CAT Bucyrus Face control with PMC®-R for shearer operation Manual

Operating manual Face control with PMC®-R for shearer operation Doc. no.: 4007 180 010 BA 00

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

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 declines all liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications obtained by technical development without prior notice!

Bucyrus DBT Europe GmbH, Lünen 2008E

Contents

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

1.3

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

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

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

1.3 1.3 1.4

2. Your safety 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 2.4

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

3.3

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

3.3

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

3.4

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

3.4

4. Installation General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Drawing number system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressure equalization on the electronic controls . . . . . . . .

4.3 4.3 4.4

Drawings as assembly aids . . . . . . . . . . . . . . . . . . . . . .

4.5

Configuring the PMC®-P XP . . . . . . . . . . . . . . . . . . . . . . 4.17 IP address of the PMC®-P XP unknown . . . . . . . . . . . . . . .

Entering new IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IP address of the PMC®-P XP known . . . . . . . . . . . . . . . . .

Establishing a connection to the PMC®-P XP via LAN . . .

Testing a connection to PMC®-P XP . . . . . . . . . . . . . . . . .

Calling up the PMC®-P from the input prompt . . . . . . . . . .

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4.17 4.21 4.22 4.25 4.27 4.28

Contents 5. Operation Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Computer maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3 5.3 5.4

Keyboard layout of the PMC®-R shearer face . . . . . .

5.5

PMC®-R display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Standby display of the PMC®-R . . . . . . . . . . . . . . . . . . . . . .

EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display of faulty sensors or sensors that are not connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 5.8 5.8

Standard display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Loading program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 Individual PMC®-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading of the underground central control . . . . . . . . . . . .

5.12 5.15

Set-up of a network with PMC®-R . . . . . . . . . . . . . . . . . 5.17 5.23 5.25 5.27 5.28 5.29 5.30

Function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 Neighboring control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequence group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.33 5.34 5.35 5.36

PMC®-R Shearer running batch . . . . . . . . . . . . . . . . . . . 5.38 Starting and stopping the shearer running batch . . . . . . . .

5.38

Block anchorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 Block anchorage in 1:1 solution . . . . . . . . . . . . . . . . . . . . . .

5.43

Measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47 Auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the default function . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.47 5.47 5.47 5.48

System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

Incomplete network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One or several PMC®-R's are without power . . . . . . . . . . .

Control unit is defective. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The displays of all PMC®-R's are flashing . . . . . . . . . . . . .

Data connection (DÜSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19

Contents 6. Technical data Face controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

PMC®-R control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Design suitable for mining . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency stop / shield locking switch . . . . . . . . . . . . . . . .

6.4 6.4

Rear side of the PMC®-R . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Plug connections for face PMC®-R . . . . . . . . . . . . . . . . . . .

6.5

Brass retaining strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Pin assignment of the plug-type connections of the PMC®-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Control system PMC®-R . . . . . . . . . . . . . . . . . . . . . . . . .

6.9

ExPC MCU2 central computer . . . . . . . . . . . . . . . . . . . . 6.12 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keyboard accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 6.17

Provider PMC®-P XP Opto Ethernet . . . . . . . . . . . . . . . 6.18 Patch cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6.21 6.21

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Solenoid driver module PMC-SD1 . . . . . . . . . . . . . . . . . 6.23

Bucyrus DBT Europe GmbH, Lünen 2008

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24

Coding plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25 Coding plug SKK24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other coding plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intelligent coding plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 6.25 6.28

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29 Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29 Reed rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32 Cables and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34 Connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35 Double adapter SKK24 female/female . . . . . . . . . . . . . 6.36 Loading cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.37 Power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38 Double power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42 Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46 Supply adapter PM4/*** and PMC/***; ATEX . . . . . . . . . . .

Optocoupler (IA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optocoupler (IA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LD coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter type PMC id BIDI 232 . . . . . . . . . . . . . . . . . . . . .

6.46 6.47 6.48 6.49 6.52

Warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55 Beepers TB27 and TP27 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents 7. For your information 7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

North America, Canada, South America . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.5

Standards and Guidelines . . . . . . . . . . . . . . . . . . . . . . . .

7.6

Referenced national standards and guidelines . . . . . . . . .

Referenced European standards and directives . . . . . . . .

7.6 7.6

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Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Face control with PMC®-R for shearer operation

1

About this manual

Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. You will also find information about the structure of the manual and the signs and symbols 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 control system of a shield support with system components that are part of the PMC® system.

The system components of the PMC® system correspond with the European directive 94/9/EC, a group I, category M2 device in accordance with EN 50014-1997 + Revisions 1 and 2 Intrinsic safety “i” EN 50020-2002.

new operating manual

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

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category in acc. with ATEX directive

Order 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 assembly/disassembly work, J correct malfunctions, J perform daily routine work on the face, J perform maintenance work, J persons who perform repair work.

Supervisory personnel who: J initiate the activities named above, J supervise the activities named above.

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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1.3

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

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

safety

Pay special attention to the “Your safety” chapter. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

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

Try to memorize the symbols and their meanings.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to moderately serious injuries and machine damage.

Notice!

Points in the text marked with this symbol draw attention to harmful situations. 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 dangerous situations.

J Items in lists are marked with bullets.

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

. Points in the text marked in this way describe individual work

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

1.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

Warning!

These points contain information on dangerous situations.

Possible consequences are death or very serious injuries.

E

Danger!

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

2

Your safety

Personnel

Your safety This chapter provides important information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. 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 and standards in this operating manual must be applied if the PMC® system is used within the European Union (EU). If the device is used outside the EU, the directives and standards which apply in those countries must be observed.

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

Observe the safety and accident prevention regulations of the following parties: J of the mining company, J of the mines inspectorate, J of the mining supervisory authorities. additional operating manuals

Also read the operating manuals of the components required to operate the face, such as electric motors, couplings, drive frames, chain tensioning devices, conveyors, drive advance devices and block anchorages, as well as any other neighboring machines which may be affected by the control apparatus. Clarify any questions 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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2.3

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

Use the PMC® system components only as intended!

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

Bucyrus DBT Europe GmbH does not accept any liability for any damage resulting from any such unauthorized use.

Ambient conditions Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust. (see DIN EN 1710) These include:

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

Important!

The voltage of the supply cable and the cable of the control system must be switched off when the local gas concentration in the areas around the mining system exceeds the parameters permitted in accordance with the regulations of 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 affect on the safety regulations and the regulations concerning firedamp protection at the mining company.

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

Prerequisites for operation The PMC® system must not be put into service until it has been ascertained that the machine controlled by the system meets the European directive 94/9/EC and the DIN EN1710 standard.

2.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

J plow path spraying/water spraying etc.

E

J adequate and consistent ventilation,

Operating conditions 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 systems for the devices/components not included in the scope of supply of this system and/or other devices/ components required for operation. These shall be marked according to the legal provisions applicable at the time they are placed on the market.

The M2 equipment may only be operated once the safety requirements according to DIN EN 1552 have been met. These include, among other things: J systems preventing unauthorized startup, J startup warning systems, J safe lockout command systems, J EMERGENCY STOP systems, J vacuum cleaning equipment, J noise protection, J warning messages.

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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 utmost concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

Always wear personal protective equipment. This includes wearing ear protectors since the noise produced by the conveyor is greater 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.

Maintain the signaling and lighting systems in working order.

Pay attention to the acoustic and optical startup warning systems.

EMERGENCY STOP

Actuate the EMERGENCY STOP switch immediately in the event of faults or irregularities during 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.

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

Storage and transport

storage temperature

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Do not store electric components containing batteries at a temperature below 15°C.

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2.5

Operating conditions The control units of the PMC®-R system can be stored a maximum of 5 years without electrical connection. The installed buffer battery is discharged after this time. This battery must then be replaced.

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

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

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

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

use system brackets

Only use holding strips from the PMC® system as brackets. Do not damage any plug insertions or other fitting surfaces.

Installation and commissioning

inclined face

When on inclined faces, secure all components by using chains e.g. on the supports.

Dispose of implements which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

Inform the supervising personnel and the face crew about any required maintenance and repair work. Provide them with information on the intended work and its probable duration.

securing

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

Secure the conveyor against unauthorized and unintentional restarting prior to any work.

replacing components

You must shut down the conveyor and mining equipment and secure them against being switched on again before replacing any defective components.

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

2.6

original parts

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

protective devices

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

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

environmental protection

E

For the handling of oils, greases, and other chemical substances, follow the safety regulations relevant to the product.

3

Storage and transport

Storage

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

Storage

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Storing the equipment corrosion protection

Components coated with anticorrosion are protected for about six months.

avoid direct exposure to sunlight

Protect the equipment against 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 15ºC and 25ºC.

moisture and dirt

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

storage

Never store electronic equipment in the open air.

The computers should be checked after a storage period of five years since the installed battery is discharged after this amount of time. They must then be replaced. The computer should be checked and the battery replaced by Bucyrus service personnel.

The system components must be checked before use after a storage period of approximately two years to find out whether the measures taken and the type of storage have caused any damage.

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

Important!

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

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

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3.3

Transport Transport Transport containers, dimensions and weights Make sure you observe the technical data sheet. It provides you with information about: J dimensions, 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. You must make sure, however, that they are not packed together with heavy and/or sharp-edged materials to avoid damage to displays, keyboards, cables and plug-type connections.

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

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 pipes are transported underground in this way, they should be allowed to warm up to the ambient temperatures before being installed on site.

Pipe and cable connections must be protected carefully for sea transport. The devices must be packed carefully so that they are sea-proof.

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

Caution!

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

3.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

low temperatures

E

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

4

Installation

General information

Installation General information Important!

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

Install the PMC®-R system initially only under supervision of expert personnel of DBT.

Drawing number system The PMC®-R system is illustrated in drawings for the installation.

Fig. 1:

Example

4007 177 020 00 00 Without variant Project drawing Subproject system overview Project number for Lazy shearer Drawing for automation included

Bucyrus DBT Europe GmbH, Lünen 2008

E

The original drawings contain all part numbers which refer to the part lists. The drawings shown here are only intended for the general understanding. They are not construction drawings. The document numbering is based on the numbering system described above.

4007 xxx 010 BA 00 for face controller 010 corresponds to the drawing number for the support.

The documentation in the document with the number 4007 xxx 010 BA 00 is included for the drawing numbers 020 System and special shield 0y0.

For the design-specific layout, the original drawings with part lists and part numbers should be used for the precise assignment. Help for finding the individual system parts can be found in Chapter 6 of this operating manual, in which the main system parts are illustrated by means of drawings and/or pictures. In addition, technical details and operating modes are explained.

Required tools The following tools are required to install system components underground: Installation of the brass retaining strip and the PMC®-R on the brass retaining strip: 10 mm Allen key Changing a keyboard protective cover, actuating the venting screw: 4 mm Allen key Installation of SKK24 connectors: All further installations in the PMC®-R system can be performed with a sturdy screwdriver and multigrip pliers.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.3

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

Pressure equalization on 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. 2).

. 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 wrench size), which must be loosened by a few turns at the set-up location in order to equalize the pressure between the ambient air and the air inside the housing.

When the pressure is equalized, this is indicated by a hissing noise.

Vent screw for PMC®-R

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 2:

Notice!

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

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

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

Caution!

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

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

4.4

Face control with PMC®-R for shearer operation

Drawings as assembly aids Drawings as assembly aids Fig. 3:

Support 1 4

F

A

2 5

6 3 7

8

1 PMC®-R control unit 2 valve connection strip 3 valve manifold

6 reed rod, sliding canopy 7 reed rod, relay bar assembly 8 reed rod, flipper

4 rear side of the PMC®-R

A left neighboring shield F right neighboring shield

5 pressure sensor

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VRVT / 01

4.5

Drawings as assembly aids Fig. 4:

Segment shield 1 4

A

F

2

5

6 3 7 9 8

1 PMC®-R control unit 2 valve connection strip 3 valve manifold

7 reed rod, relay bar assembly 8 reed rod, flipper 9 hydraulic operating symbols

4 rear side of the PMC®-R

A left neighboring shield F right neighboring shield

5 pressure sensor 6 reed rod, sliding canopy

4.6

Face control with PMC®-R for shearer operation

Doc. no.: 4007 180 010 BA 00

VRVT / 01

F CST data

C Eickhoff shearer data D serial DF1 protocol E face data

A FO Ethernet 10 MBit B ethernet

MONOMODE 20 PC above ground 21 optocoupler

ETHERNET;ATEX 19 FO ST-ST ADAPTER

16 OHR XP box see 4007 177 090 00 00 17 PROLINX 18 converter PMC XDSL OPTO

15 barrier

17

4

d

16

8

21

5

8

3

21

4

C

15

B

B

8 8

7

6

19 A 20 18 4

4

F

E

A

11 4

9 10

1

12

4

13

2

12

11

14

13

4

Fig. 5:

14 PMC®-R drive advance device

3 OHR XP box (see drawing 4007 177 090 00 00 page 4.16) 4 power supply 5 FO Ethernet fiber-optic cable 10 MBit 6 switch Ntron 7 PMC®-P Portux 8 PMC ID BIDI RS232 coupler 9 server-O1 VCU central unit underground 10 PMC®-V 11 power adapter 12 LD coupler, type A 13 LD coupler, type B

1 VCU central unit underground 2 keyboard

Drawings as assembly aids

System drawing, sheet 1 of 3

4.7

4.8

G to the first face shield

B ethernet C Eickhoff shearer data D serial DF1 protocol E face data F CST data

19 FO ST-ST ADAPTER MONOMODE 20 PC above ground A FO Ethernet 10 MBit

17 PROLINX 18 converter PMC XDSL OPTO ETHERNET;ATEX

17

d

16

8

5

8

3

4

C

15

B

B

8 8

7

6

19 A 20 18 4

9 10

E F

A

4

11

1

12

4

2

G

12

11

14

13

4

Fig. 6:

4 power supply 5 FO Ethernet fiber-optic cable, 10-bit 6 switch Ntron 7 PMC®-P Portux 8 PMC ID BIDI RS232 coupler 9 server-O1 VCU central unit underground 10 PMC®-V 11 power adapter 12 LD coupler, type A 13 LD coupler, type B 14 PMC®-R drive advance device 15 barrier 16 OHR XP box see 4007 177 090 00 00

1 VCU central unit underground 2 keyboard 3 OHR XP box (see drawing 4007 177 090 00 00 page 4.16)

Drawings as assembly aids System drawing sheet 2 of 3

Face control with PMC®-R for shearer operation

Drawings as assembly aids Fig. 7:

System drawing, sheet 3 of 3

A 2 1

3

1

3

1

....

3

3

1

3

1

3

1 optocoupler 2 LD coupler 3 power supply A to the drive advance device * coding plug in shields with block anchorage (27K) ** coding plug in first face PMC®-R B2 (numerator) *** face pressure monitoring, return pressure **** coding plug in shields with right anchoring device OS4 on valve strip **** coding plug in shields with left anchoring device OS4 on valve strip

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.9

4.10

parameter input

A to above ground

37-p 37-pin cable between PMC®-D and CST gearbox

19 face monitoring station MK motor enable contact MV motor current measurement 4-20 mA PB Profibus

(for face computer chain)

17 Eickhoff entry station 18 PMC®-R server

14 power supply 15 OHR XP box 16 visualization computer, underground (central control)

11

8

37-p

10

PB

9

7

18

MK PB

14

17

6

MV 19

MV

13

15

A

PB 12

MK

MK

16

4 PB

PB

5

3

MK PB 2

1 37-p

Fig. 8:

5 power supply 6 distribution box 7 PMC®-V/ABA visualization, parameter input 8 PMC®-D/CA gearbox control system 9 power supply 10 CST tail gate 11 PMC®-R Chain tensioner tail gate 12 distribution box 13 PMC®-V/ABA visualization,

1 CST head gate 2 PMC®-D/CA gearbox control system 3 PMC®-V/ABA visualization, parameter input 4 distribution box

Drawings as assembly aids Gearbox control system overview, sheet 1 of 4

Face control with PMC®-R for shearer operation

Drawings as assembly aids Fig. 9:

Gearbox control system, sheet 2 of 4

A 1

4

B

3 2

MKHI

MVHI

MKHA

MVHA

5

1 PMC®-V/ABA visualization, parameter entry 2 termination plug for Profibus 3 distribution box 4 power supply 5 face monitoring station

MV motor current HG head gate TG tail gate A data to OHR XP box B 7x2x0.5 mm2 to the head gate

MK motor enable contact

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.11

Drawings as assembly aids Fig. 10: Gearbox control system, head gate, sheet 3 of 4

1

37-p

PB

2

PB 3 PB

5

A

4 B 1 CST head gate 2 PMC®-D/CA gearbox control system, head gate 3 PMC®-V/ABA visualization and parameter entry, head gate 4 power supply 5 distribution box PB Profibus A 7x2x0.5 mm2 to face monitoring station B 7x2x0.5 mm2 to the tail gate 37-p 37-pin cable between the gearbox and PMC®-D

4.12

Face control with PMC®-R for shearer operation

Drawings as assembly aids Fig. 11: Gearbox control system, tail gate, sheet 4 of 4

1

37-p

PB

2

4

3

PB

6

A

MKHI

8

5

7 5

7 PMC®-R chain tensioner, tail gate MKHI motor enable contact, tail gate PB Profibus A 7x2x0.5 mm2 to the head gate

1 2

CST tail gate PMC®-D/CA gearbox control system,

3 4 5

termination plug for Profibus PMC®-V/ABA visualization and parameter entry tail gate 37-p 37-pin cable between the gearbox and PMC®-D power supply

6

distribution box

tail gate

Doc. no.: 4007 180 010 BA 00

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4.13

Drawings as assembly aids Fig. 12: Chain tensioner

A

10

2 3

4 1

3

3

5

7

6

8

9

1 chain tensioner PMC®-R rear view 2 optocoupler 3 SKK24 double adapter female/female

7 warning lamp 8 pressure sensor 9 reed rod for chain tensioner

4 power supply 5 valve connection strip

10 PMC INTELLIGENT CODING PLUG; ATEX A to PMC®-D tail gate

6 control valves

4.14

Face control with PMC®-R for shearer operation

Doc. no.: 4007 180 010 BA 00

VRVT / 01

A to the first face shield B to the PMC®-R server

13 reed rod, shifting ram 2 14 pressure sensor, shifting ram 1 15 pressure sensor, shifting ram 2

9 backflush filter, water 10 warning lamp, advancing equipment 11 floating contact 12 reed rod, shifting ram 1

2 PMC intelligent coding plug; ATEX 3 SKK24 double adapter, female/female 4 LD coupler, type A 5 power supply A 6 valve connection strip 7 valve, advancing equipment 8 backflush filter, hydraulic system

1 PMC®-R drive advance device, rear view

15

3

4

14

13

1

12

2

3

3

3

5

7

6

10

8

11

9

16

B

Drawings as assembly aids

Fig. 13: Drive pushing device, head gate

4.15

Drawings as assembly aids Fig. 14: Data transmission OHR XP box

F

1 I 5 4

A

E

2 I

B

I 7

6

H

3

G

H H 6

6 I

I C

d

1 DSL modem (provided by OHR) 2 FO ETHERNET SWITCH NTRON 306FXE 3 PMC®-P Portux 4 clamping strip

B to Eickhoff entry station C PMC®-R data D CST data 2 E FO Ethernet (fiber-optic cable)

5 power supply 6 PMC ID BIDI232 COUPLER;CABLE GLAND 7 clamping strip

F above ground central control (provided by mining company) G Eickhoff shearer data H CABLE DSUB9F/OPEN;800LG (UV) (Cu)

A line to OHR

I LAN PATCH CABLE CAT5 L=0.5 M SHIELDED (Ethernet Cu) iex-protected cable

4.16

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP Configuring the PMC®-P XP Important!

