Cat Bucyrus 30M Continuous Miner OPERATING MANUAL 312494 - PDF DOWNLOAD

OPERATING MANUAL Bucyrus America, Inc. 30M Continuous Miner Doc. No.: 312494 Serial No.:02-07-08

BUCYRUS AMERICA, INC. 2045 WEST PIKE STREET HOUSTON, PA 15342-1010

DOC.No. 312494-BA

Phone (724) 743-1200 FAX (724) 743-1201

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Bucyrus America, Inc. 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 without the written consent of Bucyrus America, Inc. Bucyrus America, Inc. declines all liability for direct or indirect consequences of all printing / typing errors.

This publication can be revised without prior notice.

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INDEX 1

ABOUT THIS MANUAL ..................................................................................................................................5 ABOUT THIS MANUAL ................................................................................................................................................8 What is the purpose of this operating manual?....................................................................................................9

2

YOUR SAFETY ...............................................................................................................................................11

OPERATING CONDITIONS ..................................................................................................................................14 PRODUCT TRANSPORT: .................................................................................................................................14 CABLE PROTECTION ......................................................................................................................................14 SAFETY INSTRUCTIONS ............................................................................................................................................15 STORAGE AND TRANSPORT ......................................................................................................................................18 HYDRAULICS ..........................................................................................................................................................19

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STORAGE AND TRANSPORT .....................................................................................................................21

STORAGE AND TRANSPORT ..............................................................................................................................22 STORAGE .................................................................................................................................................................23 TRANSPORT ............................................................................................................................................................24

4

INSTALLATION .............................................................................................................................................27

5

OPERATION ...................................................................................................................................................35 Tram Controls ....................................................................................................................................................54

MACHINE LIGHTING............................................................................................................................................69 METHANE MONITOR READOUT UNIT............................................................................................................69

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TECHNICAL DATA .......................................................................................................................................73

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FOR YOUR INFORMATION........................................................................................................................77

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PREFACE This manual is intended to provide basic operating information on Bucyrus 30M class continuous miners. Additional information can be obtained by referring to the Parts Book supplied with your machine, or by contacting your local Bucyrus America, Inc. representative. The illustrations, descriptions and procedures contained in this manual pertained to the machine as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. Bucyrus America, Inc. reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.

The machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies. At the completion of manufacturing, this machine was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this machine, without the consent of Bucyrus America, Inc. and these agencies, may void these approvals and render the machine illegal or dangerous for use.

Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.

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About this manual This chapter contains important information, which will simplify your work.

In addition, it contains information about the structure of the manual and the characters and symbols used.

Before starting work right operating manual

If you use an operating manual, which has not been written for your 30M Continuous Miner type, you will endanger yourself and others. Ensure that the data on the 30M Continuous Miner corresponds to that in the operating manual.

type

This operating manual belongs to: BUCYRUS AMERICA, INC. 30M CONTINUOUS MINER Serial No.: 02-07-08 The operating manual is to be used only for this 30M CONTINUOUS MINER.

new operating manual

An operating manual for the 30M Continuous Miner must always be available at the place of operation.

Send for a new manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for all persons working with or on the 30M Continuous Miner.

All personnel working at the face or in the working section must have read this operating manual.

This includes persons: ¾ responsible for transport, ¾ developing the raise, ¾ carrying out erection / disassembly, ¾ operating the 30M Continuous Miner, ¾ eliminating faults, ¾ carrying out daily routine work at the face or in the entry, ¾ carrying out maintenance operations, ¾ carrying out repairs. supervisory persons: ¾ instructing and/or ¾ supervising the above activities.

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What is the purpose of this operating manual? efficiency

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the 30M Continuous Miner.

Read this operating manual completely and carefully. In particular, pay attention to the safety instructions.

Note the appearance and meaning of the safety and warning symbols.

service

If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For Your Information”.

safety

Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. Observe the information and follow the instructions contained in this operating manual.

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual. Pay particular attention to these points.

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.

WARNING! These points contain information on dangerous situations. Possible consequences are: Very serious injury or even death.

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

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

Possible consequences are: Damage to the 30M Continuous Miner or damage in the immediate 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.

¾ Items in lists are marked with bullets.

-- Points in sub-lists are marked with a long dash at the start of the line.

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

Follow these instructions step-by-step.

They will help you carry out your work faster and, more importantly, safer.

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Your Safety

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Your Safety

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Your Safety

Your safety This chapter contains important information for your safety.

Please read this chapter particularly carefully. The safety instructions and behavioral rules are intended to protect you from any dangerous situations and to help you carry out your work as safely as possible. state-of-the-art

The 30M Continuous Miner has been manufactured to the state-ofthe-art and in accordance with recognized safety engineering 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, which could impair the safety of the 30M Continuous Miner. All modifications and changes must be approved by Bucyrus America, Inc. In addition to this operating manual, please be sure to observe the relevant regulations and accident prevention ordinance applicable at your mine.

Observe the safety and accident prevention regulations: ¾ of the mine, ¾ of the Mine’s State and Federal Inspectors and ¾ of the mining supervisory authorities

further operating manuals Please read the operating manual, of the components required for

operation, carefully and thoroughly. Clarify any questions before starting work.

Personnel Erection and repair As a fundamental rule - erection and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Erection and repair work on: ¾ safety components (pressure relief valves, extinguishers, etc.) ¾ the electronics (controllers, etc.) ¾ the hydraulics may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine. .

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Your Safety

Operating conditions Intended use The 30M Continuous Miner, or the Miner, as it is commonly called, provides the means of: ¾ ¾ ¾ ¾

Extracting coal, Loading it onto a belt Loading it into a shuttle car Dumping it onto the ground and loading it later

PRODUCT TRANSPORT: The chain/flights are driven by a sprocket meshing with the chain at the front end of the miner to ensure efficient transportation of the product. The sprocket is integral with the drive’s gear box.

To keep the correct tension on the chain, an essential part of successful operation, a Chain Tensioning Device is fitted to the tail end of the miner. This is a hydraulic chain tensioning system.

Applications not expressly listed as intended uses are unauthorized uses and must not be carried out with the Miner.

Bucyrus America, Inc. accepts no liability for injury or damage resulting from any such unauthorized use.

CABLE PROTECTION High voltage cables and high-pressure water hoses run along the helper’s side of the Miner and require protection form moving equipment, the Miner and the general mining environment.

Cables and hoses must be kept safe from the environment, run without kinking and are visible for random inspection.

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Your Safety

Unauthorized use

Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

Always wear your personal protective equipment.

protective equipment

This also means wearing ear protectors, as the noise emissions from the Miner is in excess of 85 dB(A).

Inform your colleagues: ¾ Where exactly you are working. ¾ What work you are carrying out. ¾ How long you expect the work to take.

condition

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

information signs

Observe the signs on the Miner.

EMERGENCY-STOP

Press the EMERGENCY STOP palm button immediately in the event of faults or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be immediately taken.

Secure to prevent restarting Secure the Miner to prevent restarting:

¾ Maintenance operations ¾ Inspection operations ¾ Repair operations block working area

Isolate your working.

moving parts

Never allow parts of your body to come between parts, which could move, such as e.g.: ¾ ¾ ¾ ¾ ¾

Chains Flights Chain sprockets Cutting Head Loading Pan

.

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Your Safety

GENERAL SAFETY PRECAUTIONS Safety procedures for operating a Bucyrus 30M continuous miner begin with understanding that the smallest incident of carelessness may result in serious injury or death to you and your co-workers.

The miner should never be regarded as harmless simply because the power is not on. It should always be treated with high respect as a dangerous piece of machinery. It is essential that you become completely familiar with your miner, its controls and where they are located – especially all emergency controls.

While operating the miner, you must be aware of what you and your machine are doing at all times. You must know where your co-workers are, what other operations are going on nearby, and the mining and geological conditions in which you are working.

When you are finished operating the miner, stop it and disconnect the power before starting any maintenance or adjustments. NEVER TAKE SHORTCUTS WHICH MAY RESULT IN SAFETY RISKS.

WARNING

AFTER TURNING OFF POWER TO THE MINER, NEVER WALK AWAY AND LEAVE THE TRANSMITTER TURNED ON. FAILURE TO TURN THE TRANSMITTER OFF COULD RESULT IN AN ACCIDENT CAUSING SERIOUS INJURY OR LOSS OF LIFE.

Observe proper safety procedures at all times. You must develop good safety habits which will be vital to your own safety and that of your coworkers. Remember, the life you protect will likely be your own.

GENERAL PRECAUTIONS Permissible Electrical Enclosures.

These compartments have been designed, constructed and assembled by the manufacturer in compliance with the standards established for certified explosion-proof enclosures. The WARNING permissibility of these enclosures should be confirmed after service has been performed and at routine intervals thereafter. Failure to maintain components to OEM specifications could create a hazardous condition resulting in fire or explosion. Serious injury or death could occur if permissibility is not maintained.

WARNING

Before starting this machine or operating any controls, make certain that you have read this Operator’s Manual and have been trained in the proper operation of this machine, and are thoroughly familiar with all controls.

Failure to do so could result in an accident causing serious injury or death to you or other personnel.

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Your Safety

WARNING

Do not make any type of temporary trailing cable connections on this machine. Severe injury or death from electrocution will occur if contact is made with the high voltage power supply.

Be certain that all electrical power to this machine has been disconnected before performing any adjustment, repair or parts replacement procedures. To “DISCONNECT” means to tag, lock out and physically WARNING remove the trailing cable from the power center by the person performing the maintenance work. Any other interpretation of the term “DISCONNECT” is not accurate as used in this manual. This equipment is electrically powered.

Failure to comply with this warning could result in serious injury or death.

WARNING

WARNING

WARNING

WARNING

WARNING

Never work in the electrical enclosures, or perform any service or maintenance work, unless electrical power to the machine has been physically disconnected. Never use Emergency Stops as a means of disconnecting electrical power. Emergency Stops are not intended to serve as electrical disconnects. Some merely interrupt the motor control circuits and do not remove line power to the machine. Failure to comply could result in an accident causing serious injury or death to you or other personnel.

Do not alter, remove or bypass any emergency stop device. Failure to so could result in serious injury or death since the proper operation of these devices may be critical in emergency situations.

Shut off the machine and relieve the hydraulic pressure before disconnecting any hydraulic line or fitting. Hydraulic lines are under high pressure. Failure to relieve this pressure could result in serious injury from hot pressurized oil.

Never work under any part of this machine that is supported by a hydraulic cylinder, regardless of built-in safety features such as load-lock valve. Install enough blocking to support the machine component safely or lower that component to the ground. Failure to do so could result in serious injury or death from crushing if the component falls.

Perform welding or burning operations only in a safe and approved area, and in accordance with existing laws and safe practice. Failure to do so could cause a fire or explosion resulting in severe injury or death.

Never use fingers to check the alignment of pin bores. Pinched, broken or severed fingers could result if components shift while doing so.

WARNING

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

Do not store materials or parts in the travel route or in your working area.

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

Ensure that the transport locks are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

striking device

Attach lifting equipment only to the lifting points provided. Pay attention to the different load limits of the lifting points. Observe the instructions on the transport sheets.

Use lifting equipment, which is in good condition and is designed for the loads to be handled.

Use only transport belts for lifting round parts. Never use chains or steel ropes.

Do not damage the treated surfaces of shafts, sealing surfaces, etc.

Erection and commissioning

Inclined storage

If stored at an angle, secure all individual parts using chains or stell ropes to ensure the parts are secure.

environmental acceptability When working with oils, greases and other chemical substances,

observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc., which are soiled with oil, grease or other chemical substances in an environmentally safe manner.

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Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluids can penetrate the skin and cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics may be allowed to work on the hydraulic system.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: ¾ The hoses are not pinched or trapped. ¾ The hoses have no bubbles or blisters. ¾ The hoses or the outer sheathes of the hoses are not abnormally rigid or hard. ¾ The outer sheath of the hoses are not damaged. ¾ The connectors are securely inserted into the sockets. ¾ The connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

If hydraulic hose couplers are difficult to disconnect, or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressuring the system again. permissible tubing

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn Orings.

Replace hydraulic hoses only with hoses of the same or of a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses, which are more than 2 years old, even if they have no visible signs of damage.

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Storage

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STORAGE and TRANSPORT

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Storage

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Storage

Storage and Transport This chapter contains important information on the correct storage and transport of the Miner. Observance of the instructions and tips will increase the service life and availability of the Miner. You will also be able to carry out the transport work quicker and safer.

Paying careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage Storage of the Equipment Components coated with temporary corrosion inhibitor are protected for around six months. Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 60 F (15 C) to 78 F (25 C).

Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components must not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

During long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It must be stored in a dry, well ventilated room.

After a storage period of approx. two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus America, Inc. Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.

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Storage IMPORTANT! ENSURE WHEN STORING THAT ANY NEW SUPPLIES ARE STORED SEPARATELY FROM EXISTING STOCKS IN SUCH A WAY THAT ON REMOVAL, OLD STOCKS ARE TAKEN FIRST. protection against frost damage for oil cooling

Before transporting or storing gearboxes with oil cooler at ambient temperatures below freezing, the oil cooler must be flushed with antifreeze.

Transport Load Units; Dimensions and Weights Observe the transport sheets for the various transport units. They contain information on: ¾ ¾ ¾ ¾

Dimensions Weight Lifting points Center of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and erection.

WARNING!

USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR TRANSPORTING LOADS. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.

Before Transport temperatures below freezing

Transport of equipment at temperatures between –21° C and 40°C is only permissible when certain measures were taken, to meet these conditions, at the design and manufacturing stages.

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at low temperatures.

During transport of this equipment, measures must be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum of 25 kph for truck transport.

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Storage Antifreeze Measures for Oil Cooler

Before transporting, the oil cooler must be flushed with anti-freeze.

electrical and electronic

Electrical and electronic components must be removed for over seas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

components

If the electrical cables remain in the equipment, they must be carefully protected against transport damage and soiling of the connections.

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Storage

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Installation

Hydraulics handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluids can penetrate the skin and cause serious infections.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics may be allowed to work on the hydraulic system.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: ¾ The hoses are not pinched or trapped. ¾ The hoses have no bubbles or blisters. ¾ The hoses or the outer sheathes of the hoses are not abnormally rigid or hard. ¾ The outer sheath of the hoses are not damaged. ¾ The connectors are securely inserted into the sockets. ¾ The connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

If hydraulic hose couplers are difficult to disconnect, or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressuring the system again. permissible tubing

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn Orings.

Replace hydraulic hoses only with hoses of the same or of a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses, which are more than 2 years old, even if they have no visible signs of damage.

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Installation

Start-Up Miner Operator Qualifications The miner operator must be completely familiar with all features and controls of this machine in order to operate it safely and productively.

This requires OEM training as available, a thorough study of this manual, and a visual inspection of the actual machine.

The following sections of this manual outline essential procedures and cautions for starting the miner prior to mining operations.

Pre-Shift Inspection

WARNING

•

• •

• •

•

•

ALL PRE-SHIFT INSPECTIONS AND MAINTENANCE WORK MUST BE DONE UNDER PROPERLY SUPPORTED ROOF in accordance with Federal, State and Local safety laws and safety rules dictated by the mining company.

Check the operational report from the prior shift to note any problems or discrepancies with the miner. If such problems still exist, notify the shift or maintenance foreman and determine a plan of action for correcting the problems. In any case, do not start up the machine if problems exist which may cause safety hazards or danger.

Use the wash-down hose to clean off the machine as much as practical.

Conduct a visual walk-around inspection of the miner to look for signs of leaks in hydraulic cylinders and hoses, water hoses and gear boxes, frayed electrical cables, damaged or plugged water sprays, or other visible problems.

Check the dust collector filter screen and clean it with the washdown hose as necessary.

Ensure that all machine covers are in place and properly secured.

Ensure that maintenance personnel have checked all lubrication points on the miner for proper oil levels in gear boxes and adequate greasing at grease fittings in accordance with OEM recommended practice.

Check the full length of the trailing cable for damage. Ensure that the trailing cable is properly suspended across intersections, and that the trailing cable clamp at the miner is secure.

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Installation Miner Start-Up

C CAUTION

C

Do not start up and operate the miner unless all daily checks and scheduled maintenance have been completed. Do not start up the miner until any noted operational faults have been corrected.

Only trained and authorized operators, or trainees under a supervising instructor, should operate this miner.

CAUTION

WARNING

• •

MAKE SURE, BY A VISUAL CHECK AND A SHOUTED WARNING, THAT ALL PERSONNEL ARE COMPLETELY CLEAR OF THE MINER BEFORE START-UP. Also check that any loose material, tools, oil cans or other objects are cleared from the area before starting the machine.

Energize the main circuit breaker at the power center to enable power up to the miner.

Turn the following manual circuit breaker handles, located on the control case and illustrated in Figure 2-1.2, to the ON position:

o MAIN CIRCUIT BREAKER (1000VAC power to the miner) o CONTROL CIRCUIT BREAKER (120VAC power to machine controls) o TRACTION MOTOR BREAKER (1000VAC power to the tram transformer and the dust collector fan motor) For the following activities, the operator can refer to the radio transmitter control and operation details given in Section 2-2.

• •

Turn on the radio transmitter by pressing the green TX PWR ON pushbutton.

Turn on the pump motor by first pressing the green ENABLE pushbutton, then moving the PUMP toggle switch to the START position. Listen for any abnormal sounds from the pump, which could indicate oil starvation of the pump.

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Installation

WARNING

IF ANY OTHER MACHINE FUNCTION OPERATES AT THIS TIME, PUSH THE MACHINE STOP BUTTON TO DE-ENERGIZE THE MINER IMMEDIATELY; A FAULT IS PRESENT IN THE SYSTEM.

Before further operations, the operator should do another visual walkaround inspection to check for hydraulic leaks and proper machine lighting.

NOTICE

•

Turn on the machine lights by pressing the green LIGHTS pushbutton.

WARNING

• • • • •

•

STAND WELL CLEAR OF THE MINER DURING OPERATION AND MOVEMENT OF THE VARIOUS MACHINE COMPONENTS, AND ENSURE THAT OTHER PERSONNEL ARE ALSO AWAY FROM THE MINER.

