CAT Armored Face Conveyor PMC®-DV Drive Control System Drive control UEL (BSL) Operation & Mainten

BI622555

Translation of the original operating manual

Operating manual PMC®-D/V Drive Control System Drive control UEL (BSL) Doc. No.: 1999 001 037 BA 00

Bucyrus Europe GmbH Industriestraße 1 Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com D-44534 Lünen Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

BI622555

Translation of the original operating manual.

Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus assumes no liability for direct or indirect consequences of misprints.

We reserve the right to introduce modifications as a result of technical developments without prior notice.

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Contents

Contents 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

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

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

Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

2.4

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

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

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

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

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

3.3

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

3.4

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

3.4

4. Installation

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General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure equalization at the electronic controls . . . . . . . .

4.3 4.4

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

4.5

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

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

4.6 4.6

Maintenance of the control units . . . . . . . . . . . . . . . . . .

4.6

Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

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Contents 5. Operation Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

PMC-V keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

LEDs on the PMC-V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

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

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

5.6 5.7

Global menu level, PMC Drive control . . . . . . . . . . . . . 5.11 System selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Software/serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5.12 5.13 5.16 5.17 5.18 5.20 5.21 5.22

CM system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24 BSL system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Drive units BSL1 and BSL2 . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Process functions on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Motor overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

5.27 5.28 5.28 5.29 5.30 5.31 5.32 5.35 5.36 5.37 5.37 5.38 5.38 5.39 5.40 5.41

Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 Parameter status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Device selection, PIP diagnostics . . . . . . . . . . . . . . . . . . . .

External connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.44 5.45 5.46

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Condition Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.3

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

6.4

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

6.4

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

6.4

UEL distribution box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Splitter box PMC OS 37 SPB . . . . . . . . . . . . . . . . . . . . . .

6.9

Provider PMC-P XP Opto Ethernet . . . . . . . . . . . . . . . . 6.10 Patch cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fiber-optic device socket . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 6.13

7. For your information 7.3

Applied standards and directives . . . . . . . . . . . . . . . . . . . . .

7.3

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Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

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1

About this manual

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Before starting work

About this manual This chapter contains important information that makes 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

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.

This operating manual belongs to the PMC®-D Drive Control System for BSL with UEL gearbox.

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

According to the European Directive 94/9/EC, the components of the PMC system belong to equipment group I, category M2.

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

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

Purpose of this operating manual efficiency

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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.

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Before starting work 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. service

safety

Should you have any questions, please contact our Service Department. Our service address can be found in the chapter titled “For your information”.

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

Observe this information and follow the instructions.

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

Memorize the symbols and their meanings.

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.

Aids Excerpts of the menu structure are provided at the start of a new section to make it easier for you to see where you are in the menu structure.

Device information

Software/serial numbers

Voltage supply

The topics dealt with in the section are highlighted in yellow.

1.4

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Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

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Danger!

Text passages indicated with this symbol draw your attention to impending danger. Possible consequences are very serious injury or even death.

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Before starting work J 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

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

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Before starting work

1.6

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Your safety

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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 are intended to help you avoid hazardous situations and 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.

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.

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

use outside the EU

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

accident prevention regulations

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

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use within the EU

Observe the safety and accident prevention regulations of the following parties: J of the mining company, J of the mines inspectorate and J 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 device. 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 only by service personnel of the manufacturer.

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Operating conditions Operating conditions Intended use The PMC system has been developed and manufactured to control underground systems.

This PMC system is configured for the control of drives.

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.

Bucyrus Europe GmbH assumes no liability for damage caused by unauthorized use.

These include: J adequate and consistent ventilation J water spraying system

If the firedamp concentration in the free cross-section of the parts of the face which are continuously ventilated reaches a percentage of the lower explosion limit (LEL) defined by applicable national legislation, the M2 device must be switched off.

Important!

The voltage of the supply cable and control system cable must be switched off if the local gas concentration in the areas around the mining equipment exceeds the parameters permitted in accordance with the safety regulations in coal mines.

It may only be switched on again by authorized persons.

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 is to be stopped immediately and secured against being switched on again 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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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).

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Ambient conditions

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Basic principles Prerequisites for operation The startup of the entire PMC system is forbidden 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 operating company must meet the safety requirements or install the required safety equipment 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

M2 equipment may only be operated once the safety requirements according to DIN EN 1552 have been met. This includes: J systems preventing unauthorized starting, J startup warning systems, J safe shutdown command systems, J emergency-stop devices,

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J vacuum-cleaning equipment, Bucyrus Europe GmbH, Lünen 2011

J noise protection, J warnings

All electrical equipment required to operate the face must be designated according to the legal provisions applicable at the time when it is placed on the market.

Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

Always wear your personal protective clothing and equipment. This includes wearing ear protection since the noise emitted by the conveyor is louder than 85 dB(A).

Inform your colleagues about: J your exact location, J the work you are carrying out J 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.

Actuate the EMERGENCY STOP switch also if safety equipment, such as firedamp protection systems, breaks down.

Do not allow any limbs to become trapped between components which could move towards each other, such as conveyors and supports etc.

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Storage and transport support locking

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

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

Inform the persons involved 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 stay 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

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 devices against unauthorized and unintentional restarting before all operations.

replacing components

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

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

original parts

protective devices

2.6

Only use spare parts which meet the technical requirements. This can only be ensured by using original Bucyrus Europe GmbH spare parts. Please refer to the spare parts lists for the order numbers.

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

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

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inclined face

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Storage and transport

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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 make your day-to-day work easier.

Storage Storing the equipment corrosion protection

no direct exposure to sunlight

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dirt and moisture

storage

Components with anticorrosion protection are protected for about six months.

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

Do not remove, in particular, any plugs, temporary covers or protective caps. Use the plugs, temporary covers and protective caps 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!

After a storage period of 5 years at room temperature*, the installed battery is empty. It must then be replaced.

The battery may be replaced only above ground by personnel authorized by Bucyrus Europe GmbH. After a storage period of about two years, the system components must be checked before use to find out whether any damage has been caused by the storage.

Seals, hose lines and lines are subject to natural aging even if they are stored properly. Do not use these components any more.

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 when placing them in storage.

* Deviating temperatures reduce the service life of the battery.

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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: J dimensions and J weights

The computers and interfaces of the PMC system which belong to the same operating point can be transported in the same transport container. However, you must make sure that they are not packed together with heavy and/or sharp-edged materials to avoid damage to displays, keyboards, cables and plug-type connections.

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

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 do not damage the displays and keyboard protective covers. This is usually done by Bucyrus personnel before dispatch via air freight.

Caution!

Make sure that the vent screws are closed before starting up the control units so that the electronic components are protected from dirt, moisture and firedamp (intrinsically safe).

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Caution!

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

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Equipment which can be damaged by strong magnetic fields must not be transported by magnet cranes. This applies, for example, to electronic devices and cylinders with reed rods for stroke measurement.

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Installation

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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 Bucyrus Europe GmbH.

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

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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.

J PMC-D control unit with 7-segment display J visualization device PMC-V with monitor and keypad J sensor/actuator connection box J retaining strip J line for the connection between the control unit PMC -D and the

sensor/actuator connection box Fig. 1:

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General notes

Pressure equalization at the electronic controls The controls must be vented on site after installation and transport.

There is a vent screw for this purpose on the side of the housing (Fig. 3).

. Open the screw to equalize the pressure and close it again afterwards (by hand).

Notice!

All controls have a vent screw (hex. socket, 4 mm width across flats), which must be loosened a few turns at the place of operation in order to equalize the pressure between the ambient air and the air inside the housing.

When the pressure is equalized, you can tell this by a hissing noise.

Fig. 3:

Vent screw on PMC-V

Notice!

If this ventilation is not done, the keypad protective cover and the keypad could be damaged.

When transporting to low depths, the keypad can also malfunction, since the keypad protective cover is pressed onto the keypad switches.

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PMC-V visualization device

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Fig. 2:

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Installing control units When transporting by air, this screw is loosened before shipping to ensure that the described pressure equalization occurs during the flight (great altitude difference).

Caution!

The vent screw must be screwed in by hand after transport to avoid contamination by dust and moisture and ensure firedamp protection (intrinsically safe).

Tighten the screw only by hand. Higher torques can destroy the O-ring seal behind.

