CAT Operator Manual DBT 30MB3 Continuous Miner BI643669 - PDF DOWNLOAD

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Technical Manual

BI643669

Development & Diesel

Operator Manual 30MB3 Continuous Miner, Oaky Creek No.1

Mining to Success

BI643669

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

SECTION 1 Handbook Objective

30MB3 OPERATORS MANUAL

Section 1

Page 1 of 4

Handbook Objective

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Title Page Document Title:

Oaky Creek No 1 Mine 30MB3 User Manual

Document Number: Issue:

Version 1

Revision:

0

Date of Issue:

January 2006

Author:

Signature:

Authorised:

Signature:

Revision History Issue Revision

Section 1

Status

Date

Page 2 of 4

By

Authorised

Handbook Objective

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Table of Contents HANDBOOK OBJECTIVES ................................................................................................... 4

Section 1

Page 3 of 4

Handbook Objective

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

HANDBOOK OBJECTIVES This operator handbook has been compiled by DBT Australia to assist you, as part of the TEAM, to operate this machine with safety and efficiency.

Section 1

Page 4 of 4

Handbook Objective

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

SECTION 2 Notes To The Operator

30MB3 OPERATORS MANUAL

Section 2

Page 1 of 4

Notes to the Operator

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Table of Contents 2.1

NOTES, CAUTIONS AND WARNINGS ......................................................... 3

2.2

OPERATING PROCEDURES......................................................................... 4

Section 2

Page 2 of 4

Notes to the Operator

BI643669

DBT Australia Pty Ltd

2.1

Operators Manual for the 30MB3

NOTES, CAUTIONS AND WARNINGS

ALL applicable NOTES, CAUTIONS AND WARNINGS listed in this Manual are to be included in the support documents following the same format as defined below.

Follow NOTES, CAUTIONS and WARNINGS found in the Handout.

IMPORTANT Indicates a procedure or condition that is essential for the operator to know.

Section 2

CAUTION:

Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.

WARNING:

Indicates an action or condition that, if not followed, could cause injury to the operator or other personnel.

Page 3 of 4

Notes to the Operator

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DBT Australia Pty Ltd

2.2 

Operators Manual for the 30MB3

OPERATING PROCEDURES Operating procedures are written with the intention of being correct. If you do notice errors within the procedures, it is an important part of our company’s Quality Processes that we be notified quickly so that any problem can be corrected.

THOUGHT PROCESSES THAT WILL HELP TO KEEP OPERATORS INJURY FREE Is the procedure Correct?

YES

NO

Am I following the correct procedure?

STOP

YES

WAY TO GO

NO

Take corrective action!

If necessary consult with team members

STOP

Correction Resolved

WHY NOT

YES

NO

STOP ACT NOW! FOLLOW CORRECT PROCEDURE

Take corrective action!

Consult with Responsible Person/s Correction Resolved

Section 2

Page 4 of 4

Notes to the Operator

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

SECTION 3 Defects, Hazards and Safety

30MB3 OPERATORS MANUAL

Section 3

Page 1 of 8

Defects, Hazards & Safety

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

TABLE OF CONTENTS DEFECTS AND HAZARDS .......................................................................................... 3 SAFETY & MAINTENANCE PRACTICES ................................................................... 4 OAKY CREEK NO 1 MINE PROCEDURES REFERRED TO IN THIS DOCUMENT .. 5 Oaky Creek No 1 Mine Standard Operating Procedure for isolating and tagging . 5 SOP00780C1 ........................................................................................................ 5 HEAD STOPS .............................................................................................................. 6 SOP00780C1 ........................................................................................................ 6

Section 3

Page 2 of 8

Defects, Hazards & Safety

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

DEFECTS AND HAZARDS The TEAM promotes healthy, safe and environmentally acceptable practices in everything we do. 

We actively identify hazards and defects.



We act to eradicate hazards and defects.



We anticipate potential outcomes.



We intervene to prevent failure.



We are aware of broader mine issues.



We maintain good housekeeping.



We share information.



We follow procedures where provided.



We care for own and our TEAM’S welfare.

Section 3

Page 3 of 8

Defects, Hazards & Safety

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

SAFETY & MAINTENANCE PRACTICES It is essential that all personnel are clear of machine prior to start up operating all personnel to be clear of conveyor boom and cutter head. Operator must be aware of his location to avoid crush potential.

Never put yourself or any other person in any position that should machine fail to respond correctly or if in normal operation creates a position whereby no escape is possible.

IMPORTANT: Refer to Oaky Creek No 1 Mine Standard Operating Procedure for isolating and tagging SOP0078OCI “One fraction of a second of carelessness can result in a lifetime of suffering for yourself or other team members”.

To understand this statement is the beginning of effective safe work practices. 

Safety risks are created when you shortcut Standard Procedures.



Machinery is like a loaded gun - even if it is not running or is switched off.



When doing tests with the machine on running:   





Stop machine and isolate to set up test.

Stand clear and observe test.

Stop machine and isolate before disconnecting test.

When repairing, replacing or fitting heavy components:  Use blocks, and supports to prevent components tipping, sliding or moving out of position.

When working under the heads, shovel or tail:  Make sure that safety stops are securely in place at all times.  When testing the machine in any way:  Ensure that personnel are clear of the machine at all times when testing and isolate functions that are not required.

IMPORTANT: The conveying cutter head and traction can be isolated independently.

Section 3

Page 4 of 8

Defects, Hazards & Safety

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

OAKY CREEK NO 1 MINE PROCEDURES REFERRED TO IN THIS DOCUMENT 

Section 3

Oaky Creek No 1 Mine Standard Operating Procedure for isolating and tagging SOP00780C1

Page 5 of 8

Defects, Hazards & Safety

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

HEAD STOPS Before commencing work near or under cutter head - fit head stops as shown in photo. Stops (L) (R) is carried on board machine. Also isolate main circuit breaker, traction, conveyor and cutter breakers and tag prior to working in this area.

Procedure for fitting head stops are as follows:   

Isolate Cutter circuit breaker Remove head stops mounted on the Left Hand and Right Hand covers (3.2) in front of supply pods and leave lying upon platforms.

Climb upon bolting platforms using walkways

IMPORTANT: Oaky Creek No 1 Mine Standard Operating Procedure for isolating and tagging SOP00780C1.   

With an operator by your side, start the machine, lower the gathering head to the floor and raise the auger head to a suitable height to fit stops.

Carefully locating stops into mounting areas (3.1) from the bolting platforms on the Left and Right hand sides.

With Miner still running slowly lower cutter head onto the manufactured stops ensuring to take the weight of the auger head.

WARNING:

Isolate Miner as per Oaky Creek No 1 Mine isolation procedures.

Safety Stop

Section 3

Page 6 of 8

Defects, Hazards & Safety

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Cutter stop positions

Cutter stop fixing mounts

Cutter Head Stops fixed to PODs LH and RH sides

Cutter stop storage mount

Section 3

Page 7 of 8

Defects, Hazards & Safety

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

CONVEYOR STOP Before commencing work in or around conveyors ensure the conveyor safety bar is used. Ensure conveyor is rested on conveyor safety bar before any work is commenced. Also isolate and tag machine prior to any work in this area.

Procedure for fitting conveyor stop is as follows: WARNING:

 

Isolate Miner as per Oaky Creek No 1 Mine isolation procedures.

Isolate conveyor, cutter head and traction circuit breakers.

With operator by your side, start the machine

IMPORTANT: Refer to Oaky Creek No 1 Mine Standard Operating Procedure for isolating and tagging SOP0078OCI

  

Section 3

Raise the conveyor to a suitable height to swing the stop vertically (3.3).

Check that the pins are secure and in place.

Ensure hands are clear from the top of stop and holding mid section of stop, lower the conveyor onto stop. Ensure that it is located in its holding mount properly.

Page 8 of 8

Defects, Hazards & Safety

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

CONVEYOR SAFETY STOP

Position of the stop whist supporting the conveyor.

Conveyor stop positioning and mount

Section 3

Page 9 of 8

Defects, Hazards & Safety

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BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

SECTION 4 Access On And Off The Machine

30MB3 OPERATORS MANUAL

Section 4

Page 1 of 3

Access on and off the Machine

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Table of Contents 4.1

ACCESS ON AND OFF MACHINE ............................................................... 3

Section 4

Page 2 of 3

Access on and off the Machine

BI643669

DBT Australia Pty Ltd

4.1

Operators Manual for the 30MB3

ACCESS ON AND OFF MACHINE

Climb on and off the miner only where steps or grab irons are provided.

Use both hands when mounting and dismounting and face the vehicle.

Never get on or off a moving continuous miner, and never jump off a continuous miner.



Climb up and down the ladders by facing the ladder.



Never climb down with your back facing the ladder rungs.



Be very careful on the bottom steps, especially in muddy conditions.



Always maintain three point contact where possible.

Handle grip shown for access to the platform upon the Right Hand side of the machine.

The same handle grip is fitted to the left side of the machine.

Use access platforms when performing maintenance or bolting

Section 4

Page 3 of 3

Access on and off the Machine

BI643669

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

SECTION 5

Machine Description

30MB3 OPERATORS MANUAL

Section 5

Page 1 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

TABLE OF CONTENTS 5.1

MACHINE DESCRIPTION – 30MB3 ............................................................................... 3

General ................................................................................................................................ 3 Specifications ...................................................................................................................... 4 Component Layout .............................................................................................................. 5 Main Chassis ....................................................................................................................... 6 Cutting Head Assembly ....................................................................................................... 7 Gathering Head Assembly .................................................................................................. 9 Conveyor Assembly .......................................................................................................... 10 Traction Drive System ....................................................................................................... 11 Hydraulic System .............................................................................................................. 13 Machine Hydraulic Layout ................................................................................................. 14 Drill Rigs ............................................................................................................................ 16 Rib Protection .................................................................................................................... 17 Shield................................................................................................................................. 17 Bolting, Mining and Maintenance Modes. ......................................................................... 18 Water System .................................................................................................................... 19 Machine Water Component Layout................................................................................... 20

Section 5

Page 2 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

5.1

Operators Manual for the 30MB3

MACHINE DESCRIPTION – 30MB3

General The 30MB3 miner is a radio-controlled drum-type continuous miner with appropriate weight, balance, cutting and loading power to enable the productive mining of coal and other soft mineral in seams ranging from 1,900mm up to 4,100mm thick.