Using the CUTTING HEAD RAISE/LOWER toggle switch, raise and lower the cutting head and check for proper operation.

Using the GATHERING HEAD RAISE/FLOAT toggle switch, raise and lower the gathering head and check for proper operation.

Using the CONVEYOR RAISE/LOWER toggle switch, raise and lower the conveyor and check for proper operation.

Using the CONV SWING LEFT/RIGHT toggle switch, swing the discharge conveyor right and left to full travel and check for smooth operation.

Start the conveyor and CLAs by pressing the green ENABLE pushbutton, then moving the CONVEYOR START toggle switch to the START position. Check the conveyor chain and CLA’s for proper operation.

Check the conveyor chain for proper tension by swinging the discharge conveyor right or left to its full 45o position and observing the chain behavior at the gathering head footshaft. A loose chain will tend to rise up off the deck immediately after disengaging from the footshaft sprocket.

• Before tramming the miner, observe these cautions: • • •

Ensure that all machine lights are on.

Check both the trailing cable and water hose for sufficient slack and freedom.

Lower the cutting head halfway and raise the gathering head off the mine bottom.

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Installation

WARNING

NOTICE

• •

PRIOR TO TRAMMING THE MACHINE, MAKE SURE BY A VISUAL CHECK AND A SHOUTED WARNING, THAT OTHER PERSONNEL ARE CLEAR OF THE MINER AND THAT THEY ARE AWARE THAT IT WILL BE TRAMMED.

Remember that the TRAM ENABLE signal is only valid for 2 seconds. If the operator delays tramming the miner for more than 2 seconds, the TRAM ENABLE switch must again be used. The TRAM ENABLE switch takes the place of the traditional “dead man” foot pedal on miners equipped with an operator’s pit.

Select a tram speed by pressing the green TRAM HIGH or the red TRAM LOW pushbutton.

The miner is trammed by moving the TRAM ENABLE toggle switch either forward or backward, then using the TRAM joystick controls to move the miner.

WARNING

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AFTER TURNING OFF POWER TO THE MINER, NEVER WALK AWAY AND LEAVE THE TRANSMITTER TURNED ON. FAILURE TOP TURN THE TRANSMITTER OFF COULD RESULT IN AN ACCIDENT CAUSING SERIOUS INJURY OR LOSS OF LIFE.

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Operation

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Operation

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Operation

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Operation

Mining Operations It is presumed that the operator of this machine is experienced in continuous mining techniques. This section of the manual will present some basic rudiments of continuous miner mining operations, but should not be considered in any way as a complete how-to of mining techniques.

It is recognized that each miner operator will have his own methods and techniques which work best for him.

One of the keys to good productivity with a continuous miner is to know the correct depth of sump which, when the cutting cycle is completed with shear-down, gives enough coal to adequately fill one haulage vehicle.

Another important factor is to do as much advance cutting as possible, while awaiting the haulage vehicle, to load up the gathering head pan.

When the vehicle arrives, the gathering head can then work at maximum efficiency to load out the accumulated coal while the remainder of the cutting cycle is being completed.

The following discussion outlines the various steps of an efficient continuous miner mining cycle.

Preparation of the Face for the Next Cut Figure 3-3.1 shows a continuous miner approaching a freshly cut face.

The operator has the cutting head lowered to prepare for making a 2’ to 3’ deep sump cut at the bottom of the face. This is done to make clearance for the gathering head blade when the miner is sumping at the top of the face. In this manner, the miner can make a deeper sump into the top of the face.

Figure 3-3.2 shows the miner having made a 30” sump cut at the bottom of the face. The operator will now back the miner out of the cut and raise the cutting head to the mine roof.

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Fi gure 3-3.2 Miner Approaches Face

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Operation As shown in Figure 3-3.3, the operator has backed out of the bottom cut and raised the cutting head to the roof, positioning the miner for making a top sump.

The Next Face Cut Having cut bottom clearance for the gathering head blade, the operator can now make a deep sump at the top such as a full drum diameter as shown in Figure 3-3.4. He can commence his downcut until his gathering head pan is full.

Figure 3-3.3 Miner Backs Out, Raises Cutting Head for Top Sump

Figure 3-3.4 Miner Sumps in at Top and Begins Downcut

Optimally, all this is being done while awaiting the next haulage car so that maximum loading rate can be achieved when the car arrives.

While loading the haulage car, the operator completes the downcut to the mine bottom, seen in Figure 3-3.5.

Depending on the depth of the top sump, a small cusp of coal will be left behind the drum on the Figure 3-3.5 Miner Completes Downcut with mine bottom. This cusp Small Cusp Remaining is removed by backing the miner out of the face a small distance while the cutting head is running.

The miner is now in a similar position as that shown in Figure 3-2.1 and the operator can proceed with the next cutting cycle.

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Operation

Using the Stabilizer Shoe The stabilizer shoe is located under the rear deck of the main frame and beneath the conveyor. It is hinged at its front edge and is lowered by a hydraulic cylinder.

The stabilizer shoe serves two purposes: • •

To elevate the rear of the miner for maintenance work.

To provide a higher downcut force at the coal face while shearing down during mining operations.

The advantage of increasing downcut force at the face while shearing down is important particularly when cutting hard coal seams. Figure 3-3.6 illustrates the advantage of the stabilizer shoe in the downcut application.

Downcut Force

Machine Weight

Lever Arm W/O Stab Shoe Lever Arm With Stab Shoe

Figure 3-3.6 Effect of Using Stabilizer Shoe on Downcut Force

The miner is shown in the middle of its shearing down cycle. Without the stabilizer shoe deployed, the machine will tend to rock back on the rear of the crawlers. The distance from the miner’s center-of-mass to the rear of the crawlers is denoted in Figure 3-2.6 by “Lever Arm without Stab Shoe”.

Conversely, with the stabilizer shoe deployed, the miner will now tend to rock back on the shoe, providing a longer lever arm. In the case of the 30M miners the lever arm with the stab shoe down is more than twice the lever arm without the stab shoe, thus doubling the down force available for shearing down. This increase in downcut force will improve the speed and efficiency of the shear down portion of the cutting cycle.

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Operation

Shearing Up and Down Most continuous miners, including the 30M machines, have their centerof-mass located forward of the center of the crawler footprint. This weight distribution makes the miner inherently more effective in shearing down rather than up because shearing down takes advantage of the miner’s weight to maximize downcut force.

Shearing only downward requires the cutting head to be raised without cutting during each mining cycle, and a non-productive dead time is introduced in the mining cycle.

An alternative particularly useful in softer, easier cutting coal seams is to shear both up and down while advancing, thus maximizing the time spent actually cutting coal in the total cycle. This sequence is illustrated in Figures 3-3.7 and 3-3.8.

Figure 3-3.7 shows the miner having sumped in at the top of the coal face. If the operator intends to shear down and up, the depth of sump should be no more than half a drum diameter; otherwise, a cusp will be left at the bottom or top after shearing which will require trimming.

Figure 3-3.8 shows the miner in the middle of the downcut.

Figure 3-3.8 Miner Shearing Down

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Operation Having completed the downcut, Figure 3-3.9 shows the miner sumped in about half a drum diameter at the mine bottom.

Figure 3-3.9 Miner Sumping in at Mine Bottom

Finally, Figure 3-3.10 shows the miner in the middle of the upcut.

Figure 3-3.10 Miner Shearing Up

The technique of successively shearing up and down is particularly productive when the miner is working in conjunction with a continuous haulage system.

MACHINE ELECTRICAL SYSTEM AND CONTROLS It is essential for the operator to be familiar with the overall machine electrical system as well as each control element. The following provides a general description of the 30M electrical system.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

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Operation

Safety And The Miner Operator – the RED ZONE Remote Controlled Continuous Miners The advent of radio remote control as a means of operating continuous miners has brought a remarkable change in mining operations underground and especially at the coal face. On-board dust collector systems such as the ones used on the 30M miners are an essential companion to radio control, as they provide the necessary visibility of activity at the coal face for the miner operator Several advantages can be cited for the use of radio control on today’s miners. These would include: •

•

Taking the miner operator off his machine and away from the danger of roof falls which can occur near the face. While the operator’s protective canopy was a partial and practical solution to this danger, greater safety was seen in removing the operator completely from the machine.

Giving the operator a better visibility of his operating environment, especially his interface with haulage vehicles during loading. Sitting in the operator’s pit during haulage vehicle loading, the miner operator had to constantly be glancing over his left shoulder to monitor the position and height of his conveyor and the progress of loading the car. With remote control, the operator can position himself so that visibility of car loading is as good as that of the face.

However, remote control of miners introduces certain potential safety hazards which the miner operator must watch for and be aware of. While the operator is now free to position himself for convenient visibility of mining operations at the face, he can easily expose himself to the danger of being near mobile heavy equipment.

Most significantly, the operator’s greatest danger is from his continuous miner, especially when he is maneuvering it during mining operations.

The miner is capable of slewing rapidly when turning, especially when the crawlers are split. The discharge conveyor can also swing rapidly. In each of these cases, the miner operator is in danger of being hit, or worse yet, run over by his own machine. Equally dangerous is the possibility of the operator being pinned against the rib by his own miner.

Miner Operator Danger Areas, or RED ZONES Some typical situations dangerous to the miner operator are illustrated on the following pages. The danger area, or red zone, is indicated by:

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Operation

Tramming the miner from one place to another, especially maneuvering around intersections – see Figure 3-1.1. This illustrates that the operator should not place himself between his miner and the rib.

Beginning the first sump in a new cut.

The miner is against the LH rib and the discharge conveyor is swung toward the center of the entry ready for the haulage car – see Figure 3-1.2. The operator must stay clear of the discharge conveyor and the rear of the miner Sumping in the LH side of the cut – see Figure 3.1-3. As the miner penetrates the Figure 3-1.1 Tramming face, new unsupported roof is being exposed, and the operator now has an additional constraint to his movements. He must also stay clear of the haulage vehicle at the rear of the miner as it approaches the miner and while it is loading.

Figure 3-1.2 Beginning First Sump

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Figure 3-1.3 Sumping on the LH Side

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Figure 3-1.4 Reposition Miner for RH Cut

43

Operation Repositioning the miner for the RH cut – see Figure 3-1.4. Because the miner is backing out and turning in close quarters, the operator must stay behind the miner to be safe.

Sumping in the RH cut – see Figure 31.5. Again, the operator must stay away from the face where the newly-exposed roof is unsupported, as well as staying clear of the haulage vehicle while it approaches and loads.

Crosscuts. Beginning and completing crosscuts requires a lot of maneuvering of the miner and loading the haulage vehicle Figure 3-1.5 Sumping in the while at awkward positions. Crosscuts RH Cut also result in newly-exposed unsupported roof. Respecting a red danger zone is important to operator safety in these conditions.

Figure 3-1.6 shows the miner beginning a RH crosscut. The miner is nearly against the opposite LH rib, while the discharge conveyor is swung to its maximum 45o right position for loading the haulage vehicle.

Hence, the entire gure 3-1.7 RH Crosscut Figure 3-1.6 Beginning a RH Development rear of the miner is Crosscut treated as a red zone. There are two other danger areas. On the RH side, the miner forms a pinch point at the rib which must be avoided. Also, on the LH side of the miner, as the miner progresses into the rib, a sharp-angled fender will be formed which will be susceptible to sloughing and falling off.

Hence, that rib must be considered a red zone.

Figure 3-1.7 shows the RH crosscut in further development. The red zone surrounds the miner as the discharge conveyor is free to swing either way and more unsupported roof is exposed.

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Fi

Operation Pillaring. Remote control offers a significant safety advantage in partial or complete removal of the pillars in retreat mining because it places the operator further away from potential collapsing roof.

It can be seen in Figure 31.8 that much of the area around the miner must be considered a red zone, mostly because of extensive unsupported roof and the need for temporary supports under weakened roof. With remote control, the operator can position himself safely away from the miner while still retaining a good view of the mining cycle.

Figure 3-1.8 Pillaring in a LH Cut

In Figure 3-1.9, the miner is now working in the opposite RH pillar. A red zone around the miner is no longer applicable, as the operator is now excluded from the entire working area because of failing roof considerations, even with the existence of temporary roof supports.

Figure 3-1.10 Pillaring in an End Cut

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Operation Figure 3-1.10 illustrates making an additional end cut into the pillar, creating a fender of coal between the two cuts. Additional temporary roof supports have been installed.

Because of roof pressures, the fender will tend to slough its ribs in the process of eventually crushing. Hence, the operator must stay away from this fender as well as avoiding the entry and crosscut areas as shown.

Figure 3-1.10 Pillaring in an End Cut

NOTICE

The mining situations, red zones, temporary roof supports, miner positions, and any other features illustrated in this Section 3-1, are offered only as a guide to safe practices and should not be considered as complete and comprehensive regarding dangers to the miner operator or any other personnel. It is absolutely essential that the miner operator and other personnel obey all Federal, State and Local safety regulations as well as those of the mining company.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

Laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so that they: ¾ Always have a little slack.

Fig. 2: Laying hydraulic hoses, slack RIGHT

WRONG

¾ Are not twisted.

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Operation Fig. 3: Laying hydraulic hoses, twisting RIGHT

WRONG

¾ Are not bent directly behind the connections (distance min. 1.5 x nominal diameter).

Fig. 4: Laying hydraulic hoses, bending RIGHT

WRONG

¾ Cannot chafe.

Fig. 5: Laying hydraulic hoses, crossing RIGHT

¾ ¾ ¾ ¾

WRONG

Are not kinked.

Do not have to withstand tensile strains.

Are protected against thermal radiation.

Are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool, this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be:

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Operation ¾ ¾ ¾ ¾ ¾

Torn out, Kinked, Crushed, Driven over or Twisted (Fig.: 6) by the movement of the machine

Fig. 6: Laying hydraulic hoses, connections on moving parts RIGHT

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WRONG

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Operation

Primary Electrical Components

Figure 2-1-1 Location of Major Electrical Components Main Control Case The main control case is located on the right rear corner of the miner and is readily accessible from the side of the machine. Figure 2-1.2 illustrates the main control case.

The contents of the main control case include the following: •

All primary circuit breakers, i.e., the main breaker, the tram control breaker and the breaker for lighting and control relays • The RH side Emergency Stop switch • Ground check circuit test switch • Cutting motor contactors • Traction controllers • Current transformers

• •

Control Transformer Cutting Head & Conveyor Hour Meters

A swing-out panel, not shown, inside the main control case has additional components mounted to it, including: •

CLA/conveyor and pump motor contactors

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Operation • • •

Radio input/output unit Current transformers Ground Fault Monitor Tram Motor Circuit Breaker Control Circuit Breaker

Main Circuit Breaker

Ground Check Circuit Test Switch

Emergency Stop Switch

Cutting Head Hour Meter Conveyor Hour Meter Figure 2-1.2 Main Control Case Controls and Indicators

Auxiliary Box The auxiliary box is mounted on top of or near the main control case on the RH side of the machine. Its contents include: • • • • • • • • •

Area lighting transformer Methane monitor power supply Radio receiver Pendant Interface Fire Spray Battery backup Ground Fault Strobe Drive Unit Control circuit and I/S relays I/S barriers for the control pendant and radio antennae Lighting fuses

Display Box The display box, shown in Figure 2-1.3, is located on the right rear corner of the miner where it is readily visible to the operator and maintenance personnel. The display box has several features: •

A digital readout display for information related to machine operating mode, maintenance and troubleshooting.

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Operation •

•

A cutting head run/lockout switch which, when in the lockout position, disables the cutting head motors. This switch is used as a safety measure when performing maintenance when the machine is under power.

A radio/pendant control switch for enabling either the radio remote or pendant/cable control modes.

Machine Lighting Control Pendant/Radio Control Selection Run W-W/O Fan & Cutting Head Lockout

Figure 2-1.3 Display Box Details

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Operation

Radio Transmitter The radio transmitter is the primary method of controlling 30M continuous miners. It contains the switches by which the motors are started, the switches which control the hydraulic solenoids which move the various components on the machine like cutting head raise and lower, conveyor raise, lower, swing left and right and the gathering head raise and float. It also contains the switches which start the dust collector and fire suppression systems, and the emergency safety systems such as the fire water deluge start switch, and the emergency stop switches. Figure 2-2.1 shows the arrangement of switches and controls.

Radio Remote Control System Except for the circuit breaker levers located on electrical enclosures, all necessary operating controls are located on the operator’s remote control transmitter unit.

Both emergency controls, the Emergency Stop and the Fire Spray Actuator, have manual controls on the right-hand and left-hand sides of the machine as well as remote switches on the radio transmitter.

It is essential that the operator familiarize himself with all controls, their location and their function.

Figure 2-2.1 TX 942 Radio Control Transmitter

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Operation Code 1 2 3 4 5 6 7 8 9 10 11

Function Tram High and Low Speed select Or Mode Select Machine Stop switch Transmitter Power On/Off LED panel Cutting Head Start/Stop Conveyor Reverse Conveyor Start/Stop Fire Suppression Spray On Dust Control Sprays On/Off Machine Stop Override button Enable button for motor starts

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Code 12

Function Machine Lights On/Off

13 14 15 16 17 18 19 20 21

Pump Motor Start/Stop Tramming controls Tramming Enable Stabilizer Shoe Lower/Raise Manual Dust Collector Fan On/Off Conveyor Raise/Lower Conveyor Swing Right/Left Gathering Head Float/Raise Cutting Head Lower/Raise

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Operation

Tram Controls (See Balloons 1, 14 and 15 in Figure 2-2.1 and Table 2-2.1) Three speeds in forward and two in reverse direction are provided for tramming the 30M miner: • • •

SUMP speed, ranging from zero to 20 feet/minute.

LOW speed, ranging from zero to 42 feet/minute.

HIGH speed, ranging from zero to 85 feet/minute.

While in LOW or HIGH tram, tramming speed is infinitely variable from zero to the maximum speed in that range.

The only time the miner is in sump speed is when the cutting head is operating. If the machine is being operated in any other speed, such as moving the machine from one place to another, the tram control system will automatically change to SUMP speed if for any reason the cutting head motors are started.

Similarly, during tramming in LOW or HIGH speed, if the crawlers are split, or if one crawler is stationary and the other is moving, in either case to make a hard turn, the tram control system will automatically change to SUMP speed as a safety precaution.