The screen shots seen here in this description on how to configure the PMC-P XP are taken from Windows XP. This means that the windows could look different in other Windows programs.

There are two ways to set up the PMC®-P XP (1). If the device is installed underground and there is a connection to above ground, you can see into the PMC®-P XP with the PC (5) from above ground and configure the device. If there is no connection to above ground or there are line problems or the connection is not secure, the PMC®-P XP can be removed and brought above ground. The device should then be connected to a 12 V power supply (3) and be connected to the computer via the SKK24 - adapter plug (2), using a 1-Y cable (4) with tty-S0 connection with a null modem cable (4a).

In addition, a fiber-optic cable (6) must be connected to the computer via a switch (7) with an LAN cable (8). The tty s0 connection is only needed when the IP address is unknown.

Fig. 15: Sketch for the converter connections 2

8 5

6

7

4

tty s0

4A

1

tty s1

3

1 PMC®-P XP 2 SKK24 adapter - D-Sub 9 3 power-cube transfomer or DBT power supply unit, 12 V 4 Y-cable with tty s0 and tty s1 plug connection 4a null modem cable connection, serial

5 PC 6 fiber-optic cable connection via switch 7 switch 8 LAN connecting cable

Important!

The green LED lights up on the switch when there is an LAN connection (6/7/8). If this is not the case, a cross-over cable at position 8 can solve the problem.

The null modem cable is connected to the PMC®-P XP connection M1 with the SKK24-DSub 9 adapter. The configuration can be seen with the PC via this connection.

IP address of the PMC®-P XP unknown If the IP address of the PMC®-P XP is unknown, one can connect to the PMC®-P XP using hyperterminal.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.17

Configuring the PMC®-P XP Fig. 16: Windows call-up using hyperterminal

The auxiliary program “Hyperterminal” can be accessed with the mouse under “Start button/All programs/Accessories/Communication”. Click on this command. A dialog box appears “Standard telnet program” that can be closed with the “no” key.

Fig. 17: Standard confirmation

The program opens with the subwindow “Description of connection”; here you must enter a name, e.g. PMC-P. Fig. 18: Create a new connection

PMC-P

4.18

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP Confirm by pressing the “OK” button; a new window appears, “Connect with”. Select port “COM1” under “Create connection via”.

Fig. 19: Set port

Confirm the dialog box with “OK”; a new window appears, “Com1 properties” Fig. 20: Com1 properties

The connection settings are defined in this window: The following settings are defined as seen in the figure above:

Doc. no.: 4007 180 010 BA 00

J Bits per second:

115200

J Data bits:

8

J Parity:

none

VRVT / 01

4.19

Configuring the PMC®-P XP J Stop bits:

1

J Flow control:

none

Confirm with “OK”; the “PMC®-P hyperterminal” window is now accessible.

Important!

If no log-in prompt appears, pressing “Enter” can help you further.

Enter “root” as the user name into the “DBT_PMC®-P log-in” requirement. Enter “dbttux” as the password; the PMC®-P is called up.

By entering the “ifconfig” command, the current IP address is shown under “eth0”.

Fig. 21: Current IP address

The address can be used to create a network (see section: “IP address of the PMC-R known”) or a new IP address can be entered.

4.20

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP Entering new IP address The IP address is changed by entering the command “ifconfig eth0”, Fig. 22: Entering a new IP address

a “netmask”, and new mask coding, and then by confirming with “Enter”. It is, however, only valid until the next reboot.

Using the IP address that is known now, a connection via LAN and LWL lines can be made, as is described in the following section.

Thereafter, the IP address for the current reason of use is permanently set in the PMC®-P XP.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.21

Configuring the PMC®-P XP IP address of the PMC®-P XP known The “Communication” menu can be selected using the “System control” of the PC. Click on the “Start” button at the left hand bottom corner of the screen to access the “System control” link. Click on “System control” to open its corresponding window.

Fig. 23: Calling up network connections

The “Network connections” are selected from this list.

Another window opens displaying previous network connections.

Fig. 24: LAN connection

4.22

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP When the window opens, right mouse click on the “LAN connection” icon. When the pull-down menu appears, left mouse click on “Properties”. The “Properties” window now opens.

Fig. 25: LAN connection properties

a

Left mouse click on the scroll bar and drag the mouse to move the bar up and down. When scrolling down, you will see the entry “Internet protocol (TCP/IP)” which needs to be marked (see above).

Then click on the “Properties” button. Another window opens where the IP address can be entered.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.23

Configuring the PMC®-P XP Fig. 26: Internet protocol properties

The “Use following IP address” command has to be selected in this window.

Now you can assign a new, permanent IP address for the computer as seen above. In the subnetwork mask window, enter the numbers 255 into the groups; the entry is similar to the IP address of the PMC®-P. Important!

The last group of numbers in the address must differentiate for the PC and for the PMC®-P, otherwise an IP address conflict would occur and the network would not function.

Press “OK” to close the “Properties” windows.

4.24

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP Establishing a connection to the PMC®-P XP via LAN The appropriate program window is opened by calling up Internet Explorer or Mozilla. Enter the address “http://[IP address]”. For example: “http://10.158.23.233” By pressing the “Change to” button, a dialog window appears, “Establish connection to 10.158.23.233”.

Fig. 27: Establishing connection

Enter “root” for the user name and “dbttux” for the password. By pressing “OK”, the “PMC®-P homepage” is displayed.

The following categories J Status information J System maintenance J Firmware upload and info

contain the following links: Important!

If the “Establish connection to 10.158.23.233” does not appear, you must check the LAN connection (if necessary, use a different LAN cable [normal or cross-over] or change Internet Explorer/Mozilla settings).

Set the proxy setting in the Mozilla settings to “Direct connection to internet”. (Edit/Settings/More/Proxies) When using Internet Explorer, restarting the PC can help.

Status information J Show network status J Show status of PLC5 adapter J Show status of serial adapter 1 J Show status of serial adapter 2 J Show status of serial adapter 3 J Show status of serial adapter 4 J Show status of registration service

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4.25

Configuring the PMC®-P XP J Reset statistics counter

System maintenance J Change system settings J Change PMC®-P software settings J Change settings J Show system load J Reboot PMC®-P

Firmware upload and info J Firmware information J Upload firmware Fig. 28: PMC-P homepage

4.26

Face control with PMC®-R for shearer operation

Configuring the PMC®-P XP To change the IP address, select “Change system settings” under “System maintenance”: Fig. 29: System maintenance

Enter the new IP address for the PMC®-P in line “CONFIG_NET_STATISTIC_IP =”.

In line “CONFIG_NET_STATISTIC_NETMASK =” “e.g. from VCU or mining company” In line “CONFIG_NET_STATISTIC_GATEWAY =” “e.g. from VCU or mining company” Press “save” to save the new IP address and all other changes permanently. You now have to reboot the PC. See “System maintenance”: “Reboot PMC®-P”.

Testing a connection to PMC®-P XP The following can be done to test if an IP address can be called up and to see if it can answer: J Open an “Input prompt”:

– Click on “Start”/All programs/Accessories/Input prompt Alternative: “Start/Execute” – Enter “cmd” and confirm with “Enter” A “DOS” window opens; enter “ping IP address” to activate a test.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

4.27

Configuring the PMC®-P XP Fig. 30: Input prompt

4

3 1

2

3

1 = input ping with IP address 2 = 4x reply to “ping” 3 = ping statistic 4 = 4x reply, when no connection exists

A signal is sent to the IP address (here: 10.158.23.233) by pressing “Enter”; the addressed device replies. This happens four times.

Thereafter, a “Ping statistic” is displayed.

Calling up the PMC®-P from the input prompt If a connection to the PMC®-P exists, a connection can be made directly with the “telnet IP address” command.

Fig. 31: Input prompt telnet 10.158.23.233

4.28

Face control with PMC®-R for shearer operation

5

Operation

Control units

Operation Control units The system approval for the PMC® system for electrohydraulic controls also contains the PMC®-R control, among others.

Important!

Do not change any parameters or other settings before you have read the operating manuals of the PMC®-R system and the operating manuals of the machines to be controlled and the neighboring machines.

PMC®-R control unit The PMC®-R control unit is installed in a stainless steel housing and can be freely programmed for electrohydraulic tasks. It is intrinsically safe, so that it may be used in firedamp-endangered areas underground.

The keyboard can be adapted (programmed) for the various tasks.

The keyboard protective cover can be exchanged (only aboveground in potentially explosive rooms) and, thus, exchanged for covers with other key symbols according to the respective tasks.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Computer maintenance Use only suitable tools for maintenance work. In general, the PMC®-R control computer is maintenance-free. Occasionally cleaning the display contributes to operational safety. If the keyboard protective cover is defective, then the computer should be dismantled without delay and moved above ground in order to replace the keyboard protective cover with a new one, in order to avoid any soiling of the switching contacts.

Important!

Dirty contacts can lead to malfunctions.

Mounting bolts The PMC®-R computers are each screwed in place with one brass retaining strip, which, in turn, is fastened onto the shield or a control panel at an appropriate place. The PMC®-R computer has two compression springs on the rear side of the device which press against the brass retaining strip in order to support its removal during dismantling. While fastening, the computer can jam against the brass retaining strip if the mounting bolts aren't uniformly tightened.

This leads to damage to the connection contacts, both in the PMC®-R as well as the connection cable.

Important!

Always tighten mounting bolts uniformly.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

5.3

Control units The control panel The control panel consists of a keyboard, display and LEDs. Fig. 32: Example for a control panel of the PMC®-R

SAP No: 4007 004 110 04 00 SAP No: 4007 004 110 07 00 SAP No: 4007 004 110 14 00 SAP No: 4007 004 110 15 00

Plow face 1:3 Shearer face Shearer face Plow face 1:1

Covers for special applications (chain tensioner, pump control, filter control, etc.) are also available.

The row of keys below the two-row display (keys K to R) are for navigation in the program menu (see following sections).

The large mushroom-shaped buttons are protection switches. The red switch is the emergency stop switch (see the “Emergency stop” section in this chapter and the section “Emergency stop / shield locking switch” in Chapter 6 “Technical data”). The black switch is the shield locking switch with which one can protect oneself from unwanted shield movements during shield repair work (see section “Emergency stop / shield locking switch” in Chapter 6 “Technical data”).

5.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

There are various keyboard protective covers which are specifically adapted to the different control tasks. The keys can be freely allocated by the PMC®-R programmer. There are currently two standard covers for face applications:

E

An infrared sensor is located above the stop key [S], above which the so-called “jumbo LED” is located for displaying warnings and the operation of automatic functions (sequence, order, etc.).

Keyboard layout of the PMC®-R shearer face Keyboard layout of the PMC®-R shearer face In the face software, the individual keys are allocated to certain functions: Fig. 33: Foil for shearer operation

Three operating states are distinguished on the PMC®-R: J Idle mode:

– If no neighboring shield is activated, no parameters are changed and the standard display is shown (default display).

This operating mode is also referred to as no-load operation.

J Working mode:

– A neighboring shield was activated. The display shows the first menu item of the auxiliary functions (master). In working mode, one distinguishes between the master and slave. The control unit on which input is made is the master. The activated control unit is the slave.

J Input mode:

– If no neighboring shield is selected, the activated menu is displayed.

Tab. 1: Key functions of the PMC®-R Key symbol

Idle mode

Working mode

Input mode

No function

Lower shield

No function

Direct activation of GLOBAL PARAMETERS

Advance shield

No function

Display of the shield number and direct activation of service parameters

Set shield

No function

Direct activation of sequence para- Lift shield base (base lift) meters No function

Doc. no.: 4007 180 010 BA 00

No function

Retract stabilizing cylinder (lift can- No function opy)

VRVT / 01

5.5

Keyboard layout of the PMC®-R shearer face Key symbol

5.6

Idle mode

Working mode

Input mode

Activation of a group batch, left (switch direction with the P or N key)

No function

No function

Activation of a group batch, right (switch direction with the P or N key)

No function

No function

Activation of the left neighboring shield

No function

No function

Activation of the right neighboring shield

No function

No function

No function

No function

Change to the left menu column

No function

No function

Change to previous menu items

No function

No function

Change to next menu items

No function

No function

Activation of the function shown on the display

Shows the last displayed menu item

No function

Activation of the function shown on the display

No function

No function

Activation of the right menu column

Stops an automatic function

No function

No function

No function

No function

Input confirmation

Starts an automatic function

No function

No function

Activation of the 3rd right neighboring shield

Extend stabilizing cylinder (lower canopy)

No function

No function

Retract flipper

No function

Automatic positive setting

No function

Enter numeral 0

No function

Extend flipper

Enter numeral 1

No function

Retract sliding canopy

Enter numeral 2

No function

Extend sliding canopy

Enter numeral 3

No function

Pull bankpush conveyor

Enter numeral 4

Face control with PMC®-R for shearer operation

Keyboard layout of the PMC®-R shearer face Key symbol

Idle mode

Working mode

Input mode

No function

Bankpush

Enter numeral 5

No function

Push bankpush conveyor

Enter numeral 6

No function

Enter numeral 7

Cowl

No function

Enter numeral 8

Activation of the shearer running batch

No function

Enter numeral 9

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VRVT / 01

5.7

PMC®-R display PMC®-R display In the shown example, only forward movement sensors are displayed. The same applies for the pressure sensors which are listed in the top line. If no plow position is available, this is indicated on the top line in the last position by “~~~~~”.

Standby display of the PMC®-R Fig. 34: Standby display Prop pressure left/ own/right neighboring shield (in bar)

Position of the mining equipment and direction of movement

Relay bar assembly path left/own/right neighboring shield (in mm)

293

317 204 23>

325

345 316 NOM

Displays the selected mode (NOM = no mode selected)

EMERGENCY STOP Display of the EMERGENCY STOP to all PMC-Rs on the entire face. On the top line, the prop pressures and the position of the mining equipment is displayed. Below that it is indicated on which shield EMERGENCY STOP was pressed.

On the PMC-R, a list of EMERGENCY STOPS is created, ordered according to the time they occurred. If other EMERGENCY STOP buttons are pressed, the first pressed EMERGENCY STOP is always displayed first. If this is cancelled, the one that happened next is displayed.

Fig. 35: EMERGENCY STOP display EMERGENCY STOP pressed at Shield 8.

Display in the entire face

293

317 204 23>

Emergency stop No. 8

Display of faulty sensors or sensors that are not connected If a PMC®-R doesn't have a neighboring shield, NAVL (not available) is displayed at the corresponding place. The same applies for the 1:3 solution and similar variants for incomplete groups of 3 (incomplete x groups).

Fig. 36: Standby display Non-connected, defective sensors or sensors whose valve strips were switched off by support lock-out switches are represented by a tilde “~” and “?”.

5.8

No roller position available.

293

317

204 ~~~~~

~??~ ~??~ IGN NOM

Sensors ignored in the PMC®-R are indicated by IGN.

Face control with PMC®-R for shearer operation

PMC®-R display Menu structure in the PMC®-R (columns from left to right) Fig. 37: Menu structure

Menu 1.1

Menu 2.1

Menu 3.1

Menu 4.1

Menu n.1

Menu 1.2

Menu 2.2

Menu 3.2

Menu 4.2

Menu n.2

Menu 1.3

Menu 2.3

Menu 3.3

Menu 4.3

Menu n.3

Menu 1.n

Menu 2.n

Menu 3.n

Menu 4.n

Menu n.n

With the keys K (column to the left) and R (column to the right), the corresponding menu column is selected. The following list shows the menu headers.

The L and M keys scroll up and down in the menus.

Examples for menu headers Below, there are three examples for menu headers. Information about the current project can be found later in Chapter 5 of this manual.

J AUXILIARY FUNCTIONS J STATES J MEASUREMENTS (not on the server)

With the keys L (line up) and M (line down), one can navigate to the corresponding menu item and the desired function (view data, view and edit parameters ...). Passwords are required for changing parameters. There are three password levels.

J Global password J Service password J Super password

These passwords are 4-digit numbers which are input via the numerical keypad of the PMC®-R.

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5.9

Standard display Standard display 180 20

230 387

195 843

The prop pressures of the left, own, and right shields are displayed in the top line of the standard default display. The position of the mining equipment is displayed at the far right together with its status. {<<, <, =, >, >> } = {rapid direction of travel1, direction of travel1, mining equipment stationary, direction of travel2, rapid direction of travel2}.

85> NOM

The relay bar assembly values and the plowing mode or cutting mode are displayed in the bottom line.

The following sensor displays may appear: Tab. 2: Sensor displays Display in English

Display of other language

Meaning of other language

Meaning in English

----

----

Does not exist

~??~

~??~

Does not apply

NAVL

NAVL

Not available

IGN

IGN

Ignored

AT

AT

Values invalid

SC

SC

Short circuit

NC

NC

Cable break

The following displays may appear instead of sensor values: Tab. 3: Additional displays Display in English

Display of other language

>ES<

>ES<

Emergency stop on own shield

<ES>

<ES>

Emergency stop on left (F1) and right shield (A1)

>ES<

>ES<

Emergency stop on left shield (F1)

>ES<

>ES<

Emergency stop on right shield (A1)

>LC<

>LC<

Locking switch pressed on own shield

>LC<

>LC<

Locking switch pressed on left (F1) and right (A1) shield

>LC<

>LC<

Locking switch pressed on left (F1) shield

>LC<

>LC<

Locking switch pressed on right (A1) shield

>SD<

>SD<

Valve connection strip missing

= NUMERATOR yes 20 387 843 NOM

5.10

Meaning of other language

Meaning in English

The L and M keys can be used to obtain additional information about additional computer functions such as “Numerator” or “Server” and other information. The N key can be used to view the left, own or right shield. The numerator is displayed as the numerator {<=>} for all shields controlled by the corresponding controller, since the controller itself is the numerator.

Face control with PMC®-R for shearer operation

Standard display This is different with the function as blocking shield or shield with special function. In this case the function is assigned to the respective shield. < BLK shield 20 387 843

yes NOM

example:

Additional displays can appear in the bottom line if messages are pending. They are displayed one after the other by means of an internal information list and then removed from the list. If the corresponding message is still pending however, it is added to the list again and displayed. This display and the standard default display appear alternately.

The following messages, for example, are pending: J Network split J Stop

The order of the display is now in the second line: "20 387 843 NOM; SPLIT F1: x A1: y; 20 387 843 NOM; Cancel # x StopKey; 20 387 843 NOM; Each message is displayed for approximately two seconds.

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5.11

Loading program Loading program Individual PMC®-R To load the program, one requires at least the following hardware: J 1 PMC®-R J 1 voltage supply, or a plug-in power supply with 12 V DC and

SKK24 connection plug

J 1 loading cable J 1 adapter for pinning A1 to pinning C1

(parts number: 0000 006 507 93 84) BIDIR crossover

J PC or laptop Fig. 38: Connection diagram for loading the program 1

7

2 8 5

6

4

3

1 PMC®-R 2 power supply 3 replacement plug-in power supply

5 alternative connection for the power supply 6 loading cable 7 PC or laptop

4 SKK24 cable

8 adapter A1 to C1 (part number: 0000 006 507 93 84) BIDIR crossover

Beginning loading A loading program is required for loading the PMC®-R program on the PMC®-R. This program is called “bootpmc.exe”. After starting the program by double-clicking, a window appears in which the used communication channel “COM” can be clicked on.

