DOWNLOAD PDF CAT Bucyrus Newlands PM4 V5.21 Parameters Manual BI620112

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Technical Manual

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M01366

Newlands PM4 V5.21 Parameters Manual

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BI620112

Newlands PM4 Parameters V5.21

Contents PM4 MENU NAVIGATION .................................................................................................................................3 MENU PLAN ..........................................................................................................................................................3 SHORT-CUT KEYS .................................................................................................................................................3 SHORT-CUT KEYS .................................................................................................................................................4 CHANGING PARAMETERS...............................................................................................................................6 NUMERIC PARAMETERS ........................................................................................................................................6 TEXT PARAMETERS ...............................................................................................................................................6 PARAMETER DESCRIPTIONS .........................................................................................................................7 AUXILIARY FUNCTIONS .........................................................................................................................................7 Changing the Default Order ............................................................................................................................7 Operation .........................................................................................................................................................7 Example of an Auxiliary Function ...................................................................................................................8 SPECIAL AUXILIARY FUNCTIONS ...........................................................................................................................9 MEASURED VALUES ............................................................................................................................................10 GLOBAL PARAMETERS ........................................................................................................................................11 SERVICE ..............................................................................................................................................................13 AUTOSEQUENCE PARAMETERS ...........................................................................................................................20 PSA PARAMETERS ..............................................................................................................................................29 PROHIBITED ACTIONS .........................................................................................................................................31 DIAGNOSTICS ......................................................................................................................................................34 ERROR MESSAGES ..............................................................................................................................................36 SRB PARAMETERS (SHEARER RUNNING BATCH)................................................................................................38 BATCH PARAMETERS ..........................................................................................................................................46 BANKPUSH PARAMETERS ....................................................................................................................................48 CONVEYOR PULLBACK........................................................................................................................................52 BANK FLIPPERS ...................................................................................................................................................53 EMERGENCY STOP ..............................................................................................................................................55 OPERATIONAL SOFTWARE CHANGES ......................................................................................................56

Newlands V521 PM4 Parameters Manual 1.0.doc

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PM4 Menu Navigation By pushing the key ‘N’ or ‘G’ keys it is possible to select different menus. The selected menu is shown in the LED information display. or ‘I’ it is possible to scroll up and down the menu By pushing the key ‘H’ to select various menu displays. These displays provide information on the functioning of the PM4 system or allow the user to alter parameters affecting the operation of the PM4 system.

The menu plan or layout of the PM4 program is shown below.

Menu Plan IDLE DISPLAY

AUXILIARY FCTS

MEASURED VALUES

GLOBAL PARAMETER SERVICE ASQ PARAMETERS PSA PARAMETERS PROHIBITED ACTIONS

DIAGNOSTICS ERROR MESSAGES SRB PARAMETER BATCH PARAMETER BANKPUSH CONV PULLBACK BANK FLIPPERS EMERGENCY STOP

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Short-cut Keys Short-cut keys can be used to access menu displays directly, these are: Key

Short-cut Description Auxiliary Fcts Accesses the Auxiliary functions menu and selects the left hand adjacent shield Auxiliary Fcts Accesses the Auxiliary functions menu and selects the right hand adjacent shield PSA Parameters

Accesses the Positive Set menu for controlling the Positive Set Automatic operations.

SRB Parameter

Accesses the SRB Parameters menu.

Bankpush

Accesses the Bankpush Parameters menu.

Conv Pullback

Accesses the Convpullback Parameters menu.

Batch Parameters

Accesses the Batch Parameters menu.

Second Action ASQ_SRB On / Off Bank Flippers

Accesses the Bank Flippers menu I Auto

Accesses the Last Automatic Function Diagnostic menu.

Diagnostics

Accesses the Diagnostics menu.

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Error Messages

Accesses the Error Messages column.

Menu Item

Allows saving of a menu item position and then recall of the menu item position in 10 shields to the left & right of where the A key was last pressed.

Menu Item

Recalls the last shown menu item Travel Zone

Used to set, move and cancel the travel zone

Newlands V521 PM4 Parameters Manual 1.0.doc

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Changing Parameters Many of the menu displays in the PM4 menu are adjustable parameters that affect the way the supports operate. There are two types of parameters in the PM4 program.

Numeric parameters (those preceded by a * symbol) Text parameters

Parameters can be changed following the procedures below.

Many of the parameters are password protected to prevent inadvertent altering of parameters as changes to many of the parameters could result in damage to equipment or danger to operators.

Numeric Parameters Numeric parameters can be changed by

Navigate to the menu item you wish to change Press the Enter key If the parameter is password protected the screen will show PASSWORD ?

Enter the password with the Numeric keys and press the Enter key again Press the Numeric keys to enter the new parameter Press the Enter key again to save the new parameter.

Text Parameters Text parameters can be changed by

Navigate to the menu item you wish to change Press the M key (or for some parameters the K key) If the parameter is password protected the screen will show PASSWORD ?

Enter the password with the Numeric keys and press the Enter key Press the M key to scroll through the parameter options to the desired setting Press the Enter key to save the new parameter.

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Parameter Descriptions Auxiliary Functions Auxiliary functions allow operators to operate adjacent shield functions that do not have a dedicated key on the PM4 keyboard. Accessing the Auxiliary Functions menu with the menu navigation keys will display the available Auxiliary Functions but not allow operation.

Changing the Default Order Using the menu navigation keys, scroll to the function desired to be displayed first.

Press the ENTER key.

Input your password then ENTER key.

Again press the ENTER key.

Operation

To operate an auxiliary function an adjacent support must be selected using the 1 or 2 keys. . If remote operation is enabled (see remote dist. Parameter in Global Parameters) then the desired shield may be selected by pressing the ENTER key and using

and M keys. Press the K key to increase and the M key to decrease the K the distance to the shield you want to operate (adjacent shield, up to 5=5th adjacent shield).

Press the ENTER key to accept the selection and the selected shield can be operated.

Selecting an adjacent support brings up the Auxiliary Functions menu.

and ‘I’ keys are used to scroll up and down the menu of auxiliary The ‘H’ functions once the menu is accessed.

• •

Operation of the functions is made using the K and M. keys.

When the K an M keys are used to activate a function they are ‘DEADMAN’ keys. The function will be carried out only as long as the key is pressed.

Menu Display ram out

ON

baselift

UP

Newlands V521 PM4 Parameters Manual 1.0.doc

Description M-key retracts the ram cylinder, which pushes the AFC across.

M-key extends baselift cylinder.

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side seal

IN OUT

K-key retracts the side seal on the selected shield M-key extends the side seal on the selected shield

flipper

IN OUT

K-key retracts flipper, on the selected shield M-key extends flipper on the selected shield

ext.flp.

IN OUT

K-key retracts extra flipper (or sprag) on the selected shield M-key – NO FUNCTION

SET

M-key energises the high set solenoid on the selected shield

high press.

warn.lamp GR

RE

K-key activates the green warning lamp M- key activates the red warning lamp Warning Lamp Function GREEN (flashing) – Shield ASQ advancing error RED (flashing) - Fault or error on PM4 RED (steady ON) – Disabled sensor on shield

Example of an Auxiliary Function side seal

use K button to retract the side shields

Newlands V521 PM4 Parameters Manual 1.0.doc

IN OUT

use M button to extend the side shields

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Special Auxiliary Functions Special auxiliary functions are additional items in the auxiliary functions menu only available on the MG or TG solid group of SCUs (usually there are several shields at the M/G and at the T/G pushing together as a group).

These are not Deadman functions. They act as if you pressed the L key (lock on push) on all the gate supports simultaneously.

Menu Display BP MAIN

ON OFF

BP TAIL

ON OFF

Newlands V521 PM4 Parameters Manual 1.0.doc

Description K-key turns the Bankpush solid ‘ON’ at MG M-key turns the Bankpush solid ‘OFF’ at MG K-key turns the Bankpush solid ‘ON’ at TG M-key turns the Bankpush solid ‘OFF’ at TG

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Measured Values This menu has displays that show the values measured by the sensors on each support eg., leg pressures and the ram stroke value. It is not possible to change these values they are for display only.

MEASURED VALUES

Pressures values are shown in bar The ram stroke extension is displayed in % of full stroke Each of the displays can be used to show the sensor readings of the support being operated and its two neighbours.

Switch from support to support with the K and M keys.

