PDF DOWNLOAD Cat Bucyrus DBT - PMC Drive Control System - Conveyor with CST Gearbox Operating Manual

Operating Manual DBT - PMC® Drive Control System - Conveyor with CST Gearbox Doc. No.: 1999 001 009 BA 00

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

Amendments and alterations to this publication are not subject to notification. DBT GmbH (DBT) reserves all rights to this publication.

Its content is protected by copyright laws, both domestic and international. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of the DBT. DBT declines all liability for direct or indirect consequences of printing errors.

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

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Contents

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

1.3

Who this operating manual is intended for . . . . . . . . . . . . .

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

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

1.3 1.3 1.4

2. For your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

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

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

2.3 2.5

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

3.3

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

3.3

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4. Assembly Allgemeine Bemerkungen . . . . . . . . . . . . . . . . . . . . . . . .

4.3

The drawing number system . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.3 4.4

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

4.6

Assembly of the sensor/actuator junction box . . . . . . . . . .

Assembly of the connecting cable . . . . . . . . . . . . . . . . . . . .

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

4.6 4.10 4.11

5. Operation General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

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

5.4

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

5.6

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

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

5.6 5.6

PMC® Drive Control global menu level . . . . . . . . . . . . 5.11 System selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

5.12 5.13 5.16 5.17 5.19 5.20

CST drive system global menu level . . . . . . . . . . . . . . 5.22 Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process over. Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.23 5.26

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

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

Selecting operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Automatic Mode settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.27 5.28 5.28 5.31 5.33 5.37 5.40 5.41 5.41 5.41 5.42 5.43 5.44 5.45 5.47 5.49 5.50 5.51 5.51 5.52 5.53

Process configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55 Process functions on/off Process functions (contd.) . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Prefilling the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conveyor acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Pressure/slip controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.55 5.58 5.60 5.61 5.62 5.64 5.65

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

6.3

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

6.5

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

Pin assignment sensor/actuator connection box . . . . . . . .

Electrical specifications of the connections . . . . . . . . . . . .

6.5 6.7 6.8

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

7.3

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

Northamerica, Canada, Southamerica . . . . . . . . . . . . . . . .

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

South Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Referenced European standards and guidelines . . . . . . . .

7.3 7.4 7.4 7.4 7.5 7.7 7.7

PMC®-D CST

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Displaying process data . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Semiautomatic Mode settings . . . . . . . . . . . . . . . . . . . . . . . .

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

Motor/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

External Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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CST drive unit menu level . . . . . . . . . . . . . . . . . . . . . . . . 5.38

1

About this manual

Before starting work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the characters and symbols used.

Before starting work correct operating manual

application

Take care to ensure that the operating manual available to you is applicable to the respective application. Failure to do so can result in a safety hazard for yourself, others, and parts of the equipment.

Ensure that the data on the housings of the system components prove that the components are part of the PMC® Drive Control Systemand that the conveyor is equipped with CST gearboxes of DBT. This operating manual is designed for the control of a conveyor with CST - gearboxes by means of the PMC® Drive Control System.

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current operating manuals

Operating manuals for the conveyor concerned, the CST gearboxes, and motors must always be available at the place of operation. Request a new manual immediately if the present manual is no longer complete or has become illegible.

Who this operating manual is intended for The operating manual is intended for persons installing and setting up the PMC® Drive Control Systemworking with it, making operational settings, and perform trouble shooting work.

Every person working on the face, in the intersection between face and entry, or in the entry must read this operating manual.

This includes persons who: J Are in charge of transport J Perform assembly/disassembly work J Operate the conveyor J Eliminate faults J Carry out daily routine work on the face or in the entry J Perform maintenance work or J Carry out repairs.

in addition to supervisory personnel who: J Initiate and/or supervise the activities just indicated.

Purpose of this operating manual cost-effectiveness

This operating manual is intended to help you handle our product efficiently and safely. It provides important information on all activities related to the PMC® Drive Control System.

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

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1.3

Before starting work service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter “For your information”.

safety

Read the chapter “For your safety” with special attention. This chapter includes important information indicating possible hazards.

Observe the information given and follow the procedural instructions.

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

Try to memorize the symbols and their meaning.

Help!

Higher-order menus in miniature are placed in front of the respective menu item description to help you find your way around the menu structure more easily.

Caution!

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

Notice!

Paragraphs marked like this indicate harmful situations.

Possible consequences: damage to gearbox, motor, clutches, drive frame, conveyor or damage in the vicinity.

Important!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

J Items in lists are marked with bullets.

– Points in sublists are marked with a long dash at the start of the line.

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

1.4

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Warning!

These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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Danger!

Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

2

Your safety

Personnel

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. state of the art

The components of the PMC® Drive Control 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.

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

The European Directives and Standards referred to in this operating manual have to be observed when using the PMC® Drive Control 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.

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

Observe the safety and accident prevention regulations J of the mine, J of the Mines Inspectorate, and J of the mining employers’ liability insurance association further operating manuals

Please read also the operating manuals of the components required for operation, e.g. of electric motors, clutches, drive frames, chain tensioning devices, conveyors, drive shifting units, and block anchorages as well as those of further equipment located in the vicinity which may be affected by the control system. Clarify any questions 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® Drive Control Systems shall only be performed by service personnel of the manufacturer.

Conditions of application Intended use The PMC® Drive Control 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 DBT 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.

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2.3

Personnel Use the components of the PMC® Drive Control 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® Drive Control System.

DBTaccepts no liability for any damage resulting from any such unauthorised use.

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: J Plow spraying system/water spraying system and J Adequate and consistent ventilation

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® Drive Control Systemcomponents does not alter the rules and regulations relating to safety and firedamp protection in the mine.

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

Prerequisites for operation Putting the PMC® Drive Control 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.

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 (C - marking).

The M2 equipment is only allowed to be operated when the safety requirements according to prEN 1552 have been met. These include:

2.4

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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.

Personnel

J facilities preventing unauthorized starting J prestart warning systems J water spraying systems J safe lockout command systems J emergency stop systems J dust extraction systems J noise protection J 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.

Safety instructions General principles general

Always work with full concentration.

Familiarise yourself with your working environment.

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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 J Your exact location J The work you are performing J 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.

symbol plates

EMERGENCY STOP

Observe the symbol plates on the conveyor and on the adjacent machinery.

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.

securing the conveyor

Secure the conveyor while performing J Maintenance work J Inspection work J Repair work or J Failure of safety equipment, e.g.

– Firedamp protection.

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2.5

Personnel cordon off working area

Cordon off your working area widely for monorails and mobile handling systems.

movable parts

Never allow parts of your body to come between parts which could move, such as e.g.

J conveyor chains J flights (scrapers) J spill plates J chain sprockets J and between tensionable drive frame and coalface

ignition hazard

Be sure to observe the intervals specified for maintenance and checks of motors, gearboxes, chains, drive frames, adjacent machinery, and machine parts. Ensure that the machines are always adequately cooled as hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Storage and transport

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. transport safety device

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

inclined faces

On inclined faces, secure all component parts by chains, e.g. to the support units.

Assembly

use system brackets

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

Maintenance and repair Do not repair or modify the PMC® Drive Control Systemcomponents.

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

2.6

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

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

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The control units of the PMC® Drive Control Systemcan be stored for a maximum of 4 years without electrical connection. After four years, the buffer battery installed is empty and has to be replaced.

Personnel 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.

Use only spare parts which satisfy the specified technical requirements. This is only ensured with original spare parts of DBT. 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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original spare parts

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2.7

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Personnel

2.8

PMC®-D Drive

3

Storage and transport

Storage

Storage and transport This chapter contains important information on the correct stor-age and the safe transport of PMC® Drive Control Sys-temcomponents.

Observance of the instructions and tips will in-crease the service life and reliability of the system components. Reading this chapter carefully will help you to simplify your day-to-day work.

Storage corrosion protection

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

no direct exposure to sunlight

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 ca-bles - only in closed rooms at temperatures of 15°C to 25°C.

dirt and moisture

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.

short-term storage

Never store electronic equipment outdoors!

long-term storage

Make sure when storing that display and keyboard protection foils, as well as plug conduits are not damaged.

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Storing the equipment

After 4 years of storage, the computers should be checked as the battery installed will be discharged after this period of time. It will have to be replaced. Inspection and battery change should be made by DBT service personnel.

After a storage period of approx. two years, the system compo-nents must be subjected to a test before using them to find out whether the measures taken and the method of storage have prevented damage.

Important!

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Transport Transport containers, dimensions, and weights Please be sure to observe the technical data sheet. It contains information on: J dimensions, and J weights

The control units and interfaces belonging to the PMC® Drive Control Systemdesigned 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 dis-plays, keyboards, cables, and plug connectors.

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.

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3.3

Storage Caution!

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

Before transport temperatures below freezing

Electronical equipment should be transported very cautiously at low temperatures (below -10°C) as all materials will become brit-tle and may break easily at low temperatures.

When using mobile handling systems for the transport at such temperatures make sure that the units are not subjected to shock loads.

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For overseas transport, line and cable ports must be carefully protected. The PMC® Drive Control Systemdevices must be ca-refully packed for sea transport.

3.4

PMC®-D Drive

4

Installation

Allgemeine Bemerkungen

Installation Allgemeine Bemerkungen Important!

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

The drawing number system The PMC®-R System is illustrated in the following drawings for installation.

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

is the group of numbers for ECC-Automation projects.

bbb

This group of numbers is a serial number for the various projects.

mmm

This group of numbers identifies partial projects such as 010 for shield drawings or 020 for system drawings.

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These can be issued differently for each project (For assignment: see “Documentation associated with the project”)

Fig. 1:

nn

The numbers identify single parts. For project drawings, the sequence “00” is practically the only one that occurs.

pp

This group of numbers identifies variants.

Example

4007 113 130 00 00 no variants project ID partial project pump control project number for CODELCO drawing belongs to ECC department

The original drawings contain all of the parts numbers referenced in the parts lists. The drawings shown here are for the purpose of general understanding, they are not design drawings. You will find the project drawings in the “Documentation associated with the project”. These include the above-mentioned drawing number in the title as the document number. For longwall control documents, the shield drawing number determines the document number. This means that the third group of numbers is 010. The documentation belonging to this also contains the partial projects, with the exception of the descriptions of the face program and the central program. The “Documentation associated with the project” also contains special components if they were exclusively made for the project and do not belong in the standard system.

The original drawings, together with parts lists and part numbers, are to be used to ensure proper allocation of parts for correct installation in accordance with the intended design. These operating instructions in chapter 6, in which the main system parts are shown with drawings and/or illustrations, offer assistance in locating the individual parts of the system. In addition, technical details and functionality are explained.

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4.3

Allgemeine Bemerkungen Tools required The following tools are required in order to install system components underground: Installation of the brass retaining strip and the PMC®-R on the brass retaining strip : 10 mm Allen wrench Installation of the SKK24 plug: All other installation in the PMC®-R 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.

J Control unit PMC®-D with 7-segment display J Visualization unit PMC®-V with display screen and keyboard J Gateway PMC®-G with 7-segment display J Sensor-/actuator junction box

and PMC®-D control unit Fig. 2:

4.4

PMC®-D control unit

PMC®-D Drive

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J Cable for the connection between sensor-/actuator junction box

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J Holding bracket

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Allgemeine Bemerkungen

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Fig. 3:

PMC®-V visualization unit

Fig. 4:

Gateway PMC®-G

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4.5

Installing the control units Installing the control units holding bracket

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

The connected hoselines (SKK24) are secured in this hol-ding bracket by the respective staple locks to prevent them slid-ing out of the plug contacts of the control units. Each holding bracket is equipped with two captive bolts (thread M10) for fas-tening 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 ac-cordingly.

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.

Caution!

Using just the holding bracket for assembly is only recom-mended 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 mount-ing 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 re-leased 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.

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 vi-brations by a damper.

Assembly of the sensor/actuator junction box The sensor/actuator junction box is located within the gearbox. It permits to connect the internal sensor and actuator equipment to the PMC®-D control unit.

