CAT Plow PMC-D – Drive Control System Plow control UEL Operation & Maintenance Manual

Media-ID: EM027987-00-EN Doc.-No.: 1999 001 015 BA 00 09 Jun. 2017

Operating and Maintenance Manual PMC-D – Drive Control System Plow control UEL

SAFETY.CAT.COM

© 2017 CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of content

Table of content 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

1.3 1.3 1.3 1.4

1.4

2. For your safety General information for avoiding accidents . . . . .

2.3

Further operating manuals . . . . . . . . . . . . . . . . . . . .

2.3

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

2.3

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Assembly and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Conditions of application . . . . . . . . . . . . . . . . . . . . . .

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

Unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Surrounding area conditions . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.3

2.4 2.4 2.4 2.4 2.4

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

2.5

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

2.6

Installation and start-up . . . . . . . . . . . . . . . . . . . . . . .

2.6

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

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

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

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

3.3 3.3

3.3 3.3

4. Installation Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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4.3 4.3

4.4 4.5 4.5

Table of content 5. Operation General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Keyboard PMC® V . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Light emitting diodes PMC® V . . . . . . . . . . . . . . . . .

5.5

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

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

Profibus-diagnostics (intern) . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5.11 5.12 5.13 5.16 5.17 5.19 5.20

System description - Plow control . . . . . . . . . . . . . .

5.21

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

Configure process . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Global settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Position data, head gate / tail gate . . . . . . . . . . . . . .

Rapid-run enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.26 5.28 5.29 5.30 5.31 5.31 5.32

5.32 5.33 5.35 5.35 5.37 5.37 5.38 5.38 5.39 5.39 5.41 5.41 5.42

5.45 5.45 5.46

5.47 5.47 5.48

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PMC® Drive Control global menu level . . . . . . . . . .

5.5 5.6

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Password entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Table of content 6. Technical data Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

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

6.4

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

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

6.7

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

6.9

Provider PMC-P XP Opto Ethernet . . . . . . . . . . . . . .

6.10

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Patch cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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6.13 6.13

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Table of content

PMC-D UEL Plow

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.

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

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current operating manuals

Operating manuals for the conveyor 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.

Caterpillar Global Mining Europe GmbH, Lünen 2017

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: are in charge of transport perform assembly/disassembly work operate the conveyor correct malfunctions carry out daily routine work on the face or in the entry carry out maintenance work perform repair work as well as supervisory personnel who 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.

safety

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

Observe the information given and follow the procedural instructions.

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1.3

Service 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.

Danger!

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

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.

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.

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

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Caution!

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

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Warning!

These points contain information on dangerous situations.

Possible consequences are very serious injury or even death.

2

Your safety

General information for avoiding accidents

For your safety This chapter provides vital information for your safety.

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

General information for avoiding accidents state of the art

The components of the PMC® Systems have been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

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

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Do not make any alterations or modifications to the components of the PMC® System The units are only allowed to be opened and changed by the manufacturer. use inside of the EU

use outside of the EU

safety and accident prevention regulations

The European Directives and Standards referred to in this operating manual have to be observed when using the PMC® Systems in a member state of the European Union (EU). For use outside of the EU the directives and standards applicable in the respective countries must be observed.

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

Observe the safety and accident prevention regulations of the mine, of the Mines Inspectorate, and of the mining employers' liability insurance association

Further operating manuals Also read the operating manuals of the components required to operate the face, such as electric motors, couplings, mainframes, chain tensioning devices, conveyors, drive pushing devices and block anchorages as well as any other neighboring machines which may be affected by the control unit. Clarify any issues which arise before starting work.

Personnel Assembly and repair In general, assembly and installation work shall be performed only by persons who have been adequately trained for the special requirements. Repair work on the components of the PMC® Systems shall only be performed by service personnel of the manufacturer.

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2.3

Conditions of application Conditions of application Intended use The PMC® System is a universal control system consisting of three basic units which will be configured to meet the requirements of every individual assignment. The documentation at hand describes its use in connection with a Caterpillar conveyor equipped with CST gearboxes. Units manufactured for this application are only allowed to be used for other control assignments after the respective permission has been obtained by the manufacturer.

Use the components of the PMC® Systems only as intended!

Unauthorised use Applications which are not expressly defined as intended and/or which have not been established in consultation with the manufacturer are unauthorized uses and are not allowed to be performed with the PMC® System.

Surrounding area conditions Suitable measures must be taken by the operator to combat the explosion hazards due to firedamp or the ignition of dust which might occur in a mine (see prEN 1710).

Among them are included the following, for example: Adequate and consistent ventilation Plow spraying system/water spraying system and If the mine gas concentration in the free cross section of the consistently ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL) as defined in the respective national laws the M2 equipment has to be deenergized.

It may only be restarted by an authorized person.

The atmosphere in the mine has to be monitored in the hazardous locations to permit disconnecting the power supply of all pieces of equipment except of those which are relevant for the safety and suitable for use in potentially explosive atmospheres.

The M2 equipment has to be stopped at once and secured to prevent a restart if firedamp protection facilities are found to be damaged.

The use of the PMC® Systemcomponents does not alter the rules and regulations relating to safety and firedamp protection in the mine.

The components of the PMC® System are intrinsically safe and have been manufactured on the basis of recognized rules of motorering.

Prerequisites for operation Putting the PMC® Systeminto service is prohibited until the machine to be controlled by the system has been found to comply with the European Directive 94/9/EC and the Standard prEN 1710.

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Caterpillar Global Mining Europe GmbH accepts no liability for any damage resulting from any such unauthorised use.

Basic principles As the control system supplied is only part of an overall system the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation.

These shall be marked according to the legal provisions applicable at the time they are placed on the market. safety requirements according to prEN 1552

The M2 equipment is only allowed to be operated when the safety requirements according to prEN 1552 have been met. These include: systems preventing unauthorized starting prestart warning systems safe lockout command systems emergency stop systems dust extraction systems noise protection

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warning statements etc.

The electrical apparatus required for operating the conveyor shall be marked according to the legal provisions applicable at the time they are placed on the market.

Basic principles general

Always work with full concentration.

Familiarise yourself with your working environment.

protective equipment

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by the conveyor may at times exceed 85 dB(A).

Inform your coworkers of Your exact location The work you are performing The amount of time which you will probably require.

safety devices

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

Keep the signalling and lighting systems in a proper functional condition.

Observe the acoustic and optical startup warnings of the conveyor.

EMERGENCY STOP

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken without delay.

Also operate the EMERGENCY STOP switch if protective devices such as for example firedamp protection devices fail.

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

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Storage and transport Storage and transport The control units of the PMC® Systemcan be stored for a maximum of 5 years without electrical connection. After this time, the buffer battery installed is empty and has to be replaced.

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

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

Inform the persons involved about the intended transport route and the anticipated duration of transport.

use system brackets

Ensure that transport safety devices are attached and packaging is provided properly. Never stand under unsupported parts or suspended loads.