Installing control units

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retaining strip

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

On this retaining 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 retaining strip is equipped with two captive mounted screws (M10 thread) for fastening to the control units. The screws are constructed so that when they are screwed into the control unit, the hose lines held on the retaining 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 retaining strip and those of the control units must be protected from contamination.

fastening via the retaining strip

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

Using these screws and the corresponding spacer sleeves, the retaining 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 retaining strip is only recommended when the control unit is not subject to constant vibrations.

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. In this case, the retaining strip is connected to the control unit only. Likewise, in order to disconnect the hose lines from the control unit, only the screws on the retaining strip have to be released. The retaining 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 retaining strip and two points on the rear side of the control unit. In addition, the device should be mounted on vibration dampers.

protective housing

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

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Maintenance of the control units 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. 4:

PMC data stick

Installing Profibus connections

To connect devices of the PMC Drive Control System to Profibus, special hose lines are supplied by Bucyrus, 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 Bucyrus. 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.

Maintenance of the control units Use only suitable tools for maintenance work. The PMC-D and PMC-V are generally maintenance-free. To ensure safe, reliable operation, you should occasionally clean the display screen and the keypad. If the keypad protective cover is defective, you should immediately remove the device and replace the keypad protective cover with a new one above ground to avoid any soiling of the switching contacts.

Notice!

Dirty contacts can lead to malfunctions.

4.6

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

Important!

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

Other lines will lead to communication failure.

E

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.

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Maintenance of the control units Replacing the battery The buffer battery of a control unit of the PMC system lasts for 5 years at room temperature*. Please schedule the replacement of the battery before this time expires, since otherwise parameter values and position data could be lost unexpectedly.

The battery may be replaced only above ground by personnel authorized by Bucyrus Europe GmbH.

Bucyrus Europe GmbH, Lünen 2011

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Notice!

If the power supply from the buffer battery fails, parameter values are replaced by default values and some calculated values (such as position data) are lost. If you modified any parameter values, you will then need to enter them again.

Have the battery replaced in good time so that this does not happen during operation.

* Deviating temperatures reduce the service life of the battery.

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Maintenance of the control units

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PMC-D/V drive control UEL (BSL)

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5

Operation

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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.

Important!

All specifications for parameters and values given in this chapter are examples only.

Basic principles Structure of the PMC Drive Control System

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The PMC Drive Control System is designed as a distributed system. Data is exchanged between the devices 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.

There are two basic devices available for the system setup.

J The PMC-V device (V = Visualization) serves as a display and operating unit for all control systems connected to the Profibus line.

J Each PMC-D device (D = Drive) takes over a specific control task. For example, in the case of a conveyor's gearboxes, a PMC-D device is allocated to each drive unit.

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

The inputs and outputs (I/O) on the PMC-V can be used by the basic devices (e.g. motor enable, motor currents).

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

Here, operation is possible from any PMC-V device 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 devices. On the third level, functions are stored which apply to a directly activated device within the higher-ordered system.

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 highlighted in reverse video (light text on dark background; see Fig. 6).

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 device. If no device has been directly activated, the field will display the name of the PMC-V device being used for operation.

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Basic principles Fig. 5:

Levels of the menu tree Global functions

G1

BSL system

Visualization

CM system

V1

Gn

BSL1

Vn

BSL2

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

Screen mask structure Menu level or system name

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 the date/time

System-specific information

5.4

Status information

PMC-D/V drive control UEL (BSL)

E

Name of the screen mask

Bucyrus Europe GmbH, Lünen 2011

Fig. 6:

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PMC-V keypad PMC-V keypad The keypad of a PMC-V visualization device is shown in Fig. 7. See page 5.5. An LED is allocated to each of the 24 keys, which lights up when the keys are correctly pressed. The keypad is for navigating through the menu tree provided on the screen, for inputting numeric values and for directly activating special functions.

The desired selection is made in the menu using the “up” and “down” arrow keys. The selected menu item is shown highlighted on the screen.

Keypad of the PMC-V visualization device

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Fig. 7:

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

Pressing the “Cancel” key takes you to the mask from which the current mask was called. Changes in the current mask are ignored.

The entry of a numeric 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, you can jump from any screen mask directly to the beginning of the active menu level.

With this key, you 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.

...

...

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On the PMC Drive Control System, only numeric values are expected as input. This applies, for example, to the entry of setpoints 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.

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LEDs on the PMC-V Some keys on the keypad are assigned two functions. 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.

+

By pressing the “Shift” key together with the “left” or “right” arrow key, you can switch between different end devices on the local level. This gives you quick access to the same screen mask on a different device, without going all the way through the menu structure.

+

One green, one yellow and one red LED are arranged below the screen of the PMC-V visualization device. They signal different types of messages. When messages rated as warnings are entered on the message list, 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 device is connected to its operating voltage.

Fig. 8:

Meaning of the LEDs on the PMC-V

Errors need to be acknowledged Warnings are present Operating voltage is present

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.

5.6

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

LEDs

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LEDs on the PMC-V

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LEDs on the PMC-V Defined key functions Direct activation of system messages Fig. 9:

Menu tree for system messages (“Caution” key) F1: Acknowledge message

All systems

F2: Acknowledge device message

Visualization

F3: System selection

System messages

Condition Monitoring

Beam stage loader (BSL)

E

All messages

Bucyrus Europe GmbH, Lünen 2011

F4: Select message type

Errors only

Warnings only

Information only

Pressing the key shown at the left (“Caution” symbol) takes you from any screen mask to the list with the system messages. This list displays all messages of the PMC Drive Control System irrespective of which device generated the message. A distinction is made between error messages, warnings and information.

You can use the “F1” key to acknowledge general messages.

You can use the “F2” key to acknowledge device messages (on the local level).

+

You can use the key combination “Shift” + “F2” to acknowledge all messages from all devices.

Press the “F3” key to go to the messages for individual systems.

You can use the “F4“ key to restrict the selection of messages to various message types.

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LEDs on the PMC-V 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 brought up for the individual short messages. Fig. 9 (page 5.7) shows the menu tree available within the system message display.

When “System messages” is selected, the mask shown in Fig. 10 appears with the messages matching the selection criteria (filter) last activated (see also Fig. 12). In the bottom line on the screen, the selection criteria for the displayed messages are given.

Fig. 10: System messages

F1:Ackn. message F3: Select system All systems

F2:Ackn. device mess.

F4: Select msg type All messages

In the shown example, “All messages” of “All systems” are shown in the mask.

J 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”.

J Source

The name of the generator of the message is specified here. If this is a PMC-D device, the name is extended with a short designation for the system.

J 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 device must be selected and then the corresponding function key pressed. Pressing “Shift” + “F2” acknowledges all messages of all devices.

If you select a line and then press the “Enter” key, a new screen mask appears with one message.

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PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

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System messages Global Local V3 No. Source Short description 125F BSL1 Cooling oil temperature too high 245F BSL1 System pressure too low 045I V1 Communication V1 activated

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LEDs on the PMC-V Fig. 11: Detailed message description

System message No. Type Source 125 Error BSL1

Global Local V3 Cancel 03/29/05 Yes 13:34:45

Maximum cooling oil temperature exceeded.

All systems

All messages

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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

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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. There are two screen masks, accessed via the function keys F3 and F4, which can be used to make this selection.

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LEDs on the PMC-V Fig. 12: Filtering system messages (“Caution” key) All systems

Visualization

F3: System selection

Condition Monitoring

Beam stage loader (BSL)

All messages

Errors only

Warnings only

Information only

The selections made via these two menu items are retained in the local PMC-V device 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.

Direct activation of language change and units of measurement The language used for the text output on the screen can be locally changed at any time on the PMC-V device 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. You can also switch between metric units of measurement (SI) and imperial units of measurement (U.S. customary units).

5.10

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

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F4: Select message type

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Global menu level, PMC Drive control Global menu level, PMC Drive control Fig. 13: Global menu level and level of the control systems CM system

Device selection

Process overview

Drive unit selection

System selection

BSL system

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System configuration

Select operating mode

Parameter status

Profibus diagnostics

Visualization

Device selection

Device information

Software/ serial numbers

Parameter status

Display settings

Voltage supply

Setting the date/time

Fig. 13 shows the menu tree containing the functions which can be activated on the global level of the PMC Drive Control System. The column on the left (the start screen) contains all functions which are independent of the implemented control systems and of the specific functions of the PMC-V devices. Every time a PMC-V device is switched on, the start menu of this menu tree is displayed (the yellow fields).