Fig. 39: Window “Setup COM port”

If the incorrect port was selected and confirmed with OK, the “bootpmc” window appears with the error message “Port:comX is not available!!” (The connection comX with X = 1...6 is not available.)

5.12

Face control with PMC®-R for shearer operation

Loading program Fig. 40: “Bootpmc” window (error message)

If the correct port is selected, the booting program begins.

Fig. 41: Booting program window

1

2 3

6

4

5 7 9

8

10

1 clears the existing PMC®-R program

6 display of the PC connection with transmission rate, PMC®-R messages 3 display of the program found on the PC 7 connects with a diagnostics program segment for finding program data 8 display of the PC port configurations

2 starts loading the found program (see Item 10)

4 indication of the loading progress 5 display of the type of connection for the PMC®-R (OFF LINE no connection, PMC BOOTER There is a connection to the booter) 9 buffer display 10 data display

Once the data connection is OK, the program must first be deleted on the connected PMC®-R with the “Erase Application” (1) key.

Display of the PMC®-R:

0<F

1

A> 0

No Prg.: WAITING

Afterwards, click on the “Start Transmission” key.

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5.13

Loading program Fig. 42: Loading window after pressing the start key, Item 2 Fig. 41

1

2

3

1 status window 2 display of the transmitted data 3 connection status

The new program begins booting when the Start key (Item 2, Fig. 41).

The PMC®-R display shows the loading progress with the number of uploaded data packets. For better readability, the display is only refreshed every two seconds, which makes the display appear to jump.

0<F

1

A> 0

Receive 7194

0

After the loading operation, the connection status on the PC window says OFF LINE again and the PMC®-R runs through a few start and initialization steps. Once these are completed, the PMC®-R goes to the default window.

Default display This is displayed when: J no numbering has taken place on the network yet, J an unexpected coding plug has been found, J an expected coding plug was not found.

- Wrong type -

No.: * Pr.: *

5.14

0

Face control with PMC®-R for shearer operation

Loading program If no sensors are connected, ~~~ is displayed instead of measurements.

If no neighboring shield is present, the display flashes.