During normal mining operations, the traction system is operated by radio remote control. A secondary method of tramming the machine is with the manual pendant controller, attached to the machine with an umbilical cord (see Section 2-4).

WARNING

Before starting the machine or operating any controls, you must have read this operating manual, have been trained in the proper operation of the machine, and be thoroughly familiar with all controls. Failure to do so could result in an accident causing serious injury or death to you or other personnel.

To tram the miner, first press and hold the HIGH TRAM or LOW TRAM pushbutton to select tramming speed. Next, move the TRAM ENABLE toggle switch in either the forward or backward direction. This enables the TRAM lever controls for a period of 2 seconds. The TRAM lever controls can then be used to move the machine forward, backward, right and left in any combination. If the Tram lever controls are left idle for 2 seconds or longer, the Tram Enable toggle switch must again be used to enable further tramming.

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Operation

Communication Mode Setting (See Balloons 1, 11 and 12 in Figure 2-2.1 and Tables 2-2.1 and 2-2.2) The transmitter and receiver communicate with each other through one of four unique binary encoding modes, 1, 2, 3 and 4. This enables up to four miners to be operated safely within communicating distance of each other, but without the hazard of crosstalk signals occurring. The receiver, located in the Auxiliary Box, has a 4-position mode selector switch, and both transmitter and receiver must be set to a matching mode number.

If the radio transmitter and receiver mode selection are not identical, the transmitter will not operate the miner. To confirm the receiver mode, look at the Display Box digital readout panel. The text on Row 6, LH side of the display, will indicate Mode 1, 2, 3 or 4. The NOTICE transmitter mode will be indicated by the blink pattern of the Mode LED light – see Table 2-2.3.

In the event that the transmitter mode must be changed to match that of the receiver, the HIGH TRAM and LOW TRAM buttons have a secondary use for this purpose.

To increase the mode setting, press and hold both ENABLE (NOT TRAM ENABLE) and LIGHTS buttons, then TRAM HIGH to increase the transmitter mode number.

To decrease the mode setting, press and hold both ENABLE (NOT TRAM ENABLE) and LIGHTS buttons, then TRAM LOW to decrease the transmitter mode number.

Cutting Head Controls (See Balloons 5, 11 and 21 in Figure 2-2.1 and Tables 2-2.1 and 2-2.2)

WARNING

Before starting the machine or operating any controls, you must have read this operating manual, have been trained in the proper operation of the machine, and be thoroughly familiar with all controls. Failure to do so could result in an accident causing serious injury or death to you or other personnel.

The cutting head is started by first depressing and holding the ENABLE pushbutton, then pulling the CUTTING HEAD START/STOP switch backward to the START position. This two-handed procedure minimizes the possibility of accidental starting of the cutting head.

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Operation A rotary CUTTING HEAD LOCKOUT switch is located on the left hand side of the Display Box (see Figure 2-1.6). This switch is used while moving the miner to prevent accidental starting of the cutting head.

During cutting operations, the cutting head is raised and lowered by operating the CUTTING HEAD RAISE/LOWER toggle switch on the radio transmitter. The operator must push the switch forward to lower the head and pull the switch rearward to raise the head.

Conveyor Controls (See Balloons 6, 7, 18 and 19 in Figure 2-2.1 and Tables 2-2.1 and 2-2.2) Conveyor Start The gathering head CLAs and the conveyor chain are started and run simultaneously by the CONVEYOR START/STOP switch. The pump motor must be running to enable starting this function.

WARNING

Before starting the machine or operating any controls, you must have read this operating manual, have been trained in the proper operation of the machine, and be thoroughly familiar with all controls. Failure to do so could result in an accident causing serious injury or death to you or other personnel.

To start the conveyor, press and hold the ENABLE button, then move the CONVEYOR START/STOP toggle switch rearward to the START position.

At times, the conveyor chain may need to be reversed to dislodge rock or debris that has been carried into the conveyor chain return area and has jammed the chain. To reverse the conveyor chain, press and hold both the ENABLE button and CONVEYOR REVERSE button, then move the CONVEYOR START/STOP toggle switch rearward to the START position.

To stop the conveyor from traveling in reverse, release any of the pushbuttons. To stop the motor, move the START/STOP toggle switch forward to the STOP position.

The conveyor can only be reversed for short time intervals and is subject to limited successive reverse starts in a certain period of time as governed by the microprocessor logic.

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Operation Conveyor Raise /Lower

WARNING

Never walk or stand under the conveyor AT ANY TIME unless the conveyor is stationary and is blocked with the conveyor safety stand or crib blocks.

The conveyor could fall and cause serious injury or death.

The conveyor boom is raised or lowered with the CONVEYOR RAISE/LOWER switch.

To raise the conveyor, pull the CONVEYOR RAISE/LOWER toggle switch rearward to the RAISE position. Likewise, to lower the conveyor, push the toggle switch forward to the LOWER position. This is a momentary command that, when released, spring-returns to the center position and conveyor movement is stopped.

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Operation Conveyor Swing The discharge conveyor is pivoted just at the rear bumper of the miner to allow it to swing a maximum of 45o from side to side to facilitate loading haulage vehicles and maneuvering the miner.

WARNING

Always stay clear of the discharge conveyor when the miner is under power. The conveyor can swing rapidly and can strike personnel or pin them against the rib. Failure to do so could result in an accident causing serious injury or death to you or other personnel.

To swing the discharge conveyor to the right or left, move the CONVEYOR SWING toggle switch to the RIGHT or LEFT positions. As with conveyor Raise/Lower, this is a momentary command that, when released, spring-returns to the center position and conveyor movement is stopped.

Gathering Head Controls (See Balloon 20 in Figure 2-2.1 and Table 2.2-2) Gathering Head Raise/Float

C

Never place any part of your person underneath the gathering head when it is raised off the mine bottom. If maintenance work is required, the gathering head should be blocked so that it is not supported by the CAUTION gathering head hydraulic cylinders. Failure to block the gathering head could result in an accident causing serious injury or death.

The gathering head has two primary operating positions. It is raised well off the ground when tramming from one place to another.

During mining and cleaning up operations, the gathering head is maintained in the float position so it will follow the contour of the mine bottom.

To raise the gathering head, move the GATHERING HEAD FLOAT/RAISE toggle switch rearward to the RAISE position until the desired height is reached. Releasing the spring-return toggle switch will stop the movement of the gathering head. To float the gathering head, move the GATHERING HEAD FLOAT/RAISE toggle switch forward to the FLOAT position until the gathering head is resting on the mine bottom.

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Operation

Stabilizer Shoe Controls (See Balloon 16 on Figure 2-2.1 and Table 2-2.2) The stabilizer shoe is located under the rear of the miner and is used to stabilize the rear of the miner and increase its downcut leverage when the machine is cutting. The stabilizer shoe can also be used to raise the rear of the machine for maintenance purposes.

C

Never place any part of your person underneath the miner when the stabilizer shoe is deployed. If maintenance work is required, the rear of the miner should be blocked so that it is not supported by the stabilizer shoe CAUTION hydraulic cylinder. Failure to block the rear of the miner could result in an accident causing serious injury or death.

To lower the stabilizer shoe, move the STAB RAISE/LOWER toggle switch forward to the LOWER position until the rear of the miner is at the desired height. To retract the stabilizer shoe and lower the rear of the miner, move the STAB RAISE/LOWER toggle switch rearward to the RAISE position long enough to completely stow the stabilizer shoe.

WARNING

AFTER TURNING OFF POWER TO THE MINER, NEVER WALK AWAY AND LEAVE THE TRANSMITTER TURNED ON. FAILURE TOP TURN THE TRANSMITTER OFF COULD RESULT IN AN ACCIDENT CAUSING SERIOUS INJURY OR LOSS OF LIFE

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Operation

Controls Summary The following tables offer a convenient detail summary of the various remote control switches and indicators available to the operator on the radio transmitter.

Table 2-2.1 Motor Controls – procedures required to run the motors (Code numbers refer to balloons on Figure 2-2.1): Code 1

Switch/Button Primary Usage: Tram High – Green Pushbutton [Secondary Usage: Mode Up]

Function Puts the miner in High Tram

Primary Usage: Tram Low – Red Pushbutton [Secondary Usage: Mode Down]

Puts the miner in intermediate (low) tram

2

Machine Stop

Shuts down the miner

3

TX On - Green Pushbutton

Used to energize the Transmitter

3

TX Off - Red Pushbutton

Used to de-energize the Transmitter

5

Cutter Start/ Stop - Return to Center Toggle Switch

Controls both cutting motors.

6

Conveyor Reverse - Green Pushbutton

Reverse the conveyor chain

1

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[Changes transmitter mode up}

[Changes transmitter mode down]

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Operation Press the Tram High button to put the miner into high tram. Maximum speed is 85 ft/min.

[Press and hold both Enable and Lights buttons, then Tram High to increase transmitter mode] Press the Tram Low button to put the miner into low tram. Maximum speed is 42 ft/min.

[Press and hold both Enable and Lights buttons, then Tram Low to decrease transmitter mode] When the red Machine Stop button is pressed it (1) overrides all other machine controls; (2) removes power from machine movement actuators; and (3) causes all moving parts to stop within the shortest possible time. Resetting of the manual stop requires a manual reset at the power center.

Press the TX On button down once. You will see the following indication lights turn on: Battery, Mode. There are 4 modes and they can be determined by watching how many times the mode light quickly flashes, then there is a pause and the sequence is repeated (see LED Descriptions).

Press the TX Off button down once. You will see the battery light flash then the transmitter will power down.

Press and hold the Enable button, then push the Cutter Start/Stop toggle switch to the Start position. Once the cutting head starts, release the Enable pushbutton then the Cutter Toggle Switch. To stop the cutting motors, push the Cutter Start/Stop toggle switch to the Stop position.

Press and hold both the Enable button and Conveyor REV button, then press the Conveyor Start/Stop toggle switch to the Start position. To stop the conveyor from traveling in reverse, release any of the pushbuttons. To stop the motor, push the Start/Stop button to the Stop position.

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Operation Table 2-2.1 Motor Controls – procedures required to run the motors (Continued): Code 7

Switch/Button Conveyor Start/ Stop Return to Center Toggle Switch

Function Controls the conveyor and gathering motor.

10

MSTOP OVR - Green Pushbutton

Ability to override an activated machine stop pushbutton

11

Enable Button - Green Pushbutton

Enables starting the Pump, Cutter, Conveyor, and Gathering Head motors.

13

Pump Start/ Stop - Return to Center Toggle Switch

Controls the hydraulic pump motor.

14

Dual Tram Levers - Return to Center Levers

Left and right levers independently control the crawler direction.

15

Tram Enable - Return to Center Toggle Switch

Enables the Tram function for 2 seconds.

17

MANUAL FAN - - Red Pushbutton

Ability to manually run the dust collector fan

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Operation Press and hold the Enable button, then push the Conveyor Start/Stop toggle switch to the Start position. Once the conveyor starts, release the Enable button and then the Conveyor Start/Stop toggle switch. To stop the conveyor motor, push the Conveyor Start/Stop toggle switch to the Stop position.

Press the Enable button, then press the green MSTOP OVR button. Hold both buttons as long as the command is required.

To stop the command, release either the Enable button or MSTOP OVR button.

Press and hold the Enable button and the corresponding motor toggle switch. Once the motor has started, you can release the enable button and motor switch. NOTE: THE PUMP MOTOR WILL NOT BE ENABLED IF AN ACTIVE COMMAND IS STILL PRESENT. (TIP - LOOK AT THE SWITCH ACTIVE LIGHT TO SEE IF IT IS ON) Press the Enable button, then push the Pump Start/Stop toggle switch to the Start position. Once the pump starts, release the Enable button and then the Pump Start/Stop toggle switch. To stop the pump motor, push the Pump Start/Stop toggle switch to the Stop position. THE PUMP MOTOR MUST BE ENERGIZED TO INITIALIZE ALL OTHER TRANSMITTER FUNCTIONS. Only the fire sprays can be energized without the pump.

Move the tram levers up to move forward and back for reverse. The tram levers must be moved within 2 seconds; otherwise the Tram Enable button will drop out.

Push the Tram Enable toggle switch in either direction. The tram levers must be activated within 2 seconds or the tram will drop out. NOTE: THE TRAM WILL NOT ENABLE IF ONE OF THE TRAM LEVERS IS SENDING AN ACTIVE COMMAND. (TIP – CHECK THE SWITCH ACTIVE LIGHT TO SEE IF IT IS ON) Press and hold the Enable button, then push the MANUAL FAN button. To stop the command, the pump motor must be shut down.

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Operation Table 2-2.2 Hydraulic Functions – procedures required to run the following hydraulic-activated functions (Code numbers refer to balloons on Figure 2-2.1): Code Switch/Button 8

Fire - Red Pushbutton

9

Dust - Two Position Toggle Switch

12

Machine Lights Green Push Button

Function

Operation

Turns the fire suppression system ON/OFF. This is a Latched Command. You must manually turn off the fire sprays or they will continue to run.

Press the red Fire button to turn on the fire sprays. To remove the fire spray command, the transmitter must be shut done and powered up.

See Section 2-3 for further details.

Turns the dust sprays On/Off. This is a Latched Command. Note that the Dust ON/OFF toggle switch is not a return-tocenter switch.

Ability to energize/ reenergize miner lighting according to the position of the manual light selector switch on the Display Box.

16

Stabilizer Shoe (STAB)

Raises and lowers the Stabilizer Shoe

18

Conveyor Raise/Lower

Raises and lowers the Conveyor

19

Conveyor Swing

Swings the discharge conveyor left and right.

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See Section 2-3 for further details.

Push the Dust On/Off toggle switch to the ON position to turn on the dust sprays. To stop the dust sprays, push the Dust On/Off toggle switch to the OFF position.

Press the Machine Lights button to turn on the lights. Press the button a second time to turn the lights off.

See Section 2-4 for further details.

Push the Stab Lower/Raise toggle switch to the Raise position to raise the back end of the miner. To lower the miner, push the Stab Lower/Raise toggle switch to the Lower position.

This is a momentary command that, when released, spring-returns to the center position and the stabilizer shoe movement is stopped.

To raise the conveyor, push the Conveyor Lower/Raise toggle switch to the Raise position. To lower the conveyor, push the Conveyor Lower/Raise toggle switch to the Lower position. This is a momentary command that, when released, springreturns to the center position and conveyor movement is stopped.

To move the discharge conveyor to the Left or Right from the center position, push the Conveyor Swing toggle switch in the corresponding direction.

Release the toggle to stop movement.

This is a momentary command that when released spring returns to the center position and the activity is stopped.

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Operation Table 2-2.2 Hydraulic Functions – procedures required to run the following hydraulic-activated functions (Continued) Code Switch/Button

Function

Operation

20

Gathering Head Raise/Float

Raises and lowers (to a float position) the gathering head. The toggle switch is selfcentering. It is a Latched Command in the Float position.

21

Cutting Head Raise/Lower

Raises and lowers the cutting head

To raise the gathering head or float it on the mine bottom, move the Gathering Head Raise/Float toggle switch from the center position to the corresponding position. If Raise is commanded, releasing the toggle stops the movement. If Float is commanded, the gathering head will continue lowering to the mine bottom.

To raise the cutting head, push the Cutter Head Raise/Lower toggle switch from the center position to the corresponding position. Release the toggle to stop movement. This is a momentary command that when released spring returns to the center position and the activity is stopped.

Table 2-2.3 LED Descriptions – describes the function of the LED indicator lights on the Transmitter – see balloon No. 4 on Figure 2-2.1: Battery

LED

Color Red

Mode

Red

Switch Active

Red

Tram Enable

Red

Latch (Motor) On

Red

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Function Flashes. A flashing LED means that battery strength is good. A double blink –pause- double blink LED means the batteries need to be changed (approx. 24hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When the LED double blinks the batteries should be changed without delay.

Flashes. The flashing pattern indicates the binary encoding which matches the transmitter to the receiver.

MODE 1 - One blink then pause MODE 2 - Two blinks then pause MODE 3 - Three blinks the pause MODE 4 - Four blinks then pause On Steady. The Switch Active LED indicates that a function has been requested. Once a function has been initiated the SWITCH ACTIVE LED turns “ON” (red) and once the command is removed the LED will turn off.

Flashes. The Tram Enable LED indicates that the Tram Lever is enabled by pulsing at fast rate. Once the tram is in motion, the Switch Active light is energized and the tram enable light turns off. Any time a tram lever is not in the zero position while enabled, the Tram Enable LED will be pulsing for only 2 seconds. Tram Enable can be active if, and only if, there is no direction commanded by either tram lever before the Tram Enable toggle switch is activated.

On Steady. When the Dust/Fire/Gathering Head Float commands have been initiated, the LED turns “ON” (red). When the command is removed, the LED will turn off.

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Manual Emergency Controls And Indicators on the Machine Emergency Machine Stop Manual Controls The 30M miners have two manual Emergency Stop buttons located at the RH and LH rear sides of the machine. Installation of these Emergency Stop buttons may vary from one machine to another, but they have two characteristics in common: 1) they are always positioned on the rear of each side of the machine so that they are readily accessible to the operator or other personnel without going forward and being under unsupported roof, and 2) they are painted red for maximum visibility – see Figures 2-3.1 and 2-

RH Side Fire Spray Lever

RH Side Emergency Stop button

Ground Fault Indicator Strobe

RH Side Fire Spray Shutoff Lever

Figure 2-3.1 RH Side Emergency Stop Button and Fire Spray Lever

3.2.

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Operation

LH Side Emergency Stop Button (behind protective rub rail)

LH Side Fire Spray level Figure 2-3.2 LH Side Emergency Stop Button and Fire Spray Lever

Emergency Fire Spray Manual Controls The 30M miners have two manual Fire Spray lever-operated ball valves located at the RH and LH rear sides of the machine. These Fire Spray levers are also painted red for visibility – see again Figures 2-3.1 and

2-3.2.

NOTICE

The fire sprays can work in the absence of 120VAC control power. If control power is lost, battery backup power for spray operation is provided from the Auxiliary Box on a 15-minute timer. After the timer has timed out, the fire sprays cannot be activated.