The machine is mounted on crawler tracks that provide full mobility and sharp turning radius in both bord and pillar and long wall development mining plans. The ranging cutting head mines material from the solid face using a chainless rotating drum, and a East West configuration gathering head with high speed conveyor efficiently moves mined material to a haulage system behind the miner.

The machine's weight and balance is designed to mine most efficiently by either sumping into the face at the top or bottom of the seam, and ripping material to the bottom or top of the seam.

Figure (Mechanical Components) shows a general arrangement of major mechanical components. A full description of the various major sub-systems of the 30MB3 follows.

Section 5

Page 3 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Specifications Length Cutting Width Max Cutting Height Weight Cutting Frame Cutter Head Gearcase Cutter Head Conveyor Assembly Gathering Assembly Ground Clearance Undercut Capacity Tramming Speed

Tracks Brakes Drives Steering

Section 5

11,931 mm 5,200 mm 4,100 mm 83,000 kg 9,000 kg – Complete with Motors 13,500 kg 22,500 kg – Total Assembly 7,900 kg – Intermediate & Discharge 13,600 kg – Complete with Rigs & shields 350 mm 249 mm 1st = 0 – 10 Metres/Minute 2nd = 13 Metres/Minute 3rd = 26 Metres/Minute Crawler Type LH & RH Independent Oil Flushed Spring Applied Park Brake Electrical – Mechanical Hydraulic Skid Steer

Page 4 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Component Layout EAST/WEST CONVEYOR HYDRAULIC MOTORS

LH MINING/BOLTING /MAINTENANCE DIVERSION VALVE

ROOF BOLTERS

CONVEYOR SWING CYLINDER

CUTTING HEAD GEARCASE

CUTTER MOTORS

DISCHARGE CONVEYOR CONVEYOR SWING CYLINDER RH MINING/BOLTING /MAINTENANCE SELECTION VALVE

Right Hand

MATERIAL POD ISOLATOR ENCLOSURE

CONVEYOR SWING CYLINDER

EAST/WEST CONVEYOR HYDRAULIC MOTORS

MESH SLIDE RAIL

ROOF BOLTERS

RIB BOLTER

CUTTING HEAD GEARCASE

ROOF BOLTER CONTROLS

CONVEYOR DRIVE GEARBOX

ROOF BOLTER

CONVEYOR DRIVE MOTOR

STABILISER SHOE

TRACTION MOTOR

HYDRAULIC PUMP

RIB PROTECTION PLATFORM

PUMP MOTOR

CUTTING HEAD GEARCASE

ROOF BOLTER CONTROLS

MATERIAL POD RIB BOLTER

MESH SLIDE RAIL

Left Hand

CONTROL CASE CONVEYOR SWING CYLINDER

ROOF BOLTER

CONVEYOR DRIVE GEARBOX RIB PROTECTION PLATFORM

HYDRAULIC PUMP

TRACTION MOTOR

STABILISER SHOE

CONVEYOR DRIVE MOTOR

PUMP MOTOR

Section 5

Page 5 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Main Chassis

CONVEYOR PIVOT POINT

GATHERING HEAD PIVOT POINT CUTTING HEAD PIVOT POINT GATHERING HEAD PIVOT POINT

HYDRAULIC TANK

GATHERING HEAD PIVOT POINT

Main Chassis

The main chassis of the machine is a robust box-type structure of high-strength steel construction that provides the following: Mounting of the RH and LH crawler tracks and their independent drive systems and take-up provisions.

   

Independent pivots for mounting the cutting head and gathering head and conveyor components and their associated hydraulic cylinders for articulation.

An integral hydraulic oil tank along with two electric motor/hydraulic pump assembly‘s and associated valves and piping.

A rear stabiliser and its articulating hydraulic cylinder for improving leverage forces during shear-down in the cutting sequence.

Mounting provisions for all major electrical system components and their associated wiring.

Section 5

Page 6 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Cutting Head Assembly The cutting head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated for vertical-ranging cutting of the coal seam.

The independent pivots allow removal of the cutting head assembly without disturbing the gathering head or conveyor components.

LEFT CUTTER DRUM

CENTRE CUTTER DRUM RIGHT CUTTER DRUM RIGHT PULL-IN ASSEMBLY

LEFT PULL-IN ASSEMBLY

WATER SPRAY BLOCKS

WATER SPRAY BLOCKS INPUT GEARCASE RIGHT SIDE ELECTRIC MOTORS CUTTER CLUTCH

CUTTER CLUTCH

CUTTER HEAD COVERS

CUTTER HEAD COVERS

CUTTER HEAD PIVOT POINT CUTTER HEAD DUST BELT

Cutter Head Frame

The cutting head assembly consists of the following:





The cutting head support frame, a robust box structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two cutting head raise cylinders, and a major bolting flange to which the cutting head drive assembly mounts.

The cutting head gear case assembly, which consists of a input gear case and water-cooled 173 kW AC electric drive motor for each of the RH and LH sides, a final drive gear case which includes drive gearing, a main drive shaft and mounting points for the 1067mm diameter RH, LH, intermediate and centre drums, and a major bolting flange for mounting onto the cutting head support frame. The outer cutting drums are independently mounted to the major bolting flange and have an extension/retraction of 300mm each side from 5200mm to 4600mm and can be removed as an assembly.

Section 5

Page 7 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

The cutting head assembly is raised and lowered by two (2) heavy-duty hydraulic cylinders mounted to the main chassis at their lower ends and attached at their upper ends to main longitudinal structural members of the cutting head support frame. These cylinders enable the cutting head assembly to range from 249 mm below ground level to a maximum height of 4100mm.

The power train of the cutting head consists of RH and LH sides, which tie together at the common main drive shaft, allowing the combined power of both electric drive motors to be available at any point on the cutting drums.

Section 5

Page 8 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Gathering Head Assembly

Gathering Head Assembly

The gathering head assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated to adjust the gathering head for uneven floor conditions and for tramming the miner from place to place. The independent pivots allow removal of the gathering head assembly without disturbing the cutting head or discharge conveyor.

The gathering head assembly includes the following:



The gathering head structure consists of RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two gathering head raise cylinders, extendible plows compatible with extendible widths of the cutter head widths and shields mounted on rear of structure to support the roof bolting rigs.

The gathering head assembly is raised and lowered by two hydraulic cylinders, which are mounted to the main chassis at their lower ends and attached to points of the gathering head structure at their upper ends. These cylinders allow vertical ranging of the forward edge of the gathering head from 200 mm below floor level to 537 mm above floor level.

A cross conveying system consisting of cross flight chains driven by hydraulic motors.

This set up allows forward mounting of the roof drills so that poor roof may be supported. The cross flight chains gathers the mined material at the front of the machine and conveys the material on to the conveyor in the centre of the machine.

The system consists of hydraulic motors connected to a drive shaft which has a sprocket for driving the cross conveyor chains.

The gathering head structure includes a special noise-damped running deck for the conveyor chain to minimise noise generation

Section 5

Page 9 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Conveyor Assembly

The conveyor assembly is attached to the main chassis at RH and LH independent pivot points around which the assembly is articulated vertically to assist in optimum loading into the haulage vehicle. Independent pivots allow removal of the conveyor assembly without disturbing the cutting head or gathering head components.

The conveyor assembly includes the following:



An intermediate conveyor structure which includes the RH/LH pivot points for attaching to the main chassis, upper mounting clevises for the two conveyor raise cylinders, and a horizontal pivot arrangement at the rear for mounting the rear conveyor subassembly.

A rear conveyor subassembly which includes (a) a mating horizontal pivot arrangement allowing sideward swinging movement up to 45o on either side of the machine centre line to assist in optimum loading into the haulage vehicle, and (b) Two hydraulic cylinders to maintain proper tension in the chain when the geometry of conveyor assembly changes during the operation. The intermediate and discharge conveyor structures each include a special noise-damped running deck for the conveyor chain to minimise noise generation and 914mm throat clearance for optimum loading rates. (c) Two 30 Kw electric drive motors power the rear mounted gearcase. The two gearcases are connected to the drive sprocket for driving the primary conveyor chain.

The conveyor chain drives are reversible to aid in clearing debris which might restrict conveyor chain movement.

Section 5

Page 10 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Traction Drive System

HYDRAULIC TANK

RIGHT TRACK FRAME

CRAWLER DRIVE SPROCKET

ELECTRIC TRACTION MOTOR

CRAWLER TAKE-UP ROLLER

TRACTION PLANETARY

CRAWLER TAKE-UP ROLLER

TRACTION PLANETARY

ELECTRIC TRACTION MOTOR

CRAWLER PADS

Traction Assembly

The traction drive system provides the necessary mobility for the 30MB3 miner to mine coal and to tram from place to place as needed. It includes:

 

Independent RH and LH drive systems, each consisting of a water-cooled 55 kW DC variable-speed electric motor mounted to a drive gear case that powers drive sprockets to provide motion to the respective RH or LH crawler chain.

A forward-mounted crawler chain idler roller on each side which is equipped with a grease-powered piston to adjust the crawler chain to its proper tension; once adjusted by movement of the grease, the idler roller is locked into position by a necessary number of shims, and pressure in the grease piston is relieved. An AC/DC solid-state electronic drive logic system which provides the operator with three speed ranges: (a) High speed which moves the miner at a rate of 26 metres/min, used

mainly for flitting from one working face to another (b) Intermediate speed at a rate of 13 metres/min, used mainly for rapid re-

positioning of the miner within the face area (c) Sump speed, fully adjustable by the operator to a preset value ranging

from 0 to 10 metres/min for sumping the miner into the coal face. The adjustable sump speed setting allows the operator to select an optimum cutting speed when face hardness conditions vary, eg. Rock inclusions or roof/floor cutting.