Use only holding brackets of the PMC® System. Do not damage any connector conduits or any other mating surfaces.

inclined faces

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Installation and start-up On inclined faces, secure all component parts by chains, e.g. to the support units.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product. environmental protection

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

Inform the supervisory personnel and the face crew of any maintenance and repair operations which may be required. Give them information on the intended operations and the anticipated duration.

securing

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

Lock out the conveyor and secure it to prevent unauthorized and unintentional restarting.

replacing components

Stop and lockout the conveyor and the mining machine to prevent from restarting before replacing any defective components.

Immediately remove defective components from the face in order not to hinder the crew and to prevent these parts being reinstalled elsewhere.

Pass the components on for servicing without delay.

In faces with inclines, secure spare parts e.g. with chains or hoists.

2.6

original spare parts

Use only spare parts which satisfy the specified technical requirements. This is only ensured with original spare parts of Caterpillar Global Mining Europe GmbH. Please refer to the spare parts lists for the order numbers.

protective devices

Refit any protective devices removed immediately after completion of the work and check that they function properly.

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transport safety device

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct storage and the safe transport of PMC® System components. Observance of the instructions and tips will increase the service life and reliability of the system components. Reading this chapter carefully will help you to simplify your day-to-day work.

Storage Storing the equipment corrosion protection no direct exposure to sunlight

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dirt and moisture

storage

Components provided with a corrosion protection are protected for around six months.

Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals, cables, and hose-protected cables - only in closed rooms at temperatures of 15°C to 25°C. Protect all parts of the equipment against dirt and moisture. Do not remove any blind plugs or blind caps. Avoid damage to the plug connectors and plugs. Fit the blind plugs and caps if you want to store the devices again after use.

Never store electronic equipment outdoors!

After 5 years of storage, the computers should be checked as the battery installed will be discharged after this period of time. In this case it will have to be replaced. Inspection and battery change should be made by service personnel.

After a storage period of approx. two years, the system components must be subjected to a test before using them to find out whether the storage has caused damage.

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

Important!

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

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

Transport Transport containers, dimensions, and weights Please be sure to observe the technical data sheet. It contains information on: dimensions, and weights The control units and interfaces belonging to the PMC® System designed for the same working point can be transported in the same transport container. You have to make sure, though, that they are not packed in the same container as heavy and/or sharp-edged materials to prevent damage to displays, keyboards, cables, and plug connectors.

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Transport The respective cables and hose-protected cables also must be packed and transported carefully in order to prevent damage to the plug-type and screwed connections.

Caution!

Load and transport the components carefully and concentrate on what you are doing. Protect yourself against injuries from falling parts by wearing gloves and steel toed shoes.

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

Caution!

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

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

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For overseas transport, line and cable ports must be carefully protected. The PMC® System devices must be carefully packed for sea transport.

4

Installation

Basic principles

Installation Basic principles Important!

Serious damage can be caused to control units, peripheral devices, and the machines to be controlled due to incorrect assembly.

Tools required The following tools are required in order to install system components underground: Installation of the brass retaining strip and the PMC®-D on the brass retaining strip : 10 mm Allen wrench Installation of the SKK24 plug: Caterpillar Global Mining Europe GmbH, Lünen 2017

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All other installation in the PMC® system can be carried out with a sturdy screwdriver and a pipe wrench.

Installation of system components on mounting plates etc. is carried out with the usual engineering/ mining tools.

The PMC® Drive Control Systemcomprises the following system components.

Control unit PMC®-D with 7-segment display Visualization unit PMC®-V with display screen and keyboard Sensor-/actuator junction box Holding bracket Cable for the connection between sensor-/actuator junction box and PMC®-D control unit Fig. 1:

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PMC®-D control unit

4.3

Installing the control units Fig. 2:

PMC®-V visualization unit

The control units are supplied with a holding bracket made of brass.

The connected hoselines (SKK24) are secured in this holding bracket by the respective staple locks to prevent them sliding out of the plug contacts of the control units. Each holding bracket is equipped with two captive bolts (thread M10) for fastening it to the control unit. The bolts are designed such that when inserted into the control unit they cause the hoselines fixed to the holding bracket to be pressed into the plug contacts. When taken out, the hoselines are detached from the plug contacts accordingly.

Caution!

After removal of a control unit the contacts of the hoselines fastened in the holding bracket and those of the control units must be protected against dirt.

attachment by means of holding bracket

The holding bracket is provided with two holes for hexagon socket screws (thread M12). These screws and the respective spacer sleeves permit to attach the holding bracket, for example, to a mounting plate. The advantage of this mounting variant is that the control units can be replaced easily and the hoselines can be attached in a safe and secure manner.

Caution!

Using just the holding bracket for assembly is only recommended if the control unit is not subjected to permanent vibrations.

direct attachment

The control units are provided with four threaded holes (thread M10) at the rear which permit to attach the unit direct to a mounting plate. The respective dimensions are given on the data sheet enclosed. In this case, the holding bracket is only connected to the control unit. Only the retaining strip screws need also be released in order to separate the hose pipes from the control unit. The retaining strip must be placed in such a way that the hose pipe contacts are protected against contamination and damage.

Caution!

It is recommended to fasten units which are subjected to permanent vibrations both by means of the holding bracket and at two points at the rear of the control unit. Additionally, the unit should be mounted on vibration dampers.

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holding bracket

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Installing the control units

Installing the control units protective housing

The PMC®-D control unit is generally mounted on the drive motor in a special protective housing (see gearbox documentation). In this protective housing, the control unit is fastened to the holding bracket and two points at the housing and protected against vibrations by a damper.

PMC data stick Der PMC data stick is used to save programm data and to transfer them to the PMC-D. For connection the St2 socket is used (refer to chapter 6).

Fig. 3:

PMC data stick

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Installing Profibus connections Caterpillar Global Mining Europe GmbH, Lünen 2017

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

Important!

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

Other lines will lead to communication failure.

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

Important!

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

On all devices, the connections for Profibus are labeled ST6 and ST12. It 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.

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Installing the control units

4.6

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Operation

General rules

Operation Warning!

Do not change any settings before you have read the PMC® Drive Control Systems Operating Manual and the Operating Manuals of both the machines to be operated and the ones that are adjacent to them.

General rules

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Structure of the PMC® Drive Control Systems The PMC® Drive Control System is conceived as a dispersed system. Data exchanges between the units participating in the processing of control system tasks are handled via a central communications connection in accordance with the Profibus Standard.

Different control systems can be connected to one Profibus line.

Three basic units are available for setting up the systems. The PMC® V (Visualization) unit acts as a display and operating unit for all of the control systems attached to the Profibus line. The PMC® D (Drive) unit assumes responsibility in each case for a special control system task. Thus, for example, each drive unit in a face conveyor with CST gearboxs is allocated one PMC® D unit.

The base units provide connections for recording measurement values and for setting up communication connections. The units can however be adjusted to accommodate the respective control system task through the installation of special subassemblies.