The first character in each display shows which support is being monitored. = measured values of own shield < measured values of left shield > measured values of right shield

Menu Display

Description System and return hydraulic pressure (in bar) measured at server (ports B1, B2)

= press 0

305

15

= press 1

302

12

System and return hydraulic pressure (in bar) measured at first face pressure zone (ports B1, B2)

= press 2

300

11

System and return hydraulic pressure (in bar) measured at second face pressure zone (ports B1, B2)

= press 3

297

8

System and return hydraulic pressure (in bar) measured at third face pressure zone (ports B1, B2) Right Leg Pressure on selected support

= prop

>>

325

= prop

<<

325

= ram stroke

48

Left Leg Pressure on selected support

= flipper =

tilt

= ext.

~~~ 356

~~~

r 0

Newlands V521 PM4 Parameters Manual 1.0.doc

Ram cylinder extension ( % of full stroke ) Flipper switch state ( % of full stroke ) Stabilising Ram cylinder extension (in mm) Convergence distance measurement in mm on selected support. (port B1) Rate of change of convergence sensor (mm/min)

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Global Parameters This menu contains parameters that affect the operation of all SCUs on the face.

GLOBAL PARAMETER

Pressure is shown in Bar Advancing cylinder extension is shown in % of full stroke Time is shown in 1/100 seconds

Menu Display Baselift man

ON

remote dist.

* ON

mastertime

*300

netstart

*0

face_0

*1

Newlands V521 PM4 Parameters Manual 1.0.doc

Function This controls whether baselift is activated during manual Auxiliary support advance M-key selects ON/OFF Low level password This parameter allows operation of a support up to 5 supports away from the operator using the adjacent control functions of the PM4.

If set to OFF: Adjacent functions operate normally If set to ON: Adjacent functions can operate in remote mode. After pressing the 1 or 2 key, then press the

* X appears Enter key, the display remote control where X is the remote distance. The remote distance can be adjusted using the K key (reduce distance) and the M key (increase distance). When the desired setting is reached press the Enter key and the selected support is activated. (min OFF, max ON) Medium level password This value determines the maximum time available between two keyboard actions. After this time the SCU returns to the idle mode and display. (min 300 (3 sec) max 3000 (30sec) ) Hardware key required Address of first SCU in the network. The first SCU will usually be the Server, which will usually have the number 0. (min 0, max face) Medium level password Address of first SCU on the face. Usually this will be 1. (min 1, max face) Medium level password

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face_1

*181

Side seal man. ON

side seal diff.

OFF

Tilt min.

*10

Tilt max.

*90

float tip

t.zone size

OFF

*

3

sizepsa

t.zone tmo

* 6000

Newlands V521 PM4 Parameters Manual 1.0.doc

Address of last SCU in the face. (min 1, max face) Medium level password This controls whether side seals are activated during manual Auxiliary support advance If set to ON side seals will retract while advancing & extend after support is set to transfer pressure.

M-key selects ON/OFF Medium level password If set to ON the side shield is extended with both sides of the cylinder pressurised (ie. differential push). This gives a reduced side shield extend force.

M-key selects ON/OFF Medium level password When the cylinder tilt measured value equals or is less than the value of the parameter tilt min. : 1. It cancels or prohibits the legs raise function including positive set and high pressure set.

2. It cancels or prohibits the canopy tip down function (retract stab. Cylinder) (min 0, max 100) High level password When the cylinder tilt measured value equals or is greater than the value of the parameter tilt max. : 1. it cancels or prohibits the legs raise function including positive set and high pressure set.

2. it cancels or prohibits the canopy tip up function (extend stab. Cylinder) (min 0, max 100) High level password This parameter allows the canopy to “float” during setting of the shield. When set to “on” the stabilising cylinder is piloted off during setting of the shield to allow the canopy to sit squarely to the roof.

M-key selects ON/OFF High level password This is the parameter which controls the size of the travel zone. In this case, the travel zone will be 4 shields on each side of the Initiator. (min 0, max 10) Hardware key required This is the maximum time the travel zone will suspend the shield autosequence. The travel zone on the shield must be moved or cancelled within this time or the autosequence will be cancelled. (min 500, max 30000) Hardware key required

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Service This menu contains face setup parameters.

Pressure is shown in Bar Advancing cylinder extension is shown in % of full stroke Time is shown in 1/100 seconds Current is shown in milliamperes Voltage in millivolts

Menu Display clear errors

boot to

<< >>

boot facewide

pm 4 reset

destroy prog.

Auto-ign.sensors

Z bus data

Newlands V521 PM4 Parameters Manual 1.0.doc

SERVICE

Description Allows all logged errors to be cleared from all SCUs on the face.

M-key activates function.

Low level password Allows program to be booted to adjacent SCU. The program in the shield being operated will be copied to the adjacent SCU. Medium level password Allows program to be booted to all face SCUs. The program in the shield being operated will be copied to all SCUs on the face.

M-key activates function.

Medium level password Allows a reset to be done on PM 4 system. The SCU being operated will be rebooted.

M-key activates function.

Medium level password Allows program to be destroyed on the SCU being operated.

M-key activates function.

Hardware key required Allows all invalid sensors on the whole face to be set to ‘IGNORED’.

M-key activates function.

High level password Enables the Z-bus port of the PM4 to connect and transmit data to the Data Logger M-key activates function.

High level password

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targetline

*2

conv. Diff

* 200

line delta

∗ 10

pos. pres.

∗ 100

MG group

∗4

TG group

∗4

Newlands V521 PM4 Parameters Manual 1.0.doc

Used with VShields monitoring.

Enables or disables the targetline advance function.

0 = The targetline function is disabled 1 = The targetline function is enabled only for SRB operation.

2 = The targetline function is enabled for all shield autosequence operations. (min 0, max 2) Hardware key required Used for the VShields monitoring.

This is the maximum conveyor position difference (mm) between neighbouring shields. If the difference between neighbouring shields exceeds this value and (pressure > pos.pres.), the monitoring system will move the shield to a position between its neighbours. (min 1, max 2000) Hidden Parameter Hardware key required Used for the VShields monitoring.

Value to move the targetline with the targetline up/down buttons (min 10, max 100) Hidden Parameter Hardware key required Used for the VShields monitoring.

The pressure value used for the conv.diff calculation. (min 10, max 450) Hidden Parameter Hardware key required Number of maingate shields on the face. These are usually re-advanced after the bankpush (determined by the setting of MG group mode). These can be programmed separately. (min 0, max 10) Hardware key required Number of tailgate shields on the face. These are usually re-advanced after the bankpush (determined by the setting of TG group mode). These can be programmed separately. (min 0, max 10) Hardware key required

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MG group mode

*0

TG group mode

*0

MG seq.

∗2

TG seq.

∗2

MG trans

∗2

Newlands V521 PM4 Parameters Manual 1.0.doc

This parameter dictates the mode of operation of the maingate end shields.

0 = The maingate end shields will NOT re-advance immediately after the SRB bankpush.

1 = The maingate end shields will re-advance immediately only after the 1st bankpush in BIDI mode.

2 = The maingate end shields will re-advance immediately after every SRB bankpush.

Medium level password This parameter dictates the mode of operation of the tailgate end shields.

0 = The tailgate end shields will NOT re-advance immediately after the SRB bankpush.

1 = The tailgate end shields will re-advance only after the 1st bankpush in BIDI mode.

2 = The tailgate end shields Medium level password Sets the sequence order of the maingate shield advance 1 = The maingate shields advance in the order 1 then 2 then 3 then 4 ….

2 = The maingate shields advance in the order 2 then 1 then 3 then 4 ….

3 = The maingate shields advance in the order 3 then 2 then 1 then 4 …. (min 0, max 4) Hardware key required Sets the sequence order of the tailgate shield advance 1 = The tailgate shields advance in the order last then 2nd last then 3rd last then 4th ….

2 = The tailgate shields advance in the order 2nd last then last then 3rd last then 4th ….

3 = The tailgate shields advance in the order 3rd last then 2nd last then last then 4th …. (min 0, max 4) Hardware key required Number of maingate transition shields on the face.