Section 5

Page 11 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

The traction drive control system provides the operator with the capability to run either RH or LH crawler chain in forward or reverse independently for maximum manoeuvrability, ie. The miner may be pivoted about its central vertical axis. The RH and LH drive trains are each equipped with fully enclosed multiple-disc fail-safe hydraulic flushed parking brakes that are spring-applied and hydraulically released.

The crawler chains are manufactured from high-alloy wear-resistant steel for maximum life, and are equipped with grouser ridges to enhance traction in both soft and hard floor conditions.

Section 5

Page 12 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Hydraulic System The 30MB3 hydraulic systems is fed from the main reservoir contained as an integral part of the main chassis structure. Capacity of the reservoir is 750 litres; capacity of the total system including the main reservoir, full cylinders, hoses, etc is 1000 litres.

Hydraulic oil level in the reservoir can be monitored by a ball valve located on the LH side above traction gear case. Sight glasses are fitted on either side of the mainframe beside traction motors and the tank is equipped with an oil level float switch which shuts off the machine operation in the event that reservoir level goes below a safe limit. Hydraulic power for the miner is provided by two 67 kW water-cooled AC electric motors which drives two (2) Rexroth variable displacement hydraulic pump. The RH pump delivers oil to the main control valve for hydraulic mining and drilling functions.

The LH pump delivers oil to drive the left east west conveyor and to the drill rigs. The rib protection system is operated in mining mode. The pump/ motor assembly are located within the RH and LH crawler frames. The pumps provide 260 Litres/min @ a maximum pressure of 200 BAR

Main Valve Bank

Section 5

Page 13 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Machine Hydraulic Layout

Section 5

Page 14 of 21

Machine Description

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DBT Australia Pty Ltd

Section 5

Operators Manual for the 30MB3

Page 15 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Drill Rigs The 30MB3 miner drilling capabilities consist of duel roof drilling and single rib drilling on both sides of the machine. The roof rigs are independently mounted to a shield which is hinged to the gathering head chassis and the rib drilling unit is mounted to the mainframe chassis. Both units are operated from an operator’s platform and consist of side platforms on both sides of the machine for accessing roof bolting supplies.

Dual Roof Rig

Single Rib Rig Section 5

Page 16 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Rib Protection Rib protection consists of a hydraulic extendible shield towards the rib horizontally for the operators placement. This safety device must be used in conjunction with rib drilling. When in mining mode the miner can be trammed forward in low speed without retracting the shields. This is for lining up next bolting line. The shields are to be fully retracted before cutting can take place from face to face due.

Rib Protection Shield

Section 5

Page 17 of 21

Machine Description

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DBT Australia Pty Ltd

Operators Manual for the 30MB3

Bolting, Mining and Maintenance Modes Bolting, Mining and maintenance modes have been fitted to the 30MB3 Miner and can be selected by operating a diversion valve as per its tagging, this valve is mounted upon the Right Hand side of the Miner beside the rib drilling rig.

NOTE:

Refer to Section 9 for the procedures in using the Bolting, Mining And Maintenance Mode diversion selector.

Mode selection valve

Section 5

Page 18 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Water System The water distribution system on the 30MB3 miner serves several primary purposes: (a) It is circulated through the electric motors for the hydraulic pumps, cutting head, gathering head and traction system, the main control case and traction transformer case, to provide cooling, as well as supply to the bolting rigs. (b) It feeds water sprays around the cutting head, gathering head and conveyor to help control and contain dusty air. Fitted in the spray circuit are two 3 – way ball valves for changing the direction of spray patterns to suit mining conditions. These two valves are mounted on the top of the cutter head frame structure Auxiliary circuits provide unfiltered flow to wash-down hoses on each side of the machine.

3 – WAY ball valves for redirection of spays behind headlights

Essential components of the water system, and their locations, are shown on drawing (Water Spray Components).

A power tram unit can supply water to be pumped via the main supply inlet which provides cooling water to the pump and traction motors, the main control case, and the traction transformer and a quick-disconnect coupling allows water to be returned to the power tram unit during flitting of the machine from one working face to another.

Mine water Supply

Return Power Tram Outlet

Mounted beside drivers cabin RH side of machine

Section 5

Page 19 of 21

Machine Description

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3

Machine Water Component Layout

Section 5

Page 20 of 21

Machine Description

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DBT Australia Pty Ltd

Section 5

Operators Manual for the 30MB3

Page 21 of 21

Machine Description

BI643669

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3 Miner

SECTION 6 Controls And Their Functions

30MB3 OPERATORS MANUAL

Section 6

Page 1 of 29

Controls and their Functions

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3 Miner

Table of Contents CONTROLS AND THEIR FUNCTIONS

3

6.1

3

CIRCUIT ISOLATORS

Main Circuit Breaker Cutter Circuit Breaker Pump - Traction Circuit Breaker Gathering Heads (Conveyor) Circuit Breaker Control and Light Breakers Traction AC Circuit Breakers

6.2

3 3 4 4 5 5

PUSH BUTTONS

6

110V Control E/L Test Traction Earth Leakage Test Traction Earth Leakage Reset

6 6 6

6.3

MACHINE EMERGENCY STOPS

7

Left Side Rear Lanyard Machine Emergency Stop Right Side Rear Lanyard Machine Emergency Stop Left Side Bolting Platform Machine Emergency Stop Right Side Bolting Platform Machine Emergency Stop

7 8 9 10

6.4

MACHINE LAYOUT

11

Machine Electrical Layout

6.5

11

RADIO REMOTE CONTROL SYSTEM

Remote Control Transmitter Transmitter Maintenance & Battery Charger Display Unit Navigation Functions Display - Main Screen Thermistor Module Power Supply Module Solenoid Module Traction Module I/O Module Control Module Inclinometer

12 12 19 20 20 20 23 25 25 25 25 26 26

6.6

INDICATOR LED’s

26

6.7

MODES OF CONTROL

27

Radio / Pendant Mode Switch Radio Mode Pendant Mode

6.8

27 27 27

NOTES

Section 6

29

Page 2 of 29

Controls and their Functions

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3 Miner

CONTROLS AND THEIR FUNCTIONS

The main circuit breaker does not remove power from the trailing cable or the incoming line side of the breaker. Alw ays disconnect pow er from the machine at the power centre before major electrical repairs or maintenance.

Never attempt to start or move this machine unless you are familiar w ith all controls and emergency stop devices. Be certain the area around the machine is clear of other mine personnel whilst operating.

6.1

CIRCUIT ISOLATORS

The 30MB3 has (6) six external Circuit Breaker operating handles: 1.

2.

3.

4.

5.

6.

Main Circuit Breaker - opens all circuits.

Cutter Circuit Breaker - opens Right & Left Cutter Motors.

Pump - Traction Circuit Breaker - opens Pump Motors and Traction Transformer.

Conveyor Circuit Breaker - opens Right & Left Conveyor Motors.

110V Control and 12V Lighting Circuit Breakers - opens control & lighting.

Traction Circuit Breakers - opens 380V AC supplies to Right & Left Traction SCR Drive Units.

Main Circuit Breaker The Main Circuit Breaker is located in the lower compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle can be turned to the OFF position and removed.

This handle is used to unlock the main control case.

Pull the handle upwards to turn ON.

Cutter Circuit Breaker The Cutter Circuit Breaker is located in the top compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Cutter motors If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Cutter Circuit Breaker Trip”. When flitting the machine or in maintenance mode, turn Cutter Circuit Breaker “OFF” and tag out.

This circuit breaker must be isolated to operate in maintenance mode

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Operators Manual for the 30MB3 Miner

Pump - Traction Circuit Breaker The Pump - Traction Circuit Breaker is located in the top compartment of the flameproof Display Enclosure located on the right hand side of the machine. The operating handle which is on the right hand end of the enclosure, can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Pump motors & Traction Transformer.

If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Pump – Traction Circuit Breaker Trip”.

Gathering Heads (Conveyor) Circuit Breaker The Gathering Heads (Conveyor) Circuit Breaker is located in the top compartment of the flameproof Display Enclosure which is located on the right hand side of the machine. The operating handle can be turned to the OFF position and locked in the OFF position.

This circuit breaker is used to provide whole current isolation for the Gathering Head motors.

If this circuit breaker is OFF, tripped or isolated, it will be indicated on the display screen as “Gathering Heads Circuit Breaker Trip”. When flitting the machine or in maintenance mode, turn Gathering Heads Circuit Breaker “OFF” and tag out.

IMPORTANT: The conveyor and cutter circuit breaker must be isolated to operate in maintenance mode

Cutter Circuit Breaker

Pump – Traction Circuit Breaker

Screen Scroll Pages 1 to 20

Conveyor Circuit Breaker

Main Circuit Breaker

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Operators Manual for the 30MB3 Miner

Control and Light Breakers The control and lights breaker handle is a thin lever located on the top right hand side of the flameproof Main Control Case, which is on the left hand side of the machine.

The lever is pushed in to turn both circuit breakers ON and pulled out to turn circuit breakers OFF. If the machine is powered and these circuit breakers are ON, the green 110V Control LED indication light should be indicating healthy, behind the viewing window on the Main Control Case.

Traction AC Circuit Breakers The Traction AC Circuit Breakers are located in the flameproof Main Control Case and operated via the operating handle located on the front right hand side on the Main Control Case.

These isolate the AC power to the SCR Traction Drive Units. The circuit breakers are switched on by moving the handle to the left. If a circuit breaker has tripped it must be reset by turning the handle fully to the OFF position before it can be turned back on.

Whenever working on the traction, setting conveyor stops or head stops ensure both circuit breakers are opened and tagged.

IMPORTANT: This circuit breaker must be isolated to operate in maintenance mode

Control & Lights Circuit Breakers 1 Lever

Traction Circuit Breakers 1 Handle

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6.2

Operators Manual for the 30MB3 Miner

PUSH BUTTONS

On the front right hand side of the flameproof Main Control Case, there is (5) five push button operators.

