P.O. BOX 234, ROCKY GAP, VA

Transcription

1 BC-PRO O& &T Man nual With Rem mote Station Mine Moni itoring Manual Part Number September 22, 2009 AMERICAN MINE RESEARCH, INC P.O. BOX 234, ROCKY GAP, VA

2 PH FAX TABLE OF CONTENTS TITLE PAGE Table of Content.2 Introduction..3 General..3 Operation Details 4 Equipment & Instrumentation.5 Equipment Operation.5 Fault Logic...6 Operator Interface.7 Main Screen 7 Roller Screens 8 Dust Control Screen.8 Input Screen..9 Analog Screens.10 System Screen 11 Roller Configure Screens.12 System Configure Screen 13 Analog Configure Screens. 14 Speed Sensor Mounting Troubleshooting..17 General..17 Communication..18 PanelView...19 PLC 19 Block Diagrams 21 2

3 General Operation The BC PRO BELT CONTROL PRO serves as a belt starter control unit and a MC 4000 monitoring system remote. The belt starter function combines many of the belt head inputs and outputs in one unit to simplify installation and troubleshooting. When the BELT CONTROL PRO is connected to the monitoring system communication line, all information about the status of the belt head that is available at the BELT CONTROL PRO is sent to the monitor system master station as well. The front panel mounted PanelView display provides the user interface to gather the status and to perform the configuration of the BELT CONTROL PRO. In general, the interface allows the user to calibrate and configure the BELT CONTROL PRO to match the belt head system installation. It also allows the user to determine whether the belt is running or stopped, is it sequence, slip, pull cord, etc? The BELT CONTROL PRO operates from 120 VAC and has a re chargeable battery back up for the atmosphere monitoring system. The atmosphere monitoring system will operate for 8 hours during power off conditions to provide information to the monitor system master station and power to sensors connected to it. Inductive type proximity sensors provide speed inputs to perform belt sequence, under speed, true slip, and dust suppression at the belt head. Because the BELT CONTROL PRO is microprocessor based, very quick and accurate calculations are made to determine that the belt head system is performing within the configured limits. All speeds sensor inputs are used to generate belt system roller speeds and theses are used to configure the belt head system. These roller speeds may be viewed on the PanelView display from the main screen. The BELT CONTROL PRO is used as to monitor system remote, belt roller system speeds are also sent to the monitor system master station. The true slip function, when compared to the normal belt head slip, is far superior because it is very precise and it protects the belt during startup. The normal belt head slip function is nothing more than under speed switch. It is very inaccurate and it is bypassed during belt startup. True slip is performed by monitoring the belt drive roller speed and comparing it to the belt roller speed. The ratio of the belt speed to drive roller speed if fixed and has been calculated by the BELT MASTER during configuration of the unit. Even during startup, if the present belt speed is less than the calculated belt speed value as determined from the drive roller speed and the preset percentage slip, the belt is slipping and the belt is stopped. Belt under speed is determined by using the drive roller speed sensor input instead of the belt roller speed sensor input. The BELT CONTROL PRO uses the sequence speed sensor input to monitor the receiving belt speed and stops the dumping belt if the receiving belt is not moving fast enough. A speed sensor is also mounted to the dumping belt trough roller to determine that the belt is loaded with material. This speed sensor input is used by the BELT CONTROL PRO to operate the dust suppression system. Variation from perfect belt head operation is allowed and the deviation percentages for belt slip, drive roller under speed, sequence belt under speed, and dust suppression roller speed is entered via the front PanelView display. 3