The start menu offers the following selection options: J System selection (selection of a subordinate system),

page 5.12.

J System configuration (display and modification of the configura-

tion of a subordinate system), page 5.13.

J Profibus diagnostics (diagnosis of the internal Profibus),

page 5.16.

J Device information (information regarding the structure and

software version of the individual devices), page 5.17.

J Display settings (modification of the display screen settings on

the PMC-V device currently being used), page 5.21.

J Setting the date/time (setting the date and time for the

PMC Drive Control System), page 5.22.

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Global menu level, PMC Drive control System selection Fig. 14: Global menu level, system selection CM system

System selection

System configuration

BSL system

Visualization

Profibus diagnostics

Device information

Setting the date/time

A selection list appears containing the subordinate systems available locally.

J CM system (diagnostics), see page 5.24 J BSL system (control), see page 5.27 J Visualization, see page 5.43

Fundamentally, at least one PMC-V device 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.

Selecting a system takes you to the next menu level. Each CM system has its own specific operating manual. The menus for the PMC-V devices (visualization) will be described later.

5.12

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

E

Display settings

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Global menu level, PMC Drive control System configuration Fig. 15: Global menu level, system configuration System selection

System configuration

Profibus diagnostics

Device information

Display settings

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Setting the date/time

For a PMC-D device, the loaded software and hardware determine which control system it belongs to. Within a control system, which typically consists of several PMC-D devices, the exact behavior of a device can depend on the installation site, however. Therefore, a PMC-D device must fundamentally be notified about the installation site. If site-dependent device 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 device. Incorrect information can lead to major damage to the controlling system.

When assigning names or installation sites, the devices are identified by their serial number. The serial number is written on the name plate of the device.

Important!

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

When system configuration is selected, a mask appears on the screen containing the information shown in Table 1. Here, all devices are displayed which are locally stored as the system configuration by the PMC-V device currently being used. The assigned name/installation site is specified in the “Conf.” column (“Configured”). 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 “Addr.” column (Profibus address). If a name or installation site has already been assigned to the devices, the designation stored in the devices is displayed in the “Found” column. Otherwise, this entry remains blank.

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Global menu level, PMC Drive control If there are other devices 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 devices already have a name or installation site, it is specified in the “Found” column.

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

If a device 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 device 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 numeric values are shown in the “CRC” column.

Type

Conf.

Found

Addr

CRC

0560040003

V

V1

V1

007

000680

0560040004

V

V2

V2

004

052677

0550090061

D-BSL

BSL1

BSL1

008

052677

0550040016

D-CM

---

---

016

002125

J Serial no.

The serial number written on the name plate of the device.

J Type

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

J Conf.

The “Configured” column contains the names stored in the currently used PMC-V device as the system configuration. If new devices were connected to the system, there are no entries in this column.

J Found

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

J Addr

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

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

J CRC

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

5.14

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

Serial no.

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Tab. 1: System configuration

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Global menu level, PMC Drive control activate configuration [F1]

delete entry [F2]

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

By pressing the “F2” key, the selected device is removed from the system configuration. The name/installation site is deleted from the “Conf.” column. After receiving the system configuration, it is not transferred to the selected device; instead, the previously valid configuration is completely deleted, so that the device 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 devices.

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

Fig. 16: Name/installation site selection

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Assign name/installation site Bucyrus Europe GmbH, Lünen 2011

HG1 HG2 TG1 TG2 HG TG V1 V2 example:

In Table 1 (page 5.14), there is no installation site yet assigned to the PMC-D device listed in the last line, which belongs to the system for controlling a conveyor with UEL gearboxes. The serial number tells the user that this device was installed as CM1.

After selecting the device and pressing the “Enter” key, a list appears displaying (among other things) up to four possible installation sites, CM1 to CM4. In this list, the user selects the short designation “CM1”, which is entered in the “Conf.” column when the “Enter” key is pressed. The selection of an installation site which does not belong to the system is rejected with an error message.

In order for this configuration to be known to the selected device 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 devices of the system are restarted.

Important!

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

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Global menu level, PMC Drive control Profibus diagnostics (internal) Fig. 17: Global menu level, Profibus diagnostics System selection

System configuration

Profibus diagnostics

Device information

Display settings

Data is exchanged between the devices of the PMC Drive Control System via a bus system in accordance with the Profibus standard.

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

Notice!

Do not connect devices to the internal Profibus which do not belong to the PMC Drive Control System, otherwise correct functioning of the control systems cannot be guaranteed.

Tab. 2: Profibus diagnostics (internal) Device

Addr

Recv. tel.

Sent tel.

Send er- Bus ror error

Timeout error

V1

021

347

322

000

000

000000002

V2

025

453

418

000

001

000000000

V6

022

348

287

000

000

000000000

CM1

023

759

243

000

002

000000001

The display of the internal Profibus diagnostics provides the following information: J Device

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

J Addr

The address with which the device can be addressed on the Profibus.

J Recv. tel.

The number of telegrams received by the device.

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Setting the date/time

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Global menu level, PMC Drive control J Sent tel.

The number of telegrams sent by the device.

J Send error

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

J 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 device is turned on.

J Timeout error

The number of expected logs which do not appear within a defined time window.

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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Important!

The error counters do not 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 Fig. 18: Global menu level, device information System selection

System configuration

Profibus diagnostics

Device information

Software/ serial numbers

Display settings

Voltage supply

Setting the date/time

When “Device information” is selected, a mask appears with further selection options (see Fig. 18).

J Software/serial numbers

Information about the software in use and the serial numbers of the subassemblies J Voltage supply

Information about the voltage supply and temperature

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Global menu level, PMC Drive control Software/serial number This menu item contains information about connected and configured devices and the software in use.

Tab. 3: Device information, software/serial numbers Device

Type

Serial no.

V1

V

0560040003

Configuration:

AFC13

CPU:

541040045

Program:

000040605

V_IO:

545040058

Date:

03/28/2011

PMU:

555040056

Time:

15:06:22

PCM:

543040053

FPGA1:

003020201

VGA:

542040046

FPGA2:

004020201

CPLD:

000000620

J Device

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

J Type

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

J Serial no.

The serial number written on the name plate of the device.

5.18

PMC-D/V drive control UEL (BSL)

E

Software ID

Bucyrus Europe GmbH, Lünen 2011

Component ser. no.

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

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

– 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 devices.

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

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

Bucyrus Europe GmbH, Lünen 2011

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

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

– PCM (PMC Profibus Com-Module) This subassembly allows communication with an external Profibus.

J 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 device computer and defines the device 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 device function using these programs.

– CPLD (Complex Programmable Logic Device) Is loaded when the devices are produced and sets functions which may not be modified. next device [Shift + F1] previous device [Shift + F2]

You can use the key combinations “Shift” + “F1” and “Shift” + “F2” to go to the next or previous device.

In the startup phase of a device, it is checked whether the existing hardware and the FPGA programs are appropriate for the desired device 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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Global menu level, PMC Drive control After a device has been started up without errors, the version number of the active program is compared with the other devices working in the same network. This check is only done between devices 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 devices and the startup of the device network in question is stopped.

Important!

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

Voltage supply Fig. 19: Global menu level, voltage supply System selection

System configuration

Device information

Software/ serial numbers

Display settings

Voltage supply

Bucyrus Europe GmbH, Lünen 2011

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Profibus diagnostics

Setting the date/time Tab. 4: Device information, voltage supply Device

Type

Serial no.

V1

V

0560040003

Measured value

Min.

Max.

Limiting current [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

8.2 V

00.0

00.0

00.0

000

3.3/5 V

OK

Temperature

00.0 °C

With the “Voltage supply” menu item, you can view the different voltages, associated current in mA and temperature allocated to the respective device.

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Global menu level, PMC Drive control Display settings Fig. 20: Global menu level, display settings System selection

System configuration

Profibus diagnostics

Device information

Display settings

Bucyrus Europe GmbH, Lünen 2011

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Setting the date/time

When you select this menu item, you can modify the following settings: J Contrast J Brightness

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.