The complete module mainly comprises three parts, namely the junction box with the bushes for connecting the sensors and ac-tuators, a cable of approx. 2.5 m length, and a housing conduit.

These three parts are firmly interconnected and must therefore be regarded as one module.

4.6

PMC®-D Drive

E

The holding bracket is provided with two holes for hexagon so-cket 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.

Bucyrus DBT Europe GmbH, Lünen 2008

attachment by means of holding bracket

Installing the control units Fig. 5:

The sensor/actuator junction box comes supplied mounted in the chamber of the gearbox supply unit which is protected by the L.H. square cover (seen from the motor) and connected with the internal sensors and actuators. Only the conduit at the R.H. wall of the supply unit facing the motor can be seen from the outside. The thread and the contacts of the conduit must always be pro-tected by the plastic cap supplied. Any damage of the conduit would require the complete sensor/actuator junction box to be replaced.

E

Bucyrus DBT Europe GmbH, Lünen 2008

Sensor/actuator junction box with housing conduit

junction box, cable

The sensor/actuator junction box is fastened to a mounting plate provided in the gearbox by means of four bolts (M8x10). When laying the cable inside the gearbox care should be taken to en-sure that the cable will not be kinked.

Fig. 6:

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Sensor/actuator junction box installed in a CST gearbox

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4.7

Installing the control units

Caution!

If a defect is present in feedthrough, then the entire subassembly (comprising connection box, conduit and feedthrough) needs to be replaced. It is for that reason that the feedthrough is always to be protected with the plastic cap provided.

Take care not to damage the conduit as even the slightest defect at the thread could cause assembly problems. When transporting the gearbox, generally use the points of at-tachment provided. conduit

4.8

When installing the conduit take care to ensure that it is correctly placed into the recess milled into the inside wall of the gearbox (antitwist protection). The nut (SW 60) for fastening the conduit in the gearbox wall is provided with one o-ring each at its fronts. The o-ring which seals off the inner chamber of the gearbox has to be greased before fitting and tightening the nut.

PMC®-D Drive

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Sensor/actuator junction box conduit

Bucyrus DBT Europe GmbH, Lünen 2008

Fig. 7:

Installing the control units Sensor/actuator junction box conduit (inside)

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Fig. 8:

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4.9

Installing the control units Assembly of the connecting cable The connection between the sensor/actuator junction box and the PMC®-D control unit is provided by a cable which is equipped with a 90 degree right angle plug. These plugs can be swung along the axis in longitudinal direction to the contacts within a range of 180 degrees thus allowing the direction of the cable out-let to be adapted to the fitting conditions.

Connecting cable attached at gearbox

connecting cable

Both the cable entry gland in the gearbox and the PMC®-D con-nection are provided with o-rings at the front ends of the fasten-ing nuts. These have to be greased before installing the connect-ing cable. The cap nuts of the connecting cable must be tight-ened against these o-rings to protect the thread of the connections against moisture and to ensure a safe connection of the contacts.

Important!

The connecting cable between the gearbox and the PMC®-D is no hoseline and therefore has to be laid such as to ensure that it is protected against mechanical damage, e.g. by rock falls.

4.10

PMC®-D Drive

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Fig. 9:

Installing the control units Fig. 10: PMC®-D control unit with connecting cable

Installing Profibus connections

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The units of the PMC® Drive Control Systems communicate with one another via a bus system in accordance with the Profibus Standard. Two wires are required in the connection line between the units that must be twisted together (twisted pair). This twist-ing must also be maintained in any intervening distributors that may be installed.

Important!

Use only lines that are twisted together (twisted pairs) for setting up the Profibus connections. Other lines will lead to breakdowns in communications.

Special hose pipes are supplied by DBT for connecting the units of the PMC® Drive Control Systems to the Profibus which are covered at both ends with a white shrink hose approximately 10 cm in length.

Important!

Use only the hose pipes supplied by DBT that are marked with white shrink hose for connecting the units to the Profi-bus. The use of any other hose pipe will lead to breakdowns in communications.

The connections for the Profibus are marked with ST6 and ST12 for all units. It does not matter to which plug the line coming from the preceding unit or the one going to the next unit are attached. The important thing is to attach termination resistors to the first and the last units in the chain on each of the unoccupied plugs left over.

Important!

Close off the Profibus line on the first and the last unit by mounting termination resistors. The absence of a termina-tion resistor will lead to severe communication disruptions.

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4.11

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Installing the control units

4.12

PMC®-D Drive

5

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 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.

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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® G (Gateway) unit is intended for communications with external systems and can also be used by all control systems. 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 or PMC® G 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.

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5.3

Keyboard PMC® V

Fig. 11: Levels of the menu tree Globale Funktionen

Gateway

G1

Gn

V1

CST-Antriebssystem

Hobelsystem

Visualisierung

Vn

HA

HA1

HI

HA2

HI1

HI2

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.

Fig. 12: Structure of the monitor screen masks Menu level or system name

Device name

Start menu

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Name of display mask

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

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

System specific status information

Keyboard PMC® V The keyboard of a PMC® V visualization unit is shown in Fig. 13 page 5.5. 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.

5.4

PMC®-D Drive

Keyboard PMC® V Fig. 13: 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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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.

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.

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5.5

Light emitting diodes PMC® V 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.

Fig. 14: Menu tree of the system messages

?

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!

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.

5.6

PMC®-D Drive

Light emitting diodes PMC® V 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. 14, page 5.6 shows the menu tree that can be navigated through within the presentation of the system messages.

After the system messages have been selected, the mask shown in Fig. 15 appears on the monitor screen. The selection criteria for the displayed messages are specified in the lowest line on the monitor.

Fig. 15: System messages

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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

F1:Ackn. message F2:Ackn. device F3: select system F4: Select msg type all Systems all messages In the example shown, “all messages” from “all systems” are presented in the mask.

J 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).

J 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.

J Brief description

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

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5.7

Light emitting diodes PMC® V 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.

Fig. 16: 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.

E

all messages

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. 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. 17: System selection messages

System selection lokal V3

global local V3

CST drive system Plow control system CM system Visualization

all systems

5.8

all messages

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

all systems

Light emitting diodes PMC® V

Fig. 18: Selecting message type

Selecting msg type

global local V3

all messages only errors only warnings only information

all systems

all Messages

E

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.

Bucyrus DBT Europe GmbH, Lünen 2008

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. 19: Language selection

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Jump to previous display item

5.10

PMC®-D Drive

PMC® Drive Control global menu level PMC® Drive Control global menu level Fig. 20: 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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065

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

lokal V3

Diagnostics PB intern Global lokal V3 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

System config.

Global lokal V3 Serial no. Type Conf. Found Addr. CRC 560040047 Name/Place 560 D-CST HA1 ofHA1 047 052677 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:Reset error counters

F1:Activete conf.

F2:Delete entry

-----

-----

Device information Date: Time:

Global

lokal V3

12/06/2007 15:23:38

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

Software/serial no.s

UTC = Universal Time Coordinated

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

CST

Visualization

lokal V3

lokal V3

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

Meas.val Date: Time:

lokal V3

NOVAJA

Component ser no.

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

Voltage supply

Plow control system

F2:Delete entry

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. 20 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 and PMC® G 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: J Selection of a system in cascaded arrangement,

System

selection, page 5.12.

J Display and modification of the configuration of a system in

cascaded arrangement.

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System configuration, page 5.12.

5.11

PMC® Drive Control global menu level J Diagnostics of the internal Profibus.

Profibus diagnostics

(internal), page 5.16.

J Information concerning the construction and the software

version of the individual units.

5.18.

Device information, page

J Modification of the monitor screen settings of the currently used

PMC® V unit.

Display settings, page 5.20.

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

Setting date/time, page 5.21.

Fig. 21: 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. 22: System selection

System selection

Global local V3

CST--drive system Plow control system Visualisation Gateway

5.12

PMC®-D Drive

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

PMC® Drive Control global menu level 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) and PMC® G units (Gateway) are explained later.

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 and PMC® G 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 or PMC® G 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 or PMC® G 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. 23, 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.

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5.13

PMC® Drive Control global menu level 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.

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.

Fig. 23: System configuration

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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

J Serial No.

The serial number that is entered on the nameplate of the unit.

J Type

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

J 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.

J 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 Drive

PMC® Drive Control global menu level J 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.

J 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. 24: 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. 23 (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.

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.

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.

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 or PMC®-G 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. 25: Profibus diagnostics (internal)

Diagnostics PB intern Global local V3 Device PBaddr. Recv. Send. Error tel. tel. Send Bus CST--HG1 047 567 347 000 000 V3 021 013 721 000 000 V1 003 990 866 000 000 V2 004 741 883 000 000 CST--TG1 001 965 283 000 002 CST--HG2 012 676 297 000 000

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

-- -- -- --

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

5.16

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

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Profibus-diagnostics (intern)

PMC® Drive Control global menu level J 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.

J PBaddr.

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

J Recv. tel.

The number of telegrams received by the unit.

J Send. Tel.

The number of telegrams sent by the unit.

J Send. (ing) errors

The number of errors which occurred during an attempt to send a telegram.

J 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.

Bucyrus DBT Europe GmbH, Lünen 2008

E

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. 27, page 5.18 will be displayed on the monitor screen. It contains information concerning the individual units of the PMC® Drive Control Systems.

Fig. 26: 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. 27: Device information

Device information Global local V3 Device Type Serial No. CST--HG1 D--CST 560040047 Component--SerNo CPU: 541040047 D--IO: 551040048 PMU: 531030005 PVC: 552050055 7--Seg: 544030004 CPLD:

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

F1: Next device

F2: prev. device

J 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.

J Serial No.

The serial number that is entered on the nameplate of the unit.

J 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® V or PMC® G unit.

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

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

5.18

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

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

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J Type

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.

J 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.

– 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.

Bucyrus DBT Europe GmbH, Lünen 2008

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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.

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5.19

PMC® Drive Control global menu level Fig. 28: 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 Drive

Bucyrus DBT Europe GmbH, Lünen 2008

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.

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Setting date/time

PMC® Drive Control global menu level Fig. 29: 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

J 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”.

J Local time, date Bucyrus DBT Europe GmbH, Lünen 2008

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

J Local time, UTC

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

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5.21

CST drive system global menu level CST drive system global menu level The menu tree illustrated in Fig. 30 (page 5.22) shows the monitor screen masks with the help of which the global functions of a CST drive system for a drag link conveyor can be selected. This menu tree is reached from the global menu level of the PMC® Drive Control Systems by means of the corresponding system selection.

The abbreviation “CST” (Controlled Start Transmission) for the selected system is displayed in the middle column of the first monitor screen line.

Fig. 30: CST drive system global menu tree Start menu CST Process overview lokal V3 HG1 HG2 TG1 TG2 Input speed 1499,0 1499,01493,9 -----Motor power 0129,0 0131,0 0234,0 -----Clutchpress 0015,8 0015,8 0019,4 -----Actual slip 003,50 003,50 000,20 -----Target slip 003,50 003,50 000,20 -----Outp. speed 0044,7 0044,7 0044,7 -----Sys. Press. 0100,0 0100,0 0100,0 -----Diff.press. 0000,0 0000,0 0000,0 -----Oil press 0003,0 0003,0 0003,0 -----Drive state run run run -----Drive rel. no no no ------

CST

lokal V3

Date: 12.06.2007 Time: 15:24:56

Parameter status CST lokal V3 Parameter Parameter In System copy block status identical from HG1 local User Yes --HA2 local User HG2 No --TG1 local User Yes --TG2 local ------global User Yes ---

Process overview Prozessübersicht Process overv. Contd.

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

lokal V1

Select operating mode Run mode: Automatic

CST

lokal V3

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

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

Automatic

Automatic

Automatic

Motor curr. overview CST lokal V3 Motor- Curr.