This is used to force the system to advance the shields from the gate end to prevent catching of side shields and breaking hoses on staggered supports. (min 0, max 10) Hardware key required

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∗2

TG trans

MG solid

*6

TG solid

*5

MG diff adv

*0

TG diff adv

*0

Press.sens. 1

∗ 72

Press.sens. 2

∗ 108

Press.sens. 3

∗ 144

Min_syspress

∗ 150

Newlands V521 PM4 Parameters Manual 1.0.doc

Number of tailgate transition shields on the face. This is used to force the system to advance the shields from the gate end sequentially to prevent catching of side shields and breaking hoses on staggered supports. (min 0, max 10) Hardware key required Number of shields at the Maingate that will Bankpush as a group. (min 1, max 32) Hardware key required Number of shields at the Tailgate that will Bankpush as a group (min 1, max 32) Hardware key required Number of supports in the maingate to be on differential advance (both sides of the cylinder are pressurised to reduce the advancing force). (min 0, max 10) High level password Number of supports in the tailgate to be on differential advance (both sides of the cylinder are pressurised to reduce the advancing force). (min 0, max 10) High level password Sets the shield number where the first face pressure and return pressure sensors are connected. (min 0, max face) High level password Sets the shield number where the second face pressure and return pressure sensors are connected. (min 0, max face) High level password Sets the shield number where the third face pressure and return pressure sensors are connected. (min 0, max face) High level password The minimum hydraulic system pressure needed to allow automatic operations on the face to continue.

If the measured hydraulic pressure drops below this value, SRB and all automatic functions will be cancelled. (min 0, max 500) High level password

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∗ 50

Max_retpress

Press filter

face dir:

∗15

right

valve check

*0

DISP br.

-

+

LEDs br.

-

+

Newlands

5.21

BSL stop

∗ 0

Newlands V521 PM4 Parameters Manual 1.0.doc

The maximum hydraulic system return pressure to allow automatic operations on the face to continue.

If the measured hydraulic return pressure increases above this value, SRB and all automatic functions will be cancelled. (min 0, max 500) High level password Timer (in seconds) used to filter out system pressure dips, return pressure spikes before automatic operations are cancelled by a low system or high return pressure error.

This is also the time delay used before the low system or high return pressure error is cleared when the system or return pressures resume their normal operating range. (min 0, max 100) High level password Direction of face (the direction that support numbers increase looking at the goaf).

Hardware key required This is the number of retries or checks the system will do on a solenoid driver before it shows an error and locks Sol Driver out ‘0’ means OFF. (min 0, max 10) Hardware key required Allows increase or decrease in display brightness.

Use the K key to increase brightness and the M key to reduce brightness.

Medium level password Allows increase or decrease in LED brightness.

Use the K key to increase brightness and the M key to reduce brightness.

Medium level password Face program version number NB. Hot key is the enter key Enables the BSL stop switch function. = 0 there is no BSL stop switch connected = 1 BSL stop switch is connected to port E1 of server.

Server only (min 0, max 1) Hardware key required

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BSL bp acc.

∗ 0

BSL bp tmo.

∗ 120

earthfault

∗ 20

convgalarm

∗ 200

BEEPER

OFF

PLC offset :

Para.break :

0

50

Newlands V521 PM4 Parameters Manual 1.0.doc

Enables the BSL bankpush accept button function. = 0 there is no BSL bankpush accept button connected = 1 BSL bankpush accept button is connected to port C1 of server.

Server only (min 0, max 1) Hardware key required Timeout for BSL bankpush accept button response.

If the BSL bankpush accept button is not pressed within this time then the prewarning for the MG bankpush will timeout and the MG will have to be pushed manually.

Server only (min 0, max 300) seconds High level password Earthfault sensor fault level.

If the earth fault sensor connected on face shields at port B2 (optional) detects an earth fault resistance of less than this value an earth fault error will be generated. (min 0, max 100) k ohm High level password Convergence Alarm sensor rate fault level.

If the rate of convergence of the convergence sensor connected on face shields at port B1 (optional) is greater than this value, a convergence fault error will be generated. (min 0, max 1500) mm/min High level password Testing purposes only Produces a 20 second tone to allow testing and calibration of the audible beeper.

M-key activates function.

Hardware key required Distance between transmitted shearer position and the centre of the shearer when using serial shearer tracking.

Server only. (min 0, max 10) Hardware key required Time delay between parameter telegrams sent into the face from Vshields.

Server Only. (min 0, max 100) Hardware Key Required

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SHR. speed

600

L1 Password

4711

L2 Password

5589

L3 Password

6583

Newlands V521 PM4 Parameters Manual 1.0.doc

Testing Purposes Only When running in simulation mode this is the delay time before the shearer moves to the next shield.

Server only. (min 100, max 1500) Hardware key required The parameter that sets the Low level software Password. (min 0, max 9999) Hardware key required The parameter that sets the Medium level software Password. (min 0, max 9999) Hardware key required The parameter that sets the High level software Password. (min 0, max 9999) Hardware key required

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Autosequence Parameters These parameters control the functions of autosequences facewide.

Pressure is shown in Bar Advancing cylinder extension is shown in % of full stroke Time is shown in 1/100 seconds

Menu Display Contact adv. F

*1

Contact adv. G

*0

Y0F low_adv

*1

Y0G low_adv

*0

Newlands V521 PM4 Parameters Manual 1.0.doc

ASQ PARAMETERS

Description This parameter controls whether contact advance is active during shield autosequence on face shields 0 = Contact advance not active 1 = Allows the shield advance to commence as soon as the shield sees the P0 lower pressure and before the lowering timer has expired.

The contact advance only work if both pressure sensors are valid and not ignored Low level password This parameter controls whether contact advance is active during shield autosequence on gate shields 0 = Contact advance not active 1 = Allows the shield advance to commence as soon as the shield sees the P0 lower pressure and before the lowering timer has expired.

The contact advance only work if both pressure sensors are valid and not ignored Low level password This parameter controls the way face shields are lowered & advanced during shield autosequence Y0=0 first lowering (T1), then advancing (T2) Y0=1 , lowering (T1) and advancing (T2) simultaneously (T1 may be a shorter time than T2) Y0=2 , lowering (T2) and advancing (T2) Simultaneously High level password This parameter controls the way gate end shields are lowered & advanced during shield autosequence Y0=0 , first lowering (T1), then advancing (T2) Y0=1 , lowering (T1) and advancing (T2) simultaneously(T1 may be a shorter time than T2) Y0=2 , lowering (T2) and advancing (T2) High level password

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Y1F tip_func.

*0

Y1G tip_func.

*0

Y2 sides.ret

*0

Newlands V521 PM4 Parameters Manual 1.0.doc

This parameter controls what canopy cylinders do during shield autosequence for face shields.

Y1F=0 , canopy cylinder does nothing Y1F=1 , canopy cylinder is retracted after shield lower (tip up) Y1F=2 , canopy cylinder is extended after shield lower (tip down) High level password This parameter controls what canopy cylinders do during shield autosequence for gate end shields.

Y1G=0 , canopy cylinder does nothing Y1G=1 , canopy cylinder is retracted after shield lower (tip up) Y1G=2 , canopy cylinder is extended after shield lower (tip down) High level password This parameter controls what side seals do during batch operations.

Y2 = 0, side seal does nothing. Spring pressure only Y2 = 1 during Lower – Do Nothing (Spring pressure) during Advance – Extend Side Seals during Setting – Do Nothing (Spring pressure) Y2 = 2 during lower – do nothing (spring pressure) during advance – Extend side seals during setting – Extend side seals Y2 = 3 during lower – do nothing (spring pressure) during advance – do nothing (spring pressure) during setting – Extend side seals Y2 = 4 during lower – do nothing (spring pressure) during advance – do nothing (spring pressure) during setting – Retract side seals Y2 = 5 during lower – do nothing (spring pressure only) during advance – Extend side seals during setting – Retract side seals Y2 = 6 during lower – do nothing (spring pressure) during advance – Retract side seals during setting – do nothing (spring pressure) Y2 = 7 during lower – do nothing (spring pressure) during advance – retract side seals during setting – retract side seals Y2 = 8 during lower – retract side seals during advance – retract side seals during setting – retract side seals Y2 = 9 during lower – retract side seals during advance – retract side seals during setting – Extend side seals Medium level password

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Y3 adv.+set.

*1

Y4 refill

*2

Y6 anti-pull

*1

Y7 sides.neig.

*0

Y9 flip.ret.

*1

Y10 flip.ext.

*0

This parameter controls whether the advancing cylinder is activated during setting of the support.

Y3=1 , continue advancing during setting, to avoid support sliding back when making roof contact Y3=0 , not active while setting High level password This parameter controls whether the advancing cylinder is pressurised during shield autosequence to push out any slack in relay bar assembly.

Y4=0 no refill during an ASQ Y4=1 advancing cylinder is refilled after an autosequence is complete for time T12 refill.

Y4=2 , advancing cylinder is refilled for time T12 refill after P1 transfer pressure is reached during the setting phase of an autosequence.

High level password This parameter controls whether anti-pullback is activated during shield autosequence.

