that a termination resistance be plugged into the free plug on both the first device and last device in the chain.

Important!

Terminate the Profibus line to the first and last device by plugging in a termination resistance. A missing termination resistance will lead to major communication disturbances.

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4.9

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Installing control units

4.10

PMC-D CST

5

Operation

Basic principles

Operation Warning!

Do not change any settings before you have read the operating manual of the PMC Drive Control System and the operating manuals of the machines to be controlled and the neighboring machines.

Basic principles Structure of the PMC® Drive Control System The PMC Drive Control System is designed as a distributed system. Data is exchanged between the units involved with processing the control task via a central communication connection in accordance with the Profibus standard. Different control systems can be connected to one Profibus line.

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There are three basic units available for the system setup. The PMC-V unit (visualization) serves as a display and operating unit for all control systems connected to the Profibus line. The PMC-D unit (drive) takes over a special control task. For example, in the case of a face conveyor with CST gearboxes, a PMC-D unit is allocated to each drive unit.

The basic units provide connections for recording measurements and for establishing communication connections. By installing special subassemblies, however, the units can be adapted to the respective control task.

The PMC-V unit can forward the motor currents of the plow drives measured by certain third-party suppliers, so that the measurements can be displayed in the visualization programs VPlow and, with an activated OPC connection, VShield.

Operational concept The PMC Drive Control System is operated via the PMC-V units.

Here, operation is possible from any PMC-V unit in the system.

Menus are provided on the screen, from which the desired menu item can be selected using the keypad. Afterwards, either another menu appears, or an input/output mask.

The so-called menu tree, which is navigated through in this way, is divided into three levels. The first level, the global level, contains functions having to do with the entire PMC Drive Control System, and are therefore independent of the individual control systems.

The second level contains global functions, which, however, apply to a special control system or for all PMC-V units. On the third level, functions are stored which apply to a directly activated unit within the higher-ordered system. In the control system, those are exclusively PMC-D units, which are identified based on where they are installed (HG = head gate, TG = tail gate).

Which level of the menu tree and which menu or input/output mask is active is displayed on the screen on the first line, which is darkly highlighted.

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5.3

PMC-Vkeypad The first field indicates the name of the selected screen mask. In the second field, “Global” is displayed for the first menu level, or the name of the selected system. The third field shows the name of the currently activated unit. As long as no unit has been directly activated, the name of the PMC-V unit is displayed which is used for operation.

Fig. 10:

Levels of the menu tree Global functions

Gn

V1

Vn

HG

HG1

TG

HG2

TG1

TG2

To make this point clear, “local V3” is displayed, for example, when the PMC-V unit was assigned the name “V3”. In both fields of the last line, system-specific status information is output.

Fig. 11:

Screen mask structure Menu level or system name

Name of the screen mask

Start menu

Device name

Global Local V3 Date: 03/30/05 Time: 3.23:38 PM

System selection System configuration Profibus diagnostics (internal) Device information Display settings Setting date/time

System-specific status information

PMC-Vkeypad The keypad of a PMC-V visualization unit is shown in Fig. 12. See page 5.5. An LED is allocated to each of the 24 keys, which light up when the keys are correctly pressed. The keypad is for navigating through the menu tree provided on the screen, for inputting number values and for directly activating special functions.

5.4

PMC-D CST

E

G1

CST drive system

Plow system

Visualization

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Gateway

PMC-Vkeypad The desired selection is made in the menu using the “up”, “down”, “left” and “right” arrow keys. The selected menu item is shown highlighted on the screen.

Keypad of the PMC-V visualization unit

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Fig. 12:

The selected highlighted menu item is activated with the “Enter” key. An input, e.g. of a number value or a password, is completed by pressing this key.

If the “Cancel” key is pressed, the mask is jumped to from which the current mask was called. Changes in the current mask are ignored. The entry of a number value or password is canceled.

By pressing this key (“Caution” symbol), the screen changes from any screen mask to the display of a list with system messages. If the list is exited by pressing the “Cancel” key, the display changes back to the previously exited screen mask.

With the “Home” key, one can jump from any screen mask directly to the beginning of the active menu level.

With this key, one can jump from any screen mask directly into the “Language selection” menu. After confirming the language selection with the “Enter” key, the previously exited screen mask is displayed again in the newly chosen language. ...

On the PMC Drive Control System, only number values are expected as input. This applies, for example, to the entry of target values and parameter values, as well as passwords. If text input is expected, a corresponding selection list is always provided.

...

On the left side of the keypad are the function keys F1 to F4. With each of these keys, a function is activated, which is described in the respective screen masks.

Three keys on the keypad are doubly assigned. This second key function, whose symbol is in the top right corner of the key, can be activated by pressing the “Shift” key along with the key of the desired function. The secondary functions of the arrow keys allow the input of a “+” or “-” character, and using the “?” character, help text can be displayed.

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5.5

PMC-VLEDs PMC-VLEDs LEDs

One green, one yellow and one red LED are arranged below the screen of the PMC-V visualization unit. When the green LED flashes, this indicates that the unit is connected to a power supply.

The yellow and the red LEDs signalize the presence of warnings/ error messages in the list of system messages (see page 5.7).

Password input Some menus and input masks are password-protected. A password consists of four numbers, which appear on the screen as asterisks for each number entered. The password entry is completed with the “Enter” key. The password has a time limit, i.e., after a monitored time of 20 seconds without pressing a key, the password must be entered again. If a key is pressed during the monitored time, the time period is extended again by 20 seconds.

System messages menu tree

!

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Fig. 13:

?

Jump to previous display item

5.6

PMC-D CST

PMC-VLEDs Defined key functions Direct activation of system messages By pressing the key shown at the left (“Caution” symbol), the screen branches off from any screen mask to the list with the system messages. Here, all messages of the PMC Drive Control System are displayed, irrespective of on which unit the message was generated. A distinction is made between error messages, warnings and information.

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PMC-VLEDs

The different message types are signalized by the LEDs below the screen of the PMC-V unit. If messages are entered on the list, which are rated as warnings, this is indicated by the yellow LED flashing. If the red LED flashes, this means that error messages are on the list, which have to be acknowledged by the operator. Information messages are not indicated by the LEDs, since they have no effect on the function of the PMC Drive Control System. The green LED makes no reference to the message list, but indicates that the unit is connected to its operating voltage.

Filters can be set on the system message list so that only those messages are displayed which are currently of interest. These settings are retained, even after the message list is exited. More detailed descriptions can also be called up for the individual short messages. Fig. 13 (see page 5.6) shows the menu tree which can be run through within the system message display.

After activating the system messages, the mask shown in Fig. 14 appears on the screen. In the bottom line on the screen, the selection criteria for the displayed messages are given.

Fig. 14:

System message

System messages Global Local V3 No. Source Brief description 125F CST--HG1 Cooling oil temperature too high 245F PLO--TG System pressure too low 045I V1 Communications V1 activated 140W CST--TG1 Unit temperature too high

F1:Ackn. message F2:Ackn. device F3: Select system F4: Select msg type All systems All messages In the shown example, “All messages” of “All systems” are shown in the mask.

No. In this column, the internal message numbers are displayed, followed by either the letter E, W or I, which stand for the message types “Error”, “Warning” or “Information”.

Source The name of the generator of the message is specified here.

If this is a PMC-D unit, the name is extended with a short designation for the system.

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5.7

PMC-VLEDs Short description In the last column there is a short description of the message. acknowledging messages

A single message can be acknowledged with the F1 function key, and all messages from one source can be acknowledged with F2.

To do this, the line with the desired message or with the desired unit must be selected and then the corresponding function key pressed.

If the “Enter” key is pressed after selecting a line, a new screen mask is opened where a detailed message description is displayed.

Fig. 15:

Detailed message description

System message Global Local V3 No. Type Source Cancel 03/29/05 125 Error CST--HG1 Yes 1:34:45PM

All messages

The message number, message type and source of the message are also given in this mask. Furthermore, in the “Cancel” column, it is indicated whether the cause of the message leads to the respective system shutting down. In the last column, the date and time are given for when the message was created. filtering messages

5.8

In order to be able to show the messages in a clearly arranged way, especially for troubleshooting purposes, there is the option of filtering messages according to the system they belong to and according to the type of message. For this, two screen masks are available via the function keys F3 and F4, which can be used to make this selection.

PMC-D CST

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All systems

E

The temperature of the cooling oil in the CST gearbox has exceeded the permissible maximum value. Further heating of the cooling oil will lead to damage to the clutch linings.

Resume operation only when the cooling oil temperature has dropped below the warning level set in the system.

PMC-VLEDs Fig. 16:

System selection messages

Global Local V3

System selection Local V3

CST drive system Plow control CM system Visualization

All messages

E

All systems EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 17:

Selecting the message type

Selecting msg type

Global Local V3

All messages Errors only Warnings only Info only

All systems

All messages

The selections made on these two masks are retained in the local PMC-V unit even after exiting the display for the system messages.

The current selection is displayed again in the bottom line of the masks when the system messages are activated again.

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5.9

PMC-VLEDs Direct activation of language change The language used for the text output on the screen can be locally changed at any time on the PMC-V unit used for operation. After pressing the key shown at the left, a list is displayed where the languages German, English and the national language of the place of operation are offered for selection. Here, the selection text is displayed in the respective language. After confirming the selection with the “Enter” key, the current mask is displayed in the selected language. In the shown example, the languages German, English and Russian are available.

Language selection

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Fig. 18:

Jump to previous display item

5.10

PMC-D CST

Global menu level, PMC Drive control Global menu level, PMC Drive control Fig. 19:

Global menu tree of the PMC Drive Control System Power on

Start menu Global

System selection

Global Date: Time:

lokal V3

lokal V3

12/06/2007 15:23:38

System selection Systemanwahl System configuration Profibus-diagnostics (intern) Device information Display setting Setting date/time

CST-Antriebssystem CST drive system Plow control system CM system Visualization

Global lokal V3 System configuration Serial no. Type Conf. Found Addr. CRC 560040047 D-CST HA1 HA1 047 052677 560 560040021 V V3 V3 021 052677 560040004 V V2 V2 004 052677 560040050 D-HOB HA HA 007 052677 550040001 D-CST HI1 HI1 001 052677 560040003 V V1 V1 003 052677 550040013 D-HOB HI HI 017 052677 560040012 D-CST HA2 HA2 012 052677

F1:Activete conf.

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Display setting Brightness: 050% Contrast: 050%

Global

lokal V3

Brightness (G) 065

Global lokal V3 Diagnostics PB intern Device Add Rec Snd. Error Tel Tel Snd Bus Timeout Plow-TG 047 067 347 000 000 000000002 V3 021 013 721 000 000 000000000 V1 003 990 866 000 000 000000000 V2 004 741 883 000 000 000000000 CST-HI1 001 695 283 000 002 000000000 CST-HA2 012 676 297 000 000 000000000

F1:Reset error counters

F2:Delete entry

System config.

Global lokal V3 Serial no. Type Conf. Found Addr. CRC 560 560040047 D-CST HA1 ofHA1 047 052677 Name/Place installation 560040021 V V3 V3 021 052677 HA1 HG1 560040004 V V2 V2 004 052677 HG2 560040050 D-HOB HA HA 007 052677 TG1 550040001 D-CST HI1 HI1 001 052677 HI2 560040003 V V1 V1 003 052677 HG 550040013 D-HOB HI HI 017 052677 TG 560040012 D-CST HA2 HA2 012 052677 V1 V2 F1:Activete conf.

F2:Delete entry

-----

Settine date/time Global DST:: ja Local time: 13:45:23 Date: 30.11.2007 Time zone: UTC +01:00

lokal V3

Device information Date: Time:

Global

lokal V3

12/06/2007 15:23:38

UTC = Universal Time Coordinated

Global Device information Device Type Serial No. V1 V 560040047 Mine setup:

Software/serial no.s

Voltage supply Device Type CST-HA1 D-CST Start menu

CST

Process overview Prozessübersicht Process overv. Contd.

Motor curr. overview Device selection Select operating mode Parameter status Automatic mode settings Load sharing controller

CM system

Visualization

12/06/2007 15:23:38

Software-ID Programm: 0000010009 Datum: 29.03.2005 Zeit: 13:12:45 FPGA1: 0003020201 FPGA2: 0004020201 CPLD: 0000001400

Global Serial No. 560040047

lokal V3

lokal V3 Meas.val

Date: Time:

lokal V3

NOVAJA

Component ser no.

CPU: 541040047 D-IO: 551040048 PMU: 531030005 PVC: 552050055 7-Seg: 544030004

Voltage supply

Plow control system

-----

Min.

Max.

Input 00.6 00.6 00.6 12V_A 00.0 00.0 00.0 12V_B 00.0 00.0 00.0 12V_C 00.0 00.0 00.0 12V_D 00.0 00.0 00.0 8,2V 00.0 00.0 00.0 3,3/5V ok Temperatur F1: Min/Max rücksetzen

curr.limit [mA] 000 000 000 000 000 00.0

Automatic

Fig. 19 shows the menu tree, the functions of which can be activated on the global level of the PMC Drive Control System. All functions are stored here, which are independent of the realized control systems and the special functions of the PMC®-V units. After switching on a PMC-V unit, the start menu of this menu tree is always displayed.