Operating concept Operation of the PMC® Drive Control Systems is handled with the PMC® V units. This means that it is possible to operate any given PMC® V unit in the system. Menus are offered on the monitor screen from which the desired menu item can be selected with the help of the keyboard, after which either a further menu or an input/ output mask is displayed.

The socalled menu tree which is worked through in this manner is subdivided into three levels. The first or global level contains functions which affect the entire PMC® Drive Control System, thus meaning they are independent of individual control systems. The second level contains global functions which are however valid for either one special control system or for all PMC® V units. The functions which are stored in the third level are those which affect units directly selected from within the higherlevel system. In the control systems, these are exclusively PMC® D units which are identified in accordance with their installation locations (HG = Headgate Drive, TG = Tailgate Drive).

The first line on the monitor screen with dark highlighting shows which level of the menu tree and which menu or which input/ output mask is active. The first field displays the name of the selected monitor screen mask. Either “Global” - for the first menu level or the name of the selected system is shown in the second field.

The third field shows the name of the currently selected unit. As long as no unit has been selected directly, the name of the PMC® V unit will be shown at which the operation is taking place.

In order to highlight this clearly, “local V3” will for example be displayed if the PMC® V unit has been assigned the name “V3”. Systemspecific status information is displayed in the two fields of the last line.

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5.3

Keyboard PMC® V Fig. 4:

Structure of the monitor screen masks Menu level or system name

Name of display mask

Start menu

Device name

Global local V3 Date: 11/28/2005 Time: 8:12:39 PM

System specific status information

Keyboard PMC® V The keyboard of a PMC® V visualization unit is shown in Fig. 5 page 5.4. One light-emitting diode (LED) is allocated to each of the 24 keys which will light up when the key is actuated correctly.

The keyboard is used for navigating through the menu tree offered on the monitor screen, for entering numerical values and for selecting special functions directly.

The four arrow keys “up”, “down”, “left” and “right” are used for navigating to the desired selection within a menu. The selected menu item is presented in inverted form on the monitor screen.

Fig. 5:

Keyboard of the PMC® V visualization unit

The selected and inverted menu item shown is activated with the Enter key. Pressing this key completes an entry, e.g. of a numerical value or of a password.

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

Light emitting diodes PMC® V The Cancel key is used to jump back to the mask from which the current mask was called up. Changes made in the current mask are ignored. The entering of a numerical value or a password is cancelled.

Actuating this key (symbol: Caution) will cause the operator to exit any given monitor screen mask and to proceed to the display of a list with system messages. If the list is exited by actuating the Cancel key, then the display will change back to the previously exited monitor screen mask.

The “Home” key can be used to jump directly from any given monitor screen mask back to the start of the active menu level.

This key is used to proceed directly from any given monitor screen mask to the “Language selection” menu. After selection of a language has been confirmed with the help of the Enter key, the previously exited monitor screen mask is displayed once again in the newly selected language.

Only numerical values are expected when making entries in the PMC® Drive Control System. This applies not only to the entry of nominal values and parameter values, but also to passwords. If a text entry is anticipated, then a corresponding selection list will always be provided to choose from.

...

The function keys F1 to F4 are located on the lefthand side of the keypad. These keys are used to select one of the functions described in the respective monitor screen masks.

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...

Three keys on the keypad have double assignments. This second key function, the symbol for which is located in the upper righthand corner of the key, can be reached by simultaneously pressing the Shift key and the key with the desired function. The second functions of the arrow keys make it possible to enter a “+” or a “-” sign, using the “?” makes it possible to display Help texts.

Light emitting diodes PMC® V light emitting diodes (LEDs)

One green, one yellow and one red LED are arranged underneath the monitor of the PMC® V visualization unit. If the green LED is flashing, then that means that the unit is connected to a voltage supply. The yellow and the red LEDs signal the presence of warnings and/or error messages in the list of system messages (see page 5.7).

Password entry Some menus and input masks are protected by passwords. A password is made up of four digits, each of which is represented by an asterisk when the password is entered. The entry of the password is completed by pressing the Enter key. The password has a time limitation, i.e. the password will need to be reentered if a 20-second monitoring period has passed without a key being actuated. The time period is extended by an additional 20 seconds when a key is actuated within the monitoring period.

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5.5

Light emitting diodes PMC® V Fig. 6:

Menu tree of the system messages

?

Jump to previous display item

Defined key functions Direct selection of system messages Actuating the adjoining key (symbol: Caution) will cause the operator to exit any given monitor screen mask and to proceed to the list of system messages. All of the messages of the PMC® Drive Control Systems are displayed here, no matter which unit generated the message originally. A distinction is made between error messages, warnings and information. light emitting diodes PMC® V

The different types of messages are also signalled by the LEDs underneath the monitor on the PMC® V unit. If messages are entered on the list which are rated as warnings, then this will be displayed by the flashing of the yellow LED. The flashing of the red LED means that error messages have been entered on the list that need to be acknowledged by the operator. Information messages are not indicated with the LEDs, because the registered events have no influence on the functioning of the PMC® Drive Control Systems. The green LED has no connection with the message list, but rather indicates that the unit is connected to its operating voltage.

Filters can be set on the list of system messages so that only those messages are displayed which are of current interest. This setting remains in effect, even after the message list is exited. More detailed descriptions can also be called up concerning the individual short messages. Fig. 6, page 5.6 shows the menu tree that can be navigated through within the presentation of the system messages.

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Light emitting diodes PMC® V After the system messages have been selected, the mask shown in Fig. 7 appears on the monitor screen. The selection criteria for the displayed messages are specified in the lowest line on the monitor.

Fig. 7:

System messages

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

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F1:Ackn. message F2:Ackn. device F3: select system F4: Select msg type all Systems all messages Caterpillar Global Mining Europe GmbH, Lünen 2017

In the example shown, “all messages” from “all systems” are presented in the mask.

No. The internal numbers of messages are displayed in this column, followed by one of the letters of the alphabet (F, W or I) to indicate the message type (either Error, Warning or Information, respectively).

Source The name of the generator of the message is given here. If this is a PMC® D unit, then the name is expanded to include an abbreviation for the system.

Brief description A brief description of the message is to be found in the last column. acknowledging messages

Individual messages can be acknowledged with the function key F1 and all messages of a source can be acknowledged with F2. In order for this to be successful, the line with the desired message or with the desired unit needs to be selected, after which the corresponding function key is actuated.

If the Enter key is actuated after the selection of a line, then a new monitor screen mask is opened containing a detailed message description.

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5.7

Light emitting diodes PMC® V Fig. 8:

Detailed message description

System messages Global local V3 No. Type Source Cancel. 29.03.05 125 Error CST--HG1 Yes 13:34:45 The cooling oil temperature of CST drive has exceeded the maximum value. A further temperature increase leads to demage of clutch friction layer. The drives may be restarted, in case temperature decreases below the configured prewarning value.

all systems

filtering messages

It is possible to filter the messages according to message type and to the system to which they belong in order to present them in a more comprehensible overview, particularly during troubleshooting efforts. Two monitor screen masks are to be found above the function keys F3 and F4 with the help of which this selection can be made.