4 Operation Details The conventional belt starter control switches located on the BELT CONTROL PRO front panel provide the primary means for controlling the belt. The locking type emergency STOP switch interrupts the belt start control circuit to insure the belt will stop when it is pushed. The BELT CONTROL PRO also monitors the STOP switch to de energize the belt start relay, terminate the present control sequence, and initialize the BELT CONTROL PRO for the next start sequence. When the BELT CONTROL PRO stops the belt for any reason the belt may not restarted until the STOP time has expired. This is necessary to allow fluid coupling drives to drain. When the AUTO/OFF/MANUAL switch is placed to the OFF position, the same events occur as described above for the STOP switch. Note: During operation of the BELT CONTROL PRO, the BELT DRIVE STATUS MENU may be used to display the belt drive status at reason for belt stoppage. When the AUTO/OFF/MANUAL switch is placed to the AUTO position, the BELT CONTROL PRO checks the sequence belt for proper speed and begins the PRESTART period. During the PRESTART period, the BELT CONTROL PRO activates the audible/ visual alarm to warn personnel that the belt will start at the end of the PRESTART period. At the end of the PRESTART period, the audible/visual alarm is deactivated. Next begins the START period of the belt start sequence if all other start conditions are satisfied. During the START period, the BELT CONTROL PRO begins monitoring the belt for true slip. At the end of the start period (or as soon as the drive roller has reached normal running speed), the BELT CONTROL PRO begins monitoring the drive roller for under speed. When the AUTO/OFF/ MANUAL switch is placed to the MANUAL position, the BELT MASTER ignores the sequence belt condition and the belt is ready to begin the PRESTART period of the belt start sequence, if all other start conditions are satisfied. At the end of the PRESTART period of the belt start sequence, if all other start conditions are satisfied the same as in AUTO, audible/visual alarm is de activated, the belt starts, and the BELT MASTER begins monitoring the belt for true slip. The belt is still monitored for true slip and under speed as described above for the AUTO switch position. Note: The length of the prestart, start periods and stop periods are user defined and are a part of the BELT MASTER configuration. Note: If the sequence speed sensor does read as required for AUTO! In MANUAL, the belt will stop to prevent false operation of belt system conditions. The JOG button (See Figure 8) is a PanelView touch button that will start the belt after the PRESTART period by ignoring the sequence belt condition and all other status inputs except the remote and deluge switches. The belt is still monitored for true slip and under speed as described above for the MANUAL switch position. Note: The JOG button must be pushed continuously to perform the JOG function and JOG belt function can be performed only with the AUTO/OFF/MANUAL switch in the MANUAL position. 4

5 Equipment and Instrumentation Motor 1 Motor 2 Speed Sensor 1 Drive Roller RPM Speed Speed Sensor 2 Belt Roller RPM Speed Speed Sensor 3 Sequence Roller RPM Speed Speed Sensor 4 Dust Roller RPM Speed Equipment Operation The BC PRO uses Allen Bradley MicroLogix 1100 PLC and AMR LS 3040 speed sensors. Belt speed is monitored by two speed sensors (Drive Roller and Belt Roller). The speed sensors are used to detect a slip condition when the belt is starting or under load. The Sequence Roller speed sensor monitors belt speed of the next sequencing belt. If the next sequencing belt stops the BC PRO will stop the belt drive and prevent a GOB or boney pile on the sequencing belt that would cause the sequencing belt not to start. The Dust Roller RPM speed sensor is part of the dust suppression system of the belt drive. If the belt is under load and the Dust Roller speed sensor is reading the preset RPM, then the BC PRO will set an output relay that will start a set of water sprayers. The BC PRO has 18 digital inputs. Four are reserved for internal monitoring of Auto, Manual, CB PRO faults, and belt status open/closed. Two are for monitoring Remote Line and Deluge. Four are for belt rollers (Drive, Belt, Sequence, & Dust). Two are spill switches (Head & Tail). 1 is Fluid Coupling Over Temperature, Belt Misalignment, and GOB switch. Lastly are three unassigned or configurable channels. The BC PRO has four analog inputs. All four are unassigned or configurable channels. The BC PRO has six digital outputs. All six are reserved for internal CB PRO reset, Horn, Dust suppression, Belt status and Start commands 1 & 2. 5

6 Fault Logic The BC PRO is programmed with fault logic so that if any of the faults listed below occur, both CB PROs will shut off. The fault must be reset to restart the belt again: CB PRO faults. Deluge opened. GOB switch tripped. Belt Misalignment switch tripped. Other faults after being cleared will restart belt: Remote switch open Fluid Coupling Over Temperature Any of the three (3) spare digital channels, if enabled. 6