The start menu offers the following selection options: Activation of a subordinate system  System selection, page 5.12.

Display and modification of the configuration of a subordinate system  System configuration, page 5.13.

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5.11

Global menu level, PMC Drive control Diagnosis of the internal Profibus  Profibus diagnostics (internal), page 5.17.

Information about the structure and the software status of the individual units  Device information, page 5.18.

Changing the display settings of the currently used PMC-V unit.  Display setting, page 5.21.

Setting the date and time for the PMC Drive Control System.  Setting date/time, page 5.21.

Fig. 20:

Global start menu

Start menu

Global Local V3 Date: 03/30/05 Time: 3.23:38PM

5.12

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System selection System configuration Profibus diagnostics (internal) Device information Display setting Setting date/time

PMC-D CST

Global menu level, PMC Drive control System selection A selection list is displayed in which the subordinate systems which are available on site are entered. Fundamentally, at least one PMC-V unit is always required for operating the PMC Drive Control System, so the “Visualization” selection is always displayed. Also, there must be at least one control system. The other selection options shown in the example don't necessarily have to be present on every system.

Fig. 21:

System selection, CST gearbox

System selection

Global Local V3

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CST drive system Plow control system CM system Visualization

The activation of a system leads to the next menu level. Special operating instructions exist for each control system, where the menu guidance is described. The menus for the PMC-V units (visualization) will be described later.

System configuration For a PMC-D unit, the loaded software and hardware determine to which control system it belongs. Within a control system, which typically consists of several PMC-D units, the exact behavior of a unit can depend on the installation site, however. Therefore, a PMC-D unit must fundamentally be notified about the installation site. If site-dependent unit behavior is required in the control system, the software orients itself toward this specification.

Caution!

Make sure you specify the correct installation site of the PMC-D unit. Incorrect information can lead to major damage to the controlling system.

The behavior of the PMC-V units is always the same and does not depend on the installation site. For this reason, only a unique name is assigned to them, in order to be able to identify them in the PMC Drive Control System. If such a unit is exchanged, the new unit should be assigned the same name as the exchanged unit, though, especially when values are recorded via its measuring inputs for the control system. The configuration of these measuring inputs, including the name of the PMC-V unit, is stored in the PMC-D units which process the measuring values. These units will attempt to initialize these measuring inputs again, and use the saved unit names when they do so.

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5.13

Global menu level, PMC Drive control Important!

When exchanging a PMC-V unit, always assign the new unit the name of the exchanged unit, if possible. This way you avoid unnecessary additional work.

The units are identified based on their serial number for assigning names or the installation sites. The serial number is written on the type plate of the unit.

If there are other units active on the Profibus which are not listed in the local system configuration, these are additionally displayed.

The entry in the “Conf.” column remains blank. If these units already have a name or installation site, they are specified in the “Found” column.

All changes to the system configuration are forwarded to the units of the PMC Drive Control System by pressing the “F1” key and are saved there. After the units have confirmed they received the data, a restart is initiated by the PMC-V unit. After the units start up, the new system configuration is active.

If a unit is not actively included in the system when a change is made and could therefore not be informed about the changes, or if there has not yet been a restart, the unit works with the system configuration which was valid at the time of the last restart. Therefore, it is possible that different names or installation sites appear in the “Conf.” and “Found” columns and different number values are shown in the “CRC” column.

5.14

PMC-D CST

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After activating the system configuration, the mask shown in Fig. 21 (see page 5.13) is displayed on the screen. Here, all units are displayed which are locally stored as the system configuration by the PMC-V unit currently being used. In the “Conf.” column (configured), the allocated name / installation location is specified. If these units can be addressed via the internal Profibus, the Profibus address of the unit, which is automatically assigned by the PMC drive control system, is displayed in the “PBaddr” column (Profibus address). If a name or installation site has already been assigned to the units, the designation stored in the units is displayed in the “Found” column. Otherwise, this entry remains blank.

E

Important!

When installing a unit, write down the serial number written on the type plate. You will need this number for the system configuration.

Global menu level, PMC Drive control Fig. 22:

System configuration

System configuration Global Local V3 Serial no. Type Conf. Found. PBaddr. CRC 560040047 D--CST HG1 HG1 047 052677 560040021 V V3 V3 021 052677 560040004 V V2 V2 004 052677 560040050 D--PLO HG HG 007 052677 550040001 D--CST TG1 TG1 001 052677 560040003 V V1 V1 003 052677 550040013 D--PLO TG TG 017 052677 560040012 D--CST ------ ------ 012 002125 F1:Activate conf.

F2: Delete entry

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Serial no.

The serial number written on the type plate of the unit.

Type Type of unit. Here, the letter V stands for PMC-V and D for PMC-D. For PMC-D units, an additional short description is given for the control system.

Conf.

In the “Configured” column, names are entered which are stored in the currently used PMC-V unit as the system configuration. If new units were connected to the system, there are no entries in this column.

Found In the “Found” column, names or installation sites are entered which were stored as the valid designation the last time the unit was restarted.

PBaddr The address with which the unit can be addressed on the Profibus. It is automatically assigned by the PMC Drive Control System. If units are entered in the local system configuration which are not active on the Profibus, there is no entry in this column.

The PMC-V unit, on which the system configuration is currently displayed, can be displayed without an entry in this column. In this case, it was not possible for the unit to actively log onto the Profibus, or it withdrew due to extreme disturbances on the Profibus system.

CRC The checksum (Cyclic Redundancy Check) in the last column is formed via the active system configuration in the individual units. An identical number value means that the units are working with the same configuration. activating the configuration

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By pressing the “F1” key, the system configuration is transferred to all units in the PMC Drive Control System. After a restart of all units, initiated by the PMC-V unit, the system configuration is active.

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5.15

Global menu level, PMC Drive control deleting an entry

By pressing the “F2” key, the selected unit is removed from the system configuration. The name/installation site is deleted from the “Conf.” column. After receiving the system configuration, this is not transferred to the selected unit, but the previously valid configuration is completely deleted, so that the unit no longer has a system configuration after a restart.

Important!

The system configuration is error-free when the same name/installation site appears in the “Conf.“ and “Found” columns and when the same value is displayed in the “CRC” column for all units.

To assign a name/installation site, the desired unit is selected with the arrow keys and the “Enter” key is pressed. A selection list is provided with names and installation sites.

Name/installation site selection E

System configuration Global Local V3 Serial no. Type Conf. Found PBaddr. CRC 560040047 Assign D--CSTname/installation HG1 HG1 047site052677 560040021 V V3 V3 HG1021 052677 560040004 V V2 V2 HG2004 052677 560040050 D--PLO HG TG1HG 007 052677 550040001 D--CST TGI1 TG2 TG1 001 052677 560040003 V V1 V1 HG 003 052677 550040013 D--PLO TG TG TG 017 052677 560040012 D--CST -----V1 - ------ 012 002125 V2

F1:Activate conf.

-- -- -- -example:

F2: Delete entry -- -- -- -- --

In Fig. 22 (page 5.15), there is installation site yet assigned to the PMC-D unit listed in the last line, which belongs to the system for controlling a conveyor with CST gearboxes. Based on the serial number, the user sees that this unit was installed on head gate 2.

After selecting the unit and pressing the “Enter” key, a list is displayed in which the max. of four possible installation sites, head gates 1 and 2 and tail gates 1 and 2, are displayed, among other things. In this list, the user selects the short designation “HG2”, which is entered in the “Conf.” column after pressing the “Enter” key. The selection of an installation site which does not belong to the CST system is rejected with an error message.

In order for this configuration to be known to the selected unit as well as to the entire system, it must be distributed in the system by pressing the “F1” key. To accept the new system configuration, all units of the system are restarted.

Important!

All units of the PMC Drive Control System are restarted when accepting a new system configuration. As a result, all enable signals for the systems to be controlled are canceled.

5.16

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 23:

Global menu level, PMC Drive control Profibus diagnostics (internal) Data is exchanged between the units of the PMC Drive Control System via a bus system in accordance with the Profibus standard.

No unit may be connected to this internal communication system which does not belong to the PMC Drive Control System. The external systems communicate exclusively via the second Profibus connection of the PMC-V units or via serial connections.

Notice!

Do not connect units to the internal Profibus which don't belong to the PMC Drive Control System. The correct function of the control systems can then no longer be guaranteed.

Fig. 24:

Profibus diagnostics (internal)

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Profibus diagnostics (internal) Global Local V3 Device PBaddr. Recv. Sent Error tel. tel. Send Bus CST--HG1 047 567 347 000 000 V3 021 013 721 000 000 V1 003 990 866 000 000 V2 004 741 883 000 000 CST--TG1 001 965 283 000 002 CST--HG2 012 676 297 000 000

F1: reset error counters -- -- -- --

-- -- -- --

The display of the internal Profibus diagnostics provides the following information: Device The name or installation site assigned by the user during system configuration. For PMC-D units, an additional short description is given for the control system.

PBaddr.

The address at which the unit can be addressed on the Profibus.

Recv. tel.

The number of telegrams received by the unit.

Sent tel.

The number of telegrams sent by the unit.

Send. error The number of errors which occurred while attempting to send a telegram.

Bus error The number of detected errors which are due to disturbances on Profibus. This counter is incremented up when, for example, the connection to Profibus is plugged in when the unit is turned on.

All counters start again at zero when the maximum value of 999 has been reached. The error counter can be reset to zero by pressing the “F1” key.

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5.17

Global menu level, PMC Drive control Important!

The error counters don't have to be at zero for proper operation. Sporadic disturbances are tolerated by the PMC Drive Control System. Only when the error counters continuously increase is there an error in the Profibus communication system.

Device information After activating unit information, the mask shown in Fig. 26 is displayed on the screen. It contains information about the individual units of the PMC Drive Control System.

Interim window

Device information

Global Local V1

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Fig. 25:

Fig. 26:

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Software/serial no.

Voltage supply

Device information

Device information Global Local V3 Device Type Serial No. CST--HG1 D--CST 560040047 Component ser.no.

CPU: 541040047 D--IO: 551040048 PMU: 531030005 PVC: 552050055 7--Seg: 544030004 CPLD:

Software ID Program: 000010009 Date: 11/21/2007 Time: 1:12:45 PM FPGA1: 003020201 FPGA2: 004020201 000001400

Device The name or installation site assigned by the user at system configuration. For PMC-D units, an additional short description is given for the control system.

Type Type of unit. Here, the letter V stands for PMC-V and D for PMC-D. For PMC-D units, an additional short description is given for the control system.

Serial no.

The serial number written on the type plate of the unit.

5.18

PMC-D CST

Global menu level, PMC Drive control Component ser. no.

The serial numbers of the subassemblies which are installed in the unit. The following subassemblies can be displayed for the various units: – CPU (CPU32) This subassembly contains the complete computer of the units.

– PMU (Power Management Unit Type 1) This subassembly provides the required voltages, carries the buffer battery for securing the parameters when switched off and limits the output currents to the external connections of the units.

– D-IO (PMC-D I-O) The central subassembly of a PMC-D unit. All externally reachable inputs and outputs are integrated in this subassembly.

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– D-IO (PMC-VG I-O) The central subassembly of a PMC-V unit. All externally reachable inputs and outputs are integrated in this subassembly.

– PVC (PMC-D Proportional Valve Control) This subassembly for actuating the valve for the pressure setting in the clutch of a CST gearbox.

– 7-Seg (PMC® 7 Segment display) The display unit of a PMC-D unit.

– VGA (PMC-VGA interface) The subassembly for actuating the screen unit of a PMC-V unit.

– PCM (PMC® Profibus Com module) This subassembly allows communication with an external Profibus.

Software ID The version numbers of the active software. The individual components can be exchanged on site except for the components designated CPLD. – Program The program which is run by the unit computer and defines the unit function. The date and time indicate the time this program was created.

– FPGA1 and 2 (Field Programmable Gate Arrays) The hardware settings and the preprocessing of the measured values are adapted to the desired unit function using these programs.

– CPLD (Complex Programmable Logic Device) Is loaded when the units are produced and sets functions which may not be modified. next unit / previous unit

The next or previous unit can be switched to with the “F1” and “F2” function keys.

In the startup phase of a unit, it is checked whether the existing hardware and the FPGA programs are appropriate for the desired unit functionality. Here, non-existing as well as redundant hardware components and incorrect programs for the FPGAs lead to an error message on the local display unit and to the abort of the startup.

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5.19

Global menu level, PMC Drive control After a unit has been started up without errors, the version number of the active program is compared with the other units working in the same network. This check is only done between units which are already configured on the PMC Drive Control System. When there is a disagreement in the version status, an error message is output to the PMC-V units and the startup of the unit network in question is stopped.

Important!

The software in the units of the PMC Drive Control System checks whether the internal hardware matches the desired unit function at startup. If there are any inconsistencies, startup is terminated.

Voltage supply Voltage supply

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Voltage supply Global Local V1 Unit Type Serial no.