Tied to S_ref.perc. – AFC must be pushed to this value before anti-pullback operates Y6=1 When shield activates on an autosequence it activates the shifting cylinder of adjacent shields to prevent pullback.

Y6=0 Will not activate adjacent shield rams High level password This parameter controls what side seals do during autosequence operations.

Y7=2 extend side seal on shield with higher number together with own side seal.

Y7=1 retract side seal on shield with higher number together with own side seal (clears side seals from advancing supports) Y7=0 do not activate neighbour’s side seal Medium level password This parameter controls what flippers do during autosequence operations.

Y9=1 , retract flipper while lowering (always for SRB) Y9=0 , do not retract flipper while lowering Medium level password This parameter controls what flippers do during autosequence operations.

Y10=1 , extend flipper after ASQ completion (never for SRB, SRB uses distance from shearer)

Y10=0 , do not extend flipper after ASQ Medium level password

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Y11F baselift

*3 1

Y11G baselift

*3 1

Newlands V521 PM4 Parameters Manual 1.0.doc

This parameter controls what the baselift cylinder does during autosequence operations on face shields.

Y11F=0 Baselift is not activated.

Y11F=1 Baselift is activated while support is lowered defined by T1 lower Y11F=2 Base lift when advancing only. Prior to advancing the base lift solenoid is energised for the time set by T17 lift and remains energised during the advance of the shield until the shield reaches the stroke as indicated by S2F lift_str.

Should the reed rod be disabled the solenoid will remain energised for the period the shield advance remains active.

Y11F=3 Base lift on LOWER and ADVANCE. Base lift is energised simultaneously with legs lower and advance of the shield until the shield reaches S2F lift_str where it will switch off. If the reed rod is disabled the baselift will remain on when shield advance is on.

High level password This parameter controls what the baselift cylinder does during autosequence operations on gate shields.

Y11G=0 Baselift is not activated.

Y11G=1 Baselift is activated while support is lowered defined by T1 lower Y11G=2 Base lift when advancing only. Prior to advancing the base lift solenoid is energised for the time set by T17 lift and remains energised during the advance of the shield until the shield reaches the stroke as indicated by S2G lift_str.

Should the reed rod be disabled the solenoid will remain energised for the period the shield advance remains active.

Y11G=3 Base lift on LOWER and ADVANCE. Base lift is energised simultaneously with legs lower and advance of the shield until the shield reaches S2G lift_str where it will switch off. If the reed rod is disabled the baselift will remain on when shield advance is on.

High level password

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Y12F retrylift

*1

Y12G retrylift

*1

C0 adv.retry

*2

C1 retry_tip

*2

T0 neig. set

*6000

T1 lower

*1200

T2 advance

*1100

Newlands V521 PM4 Parameters Manual 1.0.doc

This parameter controls what the baselift cylinder does during a “retry” of an autosequence on face shields.

Y12F=1 Baselift operates as per Y11F baselift settings.

Y12F=0 Baselift is not activated during an autosequence retry.

Note: With baselift activated on advance (Y11F baselift =2 or 3) during retries with Y12F retrylift = 1, Baselift remains on during the relower cycle for the shield to maintain roof contact.

High level password This parameter controls what the baselift cylinder does during a “retry” of an autosequence on gate shields.

Y12G=1 Baselift operates as per Y11G baselift settings.

Y12G=0 Baselift is not activated during an autosequence retry.

Note: With baselift activated on advance (Y11G baselift =2 or 3) during retries with Y12G retrylift = 1, Baselift remains on during the relower cycle for the shield to maintain roof contact.

High level password Max. number of retries for advancing if the shield does not reach end (full) stroke (S0 ad.stroke) in time T2 advance. (min 0, max 4) High level password Controls whether the shield lowers its tip when relowering due to a failed advance attempt. (min 0, max 3) 0 = no tip lowering 1 = tip down 1st attempt 2 = tip down 2nd attempt 3 = Tip down 3rd attempt High level password Maximum time that a support waits for neighbouring shields to be set to transfer pressure. P1 transfer. If this time is exceeded the autosequence is cancelled. (min 100, max 6000) High level password Time for shield lowering. (min 0, max 2000) Medium level password Maximum time for shield advance. If this period is exceeded a timeout occurs. (min 100, max 2000) Medium level password

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T3 relower

*400

T4 adv.set

*700

T5 set

*2000

T6 readv.

*600

T7 lowerPO

*600

Time for re-lowering if the shield does not reach S0 ad.stroke in time T2 advance. (min 0, max 2000) Medium level password Time to keep advancing cylinder activated until transfer pressure P1 transfer is reached if Y3 adv.+set is active (min 0, max 2000) Medium level password Time for shield to reach setting pressure P2 set. (min 100, max 2000) Medium level password Time for readvancing after which a timeout occurs (min 0, max 2000) Medium level password Time for pressure P0 lower to be sensed after which a lowering error occurs. If does not reach P0 lower after this time, the support will reset to the roof.

This timer runs in parallel with the lowering timers T1 lower & T10 prelower. (min 100, max 2000)

T8 tip_rel.

*100

T9 tip_low

*100

T10 prelow.

*600

T11 trwait

*10000

T12F refill

*15

Newlands V521 PM4 Parameters Manual 1.0.doc

Medium level password Time for activating stabilising cylinder if C1 retry tip is set to 1,2 or 3 and the support re-lowers. (min 0, max 2000) Medium level password Time for activating stabilising cylinder if Y1 tip_func. is active, after the T10 prelower initial lowering time. (tip up/down) (min 0, max 2000) Medium level password Prelowering Time for shield to clear the roof before the simultaneous lower and advance if Y0 low_adv is active. If tip function is active (Y1 tip_func.) then tip will activate after prelower time. (min 0, max 2000) Medium level password Maximum time for transition shields to wait for a neighbouring gate shield to advance. (min 0, max 18000) High level password Time of shifting cylinder activation to push out slack in relay bar system if Y4 refill is active (min 0, max 300) Medium level password

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T12G refill

*10

T13 flp_ex.

*500

T14 sides.

*200

T15 MG_lwr

* 300

T16 TG_lwr.

*300

T17 lift

*30

P0 lower

*85

P1 transfer

*120

P2 set

*260

S0 ad.stroke

*3

Newlands V521 PM4 Parameters Manual 1.0.doc

Time of shifting cylinder activation to push out slack in relay bar system if Y4 refill is active (min 0, max 300) Medium level password Time of flipper cylinder extension after ASQ if Y10 is ON Function only on special gate shields (min 0, max 1000) Medium level password Maximum time for side shield activation. (min 0, max 1000) Medium level password Extra lowering time for MG supports to clear roof bolts. (min 0, max 1000) Medium level password Extra lowering time for TG supports to clear roof bolts. (min 0, max 1000) Medium level password Time for baselift activation after support lowers and before shield advances. This allows baselift to extend properly before the shield advances. (min 0, max 1000) Medium level password Prop pressure must get below this value within time T7 lower P0, or lowering error will occur and support will set.

Advance will not commence before T10/T1 times out. (min 50, max 150) High level password Transfer pressure P1. Depending on the state of parameter NB neigh_P1 neighbouring shields must be set to this pressure to allow the support to lower. (min 100, max 250) High level password Leg cylinder setting pressure P2. A shield will set to this pressure during an autosequence. A setting error occurs if this pressure is not reached in time T5 set (min 150, max 450) High level password Stroke value (in %) to turn off advancing cylinder valve activation. Setting commences when this stroke is reached.

Advance is successful by reaching S0 ad. stroke. If system does not see this figure, it will try to readvance shield (min 0, max 20) High level password

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S1 slack

*8

S2F lift_str.

*35

S2G lift_str.

*25

S3 flp.r.ram

*2

NB neigh_P1

*1

SEMA asq_start

*0

Newlands V521 PM4 Parameters Manual 1.0.doc

Slack between relay bar and the conveyor connection expressed in % of full stroke.

With Y4 refill active the shield will not start autosequence if ram stroke is below (S0 ad. stroke + S1 slack) (min 0, max 20) NB. With Y4 refill set to 0, S1 slack will have no effect High level password When the baselift cylinder is activated during support advance (Y11F=1) the baselift will be deactivated when the support reaches the % advance set in this parameter for face shields.

Note: If S2F lift_str = 0, then baselift will remain energised at the end of the advance and during the setting of the shield until transfer pressure P1 transfer is reached. (min 0, max 100) Medium level password When the baselift cylinder is activated during support advance (Y11G=1) the baselift will be deactivated when the support reaches the % advance set in this parameter for gate shields.