7 Operator Interface (PanelView550) The BC PRO uses an Allen Brady PanelView550 Touch Screen operator interface. This interface gives the operator the capability to reset faults and calibrate speed rollers. This section describes how to use the PanelView The Main screen shows common details for belt status (See Figure 1) Figure 1 Main Screen 1. Roller details use graphical needle gauges to show RPMs of roller and a status area for belt OK or LOW. 2. Reset button is for resetting faults that can be reset by BC PRO (other faults would be CB PRO or Ground Faults) 3. Quick Reference Buttons are used to GoTo a general detail screen for the Digital or Analog channels. 4. Belt Status shows the current status of the belts. 5. Selected Screen indicates the screen that will be displayed if the GoTo screen button is touched. 6. Scroll Up & Down Buttons allow you to scroll through all of the root screens. 7

8 The Roller Screens show the time delay and calibration set points (See Figure 2) Figure 2 Drive Roller Details The Dust Control Screen shows the time on/off delay, calibration set points, and a button for turning the controls On or Off (See Figure 3) Figure 3 Dust Control Details 1. Time On Delay shows the time that the dust suppression system will be delayed before it will turn On and the Time Off Delay shows the delay timee that the system will continue to run after the signal to shut off is received. 8

9 2. Control Button allows you to turn on or shut off the dust suppression system. The Inputs Screen shows digital status of the PLC inputs (See Figure 4) Figure 4 PLC Input Details 1. CB Open shows Open or Closed 2. Spill Tail shows Ok or Faulted 3. CB Fault shows Ok or Faulted 4. Deluge shows Ok or Fire 5. Remote showss Ok or Open 9

10 The Analog Screens show the details of the analog channel (1 4) and the channels can be custom named (See Figure 5) Figure 5 Analog Screen 1. The Calibration Set Point is the scaled high set pointt of the channel. 2. The Alarm Type is set to Alarm Only or Kill Belt Enabled. This allows you to shut off the belts if a high limit alarm is critical to belt operation. 3. The High Alarm Set Point & Alarming On or Off shows the high limit set point. This limit is activated by the Alarming On or Alarming Off function. 4. The Low Alarm Set Point & Alarming On or Off shows the low limit set point. This limit is activated by the Alarming On or Alarming Off function. 5. The Time is located in the middle of the high and low Alarming On/Off display and is the time delay for both set points before the alarms or kill belt takes affect. 10

11 The System Screen is for manual jogging the belt, accessing system configuration screens, factory setting screen, and allows you to clean the screen (See Figure 6) Figure 6 System Screen 1. The Jog Button is used to manually jog the belt: The selector switch on the front of the BC PRhave jogged the must be set to Manual. Touch and continue to touchh the Jog Button until you belt to the desired location. 2. The Configuration Screen Button takes you to the Allen Bradley default PanelView system configuration screen. This allows you to change factory settings such as IP address, etc (Seee PanelView 550 Manual). 3. The Clean Screen Button opens a blank screen with only one small button thatt will return you to the System Screen. This allows you to clean the screen without touching unwanted buttons. 4. The System Screen has a Selected Screen option thatt is not found on other screens (below Status). By scrolling through the select screens with the up and down arrows you will find the new screen called Main CNFG. If selected, this will take you to the main details configuration screen of the BC PRO. You can then edit (enable, disable, etc.) the inputs and outputs. Upon selecting the Main CNFG, you will be prompted to enter the password (9281). This will display the Main CNFG screen. From thiss screen you will be able to go to all digital and analog channel input or output screens. Note that the Selected Screens has changed to reflect the configuration screens, for example; Inputs is now Inputs CNFG. To return to regular operation screens selectt the Main RTN screen. 11

12 The Roller Configure screens allow you to change the percent deadband, time delay, enable/disable, and calibrate the roller (Seee Figure 7). Figure 7 Roller Configure 1. The Percent Deadband Button is used to change the deadband percentage is the precent which the roller speed is considered out of range and the time delay starts counting. Percent Deadband can be set from 1 to 50 percent. Example of percent deadband: If set to 5% and the roller is calibrated to 100 RPM, the processor will nott see a problem unless the RPM is below 95 RPM because 5% of 100 RPM is 95 RPM. 2. The Calibration Button is used to calibrate the speedd sensor at maximum RPM. To calibrate, operate the belt and once the belt is up to max RPM and touch the Calibration Button. The value for the max speed is recorded and automatically scaled for percent deadband. 3. The Time Delay Button is used to set the time delay before a faultt condition is detected. This value can be set from 1 to 120 seconds. 4. The Enable Button is used to enable or disable the roller. 12