Fig. 9:

System selection messages

System selection

global local V3 lokal V3

CST drive system Plow control system CM system Visualization

all systems

5.8

all messages

PMC-D UEL Plow

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The message number, the message type and the source of the message are also specified in this mask. In addition, an indication is also made in this “Cancel” column as to whether or not the cause of the message will lead to a shutdown of the respective system.

The date and time that the message occurred are specified in the last column.

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all messages

Light emitting diodes PMC® V Fig. 10:

Selecting message type

Selecting msg type

global local V3

all messages only errors only warnings only information

all systems

all Messages

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The selection made through these two masks will also remain in effect for the system messages in the local PMC® V unit, even after the display has been exited. The current selection will be redisplayed in the lowest line of the masks when the system messages are once again selected.

Language switchover direct selection The language used for the text output on the monitor screen can be switched over locally at any time on the PMC® V unit being used for operations. Once the adjacent key has been actuated, a list is displayed in which the languages German, English and the national language valid for the place of operation are offered for selection.

The selection text will be shown thereby in the respective language.

After the selection has been confirmed with the Enter key, the current mask will be displayed in the selected language. The languages German, English and Russian are available in the example shown.

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5.9

Light emitting diodes PMC® V Fig. 11:

Language selection

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Jump to previous display item

5.10

PMC-D UEL Plow

PMC® Drive Control global menu level PMC® Drive Control global menu level Fig. 12:

Global menu tree PMC® Drive Control System Power on

Start menu System selection

Global

Global Date: Time:

lokal V3

lokal V3

12/06/2007 15:23:38

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

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

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

F1:Activete conf.

Display setting Brightness: 050% Contrast: 050%

Global

lokal V3

Brightness (G)

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

F1:Reset error counters

F2:Delete entry

System config.

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

F2:Delete entry -----

-----

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

lokal V3

Device information Date: Time:

Global

lokal V3

12/06/2007 15:23:38

Mine setup:

Software/serial no.s

UTC = Universal Time Coordinated

Global Device information Device Type Serial No. V1 V 560040047

Voltage supply Device Type CST-HA1 D-CST

Plow control system

Start menu

CST 12/06/2007 15:23:38

Process overview Prozessübersicht Process overv. Contd.

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

CM system

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

Global Serial No. 560040047

lokal V3

lokal V3 Meas.val

Date: Time:

Visualization

NOVAJA

Component ser no.

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

Voltage supply

lokal V3

Min.

Max.

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

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

Automatic

Fig. 12 shows the menu tree whose functions can be selected at the global level of the PMC® Drive Control Systems. All of the functions are stored in it that are independent of the implemented control system and of the special functions of the PMC® V units. The Start menu of this menu tree is always displayed after each PMC® V unit has been switched on.

The Start menu offers the following selection options: Selection of a system in cascaded arrangement,  System selection, page 5.12.

Display and modification of the configuration of a system in cascaded arrangement.  System configuration, page 5.12.

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5.11

PMC® Drive Control global menu level Diagnostics of the internal Profibus.  Profibus diagnostics (internal), page 5.16.

Information concerning the construction and the software version of the individual units.  Device information, page 5.18.

Modification of the monitor screen settings of the currently used PMC® V unit.  Display settings, page 5.20.

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

Fig. 13:

Global Start menu

Start menu

Global local V3 Date: 12.06.2007 Zeit: 15.23:38

System selection A selection list is displayed in which the systems in cascaded arrangement are entered that are available onsite. As a basic rule, at least one PMC® V unit is always required for the operation of the PMC® Drive Control Systems to ensure that the “Visualization” selection is always displayed. Similarly, at least one control system is always present. The other selection options shown in the example need not be available on every system.

Fig. 14:

System selection

System selection

Global local V3

CST--drive system Plow control system Visualisation Gateway

The selection of a system leads to the next menu level. Special Operating Manuals exist for each of the control systems in which the respective menu guidance is described. The menus for the PMC® V units (Visualization) are explained later.

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PMC-D UEL Plow

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

PMC® Drive Control global menu level System configuration The loaded software and the hardware determine the control system to which a PMC® D unit belongs. In the context of an operating system, however, which as a rule is comprised of several PMC® D units, the precise behaviour of a unit may be dependent on the installation site. It is a basic requirement for this reason that each PMC® D unit be informed of its installation site. If a sitedependent behaviour of the unit is necessary in the control system, the software will orient itself to this specification.

Caution!

Do not fail to specify the correct installation site of PMC® D. An incorrect entry can lead to largescale damage to the system being operated.

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The behaviour of the PMC® V units is always the same and always independent of the installation site. They are assigned only a single unambiguous name for that reason, in order to be able to identify them in the PMC® Drive Control System. If such a unit is replaced, then the new unit should however be assigned the same name as the one that was replaced, particularly in cases where values for the control systems are recorded via its measurement inputs. The configuration of these measurement inputs, including that of the name of the PMC® V unit, is stored in the PMC® D units which process the measured values. These units will attempt to reinitiate these measurement inputs and to use the stored unit name while doing so.

Important!

When replacing a PMC® V unit, always assign the name of the unit that has been replaced to the new unit wherever possible.

This will permit you to avoid additional work.

The serial numbers of the units are used to identify them for the assignment of names and/or installation sites. The serial number is entered on the nameplate of the unit.

Important!

When installing a unit, note the serial number entered on the nameplate. You will need this number for configuring the system.

After the system configuration has been selected, the mask shown in Fig. 15, see page 5.14 will be outputted on the monitor screen.

All the units are displayed here that are stored locally by the currently used PMC® V unit as the system configuration. The name and/or installation site assigned is specified in the “Conf.” (configured) column. If these units can be addressed via the internal Profibus, then the Profibus address automatically assigned by the PMC Drive Control System will be displayed in the “PBadr.”

(Profibus address) column. If a name or installation site has already been assigned to the units, then the designation stored in the units will be displayed in the “Found” column; otherwise this entry remains empty.

If additional units that are not listed in the local system configuration are active at the Profibus, then these will also be displayed.

The entry in the “Conf.” column remains empty. If these units are already in possession of a name or an installation site, then these will be specified in the “Found” column.

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5.13

PMC® Drive Control global menu level All modifications to the system configuration will be transmitted to the units of the PMC® Drive Control Systems and stored there by actuating the “F1” key. After the units have confirmed that they have received the data, a restart is initiated by the PMC® V unit.

The new system configuration is active after the startup of the units.

If a unit is not actively integrated into the system at the time of a modification, for which reason it could not be informed of the modifications or if no restart has yet been carried out, then it will function under the system configuration that was valid at the time of the last restart. It is possible for that reason that different names or installation sites may appear in the “Conf.” and “Found” columns and that different numbers may appear in the “CRC” column.