Note: If S2G lift_str = 0, then baselift will remain energised at the end of the advance and during the setting of the shield until transfer pressure P1 transfer is reached. (min 0, max 100) Medium level password Target extension for the flipper to reach when retracting during ASQ if Y9 = 1. Solenoid deactivates when this extension is achieved. (min 0, max 100) Medium level password Parameter setting the number of neighbouring shields that must have transfer pressure P1 transfer to allow an autosequence of a shield to commence.

0 = none 1 = one 2 = both High level password Shield is allowed to start an autosequence when the following conditions are met.

0 = when neighbouring shield has reached transfer pressure 1 = when neighbouring shield has started setting High level password

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prew. time

*100

Newlands V521 PM4 Parameters Manual 1.0.doc

Prewarning time that warning tone sounds before any autosequence will start. (min 100, max 1000) Hardware key required

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PSA Parameters This menu contains parameters that control the Positive Set Automatic operations of all SCUs on the face.

PSA PARAMETERS

Pressure is shown in Bar Time is shown in 1/100 seconds

Menu Display psa grp

PSA

*5

ON

OFF

High Press.

*1

psa_P 0

* 100

psa_P 1

*250

psa_P 2

*290

hi set_P0

* 220

Newlands V521 PM4 Parameters Manual 1.0.doc

Function This designates the number of shields that the group positive set enable / disable can operate at once. (min 1, max 20) Medium level password Positive Set Automatic can be switched ON/OFF on all SCU’s facewide using the K or M keys.

High level password High Pressure Set Automatic can be switched ON/OFF on all SCU’s facewide. This also operates the High Pressure Set Dump valve solenoid High level password Positive Set Automatic (PSA) activating pressure. Below this pressure (P0) PSA will NOT be activated!

In manual adjacent operations, PSA is suspended until the manual operation is complete, ie key 3 will be lit. (min 120, max 450) High level password Positive Set Automatic (PSA) re-activating pressure. If shield pressure drops below this value the shield will reset to the P2 pressure. (min 150, max 450) High level password Positive Set Automatic (PSA) setting pressure. Pressure the shield will set to after psa activates. (min 200, max 450) High level password High Pressure Set activating pressure. Below this pressure the high pressure set solenoid will NOT be activated! (min 150, max 500) High level password

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hi set_ P1

* 340

hi set_P2

* 360

psa_Pdiff

*15

psa_T 0

*2500

psa_T 1

*1500

psa_C

*3

High Pressure Set re-activating pressure. If shield pressure drops below this value the shield will reset to the hi set_P2 pressure. (min 250, max 500) High level password High Pressure Set setting pressure. Pressure the shield will set to after the high pressure set solenoid activates. (min 250, max 500) High level password Pressure difference between measured system pressure and shield leg pressure to initiate positive set if the guaranteed set function is set to operate. (min 10, max 100) High level password Time allowed for Positive Set Automatic to reach setting pressure psa_P2. (min 500, max 5000) High level password Time delay between attempts to reach the Positive Set Pressure psa_P2. (min 500, max 30000) High level password Number of positive set attempts made by PM 4 system to reach pressure psa_P2.

0 = Guaranteed set function active

hi set_C

*3

Newlands V521 PM4 Parameters Manual 1.0.doc

NB. If the psa_P2 pressure is not reached after this number of attempts the PSA is switched “OFF” for that support and the LED 3 flashes as an error indication.

Positive Set is reactivated after the support is reset either manually or during an auto sequence. (min 0, max 4) High level password Number of hi set attempts made by PM 4 system to reach pressure hi set_P2. (min 0, max 4) High level password

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Prohibited Actions This menu allows the user to switch functions and sensor Reading inputs ON or OFF.

PROHIBIT ACTIONS

Parameters in this list can be global or local parameters.

Menu Display Leg pres type

0

autosequence

ON

SRB ASQ

ON

Batch ASQ

ON

bankpush

ON

SRB bankpush

ON

Newlands V521 PM4 Parameters Manual 1.0.doc

Description Sets the leg pressure transducer type fitted to shield.

0 = 450 bar sensor 1 = 600 bar sensor This is a local parameter affecting only the shield where the parameter is changed.

Medium level password Use the M-key to allow (ON) or turn off (OFF) autosequence actions.

This is a local parameter affecting only the shield where the parameter is changed.

Medium level password Use the M-key to allow (ON) or turn off (OFF) support autosequences when running in SRB. This is a local parameter affecting only the shield where the parameter is changed.

No Password Use the M-key to allow (ON) or turn off (OFF) batch support autosequences when running in batch mode.

This is a local parameter affecting only the shield where the parameter is changed.

Medium level password Use the M-key to allow (ON) or turn off (OFF) Bankpush actions.

This is a local parameter affecting only the shield where the parameter is changed.

Medium level password Use the M-key to allow (ON) or turn off (OFF) SRB initiated Bankpush actions.

This is a local parameter affecting only the shield where the parameter is changed.

Medium level password

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convpullback

positive set

ON

ON

Bank flipper

ON

Baselift

ON

ignore prop

> OFF

ignore prop

< OFF

ignore ram

OFF

Ignore flip.

OFF

Ignore tilt

OFF

Ignore efault

ON

Newlands V521 PM4 Parameters Manual 1.0.doc

Use the M-key to allow (ON) or turn off (OFF) Conveyor Pullback operations.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) Positive Set operations.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) bank flipper operations.

This is a local parameter for one shield.

No Password Use the M-key to allow (ON) or turn off (OFF) baselift operations.

This is a local parameter for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring pressure sensor readings in the right hand leg. If set to ON the pressure sensor readings will be ignored.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring pressure sensor readings in the left hand leg. If set to ON the pressure sensor readings will be ignored.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring ram sensor (reed rod) readings. If set to ON the ram sensor readings will be ignored.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring the flipper sensor (reed rod). If set to ON the flipper sensor reading will be ignored.

Function only on special gate shields This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring tilt ram sensor (reed rod) readings. If set to ON the tilt ram sensor readings will be ignored.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring the earth fault sensor at port B2. If set to ON the earth fault sensor readings and errors will be ignored.

This is a local parameter only for one shield.

High level password

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Ignore converg

Use the M-key to allow (ON) or turn off (OFF) the convergence sensor at port B1 (if installed) on a particular support. If set to ON the convergence sensor readings and errors will be ignored.

This is a local parameter only for one shield.

Medium level password Use the M-key to allow (ON) or turn off (OFF) ignoring the system pressure sensor. If set to ON the system pressure sensor reading will be ignored and the system pressure shutdown function is disabled.

Server only.

High level password Use the M-key to allow (ON) or turn off (OFF) ignoring the return pressure sensor. If set to ON the return pressure sensor reading will be ignored and the return pressure shutdown function is disabled.

Server only.

High level password Use the M-key to allow (ON) or turn off (OFF) simulation mode. If set to ON simulation mode is enabled and sensor readings are simulated for testing purposes. This is a local parameter only for one shield.

Hidden parameter Hardware key required Use the M-key to allow (ON) or turn off (OFF) the audible alarm on the PM4 SCU. This is a global parameter.

Hidden parameter Hardware key required

ON

Ign. syspres

ON

Ign. retpres

ON

SIMULATION

OFF

FULL BEEPER

ON

For the ‘ignore’ settings PM 4 will act as if the reading was as expected during normal operation, eg, ram is fully retracted after shield advance, ram is fully extended after bankpush, etc.

All sensor related functions will be active for their set timeout periods, yet not trigger the associated error messages.

Newlands V521 PM4 Parameters Manual 1.0.doc

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Diagnostics This menu contains maintenance and fault finding information.

Pressure is shown in Bar Advancing cylinder extension is shown in % of full stroke Time is shown in 1/100 seconds Current is shown in milliamperes Voltage in millivolts

Menu Display n: * x

b0

l-split

e 181

xxx

yyy

last EMStop

yyy

xxxx

yyyy

SENS:

xxxx

yyyy

DRV:

xxx

yyy

earthfault

Description Access via D key. n = shield number of current shield b = network beginning shield number e = network end shield number Displays the last network split xxx = network start at last recorded split yyy = network end at last recorded split Displays the last shield number where an emergency stop was activated.

EXT = Voltage to SCU SB = Voltage to Sensor Bank NB. Low voltage on the sensor bank can indicate a short circuit on one or more sensors.