Emergency Fire Spray Shutdown In the event that the emergency fire sprays have been activated, either by the radio transmitter control or the on-board manual control, the fire spray valve will remain locked in the spray mode by pilot water pressure until it is physically de-activated.

De-activation of the fire spray valve is accomplished manually by rotating the yellow lever-operated ball valve located on the RH rear of the miner (see Figure 2-3.1) near the red RH fire spray activation lever. This results in relieving pilot water pressure at the fire spray valve. While this pilot pressure is off, the operator must check to ensure that both manual fire spray valves are turned off; otherwise, when the yellow fire spray deactivation lever is turned off, the fire sprays will reactivate.

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NOTICE

If the fire sprays have been activated by the radio transmitter, the red Fire Spray pushbutton is in a “latched” condition (see Table 2-2.2, Code 8). To undo the “latched” condition after the fire sprays have been deactivated, the transmitter must be powered down.

Ground Fault Indicator Strobe Light This light indicates the presence of a ground fault somewhere in the electrical control circuits. The light is a bright red strobe light and is located on the RH side of the miner, as shown in Figure 2-3.1.

WARNING

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WHEN THE PRESENCE OF A GROUND FAULT IS INDICATED, IT IS IMPORTANT TO STOP OPERATING THE MACHINE IMMEDIATELY AND TROUBLESHOOT THE ELECTRICAL SYSTEM TO FIND AND REPAIR THE FAULT. If a second fault should occur before the initial fault has been eliminated, the miner could operate in an unsafe and erratic way. Failure to heed this warning could result in an accident causing serious injury or death.

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Auxiliary Controls and Indicators Remote Umbilical Pendant Control The 30M can be operated using a pendant control connected to the miner by an umbilical cable - see Figure 2-4.1. This control is used in the event that the operator loses his radio link with the miner. The pendant control can then be used to safely recover the miner from the face to a safe area under supported roof for troubleshooting and maintenance.

The pendant controller allows limited operation of the machine: tramming and pump motor activation to provide hydraulic power to raise or lower the cutting head.

In order to use the manual pendant it must be connected to the machine. The pendant has a pigtail, approximately 12’ long with a male connector, permanently attached – see Figure 24.1.

The auxiliary box has a cable with a female connector wired into gland JJ for attachment of the pendant pigtail. This pigtail is stowed onboard the miner in a protected area - see Figure 2-4.2.

Figure 2-4.1 Remote Pendant Control

In addition, a 20’-long umbilical cable is provided with the pendant to provide sufficient length for safe operation of the miner during recovery as necessary.

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Operation

Umbilical Cable

LH Rear of Miner Control Case Auxiliary Box

Auxiliary Box/Pendant Input Cable (stowed)

Cable Clamp Control Pendant

Figure 2-4.2 Remote Pendant Control Arrangement

The pendant controller and its umbilical cord should be stored in a protected location on the working section, away from the continuous miner, to prevent accidental damage.

The umbilical cord is connected to the pendant interface through an umbilical pigtail-with-connector installed through one of the permissible glands on the auxiliary control case.

After plugging the umbilical cord in, rotate the RADIO/PENDANT rotary switch, located on the Display box, to the PENDANT CONTROL position – see Figure 2-1.5.

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Machine Lighting The 30M is equipped with both headlights and area lights. A rotary switch located on the Display Box (see Figure 2 -1.5) provides three options for machine lighting: 1) headlights only, 2) area lights only, and 3) both headlights and area lights. Operation of the LIGHTS button on the radio transmitter will provide machine lighting according to which position has been selected on the lighting switch on the Display Box. Additional Water Controls On the LH side of the miner at the rear, adjacent to the dust collector fan, there can be up to three lever-operated ball-valves to control water flow.

One can be for back-flushing the dust collector sump in order to clean out accumulated debris. Another can be for back-flushing the sump strainer.

A third one can be for operating dust sprays manually for test purposes.

These additional valve levers are painted yellow and will be marked accordingly; two of these valves can be seen in Figure 2-3.2.

There will also be water hose connection ports on the RH and LH sides of the rear of the miner. These are used to clean off the top and sides of the miner as necessary.

Methane Monitor Readout Unit All 30M miners are equipped with a methane monitor system which maintains a continuous check on methane gas concentration in the atmosphere around a detector head located as close to the face as practical.

The methane monitor system consists of a power supply, located in the auxiliary control box, a readout unit mounted usually on the right rear corner of the machine (see Figure 2-4.2), and a detector attached to the underside of the cutting head.

Miners may also be equipped with a second slave readout unit on the LH rear of the miner.

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A typical readout unit is shown in Figure 2-4.3. LED indicators display the percentage of methane gas in large numerals. Other LEDs indicate LOW alarm level, HIGH alarm level and the presence of a malfunction in the methane detection system.

The LOW Alarm LED lights when methane gas content reaches 1.0%, and goes out when the content drops below 0.9%.

The HIGH Alarm LED lights when methane concentration reaches 2.0%. Simultaneously, the machine control relay in the power supply unit will de-energize power to the miner.

The control unit automatically resets when the methane concentration level drops below 1.9%.

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Operation

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Technical Data

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Technical Data

6

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Technical Data

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Technical Data

Technical Data Please see spare parts list for technical information.

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Technical Data

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For Your Information

7

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For Your Information

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For Your Information

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For Your Information

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 directly.

Service address Bucyrus America, Inc. (Headquarters & Manufacturing Facility) 2045 West Pike Street Houston, PA 15342-1010 Telephone (724) 743-1200 FAX (724) 743-1201 Bucyrus America, Inc. (Service & Rebuild Facility) Berry Road Washington, PA 15301 Telephone (724) 743-1200 FAX (724) 228-2177 Bucyrus America, Inc. (Service & Rebuild Facility) Norris City, Illinois 635 Illinois Highway 1 Norris City, Il 62869 Telephone (618) 378-3441 FAX (618) 378-3106 Bucyrus America, Inc. (Service & Rebuild Facility) Oak Hill, West Virginia 843 Lochgelly Road Oak Hill, WV 25901 Telephone (304) 469-3302 FAX (304) 465-0450

Internet: http://www.bucyrus.com

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For Your Information

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BUCYRUS CONTINUOUS MINER TX-944 OPERATION MANUAL

AS PROVIDED BY: Cervis Inc. 330 Perry Highway Harmony, PA 16037 Phone (724) 452-3775 Fax(724) 452-3779

E-mail sales@Cervis.net

INTRODUCTION This manual describes the operation and maintenance of the radio control system using the model TX-944 transmitter/endstation. Specific sections of this manual are used to explain each major component of the complete remote control system, their general operation, and a general trouble shooting section. Please read this manual in its entirety and become familiar with the systems operation before controlling energized equipment. Understanding the operational features of the system is REQUIRED for safe operation.

System Warning IF MALFUNCTIONS OCCUR IN ANY ASPECT OF THE TRANSMITTER OR RECEIVERS OPERATION DO NOT CONTINUE TO OPERATE; POWER DOWN THE SYSTEM AND RETURN IT TO THE FACTORY FOR INSPECTION AND REPAIR. WHEN THE SYSTEM IS IN USE IF ANY PART OF THE UNIT IS DAMAGED PHYSICALLY DISCONTINUE OPERATION AND RETURN IT TO THE FACTORY FOR INPECTION AND REPAIR. AT ANY TIME DURING USAGE OF THE TX-9XX / RX9XX SYSTEM ANY DAMAGE IS FOUND PHYSICALLY OR ELECTRONICALLY IT IS CRUCIAL FOR THE SAFETY OF THE OPERATOR AND OTHERS IN THE OPERATING AREA THAT THE SYSTEM IS NOT ALLOWED TO CONTINUE IN OPERATION.

SAFETY RECOMMENDATIONS Ghosting (gosting), v., 1. Unplanned movement, machines that use Computer Control Technology.

The Mine Safety and Health Administration has recognized a problem involving malfunctions of electro-hydraulic shield advance systems at various longwall installations. This has lead MSHA to issue the following recommendations for the safe operation of all computer controlled mining equipment to prevent the condition known as ‘ghosting’.

The recommendations are as follows: 1.

1. Mine personnel who operate this equipment should be trained to insure the proper operational procedures and sequences are used to recognize improper system operation, alarms, and displays.

2.

2. Maintenance of the system is critical for safe operation. Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3.

3. Mine personnel should be made aware that the entry of moisture or water into the transmitter or umbilical enclosure could cause undesired machine movements.

Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field. When signs of moisture or water are observed in the control unit enclosure, the units must be immediately replaced.

4.

4. Any abnormal operational sequences of the system, alarm displays, or unintended machine movement which might be due to a software programming error should be noted, reported to the manufacture, and corrected immediately.

5.

5. Any equipment removed to correct “ghosting” problems should be sent to the manufacture to determine the exact cause of the problem. Corrective action will then be taken by either the manufacture or the operator to prevent similar occurrences.

6.

6. Whenever an unplanned machine movement is observed, the hardwired emergency stop system should be activated, not the stop button on the electronic control unit.

These recommendations, though originally made in response to the unplanned movement of longwall shield advance systems utilizing computer control technology, are equally applicable to all equipment with machine control circuits utilizing computer control technology. The recommendations above should be followed on a continuing basis on all machines utilizing computer control technology.

System Components The system consists of a transmitter/endstation and a receiver. The OEM completes the entire machine by adding electro/hydraulic interface components as well as relay/contactor hardware for the motor stop/start and/or machine shutdown.

Transmitter (TX-944) The TX-944 is a mobile hand operated transmitter for the radio control system. The enclosure is black polycarbonate and is rated to the specifications of a NEMA 4 enclosure. Inside the transmitter enclosure is the RF, CPU - Switch PCB, and an internal antenna. The radio frequency is modulated around a center frequency of 466.2500Mhz. Output power is approximately 20mW used in a pulsed operation.

Machine operations are hand operated via the 8 pushbuttons, 13 toggle switches, 2 tram

levers and a big red machine stop button. All functions on the transmitter are labeled clearly; at any time during operation if a label comes off or is covered with dust it is recommended for safe operation that it be replaced or cleaned before continuing operation. For operator feedback there are six LEDs are used to show BATTERY LIFE, ERROR, LINK REQUEST/SHUTDOWN, SWITCH ACTIVE/LOW BATTERY, TRAM ENABLE/INACTIVITY, and LINK ACKNOWLEDGE/COMMANDED POWER DOWN. Batteries are removable. Replacement batteries are removed and replaced via a compartment on the side of the transmitter. Only batteries that are approved by MSHA for use with this transmitter should be used.

ENDSTATION The endstation operation is accomplished by connecting the endstation cable to the bottom of the transmitter. The operation of the endstation will be exactly the same as the operation of the handheld in the transmitter mode. As soon as the transmitter is connected to the machine by using the endstation cable the system will use the endstation as the only source to control the machine. The endstation will now have full control of the receiver. If a transmitter and endstation are on at the same time the endstation will be in control because the MCU will have sensed a connection with an endstation. It will also exchange serial numbers with the endstation and will only respond with that transmitter.

RECEIVER/DECODER (RX-944) The RX-944 is a compact receiver for the remote control system. Inside the extruded shell are the PCBs used to receive the transmitted signal, decode and validate it, and repackage the data stream for transmission to the MCU via a rs232 serial link. There is a reference decal on the top of the unit that corresponds with drawing # 03115500 to aid in installation.. The receiver features 4 leds on the front to aid in the operation of the system. The antenna attachment is located on the face of the receiver and is for Structured Mining Systems P.N. # ANT-100.

OPERATIONAL SAFETY FEATURES

TRANSMITTER FEATURES:

1.) Switch Scan PWR Up- Each time the transmitter is switched on, all switches are scanned to ensure they are in an inactive state. The transmitter will send an error code to the MCU specifying which switch is not working In the event that more than one switch is stuck the MCU will display only one until it is corrected then it will display the next one affected. This will repeat until all switches are cleared. The transmitter can be shut down with the TX POWER OFF button or the MACHINE STOP BUTTON. 2.) Low Voltage Shutdown- Battery voltage is continuously monitored by an analog input channel of the micro-controller and the transmitter will shut itself down before the voltage decays to a value which could possibly affect proper microcontroller operation. The transmitter will display the cause of the shutdown by lighting the “low battery” led while shutting down and transmit low voltage

shutdown commands..

4.)

MACHINE STOP- This transmitter incorporates a distinctive large red button labeled OFF. Upon depressing this button a string of Power Down commands will be sent to the receiver and the machine will commence operation.

Activating the MACHINE STOP BUTTON will also trip the power center relay if set in the menu screen of the MCU.

5.)

Two Hand Start- Outputs which mandate additional safety consideration such as motor starts which require two-handed initiations. They usually include an enable button. Additionally, a time delay is incorporated such that both buttons must be held for a period of time before the function is enabled. The pump start will require that the enable button be pressed first then the pump start toggle switch be thrown.

6.) Inactivity Shutdown-All transmitters utilize an internal timer which is reset by the operation of any switch. If this timer expires then the transmitter and machine will shut down. The inactivity time is for the TX-944 is 5 minutes.

GENERAL OPERATION Note: Upon power-up, all transmitter functions must be OFF. This includes all latched functions. If any transmitter functions are engaged upon receiver power-up, the receiver will regard that transmitter as faulty and it will begin to send error information to the MCU to be put on the main display. These stuck button error messages will not be entered into the error log. Resetting all transmitter/endstation functions to idle position will reset this safety feature.

Startup Procedures: To begin, there are two different start-up procedures. The first is if the transmitter having either never before operated the miner or another transmitter previously had operated the miner. The second is if the transmitter was the last one to operate the miner.

If this is the first time that the transmitter is going to be used with the miner then it will have to be logged in using the umbilical cord.

The first time a transmitter is used with the machine or the first time the transmitter is used after another transmitter is used you must go through a “Teach Learn” sequence. The transmitter will have to be turned upside down and the port for plugging the umbilical cord will be visible on the bottom. It is easily recognizable by the silver cap on the end. See FIG 1.

FIG 1.

Remove the plug by unscrewing the black ring and plug the umbilical into it (See FIG 2.) then press the ON button

FIG 2.

. The left top led, UMB MSG, (umbilical messages) and the left bottom led, LINK REQ, (link request) will flash and then the, LINK ACK, (link acknowledge) will flash once for verifying that the serial number provided by the MCU is the same one as in it memory or twice for logging in it in memory as a new machine that it is connected to.

The description of the LEDs are discussed in the next section.

Once this process is done the handheld can be used as an endstation or unplugged from the machine and used as a transmitter. Since the machine unit holds only one serial

number (transmitter’s ID ) and the handhelds only hold one serial number at a time (machine unit’s ID ) They will only communicate with each other. If there is another handheld in the area it will not communicate with the machine but it might cause some interference such as a lower number of messages per second that the system is capable of operating.

If the transmitter is the last one that had been used with the miner then there is no need to go through the “teach learn” sequence again. The transmitter can now be turned on and operated normally.

The transmitter will not work as a “radio transmitter” without the silver plug attached and screwed into the bottom of the unit.

TRANSMITTER MODEL TX-944 LED DESCRIPTIONS

FIG 3.

BATTERY/UMB MSG – In transmitter mode, this LED will blink at a rate to give a general indication of the battery condition. A rapid blink indicates a relatively

full battery and a slow blink indicates a relatively weak battery. When approximately 8 hours of battery life remains, this LED will enter a different blink pattern. There will be two blinks followed by a longer pause and then two blinks again. This pattern will continue indicating that fresh batteries are needed. When in umbilical mode, this LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at 10 times per second.

ERROR – This LED indicates an internal error within the transmitter and it should be replaced. Note that all LED’s come on briefly during power up to prove that they are working. The ERROR LED on briefly at power up is normal.

When this LED is on after power up, the transmitter should be returned for repair.

LINK REQUEST/SHUTDOWN – When the transmitter is connected as an umbilical, it will attempt to LINK to the MCU (refer to TEACH/LEARN discussion). This LED will blink for each link request sent to the MCU. When the transmitter switches off, this LED serves a second purpose in that it indicates that a shutdown is in progress and power down messages are being sent to the MCU. At the same time, one of three other LED’s will indicate why the transmitter is powering down: Commanded (Operator initiated), Inactivity or Low Battery (see following paragraphs).

SWITCH ACTIVE/LOW BATTERY – After power up this LED is used to indicate a “stuck switch”. ALL switches must be in their neutral or safe position before the transmitter is allowed to become operational. If after power up (i.e. TX PWR ON depressed), this LED illuminates and stays illuminated (solid) then there is a “stuck” switch. In this condition, no other switches on the transmitter will be operational. The transmitter will send the error condition to the MCU and the system will display which switch is “stuck”. This switch must be replaced before proper operation will resume. After power up, any switch that is operated will result in this LED being solidly on while the switch is operated. In this manner, all switches can be verified locally at the transmitter. To see if the transmitter switch is being properly read, operate the switch and observe the SW ACTIVE LED. Note that only one switch will be indicated at any time as this LED is common for all switches. Also while in normal operation, certain switches are timed to maintain safety features, primarily two handed starts. If for example the ENABLE button is held down for more than 15 seconds, then the transmitter will enter an error mode. If this occurs then all command will cease to operate and an error code will be sent to the machine. To resume normal operation, the ENABLE button must be released. Switches that are timed in this manner are: a) ENABLE b) SHIFT c) TRAM ENABLE d) PUMP START e) CONV START

f) CONV REV g) CUTTER START

Note that in normal operation, all of these switches are held operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and other enabled functions unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly on switch.

Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a low battery condition.

TRAM ENABLE/INACTIVITY – This LED indicates that the tram levers are armed (active) and that any operation of the tram levers will result in machine movement.

Conversely, if this LED is off, then the tram levers are dead. Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was inactivity (no switch operation for 5 minutes).

LINK ACK/COMMANDED POWER DOWN – During the TEACH/LEARN process, this LED indicates that a link response (acknowledgement) has been received back at the transmitter from the MCU. If the transmitter was re-linked back to the same MCU (machine), then this LED will flash once. If this is a new link to a different MCU (machine), then this LED will flash twice. Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a commanded power down (operated initiated) as a result of the operator pressing either the MACHINE STOP mushroom head or the TX PWR OFF pushbutton.