The bottom (2) two push buttons are spare operators and are not used for any functions.

Control Earth Leakage Test Traction Earth Leakage Test Traction Earth Leakage Reset Spare – Not Used Spare - Not Used

110V Control E/L Test This is the first push button from the top and is used to carry out an earth leakage test on the 110V control circuit.

When pressed, the 110V Control Circuit Breaker, will trip. This circuit breaker is reset by operating the 110V Control Circuit Breaker operating lever.

Traction Earth Leakage Test This is the second push button from the top and is used to carry out an earth leakage test on the secondary of the Traction Transformer.

As an operation of a track, is required for this test to be carried out, the machine is required to be jacked up so that the tracks are off the ground, allowing safe movement of the tracks whilst operating Traction E/L Test button.

Traction earth leakage trip is indicated via a red LED Traction E/L Trip behind the viewing window in the Main Control Case.

Traction will be disabled when Traction E/L is tripped. A message “Traction Earth Leakage Trip” will appear on the display screen.

Traction Earth Leakage Reset This is the third push button from the top and is used to reset an earth leakage fault on the secondary of the Traction Transformer.

Section 6

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6.3

Operators Manual for the 30MB3 Miner

MACHINE EMERGENCY STOPS

There are (4) four Machine Emergency Stops available around the machine.    

Left Side Lanyard Machine Emergency Stop Right Side Lanyard Machine Emergency Stop Left Side Bolting Platform Machine Emergency Stop Right Side Bolting Platform Machine Emergency Stop

Operation of any of the above Machine Emergency Stops will result in the pumps stopping. If a pump start is attempted whilst a Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

Left Side Rear Lanyard Machine Emergency Stop The Left Side Lanyard Machine Emergency Stop is located at the left side rear of the machine along side of the flameproof Display Enclosure.

The Stop is mounted on its side with a lanyard cable running from the stop switch operator to an anchor point on the outbye end of the Bolting Platform.

Operation of the lanyard cable or pushing the Stop mechanism, will result in the pumps stopping. As the lanyard switch latches once it’s operated, should a pump start be attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the lanyard mechanism, pull the stop button out.

LHS Lanyard Machine Emergency Stop Button

Section 6

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Operators Manual for the 30MB3 Miner

Right Side Rear Lanyard Machine Emergency Stop The Right Side Lanyard Machine Emergency Stop is located at the right side rear of the machine along side of the flameproof Main Control Case.

The Stop is mounted on its side with a lanyard cable running from the stop switch operator to an anchor point on the outbye end of the Bolting Platform.

Operation of the lanyard cable or pushing the Stop mechanism, will result in the pumps stopping. As the lanyard switch latches once it’s operated, should a pump start be attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the lanyard mechanism, pull the stop button out.

RHS Lanyard Machine Emergency Stop Button

Section 6

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Operators Manual for the 30MB3 Miner

Left Side Bolting Platform Machine Emergency Stop The Left Side Bolting Platform Machine Emergency Stop is located on the conveyor side of the left side bolting platform.

Operation of the emergency stop will result in the pumps stopping. As the stop switch latches once operated, if a pump start is attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the stop switch, pull out the push button head.

LHS Bolting Platform Machine Emergency Stop

Section 6

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Operators Manual for the 30MB3 Miner

Right Side Bolting Platform Machine Emergency Stop The Right Side Bolting Platform Machine Emergency Stop is located on the conveyor side of the right side bolting platform.

Operation of the emergency stop will result in the pumps stopping. As the stop switch latches once operated, if a pump start is attempted whilst the Stop is latched, the message “Machine Emergency Stop Pressed” will be displayed to indicate the condition.

To reset the stop switch, pull out the push button head.

RHS Bolting Platform Machine Emergency Stop

Section 6

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6.4

Operators Manual for the 30MB3 Miner

MACHINE LAYOUT

Machine Electrical Layout

Section 6

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6.5

Operators Manual for the 30MB3 Miner

RADIO REMOTE CONTROL SYSTEM At all times, the machine must be operated in a safe manner. This means operating w ithin the rules stipulated by the mine management and regulatory authorities. Refer to Oaky Creek No. 1 Mine SOP0078OC1.

Operating under remote control requires that a number of specific safety precautions be followed.

Operators must fully familiarise themselves with the radio control functions and how they operate.

The cable handler must be in full view of the operator at all times, and only proceed forward of the operator after the operator has been informed.

Only one transmitter should be available to control the machine at any one time.

The control system automates the mining operation and enables remote control, so that the operator can operate machines from the best vantage point. The system also has a series of interlocks to prevent incorrect operating sequences.

Remote Control Transmitter The remote control transmitter provides control of the machine's functions. The portable remote control unit uses a sophisticated communications protocol to protect against interference and spurious operation of the miner. It communicates with the microprocessor control unit mounted on the miner using radio signals in the UHF band.

The remote control unit has rechargeable batteries that have enough capacity for up to 18 hours of continuous use.

The remote control transmitter has 12 switches. All of these are spring-loaded in the centre position.

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Operators Manual for the 30MB3 Miner

For some functions, such as turning on the cutters, you need to press the switch only momentarily. For other functions you need to press and hold the switches while the operation continues, such as tramming.

Most switches have two (2) functions - these functions are identified and selected as follows: Primary function - the switch operation is coloured black. To activate the primary function of a switch, you need to press only that switch.

Secondary function - the switch operation is enclosed in square brackets. To activate a secondary function, you need to first press the switch [SHIFT] and then, while still holding the [SHIFT] switch, press the other switches within two (2) seconds. The [SHIFT] switch should always be pressed slightly before the other switches. The switches can then be released in any order.

Emergency or stop functions are coloured red.

Section 6

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Operators Manual for the 30MB3 Miner

Radio signal continuity If the remote control is turned off or stops transmitting for any reason, the receiver unit will detect the loss of the radio signal and stop the machine. If no function is selected for five (5) minutes, the console will automatically turn itself off, causing the machine to stop as well.

Turn the transmitter on 

Press the ON switch and hold it for two seconds until transmitter number and the message ‘ON’ are displayed.

If you have successfully turned the transmitter on, it will maintain continuous communications with the control unit until turned off.

IMPORTANT Transmitter must be turned on beside the machine. If power is lost, the transmitter must be turned off and then on again

Turn the transmitter off 

Press the OFF switch.

This will also stop any machine that is turned on or operating after a delay of one second.

Stop Pressing the STOP switch in either direction will cause all functions on the mining machine to cease immediately. The hydraulic pump will be turned off.

Section 6

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Operators Manual for the 30MB3 Miner

Siren The 30MB3 miner is equipped with a warning siren that sounds when you select certain functions, such as starting the pump. The duration of the siren sound is adjustable.

The selected function will not operate until after the siren has stopped.

Start-up tests The controller always performs the following tests when the machine is powered up.

Hydraulic Pumps Start pump 

Press and hold the [SHIFT] and [PUMP ON] switches together. The Siren will sound for two seconds and then the pump will start.



Release both switches.

Be careful to release the pump switch before the select switch or you will turn the pump off.

From here, you can perform either tramming or cutting operations.

Stop pumps 

Press [PUMP OFF]

IMPORTANT The pumps will also stop immediately if the STOP is activated Section 6

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Operators Manual for the 30MB3 Miner

Raise Cutter 

Press the SHEARER UP switch.

The cutter will rise until the preset upper boom limit is reached or the switch is released.

Lower Cutter 

Press the SHEARER DWN switch.

The cutter will lower until the preset lower boom limit is reached or the switch is released.

Conveyor up 

Press the CONVEYOR UP switch. The conveyor will continue to rise until it reaches the upper limit or you release-the switch.

Conveyor down 

Press the CONVEYOR DWN switch. The conveyor will continue to lower until it reaches the lower limit or you release the switch.

Conveyor left 

Press the CONVEYOR LEFT switch. The conveyor will continue to move left until it reaches the left limit or you release the switch.

Conveyor right 

Press the CONVEYOR RIGHT switch. The conveyor will continue to move right until it reaches the right limit or you release the switch.

Apron Float 

Press and hold the APRON FLOAT switch to lower the apron.

The apron will keep lowering until it is fully down.

IMPORTANT It will then be in floating mode. It will stay in floating mode until raised or pump is switched off

Apron up 

Press and hold the Apron UP switch to raise the apron.

The apron will keep rising until it is fully up or the switch is released.

Lower stabiliser 

Press and hold the STAB DWN switch to raise the machine.

The stabilisers will keep lowering until they are fully extended or the switch is released.

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Operators Manual for the 30MB3 Miner

Raise stabiliser 

Press and hold the STAB UP switch to lower the machine.

The stabilisers will keep rising until they are fully extended or the switch is released.

Water There is one (1) water circuit for the cutter head sprays. You can start and stop the head sprays manually.

To start the head sprays: 

Toggle WATER switch to start the high-pressure water jets.



Toggle WATER switch again to stop the high-pressure water jets.

Cutters Starting of the Cutter motors is staggered to avoid excessive current inrush that might result if both motors were started at the same time. After the first motor is started, there is a delay of two or three seconds before the second motor starts.

The first motor to be started is chosen automatically by the control system and alternates from left to right for successive starts.

Start Cutters 

Press the [SHIFT] and [CUTTER ON] switches.

The siren will sound for two seconds before the cutters are started.

The water sprays will come on automatically. 

Release both switches.

Stop Cutters 

Press CUTTER OFF switch.



Release both switches.



Machine sprays stop.

IMPORTANT The cutters will stop immediately whenever the STOP is activated or the hydraulic pumps are stopped

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Operators Manual for the 30MB3 Miner

Tramming The left and right tramming switches can be used:   

Together (for same direction) Singularly (one at a time for turning) Differentially (opposite directions for pirouetting).

The siren sounds intermittently (beep, beep, beep) whenever either of the tramming switches is selected to reverse. The siren stops as soon as the switch (or switches) are released or moved to forward.

The machine can tram at any of three speeds, both in the forward direction and in reverse.

The actual speed can be changed in Setup mode.