Current measure on SCU xxxx = actual measured current in mA yyyy = maximum recorded current in mA

EXT xxxx SB yyyy

SCU:

DIAGNOSTICS

Current measure on sensor board xxxx = actual measured current in mA yyyy = maximum recorded current in mA zz

xxxx

Newlands V521 PM4 Parameters Manual 1.0.doc

Current measure on solenoid driver xxx = actual measured current in mA yyy = maximum recorded current in mA zz = number of valves operating when maximum current recorded resistance measure from earth fault sensor (optional) xxxx = actual measured resistance to earth in kohms

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RL 1

1 RR 1

1

Displays buffer number of a DiBi error.

Right Direction and Left Direction.

BIDIBuf. R~~~ L~~~

Cycle time:

Shield cyle time (seconds) Time taken for shield to complete last autosequence cycle

nnn

Loop time: mmm nnn

l_auto Bpush

13

Cancelled fr.

code number

Counts of the failed data packet acknowledgments to the right and left SCU.This is an indication of the integrity of the communications between SCUs. This will not affect the system unless the number is continuously counting up.

25

0

AS :S nn F nn P nn

Newlands V521 PM4 Parameters Manual 1.0.doc

Program loop time (milliseconds) mmm = Time taken for PM4 program to be executed. nnn = Maximum loop time recorded The last performed automatic function is shown in this display. The number shown is the number of the support that the automatic function was performed from.

Indicates the last cancelled action position (ie. where the Stop button was last pressed).

Indicates type of coding plug in the SCU (should be 0 for face SCUs, 5 for server) S = Current SRB sequence step status F = Current SRB function status P = SRB marker position. The SRB marker is the moving trigger point that initiates support functions such as an autosequence or bankpush when running in SRB. Note that the SRB marker is advanced when a support reaches transfer pressure.

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Error Messages This menu shows all the error messages recorded since the last power reset.

ERROR MESSAGES

These error messages can be used for trouble shooting.

NO ERRORS

Error Message

Description

Application Errors Batch timeout CP timout CP trans.press CP reed bar BP aborted BP neighb.diff BP timeout BP trans.press BP reed bar BP <> reed bar Positive set tmo TS not advanced << trans pr >> Setting pressure No trans press Lowering press Advancing error No net number adj. trav.zone!!

Trav.collision> Trav.collision< <<ACK missing >>ACK missing SRB pos. jumped SRB cal\ncel xxx low sys. Pressure

Newlands V521 PM4 Parameters Manual 1.0.doc

Batch timed out before successful completion (refer batch_TM0) Conveyor Pullback timed out before successful completion Conv. Pullback aborted shield NOT set to transfer press.

Conv. Pullback aborted shield has bad reed rod Bankpush aborted around shield with bad reed rod (displayed on all shields in bankpush group) Bankpush Delta Exceeded at BP Start Bank Push timed out before successful completion Bankpush Aborted shield had no transfer pressure Bankpush Aborted because of bad reed rod Bankpush Aborted because of bad neighbor reed rod Positive set timed out prior to successful completion Transition shield not advanced T_12 timed out ASQ timed out. No transfer pressure on neighbour (batch To) Shield could not reach setting pressure (T5 set expired) Shield could not reach transfer pressure Shield could not lower below Batch P0, Batch T8 expired ASQ timed out after retries (Batch C0) expired SCU does not have an address Different travel zone active on an adjacent shield The travel zone collided with another travel zone The travel zone collided with another travel zone Acknowledgement not received from left neighbour, Autosequence denied Acknowledgement not received from left neighbour, Autosequence denied Position jumped more than the setting of S_pos jump parameter Display wrong SRB position after position jump System hydraulic pressure is too low

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Sensor Errors Press sensor>> Pres sensor << Ram sensor infrared sensor Sys press sensor

Right hand pressure sensor error Left hand pressure sensor error Shifting cylinder reed rod sensor error Infrared sensor error Server pressure sensor error

Internal Measurement Errors Piezo beeper

Beeper current not in expected range

Misc. Internal Errors BIDI error >>>> BIDI error <<<< Driver readback Keyboard error Solenoid error SCU was booted Code plug mispl.

No solenoid drv.

GP mismatch

Communication error to RIGHT neighbour Communication error to LEFT neighbour Error in message from solenoid driver Error on SCU keyboard Error in solenoid operation as (see valvecheck parameter in Service Column) SCU was booted since last error cancellation Server code plug in wrong SCU No solenoid driver detected Global parameter values not common throughout the face

Default Display Messages Autoseq xxx yyy Bankpush xxx yyy Convpull xxx yyy Flipper xxx Batch xxx > yyy zzz No net number No SD >> SD err << >> locked << << locked >> << locked Locked >> << not selectable Not selectable >> Xxx*xx*xxx*xxx

Newlands V521 PM4 Parameters Manual 1.0.doc

Autosequence operation in progress Bankpush operation in progress Conveyer pull back operation in progress Flipper operation in progress (retract or extend mode) Batch operation in progress Network not established No solenoid driver detected Solenoid driver locked out due to multiple readback errors This shield is locked Both neighbours are locked Left neighbour is locked Right neighbour is locked Neighbour not selectable due to any of the above items OR mastertime is running on this neighbour or no neighbour exists Neighbour not selectable due to any of the above items OR mastertime is running on this neighbour or no neighbour exists Flashing asterisks indicate network not complete

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SRB Parameters (Shearer Running Batch) This menu contains parameters for the shearer initiated running batch Or SRB. • • •

SRB PARAMETER SRB must be cancelled to make any parameter changes.

Changes cannot be made while SRB is active, ie., the H & I LEDs are ON. Changes can only be made if the operator is inside the range of SRB, ie inside S_first & S_last.

After changing SRB parameters SRB should be started again (new start as opposed to a re-start). Use the 7, 4 or 5 and Start keys.

In these displays Pressures are shown in Bar Time is shown in 1/100 seconds Menu Display Mode:

BIDI

S_roof save

OFF

S_flpext M>T

OFF

S_flpext T>M

OFF

Newlands V521 PM4 Parameters Manual 1.0.doc

Description Use the M key to change mode of operation Selects the mode of operation for operating the face.

BIDI = BI-DI cutting sequence Uni di bkwd = Uni-Di sequence with Backward snake Halfweb = Halfweb sequence Uni di fwd = Uni-Di sequence with forward snake Medium level password Use the M key to turn the roof save function ON and OFF. If SRB is not keeping up with cutting operations roof save provides roof cover immediately the S_save asq safety zone is met by advancing shields before the normal SRB initiation.

Medium level password M key to change Off Flippers are not extended on the Main to Tail run from Maingate to the Snake.

On Flippers are extended on the main to tail run Note: Applies only to SRB. Medium level password M key to change Off Flippers are not extended on the Tail to Main run from Tailgate to the Snake.

On Flippers are extended on the tail to main run Note: Applies only to SRB. Medium level password

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S_flpret. M->T

OFF

S_flpret T>M

OFF

S_ext T M

*98

S_Mode M T

*1

S_track

SER

S_First

* 1

S_last

*181

S_save ASQ

*4

Newlands V521 PM4 Parameters Manual 1.0.doc

Off Allows flippers to remain extended on the Main to Tail run from Maingate to Snake.

On Flippers are retracted on the main to tail run Note: Applies only to SRB. Medium level password M key to change Off Allows flippers to remain extended on the Tail to Main run from Tailgate to the Snake.

On Flippers are retracted on the tail to main run Note: Applies only to SRB. Medium level password When MODE is set to Halfweb this parameter sets the % AFC push on the Tail to Main cut. (min 0, max 100) High level password Selects the mode of bankpush when using SRB. Mode 0 = no bankpush Mode 1 = Manual trigger. Bankpush is delayed in the maingate area up to S_Dist Main until manually triggered. The G key flashes in maingate area (MGS_MG push) as soon as all conditions are met.

Bankpush can be triggered, using the 7, H & M keys.

Mode 2 = auto trigger BP follows the defined safety zones.

High level password Selects the mode of SRB NONE: Turns SRB operation off SERIAL: Selects the Automatic operation of the face using the shearer position information from the shearer.

MANUAL: Selects the Automatic operation of the face using manually inputted shearer position.

Use 7 + 4/5 + Start keys after selecting mode.

Medium level password Indicates the first SCU on the face in the SRB operational area, ie boundary where H & I keys are lit (min 1, max face).