Fig. 21: Display settings

Brightness: (L) 065

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Global menu level, PMC Drive control Setting the date/time Fig. 22: Global menu level, setting the date/time System selection

System configuration

Profibus diagnostics

Device information

Display settings

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

Tab. 5: Global menu level, setting the date/time Daylight savings time: Yes Local time:

08:03:25

Date:

03/29/2011

Time zone:

UTC +01:00

UTC = Universal Time Coordinated

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Setting the date/time

BI622555

Global menu level, PMC Drive control J Daylight savings time

If daylight savings time is used at the place of operation of the PMC Drive Control System, the display can be adapted to local time by selecting “Yes” or “No”.

J Local time, date

Setting of the current time and date.

J Local time UTC

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Here, you need to enter the constant time deviation between UTC and the local time at the place of operation.

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CM system CM system Fig. 23: System selection, CM system CM system

System selection

Device selection

BSL system

Visualization

CM1

Condition Monitoring

PIP diagnostics

CM commu. diagnostics

CM meas. diagnostics

A CM system is used to keep track of the condition of the equipment. The menu tree of the CM system guides you to a number of masks with diagnostic data for the connected system.

J Device selection

Here, you choose from the connected devices the device with the diagnostic data you are interested in.

J CM1, CM2

Selection of the function supported by the device, e.g. “Condition Monitoring”.

J Condition Monitoring

Choice of various diagnostic masks.

– PIP diagnostics – CM commu. diagnostics – CM meas. diagnostics

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CM2

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CM system Condition Monitoring Fig. 24: ... CM system, device selection, CM1, Condition Monitoring Condition Monitoring

CM1

PIP diagnostics

CM commu. diagnostics

CM meas. diagnostics

PIP diagnostics PIP diagnostics gives you information about the PMC-V's communication with the externally linked device (PMC-20). Received and sent telegrams are listed for every communication type. For any errors that have occurred, the error type is given as well.

Bucyrus Europe GmbH, Lünen 2011

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Tab. 6: ... CM system, device selection, CM1, Condition Monitoring, PIP diagnostics Comm. type Rec

Snd

Error

Serial

201

101

0301

PB internal

202

102

0302

J Serial

Communication with PMC-P (for PMC-V only) J PB internal

Routing via Profibus (for PMC-D and PMC-V) CM communication diagnostics Here, you are given statistics for internal data traffic.

Tab. 7: ... CM system ... Condition Monitoring, CM commu. diagnostics

Doc. no.: 1999 001 037 BA 00

Telegrams sent:

100

Telegrams received:

200

Send errors:

099

Receive errors:

199

Receive timeout:

000

Max. receive length:

00000

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CM system CM measured value diagnostics CM measured value diagnostics gives you information on the status of the individual sensors in the CM system as assigned to plug-in connectors and channels. The third column contains the valid parameter per channel in each case. For the meaning of the parameters and status codes, refer to the manual for the CM system being used.

Tab. 8: System selection, visualization, device selection, V1, PIP diagnostics 1.3

Parameter

Status

20

1

1

00

19

2

3

01

18

3

B

02

17

4

7

03

16

5

F

00

15

6

1

01

14

7

3

02

13

8

B

03

Bucyrus Europe GmbH, Lünen 2011

Connector Channel

E

Software ID:

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BSL system BSL system Fig. 25: System selection, BSL system

System selection

CM system

Process overview

BSL system

Drive unit selection

BSL1

Visualization

Select operating mode

BSL2

Motor/Gearbox

Parameter status

The BSL system contains all setting options and displays required for control of the BSL. The BSL system is divided into the following: E

J Process overview Bucyrus Europe GmbH, Lünen 2011

J Drive unit selection, see page 5.28 J Select operating mode, see page 5.40 J Parameter status, see page 5.41

Process overview Fig. 26: System selection, BSL system, process overview Process overview

BSL system

Drive unit selection

Select operating mode

Parameter status

The control-relevant sensor data from both drive units (if present) is specified here. It is provided as information for the user. It is not possible to enter anything here.

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BSL system Tab. 9: ... BSL system, process overview BSL1 Input speed

1480.0 rpm.

Outp. speed

0033.0 rpm

Clutch pressure

020.0 bar

2nd pressure stage

080.0 bar

System pressure

Yes

Clutch slip

002.00 %

Temp. gearbox

075.0 °C

Temp. clutch

070.0 °C

Dr. status

Stop

BSL2

You can use the arrow keys to move up and down through the lines. If there is an error, the corresponding line is highlighted. In such cases, you can use “Display process data” on the local level to view information about the error (see “Display process data”, page 5.29).

Drive selection

Process overview

BSL system

Drive unit selection

BSL1

Select operating mode

BSL2

Parameter status

Under “Drive selection” you can select a drive unit in order to view or edit its local data. The drive unit BSL1 is always present. BSL2 is optional.

Drive units BSL1 and BSL2 Fig. 28: System selection, BSL system, drive selection, BSL1 Display process data

BSL1/2

Process configuration

Clutch pressure inspection

Motor/Gearbox

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Fig. 27: System selection, BSL system, drive selection, BSL 1/2

BI622555

BSL system Here you can access the local data for the control of the selected drive unit (BSL1 or BSL2).

J Display process data

Displays data regarding the status of a sensor (see page 5.29).

J Process configuration

Takes you to further submenus for process configuration (see page 5.30).

J Clutch pressure inspection

Contains clutch pressure settings (see page 5.37).

J Motor/Gearbox

Takes you to further submenus for temperature monitoring, selection of the gearbox type and to motor data (see page 5.37).

Display process data Fig. 29: ... BSL system, drive selection, BSL1, display process data Display process data

Process configuration

Bucyrus Europe GmbH, Lünen 2011

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BSL1

Clutch pressure inspection

Motor/Gearbox

The control-relevant sensor data from the selected drive unit is specified here. It is not possible to enter anything here.

Tab. 10: ... drive selection, BSL1, display process data Input speed

1480.0 rpm.

Outp. speed

0033.0 rpm

Clutch pressure

020.0 bar

2nd pressure stage

080.0 bar

System pressure

Yes

Clutch slip

002.00 %

Temp. gearbox

075.0 °C

Temp. clutch

070.0 °C

Dr. status

Stop

If there is a special status, the corresponding line is highlighted.

You can use the arrow keys to go to that line and press “Enter” to open an additional window with information about that status. The statuses are defined. The relevant status is highlighted.

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BSL system Fig. 30: Error messages of the sensors Sensor information Sensor: output speed Wire break, short circuit Measured value: 1480.0 rpm. > Upper limit < Lower limit uninitialized set inactive Previous data

In the above example, the system is reporting a short circuit for the sensor for output speed. The relevant status is highlighted.

Process configuration Fig. 31: System selection, BSL system, drive selection, BSL1, process configuration Process functions on/off

Process configuration

Overload settings

Clutch pressure inspection

Motor overload

Motor/Gearbox

Pressure settings

BSL1

The menu tree shown in Fig. 31 summarizes all functions which allow the configuration of the control and regulation processes for the selected drive unit (path: System selection\BSL system\Drive selection\BSL1\Process configuration). After selecting the “Process configuration” menu item in the start menu of the “BSL1” menu level, the following selection options are available: J Process functions on/off

(activation and deactivation of process functions).

J Overload settings

(slippage values) J Motor overload

(overload settings for the motors) J Pressure settings

(working pressure)

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Display process data

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BSL system Process functions on/off Fig. 32: ... BSL system, drive selection, BSL1, process configuration, process functions on/off Process functions on/off

Display process data

Overload settings

Process configuration

Motor overload

Clutch pressure inspection

Pressure settings

BSL1

Motor/Gearbox

Bucyrus Europe GmbH, Lünen 2011

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In the “Process functions on/off” input mask, you can define which measured values are to be monitored and evaluated for control (Active) and which are to be ignored (OFF).

If a measured value is set to active, it 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 drives. In order to prevent this, the evaluation of some measured values can be deactivated by the operator, so that the machinery can continue to be used in emergency operation. The control and regulation process ignores the measured values in this case. The display of the measured values on the screen of the PMC-V device is not affected by the evaluation deactivation.

