Cat Bucyrus PMC-D Drive Control System Plow control UEL Operating manual

Operating manual PMC®-D Drive Control System Plow control UEL Doc. No.: 1999 001 015 BA 00

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

Amendments and alterations to this publication are not subject to notification. Bucyruc GmbH 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 Bucyruc.

Bucyruc declines any liability for direct or indirect consequences of printing errors.

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

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Contents

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

1.5

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

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

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

1.5 1.5 1.6

2. Your safety Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

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

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

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

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.3 2.3 2.3 2.4

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

3.3

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

3.3

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

4.3

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

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

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

4.3 4.4 4.4

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

4.7

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

4.8

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

5.3

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

5.4

PMC®-V LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

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

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

5.6 5.6

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

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

Profibus diagnosis (internal) . . . . . . . . . . . . . . . . . . . . . . . . .

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

Screen settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set date/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 5.13 5.17 5.18 5.20 5.20

System description - Plow control . . . . . . . . . . . . . . . . 5.21 Doc. No.: 1999 001 015 BA 00

Contents Global menu level - Plow control . . . . . . . . . . . . . . . . . . 5.25 Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Switch overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive unit selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Process data Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.26 5.28 5.29 5.30 5.31 5.31 5.32

Configure process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

Menu level - Plow control, global settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 Global settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Face data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.46 5.47

Position data, head gate / tail gate . . . . . . . . . . . . . . . . 5.48 Rapid-run enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set plow type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.48 5.49

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

6.3

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

6.5

Pin assignment PMC®-V and PMC®-G . . . . . . . . . . . . . . .

6.5

UEL DISTRIBUTION BOX . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Splitterbox PMC OS 37 SPB . . . . . . . . . . . . . . . . . . . . . .

6.9

7. For your information Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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5.33 5.36 5.36 5.38 5.38 5.39 5.39 5.40 5.40 5.42 5.42 5.43 Bucyrus DBT Europe GmbH, Lünen 2008

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

Process functions (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Inspection of coupling pressure . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Set gearbox type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Enter plow position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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. It provides you with information about the structure of the manual and the symbols used in it.

Before starting work applicable operating manual

case of operation

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

Make sure that the specifications for the housings of the system components belong to the PMC® Drive Control System and that the CST gearboxes from the company DBT are really installed on the conveyor.

This operating manual is for the control of a conveyor with CST gearboxes by the PMC® Drive Control System.

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current operating manuals

Operating manuals for the conveyor, CST gearboxes and motors in question must always be available at the place of operation. Order copies of the respective operating manuals immediately if the existing ones are no longer complete or legible.

Persons for whom the operating manual is intended The operating manual is intended for those persons who set up the PMC® Drive Control 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 perform assembly/disassembly work J operate the conveyor J correct malfunctions J carry out daily routine work on the face or in the entry J carry out maintenance work J perform repair work

as well as supervisory personnel who J authorize and/or supervise the tasks above.

Purpose of this operating manual cost-effectiveness

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® Drive Control System.

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

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1.5

Before starting work 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

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

Observe the information given and follow the procedural instructions.

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

Try to memorize the symbols and their meanings.

Aids!

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

Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to 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 indicated by bullets.

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

. Text passages indicated in this way describe individual work steps.

1.6

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Danger!

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

2

Your safety

Operating conditions

Your safety Operating conditions Intended use The PMC®-R system has been developed and manufactured to control support frames. The PMC®-R 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®-R system.

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

Ambient conditions

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Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust.

These include: J adequate and consistent ventilation J plow water curtain/water spraying etc.

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

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®-R 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®-R systems are intrinsically safe and have been manufactured according to approved technical regulations.

Prerequisites for operation The PMC®-R 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.

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2.3

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. They must be designated according to the legal provisions applicable at the time they are placed on the market ( - marking).

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 water-sprinkling systems J safe lock-out command systems J EMERGENCY STOP systems J vacuum-cleaning equipment J noise protection J warning messages, etc.

Safety instructions Basic principles general

Always work with concentration.

Familiarize yourself with your working environment.

protective clothing and equipment

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

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

safety equipment

Start the conveyor only when it is in a good and safe condition and all safety equipment, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Maintain the signaling and lighting systems in a functional order.

Pay special attention to the conveyor’s acoustic and optical start-up warning equipment.

symbol plates EMERGENCY STOP

Observe the signs on the conveyor and on the nearby mechanical equipment.

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Notify your supervisor of any peculiarity, so that necessary action can be taken immediately.

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

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Electrical equipment required to operate the conveyor shall be marked according to the legal provisions applicable at the time when it is placed on the market.

Operating conditions

lock out

Secure the conveyor against restarting while carrying out: J maintenance work J inspection work J repair work J failure of safety equipment, e.g.:

– firedamp protection. cordon off working area

Secure your working area using a wide range for monorail and floor conveying devices.

moving parts

Never allow parts of your body to come between parts which could move, such as e.g.: J conveyor chains J flights J spill plates J chain sprockets J chain tensionable drive frame and shield.

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danger of explosion

Make sure you adhere to the maintenance and checking intervals for the motor, gearbox, chains, drive frame, nearby machines and machine components. Be sure that the machines are adequately cooled, since hot surfaces might cause potentially explosive atmospheres (air) and dust to ignite.

Storage and transport The control units of the PMC® drive control system can be stored a maximum of 4 years without electrical connection. The installed buffer battery is discharged after four years. This battery must then be replaced.

Observe the specified storage periods and the storage instructions.

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 securing devices

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

inclined faces

On an inclined face secure all individual parts using chains, e.g., on the supports.

Installation

using system brackets

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

Maintenance and repair Do not make any repairs on or modifications to the components of the PMC® drive control system.

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.

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Operating conditions 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.

Secure the replacement parts against slipping on inclined faces by using chains or lifting gear, for example.

Only use spare parts which satisfy the specified technical requirements. This is only ensured with original DBT replacement parts.

Please refer to the replacement parts lists for the order numbers.

protective devices

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

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original spare parts

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Storage and transport

Storage

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

Storage Storing the equipment 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 15°C and 25°C.

moisture and dirt

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

Never store electronic equipment in the open air.

long-term storage

When putting stock into storage, make sure that the membranes, which seal the monitor and keyboard, and the plug-type connections aren’t damaged.

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short-term storage

The devices should be checked after a storage period of five years since the installed battery is discharged after this amount of time.

This must then be replaced. The check and the battery replacement must be carried out by DBT 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 prevented damage.

Important!

Ensure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

Transport Transport containers, dimensions and weights Make sure you observe the technical data sheet. It provides you with information about: J dimensions and J weights

The devices belonging to the PMC® Drive Control 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 monitors, keyboards, cables and plug-type connections.

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3.3

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

Caution!

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

Before transport low temperatures

Electronic equipment should be transported very carefully at low temperatures (below -10°C) since all materials become brittle and fragile at low temperatures.

When transporting with floor conveying devices, at such temperatures, it must be made sure that the devices aren’t subjected to sudden impact loads.

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Pipe and cable connections must be protected carefully for sea transport. The devices of the PMC® Drive Control System must be carefully so that they are sea-proof.

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Installation

General notes

Installation General notes Important!

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

Install the PMC®-D/V system initially only under supervision of expert personnel of DBT Automation.

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

The drawing number for projects is: 4007 bbb mmm nn pp 4007

is the number range for D-E-C automation projects.

bbb

This number block represents a serial number for the different projects.

mmm

This number block designates subprojects such as 010 for support drawing or 020 for system drawing.

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They can be assigned differently for each project (assignment: see “Project-related documentation”)

Fig. 1:

nn

The digits designate components. “00” is virtually the only number sequence to appear for project drawings.

pp

This digit sequence designates the variant.

Example

4007 113 130 00 00 Without variant Project drawing Pump control subproject Project number for CODELCO Drawing belonging to the EC department

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.

Subprojects, such as the chain tensioner or gearbox control system, are documented with drawings having changing end number groups.

For this, these (changing) numbers come from the corresponding documentation numbers: 4007 xxx 0zz

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4.3

General notes

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.

Tools required The following tools are required to install system components underground: Installation of the brass retaining strip and the PMC®-D/V on the brass retaining strip: 10 mm socket key Changing a keyboard protective cover, actuating the venting screw: 4 mm socket key Installation of SKK24 connectors:

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

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

J control unit PMC® D with 7-segment display J visualization device PMC® V with monitor and keyboard J gateway PMC® G with 7-segment display J sensor/actuator connection box J holding strip J line for the connection between the control unit PMC® D and

the sensor/actuator connection box

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

There is a venting 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).

Important!

All controls have a venting 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, you can tell this by the hissing noise.

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All further installations in the PMC®-R system can be performed with a sturdy screwdriver and multigrip pliers.

General notes Fig. 2:

Venting screw for PMC®-R

Important!

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 on the keyboard switch.

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

Caution!

In this case, the venting 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.

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4.5

General notes Control unit PMC®-D

Fig. 4:

Visualization device PMC®-V

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Fig. 3:

PMC®-D Plow control UEL

Installing control units

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Fig. 5:

Installing control units holding strip

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

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

Caution!

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

fastening via the holding strip

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

Using these screws and the corresponding spacer sleeves, the holding strop can be fastened to a mounting plate, for example.