Curr. Meas. Measure strom A B aktive on HG1 0129 0064 0065 R+L V1 HG1 HGA2 0130 ---0065 HG2 0086 TG1 0234 0117 0117 A+B V2 TG1 TG2 -------------- ---

Load sharing control.

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

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

Minimum slip value:

Automatic

0.20 %

Automatic

Drive selection

CST

lokal V3

Automatic

CST

Start menu

HA1

Date: 12.06.2007 Time: 15:24:56

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

Automatic

Display process Prozessdaten anzeigen data Process data contd.

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

Automatic

The Start menu offers the following selection options: J Display of the most important processing dimensions across all

drive units.

5.22

Process overview, page 5.23.

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

Process overv. Contd.

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

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Automatic

Automatic

CST drive system global menu level J Display of the motor currents across all drive units.

Selecting operating mode, page 5.27.

J Selection of an individual drive unit.

Drive selection,

page 5.28 J Settings for the automatic mode of the conveyor system.

Automatic Mode settings, page 5.34.

J Overview of the status of the stored global and local parameter

blocks of the PMC® D units.

Parameter status, page 5.31.

J Settings for operating the conveyor system in automatic mode.

Automatic settings, page 5.34.

J Settings for the control algorithm for load sharing between the

individual drive units.

Load sharing controller, page 5.37.

Fig. 31: CST drive system start menu

Start menu

CST

local V3

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Proceess overview Process overv. contd.

Motor current overview Drive selection Select run mode Parameter status Automatic mode setttings Load shearing controller Automatic

Motors released

Process overview Start me nu

CST Date: Time:

Pr ocess overview Process overvi ew Motor current overview Drive selectio n Select run mod e Parameter stat us Automatic mode settings Load sharing c ontroller

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The current values of the most important processing dimensions for all of the conveyor system drive units are displayed in the Process overview. This makes it possible to have a rapid overview of the operating status of the installation. Dark highlighting is used to indicate the respective values in the event of errors in the recording of measurement values. To determine the precise cause of the error, the affected drive needs to be selected and the mask for displaying the local process data needs to be called up (Displaying process data, page 31).

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5.23

CST drive system global menu level Fig. 32: Process overview

Process overview CST HG1 HG2 TG1 Input speed 1499,0 1499,0 1493,9 Motor curr. 0129,0 0131,0 0234,0 Clutchpress 0015,8 0015,8 0019,4 Actual slip 003,50 003,50 000,20 Target slip 003,50 003,50 000,20 Outp. speed 0044,7 0044,7 0044,7 Sys. press. 0100,0 0100,0 0100,0 Diff.press. 0000,0 0000,0 0000,0 Oil press. 0003,0 0003,0 0003,0 Oil temp. 0053,0 0062,5 0058,0 Drive state run run run Drive rel. no no no Automatic

local V3

Motors released

J Input speed [speed]

The speed of the drive motor.

J Motor current [A]

The pressure built up in the pressure chamber of the clutch by which the clutch discs of the input side and the output side are pressed together. This pressure is set to a specified nominal value on the basis of the system pressure with the aid of the servo valve and of a highresolution pressure sensor of the PMC® D unit. The output power of the gearbox can be varied with the help of the clutch pressure.

J Actual Slip [%]

The slip in the clutch which is set by the PMC® D unit.

J Target slip [%]

The slip in the clutch which is to be set by the PMC® D unit.





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

nan = Input speed nab = Output speed ü = Gear ratio J Output speed [rpm]

The speed at the output of the gearbox J System pressure [bar]

The pressure for the control system of the CST clutch built up within the gearbox. A pressure switch is used to monitor the pressure that is set to 100 bar which switches at a minimum pressure of 80 bar. The required pressure of 100 bar is always displayed on the monitor screen after the switchover. If the system pressure falls below the minimum pressure level then the drive will be switched off.

5.24

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

J Clutch pressure [bar]

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The power consumption of the drive motor.

CST drive system global menu level J Differential pressure [bar]

The differential pressure between the input and the output of the filter in the hydraulic circuit to the pressure chamber of the clutch. A pressure switch is used to monitor the differential pressure that switches at a minimum pressure of 6.9 bar. 7 bar is always displayed on the monitor screen as the pressure after the switchover. If the system pressure rises above 6.9 bar, then the drive will be switched off.

J Cooling oil pressure [bar]

The builtup pressure within the gearbox with which the gear oil is pressed on through between the fins of the clutch. The oil is used to remove the heat that arises in the clutch and to maintain the thin film of oil that separates the clutch linings from one another and protects them against damage. The drive is switched off once the cooling oil pressure goes outside the valid range of between 1.0 and 3.8 bar.

J Oil temperature [°F]

The oil temperature in the oil sump of the gearbox. The oil serves the dual purpose of both lubricating all movable parts in the gearbox and cooling the clutch, in addition to being used as an operating oil for the pressure buildup in the clutch. The drive is switched off once the oil temperature goes outside of the -20°C to 90°C range.

J Drive Bucyrus DBT Europe GmbH, Lünen 2008

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The operating statuses of the drive units are displayed, particularly that of the startup phase. These operating statuses are dependent to a certain extent on the selected operating mode. The following abbreviations are displayed: – Stop The operating mode “Stop” has been selected.

– WtMot, Waiting for motor Waiting for the startup of the drive motor.

– MotSta, Motor starts The minimum speed has been detected, now waiting for the stable final speed to be reached.

– MotRun, Motor is running The drive motor has started correctly and is thus ready for operation.

– StaDly, Delayed start The delayed start function is running in the “Semiautomatic” operating mode in order to compensate for the motoron sequence.

– MotSyn, Motors synchronised The PMC® D units are waiting in the “Automatic” operating mode for the message that all motors have started correctly.

The startup of the conveyor is cancelled if this message has not been received within the specified time window (Automatic Mode settings, page 5.34).

– ChnDly, Chain tensioner delay This abbreviation is displayed only if the automatic pretensioning of the chain in the CST drive system has been activated.

The PMC® D unit to which the clamping fixture is connected waits in the “Automatic” operating mode to be notified that the

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5.25

CST drive system global menu level tensioning procedure has been completed. The startup of the conveyor is cancelled if the message is not received within the specified time window.

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

– ChnSyn, Chain tensioner synchronised This abbreviation is displayed only if the automatic pretensioning of the chain in the CST drive system has been activated.

All PMC® D units to which no clamping fixture is connected wait in the “Automatic” operating mode for notification that the tensioning of the chain has been completed. The startup of the conveyor is cancelled if the message is not received within the specified time window – PreFil, Prefilling The clutch of the local drive unit is prefilled.

– AccSyn Breakaway/Accelerate conveyor synchronised Waiting in the “Automatic” operating mode for all drive units to report the correct acceleration of the conveyor. The startup of the conveyor is cancelled if this message has not been received within the specified time window (Automatic Mode settings, page 5.34).

– run The drive unit is running in the selected operating mode – SftStp, Soft stop, The drive unit performs a normal switchoff.

– Error An error has been detected by the local PMC® D unit. This error is reported to the other PMC® D units and the drive unit is switched off immediately.

– ExtStp, External stop The drive unit has been switched off due to an error message from a different PMC® D unit.

Process over. Cont.

J Diff. pressure2

System-specific display of a second differential oil pressure switch (if the switch is not at HGnd in the current system, this display is not shown)

5.26

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

– AccSpr, Breakaway/Accelerate conveyor The drive unit attempts to accelerate the conveyor from a standstill.

E

– PreSyn, Prefilling synchronised Waiting in the “Automatic” operating mode for the message that all clutches have been prefilled. The startup of the conveyor is cancelled if this message has not been received within the specified time window (Automatic Mode settings, page 5.34.

CST drive system global menu level J Temperatures

– Hydraulic p.

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

Motor current overview Start me nu

CST Date: Time:

Process overvi ew Motor current overview Drive selectio n Select run mod e Parameter stat us Automatic mode settings Load sharing c ontroller

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tandem motors

This display offers an overview of the current consumed by each drive motor, which is derived from the total of the two individual currents in Windings A and B (see Fig. 59). This division is necessary in order to be able to display the individual currents from tandem motors. When there is one standard motor, only one winding is actively switched, which means that the motor current is identical with the with the winding current (Motor data, Fig. 59, page 5.50). In addition, the names and/or the installation sites of the units are displayed in the motor current overview by means of which the currents are registered.

Two separate stator windings are mounted in sequence in an motor housing with these motors. The output shaft correspondingly bears two rotor windings, which means that the total drive output generated by all of the individual machines is available to their common shaft.

In normal mode, both windings are active with a tandem motor and the total current is achieved by adding together the two coil winding currents. If one measured value is faulty and is removed from the evaluation by the user (Process functions on/off, page 5.56), ), then the entire current is determined by doubling the remaining measurement values. The same applies when only one measurement channel is available. If a winding fails, then it must be deactivated (Motor data, Fig. 59, page 5.50) and the tandem motor is treated like a standard motor. The motor current then corresponds to that of the remaining winding current.

Fig. 33: Motor current overview

Motor current overview CST local V3 Motor-- Curr. Curr. Meas. Measure curr. A B active on HG1 0129 0064 0065 A+B V1 HG1 HG2 0130 -------- 0065 A+B HG2 TG1 0234 0086 0117 A+B V2 TG1 TG2 -------- -------- -------- ------ ------ ------

Automatic

Motors released

J Motor current [A]

The entire current consumed by the machine

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5.27

CST drive system global menu level J Current A [A]

The current consumed by current A J Current B [A]

The current consumed by current B J Meas. active

A is always displayed with motors having only one stator winding. A tandem motor can be operated with only one winding, which means that A, B or A+B can be displayed.

J Measurement on

The name and/or the installation site of the units from which the motor currents are recorded. The designation on the left indicates the unit for recording the current from Winding A and the designation on the right indicates the unit at which the current from Winding B is recorded.

Drive selection CST Date: Time:

Process overvi ew Motor current overview Drive selecti selectioon n Select run mod e Parameter stat us Automatic mode settings Load sharing c ontroller

A selection list is displayed in which indicates the drive units that can be accessed through the internal Profibus system. The selection of a drive unit leads to the menu level of the individual PMC® D units.

>

Fig. 34: Drive selection

Drive selection

CST

local V3

Motors release d

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Start me nu

Date: 30.03.2005 Time: 15:24:56 Head Gate 1 (HG1) Head Gate 2 (HG2) Tail Gate 1 (TG1)

Automatic

Motors released

Functions can be selected here which affect only the selected drive unit (CST drive unit menu level, page 5.38).

Selecting operating mode Start me nu

CST Date: Time:

Process overvi ew Motor current overview Drive selectio n Select operati operat ing ng mode Parameter stat us Automatic mode settings Load sharing c ontroller

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The operating mode of the conveyor system can be set using the displayed selection list. The “Stop” operating mode must always be used as an interim step when making any operating mode changeovers.

>

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PMC®-D Drive

CST drive system global menu level Fig. 35: Selecting operating mode

Selecting operating mode run mode: Automatic

CST

Local V3

Run mode (G) Stop Automatic Semiauto Inspection

Automatic

Motors released

Important!

For reasons of safety, the “Stop” operating mode must always be selected when making operating mode changeovers before the new operating mode can be set up

E

The following operation mode can be set up: Bucyrus DBT Europe GmbH, Lünen 2008

J Stop

A normal switchoff is initiated at all drive units while the conveyor is running (Normal switchoff. The pressure in the clutches is released completely and the contacts for enabling the motor are opened.

J Automatic

The standard operating mode for the conveyor. This operating mode is predicated on both a correctly functioning motor current measurement and a reliable communications via the internal Profibus system. Only then the correct functioning of the two essential characteristics of this operating mode is guaranteed: – Smooth start of the conveyor The outputs of the drive units are all made available at the same instant in order to set the conveyor in motion by means of the coordination of the startups of the individual drive units.