CONVEYOR STOP: Moving the conveyor lever to the stop position will send a signal to stop the conveyor. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR START: This action will start the conveyor. This action requires the enable button to be pressed concurrently. This lever is momentary and does not have to be held in this position. The toggle switch will be scanned upon startup. If the switch is held for more than 15 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen.

FIRE: This action will start the fire suppression on the miner. The lever is momentary and does not have to be held in this position. The switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

LIGHTS: This action will activate and deactivate the lights. This function is latched function. It will turn on the lights when the toggle switch is pushed and released. If it is pushed again the light will be turned out. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

DUST OFF: This function will turn off the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

DUST ON: This function will turn on the dust spray. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

FAN OFF: This action will turn off the fan (scrubber). This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

FAN ON: This action will turn on the fan (scrubber). . This action requires the enable button to be pressed concurrently. This function is latched function. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

PUMP STOP: This function will turn off the pump. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

PUMP START: This function will start the pump. This action requires the enable button to be pressed before the lever is activated. This lever is momentary but has to be held in this position for half a second before the transmitter will transfer the command. The toggle switch will be scanned upon startup. If the switch is held for more than 15 seconds an error will occur and the transmitter will issue standard motor shutdowns and display the error on the view screen CUTTER HEAD LOWER: This function will lower the

cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CUTTER HEAD RAISE: This function will raise the cutter head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

GATHERING HEAD FLOAT: This function will allow the Gathering head to float.

This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

GATHERING HEAD RAISE: This function will raise the Gathering head. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR SWING LEFT: This function will swing the conveyor to the left. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR SWING RIGHT: This function will swing the conveyor to the right.

This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR LOWER: This function will lower the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

CONVEYOR RAISE: This function will raise the conveyor. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

BREAKER RESET: This function will reset the breaker. . This action requires the enable button to be pressed concurrently. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

BREAKER ON: This function will turn on the breaker. . This action requires the enable button to be pressed concurrently. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

STAB LOWER: This function will lower the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

STAB RAISE: This function will raise the stab in the back of the machine. It will operate as long as the switch is thrown or until the limit is reached on the miner. This

switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAM ENABLE: This toggle switch whether pushed left or right will activate the tram enable on the transmitter. It will be active for 3 seconds until a tram lever is activated. If at the end of 3 seconds the trams are not activated the enable will go out and all tram activity will be disabled. The function will not engage until the tram levers are in the center position. The tram enable will also be reset if the pump start is activated. The tram enable is checked upon start up and if active at startup will cause an error to be displayed on the view screen. This toggle switch will generate an error if held on for more than 15 seconds and will send shutdown codes.

SHIFT: This button is yellow on the transmitter and will be used in conjunction with the lower right 6 toggle switches. On these switches are the functions that they will command. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

MSTOP OVERIDE: This button will override the machine stop button on the left side of the miner. This button should be held down while the pump is started and during tramming. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

ENABLE: The enable button will be used in conjunction with other switches. These switches will be marked with their function in green. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen. This toggle switch will generate an error if held on for more than 15 seconds and will send shutdown codes.

TX POWER ON: This push button is the “ON” button for the transmitter. This is the only function of this button TX POWER OFF: This button will turn off the transmitter. It will initiate a shutdown sequence that will shut off all pumps and put the machine in a safe state. It will transmit these command 20 times and then shut off the transmitter.

TRAM HIGH: This button will put the miner in high tram. The button is a latch function. This button will only put the miner in high tram. While in high tram pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAM LOW: This button will put the miner in low tram. The button is a latch function.

This button will only put the miner in low tram. While in low tram pressing this button will have no effect. This switch will be scanned upon startup and if held while starting up it will generate an error that will be displayed on the view screen.

TRAMMING There are two tram levers on the transmitter. They each control one of the trams. See Fig 5. FIG 5.

TRAMMING Cont…

Before tramming can occur the hydraulic pump must be started. See PUMP START. Once this has been done then the Tram Enable must be pressed either to the left or the right.

The enable switch lever is the first lever to the right of the tram levers. See Fig 5.

The tram lever must be operated within approximately 3 seconds after the enable is activated or the function will timeout and the enable will have to be pressed again to activate the trams.

When the tram enable is active the tram enable light will be lit. See Fig 3 for location of this LED. There are 3 tramming speeds available to the operator. The first is SUMP. It is the lowest of speeds and is used while digging into the coal face. This speed will automatically be engaged when the miner comes into contact with the coal face. It will also be automatically selected when one tram is used alone or the trams are operated in different directions (“splitting the cats”). The miner will default on start up to the next speed, LOW TRAM speed. HIGH TRAM speed can be selected by pressing the high tram button on the transmitter.

The relationship between lever position and speed command can be seen on the view screen on the miner. The tram control signals from the transmitter can be seen in the lower left portion of the screen labeled TRACTION FT/MIN. See Fig below.

MACHINE DISPLAYS FOR VARIOUS ACTIONS On the miner itself there is a view screen that can be accessed by the operator of the transmitter. To navigate the menu system use the yellow shift button with the switches that have yellow labels. Refer to Fig 4 the Breaker Reset/on switch is also used to page up or page down in the menu system. Next to it, the Conveyor lower/raise switch is to change the value inside the menu. Up meaning to increase the value and down to decrease the value.

Following is a list of menus accessible by the operator of the transmitter in order that they occur on the miner. The default menu is Remote Runtime Status and is what the machine will display when started up.

This is the fault log screen. The machine will display faults and errors that occur during its operation. Only those faults that cause a motor to unintentionally shutdown will be logged into memory for later analysis. An example is if the miner is shut down when the MACHINE STOP Button is pressed it will be displayed here. If the miner stops because of an over temperature on the cutter motor then it will be displayed here and logged into flash memory.

This menu is a graphical overview motor currents and motor temperatures. Also displayed is the temperature of the tram transformer. Also useful is the display of the machine voltage.

This menu is the default menu that is displayed when the miner is powered up. It will show currents and temperatures for all the motors graphically. In the upper right corner it will show the status of the transmitter. The green light is to show a valid command is being transmitted. The bar graph changes color depending whether they are high or low.

The battery voltage of the transmitter is shown. A Red battery text will indicate that the battery is very near empty. The battery should be changed if the battery text is red in color. The RF signal indicates the relative strength of the RF signal. A low signal does not mean that there is a loss of information transmitted to the miner. Remember, the signal is digital in nature and will either work or not work. So a low value for the strength will mean that the miner is approaching a point where signal loss can occur. This graphic can be used to tell if there is something wrong with the transmitter. If you hold the transmitter near the antenna and there is a low signal then you should investigate the antenna cabling first and then the transmitter should be checked for low power output.

Another diagnostic tool is messages/second. When there is an active command this number should be around 8 to 12. If the transmitter is idle for 1 second this will decrease to 4 to 7 messages/second to save battery life. If there is interference from another transmitter then this will decrease the number of valid packets (messages) from the transmitter and the number will be smaller.

This screen gives a detailed view of the pump motor and its history for one minute. The screen will display immediately the pump motor current and the temperature in the blue bars graphs. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This screen gives a detailed view of the fan motor and its history for one minute. The screen will display immediately the fan motor current in the blue bar graph. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

In this menu the left and the right cutting motors currents and temperatures will be displayed and the history for one minute.

The screen will display immediately the cutting motor currents and the temperatures in the blue bars graphs for each motor. In the graphics area the current will be shown from right to left, the right most side of the screen will be the most recent measurements.

The right cutter motor will be colored green and the left motor will be colored blue.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This screen will display the CLA left and right motor status. The blue bar graphics will display the immediate values for the current and temperature. In the graphics area will be a one minute history of the motor currents. The current will be shown from right to left, the right most side of the screen will be the most recent measurements. The right CLA motor will be colored green and the left motor will be colored blue.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

In this menu the tram motor status will be displayed. The currents and the voltages for the left and right motors will be displayed as blue bars for the immediate values. A 1 minute history will be displayed for the voltage and the current for each motor. The left motor current will be blue. The left motor voltage will be red. The right current will be displayed in green. And the right voltage will be displayed in pink.

The transmitter status box ie., battery, rf signal etc will be active in this screen.

This is page one of four screens that display input/output status.

This is screen two of four status screens. As you can see the transmitter was communicating with the miner as the transmitter active status light was lit. Also note that in the upper right hand corner the battery voltage value was being sent. The receiver was measuring a moderate rf signal, no trams were active and no active command was being sent. The transmitter will always communicate with the miner even though there is no active command being sent.

This is page three of the status pages.

This is page four of four status pages. These status lights can be used to diagnose a fault in the machine if needed. If a status light is on because a command has been sent by the transmitter then you know that the transmitter is ok. You know the receiver is ok and the computer inside the miner is getting the command. Next look downstream from the computer for a fault in the wiring or a bad component.

This page will be for helpful hints in running the machine. It is not finished yet.

This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. When the operator presses the Machine Stop button on the transmitter the value that this screen contains will decide if the power center relay will trip or not. This screen is accessible by using the IR pendent.

This screen is not accessible to the operator of the transmitter. The operator should be aware of the setting of this parameter. The tilt sensor always sends the signal to the MCU but is only acted upon if this menu item is set. This screen is accessible by using the IR pendent.

This menu shows what happens when the tram levers are not in the center position when the transmitter is turned on. The error in red states the first error the transmitter sees in itself. It is saying that the left tram lever is stuck . With all error conditions such as stuck buttons on power up and stuck motor function switches and enables the transmitter will only send these error codes and can not be used until all errors are cleared.

This menu shows what happens when the pump start toggle is held in the start position.

The error is sent and visible on the screen.

Reading the Led Indicators Left to Right

POWER DOWN EVENTS There are currently four types of shut down modes for the RX-944 receiver. They are a “commanded power down”, “low battery shutdown.”, “inactivity shutdown”, and “loss of signal”. They are two separate and distinct ways of shutting down remote control operations.

Loss of Communication, Low Battery and Inactivity Power Down: A loss of communication power down is not initiated, but occurs due to a loss of communication between the transmitter and receiver for 2 sec. Typically, this occurs when a battery is weak, circuit malfunction occurs, the transmitter is out of range, or the antenna is being blocked or has a broken connection affecting the transmitter range.

When the receiver sees a loss of communication, a two-part power down occurs. After

one second the receiver will: 1.) Clear all non-latched outputs( Front/Rear Cylinders, and Tram commands) 2.) Set the power down bit in the Allen Bradley serial message (if a PLC is installed) 3.) Clear all outputs to OFF, Removing power from PUMP MOTOR. 4.) Wait for 2 sec. For power to be removed. If this does not occur, the receiver will return to a search condition and wait for a transmitter to turn ON. A low battery shutdown will display on the machine screen that the reason for shutting down was due to low battery voltage.

After 5 minutes the transmitter will auto shutoff. This will include shutdown messages sent to the MCU to turn off motor and hydraulic functions.

Commanded: A commanded power down is initiated by pressing the stop button on the handheld. It can also be shut down by pressing the machine stop button. The hand held will start and send 20 power down commands and then shut off. If in the menu system page “Machine Stop Shutdown Function”, the power center trip value is set then the command will be sent to trip the power center relay.

BATTERIES

One of the most beneficial features of the new transmitter style is its power design. The TX-9XX has a continuous operational life of approx. 120 hours. The power source is two 9 volt batteries. A BAT LED monitors battery life. A fast flashing LED means that battery strength is good. A slow flashing light means that the batteries are more than half used up. A double blink – pause- double blink LED means the batteries need to be changed (approx. 8 hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When the LED double blinks the batteries should be replaced. The battery compartment is polarized so the batteries can be inserted but the contact will only be made with the batteries in the correct orientation. Inside the compartment one contact is larger than the other corresponding to the larger contact on the battery. The battery compartment door should be closed with the screws finger tight.

RECEIVER FEATURES: 1.) Redundant Watchdog- The receiver incorporates the internal watchdog as described for the transmitter. In addition the receiver circuits include an external hardware based watchdog circuit to reset all outputs in the event of a microcontroller failure. This circuit is redundant to the internal watchdog and monitors the constant toggling of a dedicated I/O pin. Steady state values on the I/O pin, either low or high, will trip the external watchdog and reset

the receiver.

Note: Any time during operations that communications are lost between the transmitter and the receiver all outputs of the receiver will be cleared and it will begin scanning for the transmitter that contains the last serial number that was connected to it.

RADIO RECEIVER MODEL RX-944 LED DISCRIPTIONS

1 – Watchdog, blinks once per second to indicate that power has been applied and than internal processor is alive and working.

2 – Pre-Amble Detect, blinks to indicate that transmitter on the correct frequency has been detected. This LED should blink approximately 10 times per second as soon as a transmitter is switched on in the vicinity of the machine.

3 – Valid Message, blinks to indicate that valid messages from a transmitter on the correct frequency are being received. Note: This does NOT mean that the transmitter is the serial number that has been “TAUGHT” to the Machine Control Unit. All transmitter messages that pass the CRC tests are passed to the MCU for evaluation.

4 – Link LED, indicates that a sufficient number of messages are being received to qualify as a “link” and the system should not drop out.

Led’s 5 through 8 are for future use

WARNING! FAILURE TO READ THIS BEFORE INSTALLATION CAN RESULT IN INJURY OR DEATH. It is the responsibility of the installation technician to read and understand the following prior to installing and RX944. It is crucial that during installation of any RX-944 the mode be unique to any other receiver in the area. At the time of installation a definitive check on the modes of all receivers in the area must occur. Note the modes of each receiver and select a mode that is unique for the installation. Failure to do so may result in two receivers accepting signals from one transmitter. Two machines would be controlled by one transmitter resulting in unwanted movement. This is essential to ensure safe operation.

BELOW IS MSHA PROGRAM INFORMATION BULLETIN P03-03 RECOMMENDED DESIGN SAFEGUARDS FOR PERMISSIBLE REMOTE CONTROLLED MINING MACHINE U.S. Department of Labor

Mine Safety and Health Administration 1100 Wilson Boulevard Arlington, Virginia 22209-3939

ISSUE DATE: FEBRUARY 25, 2003

PROGRAM INFORMATION BULLETIN NO. P03-3

FROM:

MARK E. SKILES Director of Technical Support

RAY McKINNEY

Administrator for

Coal Mine Safety and Health

ROBERT M. FRIEND Administrator for

Metal and Nonmetal Mine Safety and Health SUBJECT: Recommended Design Safeguards for Permissible Remote Controlled Continuous Mining Machines Who needs to have this information?

Operators of underground coal or gassy metal and nonmetal mines, manufacturers of remote controllers and remote controlled continuous mining machines, Mine Safety and Health Administration (MSHA) enforcement personnel, miners' representatives, state mining agencies, and other interested parties need this information.

What equipment is affected by this bulletin?

This Program Information Bulletin (PIB) applies to new designs of permissible remote controlled continuous mining machines approved under Title 30 of the Code of Federal Regulations (30 CFR), Part 18 and to existing approved equipment in use in the mines as well. It applies to remote controllers that are portable and hand carried, or worn on the operator's body, to remotely control continuous mining machines from a location off the machine but in close proximity to and in visual and audible range of the machine being controlled. It is applicable to remote control systems using radio, infra-red or direct tethered electrical connection methods.

What is the purpose of this bulletin?

The purpose of this bulletin is to inform the mining industry of recommended safety design features for remote controlled continuous mining machines. These recommendations could help reduce the number of accidents resulting from the use of such equipment. This bulletin recommends safety design features for the following functions: .(1) Remote Emergency Stop Devices, located on remote controllers, that initiate an emergency shutdown function on remote controlled continuous mining machines; .(2) Prevention of accidental activation of machine tramming functions; and .(3) Reduction of the machine slew rate when the tram controls are split or singularly activated.

What is the background for this bulletin?

A review of thirteen fatal accidents involving the use of remote controlled continuous mining machines since 1988 reveals that two of these accidents were associated with the accessibility of the remote emergency stop device. Three accidents involved the bypassing of mechanical interlock safety devices on tram controls and eight accidents involved accidental activation of the tram controls.

Concerns With the Design of Remote Emergency Stop Devices In one accident, a remote controlled continuous mining machine operator was fatally injured when he was crushed between the continuous mining machine and coal rib. The remote controller did not have an emergency stop device that was readily accessible in the event of an emergency. In another accident, a maintenance helper sustained fatal crushing injuries when he became trapped between the conveyor boom and the mine roof. The chain conveyor became activated due to an electrical short inside the remote controller. The availability of a readily accessible emergency stop device may have saved the victim's life.

Good ergonomic design for a remote emergency stop device allows the device to be quickly and easily activated in an emergency. The device should be readily accessible, prominently located, and clearly differentiated from other controls. Existing emergency stop devices do not consistently utilize these design features, and as a result, confusion and delays in activating the device in an emergency situation can occur.

Concerns With Bypassing Mechanical Interlock Safety Devices on Tram Controls There have been three fatal "caught-between" type accidents where the mechanical interlocks on the remote controller tram controls were defeated by the use of tape, thereby bypassing protection against accidental activation. Taping the interlocks was identified as a contributing factor to all three accidents.

PIBs P97-31, P98-19, and P00-14 were issued to emphasize the importance of the mechanical interlocks and warn of the safety hazards associated with bypassing this safety feature. The use of same-hand activated mechanical release devices on tram controls proved to be inconvenient and difficult to operate over a working shift and are often bypassed by machine operators. These devices have not proven to be an effective means for preventing accidental activation.

Concerns With Accidental Tram Control Activation A review of accident data identified eight reported accidents (fatal or nonfatal) involving accidental tram control activation on remote controlled continuous mining machines. Of these eight accidents, four (including one fatal) have been attributed to a cable falling across the remote controller while it was left unattended, causing the tram controls to be activated. The other four were attributed to unintentional body contact. The need to prevent accidental tram control activation is recognized and has been addressed in most designs. However, all designs should incorporate these safety features to prevent accidental activation of the tram controls.

Accident analysis has also identified the need for limiting the maximum slew rate of the machine under tram control settings that produce a pivoting action of the machine.

Limiting the slew rate under these conditions has the potential to reduce pinning hazards to operators unintentionally positioned at machine pinch points.

What is being recommended through this bulletin?