The advantage of this installation variant is the easy exchangeability of the control units and the secure fastening of the hose lines.

Caution!

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

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4.7

Installing control units direct fastening

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

Caution!

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

protective housing

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

Important!

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

Other lines will lead to communication failure.

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

Important!

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

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

Important!

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

4.8

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

Installing Profibus connections

5

Operation

Basic principles

Operation Warning!

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

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There are three basic devices available for the system setup. The PMC®-V device (visualization) serves as a display and operating unit for all control systems connected to the Profibus line. The PMC®-G device (gateway) is intended for communication with external systems and can also be used by all control systems. The PMC®-D device (drive) takes over a special control task. For example, in the case of a plow system with UEL gearboxes, a PMC®-D device is allocated to each drive unit.

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

Operational concept The PMC®-Drive Control System is operated via the PMC®-V devices. Here, operation is possible from any PMC®-V device in the system. Menus are provided on the screen, from which the desired menu item can be selected using the keypad. Afterwards, either another menu appears, or an input/output mask.

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

The second level contains global functions, which, however, apply for a special control system or for all PMC®-V or PMC®-G devices.

On the third level, functions are stored which apply to a directly activated device within the higher-ordered system. In the control system, those are exclusively PMC®-D devices, which are identified based on where they are installed (HA = head gate, HI = tail gate).

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

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

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5.3

PMC®-V keypad Fig. 6:

Levels of the menu tree Global functions

Gateway

G1

Gn

V1

CST drive system

Plow system

Visualization

Vn

HA

HA1

HI

HA2

HI1

HI2

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

Screen mask structure

Name of the screen mask

Menu level or system name

Start menu

Device name

Global Local V3 E

Fig. 7:

Bucyrus DBT Europe GmbH, Lünen 2008

Date: 30.03.05 Time: 15.23:38 System activation System configuration Profibus diagnosis (intern) Device information Screen settings Set date/time

System-specific status information

PMC®-V keypad The keypad of a PMC®-V visualization device is shown in Fig. 8.

See page 5.5. An LED is allocated to each of the 24 keys, which light up when the keys are correctly pressed. The keypad is for navigating through the menu tree provided on the screen, for inputting number values and for directly activating special functions.

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

5.4

PMC®-D Plow control UEL

PMC®-V keypad Fig. 8:

Keypad of the PMC®-V visualization device

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

Bucyrus DBT Europe GmbH, Lünen 2008

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

By pressing this key (Caution symbol), the screen changes from any screen mask to the display of a list with system messages.

If the list is exited by pressing the “Cancel” key, the display changes back to the previously exited screen mask.

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

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

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

...

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

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

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5.5

PMC®-V LEDs PMC®-V LEDs LEDs

One green, one yellow and one red LED are arranged under the screen of the PMC®-V visualization device. When the green LED flashes, this is an indication that the device is connected to a power supply. The yellow and the red LEDs signalize the presence of warnings/error messages in the list of system messages (see page 5.7).

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

Fig. 9:

System messages menu tree

?

System messages Global Local V3 MNo. Source Brief description 125 F CST-HA1 Cooling oil temperature too high 245F HOB-HI System pressure too low 045I V1 Communication V1 activated 140W CST-HI1 Device temperature too high

The temperature of the cooling oil in the CST gearbox has exceeded the approved upper value. Continued heating of the cooling oil results in damage to the clutch linings. Resume operation only when the cooling oil temperature has dropped below the warning level set in the system.

All systems System selection

Global

All messages

Local V3 Select message type

All systems CST drive unit Plow control Visualization Gateway

All systems

F1:Ack. message F3: Activate system All systems

F2:Ack. device mess.

F4: Select message type All messages

Global

Local V3

All All messages messages Errors only Warnings only Information only

System messages Global Local V3 MNo. Source Brief description 125 F CST-HA1 Cooling oil temperature too high 140W CST-HI1 Device temperature too high

All messages All systems

F1:Ack. message

FF2:Ack. device mess.

F3:System selection CST drive unit

F4:Select message type All messages

All messages

Jump back to the previously exited display

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

5.6

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

!

E

System message Global Local V3 No. Type Source Cancel 29.03.05 125 Error CST-HA1 Yes 13:34:45

PMC®-V LEDs PMC®-V LEDs

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

Filters can be set on the system message list so that only those messages are displayed which are currently of interest. These settings are retained, even after the message list is exited. More detailed descriptions can also be called up for the individual short messages. Fig. 9 (see page 5.6) shows the menu tree which can be run through within the system message display.

After activating the system messages, the mask shown in Fig. 10 appears on the screen. In the bottom line on the screen, the selection criteria for the displayed messages are given.

Fig. 10: System messages

Bucyrus DBT Europe GmbH, Lünen 2008

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System messages Global Local V3 MNo. Source Short description 125F CST--HA1 Cooling oil temperature too high 245F HOB--HI System pressure too low 045I V1 Communication V1 activated 140W CST--HI1 Device temperature too high

F1:Ack. message F2:Ack. device mess.

F3: Activate system F4: Select message type All systems All messages In the shown example, “All messages” of “All systems” are shown in the mask.

J MNo.

In this column, the internal message numbers are displayed, followed by either the letter E, W or I, which stand for the message types “Error”, “Warning” or “Information”.

J Source

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

J Short description

In the last column there’s a short description of the message.

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5.7

PMC®-V LEDs acknowledging messages

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

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

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

Fig. 11: Detailed message description

System message Global Local V3 No. Type Source Abort 29.03.05 125 Error CST--HA1 Yes 13:34:45 The temperature of the cooling oil in the CST gearbox has exceeded the permissible maximum value. Further heating of the cooling oil will lead to damage to the coupling linings.

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

E

All messages

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

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

Fig. 12: System activation messages

System selection

Global Local V3 Local V3

All systems CST drive unit Plow control Visualization Gateway

All systems

5.8

All messages

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

All systems

PMC®-V LEDs Fig. 13: Selecting the message type

Select message type

Global Local V3

All messages Errors only Warnings only Info only

All systems

All messages

The selections made on these two masks are retained in the local PMC®-V device even after exiting the display for the system messages. The current selection is displayed again in the bottom line of the masks when the system messages are activated again.

Direct activation of language change Bucyrus DBT Europe GmbH, Lünen 2008

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

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5.9

PMC®-V LEDs Fig. 14: Language selection

Language selection Global Local V3

Bucyrus DBT Europe GmbH, Lünen 2008

Jump back to the previously exited display

E

German English Русский

5.10

PMC®-D Plow control UEL

Global menu level, PMC®-Drive control Global menu level, PMC®-Drive control Fig. 15: Global menu tree of the PMC®-Drive Control System Switc hing on device St art menu Sy stem sel ectio n

Glo bal

Glo bal

Loca l V3

Date : 30. 03.0 5 Time : 15 :23: 38

Loca l V3

Sy stem sele ctio n Syst em c onfi gurat ion Prof ibus dia gnosi s (i nter nal) Devi ce i nfor matio n Moni tor sett ing Set date /tim e

CS T dr ive s yste m Pl ow c ontro l Vi sual izati on Ga tewa y

Gl obal S yste m con figu rati on Local V3 S eria l no. Ty pe C onf. Fnd. PBadd .

C 5 RC 6004 60 0047 D-CS T H A1 H A1 047 0526 77 5 6004 0021 V V3 V3 021 0526 77 5 6004 0004 V V2 V2 004 0526 77 5 6004 0050 D-HO B H A HA 007 0526 77 5 5004 0001 D-CS T H I1 H I1 001 0526 77 5 6004 0003 V V1 V1 003 0526 77 5 5004 0013 D-HO B H I HI 017 0526 77 5 6004 0012 D-CS T H A2 H A2 012 0526 77

F1: Acti vate conf .

M onit or se ttin g Bri ghtn ess: 050 % Bri Cont rast : 050% ght

Glo bal

Loca l V3

Bri ghtn ess (L) 0 65

Prof ibus int. dia gnosi s Globa l Loca l V3 Devic e PBad d. R ec.

Tra ns.

E rror T el. Tel . Se nd Bu s CST -HA1 047 CST 5 67 347 0 00 00 0 V3 021 0 13 721 0 00 000 V1 003 9 90 866 0 00 000 V2 004 7 41 883 0 00 000 CST- HI1 001 6 95 283 0 00 002 CST- HA2 012 6 76 297 0 00 000

Bucyrus DBT Europe GmbH, Lünen 2008

E

Res et er ror coun ter

Se t da te/t ime Glo bal Da ht s aving s ti me: On So ylig m Lo cal time : 1 3:45 :23 Da te: 3 0.03 .2005 Lo cal time : U TC + 01:00

Loca l V3

UT C = Unive rsal Time Coo rdin ated

De vice info rmati on Gl obal Devi ce Typ e Seri al n o.

CST- HA1 D-C ST 5 6004 0047

D ispl ay sy stem con fig. Gl obal Local V3 S eria l no. Ty pe Conf. Fnd .PBad d.