System configuration

F1: Activate conf.

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System configuration Global local V3 Serial Nr. Type Conf. Found PBaddr CRC 560040047 D--CST HG1 HG1 047 052677 560040021 V V3 V3 003 052677 560040004 V V2 V2 004 052677 560040050 D--PLO HG HG 007 052677 550040001 D--CST TG1 TG1 001 052677 560040003 V V1 V1 003 052677 550040013 D--PLO TG TG 017 052677 560040012 D--CST ------ ------ 012 002125 F2: Delete entry

Serial No. The serial number that is entered on the nameplate of the unit.

Type Type of the unit. The letters of the alphabet used indicate the following: V for PMC® V and D for PMC® D. An abbreviated name for the control system is specified in addition for the PMC® D units.

Conf.

The names entered in the “Configured” column are those which are stored as the system configuration in the PMC® V unit currently being used. If new units are connected to the system, then no entry is present in this column.

Found The names or installation sites which were stored as valid designations at the time of the last restart of the unit are entered in the “Found” column.

5.14

PMC-D UEL Plow

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Fig. 15:

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

The PMC® V unit at which the system configuration is currently being displayed can also be shown without an entry in this column. It was not possible in such cases for the unit to log in actively on the Profibus or it has withdrawn itself from the Profibus because of extreme disruptions on the bus system.

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

Actuating the “F1” key will cause the system configuration displayed on the monitor screen to be transmitted to all units in the PMC® Drive Control System and activated there. The units will then carry out a restart on their own.

deleting entries

Actuating the “F2” key will delete the selected unit from the system configuration. The name or installation site will be deleted from the “Conf.” column. After the system configuration is received, it will not be applied in the selected unit but will rather the previously valid configuration will be completely deleted, so that the unit will have no system configuration at all any more after a restart.

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activating the configuration

Important!

The system configuration is errorfree if the entries in the “Conf.” and “Found” columns each haves the same name or installation site and if the same value is displayed for all units in the “CRC” column.

To assign a name and/or an installation site, the desired unit is selected with the arrow keys and the Enter key is actuated. A list containing names and installation sites is offered to choose from.

Fig. 16:

Selection of name/installation site

System configuration Global local V3 Serial Nr. Type Conf. Found PBaddr. CRC 560040047 D--CST HA1 HA1 047 052677 HG1021 052677 560040021 V V3 V3 HG2004 052677 560040004 V V2 V2 TG1HA 007 052677 560040050 D--HOB HA 550040001 D--CST HI1TG2 HI1 001 052677 HG 003 052677 560040003 V V1 V1 550040013 D--HOB HITGHI 017 052677 560040012 D--CST ------V1------ 012 002125 V2 F1: Activate conf.

-- -- -- --

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

5.15

PMC® Drive Control global menu level example:

In Fig. 15 (page 5.14), the PMC® D unit listed in the last line that belongs to the system for operating a conveyor with CST gearboxes has not yet been assigned an installation site. On the basis of the serial number, the operator recognises that he has mounted this unit on Head gate 2.

After the unit has been selected and the Enter key has been actuated, a list is displayed in which the maximum of four installation sites (Headgate Drives 1 and 2 and Tailgate Drives 1 and 2) are also shown, among other things. The operator selects the abbreviation “HG2” from this list, which is then entered in the “Conf.” column once the Enter key has been actuated. The selection of an installation site which does not belong to the CST system will be rejected with an error message.

Profibus-diagnostics (intern) The data exchange between the units of the PMC® Drive Control Systems takes place via a bus system in accordance with the Profibus Standard. No unit is permitted to be connected with this internal communications system that does not belong to the PMC® Drive Control System. Communications with external systems takes place exclusively via the second Profibus connection of the PMC® V units or through serial connections.

Notice!

Do not connect any units to the internal Profibus that do not belong to the PMC® Drive Control System. Correct functioning of the control systems can no longer be guaranteed.

Fig. 17:

Profibus diagnostics (internal)

Diagnostics PB intern Device PBaddr. Recv. tel.

CST--HG1 047 567 V3 021 013 721 V1 003 990 866 V2 004 741 883 CST--TG1 001 965 CST--HG2 012 676

Global local V3 Send. Error tel. Send Bus 347 000 000 000 000 000 000 000 000 283 000 002 297 000 000

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

-- -- -- --

The display of the internal Profibus diagnostics makes the following information available:

5.16

PMC-D UEL Plow

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Important!

All units of the PMC® Drive Control Systems perform a restart when a new system configuration is applied. This causes a cancellation of all the enabling signals issued for the systems to be operated.

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This configuration must be distributed throughout the system by actuating the “F1” key in order to make it known not only to the selected unit but also to the entire system. All the units of the system perform a restart for the purpose of applying the new system configuration.

PMC® Drive Control global menu level Device The name or installation site assigned by the user for the system configuration. An abbreviated name for the control system is specified in addition for the PMC® D units.

PBaddr.

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

Recv. tel.

The number of telegrams received by the unit.

Send. Tel. The number of telegrams sent by the unit.

Send. (ing) errors The number of errors which occurred during an attempt to send a telegram.

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Bus Errors The number of errors caused by disruptions which have been recognised on the Profibus. These counters are added up, e.g. when the connection to the Profibus is plugged on when the unit is switched on.

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

Important!

The error counters need not be set to zero for correct operation. Sporadic malfunctions are tolerated by the PMC® Drive Control System. It is not until the error counters display continually increasing numbers that there is an error present in the Profibus communications system.

Device information After the device information has been selected, the mask shown in Fig. 19, page 5.18 will be displayed on the monitor screen. It contains information concerning the individual units of the PMC® Drive Control Systems.

Fig. 18:

Interim window

Device information

Global Lokal V1

Software/Serial no.

Voltage supply

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5.17

PMC® Drive Control global menu level Fig. 19:

Device information

Device information Global local V3 Device Type Serial No. CST--HG1 D--CST 560040047

F2: prev. device

Device The name or installation site assigned by the user for the system configuration. An abbreviated name for the control system is specified in addition for the PMC® D units.

Type Type of the unit. The letters of the alphabet used indicate the following: V for PMC® V and D for PMC® D. An abbreviated name for the control system is included in addition for the PMC® D units.

Serial No. The serial number that is entered on the nameplate of the unit.

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

– PMU (Power Management Unit Type 1) The subassembly provides the voltages required in the unit, carries the buffer battery for securing the parameters during the switched-off status and limits the outgoing currents at the external connections of the units.

– D-IO (PMC®-D I-O) The central subassembly of a PMC® D unit.

All of the externally accessible inputs and outputs are integrated on this subassembly.

– V-IO (PMC®-V I-O) The central subassembly of a PMC® V unit.

All of the externally accessible inputs and outputs are integrated on this subassembly.

– PVC (PMC®-D Proportional Valve Control) The subassembly for activation of the valve for pressure settings in a CST gearbox clutch.