13 The System Configure screen is used to set the horn time, hold time, and motor start type (See Figure 8). Figure 8 System Configure The Hold Time Button is used to adjust the holding time after the last motor starter starts till the BC For the standard BC PRO to CB PRO application, the motor starts must be set to momentary (Moment) start. Other starter systems may need to be setup for maintained close (Latch) start. PRO starts examining the rollers, digital, analog, etc. for faults before shutting off the belts. The Motor 1 & 2 Buttons are used to set the type of motor starts that are required to start the motors. The Horn Time Button is used to set the amount of time thee horn will sound before the belts will start. The time can be set between 5 and 360 seconds. 13

14 The Analog Configuration Screens allow you to change the analog channel name and units, alarm time delay, alarm only or kill belt, set alarm high or low limits, and calibrate the analog channel. These screens also have a help button for calibration problems (See Figure 9). Figure 9 Analog Configuration Screen 14

15 Speed Sensor Mounting It is recommended that a welded key stock target (See Figure 10) be added to the rollers to be monitored. Targets consisting of chisel notches are not recommended because they do not present a well defined target for the speed sensor. The drawing below shows a bottom roller with a single target being used to monitor belt speed and sequence. However, a single target may be added to one of the outside rollers of the top roller assembly with the same results. It is important that the belt always be in contact with the roller when monitoring belt speed and sequence. Select a roller near the end of the receiving belt to monitor sequencee and a roller near the endd of the dumping belt to monitor belt speed. Monitoring the drive roller is accomplished by adding a single target to the side of the drive roller. The dust suppression sensor target should be addedd to the top roller assembly trough roller. The belt should be in contact with the roller when the belt is loaded and the belt should move away from the roller when the belt is empty. Figure 10 Key Stock Mounting Details The speed sensors can be mounted to the roller structures using the AMR supplied angle iron and tie should be perpendicular to the roller surface and spaced 1/ /8 to 1/4 inch from the roller target. Insure that the sensor does not come in contact with the belt or wraps. Weld the angle iron to the structure such that the sensor does not vibrate. The sensor end roller. 15

16 Figure 11 Top & Bottom Roller Assembly 16

17 Troubleshooting BC PRO 1) Insure that 120 VAC is supplied to the Remote Unit TB3-1&2, the AC Power ON switch is ON and the AC lamp is ON. 2) Insure that the voltage output measured across both batteries is greater than 22 VDC and the DC Power ON switch is ON 3) Verify that the DC Power ON lamp turns ON when the Power ON Reset switch is momentarily pressed. If the DC Power ON lamp comes ON and then turns OFF when the Power ON Reset switch is released, place the Kill Enable/Disable switch to Disable and repeat step 4 again. 4) If the DC Power ON lamp stays ON, the Master Station has commanded the Remote power OFF and placing the Kill switch to Disable bypasses the Master Station command to Kill power to the Remote. Be sure to place the Kill Enable/Disable switch to Enable once the Master Station has commanded the Remote power to ON. 5) After the DC Power ON lamp comes ON and stays ON, verify the following conditions: a) The SixNet Media Converter power ON LED is ON; b) The voltage measured across both batteries is either increasing (which means the batteries are being charged) or the battery voltage is greater than 27 VDC (which means the batteries are fully charged). This confirms the Power Supply PC board battery changing circuitry is functional. c) Measure 24 VDC between pins 1 and 2 of J4 on the Gateway PC board. This confirms the Power Supply PC board 24 VDC power supply circuitry is functional. d) The Gateway Ethernet Interface Module Activity LED should blink every 10 seconds even though there may not be an Ethernet connection. e) Confirm the presence of 24 VDC at pins 1 and 2 of each Gateway PC board OUT port connectors. If the voltage is not present at all of the port connectors, remove the plug from that port to eliminate the possibility of a cable short and measure the port pins again. NOTE: The Gateway PC board will remove power from the OUT port if the DS1 (POWER) switch is ON and the current draw is greater than 400 milliamps. If the voltage is still not available at the port, either the power has been commanded OFF from the Master Station or the port power control IC has failed. In the event the Gateway does remove 24 VDC from the output port, it will notify the Master Station. 17