If no valve strip is connected, “VL” is displayed.

~~~ : VL

:

VL

No.: : Pr.: :

0

A PMC®-R loaded with the correct program can now be taken underground and connected to the chain of the face PMC®-R. The program is loaded onto the face PMC®-R with the command “Boot facewide” in the “Service” menu.

Loading of the underground central control Once the entire PMC®-R chain is set up with the PMC®-R server and central control computer and the communication between the central control and server as well as the server and face PMC®-R is OK, a new PMC®-R program can also be loaded from the central control to the PMC®-R. To do this, the program must be loaded on the central control computer.

Fig. 43: Housing of the underground central control MCU 2

1

2

1

3 2

1 explosion-proof housing 2 terminal box 3 cover of the terminal box

For this, the central control must be disconnected from the power.

Afterwards, the cover of the terminal box (3) is opened. A USB port for a USB memory stick can be found in the terminal box.

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5.15

Loading program Warning!

After connecting the memory stick, the terminal box must be screwed back in accordance with regulations. Afterwards, the central control may be reconnected to the power. (Ex protection) The further procedure corresponds to that shown previously starting from “Beginning loading”.

Transfer PMC®-R program from PMC®-R to PMC®-R (boot)

. Keep pressing the “R” key until the “SERVICE” menu item is displayed.

. Then keep pressing the “M” key until the “Boot facewide (P)” menu item is displayed.

. Then press the “P” key. “Password ?” appears on the display is then displayed.

. Now enter the password. Then “Password ?!!!!” appears on the display. Complete password entry by pressing the “Enter” key

. “Boot facewide (P)” appears on the display again. The program is transferred by pressing the “P” key.

On the display of the PMC®-R, which transfers the program, Send. (running number) is then displayed. On the PMC®-R, which receives a program, the following appears on the display: Receive (running number) After the program has been transferred, all computers are automatically reset.

When the computers are booted, the program version can be queried by pressing the “Enter” key.

5.16

Face control with PMC®-R for shearer operation

Set-up of a network with PMC®-R Set-up of a network with PMC®-R In the program, the programmer determines with which coding plug(s) the functions of the J server, J network number generator (numerator), J special shields existing on the network (block anchorage, shield

at the face edge, control unit, etc.) are determined.

In the following, the standard version from Bucyrus DBT Europe GmbH is described.

At a minimum, the following system components are required to set up a functional network to test the delivered program: J 3 PMC®-R control units, J 2 solenoid drivers, J 1 coding plug, 10 kOhm (server), J 1 coding plug, 15 kOhm (numerator), J 2 neighbor cables, J 2 connection cables PMC®-R solenoid driver (solenoid driver

cable),

J 1 power supply, J 1 cable SKK24-SKK24.

Fig. 44: Example of a test set-up

1

4

4

Head gate 2

1

3

5

5 1

F1 A1 8

6

6 C1

Tail gate

Conveying direction

7 1 PMC®-R 2 coding plug, 10 kOhm on B2 3 coding plug, 15 kOhm on B2 4 valve strip

5 valve strip cable 6 neighboring shield cable 7 voltage supply 8 SKK24-SKK24 cable

unit start-up

Once the PMC®-R chain has been supplied with power, the units start up. If no program is loaded, then the start-up will end with the display message, “Waiting no prog”.

loading program

If a program needs to be loaded, then you will need a loading cable, which is to be connected to port C1 of the first PMC®-R and to the PC (see also the Chapter “Loading program”). If a program is loaded in one of the PMC®-R's used, then the other PMC®-R's that have no program will automatically obtain the program as soon as they have power and a bidirectional connection is present. If different program versions are contained in the computers used, then a message will be shown to this effect (Diff. Prog).

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5.17

Set-up of a network with PMC®-R The PMC®-R's now expect a decision from the operator as to which program version is to be used. This must now be sent from the computer that has the correct program to the others by means of the command “Boot throughout the face”. After booting, the PMC®-R's start up and reinstall themselves.

Important!

A functioning network does not yet exist. This is displayed by means of the flashing asterisk in the display.

In the following example, the terms “right” and “left” are used, which can be used in different ways on the PMC-R chain. If one is looking at the display of a PMC-R installed on a shield, the emergency stop unit is on the “right”, so the right neighboring shield is then on the side with the emergency stop unit. If one looks toward the coal face, however, the neighboring shield which has just been defined as the right one is to the left of the observer. To get around this problem, the term “from the mining point of view” has been defined.

“From the mining point of view” defines “right and left” with the view toward the coal face.

The “Network parameters” must first be set. Settings for the test set-up in Fig. 44 in brackets { } setting up the network

The following parameters must be set up and/or checked in the “System parameters” menu: J HG direction (from the mining point of view) is conveyed in dir-

ection A1 in the example. {0}

– 1 = Conveying direction F1 – 0 = Conveying direction A1 J HG server = Number of servers on the head gate {1}

– 1 = 1 server on the head gate – 0 = No servers on the head gate J HG drive = Number of drive shields on the head gate {0}

– 0 = Without drive shields – 1 = 1 drive shield (maximum of 3 drive shields) J FaceBeginning = First shield in the shield column {1} J FaceMg1Size = Shield group size (number of shields controlled

by one PMC®-R) {1}

The coding plug for the server puts an internal permanent numbering into effect.

J TG drive = Number of drive shields on the tail gate {0}

– 0 = Without drive shields – 1 = Maximum of 3 drive shields J TG server = Number of servers on the tail gate

– 1 = 1 server on the tail gate – 0 = No servers on the tail gate J End of the longwall = Last shield {2} J Mastercod = Shield number in which the coding plug is inser-

ted. {1}

5.18

Face control with PMC®-R for shearer operation

Troubleshooting Troubleshooting On the following pages, various frequently occurring errors are described in the order of their being mentioned above, and it is shown how the cause can be narrowed down with the aid of flow diagrams.

In general, however, it can be said that it's usually the line or cable connections which are defective. Rarely is it a component.

The beginning (occurring error) is marked in red (solid line).

Test activities which lead to a decision are shown inside a rhombus.

Activities which lead to a remedy are shown in ochre-colored (dashed-line) parallelograms.

The target remedy of the error is shown in green (dotted line).

J Selected shield function is not executed.

J Incomplete network.

J One or several PMC®-R's are without power.

J A PMC®-R control is defective (no replacement on the face).

J Short-term shutdown of a power group after activating a shield

function.

J The displays of all PMC®-R's flash to indicate an incomplete

network.

J Data connection (DÜSE) between underground central control

and above-ground central control.

The following figure shows the basic structure of a PMC®-R network, which one should intensively memorize.

Important!

The current group size depends on the number and current consumption of the connected valves which have to be fed from one power supply, or depends on the nominal power of the power supply.

The following examples only show the basic facts.

Fig. 45: Principle of a PMC®-R network 1

2

TA

TA PMC®-R No. 8

PMC®-R No. 9

PMC®-R No. 10

PMC®-R No. 11

PMC®-R No. 12

PMC®-R No. 13

PMC®-R No. 14

PMC®-R No. 15

PMC®-R No. 16

PMC®-R No. 17

PMC®-R No. 18

1 power supply, 12 V 2 integrated supply adapter

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5.19

Troubleshooting Selected shield function is not executed Fig. 46: Search tree for error description 1 Start

Check whether the other functions can be activated.

yes

no

no

Continue with example (1) Page 5.22

Check whether the power supply is OK

no

Exchange power supply

yes

Check whether there is pressure in the system.

yes

Check whether the function diode of the activated PMC®-R is illuminated when the function is activated.

Exchange cable

PMC®-R has power

yes

no

2

Check whether there is power on the PMC®-R *)

no

no

Y

Check PMC®-R by

exchanging the PMC®-R's with each other

yes PMC-R and neighboring cable are OK. See: Comment Z

2

End

Switch on pumps

comment Y

Neighboring computer defective or diode of the activated neighboring control is defective

*) = When the display and LEDs are illuminated, there is power.

5.20

Face control with PMC®-R for shearer operation

Troubleshooting . Exchange neighboring computer for a working neighboring

device and check whether the error moves with it. If necessary, install a spare unit.

comment Z

Check the message on the display of the non-reacting PMC®-R: The following message can be displayed:

G 320 ::::P M C- R ::::

316

This means that the left control is disabled.

The display of the disabled control shows the letter “G” 3x because disabling the control always disables the neighboring shields as well.

In the event of an error, either the lock-out switch is pressed now, or the lock-out switch is defective.

. Unlock lock-out switch or exchange the control for a spare.

VL 320 ::::P M C- R ::::

316

The following causes are possible: J PMC®-R output to the valve strip is defective (rare), J Solenoid driver module is defective (rare), J The connecting cable between the PMC®-R controls is

defective (common).

. Exchange PMC®-R control unit . Exchange solenoid driver module . Exchange the connecting cable between the PMC®-R and the valve strip

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5.21

Troubleshooting Example 1 Fig. 47: Search tree for Example 1 “Shield function - Lower” is not executed.

1

Shield function “Lower” in shield 10 doesn't react

E.g., exchange the “Lower” and “Advance” valve cables.

Check whether the function is executed.

E.g., activate “Lower” function. “Advance” is expected and vice versa.

no

The solenoid valve or the pilot valve is defective.

no

yes

Check whether other functions can also be activated.

yes

Exchange the valve disc (see “Hydraulic system” instructions) Error still exists.

Valve strip defective: A Exchange valve cable B Exchange valve strip

Change the valve cables and check again.

Function OK

Valve strip output and valve cable are OK. One of the plug connections is probably defective.

I.e., exchange valve cable.

Important!

After troubleshooting, connect the “Lower” and “Advance” valve cables back into their correct positions.

5.22

Face control with PMC®-R for shearer operation

Troubleshooting Incomplete network example 2

In the face with a total of 180 shields, an SKK24 hose cable was damaged between the PMC®-R controls. This is indicated on the entire face with the flashing star on the display.

No.: : 1:Pr:: ~~~ ~~~~ No.: : 1:Pr:: ~~~ The text and star of the upper display line flash alternately.

If this type of malfunction occurs, the network can be checked on any PMC®-R control unit.

. This is done by pressing the “C” key on one of the face PMC®“-R's. The network display appears:

ShieldNo 43 113 6 N 0 : : : : PMC-R : : : : This is the display for one's own shield number. Here: 43 The display can be scrolled with the “M” key: The next display is:

s: 34 180 ( 501 : : : : PMC-R : : :

180)

This display means: 34 = first detected shield number 180 = last detected shield number In parentheses: 501 = expected server number 180 = expected last shield number That means that there is a network interruption between shield 33 and shield 34.

Important!

No automatic functions can be executed in the case of a network interruption. Active automatic functions are interrupted.

The cause can be searched for according to the following search tree:

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5.23

Troubleshooting Example 2 Network interruption Fig. 48: Search tree error description “Incomplete network” Start

Check whether the non-detected control units have power.

no

yes Communication between PMC®-R No. 33 and No. 34 is disturbed.

Power supply is malfunctioning.

Possible causes Possible causes

Neighboring PMC®-R interface defective (pins 2, 3)

Exchange PMC®-R 33.

If the error continues to occur, exchange PMC®-R 34.

Neighboring PMC®-R interface defective (pins 1, 4) Neighboring cable defective (pins 2, 3)

Exchange neighboring cable.

Breakout box defective

Exchange breakout box

Exchange PMC®-R 33.

If the error continues to occur, exchange PMC®-R 34.

Neighboring cable defective (pins 1, 4)

Exchange neighboring cable.

Important!

If a whole power group is without power, there is either a short circuit or the corresponding power supply is defective.

5.24

Face control with PMC®-R for shearer operation

Troubleshooting check:

If the power supply is delivering power (LEDs illuminated), the corresponding hose cable is defective.

. Exchange the hose cable.

If the error continues to occur, the corresponding SKK24 connection is defective.

. Exchange power supply / breakout box / PMC®-R hose cable One or several PMC®-R's are without power This error description can be distinguished in the following subcases: approach 1

All PMC®-R's which are fed by one power supply are without power.

approach 2

All PMC®-R's of one power group are without power.

approach 3

A power group is temporarily without power.

approach 4

Part of a power group is without power.

For 1st approach: All PMC®-R's which are fed from one power supply are without power.

causes

1. Power supply failed.

2. Both connection hose cables are defective (unlikely).

3. Power adapter of the power supply is defective.

. In cases 1 and 3: Exchange the power supply. . In case 2: Exchange the hose cable.

For 2nd approach: All PMC®-R's of one power group are without power. causes

1. Supply adapter defective 2. Supply hose cable defective 3. Connection to control unit defective 4. Short circuit

procedure

See search tree, example 2

. In case 1: Exchange power supply . In cases 2 and 4: Exchange hose cable . In case 3: Exchange the corresponding PMC®-R For 3rd approach: One power group is temporarily without power causes

1. Defective valve 2. Damaged valve cable 3. Defective valve strip

procedure

Doc. no.: 4007 180 010 BA 00

(See error description 5)

VRVT / 01

5.25

Troubleshooting For 4th approach: One part of a power group is without power The following figure shows example 3: Three PMC®-R controls are without power.

Fig. 49: Example 3: Three PMC®-R controls are without power 1

2 A1

F1 TA

TA PMC®-R No. 8

PMC®-R No. 9

PMC®-R No. 10

PMC®-R No. 11

PMC®-R No. 12

PMC®-R No. 13

PMC®-R No. 14

PMC®-R No. 15

PMC®-R No. 16

PMC®-R No. 17

PMC®-R No. 18

1 power supply, 12 V 2 integrated supply adapter

If part of a power group is without power, this is an indication of a cable interruption. causes

1. Hose cable between units 13 and 14 is defective 2. Neighboring interface on unit 13 is defective 3. Neighboring interface on unit 14 is defective

. If the supply hose cable is exchanged and the error continues

to occur, it must be made sure that no control unit is defective.

You can proceed according to the following search tree.

Fig. 50: Search tree for example 3: A part of a power group is without power (Part 1)

Start

Three PMC®-R controls are without power

Exchange the two control units 12 and 14.

Control unit 12 is defective

Exchange control unit 12

yes

Check whether the devices 9, 10 and 11 are without power.

no

Exchange the two control units 12 and 13.

1

5.26

Face control with PMC®-R for shearer operation

Troubleshooting Fig. 51: Example 3: Part 2 1

no

Check whether the devices 9 to 12 are without power.

Exchange the supply hose cable yes Control unit 12 is defective

Exchange control unit 12

If there are two or only one control unit(s) without power, proceed as described above.

Control unit is defective.

A PMC®-R control is defective (no replacement on the face) If one PMC®-R control is defective, the PMC®-R network is incomplete. In this case, no automatic functions can be executed. examples

Shield sequence in automatic mode Shield sequence in batch Advancing conveyor as function in the group (“bankpush”) Pull back conveyor Automatic positive setting In the case of an incomplete network, it's still possible to control the shields via the dead-man functions. All individual functions can be activated by the neighboring control.

In order to re-establish normal operation, the network must be completed. If there is no spare PMC®-R control unit on the face, then the following temporary solution can be used.

. 1. Remove the defective PMC®-R. . 2. Remove the last PMC®-R on the face and install it in the place of the defective PMC®-R.

. 3. Reset the network parameters. In the “New SYS

Parameters” menu, lower the “Face end” parameter by one shield.

example 4

Doc. no.: 4007 180 010 BA 00

On a face with 180 shields, it was determined that the PMC®-R control of shield no. 50 is defective. After removing the PMC®-R control from support no. 50 and installing the PMC®-R control from support no. 180 into shield no. 50, the “Face end” parameter must then be set from 180 to 179.

VRVT / 01

5.27

Troubleshooting Important!

This option should only be used in an emergency. The last shield without the PMC®-R control must then be operated via manual function valves.

Short-term shutdown description

Short-term shutdown of a power group after activating a shield function.

When a function is being executed, the power group is without power for a short time and then reboots.

causes

1. The electrically operated valve of the function is defective.

2. The valve cable of the selected function is defective.

3. The solenoid driver is defective.

measure 1

. Disconnect the valve cable from the valve of the function causing the malfunction.

test

Activate the same function again and check whether the malfunction occurs again.

J YES = Solenoid driver defective (see measure 2) J NO = The valve coil is defective.

. The valve disc must be exchanged. (see hydraulic system operating instructions)

measure 2

. Disconnect the valve cable from the solenoid driver of the function causing the malfunction.

test

Activate the same function again and check whether the malfunction occurs again.

J YES = The solenoid driver is defective.

. Exchange the solenoid driver.

5.28

Face control with PMC®-R for shearer operation

Troubleshooting troubleshooting

The displays of all PMC®-R's are flashing The display on the display window of all PMC®-R's flash to indicate the network isn't complete. The PMC®-R server takes over the constant PMC®-R numbering. The PMC®-R's up to the point of interruption are still constantly being numbered. The PMC®-R's after the point of interruption can no longer be addressed. The face PMC®-R's keep their numbering until the next power failure. When this error indication occurs (flashing display), it is possible to operate the supports manually from the neighboring control.

example 5

The connection of PMC®-R no. 32 is interrupted after PMC®-R no. 33 (face with 180 shields)

. In the range from shield 1 to 32, press the “C” key and then the “M” key:

display

s: 501 32 ( 501 : : : : PMC-R : : :

180)

501 = server is detected 32 = last detected shield

In parentheses: 501 Server expected, 180 Last expected shield The network interruption must therefore lie above shield 32.

. In the range from shield 32 to 180, press the “C” key and then the “M” key:

display

s: 33 180 ( 501 : : : : PMC-R : : :

meaning

33 = First detected shield

180)

180 = Last detected shield In parentheses: 501 Server expected, 180 Last expected shield The network interruption must therefore lie below shield 33. causes

1. Defective neighboring cable 2. Defective neighboring interface 3. Defective breakout box 4. Defective supply adapter (power supply)

. Exchange defective part for spare part.

Important!

An interruption in the PMC®-R chain must be repaired immediately since a pressed shield emergency stop button is ineffective in the cut-off part of the face.

No automatic functions can be executed in the case of a network interruption. Active automatic functions are interrupted.

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5.29

Troubleshooting Data connection (DÜSE) Data connection (DÜSE) between the central control underground and the central control above ground If the central software is installed and started on the central control, one can make the window of the ShieldDataDriver visible by double-clicking the DBT button on the Windows status bar.

Fig. 52: Windows display - DBT ShieldDataDriver and ShieldDataDriver window

By clicking on the “Com. States” button, the “Communication States” window appears.

Fig. 53: “Communication States” window

In the “Communication States” window, a red circle indicates whether there is a connection to the face or central control.

Meanings: 1 = there is a connection 0 = no connection On the “VShield” visualization software, at the lower left corner of the screen there's a display field of the connection status (see next page)

5.30

Face control with PMC®-R for shearer operation

Troubleshooting Fig. 54: “VShield” connection display 3 1

4

5 2

1 no connection 2 connection OK 3 no connection from VDataDriver to VShield 4 connection from VDataDriver to VShield OK 5 connection to the face OK

Important!

Further troubleshooting according to the following pattern is only possible on the MCU 1 (PM4) central control.

Troubleshooting on the new MCU 2 system (PMC-®R) is not possible.

In the event of an error, it is now possible to set jumpers at various positions.

Test 1: On above-ground PC:

. Pull out the plug of the connection to the DÜSE above ground.

Set a jumper at the 9-pin D-Sub connection between pins 2 and 3.

With this jumper, the communication status line should display 1 = connection ok.

Test 2: On the cable between PC and DÜSE above ground

. Pull out the plug to the DÜSE above ground. Input UDI/GN:

Set jumper at 25-pin D-Sub plug between pins 2 and 3. Check the status window.

Test 3: On the DÜSE above ground:

. Disconnect cable. Set bridge between terminals 1 and 9 as well as 2 and 10.

Check the status window.

Test 4: On the cable:

. Disconnect the cable to above ground.

Set a jumper at the ends of the cable, DAa and DEa as well as DAb and DEb. Check the status window.

Test 5: On the DÜSE unit: Connection space TTY

. Disconnect cable Set a jumper at the terminals +DA and +DE as well as -DA and -DE. Check the status window.

Important!

If, when checking the status window, a 1 is displayed and in the line for receiving errors no counter increments, the data path between the last test site and the central control is OK.

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5.31

Troubleshooting Fig. 55: DÜSE path system PC above ground 9-pin D-sub RxD TxD Ground 2 3 7 Socket Plug 3 2 7 TxD RxD Ground 25-pin D-sub Green plug 10 b

9 a

2 b

Düse above ground UDI/GN

1 a

DEb DEa DAb DAa Connection space, remote Düse 5i/l underground

DE DE DA DA 4

1

3

2

+/-Ub+/-Ub

NSE power supply

1:TX+ Green

4: TX-

PMC®-R/ TTY.BIDI SKK24

2: RX+ 1 white 2 brown 3 green

3: RX-

TTY

BIDI

4 yellow

5.32

Face control with PMC®-R for shearer operation

Function descriptions Function descriptions Neighboring control In order to control a shield with a neighboring function, proceed as follows: Danger!

Make sure that no one is on the shield to be actuated.

. First, you must always activate the corresponding neighboring shield.

If the master timer has elapsed, you must reactivate the neighboring shield by pressing the “I” or “H” key. After the master timer has elapsed without pressing another key, the PMC®-R returns to its idle state automatically.

The right or left shield (from the perspective of the operator) is activated with the “I” or “H” key (in direction of arrow).

If you press this key, you'll hear the beeper sound as a response.

The LED of the pressed key is illuminated as long as the master timer is set.

While the own PMC®-R is in master mode (for master timer, see “Global parameters” menu), the individual control functions on the neighboring shield can be activated and started. The master timer counter restarts every time a key is pressed. example

Directly activated functions on the neighboring control, example of a manual sequence

. First press either the “I” key or “H” key, depending on which shield you would like to activate.

. Afterwards, press the “A” key to lower the shield. (The function ends when the key is released.) Then:

. Afterwards, press the “B” key to advance the shield. (The function ends when the key is released.)

. Press the “C” key to set the shield (the function ends when the key is released).

Important!

If the master timer has elapsed, you must reactivate the neighboring shield by pressing the “I” or “H” key. After the master timer has elapsed without pressing a key, the PMC®-R returns to its idle state automatically.

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5.33