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

5.18

PMC-D UEL Plow

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F1: Next device

Software--ID Program: 000010009 Date: 29.03.05 Time: 13:12:45 FPGA1: 003020201 FPGA2: 004020201 000001400

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

PMC® Drive Control global menu level – VGA (PMC®-VGA Interface) The subassembly for activation of the monitor unit of a PMC® V unit.

– PCM (PMC® Profibus Com-Module) The subassembly makes possible communications with an external Profibus.

Software-ID The version number of the active software. The individual components can be replaced on site, except for those which have the CPLD designation.

– ProgramThe program which is executed by the unit computer and which determines the function of the unit. The date and the time indicate the point in time that this program was created.

– FPGA1 und 2 (Field Programmable Gate Array) The setting of the hardware and the advance processing of the measurement values is accommodated to the desired function of the units with the aid of these programs.

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E

– CPLD (Complex Programmable Logic Device) Is loaded at the time the units are manufactured and sets functions that are not permitted to be modified later. next unit/previous unit

Once can switch to the next or to the previous unit with the function keys “F1” and “F2”.

A check is made during the startup phase for a unit to determine whether the existing hardware and the programs of the FPGAs are suited for the desired function of the unit. The absence of necessary hardware components or the presence of superfluous ones or incorrect programs for the FPGAs on the local display unit will lead to an error message and to the cancellation of the startup.

Once the startup of a unit has been errorfree, the version number of the active program is compared with the other units operating in the same aggregate. This inspection only takes place between units which have already been configured in the PMC® Drive Control System. In the event of inconsistencies in the version statuses, an error message is outputted on the PMC® V units and the startup of the affected group of units is prevented.

Important!

The software in the units of the PMC® Drive Control Systems checks during the startup stage to see whether the internal hardware is suitable for the desired function of the unit. The startup is cancelled if there are inconsistencies.

Display settings After this menu item has been selected, the current contrast and brightness settings for the monitor are displayed in percentages.

After one of the two possible settings has been selected, a bar is displayed, the length of which represents the current value. The value can be altered in 5% increments using the arrow keys “up” and “down” or “right” and “left”. The setting is applied and stored by actuating the Enter key.

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.19

PMC® Drive Control global menu level Fig. 20:

Display settings

Display setting Brightness Contrast: 050 %

Global local V3

Brightness: (G) 065

The UTC is referenced to the Greenwich Meridian (Great Britain 0° longitude). The current local time is determined by adding or subtracting an officially defined constant time differential to or from the UTC. In the PMC® Drive Control System there is a unit which is responsible for maintaining clock time as a reference unit. The question of which unit assumes responsibility for this task is determined automatically. This unit compares the local clocks in the other units with its own clock at regular intervals. The clock in the reference unit can either be set by the operator or it is adjusted by a higherlevel system via transmission of time and date.

5.20

PMC-D UEL Plow

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The date and the time are maintained in the PMC® Drive Control System. This information is necessary in order to be able to include in the message to the operator the time that an event occurs, e.g. the detection of an error. Universal world time (UTC, Universal Time Coordinated) is used within the system for the generation of this time stamp. As a result, no jumps in time occur, as for example when the system changes over from regular to daylight savings time or in cases where different pieces of information which were logged on different systems with different local time settings are to be compared with one another in terms of chronological correlations.

E

Set date/time

System description - Plow control Fig. 21:

Setting date/time

Setting date/time DST: No Local Time: 13:45:23 Date: 30.03.2005 Time Zone: UTC +01:00

Global local V3

UTC = Universal Time Coordinated

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DST Daylight Savings Time If a distinction is made at the place of operation of the PMC® Drive Control Systems between daylight savings time and regular time, then the display of the local time can be adjusted by selecting “No” or “Yes”.

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

Local time, UTC The constant time differential between UTC and local time at the place of operation needs to be entered here.

System description - Plow control The principle system structure of a plow control is shown in Fig. 22 (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.

VLSA / 09

5.21

System description - Plow control System structure - Plow control

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

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.

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.

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 UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

Fig. 22:

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.

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E

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.

Fig. 23:

Position information - Plow control

position information

Doc. no.: 1999 001 015 BA 00

For correct function, the positions shown in Fig. 23 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:

VLSA / 09

5.23

System description - Plow control 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.

Distance B, B° [m] The distance of the side facing the drive of the respectively first face shield.

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.

S2, S2° (distance F, G, [shield number]) 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. plow speed

5.24

In Fig. 23 (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 UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

S1, S1° (distance E, H [shield number]) Position of the limit switches. The switches are always mounted in the middle of the shield.

E

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.

Global menu level - Plow control Global menu level - Plow control Fig. 24:

Menu tree - Plow control S tart m enu

Pr oces s ov ervie w Pl ow p ositi on Pl ow p ositi on Pl ow s peed Pl ow d irect ion Co upli ng pr essu re 2n d pr essur e st age Sy stem pres sure Sl ippa ge A Sl ippa ge B Dr ive unit

Pl ow

Loca l V1

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

Plo w L ocal V1 HA HA 1 23.4 123 .4 m 0 23.5 02 3.5 s hiel d 1 .25 m/s H A<-- HI HA< --HI 0 .30 0.3 0 ba r 0 .80 0.8 0 ba r No No 0 00.0 000 .0 % 0 00.0 000 .0 % 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

Loca l V1

Plo w 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

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E

Autom atic

Sw itch ove rview

Limi t sw itch A Limi t sw itch B Sync -swi tch A Sync -swi tch B Plow pos itio n Plow dir ecti on

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

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

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 - ---

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

Au tomat ic

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

Start men u

Plo w

HA

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

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

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

The menu tree shown in Fig. 24 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.

Process overview, page 5.26 Display of the installation site and the switch states of the synchronous and limit switches.

Switch overview, page 5.29 Selection of a drive unit.

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.25

Global menu level - Plow control Drive unit selection, 5.30 Operating mode setting of the plow control.

Selecting the operating mode, page 5.41 Input of the current plow position.

Entering the plow position, page 5.41 Overview of the status of the global and local parameter blocks stored in the PMC-D devices.

Parameter status, page 5.42 Activation of a subordinate menu tree for setting the global parameters of the plow control.

Global settings, starting on page 5.45 Fig. 25:

Start menu - Plow control

Start menu

Plow

Local V1

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Process overview Process overv. cont.

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

E

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 5.31).

PMC-D UEL Plow

Global menu level - Plow control Fig. 26:

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:

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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.

Plow position in shield numbers 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.

Plow speed 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

Coupling pressure The pressure in the discharge chamber of the coupling.

2nd pressure stage System pressure Slippage A Slippage B

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.27

Global menu level - Plow control 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.

– ExtStop, External stop Due to an error message on another PMC®-D device, the drive unit enable is canceled by opening 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: Temperatures on the head gate and tail gate – Temp. gearbox – Temp. coupling

PMC-D UEL Plow

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– 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.