-------- -------- 000000000 Meas. value Min. Max. Curr. limit [mA] Input 00.6 00.6 00.6 000 12V_A 00.0 00.0 00.0 000 12V_B 00.0 00.0 00.0 000 12V_C 00.0 00.0 00.0 000 12V_D 00.0 00.0 00.0 000 8.2V 00.0 00.0 00.0 000 3.3/5V ok Temperature 00.0 F1: Min/Max reset

With the “Voltage supply” menu item, the different voltages, associated current in mA and temperature allocated to the respective unit can be looked up.

Display settings After this menu item has been selected, the current contrast settings and the brightness of the screen are displayed in %. After selecting the two setting options, a bar is displayed which shows the current value by its length. With the “up”, “down” or “right” and “left” arrow keys, the value can be changed in steps of 5%. The setting is accepted and saved by pressing the “Enter” key.

5.20

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 27:

Global menu level, PMC Drive control Fig. 28:

Display settings

Display setting Brightness: 050 % Contrast: 050 %

Global Local V3

Brightness (L)

E

065

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Setting the date/time The date and time are kept on the PMC Drive Control System. This information is necessary in order to note the time of an event (e.g., detection of an error) in the message to the user. Within the system, the “universal time coordinated” (UTC) is used for generating this time stamp. This way, there are no time jumps, e.g. when the system is switched from standard time to daylight savings time, or when information, which is logged on different systems with different local settings, is to be compared relative to time.

The UTC refers to Greenwich Mean Time. The current local time is determined by or subtracting a constant time difference, which is officially deadding fined for every location, to the UTC. One unit acting as the reference unit is responsible for keeping the time on the PMC Drive Control System. Which unit takes over this task is determined automatically. This unit synchronizes the local clocks in the other units with its clock at regular intervals. The clock in the reference unit can either be set by the user or it is adjusted by a higher-ordered system by transferring the time and date.

Fig. 29:

Setting the date and time

Setting date/time Daylight savinme: Yes Local time: 1:45:23 PM Date: 03/30/2005 Local time: UTC +01:00

Global Local V3

UTC = Universal Time Coordinated

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5.21

Global menu level of the CST drive system Daylight savings time If standard time and daylight savings time are distinguished at the place of operation of the PMC Drive Control System, the display can be adapted to local time by selecting “Yes” or “No”.

Local time, date Setting of the current time and date.

Local time UTC Here, the constant time deviation between UTC and the local time at the place of operation must be entered.

5.22

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

The menu tree in Fig. 30 (page 5.23) shows the screen masks which are used to select the global functions of a CST drive system for an armored face conveyor. This menu tree can be reached from the global menu level of the PMC Drive Control System via the corresponding system selection. In the middle column of the first line on the screen, the short designation “CST” (Controlled Start Transmission) is displayed for the activated system.

E

Global menu level of the CST drive system

Global menu level of the CST drive system Fig. 30:

Global menu tree, CST drive system Start menu

Process overview HG1 Input speed 1499,0 Motor power 0129,0 Clutchpress 0015,8 Actual slip 003,50 Target slip 003,50 Outp. speed 0044,7 Sys. Press. 0100,0 Diff.press. 0000,0 Oil press 0003,0 Drive state run Drive rel. no

CST

lokal V3

Date: 12.06.2007 Time: 15:24:56

CST lokal V3 HG2 TG1 TG2 1499,01493,9 -----0131,0 0234,0 -----0015,8 0019,4 -----003,50 000,20 -----003,50 000,20 -----0044,7 0044,7 -----0100,0 0100,0 -----0000,0 0000,0 -----0003,0 0003,0 -----run run -----no no ------

Parameter status Parameter Parameter block status HG1 local User HA2 HG2 local User TG1 local User TG2 local --global User

Process overview Prozessübersicht Process overv. Contd.

Motor curr. overview Drive selection Select operating mode Parameter status Automatic mode status Load sharing controller

CST In System identical Yes No Yes --Yes

lokal V3 copy from -----------

Automatic Automatic

Automatic

Process overv. Contd.

CST HG1 TG1 diff.press. 000000 000000 Temperatures Hydr. plate 0049 0058 Oil sump 0000 0000

lokal V1

Select operating mode Run mode: Automatic

CST

lokal V3

Datum: Run mode30.03.05 (G) Zeit: 15:24:56 Stop Automatik Automatic Semiauto Inspection

Parameter status CST lokal V3 Parameter Parameter System Kopieren Unit Parameter blockImHG2 satz status gleich von HA1 BU HA1 lokal Benutzer Ja --HG2 U HA2 lokal Benutzer Ja --TG1 U HI1 lokal Benutzer Ja --TG2 --HI2 lokal setting ------Factory global Benutzer Ja --values modified by user different from the copies factory setting reset to factory setting

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U = U*= W = R =

Automatic

Motor curr. overview CST Motor- Curr.

Curr. Meas. strom A B aktive HG1 0129 0064 0065 R+L HGA2 0130 ---0065 HG2 0086 TG1 0234 0117 0117 A+B TG2 ------------

lokal V3 Measure on V1 HG1 V2 TG1 --- ---

Automatic

Automatic

Load sharing control. lokal V3 CST Load distribution between head gates P-amplific. factor: 02,00 I-amplific. factor: 00,25 Load distribution head to tail gate P-amplific. Factor: 02,50 I-amplific. factor: 00,25 Load distribution between Tail gates P-amplific. factor: 01,00 I-amplific. factor: 01,00

Auto. Mode settings CST lokal V3 Master unit load sharing: HG1 Number of drives: 2 Time win. for entire sys.startup Motor startup: 15,0 s Clutch prefill: 07,0 s Accelerating the conveyor: 25,0 s Load limits Low load range: 040 % Havy load range: 070 % Tail-end drive load evaluation Low load range: 180 % Havy load range: 100 %

Minimum slip value:

Automatic

0.20 %

Automatic

Automatic

Drive selection

CST

lokal V3

Start menu

CST

HA1

Date: 12.06.2007 Time: 15:24:56 Prozessdaten anzeigen Display process data Process data contd.

Process configuration Semiautomatic settings Clutch pressure inspection Motor/gearbox External connections

Head gate 1 (HG1) Hauptantrieb 1 (HA1) Head gate 2 (HG2) Tail gate 1 (TG1)

Automatic

Automatic

The start menu offers the following selection options: Display of the most important process parameters over all drive units.  Process overview, page 5.24 Display of the current motor currents over all drive units.  Motor current overview, page 5.28.

Selection of an individual drive unit.  Drive selection, page 5.29.

Operating mode setting of the conveyor system.  Select operating mode, page LEERER MERKER Overview of the status of the stored global and local parameter blocks of PMC-D units.  Parameter status, page 5.33 Settings for operating the conveyor system in automatic mode.  Automatic mode settings, page 5.36.

Settings for the control algorithm for load sharing between the individual drive units.  Load sharing controller, page 5.38.

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5.23

Global menu level of the CST drive system Fig. 31:

Start menu - CST drive system

Start menu

CST

Local V3

Date: 03/30/2005 Time: 3:24:56PM Process overview Process overv. cont.

Motor current overview Drive selection Select operating mode Parameter status Automatic mode settings Load sharing controller

Process overview Start me nu

CST Date: Time:

11/29/2005 4:08:30 PM

Process Process overview Motor current overview Drive selection Select run mode Parameter status Automatic mode settings Load sharing controller

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Motors released

In the process overview, the current values of the most important process parameters of all drive units of the conveyor system are displayed. This provides a quick overview of the operating state of the system. In the event of errors in the data acquisition, the corresponding values are darkly highlighted. To determine the exact cause of the error, the affected drive unit must be activated and the mask for showing the local process data called up (Displaying process data, page 5.41).

Fig. 32:

Process overview

Process overview CST Local V3 HG1 HG2 TG1 TG2 Input speed 1499.0 1499.0 1493.9 -----------Motor curr. 000000 000000 000000 -----------Clutch press 0015.8 0015.8 0019.4 -----------Actual slip 003.50 003.50 000.20 -----------Target slip 003.50 003.50 000.20 -----------Output speed 0044.7 0044.7 0044.7 -----------Sys. press. 0100.0 0100.0 0100.0 -----------Diff. press. 0000.0 0000.0 0000.0 -----------Oil press 0003.0 0003.0 0003.0 -----------Drive state run run run -----------Drive rel. no no no -----------Automatic Input speed [rpm] The speed of the drive motor.

Motor power The current consumption of the drive motor.

Clutch pressure The pressure which is built up in the pressure chamber of the clutch, with which the discs of the input and output sides of the clutch are pressed together. This pressure is set to a specified nominal value based on the system pressure using the servo valve and a high-resolution pressure sensor from the PMC-D unit. The output power of the gearbox can be varied with the clutch pressure.

5.24

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Automatic

Global menu level of the CST drive system Actual slip [%] The slip in the clutch which is set by the PMC-D unit.

Target slip [%] The slip in the clutch which is to be set by the PMC-D unit.





n Actual slip = 100 ⋅ 1 − ü ⋅ n ab [%] an

nin = input speed nout = output speed ü = Gearbox ratio Output speed The speed at the output of the gearbox

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System pressure [bar] The pressure built up inside the gearbox for controlling the CST clutch. A pressure switch is used for measuring the pressure set to 100 bar, which switches at a minimum pressure of 80 bar. On the screen, the nominal pressure of 100 bar is always displayed after switching over. If the system pressure drops below the minimum pressure, the drive is switched off.

Differential pressure The differential pressure between the input and output of the filter in the hydraulic circuit to the pressure chamber of the clutch. A pressure switch is used for measuring the differential pressure, which switches at a minimum pressure of 6.9 bar. On the screen, 7 bar is always displayed as the pressure after switching over. If the system pressure increases above 6.9 bar, the drive is switched off.

Cooling oil pressure The pressure built up inside the gearbox with which the gear oil is pressed through between the discs of the clutch. The oil is for dissipating the heat which develops in the clutch and maintaining the thin film of oil which separates the clutch linings from each other, thereby protecting them from damage. The drive is switched off if the cooling oil pressure leaves the valid range between 1.0 and 3.8 bar.

Drive status The operating states of the drive units, particularly those of the startup phase, are displayed. These operating states sometimes depend on the selected operating mode. The following short designations are displayed: – Stop The operating mode “Stop” has been selected.

– WTMot, wait for motor It is waited until the drive motor has been started up.

– MotSta, motor is starting The minimum speed has been detected and it is waited until the stable final speed has been reached.

– MotLft, motor running The drive motor has started up correctly and is therefore ready for operation.

– StVerz, start delay In “Semiautomatic” mode, the start delay runs down to compensate for the different switch-on times of the motors.

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5.25

Global menu level of the CST drive system – MotSyn, motors, synchronous In “Automatic” mode, the PMC-D units wait for the signal that all motors have started up correctly. The start-up of the conveyor is canceled if this signal is not received within the specified time window (Automatic settings, page 5.36).

– VorFül, prefilling The clutch of the local drive unit is prefilled.

– VorSyn, prefilling, synchronous In “Automatic” mode, the signal is waited for that all clutches have been prefilled. The start-up of the conveyor is canceled if this signal is not received within the specified time window (Automatic settings, page 5.36).

– Losbr, breakaway/accelerate conveyor The drive unit attempts to accelerate the conveyor out of a standstill.

– LosSyn breakaway/accelerate conveyor, synchronous In “Automatic” mode, it is waited until all drive units signal the correct acceleration of the conveyor. The start-up of the conveyor is canceled if this signal is not received within the specified time window. (Automatic settings, page 5.36).

– running The drive unit is running in the selected operating mode.

– SftHlt, smooth stop The drive unit executes a normal shutdown.

– Error The local PMC-D unit has detected an error. This error is reported to the other PMC-D units and the drive unit is switched off immediately.

– ExtHlt, external stop The drive unit was switched off due to an error message from another PMC-D unit.

Drive rel..

Indication that drive is enabled Possible indications: – yes – no

5.26

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

– In “Automatic” mode, all PMC-D units to which no tensioner is connected wait for the signal that the tensioning of the chain has been completed. The start-up of the conveyor is canceled if this signal is not received within the specified time window Even if no automatic tensioning unit is available, this designation will still be displayed briefly.

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– KtVerz, chain tensioner delay In “Automatic” mode, the PMC-D unit, to which the tensioner is connected, waits for the finished signal of the tensioning procedure. The start-up of the conveyor is canceled if the signal is not received within the specified time window.

The delay time for the automatic tensioning of the chain runs in all PMC-D units in the “Semiautomatic” mode.

Even if no automatic tensioning unit is available, this designation will still be displayed briefly.

Global menu level of the CST drive system Process overv. cont.

Diff. pressure 2 System-specific display of a second differential oil pressure switch (if the switch is not at hand in the current system, this display is not shown) Temperatures – Hydraulic p.

The oil temperature in the oil sump of the gearbox. The oil lubricates all moving parts in the gearbox, cools the clutch and is used as the control oil for pressure build-up in the clutch as well. The drive unit is switched off when the oil temperature is outside a range of -20C to 90C. – Oil sump If there is an oil sump temperature measuring unit, the temperature in the oil sump is displayed. (system-specific) EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Motor current overview Start me nu

CST Date: Time:

Process overview Motor current overview Drive selection Select run mode Parameter status Automatic mode settings Load sharing controller

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11/29/2005 4:08:30 PM

>

Motors released

This display gives an overview of the current consumed by each drive motor, which results from the sum of both individual currents in the windings A and B (see Fig. 33). This division is necessary to be able to show the individual currents of tandem motors. In the case of a standard motor, only one winding is active so that the motor current is identical to the winding current (Motor data, page 5.51, page 5.61). In addition, in the motor current overview, the name / installation location of the units are displayed, via which the currents are measured.