With the BSL1 drive unit, you have the following options to choose from: Tab. 11: ... BSL1, process configuration, process functions on/off Measurement evaluation

Selection

Input speed

Active/OFF

Clutch pressure

Active/OFF

Pressure sensor 2nd stage

Active/OFF

System pressure switch

Active/OFF

Temp. gearbox

Active/OFF

Temp. clutch

Active/OFF

J Input speed

The input speed is an essential value for the control of the gearbox. It is used to determine the speed of the conveyor. An error (e.g. sensor failure) leads to immediate shutdown of the machinery. You can switch off evaluation of the input speed temporarily in order to continue operating the machinery until the error is remedied.

J Clutch pressure

Measurement of the hydraulic pressure applied to the multi-disk clutch of the UEL gearbox.

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BSL system J Pressure sensor 2nd stage

Pressure sensor for the second reduction stage to approx.

60 bar.

J System pressure switch

Pressure switch for the 100 bar reduction. The system pressure is monitored. If there is not enough pressure available, no enable is given for the machinery.

J Temperature, gearbox

Monitoring of the gearbox temperature (oil sump) J Temperature, clutch

Monitoring of the clutch temperature (sensor near the multi-disk clutch)

Overload settings Fig. 33: ... BSL system, drive selection, BSL1, process configuration, overload settings Process functions on/off

Overload settings

Process configuration

Motor overload

Clutch pressure inspection

Pressure settings

BSL1

Motor/Gearbox

Overload detection when input speed active Detection of overload is necessary to protect the multi-disk clutch of the UEL gearbox. The system uses the values measured by the slippage sensor to detect whether there is a hard or soft blockage.

These values are compared with limits to be entered by the operator; if the limits are exceeded, the machinery is shut down.

Tab. 12: ... BSL1, process configuration, overload settings Overload detection when input speed active Max. slippage limit

30%

- permissible for

0.2 S

Min. slippage value

0.5%

- permissible for

10.0 S

Overload detection when input speed OFF Change in output speed between 2 sensor wheel teeth: >

5.32

0.08 *nominal speed

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

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Display process data

BI622555

BSL system J Max. slippage limit

If the measured slippage exceeds the set value for more than one time window, an error message appears and the control shuts down the machinery.

– permissible for Time window (e.g. 0.2 seconds) in which the control tolerates values exceeding the maximum slippage limit, without the control shutting down the machinery.

J Min. slippage limit

If the slippage is below the minimum slippage limit during overload, the machinery is operating in the permitted range.

If the slippage exceeds the minimum slippage limit but is still below the maximum slippage limit, it is tolerated for a somewhat larger time window (e.g. 10 seconds). If the measured slippage (e.g. between 5% and 30%) exceeds the time window, the control shuts down the machinery.

– permissible for Time window (e.g. 10 seconds) in which the control tolerates values exceeding the minimum slippage limit, without the control shutting down the machinery.

E

Tab. 13: Slippage limits for overload, with example values Bucyrus Europe GmbH, Lünen 2011

Slippage value

permissible for

Meaning

> 30%

0.2 S

If value exceeds limit for 0.2 seconds, the machinery shuts down

5% to 30%

10 S

If value exceeds limit for 10 seconds, the machinery shuts down

< 5%

Tolerated slippage

Examples J Assumed:

The slippage is 25%.

If the slippage does not drop below 5% within 10 seconds, the control shuts down the machinery.

J Assumed:

The slippage rises to 31% within 6 seconds.

The control shuts down the machinery if: – the slippage does not fall to less than 30% within 0.2 seconds and – does not fall below 5% within 4 seconds.

Overload detection when input speed OFF If you have set the input speed to OFF, e.g. due to a defective sensor, overload detection is carried out using the output speed.

If the change in the output speed per minute between two sensor wheel teeth is greater than x% of the nominal speed, the machinery shuts down. The default value is 8% (factor 0.08).

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BSL system Fig. 34: Window for the slippage limits, with example values t [s] A

10

B

0.2

C 5%

Slippage [%]

30%

A = absolutely impermissible slippage values B = conditionally impermissible slippage values C = conditionally permissible slippage values

J If the machinery runs into the ranges labeled A, it is shut down

without delay.

J In the 5% to 30% slippage range (B), the machinery is shut

J Normal (not conditional) operation is when there is 0% slippage.

Important!

The aforementioned values apply for the settings in the shown example (see Table 12)

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Bucyrus Europe GmbH, Lünen 2011

J Slippage of less than 5% is tolerated (no error).

E

down after 10 seconds.

BI622555

BSL system Motor overload Fig. 35: ... BSL system, drive selection, BSL1, process configuration, motor overload Process functions on/off

Display process data

Overload settings

Process configuration

Motor overload

Clutch pressure inspection

Pressure settings

BSL1

Motor/Gearbox

Bucyrus Europe GmbH, Lünen 2011

E

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 control cancels the enable signal for the motors.

Tab. 14: ... BSL1, process configuration, motor overload Motor overload Motor speed: <

0.85 *synchronous speed

- permissible for

2.0 s

J Motor speed

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

J permissible for (time window)

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

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BSL system Pressure settings Fig. 36: ... BSL system, drive selection, BSL1, process configuration, pressure settings Process functions on/off

BSL1

Display process data

Overload settings

Process configuration

Motor overload

Clutch pressure inspection

Pressure settings

Motor/Gearbox

BSL

Working pressure

34 bar

BSL1

Bucyrus Europe GmbH, Lünen 2011

Pressure settings

Automatic J Working pressure

Setting of the clutch pressure of the UEL gearbox.

The value set here provides protection from chain breaks.

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Fig. 37: Pressure settings

PMC-D/V drive control UEL (BSL)

BI622555

BSL system Clutch pressure inspection Fig. 38: ... BSL system, drive selection, BSL1, clutch pressure inspection

Display process data

Process configuration

BSL1

Clutch pressure inspection

Motor/Gearbox

Bucyrus Europe GmbH, Lünen 2011

E

Tab. 15: ... BSL system, drive selection, BSL1, clutch pressure inspection Pressure setpoint

0000.0 bar

Clutch pressure

020.0 bar

Valve, raise pressure

00.0 mA

Valve, lower pressure

00.0 mA

J Pressure setpoint

Target pressure on the clutch.

J Clutch pressure

Display value of the applied pressure.

J Valve, raise pressure

Display value of the applied pressure.

J Valve, lower pressure

Display value of the applied pressure.

Motor/gearbox Fig. 39: ... BSL system, drive selection, BSL1, motor/gearbox, temperature monitoring Display process data

Process configuration

BSL1

Clutch pressure inspection

Temperature monitoring

Motor/Gearbox

Gearbox type setting

Motor data

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BSL system Temperature monitoring Here, you can define the warning temperatures and the time window until the next warning or until shutdown for the gearbox and clutch. If the gearbox temperature reaches the warning temperature, the control shuts down the drive unit. You can then restart the machinery. However, if the temperature stays above the warning temperature after the time specified under “Next warning in”, the control will shut the drive down again.

Below these parameters, there is a note about the maximum temperature permitted. If that temperature is reached, the machinery shuts down and cannot be restarted.

Tab. 16: ... BSL1, motor/gearbox, temperature monitoring Gearbox temperature Warning at

75°C

Next warning in

30 minutes

> 90 °C: shutdown of the conveyor system Clutch temperature Warning at

75°C

Next warning in

30 minutes

Gearbox type setting Fig. 40: System selection, BSL system, drive selection, BSL1, process configuration Display process data

BSL1

Process configuration

Clutch pressure inspection

Temperature monitoring

Motor/Gearbox

Gearbox type setting

Motor data

Tab. 17: ... BSL system, drive selection, BSL1, clutch pressure inspection Gearbox type:

KP-35 UEL 16:1

Gearbox reduction

16.000

Number of teeth, output sensor 016 wheel Number of teeth, ring gear sensor wheel

024

Number of teeth, planet carrier

010

If the “Enter” key is pressed, a selection list is opened with the available Bucyrus gearboxes. You can also choose a user-defined gearbox.

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> 100 °C: shutdown of the conveyor system

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BSL system Motor data Fig. 41: System selection, BSL system, drive selection, BSL1, process configuration Display process data

Process configuration

BSL1

Clutch pressure inspection

Temperature monitoring

Motor/Gearbox

Gearbox type setting

Motor data

Fig. 42: Start menu Bucyrus Europe GmbH, Lünen 2011

E

Motor data Nominal speed Synchronous speed

BSL

BSL1

1480 rpm.

1500 rpm.

Automatic The “Set chain sprocket” menu item works the same way as described for “Gearbox type setting”.