MSHA recommends certain design safeguards and training: I. Design SafeguardsEquipment manufacturers should implement the design safeguards in all new designs. MSHA also recommends that manufacturers of existing approved remote controllers and remote controlled continuous mining machines currently in use modify their equipment, to the extent possible, to include the recommended safeguards.

Design changes should be submitted for MSHA approval under 30 CFR, Part 18. Field testing of remote controlled equipment is recommended before a design is finalized and submitted for approval. MSHA's Experimental Permit Program may be used to allow field testing.

MSHA recommends that the following design features be addressed: Remote Emergency Stop Device The remote controller should be equipped with a remote emergency stop device that: (1) Overrides all other machine controls; (2) Removes power from machine movement actuators; and (3) Causes all moving parts to stop within the shortest possible time. Resetting of remote emergency stop devices requiring manual reset, or release of momentary action remote emergency stop devices, should not cause any function of the machine to operate.

In mines utilizing extended cuts, the emergency stop device should cause the

circuit breaker at the power center to trip rather than the onboard machine circuit breaker, if a circuit breaker is used for removing power from machine movement actuators.

The remote emergency stop device should be: .(1) Differentiated from other controls by size (larger) or shape; .(2) Located in a readily accessible, prominent location in the operator's direct field of vision on the remote controller's main control panel; .(3) Colored red; .(4) Activated by a pushing action perpendicular to the controller's main control panel surface. Note: For example, a red, mushroom-head shaped switch actuator, may be used for this purpose, but other designs meeting the general recommendation could be used.

The remote emergency stop device should be clearly labeled "Emergency Stop," and should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block its activation. Ready access to the remote emergency stop device should not be hindered by the proximity of other controls or by mechanical guards. The design should consider the need for additional spacing when gloves are worn.

Operation of the remote emergency stop device should be tested during the machine preoperational checks.

Accidental Tram Activation Protection All control devices, such as buttons, levers and joysticks, used for controlling the tramming function of remote controlled machinery, should be designed such that the tramming function stops when the device is released.

The remote controller actuating controls for the machine tram function should be designed to reduce the likelihood of unintentional activation. Tramming functions can be activated when cables or other material fall on the controls, or with unintentional hand or body contact. Recessed selector switches, shrouded selector switches, deadman control, two-hand control, or sequential two-switch operation such as use of a tram function enable switch should be used. These safety features should be ergonomically designed, tamper-resistant, and not interfere with the normal operation of the mining equipment.

When sequential two-switch operation (tram enable switch) is used, a tram function inactivity timer should be provided to disable the tram function if the tram controls are not activated within a pre-programmed time period. The tram function inactivity timer should be set as low as reasonably practicable, consistent with convenient machine operation. Five seconds is the recommended maximum inactivity timer setting.

The controls actuating the machine tramming function should be protected against the entry or buildup of coal, dust, or other foreign material that could hinder or block their activation or movement. Note: The use of rubber boots or other effective means could be used for this purpose.

The use of same-hand activated mechanical release devices on tram controls, such as lift-to-operate mechanical interlocks on tram control levers, should be eliminated. Note: Safeguarding devices that impede convenient operation and that prove to be tiring over a working shift are often bypassed by operators.

The use of a "global" guarding method, such as a raised guard rail surrounding all the switches on the control panel, is not a recommended method for preventing accidental tram control activation when used as the only prevention method. Note: This guarding method does not provide adequate protection against accidental activation by cables of various sizes or other foreign objects and may result in accidental control activation when using the guardrail as a carrying handle. Attention must be paid in the design to ensure that the use of any mechanical guarding methods does not hinder activation of the remote emergency stop device.

Machine Slew Rate Control Remote controlled machinery utilizing a machine tramming function should be equipped with control circuits that reduce the machine rotational slew rate when the tram controls are set with one control forward and one control reverse (split cat) or a single control forward or reverse (hard turn) position. When the tram controls are split or set in a hard turn position, the tram speed of the activated drive(s) should be limited to no greater than the slowest operational tram speed provided on the machine, in order to minimize the slew rate (rotational speed) of the machine.

The slew rate of the machine needs to be minimized to obtain a pivoting action of the machine that reduces potential "caught-between" type hazards to machine operators inadvertently positioned at machine pinch points.

II. TrainingMSHA recommends that mine operators establish safe work practices and provide training for personnel addressing the safe operation and maintenance of remote controllers and remote controlled continuous mining machines. The training should address all danger areas applicable to specific machines and mining operations. Particular emphasis needs to be placed on the machine operator's and maintenance personnel's position when working near energized machines. Machine operators should be trained to check that safety features on remote controllers are operating properly and are not defeated. In addition, MSHA urges mine operators to regularly ensure that established safe work practices are being followed.

What is the authority for this bulletin?

Title 30 Code of Federal Regulations, Section 18.20(b), 57.12002, and 75.520.

Is this program information bulletin on the Internet?

This bulletin may be viewed on the World Wide Web by accessing the MSHA home page (http://www.msha.gov) and then choosing "Statutory and Regulatory Information" and "Compliance Assistance Information."

Who are the MSHA contact persons for this program information bulletin?

Coal Mine Safety and Health, Safety Division Erik Sherer, (202) 693-9523 E-mail: Sherer.Erik@dol.gov Metal and Nonmetal Mine Safety and Health, Safety Division Thomas Loyd, (202) 693-9645 E-mail: Loyd.Thomas@dol.gov

Technical Support, Approval and Certification Center David C. Chirdon, (304) 547-2026 E-mail: Chirdon.David@dol.gov Who will receive this program information bulletin?

MSHA Program Policy Manual Holders Underground Mine Operators Equipment Manufacturers Special Interest Groups Miners' Representatives Repair and Rebuild Facilities

Coal Mine Safety and Health The Red Zone

IT HURTS TO BE IN THE “RED ZONE” Entering the “RED ZONE” continues to result in mine fatalities and injuries. A recent non-fatal roof fall accident occurred that resulted in injuries to two miners who were working in the “RED ZONE”. The miners were loading supplies onto the roof bolting machine from a battery scoop. The roof bolting machine was positioned at the mouth of an unbolted right crosscut and the scoop was positioned to the right-rear of the bolting machine with the bucket extending into the “RED ZONE”. The miners were in front of the bucket, between the first and second row of roof bolts, moving supplies to the roof bolting machine when the roof material fell. Draw rock fell along the right rib of the

unsupported area and extended into where the men were working, striking and injuring both miners. Fortunately, the injuries were not life threatening.

Best practices to prevent such an accident from re-occurring include moving the roof bolting machine and the scoop to a safe area outby the newly developed crosscut. This would prevent the miners exposure to the hazards created by working close to the unsupported area or the need to perform work in the “RED ZONE”.

Please take time to re-instruct all miners as to the location of the “RED ZONE” as shown in your mine’s approved roof control plan. Working in the “RED ZONE” is not much different from working in an unsupported area. Roof material that begins to fall in the unbolted area doesn’t always stop at the first row of roof bolts. When that happens, it hurts to be in the “RED ZONE”.

Remote Control System for Continuous Miners

Troubleshooting Guide

Bucyrus America Inc. 2045 West Pike Street Houston PA 15342-1010

PUBLICATION DISCLAIMER AND COPYRIGHT

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations nor to provide for every possible contingency in connection with troubleshooting and maintenance. Features may be described herein which are not present in all systems. BUCYRUS assumes no obligation of notice to holders of this

document with respect to changes subsequently made.

BUCYRUS makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability of fitness for purpose shall apply.

GENERAL SAFETY NOTICES

This section addresses some general safety guidelines involved with BUCYRUS products. These guidelines are intended to promote safe usage of equipment.

This section is not intended to replace present safety practices at your site.

It is the responsibility of the contractor, installer, purchaser, owner, and user to install, maintain, and operate the parts or components manufactured and supplied by DBT in such a manner as to comply with the MSHA Safety Standards and all state and local laws, ordinances, regulations.

WARNING: If malfunctions occur in any aspect to the transmitter or receiver operation do not continue to operate; power down the system, fill out the service tag, and return it to the factory for inspection and repair. When the system is in use and if any part of the unit is damaged physically, discontinue operation and return it to the factory for inspection and repair. At anytime during usage of the system any damage is found physically or electronically, it is crucial for the safety of

the operator and others in the operating area that the system is not allowed to continue in operation.

SAFETY RECOMMENDATIONS Ghosting (gosting), v., 1: Unplanned movement by machines that use Computer Control Technology.

The Mine Safety and Health Administration has recognized a problem involving malfunctions of electro-hydraulic shield advance systems at various longwall installations. This has lead MSHA to issue the following recommendations for the safe operation of all computer controlled mining equipment to prevent the condition known as ‘ghosting’.

The recommendations are as follows: 1.

1. Mine personnel who operate this equipment should be trained to insure the proper operational procedures and sequences are used to recognize improper system operation, alarms, and displays.

2.

2. Maintenance of the system is critical for safe operation. Hardware malfunctions, such as sticking solenoid valves, should be immediately repaired.

3.

3. Mine personnel should be made aware that the entry of moisture or water into the transmitter or umbilical enclosure could cause undesired machine movements. Transmitter cases should be inspected for damage that could compromise the sealing features designed into these units and allow moisture entry. Signs of mechanical distortion or bent control housings, damaged gaskets or seals, damaged keypads, corrosion, or evidence of internal moisture indicate that the enclosure sealing may have been compromised. The control unit enclosures should not be disassembled for inspection because proper resealing is too difficult to accomplish in the field.

When signs of moisture or water are observed in the control unit enclosure, the units must be immediately replaced.

4.

4. Any abnormal operational sequences of the system, alarm displays, or unintended machine movement which might be due to a software

programming error should be noted, reported to the manufacturer, and corrected immediately.

5.

5. Any equipment removed to correct “ghosting” problems should be sent to the manufacturer to determine the exact cause of the problem.

Corrective action will then be taken by either the manufacturer or the operator to prevent similar occurrences.

6.

6. Whenever an unplanned machine movement is observed, the hardwired emergency stop system should be activated, not the stop button on the electronic control unit.

These recommendations, though originally made in response to the unplanned movement of longwall shield advance systems utilizing computer control technology, are equally applicable to all equipment with machine control circuits utilizing computer control technology.

The recommendations above should be followed on a continuing basis on all machines utilizing computer control technology.

MANUAL

CONTENTS

Table of Contents Please read the important information contained in the previous section titled GENERAL SAFETY NOTICES. Section/Paragraph Page

SECTION 1. HOW ..........................1

TO

TROUBLESHOOT

SECTION 2.

SYSTEM ..............................................3

STATUS

THIS

SYSTEM

INDICATORS

2.1 Introduction.................................................................................................. .3

2.2 Status LED ......................................................3 2.3

Functional

Status

Categorization

LED

Response

Analysis....................................................................6 SECTION

3.

ALARMS,

WARNINGS,

AND

DISPLAY

INFORMATION..21

3.1

Coded

Alarms

and

Warnings

....................................................................22 3.1.1

Alarm

Codes

...........................................................................................22

3.1.2

Warning

Codes

.......................................................................................24 3.2

Informational

Messages

.............................................................................29 SECTION

4.

..........................................31

COMPONENT

IDENTIFICATION

4.1

Remote

Control

System

Components

.......................................................31

4.2

Remote

Control

System

Components

Tie-

in............................................31

List of Tables Table Page Table 2.1 MCU944 LED Functional Categories ......................................................5 Table 2.2a MCU944 Status LED Response Analysis (R1 & R2) ............................6 Table 2.2b MCU944 Status LED Response Analysis (R3 & R4) ............................7 Table 2.2c MCU944 Status LED Response Analysis (R5 & R6) ............................8 Table 2.2d MCU944 Status LED Response Analysis (R11 & R12) ........................9 Table 2.2e MCU944 Status LED Response Analysis (R13 & R14) ......................11 Table 2.2f MCU944 Status LED Response Analysis (R15 to R20).......................11 Table 2.2g MCU944 Status LED Response Analysis (R21 & R22) ......................12 Table 2.3 TX944 Status LED Response Analysis ..................................................13 Table 2.4 RX944 Status LED Response Analysis ..................................................17 Table 2.5 CPS944 Status LED Response Analysis ................................................18 Table 2.6 DCD100 Status LED Response Analysis ...............................................19 Table 3.1 Display Screen Top Banner General

Description...................................21 Table 3.2 Alarm Codes ...........................................................................................22 Table 3.3 Warning Codes........................................................................................24 Table 3.4 Informational Messages ..........................................................................29 Table 4.1 System Components ...............................................................................31

List of Figures Figure Page Figure 2.1 MCU944 Custom PLC Status LEDs .......................................................3 Figure 2.2 TX944 Transmitter Status LEDs ...........................................................13 Figure 2.3 RX944 Receiver Status LEDs ...............................................................17 Figure 2.4 CPS944 Power Supply Status LEDs .....................................................18 Figure 2.5 DCD100 DC Tram Drive Status LEDs .................................................19 Figure 3.1 Display Screen Messages ......................................................................21 Figure 4.1 Remote Control System Components Layout .......................................32 Page 1 of 30

SECTION 1.

HOW TO TROUBLESHOOT THIS SYSTEM

This system has visual troubleshooting aids to allow operators and maintenance personnel to quickly determine the cause of most operating faults. These troubleshooting aids consist of: WARNING: Before troubleshooting beyond the level of observing the fault log, read this entire manual and contact your supervisor. .

• Display -Graphics or text device that shows run time data and fault log. .

• Fault Message -A machine local graphics display message that appears for 10 seconds when the system detects a fault. .

• Fault Log -A permanent, machine-local, displayed timestamped record of the fault. It can be paged from the remote control transmitter. .

• Operational Error Message -A machine local graphics display message that appears whenever an action is prevented from execution due to a fault condition. .

• LED Indicators -Light emitting diode (LED) indicators are placed strategically on most system sub-assemblies for aid in troubleshooting.

When you experience any fault: Page to the fault log and try to redo faulted machine function while watching for fault message at display.

If fault reoccurs, note message from display or log and proceed to Section 2 to troubleshoot using system LED indicators.

Page 2 of 30

When troubleshooting the system, the following points should be noted:

.

• The remote control system does not recognize problems in the machine hydraulic system unrelated to the pump motor. .

• Most faults only affect one machine function. However, if dependent faults should occur, the most significant fault message appears first, then the next after the first fault is corrected, and so on. .

• The system will not recognize power lost to the machine unless initiated by the machine control unit. In that case, the system will indicate such action once power to the machine has been restored.

Page 3 of 30

SECTION 2.

SYSTEM STATUS INDICATORS 2.1 Introduction WARNING: Although this guide includes measurement information, it is not intended to imply breaching of any methane or hazardous isolation barriers to make actual measurements.

Contact your supervisor if it is suspected that a more comprehensive troubleshooting method is required.

A sufficient complement of status LEDs is provided on the MCU944 to assist in quickly determining the source of most problems that may arise during operation. Additional status LEDs are provided on the RX944, TX944, CPS944, and DCD100 units.

2.2 Status LED Functional Categorization The majority of status LEDs of interest in troubleshooting this remote radio control system are located on the MCU944. Each LED has a one-to-one correspondence with its connector pin. The layout of the connectors on the face plate is such that pins, and thus the LEDs, are grouped in functional categories as described in Table 2.1 and shown in Figure 2.1.

NOTE: LED locations on the MCU944 are with reference to their associated connector. The LEDs are located to the right of their connector.

WARNING: Only qualified personnel with approved training on this equipment and knowledgeable of MSHA safety requirements should perform troubleshooting of this system.

Page 4 of 30 Page 5 of 30

Generally, an abnormal status indication can be quickly attributed to either a fault in a component of the remote control system or controlled machine.

Table 2.1 MCU944 LED Functional Categories

Functional Category

LED Loc. R1-R6

A contact output. Either a solenoid output or a relay output. When ON, contact should be closed.

R11

120VAC inputs. When ON, 120VAC is present. For normal operation of the miner, MACHINE STOP (R11-1) and LEFT STOP (R11-2) LEDs should be ON.

R12

120VAC inputs. When ON, 120VAC is present.

R13

12VDC inputs and outputs.

Top Three LEDs are associated with outputs Bottom Three LEDs are associated with inputs.

R14

(Future Use)

R15

Top LED: Flashes whenever the MCU944 is transmitting. At the moment, this will only occur during Teach/Learn. In Teach/Learn, the top LED will flash a minimum of three times during a successful Teach/Learn cycle.

Bottom LED: Flashes whenever the MCU944 has received valid messages from the Receiver (RX944). This can only occur if the mode is not LOCAL, checksum is valid, and proper transmitter is communicating to MCU944.

R16

Top LED: Indicates whenever the display is transmitting.

Bottom LED: Indicates when the display responds to the MCU944.

R17

Top LED: Flashes whenever there is activity between the MCU944 and IR receiver.

R18

Top LED: Flashes quickly (looks steady) whenever the MCU944 is transmitting.

Bottom LED: Flashes quickly (looks steady) whenever a valid message has been received from either the left or right drive.

R19

Not used.

R20

Indicates activity with respect to the download/debug cable connection.

R21

Not used.

R22

Indicates voltage levels inside the MCU944. Top LED: Indicates +5V is present.

Middle LED: Indicates +12V is present. Bottom LED: Flashes whenever the MCU944 is in UMBILICAL mode with the TX944.

Page 6 of 30

Table 2.1 MCU944 LED Functional Categories LED Loc. Functional Category Rotary Top LED: (Located left of the rotary switch) flashes whenever there have been multiple internal backplane communication errors inside the MCU944.

Switch Other Three LEDs: Engineering Use..

2.3 MCU944 Status LED Descriptions Use Tables 2.2 through 2.6 to troubleshoot the system using the status LEDs. Generally, LED locations and functions are associated with their respective connector designations Rx. Table 2.2 has been divided into several sub-tables to allow quick access to specific status LED analysis locations on the MCU944 from the Table of Contents.

Table 2.2a MCU944 Status LED Description (R1 & R2) LED Function

Description

LED Loc.

NOT USED

R1-1

Not Used

FAN WATER SPRAY SOLENOID

R1-2

On when fan water spray solenoid is energized. Action is slaved to fan operation.

AUX SOLENOID OUTPUT #6 (MOMENTARY)

R1-3

Active when contact is closed. Action is momentary and controlled from transmitter.