The continuous miner is always in Speed 1 when tramming mode is first selected. To engage the next speed range, toggle the TRAM 2-3 switch while operating one or both tramming switches.

When the miner has been tramming: 

Press the TRAM 2 - 3 switch to increase speed.

While the miner is still running: 

Press TRAM 2 - 3 switch to increase the speed again.

While the miner continues to run, you can only change between speeds 2 and 3. To return to speed 1, you must stop tramming and start again.

Tram reverse can operate in all 3 speeds, however if the cutters are running, once speed 2 is activated, the cutters will stop.

Gathering Heads – Conveyor The Gathering Head motors at the rear of the discharge conveyor drives the chain conveyor. Conveyor forward and reverse functions on the transmitter, start the gathering heads. The hydraulic driven east west conveyor chains start up 2 seconds after the main conveyor.

Conveyor Forward 

Press the [SHIFT] and CONVEYOR [ON] switches together.

The siren will sound for two (2) seconds before conveyor starts.

Conveyor Reverse 

Press and hold the [SHIFT] and CONVEYOR [REV] switches together.

After a short delay, the conveyor will start running in the reverse direction and continue to do so until the switches are released.

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Operators Manual for the 30MB3 Miner

East West Forward only 

Press and hold the [SHIFT] and CONVEYOR [FORWARD] and [TRAM 3].

East West Reverse only 

Press and hold the [SHIFT] and CONVEYOR [REV] and [TRAM 3].

Conveyor Stop If the conveyor is already operating in forward, pressing the CONVEYOR OFF switch will stop it.

Lights The lights can be operated on and off by [SHIFT] and [LIGHTS].

Transmitter Maintenance & Battery Charger

Before taking the transmitter off charge, ensure the green light is on the appropriate channel of the charger to indicate the battery has been fully charged and is in good order.

Switch on the transmitter and ensure the battery/charger is receiving a signal from the transmitter. Operate each switch to ensure each function is indicated on the battery charger screen.

Ensure all dirt and moisture is removed from the top of the transmitter before it is placed on charge after each shift. Inspect transmitter for any damage.

Every week the top plate should be removed from the transmitter and all material removed from around the switches by soft brush and all switches inspected for any damage including membrane around switches.

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Operators Manual for the 30MB3 Miner

When transporting to machine ensure transmitter is secured to prevent damage.

Also ensure whenever transmitter is put down at face that it is located in safe position.

Display Unit A display screen is provided on the right hand side of the machine. This provides the operator/tradesman with fault information, machine modes and performance information. A switch is situated under the display screen which selects either ‘Radio’ mode or ‘Pendant’ mode.

Navigation Functions The main machine display can be changed using the Navigation System. To enter the radio system Navigation mode the following steps must be followed.

1. Press [SHIFT] and [MENU] (WATER switch) and hold for approx 2 seconds 2. Press [SHIFT] and [NAV] (CON left or right) to move through consecutive screens or enter the page number of the screen to be viewed using the numbers 1 through to 0. ie to access page 201 use and hold [SHIFT] then press [MENU] and release, press switches 2 (STAB DOWN), then 0 (FAN OFF), then 1 (TRAM 2-3), then # (CON UP).

This will then open page 201 Remote Console.

If an error is made when inputting page numbers, then * (CUTTER OFF) can be used to start over. After pressing # the [SHIFT] and [MENU] key needs to be used again, this navigation function will also time out after a short period

Alternative Navigate using the screen scroll button shown on page 4 of this section. This button will allow operator to scroll screens 1 to 20.

Display - Main Screen

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Operators Manual for the 30MB3 Miner

This Main Monitor display screen includes :1.

2.

3.

4.

5.

Machine status indicated by Fault (red), Trip (orange), or OK (green) Machine Mode – Mining, Bolting or Maintenance indicated in blue Radio channel 1 through to 8 under remote graphic and in red Clock and Date top of screen with Title and page number Functions in use indicated in yellow and by top right remote graphic (toggle turns red) 6. Faults and Trips (scrolling if more than one) indicated in red 7. Motor States, if running lit in red to indicate warning of operation 8. Left and right pump current (Amps) and Motor Temperature (Celsius) 9. Left and right cutter current (Amps) and Motor Temperature (Celsius) 10. Left and right conveyor current (Amps) and Motor Temperature (Celsius) 11. Left and right traction (Amps) and Motor Temperature (Celsius) 12. Machine Voltage and Methane Level 13. Remote indications including :  SIGNAL : Indicates green when healthy  BATTERY: Indicates flashing red when battery voltage is low  STOP: Indicates red when remote stop activated

Production Monitor Screen N01

The Production Monitor is Page 2 on the display screen menu and this screen includes:   Section 6

Left and right Cutter motor currents by phase and displays overall current on a real time graph.

Indicates the % speed of the Traction, and gives the ability to monitor Traction ramp up and down relative to Cutter Load when cutting Indicates roof and floor clearance of the cutting drum via onboard Inclinometers.

These values can be adjusted and are stored in the Set up area.

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  

Operators Manual for the 30MB3 Miner

Running status of cutting drum via animation and colour, if running, the drum animation spins, and is red. If drum colour is flashing, this indicates the drum is outside inclinometer values.

Direction arrows, change red to represent the drum travelling vertically up or down.

Boom override status.

To operate the Boom Override mode operate [SHIFT], TRAM 3 and TRAM 4 keys and hold together for one second. The audible alarm will sound when the mode has changed.

To return to limits mode operate [SHIFT], TRAM 3 and TRAM 4 keys again and the Cutter Head will now shear between the top and bottom limits.

NOTE: The operation will reset to limits mode whenever the Pump Motor is restarted.

Production Monitor Screen N02

The production monitor is found on page 9 The changes incorporate:  Large numerical display  The diameter of the Cutter Drum has been included in the readout.

As shown on the example, when the Cutter Drum is on the floor (0 cm) the roof reference will read 106 cm (Cutter Drum diameter).  The display will display a negative reading when the Cutter Boom is taken below 0 cm (floor reading).

The maximum negative reading will be -30cm.  The Roof Datum (top limit) displayed at the bottom right of the production page.  The ability to set the Roof Datum (top limit) from the production page when required Section 6

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Operators Manual for the 30MB3 Miner

To set a new roof datum (top limit) operate the [SHIFT], TRAM 1 and TRAM 2 keys and hold together for one second.

The new roof datum will then be displayed on the bottom right of the screen.

PRODUCTION PAGE FOR ULAN/GLENNIES/OAKY CREEK NO.1 30MB3 MINER A new Production monitor page has been supplied for the 30MB3 Miner.

The changes incorporate: 

Large numerical display



The diameter of the Cutter Drum has been included in the readout.

As shown on the example, when the Cutter Drum is on the floor (0 cm) the roof reference will read 106 cm (Cutter Drum diameter).



The display will display a negative reading when the Cutter Boom is taken below 0 cm (floor reading).

The maximum negative reading will be -30cm.



The Roof Datum (top limit) displayed at the bottom right of the production page.



The ability to set the Roof Datum (top limit) from the production page when required

Section 6

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Operators Manual for the 30MB3 Miner

Operating Instructions The new production monitor is found on page 9

To enter the radio system Navigation mode the following steps must be followed.

3. Press [SHIFT] and [MENU] (WATER switch) and hold for approx 2 seconds or until the main heading flashes.

4. Press [SHIFT] and [NAV] (CON left or right) to move through consecutive screens or enter the page number of the screen to be viewed using the numbers 1 through to 0. ie to access page 9 use and hold [SHIFT] then press [MENU] and release after two seconds, press switch 9 (CON DWN), then # (CON UP). This will then open page 9, the new PRODUCTION MONITOR. If an error is made when inputting page numbers, then * (CUTTER OFF) can be used to start over. After pressing # the [SHIFT] and [MENU] key needs to be used again, this navigation function will also time out after a short period.

BOOM OVERRIDE To operate the Boom Override mode operate [SHIFT], TRAM 3 and TRAM 4 keys and hold together for one second. The audible alarm will sound when the mode has changed.

To return to limits mode operate [SHIFT], TRAM 3 and TRAM 4 keys again and the Cutter Head will now shear between the top and bottom limits.

NOTE: The operation will reset to limits mode whenever the Pump Motor is restarted.

ROOF DATUM SET This function allows a new top limit to be set dynamically when required.

To set a new roof datum (top limit) operate the [SHIFT], TRAM 1 and TRAM 2 keys and hold together for one second.

The new roof datum will then be displayed on the bottom right of the screen.

SHEAR DIRECTION Shear up direction is shown by the top arrow of the display changing to red in color, and the cutter head moving in an upwards direction.

Shear down direction is shown by the bottom arrow of the display changing to red in color, and the cutter head moving in a downwards direction.

Section 6

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Operators Manual for the 30MB3 Miner

Thermistor Module The thermistor unit monitors the resistance of the thermistors mounted in the motors. If the resistance exceeds a limit the unit provides a signal to tell the control system to trip the appropriate motor.

Power Supply Module The power supply module converts 110Vac supply to 24Vdc. The 24Vdc provides power to each of the other Modules.

Solenoid Module This module provides the control of solenoid functions and protection against stuck spool.

The solenoid module contains for each output, two internal relays is series. When an output is turned ON, these relays are turned on separately, and the internal feedback is checked for each. When there is a problem with the solenoid module, the pump will be turned OFF, and the following messages can be displayed :    

Solenoid short.

Fault on PCB due to closed relay when should be open Fault on PCB due to open relay when should be closed.

Missing feedback reference input.

Connection to 1 "Sol PCB1 Short" "Sol PCB2 Short" "Sol PCB1 Fault" "Sol PCB2 Fault"

Possible causes for these faults :

Solenoid short.



Fault on PCB due to closed relay when should be open.10Vac at output when output should be off.

IMPORTANT The solenoid short detection is a hardware trip at 7 amps peak.

Traction Module Controls DC reference voltages for power modules, monitors currents and voltages of the traction circuit.

I/O Module Monitors inputs and controls outputs and relays.