C 6004 RC 0047 D-CSname T H/ins A1 talla H A1 tion 047 sit 0526 5 60 As sign e 77 5 6004 0021 V V3 V3 021 0526 77 HA 1 5 6004 0004 V V2 V2 004 0526 77 HA 2 5 6004 0050 D-HO B H A HA 007 0526 77 HI 1 5 5004 0001 D-CS T H I1 H I1 001 0526 77 HI 2 5 6004 0003 V V1 V1 003 0526 77 HA 5 5004 0013 D-HO B H I HI 017 0526 77 HI 5 6004 0012 D-CS T H A2 H A2 012 0526 77 V1 V2 F1:A ctiv ate conf.

F2: Delet e en try

- ----

---- -

Lo cal V 3

Subas semb ly s erial no.

C PU: D -IO: P MU: PVC: 7-Seg :

54 1040 047 55 1040 048 53 1030 005 5 5205 0055 5 4403 0004

F 1:Ne xt d evice

Plow c ontrol

F2: Delet e en try

Star t men u

Prog ram: 0000 0100 09 Dat e: 29.0 3.20 05 Tim e: 13: 12:4 5 FPG A1: 00 0302 0201 FPG A2: 00 0402 0201 CPL D: 00 0000 1400 F2: Pre vious dev ice

C ST

Lo cal V 3

Dat e: 30 .03. 05 Tim e: 15 :24: 56 Proc ess overv ieww Pr ocess ove rvie M otor curr ent over view D rive unit sel ecti on S elec t ope rati ng m ode P aram eter stat us A utom atic sett ings L oad shari ng c ontr oller

Visualisation

Gateway

Au tomat ic

Fig. 15 shows the menu tree, of which the functions can be activated on the global level of the PMC®-Drive Control System. All functions are stored here, which are independent of the realized control systems and the special functions of the PMC® -V and -G devices. After switching on a PMC®-V device, the start menu of this menu tree is always displayed.

The start menu offers the following selection options: J Activation of a subordinate system

page 5.12.

System activation,

J Display and modification of the configuration of a subordinate

system

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System configuration, page 5.13.

5.11

Global menu level, PMC®-Drive control J Diagnosis of the internal Profibus

(internal), page 5.17.

Profibus diagnosis

J Information about the structure and the software status of the

individual devices

Device information, page 5.18.

J Changing the screen settings of the currently used PMC® -V de-

vice.

Screen settings, page 5.20.

J Setting the date and time for the PMC® -Drive Control System.

Setting the date/time, page 5.21.

Fig. 16: Global start menu

Start menu

Global Local V3 Date: 30.03.05 Time: 15.23:38

Bucyrus DBT Europe GmbH, Lünen 2008

E

System activation System configuration Profibus diagnosis (internal) Device information Screen settings Set date/time

5.12

PMC®-D Plow control UEL

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

Fig. 17: System activation, CST gearbox

System selection

Global Local V3

Bucyrus DBT Europe GmbH, Lünen 2008

E

CST drive system Plow control Visualization Gateway

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

System configuration Start menu

Global

Local V3

System activation System configuration Profibus diagnosis (internal) Device information Screen settings Setting the date/time

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

Caution!

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

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

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5.13

Global menu level, PMC®-Drive control Important!

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

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

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

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

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

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

5.14

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

After activating the system configuration, the mask shown in Fig. 17 (see page 5.13) is displayed on the screen. Here, all devices are displayed which are locally stored as the system configuration by the PMC®-V device currently being used. The allocated name/ installation site is specified in the “Conf.” column (configured).

If these devices can be addressed via the internal Profibus, the Profibus address of the device, which is automatically assigned by the PMC drive control system, is displayed in the “PBadd” column (Profibus address). If a name or installation site has already been assigned to the devices, the designation stored in the devices is displayed in the “Fnd” column (found). Otherwise, this entry remains blank.

E

Important!

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

Global menu level, PMC®-Drive control Fig. 18: System configuration

System configuration Global Local V3 Serial no. Type Conf. Fnd. PBadd. CRC 560040047 D--CST HA1 HA1 047 052677 560040021 V V3 V3 021 052677 560040004 V V2 V2 004 052677 560040050 D--HOB HA HA 007 052677 550040001 D--CST HI1 HI1 001 052677 560040003 V V1 V1 003 052677 550040013 D--HOB HI HI 017 052677 560040012 D--CST ------ -----012 002125 F1: Activate config.

F2: Delete entry

J Serial no.

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

J Type

E

Type of device. Here, the letter V stands for PMC®-V, G for PMC®-G and D for PMC®-D. For the PMC®-D devices, there is an additional abbreviation given for the control system.

Bucyrus DBT Europe GmbH, Lünen 2008

J Conf.

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

J Fnd.

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

J PBadd

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

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

J CRC

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

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5.15

Global menu level, PMC®-Drive control activating configuration

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

deleting entry

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

Important!

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

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

V2

F1: Activate config.

-- -- -- -example:

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

In Fig. 18 (page 5.15), there is installation site yet assigned to the PMC®-D device listed in the last line, which belongs to the system for controlling a conveyor with CST gearboxes. Based on the serial number, the user sees that this device was installed on head gate 2.

After selecting the device and pressing the “Enter” key, a list is displayed in which the 4 maximally possible installation sites, head gates 1 and 2 and tail gates 1 and 2, are displayed, among other things. In this list, the user selects the abbreviation “HA2”, which is entered in the “Conf.” column after pressing the “Enter” key. The selection of an installation site which does not belong to the CST system is rejected with an error message.

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

5.16

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

System configuration Global Local V3 Serial no. Type Conf. Fnd. PBadd. CRC 560040047 D--CST HA1 HA1 047 052677 560040021 V V3 V3 HA1021 052677 560040004 V V2 V2 HA2004 052677 560040050 D--HOB HA HI1 HA 007 052677 550040001 D--CST HI1 HI2HI1 001 052677 560040003 V V1 V1 HA 003 052677 550040013 D--HOB HI HI HI 017 052677 560040012 D--CST -----V1 - ------ 012 002125

E

Fig. 19: Name/installation site selection

Global menu level, PMC®-Drive control Important!

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

Profibus diagnosis (internal) Start menu

Global

Local V3

Date: 30.03.05 Time: 15:23:38 System selection System configuration Profibus diagnosis (internal) Device information Monitor setting Set date/time

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

No device may be connected to this internal communication system which doesn’t belong to the PMC®-Drive Control System. The external systems communicate exclusively via the second Profibus connection of the PMC®-V or -G devices or via serial connections.

Notice!

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

Fig. 20: Profibus diagnosis (internal)

Bucyrus DBT Europe GmbH, Lünen 2008

E

Profibus int. diagnosis Global Local V3 Device PBadd. Rec. Trans. Error Tel. Tel. Send Bus CST--HA1 047 567 347 000 000 V3 021 013 721 000 000 V1 003 990 866 000 000 V2 004 741 883 000 000 CST--HI1 001 965 283 000 002 CST--HA2 012 676 297 000 000

F1: Reset error counter -- -- -- --

-- -- -- --

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

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

J PBadd.

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

J Rec. Tel.

The number of telegrams received by the device.

J Sent Tel.

The number of telegrams sent by the device.

J Send. error

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

Doc. No.: 1999 001 015 BA 00

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5.17

Global menu level, PMC®-Drive control J Bus error

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

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

Important!

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

Device information Local V3

Date: 30.03.05 Time: 15:23:38 System selection System configuration Profibus diagnosis (internal) Device information Monitor setting Set date/time

After activating device information, the mask shown in Fig. 21 is displayed on the screen. It contains information about the individual devices of the PMC®-Drive Control Systems.

Fig. 21:

Device information Global Local V3 Device Type Serial no.

CST--HA1 D--CST 560040047 Subassembly ser.no. Software ID CPU: 541040047 Program: 000010009 D--IO: 551040048 Date: 29.03.05 PMU: 531030005 Time: 13:12:45 PVC: 552050055 FPGA1: 003020201 7--Seg: 544030004 FPGA2: 004020201 CPLD: 000001400 F1: Next device

F2: Previous device

J Device

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

J Type

Type of device. Here, the letter V stands for PMC®-V, G for PMC®-G and D for PMC®-D. For the PMC®-D devices, there is an additional abbreviation added for the control system.

J Serial no.

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

5.18

PMC®-D Plow control UEL

E

Global

Bucyrus DBT Europe GmbH, Lünen 2008

Start menu

Global menu level, PMC®-Drive control J Subassembly ser. no.

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

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

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

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

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

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

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

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

J Software ID

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

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

– CPLD (Complex Programmable Logic Device) Is loaded when the devices are produced and sets functions which may not be modified.

next device / previous device

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

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

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5.19

Global menu level, PMC®-Drive control After a device has been started up without errors, the version number of the active program is compared with the other devices working in the same network. This check is only done between devices which are already configured on the PMC®-Drive Control System.

When there is a disagreement in the version status, an error message is output to the PMC®-V devices and the startup of the device network in question is stopped.

Important!

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

Screen settings Start menu

Global

Local V3

Date: 30.03.05 Time: 15:23:38 System configuration System selection Profibus diagnosis (internal) Device information Monitor settings Screen setting Set date/time

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

Fig. 22: Screen settings

Screen setting Brightness: 050 % Contrast: 050 %

Bucyrus DBT Europe GmbH, Lünen 2008

E

Global Local V3

Brightness (L) 065

Set date/time Start menu

Global

Local V3

Date: 30.03.05 Time: 15:23:38 System selection System configuration Profibus diagnosis (internal) Device information Screen setting Set Set date/time date/time

The date and time are kept on the PMC®-Drive Control System.