Hardware key required Indicates the last SCU on the face in the SRB operational area, ie boundary where H & I keys are lit (min 1, max face) Medium level Password Distance (safety zone) behind the shearer leading drum that a shield will perform an autosequence. ( e.g. shearer position = 64, S_save ASQ = 2, nearest shield allowed to autosequence: # 66) (min 1, max 50) Hardware key required

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S_roof save #

5

S_Save BP

*9

S_BP type

*1

S_Dist MAIN

*20

The spacing of shields being advanced under S_roofsave mode eg. if set to 3, every 3rd support will be advanced. (min 2, max 5) High level password Distance (safety zone) behind the leading drum of the shearer that the first shield will perform a bankpush sequence (min 2, max 50).

Hardware key required This allows the SRB bankpush to operate in different modes: 1 = This type of push produces a snake as defined by BP_snake. Shields will push to the calculated target ramstroke to form a controlled snake.

2 = All shields in group try to reach BP extens or push for BP timeout.

High level password This parameter is the trigger point for maingate shield advance to commence after the shearer leaves the maingate. This should be set so the shearer can do a cleanup in the gate area without passing this trigger point.

(The Shearer must also have passed S_turn MAIN for maingate shield advance to commence)

S_Dist TAIL

*170

(min 1, max face) Hardware key required This parameter is the trigger point for tailgate shield advance to commence after the shearer leaves the tailgate. This should be set so the shearer can do a cleanup in the gate area without passing this trigger point.

(The Shearer must also have passed S_turn TAIL for tailgate shield advance to commence)

S_ctd MAIN

*4

Newlands V521 PM4 Parameters Manual 1.0.doc

(min 1, max face) Hardware key required Number of shields from the shearer position (as indicated on the PM4 display) to the centre of maingate drum. Note this value may need to be varied when changing between serial and infra red shearer tracking modes. (min 0, max 50) Hardware key required

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S_ctd TAIL

*4

S_Turn MAIN

*9

Number of shields from the shearer position (as indicated on the PM4 display) to the centre of tailgate drum. Note this value may need to be varied when changing between serial and infra red shearer tracking modes. (min 0, max 50).

Hardware key required The shearer must pass this point to indicate the completion of the cutting/flitting run and that the shearer has arrived at the maingate (this trigger point is used in conjunction with S_Dist MAIN to initiate maingate functions)

S_Turn TAIL

*176

(min 1, max face).

Hardware key required The shearer must pass this point to indicate the completion of the cutting/flitting run and that the shearer has arrived at the tailgate (this trigger point is used in conjunction with S_Dist TAIL to initiate tailgate functions)

S_push MAIN

S_ Push TAIL

*28 *162

S_MG push

32

S_TG push

158

S_BP MAIN

1

Newlands V521 PM4 Parameters Manual 1.0.doc

( min 1, max face).

Hardware key required The LAST shield on full push at the MG end of the face.

Hardware key required The LAST shield on full push at the tailgate end of the face.

Hardware key required Trigger point for MG bankpush. Shearer position (centre) must be past this point before the bankpush will commence from the MG (min 1, max face).

Hardware key required Trigger point for TG bankpush. Shearer position (centre) must be past this point before the bankpush will commence from the TG. (min 1, max face).

Hardware key required This allows the SRB Bankpush in the Main gate to operate in different directions: 1 = This will initiate the push in the gate and it will travel to S_push MAIN, with a delay determined

by BP_delay.

2 = This will initiate the push at S_push MAIN and it will travel to the gate, with a delay determined

by BP_delay.

High level password

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S_BP TAIL

1

S_ Autoseq #

*5

S_enter MAIN

*8

S_enter TAIL

*171

S_prew.offs

*1

S_flp. First

*5

S_flp. Last

*175

S_flpret.dist

*15

Newlands V521 PM4 Parameters Manual 1.0.doc

This allows the SRB Bankpush in the Main gate to operate in different directions: 1 = This will initiate the push in the gate and it will travel to S_push TAIL, with a delay determined

by BP_delay.

2 = This will initiate the push at S_push TAIL and it will travel to the gate, with a delay determined

by BP_delay.

High level password Size of the group of shields that will be activated for shield advance operation in SRB. If this is set to 4, a maximum of 2 alternate supports will advance simultaneously (adjacent supports will never be lowered simultaneously). (min 1, max 10).

High level password First shield NOT to advance at the MG on the Tail to Main cut when entering the MG. (min 1, max face) Hardware key required First shield NOT to advance at the TG on the Main to Tail cut when entering the TG. (min 1, max face) Hardware key required The number of supports in front of the sequence that the pre-warning signal will be initiated. This allows advance warning that shields will soon move. (min 1, max 10) Hardware key required The number of the first support where the flipper is to be operated in SRB. Flippers on supports below this number are not activated for extend or retract in SRB (min 1, max face) Medium level password The number of the last support where the flipper is to be operated in SRB. Flippers on supports above this number are not activated for extend or retract in SRB (min 1, max face) Medium level password The number of shields in front of shearer leading drum the flippers will automatically retract in SRB (min 2, max 30).

Medium level password

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S_flpext.dist

*13

S_safety zone

*5

The number of shields behind the shearer leading drum the flippers will automatically extend in SRB (min 2, max 30).

Medium level password Anticollision safety zone around drums (+/-) Shields must not advance

Safety Zone

Shields must not exceed lowering time (S-lower maxc)

Safety Zone

Flippers must be retracted between here

S_coll str

* 70

S_lower max. *1000

S_abs

S_zone SER

*5

*6

Newlands V521 PM4 Parameters Manual 1.0.doc

(min 1, max 10) Hardware key required Minimum ramstroke before advanced shield stops shearer (% ramstroke). (min 0, max 100) High level password Max. accumulated lowering time before lowered shield stops shearer (1/100 sec). (min 0, max 1000) Hardware key required MANUAL mode: Input using 7 & start Max. distance from last input position at which a new shearer position can be input to have SRB continue.

Last input position + S_ABS will have 7 key flashing.

Input position is at M/G drum.

The 7-key will be flashing across this distance.

In manual add S_ABS as a ‘safety zone’ to all functions offset from shearer lead drum on initiation of SRB. (min 1, max 10) Hardware key required This parameter determines the area around the shearer centre that a newstart or restart can be initiated in serial or infra-red SRB modes. (min 0, max 10).

Hardware key required

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S_zone MAN

S_offset

S_pos. jump

*6

* 12

*3

S_ref dist

*2

S_refperc

*975

S_track [min]

*5

Newlands V521 PM4 Parameters Manual 1.0.doc

This parameter determines the area around the shearer centre that a restart can be initiated in manual mode. (min 0, max 20) Also the positive offset from position input in manual mode to acquired shearer position (eg 4), assuming the operator inputs the shearer position while standing adjacent to the MG drum.

Restart allowed at MG drum +/- 4 Hardware key required Distance from the shearer position that the Prime point will be set back when the 7, 4 or 5 and start keys are pressed.

Initiation only, no function will catch up beyond this point automatically, manual batch must be used. (min 1, max 20) Hardware key required This parameter defines the size of position jump that will abort SRB operation. If the system sees a position jump by this parameter setting or higher SRB will be cancelled and a SRB pos. jumped error will be displayed.

Hidden parameter (min 2, max 5) Hardware key required Distance ahead of the leading drum that the advancing cylinders will be put on push before the shearer arrives at that point (refill function).

This is to make sure the AFC is at full stroke and cannot be pushed back by the shearer and cause face alignment problems. (min 1, max 30) Hardware key required System must see at least this stroke or refill will not occur. Extension shown in cm. (min 80, max 100) Hardware key required Time in minutes that SRB stays active after the shearer position is lost to the PM 4 system. SRB will continue if the shearer position becomes active again within this time period.

If this time is exceeded SRB will be cancelled and must be re-initiated with the 7, 4 or 5 & Start keys. (min 1, max 30) Hardware key required

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S_restart_t

*5

Newlands V521 PM4 Parameters Manual 1.0.doc

Time in minutes after SRB has been suspended by using the ‘stop/del’ key that a SRB may be restarted by using the 7, H & M keys. If this time is exceeded SRB will be cancelled and must be re-initiated with the 7, 4 or 5 & Start keys.

0 = the SRB restart function is disabled. (min 0, max 30) Hardware key required

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Batch Parameters These parameters control the batch functions facewide.

Pressure is shown in Bar Advancing cylinder extension is shown in cm Time is shown in 1/100 seconds

Menu Display taper start

*~~~

taper 0 ext

*100

taper end

*~~~

Taper 1 ext

batch grp.

Taper diff.