DUST SUPPRESSION

R1-4

Active when dust suppression is closed. Action is controlled from transmitter.

CUTTER RAISE SOLENOID

R1-5

Active when cutter raise contact is closed. Action is controlled from transmitter.

GATHERING HEAD FLOAT SOLENOID

R1-6

Active when gathering head float contact is closed.

This action will latch and is deactivated only when gathering head raise solenoid is active or pump is inactive. Requires pump active prior to use.

CUTTER LOWER SOLENOID

R2-3

Active when contact is closed. Action is controlled by transmitter.

CONVEYOR RAISE SOLENOID

R2-4

Active when contact is closed. Action is controlled by transmitter.

CONVEOR LOWER SOLENOID

R2-5

Active when contact is closed. Action is controlled by transmitter.

CNVYR SWING LEFT SOLENOID

R2-6

Active when contact is closed. Action is controlled by transmitter.

Page 7 of 30

Table 2.2a MCU944 Status LED Description (R1 & R2) LED Function

LED Loc.

Description

CNVYR SWING RIGHT SOLENOID

R2-7

Active when contact is closed. Action is controlled by transmitter.

STAB UP SOLENOID

R2-8

Active when contact is closed. Action is controlled by transmitter.

STAB DOWN SOLENOID

R2-9

Active when contact is closed. Action is controlled by transmitter.

GATHERING HEAD RAISE SOLENOID

R2-10

Active when contact is closed. Action is controlled by transmitter.

Table 2.2b MCU944 Status LED Description (R3 & R4) LED Function

LED Loc.

Description

AUX OUTPUT #7 (LATCHED)

R3-1

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

AUX OUTPUT #8 (LATCHED)

R3-2

Active when contact is closed. Contact will latch upon momentary activation and is controlled from the transmitter.

CONVEYOR REV CONTACTOR

R3-3

Active when reverse conveyor contact is closed.

FAN CONTACTOR

R3-4

Active when fan contact is closed.

AUX OUTPUT #5 MOMENTARY

R4-3

Active when contact is closed. Action is momentary.

LOW OIL ALARM OUTPUT

R4-4

Active when contact is closed. Action is predicated upon configuration.

CNTRL GND FAULT ALARM OUTPUT

R4-5

Active when contact is closed.

HEADLIGHTS

R4-6

Active when contact is closed. Action is controlled by transmitter.

PUMP CONTACTOR

R4-7

Active when contact is closed.

LEFT CUTTER CONTACTOR

R4-8

Active when contact is closed.

RIGHT CUTTER CONTACTOR

R4-9

Active when contact is closed.

Page 8 of 30

Table 2.2b MCU944 Status LED Description (R3 & R4) LED Function

LED Loc.

CONVEYOR FWD CONTACTOR

R4-10

Description Active when contact is closed.

Table 2.2c MCU944 Status LED Description (R5 & R6) LED Function

LED Loc.

Description

REDUNDANT RIGHT CUTTER

R5-1/2

Active when contact is closed.

REDUNDANT LEFT CUTTER

R5-3/4

Active when contact is closed.

BREAKER ON (ALT)

R6-3

Active when Breaker ON contact closed. Action is controlled from transmitter.

BREAKER OFF (ALT)

R6-4

Active when Breaker OFF contact closed. Action is controlled from transmitter.

BRAKE RELEASE

R6-5

Active when Brake Release contact closed. Brake Release contact will activate when tram is authorized.

SPARE #1

R6-6

Active when spare contact closed.

SPARE #2

R6-7

Active when spare contact closed.

SPARE #3

R6-8

Active when spare contact closed.

AUX SOLENOID OUTPUT #3 (MOMENTARY)

R6-9

Active when contact is closed. Action is momentary.

AUX OUTPUT #4 (LATCHED/PUMP)

R6-10

Active when contact is closed. This contact requires that the pump be operating prior to use. Action is momentary and controlled from transmitter.

Page 9 of 30

NOTE: There are no LEDs associated with connector functions R7 through R10.

Table 2.2d MCU944 Status LED Description (R11 & R12) LED Function

LED Loc.

Description

MACHINE STOP

R11-1

Active when 120VAC is present. When not present, indicates that machine stop is pressed. Operation is prevented unless machine stop override from transmitter utilized.

LEFT STOP

R11-2

Active when 120VAC is present. When not present, indicates that left stop is pressed. Operation is prevented unless machine stop override from transmitter utilized.

CUTTER RUN

R11-3

Active when 120VAC is present. When present, cutter motor operation is desired. When not present, this input will deactivate the cutter motors only in LOCAL mode.

PUMP RUN

R11-4

Active when 120VAC is present. When present, pump motor operation is desired. When not present, this input will deactivate the pump motor only in LOCAL mode.

CONVEYOR RUN

R11-5

Active when 120VAC is present. When present, conveyor motor operation is desired. When not present, this input will deactivate the conveyor motors only in LOCAL mode.

MINER TYPE #1

R11-6

Active when 120VAC is present. Used in conjunction with miner type #2 input to notify the MCU944 whether CM is 30M, 25M0, 25M1, or 25M2/25M3.

MINER TYPE #2

R11-7

Active when 120VAC is present. Used in conjunction with miner type #1 input to notify the MCU944 whether CM is 30M, 25M0, 25M1, or 25M2/25M3.

METHANE MONITOR OK

R11-8

Active when 120VAC is present. When present, indicates that methane monitor is functioning properly and methane levels are within acceptable limits.

CB2 BREAKER

R12-1

Active when 120VAC is present.

EMERGENCY TRAM

R12-2

Active when 120VAC is present.

MAN SCRUBBER (FAN) RUN

R12-3

Active when 120VAC is present.

CUTTER RUN WITH FAN

R12-4

Active when 120VAC is present.

CUTTER LOCKOUT

R12-5

Active when 120VAC is present.

MOTOR START/TRAM ENABLE (LOCAL)

R12-6

Active when 120VAC is present. This input must be present prior to any motor start in LOCAL mode.

Page 10 of 30

Table 2.2d MCU944 Status LED Description (R11 & R12) LED Function

LED Loc.

Description

REMOTE

R12-7

Active when 120VAC is present.

ANY INPUT ON R9

R12-8

Active when 120VAC is present at any input on connector R9.

Page 11 of 30

Table 2.2e MCU944 Status LED Description (R13 & R14) LED Function

LED Loc.

Description

FIRE SUPPRESSION

R13-1

Active when fire suppression contact is closed. The fire suppression contact, when fire suppression is initiated, will stay active for 10 seconds. Controlled from transmitter.

BREAKER ON

R13-1

Active when Breaker ON contact closed. Controlled from transmitter.

BREAKER OFF

R13-1

Active when Breaker OFF contact closed. Controlled from transmitter.

+12 VDC OUTPUT

R13-1

Indicates +12V I/O have power.

LOW OIL LOCKOUT

R13-1

Active when low oil lockout input sensor is active.

LOW OIL ALARM

R13-1

Active when low oil alarm input sensor is active.

SPARE DC INPUT

R13-1

Unused

+5.0 VDC TO TRAM LEVERS

R14-1

Indicates +5V I/O have power.

RIGHT TRAM PROPORTIONAL SIGNAL

R14-1

NOT USED. Replaced with emergency tram pendant.

Proportional LED output directly related to the tram command in LOCAL mode.

RIGHT TRAM FWD CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when right forward command is given in LOCAL mode.

RIGHT TRAM REV CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when right reverse command is given in LOCAL mode.

LEFT RRAM (PROPORTIONAL)

R14-1

NOT USED. Replaced with emergency tram pendant.

Proportional LED output directly related to the tram command in LOCAL mode.

LEFT TRAM FWD CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when left forward command is given in LOCAL mode.

LEFT TRAM REV CONTACT

R14-1

NOT USED. Replaced with emergency tram pendant.

Active when left reverse command is given in LOCAL mode.

Table 2.2f MCU944 Status LED Description (R15 to R20) Page 12 of 30

LED Function

LED Loc.

Description

RADIO RECEIVER TX

R15-1/2

Active when MCU944 transmits out.

RADIO RECEIVER RX

R15-3/4

Active when MCU944 receives packets specific to its ID.

DISPLAY TX

R16-1/2

Active when MCU944 receives packets.

DISPLAY RX

R16-3/4

Active when MCU944 transmits out.

IR PENDENT TX

R17-1/2

Active when MCU944 receives valid packets.

IR PENDENT TX RECEIVED

R17-3/4

Active when MCU944 receives valid packets.

MCU944 TX TO TRACTION DRIVE

R18-1

Active when MCU944 transmits out.

MCU944 RX FROM TRACTION DRIVE

R18-2

Active when MCU944 receives valid messages.

NO LEDS

R19

DOWNLOAD/DEBUG TX

R20-3

Active when MCU944 transmits out.

DOWNLOAD/DEBUG RX

R20-2

Active when MCU944 receives bytes.

Table 2.2g MCU944 Status LED Description (R21 & R22) LED Function

LED Loc.

Description

GP10

R21

Unused

+5V

R22-2/3

Indicates when +5V is active. This voltage is required to operate the MCU944.

+12V

R-22-4/5

Indicates when +12V is active. This voltage is required to operate the MCU944 in normal modes. It is deliberately deactivated in battery mode until required.

UMBILICAL (PENDANT ACTIVITY)

R22-6

Indicates when transmitter is connected to the MCU944 via umbilical cable and is active.

HARDWARE FAILURE (TOGGLE)

SW Hole Plug

Flashes whenever there is a hardware failure internal to the MCU944.

MODBUS COMM ERROR (TOGGLE) IR PENDANT COMM ERROR (TOGGLE) WRITE TO EEPROM (TOGGLE)

Page 13 of 30

Refer to separate documentation for additional information on the TX944 Transmitter. Use Figure 2.2 as a location reference for the TX944 Transmitter.

Figure 2.2 TX944 Transmitter Status LEDs Table 2.3 TX944 Status LED Response Analysis LED Function Description BATTERY/UMB MSG NOTE: THIS LED HAS 2 FUNTIONS BATTERY Transmitter Mode: A flashing LED means that battery strength is good. A double blink –pause- double blink LED means the batteries need to be changed (approx. 24hrs left). The transmitter will run until the batteries are dead, but performance and range will diminish quickly and could be unsafe if trying to operate from a long range. When the LED double blinks the batteries should be changed without delay.

Umbilical Message: LED blinks indicating that a message has been sent to the MCU. The blink rate should be steady at 10

times per second.

Page 14 of 30

Table 2.3 TX944 Status LED Response Analysis

LED Function

Description LED does come on briefly after power up. If this LED is ON after power up, the transmitter should be returned for repair.

ERROR

LINK REQUEST/SHUTDOWN

NOTE: THIS LED HAS 2 FUNTIONS LINK Request: When the transmitter is connected umbilically, it will attempt to link to the MCU. Shutdown: When the transmitter switches off, this indicates that a shutdown is in progress and power down messages are being sent to the MCU. ** At the same time, one of three LED’s to the right will indicate why the transmitter is powering down: Commanded (Operator initiated), Inactivity or Low Battery (See paragraphs below).

Page 15 of 30

Table 2.3 TX944 Status LED Response Analysis LED Function SWITCH ACTIVE/LOW BATTERY

Description NOTE: THIS LED HAS 2 FUNTIONS Switch Active: After power up this LED is used to indicate a “stuck switch”. .

• ALL switches must be in their neutral or safe position before the transmitter is allowed to become operational. .

• If after power up (i.e. TX PWR ON depressed) LED lights and stays ON (solid) then there is a “stuck” switch. In this condition, no other switches on the transmitter will be operational. .

• Faulty Condition: The transmitter will send the error condition to the MCU and the system will display which switch is “stuck”. This switch must be replaced before proper operation will resume. .

• After power up, any switch that is operated will result in this LED being solidly ON while the switch is operated. In this manner, all switches can be verified locally at the transmitter.

.

• To see if the transmitter switch is being properly read, operate the switch and observe the SW ACTIVE LED. .

• Note that only one switch can be operated at any time as this LED is common for all switches. Also while in normal operation, certain switches are timed to maintain safety features primarily as two handed starts. If for example the ENABLE button is held down for more than 25 seconds, then the transmitter will enter an error mode. If this occurs then all commands will cease to operate and an error code will be sent to the machine. .

• To resume normal operation, the ENABLE button must be released. Switches that are timed in this manner are ENABLE, SHIFT, TRAM ENABLE, PUMP START, CONV START, CONV REV, and CUTTER START. Note : In normal operation, all of these switches are to be operated for only short periods of time. A constantly held condition would be abnormal and defeat two handed starts and make other enabled functions unsafe. Therefore, these switches are monitored and timed during normal operation to prevent the possibility of a constantly ON switch.

Shutdown via Low Battery: Upon shutdown, this LED will illuminate in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a low battery condition.

Page 16 of 30

Table 2.3 TX944 Status LED Response Analysis

Description

LED Function TRAM ENABLE/INACTIVITY

NOTE: THIS LED HAS 2 FUNTIONS Tram Enable: Indicates that the tram levers are armed (active) and that any operation of the tram levers will result in machine movement. Conversely, if this LED is OFF, then the tram levers are dead.

Shutdown via Inactivity: Upon shutdown, this LED will light in

LINK ACK/COMMANDED POWER DOWN

conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was inactivity (no switch operation for 5 minutes).

NOTE: THIS LED HAS 2 FUNTIONS Link Acknowledge: During the TEACH/LEARN process, LED indicates that a link response (acknowledgment) has been received back at the transmitter from the MCU. I • f the transmitter was re-linked back to the same MCU (machine), then this LED will flash once.

• If this is a new link to a different MCU (machine), then this LED will flash twice.

Shutdown via Power Down: Upon shutdown, this LED will light in conjunction with the SHUTDOWN LED to indicate that the reason the TX shut off was a commanded power down (operated or initiated) as a result of the operator pressing either the MACHINE STOP mushroom head or the TX PWR OFF

pushbutton.

Page 17 of 30

The RX944 Receiver is approximately 6 inches long and 2 inches high. It is located on the Swing Panel of the Main Control Case of the 25M Miner and in the Radio Receiver Case of the 30M Miner. The device runs on 12V via R1-1 and R1-2.

Figure 2.3 RX944 Receiver Status LEDs Table 2.4 RX944 Status LED Description LED Function

LED

Description

WATCHDOG

1

Flashes once Per Second to indicate that power has been applied and that internal processor is alive and working.

PRE-AMBLE DETECTED

2

Blinks to indicate that transmitter is on the correct frequency and has been detected. This LED should blink approximately 10 times per second as soon as a transmitter is switched ON in the vicinity of the machine.

VALID MESSAGE

3

Blinks to indicate that valid messages from a transmitter on the correct frequency are being received.

Note: This does NOT mean that the transmitter is the serial number that has been “TAUGHT” to the Machine Control Unit. Check top Right Hand Corner of Graphics Display for TX944 Serial Number (See Section 3.0).

LINK RECEIVED

4

Steady On: Indicates that a sufficient number of messages are being received from the TX944 to operate and the system should not drop out.

NOT USED

5-8

Reserved for future use.

Page 18 of 30

The CPS944 Capacitor Backup is approximately 6 inches long and 6 inches high. It is located on the Swing Panel of the Main Control Case of the 25M and in 30M Miners. The device runs on 120VAC via R2-2 and R2-3.

Figure 2.4 CPS944 Power Supply Status LEDs Table 2.5 CPS944 Status LED Response Analysis LED Function

LED

Description

+12VDC OUTPUT ACTIVE

1

Active in Battery Mode.

+5VDC OUTPUT ACTIVE

2

Active in Battery Mode.

120VAC INPUT PRESENT

3

Active when not in Battery Mode.

Page 19 of 30

The DCD100 DC Tram Drive is located in the Tram Case of the 25M Miner and in the Control Case of the 30M Miner. The device runs on 120VAC via D1-1 and D1-2.

Figure 2.5 DCD100 DC Tram Drive Status LEDs Table 2.6 DCD100 Status LED Response Analysis LED Function

LED

Description

LOCAL FWD

1

Indicates FWD direction command in LOCAL CTRL.

LOCAL REV

2

Indicates REV direction command in LOCAL CTRL.

UNUSED

3

UNUSED

4

AC PRESENT

AC

Indicates when 120 VAC power is available.

TRANSMIT OUT

TX

Indicates transmission by unit over serial COM port.

RECEIVED IN

RX

Indicates reception by unit over serial COM port.

WATCHDOG

WDG

Indicates unit is active and operating code.

PROPORTIONAL OUTPUT

OUT

Will blink when active. Rate of blinking is directly related to the magnitude of the command.

FORWARD DIRECTION

RT (FWD)

Indicates when commanded output direction is FWD.

REVERSE DIRECTION

LT (REV)

Indicates when commanded output direction is REV.

Page 21 of 30

SECTION 3. ALARMS, WARNINGS, AND DISPLAY INFORMATION The purpose of this section is to provide service personnel with the complement of possible alarms, warnings, and information that are designed into the system for troubleshooting purposes. The system is capable of sensing many possible abnormal conditions associated with these message categories. When an abnormal state is sensed, an appropriate message is displayed on all screens for 10 seconds, in addition to being logged (see Section 1). The basic organization of the display screen message banner is provided in Figure 3.1 and Table 3.1.

Figure 3.1 Display Screen Messages Table 3.1 Display Screen Top Banner General Description Fine #

Description

1

Fault log message, warning message, informational message block.

2

Miner type.

3

MCU944 mode.

4

Battery voltage.

5

Transmitter serial number.

6

Commanded input message indication.

7

Messages per second from transmitter.

8

RF signal strength.

9

Active input indicator.

Page

22

of

30

3.1 Coded Alarms and Warnings Alarms and warning codes are distinguished by the prefix letter A and W, respectively.

3.1.1 Alarm Codes Refer to Table 3.2 for the descriptions of system ALARM codes.

Table 3.2 Alarm Codes

Description

Code A001 A002 A003 A004 A005 A006 A007 A008 A010 A011 A012 A013 A017 A018 A019

Backplane Transfer Fault: Backplane Transfer Fault: Backplane Transfer Fault: Backplane Xfer Fault: Backplane Transfer Fault: Relay Output Error Relay Output Error Relay Output Error Enable PushButton Stuck Transmitter shutdown Transmitter shutdown Transmitter shutdown Pump shutdown Pump shutdown Pump shutdown

CPU to PWM/Tram PCB CPU to Relay Card 1 CPU to Relay Card 2 CPU to Motor Current Analog Card CPU to RTD Analog Card Relay Card 1 Relay Card 2 Relay Card 3 Low battery Inactivity period expired Data link loss LOW OIL LOCKOUT for 5 sec.