E

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

Global menu level - Plow control Switch overview Plow V1

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

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. 27:

Switch overview

Switch overview

Local V1

Plow position Plow direction

023.5 HA<----HI

023.5 shield HA<---- HI

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E

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

HA Shield X 005 --- 020 --

Plow HI Shield X 195 --- 180 --

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

VLSA / 09

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

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. 28:

Drive unit selection

Automatic

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

Local V1

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

After selecting the desired drive unit and confirming with “Enter”, the following screen mask is displayed: Start menu Fig. 29:

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 UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

Global menu level - Plow control Display process data Fig. 30:

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

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E

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).

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

Process data Cont.

Fig. 31:

Process data continued

Process data Cont.

Temperatures Temp. gearbox Temp. coupling

Plow

HA

060.0°C 070.0°C

Automatic

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.31

Configure process Display switches Fig. 32:

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

Caterpillar Global Mining Europe GmbH, Lünen 2017

Fig. 33:

E

Configure process Menu level - Plow drive unit, Configure process Configure process

Plow

HA1

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

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

Automatic

HA1

Plow

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

Automatic

Process functions 2

Overload settings

30.00 % 0.20 s 05.00 % 10.00 s

Automatic

Plow Active Active Active Active Active

HA1

Pressure settings

Plow

Working pressure

30.00 bar

Pressure ramp Ramp end value

05.0 bar/s 05.0 bar

HA1

Automatic

In the menu tree shown in Fig. 33, 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: Activation/deactivation of process functions.  Process functions on/off (page 5.33).

Process functions 2  Pressure settings, coupling, temperatures page 5.35.

Overload settings  Slippage, page 5.35.

Pressure settings  Working pressure, page 5.37.

5.32

PMC-D UEL Plow

Configure process Fig. 34:

Configure process

Configure process

CST

HA1

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Automatic

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Process functions on/off Configure process

Plow

HA1

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. 35. 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. 35:

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

VLSA / 09

5.33

Configure process 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:

– 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.

5.34

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

– 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.

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.

Configure process

Configure process

Plow

HA1

Process functions (cont.)

Fig. 36:

Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Process functions (cont.)

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

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E

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

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

– 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

Overload settings HA1

Fig. 37: Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Overload 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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.35

Configure process 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.

Fig. 38:

Window for the slippage limits

S 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. 37, page 5.35)

5.36

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

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

E

– 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).

Configure process

Configure process

Plow

Pressure settings HA1

Fig. 39: Process functions on/off Process functions (cont.)

Overload settings Pressure settings

Automatic

Overload settings

Pressure settings

Plow

HA1

Working pressure

30 bar

Pressure ramp Ramp end value

05.0 bar/s 05.0 bar

Automatic

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Working pressure 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.

Pressure ramp 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.

Ramp end value is the value to which the pressure is reduced.

Inspection of coupling pressure Fig. 40:

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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.37

Configure process 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.

Coupling pressure Display value of the applied pressure Increase valve pressure The valve should not be actuated during inspection. For this reason, the input electric power should be zero.

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

HA

Motor/gearbox Fig. 41:

Display process data Process data Cont.

Display switches Configure process Inspection of coupling pressure Motor/gearbox

Start menu

Motor/gearbox

Plow

HA

Date: 17.10.2007 Time: 7:26:17

E

Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

Start menu

Automatic

Temperature monitoring Motor data Set gearbox type Set chain sprocket

Automatic

Temperature monitoring Fig. 42:

Start menu

Temperature monitoring

Plow

HA

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

Automatic

5.38

PMC-D UEL Plow

Configure process Motor data Fig. 43:

Start menu

Motor data Nominal motor speed (fast) Nominal motor speed (slow

Plow

HA

1480 rpm 0493 rpm

Automatic

E

Set gearbox type Caterpillar Global Mining Europe GmbH, Lünen 2017

Fig. 44:

Set gearbox type

Set gearbox type Gearbox type: P--15 ÜL 16:1 Gearbox ratio: Number of teeth, drive unit measuring wheel: Number of teeth, internal gear measuring wheel:

Plow

HA

21,000 024 024

Direction of rotation reversal: Yes

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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.39

Configure process Fig. 45:

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

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

5.40

PMC-D UEL Plow

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. 46:

Select operating mode

Automatic

Select operating mode Operating mode: Automatic

Plow

Local V1

Operating mode (G)

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Stop Automatic Inspection

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

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.

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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.41

Configure process Fig. 47:

Entering plow position

Enter plow position HA HI Plow position 023.5

Plow

Local V1

023.5 face shield

Automatic

Fig. 48:

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

5.42

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

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. 48.

E

Parameter status

Configure process 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.

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.

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Same in system 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.

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. 49). 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. 49. 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.

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.43

Configure process Fig. 49:

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:

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

W The parameter values are equivalent to the factory settings 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:

5.44

The example shown in Fig. 49 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.

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

B The factory settings were changed by the user.

Menu level - Plow control, Menu level - Plow control, global settings Fig. 50: Global menu tree - Plow control, global settings Global settings Plow

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

Local V1

Plow Date: Time: CST

200 - 05 1.500 m

Local V1 Set plow type

17.10.2007 10:58:22 Drive unit

Plow body: Place of magnet installation:

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

Plow data Distance - Stop points - Magnet next stop

Plow

Local V1

Type 5.7 toward HI

2.260 mm 0.350 mm

Automatic Automatic

Automatic

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

Plow

Local V1

005 face shield 020 face shield

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

Plow

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) - Magnet next Typestop GH 42/1 (sensor) Type GH 42/2 User-defined

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

Set plow type

Automatic

Automatic

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: Input of the face data relevant for the plow control Information about the switch positions and control points on the head gate Information about the switch positions and control points on the tail gate Rapid-run enable when the drive areas are exited Selection of the used plow type

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.45

Menu level - Plow control, Fig. 51:

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

Plow

Date: 17.10.2007 Time: 10:58:22

Local V1

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.

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

Fig. 52:

Face data

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

Plow Local V1 200 --05 1.500 m

Automatic 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.

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.

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.

5.46

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

Global settings

E

Face data

Position data, head gate / tail gate Fig. 53:

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

Position data, head gate / tail gate Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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.

Fig. 54:

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

Local V1

17.10.2007 10:58:22 Drive unit

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

Doc. no.: 1999 001 015 BA 00

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.

VLSA / 09

5.47

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

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

Fig. 56:

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 Plow body The plow body considered by the control system 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.

5.48

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

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.

E

Set plow type

Position data, head gate / tail gate 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 Caterpillar.

– Furthermore, a user-defined plow can also be selected. After selection, the data allocated to the plow is displayed in the basic mask.