Tandem motors In the case of these motors, two separate stator windings are mounted one after the other in a motor housing. The output shaft carries two rotor windings, accordingly, so that the sum of the drive power generated by each individual machine is available to the common shaft.

In normal operation, both windings are active for a tandem motor and the total current results from adding both winding currents. If a measured value is disturbed and is removed from the evaluation by the user (Process functions on/off, page 5.57), the total current is determined by doubling the remaining measured value. The same applies when there is only one measuring channel. If one winding fails, it must be deactivated (Motor data, page 5.51, page 5.61) and the tandem motor is treated as a standard motor. The motor current is then equivalent to the remaining winding current.

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5.27

Global menu level of the CST drive system Fig. 33:

Motor current overview

Motor current overview Motor-- Curr. Curr. curr.

A B active HG1 0129 0064 0065 HG2 0130 -------- 0065 TG1 0234 0086 0117 TG2 -------- -------- --------

CST Local V3 Meas. Measure on A+B V1 HG1 A+B HG2 A+B V2 TG1 ------ ------ ------

Automatic

Winding A [A] The current drawn by winding A Winding B [A] The current drawn by winding B Active winding For a motor with only one stator winding, A is always displayed.

A tandem motor can only be operated with one winding, so that A, B, or A+B can be displayed.

Measurement on The name or installation location of the units which measure the motor currents. Here, the designation on the left indicates the unit for measuring the current of winding A and the designation on the right indicates the unit on which the current of winding B is measured.

5.28

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Motor current [A] The total current consumed by the machine

Global menu level of the CST drive system Drive selection Start me nu

CST Date: Time:

Process overview Motor current overview selection Drive selecti on Select run mode Parameter status Automatic mode settings Load sharing controller

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A selection list is displayed in which the drive units reachable via the internal Profibus system are entered. Selecting a drive unit leads to the menu level of the individual PMC-D units.

Fig. 34:

Drive selection

Drive selection

CST

Local V3

Motors released

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Head gate 1 (HG1) Head gate 2 (HG2) Tail gate 1 (TG1)

Automatic Here, functions can be activated which only affect the selected drive unit (Menu level of CST drive unit, page 5.39.)

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5.29

Global menu level of the CST drive system Select operating mode Start me nu

CST Date: Time:

Process overview Motor current overview Drive selection Select operat operating ing mode Parameter status Automatic mode settings Load sharing controller

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The operating mode of the conveyor system can be set via the displayed selection list. The operating mode must always be changed with the “Stop” operating mode as an intermediate step.

Fig. 35:

Selecting the operating mode

Select operating mode Operating mode: Automatic

CST

Local V3

Motors released

Operating mode (G)

Automatic Important!

When changing the operating mode, for reasons of safety, “Stop” mode must always be activated before the new operating mode can be set.

When the conveyor is very heavily loaded, you can select the “Heavy load startup” function when selecting the operating mode to start up the conveyor as smoothly as possible. Here, you also define the time window, after which the drives change back to the normal status of the selected operating mode. The parameters for setting the heavy load start-up can be found under “Configuring the process” (starting on page 5.56). You can select more tolerant values for the heavy load startup than for the normal overload settings. This way you can more strongly accelerate the conveyor.

Fig. 36:

1 2

5.30

“Selecting the operating mode” with heavy load startup

3 4

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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Stop Automatic Semiauto Inspection Emergency operation

Global menu level of the CST drive system The following operating modes can be set: Stop When the conveyor is running, a normal shutdown is initiated on all drive units (normal shutdown). The pressure in the clutches is completely relieved and the contacts for releasing the motor are opened.

Automatic The standard operating mode of the conveyor. This operating mode requires both a correctly functioning motor current measurement as well as reliable communication via the internal Profibus system. Only then is the correct function of both major features of this operating mode guaranteed:

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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– Smooth startup of the conveyor By coordinating the startups of the individual drive units, the power of all drive units is available at the same time in order to put the conveyor in motion. For this, it is waited until all motors have started up (Motor startup, page 5.61), before beginning with prefilling all CST clutches (Prefill clutch, page 5.62). After this operation is completed, the acceleration phase of the conveyors is started on all drive units (Accelerating the conveyor, page 5.63). This way, the maximum force can be initiated in the chain so that even a very heavily loaded conveyor can be put into motion in order to accelerate it under control to its nominal speed.

– Load sharing After the conveyor has been put into motion, the controller for sharing the load among the drive units is enabled. Hereby, the load of the drive units is judged based on the measured motor currents and is adapted to the load status of the conveyor by means of a slip specification for the individual CST clutches. Three load statuses are distinguished. The low load range, the medium load range and the heavy load range. In all of these load ranges, a different strategy is applied for load sharing among the drive units. Load sharing can only be executed by one of the PMC-D units. Which unit should take on this task can be freely selected (Automatic settings, page 5.36).

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5.31

Global menu level of the CST drive system

Fig. 37:

Motor startup TG1

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

– Smooth startup of the conveyor in semiautomatic mode In order for the mains supply not to be overloaded underground, the drive motors are usually not switched on at the same time. The PMC-D units, however, detect that the conveyor is to be started by the startup of the motor. Therefore, all drive units would close their clutches with the same time delay with which the motors are switched on. In order for the power of all drive units to be available for accelerating the conveyor at the same time even without communication between the PMC-D units, an individual delay time can be set for each drive unit (Semiautomatic settings, page 5.43). This delay time is added after the motor starts up. This way, the power of all drive units will be available for accelerating the conveyor, as in “Automatic” mode.

Semiautomatic startup delay

Motor startup HG1

Accelerate conveyor

Motor startup HG2

Startup delay HG2

Prefilling clutches

Startup delay HG1 Startup delay TG1

– Target slip specification In semiautomatic mode, automatic load sharing is not active.

The load percentage of the individual drive units can only be influenced by setting a target for the clutch slip (Semiautomatic settings, page 5.43).

Inspection In this operating mode, once the motor has been started up correctly, the target value for the pressure on the CST clutch can be changed via the arrow keys of the PMC-V unit in two defined steps (Inspection of clutch pressure). This set pressure specification is limited to the selected drive unit.5.44 All other drives don't apply any pressure to the clutch, even while the drive machine is running.

5.32

E

Semiautomatic In this semiautomatic operating mode, the drive units work independently of one another. Therefore, for this operating mode, communication between the PMC-D units is not necessary.

Also, the motor currents do not have to be evaluated.

PMC-D CST

Global menu level of the CST drive system Emergency operation In this operating mode, the PMC-D switches a valve for emergency operation. In emergency operation, you do not have any control over the drive via the PMC-D. All monitoring functions are deactivated in this operating mode. Now you have two ways of manually controlling the gearbox: – Emergency operation with high pressure pump – Emergency operation with hand pump Important!

Additional information about emergency operation can be found in the operating manual of the gearbox.

Parameter status Start me nu

CST

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Date: Time:

Process overview Motor current overview Drive selection Selecting operating mode Parameter sta status tus Automatic settings Load sharing controller

Automati c

>

Motors released

The functions for the control system of a conveyor with CST drive units can be influenced by setting parameters. The factory settings saved when the PMC-D units are delivered guarantee only a basic system setting. These must be adapted to the requirements at the place of operation.

The system distinguishes between global parameters, which apply for the entire control system, and local parameters, which apply for the respective drive unit. The global parameters are fundamentally stored in all PMC-D units. For the system to function, it would be sufficient to only store the local parameters in the units to which they are allocated. This means, however, that when a unit is exchanged, the changed local parameters must be input again. To avoid this, a copy of the local parameters of the other unit is stored on each PMC-D unit. This way, a new unit can take over both the global as well as the local parameters of a unit with the current parameter blocks. The parameter reconciliation is done via the screen mask shown in Fig. 38.

Fig. 38:

Parameter status

Parameter status CST Parameter Parameter Identical Copy block status in system from HG1 local User Yes -----HG2 local User No -----TG1 local User Yes -----TG2 local ------ ------ -----global User Yes ------

Local V3

Automatic Parameter block Designation for the type of parameter block. The various local parameter blocks are named according to the installation sites of the PMC-D units.

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5.33

Global menu level of the CST drive system Parameter status Short designation for the state of the parameter block in the unit allocated to it. The following short designations are displayed: – User The factory settings have been changed by the user.

– Fact. set.

The parameter block was reset by the user to factory settings, or a new unit was installed.

– Copy from After selecting a parameter block and pressing the “Enter” key, a list is displayed in which all existing units and the factory settings are offered for selection (Fig. 39). The installation site of the selected unit, from which all other units are to accept the parameter block, is displayed in this column during this acceptance.

Important!

The parameter status is error-free when “Yes” is entered for every parameter block in the “Same in system” column. The control system is only ready for operation when the parameter status is error-free.

The list for selecting the unit, from which the parameter block is to be copied, is shown in Fig. 39. In addition to the unit designations, the status of the parameter block in the individual units is also displayed. Copying parameter blocks which are labeled with “W” or “R” is not allowed, in order to prevent accidentally resetting the parameters to the factory settings. Resetting the parameter values to factory settings is only possible via the “Factory settings” selection.

5.34

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

– Identical in system In this column, it is displayed whether the copies of parameter blocks stored in the individual units are identical. If there is “Yes” entered in all rows, the system is error-free with regard to parameter management. If there is a “No”, the affected parameter block must be reconciled.

E

– ResetDuring the automatic parameter block check by the unit, an error was discovered and the parameter values were reset to the factory settings.

Global menu level of the CST drive system Fig. 39:

Copying parameter block

Parameter status

CST

Local V3

Unit Parameter block HG2 HG1 U HG2 U* TG1 U TG2 -----Factory setting U = values modified by the user U*= different from the copies F = factory setting R = reset to factory setting Automatic EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

The status of the parameter block is labeled with the following short designations: U The factory settings were changed by the user.

U* The comparison between the locally stored parameter block and the copies stored in the other units indicated a difference.

F The parameter values are equivalent to the factory settings R During the automatic parameter block check by the unit, an error was discovered and the parameter values were reset to the factory settings. example:

Doc. no.: 1999 001 009 BA 00

The example shown in Fig. 39 shows that local parameters in the PMC-D unit of head gate 2 were changed without the copies in the other units being reconciled. This is possible when there was no communication connection between the units at the time the parameter was changed. In this case, the user must decide with which parameters the PMC-D unit on head gate 2 should continue to work.

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5.35

Global menu level of the CST drive system Automatic settings Date: Time:

11/29/2005 4:08:30 PM

Process overview Motor current overview Drive selection Selecting operating mode Parameter status Automatic set settings tings Load sharing controller

Automati c

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Motors release d

“Automatic” mode is the standard operating mode of the conveyor system (Automatic operating mode, starting from page 5.30). This operating mode requires both a correctly functioning motor current measurement as well as reliable communication via the internal Profibus system. The screen mask shown in Fig. 40 shows all settings which are required for automatic mode. These settings apply to all drive units.

Fig. 40:

Automatic settings

Auto mode settings CST Master unit load sharing: HG1 No. of drives: Time window for entire sys. startup Motor startup: 15.0 s Clutch prefill: 07.0 s Accelerating the conveyor: 25.0 s Load limits Low load range: 040 % Heavy load range: 070 % Tail--end drive load evaluation Low load range: 180 % Heavy load range: 100 %

Local V3

E

CST

Automatic Master unit load sharing Name or installation location of the PMC-D unit which is responsible for load sharing among the drive units.

Number of drives Number of usable drive units.

Monitoring times for the startup of the entire system: Time window for motor startup The correct motor startup must be signaled within this time window for all drive units (Motor startup, page 5.61). If the time window is exceeded, the conveyor startup is canceled.

Clutch prefilling time window The correct prefilling of the clutch must be signaled within this time window by all drive units (Prefilling clutch, page 5.62). If the time window is exceeded, the conveyor startup is canceled.

Conveyor acceleration time window Within this time window, all drive units must signal the correct acceleration of the conveyor (Accelerating the conveyor, page 5.63). Otherwise, the conveyor startup will be canceled.

Important!

The time window for starting up the entire system must be bigger than the corresponding time window for the individual drive units.

Settings for load sharing among the drive units: Load limit, low load range Specified in percent, with respect to the sum of the nominal currents of all motors.

Load limit, heavy load range Specified in percent, with respect to the sum of the nominal currents of all motors.

5.36

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Start me nu

Global menu level of the CST drive system Tail gate load weighting, low load range Specified in percent, with respect to the current consumption of the head gate.

Tail gate load weighting, heavy load range Specified in percent, with respect to the current consumption of the head gate. load sharing

The load-sharing process prevents a slack chain from forming at the head gate. In addition, the entire load range of the conveyor is divided into three parts by specifying two load limits. In the low load range, the tail gate power is increased by a specifiable factor (load weighting) as compared to the head gate. In the middle load range, the power of the tail gate is controlled so that at the limit for the heavy load range, the ratio for the input of the head gate is equivalent to the load weighting valid for the heavy load range. This ratio is maintained in the entire heavy load range.