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

The UTC refers to Greenwich Mean Time. The current local time is determined by adding or subtracting a constant time difference, which is officially defined for every location, to the UTC.

5.20

PMC®-D Plow control UEL

System description - Plow control One device acting as the reference device is responsible for keeping the time on the PMC®-Drive Control System. Which device takes over this task is determined automatically. This device synchronizes the local clocks in the other devices with its clock at regular intervals. The clock in the reference device can either be set by the user or it is adjusted by a higher-ordered system by transferring the time and date.

Fig. 23:

Set date/time Global Local V3 Daylight savings time: On Local time: 13:45:23 Date: 30.03.2005 Local time: UTC +01:00

E

UTC = Universal Time Coordinated

Bucyrus DBT Europe GmbH, Lünen 2008

J Daylight savings time

If standard time and daylight savings time are distinguished at the place of operation of the PMC®-Drive Control System, the display can be adapted to local time by selecting “On” or “Off”.

J Local time, date

Setting of the current time and date.

J Local time UTC

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

System description - Plow control The principle system structure of a plow control is shown in Fig. 24 (5.22). gearbox

Doc. No.: 1999 001 015 BA 00

The gearboxes used in the drive units are equipped with a disk coupling, whose contact pressure, and therefore the maximum torque which can be transferred to the output, can be hydraulically set.

If this torque is no longer sufficient to keep the plow in motion, the coupling starts to slip. This function is for protecting the plow chain.

The coupling pressure is set so that if there is plow blockage, the force induced in the chain lies below the permissible maximum force. To protect the coupling from overheating, the movement which occurs during slipping between the drive and output sides of the coupling is registered by sensors, and leads to the plow system shutting down when a time limit is exceeded.

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5.21

System description - Plow control Fig. 24: System structure - Plow control

The plow position is autonomously registered by each of the PMC®-D devices using two sensors at the output of the drive units.

In order to compensate for tolerances and disturbances, e.g. the slipping over the chain wheel, every drive unit is allocated two magnetic switches, which are mounted in the pans of the face conveyor.

These two switches, called limit switches and synchronous switches, each consist of two switch elements for safety reasons, which send a signal to the PMC®-D device independently of each other when run over by the plow. The system is notified about the position of the magnetic switches via the user interface, so that the plow position can be set to the position of the magnetic switches when the signals are received. The switch signals are triggered by a magnet mounted in the plow body.

J The plow position in meters indicates the distance of the middle

of the plow body from the head gate. The position 0 m is reached when the plow is at the end stop of the head gate.

J The plow position in shield numbers is displayed as a number

with one decimal place. The numbers in front of the decimal indicate the number of the shield where the middle of the plow body is located. The number after the decimal indicates the position of the middle of the plow within the shield in steps of one tenth of the shield width. If, for example, the value 2.5 is displayed, the middle of the plow body is in the middle of the face shield with the number 2.

The face shields are numbered in increasing order from the first face shield at the head gate toward the tail gate, and in the direction toward the head gate in decreasing order. The shield number 0 is not assigned. The shield number changes at the side of the shield facing the head gate. The number of the first face shield can be entered in the range of 10 to 470. The plow position is saved in the devices so that it is secured against power failures.

5.22

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

plow position

E

SB: Splitterbox PH: Proportional hydraulics MF: Motor enable SF: Rapid-run enable S1, S1°: Limit switches S2, S2°: Synchronous switches PB: Profibus

System description - Plow control enable signals

The two PMC-D devices check the functional capability of the control system independently of each other and signalize that the plow control is ready for operation by setting the “motor enable” signal.

If the motor enable is canceled during operation, the drive motors must be immediately shut down.

The “rapid-run enable” signal is available on the PMC®-V device with the name V1. This signal is set for the plow exiting the drive areas and stays set until a point on the face course (adjustable) has been reached. Here, the rapid-run enable is canceled and the drive motors must be switched to slow. The rapid run can be disabled by the operator, separately for both directions of travel.

When the plow enters the drive areas, the “motor enable” signal is canceled from both PMC®-D devices at the shut-down point and it is waited until the plow has stopped. Afterwards, the “motor enable” signals are immediately activated again and the signal for the rapidrun enable is also set. This way, the plow can leave the drive area at high speed. The enable signals are canceled immediately when the plow continues to move toward the drive unit after the motors have been switched on.

The devices signalize the enable by closing the potential-free relay contact. These contacts must be included in the control of the drive machines when the overall system is set up.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 25: Position information - Plow control

position information

Doc. No.: 1999 001 015 BA 00

For correct function, the positions shown in Fig. 25 must be made known to the system. Here, a distinction is made between the information in shield numbers, which refers to the side of the first face shield (n) facing the head gate, and the information in meters, which is measured by the respective plow end stop:

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5.23

System description - Plow control J P1, P1° (distance A, A° [m])

If the tip of the plow facing the direction of travel reaches this point when entering the respective drive area, the “motor enable” signals are canceled. The motors must be switched off immediately.

J Distance B, B° [m]

The distance of the side facing the drive of the respectively first face shield.

J P2, P2° (distance C, C° [m])

If the tip of the plow facing the direction of travel reaches this point when entering the respective drive area, the coupling pressure on this drive unit is lowered to the value defined by the pressure drop.

J P3, P3° (distance D, K [shield number])

If the tip of the plow facing the direction of travel reaches this point when entering the respective drive area, the rapid-run enable is canceled. The motors must immediately switch to slow.

J S1, S1° (distance E, H [shield number])

Position of the limit switches. The switches are always mounted in the middle of the shield. Operation

plow speed

5.24

In Fig. 25 (5.23), the slow plow speed is labeled V1. It must be maintained when entering the drive areas starting from point P3 or P3°. The arrows labeled with V* indicate the range and direction for the rapid run of the plow. The slow plow speed can also be allocated to these ranges by the operator.

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

Position of the synchronous switches. The switches are always mounted in the middle of the shield. In addition to the position information, the width of the face shields (L), the number of face shields (N) and the number of the first face shield on the head gate (n) must be entered.

E

J S2, S2° (distance F, G, [shield number])

Global menu level - Plow control Fig. 26: Menu tree - Plow control S tart m enu Pr oces s ov ervie w

Pl ow

Loca l V1

Date : 12. 10.2 007 Time : 15: 24:5 6

Plo w

L ocal V1 HA HA Pl ow p ositi on 1 23.4 123 .4 m Pl ow p ositi on 0 23.5 02 3.5 s hiel d Pl ow s peed 1 .25 m/s Pl ow d irect ion H A<-- HI HA< --HI Co upli ng pr essu re 0 .30 0.3 0 ba r 2n d pr essur e st age 0 .80 0.8 0 ba r Sy stem pres sure No No Sl ippa ge A 0 00.0 000 .0 % Sl ippa ge B 0 00.0 000 .0 % Dr ive unit I nit Ini t

S elec t ope rati ng m ode P low Ope rati ng mo de: auto matic

Local V1

Proc ess o verv iew Proc ess o ver. Con t.

Swit ch ov ervi ew Driv e uni t se lect ion > Sele ct op erat ing mode Ente r plo w po siti on Para meter sta tus Glob al se ttin gs A utom atic

Au toma tic

A utom atic

Proc ess o verv . co nt.

HA Te mper ature s Te mp. gearb ox Te mp. coupl ing

Plo w

Loca l V1 HA

0 60.0 0 70.0

Pl ow p ositi on Plo w po siti on

Plo w Lo cal V1 HA HA 23.5 Fac e shi eld

060 .0 °C 070 .0 °C

Sel ect opera ting mod e Plo w L ocal V1 Ope rati ng m ode: Auto mati c rat Op erat ing m ode (G); D ate: 30.0 3.05 T ime: 15: 24:5 6 S top A utom atic In spec tion

omat ic AAut utom atic

Autom atic

Limi t sw itch A Limi t sw itch B Sync -swi tch A Sync -swi tch B

Plo w HA Sh ield x 00 5 - 0 20 -

Plow pos itio n Plow dir ecti on

0 23.5 02 3.5 shie ld HA<- -HI H A<-- HI

Bucyrus DBT Europe GmbH, Lünen 2008

E

Sw itch ove rview

Loca l V1 HA Shi eld x 195 - 18 0 -

Au tomat ic

Pa rame ter s tatu s

Plow

Loca l V1

Par amet er P arame ter Same in C opy blo ck statu s sy stem f rom HA loca l User Y es - --HI loca l User Y es - --glo bal fact. set . Y es - ---

Aut omat ic

Dr ive unit sele ction

Pl ow

G lobal set tings

P low Date: 12. 10.2 007

Local V1

Fa ce d ata Po siti on da ta H A Po siti on da ta H I Ra pid- run e nabl e Se t pl ow ty pe

Aut omat ic

Loca l V1

Date : 17 .10. 2007 Time : 13 :10: 55

Head gat e (HA ) Tail gat e (HI )

Start men u

Plo w

HA

D ate: 17.1 0.200 7 T ime: 15: 24:56

Fac e da ta Pl ow Lo cal V 1 N umber fa ce sh ield s 1 96 N umber 1st face shi eld - 05 S hield wid th 1. 500 m

Disp lay proce ss d ata Proc ess data Cont .