The startups of all motors are first awaited for this purpose (Motor start, page 5.59) – before the prefilling of all CST clutches is started (Prefilling the clutch, page 5.60). Once this process has been completed, the acceleration phase of the conveyor is started in synchronised fashion at all drive units (Conveyor acceleration, page 5.61). The maximum force can thereby be introduced into the chain, so that even a very heavily loaded conveyor can still be set into motion in order to accelerate it subsequently in controlled fashion to its nominal speed.

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5.29

CST drive system global menu level – Load sharing After the conveyor has been set into motion, the controller for load sharing between the drive units is enabled. The load on the drive units is assessed on the basis of the measured motor currents and adjusted by means of a default slip specification for the individual CST clutches to the load status of the conveyor. A distinction is made between three load statuses: the light load range, the medium load range and the heavy load range. A different strategy for load sharing between drive units is applied in each of these load ranges.

Load sharing can only be carried out by one of the PMC® D units. Any of these units can be selected to be responsible for this task (Automatic Mode settings, page 5.34).

J Semiautomatic

Fig. 36: Semiautomatic startup delay start AFC accelleration Motor startup Motor startup Motor startup TG1 HG1 HG2

Start delay HG2

prefill clutch

Start delay HG1 Start delay TG1

5.30

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

– Smooth start of the conveyor In order to ensure that the power supply underground does not become overloaded, the switching on of the drive motors is performed as a rule nonsimultaneously. The PMC® D units do however recognise as a result of the motor being started up that the conveyor is to be started. All of the drive units that have the same time delay for switching on the motors would otherwise close their clutches for that reason. In order to ensure that the total output of all the drive units is made available at the same time for the acceleration of the conveyor, even without communications between the PMC® D units, an individual delay time can be set for each drive unit (Semiautomatic Mode settings, page 5.42). This delay time is inserted after the startup of the motor. As a result, the total output of all of the drive units is made available for the acceleration of the conveyor at the same time, just as is the case with the Automatic operating mode.

E

In this semiautomatic operating mode, the drive units function independently of one another. Communication between the PMC® D units is for that reason not necessary with this operating mode. Assessment of the motor currents can also be dispensed with.

CST drive system global menu level

– Target slip default setting No automatic load sharing is active in the semiautomatic operating mode. The different load shares of the individual drive units can be modified only by setting a target value for the slip of the clutch (Semiautomatic Mode settings, page 5.42).

J Inspection Once the motor has started up correctly, the nominal value for the pressure in the CST clutch can be increased and decreased in defined steps by actuating the arrow keys on the PMC® V unit (Clutch pressure inspection, page 5.43). The stepwidth is adjustable. This nominal pressure specification is limited to the selected drive. No other drive will put pressure on its clutch, not even if the motor is running.

Parameter status Start me nu

CST Date: Time:

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Process overvi ew Motor current overview Drive selectio n Selecting oper ating mode Parameter sta stattus us Automatic sett ings Load sharing c ontroller

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The system for controlling a conveyor with CST drive units can be influenced by setting up parameters for its function. The factory settings stored in the PMC® D units at the time of the delivery guarantee only basic settings for the system. These need to be adjusted to accommodate the requirements of the place of operation.

The system distinguishes between global parameters, which apply throughout the entire control system, and local parameters, which are respectively valid for a single drive unit. The global parameters are stored as a general principally in all PMC® D units. To ensure the functioning of the system, it would be sufficient to store the local parameters only in those units to which they are assigned.

This would however mean that the modified local parameters would have to be reentered each time a unit is replaced. To prevent this from happening, a respective copy of the local parameters of the other units is stored in each PMC® D unit. As a result, a new unit can adopt both the global and the local parameters of a unit along with the current parameter blocks. The alignment of the parameters takes place through the monitor screen mask displayed in Fig. 37.

Fig. 37: Parameter status

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

Automatic

local V3

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J Parameter block

Designation for the parameter block type. The various local parameter blocks are marked with the installation sites of the PMC® D units.

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5.31

CST drive system global menu level J Parameter status

Abbreviated designation for the state of the parameter block in the unit allocated to it. The following abbreviated names are displayed: – User The factory settings have been modified by the user.

– FactSet. The parameter block was reset back to the factory settings by the user or a newly manufactured unit has been installed.

– Reset An error was discovered during the monitoring of the parameter block that is carried out automatically by the unit and the values of the parameters have been reset to the factory settings.

J Identical in the system

This column contains an indication as to whether or not the copies of a parameter block stored in the individual units are identical. If “Yes” is entered in all the lines, then the system is errorfree in the parameter administration sector. If there is a “No”, then an alignment must be performed for the affected parameter block.

Important!

The parameter status is errorfree if a “Yes” is entered for every parameter in the “Same in the system” column. The control system is ready for operation only when the parameter status is errorfree.

The list for the selection of the unit from which the parameter block is to be copied is presented in Fig. 38 . In addition to the unit designations, the status of the parameter block in the individual units is also displayed. The copying of parameter blocks that are marked with “F” or “R” is not permitted in order to prevent any involuntary resetting of the parameters back to the original factory settings. Resetting the parameter values to the factory settings is possible only by selecting “Factory setting”.

5.32

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

After a parameter block has been selected and the Enter key has been actuated, a list is displayed in which all of the existing units and the factory settings are offered for selection purposes (Fig. 37). The installation site of the selected unit from which all other units are to apply the parameter block is displayed in this column for the duration of the application.

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J Copy from

CST drive system global menu level Fig. 38: Copying the parameter block

Parameter status CST local V3 Parameter Parameter Im System Kopieren Unit Parameter block HG2 satz HG1 status U gleich von HA1 lokal Benutzer Ja -----HG2 U* HA2 lokal Benutzer Nein -----TG1 U HI1 lokal Benutzer Ja --TG2 -----HI2 lokal ------Factory setting global Benutzer Ja -----U = values modified by the user U*= different from the copies F = factory setting R = reset to factory setting Automatic

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The status of the parameter block is marked with the abbreviations: J U

The factory settings have been modified by the user.

J U*

Bucyrus DBT Europe GmbH, Lünen 2008

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The comparison of the locally stored parameter block with the copies of the same parameter block stored in the other units has revealed a discrepancy.

J F

The values of the parameters correspond to the factory settings J R

An error was discovered during the monitoring of the parameter block that is carried out automatically by the unit and the values of the parameters have been reset to the factory settings. example:

The example presented in Fig. 38 shows that local parameters in the PMC® D unit of Head Drive 2 have been modified without a comparison being made with the copies in the other units. This is possible if no communication connections between the units were functioning at the time of the parameter change. The user needs to make a decision in such cases as to which parameters the PMC® D unit on the Head Drive 2 should continue to work with.

Automatic Mode settings Start me nu

CST Date: Time:

11/29/2005 4:08:30 PM

Process overvi ew Motor current overview Drive selectio n Selecting oper ating mode Parameter stat us Automatic set setttings ings Load sharing c ontroller

Automati c

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The “Automatic” operating mode is the standard operating mode for the conveyor system (Automatic operating mode, page 5.34). This operating mode is predicated on both a correctly functioning motor current measurement as well as reliable communications via the internal Profibus system. The monitor screen mask illustrated in Fig. 39 shows all of the settings which are necessary for the automatic mode. These settings apply for all drive units.

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5.33

CST drive system global menu level Fig. 39: Automatic settings

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

local V3

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J Master unit load sharing

Name and/or installation site of the PMC® D unit which is responsible for the load sharing between the drive units.

J Number of drives

Important!

The time window for the startup of the entire system needs to be larger than the corresponding time window for the individual drive units.

Settings for the load sharing between the drive units: J Upper limit for the low load range respectively lower limit for the mid load range.

Specification in percent in reference to the total of the nominal currents for all motors.

J Upper limit for the mid load range respectively lower limit for the heavy load range.

Specification in percent in reference to the total of the nominal currents for all motors.

J Load evaluation tailend drives low load range Specification in percent in reference to the power consumption of the head drive.

5.34

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

Monitoring times for the startup of the entire system: J Time window for startup of the motors The correct startup of the motors needs to be reported by all drive units within this time window (Motor start, page 5.59). If the time window is exceeded, then the startup of the conveyor will be cancelled.

J Time window for prefilling the clutch The correct prefilling of the clutch needs to be reported by all drive units within this time window (Prefilling the clutch, page 5.60). If the time window is exceeded, then the startup of the conveyor will be cancelled.

J Time window for accelerating conveyor The correct acceleration of the conveyor needs to be reported by all drive units within this time window (Conveyor acceleration, page 5.61). Otherwise the startup of the conveyor will be cancelled.

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Number of drive units available for use.

CST drive system global menu level J Load evaluation tailend drives heavy load range

Specification in percent in reference to the power consumption of the dead drive. load sharing

The procedure for load sharing prevents the formation of slack chain both at the bottom of the Headgate driveframe (dangerous due to possible interference with stageloader chain) and at the chain outlet of the Tailgate driveframe. The entire load range of the conveyor is thereby divided up by the specification of two load limits in three subareas. In the lowload range, the power of the tailend drive is raised in comparison with the head drive by a preset factor (load evaluation). In the medium load range, the power of the tailend drive is controlled in such a way that the relation to the power consumption of the head drive corresponds to the load evaluation that is valid for the heavy load range at the boundary of the area of heavier loads. This relation remains in effect throughout the entire heavy load range.

The load sharing for one conveyor with three drive units is presented In Fig. 40 In the low load range, the tailend drive first increases the power given off to the conveyor and thus its own power consumption. It is not until the current of the tailend drive has achieved the value specified by the load evaluation and the idle current of the head drive that the head drive will also become actively integrated into the conveyor drive.

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 40: Load sharing I Imax = Sum(IN(HG,TG))

Limit heavy load range * Imax

Limit low load range *Imax

Itot IHG1+HG2 ITG1

No load current HG1+HG2 Low load range

Heavy load range

Mid load range

AFC load

The control system locks onto the loading of the conveyor from the power consumption of all drive motors. The nominal load is achieved once all motors have taken on their nominal current levels. The specification of the load limits is therefore given in percent in terms of the total of the nominal currents.

The load evaluation determines the current of the tailend drive in comparison with the head drive in terms of the respective nominal current, for which four drive units are taken into account as a general principle.





IHG2 I HG2 I HG1 IHG1 + = Loadevaluation ⋅ + I HINominal IHG2Nominal IHG1Nominal I HG2Nominal

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5.35

CST drive system global menu level The sagging of the chain in the direction of travel directly behind the chain sprocket is referred to as “slack chain”. As a result of their design, drag link conveyors are subject to the danger of a slack chain. This is connected with the segmented construction of such conveyors, among other things, which on the one hand permits accommodation to the changing profile of the working edge during mining while resulting on the other hand in an expansion and/or relaxation of the chain. A chain which has too little tension will however bring with it the danger of the formation of a slack chain on the main drive and/or on the tailend drive. While this will not lead to problems on the tailend drive except in extreme cases, a slack chain on the head drive can lead to blockage and severe chain damage because of the limited space in the bottom portion of the machine frame. It is therefore absolutely necessary that the chain in the bottom race always be kept sufficiently tensioned. The necessary traction force in the bottom race is greater than that in the carrying run, because of the greater friction, particularly in cases of conveyors running either without a load or only with a light one. A greater power consumption must therefore be allocated to the tailend drive in the area of low conveyor loads than the one for the head drive.

Bucyrus DBT Europe GmbH, Lünen 2008

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slack chain

5.36

PMC®-D Drive

CST drive system global menu level Load sharing controller Start me nu

CST Date: Time:

Process overvi ew Motor current overview Drive selectio n Selecting oper ating mode Parameter stat us Automatic sett ings Load sharing ccontroller ontroller

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The setting of the controller for the load sharing between the drive units is carried out through the monitor screen masks displayed in Fig. 41 These settings are not to be modified except by specially trained manufacturer’s service personnel.

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Fig. 41: Load sharing controller

Load sharing controller CST Load distribution between head gates P--amplific. factor: 02,00 I--amplific. factor: 00,25 Load distribution head to tale gate P--amplific. factor: 02,50 I--amplific. factor: 00,25 Load distribution between tailgates P--amplific. factor: 01,00 I--amplific. factor: 01,00

local V3

Minimum slip value: 0,20 Automatic

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Notice!