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

In Fig. 41, load sharing for a conveyor with three drive units is shown. In the low load range, first the tail gate increases the power output to the conveyor, and with this, its current consumption. Only when the current of the tail gate has reached the value specified by the load weighting and the idle current of the head gate does the head gate also become actively included in the drive of the conveyor.

Fig. 41: I

Load sharing Imax = Sum(IN(HG, TG))

Heavy load limit * Imax

Low load limit *Imax

Itot IHG1+HG2 ITG 1

Idle current HG1+HG2 Low load range

Middle load range

Heavy load rangeConveyor load

The control system determines the conveyor loading from the current consumption of all drive motors. The nominal load is reached when all motors consume their nominal current. That is why the load limits are specified in percent with respect to the sum of all nominal currents.

The load weighting determines the current of the tail gate as opposed to the current of the head gate, with respect to the respective nominal current, whereby, fundamentally, four drive units are taken into consideration.



I I I HI1 IHA1 + HI2 = load weighting ⋅ + HA2 I HINenn IHI2Nenn IHA1Nenn I HA2Nenn

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

5.37

Global menu level of the CST drive system A slack chain is when the chain sags in the running direction directly behind the chain wheel. Armored face conveyors are subject to the risk of slack chain formation due to their design. Among other things, this is due to the segmented structure of such conveyors, which, on the one hand, allows them to adapt themselves to the changing profile of the mining edge, and on the other hand, results in the expansion or relaxation of the chain. A chain with too little tension, however, harbors the risk of slack chain forming in the head gate and/or tail gate. While this leads to problems on the tail gate only in extreme cases, a slack chain on the head gate can lead to jamming and serious chain damage due to the small amount of free space in the bottom part of the drive frame. Therefore, it is absolutely mandatory that the chain always be sufficiently tensioned in the bottom race. Particularly in the case of a conveyor with no load or with a small load, the required pulling force in the bottom race is greater than in the upper race due to the higher friction. Therefore, in the range of low conveyor loads, a greater input must be assigned to the tail gate than the head gate.

Start me nu

CST Date: Time:

Process overview Motor current overview Drive selection Selecting operating mode Parameter status Automatic settings Load sharing controller

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Motors release d

E

Load sharing controller The controller for load sharing among the drive units is set via the screen mask shown in Fig. 42. These settings may only be changed by specially trained personnel from the manufacturer.

Fig. 42:

Load sharing controller

Load sharing controller CST Load distribution among head gates P--amplification factor: 02.00 I--amplification factor: 00.25 Load distribution head to tail gates P--amplification factor: 02.50 I--amplification factor: 00.25 Load distribution among tail gates P--amplification factor: 01.00 I--amplification factor: 01.00

Local V3

Minimal slippage value: 0.20 % Automatic Notice!

The controller settings may only be changed by specially trained personnel from the manufacturer. Faulty settings can lead to considerable damage to the conveyor system.

5.38

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

slack chain

Menu level for CST drive unit Menu level for CST drive unit Fig. 43:

Menu level for CST drive unit CST

Start menu Display process data Input speed 1497,2 Motor power 0107,0 Clutchpress 0015.8 003,50 Actual slip Target slip 003,50 Outp. speed 0043,3 Sys. Press.

0100,0 Diff-druck 0000,0 Diff press -000,8 Oil temp.

0053,0 Drive state run

CST U/min A bar % % rpm bar bar bar °C

HA1

Date: 12.06.2007 Time: 15:24:56

HA1

Motor/gearbox

CST

HA1

Date: 12.06.2007 Time: 15:24:56

Display process Prozessdaten anzeigen data Process data contd.

Process configuration Semiautomatic settings Clutch pressure inspection Motor/gearbox External connections

Gear oil monitoring Prozessdaten anzeigen Motor diagnostics Gearbox type setting User-defined gearbox Motor data Local motor current Remote motor current

Automatic

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Automatic

Automatic

Process daten anzeigen CST HA1 Input speed 1497,2 U/min Motor powerSensor 0107,0 A information Clutchpress 0015.8 bar Actual slip 003,50speed % Sensor: Input Target slip 003,50 Short % Line breakage Leitungsbruch circuit Outp. speed 003,50 0043,3 %rpm Press. value: 0100,02000 bar rpm Sys.Measured Diff-druck 0000,0 bar > upper limit -000,8 < lower limit DiffNot press -000,8 bar Set to inactive initialized Oil temp.

0053,0 °C Drive state -000,8 run Outdated

Semiauto settings Target slip: Start delay:

Automatic

Automatic

Gearbox type setting CST Gearbox type: P-45 CST 33:1

HA1

Gearbox selection (L): Gear ratio: 33,353 KP-45 CST 50:1 No. of teeth input meas. whe 054 P-65 CST 33:1 whee01,588 Trans.ratio motor/meas.

P-65outp.meas.

CST 39:1 wheel: 154 No. of teeth ControllerP-65 basic CSTsettings 50:1 P-amplif.pressure ratio: 1000 KP-65 CST 33:1 I-amplif.pressure ratio: 0000 KP-65 CST 39:1 P-amplif.slip control: 07.00 KP-65 CST 50:1 I-amplif.slip control: 35.00 User-defined

Automatic

CST 00,50 % 04,00 s

HA1

External connections

CST

HA1

Date: 12.06.2007 Time: 15:24:56

Chain tensioner PMC-V Connection/ext. device

Automatic

Clutch press. Insp.

Clutch press.set value Clutch press.act. value Input speed Outp. Speed Servo 1 current Servo 2 current

CST HA1 00,0 bar 0015.8 bar 1499.0 rpm 0044.7 rpm 000 mA 000 mA

Clutch press. set value (L) 18,6

Inspection

Process configuration

CST

HA1

external connections

Prozessfunktionen aktivieren Process function on/off Process functions (contd.)

Motor startup recognition Clutch prefill Accelerating the conveyor Conveyor shutdown Overload settings Pressure/slip controller

Automatic

The menu tree shown in Fig. 43 shows the screen masks which can be used to change the local settings of the selected drive unit.

This menu tree can be reached from the global menu level of the CST drive system by selecting a drive unit. The name of the drive unit is displayed in the right column of the first screen line.

The start menu offers the following selection options: Display of the most important process parameters of the drive unit.  Display process data.

Selection of a subordinate menu tree for setting the local control and regulation process. Process configuration (page 5.57).

Settings for “Semiautomatic” mode.  Semiautomatic settings (page 5.43).

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5.39

Menu level for CST drive unit Setting of the clutch pressure in “Inspection” mode.  Clutch pressure inspection (page 5.44).

Motor and gearbox data, setting the characteristic values of the drive motor, selection of the gearbox used in the drive unit.  Setting the gearbox type (page 5.50).

Settings for the inclusion of serially connected units in the PMC Drive Control System.  External connections Fig. 44:

Start menu - CST drive unit

Start menu

CST

HG1

Date: 03/30/2005 Time: 3:24:56PM

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E

Display process data Process data contd.

Process configuration Semiautomatic settings Clutch pressure inspection Motor/Gearbox External connections

Automatic

5.40

PMC-D CST

Menu level for CST drive unit Display process data St art menu

CST

HG 1

Datum: 30.03.2005 Date: 30.03.2005 Zeit: 15:24:56 Time: 15:24:56 Display process data Process configuration > Semiautomatic settings Clutch pressure inspection External connections > Gearbox type setting User-defined gearbox Motor data

Autom atic

In this overview, the current values of the most important process parameters of the drive unit are displayed. The process parameters are equivalent to those parameters shown in the overview for all drive units (Process overview, page 5.24). In the screen mask shown here, an exact description of the cause of error can be called up for the measured values characterized as being faulty.

Motors released

Fig. 45:

Display process data

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Display process data Input speed 1497.2 rpm Motor power 0107.0 A Clutch press. 0015.8 bar Actual slip 003.50 % Target slip 003.50 % Output speed 0043.3 rpm Sys. press. 0100.0 bar Diff. press. 0000.0 bar Oil press. --000.8 bar Oil temp.

0053.0 °C Drive status run

CST

HG1

Automatic A faulty measurement is shown darkly highlighted on the display.

After selecting the process parameters in question and pressing the “Enter” key, a window is shown in which the additional information about the cause of error is displayed.

Fig. 46:

Sensor information

Display process data CST Input speed 1497.2 rpm Motor curr.

0107.0 A Sensor information Wind. A 0053.0 A Wind.

B 0054.0 A oil pressure Sensor: cooling Clutch press.

0015.8 bar Line break short circuit Actual slip 003.50 % Target slip 003.50 % --000.8 bar Measured value: Outp.>Upper speed limit 0043.3 <Lower rpm limit Sys. press.

0100.0 bar uninitialized set to inactive Diff. press. 0000.0 bar Oil press.

--000.8 bar Old data Oil temp. 0053.0 C Drive run Automatic

HG1

In this window, the determined causes for the error message are shown darkly highlighted. Three sources of error are distinguished here:

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5.41

Menu level for CST drive unit Sensor – Line break Interruption in the line connection between the sensor and the measurement input in the PMC-D unit.

– Short circuit Short circuit in the line between the sensor and the measurement input in the PMC-D unit.

Measured value – > Upper limit The measured value exceeds the permissible maximum value.

– Set to inactive The inclusion of the measured value in the control and regulation process was deactivated (Process functions on/off, page 5.57) Communication – Old data The data is no longer cyclically updated. The last valid measured value and the last valid sensor information are displayed.

Process data cont.

2nd differential pressure If a second differential pressure switch has been installed, its measured value is displayed here.

Temperatures – Hydraulic plate The oil temperature of the gearbox. The oil lubricates all moving parts in the gearbox, cools the clutch and is used as the control oil for pressure build-up in the clutch as well. The drive unit is switched off when the oil temperature is outside a range of -20C to 90C. – Oil sump If there is an oil sump temperature measuring unit, the temperature in the oil sump is displayed. (system-specific)

Process configuration (see next chapter, page 5.56)

5.42

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

– Uninitialized No measured value has been determined yet for the process parameter since the PMC-D unit was started up. This particularly applies to measured values which are measured by other units and are transferred to the target unit via a communication connection.

E

– < Lower limit The measured value falls short of the permissible minimum value.

Menu level for CST drive unit Semiautomatic settings St art menu

CST

HG 1

Datum: 30.03.2005 Zeit: 15:24:56 Display process data Process configuration > Semiautomatic settings Clutch pressure inspection External connections > Gearbox type setting User-defined gearbox Motor data

Motors release d

Fig. 47:

Semiautomatic settings

Semiautomatic settings Target slip: 00.50% Start delay: 04.00 s

CST

HG1

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Autom atic

In “Semiautomatic” mode, an individual startup delay has to be set for each drive unit in order to compensate for the mostly different switch-on times of the motors (Semiautomatic, page 5.43). Furthermore, by specifying the target slip, the load percentage of the drive unit can be set on the total load determined by the conveyor load.

Automatic Target slip The slip in the drive unit clutch, set by the PMC-D unit after the conveyor starts up.

Start delay After the correct startup of the drive motor, this time is waited until the startup of the conveyor is continued.

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5.43

Menu level for CST drive unit Clutch pressure inspection Startmenü

CST

HA1

Datum: 30.03.2005 Zeit: 15:24:56 Prozessdaten anzeigen Prozess konfigurieren Semiautomatikeinstellungen Inspektion Kupplungsdruck externe Anbindungen Getriebtyp einstellen Benutzerdefiniertes Getriebe Motordaten Automatik

In “Inspection” mode, after the motor has started up correctly, the setpoint for the pressure in the clutch of the drive unit can be changed using the arrow keys on the PMC-V unit in two defined steps. The PMC-D unit sets the clutch pressure to the specified value synchronously with the input.

Fig. 48:

Clutch pressure inspection

Clutch pressure inspection CST Target value clutch pressure: 00.0 bar

HG1

Target value clutch pressure (L)

Automatic After pressing the “Enter” key, a bar appears which indicates the current setpoint by its length. This setpoint can be changed in steps of 1 bar with the “up” and “down” arrow keys and in steps of 0.1 bar with the “right” and “left” arrow keys. The “Enter” key must be pressed again to exit the setpoint specification. Afterward, the bar disappears and the setpoint is set to zero so that the clutch is immediately released again.

Motor/gearbox Fig. 49:

Motor/gearbox

Motor/Gearbox CST Date: 12/03/2007 Time: 1:13:55PM

HG1

Gear oil monitoring Motor diagnostics > Gearbox type setting User--defined gearbox Motor data Local motor current Remote motor current

Automatic

Motor enable

The PMC-D/V system is informed of the settings for the motors and gearboxes used for the current system in the Motor/Gearbox submenu. The data of the machines can also be queried. The following menu items can be retrieved:

5.44

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

18.6

Menu level for CST drive unit Gear oil monitoring Motor diagnostics with active and reactive power, temperatures of housing and cooling water flow – Motor windings with current, voltage, temperature – Bearing monitoring with vibration speed and temperature on drive-unit and non-drive-unit sides

E

– Process functions on/off, temperature measurements, vibration measurements of: –

Motor windings 1, 2 and 3

–

XP enclosure

–

Bearing drive side and non-drive side

–

Cooling water feed and drainage

–

Vibration 1 and 2

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Gearbox type settings User-defined gearbox Motor data Local motor current Remote motor current

Gear oil monitoring When the gear oil temperature is measured, the conveyor system can be monitored depending on the gear oil temperature.