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Operators Manual for the 30MB3 Miner

Control Module 

Incorporates the main microprocessor. Stores the relevant machine software.



Relays information to the display unit.



Receives information from remote control unit.

Inclinometer The inclinometer is used to indicate the cutting head height. The top and bottom cutting heights are referenced to the horizontal zero position. You will not be able to shear beyond these limits unless boom override mode is enabled.

To override the Inclinometer with the pumps running, using the transmitter operate the [SHIFT] then TRAM 3 and TRAM 4.

Override will stay on until the pumps are turned off.

6.6

INDICATOR LED’s

A panel of LED’s is visible through the viewing window in the Main Control Case. The LED’s indicate the following :1.

2.

3.

4.

110V Control – (Green – healthy) Control supply is ON Radio 24V – (Amber – healthy) 24V supply to Radio system is ON E/Stops Healthy – (Green – healthy) Machine Emergency Stops are all out Traction E/L Trip – (Red – Tripped) This will appear on power up, after an Traction E/L Test or if there is an earth fault on the traction circuit.

5. Pendant Mode – (Green – on) Indicates that pendant mode is selected. Radio is not able to be used in this mode.

6. Pump Overload – (Red – Tripped) Indicates that the manual pump overload had tripped. This will only operated when pendant mode is selected.

LED Indicators Inside Panel Window

Section 6

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6.7

Operators Manual for the 30MB3 Miner

MODES OF CONTROL

Radio / Pendant Mode Switch The miner can be operated in (2) two modes of control : 

Radio Mode Pendant Mode

The mode selector switch is located on the front of the flameproof Display Enclosure and has an OFF position between the two modes.

Screen Scroll Pages 1 to 20 Methane Override / Reset

Radio / Pendant Mode Switch Diode/Pilot Select Radio Mode When the miner is in Radio mode, it is controlled via the radio system and transmitter. The pendant circuits are isolated via the mode switch.

Pendant Mode The Pendant mode provides the ability to start the pump and tram at sump speed in both forward and reverse directions in the event of an EMERGENCY ONLY. It does not provide for production or maintenance operation.

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Operators Manual for the 30MB3 Miner

The Pendant consists four tramming buttons:   

Left Tram Forward Right Tram Forward Left Tram Reverse Right Tram Reverse.

All tramming buttons are spring return to the off / neutral position. There is also a detented Machine stop button, which is normally in the “in” position when not in use. This stop button is only in use when the pendant mode is selected.

To activate the Pendant, turn the mode selector switch to Pendant. When the Pendant stop button is pulled out, the pumps will start and the tramming buttons are ready for operation.

IMPORTANT The siren will sound continuously while Pendant mode is selected.

Section 6

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Operators Manual for the 30MB3 Miner

NOTES

………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… …………………………………………………………………………………………………………

Section 6

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Controls and their Functions

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Operators Manual for the 30MB3 Miner

SECTION 7 Pre-Start Checks

30MB3 OPERATORS MANUAL

Section 7

Page 1 of 4

Pre-Start Checks

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Operators Manual for the 30MB3 Miner

Table of Contents 7.1 PRE-START FUNCTIONS ............................................................................. 3 Inspections ............................................................................................................ 3

Section 7

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Pre-Start Checks

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7.1

Operators Manual for the 30MB3 Miner

PRE-START FUNCTIONS

Prior to putting the miner into operation the machine and surrounding area should be subjected to a systematic inspection to ensure that: 1. The area about to be worked can be done so in safety for both the operator and

machine.

2. The miner can be operated safely.

Inspections The inspections should include the following items prior to starting the miner :1. Ensure that you are aware of section plan and at what stage the mining

sequence is up too.

2. Examine water hose and cable from gate end box to the miner: 3. Ensure cable and water hose will not be damaged by large amounts of coal and

debris (free falling from rib or roof) or by other machinery running over the cable and/or water hose.

4. Check the condition of roof and face in the immediate area of operations and

check the state of ventilation.

5. Check that there are no “Out of Service” or “Danger” tags on the machine.

6. Ensure all guards are in correct position and are secure.

7. Ensure that miner is free of large amounts of coal and debris.

8. Ensure that all exposed hoses and cables are safely positioned and free from

damage.

9. Ensure lights are secure and lenses are clean and not cracked or broken.

10. Ensure stop buttons are in the correct position. Correct position is out for drill

rig stops.

11. Ensure that no foreign items (eg. service tools and equipment) have been left

on and/or in the miner and/or in front or at the rear of the miner.

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Operators Manual for the 30MB3 Miner

12. Ensure all safety posts drill rigs and platforms are in position and secure.

13. Check that fire extinguisher is in position and in a serviceable condition.

14. Ensure all visible flameproof equipment including cables and glands are not

damaged which may render miner not flameproof.

15. Ensure operator service points have been checked: a. Cutter head has a full complement of sharp picks. b. All oil levels register the correct amount of fluid. c.

The inlet water filter is clean (bag type). Remove and clean bag.

d. Water sprays are in place and clear. e. Hydraulic filter indicators. (If fitted) 16. Check that the operating area is clear and that personnel are aware the miner is

about to start.

Section 7

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SECTION 8 Start-Up Procedure

30MB3 OPERATORS MANUAL

Section 8

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Start-up Procedure

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Table of Contents 8.1

START UP FUNCTIONS ............................................................................... 3

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Start-up Procedure

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IMPORTANT Having completed the Pre-Start checks and rectified any anomalies found, the miner can then be started and placed into production.

IMPORTANT Procedures listed in Oaky Creek No 1 Mine - Procedures for the Remote Control Operations for Continuous Miners – Managers Rules Remote Control Operation.

8.1   

START UP FUNCTIONS Check main circuit breaker is on.

Check handle on inlet water filter handle is in the correct position.

Check if the receiver box displayed is lit.

Using the radio transmitter outlined in Section 6 :    

Activate the headlights.

Ensure all personnel are well clear of miner before starting.

Audible alarm.

Start the pump motors.

Check the operation of the stop switch. Restarting the miner, check that the following functions operated correctly.

Stand well clear of the miner and ensure all personnel are well clear when checking for the following functions: 1.

2.

3.

4.

5.

6.

7.

Cutter head - raise and lower.

Shovel - raise and lower.

Stabiliser - raise and lower.

Conveyor - raise and lower.

Conveyor Swing - right and left.

Traction - forward and reverse (in all three (3) speeds).

Water Sprays - on and off.

Check the following operations: 1.

2.

3.

4.

Pump - on and off.

Cutter Head - on and off.

Conveyor - on and off Mining, Maintenance and bolting modes on the manual diversion valve.  Check that there are no unusual noises or vibrations.  Check (with pump motor only running) for any oil and/or water leaks around miner.

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Start-up Procedure

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Operators Manual for the 30MB3 Miner

IMPORTANT Oaky Creek No 1 Mine – Continuous Miner Remote Control (RC) Transmitter Function Test Report form – Document.

IMPORTANT Whilst each of these items should be checked before starting the miner at the beginning of each shift, it is also necessary to maintain a constant awareness of these points each time the miner is restarted in the course of the shift

Never operate the miner if any picks are missing, blunt or damaged. These must be replaced immediately.

Failure to do so may cause. Damage to cutter drums. Checking of cutter drums is outlined in “Pre-Start Functions” Section 7.

Providing the items in sections “Pre-Start Functions” and “StartUp Functions” have been checked positive, the miner is now ready for coal production.

Section 8

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Start-up Procedure

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SECTION 9 Operating

30MB3 OPERATORS MANUAL

Section 9

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Operating

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Table of Contents 9.1 USING 30MB3 MINER ................................................................................... 3 Precautions ........................................................................................................... 3 9.2

BOLTING, MINING & MAINTENANCE MODE SELECTOR ......................... 4

9.3 MINING MODE .............................................................................................. 5 Cutting Cycle ......................................................................................................... 5 Flitting .................................................................................................................... 6 9.4 MAINTENANCE MODE ................................................................................. 7 Hydraulic Oil Power Fill ......................................................................................... 7 Gear Case Oil Power Fill ....................................................................................... 7 9.5

BOLTING MODE ........................................................................................... 9

Section 9

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9.1

Operators Manual for the 30MB3 Miner

USING 30MB3 MINER

Before starting coal production in a single pass environment, a procedure will have to be in place and all members of the crew must be aware of their tasks and when each member is required to perform the task ensuring the system operates safely and effectively.

Precautions To operate the 30MB3 miners efficiently in this type of coal cutting system a number of items are required to be in place: 1.

Correct power supply to Section.

2.

Correct Colliery ventilation supply.

3.

Ensure water is on machine.

IMPORTANT Refer to Oaky Creek No 1 Mine SOP00780CI

Section 9

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9.2

Operators Manual for the 30MB3 Miner

BOLTING, MINING & MAINTENANCE MODE SELECTOR

Selection of the (3) three different modes able to be selected, is controlled by the hydraulic diversion valve located on the right hand side bolting platform.

The three different modes available are:1.

Mining Mode

2.

Maintenance Mode

3.

Bolting Mode

Each mode is selected by operating the diversion valve lever to the required mode.

Each mode is monitored by the electrical control system via pressure switches.

There is both electrical and hydraulic isolation interlocking provided on each mode.

Mode selection valve

Section 9

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9.3

Operators Manual for the 30MB3 Miner

MINING MODE

Cutting Cycle IMPORTANT Ensure that the both side drill rigs are in the parked position. If not, go to Bolting Mode and park both drill rigs and return back to Mining Mode.

Select “Mining Mode” on the Mode Selector diversion valve.

Mining mode will allow the miner to cut and tram Steps for cutting cycle are as per following steps:1.

Carry out pre start checks

2.

Start pump motors.

3.

Raise conveyor to allow haulage vehicle to move under the conveyor.

4.

Lower apron.

5.

Start gathering head.

6.

Start cutter head. Note: water start auto with cutter start.

7.

Tram miner to coal face, cleaning up coal spillage on the way.

8.

Raise cutter head to roof height.

9.

Tram miner forward 1 metre cutting.

10.

Progressively lower cutting head cutting to floor height.