18 6) Sixnet Media Converter Confirm 24 VDC is connected to P1 and (-) of the Sixnet module power connector and the Power LED is ON. Confirm that the Outby Tx/Rx and the Inby Tx/Rx fiber optic cables are connected to the module fiber ports. If there is ethernet activity on the fiber cable, the port ACT LEDs should blink. Confirm that one of the Sixnet Media Converter module RJ45 ethernet ports is connected to the Ethernet Gateway PC board. The activity LED associated with that RJ45 port should blink in unison with the fiber port activity LED. 7) Ethernet Gateway PCBoard Insure that the Gateway PC board is installed properly according to the Installation (Section 3) of this manual. Insure that the Gateway PC board has 24 VDC at connector J4-1 and J4-2. Confirm the presence of 24 VDC at pins 1 and 2 of each Gateway PC board OUT port connectors. If the voltage is not present at all of the port connectors, remove the plug from that port to eliminate the possibility of a cable short and measure the port pins again. NOTE: The Gateway PC board will remove power from the OUT port if the DS1 (POWER) switch is ON and the current draw is greater than 400 milliamperes. If the voltage is still not available at the port, either the power has been commanded OFF from the Master Station or the port power control IC has failed. In the event the Gateway does remove 24 VDC from the output port, it will notify the Master Station. Verify the Ethernet cable is connected, the processor LNK (green LED) is ON and the processor ACT (yellow LED) is blinking. When the Gateway receives Modbus TCP/IP requests it sends a request to the three output ports causing the TX LEDs to blink. If a sensor or remote connected to the Output Port responds to the request for data, the corresponding RX LED will blink and the TXIN LED will blink. If a sensor or remote fails to respond to request, move the port output cable to another port to test if the port has failed. The Gateway PC board monitors each OUT port COMM (+) and COMM ( ) line for abnormal (wires shorted to each other or wire/s shorted to 24 VDC or to GND) conditions. If a short condition exits, the Gateway PC board will disable communication to that port until the short condition is removed. The Gateway PC board will notify the Master Station that communications with the port has been disabled. If a sensor or remote fails to respond to request, move the port output cable to another port. 18

19 8) Using the Master Station If a particular branch of the monitoring system is experiencing communications problems, use the Analog, Digital and Control data returned from the Gateway to determine the problem source. Observe the Control Channel Status and insure the Port is enabled and Power is ON. Use the Digital Channel Status to observe the Port Short and Port Open states. Use the Digital Channels Status to confirm AC Power ON and Battery Status. Use the Analog Channels Data to verify the Power Supply voltage is between 15 VDC and 28 VDC. Use the Analog Channels Data to verify the Port Bias voltage is between 0.15 VDC and 0.45 VDC. Use the Analog Channels Data to verify the Port Level voltage is greater than 0.5 VDC. Use the Analog Channels Data to verify the Port Draw current is consistent with the devices being powered from the port. Use the Analog Channels Data to verify the Port Errors is not excessive. 9) PanelView 550 Terminal does not power up. o Improper connection to power source. o Incorrect input voltage level. No communications with MicroLogix. o Communications (COMM) fault. o PLC is not in run mode. No communications with PLC but COMM LED is active. o PanelView is trying to communicate with a PLC at a different address. 10) MicroLogix PLC Controller Status LED Indicators o Power Off = No input power, or power error condition Green = Power On o Run Off = Not executing the user program Green = Executing the user program o Fault Off = No fault detected Red Flashing = Application fault detected Red = Controller hardware faulted o Force Off = No forces installed (normal) Amber = Forces installed 19

20 11) Expansion I/O Modules Module Status LED State o On = Proper Operation o Off = Module Fault Cycle power. If condition persists, replace the module. More detail about troubleshooting the BC-PRO can be found in the Master Manual (Part # ) 20

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