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BSL system Select operating mode Fig. 43: System selection, BSL system, drive selection, BSL1, process configuration Process overview

Drive unit selection

BSL system

Stop Select operating mode

Automatic Inspection

Parameter status

The operating mode of the machinery can be set via the displayed selection list. From the “Select operating mode” window, press the “Enter” key to access the input mask. The operating mode must always be changed with the “Stop” operating mode as an intermediate step.

The contacts for motor enable are opened. The drive motors must be immediately shut down during running operation.

J Automatic

If there are no error messages on the system, the contacts for motor enable are closed.

J Inspection

In this mode, after the motor has started up correctly, the setpoint for the pressure in the clutch can be changed using the arrow keys on the PMC-V unit in two defined steps (clutch pressure inspection). This pressure setpoint specification is restricted to the selected drive unit. All other drives will not apply any pressure to the clutch, even while the drive machine is running.

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J Stop

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BSL system Parameter status Fig. 44: System selection, BSL system, drive selection, BSL1, process configuration Process overview

Drive unit selection

BSL system

Select operating mode

Parameter status

Bucyrus Europe GmbH, Lünen 2011

E

The functions of the machinery control system can be influenced by setting parameters. The factory settings saved when the PMC-D devices 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 to the entire control system, and local parameters, which apply to the respective drive unit. The global parameters are always stored in both PMC-D devices. For the system to function, it would be sufficient to store the local parameters only in the device to which they are allocated. This means, however, that when a device is exchanged, the changed local parameters must be input again. To avoid this, a copy of the local parameters of the other device is stored on each PMC-D device. This way, a new device can take over both the global as well as the local parameters of the device with the current parameter blocks. Table 18 shows the contents of the input mask for reconciliation of the parameters.

Tab. 18: System selection, BSL system, parameter status Identical in system

Copy from

Parameter block

Parameter status

BSL1 local

User

Yes

---

Global

Fact. set.

Yes

---

J 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 devices.

J Parameter status

Short designation for the state of the parameter block in the device 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 device was installed.

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

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BSL system J Identical in system

This column displays whether the copies of parameter blocks stored in the individual devices 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.

J Copy from

After selecting a parameter block and pressing the “Enter” key, a list is displayed (after entry of a password) in which the factory setting is offered for selection. “Factory setting” is shown in this column while the data is being transferred.

Bucyrus Europe GmbH, Lünen 2011

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Important!

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

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Visualization Visualization Fig. 45: System selection, visualization CM system

BSL system

System selection

Visualization

Device selection

Bucyrus Europe GmbH, Lünen 2011

E

Parameter status

V1

External connection

PMC-P

V2

PIP diagnostics

VCU

Connection/ ext. device

Activate end devices

Data transfer diagnostics

Communication

Interface setting

Protocol settings

Activate settings

The data recorded by the PMC-D devices and other devices is visualized in text form by PMC-V devices with a multi-line display screen. A few settings need to be entered to allow the connected devices to communicate. Diagnostics are available for any communication errors that may occur.

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Visualization Parameter status Fig. 46: System selection, visualization, parameter status CM system

BSL system

System selection

Visualization

Device selection

Parameter status

Tab. 19: System selection, visualization, parameter status Identical in system

Copy from

Parameter block

Parameter status

V1 local

User

Yes

---

V2 local

User

Yes

---

V3 local

User

No

---

Global

User

Yes

---

J Parameter block

Designation for the type of parameter block. The various local parameter blocks are named according to the installation sites of the PMC-V devices.

J Parameter status

Short designation for the state of the parameter block in the device 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 device was installed.

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

5.44

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

The factory settings saved when the devices are delivered guarantee only a basic setting. These must be adapted to the requirements at the place of operation. Adapt the settings on one device and copy the configuration to the other devices. If a device needs to be replaced, you can copy the software and the configuration from an existing device to the new device. Table 19 shows an example of the contents of the input mask for reconciliation of the parameters. In the example, you need to run a reconciliation for device V3.

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“Visualization, Parameter status” gives you a comparison of the available PMC-V devices. If there are differences in their configuration, you can reconcile the devices.

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Visualization J Identical in system

This column displays whether the copies of parameter blocks stored in the individual devices 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.

J Copy from

After selecting a parameter block and pressing the “Enter” key, a list is displayed (following password entry) in which the factory setting is offered for selection. “Factory setting” is shown in this column while the data is being transferred.

Important!

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

Device selection, PIP diagnostics Fig. 47: System selection, visualization, device selection, V1, PIP diagnostics Visualization Bucyrus Europe GmbH, Lünen 2011

E

Device selection

Parameter status

V1

External connection

V2

PIP diagnostics

PIP diagnostics gives you information about the selected PMC-V device's communication with the externally connected device. Received and sent telegrams are listed for every communication type.

For any errors that have occurred, the error type is given as well.

Tab. 20: System selection, visualization, device selection, V1, PIP diagnostics Comm. type Rec

Snd

Error

Serial

201

101

0301

PB internal

202

102

0302

J Serial

Communication with PMC-P (for PMC-V only) J PB internal

Routing via Profibus (for PMC-D and PMC-V) You can use the “F1” key to reset the counter.

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Visualization External connection Fig. 48: ... visualization, device selection, V1, external connection ...

External connection

V1

PMC-P

PIP diagnostics

VCU

Connection/ ext. device

Connection/ext. device

An input mask appears where (after entering a password) you can select the connection port on the PMC-V from a list. The same applies to the selection of the external device.

Tab. 21: ... device selection, V1, external connection, connection ext. device Connection:

St3

External device:

PMC-P

The following devices might be offered for selection: J PMC-P J CompactLogix (PM) J PMC-R plow travel J Elgor + Hansen J VCU

PMC-P A PMC-P can be used on a PMC-V to connect devices that do not directly belong to the PMC-D/V system, so-called external devices.

A PMC-P has four serial interfaces, an Ethernet interface, a USB port, and, depending on the version, an optical output (see chapter 6, page 6.4). The following devices usually communicate via a PMC-P: J PMC-R J PLC-5

Communication with customer's PLC system

5.46

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

Connection ST3 is usually used for connecting a PMC-P or a VCU. Connection ST4 is used when necessary for connecting units such as a CompLogix (PM, active power measurement) or a PMC-R for recording plow travel.

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Under “Connection/ext. device”, you can select the port (communication line) on the PMC-V to which a certain device is connected.

After entering a password, you can assign the connection and the device to each other in a list (it is not necessary for all the devices in the list to be actually present in your system). In the example given in Table 21, a PMC-P is located at connection ST3 on the PMC-V.

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Visualization J VDrive

Computer program for graphical visualization J PMC-IP for CM (Condition Monitoring)

The Ethernet interface is used for purposes such as communication with the VDrive visualization program or a PLC-5. Any number of devices can communicate with the PMC-V via Ethernet. The individual devices are identified and addressed via their IP address.

The PMC-R communicates via a serial connection. For devices a long distance away, you can use an optical connection for serial communication. In that case, a PMC-P is also needed at the remote end of the optical line to connect the end device to a serial port.

VCU A VCU device acts as an external system supplying process data to the control. You can connect the device to ST3.

The other masks work in a similar way to the one for the PMC-P.

Activate end devices

Bucyrus Europe GmbH, Lünen 2011

E

Fig. 49: ... device selection, V1, external connection, PMC-P, activate end devices.

PMC-P

Activate end devices

Data transfer diagnostics

Communication

Interface setting

Protocol settings

VCU

Activate settings

Connection/ ext. device

Here, after entering a password, you can activate or switch off end devices which have been set up.

Tab. 22: ... device selection, V1, external connection, PMC-P, activate end devices Communication with V-Drive

Active / OFF

V-BSL

Active / OFF

V-Plow

Active / OFF

PMC-R

Active / OFF

Shearer

Active / OFF

PLC

Active / OFF

PMC-IP

Active / OFF

PMC-IP communication is activated when the computer is restarted (PMC-V reset).

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Visualization Communication Fig. 50: ... device selection, V1, external connection, PMC-P, communication.

PMC-P

VCU

Connection/ ext. device

Activate end devices

Data transfer diagnostics

Communication

Interface setting

Protocol settings

Activate settings

Bucyrus Europe GmbH, Lünen 2011

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In this menu, you can run diagnostics for the data transfer to and from a PMC-P connected to ST3 (Table 23). You can also change the settings for the interface (Table 24) and for the communication protocol (Table 25). Afterwards, you must activate the settings (Table 26).