Fig. 50:

Gear oil monitoring

Gear oil monitoring

CST

HG1

Prewarning at: > 075 Next warning in: 90°C: AFC shutdown!

Oil level (reference): 040 cm

Automatic

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Motor enable

5.45

Menu level for CST drive unit Motor diagnostics Fig. 51:

Motor diagnostics

Motor diagnostics CST Date: 12/03/2007 Time: 1:13:55PM

HG1

Motor Motor windings Bearing monitoring Process functions on/off

E

Motor enable

The “Motor” command opens a window, in which the active and reactive power and the temperatures of the XP enclosure and cooling water feed are displayed (see Fig. 52, page 5.46).

Fig. 52:

Motor

Motor Real power: React. power: Temperature XP Enclosure: Cool. water inlet:

Automatic

CST 000000 kW 000000 KVAr

HG1

000000 °C 000000 °C

Motor enable

When the cursor (black background) is placed on one of the required lines, the information from the connected sensor can be opened with the “Enter” key.

5.46

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Automatic

Menu level for CST drive unit Fig. 53:

Motor windings

Motor diagnostics

CST

HG1

Motor Motor windings Bearing monitoring Process functions on/off

Automatic

Motor enable

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

The “Enter” key opens a display field for current, voltage and temperature of the motor windings (in the menu item displayed at head gate 1, see right column of header).

Fig. 54:

Bearing monitoring

Motor diagnostics

CST

HG1

Motor Motor windings Bearing monitoring Process functions on/off

Automatic

Motor enable

The “Enter” key opens a display field for bearing vibrations and temperatures at the drive-unit and non-drive-unit side of the motor (in the menu item displayed at head gate 1, see right column of header).

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5.47

Menu level for CST drive unit Fig. 55:

Process functions on/off

Motor diagnostics

CST

HG1

Motor Motor windings Bearing monitoring Process functions on/off

In the “Process functions on/off” menu item, sensors can be activated or deactivated (set bridges).

Fig. 56:

Process functions 1

Process functions 1 CST HG1 Temperature measurement eval.

Motor phase 1 on Motor phase 2 on Motor phase 3 off XP enclosure on Bearing drive on Bearing rear on Cooling water inlet on Cool. water outlet off Vibration 1 on Vibration 2 on Monitoring Automatic

Motor enable

Gearbox type setting St art menu

CST

HG 1

Datum: 30.03.2005 Zeit: 15:24:56 Display process data Process configuration > Semiautomatic settings Clutch pressure inspection External connections > Gearbox type setting User-defined gearbox Motor data

Autom atic

5.48

For the conveyor system to work, it is mandatory that the used gearbox designation be correctly specified. Important data is transferred to the control system with this information, which is absolutely necessary for error-free function. An incorrectly set gearbox type can lead to damage to the conveyor system.

Motors released

PMC-D CST

E

Motor enable EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Automatic

Menu level for CST drive unit Fig. 57:

Gearbox type setting Gearbox type: P--45 CST 33:1

CST

HG1

Gear ratio: 33.353 No. of teeth input meas. wheel: 054 Trans.ratio motor/meas. wheel: 01.588 No. of teeth output meas. wheel: 154 Controller basic settings P--amplif. pressure ratio: 1000 I--amplif. pressure ratio: 0000 P--amplif. slip control: 07.00 I--amplif slip control: 35.00 Automatic EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Gearbox type The gearbox type used by the control system.

Gear ratio Exact ratio of the gearbox between the input and output with a rigid clutch.

Number of teeth, input measuring wheel Measuring wheel for determining the input speed.

Trans. ratio, motor/meas. wheel Exact ratio between the drive shaft of the motor / gearbox and the measuring wheel for measuring the input speed.

Number of teeth, output measuring wheel Measuring wheel for determining the output speed.

Controller basic settings Basic settings for the pressure and slip controls implemented in the PMC-D units are allocated to each gearbox type. The values set in the “Pressure/slip control” screen mask are based on these specifications (Pressure/slip control, page 5.68).

The gearbox type is set by selecting it from the list, which is displayed after pressing the “Enter” key (Fig. 58). All gearboxes with CST clutches manufactured by Caterpillar are given in this list. Furthermore, a user-defined gearbox can also be selected (Userdefined gearbox, page 5.50). After selecting the used gearbox and confirming with the “Enter” key, this gearbox type is accepted by the control system. The data allocated to the gearbox is displayed in the basic mask.

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5.49

Menu level for CST drive unit Fig. 58:

Gearbox type selection

Gearbox type setting CST Gearbox type: P--45 CST 33:1 Gear ratio: 33.353 -45 meas.

CST wheel: 50:1 No. of teethKPinput P-65 CST 33:1 Trans.ratio motor/meas. wheel: -65 CST 39:1 No. of teethPoutput meas. wheel: P-65 CST 50:1 Controller basic settings KP--65 CST P--amplif. pressure ratio:33:1 1000 KP-65 CST I--amplif. pressure ratio: 39:1 KP-control: -65 CST 50:1 P--amplif. slip 07.00 KP-115 CST 35.00 39:1 I--amplif slip control: user--defined

HG1

054 01.588 154

User-defined gearbox St art menu

CST

HG 1

Datum: 30.03.2005 Zeit: 15:24:56 Display process data Process configuration > Semiautomatic settings Clutch pressure inspection External connections > Gearbox type setting User-defined gearbox Motor data

Autom atic

Motors released

If a gearbox is modified at the place of operation, e.g. for measuring the input speed directly on the motor shaft, the gearbox data must be adapted. For this, data of the currently set gearbox can be accepted into the user-defined gearbox and changed. After activating the gearbox under the menu item “Gearbox type setting”, the new data is applied by the control system. One user-defined gearbox can be created per drive unit.

Fig. 59:

User-defined gearbox

User--defined gearbox CST HG1 Current gearbox type: P--45 CST 33:1 Apply data: No User--defined gearbox Gear ratio: 00.000 No. of teeth input meas. wheel: Trans. ratio motor/meas. wheel: No. of teeth output meas. wheel: Controller basic settings: P--amplif. pressure ratio: 0000 I--amplif. pressure ratio: 0000 P--amplif. slip control: 00.00 I--amplif. slip control: 00.00

000 00.000 000

Automatic Current gearbox type The gearbox type selected for the drive unit.

Apply data By selecting “Yes”, the data of the currently selected gearbox type is applied in the user-defined gearbox and displayed on the screen.

Afterwards, this data can be modified.

For a description of the gearbox data, see “Gearbox type setting”, page 5.50.

5.50

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Notice!

Make sure that the correct gearbox type is set for each drive unit. The specification of an incorrect gearbox type can lead to considerable damage to the conveyor system.

E

Automatic

Menu level for CST drive unit Notice!

The gearbox data must be input exactly with all decimal places.

The basic settings of the controller may only be changed after consulting with the manufacturer. Incorrect or inexactly input data can lead to considerable damage on the conveyor system.

Motor data St art menu

CST

HG 1

Datum: 30.03.2005 Zeit: 15:24:56 Display process data Process configuration > Semiautomatic settings Clutch pressure inspection External connections > Gearbox type setting User-defined gearbox Motor data

Autom atic

Motors release d

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

tandem motor

The control system requires the exact drive motor data for executing different functions. These include functions, such as the detection of a motor startup, a motor overload or conveyor jamming.

The special setup of tandem motors is taken into account in that individual windings of such a machine can be actively set. The calculation of the total current of the drive motor is influenced by this specification (Motor current overview, page 5.28) and, with this, for example, the load sharing among the drive units.

In the case a tandem motor, two separate stator windings are mounted one after the other in a motor housing. The output shaft carries two rotor windings, accordingly, so that the sum of the drive power generated by each individual machine is available to the common shaft.

Fig. 60:

Motor data

Motor data Synchronous speed: Nominal speed: Nominal power:

CST 1500 rpm 1480 rpm 0000 kW

HG1

Automatic Synchronous speed The synchronous speed of the drive motor.

Nominal speed The nominal speed of the drive motor.

Nominal power The nominal power of the drive motor.

Doc. no.: 1999 001 009 BA 00

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5.51

Menu level for CST drive unit Local motor current Local motor current

Local motor current Input signal: .

Offset: ...

Max. value: ....

Automatic

HG1

0064 A

Motor enable

E

Motor current:

CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 61:

Input signal Offset Max. value Motor current

Remote motor current Fig. 62:

Remote motor current

Remote motor current Measuring unit: .

Connection: .

Input signal: 5...15 Hz Offset: 0000 A Max. value: 0400 A Motor current:

Automatic

CST

HG1

0065 A

Motor enable

Measuring unit Connection Input signal Offset Max. value Motor current

5.52

PMC-D CST

Menu level for CST drive unit External connections Fig. 63:

External connections

External connections CST Date: 12/04/2007 Time: 12:13:45PM

HG1

Chain tensioner > Connection/ext. units

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E

Automatic

Motor enable

In the “External connections” menu item, external units can be linked up to the system (example: chain tensioner to PMC-®R).

Chain tensioner Display of process data in the “Display process data” sub-item.

– Communication In the “Communication” menu item, settings for data exchange between the PMC-D system and external units are made.

–

Diagnosis data transmission Display of current settings

–

Interface setting Settings of the current interface

–

Log settings

–

Activate settings Activation of the changed settings

Connection/ext. units Here the system is informed of which PMC-D connection the chain tensioner is connected to.

Doc. no.: 1999 001 009 BA 00

VRSU / 08

5.53

Menu level for CST drive unit Chain tensioner Fig. 64:

Chain tensioner

Chain tensioner

CST Date: 12/04/2007 Time: 12:13:45PM

HG1

Display process data Communication >

E

Motor enable

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Automatic Display process data Fig. 65:

Display process data

Display process data Chain tensioner timeout:

CST 0017

Clamping cylinder pressure: Clamping cylinder extens.:

Automatic

HG1

00000 bar 0000 mm

Motor enable

The tensioner cylinder pressure and the path of the tensioner cylinder are displayed.

5.54

PMC-D CST

Menu level for CST drive unit Communication The “Communication” submenu provides the following settings and displays: Fig. 66:

Communication

Ext. communication CST Date: 12/04/2007 Time: 12:13:45PM

HG1

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Data transmission diagnostics Interface settings Log settings Activate settings

Automatic

Motor enable

Data transmission diagnostics Display of the values set for data transmission Interface setting Options for changing the interface Log settings Settings for data log Activate settings

Doc. no.: 1999 001 009 BA 00

VRSU / 08

5.55

Process configuration Process configuration Fig. 67:

Menu level - CST drive unit, process configuration Process configuration

CST

HA1

Process funktions on/off Prozessfunktionen aktivieren Process functions (contd.)

Motor startup recognition Clutch prefill Accelerating the conveyor Conveyor shutdown Overload settings Pressure/slip controller

Automatic

CST Process functions 1 HA1 Measured value assessment Input speed Off Cooling oil pressure Off System pressure Off Differential pressure off Oil temperature (hydraulics) Active

Motor startup recogn.

CST HA1 Time window: 05,0 s D Motor speed: > 0,95 *Synchronous speed - stable for: 01,0 s

Clutch prefill Time window: Ramp: Set pressure: - stable for: Tolerance (+,-):

CST

HA1

02,0 s 10,0 bar 01,0 s 02,0 bar

Coil test: .

Max. coil current. ....

Active Active Off Automatic

Automatik

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Motor overload Conveyor blockage Chain tensioner

E

Monitoring

Automatic Automatik

Pressure/slip control.

Pressure control P-amplific. factor: I-amplific. factor: Slip control P-amplific. factor: I-amplific. factor: Filter coefficients Clutch pressure: Input speed: Output speed: Current limit P-coil: Current limit I-coil:

Automatic

CST 01,00 . . .

01,00 01,00

HA1

Conveyor shutdown

Normal switchoff Press. Red. Rate: - max. ramp time: resid. press.: hold for:

CST

40.0 02.0 10.0 00.5

HA1

bar/s s bar s

Accelerate conveyor Time window:

CST 20,0 s

Press. Incr. rate:: HG delay: - with pressure: Max. pressure: Target slip:

04,0 bar/s 02,0 s 12,0 bar 100,0 bar 00,2 %

HA1

0,154 0,154 0,154 .. ..

Automatic

Overload settings Motor overload Time window: Motor power:

Automatic

CST

HA1

01.5 s 1.80*Nominal power

Convesor blockage -Time window: 0.15 s Motor spped: < 0.90*Syncron. speed -Modification of output speed between 2 M.wheel teeth:> 0.08*Nominal speed

In the menu tree shown in Fig. 67, all functions are summarized which allow the configuration of the control and regulation process for the selected drive unit. After selecting the “Process configuration” menu item in the start menu of the “CST drive unit” menu level, the following selection options are available: Activation/deactivation of process functions.  Process functions on/off (page 5.57).