11.

Tram miner forward 1 metre cutting.

12.

Progressively raise cutter head cutting to roof height.

13.

Continue the cycle until the cut has been advanced far enough.

IMPORTANT The length of the cut will primarily be determined by the roof and rib conditions. Bolt roof and ribs as per Managers rules. Refer to Drill Rig Operators Manual for correct procedures

Section 9

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Operators Manual for the 30MB3 Miner

Flitting Flitting allows for flitting of the miner with full hydraulic functions available to the operator.

IMPORTANT Drilling Rigs on both sides need to be in the parked position before tramming or Flitting.

IMPORTANT Prior to flitting, isolate the cutter and gathering head circuit breakers and tag out as per mine isolation procedures also place the conveyor swing isolating value in the off position

1.

Ensure the cutter and gathering head circuit breakers are isolated and tagged out as per mine isolation procedures.

2.

Select “Mining Mode” on the Mode Selector diversion valve.

3.

Remove/fold up rear platforms as well as side platforms

4.

Ensure all personnel are clear of machine prior to start up.

5.

Once personnel clear, start machine and raise lower head to suit tramming, check conveyor boom, retract cutter barrel extensions and gathering head plows etc prior to flit or bolting operation.

6.

Operate machine to suit conditions - flit machine in slow speed. If flitting on grades up or down - ensure extra distance and time is allowed to stop.

Poor floor conditions could cause machine to slip.

7.

Ensure cable handlers and cable is clear and free from possible damage.

Section 9

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Operating

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9.4

Operators Manual for the 30MB3 Miner

MAINTENANCE MODE

There are (2) two power on operations available in Maintenance Mode on the miner.

1. Hydraulic Oil Power Fill 2. Gear Case Oil Power Fill

IMPORTANT Prior to selecting Maintenance Mode, isolate the CUTTER, CONVEYOR & TRACTION circuit breakers and tag out as per mine isolation procedures. Interlocking in the radio system will stop pumps if all three circuit breakers are not isolated.

Hydraulic Oil Power Fill The following procedure is to be followed to carryout hydraulic oil power fill tasks safely:1. Ensure Cutter, Gathering Head and Traction circuit breakers are isolated and tagged out.

2. Connect oil drum line to the fill hose located on the in bye end of the flameproof Main Control Case enclosure.

3. Open the oil full ball valve which is mounted near the filler hose.

4. Place the Power Fill diversion valve to the Hydraulic Oil position (pull forward) 5. Select “Maintenance Mode” on the Mode Selector diversion valve.

6. Start pumps and leave Power Fill diversion valve in the Hydraulic Oil position until oil runs out of the oil full ball valve.

7. Place Power Fill diversion valve into the neutral position.

8. Close oil full ball valve.

Gear Case Oil Power Fill The following procedure is to be followed to carryout gear case oil power fill tasks safely:1. Ensure Cutter, Gathering Head and Traction circuit breakers are isolated and tagged out.

2. Connect gear oil drum line to the fill hose located on the out bye end of the Section 9

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flameproof Main Control Case enclosure.

3. Place the Power Fill diversion valve to the Gear Case Oil position (push back) 4. Select “Maintenance Mode” on the Mode Selector diversion valve.

5. Start pumps and leave Power Fill diversion valve in the Gear Case Oil position.

6. Gear case oil should be present at the filler gun.

7. Place Power Fill diversion valve into the neutral position when finished.

Section 9

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9.5

Operators Manual for the 30MB3 Miner

BOLTING MODE

IMPORTANT When Bolting mode is selected, all hydraulic functions other than those associated with the drill rigs are disabled.

The following procedure should be used to gain access to bolting mode:1.

Position the miner where bolting is required.

2.

Select “Bolting Mode” on the Mode Selector diversion valve.

3.

Carry out bolting as required

4.

Park both side drill rigs when finished

5.

Select “Mining Mode” on the Mode Selector diversion valve so that cutting & tram cycle can proceed.

Section 9

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Operating

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Operators Manual for the 30MB3 Miner

SECTION 10 Shutdown Procedure

30MB3 OPERATORS MANUAL

Section 10

Page 1 of 3

Shutdown Procedure

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Operators Manual for the 30MB3 Miner

Table of Contents 10.1 SHUTDOWN FUNCTIONS ............................................................................ 3 Parking .................................................................................................................. 3 Shutdown Checks ................................................................................................. 3

Section 10

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Shutdown Procedure

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10.1

Operators Manual for the 30MB3 Miner

SHUTDOWN FUNCTIONS

Parking On completion of the shift, the miner should be parked in an area where the following conditions prevail: 1.

The roof and rib have been secured.

2.

The area is well ventilated.

3.

The miner will not be affected by a slow or sudden influx of water.

Shutdown Checks Before shutting the miner down, the following items should be completed: 1.

The shovel lowered to the ground and empty.

2.

The cutter head lowered to the ground.

3.

The conveyor lowered.

4.

Ensure the stabiliser is up.

5.

Park or close up all drill rigs and associated platforms

6.

Stop the pump motors using the off toggle on the transmitter or by using one of the (4) four different points around the miner (if a stop button is used, be sure to reset the stop button when the miner has stopped, that is pull stop buttons out or push lanyard button in to reset).

7.

Turn off or remove the water supply to the miner.

8.

Any unusual noises or vibrations are to be reported to the section supervisor and/or to maintenance personnel.

9.

Any components or part of the miner that has been damaged or partly dislodged during the shift should be reported to the section's supervisor or maintenance personnel.

Section 10

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Shutdown Procedure

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Operators Manual for the 30MB3 Miner

SECTION 11 Emergency Shutdown

30MB3 OPERATORS MANUAL

Section 11

Page 1 of 7

Emergency Shutdown

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Operators Manual for the 30MB3 Miner

Table of Contents 11.1

EMERGENCY SHUTDOWN – 30MB3 CONTINUOUS MINER ..................... 3

11.2 EMERGENCY PROCEDURES WHILST OPERATING ................................... 6 Fire Emergency Procedure ................................................................................... 6 Basic Emergency Procedure ................................................................................. 6

Section 11

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Emergency Shutdown

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11.1

Operators Manual for the 30MB3 Miner

EMERGENCY SHUTDOWN – 30MB3 CONTINUOUS MINER

In the event of an emergency, the miner can be shutdown in a number of ways.

1. The electrical power is removed from all drive motors, resulting in all moving parts coming to rest and the tram brakes being applied. a)

By toggling the STOP key on the radio transmitter.

b)

By operating either side rear lanyard machine emergency stops.

c) By operating a machine emergency stop switch located on either side bolting platforms. d) By operating the handle of the main circuit breaker to the OFF position. e) By toggling the [SHIFT] key to ON and the STOP key to [PILOT] on the radio transmitter. This will activate the radio PILOT TRIP function, opening the pilot circuit and will remove power from the miner at the DCB or transformer.

2. Following a 2 second time delay for this function to active, the electrical power is removed from all drive motors resulting in all moving parts coming to rest and the tram brakes being applied. a) By toggling the [SHIFT] key on the radio transmitter to the OFF position for (2) two seconds.

IMPORTANT This is not an instantaneous shutdown. There is a 2 second time delay.

Transmitter Stops Transmitter STOP key and [PILOT] key

Transmitter [SHIFT] key and OFF key

Section 11

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Emergency Shutdown

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Operators Manual for the 30MB3 Miner

Right Machine Emergency Stop

Stop button and lanyard junction

Push reset button

Lanyard pull stop cable

Left Machine Emergency Stop

Push reset button

Lanyard pull stop cable Stop button and lanyard junction

Section 11

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Emergency Shutdown

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Operators Manual for the 30MB3 Miner

Side Bolting Platform Machine Emergency Stop Platform Stop

Section 11

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Emergency Shutdown

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Operators Manual for the 30MB3 Miner

11.2 EMERGENCY PROCEDURES WHILST OPERATING Fire Emergency Procedure In the case of fire on or around the miner: 1.

Stop all face equipment immediately.

2.

Have the power to the face isolated at the D.C.B.

3.

If it is safe to do so, retrieve the fire extinguisher from the miner and move to the intake side of the fire zone.

4.

If it is not safe, then collect an extinguisher from the nearest location.

5.

Attempt to extinguish the fire from the intake side. If unable to extinguish the fire, commence mine fire fighting procedures.

6.

If able to extinguish the fire:  Do not attempt to move the miner  Place a “Danger Tag” on the miner and the D.C.B.  Advise the Mining Official and the control room immediately.

IMPORTANT The miner is equipped with two (2) dry chemical fire extinguisher with a rating of 80 BE. Always check that it is serviceable as part of the miner’s pre-start checks. Report any deficiencies.

Basic Emergency Procedure The Coal Mining Act defines an “emergency situation” as any set of circumstances occurring at a mine which involves the loss of life, or injury to any person, or a real or apparent immediate danger of the loss of life of or injury to any person and which requires a co-ordinated response.

If a person becomes aware of any situation which requires, or may require, prompt first aid and/or emergency assistance, that person should put into effect the emergency procedure at the mine to report the incident.

Section 11

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Emergency Shutdown

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What to Do In The Case of Emergency: IMPORTANT Refer to Oaky Creek No 1 Mine procedures. Do not hang up immediately as you may be required to give further information or receive instructions on dealing with the emergency.

MINIMISE THE USE OF COMMUNICATION SYSTEMS TO LEAVE THE LINES CLEAR FOR EMERGENCY COMMUNICATIONS TRAFFIC.

Section 11

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Emergency Shutdown

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SECTION 12 Operator Servicing And Maintenance

30MB3 OPERATORS MANUAL

Section 12

Page 1 of 8

Operator Servicing & Maintenance

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Operators Manual for the 30MB3

Table of Contents 12.1

Operator Servicing and Maintenance ......................................................... 3

12.2

Repair or Replace Water Sprays ................................................................. 4

12.3

Machine Cutting Picks ................................................................................. 5

12.4

Check and Fill Hydraulic Oil Reservoir ...................................................... 6

12.5

Notes ............................................................................................................ 8

Section 12

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Operator Servicing & Maintenance

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12.1

Operators Manual for the 30MB3

Operator Servicing and Maintenance

Prior to any work taking place on miner, full isolation is to be done as per Oaky Creek No 1 Mine Managers Regulations and tagging procedures.