Disp lay switc hes Conf igur e pro cess Insp ecti on of cou plin g pre ssur e Moto r/ge arbox

Au toma tic Aut omat ic

Global menu level - Plow control The menu tree shown in Fig. 26 shows the screen masks, which can be used to activate the global functions of the plow control.

This menu tree can be reached from the highest menu level of the PMC® Drive Control System via the system selection. In the middle column of the first line on the screen, the text “Plow” is displayed as the designation of the activated system. The start menu offers the following selection options: Display of the most important process parameters over all drive units.

J Process overview, page 5.27 Display of the installation site and the switch states of the synchronous and limit switches.

J Switch overview, page 5.29

Selection of a drive unit.

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5.25

Global menu level - Plow control J Drive unit activation, 5.30

Operating mode setting of the plow control.

J Selecting the operating mode, page 5.42

Input of the current plow position.

J Entering the plow position, page 5.43

Overview of the status of the global and local parameter blocks stored in the PMC-D devices.

J Parameter status, page 5.43

Activation of a subordinate menu tree for setting the global parameters of the plow control.

J Global settings, starting on page 5.46 Fig. 27: Start menu - Plow control

Start menu

Plow

Local V1

Bucyrus DBT Europe GmbH, Lünen 2008

Process overview Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings >

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Date: 17.10.2007 Time: 15:24:56

>

Automatic

Process overview Start menu Date: 17.10.2007 Time: 15:24:56

Process overview

Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings

Automatic

5.26

Plow

V1

In the process overview, the current values of the most important process parameters of all drive units of the conveyor system are displayed. This provides a quick overview of the operating state of the system. In the event of errors in the data acquisition, the corresponding values are darkly highlighted. To determine the exact cause of the error, the affected drive must be activated and the mask for showing the local process data called up (Displaying process data, page 5.47).

PMC®-D Plow control UEL

Global menu level - Plow control Fig. 28: Process overview

Process overview

HA Plow position 123.4 Plow position 023.5 Plow speed 1.25 Plow direction HA<----HI Coupling pressure 030.0 2nd pressure stage 080.0 System pressure No Slippage A 000.0 Slippage B 000.0 Drive Init

Automatic

Plow Local V1 HI 123.4 m 023.5 shield 1.25 m/s HA<----HI 030.0 bar 080.0 bar No 000.0 % 000.0 % Init

Enable motors

The following process values are displayed: J Plow position in meters

The distance of the middle of the plow body from the head gate.

The position 0 m is reached when the plow is at the end stop of the head gate.

E

J Plow position in shield numbers

Bucyrus DBT Europe GmbH, Lünen 2008

The plow position in shield numbers is represented by a number with one decimal place. The numbers in front of the decimal indicate the number of the shield where the middle of the plow body is located. The number after the decimal indicates the position of the middle of the plow within the shield in steps of one tenth of the shield width.

J Plow speed J Plow direction

The plow direction is indicated by the following symbols: – -->

Slow run in the displayed direction

– ==>

Rapid run in the displayed direction

– |> ; <| Plow stands still, the arrow points in the last direction of travel – |

Plow stands still, last direction of travel unknown

– ?

Plow position unknown in the system

J Coupling pressure

The pressure in the discharge chamber of the coupling.

J 2nd pressure stage J System pressure J Slippage A J Slippage B

Doc. No.: 1999 001 015 BA 00

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5.27

Global menu level - Plow control J Drive

The operating states of the PMC®-D device and the drive unit are displayed. The following abbreviations are displayed: – Init The device is being initiated and attempts to reconcile the plow position with the PMC®-D device of the other drive unit.

If this is not successful, an error message is output and this state is maintained.

– SynCfg, synchronous configuration The own configuration is completed and it is waited until the configuration of the other device is finished.

– Stop „Stop“ mode was selected.

– Ready The drive unit is ready for operation. The enable for starting the drive motors is given by closing the relay contact.

Process overv. cont.

Start menu

Plow V1

Date: 17.10.2007 Process overview Time: 15:24:56

Process overview

Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings

Automatic

5.28

This is the continuation of the table in the “Process overview” menu item: J Temperatures on the head gate and tail gate

– Temp. gearbox – Temp. coupling

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

– ExtStop, External stop Due to an error message on another PMC®-D device, the drive unit enable is canceled by opening the relay contact.

E

– Error The PMC®-D device has detected a local error. This error is signaled on other PMC®-D devices and the enable for the drive unit is canceled by opening the relay contact.

Global menu level - Plow control Switch overview Start menu Date: 17.10.2007 Time: 15:24:56

Plow V1

Process overview Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings

Automatic

Two magnetic switches are allocated to every drive unit, which are mounted in the pans of the face conveyor. These two switches, called limit switches and synchronous switches, each consist of two switch elements, A and B, for safety reasons, which send a signal to the PMC®-D device independently of each other when run over by the plow.

Fig. 29: Switch overview

Switch overview Limit switch A Limit switch B Sync--switch A Sync--switch B

HA Shield X 005 --- 020 --

Plow HI Shield X 195 --- 180 --

Local V1

Plow position Plow direction

023.5 HA<----HI

023.5 shield HA<---- HI

Bucyrus DBT Europe GmbH, Lünen 2008

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Automatic In this screen mask, the signal states of the switches are displayed.

The “X” indicates that the switch was activated by the plow running over it. Here, the display is prolonged to approx. 2 seconds, in order to make the short impulse which occurs as the plow drives over visible to the observer. For orientational purposes, the installation positions of the switches are displayed, as well as the plow position and direction of travel determined by the two PMC®-D devices.

Doc. No.: 1999 001 015 BA 00

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5.29

Global menu level - Plow control Drive unit selection Start menu

Plow V1

Date: 17.10.2007 Time: 15:24:56

Process overview Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings

Automatic

A selection list is displayed in which the drive units reachable via the internal Profibus system are entered. Selecting a drive unit leads to the menu level of the individual PMC®-D devices. Here, functions can be activated which only affect the selected drive unit (menu level of plow drive unit).

Fig. 30: Drive unit selection

Drive unit selection Plow Date: 17.10.2007 Time: 7:26:17

Local V1

Head gate 1 (HA) Tail gate 1 (HI)

After selecting the desired drive unit and confirming with “Enter”, the following screen mask is displayed: Start menu Fig. 31: Start menu

Start menu

Plow

Ha

Date: 17.10.2007 Time: 7:26:17

Display process data Process data cont.

Display switches Configure process > Inspection of coupling pressure Motor/gearbox > Automatic

5.30

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

Here, functions can be activated which only affect the selected drive unit (menu level of plow drive unit).

E

Automatic

Global menu level - Plow control Display process data Fig. 32: Display process data

Display process data

Plow

Plow position Plow position Plow speed Plow direction Coupling pressure 2nd pressure stage System pressure Slippage A Slippage B Drive unit

123.4 m 023.5 shield 1.25 m/s HA<----HI 030.0 bar 080.0 bar no 000.0 % 000.0 $ Init

HA

Automatic Under the “Display process data” menu item, the following data is displayed. By selecting with the cursor and pressing the “Enter” key, sensor information is output about the selected measurement (shown via the display window).

E

J Plow position in meters (m)

Bucyrus DBT Europe GmbH, Lünen 2008

J Plow position in shields J Plow speed in m/s J Plow direction J Coupling pressure in bar J 2nd pressure stage in bar J System pressure (no = not initialized, not available) J Slippage A J Slippage B J Drive unit

Process data Cont.

Fig. 33: Start menu

Process data Cont.

Plow

Temperatures Temp. gearbox Temp. coupling

060.0°C 070.0°C

HA

Automatic

Doc. No.: 1999 001 015 BA 00

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5.31

Configure process Display switches Fig. 34: Display switches

Display switches

Plow

Limit switch A Limit switch B Sync--switch A Sync--switch B

X ----

Plow position Plow direction

023.5 HA<----HI

HA

shield

Automatic

Configure process Fig. 35: Menu level - Plow drive unit, Configure process Configure process

Plow

HA1

E

Date: 08.05.2008 Time: 08:34:00 Act Proce iva ss te func proc tio ess nsfu on/ nct off ions

Bucyrus DBT Europe GmbH, Lünen 2008

Process functions (cont.)

Overload settings Pressure settings

Automatic

Process functions Measurement evaluation Sync-switch A Sync-switch B Limit switch A Limit switch B Drive speed Drive speed Slippage sensor Slippage sensor

Plow

HA1

Active OFF OFF OFF OFF OFF Active Active

HA1

Plow

Max. slippage limit - permissible for Min. slippage value - permisissble for

Automatic

30.00 % 0.20 s 05.00 % 10.00 s

Automatic

Process functions 2

Plow

Measurement evaluation Coupling pressure Pressure sensor 2nd stage System pressure switch Temperature gearbox Temperature coupling

Active Active Active Active Active

Automatic

Overload settings

Overload detection

HA1

Pressure settings

HA1

Plow

Working pressure

30.00 bar

Pressure ramp Ramp end value

05.0 bar/s 05.0 bar

Automatic

In the menu tree shown in Fig. 35, all functions are summarized which allow the configuration of the control and regulation processes for the selected drive unit (path: Plow control\Drive unit selection\Head gate[or Tail gate]\Configure process). After selecting the “Configure process” menu item in the start menu of the “CST drive unit” menu level, the following selection options are available: J Activation/deactivation of process functions.