Settings which are used to detect the startup of the drive motor.  Motor startup, page 5.60.

Specifications for prefilling the clutch.  Clutch prefill, page 5.62.

Settings for the acceleration phase of the conveyor.  Accelerating the conveyor, page 5.63.

Settings for the normal shutdown and emergency shutdown of the conveyor.  Conveyor shutdown, page 5.66.

5.56

PMC-D CST

Process configuration Overload settings Controller settings for controlling the clutch pressure and slip.  Pressure/slip controller, (page 5.68).

Fig. 68:

Process configuration

Process configuration

CST

HG1

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Process functions on/off Motor startup recognition Clutch prefill Accelerating the conveyor Heavy load startup Conveyor shutdown Pressure/slip controller

Automatic

Process functions on/off Process functions (contd.)

Some control and regulation process functions can be activated/deactivated with the input mask shown in Fig. 69. Here, a distinction is made in the mask between the evaluation of measurements, internal monitoring functions and the monitoring of additional functions which don't directly belong to the control process, e.g. the automatic tensioning of the chain.

Fig. 69:

Process functions on/off

Process functions 1 CST Measured value assessment Input speed active Cooling oil pressure active System pressure active Differential pressure active Oil temperature off Motor current winding A active Motor current winding B active Monitoring Motor overload active Conveyor blockage active Chain tensioner off

HG1

Automatic

Doc. no.: 1999 001 009 BA 00

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5.57

Process configuration

– Cooling oil pressure The clutch can no longer be protected from damage caused by insufficient pressure and, related to this, an insufficient flow rate. The cooling oil flows between the linings of the input and output side of the clutch. It serves to dissipate the heat that forms and to maintain the thin film of oil which separates the clutch linings from each other to prevent their destruction.

– System pressure If the system pressure is too low, when prefilling the clutch or accelerating the conveyor, the desired pressure values might not be reached so that the startup operation is canceled.

– Differential pressure By measuring the differential pressure, the permeability of the filter in the hydraulic circuit toward the pressure chamber of the clutch is monitored. When prefilling the clutch or breaking away the conveyor, a clogged filter can result in the desired pressure values not being reached so that the startup operation is canceled.

– Oil temperature The oil temperature of the gearbox is measured. The oil lubricates all moving parts in the gearbox, cools the clutch and is also used for pressure build-up in the clutch. If the temperature is too high, this can permanently damage the oil, which could lead to damage to the gearbox bearings and the clutch.

– Motor current Load sharing among the drive units of the conveyor system is done in automatic mode via the magnitude of the respective motor current. Therefore, automatic mode is no longer possible without measuring the motor current.Similarly, a drive machine overload can no longer be detected. The startup of the motor is then only detected by measuring the speed.

By using a tandem motor, the evaluation of a current measurement can be deactivated without there being limitations in system functionality.

5.58

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

– Input speed The input speed is set constant to the specified nominal speed of the drive motor in the software. This way, all monitoring functions which have to do with the input speed are no longer possible. The starting of the motors can only be detected via the motor current (Motor startup, page 5.61). Similarly, conveyor jamming can no longer be detected via the drop in the motor speed (Conveyor jamming, page 5.66).

E

Measurement evaluation An actively switched measurement is included in the control and regulation process sequence. This way, errors in data acquisition as well as falling short of/exceeding limit values lead to the immediate shutdown of the conveyor. In order to prevent this, some measurement evaluations can be deactivated by the operator, so that the conveyor can continue to be used in emergency operation. The control and regulation process ignores the recorded measurements in this case. The display of the measurements on the screen of the PMC-V unit is not affected by the evaluation deactivation.

By deactivating monitoring, the following functions are deactivated:

Process configuration Monitoring – Motor overload The drive motor is no longer protected from an overload by monitoring the current consumption.

– Conveyor blockage Both methods for detecting blockage, monitoring the drive speed and the detection of a speed breakdown on the drive of the gearbox are deactivated. The chain is therefore no longer protected.

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– Chain tensioner Pre-tensioning the chain is monitored by the PMC-D unit, to which the tensioner is connected. To prevent the conveyor from being shutdown due to tensioner errors, the monitoring function can be deactivated. The signaled errors are then only rated as a warning in the CST system. These warnings continue to be displayed on the PMC-V units, but are ignored by the control and regulation process. However, the time window in which the tensioning procedure must be completed, at latest, is still taken into consideration in the startup phase of the conveyor. This waiting time is added both in “Automatic” mode as well as “Semiautomatic” mode before the startup is continued with prefilling the clutches. PMC-D units, to which no tensioner is connected, ignore the selected setting.

Fig. 70:

Process functions (cont.)

Process functions 2 Monitoring PVC coil 1 .

PVC coil 2 .

Synchronize motor enable .

2nd differential pressure

XXXXXXXXXXX XXXX

Doc. no.: 1999 001 009 BA 00

VRSU / 08

CST

HG1

.

XXXXXXXXXXX XXXX

5.59

Process configuration Motor startup recognition The PMC-D units do not receive direct information about the desire of the operator to start the conveyor. The units detect this indirectly via the startup of the motors. To detect this, the current consumption of the motor must be at least 0.2 times that of its nominal current for a short period and the speed must reach a minimum value of 600 rpm. This startup recognition is fixed in the software and cannot be changed by the operator.

5.60

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

The start of the conveyor can only be continued when the startup operation of the drive motor has been completed. To detect this, a time window can be defined in the input mask shown in Fig. 72, within which the speed for the duration of the monitoring time must stably lie above the specified limit. If the speed breaks down, e.g. due to a star-delta switchover, the monitoring time starts over. If the motor does not reach the desired speed within the time window, the start operation of the conveyor is canceled with an error message.

E

Important!

A drive unit cannot be put into operation if both the motor current as well as the input speed cannot be measured by the allocated PMC-D unit.

Process configuration Fig. 71:

Motor startup

Motor speed

Synchronization number

Minimum speed Stable speed Motor started up

Stable speed

600 rpm

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E

Motor startup time window Fig. 72:

Motor startup recognition

Motor startup recognition CST HG1 Time window: 05.0 s Motor speed: > 0.95 * Synchronous speed -- stable for: 01.0 s

Automatic Time window The maximum time period in which the correct startup of the motor is checked.

Motor speed The limit over which the motor speed must lie during the monitoring time.

Motor speed stable for(monitoring time) If the motor speed lies above the specified limit within this monitoring time, it is assumed that the motor is starting up correctly.

Clutch prefill After the drive motor starts up, the pressure chamber of the clutch is prefilled up to the specified pressure. This pressure must be selected such that a non-loaded conveyor does not start moving yet.

By prefilling, all electronics and hydraulics required for clutch control are checked before the actual startup. Furthermore, the clutch is set at a working point in which mechanical tolerances are compensated.

Doc. no.: 1999 001 009 BA 00

VRSU / 08

5.61

Process configuration The prefilling operation is completed when the clutch pressure lies stably in the tolerance range of the nominal pressure specification for the specified time within the time window. If this target cannot be reached, the startup of the conveyor is canceled with an error message.

Fig. 73:

CST clutch prefill

Clutch prefill Time window: 02.0 s Ramp: ....

Set pressure: 10.0 bar -- stable for: 01.0 s Tolerance (+,--): 02.0 bar

CST

HG1

Automatic Time window The maximum time period in which the correct clutch prefilling is checked. The time window is started after the motor starts up correctly.

Set pressure The clutch pressure which is to be reached by prefilling.

Pressure stable for This monitoring time is started when the minimum pressure (nominal pressure - tolerance) is reached. If the clutch pressure remains stable in the tolerance range of the nominal pressure specification within this time, the prefilling operation is considered to be completed. If the clutch pressure lies outside of the tolerance range for a short time, the monitoring time starts over when it reenters the tolerance range.

Tolerance The maximum deviation of the clutch pressure from the specified setpoint. Within this tolerance range, the prefilling pressure is still rated as being correct. Since a P-controller is used for setting the clutch pressure, in principle, it can be ruled out that the setpoint is set exactly.

5.62

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Coil test: ....

Max. coil current: ....

Process configuration Accelerating the conveyor After prefilling the pressure chamber of the clutch, it is attempted to accelerate the conveyor. To do this, first pressure in the clutch is increased both on the head gate as well as the tail gate with a specified pressure increase rate. If a defined pressure value is reached on the head gate, the pressure rise is interrupted here for a short time. The pressure rise on the tail gate is continued, so that this can force can be introduced earlier to the chain than on the head gate, so that the chain in the bottom race can be tensioned. After the delay time has elapsed, the pressure rise on the head gate is continued. If, within this time window, the conveyor is put into motion and if the slip reaches the specified setpoint, the acceleration operation is completed successfully. Otherwise, an error message is output and the startup of the conveyor is canceled.

Fig. 74:

Prefilling the clutch, accelerating the conveyor

Clutch prefilled

Tail gate pressure curve

Head gate pressure curve

Pressure stable?

Motor started up

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E

Clutch pressure Maximum pressure

Pressure delay Prefilling pressure

Head gate delay t Time window for accelerTime window ating the conveyor for prefilling the clutch

Fig. 75:

Accelerating the conveyor

Accelerating the conveyor CST Time window: 20.0 s Press. incr. rate: 04.0 bar HG delay: 02.0 s -- with pressure: 12.0 bar Maximum pressure: 100.0 bar Target slip: 00.2 %

HG1

Automatic

Doc. no.: 1999 001 009 BA 00

VRSU / 08

5.63

Process configuration Time window The maximum time period in which it is attempted to put the conveyor into motion and to reach the specified target slip in the clutch. The time window is started after the pressure chamber of the clutch is correctly prefilled.

Pressure increase rate The speed with which the pressure is increased in the pressure chamber of the clutch.

Maximum pressure The maximum pressure which is to be set in the pressure chamber of the clutch. Once this value is reached, the pressure build-up is ended and the pressure is kept constant at this value.

Target slip Reaching this value within the time window indicates the successful acceleration of the conveyor.

Important!

The settings necessary to accelerate the conveyor do not depend on each other. If a low pressure increase rate or a long delay time is set without adjusting the time window accordingly, it is possible that the desired maximum pressure in the clutch will never be reached.

Although these values can be set individually for each drive unit, it is practical to set the same pressure increase rate on all drive units.

5.64

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Head gate delay with pressure The pressure at which the pressure rise in the clutch of the head gate is interrupted for the delay time. This value is managed as a global parameter in the CST system, i.e. it is valid for all drive units.

E

Head gate (HG) delay The time in which the pressure in the clutch of the head gate is kept constant at the specified value. This value is managed as a global parameter in the CST system, i.e. it is valid for all drive units.

Process configuration Heavy load startup When the conveyor is overloaded, you can define a few parameters here to start up the conveyor as smoothly as possible with a very high load. The heavy load startup is activated by selecting the operating mode. There, you also define the time window, after which the drives change back to the normal status of the selected operating mode (see page 5.30).

Parameters for the heavy load startup

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E

Fig. 76:

Pressure increase rate The speed with which the pressure is increased in the pressure chamber of the clutch.

See also “Accelerating the conveyor” and Fig. 74, page 5.63.

Head gate (HG) delay The time in which the pressure in the clutch of the head gate is kept constant at the specified value. This value is managed as a global parameter in the CST system, i.e. it is valid for all drive units.

See also “Accelerating the conveyor”, Fig. 74, page 5.63.

Motor overload (see overload settings on page 5.67) Conveyor blockage (see overload settings on page 5.67)

Conveyor shutdown The conveyor is stopped based on four events. For one thing, due to the normal shutdown, which is triggered by switching off the drive motors or by switching over to “Stop” mode. For another, due to three different emergency shutdowns. These are triggered when an excessively high motor current is detected, the motor speed is lower than a specified limit in a monitoring period, or when the change in drive speed exceeds a specified maximum value. Fig. 77 shows the input mask in which these four shutdown events can be configured.

Doc. no.: 1999 001 009 BA 00

VRSU / 08

5.65

Process configuration Fig. 77:

Conveyor shutdown

Conveyor shutdown Normal switch--off Press. red. rate: 40.0 bar/ s --max. ramp time: 02.0 Resid. press.: 10.0 bar hold for: 00.5 s

CST

HG1

– Pressure reduction rate The speed at which the clutch pressure is reduced until it reaches the residual pressure.

– Max. ramp time Entire time window for switching off the conveyor.

– Residual pressure The clutch pressure which is held for approx. one second before the clutch is completely released.

5.66

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Normal switch-off The dropping drive speed caused by the motor being switched off is interpreted by the PMC-D unit as a blockage at first, since the speed lies below the limit in the time window specified there. Only when the motor current is subsequently checked and current is no longer measured is a normal switch-off assumed. The clutch pressure is lowered to the residual pressure with the specified pressure reduction rate and is held there for approx. one second. Afterwards, the clutch is completely released. The enable for starting up the motors is canceled.

Thanks to this controlled lowering of the clutch pressure, the chain is relaxed slowly, which prevents the chain from jerking back.