Automatic sequence Sequence controlled manually The sequence consists of the shield being automatically pulled forwards with the partial functions “Lower”, “Pull shield” and “Set shield”. The operator starts the autosequence at the adjacent shield.

The following keys must be pressed:

. Press either the “I” or “H” key, depending on which shield you would like to activate.

. Now press the “Start” (“U”) key The PMC®-R in “slave” mode now starts the sequence. After a warning, the shield is lowered, pulled forward and set.

You can interrupt this automatic cycle with the “Stop” key.

Sequence parameters time parameters

The following time parameters are decisive for these functions: J T1 lower = time parameter for the duration of the lowering

operation

J T2 advance = time parameter for the duration of pulling the

shield forward

J T5 set = time parameter for the duration of the setting operation pressure parameters

In addition, the following pressure parameters are used: J AP0 lower = Pressure parameter for the lowering operation J AP1 trans = Pressure parameter for activating the next shield J AP2 set = Pressure parameter for the setting operation

automatic check of pressure value before beginning of sequence

If a sequence is initiated on a face shield, it is first checked whether the two directly neighboring shields are set, i.e. whether the pressure value “AP1 Trans” is exceeded.

Important!

If this isn't the case, the shield may not start an automatic sequence.

The “Lower shield” function: If the conditions are met (see above), the shield starts the lowering function for the time “T1 lower”.

prop pressure check

relowering

adjustable number of relowering attempts

After this time has elapsed, by querying the pressure sensor, it is checked whether the achieved prop pressure has dropped below the pressure parameter value “AP0 lower”.

If the prop pressure has not dropped below the pressure parameter “AP0 lower”, the shield is relowered for the time parameter “T3 relow”.

The number of possible relowering attempts is specified with the “C0 Adv. retry” parameter.

Important!

If the pressure parameter “AP0 lower” is not fallen short of even after the resetting attempts, the shield is set and an error message is output.

5.34

Face control with PMC®-R for shearer operation

Once the pressure parameter “P0 lower” is fallen short of, the “Pull shield” function is started.

The “Pull shield” function: automatic check of the relay bar assembly path

readvancing operation

To pull the shield to a specified final stroke, there is the time parameter “T2 advance”. By means of the reed rod built into the shifting ram, the relay bar assembly path traveled is constantly measured. If the final stroke is reached within this time parameter, the advancing operation is ended.

If the specified final stroke is not reached within the time parameter, the readvancing operation is initiated. The time parameter “T7 Readva” is for reaching the final stroke during the readvancing operation.

Important!

If the final stroke is not reached within this time parameter either, the shield is set and an error message is output.

Once the final stroke has been reached, the “Set shield” function is started.

The “Set shield” function: For setting the shield up to the pressure parameter “P2 Set”, there is the time parameter “T5 set”.

The pressure in the prop is constantly measured with a pressure sensor.

If the pressure parameter “AP2 set” is exceeded within the time parameter, the set operation is finished.

Important!

If the value of the pressure parameter “AP2 set” is not exceeded within the time set with the time parameter “T5 Set”, an error message is output.

If the pressure parameter “AP2 set” has been exceeded, the sequence of the shield is finished.

Further options Additional options for the shield sequence: J It is possible to extend the stabilizing cylinder during the “Lower

shield” function.

– To do this, the parameter “AS1 Eckzyl_R” is to be set to “1”.

In this case, the stabilizing cylinder is extended for the time parameter “AT10 EckZy_R”.

J It is possible to extend the stabilizing cylinder during the

“Relower shield” function.

– To do this, the parameter “AC1 NaSetzEck” is to be set to “1”. In this case, the stabilizing cylinder is extended for the time parameter “AT9 EckNa” during the first relowering attempt.

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5.35

J It is possible to activate the functions “Lower shield” and “Pull

shield” at the same time.

– The corresponding parameter is “S0 Pull/Lower”. If the parameter is set to “1”, first the shield is lowered for the time parameter “T11”, and then the shield is simultaneously further lowered for the time parameter “T1” and pulled forward for the time parameter “T2”.

– If the parameter is set to “2”, first the shield is lowered for the time parameter “T11”, and then the shield is simultaneously further lowered and pulled forward for the time parameter “T2”.

J It is possible to pull the shield forward during setting. This pre-

vents the shield from slipping back during the setting operation.

– To do this, the parameter “S5 Adv+Set” is to be set to “1”.

J Depending on the face and support variants, there are other

shield sequence options:

– The gap seal can be retracted during the sequence.

– Backlash compensation can be applied after a shield sequence.

– The baselift cylinder can be activated simultaneously with the “Pull shield” function.

– During the shield sequence, the canopy roof water spraying system can be activated.

Sequence group The shields can be controlled in a group in such a way that they work through the procedure one after an other in an automatic sequence.

To start the group, press one of the keys: Plow program 1:3: “7” or “9”.

Shearer program: “F” or “G” If you would like to select a group to the right (when looking at the PMC®-R) of your own location, press the “9 (G)” key. (The size of the group is set in the menu “Sequence parameters”) The “7 (F)” key selects a group to the left of your location (when looking at the PMC®-R). example:

Control of neighboring sequence groups Key “9 (G)” was pressed in shield 106.

Your PMC®-R displays the following: Fig. 56: The PMC®-R display First shield in the Direction of sequence group the sequence

Last shield in the sequence group

109 > 114 325

345 316 NOM

With the “P” key, you can change the direction of the sequence.

5.36

Face control with PMC®-R for shearer operation

Press the “Start” key once the display shows the correct shield numbers and the correct sequence direction.

After the warning, shield “109” begins a sequence. After shield 109 has run through the entire automatic sequence, shield 110 begins a sequence. This proceeds in sequence until shield 114 has carried out its automatic sequence.

With the “Sequence type” parameter, you can determine the type of group sequence: J Either one after the other as described above or J First every second shield in sequence and then every shield in

between, within the selected group.

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5.37

PMC®-R Shearer running batch PMC®-R Shearer running batch Starting and stopping the shearer running batch The shearer running batch can only be started in the range of the position of the shearer.

. Start the shearer running batch by pressing the “9” key.

After pressing the “9” key, the following display appears: NOM: ::: PMC - R:::

1 > 276

Start in head gate direction

Start in tail gate direction

After selecting the direction with either the “N” or “P” key, press the “U” key.

Each PMC®-R then shows “S+A” in the display.

Press the “7” and “L” key to stop the shearer running batch.

The display shows: S + A: SRB cancel ::: PMC - R:::

↓

Press this key to stop the shearer running batch

The parameter reference points are explained in the following so that you can set the parameter values to be entered to the appropriate face program. If the programmers are aware of all information concerning the face, they can pre-set the settings in the program so that the correct parameters are set after loading a new program version.

Important!

However, we still suggest checking the parameters after loading a new version or booting.

5.38

Face control with PMC®-R for shearer operation

PMC®-R Shearer running batch Fig. 57: Mobile cutting assembly 1

S_dist_tail

Position of the shearer 1

276

Shearer running batch range, shield 1 to the end

Example of start situation for the shearer running batch: J The conveyor is level and is completely pushed forward.

J The shearer is at the tail gate and ready to make a cut in the

direction of the head gate.

Fig. 58: Shearer running batch 2

S_dist main

S_dist tail

Position of the shearer 1

Release of sequences behind the shearer

Shearer running batch range, shield 1 to the end

276

The shearer now travels toward the head gate.

When the shearer reaches the “S_dist_Tail” position, the shields that are behind the shearer further away from it than “S_ctd tail” + “S_save ASQ” begin to run a sequence (see also Fig. 59 “Shearer running batch 3”) The pathway is pulled closed.

When the shearer travels from the head gate to the tail gate, the same applies to the “S_dist main” and “S_ctd main” + “S_save ASQ” parameters.

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5.39

PMC®-R Shearer running batch Fig. 59: Shearer running batch 3

a

Position of the shearer 1

b

S_save ASQ

Shearer running batch range, shield 1 to the end

276

A = S_ctd Main = length of the shearer from the installation site of the infrared transmitter toward the head gate B = S_ctd Tail = length of the shearer from the installation site of the infrared transmitter toward the tail gate

Safe distance for sequence behind the shearer (ASQ) The range behind the shearer is set with the “S_save ASQ” parameter in which sequences may not be run (safe distance, input in number of shields, here: 3).

The installation site of the infrared transmitter is the reference point for the shearer location. The “S_ctd Tail” and “S_ctd Main” parameters define the size of the shearer. (Input in number of shields) This value must always be rounded off. example 1:

Length of the shearer from IR transmitter to the outer edge of the cutting body of the shearer toward the tail gate L1 = 6.65 m.

Shield width WS = 1.75 m L1/WS = 6.65/1.75 = 3.8 >> Number to enter for S_ctd Tail = 4 (shield) Important!

The calculated number also has to be rounded off when it is just a bit larger than the number of complete shields.

example 2:

WS = 2.00 m L1 = 6.15 m L1/BS = 6.15/2.00 = 3.075 >> Number to enter for S_ctd Tail = 4 (shield) If the installation site is not in the shearer middle, e.g. when two shearer arms different in length are available, the length can be corrected with the “S_ctd Tail” and “S_ctd Main” parameters.

The program default value for both is 4 shields.

5.40

Face control with PMC®-R for shearer operation

PMC®-R Shearer running batch Safe distance for conveyor push sequence (bankpush) Fig. 60: Shearer running batch 4

Bankpush

Position of the shearer

S_save ASQ

1

S_save BP

Shearer running batch range, shield 1 to the end

276

The safe distance for “Advance conveyor” (bankpush) is defined like the safe distance for the sequence. (see picture above) If the ctd parameters “S_ctd Tail” and “S_ctd Main” are set to “0”, the safety distances “S_save ASQ” (value in picture “Shearer running batch 4”: 2) and “S_save BP” from the shearer middle apply and they have to be selected accordingly with a larger number.

Continuation of the "Shearer running batch" function description shearer:

The shearer makes a complete cut up to the head gate.

support:

The shields behind the shearer begin to run a sequence. The distance behind the shearer depends on the size of the “S_save ASQ” parameter in number of shields.

Advancing the conveyor follows the shields that have run a sequence, at a distance from the shearer “S_save BP”, also to be entered in number of shields.

conveyor:

Important!

Be sure that the parameters for the “S_save ASQ” sequence and the “S_save BP” for advancing the conveyor agree.

The parameters have different dependencies according to the desired shearer operation mode.

Fig. 61: Shearer running batch 5 Snake

Position of the shearer 1

Bankpush S_save BP Shearer running batch range, shield 1 to the end

276

When the shearer reaches the face end and stops, the “Sequence” and “Advance conveyor” functions are stopped depending on the corresponding safe distance parameters.

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VRVT / 01

5.41

PMC®-R Shearer running batch The shearer now travels from the head gate toward the tail gate.

The leading shearer is thus placed in the upper position and the last shearer is placed in the lower position.

Fig. 62: Shearer running batch 5 Snake

Position of the shearer 1

276

Shearer running batch range, shield 1 to the end

The shields are pushed forward and the conveyor advanced subject to the “S_save ASQ” and “S_save BP” parameters. The shearer moves over the snake and thus cuts into the coal face with the next cut depth.

Fig. 63: Shearer running batch 6

S_save BP 1

S_save ASQ

Shearer running batch range, shield 1 to the end

Position of the shearer 276

Now the shearer has to move by the “S_save BP + S_save ASQ” distance over the snake. The conveyor is then level again and the conveyor travels back to the head gate in order to make a new complete cut toward the tail gate. The shields will then run another sequence and the conveyor is pushed forward so that a new snake runs behind the shearer.

5.42

Face control with PMC®-R for shearer operation

Block anchorage Block anchorage In most cases, the block anchorage is used in the plow face.

Be sure to hold and/or level the conveyor in the downward inclined face.

Block anchorage in 1:1 solution This section discusses the block anchorage in 1:1 solution (a PMC®-R controls a shield).

Important!

The terms “right” and “left” as well as “mining right” and “mining left” used in the text below are not to be confused with one another. The terms right and left are switched since the user has his back to the coal face.

If the user is looking at the display in front of the control, the position of the block anchor cylinder with a slash shown in the display is the same as the actual direction of the block anchor cylinder. In the picture shown below, the perspective is the user's view of the control and it is shown on the display cut off by a dashed-line.

Fig. 64: Principle of a block anchorage in 1:1 solution B BLK Cyl X

Z PM

PM

I/

620 524 560 PM

DIS1 BLK Cyl

\I

620 524 560 1

2

3

DIS2

1 = shield 1 2 = shield 2 Blocking shield 3 = shield 3 B = conveyor X = right block anchor cylinder, working direction mining left Z = left block anchor cylinder in working direction mining right PM = control DIS1 = display of the left block anchorage with extended relay bar assembly lengths (left, own, right) in the second line of DIS1 = the display DIS2 = display of the right block anchorage with extended relay bar assembly lengths (left, own, right) in the second line of DIS2 = the display

Caution!

Shields 1, 2, and 3 can only be pushed in a specific order to avoid damaging the block anchor cylinders and their retainers.

This order also has to be followed for the sequence.

According to the program the technical definition of the blocking shield is as follows: Important!

According to the program the shield is technically identified as a blocking shield. The block anchorage cylinder/s is/are attached next to its lifting point of the relay bar assembly on the conveyor.

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5.43

Block anchorage The shield that has a block anchor cylinder attached to its runner must be pulled first before the blocking shield is pulled when the block anchorage only has one block anchor cylinder.

When the block anchorage has two block anchor cylinders, the neighboring shields with block anchor cylinders attached to their runners and the block anchorage must be pulled one after another before the blocking shield is pulled.

Generally, the following applies: The blocking shield (2) may only be pulled first when those around it (1,3) have been pulled. The shield support unit is defined in the program to follow this requirement.

The block anchorage can contain one cylinder in only one working direction (left or right) or two cylinders in opposite working directions (left and right). The displays are shown on the PMC®-R as seen in the picture above. If two block anchors are attached, both of them are shown: BLK Cyl

\I/

620 524 560

The block anchorage parameters are listed in the following table.

Tab. 4: Block anchorage Block parameter

Meaning in English

BLK W0 *200

Maximum permitted relay bar assembly stroke in the blocking shields. When the relay bar assembly stroke is higher, it activates a sequence in the neighboring shield before moving forward.

BLK = Abbreviation for block anchorage W0 = Parameter for relay bar assembly stroke limit *200 = Value for relay bar assembly stroke limit; the star means that the parameter can be changed.

BLK T1 *6000

Waiting time until the neighboring shield has pulled forward, before the blocking shield is pulled forward.

BLK = Abbreviation for block anchorage T1 = Parameter for waiting time *6000 = Changeable value for waiting time in 1/100 sec.

BLK Cyl \|/

Installation position of the block anchor cylinder looking at the PMC®-R control. \ = Left block anchor cylinder seen from the blocking shield I = Display of the blocking shield itself (is always shown) / = Right block anchor cylinder seen from blocking shield

Time T is entered in 1/100 sec, i.e. 6000 = 60 seconds

Analogously to the block anchorage shown above, the anchoring device is to be considered as half of a block anchorage.

5.44

Face control with PMC®-R for shearer operation

Measured values Measured values

MEASURED VALUES

In this menu, only measurements are displayed, e.g. prop pressure or extended relay bar assembly path. The values are pure measurements and cannot be changed.

J Pressures are given in bar.

J The extended relay bar assembly can be displayed in % if the

total extended length or in mm.

J Each measurement display can show values for up to 5 neigh-

boring shields. One can switch from shield to shield with the “N” and “P” keys.

0=

prop >>

0= << prop

J 0=

Measurement of own shield

J x<

Measurement of left shield (in direction of arrow)

J x>

Measurement of right shield (in direction of arrow)

402

Right prop pressure (in bar) on the selected shield

402

Left prop pressure (in bar) on the selected shield

0= ramstroke 98

Extended relay bar assembly path (in %) of the total extended length

0= sys. pressure 324

Face hydraulic system pressure (in bar). Measured by the PMC®-R server, port E1

0= ret. pressure 29

Face hydraulic system return pressure (in bar). Measured by the PMC®-R server, port E2

0= Ifr

0

Infrared sensor signal strength of the installed infrared sensor

0= supp.pos.

14340

Shield position (in mm) total path of forward movement

0= conv.pos.

15232

Conveyor position (in mm) total feed path

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5.45

Measured values

0= coalline 15989 0= targetline

BSLovl.:0 DumpValve:0

Calculated path (in mm), which has been traveled since beginning of the face

0

Value up to the target line (in mm) of the conveyor, if a target line is used.

SERVER only Status of the face conveyor loading.

Status of the high-pressure shutdown.

1 = OK signal

5.46

Face control with PMC®-R for shearer operation

Parameter description Parameter description Auxiliary functions Auxiliary functions allow the operator to execute shield functions at the limit which don't have their own key on the operating keypad.

The auxiliary functions can be displayed with the navigation keys.

They don't allow the functions to be executed.

Changing the default function J The auxiliary functions can be scrolled with the navigation keys

which are the first displayed when the “H” or “I” keys are pressed.

J Press the “Enter” key.

J Enter your password.

J Press “Enter” again.

Operation In order to execute an auxiliary function of a neighboring shield, first press one of the keys, H

or I

.

Selecting a neighboring shield automatically calls up the display of the auxiliary functions With the keys “L” the menu.

and “M”

you can scroll up and down in

With the keys “N” and “P”, the functions are executed.

The functions are logically allocated to the keys “N” and “P” on the display. example:

Advance conveyor ON

PS spray

ON

The “N” and “P” keys are dead-man keys. The selected Function is executed only as long as the key is pressed.

Pressing the “P” ram out.

ON

Pressing the “N”

key activates the water spraying system.

Pressing the “P"

activates the water spray canopy.

PS Spray

Doc. no.: 4007 180 010 BA 00

key extends the shifting ram.

VRVT / 01

ON.

5.47

Parameter description Special auxiliary functions Special auxiliary functions are additional functions in the auxiliary function menu which are only available on the head or tail gate groups. (Usually there are head and tail gate shield groups which advance together) These are also dead-man functions. They work as if all group shields have the corresponding key pressed simultaneously.

Pressing the “N”

FR HG

ON OFF

FR TG

ON OFF

5.48

key switches on the common advancement on

the head gate. Pressing the “P” advancement on the head gate.

key switches off the common

Pressing the “N” the tail gate.

key switches on the common advancement on

Pressing the “P” the tail gate.

key switches off the common advancement on

Face control with PMC®-R for shearer operation

System parameters System parameters This menu contains the face settings.

J Pressure is displayed in bar.

J The advancement can be displayed in % of the total relay bar

assembly stroke or in mm. (Can't be switched online).

J Time is given in 1/100 s.

Mg Dir (0=A1;1=F1) *min: 1 0 max: 1

This value indicates the face direction. The head gate lies in the direction of the A1 or F1 port of the PMC®-R. Enter 0 or 1 according to display in parentheses

Mg Server (1=yes) * 1min: 0 max: 1

Server on head gate 1 = yes, 0 = no. The PMC®-R server requires a 10 kΩ coding plug. The intelligent coding plug is programmed to this value.

Mg Ext size * 0 min: 0 max: 10

This parameter indicates the number of shields which are additionally installed between the server and the first face shield.

Super password

FaceBeg *1 min: 1 max: 470

Number of the first face computer. This is usually 1.

FaceEnd * 145 min: 1 max: 470

Number of the last face computer

Tg Ext size * 0 min: 0 max: 10

This parameter indicates the number of shields which are installed between

Tg Server (1=yes) * 0min: 0 max: 1

Server on tail gate 1 = yes, 0 = no. The PMC®-R server requires a 10 kΩ coding plug. The intelligent coding plug is programmed to this value.

Mastercod. *1 min: 1 max: 470

Number of the shield into which the numerator coding plug is plugged. The PMC®-R numerator requires a 15 kΩ coding plug.

The intelligent coding plug is programmed to this value.

Doc. no.: 4007 180 010 BA 00

Middle password

Middle password

the last face shield and the tail gate.

VRVT / 01

5.49

System parameters

5.50

Face control with PMC®-R for shearer operation

6

Technical data

Face controls

Technical data Face controls In this chapter, the individual system parts of the PMC® system are shown and explained so far as necessary to understand the control system.

The specified approval numbers (ATEX numbers) can include additional device variants. As a result, device designations might be mentioned in these operating instructions which are not part of the current system.

Important!

The component numbers listed in this system description are given as examples for the shown components. The numbers do match the parts, but there are other numbers which apply to component variants, but designate the same parts externally.

For this reason, the actually used part numbers may differ from those shown here. For exact identification, the valid drawings and piece lists should be used.

PMC®-R control unit Bucyrus DBT Europe GmbH, Lünen 2008

E

As standard, the PMC®-R control units are used on shearer or plow faces. Depending on the number of functions to be controlled on the shield, a PMC®-R can control one or several shields.

The keyboard protection cover can be exchanged by loosening the cover plate with the Allen screws, lifting up the cover plate, exchanging the cover and refastening the cover plate. This may only be done above ground in non ex-protected rooms.

The single control unit acquires measurement values such as pressure, movement and switch settings in its own shield. From this data, the PMC®-R calculates the required commands for the single shield and automatic sequence functions, and allows them to be executed by the connected electro-hydraulic valves. The PMC®-R can control and display all functions of a shield and is simultaneously the interface between operator and machine. The PMC®-R system can control all individual shield functions based on a reliable network. As an interactive system, it allows the user to execute single shield functions as well as automatic sequence functions. Important process values are continuously displayed as an acknowledgement for the operator.

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6.3

PMC®-R control unit Fig. 65: Example for the front view of the PMC®-R

Emergency stop / shield locking switch Important!