These settings of the controller are not to be modified except by specially trained manufacturer’s service personnel.

Erroneous settings can lead to considerable damage to the conveyor system.

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5.37

CST drive unit menu level CST drive unit menu level Fig. 42: CST drive unit menu level CST

Start menu Display process data CST Input speed 1497,2 U/min Motor power 0107,0 A Clutchpress 0015.8 bar Actual slip 003,50 % Target slip 003,50 % Outp. speed 0043,3 rpm Sys. Press.

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

0053,0 °C Drive state run

HA1

Date: 12.06.2007 Time: 15:24:56

HA1

Motor/gearbox

CST

HA1

Date: 12.06.2007 Time: 15:24:56

Display process Prozessdaten anzeigen data Process data contd.

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

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

Automatic Automatic

Automatic

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

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

Semiauto settings Target slip: Start delay:

Automatic

Automatic

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

P-65outp.meas.

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

Automatic

External connections

CST

HA1

Date: 12.06.2007 Time: 15:24:56

Chain tensioner PMC-V Connection/ext. device

Automatic

Clutch press. Insp.

CST HA1 Clutch press.set value 00,0 bar Clutch press.act. value 0015.8 bar Input speed 1499.0 rpm Outp. Speed 0044.7 rpm Servo 1 current 000 mA Servo 2 current 000 mA

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HA1

HA1

Bucyrus DBT Europe GmbH, Lünen 2008

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

CST 00,50 % 04,00 s

Clutch press. set value (L) 18,6

Inspection

Process configuration

CST

HA1

external connections

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

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

Automatic

The menu tree illustrated in Fig. 42 shows the monitor screen masks with the help of which the local settings of the selected drive unit can be modified. This menu tree is reached from the global menu level of the CST drive system via the selection of a drive unit.

The name of the drive unit is displayed in the righthand column of the first line on the monitor screen.

The Start menu offers the following selection options: J Display of the most important processing dimensions of the drive unit.

Displaying process data, (page 5.40) J Selection of a menu tree in cascaded arrangement for setting the local control system and control process.

Process configuration, page 5.55).

J Settings for the “Semiautomatic” operating mode.

Semiautomatic Mode settings, page 5.42).

5.38

PMC®-D Drive

CST drive unit menu level J Setting of the clutch pressure in the “Inspection” operating

mode.

Clutch pressure inspection, page 5.43).

J Settings for the integration of serially linked units into the PMC®

Drive Control System.

External connections

J Selection of the in gearbox utilised in the drive unit.

Gearbox

type setting, (page 5.48).

J Setting the characteristic values of a modified gearbox.

User-defined gearbox, (page 5.49).

J Setting the characteristic values of the drive motor utilised.

Motor data, Fig. 59, page 5.50).

Fig. 43: CST drive unit start menu

Start menu

CST

HG1

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Display process data Process data contd.

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

Automatic

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5.39

CST drive unit menu level Displaying process data HG 1

Datum: 3 0.03.2005 Zeit: 1 5:24:56 Display proces s data Process config uration > Semiautomatic settings Clutch pressur e inspectio n External conne ctions > Gearbox type s etting User-defined g earbox Motor data

Autom atic

Motors release d

The current values of the most important processing dimensions of the drive unit are displayed in this overview. The processing dimensions correspond to the dimensions displayed in the overview for all drive units (Process overview, page 5.23). A precise description of the source of the error can be called up in the monitor screen mask shown here can for the measured values marked as being erroneous.

Fig. 44: Displaying process data

Display process data Input speed 1497,2 rpm Motor power 000000 kW Clutchpress 0015,8 bar Actual slip 003,50 % Target slip 003,50 % Outp. speed 0043,3 U/min Sys. press. 0100,0 bar Diff. press. 0000,0 bar Oilpress. --000,8 bar Oil temp. 0053,0 ٛ C Drive state run Automatic

CST

HG1

Motors released

E

CST

An erroneous measured value is shown in the display with dark highlighting. Once the affected processing dimension has been selected and the Enter key has been actuated, a window will be shown in which additional information concerning the source of the error is displayed.

Fig. 45: Sensor information

Display process data CST HG1 Input speed 1497,2 rpm Motor curr. 0107,0 A information Wind. A Sensor 0053,0 A Wind. B 0054,0 A Sensor: 0015,8 Oil press.

Clutchpress bar linebreakage Actual slip 003,50short % circuit Target slip 003,50 % value:U/min --000.8 bar Outp.Measured speed 0043,3 >upper limit lower limit Sys. press. 0100,0 bar non-initialized set to inactive Diff. press. 0000,0 bar Oilpress. --000,8 bar outdated Oil temp.

0053,0 ٛ C Drive run Automatic Motors released The causes for the error message that have been determined for the error message are shown with dark highlighting in this window.

A distinction is made thereby between three causes of errors:

5.40

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

St art menu

CST drive unit menu level J Sensor

Bucyrus DBT Europe GmbH, Lünen 2008

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– Line breakage Interruption in the line connection between the sensor and the measurement input in the PMC® D unit.

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

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

– < Lower limit The measured value fails to meet the lowest permissible value.

– Non-initialised No measured value has yet been determined for the processing dimension since the startup of the PMC® D unit.

This applies in particular to measured values which are recorded by other units and which are transmitted via communication link to the destination unit.

– Set to inactive The inclusion of the measured values in the control system and has been switched off (Process functions on/off, page 5.56) J Communications – Outdated The data are no longer given cyclical updates. The last valid measured value and the last valid sensor information are displayed.

Process data Cont.

J 2. Differential pressure

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

J Temperatures – Hydraulikplatte The oil temperature of the gearbox. The oil lubricates all moving parts in the gearbox, cools the coupling and is used as the control oil for pressure build up in the clutch as well.

The drive unit is switched off when the oil temperature is outside a range of -20°C to 90°C. – Oil sump If there is an oil sump temperature measuring device, the temperature in the oil sump is displayed. (system-specific)

Configure process (see next Chapter page 5.55)

Semiautomatic Mode settings St art menu

CST

HG 1

Datum: 3 0.03.2005 Zeit: 1 5:24:56 Display proces s data Process config uration > Semiautomatic settings Clutch pressur e inspectio n External conne ctions > Gearbox type s etting User-defined g earbox Motor data

Autom atic

An individual startup delay time needs to be set for every drive unit In the “Semiautomatic” operating mode in order to compensate for the “motor on” sequence, which vary from one another as a rule (Semiautomatic, page 5.42). In addition, the load share of the drive unit can be adjusted for a particular total load determined by the loading of the conveyor by means of the specification of a target slip.

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5.41

CST drive unit menu level Fig. 46: Semiautomatic settings

Semiautomatic settings Target slip: 00,50 % Start delay: 04,00 s

Automatic

CST

HG1

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J Target slip

The slip in the clutch of the drive unit set up by the PMC® D unit after the startup of the conveyor.

Clutch pressure inspection Startmenü

CST

HA1

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

5.42

In the Inspection operating mode, the nominal value for the pressure in the clutch of the drive unit can be changed after the motor has been started correctly. Use the arrow keys of the PMC®-V device to change the pressure in two specified increments. The PMC® D device sets the clutch pressure to the specified value while it is being entered.

After the Enter key is actuated, a bar whose length shows the current nominal value is shown. This nominal value can be changed in 1 bar steps with the “up” and “down” keys and in 0.1 bar steps with the “right” and “left” keys. To exit the nominal value entry function, actuate the Enter key again. This hides the bar and sets the nominal value to zero so the clutch is opened again immediately.

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

After correct startup of the drive motor, this amount of time is allowed to pass before the starting procedure for the conveyor is resumed.

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J Start delay

CST drive unit menu level Fig. 47: Clutch pressure inspection

Clutch press. insp.

CST Clutch press.set value 0000.0 bar Clutch press. act. value 0015.8 rpm Input speed 1499.0 rpm Outp. speed 0044.7 rpm Servo 1 current 000 mA Servo 2 current 000 mA

HG1

Clutch press. set value (L) 18,6

Automatic

Motors release

Motor/Gearbox Fig. 48: Motor/Gearbox

HA1

Bucyrus DBT Europe GmbH, Lünen 2008

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Motor/Gearbox CST Datum: 12.06.2007 Zeit: 13:13:55 Gear oil monitoring Motor diagnostics > Gearbox type setting User--defined gearbox Motor data lokal motor current Remote motor current

Automatic

Motor release

The PMC®-D/V system is informed of the settings for the motors and gearboxes used for the current system in the Motor/Gearboxes submenu®. The data of the machines can also be queried. The following menu items can be retrieved: J Gearbox oil monitoring J Motor diagnosis with active and reactive power, temperatures of housing and cooling water flow – Motor windings with current, voltage, temperature – Bearing monitoring with vibration speed and temperature on drive-unit and non-drive-unit sides – Process functions on/off, temperature measurements, vibration measurements of: – Motor winding 1,2 and 3 – XP housing – Bearing drive-unit side and non-drive-unit side – Cooling water feed and drainage – Vibration 1 and 2

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5.43

CST drive unit menu level J Gearbox type settings J User-defined gearboxes J Motor data J Motor current internal J Motor current external

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

Fig. 49: Gear oil monitoring

Gear oil monitoring

CST

HA1

Automatic

5.44

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Prewarning at: > 075 Next Warning in: 90 ˚C: AFC shutdown! Öil level (referenz): 040 cm

Motor release

PMC®-D Drive

CST drive unit menu level Motor diagnostics Fig. 50: Motor diagnostics

Motor diagnostics CST Datum: 12.06.2007 Zeit: 13:13:55

HA1

Motor Motor windings Bearing monitoring Process funktions on/off

Automatic

Motor release

The Motor command opens a window, in which the active and reactive power and the temperatures of the XP housing and cooling water feed are displayed (see Fig. 51, page 5.45).

E

Fig. 51: Motor Bucyrus DBT Europe GmbH, Lünen 2008

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

Automatic

CST 000000 KW 000000 KVAr

HA1

000000 ˚C 000000 ˚C

Motor release

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

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5.45

CST drive unit menu level Fig. 52: Motor windings

Motor diagnostics

CST

HA1

Motor Motor windings Bearing monitoring Process functions on/off

Automatic

Motor release

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

Fig. 53: Bearing monitoring

CST

HA1 Bucyrus DBT Europe GmbH, Lünen 2008

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Motor diagnostics

Motor Motor windings Bearing monitoring Process functions on/off

Automatic

Motor release

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

5.46

PMC®-D Drive

CST drive unit menu level Fig. 54: Process funktions on/off

Motor diagnostics

CST

HA1

Motor Motor windings Bearing monitoring Process functions on/off

Automatic

Motor release

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

Fig. 55: Process function 1

Bucyrus DBT Europe GmbH, Lünen 2008

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Process function 1 CST HA1 Temperature measurement eval.

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

Motor release

Gearbox type setting St art menu

CST

HG 1

Datum: 3 0.03.2005 Zeit: 1 5:24:56 Display proces s data Process config uration > Semiautomatic settings Clutch pressur e inspectio n External conne ctions > Gearbox type s etting User-defined g earbox Motor data Autom atic

It is absolutely imperative for the functioning of the conveyor system that the designation of the gearbox being utilised is specified correctly. Important data are communicated to the control system along with this specification that is absolutely mandatory for errorfree functioning. An incorrect gearbox type setting can cause damage to the conveyor system.

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5.47

CST drive unit menu level Fig. 56: Setting gearbox type

Setting gearbox type CST Gearbox type : P--45 CST 33:1

HG1

Gear ratio: 33,353 No. of teeth input meas. wheel: 054 Trans.ratio motor/meas. wheel: 01,588 No. of teeth outp.meas. wheel: 154 Controller basic settings P--amplif. pressure ratio: 1000 I--amplif. pressure ratio: 0000 P--amplif.slip control: 07,00 I--amplif.slip control: 35,00 Automatic

Motors release

J Gearbox type

The gearbox type used by the control system.