The above statement applies to any work on continuous miner including changing picks, sprays or any other work procedure.

WARNING Full current isolation required Level 2 per mine Managers Rule Remote Control Operations.

Section 12

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Operator Servicing & Maintenance

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12.2

Operators Manual for the 30MB3

REPAIR OR REPLACE WATER SPRAYS

The water system on the miner provides for water cooling of electric motors and dust suppression during normal machine operations. The water used during normal machine operations, dust control, is firstly passed through the motor water jackets and second to the water sprays. The water spray circuit has been fitted with two 3 – way ball valves which are for changing the direction of the sprays as required by the mine. (Refer to water schematic and information Section 5)).  

Place the head in the horizontal plane with the shovel on the floor and conveyor boom down.

Open cutter circuit breaker on the main panel.

WARNING Full current isolation required as per Oaky Creek No 1 Mine SOP00780C1   

Turn the water by-pass valve (located above reverse flush filter) on and walk around the machine checking for correct spray operation.

Turn water off once blocked sprays are located and lock out the ball valve with locking device fitted to handle.

Remove any spray not working correctly, then dismantle, clean and replace.

The miner is fitted with a colliery supplied water filter that is located in the driver’s compartment.

Water sprays Disc Type Water Filter

Section 12

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Operator Servicing & Maintenance

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12.3

Operators Manual for the 30MB3

MACHINE CUTTING PICKS

The cutting head on the 30MB3 Miner plays an integral part in the machines performance and its targets. It is highly important that the cutting picks are inspected during and before each shift and replaced as required. Procedure is as follows:  

Place the head in the horizontal plane upon the manufactured head stops with the shovel on the floor and conveyor boom down.

Open cutter circuit breaker on the main panel.

WARNING Full current isolation required as per mine isolation procedures.

IMPORTANT Refer to Oaky Creek No 1 Mine SOP00780C1 

Replace picks as required and report and cracks or missing blocks immediately.

Cutter Head Picks

Section 12

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Operator Servicing & Maintenance

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Operators Manual for the 30MB3

12.4 CHECK AND FILL HYDRAULIC OIL RESERVOIR The Hydraulic Reservoir upon the 30MB3 Miner contains 750 litres of 68 grade oil with the tank full. System capacity is 1000 Litres. Procedures for checking levels and filling are as follows: 

Low levels can be known in two ways. Either by a low level siren or whistle indicator also will show on main screen



Oil level checks can be done via the sight glass manifolds mounted beside the traction gear cases as shown below. Right Hand side shown only. The oil level should be higher than the bottom sight glass and lower than the top sight glass.

Hydraulic oil level sight glasses



If oil levels are deemed to be low, source Hydraulic 68 grade oil and place at the left hand side of the machine, in bye of the electrical panel. Here there is the Hydraulic oil fill hose and a ball valve for visual oil fills requirements whilst filling only. See below.

Hydraulic power fills hose

Section 12

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Operator Servicing & Maintenance

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Operators Manual for the 30MB3

IMPORTANT Open the conveyor, cutter and traction circuit breakers and select Maintenance mode as per Section 11 Bolting, Mining and Maintenance Modes

IMPORTANT Refer to Oaky Creek No 1 Mine SOP00780C1  

Start machine and proceed to Left Hand side of the miner and place hose end into oil drum and open oil level ball valve.

Locate oil diversion valve at rear of Left Side of miner and move handle as per tagging to Hydraulic Oil fill. See below,

Hydraulic Oil Fill diversion valve

Power fills pump/motor assembly



Continue to fill until oil is witnessed from the level ball valve.

Section 12

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Operator Servicing & Maintenance

5

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12.5

Operators Manual for the 30MB3

NOTES

……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ……………………………………………………………………………………………… ………………………………………………………………………………………………

Section 12

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Operators Manual for the 30MB3 Miner

SECTION 13 Trouble Shooting

30MB3 OPERATORS MANUAL

Section 13

Page 1 of 8

Trouble Shooting

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Operators Manual for the 30MB3 Miner

Table of Contents 13.1 PUMPS ........................................................................................................... 3 13.2

TRACTION ..................................................................................................... 4

13.3

CUTTERS ...................................................................................................... 5

13.4

CONVEYOR ................................................................................................... 6

13.5 MAIN CONTROL CASE INDICATORS ......................................................... 7 13.6 WATER TROUBLESHOOTING GUIDE ..................................................... 8

Section 13

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Trouble Shooting

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Operators Manual for the 30MB3 Miner

13.1 PUMPS There are a number of safety and machine protection interlocks that will stop the machine pumps or prevent it from starting:        

Transmitter must be logged on Machine Emergency Stop or Lanyard is operated Electronic Module fault Lost radio signal Left or Right pump overload (4 min.reset) Left or Right over-temperature (RTD) fault Incorrect Transmitter frequency In “Maintenance Mode”, either of the (3) circuit breakers not open Incorrect Combination of mode pressure switches.

IMPORTANT Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Section 13

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Trouble Shooting

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13.2

Operators Manual for the 30MB3 Miner

TRACTION

There are a number of safety and machine protection interlocks that prevent tramming. 

Pumps - these have to be running.



Earth leakage detected in traction circuit.



Traction transformer over-temperature (RTD) has tripped.



Either left or right traction motors have overloaded (Reset time is 4 minutes).



A shutdown in scr traction drive electronics.



Deadman pressure - the brake solenoid has not operated or the pressure switch is closed. This has to be energised to allow tramming.



Traction circuit breakers tripped.



Traction transformer Overload trip. (Reset time is 4 minutes).

If any of these conditions are not satisfied, a corresponding message will be displayed.

IMPORTANT Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Section 13

Page 4 of 8

Trouble Shooting

BI643669

DBT Australia Pty Ltd

13.3

Operators Manual for the 30MB3 Miner

CUTTERS

There are a number of safety and machine protection interlocks that prevent the cutters from being started, or stop them if they are already operating: 

Pumps - these have to be running.



Either left or right cutter motor has overloaded (ie. the motor current is too high).

Reset time is 4 minutes.



Either left or right cutter motor over-temperature (RTD) has tripped.



Water spray for cutter head has failed (low flow) or has been turned off.



Tramming SPEED 2 or SPEED 3 has been selected whilst in reverse.



Low oil level



High oil temperature.



Variation above 50% between current of each cutter motor.



The machine has to be in mining mode.

IMPORTANT Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Section 13

Page 5 of 8

Trouble Shooting

BI643669

DBT Australia Pty Ltd

13.4

Operators Manual for the 30MB3 Miner

CONVEYOR

There are a number of safety and machine protection interlocks that prevent the conveyor from being started, or stop it when it has already been started. 

Pumps - these have to be running.



Gathering Heads reverse has to be stopped, to start the gathering heads in forward.



Gathering Heads forward has to be stopped, to start the gathering heads in reverse.



Either left or right gathering head motor is overloaded (ie. the motor current is too high).



Either left or right conveyor motor over-temperature (RTD) has tripped.



Variation of 50% in motor currents.



The machine has to be in Mining mode.

IMPORTANT Turning off power to the miner or control circuits will not reset the 4 minute overload reset timers. If power is removed during an overload reset time period, the reset timer will restart at the time remaining when power was removed.

Section 13

Page 6 of 8

Trouble Shooting

BI643669

DBT Australia Pty Ltd

13.5

Operators Manual for the 30MB3 Miner

MAIN CONTROL CASE INDICATORS

A panel of LEDs are visible through the viewing window in the Main Control Case.

The LEDs indicate the following :1.

2.

3.

4.

110V Control – (Green – healthy) Control supply is ON Radio 24V – (Amber – healthy) 24V supply to Radio system is ON E/Stops Healthy – (Green – healthy) Machine Emergency Stops are all out Traction E/L Trip – (Red – Tripped) This will appear on power up, after an Traction E/L Test or if there is an earth fault on the traction circuit.

5. Pendant Mode – (Green – on) Indicates that pendant mode is selected.

Radio is not able to be used in this mode.

6. Pump Overload – (Red – Tripped) Indicates that the manual pump overload had tripped. This will only operated when pendant mode is selected.

Section 13

Page 7 of 8

Trouble Shooting

BI643669

DBT Australia Pty Ltd

13.6

Operators Manual for the 30MB3 Miner

WATER TROUBLESHOOTING GUIDE

PROBLEM: Lack of water reaching miner - water sprays WATER ISISWATER FROM REEL CONNECTED TO CONNECTED TO MINER? MINER?

CONNECT HOSE AND OPEN WATER VALVE

NO

YES NO

WATER ISISWATER PRESSURE

NO

PRESSURE AT SUPPLY SOURCE AT HOSE REEL

CORRECT WATER PRESSURE AT MINER? 100 PSI MINIMUM.

MECHANICAL SKILLS REQUIRED

YES

NO ISISWATERFLOW PASSING WATER FLOW THROUGH BAG PASSINGINLET THROUGH INLET FILTER. FILTER.CHECK FLOW AT CHECK FLOW AT WASHDOWN HOSES?

NO REPLACE FILTER BAG CLEAN FILTER

MECHANICAL SKILLS REQUIRED

WASH DOWN HOSES

YES

IS WATER PASSING THROUGH PILOT OPERATED WATER VALVES?

NO

REFER HYDRAULIC SHEET

YES

ARE MINER WATER SPRAYS OPERATING

NO

MECHANICAL SKILLS REQUIRED

Water Troubleshooting chart for Drill Rigs in Drill Rig section.

Section 13

Page 8 of 8

Trouble Shooting

BI643669

DBT Australia Pty Ltd

Operators Manual for the 30MB3 Miner

SECTION 14 ARO – Roof & Rib Bolting Equipment

30MB3 OPERATORS MANUAL

Section 14

Page 1 of 1

ARO