Process functions on/off (page 5.33).

J Process functions 2

tures page 5.36.

5.32

Pressure settings, coupling, tempera-

J Overload settings

Slippage, page 5.36.

J Pressure settings

Working pressure, page 5.38.

PMC®-D Plow control UEL

Configure process Fig. 36: Configure process

Configure process

CST

HA1

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Automatic

Process functions on/off Configure process

Plow

HA1

Bucyrus DBT Europe GmbH, Lünen 2008

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Activatefunctions process functions Process on/off Process functions (cont.)

Overload settings Pressure settings

Some control and regulation process functions can be activated/deactivated with the input mask shown in Fig. 37. Here, a distinction is made in the mask between the evaluation of measurements, internal monitoring functions and the monitoring of additional functions which don’t directly belong to the control process, e.g. the automatic tensioning of the chain.

Fig. 37: Process functions on/off

Automatic

Process functions Measurement evaluation Synch--switch A Synch--switch B Limit switch A Limit switch B Output speed A Drive speed B Slippage sensor A Slippage sensor B

Plow

HA1

Active Active Off Off Off Off Active Active

Automatic

Doc. No.: 1999 001 015 BA 00

VRVT / 01

5.33

Configure process J Measurement evaluation

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

By deactivating monitoring, the following functions are deactivated:

Bucyrus DBT Europe GmbH, Lünen 2008

E

– Sync-switches A and B, limit switches A and B In these two switches, two independent switch elements, A and B, are integrated, so that the failure of one of these switch elements can be tolerated. When the entire switch fails, the PMC®-D device loses a synchronization point for the plow position. If both switches fail, the plow position is only synchronized via the communication connection from the second PMC®-D device.

5.34

PMC®-D Plow control UEL

Configure process – Drive speed Output speed A and B The output speed of the drive unit is measured by two independent speed sensors. They are used to determine the plow speed, the plow position and the direction the plow is traveling. If one of these sensors is defective, the PMC®-D device can no longer detect the plow’s direction of travel, so the plow position can’t be determined either. The measurement of the plow speed fails when the second sensor is also defective. This information can then only be gotten from the second PMC®-D device.

Bucyrus DBT Europe GmbH, Lünen 2008

E

– Slippage sensors A and B The slippage in the UEL coupling is monitored. There are two frequency modules behind each Namur slippage sensor. One to measure high frequencies, and the other to measure low frequencies (at least 0.5 Hz). The two modules are required because the measurement of low frequencies to detect low slippage requires a much longer measuring time. Increased slippage, however, requires an immediate reaction of the control system.

Slippage detection of higher slippage values is indispensable, since the coupling can’t tolerate constant slippage (heat development, destruction of the coupling).

Slippage detection of low slippage is desired, since the coupling can also become impermissibly warm. The plow process demands no slippage, however, so this is undesirable.

Doc. No.: 1999 001 015 BA 00

VRVT / 01

5.35

Configure process

Configure process

Plow

HA1

Process functions (cont.)

Fig. 38: Process functions (cont.)

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Process functions 2 Measurement evaluation Coupling pressure Pressure sensor 2nd stage System pressure switch Temperature, gearbox Temperature, coupling

Automatic

Plow

HA1

Active Active Active Active Active

Automatic

– System pressure switch Pressure switch for the 100 bar reduction. The face pressure is monitored. If there is not enough pressure (less than 100 bar) available, no enable is given for plowing.

– Temperature, gearbox Monitoring of the gearbox temperature (oil sump) – Temperature, coupling Monitoring of the coupling temperature (sensor near the disk coupling) Configure process

Plow

HA1

Overload settings Fig. 39: Overload settings

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Overload settings

Plow

HA1

Overload detection Automatic

Max. slippage limit -- permissible for

30.00 % 0.20 s

Min. slippage value -- permissible for

05.00 % 10.00 s

Automatic

5.36

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

– Pressure sensor 2nd stage Pressure sensor for the second reduction stage to approx. 60 bar.

E

– Coupling pressure Measurement of the hydraulic pressure applied to the disk coupling of the UEL gearbox.

Configure process J Overload detection

In order to protect the disk coupling of the UEL gearbox, there must be overload detection. From these slippage sensor measurements, the system detects whether there is a hard or soft blockage. These are compared with the limits to be entered and, if exceeded, lead to the plow system shutting down.

– Max. slippage limit If the slippage exceeds the set value, the system is shut down.

– -permissible for If the measured slippage value lies below the set max. slippage value, but above the min. slippage limit (see below), the plow system is shut down after the set time.

– Min. slippage limit If the measured slippage value lies below the set min. slippage value, the plow system is shut down after the set time (-permissible for).

– -permissible for If the measured slippage value lies below the set min. slippage value, the plow system is shut down after the set time.

Fig. 40: Window for the slippage limits

E

S Bucyrus DBT Europe GmbH, Lünen 2008

A

A

A

10

C

0.2

B

A

C 5%

SLIPPAGE

30%

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

If the system runs in the areas labeled A, it is immediately shut down.

In the 5% to 30% slippage areas (B), the system is shut down after 0.2 s.

If the slippage lies below 5%, but over 0%, it is shut down after 10 s.

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

Important!

The afore-mentioned values apply for the settings in the shown example (see Fig. 39, page 5.36)

Doc. No.: 1999 001 015 BA 00

VRVT / 01

5.37

Configure process

Configure process

Plow

HA1

Pressure settings Fig. 41: Overload settings

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Automatic

Pressure settings

Plow

Working pressure

30 bar

Pressure ramp Ramp end value

05.0 bar/s 05.0 bar

HA1

Automatic J Working pressure

With the pressure ramp value, a lower pressure can be set on the coupling in the drive areas so that it runs with less pressure against the stop. Starting from a value of approx. 15 m in front of the drive unit, the working pressure is reduced by 5 bar/s up to the ramp end value of 5 bar.

This feature can be deactivated by entering 0 for the pressure ramp.

J Ramp end value

is the value to which the pressure is reduced.

Inspection of coupling pressure Fig. 42: Inspection of coupling pressure

Inspection of coupling pressure Set pressure Coupling pressure Increase valve pressure Lower valve pressure

Plow

HA

0000.0 bar 030.0 bar 00.0 mA 00.0 mA

Automatic

5.38

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

J Pressure ramp

E

Setting of the coupling pressure of the UEL gearbox.

This set value must be so high that the motor torque lies above the stalling torque during normal plow operation.

Configure process J Set pressure

For the inspection operating mode, a coupling pressure of 0 bar must be set so that the plow doesn’t start up while the motor is running during inspection. The value can be input after pressing the “Enter” key.

J Coupling pressure

Display value of the applied pressure

J Increase valve pressure

The valve should not be actuated during inspection. For this reason, the input electric power should be zero.

J Lower valve pressure

The valve should not be actuated during inspection. For this reason, the input electric power should be zero.

Start menu

Plow

HA

Motor/gearbox Fig. 43: Start menu

Display process data Process data Cont.

Display switches Configure process Inspection of coupling pressure Motor/gearbox

Motor/gearbox

Plow

HA

Date: 17.10.2007 Time: 7:26:17

Automatic

Bucyrus DBT Europe GmbH, Lünen 2008

E

Temperature monitoring Motor data Set gearbox type Set chain sprocket

Automatic

Temperature monitoring Fig. 44: Start menu

Temperature monitoring

Plow

HA

Gearbox temperature Prewarning at 75°C Next warning in 30 min. > 090°C: Plow system shutdown!

Automatic

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VRVT / 01

5.39

Configure process Motor data Fig. 45: Start menu

Motor data

Plow

Nominal motor speed (fast) Nominal motor speed (slow

1480 rpm 0493 rpm

HA

Automatic

Set gearbox type Fig. 46: Set gearbox type

Plow

Gearbox ratio: Number of teeth, drive unit measuring wheel: Number of teeth, internal gear measuring wheel:

21,000

HA Bucyrus DBT Europe GmbH, Lünen 2008

E

Set gearbox type Gearbox type: P--15 ÜL 16:1

024 024

Direction of rotation reversal: Yes

Automatic If the “Enter” key is pressed, a selection list is opened with the available Bucyrus plow gearboxes. In addition, a user-defined gearbox can be selected.

5.40

PMC®-D Plow control UEL

Configure process Fig. 47: Set gearbox type

Set gearbox type Plow HA Gearbox type: P--15 ÜL 16:1 Gearbox type (L): Gearbox ratio: 21,000 Number of teeth, unit measuring wheel: P--45 drive ÜL 28:1 024 P--45 ÜL 33:1 Number of teeth, P--45 internal ÜL 39:1gear measuring wheel: 024 P--45 ÜL 50:1 P--65 ÜL 33:1 Direction of rotation reversal: P--65 ÜL 39:1 Yes P--65 ÜL 50:1 User--defined

Automatic

Bucyrus DBT Europe GmbH, Lünen 2008

E

The “Set chain sprocket” menu item is analogous to the descriptions for setting the device type.