J Gear ratio

Exact gearbox ratio of the gearbox between drive and output with fixed clutch.

Measurement wheel for determining the drive speed.

J Transmission ratio motor/measurement wheel

Precise transmission ratio between drive shaft of the motor or input shaft of the gearbox and the measurement wheel for registering the Motor- respectively input shaft speed.

J Number of teeth in output measurement wheel

Measurement wheel for determining the output speed.

J Basic settings of the controller

Basic settings for the pressure and slip controller implemented in the PMC® D unit are assigned to each gearbox type. The values set in the “Controller pressure/slip” monitor screen mask are based on these specifications (Pressure/slip controller, page 5.65).

Adjustment of the gearbox type is made by selecting from a list that is displayed after the Enter key has been actuated (Fig. 57). All of the gearboxs with CST clutches manufactured by DBT are included in this list. In addition, a userdefined gearbox can also be selected (User-defined gearbox, page 5.49). After the selection has been made of the gearbox to be utilised and after confirmation with the Enter key, this gearbox type is applied by the control system. The data assigned to the gearbox are displayed in the basic mask.

5.48

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

E

J Number of teeth in drive measurement wheel

CST drive unit menu level Fig. 57: Gearbox type selection

Setting gearbox type CST Gearbox type : P--45 CST 33:1

HG1

Gear ratio: KP--45 CST 33,35350:1 P-65 CST 33:1 No. of teeth input meas. wheel: 054 P-65 CST Trans.ratio motor/meas.39:1 wheel: 01,588 P--65 CST wheel: 50:1 No. of teeth outp.meas.

154 KP-65 CST Controller basic settings 33:1 KP--65 CST P--amplif. pressure ratio:39:1 1000 KP-65 CST P--amplif.slip control: 50:107,00 User defined I--amplif.slip control: 35,00

Automatic

Motors release

Notice!

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

Bucyrus DBT Europe GmbH, Lünen 2008

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User-defined gearbox St art menu

CST

HG 1

Datum: 3 0.03.2005 Zeit: 1 5:24:56 Display proces s data Process config uration > Semiautomatic settings Clutch pressur e inspectio n External conne ctions > Gearbox type s etting User-defined g earbox Motor data Autom atic

Motors release d

If a gearbox is modified at the place of operation, e.g. directly on the motor shaft for recording the input speed, then the gearbox data need to be adjusted. The data for the gearbox currently set up can be applied to the user-defined gearbox and modified. After the gearbox has been activated under the menu item “Gearbox type setting”, the new data will be applied by the control system. One user-defined gearbox can be created for each drive unit.

Fig. 58: User-defined gearbox

User--defined gearbox CST HG1 Current gearbox type: P--45 CST 33:1 DApplying data: No User--defined gearbox Gera ratio: 00,000 No. of teeth input meas. wheel: 000 Trans.ratio motor/meas. wheel: 00,000 No. of teeth output meas wheel: 000 Controller basic settings: P--amplif. press. ratio: 0000 I--amplif. press. ratio: 0000 P--amplif. slip control: 00,00 I--amplif. slip control: 00,00 Automatic

Motors released

J Current gearbox type

The gearbox type selected for the drive unit.

J Applying data The data of the currently selected gearbox types are adopted for the user-defined gearbox and displayed on the monitor screen by selecting “Yes”. These data can be modified afterwards.

For a description of the gearbox data, see “Gearbox type setting” page 5.48.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.49

CST drive unit menu level Notice!

The data of the gearbox must be entered exactly, with all the numerals after the decimal point. It is not permitted to alter the basic setting of the controller except in consultation with the manufacturer. Data entered incorrectly or nonexactly can lead to considerable damage to the conveyor system.

Motor data St art menu

CST

HG 1

Datum: 3 0.03.2005 Zeit: 1 5:24:56 Display proces s data Process config uration > Semiautomatic settings Clutch pressur e inspectio n External conne ctions > Gearbox type s etting User-defined g earbox Motor data

Autom atic

Motors release d

tandem motor

The control system requires the exact data of the drive motor in order to perform various functions. Included among these functions are such things the ability to recognise an motor start, an motor overload or a blockade of the conveyor.

The special structure of tandem motors is taken into account by the fact that the individual windings of this kind of a machine can be actively set. The calculation of the overall current of the drive motor is influenced by this specification (Motor current overview, page 5.27) and thus, for example, load sharing between the drive units.

Two separate stator windings are mounted in sequence in an motor housing with a tandem motor. The output shaft correspondingly bears two rotor windings, which means that the total drive output generated by all of the individual machines is available to their common shaft.

Motor data Synchronous speed: Nominal speed: Nominal current:

CST 1500 U/min 1480 U/min 272 A

Automatic

Motors released

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 59: Motor data

HG1

J Synchronous speed

The synchronous speed of the drive motor.

J Nominal speed

The nominal speed of the drive motor J Winding nominal current

The nominal current of the drive motor. The nominal current of a winding is to be entered when a tandem motor is utilised.

5.50

PMC®-D Drive

CST drive unit menu level Local motor current Fig. 60: Local motorcurrent

Local motor current Input signal: .

Offset: ...

Max.value: ....

Motor current:

Automatic

CST

HA1

0064 A

Motor release

J Input signal J Offset J Maximal value Bucyrus DBT Europe GmbH, Lünen 2008

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J Motor current

Remote motor current Fig. 61: Remmote motor current

Motor current Intern Meassuring device: .

Connection: .

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

Automatic

CST

HA1

0065 A

Motor release

J Capturing device J Port J Input signal J Offset J Maximal value J Motor current

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.51

CST drive unit menu level External Connections Fig. 62: External Connections

External connections CST Date: 12.06.2007 Time: 12:13:45

HA1

Chain tensiioner > Connection/ext. device

Automatic

Motor release

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

–

Diagnosis data transmission Display of current settings

–

Interface setting Settings of the current interface

–

Log settings

–

Activate settings Activating the changed settings

J Connection/ext. devices

Here the system is informed of which PMC®-D connection the chain tensioner is connected to.

5.52

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

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

E

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

CST drive unit menu level Chain tensioner Fig. 63: Chain tensioner

Chain tensioner

CST

HA1

Date: 12.04.2007 Time: 12:13:45 Show process data Communikation >

Automatic

Motor release

Show process data Fig. 64: Show process data

Bucyrus DBT Europe GmbH, Lünen 2008

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Show process data Chain tensioner Timeout:

CST 0017

HA1

Clamping cylinder pressure: 00000 bar Clamping cylinder extens.: 0000 mm

Automatic

Motor release

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

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.53

CST drive unit menu level Communication The “Communication” submenu provides the following settings and displays: Fig. 65: Communication

Communication ext.

CST Date: 12.04.2007 Time: 12:13:45

HA1

Diagnostics data transmission Interface settings Protocoll settings Activate settings

Automatic

Motor release

J Data transmission diagnosis E

Display of the values set for data transmission Bucyrus DBT Europe GmbH, Lünen 2008

J Interface setting

Options for changing the interface J Log settings

Settings for data log J Activate settings

5.54

PMC®-D Drive

Process configuration Process configuration Fig. 66: CST drive unit menu level, process configuration CST

Process configuration

HA1

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

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

Automatic

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

Motor startup recogn.

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

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

CST

HA1

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

Coil test: .

Max. coil current. ....

Monitoring Motor overload Conveyor blockage Chain tensioner

Active Active Off

Automatik

Automatic

Automatic Automatik

Bucyrus DBT Europe GmbH, Lünen 2008

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Pressure/slip control.

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

CST

HA1

01,00 . . .

01,00 01,00

CST

Conveyor shutdown

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

HA1

40.0 bar/s 02.0 s 10.0 bar 00.5 s

Accelerate conveyor Time window:

CST 20,0 s

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

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

HA1

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

Automatic

Automatic

Automatic

Overload settings Motor overload Time window: Motor power:

CST

HA1

01.5 s 1.80*Nominal power

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

Process functions on/off Process functions (contd.)

All of the functions which make possible the configuration of the control system and control process for the selected drive unit are summarised in the menu tree shown in Fig. 66 The following selection options are available after the selection of the menu item “Process configuration” in the Start menu on the “CST drive unit” menu level has been made: J Activation and deactivation of process functions.

Process functions on/off, page 5.56).

J Settings with the help of which the startup of the drive motor is

recognised.

Motor start, page 5.59.

J Specifications for the prefilling of the clutch.

Prefilling the

clutch, page 5.60.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.55

Process configuration J Settings for the acceleration stage of the conveyor.

Conveyor acceleration, page 5.61.

J Settings for the normal shutdown and for the emergency

switchoffs of the conveyor.

Conveyor shutdown, page 5.63.

J Control parameter settings for controlling the clutch pressure

and the clutch slip.

Pressure/slip controller, page 5.65.

Fig. 67: Process configuration

Process configuration

CST

HG1

Date: 12.04.2007 Zeit: 12:13:45 Process function on/off Process functions (contd.)

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

Some functions of the control system and control process can be activated and/or deactivated with the aid of the entry masks illustrated in Fig. 68 . A distinction is made thereby in the mask between the assessment of measurement values, internal monitoring functions and the monitoring of auxiliary functions which do not belong directly to the control system process, such as the automatic tensioning of the chain.

Fig. 68: Process functions on/off

Process functions 1 CST Measured value assessment Input speed Aktiv Cooling oil pressure Aktiv System pressure Aktiv Differential pressure Aktiv Öil temperature Aus Motor current winding A Aktiv Motor current winding B Aktiv Monitoring Motor overload Aktiv Conveyor blockage Aktiv chain tensioner Aus Automatic

HA1

Motors released

J Measured value assessment

One actively switched measured value is included in the control system and control process. As a result, errors in the measured value assessment and the exceeding/failure to meet limit values leads to the immediate shutdown of the conveyor. To prevent this, the assessment of several measured values can be switched off by the user in order to allow the conveyor

5.56

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

E

Automatic

Process configuration system to continue to be used in emergency operation. The control system and control process ignores in such cases the measured values that have been captured. The display of the measured values on the monitor screen of the PMC® V unit is not influenced by the shutdown of the evaluation.

The following functions are switched off by the deactivation of the monitoring: – Input speed The software continues to set the input speed to the specified nominal speed of the drive motor. As a result, none of the monitoring functions that are linked to the input speed are possible any longer. The starting of the motors can no longer be recognised except by means of the motor current (Motor start, page 5.59). Similarly, blockades of the conveyor are no longer to be recognised by drops in motor speed (Blockade conveyor, Conveyor blockage page 5.64).

E

– Cooling oil pressure The clutch can no longer be protected against damage arising from insufficient pressure levels and the insufficient flow rates for cooling oil connected with them. The cooling oil flows between the coatings of the drive side and the output side of the clutch. The oil is used to remove the heat that arises and to maintain the thin film of oil that separates the clutch linings from one another and protects them against being destroyed.

Bucyrus DBT Europe GmbH, Lünen 2008

– System pressure When the clutch is being prefilled or when there is a breakaway of the conveyor, a system pressure that is too low can lead to a situation where the desired pressure values are not achieved and the startup procedure is cancelled.

– Differential pressure The permeability of the filter in the hydraulic circuit to the compression chamber of the clutch is monitored by means of the measurement of the differential pressure. When the clutch is being prefilled or when there is a breakaway of the conveyor, a clogged filter can lead to a situation where the desired pressure values are not achieved and the startup procedure is cancelled.

– Oil temperature The oil temperature is measured in the oil sump of the gearbox. The oil serves the dual purpose of both lubricating all movable parts in the gearbox and cooling the clutch, in addition to being used as an operating oil for the pressure buildup in the clutch. A temperature that is too high can cause permanent damage to the oil, which in turn can lead to damage to the gearbox bearings and to the clutch.

– Motor current The load sharing between the drive units of the conveyor system takes place in the Automatic operating mode by means of the level of the respective motor current. It is for that reason that automatic operation is no longer possible without the measurement of the motor current. Similarly, overloading of the drive machine can also not be recognised.