With the change in the European standard EN 1804-4, the following change has been incorporated in the new PMC-R programs: After pressing the EMERGENCY STOP SWITCH, no electrically actuated function on the face can be executed!

Emergency stop and shield locking switch of the PMC®-R are represented by two switches. These switches have been made waterproof through the use of a specially designed switching ram and a sealing groove for an O-ring seal. The separate switch utilization for emergency stop and shield locking switch contains no components other that the switch contacts and the wiring for the beeper. The function of the emergency stop is software-monitored, which means that the emergency stop function represents a so-called E-stop function.

The separate shield locking switch switches off the electric power supply to the valve connection strip. These two individual switches make it possible to activate a shield stop for maintenance work or for instances of diagnostics.

Use the shield locking switch for maintenance work in order to electrically switch off the valve strip.

Emergency stop Shield locking switch

6.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

The PMC®-R control unit is constructed with a housing made of stainless steel, which is hermetically sealed due to its design. The PMC®-R housing is produced without seams but with a flange upon which the keyboard bottom plate is mounted. Furthermore, it contains the emergency stop and support lock-out unit. An O-ring seal under the flange provides for consistency against water up to 3 bar external pressure. The plug side for the connection between I/O unit and electronic accessories is secured three times with the O-ring. The robust housing unit promises additional protection against external influences and a long service life with less maintenance.

E

Design suitable for mining

Rear side of the PMC®-R Important!

Shield locking switches and emergency stop switches do not interrupt the hydraulic supply of the valves. They interrupt the power supply of the valve strip.

That means that the shield functions can be actuated via the hydraulic switches.

Notice!

When you work on a shield or observe the face, ensure your own safety by pressing the shield locking switch.

Rear side of the PMC®-R Fig. 66: View of rear side of the PMC®-R

A2 B2

C2

D2

E2

F2

2

2

1

1

Bucyrus DBT Europe GmbH, Lünen 2008

E

3

A1

B1

C1

D1

E1

3

F1

1 guide pin for brass retaining strip 2 compression springs for support during dismantling 3 boreholes for fastening screw DIN ISO 4762-M 12X140-1.4301

Plug connections for face PMC®-R Tab. 5:

Pin assignments of the plug connections A1 and F1

Pin1

Pin2

Pin3

Pin4

12 V

Send data

Receive data

GND (Ground)

The function of connections A1 to F2 can be found in the projectspecific documentation.

Brass retaining strip A board with socket head screws of DIN ISO 4762-M 12X140-1.4301 is fastened on to protect the SKK24 - connections of the PMC®-R against any damage being caused during transit.

These are also used for fastening the brass retaining strip during operational status.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.5

Brass retaining strip Fig. 67: Holding strip 7

7 2

2 1

2

2

2

2

6

1

6 5

5 2

2

2

2

2

2

7

7 4

3

3

3

3

3

3

3

4

1 threaded hole for fastening with Allen screw DIN ISO 4762-M 12X140-1.4301 2 retaining sleeve with guide pin for SKK24 connector 3 bore holes for retaining clips, long 4 bore holes for fastening the brass retaining strip in the shield (on the holding sheet, among other things) 5 bore hole for guide pin of the PMC®-R

Important!

Observe the safety notes Identification:

Subject: control unit

Manufacturer:

Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen

Description:

PMC-R

Purpose:

Control unit in an electrohydraulic control system

A legible nameplate is fastened to the control unit with the following minimum specifications.

Manufacturer: Bucyrus DBT Europe GmbH Industriestr. 1; 44534 Lünen Type:

PMC-R/2

Type of protection: Identification: Certification:

6.6

I M2 EEx ib I 0158 INERIS 03ATEX0166 Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

The connections necessary according to the drawings in Chapter 4 are plugged into the corresponding ports of the PMC®-R and secured with long staples (SAP part no.: 0000 006 506 94 52). If a PMC®-R has to be exchanged now, the two M12 x 140 Allen screws are loosened and the PMC®-R is removed. The SKK24 plug of the neighboring and sensor connections remain positioned in the brass retaining strip, in order than the PMC®-R control unit can be plugged back on directly and screwed tightly.

E

6 countersunk hole for accommodating and guiding the compression springs of the PMC®-R 7 recess for applying a tool if it should have to be pried up during dismantling (be careful - dismantling must be done without any jamming to avoid damage to the plug-type connections of the PMC®-R.)

Brass retaining strip Serial no.:

XXXX XX XXXX 5th and 6th places correspond to the year of manufacture

Ambient temperature:

Ta = -20°C to +60°C

Type of protection:

EEx ib I in agreement with:

General regulations EN 50014-1997 + Revisions 1 and 2 Intrinsic safety “i”

Bucyrus DBT Europe GmbH, Lünen 2008

E

EN 50020-2002

Doc. no.: 4007 180 010 BA 00

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6.7

Brass retaining strip Pin assignment of the plug-type connections of the PMC®-R The following table lists the possible pin assignment configurations for the hardware. These are determined by the programming tailored to the application.

Tab. 6: Pin assignment of the SKK24 connections of the PMC®-R A2

C2

B2

D2

Pin3

Pin4

Pin3

Pin4

Pin3

Pin4

TX

SGND

TX

SGND

TX

SGND

E2

Pin3

Pin4

TX

SGND

Namur+

F2

Pin3

Pin4

TX

VGND

VGND

Pin3

Pin4

TX

VGND

VGND

Namur+

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

RX

12 V

RX

12 V

RX

12 V

RX

12 V

RX

12 V

RX

12 V

0 -1 mA

0 -1 mA

0 -1 mA

Namur-

Namur-

0.5- 4.5V

0.5-4.5V

0.5-4.5V

0.5-4.5V

0.5-4.5V

0 -1 mA

0 -1 mA

0 -20mA

C1

D1

E1

Pin3

Pin4

Pin3

Pin4

Pin3

Pin4

Pin3

Pin4

Pin3

Pin4

RX

GND

TX

SGND

TX

SGND

TX

SGND

TX

VGND

TX

GND

Pin2

Pin1

RX

12 V

Namur+

BIDIinterface

F1

Pin4

VGND Namur+

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

Pin2

Pin1

TX

12 V

RX

12 V

RX

12 V

RX

12 V

RX

12 V

0 -1mA

0 -1mA

Namur-

Namur-

0.5-4.5V

0.5-4.5V

0.5-4.5V

0.5-4.5V

0 -1mA

0 -1mA

BIDIinterface

0 -20mA

SGND: connected GND for sensors/external devices VGND: connected GND for valve control

Namur+: namur sensor supply Namur-: namur sensor input

RX: receiving of serial communication GND ground (power supply) TX: transmission of serial communication 0 - 20 mA: current input 0 - 1 mA: current input (0.2 - 1 mA) A1, F1 power supply A2, D1, D 2 200 mA, group can be deactivated via Pin1 B1, B2, C1, C2 60 mA E1, E2, F2 1000 mA, group can be deactivated via Pin1. in addition, the voltage is switched off via emergency stop and/or the support lock-out switch.

6.8

Face control with PMC®-R for shearer operation

E

B1 Pin3

Bucyrus DBT Europe GmbH, Lünen 2008

A1

Control system PMC®-R Control system PMC®-R Safety instructions J The control system may only be used by persons who have

successfully completed training on it.

J The operating manual must be given to all persons who are as-

signed to use the control system by the respective supervisory personnel after giving instructions.

J The operating personnel must be trained and instructed so that

they are familiar with the fundamental control and switching functions.

J The personnel must at least be familiar with the warning signals

of the control system and be able to switch off or end the control functions of the control system when dangerous situations occur.

J Do not start any control functions when there are people in the

danger zone.

J Only use components which are described in the documenta-

tion of the control system.

J In the event of malfunctions, only trained personnel is allowed

to replace defective components for original spare parts. Return defective equipment to the manufacturer for repairs.

J Only connectors, cables and components which are listed and

approved for the control system may be connected in the control system by instructed personnel.

J Only use the cables and cable cross-sections and lengths spe-

cified for the control system.

J Do not make any independent modifications to the control sys-

tem. Otherwise, the approval becomes invalid.

J The control system equipment may only be used within the spe-

cified temperature range, which can be found in the component certifications.

J Faulty seals on the individual components must be replaced

immediately.

J Make sure that the mounting bolts are firmly tightened so that

the housing is tight in accordance with IP54. Never open the housing with force.

J The meanings of the keys, displays and LED displays are

defined only with the software to be loaded. Observe the operating instructions of the software.

J Before commissioning the control system, read and observe the

operating instructions.

J The warnings in this manual and the generally valid safety regu-

lations must be observed.

J During installation and operation, make sure that the operating

instructions have been read and observed by the personnel.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.9

Control system PMC®-R Identification: Subject: Manufacturer:

Control system Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen Description: SYSTEM-PMC-R Purpose: intrinsically safe, electro-hydraulic control system.

Control of valves and sensors Display and transmission of control functions.

A nameplate must be attached to the housing of the control system which is permanently legible and has the following minimum specifications, whereby the CE-marking is 5 mm high.

Manufacturer: Type:

Bucyrus DBT Europe GmbH Industriestr.1; 44534 Lünen SYSTEM-PMC-R

Type of protection:

I M2 EEx SYST ib I

Identification: Certificate number:

0158 INERIS 03ATEX 0218

Type of protection: EEx ib I in acc. with: General regulations EN 50014-1997 A1.- A2 Intrinsic safety “i” EN 50020-1994 Intrinsically safe systems pr EN 50394-1-2002 Construction The control system is used for the intrinsically safe control of sensors and valves. The control system is still used for the evaluation, display and forwarding of control commands. The individual components, their numbers, the corresponding connection of the individual components and their parameters are specified in the EC type examination certificate for the control system.

The EC type examination certificate is a component of the operating instructions.

Function The function of the control system is defined by the loaded software. The functions can be found in the operating instructions of the software.

Connections Lines: 4 x max. 1.5 mm2 (8 x max. 1.5 mm2) Note: Hose cable with L-2YYQY 2x2x1.5 mm2 or optionally Hose cable with L-2YYQY 4x2x1.5 mm2 or optionally Cable LiYCY 4x1.5 mm2 or optionally

6.10

Face control with PMC®-R for shearer operation

Control system PMC®-R All radial thicknesses for the insulations > 0.2 mm.

Manufacturer: Bucyrus DBT Europe GmbH Maintenance notes J The control system may only be repaired and maintained by

persons who have successfully completed the appropriate training.

J If several persons are involved in carrying out repair work, all

persons involved must agree on the working procedure.

J If the activities of several work groups can influence each other,

they must clearly agree on how the work is to be done.

J Before beginning repair work, the control system must be dis-

connected from power and be locked out.

J The operating manual is distributed to all persons who are as-

signed to do repair work by the respective supervisory personnel after briefing.

J The knowledge of the switching operations of the control sys-

tem is an important precondition for safely carrying out repair work. For this reason, the operating manual and maintenance instructions of this control system are to be observed.

J Do not use corrosive liquids for cleaning control system com-

ponents.

J Only remove the protective cap from the plug at the time of

connection. Replace the protective caps of unused plugs.

J Replace defective seals immediately.

J The control system components may only be transported in the

containers provided for them. Avoid any unnecessary vibrations, impacts and contamination when doing so.

J After repair work to the control system, please check whether

the ground connections are securely connected to the housings.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.11

ExPC MCU2 central computer ExPC MCU2 central computer The following drawing shows the explosion-proof housing which encloses the underground central control computer.

Fig. 68: Explosion-proof central computer MCU2 1

1

2

2

7

6 4 5

3

4 3

1 explosion-proof computer housing 5 brass strip 2 housing cover with viewing window 6 fiber-optic cable connection RxD 3 terminal box 7 fiber-optic cable connection TxD 4 connections for SKK24 connectors (mouse, keyboard, server,...)

Device function In a separate housing with IP 54 protection, an electronic subassembly for operating various serial interfaces is installed. The device is used in the Ex area for various functions. It is completely manufactured for category M2.

The next figure shows the substructure of the ExPC housing in which the keyboard operating unit with mouse are installed.

6.12

Face control with PMC®-R for shearer operation

ExPC MCU2 central computer Master Control Unit MCU-2I */*/*/*/* Only use the MCU2 in the specified temperature range.

Installation and testing may only be carried out by personnel trained to do this.

Never open the MCU2 with force.

Only exchange defective parts for original parts, since otherwise the approval becomes invalid.

The MCU2 may only be operated in a housing which is in good condition.

Important!

Unused connectors are to be sealed.

Description The explosion-proof encapsulated personal computer (PC) with the intrinsically safe communication unit is for collecting process data underground. The data can be shown graphically and can be sent to an aboveground PC via one of the interfaces.

The MCU2 is in an explosion-protected and explosion-proof housing. The four COM interfaces and the interfaces for the keyboard and mouse are electrically isolated from the electronic components of the MCU2 and are intrinsically safe.

Technical data Dimensions and weight Weight

approx. 200 kg

Dimensions

approx. 620x800x140mm

Certifications and identification: Certification No.

02 ATEX E 254 X

Type of protection

I M2 EEx ib I

Material number

4008 031 010 00 00

Temperature range

-20°C to +60°C

Electric supply: Power supply of the explosion-proof part

110-240 V AC

Power supply of the intrinsically safe part

12 V DC, max 1.5 A

Non-intrinsically safe USB interface Components:

Doc. no.: 4007 180 010 BA 00

Processor

P III 400 MHz

RAM memory

128 MB

Data memory

1 GB Flash disk

Hard disk

30GB 2.5”

Display

18"

VRVT / 01

6.13

ExPC MCU2 central computer Resolution

1280:1024

Operating system Windows 2000 PRO EN Input equipment

keyboard with integrated mouse

Intrinsically safe interfaces: COM 1 BIDI SKK24 COM 2 TTY SKK24 COM 3 fiber-optic connection 9 µm COM 4 not assigned Components Processor

P III 400 MHz

RAM memory

128 MB

Data memory

1 GB Flash disk

Hard disk

30 GB 2.5"

Display

18"

Resolution

1280:1024

Operating system

Windows 2000 PRO EN

Input equipment keyboard with integrated mouse Type key The following type key is used: MCU-2I */*/*/*/* = blank without Profibus subassembly = PProfibus subassembly installed = blank

no I/O installed at port 4

= BBiDi with external power supply at port 4 = CBiDi with internal power supply at port 4 = TTTY external PS port 4, transmitter 1/2, receiver 3/4 = UTTY external PS port 4, transmitter 3/4, receiver 1/2 = VTTY internal PS port 4, transmitter 1/2, receiver 3/4 = WTTY internal PS port 4, transmitter 3/4, receiver 1/2 = blank

no I/O installed at port 3

= BBiDi with external power supply at port 3 = CBiDi with internal power supply at port 3 = TTTY external PS port 3, transmitter 1/2, receiver 3/4 = UTTY external PS port 3, transmitter 3/4, receiver 1/2 = VTTY internal PS port 3, transmitter 1/2, receiver 3/4 = WTTY internal PS port 3, transmitter 3/4, receiver 1/2 = blank

no I/O installed at port 2

= BBiDi with external power supply at port 2 = CBiDi with internal power supply at port 2 = TTTY external PS port 2, transmitter 1/2, receiver 3/4 = UTTY external PS port 2, transmitter 3/4, receiver 1/2 = VTTY internal PS port 2, transmitter 1/2, receiver 3/4 = WTTY internal PS port 2, transmitter 3/4, receiver 1/2 = blank

no I/O installed at port 1

= BBiDi with external power supply at port 1 = CBiDi with internal power supply at port 1 = TTTY external PS port 1, transmitter 1/2, receiver 3/4 = UTTY external PS port 1, transmitter 3/4, receiver 1/2 = VTTY internal PS port 1, transmitter 1/2, receiver 3/4 = WTTY internal PS port 1, transmitter 3/4, receiver 1/2

A few additional identification markings can be added without influencing the intrinsic safety.

6.14

Face control with PMC®-R for shearer operation

ExPC MCU2 central computer Connections The peripheral lines are electrically connected by clearly labeled connectors.

Identification DBT GmbH with address Type: MCU-2I */*/*/*/* DMT 02 ATEX E *** CE A***A F-No. ...........

I M2 EEx ib I A***A = Mark of the notified body monitoring production Master Control Unit MCU-2I */*/*/*/* The year of manufacture is coded in the F no.

The permissible ambient temperature range is -20°C to 60°C. Commissioning, installation J The device may be put into operation in Category M2.

J The power is connected via plug connectors. These may only

be professionally installed.

J Unused connectors are to be sealed.

J The equipment is designed for the IP 54 protection type (when

professionally attached to an external housing); in the event of harsh ambient conditions (e.g. sprayed water), the equipment must be additionally protected by the operator.

J Requirements for safe use from the EC type examination certi-

ficate must be observed.

J The connection to the power supply and wiring with external

circuits must be specifically certified.

J The equipment is to be electrostatically grounded.

J The device may only be operated when its housing is com-

pletely closed and in good condition.

J It is forbidden to operate the device when the housing is

damaged.

Application The devices are only approved for proper and intended use.

In the case of noncompliance, any warranty expires and manufacturer cannot be held responsible.

Servicing, maintenance Maintenance measures may only be carried out by personnel from DBT Automation or by persons specially trained by DBT Automation.

Troubleshooting No changes may be made to devices which are operated in connection with explosive areas. Repairs on the device may only be carried out by skilled personnel specifically trained and authorized to do this.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.15

ExPC MCU2 central computer Disposal The disposal of the packaging and worn parts is to be done according to the regulations of the country in which the device was installed.

Base Base dimensions Length: 629 mm Width:

427 mm

Height: 585 mm Fig. 69: Base for MCU2 2 7 7

1

7

7

4

4

5

7

7

3

6

1 front view 2 side view 3 top view 4 flap for keyboard

6.16

5 flap for storage compartment 6 locking bolt (cut out) 7 locking bolt

Face control with PMC®-R for shearer operation

ExPC MCU2 central computer Keyboard accessory Fig. 70: Keyboard with integrated mouse

1 3 2

4

1 keyboard 2 y-cable

3 SKK24 mouse plug 4 SKK24 keyboard plug

Pin

Wire color

1

white

2

brown

3

green

4

yellow

1

not assigned

2

brown

3

green

4

not assigned

Tab. 7: Keyboard pin assignment SKK24 mouse

SKK24 keyboard

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.17

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

In the event of malfunctions, the “Provider” may only be exchanged by trained personnel for functioning original devices.

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 and 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. 71:

10

1 2 4

11

8 7

4

7

4

7

4

5

5 3

6

7

1 connection for fiber-optic cable (FO) 2 connection, 12 V supply 3 provider el. / FO 4 BIDI interfaces to PMC®-R/D/V 5 Ethernet cable between Provider and PORTUX computer

6 PORTUX computer 7 PMC Opto BIDI module 8 power supply board 9 enclosed housing 10 explosion-proof housing 11 barriers

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

6.18

Face control with PMC®-R for shearer operation

Provider PMC®-P XP Opto Ethernet The following components are securely installed in the explosionproof housing: J PORTUX (6) J SWITCH (3) J PCB BARRIER (11) Tab. 8: Connection composition Port

M1

M2

M3

M4

P1

L1

Connector type SKK24

SKK24

SKK24

SKK24

SKK24

E2000

Application

BIDI

BIDI

BIDI

Voltage supply 12 V DC

Optical plug connector

BIDI

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

U0

Current strength

I0

DC

12.8 V 2A

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

Connection P1 Tab. 10: Maximum values for P1 Voltage:

Ui

DC

12.8 V

Current strength

max. Ii

Ci

2A

Internal capacitance

max.

58 nF

Internal inductance (leakage max inductance)

Li

5 μH

The Provider consists of an explosion-proof housing (10), which is installed in an enclosed housing (9) which is intrinsically safe.

The electric components which are built into the two housings are connected with insulated individual wires and FO cables.

The circuit board material, the cable insulation, the insulating board and the grouting of the plug connectors and cable feedthrough comply with the creep resistance 100 (IEC60112-1).

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

Name and address of the manufacturer Type: PMC-P XP Opto Ethernet Identification: 0158 DMT No.: DMT 06 ATEX E 048 Type of protection: I M2 EEx ib d I Serial no.: XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ambient temperature: Ta -5°C to + 50°C

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.19

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

Fig. 72: Sketch for the converter connections

L1 fiber-optic connection (pluggable) M1 to M4 SKK24 connection for data connection to PMC® system P1

SKK24 voltage, 12 V DC

M5

plug (another SKK24 possible as an option)

The connections M1 to M4 have the same pin assignments as the A1 connection of the PMC®-R (and PM4), i.e.: An optocoupler is always connected with its red connection socket.

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

The Provider is supplied with voltage with its own current-limiting power supply. The PMC® face or gearbox control systems or other PMC® applications are connected via an optocoupler. This is connected to the corresponding connection defined in the system drawing with its red connection socket.

Important!

The Provider can only be operated with a higher-ordered control system. Observe the operating instructions of this 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 Transmitter module (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

6.20

-5°C to +50°C Face control with PMC®-R for shearer operation

Provider PMC®-P XP Opto Ethernet Communication The SWITCH is connected directly to the fiber-optic socket (item L1) with 4 fiber-optic cables via max. 2 fiber-optic cable feedthroughs. The fiber-optic socket is for connecting 2 transmission and 2 receiving data connections.

The PORTUX is connected to 4 modules with 8 fiber-optic cable via max. 2 fiber-optic cable feedthroughs. Each module has 1 fiberoptic transmission and receiving connection. The fiber-optic data is converted into electric signals in the modules. These signals are conducted from each module to one connector each (items M1 to M5) for forwarding to optocouplers.

Patch cable A patch cable with the corresponding fiber-optic plug-type connections is included with delivery for connecting the Provider PMC®-P XP Opto Ethernet to the fiber-optic data line above ground provided by the mining company. This fiber-optic cable is pulled into a hydraulic protective hose like the SKK hose cable to make it less susceptible to contamination and mechanical damage.

Fig. 73: Patch cables and connectors to the Provider PMC®-P XP Opto Ethernet

Fiber-optic device socket The device socket is a reliable 4-pin plug-type connection for glass-fiber patch cables. It uses 4 standard E2000 couplings and establishes a secure connection.

Fig. 74: Device socket (outside)

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.21

Provider PMC®-P XP Opto Ethernet The device socket is a housing interface for 4 fiber-optic cables.

Four E2000 connectors are plugged within one housing. From the outside, 4 E2000 connectors can also be plugged in. These are preferably combined in a sealed connector on a mining-compatible patch cable.

The fiber-optic cable leading to above ground (provided by the customer) must be connected to the connection socket.

An E2000 connector and the associated socket are shown in the following figure (double version). The terms “right” and “left” are defined as follows: Fig. 75: Fiber-optic connection E2000

2 4 1 3

7 5 6

1 left connector 2 left coupling 3 right connector

5 green sleeve 6 black sleeve 7 lever for disengaging the connector

4 right coupling “Left” and “right” refer to the view from the cable across the connector toward the coupling.