Doc. No.: 1999 001 015 BA 00

VRVT / 01

5.41

Configure process Select operating mode Start menu

Plow V1

Date: 17.10.2007 Time: 15:24:56

Process overview Process overv. cont.

Switch overview Drive unit selection Select operating mode

Enter plow position Parameter status Global settings

The operating mode of the plow system can be set via the displayed selection list. From the “Select operating mode” window, one comes to the input mask by pressing the “Enter” key. The operating mode must always be changed with the “Stop” operating mode as an intermediate step.

Fig. 48: Select operating mode

Automatic

Select operating mode Operating mode: Automatic

Plow

Local V1

Operating mode (G) Stop Automatic Inspection

J Stop

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

J Automatic

If there are no error messages on the system, the contacts to the motor enable are closed. If rapid-run is not generally disabled by the operator, the enable contact for the rapid-run is also closed.

J Inspection

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

Enter plow position Start menu

Plow V1

Date: 17.10.2007 Time: 15:24:56

Process overview Process overv. cont.

Switch overview Drive unit selection Select operating mode Enter plow position Parameter status Global settings

The determined plow position is stored in memory secured by the internal battery in the PMC®-D devices. This way, the last determined plow position is available again, even after a power failure.

If the stored plow position doesn’t agree with the real plow position, e.g. after repairs to the plow system, the plow position can be reentered via this mask.

Automatic

5.42

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

E

Automatic

Configure process Fig. 49: Entering plow position

Enter plow position HA HI Plow position 023.5

Plow

Local V1

023.5 face shield

Automatic

Parameter status

Bucyrus DBT Europe GmbH, Lünen 2008

E

The functions for the plow control system can be influenced by setting parameters. The factory settings saved when the PMC®-D devices are delivered guarantee only a basic system setting. These must be adapted to the requirements at the place of operation. The system distinguishes between global parameters, which apply for the entire control system, and local parameters, which apply for the respective drive unit. The global parameters are fundamentally stored in both PMC®-D devices. For the system to function, it would be sufficient to only store the local parameters in the device to which they are allocated. This means, however, that when a device is exchanged, the changed local parameters must be input again.

To avoid this, a copy of the local parameters of the other device is stored on each PMC®-D device. This way, a new device can take over both the global as well as the local parameters of the device with the current parameter blocks. The parameter reconciliation is done via the screen mask shown in Fig. 50.

Fig. 50: Parameter status

Parameter status Parameter Parameter block status HA local user HI local user Global fact. set.

Plow Local V1 Same in Copy system from Yes -------Yes -------Yes --------

Automatic

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5.43

Configure process J Parameter block

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

J Parameter status

Short designation for the state of the parameter block in the device allocated to it. The following short designations are displayed: – User The factory settings have been changed by the user.

– Fact. set.

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

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

J Copy from

After selecting a parameter block and pressing the “Enter” key, a list is displayed in which all existing devices and the factory settings are offered for selection (Fig. 51). The installation site of the selected device, from which all other devices are to accept the parameter block, is displayed in this column during this acceptance.

Important!

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

The list for selecting the device, from which the parameter block is to be copied, is shown in Fig. 51. In addition to the device designations, the status of the parameter block in the individual devices is also displayed. Copying parameter blocks which are labeled with “W” or “R” is not allowed, in order to prevent accidentally resetting the parameters to the factory settings. Resetting the parameter values to factory settings is only possible via the “Factory settings” selection.

5.44

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

J Same in system

Configure process Fig. 51: Copying parameter block

Parameter status Plow Local V1 Parameter Parameter In system Copy Device Parameter block HA2 control Block HA StatusUSame from HA1 HI local User U* Yes -----HA2 local User No -----Factory settings HI1 local User Yes -----HI2 ------changed ------ ------by the user U =local values Global User Yes ------ the copies * U = different from F = factory settings R = reset to factory settings

Automatic The status of the parameter block is labeled with the following abbreviations: J B

The factory settings were changed by the user.

J B* Bucyrus DBT Europe GmbH, Lünen 2008

E

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

J W

The parameter values are equivalent to the factory settings

J R

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

Example:

Doc. No.: 1999 001 015 BA 00

The example shown in Fig. 51 shows that local parameters in the PMC® D device of head gate 2 were changed without the copies in the other devices being reconciled. This is possible when there was no communication connection between the devices at the time the parameter was changed. In this case, the user must decide with which parameters the PMC® D device on head gate 2 should continue to work.

VRVT / 01

5.45

Menu level - Plow control, Menu level - Plow control, global settings Fig. 52: Global menu tree - Plow control, global settings Global settings Face data

Plow

Number of face shields: Number of 1st face shield: Shield width:

200 - 05 1.500 m

Local V1

Plow Date: Time: CST

Local V1

17.10.2007 10:58:22 Drive unit

Face data Position data HA Position data HI Rapid-- run enable Set plow type

Set plow type

Plow

Plow body: Place of magnet installation:

Type 5.7

Local V1

toward HI

Plow data Distance - Stop points - Magnet next stop

2.260 mm 0.350 mm

Automatic Automatic

Automatic

005 face shield 020 face shield

Local V1

Rapid-- run enable Rapid run HA==>HI: enabled - if enabled up to: 011 face shield Rapid run HI==>HA: enabled - if enabled up to: 020 face shield

Plow

Local V1

Distance plow stop conveyor - 1st face shield: 03.00 m - Motor off: 35.00 m - Pressure drop: 00.00 m

Automatic

Automatic

Plow

Set plow type

Local V1

Plow body: Type 5.7 Place of magnet installation: toward HI Plow data Type 2.7 Distance Type 5.7 - Stop points 2.260 mm Type 5.7 (sensor) Typestop GH 42/1 (sensor) - Magnet next Type GH 42/2 User-defined

Automatic

The menu tree shown in Fig. 52 shows the screen masks which can be used to change the local settings of the selected drive unit.

This menu tree can be reached from the start menu of the plow drive system by selecting the “Global settings” command. The name of the drive unit is displayed in the right column of the first screen line.

Global settings In the “Global settings” submenu, the following menu items can be selected: J Input of the face data relevant for the plow control J Information about the switch positions and control points on the

head gate

J Information about the switch positions and control points on the

tail gate

J Rapid-run enable when the drive areas are exited J Selection of the used plow type

5.46

PMC®-D Plow control UEL

E

Position Limit switch: Sync-- switch:

Plow

Bucyrus DBT Europe GmbH, Lünen 2008

HA position data

Menu level - Plow control, Fig. 53: Global settings

Global settings

Plow

Local V1

Date: 17.10.2007 Time: 10:58:22 CST drive unit Face data Position data HA Position data HI Rapid--run enable Set plow type

Automatic

Face data Global settings

Plow

Local V1

Date: 17.10.2007 Time: 10:58:22

Bucyrus DBT Europe GmbH, Lünen 2008

E

Face data

Position data HA Position data HI Face- run data Rapidenable Set plow type

For the correct control of the plow, the PMC Drive Control System must know the length of the face, the number of the first face shield on the head gate and the width of the shields on the face.

Fig. 54: Face data

Face data Number of face shields: Number of 1st face shield: Shield width:

Plow Local V1 200 --05 1.500 m

Automatic J Number of face shields

This includes all shields which are mounted in the face area, independent of their designation as face shield, face edge shield or transition shield.

J Number of 1st face shield

The number assigned by the shield control unit for the first shield on the head gate mounted on the face. This number is a reference for all positions given in the form of shield numbers.

J Shield width

The width of the shields mounted on the face.

Caution!

Make sure the required values are correctly specified. All position calculations of the control system are based on these values. Incorrect information can lead to serious damage to the plow system.

Doc. No.: 1999 001 015 BA 00

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5.47

Position data, head gate / tail gate Fig. 55: Changing values

Face data Number of face shields: Number of 1st face shield: Shield width:

Plow Local V1 200 --05 1.500 m

Number of face shields (G):

200

Automatic

Fig. 56: HA position data

HA position data Position Limit switch: Sync--switch:

Plow

Local V1

005 face shield 020 face shield

Distance plow stop conveyor -- 1st face shield: 03.00 m -- Motor off: 35.00 m -- Pressure drop: 00.00 m

Automatic The data for the tail gate is set analogously.

Rapid-run enable Global settings

Plow

Date: Time: CST

17.10.2007 10:58:22 Drive unit

Face data Face data Position data HA Position data HI Rapid-- run enable

Set plow type

5.48

Local V1

The rapid-run enable is set by the control system when the plow exist the drive areas and is maintained until a shield, which is individually selectable for each direction of travel, has been reached.

In the area between these two shields, rapid running is allowed in both directions of travel. If this is not desired, the rapid-run enable can be individually disabled for each direction of travel.

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

The position of the limit switches and synchronous switches, which serve as reference points for measuring the plow position, can be entered in the screen mask. In addition to the distance between the end stop in the plow guide and the first shield on the face, points can be defined where the motors are shut down or the pressure drop on the drive unit coupling is activated.