The startup recognition of the motor takes place solely via the recording of the speed.

The assessment of a current measurement can be switched off when a tandem motor is used without causing limitations to the functioning of the system to arise.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.57

Process configuration

Fig. 69: Process funkcions (contd.)

Process functions 2 Monitoring PVC coil 1 .

PVC coil 2 .

Synchronize motor release .

2nd Differential pressure .

Automatic

CST

HA1

Motor release

Motor startup recognition The PMC® D units receive no direct information concerning the desire of the operator to start the conveyor. The units recognise this indirectly, through the startup of the motors. For this recognition to take place, the power consumption of the motor must for a short time be at least 0.2 times its nominal current and the motor speed must achieve a minimum value of 600 speed. This motor start recognition is a permanent fixture of the software and not be modified by the user.

Important!

A drive unit cannot be put into operation if motor current as well as the drive speed cannot be recorded by the PMC® D unit to which these tasks have been allocated.

5.58

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

– Motor overload The drive motor is no longer protected from an overload by power consumption monitoring.

– AFC Blockage Neither of the two methods for recognising blockages (monitoring of the input speed and recognition of a precipitous drop in output shaft speed) are any longer in effect. The protection of the chain has thus been eliminated.

– Chain tensioner The pretensioning of the chain is monitored by the PMC® D unit to which the clamping fixture is connected. The monitoring can be switched off in order to prevent the conveyor from being shutdown in the absence of the clamping fixture. The error that is registered in the CST system is merely given the status of a warning. These warnings continue to be displayed on the PMC® V units, but are ignored by the control system Nevertheless, the time window representing the very latest point at which that the tensioning procedure needs to have been completed, is taken into account in the startup stage of the conveyor. This waiting time is inserted into both the “Automatic” and “Semiautomatic” operating modes before the startup may be resumed with the prefilling of the clutches.

PMC® D units to which no clamping fixture has been connected ignore the selected setting.

E

J Monitoring

Process configuration The startup of the conveyor cannot be resumed until the drive motor startup process has been completely finished. In order to recognise that this has taken place, a time window can be defined in the entry mask illustrated in Fig. 54during which the speed for the duration of the monitoring period must remain stable below the specified limit value. If the speed collapses, e.g. because of a startriangle switchover, then the monitoring period will be restarted.

If the motor fails to achieve the desired speed during the time window, then the startup procedure for the conveyor will be cancelled with an error message.

Fig. 70: Motor start Motor speed

Motor speed steady

Motor speed steady

Bucyrus DBT Europe GmbH, Lünen 2008

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600 rpm

Motor startup successfull

minimum required motor speed

Synchronous speed

Motor startup time window Fig. 71: Motor start recognition

Motor start recognition CST HG1 Time window: 05,0 s Motor speed: > 0,95 * Synchronous speed -- stable for: 01,0 s

Automatic

Motors release

J Time window

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

J Motor speed

The limit value above which the motor speed must remain during the monitoring period.

J Speed stable for (monitoring period)

If the speed of the motor is above the prescribed limit value during this monitoring period, then it is assumed that there was a correct motor startup.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.59

Process configuration Prefilling the clutch After the drive motor has started up, the pressure chamber of the clutch is prefilled up to the specified pressure level. This pressure needs to be selected in such a way that a conveyor that is not loaded will not start moving. As a result of the prefilling, the entirety of the electronics and hydraulics necessary for the control system will be checked before the actual startup. In addition, the clutch will be set to an operating point at which the mechanical tolerances are balanced.

The prefilling process is complete if, within the time window, the clutch pressure becomes stable for the specified time within the tolerance range of the nominal pressure specification. If this goal cannot be achieved, then the conveyor startup is aborted with an error message.

Fig. 72: Prefilling the CST clutch

CST 02.0 10.0 01.0 02.0

HG1

Automatic

Motors release

J Time window

The maximum time period in which the correct prefilling of the clutch is checked. The time window is started after each correct startup of the motor.

J Set pressure

The clutch pressure that is to be achieved by means of prefilling.

J Pressure stable for

This monitoring period is started when the minimum pressure (required pressure - tolerance) has been reached. If the clutch pressure remains stable within the tolerance range of the nominal pressure specification during this time period, then the prefilling process is regarded as having been completed. If the clutch pressure lies briefly outside of the tolerance range, then the monitoring period will be restarted after the tolerance range has again been reached.

J Tolerance

The maximum deviation of the clutch pressure from the specified nominal value. The prefilling pressure continues to be considered correct when it is within this tolerance range. An exact setting of the nominal value is excluded in principle, because a P-controller is utilised for setting the clutch pressure.

5.60

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

E

Clutch prefill Timewindow: 02,0 s Set pressure: 10,0 bar -- stable for: 01,0 s Tolerance (+,--): 02,0 bar

Process configuration Conveyor acceleration After the prefilling of the clutch pressure chamber, an attempt is made to accelerate the conveyor. The pressure in the clutch is raised for this purpose, first with a prescribed pressure increase rate at both the main and the tailend drives. If a defined pressure value is achieved on the head drive, then the pressure increase will be interrupted there briefly. The pressure increase on the tailend drive is resumed in order to give it the opportunity of introducing power into the chain before the head drive does and thus to tension the chain in the bottom race. The pressure increase on the head drive is resumed after the delay time has run out. If the conveyor is set into motion within the time window and the slip achieves the prescribed nominal value, then the acceleration process is successfully completed. If not, then an error message is outputted and the startup of the conveyor is cancelled.

Fig. 73: Prefilling the clutch, acceleration of the conveyor clutch pressure

Bucyrus DBT Europe GmbH, Lünen 2008

E

Motor startup finished pressure steady?

Kupplung vorgefüllt

max. pressure

pressure delay prefill pressure

pressure ramp tailgate

pressure ramp headgate

Headgate delay t AFC acceleration time window

prefill time window

Fig. 74: Conveyor acceleration

Conveyor acceleration Time window: 20,0 s Press. incr. rate: 04,0 bar HG delay: 02,0 s -- with pressure: 12,0 bar Target slip: 100,0 %

Automatic

Doc. no.: 1999 001 009 BA 00

VRVT / 01

CST 20.0 04.0 02.0 12.0 100.0

HG1

Motors release

5.61

Process configuration

J Time window

The maximum time period for attempting to set the conveyor in motion and for reaching the prescribed nominal slip in the clutch. The time window is started after the correct prefilling of the pressure chamber of the clutch.

J Pressure increase rate

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

J Head Drive (HG) delay

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

J Head Drive delay under pressure

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

J Target slip

The attainment of this value within the time window marks the successful acceleration of the conveyor.

Important!

The settings required for the accelerations of the conveyor are not independent of one another. If a low pressure increase rate or a long delay is set without adjusting the time window accordingly, then it is possible that the desired maximum pressure in the clutch will never be achieved.

Even though these values can be set individually for each drive unit, it makes sense to set the same pressure increase rate in all drive units.

Conveyor shutdown Four different events can bring the conveyor to stop. First of all because of normal shutdown, which is triggered by switching off the drive motors or switching over to the “Stop” operating mode; secondly because of three different kinds of emergency shutdowns.

These are triggered when an overload motor current is recognised, when the motor speed within an observation time period is less than a prescribed limit value or when the rate of change of the output speed exceeds a prescribed maximum value. Fig. 58 shows the input mask in which these four shutdown events can be configured.

5.62

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

The maximum pressure that is to be set in the pressure chamber of the clutch. If this value is reached, then the pressure buildup is stopped and the pressure kept constant at this value.

E

J Maximum pressure

Process configuration Fig. 75: Conveyor shutdown

Conveyor shutdown Normal switchoff Press. red. rate: 40,0 bar/ s -- max. ramp time: 02.0 s Resid. press.: 10,0 bar -- hold for: 00.5 s

Automatic

CST

HG1

Motors release

J Normal switchoff

Bucyrus DBT Europe GmbH, Lünen 2008

E

The decreasing input speed caused by the shutdown of the motor is first interpreted by the PMC® D unit as a blockade, because the speed falls below the limit value specified in the time window there. It is not until a subsequent inspection of the motor current reveals that there is no measurable current present a normal switchoff is assumed. The clutch pressure is lowered at the specified pressure reduction rate to the residual pressure level and maintained there for approximately one second. Afterwards the clutch is opened completely. The enablement of the startup of the motors is retracted. The chain is relaxed slowly by this controlled lowering of the clutch pressure, which in turn prevents the chain from recoiling.

– Pressure reduction rate The speed with which the clutch pressure is reduced until the residual pressure level is reached.

– Residual pressure The clutch pressure that is maintained for approximately one second before the clutch is completely opened.

If the output speed collapses between the recording of two tooth flanks of the measurement wheel by more than the prescribed limit value, then this event will be interpreted as a blockade of the conveyor. The enablement of the motors is retracted and the clutch is opened as quickly as possible.

– Modification of output speed…

This value specifies the maximum permissible modification of the output speed between two tooth flanks of the measurement wheel with reference to the nominal speed of the output.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.63

Process configuration Overload settings Fig. 76: Overload settings

Overload settings Motor overload Time window: Motor power:

CST

HA1

01.5 s 1.80 *Nominal power

Conveyor blockage --Time window: 0.15 s Motor speed: 0.90 *Synchron.speed --modification of outp. speed between 2 M.wheel teeth: > 0.08 * Nominal speed

Automatic

Motor release

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

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

J Conveyor blockage

If the motor speed drops below the limit value within the entire time frame and a subsequent motor current measurement still shows a current flow, the conveyor is blocked. The motor enable is revoked and the clutch is opened as quickly as possible.

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

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

If the output speed falls by more than the specified limit value between capturing two measuring wheel edges, this event is interpreted as a conveyor blockage. The motor enable is revoked and the clutch is opened as quickly as possible.

– Output speed change…

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

5.64

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

If a motor that exceeds the specified limit value is being measured for the duration of the time frame, the motor enable is revoked and the clutch is opened as quickly as possible.

E

J Motor overload

Process configuration Pressure/slip controller The controller for the pressure and slip setting in the CST clutch can be influenced in its behaviour by the configuration of amplification factors. When making the entry, it needs to be taken into account that of these factors are in reference to the amplifications that are permanently allocated to each gearbox (Gearbox type setting, page 5.48). The measurement signals necessary for determining the actual values are smoothed with the help of adjustable filters. The corresponding filter coefficients could also be entered in this monitor screen mask.

Fig. 77: Pressure/slip controller

CST

HG1

Bucyrus DBT Europe GmbH, Lünen 2008

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Pressure/slip controller Pressure control P--amplific. factor: 01,00 Slip control P--amplific. factor: 01,00 I--amplific. factor: 01,00 Filter coefficients Clutch pressure: 0,154 Input speed: 0,154 Output speed: 0,154

Automatic

Motors release

Notice!

The settings for the controller and the adjustment of the filter coefficients may not be altered except by specially trained manufacturer’s service personnel. Erroneous settings can lead to considerable damage to the conveyor system.