Tilt Switch Active Over

A020 A022 A023 A024 A025 A026 A027 A028 A029 A030 A031 A032 A033 A034 A035 A036 A037 A038 A039 A040

Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump shutdown Pump Start toggle switch stuck Conveyor Reverse pushbutton stuck Conveyor Start toggle switch stuck Conv Shutdown Conv Shutdownt Conveyor Shutdown Conveyor Shutdown Conveyor Shutdown Conveyor Shutdown Conv Shutdown Conv Shutdown Conveyor Shutdown Conveyor Shutdown Conv Shutdown

Pump motor overload Conveyor Breaker opens (CB2) Pump Inst. Current Trip Pump Phase Imbalance Trip Pump Low Current Pump Start Switch held too long

Rt Motor Jam Current Lt Motor Jam Curren Right Motor Over Left Motor Over Right Motor Overload Left Motor Overload Rt Motor Inst Curr Trip Lt Motor Inst Curr Trip Right Trip Motor Phase Imbalance Left Motor Phase Imbalance Trip Rt Motor Low Current

Page 23 of 30

Table 3.2 Alarm Codes

Desc ription

Code A041 A042 A043 A044 A045 A046 A051 A052 A058 A059 A060 A061 A062 A063 A064 A065 A066 A067 A068

Conv Shutdown Conveyor Shutdown Conveyor Shutdown CB2 (Conveyor Breaker) Conveyor Start Switch Conveyor REV JOG Switch Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown Cutter Shutdown

Lt Motor Low Current Conveyor Reverse Switch Operated Conveyor Motor Current Differential Opens Held too long Held too long Right Motor Over Left Motor Over Right Motor Overload Left Motor Overload Rt Motor Inst. Curr Trip Lt Motor Inst. Curr Trip Right Motor Phase Imbalance Trip Left Motor Phase Imbalance Trip Right Motor Low Current Left Motor Low Current Cutter lockout switch opens Cutter Motor Current Differential LOW OIL ALARM for 5 sec

A069 A070 A072 A073 A074 A075 A080 A081 A082 A083 A084 A085 A096 A097 A098 A099 A100 A101 A102 A103 A104 A112

Cutter Shutdown Cutter Low Oil Lockout Cutter Shutdown Cutter Shutdown Cutter Start Toggle Switch Stuck Cutter Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown Fan Shutdown PLC to Rt Drive COMM Fault (All TRAM commands cleared) PLC to Lt Drive COMM Fault (All TRAM commands cleared) Machine Voltage Below Allowable Range (<80% Vnom) Machine Voltage Above Allowable Range (>117% Vnom) CurrentErrorCodeFutureUse Right Tram Motor Overload Left Tram Motor Overload Tram Enable Switch held more than 3 Sec without TRAM Tram Enable Switch Stuck Tram Shutdown

Cutter Start Switch held too long Right Motor Jam Current Left Motor Jam Current CB2 Breaker Active Instantaneous Current Trip Overload Trip Phase Imbalance Trip Low Current Trip Over Jam Current Trip

Left Drive Phase A Overcurrent

Page 24 of 30

Table 3.2 Alarm Codes

Description

Code A113 A114 A115 A116 A117 A118 A119 A120 A121 A128 A129

Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Tram Shutdown Right Drive Limited Left Drive Limited Teach/Learn Successful Teach/Learn Failed

Left Drive Phase B Overcurrent Left Drive Bus OverVoltage Left Drive OverTemperature Right Drive Phase A Overcurrent Right Drive Phase B Overcurrent Right Drive Bus OverVoltage Right Drive OverTemperature Loss of Voltage Feedback Loss of Voltage Feedback

A130

Error

Control Ground Fault

3.1.2 Warning Codes Refer to Table 3.3 for the descriptions of system WARNING codes. Table 3.3 Warning Codes Code W001 W002 W003 W008 W009 W010 W011 W017 W018 W019 W020 W021 W022 W023 W024 W025 W026 W027 W028 W029 W030

Description Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conv Rev won't start Conv Rev won't start Conv Rev won't start Conv Rev won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start Conveyor Reverse won't start

Right Conveyor Jam Left Conveyor Jam time period between fwd/rev not expired R Conv Inst Trip Reset Time Not Expired L Conv Inst Trip Reset Time Not Expired R Conv low amp Trip Res Time Not Expired L Conv low amp Trip Res Time Not Expired Pump Off Conveyor Breaker Conveyor Stop Right Conveyor Overtemp Left Conveyor Overtemp Right Conveyor Overload Left Conveyor Overload Right Conveyor Inst. Trip Left Conveyor Inst. Trip Right Conveyor Low Current Left Conveyor Low Current Right Motor Single Phase Left Motor Single Phase Cutter

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Table 3.3 Warning Codes

Description

Code W031 W032 W033 W034 W035

Conveyor Reverse won't start Conveyor Reverse won't start Pump won't start Pump won't start Pump won't start

Diff Spare Low Current Future Use Machine Voltage < 80% Vnom

W036 W037 W049 W050 W051 W052 W053 W054 W055 W056

Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start

W057 W058 W059 W060 W061 W062 W063 W064 W065 W066 W067 W081 W082 W083 W084 W085 W086 W087 W088 W089 W090 W091 W092 W093 W094 W095 W096

Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Pump won't start Conveyor Fwd won't start Conveyor Fwd won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start

Machine Voltage > 117% Vnom Conveyor Jam Tilt Switch Active LH Machine Stop is OPEN (R11 Machine Stop is OPEN (R12 PUMP Stop is operated TRAM LEVERS are not centered Low oil lockout active for 5 sec (R14 Future Use Pump Motor Temp above 150 (140 after trip) Overload trip reset time not expired Inst trip reset time not expired Cutter Tram Breaker is not set (CB6) Conveyor Breaker is not set (CB2) Conveyor FWD Start is operated Conveyor REV Start is operated Pump Phase R Conv Jam trip reset time not expired L Conv Jam trip reset time not expired Time period between fwd/rev not expired Pump Off Conveyor Breaker Conveyor Stop Right Conveyor Overtemp Left Conveyor Overtemp Right Conveyor Overload Left Conveyor Overload Right Conveyor Instant Left Conveyor Instant Right Conveyor Low Current Left Conveyor Low Current Right Phase Left Phase Cutter Diff Conveyor Reverse

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Table 3.3 Warning Codes Code

Description

W097 W098 W099 W100 W101 W102 W104 W105 W107 W108 W109 W110 W111 W113 W117 W118 W124 W125 W126 W127 W128 W129 W130 W131 W132 W133 W134 W135 W145

Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Cutter won't start Fan won't start Cutter won't start Fan won't start Fan won't start Fan won't start Fan won't start Fan won't start Tram

Right Cutter Overload trip time not expired Right Cutter Inst trip reset time not expired Right Cutter Low Current Left Cutter Overload trip time not expired Left Cutter Inst trip reset time not expired Left Cutter Low Current Low Oil Lockout CB2 Breaker Active Ground Fault Haulage xformer overtemp Right Cutter Jam Left Cutter Jam CB2 breaker active Pump not running Right Cutter Overtemp Left Cutter Overtemp Diff Right Phase Left Phase Lockout Switch Open Low Oil Cutter must be started first Fan must be started first Fan Overtemp Fan Low Current Fan Overload Fan Instant Fan Phase Right Tram Analog Reference without direction

W146

Tram

Right Tram Direction without Analog Reference

W147

Tram

Left Tram Analog Reference without direction

W148

Tram

W149 W150 W151

Tram Tram Tram

W152 W153 W154 W157

Tram Error Tram Tram Tram won't start

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Left Tram Direction without Analog Reference Command without Tram Enable Command without Pump Running Command without Tram circuit breaker closed (CB6) Reset High Tram Timeout via Tram Enable Left Tram Overload Right Tram Overload Left Drive Phase A OverCurrent

Table 3.3 Warning Codes

Desc ription

Code W158 W159 W160 W161

W162 W163 W172 W173 W174 W175 W176 W177 W178 W179 W193 W194 W195 W196 W197 W210

W211

W212 W213

W214 W215 W216

W217

Tram won't start Tram won't start Tram won't start System shutdown due to Power Center Trip Tram Tram MCU Serial Number out of range CutterLower Override due to Right Motor Cutter Lower Override due to Left Motor Cutter Raise Override due to Right Motor Cutter Raise Override due to Left Motor Tram won't Start Tram won't Start Tram won't Start Pump Shutdown LH Stop Operated Machine Stop Operated Conveyor Shutdown Cutter Shutdown Conveyor FWD Switch Operated at Start Up Conveyor REV Switch Operated at Start Up Cutter Start Switch Operated at Start Up Ventilation Only Switch Operated at Start Up Right Tram Reference Present at Start Up Left Tram Reference Present at Start Up Right Tram FWD Contact Closed at Power Up Right Tram REV Contact Closed at

Right Drive Phase A OverCurrent Left Drive Phase B OverCurrent Right Drive Phase B OverCurrent

Left Tram Communication Error Right Tram Communication Error

Left Drive Bus OverVoltage Right Drive Bus OverVoltage Left Drive Bus OverTemperature Pump Stop Operated

Conveyor Stop Operated Cutter Stop Operated

W218

W219 W220 W221 W222 W225 W226 W229 W230 W231

Power Up Left Tram FWD Contact Closed at Power Up Left Tram REV Contact Closed at Power Up Tram Enable Switch Operated at Start Up Aux relay 1 won't start Aux relay 2 won't start Cutter won't start Conveyor won't start Conveyor won't start Conveyor won't start Conveyor won't start

Pump off Pump off Machine stop override mode Machine stop override mode Machine stop override mode Machine stop override mode Machine stop override mode

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Table 3.3 Warning Codes

Description

Code W232 W301 W302 W303 W304 W305 W306 W307 W308 W309 W310 W311 W312

METHANE MONITOR NOT OK Tram Enable toggle switch stuck in position Tram Enable toggle switch stuck in position Stab toggle switch stuck in Lower position Stab toggle switch stuck in Raise position Breaker toggle switch stuck in Reset positon Breaker toggle switch stuck in On position Conveyor toggle switch stuck in Lower position Conveyor toggle switch stuck in Raise position Conv. Swing toggle switch stuck in Left position Conv. Swing toggle switch stuck in Right position Gath. Head toggle switch stuck in Float position Gath. Head toggle switch stuck in Raise position

W313 W314 W315 W316 W317 W318 W319 W320 W321 W322 W323 W324 W325 W326 W327 W328 W329 W330

Cutter Head toggle switch stuck in Lower position Cutter Head toggle switch stuck in Raise position Pump toggle switch stuck in Stop position Pump toggle switch stuck in Start position Fan toggle switch stuck in Off position Fan toggle switch stuck in On position Dust toggle switch stuck in Off position Dust toggle switch stuck in On position Fire/Lights toggle switch stuck in Fire position Fire/Lights toggle switch stuck in Lights position Conveyor toggle switch stuck in Stop position Conveyor toggle switch stuck in Start position Conveyor Reverse push button stuck Cutter toggle switch stuck in Stop position Cutter toggle switch stuck in Start position Shift push button stuck MStop Override push button stuck Enable push button stuck

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Table 3.3 Warning Codes

Description

Code W331 W332 W333 W334 W335 W336 W337 W338 W339 W342 W343 W344 W345 W346

Tram High push button stuck Tram Low push button stuck Left Tram lever stuck Right Tram lever stuck Enable push button stuck Tram Enable Button stuck Pump Start push button stuck Conveyor Start push button stuck Cutter Start push button stuck Low Battery PowerDown TimeOut PowerDown Left Tram Command without enable Right Tram Command without enable tram enable and left tram simultaneous

W347 W348 W348

tram enable and right tram simultaneous Fan Button Stuck Motor Start before enable

3.2 Informational Messages A listing of the system informational messages is provided in Table 3.4.

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SECTION 4.

COMPONENT IDENTIFICATION 4.1 Remote Control System Components The components that make up this system are listed in Table 4.1.

With exception of the TX944, all other components of this radio control system are mounted on the machine and within a methane isolation barrier enclosure. The display may be mounted on the opposite side of the machine and in its own barrier enclosure.

Table 4.1 System Components Component MCU944 RX944 TX944 CPS944 RDU944 DCD100 Display

Description Custom PLC Radio Receiver Radio Transmitter Capacitor Backup Power Supply Emergency Pendant Interface DC Tram Drive Graphics Status Display

4.2 Remote Control System Components Tie-in The basic components and their interconnections are shown in Figure 4.1. It may be necessary to use the TX944 Radio Transmitter to check the operation of the system during trouble analysis. It is assumed that maintenance personnel have been trained in the use of this equipment.

Sixty-two percent of machinery accidents involving continuous miners were operated by remote control.

There were eight fatals using remote control miners from 1990 to 1995.

The continuous miner operator and helper should follow these safe practices: � Wear reflective clothing as outer garments. � Take shorter cuts when adverse roof conditions are encountered. � Do not go inby the continuous miner operator except when required to operate the coal haulage equipment at the face. � Be aware of the location of haulage equipment when they approach the continuous miner. � Always be sure that everyone is in a safe location when starting the continuous miner. � Do not position yourself anywhere beside the continuous miner during tramming operations. (This should keep persons away from any possible pinch points.) � Ensure that all persons are beyond the continuous miner's turning radius during remote control tramming. � Be aware that wet and muddy floor conditions, dips, and rolls can cause sudden, unexpected movement of any machine. � Avoid visibility problems when tramming the miner. � Don't set the remote control unit on the continuous miner while operating it. � Ensure that all remote control continuous miners on the section are on separate frequencies. This applies to all remote control equipment on a section.

U.S. Department of Labor Mine Safety and Health Administration

� Make sure any spare transmitter kept underground is in a secure location to avoid inadvertent operation. � Take extra precautions when taking the first cut of a crosscut; the position of the operator is critical. � Ensure a crosscut is permanently supported (roof bolted) prior to taking a cut inby or starting the proposed opposite crosscut. (No work or travel shall be inby an unsupported crosscut other than when required for safety exams.) � If continuous miner breaks down inby permanent roof support, properly support the roof before repairs are made.

� Lock, tag out, and block all mining equipment before attempting repairs.

Visit the MSHA home page at www.msha.gov

Sixty-two percent of machinery accidents involving continuous miners were operated by remote control. There were eight remote control miner fatalities from 1990 to 1995.

Follow these practices when mining extended cuts: � Include extended cut procedures and precautions in the training plan. All affected persons should receive this instruction prior to beginning extended cut mining and in task training and annual refresher training. � Do not go inby the last two rows of permanent support except for gas checks, and then only to the last row of bolts. � Identify the next to last row of bolts by reflectors, lights, etc., to prevent persons from inadvertently going inby supported top. � Take extended cuts only in areas with competent roof conditions. � Know and follow the roof control plan requirements for taking extended cuts, especially the maximum depth of the cut. � Place a reference mark on the continuous miner to show when the maximum cut depth has been reached. � Do not leave extended cuts standing unsupported for prolonged periods of time. � Use additional roof supports within the last two rows of supports to prevent an unexpected fall from overriding these supports. These include extra bolts, planks, straps, etc. � Wear reflective clothing as outer garments. � encountered.

Take shorter cuts when adverse roof conditions are

U.S. Department of Labor Mine Safety and Health Administration

� Do not go inby the continuous miner operator except when required to operate the coal haulage equipment at the face. � Be aware of the location of haulage equipment when they approach the continuous miner. � Always be sure that everyone is in a safe location when starting the continuous miner. � Do not position yourself anywhere beside the continuous miner during tramming operations. (This should keep persons away from any possible pinch points.) � Ensure that all persons are beyond the continuous miner's turning radius during remote control tramming. � Be aware that wet and muddy floor conditions, dips, and rolls can cause sudden, unexpected

movement of any machine. � Avoid visibility problems when tramming the miner. � Don't set the remote control unit on the continuous miner while operating it. � Ensure that all remote control continuous miners on the section are on separate frequencies. This applies to all remote control equipment on a section. � Make sure any spare transmitter kept underground is in a secure location to avoid inadvertent operation. � Take extra precautions when taking the first lift of a crosscut; operator position is critical. � Ensure a crosscut is permanently supported (roof bolted) prior to taking a cut inby or starting the proposed opposite crosscut. (No work or travel shall be inby an unsupported crosscut other than when required for safety exams.) � If a continuous miner breaks down inby permanent roof support, properly support the roof before repairs are made. � Lock, tag out, and block all mining equipment before attempting repairs.

Visit the MSHA home page at www.msha.gov

2005 SUMMER PROP/REDZONE SPECIAL SAFETY INITIATIVE

“BEST PRACTICES” .

• Be alert for changing roof conditions. .

• Install additional roof supports where necessary. .

• Conduct a thorough visual examination of the roof, face, and ribs immediately before any work is started and thereafter as conditions warrant. .

• In areas where geological changes in roof strata are present additional safety precautions should be applied. Example: bolt straps across multiple cracks. .

• Limit the unnecessary presence of other miners at or near the pillar areas.

2005 SUMMER PROP/REDZONE

SPECIAL SAFETY INITIATIVE HAZARD ALERT BULLETIN: Unsupported Roof

Work and travel under unsupported roof is an extremely unsafe practice that continues to occur in our nation’s mines. Operating continuous miners, roof bolting machines, and scoops under unsupported roof is a recurrent violation of the standard which prohibits work and travel at this location. Bolting operations that include handling screen are especially vulnerable to passing the last row of support. Also, painting site lines or marking locations for drilling are work practices that frequently occur under unsupported roof.

“BEST PRACTICES” .

• Minimize the number of places left unbolted during the mining cycle. .

• Select carefully and maintain a consistent method of posting /identifying unsupported roof. .

• Examine work practices that occur near the last row of support. .

• Increase equipment operator’s awareness near the last row of support.