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PMC-D/V drive control UEL (BSL)

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Visualization Data transfer diagnostics Information on communication between the PMC-V and the connected device (PMC-P) is displayed here.

Tab. 23: ... PMC-P, communication, data transfer diagnostics External device:

PMC-P

Connection:

St3

Protocol:

ACD active

Sent teleg

824

Send errors

001

Recv. tel.

675

Receive err.

003

Unkn. tel.

000

Snd repeat

000

Shear.

Cu.PLC

Roof

VDrive

437

398

745

198

Recv. tel.

Bucyrus Europe GmbH, Lünen 2011

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Important!

The counters only go up to three digits. After 999 the counters start again at zero.

J Sent teleg

Telegrams that the external device has sent to its peripherals.

J Recv. tel.

Telegrams that the external device has received from its peripherals.

J Unkn. tel

The received telegram cannot be assigned.

J Send errors

An error has occurred while sending to the peripherals.

J Receive err.

An error has occurred while receiving from the peripherals.

J Snd repeat

The telegram is sent again, for example because no response was received.

J Recv. tel. Shearer

Telegrams received from shearer mining equipment.

J Recv. tel. Cu.PLC

Telegrams received from the PLC of a third-party manufacturer.

J Recv. tel. Roof

Telegrams received from the face (PMC-R).

J Recv. tel. VDrive

Telegrams received from the VDrive visualization program.

Important!

The statistics are displayed only when the external device is active (see Table 26 on page 5.51).

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Visualization Interface setting This mask gives you the option of changing the protocol settings for communication between PMC-V and PMC-P. Tab. 24: ... PMC-P, communication, interface setting External device:

PMC-P

Connection:

St3

Transmission rate:

115200 baud

- setting:

Manual

Data bits:

8

Stop bits:

1

Parity:

Even

When you select a setting, you are first asked to enter a password, then a list appears with possible values: J Transmission rate

Auto. or Manual Auto: the transmission rate is set automatically Manual: default setting; the set transmission rate is used J Data bits

7 or 8 J Stop bits

1 or 2 J Parity

Even, uneven, none, set or not set Protocol settings Here, you can select the communication protocol and define delay times.

Tab. 25: ... PMC-P, communication, protocol settings

5.50

External device:

PMC-P

Connection:

St3

Protocol:

ACD active

Acknowledgement delay time:

200 msec

- setting:

AUTO

Character delay time

050 msec

- setting:

Manual

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

J - setting

E

9600 to 115200 baud

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Visualization When you select a setting, you are first asked to enter a password, then a list appears with possible values: J Protocol

– ACD active – ACD passive – 3964R high prior – 3964R low prior – DF1 master – Packet ACD J Acknowledgement delay time

Any three digit number can be entered (number of milliseconds) – setting Auto. or Manual Auto: the delay time is set automatically relative to the transmission rate Manual: default setting; the set delay time is used J Character delay time Bucyrus Europe GmbH, Lünen 2011

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Any three digit number can be entered (number of milliseconds) – setting Auto. or Manual Auto: the delay time is set automatically relative to the transmission rate Manual: default setting; the set delay time is used Activate settings Upon connection of the configuration settings, you can activate the settings here by restarting the PMC-V. Tab. 26: ... PMC-P, communication, activate settings External device:

PMC-P

Connection:

St3

Status:

Active

Pressing the “F1” key triggers a restart of the selected device (PMC-V). This activates all modified settings.

Under “Status”, you can activate the PMC-P. You are first asked to enter a password, then a list appears with the entries “Free” and “Active”.

Important!

Only devices set to “Active” can send and receive telegrams (see Table 23).

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5.51

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Visualization

5.52

PMC-D/V drive control UEL (BSL)

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6

Technical data

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Main dimensions

Technical data Main dimensions

Bucyrus Europe GmbH, Lünen 2011

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Fig. 51: Housing dimensions PMC-V

Fig. 52: Housing dimensions PMC-D

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6.3

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Pin assignment Fig. 53: Tapped holes, rear side (all devices)

Important!

Note the battery information given in chapter 4.

Pin assignment Pin assignment, PMC-V Fig. 54: SKK24 sockets, PMC-V

Tab. 27: 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)

St6

6.4

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

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.

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Buffer battery

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Pin assignment St7

+12 V Input

Serial interface: TxD

Serial interface: RxD

GND Input

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

Option

Socket

**

St5

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

Pin 1

Pin 2

Pin 3

St5

Profibus: a (external)

Profibus: b (external)

St11

Profibus: a (external)

Profibus: b (external)

Pin 4

St11

Bucyrus Europe GmbH, Lünen 2011

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AB

Fig. 55: 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

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)

Profibus: b (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

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Pin assignment Fig. 56: Pin assignment of PMC-D20/CAM

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)

St7

St10

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

St11

+12 V (C)

St8

E

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

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

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

St9

St12

6.6

GND

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

St6

GND

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UEL distribution box UEL distribution box Fig. 57: UEL distribution box 3 3

3

3

2

1 4

1 = metal flag for fastening 2 = cover with seal 3 = screwed cable gland, M 16X1.5 4-8MM 4 = screw-in socket SKK 212M

Bucyrus Europe GmbH, Lünen 2011

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The UEL distribution box is both for connecting the NAMUR sensors for recording plow travel and slippage, as well as for connecting the temperature sensors PT100 and PPT100.

The splitter box is connected via the SKK212 connection. (for terminal diagram, see next page) On the control devices PMC-D/** and PMC-D20/***, either the splitter box of type PMC OS-37 SPB or the junction box (CST gearbox) can be connected via a 37-pin line (Item L7). Up to 2 valves and up to 15 sensors can be connected to the splitter box via 2 distribution boxes, which are sealed according to IP54 in acc. with IEC 60529.

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UEL distribution box

Bucyrus Europe GmbH, Lünen 2011

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Fig. 58: Terminal diagram of the distribution box

Terminals SKK212 1 white 2 brown 3 green 4 yellow 5 gray 6 pink 11 orange 12 transparent 9 black 10 violet 7 blue 8 rot

6.8

Terminal block 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Sensors blue NAMUR 1 plow travel blue NAMUR 2 plow travel blue NAMUR 1 slippage blue NAMUR 2 slippage brown PT100 green PT100 brown PT100 green PT100 brown PPT100 yellow PPT100 white PPT100 brown NAMUR 1 plow travel brown NAMUR 2 plow travel brown NAMUR 1 slippage brown NAMUR 2 slippage

PMC-D/V drive control UEL (BSL)

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Splitter box PMC OS 37 SPB Splitter box PMC OS 37 SPB Fig. 59: Splitter box

4

3 5

1

1

4 5

Bucyrus Europe GmbH, Lünen 2011

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2

1 = SKK212 connections for connecting to the adapter box 2 = OS 37 connection for connecting to PMC-D 3 = cover with labeling 4 = fastening holes 5 = notched fastening holes

The splitter box is used in the system to transmit sensor values to the control system from up to two adapter boxes via the OS 37 connection on the PMC-D. The distribution box of type PMC OS-37 SPB can be connected to the control units PMC-D/** and PMC-D20/*** via a 37-pin line. Up to 2 valves and up to 15 sensors can be connected to the distribution box via 2 distributors, which are sealed according to IP54 in acc. with IEC 60529.

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6.9

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Provider PMC-P XP Opto Ethernet Provider PMC-P XP Opto Ethernet Important!

In the event of malfunctions, the “Provider” may only be replaced with a functioning original device by trained personnel.

Return defective “Providers” to the manufacturer for repairs.

When a central control is installed underground near the face, a few functions which are required for the connection between the underground central control and the central control / visualization above ground already exist in the underground central control.

If a face, however, is operated without an underground central control, a “Provider” must be used for the fiber-optic connection to the central control above ground.

Important!

Do not make any modifications to the “Provider”. Otherwise, the approval becomes invalid.