Fig. 57:

Plow bodies

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

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. 58:

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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

5.49

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Position data, head gate / tail gate

5.50

PMC-D UEL Plow

6

Technical data

Main dimensions

Technical data Main dimensions Housing dimensions PMC®-V

Fig. 60:

Housing dimensions PMC®-D

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Fig. 59:

Doc. no.: 1999 001 015 BA 00

VLSA / 09

6.3

Pin assignment Rear tapped bores (all equipment)

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Fig. 61:

Pin assignment Pin assignment PMC®-V Fig. 62:

SKK24 socket PMC®-V

Tab. 1: Pin assignment PMC®-V

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1

Optocoupler Anode

Relay contact NO: a

Relay contact NO: b

Optocoupler Kathode

St2

+12V (A)

Serial interface: RxD

Serial interface: TxD

GND

St3

+12V (B)

Serial interface: RxD

Serial interface: TxD

GND

St4

+12V (C)

Serial interface: RxD

Serial interface: TxD

GND

St5

Options

Options

Options

Options

Profibus: a (intern)

Profibus: b (intern)

St6 St7

+12V Input

Serial interface: TxD

Serial interface: RxD

GND Input

St8

+12V (B)

Measurement input 1

+8,2V

GND

St9

+12V (C)

Measurement input 2

+8,2V

GND

St10

+12V (A)

Measurement input 3

+8,2V

GND

6.4

PMC-D UEL Plow

Pin assignment St11

Options

St12

Options

Option

Socket

**

St5

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

The designations of the options equal the second and third to last characters of the type designation listed on the equipment.

Pin 1

Pin 2

Pin 3

St5

Profibus: a (external)

Profibus: b (external)

St11

Profibus: a (external)

Profibus: b (external)

Pin 4

St11 AB

SKK24 socket PMC®-D

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Fig. 63:

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1 St2

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

St4

+12V (C)

St5

+12V (C)

Relay contact No: b Serial interface: TxD Serial interface: TxD Serial interface: TxD Gate input 2 Profibus: b (internal)

Optocoupler Kathode GND

St3

Relay contact No: a Serial interface: RxD Serial interface: RxD Serial interface: RxD Gate input 1 Profibus: a (internal)

St6 St7

St10

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

St11

+12V (C)

St8 St9

St12

Doc. no.: 1999 001 015 BA 00

VLSA / 09

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

GND GND GND

+8,2V

GND input GND

+8,2V

GND

+8,2V

GND

+8,2V

GND

Profibus: b (internal)

6.5

Pin assignment Pin assignment PMC®-D20/CAM

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1 St2

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

St4

+12V (C)

St5

+12V (C)

Relay contact No: b Serial interface: TxD Serial interface: TxD Serial interface: TxD Gate input 2 Profibus: b (internal)

Optocoupler Kathode GND

St3

Relay contact No: a Serial interface: RxD Serial interface: RxD Serial interface: RxD Gate input 1 Profibus: a (internal)

St6 St7

St10

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

St11

+12V (C)

St8

E

GND GND

+8,2V

GND input GND

+8,2V

GND

+8,2V

GND

+8,2V

GND

Profibus: b (internal) CM sensor -

GND

St13

not used

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

St14

not used

CM sensor +

CM sensor -

GND

St15

not used

CM sensor +

CM sensor -

GND

St16

not used

CM sensor +

CM sensor -

GND

St17

not used

CM sensor +

CM sensor -

GND

St18

not used

CM sensor +

CM sensor -

GND

St19

not used

CM sensor +

CM sensor -

GND

St20

not used

CM sensor +

CM sensor -

GND

St9

St12

6.6

GND

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

Fig. 64:

UEL distribution box UEL distribution box Fig. 65:

UEL distribution box 3 3

3

3

2

1 4

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

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

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

Doc. no.: 1999 001 015 BA 00

VLSA / 09

6.7

UEL distribution box Terminal diagram of the distribution box

Terminals SKK212

6.8

Terminal block

1 white

1

2 brown

2

3 green

3

4 yellow

4

5 gray 6 pink

Sensors blue

NAMUR 1

output speed

blue

NAMUR 2

input speed

5

brown

PT100

gear box temperature

6

green

PT100

gear box temperature

11 orange

7

brown

PT100

clutch temperature

12 transparent

8

green

PT100

clutch temperature

9 black

9

brown

PPT100

clutch pressure

10 violet

10

yellow

PPT100

clutch pressure

7 blue

11

white

PPT100

clutch pressure

8 red

12

brown

NAMUR 1

output speed

14

brown

NAMUR 2

input speed

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Fig. 66:

Splitterbox PMC OS 37 SPB Splitterbox PMC OS 37 SPB Fig. 67:

Splitterbox

4

3 5

1

1

4 5

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

2

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

VLSA / 09

6.9

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

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

Return defective “Providers” to the manufacturer for repairs.

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

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

Important!

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

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

Fig. 68:

10

1 2 4

7

4

7

4

7

4

11

8

5

5 3

6

7

9 1 2 3 4 5

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

6 7 8 9 10 11

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

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

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

6.10

PMC-D UEL Plow

Provider PMC-P XP Opto Ethernet Tab. 2: Summary of connections M2

M3

M4

P1

L1

Connector type SKK24

SKK24

SKK24

SKK24

SKK24

E2000

Application

BIDI

BIDI

BIDI

12 V DC power Optical plug-in supply connector

Connection

M1

BIDI

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

V0

Current

I0

DC

12.8 V 2A

E

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

Caterpillar Global Mining Europe GmbH, Lünen 2017

Connection P1 Tab. 4: Maximum values for P1 Voltage:

Vi

DC

12.8 V

Current

Max. Ii

Ci

2A

Internal capacitance

Max.

Internal inductance (leakage inductance)

Max.

58 nF Li

5 H

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

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

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

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

Name and address of the manufacturer Type: Code:

PMC-P XP Opto Ethernet 0158

BVS no.: Type of protection::

DMT 06 ATEX E 048 I M2 EEx ib d I

Serial no.:

XXXX XX XXXX 5th and 6th places give year of manufacturing -5C to +50C

Ambient temperature: Ta

Doc. no.: 1999 001 015 BA 00

VLSA / 09

6.11

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

L1 M1 to M4

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

P1 M5

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

E

Sketch for the converter connections

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

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

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

Important!

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

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

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

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

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

Ambient temperature Ta

6.12

-5°C to +50°C

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

Fig. 69:

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

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

Patch cable

Fig. 70:

Patch cable and connector to Provider PMC-P XP Opto Ethernet

Caterpillar Global Mining Europe GmbH, Lünen 2017

E

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

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

Fig. 71:

Doc. no.: 1999 001 015 BA 00

VLSA / 09

Device socket (external side)

6.13

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

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

An E2000 connector and the corresponding socket are shown in the following figure (double version). The terms “right” and “left” are thus defined as follows: Fig. 72:

E2000 fiber-optic connection

2 4 1 E

3

5 6

1 left plug 2 left coupling

5 green support sleeve 6 black support sleeve

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

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

6.14

PMC-D UEL Plow

Caterpillar Global Mining Europe GmbH, Lünen 2017

7