Doc. no.: 1999 001 009 BA 00

VRVT / 01

5.65

Bucyrus DBT Europe GmbH, Lünen 2008

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Process configuration

5.66

PMC®-D Drive

6

Technical data

Main dimensions

Technical data Main dimensions

Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 78: Housing dimensions PMC®-V

Fig. 79: Housing dimensions PMC®-G

Doc. no.: 1999 001 009 BA 00

VRVT / 01

6.3

Main dimensions

Bucyrus DBT Europe GmbH, Lünen 2008

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Fig. 80: Housing dimensions PMC®-D

Fig. 81: Rear tapped bores (all equipment)

6.4

PMC®-D Drive

Pin assignment Pin assignment Pin assignment PMC®-V and PMC®-G Fig. 82: SKK24 socket PMC®-V and PMC®-G

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Socket

Pin 1

Pin 2

Pin 3

Pin 4

St1

Optocoupler Anode

Relay contact 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

St11

Options

Options

Options

Options

Profibus: a (internal)

Profibus: b (internal)

St12

Options

Option

Socket

**

St5

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

Doc. no.: 1999 001 009 BA 00

VRVT / 01

6.5

Pin assignment Fig. 83: SKK24 socket PMC®-D

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)

St10

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

St11

+12V (C)

St8 St9

St12

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

GND

+8,2V

GND input GND

+8,2V

GND

+8,2V

GND

+8,2V

GND

Profibus: b (internal)

Fig. 84: Anschlussbelegung der 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

6.6

+12V input

GND GND GND

GND input

PMC®-D Drive

E

St7

GND

Bucyrus DBT Europe GmbH, Lünen 2008

St6

GND

Pin assignment St8

St10

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

St13

not used

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

St11

+12V (C)

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

+8,2V

GND

+8,2V

GND

+8,2V

GND

+8,2V

GND

Profibus: b (internal) CM sensor -

GND

Pin assignment sensor/actuator connection box Bucyrus DBT Europe GmbH, Lünen 2008

E

Fig. 85: Pin sockets sensor/actuator connection box

Doc. no.: 1999 001 009 BA 00

VRVT / 01

6.7

Pin assignment Tab. 2: Pin assignment sensor/actuator connection box Buchse

Pin1

Pin2

Pin3

Pin4

Actuator measurement quantity

A

Coil 1 A(+)

Coil 1 B(-)

Coil 2 C(+)

Coil 2 D(-)

Servo valve

B

+12V (D)

Measurement input 1

+8,2V

GND

Output speed

C

+12V (D)

Measurement input 2

+8,2V

GND

Input speed

D

+12V (D)

Measurement input 3

+8,2V

GND

Differential pressure oil filter

E

+12V (D)

Measurement input 4

+8,2V

GND

Cooling oil pressure

F

+12V (D)

Measurement input 5

+8,2V

GND

System pressure

G

+12V (D)

Measurement input 6

+8,2V

GND

H

+12V (D)

Measurement input 7

+8,2V

GND

J

+12V (D)

Measurement input A

+8,2V

Analogue GND

K

+12V (D)

Measurement input B

+8,2V

Analogue GND

Oil temperature hydraulic plate

Temperature PT100 +

Temperature PT100

Oil temperature coupling

M

Temperature PT100 +

Temperature PT100

Oil temperature

N

Temperature PT100 +

Temperature PT100

Oil sump Oil level

O

+12V (D)

Measurement input 8

+8,2V

GND

P

+12V (D)

Measurement input 9

+8,2V

GND

R

+12V (D)

Measurement input 10

+8,2V

GND

Electrical specifications of the connections J Voltage outputs

The equipment provides four 12 V (A - D) supply voltages and one 8.2 V supply voltage for supplying external devices and sensors. Each output current is restricted electronically and can be individually set using the software. The 12 V (D) supply voltage on PMC®-V equipment is not guided to the exterior. The total current of all supply voltages may not exceed the following values:

6.8

– Total 12 V current:

IExt_12V = 1,000 mA

– Total 8.2 V current:

IExt_8.2V = 100 mA

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

L

E

Clutch pressure

Pin assignment J Power supply unit connection (St7)

Input voltage: Current consumption (U0 = 12 V):

10,6 V = U0 = 13.2 V

– PMC-V / **A = 410 mA + IExt_12V = 1000 mA + IExt_8,2V = 100 mA – PMC-V / ABA = 430 mA + IExt_12V = 1000 mA + IExt_8,2V = 100 mA – PMC-D / *A = 300 mA + IExt_12V = 1000 mA + IExt_8,2V = 100 mA – PMC-D / CA = 370 mA + IExt_12V = 250 mA ((Sensor/actuator CST gearbox)) + IExt_8,2V = 18 mA ((Sensor/actuator CST gearbox)) + IExt_12V = 680 mA + IExt_8,2V = 82 mA J Optocoupler

E

The input is galvanically separated from the voltage supply of the equipment by an optocoupler. A protective circuit pre-vents the optocoupler from being destroyed by excessive or incorrectly connected input voltage.

Bucyrus DBT Europe GmbH, Lünen 2008

– Maximum input voltage: Ue = 13,2 V – Minimum input current: Ie min = 12 mA – Voltage drop (Ie = 12 mA): Ue = 2,1 V + Ie · 102 Ω – Switching frequency: fmax = 100 kHz J Relais contact

– Type of contact:

NO

– Switching voltage: Umax = 30 V – Current intensity on contact: Imax = 0,5 A – Contact rating: Pmax = 10 W J Serial interface

– Transmitter: The transmitter functions as a constant source of current for an input resistance of receiver Ri < 230 Ω. The current from Io = 18 mA equals logical “0”. When input resistance is larger, logical “0” is assigned to voltage of Uo = 4.2 V. The input resistance should not exceed 4.7 kΩ.

– Uo = 4,2 V – Io = 18 mA – Receiver: The input resistance (Ri) and the corresponding trigger levels for detecting a logical “1” (ULmax) and a logical “0” (UHmin) can be switched using the software.

– Ri = 4,7 kΩ “1”: Ue < ULmax = 1,50 V “0”: Ue > UHmin = 2,50 V – Ri = 75 Ω

Doc. no.: 1999 001 009 BA 00

VRVT / 01

6.9

Pin assignment “1”: Ue < ULmax = 0,45 V “0”: Ue > UHmin = 0,75 V J Gate input

The input signal can be linked to the GND potential of the equipment using a transistor. A current monitor protects the transistor from being destroyed by interrupting the electrical circuit after approx. 25 ms when current I = 2.3 A. J Profibus (internal)

The connections for the Profibus network used by the PMC® Drive Control System for internal communication. The con-nections of both SKK24 sockets designated by “a” or “b” are connected to each other internally. This is why the network lines can be connected to either of the two sockets.

Connec-tions “a” and “b” can also be interchanged within the network without adversely affecting the range of functions.

J Profibus (external)

The measurement input can be adjusted by setting various input resistances at test signal Ue. Whether switching, voltage or current signals are recorded can also be distinguished in this way. The software is used to make all settings.

– Proximity sensor (Namur) The sensors must be connected to the 8.2 V voltage sup-ply to be correctly evaluated. The descending edge, the transition from logical “1” to logical “0”, is evaluated.

– Input resistance:

Ri = 1 kΩ

logical “1”

Ue = 1,7 V

logical “0”

Ue = 1,5 V

Measurement frequency f = 5 kHz – Voltage measurement Measurement area:

Ue = 0 … 10 V

Input resistance: Ri = 100 kΩ, 1 kΩ – Current measurement Measurement area: Ie = 0 … 20 mA Input resistance: Ri = 310 Ω – Frequency measurement The descending edge of the test signal, the transition from logical “1” to logical “0”, is evaluated.

Input resistance: Ri = 100 kO, 1 kΩ logical “1” Ue = 1,7 V logical “0” Ue = 1,5 V

6.10

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

J Measurement input

E

The connections for an external Profibus network. The con-nections of both SKK24 sockets designated by “a” or “b” are connected to each other internally. This is why the network lines can be connected to either of the two sockets.

Connec-tions “a” and “b” can also be interchanged within the network without adversely affecting the range of functions.

Pin assignment Measurement frequency f = 5 kHz J Measurement input g A, B

These measurement inputs are designed for accurate voltage measurement and are only available on PMC®-D equipment with option C (second to last character in the type designation listed on the equipment).

– Measurement area: Ue = 0 … 5 V – Input resistance: Ri = 33 kΩ J Temperature

This input is designed for directly connecting a PT100 resis-tance thermometer. The resistor is loaded with a test current 1 mA.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Measurement area: -25°C ≥ ϑ ≥ 175°C

Doc. no.: 1999 001 009 BA 00

VRVT / 01

6.11

E Bucyrus DBT Europe GmbH, Lünen 2008

Pin assignment

6.12

PMC®-D Drive

7

For your information

Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.bucyrus.com).

Service addresses Europe Germany

Bucyrus DBT Europe GmbH Industriestraße 1 D-44534 Lünen Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: info@de.bucyrus.com

Great Britain

Bucyrus UK Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

E

Hallam Fields Road Ilkeston, Derbyshire DE7 4BS UK Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: info@gb.bucyrus.com Bucyrus UK Ltd. 2 Renshaw Place Holytown Motherwell, ML1 4UF North Lanarkshire Scotland Tel: Fax: Poland

+44 / 16 98 83 5 - 000 +44 / 16 98 83 5 - 038

Bucyrus Polska Sp. z.o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: Fax:

Russia

+48 / 32 31 70 - 500 +48 / 32 31 70 - 509

Bucyrus DBT Europe GmbH Office Moskau Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: viktor.sobolev@ru.bucyrus.com

Doc. no.: 1999 001 009 BA 00

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7.3

Our service OOO Bucyrus Service ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: evgeniya.belousova@ru.bucyrus.com

America USA

Bucyrus America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@us.bucyrus.com Bucyrus America Inc. 4041 Wurno Road Pulaski, VA 24301 +1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889 Bucyrus DBT Europe GmbH, Lünen 2008

E

Tel: Fax:

Australia Australia

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

+61 / 24 91 4 - 7144 +61 / 24 91 4 - 7169

Bucyrus Australia Underground Pty. Ltd. 14 Commercial Avenue Paget M.M.C Box 5182 Mackay, Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

Africa South Africa

Bucyrus Africa Underground Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: hetta.fuller@za.bucyrus.com

7.4

PMC®-D Drive

Our service Asia China

Bucyrus DBT Europe GmbH Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@cn.bucyrus.com Bucyrus (Langfang) Mining Machinery Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@cn.bucyrus.com Bucyrus (Tangshan) Mining Machinery Co. Ltd.

Bucyrus DBT Europe GmbH, Lünen 2008

E

No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@cn.bucyrus.com

Doc. no.: 1999 001 009 BA 00

VRVT / 01

7.5

Standards and guidelines Standards and guidelines Referenced national standards and guidelines Tab. 3: Referenced national standards and guidelines, extract

Designation

Title

DIN 2000 DIN 6789 DIN 20043 DIN 24320 DIN 24343 DIN 24346 DIN 51558-1 DIN 51575

Quality of drinking water Documentation System Plug Connectors for Hydraulics Fire-resistant hydraulic fluids Maintenance- and Inspections list for Hydraulic Systems Hydraulic Systems - DesignPrinciples Determination of the acid number Determination of sulphate ash Tensioning force, tightening torques and surface pressure for bolts T-head-bolts Lubricating greases and solid lubricants Non metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

EWN 6003 1)

1985-02 1985-02 1992-06 1985-02 2005-03

Referenced european standards and guidelines Tab. 4: Referenced european standards and guidelines, extract

Designation

Date of issue

Title

Directive of the European Parliament and the Council Directive 98/37/EWG on the approximation of the laws of the member states relating to machinery Directive of the European Parliament and the Council on the approximation of the laws of the member states Directive 94/9/EG concerning equipment and protective systems intended for use in potentially explosive atmospheres DIN EN ISO 12100-1 Safety of Machinery DIN EN ISO 12100-2 Safety of Machinery Nonelectrical equipment for potentially explosive atmosDIN EN 13463-1 pheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface Preparation of instructions DIN EN 62079 - Structuring, content and presentation Petroleum product and bituminous materials DIN ISO 3733 - Determination of water - Distillation method Underground mining machines - Equipment and compoDIN EN 1710 nents intended for use in potentiallyexplosive atmospheres in mines Mobile extraction machines on the face - Safety requireDIN EN 1552 ments for shearer loaders and plough systems -

1998-06-22

1994-03-23 2004-04 2004-04 2002-04 2004-12 2000-08 2001-11 2003-02 2006-01 2003-09

1) EWN = standard

7.6

PMC®-D Drive

Bucyrus DBT Europe GmbH, Lünen 2008

E

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

Date of issue 2000-10 1990-09 2003-09 1986-08 1982-02 1984-12 1979-07 1984-11