Fig. 60:

4

7 7

4

7

4

11

8

4

Bucyrus Europe GmbH, Lünen 2011

2

E

10

1

5

5 3

6

7

9 1 2 3 4 5

connection for fiber-optic cable connection of 12 V power supply Provider el. / fiber-optic cable BIDI interfaces to PMC-R/D/V Ethernet cable between Provider and PORTUX computer

6 7 8 9 10 11

PORTUX computer PMC Opto-BIDI modules power supply board outer housing explosion-proof housing barriers

Optical data connections are installed between the PORTUX computer (6) and the BIDI input interface modules (7).

The following components are securely installed in the explosionproof housing: J PORTUX (6) J SWITCH (3) J PCB BARRIER (11)

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PMC-D/V drive control UEL (BSL)

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Provider PMC-P XP Opto Ethernet Tab. 28: Summary of connections M2

M3

M4

P1

L1

Connector type SKK24

SKK24

SKK24

SKK24

SKK24

E2000

Application

BIDI

BIDI

BIDI

12 V DC power Optical plug-in supply connector

Connection

M1

BIDI

SKK24 pin assignments M1 to M4 (M5) Pin 1: 12 V for power supply to the optocoupler Pin 2: TX (9 V @ 600R, for up to 115.2 kBd) Pin 3: RX (165 Ohm @ 5 mA, for up to 115.2 kBd) Pin 4: GND Tab. 29: Values for M1 to M5 Voltage

V0

Current

I0

DC

12.8 V 2A

The max. external capacitance and inductance can only be determined in conjunction with the power supply used.

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Connection P1 Bucyrus Europe GmbH, Lünen 2011

Tab. 30: Maximum values for P1 Voltage:

Vi

DC

12.8 V

Current

Max. Ii

Ci

2A

Internal capacitance

Max.

Internal inductance (leakage inductance)

Max.

58 nF Li

5 H

The Provider consists of an explosion-proof housing (10) installed in an “intrinsically safe” outer housing (9).

The electrical components installed in the two housings are wired with insulated single-core cables and fiber-optic cables.

The materials of the circuit boards, cable insulation, insulating plate, connector encapsulation and the cable duct comply with tracking resistance 100 (IEC60112-1).

The insulation of the intrinsically safe and non-intrinsically safe electrical circuits to the grounded parts can withstand an alternating voltage of 1500 V. A permanently legible name plate is securely fastened to the housing of protection type “i” with the following minimum specifications.

Name and address of the manufacturer Type:

PMC-P XP Opto Ethernet

Code: BVS no.: Type of protection:: Serial no.:

0158 DMT 06 ATEX E 048 I M2 EEx ib d I XXXX XX XXXX 5th and 6th places give year of manufacturing -5C to +50C

Ambient temperature: Ta

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Provider PMC-P XP Opto Ethernet The following sketch shows the wall of the Provider housing with the connections and their designations.

fiber-optic cable connection (plug-in) SKK24 connection for data transfer to PMC system

P1 M5

SKK24 voltage 12 V DC plug (additional SKK24 possible as option)

The connections M1 to M4 have the same pin assignments as the A1 connection on the PMC-R, in other words: an optocoupler is always connected with its red connecting socket.

The Provider PMC-P XP Opto Ethernet is supplied with power by an intrinsically safe power supply unit connected to the SKK24 socket (P1).

The Provider is supplied with power by its own current-limited power supply unit. PMC face or gearbox control systems or other PMC applications are connected via an optocoupler. This optocoupler is connected with its red connecting socket on the corresponding connection as defined in the system drawing.

Important!

The Provider can only be operated together with a higherordered control system. Observe the operating instructions of that control system.

Only approved plugs, cables and devices which are defined in a higher-ordered control system may be connected to the connectors of the Provider by instructed personnel.

Additional functions and applications can be found in the project drawings.

Fiber-optic cable data circuit (Line: PORTUX intern) PORTUX transmitter Module transmitter (Line: Switch) Optical transmission power Optical transmitter

max. P0 138 mW max. P0 97 mW min. -15 dBM normal -11 dBM max. -8 dBM max. P0 0.4 mW

Ambient temperature Ta

6.12

-5°C to +50°C

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

L1 M1 to M4

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Fig. 61: Sketch for the converter connections

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Provider PMC-P XP Opto Ethernet Communication The SWITCH is connected directly to the fiber-optic socket (L1) via 4 fiber-optic cables through max. 2 fiber-optic cable ducts. The fiber-optic socket is used for connection of 2 transmission connections and 2 reception connections.

The PORTUX is connected with 4 modules via 8 fiber-optic cables through max. 2 fiber-optic cable ducts. Each module has 1 fiberoptic transmission and reception connection. The fiber-optic cable data is converted to electrical signals in the modules. These signals are conveyed by each module to a connector (M1-M5) for forwarding to an optocoupler.

Patch cable To connect the Provider PMC-P XP Opto Ethernet to the mine's fiber-optic cable leading above ground, a patch cable with the corresponding fiber-optic plug-type connections is supplied. This fiberoptic cable is sheathed in a protective hydraulic hose like the SKK hose cable, in order to make it less sensitive to contamination and mechanical damage.

Bucyrus Europe GmbH, Lünen 2011

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Fig. 62: Patch cable and connector to Provider PMC-P XP Opto Ethernet

Fiber-optic device socket The device socket provides a reliable, 4-pin plug-in connection for fiber-optic patch cables. It uses 4 standard E2000 couplings, and provides a secure connection.

Fig. 63: Device socket (external side)

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Provider PMC-P XP Opto Ethernet The device socket is a housing interface for 4 fiber-optic conductors. 4 E2000 plugs are plugged in within one housing. 4 E2000 plugs can likewise be plugged in from outside. These connectors should ideally be contained in a sealed plug on a patch cable designed for mining applications.

The fiber-optic cable leading above ground (supplied by the operator) must be connected to this connection socket.

An E2000 connector and the corresponding socket are shown in the following figure (double version). The terms “right” and “left” are thus defined as follows: Fig. 64: E2000 fiber-optic connection

2 4 1 7

3

6

1 left plug 2 left coupling

5 green support sleeve 6 black support sleeve

3 right plug 7 lever for disengaging the connector 4 right coupling “Left” and “right” are from the point of view looking from the cable over the connector to the coupling.

Definition of the light direction J from the left connector (cable with green support sleeve) into

the left socket J from the right socket into the right connector (cable with black

support sleeve)

6.14

PMC-D/V drive control UEL (BSL)

Bucyrus Europe GmbH, Lünen 2011

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5

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7

For your information

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Standards and directives

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

Standards and directives Applied standards and directives Tab. 31: Standards and directives, excerpt

Bucyrus Europe GmbH, Lünen 2011

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Designation

Date of issue

Title

EC Directive of the European Parliament and Council on Directive 2006/42/EC the approximation of the laws of the Member States relating to machinery EC Directive on the approximation of the laws of the MemDirective 94/9/EC ber States concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO Safety of machinery 12100-1/A1 DIN EN ISO 12100-2 Safety of machinery Petroleum products and bituminous materials DIN ISO 3733 - Determination of water content - Distillation methods Non-electrical devices for use in potentially explosive DIN EN 13463-1 atmospheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079-0 - Part0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces Underground mining machinery - Specification DIN EN 12321 for the safety requirements for armored face conveyors Equipment and components intended for use in potentially DIN EN 1710 explosive atmospheres in underground mines Mobile extracting machines at the face - Safety requireDIN EN 1552 ments for shearers and plow systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic self-advancing support Preparation of instructions DIN EN 62079 - Structuring, content and presentation DIN 2000 Quality of drinking water DIN 6789 Documentation system DIN 20043 Plug connectors for hydraulics DIN 24320 Fire-resistant hydraulic fluids DIN 24343 Maintenance and inspection list for hydraulic systems DIN 51558-1 Determination of the neutralization number DIN 51575 Determination of sulfated ash

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2006-05-17

1994-03-23 2004-04 2009-10 2004-04 2003-02 2009-07 2010-03 2007-11 2009-07 2008-08 2003-09 2010-05 2001-11 2000-10 1990-09 2003-09 2006-12 1982-02 1979-07 2011-01

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Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning forces, tightening torques and surface pressure for steel bolts Hammer head bolts Greases & solid lubricants Non-metallic surface protection Approval procedure for fire-resistant HFA fluids in mining

1985-02 1992-06 1985-02 2008-01

Bucyrus Europe GmbH, Lünen 2011

E

EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = works standard

7.4

PMC-D/V drive control UEL (BSL)