Definition of the light direction J From the left connector (cable with the green sleeve) to the left

socket

J From the right socket to the right connector (cable with the

black sleeve)

6.22

Face control with PMC®-R for shearer operation

Solenoid driver module PMC-SD1 Solenoid driver module PMC-SD1 The solenoid driver is placed at a distance from the PMC®-R, in accordance with the modular concept. The solenoid driver can switch up to 22 valves. A four-wire cable connects the solenoid driver with the PMC®-R. A switching circuit in the solenoid driver controls the data flow between the switching circuits and the PMC®-R and determines the validity of the values or announces a defect. The solenoid driver is completely covered by a 2-component resin cast. Three LEDs in the middle show the function of the solenoid driver on a continuous basis and provide the following information: J green LED: 12 Volts are present, J yellow LED indicates correct data flow, J red LED indicates an error in the data flow between the

PMC®-R and the solenoid driver.

Fig. 76: SOLENOID DRIVER MODULE PMC-SD1-OS4 ATEX A

B

1/2

C

d

5/6 3/4

E

F

G

9/10 7/8

H

I

X

17/18

13/14

K

19/20

15/16 11/12

J

21/22

X = Connection to PMC®-R

On the solenoid driver next to the connection for the PMC®-R, there are two groups of connections: J connections A to F (group of 6), J connections G to K (group of 5).

All connections are suitable for activating double solenoid valves.

The connections of the group of 5 (G - K) also allow sensor data to be read in.

Important!

The connecting cables to such sensors must have a crossover; they may not be connected through 1:1 (see original drawings and piece lists!)

Pin assignment of valve strip connections (See project-specific documentation) Identification: Subject: Manufacturer: Description: Purpose:

Valve/sensor logic Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen PMC/ASL* Intrinsically safe actuation of valves and sensors.

There must be writing on the valve/sensor logic which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high.

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.23

Solenoid driver module PMC-SD1 Manufacturer: Type: Type: Type:

Bucyrus DBT Europe GmbH Industriestr.1; 44534 Lünen

PMC/ASL1 with Hirschmann plug-type connector PMC/ASL2 with Escher plug-type connector PMC/ASL3 with HYDROSTAR plug-type connector

Type of protection:

I M2 EEx ia I

Identification: Serial number:

0158 XXXX XX XXXX 5th and 6th places correspond to the year of manufacture

Certificate number: Ambient temperature: Type of protection:

INERIS 02 ATEX 0028 X Ta = -20°C to +70°C EEx ia I in acc. with:

General regulations EN 50014-1997 (VDE 0170/0171) Part 1 Intrinsic safety “i” EN 50020-1994 (VDE 0170/0171) Part 7

Function The valve/sensor logic is for activating valves and sensors within a high-ordered and intrinsically safe, certified control system. Furthermore, valve and sensor signals are passed on to the control system. The exact operating modes and functions are specified in the control system documentation.

6.24

Face control with PMC®-R for shearer operation

Coding plug Coding plug Coding plug SKK24 Fig. 77: Coding plug SKK24; ATEX

The coding plug is plugged on the PMC®-R at the B2 connection and recognized and read in during start-up.

The following types of coding plugs are intended for this program: Tab. 11: SKK24 coding plug types and their allocation Type

Parts number

Coding

Function

CP1 6K8

4008 004 800 00 02

6.8 kOhm

Identification of the PM4 server

CP1 10K

4008 004 810 00 02

10 kOhm

Identification of the PMC®-R server

CP1 15K

4008 004 820 00 02

15 kOhm

Identification of the number generator

CP1 20K

4008 004 830 00 02

20 kOhm

Special shield identifier

CP1 27K

4008 004 840 00 02

27 kOhm

Special shield identifier

CP1 68K

4008 004 850 00 02

68 kOhm

Special shield identifier

Other coding plugs If a special shield identifier is required on systems in which several shields are controlled by one control, a coding plug must be installed on the valve connection strip on a special shield without a control computer. only on the PMC®-R system

Example: A coding plug is installed on the valve connection strip for the function as a blocking shield.

Doc. no.: 4007 180 010 BA 00

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6.25

Coding plug Fig. 78: Drawing CODING PLUG HIRSCHMANN CPH 27K

Fig. 79: Valve connection strip with connection marking for coding plug G d A B C E F

1/2

2/4

5/6

7/8

9/10

13/14

11/12

H

I

J

K

15/16

17/18

19/20

21/22

I

J

K

Fig. 80: Drawing CODING PLUG OS 4T

Fig. 81: SOLENOID DRIVER MODULE PMC-SD1-OS4 ATEX A

B

1/2

C

d

5/6 3/4

E

F

G

H

9/10 7/8

15/16 11/12

13/14

19/20 17/18

21/22

Connection to PMC®-R

The coding plug is connected at connection “K” (port 21/22) of the valve strip.

6.26

Face control with PMC®-R for shearer operation

Coding plug Tab. 12: Additional Hirschmann coding plugs Type

Parts number

Coding

Function

CPH 10K

4008 039 102 00 00

10 kOhm

Function coding

CPH 15K

4008 039 103 00 00

15 kOhm

Function coding

CPH 20K

4008 039 104 00 00

20 kOhm

Special shield coding

CPH 27K

4008 039 105 00 00

27 kOhm

Special shield coding

CPH 68K

4008 039 106 00 00

68 kOhm

Special shield coding

Identification: Subject: Manufacturer: Description: Purpose:

Coding plug Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen PMC coding plug Termination and coding plug.

A nameplate is to be laser-engraved on the coding plug with the following minimum specifications: Manufacturer: Type: Type of protection: Identification: Certification: Serial no.: Ambient temperature:

Bucyrus DBT Europe GmbH Industriestr. 1; 44534 Lünen PMC coding plug I M2 EEx ia I 0158 INERIS 03ATEX0066/01 XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20°C to +70°C

Type of protection: EEx ia I in agreement with: General regulations EN 50014-1997 + Revisions 1 and 2 Intrinsic safety “i” EN 50020-2002 Function The coding plug serves as a termination plug on signal lines. It is still used for software detection and coding on control units.

Parameters

Doc. no.: 4007 180 010 BA 00

Supply voltage

max. DC 13.2 V

Power supply

max. 2 A

Ambient temperature

Ta -20°C to +70°C

VRVT / 01

6.27

Intelligent coding plugs The so-called intelligent coding plug was developed in order to take over the various tasks of the previously existing coding plug. It is to be programmed according to the intended task before using it on the shield controls. By programming it, the memory chip built into the plug provides information about what coding the plug should have. The software can read in several coding tasks simultaneously. example:

Tasks of the selected control: J use on a special shield, J shield control should be a numerator, J shield is a blocking shield.

These three tasks can be entered on an intelligent coding plug.

Identification: Subject: Manufacturer: Description: Purpose:

Coding plug Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen PMC coding plug Termination and coding plug.

A nameplate is to be laser-engraved on the coding plug with the following minimum specifications:: Manufacturer: Bucyrus DBT Europe GmbH Industriestr. 1; 44534 Lünen Type: PMC coding plug Type of protection: Identification: Certification: Serial no.: Ambient temperature: Type of protection:

I M2 Ex ia I 0158 INERIS 06 ATEX 0055 X XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20°C to +70°C

Ex ia I in agreement with: EN 60079-0 : March 2004

General regulations

IEC 60079-11 : July 2006

Intrinsic safety “i”

Function: The coding plug serves as a termination plug on signal lines. It is still used for software detection and coding on control units.

Parameters

6.28

Supply voltage

max. DC 13.2 V

Power supply Maximum input capacitance Maximum input inductance

max. 2 A Ci = 240 nF with 206R in series Li = 0.

Face control with PMC®-R for shearer operation

Sensors Sensors A variety of sensors are available for utilizing all options of the PMC®-R individual controls. Analog sensors exist for pressure measurement and shifting path measurement.

Pressure sensors A pressure sensor with a very low current consumption was developed for the PMC®-R system. The basis of the pressure sensor is a “Wheatstone” measuring bridge which is attached to a ceramic membrane. A measurement-value booster, which generates a measuring voltage from 0.5 to 4.5 V for a measuring range from 0 to 600 bar, is installed in the pressure sensor housing. The hydraulic side of the pressure sensor (plug-type connector DN10) is directly connected with the measuring body of the sensor. The electrical side has an SKK24 socket for the electrical connection between the PMC®-R and sensor using SKK24 hose cables or lines. For reasons of safety in the face of mechanical loads, these cable connections should be made with hose cable. The measured values of the sensor allow simple measurements such as for shield setting, as well as special automation tasks such as positive set automatic, pull shield under roof contact or adjustable setting pressure, etc.

Fig. 82: PRESSURE SENSOR IPS 600; ATEX 8

4

2

3

1

6

5

9

4 7

1 name plate, if not lasered 6 groove for hydraulic clip 2 place for lasered type specifications 7 protective cap, SKK24 side 3 SKK24 socket 8 protective cap, hydraulics side 4 bore holes for SKK24 clip 9 bore holes for guide pins 5 sealing groove, hydraulic side with O-ring Fig. 83: Illustration of the pressure sensor

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6.29

Pressure sensors Fig. 84: Sectional drawing of the pressure sensor

1

3 2

1 SKK24 socket 2 amplifier 3 membrane

Fig. 85: Measurement diagram of the pressure sensor Signal (mA) 1

0,2 bar 0 100 supply voltage output signal ground current consumption

200

300 400 500 600

12 V Pin 1 0.2 - 1 mA Pin 2 Pin 4 10 mA

Identification type IPS: Subject: Manufacturer:

Pressure sensor Bucyrus DBT Europe Automation GmbH Industriestr. 1, 44534 Lünen Description: IPS * Purpose: Measuring system pressures There must be writing on the pressure sensor which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high: Name and address of the manufacturer Type: IPS * Type of protection: Identification: Certificate number: Serial number: Type of protection:

I M2 EEx ib I 0158 DMT 03 ATEX E 008/01 XXXX XX XXXX 5th and 6th places correspond to the year of manufacture EEx ib I in acc. with:

EN 50014: 1997 +A1 - A2 General regulations

6.30

Face control with PMC®-R for shearer operation

Pressure sensors EN 50020: 1994 Intrinsic safety “i” Description and function The pressure sensor serves to convert a system pressure into a proportional electric signal for a pressure range from 0 to 600 bar.

The pressure sensor is calibrated and tested for this pressure range.

Parameters Input voltage

Ui DC 13.2 V

Identification type PDS: Subject: Manufacturer: Description: Purpose:

Pressure sensor Bucyrus DBT Europe Automation GmbH Industriestr. 1, 44534 Lünen PDS *** Measuring system pressures

There must be writing on the pressure sensor which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high.

Name and address of the manufacturer Type: PDS 100 Type of protection: Identification: Certificate number: Ambient temperature: Serial number: Type of protection:

I M2 EEx ib I 0158 DMT 02 ATEX E 201 Ta = -20°C to +80°C XXXX XX XXXX 5th and 6th places correspond to the year of manufacture EEx ib I in acc. with:

EN 50020: 1994 Intrinsic safety “i” General regulations EN 50014: 1997 +A1 – A2 Description and function The pressure sensor serves to convert a system pressure into a proportional electric signal for a pressure range from 0 to 100 bar.

The pressure sensor is calibrated and tested for this pressure range.

Parameters Supply voltage Signal voltage Output voltage Ambient temperature

Doc. no.: 4007 180 010 BA 00

VRVT / 01

Ui DC 13.2 V DC 0 - 4 V Uo DC 13.2 V Ta -20°C to +80°C

6.31

Reed rod Reed rod The shifting unit path is measured using a reed rod, which is installed in the shifting ram. The measuring contacts are installed in a stainless steel tube and are actuated using a ring magnet, which is installed in the piston rod. The accuracy of measurement is approximately 4 mm.

Fig. 86: Sectional drawing (schematic diagram) of the measuring rod x = 100%

x = 0%

Annular magnet

Pin 1 12 V Pin 2 0.5-4.5V Pin 3 0V

Electronics

Reed contact

Ring magnet

Casting compound

Rust-free tube

Fig. 87: Measurement diagram of the reed rod Signal (V) 4.5

0.5 % Path 0

100

supply voltage 12 V signal output 0.5 V – 4.5 V current consumption

10 mA

Reed rods can be also be used for length measurements of other hydraulic cylinders, such as stabilizing cylinders and flipper cylinders or sliding canopy cylinders. Occasionally, they are also used outside of cylinders.

The plug-type connection on the reed rod is a 4-pin Lumberg plug.

If the reed rod is installed in a hydraulic cylinder, a screw-in socket with a transition from the Lumberg plug to the SKK24 socket is attached so that there can be a cable connection to the hose cable from the PMC system.

If a reed rod is used externally (outside of a hydraulic cylinder), a hose cable is required with a Lumberg cable pigtail (Lumberg socket).

Identification: Subject: Manufacturer: Description: Purpose:

6.32

Reed rod Bycurus Europe DBT Automation GmbH Industriestr. 1, 44534 Lünen RMS2-* Measurement of path lengths Face control with PMC®-R for shearer operation

Reed rod There must be writing on the reed rod which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high.

Name and address of the manufacturer Type: RMS2-* Type of protection: Identification: Certificate number: Ambient temperature: Serial number:

I M2 EEx ib I 0158 BVS 03 ATEX E 403/N1 Ta = -20°C to +85°C XXXX XX XXXX 5th and 6th places correspond to the year of manufacture

Type of protection: EEx ib I in acc. with: EN 50014: 1997 +A1 – A2 General regulations EN 50020: 2002 Intrinsic safety “i” Description and function By moving over the measuring rod with a ring magnet, the reed contacts inside the rod are actuated. These reed contacts switch partial voltages of a resistance chain connected as a voltage divider to a downstream amplifier, which generates an output voltage from 0.5 to 4.5 V corresponding to the path. Another amplifier stage generates an output voltage from 0 to 5.0 V, which is proportional to the ambient temperature of the electronics. These measuring signals are forwarded to a higher-ordered control system for processing.

Parameters

Doc. no.: 4007 180 010 BA 00

Supply voltage

U i DC 13.2 V

Ambient temperature

Ta -20°C to +85°C

VRVT / 01

6.33

Cables and lines Cables and lines Identification: Name and address of the manufacturer Type: SKK***** Type of protection:

IM1 EEx ia I

Identification: Serial number:

0158 XXXX XX XXXX 5th and 6th places correspond to the year of manufacture

Certificate number: Type of protection:

DMT 02 ATEX E 050U/N1 EEx ia I in acc. with:

EN 50014 1997+A1-A2 General regulations EN 50020:1994 Intrinsic safety “i” EN 50303:2000 Group I, Category M1 Function and use The connectors consist of a socket and a plug part and serve as electrical connections in intrinsically safe electrical circuits. They provide reliable electrical isolation, depending on the type, up to a max. of 4 different intrinsically safe electrical circuits with a total peak voltage value of 60 V. The attachment of the connectors, as well as the used cables, must be examined with a special certification process.

Parameters The parameters are specified in the component certification of the couplers. The component certification is a component of the complete user information.

6.34

Face control with PMC®-R for shearer operation

Connecting cable Connecting cable Connecting hose cable for protected connections between the SKK24 and other plug connector types.

The connection between, e.g., external shield support locking switch and PM4 in the shields in which no PM4 is installed is established with hose cables with Hirschmann ends.

Fig. 88: HOSE CABLES with various ends 6

4

2 1

2

1

3

7

5

1 fastening device for Talember 2 cable end with Hirschmann connector 3 part of cable in protective hose 4 cable end with OS4T connector

5 cable end with SKK24 connector with PG9 cable gland 6 cable end open 7 cable end Lumberg socket

Tab. 13: Allocation of the HOSE CABLE Pin

Pin assignments

Core

Pin

1

+12 Volt

White

1

2

Data

Brown

2

3

Data

Green

3

4

Ground (GND)

Yellow

4

Other pin assignments are explained in the project-specific descriptions.

Fig. 89: SKK24 female insert with pin numbers

1 4

2 1 3 4

2 3

Pin number

SKK24 male insert with pin numbers

Front view of connection socket

Doc. no.: 4007 180 010 BA 00

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Pin number

Front view of the connection plug

6.35

Double adapter SKK24 female/female Double adapter SKK24 female/female A double adapter is required for connecting two cables with SKK24 plugs. Simply connecting two cables is not possible in the PMC hose cable system. The formation of the SKK24 plug and the pin assignment system both prevent this. The 1:1 connection causes the plug inserts to cross-over, as seen in the sketch displayed below.

Fig. 90: 1:1 cable system 2

1

3

4

Cores 1 and 2

Cores 3 and 4 1 pin 1 white 2 pin 2 brown

2

1

3

4

3 pin 3 yellow 4 pin 4 green

Because the double adapter is assigned the same way as the cable, it functions like an additional cable so that the crossover can be reversed.

Fig. 91: Connection between two cables with double adapter cables2

cables1 white/brown

(yellow/green)

white/brown

yellow/green

(white/brown)

yellow/green

adapter

Fig. 92: Double adapter for connecting two SKK24 - hose cables 1 1 2 2

1 SKK24 sockets 2 bore holes for clamps

This double adapter is intended for the extension of SKK24 cables. (optional system part)

6.36

Face control with PMC®-R for shearer operation

Loading cable Loading cable A loading cable is required in order to be able to load a program into the PMC®-R. This is connected to the PMC®-R connection C1 and with the DSUB coupling to the serial connection of the computer from which the program is to be loaded.

Fig. 93: Loading cable 2

1

1 connection DSUB for PC 2 connection SKK24 for PMC®-R unit (Port C1) Pin DSUB 9

Pin assignments

Wire color

PIN SKK24

-

+12 Volt

White

1

2

Data

Brown

2

3

Data

Green

3

5

Ground (GND)

Yellow

4

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6.37

Power supplies Power supplies The figure shows an explosion-protected housing of a power supply for the PMC®-R with integrated supply adapter. The double power supply contains two intrinsically safe 12 V direct-current power supplies, one for each group of shields. The size of the current groups is dependent on the number of valves to be switched and on the number of other electricity consumers.

Fig. 94: Double power supply with integrated supply adapter; ATEX

1

2 3 1 supply voltage connection 2 connection for PMC®-R Port A1 3 connection for PMC®-R Port F1

Technical data Designation

Technical data

Weight

20.5 kg

Dimensions

372x264x107 mm

Certification no.

BVS 03 ATEX E 249

Type of protection

ATEX I M2 EEx d [ib] I

Material no.

4008 022 010 00 XX

Temperature range

-20°C to +50°C

Primary circuit supply voltage

AC 80 V to 265 V

Primary circuit max. supply current

AC 20 A

Intrinsically safe output circuit nominal voltage

12 V

Intrinsically safe output circuit max. voltage

12.4 V

Intrinsically safe output circuit max. current

2a

Max. connectable capacitance Co

30 μF

6.38

Face control with PMC®-R for shearer operation

Power supplies Designation

Technical data

Max. connectable inductance Lo

30 μH

Intrinsically safe connection Pin assignment X4 / X5

Pin 1

12 V

Pin 2

BIDI

Pin 3

BIDI

Pin 4

GND

Min. cable cross section, primary circuit

6 mm2

Cable cross section of the connecting cable of the primary circuit

25-28 mm2

Connecting cable of the intrinsically safe output

SKK24 system cable

J The seal faces may not be reworked.

J The explosion-proof housing may only be opened when the

power is disconnected.

Identification: Subject: Manufacturer:

Power supply Bucyrus DBT Europe GmbH Industriestr.1, 44534 Lünen Description: SPU***-**-*,*-***

Purpose:

Intrinsically safe power supply and data transmission of two electrical circuits

Two nameplates are to be securely fastened to the cast housing with the following minimum specifications, permanently legible. One plate is securely fastened to the outer wall and the second plate on the inside: Name and address of the manufacturer Type: SPU***-**-*,*-*** Identification: DMT No.:

0158 BVS 03 ATEX E 249

Type of protection: Serial no.:

I M2 EEx d [ib] I XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20°C to + 50°C

Ambient temperature:

Furthermore, a warning sign “Do not open with power connected” is securely fastened to the housing cover. The two intrinsically safely connected plug connectors are clearly labeled with X4 and X5 on the terminal box.

Type of protection:

EEx d [ib] I in acc. with:

EN 50014-1997 +A1-A2 General regulations EN 50018-2000 Explosion-proof encapsulation EN 50020-1994 Intrinsic safety “i”

Doc. no.: 4007 180 010 BA 00

VRVT / 01

6.39

Power supplies Type key Type SPU *** - ** -*;*- *** Type of distributor board Nominal output current Nominal output voltage Supply voltage Single power unit Power circuit SPU42-**-*,*-*** = Supply voltage AC 19 V to 50 V; DC 18 to 70 V SPU230-**-*,*-*** Supply voltage AC 33 V to 276 V; DC 35 to 362 V SPU***-**-*;*-*** Max. supply current AC 9 A DC 9 A Output circuit voltage intrinsically safe SPU***-12-*,*-*** Nominal voltage DC 12 V; max. voltage DC 12.8 V SPU***-05-3.2-UN Nominal voltage DC 5 V; max. voltage DC 5.8 V Output circuit current intrinsically safe SPU***-12-1.0-*** Nominal current 920 mA max. current 1.1 A SPU***-12-1.4-*** Nominal current 1.4 A; max. current 1.58 A SPU***-05-3.2-UN Nominal current 3.2 A; max. current 3.58 A Circuit board SPU***-**-*,*-UN with distributor board 4008.032.011.01.00 SPU***-**-*-*-PMC with BIDI coupler circuit board 4008.004.263.01.00 SPU***-**-*,*-PM4 with BIDI coupler circuit board 4008.004.572.01.00 Notice!

The version with the nominal output voltage DC 5 V is only possible with the nominal current of 3.2 A and the UN circuit board.

Construction The power supply consists of an explosion-proof housing and a securely fastened attachment housing with intrinsically safe type of protection, which are electrically connected with each other by means of an explosion-proof cable feedthrough (item X3). The following components are securely installed in the explosion-proof housing: – Power supply (item N1) – Terminal base (item K1) – Test switch (item S1) – Terminal element (item S2) – Plug (item X9) A circuit board is installed in the attachment housing (item PMC, PM4 or UN).

6.40

Face control with PMC®-R for shearer operation

Power supplies Block diagram EXPLOSION--PROOF HOUSING FLAME PROOF CASING X2

L2 OUTPUT

Optional

Intrinsically safe case Intrinsically safe housing Type SPUxxx--xx--x,x--PMC or Type SPUxxx--xx--x,x--PM4

3‡

OUTPUT

D1

S1

8

6

4

2

7

5

3

1

X4

R1

D2 R2

2‡

PCB UN S2 1‡

K1 L1

L2

N1

N2

X5

X1

L1 INPUT

PCB PMC

3‡

INPUT P1

Intrinsically safe case Intrinsically safe housing Type SPUxxx--xx--x,x--UN R1

P2

PCB PM4

Pe1

X9

N1

D2

D1

X4

X3

ODER/OR

1‡

=

INTRINSICALLY SAFE POWER SUPPLY OUTPUT 1 (N1)

2‡

=

INTRINSICALLY SAFE POWER IN CIRCUIT

3‡

=

NOT INTRINSICALLY SAFE CIRCUIT

R2

1‡

X3

PCB UN 1‡

X9

X5

S2 M 2.5:1

22

23

24

25

Function The non-intrinsically safe supply is connected via the cable (item L1) and the cable entry (item X1). The individual wires of the cable are fed to the terminal block (item K1). This is where the power supply (item N1) is supplied and the test and off switches (item S1) are connected. The terminal element (item S2) is required for a higher-ordered monitoring device.

The non-intrinsically safe supply of additional devices comes from the terminal block, the cable feedthrough (item X2) and the cable (item L2). The individual wires of the cable feedthrough (item X3) are applied to the plug (item X9) in an explosion-proof room and, from there, lead to the intrinsically safe output of the power supply (item N1).

Intrinsically safe connection, type PMC or PM4 If the circuit board, item PMC or PM4, is installed, an intrinsically safe output and data circuit are connected via the plug connector, item X5, and is indicated via the LED L5. A second intrinsically safe input and data circuit are connected via the plug connector, item X4, and is indicated by LED L4.

Intrinsically safe connection, type UN If the circuit board, item UN, is installed, an intrinsically safe output circuit is connected via the plug connectors X4 and X5 and are indicated by the LEDs L4 and L5.

Parameters The parameters are specified in the EC type examination certificate of the power supply. The EC type examination certificate is a component of the complete operating instructions.

Doc. no.: 4007 180 010 BA 00

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6.41

Double power supply Double power supply Identification: Subject: Manufacturer: Designation: Purpose:

Double power supply Bucyrus DBT Europe GmbH Industriestr.1, 44534 Lünen DPU***-**-*,*-*** Intrinsically safe double power supply and data transmission of two electrical circuits

Two nameplates are to be securely fastened to the cast housing with the following minimum specifications, permanently legible. One plate is securely fastened to the outer wall and the second plate on the inside: Name and address of the manufacturer Type:

DPU***-**-*,*-***

Identification: DMT No.:

0158 BVS 03 ATEX E 249/N2

Type of protection: Serial no.: Ambient temperature:

I M2 EEx d [ib] I XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20° C to + 50° C

Furthermore, a warning sign “Do not open with power connected” is securely fastened to the housing cover. The two intrinsically safely connected plug connectors are clearly labeled with X4 and X5 on the terminal box.

Type of protection: EEx d [ib] I in acc. with: EN 50014-1997 +A1-A2 General regulations EN 50018-2000 Explosion-proof encapsulation EN 50020-1994 Intrinsic safety “i” Type key Type DPU *** - ** -*;*- *** Type of distributor board Nominal output current Nominal output voltage Supply voltage Double power unit Power circuit DPU230-**-*,*-***

Supply voltage AC 80 V to 265 V max. supply current AC 20 A

Output circuit voltage intrinsically safe (2 electrical circuits) DPU***-12-*,*-*** Nominal voltage for each electrical circuit DC 12 V

6.42

Face control with PMC®-R for shearer operation

Double power supply Max. voltage per electrical circuit DC 12.4 V Output circuit current intrinsically safe (2 electrical circuits) DPU***-12-2.0-*** Nominal current for each electrical circuit 2.0 A; Max. current for each electrical circuit 2.0 A Circuit board DPU***-**-*,*-UN with distributor board 4008.032.011.01.00 DPU***-**-*-*-PMC with BIDI coupler circuit board 4008.004.263.01.00 DPU***-**-*,*-PM4 with BIDI coupler circuit board 4008.004.572.01.00 Construction The double power supply consists of an explosion-proof housing and a securely fastened attachment housing with intrinsically safe type of protection, which are electrically connected with each other by means of an explosion-proof cable feedthrough (item X3).

The following components are securely installed in the explosionproof housing: – Double power supply (item N1) – Terminal base (item K1) – Test switch (item S1) – Terminal element (item S2) – Plug (item X9) A circuit board is installed in the attachment housing (item PMC, PM4 or UN).

Block diagram EXPLOSION--PROOF HOUSING FLAME PROOF CASING X2

L2 OUTPUT 3‡

OUTPUT

S1

8

6

4

2

7

5

3

1

S2

S2

M 2.5:1

K1 L1

P2

N1

N2

P1

L2

X1

L1 INPUT 3‡

22

INPUT

23

24

25

Pe1

N1

INTRINSICALLY SAFE CASING INTRINSICALLY SAFE HOUSING

X4

L4

L5

R1

R2

X3

2‡

PCB PMC ODER/OR 1‡

1‡

=

INTRINSICALLY SAFE POWER SUPPLY OUTPUT 1 (N1)

2‡

=

INTRINSICALLY SAFE POWER SUPPLY OUTPUT 2 (N1)

3‡

=

NOT INTRINSICALLY SAFE CIRCUIT

X9

PCB PM4

X5

Optional

X4

L4

L5

R1

R2 PCB UN

2‡

X3

X9

1‡

X5

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6.43

Double power supply Function The non-intrinsically safe supply is connected via the cable (item L1) and the cable entry (item X1). The individual wires of the cable are fed to the terminal block (item K1). This is where the power supply (item N1) is supplied and the test and off switches (item S1) are connected. The terminal element (item S2) is required for a higher-ordered monitoring device.

The non-intrinsically safe supply of additional devices comes from the terminal block, the cable feedthrough (item X2) and the cable (item L2).

The individual wires of the cable feedthrough (item X3) are applied to the plug (item X9) in an explosion-proof room and from there lead to the 2 intrinsically safe outputs of the power supply (item N1).

Intrinsically safe connection, type PMC or PM4 If the circuit board, item PMC or PM4, is installed, two intrinsically safe output and data circuits are connected via the plug connector, items X4 and X5, and is indicated via the LEDs L4 and L5.

Intrinsically safe connection, type UN If the circuit board, item UN, is installed, two intrinsically safe output circuits are connected via the plug connectors X4 and X5 and are indicated by the LEDs L4 and L5.

Parameters: The parameters are specified in the EC type examination certificate of the power supply. The EC type examination certificate is a component of the complete operating instructions.

Maintenance notes J The power supply may only be repaired and maintained by per-

sons who have successfully completed the appropriate training.

J The power supply may only be connected according to the

electrical diagram by instructed skilled personnel.

J If several persons are involved in carrying out repair work, all

persons involved must agree on the working procedure.

J If the activities of several work groups can influence each other,

they must clearly agree on how the work is to be done.

J The knowledge of the switching operations of the higher-

ordered control is an important precondition for safely carrying out repair work. For this reason, the operating manual and maintenance instructions of this control are to be observed.

J The operating manual is distributed to all persons (must provide

signature) who are assigned to do repair work by the respective supervisory personnel after briefing.

J Repairs on the explosion-proof housing may only be carried out

by the manufacturer.

J Do not open the housing cover when the power is connected.

Secure against switching on again.

J Switch off the voltage when connecting non-intrinsically safe

cables. Secure against switching on again. Always keep the surface of the cover clean.

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Face control with PMC®-R for shearer operation

Double power supply J The screws for the explosion-proof connections must be se-

curely tightened. Check at the maintenance intervals and keep a record.

J No corrosive liquids are to be used for cleaning the power

supply.

J Only remove the protective caps from plugs when they are con-

nected. Replace the protective caps of unused plugs.

J Replace defective seals immediately.

J The power supply may only be transported in the containers

provided for them. Avoid any unnecessary vibrations, impacts and contamination when doing so.

J Store the power supply only in dry rooms with an ambient tem-

perature of -20°C to +50°C.

J The warning on the cover of the power supply “Do not open

with power connected” is to be observed at all times.

J The maximum current strength in the feed line of at least 6 mm2

may not exceed 9 A, even if further consumers are connected in series.

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Coupler Coupler Supply adapter PM4/*** and PMC/***; ATEX The supply adapters have the function of supplying a PMC system with voltage. There are different types of couplers, depending on the purpose and the location of where the system is used.

Fig. 95: POWER SUPPLY ADAPTER PMC/V1; ATEX

1

1

2

1 SKK24 socket for data transmission and voltage connected devices 2 SKK24 - socket for voltage supply Fig. 96: Sketch wiring diagram power supply adapter 1 2 3 4

1 2 3 4

1

+ 12 V Data Data Ground

4

Identification: Subject: Manufacturer:

Distributor Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen Description: PMC/V1 or PMC/V2 Purpose: Distribution of an intrinsically safe electrical circuit.

A legible nameplate is securely fastened to the distributor with the following minimum specifications.

Manufacturer: Type: Type of protection: Identification: Certification: Serial no.: Ambient temperature:

6.46

Bucyrus DBT Europe GmbH Industriestr. 1; 44534 Lünen PMC/V1 or PMC/V2 I M2 EEx ia I 0158 INERIS 02ATEX0095 XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20°C to +70°C Face control with PMC®-R for shearer operation

Coupler Type of protection: EEx ia I in agreement with: General regulations EN 50014-1997 + Revisions 1 and 2 Intrinsic safety “i” EN 50020-1994 Function The distributor contains no electronic components and is only connected to an intrinsically safe electrical circuit. The distributor consists of a steel housing with 3 securely fastened plugs and is completely filled with grouting resin.

The exact function of the distributor is specified in a higher-ordered control system.

Parameters Distributor types PMC/V1 and PMC/V2 Supply voltage

max. DC 13.2 V

Current strength

max. 2 A

Lo

0H; Co 0C

Ambient temperature

Ta -20°C to +70°C

Optocoupler (IA) The optocoupler is required for the galvanic isolation of two neighboring electrical circuits. The data from one electrical circuit can be transmitted to the other by means of optical coupling while the two electrical circuits are isolated from one another. This optocoupler is offered in a plastic version.

Fig. 97: Optocoupler PMC II2 BIDI COUPLER;ATEX 1

2

2

3

3

2

2

1 SKK24 connection (marked in red for A1 connection port of the PMC®-R) 2 bore hole for fastening the BIDI coupler 3 bore holes for the SKK24 retaining clips

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6.47

Coupler Fig. 98: Example for assembly

A1

Re d

F1

Important!

The SKK24 socket marked in red must be connected with the PMC®-R A1 port. The PMC®-R network cannot function if the red SKK24 socket is not connected to the PMC®-R A1 port.

Optocoupler (IA) The optocoupler is installed in a stainless steel housing and cast in silicone resin.

Fig. 99: Isolations adapter PM4/IC2;ATEX

3

2

3 1

3 2 1 SKK24 connection (red for the connection of the A1 Port of the PM4) 2 bore hole for fastening the BIDI coupler 3 bore holes for the SKK24 retaining clips Fig. 100: Example for assembly

A1

Re d

F1

Important!

The SKK24 socket marked in red must be connected with the PM4 A1 port. The PM4 network cannot function if the red SKK24 socket is not connected to the PM4 A1 port.

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Face control with PMC®-R for shearer operation

Coupler Fig. 101: Block diagram

5 2 4

1

2

3

4

1 voltage supply 12 V Pin 1 2 transmit data Pin 2

1 3

4 ground Pin 4 5 optocoupler

3 receive data Pin 3

Type code The couplers are designed such that they are adapted to the different control systems, depending on type.

Type PMC/*** Type PM4/*** Type PM*/PC1 Type PM*/PC2 Type PM*/IC1 Type PM*/IC2

Adaptation to PMC control system Adaptation to PM4 control system Power coupler 1 1 supply connection Power coupler 2 2 supply connections Isolation (opto) coupler 1 Metal housing Isolation (opto) coupler 2 Plastic housing

LD coupler Coupler for long entry between Server PMC®-R and first segment shield Fig. 102: LD coupler type A 1

1

1 3

2

1 fastening holes 2 SKK24 connection RS 485 3 SKK24 connection BIDI (marked in red)

Two different LD couplers exist for the connection between the face and the server, type A and type B. Type A is installed in the first segment shield, type B in the vicinity of the server (see system drawings)

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Coupler The SKK24 sockets on the LD coupler, type B, are both bronzecolored and labeled as RS485 and BIDI connections (F1) on the housing.

The RS485 interfaces of the two couplers A and B are connected with each other over the long segment to be bridged over with a four-wire control cable.

Identification: Subject: Manufacturer:

Module Bucyrus DBT Europe GmbH Industriestr.1, 44534 Lünen Designation: PMC-LD-* Purpose: Conversion of intrinsically safe BIDI signals into RS486 signals and vice versa.

A permanently legible nameplate is securely fastened to each housing with the following minimum specifications.

Manufacturer: Type:

Bucyrus DBT Europe GmbH Industriestr.1, 44534 Lünen PMC-LD-*

Identification: Approval:

0158 IBExU 04 ATEX 1016 X

Type of protection: Serial no.:

I M2 EEx ib I XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ta = -20°C to + 70°C

Ambient temperature: Type of protection: EEx ib I in acc. with:

EN 50014-1997 +A1-A2 General regulations EN 50020-2002 Intrinsic safety “i” Structure and function The electrical components of the modules are each installed in a metal housing and cast.

There are three different module versions, which are distinguished as follows: Coupler module, type PMC-LD-A A circuit board is securely installed in the coupler module, which is electrically connected to 2 labeled plug connectors (BIDI, RS485) via insulated individual wires. The coupler module is wired such that it converts BIDI signals into RS485 signals.

Coupler module, type PMC-LD-B The coupler module is mechanically equivalent to the coupler module of type PMC-LD-A. The difference is that the coupler module PMC-LD-B is wired such that it converts RS485 signals into BIDI signals. The two plug connectors are labeled accordingly (RS485, BIDI).

Repeater module, type PMC-LD-R

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Coupler Two identical circuit boards are securely installed in the repeater module.

The two circuit boards are each electrically connected via a cable, each of which is attached to a circuit board plug connector. The cables are fed into the housing through the labeled cable entries (RS485). The circuit board power supply goes via the plug connector (POWER) and the insulated individual wires.

On the first circuit board, RS485 signals are converted into BIDI signals, amplified and forwarded to the second circuit board with insulated individual wires. There, the BIDI signals are converted back into RS485 signals.

Parameters Coupler module, type PMC-LD-A and type PMC-LD-B - BIDI supply plug (X2, pins 1 and 4) Input voltage Ui DC 12.8 V Current strength Ii 2.0 A Effective internal capacitance Ci negligible Effective internal inductance Li negligible - BIDI signal plug (X2, pins 2 and 3) Voltage Ui DC 12.8 V Current strength IN <15 mA Effective internal capacitance Ci negligible Effective internal inductance Li negligible - RS485 plug (X1, pins 1, 2 and pins 3, 4) Voltage Uo DC 5.0 V Current strength Io 491 mA External power Po 535 mW External capacitance Co 2 mF External inductance Lo 2 mH Repeater module, type PMC-LD-R - POWER supply plug (X3, pins 1 and 4) Input voltage Ui DC 12.8 V Current strength Ii 2.0 A Effective internal capacitance Ci negligible Effective internal inductance Li negligible - 2 RS485 entries Terminals 1, 2 transmission, terminals 3, 4 receiving Voltage Uo DC 5.0 V Current strength Io 491 mA

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Coupler External capacitance Co 2 mF External power Po 535 mW External inductance Lo 2 mH Ambient temperature Ta -20°C to + 70°C

Converter type PMC id BIDI 232 The converter is for converting intrinsically safe BIDI signals into non-intrinsically safe RS232 signals and vice versa. The connection of the intrinsically safe electrical circuit with BIDI signals to a certified control system must be specially tested and certified. The converter must be installed in another housing. This installation must be specially evaluated and certified.

Fig. 103: Converter type PMC id BIDI 232

The intrinsically safe electric power supply and the transmission (TX) and reception (RX) of electrical signals from the OPTO BIDI circuit board go via the BIDI connection.

The non-intrinsically safe electric power supply and the transmission (TX) and reception (RX) of electrical signals from the OPTO 232 circuit board go via the RS232 connection. The electrical signals are converted into optical signals on both circuit boards. The two circuit boards, intrinsically safely separated from each other, are connected via two fiber-optic cables which are at least 50 mm long. The two fiber-optic cables are wired through two holes in the partition and sealed with silicone and are mechanically protected.

Identification: Object: Converter Manufacturer: Designation: Purpose:

6.52

Bucyrus DBT Europe GmbH Industriestraße 1, 44534 Lünen PMC id BIDI 232 Conversion of intrinsically safe BIDI signals into non-intrinsically safe RS232 signals and vice versa.

Face control with PMC®-R for shearer operation

Coupler A legible nameplate is fastened to the housing with the following minimum specifications. The minimum specifications can also be permanently laser-engraved onto the housing.

Name and address of the manufacturer Type: PMC id BIDI 232 Identification: Certification:

0158 BVS 06 ATEX E 152 X

Type of protection: Serial no.:

I (M2) [Ex ib] I XXXX XX XXXX 5th and 6th places correspond to the year of manufacturing Ambient temperature: Ta = -20°C to +70°C Furthermore, the spaces are marked as follows on the outside at the cable entries and/or sockets and on the inside near the connection plug: - “Intrinsically safe” area BIDI - Non-intrinsically safe area RS232 Type of protection: Ex ib I in accordance with: DIN EN 60079-0, 2004 General regulations IEC 60079-11, 2006 Intrinsic safety “i” Mechanical set-up The converter consists of a housing with two installation spaces, which are separated by a partition. The housing, and therefore both installation spaces, are sealed with a cover and a plate seal in accordance with IP 54, IEC 529. There are two optional openings in the cover which are each sealed tightly with an embedded viewing window.

For the electrical connection, there are the following options: 2 cable entries with a multiple seal for 4 single lines with an outer diameter of 3 mm 2 cable entries with a seal for one line with an outer diameter of 7 to 13 mm 2 four-pinned sockets The cable entries and sockets are leak-tight in accordance with IP54, IEC 529. For this, the installation instructions in the operating instructions must be observed.

Electrical set-up The intrinsically safe electric power supply and the transmission (TX) and reception (RX) of electrical signals from the OPTO BIDI circuit board go via the BIDI connection.

The non-intrinsically safe electric power supply and the transmission (TX) and reception (RX) of electrical signals from the OPTO 232 circuit board go via the RS232 connection.

The electrical signals are converted into optical signals on both circuit boards. The two circuit boards, intrinsically safely separated from each other, are connected via two fiber-optic cables which are at least 50 mm long. The two fiber-optic cables are wired through two holes in the partition and sealed with silicone and are mechanically protected.

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Coupler Parameters BIDI (intrinsically safe) Supply voltage max. Ui DC 12.8 V Internal capacitance Ci negligible Internal inductance Li negligible RS232 (non-intrinsically safe) Nominal supply voltage Un Voltage Um Ambient temperature Ta

DC ±15V AC/DC 500V -20°C to +70°C

The converter may only be installed, repaired and maintained by persons who have successfully completed the appropriate training.

If several persons are involved in carrying out repair work, all persons involved must agree on the working procedure.

If the activities of several work groups can influence each other, they must clearly agree on how the work is to be done.

The instructions are distributed to all persons who are assigned to do repair work by the respective supervisory personnel after briefing.

The knowledge of the switching operations of the higher-ordered control is an important precondition for safely carrying out repair work. For this reason, the operating manual and installation and maintenance instructions of this control are to be observed.

No corrosive liquids are to be used for cleaning the converter.

Only remove the protective caps from plugs when they are connected. Unused plugs should have their protective caps replaced.

When single wires and cables are connected, make sure that their diameters fit the seals of the cable entries so that the seal satisfies IP54.

The length of the 2 fiber-optic cables is specified to be at least 50 mm by the manufacturer and may not be reduced. Otherwise, there is no reliable isolation of the intrinsically safe and the non-intrinsically safe electrical circuits.

The converter must be installed in an appropriate housing. The installation must be specially certified.

When installing the converter, make absolutely sure that there is a permanent and reliable ground connection.

Replace defective seals immediately.

Only transport the converter in the containers provided for it. Avoid any unnecessary vibrations, impacts and contamination when doing so.

Store the converter only in dry rooms with an ambient temperature of -20°C to + 70°C. The converter may only be accessible to skilled personnel.

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Face control with PMC®-R for shearer operation

Warning lamp Warning lamp The warning lamp WL is available in the single-colored version WL1-* and in the two-colored version WL 2-* Fig. 104: WARNING LAMP TYPE WL1-1 RED;ATEX

The warning lamp can also be connected externally to the control, parallel to the jump diodes on the control.

The warning lamp WL2-1 serves as a visual warning on a shield support on a face. With a higher-ordered control unit, the orange or green LEDs can be actuated independently of one another.

Weight Dimensions

0.45 kg 100x75x50 mm

Safety instructions (For safety notes, see Chapter 2) Identification: Subject: Manufacturer:

Warning lamp Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen Description: WL1-* and WL2-* Purpose: Warning lamp actuated with an intrinsically safe electrical circuit.

There must be writing on the warning lamp which is permanently legible and has the following minimum specifications, whereby the CE-marking is at least 5 mm high.

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6.55

Warning lamp Manufacturer:

Bucyrus DBT Europe GmbH Industriestr. 1, 44534 Lünen WL*-1 (with Hirschmann connector) or Type: WL*-2 (with O-ring snap-on connector)

Type:

Type of protection: Identification: Serial number: Certificate number: Ambient temperature:

IM2 EEx ia I 0158 XXXX XX XXXX 5th and 6th places correspond to the year of manufacture DMT 01 ATEX E.111/N1 Ta = -20°C to +70°C

Type of protection: EEx ia I in acc. with: General regulations EN 50014-1997 (VDE 0170/0171) Part 1 Intrinsic safety “i” EN 50020-1994 (VDE 0170/0171) Part 7 Function The flashing warning lamp (WL1-*) is supplied with an intrinsically safe electrical circuit via a plug connector. The warning lamp is actuated via a higher-ordered, intrinsically safe certified control system. The warning lamp WL2-* doesn't flash. It is actuated by an external control unit.

Parameters An intrinsically safe electrical circuit with the following values is connected to the plug connector.

Voltage:

max. DC 13.2 V

Ambient temperature Ta -20°C to +70°C

Beepers TB27 and TP27 Fig. 105:Beeper TP27

The beeper is installed in various devices.

6.56

Face control with PMC®-R for shearer operation

7

For your information

Service addresses

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

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestrasse 1 D-44534 Lünen, Germany Tel: +49 / 23 06 70 9 – 0 Fax: +49 / 23 06 70 9 – 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tel: Fax: Email:

+44 / 11 59 51 - 2500 +44 / 11 59 32 - 9683 info@gb.bucyrus.com

Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44/16 98 83 5 - 000 +44/16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus DBT Europe GmbH Office Moscow Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moscow Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 – 3441 Fax: +7 / 38 43 35 – 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

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7.3

Service addresses North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 Tel: Fax:

+1/54 09 80 - 4530 +1/54 09 94 - 3889

Australia Bucyrus Australia Underground Pty. Ltd. Customer Service 20 Killara Close, Beresfield, New South Wales 2322 E

+61/24 91 4 - 7144 +61/24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61/74 95 2 - 0000 +61/74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

7.4

Face control with PMC®-R for shearer operation

Bucyrus DBT Europe GmbH, Lünen 2008

Tel: Fax:

Service addresses Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

E

No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

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7.5

Standards and Guidelines Standards and Guidelines Referenced national standards and guidelines Tab. 14: National standards and directives, extract

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation System Plug connectors for hydraulics Fire-resistant hydraulic fluids Maintenance and inspection list for hydraulic systems Hydraulic systems - general rules for application Determination of the neutralization number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Nonmetallic (coating) surface protection Approval procedure for fire-resistant HFA fluids in mining

EWN 6003 1) EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

Date of issue 2000-10 1990-09 2003-09 2006-12 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2008-01

Referenced European standards and directives Tab. 15: European standards and directives, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council on 1998-06-22 the approximation of the laws of the Member States relating to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and Directive 94/9/EC 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of machinery 2004-04 DIN EN ISO 12100-2 Safety of machinery 2004-04 Non-electrical equipment for potentially explosive atmoDIN EN 13463-1 2007-05 spheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 2004-12 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man-machine interfaces 2000-08 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water - Distillation method Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shear loaders and plough systems Directive 98/37/EEC

1) EWN = Bucyrus works standard

7.6

Face control with PMC®-R for shearer operation

E

Title

Bucyrus DBT Europe GmbH, Lünen 2008

Designation