E

Automatic

Process configuration Overload settings Fig. 78:

Overload settings

Overload settings Motor overload Time window: Motor power:

CST

HG1

01.5 s 1.80 *Nominal power

Conveyor blockage --Time : 0.15 s Motor spewindowed: 0.90 *Synchron. speed --Modification of output speed between 2 m. wheel teeth: > 0.08 * Nominal speed

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E

Automatic

Motor enable

Motor overload If a motor that exceeds the specified limit value is being measured for the duration of the time window, the motor enable is canceled and the clutch is released as quickly as possible.

– Time window The period of time in which the motor current has to be above the specified limit value in order to detect a motor overload.

– Motor current The limit value, above which the motor current must be within the time window in order to detect a motor overload.

Conveyor blockage If the motor speed drops below the limit value within the entire time window and a subsequent motor current measurement still shows a current flow, the conveyor is blocked. The motor enable is canceled and the clutch is released as quickly as possible.

– Time window The time period in which the motor speed has to be below the specified limit value in order to detect a blockage.

– Motor speed The limit value below which the motor speed has to be within the time window in order to detect a blockage.

If the output speed breaks down between the measurement of two tooth edges of the measuring wheel by more than the specified limit, this event is interpreted as a conveyor blockage. The motor enable is canceled and the clutch is released as quickly as possible.

– Modification of output speed…

This value specifies the maximal approved change in the output speed between two measuring wheel edges with reference to the rated speed of the output.

Doc. no.: 1999 001 009 BA 00

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5.67

Process configuration Pressure/slip controller The controllers for the pressure and slip settings in the CST clutch can be influenced by adjusting the amplification factors. When entering, take into account that these factors refer to the amplifications permanently allocated to each gearbox (Gearbox type settings, see page 5.50). The measuring signals required to determine the actual values are smoothened with adjustable filters. The corresponding filter coefficients can also be entered in this screen mask.

Pressure/slip controller

CST

HG1

E

Pressure/slip controller Pressure control P--amplific. factor: 01.00 I--amplific. factor: .....

Slip control P--amplific. factor: 01.00 I--amplific. factor: 01.00 Filter coefficients Clutch pressure: 0.154 Input speed: 0.154 Output speed: 0.154 Current limit, P coil: .....

Current limit, I coil: .....

Automatic

Notice!

The settings for the controller and filter coefficients may only be changed by specially trained service personnel from the manufacturer. Faulty settings can lead to considerable damage to the conveyor system.

5.68

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Fig. 79:

6

Technical data

Main dimensions

Technical data Main dimensions Housing dimensions PMC-V

Fig. 81:

Housing dimensions PMC-D

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Fig. 80:

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VRSU / 08

6.3

Pin assignment Tapped holes, rear side (all devices)

Buffer battery The installed battery allows the parameter values to be saved even if the power supply is interrupted. If the battery is discharged, the function is disturbed after restarting, but there are no safety-related consequences.

The service life of the battery is normally more than 5 years. The battery must be exchanged by service personnel.

Pin assignment Pin assignment, PMC®-V Fig. 83:

SKK24 sockets PMC®-V

Tab. 1: Pin assignment, PMC®-V Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1

Optocoupler anode

Relay contact, N/O contact: a

Relay contact, N/O contact: b

Optocoupler cathode

St2

+12 V (A)

Serial interface: RxD

Serial interface: TxD

GND

St3

+12 V (B)

Serial interface: RxD

Serial interface: TxD

GND

St4

+12 V (C)

Serial interface: RxD

Serial interface: TxD

GND

St5

Options

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

Serial interface: TxD

Serial interface: RxD

St6 St7

6.4

+12 V Input

GND Input

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

Fig. 82:

Pin assignment St8

+12 V (B)

Measurement input 1

+8.2 V

GND

St9

+12 V (C)

Measurement input 2

+8.2 V

GND

St10

+12 V (A)

Measurement input 3

+8.2 V

GND

St11

Options

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

St12

Options

The option designations correspond to the last two characters on the type designation specified on the device.

Tab. 2: Options for St5 and St11 Option

Socket

**

St5

Pin 1

Pin 2

Pin 3

St5

Profibus: a (external)

Profibus: b (external)

St11

Profibus: a (external)

Profibus: b (external)

Pin 4

St11

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

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AB

Fig. 84:

SKK24 sockets, PMC-D

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1 St2

Optocoupler anode +12 V (A) +12 V (B)

St4

+12 V (C)

St5

+12 V (C)

Relay contact N/O contact: b Serial interface: TxD Serial interface: TxD Serial interface: TxD Gate input 2 Profibus: b (internal)

Optocoupler cathode GND

St3

Relay contact N/O contact: a Serial interface: RxD Serial interface: RxD Serial interface: RxD Gate input 1 Profibus: a (internal)

St6 St7

St10

+12 V Input Measurement input 4 Measurement input 5 +12 V (C)

St11

+12 V (C)

St8 St9

St12

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Measurement input 1 Measurement input 2 Measurement input 3 Measurement input 6 Profibus: a (internal)

GND GND GND

+8.2 V

GND Input GND

+8.2 V

GND

+8.2 V

GND

+8.2 V

GND

Profibus: b (internal)

6.5

Pin assignment Fig. 85:

Pin assignment of PMC-D20/CAM

Pin 1

Pin 2

Pin 3

Pin 4

St1 St2

Optocoupler anode +12 V (A) +12 V (B)

St4

+12 V (C)

St5

+12 V (C)

Relay contact, N/O contact: b Serial interface: TxD Serial interface: TxD Serial interface: TxD Gate input 2 Profibus: b (internal)

Optocoupler cathode GND

St3

Relay contact, N/O contact: a Serial interface: RxD Serial interface: RxD Serial interface: RxD Gate input 1 Profibus: a (internal)

St7

St10

+12 V Input Measurement input 4 Measurement input 5 +12 V (C)

St11

+12 V (C)

St8

GND GND

+8.2 V

GND Input GND

+8.2 V

GND

+8.2 V

GND

+8.2 V

GND

Profibus: b (internal) CM sensor -

GND

St13

not used

St14

not used

CM sensor +

CM sensor -

GND

St15

not used

CM sensor +

CM sensor -

GND

St16

not used

CM sensor +

CM sensor -

GND

St17

not used

CM sensor +

CM sensor -

GND

St18

not used

CM sensor +

CM sensor -

GND

St19

not used

CM sensor +

CM sensor -

GND

St20

not used

CM sensor +

CM sensor -

GND

St12

6.6

GND

Measurement input 1 Measurement input 2 Measurement input 3 Measurement input 6 Profibus: a (internal) CM sensor +

St9

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

St6

E

Socket

PMC-D CST

Pin assignment Sensor/actuator terminal box pin assignments Fig. 86:

Tab. 3: Sensor/actuator terminal box pin assignments

E EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

Sensor/actuator terminal box connecting sockets

Socket

Pin1

Pin2

Pin3

Pin4

Actuator measurement

A

Coil 1 A(+)

Coil 1 B(-)

Coil 2 C(+)

Coil 2 D(-)

Servo valve

B

+12 V (D)

Measurement input 1

+8.2 V

GND

Output speed

C

+12 V (D)

Measurement input 2

+8.2 V

GND

Input speed

D

+12 V (D)

Measurement input 3

+8.2 V

GND

Differential pressure, oil filter

E

+12 V (D)

Measurement input 4

+8.2 V

GND

Cooling oil pressure

F

+12 V (D)

Measurement input 5

+8.2 V

GND

System pressure

G

+12 V (D)

Measurement input 6

+8.2 V

GND

H

+12 V (D)

Measurement input 7

+8.2 V

GND

J

+12 V (D)

Measurement input A

+8.2 V

Analog GND

K

+12 V (D)

Measurement input B

+8.2 V

Analog GND

Oil temperature, hydraulic plate

Clutch pressure

L

Temperature PT100 +

Temperature PT100

Oil temperature, clutch

M

Temperature PT100 +

Temperature PT100

Oil temperature

N

Temperature PT100 +

Temperature PT100

Oil sump Oil level

O

+12 V (D)

Measurement input 8

+8.2 V

GND

P

+12 V (D)

Measurement input 9

+8.2 V

GND

R

+12 V (D)

Measurement input 10

+8.2 V

GND

Doc. no.: 1999 001 009 BA 00

VRSU / 08

6.7

Pin assignment Electric specification of the connections of the sensor/actuator terminal box Voltage outputs The devices provide four supply voltages, 12 V (A - D), and a supply voltage, 8.2 V, for feeding external devices and sensors.

The output current is electronically limited in each case and can be individually set by the software. The 12 V (D) supply voltage is not fed externally to the PMC®-V units. The total current of all supply voltages must not exceed the following values: – Total current 12 V:

IExt_12 V = 1000 mA

– Total current 8.2 V:

IExt_8.2V = 100 mA

Power supply connection (St7) Input voltage: Current consumption (U0 = 12 V):

10.6 V = U0 = 13.2 V

– PMC-V / ABA = 430 mA + IExt_12 V = 1000 mA + IExt_8.2V = 100 mA – PMC-D / *A = 300 mA + IExt_12 V = 1000 mA + IExt_8.2V = 100 mA – PMC-D / CA = 370 mA + IExt_12 V = 250 mA (sensors/actuators of CST gearbox) + IExt_8.2V = 18 mA (sensors/actuators of CST gearbox) + IExt_12 V = 680 mA + IExt_8.2V = 82 mA Optocoupler The input is galvanically separated from the voltage supply of the device by the optocoupler. A protective circuit protects the optocoupler from being destroyed by an excessively high or incorrectly connected input voltage.

– Maximum input voltage: Ue = 13.2 V – Minimum input current: Ie min = 12 mA – Voltage drop (Ie = 12 mA): Ue = 2.1 V + Ie · 102  – Switching frequency: fmax = 100 kHz Relay contact – Type of contact: NO contact – Switching voltage: Umax = 30 V – Current intensity on contact: Imax = 0.5 A – Contact rating: Pmax = 10 W

6.8

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

– PMC-V / **A = 410 mA + IExt_12 V = 1000 mA + IExt_8.2V = 100 mA

Pin assignment Serial interface – Transmitter: The transmitter works as a constant current source with a receiver input resistance of Ri < 230 . The current Io = 18 mA is equivalent to a logical “0”. For larger input resistances, the logical “0” is allocated a voltage of Uo = 4.2 V. The input resistance should not be greater than 4.7 k.

– Uo = 4.2 V – Io = 18 mA – Receiver: The input resistance (Ri) and the associated switching threshold for detecting a logical “1” (ULmax) and a logical “0” (UHmin) can be switched by the software.

– Ri = 4.7 k E

"1"Ue < ULmax = 1.50 V EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

"0": Ue > UHmin = 2.50 V – Ri = 75  "1": Ue < ULmax = 0.45 V "0": Ue > UHmin = 0.75 V Gate input Using a transistor, the input signal is connected to the GND potential of the unit. A current monitor protects the transistor from being destroyed by interrupting the circuit at a current of I = 2.3 A after approx. 25 ms.

Profibus (internal) The connections for the Profibus network used by the PMC Drive® Control System for internal communication. The connections of the two SKK24 sockets designated with “a” or “b” are connected with each other internally. Therefore, the network cables can be connected to either of the two sockets. Similarly, the connections “a” and “b” can be exchanged within the network without impairing the functionality.

Profibus (external) The connections for an external Profibus network. The connections of the two SKK24 sockets designated with “a” or “b” are connected with each other internally. Therefore, the network cables can be connected to either of the two sockets. Similarly, the connections “a” and “b” can be exchanged within the network without impairing the functionality.

Measurement input The measurement input can be adapted to the measured signal Ue by adjusting different input resistances. Similarly, a distinction can be made between the measurement of switching, voltage and current signals. All settings are executed by the software.

– Proximity sensor (Namur) For correct evaluation, these sensors must be connected to the 8.2 V voltage supply. The falling edge, the transition from logical “1” to logical “0”, of the measured signal is evaluated.

Doc. no.: 1999 001 009 BA 00

VRSU / 08

6.9

Pin assignment – Input resistance: Ri = 1 k logical “1” Ue = 1.7 V logical “0” Ue = 1.5 V Measuring frequency f = 5 kHz – Voltage measurement Measurement area: Ue = 0 … 10 V Input resistance: Ri = 100 k, 1 k Measurement area: Ie = 0 … 20 mA Input resistance: Ri = 310  – Frequency measurement The falling edge, the transition from logical “1” to logical “0”, of the measured signal is evaluated.

Input resistance: Ri = 100 kΩ, 1 k logical “1” Ue = 1.7 V logical “0” Ue = 1.5 V Measuring frequency f = 5 kHz Measurement input A, B These measurement inputs are designed for a precise voltage measurement and are only available on a PMC-D unit with the option C (second-to-last character in the type designation specified on the device).

– Measurement area: Ue = 0 … 5 V – Input resistance: Ri = 33 k Temperature This input is designed for the direct connection of a PT100 measuring resistor. The resistor is loaded with a measuring current of 1 mA. Measurement area: -25°C 175°C

6.10

PMC-D CST

EM010401 / Caterpillar Global Mining Europe GmbH, Lünen 2012

E

– Current measurement