E

Position data, head gate / tail gate

Position data, head gate / tail gate Fig. 57: Rapid-run enable

Rapid--run enable Plow Rapid run HA==>HI: enabled -- if enabled up to: 011 face shield Rapid run HI==>HA: enabled -- if enabled up to: 020 face shield

Local V1

Automatic

Set plow type

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Fig. 58: Setting the plow type

Set plow type Plow body: Place of magnet installation: Plow data Distance -- Stop points -- Magnet next stop

Plow

Local V1

Type 5.7 toward HI

2.260 mm 0.350 mm

Automatic J Plow body

The plow body considered by the control system

J Place of magnet installation

The switch functions of the synchronous and limit switches are triggered by a magnet mounted in the plow body. The two possible mounting positions lie symmetric to the middle of the plow body. For the control system to function correctly, it must be specified whether the magnet is mounted toward the head gate or tail gate when looking from the face support to the center of the plow.

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5.49

Position data, head gate / tail gate J Plow data

– Distance stop points The distance between the two stop points of the plow body.

At these points, the plow is stopped by the end stop in the plow guide of the conveyor.

– Distance magnet next stop The distance between the mounting position of the magnet and the next stop point. The plow type is set by selecting it from the list which is displayed after pressing the “Enter” key.

In this list are all plows manufactured by DBT. – Furthermore, a user-defined plow can also be selected (userdefined plow, page XXX). After selection, the data allocated to the plow is displayed in the basic mask.

Automatic Caution!

Make sure that the correct plow type has been set and that the correct mounting position of the magnet is specified. Incorrect information can lead to considerable damage to the plow system.

Fig. 60: Place of magnet installation

Set plow type Plow Local V1 Plow body: Type 5.7 Place of Place magnet of installation: magnet installation (G): toward HI Plow data Distance toward 2.260 mm -- Stop points -- Magnet next stop HA 0.350 mm toward HI

Automatic

5.50

PMC®-D Plow control UEL

Bucyrus DBT Europe GmbH, Lünen 2008

Set plow type Plow Local V1 Plow body: Type 5.7 Place of magnetPlow installation: body (G): toward HI Type 2.7 Plow data Type 5.7 Distance Type 5.7 (sensor) Type GH 42/1 (sensor) -- Stop points 2.260 mm Type GH 0.350 42/2 mm -- Magnet next stop User--defined

E

Fig. 59: Plow bodies

6

Technical data

Main dimensions

Technical data Main dimensions

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 61: Housing dimensions PMC®-V

Fig. 62: Housing dimensions PMC®-G

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6.3

Main dimensions

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 63: Housing dimensions PMC®-D

Fig. 64: Tapped holes, rear side (all devices)

6.4

PMC®-D Plow control UEL

Pin assignment Pin assignment Pin assignment PMC®-V and PMC®-G Fig. 65: SKK24 sockets, PMC®-V and PMC®-G

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tab. 1: Pin assignment PMC®-V and PMC®-G

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1

Optocoupler Anode

Relay contact N/O contact: a

Relay contact N/O contact: b

Optocoupler Cathode

St2

+12 V (A)

Serial interface: RxD

Serial interface: TxD

GND

St3

+12 V (B)

Serial interface: RxD

Serial interface: TxD

GND

St4

+12 V (C)

Serial interface: RxD

Serial interface: TxD

GND

St5

Options

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

St6 St7

+12 V Input

Serial interface: TxD

Serial interface: RxD

GND Input

St8

+12 V (B)

Measurement input 1

+8.2 V

GND

St9

+12 V (C)

Measurement input 2

+8.2 V

GND

St10

+12 V (A)

Measurement input 3

+8.2 V

GND

St11

Options

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

St12

Options

Option

Socket

**

St5

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

Pin 1

Pin 2

Pin 3

St5

Profibus: a (external)

Profibus: b (external)

St11

Profibus: a (external)

Profibus: b (external)

Pin 4

St11 AB

Doc. No.: 1999 001 015 BA 00

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6.5

Pin assignment Fig. 66: SKK24 sockets PMC®-D

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1 St2

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

St4

+12 V (C)

St5

+12 V (C)

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

Optocoupler Cathode GND

St3

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

St10

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

St11

+12 V (C)

St8 St9

St12

6.6

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

GND

+8.2 V

GND Input GND

+8.2 V

GND

+8.2 V

GND

+8.2 V

GND

Profibus: b (internal)

PMC®-D Plow control UEL

E

St7

GND

Bucyrus DBT Europe GmbH, Lünen 2008

St6

GND

UEL DISTRIBUTION BOX UEL DISTRIBUTION BOX Fig. 67: UEL distribution box 3 3

3

3

2

1 4

1 = Metal flag for fastening 2 = Cover with seal 3 = Screwed cable gland, M 16X1.5 4-8MM 4 = Screw-in socket SKK 212M

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

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

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6.7

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

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

6.8 Bucyrus DBT Europe GmbH, Lünen 2008

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

E

UEL DISTRIBUTION BOX

Fig. 68: Terminal diagram of the distribution box

PMC®-D Plow control UEL

Splitterbox PMC OS 37 SPB Splitterbox PMC OS 37 SPB Fig. 69: Splitterbox

4

3

1

5 1

4 2

5

Bucyrus DBT Europe GmbH, Lünen 2008

E

1 = SKK212 connections for connecting to the adapter box 2 = OS 37 connection for connecting to the PMC®-D 3 = Cover with labeling 4 = Fastening bores 5 = Notched fastening bores

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

Doc. No.: 1999 001 015 BA 00

VRVT / 01

6.9

Bucyrus DBT Europe GmbH, Lünen 2008

E

Splitterbox PMC OS 37 SPB

6.10

PMC®-D Plow control UEL

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: Fax: Email:

Great Britain

+49 / 23 06 70 9 - 0 +49 / 23 06 70 9 - 1421 info@de.bucyrus.com

Bucyrus UK Ltd. Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK

Bucyrus DBT Europe GmbH, Lünen 2008

E

Tel: +44 / 11 59 51 - 2500 Fax: +44 */ 11 59 32 - 9683 E-mail: 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: Fax: Email:

Doc. No.: 1999 001 015 BA 00

VRVT / 01

+7 / 49 56 23 - 5396 +7 / 49 59 24 - 8363 viktor.sobolev@ru.bucyrus.com

7.3

Service addresses OE Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: Fax: Email:

+7 / 38 43 35 - 3441 +7 / 38 43 35 - 3442 evgeniya.belousova@ru.bucyrus.com

North America, Canada, South America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010, USA Tel: Fax: Email:

+1 / 72 47 43 - 1200 +1 / 72 47 43 - 1201 info@us.bucyrus.com

Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 +1/54 09 80 - 4530 +1/54 09 94 - 3889 Bucyrus DBT Europe GmbH, Lünen 2008

E

Tel: Fax:

Australia Bucyrus Australia Underground Pty. Ltd. Customer Service 20 Killara Close, Beresfield, New South Wales 2322 Tel: Fax:

+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: Fax: Email:

7.4

+ 27 / 11 82 5 - 8212 + 27 / 11 82 5 - 7389 hetta.fuller@za.bucyrus.com

PMC®-D Plow control UEL

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: Fax: Email:

+86 / 10 65 88 - 2998 +86 / 10 65 88 - 6570 Info.beijing@cn.bucyrus.com

Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: Fax: Email:

+ 86 / 31 66 08 6 - 840 (& 841, 842, 843) + 86 / 31 66 08 6 - 845 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: Fax: Email:

Doc. No.: 1999 001 015 BA 00

VRVT / 01

+86 / 31 53 20 - 3117 (& 3445, 3404) +86 / 31 53 20 - 3438 Info.tangshan@cn.bucyrus.com

7.5

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 2: 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 hydraulic system Fire-resistant hydraulic fluids Maintenance and inspection for hydraulic systems Hydraulic systems - Design principles Determination of the acid number Determination of sulfate ash Tensioning force, tightening torques and surface pressure for bolts T-head bolts Lubricating greases & solid lubricants Non-metallic (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 1986-08 1982-02 1984-12 1979-07 1984-11 1985-02 1985-02 1992-06 1985-02 2005-03

Referenced European standards and directives Tab. 3: European standards and directives, extract

Designation 98/37/EC directive

94/9/EC directive DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN 13463-1 DIN EN 60079 DIN EN 60445 DIN EN 62079 DIN ISO 3733 DIN EN 1710 DIN EN 1552

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 1994-03-23 protective systems intended for use in potentially explosive atmospheres Safety of Machinery 2004-04 Safety of Machinery 2004-04 Non-electrical equipment for potentially explosive atmos2002-04 pheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres 2004-12 - Part 0: General requirements Basic and safety principles for man-machine interface 2000-08 Preparation of instructions 2001-11 - Structuring, content and presentation Petroleum products and bituminous materials 2003-02 - Determination of water - Distillation method Equipment and components intended for use in potentially 2006-01 explosive atmospheres in underground mines Mobile extracting machines at the face - safety require2003-09 ments for shear loaders and plough systems 1)

7.6

EWN = Bucyrus works standard

PMC®-D Plow control UEL

E

Title

Bucyrus DBT Europe GmbH, Lünen 2008

Designation