*0

*4

OFF

Newlands V521 PM4 Parameters Manual 1.0.doc

BATCH PARAMETER

Description The shield number where the tapered support advance starts. This support will advance to the extension set in the taper 0 ext parameter (see below). (min 1, max face) The target extension at the start of the taper. An 80cm taper 0 ext. means that the taper start support will advance to 80% of full stroke (or will advance 20% of the ram stroke). (min 0, max 100) The shield number where the tapered support advance finishes. This support will advance to the extension set in the taper 1 ext parameter (see below). (min 1, max face) The target extension at the end of the taper. A 0% taper 1 ext. means that the taper end support will advance to 0% of full stroke (or will fully advance). (min 0, max 100) Number of shields in a group that will advance in a batch. (min 2, max 10) Medium level password Used to enable the taper advance to be either a full force or reduced force advance by pressurising both sides of the DA ram during a taper advance.

Use the M key to change On = both sides of the DA ram are pressurised for a reduced force advance Off = normal “full force” advance operation.

Medium level password

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batch mode

TMO batchgrp

RAND

*3000

Newlands V521 PM4 Parameters Manual 1.0.doc

Controls the sequence of support advance in batch.

SEQU = supports are advanced in sequence RAND = supports in the batch range are advanced in Random order RABB = supports are advanced in alternate pairs eg.

1&3, then 2&4 etc.

Medium level password Maximum time allowed for a batch group of (N) shields to perform a batch in SEQ or RABB modes.

Max time = (N) x TMO batchgrp (min 1000, max 3000) Hardware key required

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Bankpush Parameters This menu contains the BankPush parameters.

Pressure is shown in Bar Advancing cylinder extension is shown in % of full stroke Time is shown in 1/100 seconds

Menu Display BP start

~~~

BP end

~~~

BP type

*SNAKE

BP reset

BP grp

lcl

gbl

*20

Newlands V521 PM4 Parameters Manual 1.0.doc

BANKPUSH

Description This designates the starting shield for a specific bankpush range. Specific bankpush range values are stored in individual SCUs. A specific bankpush must be initiated from the SCU where the values were stored. (min 1, max face) This designates the ending shield for a specific bankpush range. Specific bankpush range values are stored in individual SCUs. A specific bankpush must be initiated from the SCU where the values were stored. (min 1, max face) This allows the bankpush to operate in different modes: SNAKE = This type of push produces a snake as defined by BP snake. Supports outside of the snake area push to BP extens.

ALL = Every shield is activated for Bankpush. All shields in group try to reach BP extens or push for BP timeout.

TAPER = Every shield is activated in the defined start and end range and the AFC push will be tapered in the desired direction from 100 to 0 NB: Start shield will fully push Hardware key required K-key Resets bankpush start and end parameters locally on this SCU. M-key Resets bankpush start and end parameters globally on all SCUs. Low level password This designates the group size for Bankpush to operate. (min 1, max 30) Medium level password

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BP_snake

*16

BP Offset

*1

B P fa c e

* 1

BP extens.

*100

.

BP MG extens

*100

.

BP TG extens

*100

BP Start grp

*3

BP delay

*20

BP min. press

*40

BP timeout

*12000

Newlands V521 PM4 Parameters Manual 1.0.doc

Defines snake length ( min 1, max 20 ).

Hardware key required Offsets the start of a bankpush group by the number of shields this parameter is set to ie., when starting a bankpush the group will start at the neighbouring shield plus the offset instead of starting at the neighbouring shield.

Low level password Allows user to reduce the number of shields actively pushing during bankpush.

1 = all shields will push 2 = every second shield will push 3 = every third shield will push.

Note: This parameter also affects bank push under SRB. (min 1, max 3) Medium level password Defines the desired bankpush stroke. (min 10, max 100) Low level password Defines the desired bankpush stroke for the first MG shield. The Maingate and transition shields will taper back to the extension of the first face shield (min 10, max 100) Low level password Defines the desired bankpush stroke for the last TG shield. The Tailgate and transition shields will taper back to the extension of the last face shield (min 10, max 100) Low level password Number of shields that push the conveyor together at the start of Bankpush group. (min 0, max 5) Hardware key required Time delay between each shields push solenoid activating inside a bankpush group. (min 0, max 1000) Hardware key required Leg pressure value the shield has to have to perform a bankpush. (min 0, max 300) Medium level password Maximum time for bankpush to reach the desired stroke. (min 0, max 18000) High level password

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B P su sp en d

* 20

BP protect

* 40

BP abort

*6

BP ram_safe

*2

BP_suspend: 0: No Bankpush suspend BP_suspend: 1-100: Bankpush suspend is active.

If the neighbour stroke is below the BP suspend the Bankpush will work as normal.

If the neighbour stroke is between BP suspend and BP protect the valves inside the BP_abort zone will be switched off but the BP function is still active. If inside BP_timeout the neighbour stroke falls back within the BP_ suspend limit the valves will be switched on again. (min 0, max 120) Hardware key required Safety parameter to abort bankpush if stroke difference between two shields exceeds BP_Protect. This prevents damage to the relay bar system. (min 0, max 120) Hardware key required Number of shields that bankpush will abort on either side of a shield if an error is noted. (min 0, max 10) Hardware key required This parameter allows the adjustment of the type of shifting ram protection. This is a global parameter. It affects the whole face.

If BP ramsafe = 0 Protection is switched OFF throughout the face. This disables BP suspend and BP protect. This mode is to be considered a maintenance feature that may be used from time to time by the BUCYRUS Automation or Service department during commissioning.

If BP ramsafe = 1 suspend and protect is active. Also any individual shield with either an “Ignored” or faulty reed rod will cause a Bank Push abort for the area of BP abort around the shield.

If BP ramsafe = 2 suspend and protect is active. Also if 2 adjacent shields have either an “Ignored” or faulty reed rod will cause a Bank Push abort for the area of BP abort around the two shields.

If BP ramsafe = 3 suspend and protect is active. Also if there are 3 adjacent shields with either an “Ignored” or faulty reed rods will cause a Bank Push abort for the area of BP abort around the three shields.

Hardware key required

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L-key ext.

*100

c. push_T

*6000

Newlands V521 PM4 Parameters Manual 1.0.doc

Final stroke to be reached with the L-key ram lock (min 0, max 100) Low level password Time for the L-key to stay ON (lock on push) to reach set stroke. ( min 0 , max 9999) Medium level password

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Conveyor Pullback This menu contains parameters affecting Conveyor Pullback operations.

Pressure is shown in Bar Advancing cylinder extension is shown in cm Time is shown in 1/100 seconds

Menu Display *90

CP extens.

CP group

*20

CP diff

ON

CP delay

*30

CP startgrp.

*3

CP timeout

*2000

Newlands V521 PM4 Parameters Manual 1.0.doc

CONV PULLBACK

Description The stroke that will remain on shifting cylinder after the conveyor is pulled back.

NB. If set to 0 the AFC will be fully pulled back. (min 0, max 100) Low level password Number of shields that will pull the conveyor back. (min 1, max 20) Low level password Used to enable the conveyor pullback operation to be either a full force or reduced force pull by pressurising both sides of the DA ram during a conveyor pullback.

Use the M key to change On = both sides of the DA ram are pressurised for a reduced force pull Off = normal “full force” pullback operation.

Medium level password Delay between each shield activated in a Conveyor Pullback sequence. (min 0, max 1000) Hardware key required Number of shields activated at the same time at the start of a Conveyor Pullback sequence. (min 0, max 5) Hardware key required Maximum time allowed for the Conveyor Pullback to reach the desired stroke. (min 500, max 10000) High level password

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Bank Flippers This menu contains parameters controlling Bank Flipper operations.

BANK FLIPPERS

Menu Display BF start

* ~~~

BF end

* ~~~

BF group

*5

BF # at once

*5

BF prew

*200

flipp.ext T1

* 500

flipp.ext T2

*0

flipp.ext T3

* 1000

Newlands V521 PM4 Parameters Manual 1.0.doc

Description This designates the starting support for the group Flippers to operate from. (min 1, max face) This designates the ending support for the group Flippers to operate from. (min 1, max face) This designates the group size for Bank Flipper to operate when using the adjacent group function keys. (min 1, max 5) Low level password This designates the number of Flippers to operate at one time within a group operation. (min 1, max 5) Low level password This time the pre-warning signal will sound before the Bank flipper operation commences. (min 200, max 900) High level password Time for flipper to extend before T2. This timer is used to extend the flipper so the flipper extension can be retracted. (min 0, max 2000) High level password Time for flipper extension to retract before flipper is extended to the roof/face. (min 0, max 2000) Low level password Time for flipper to extend to reach final position. (min 0, max 2000) Low level password

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flp.ext.ram * 60

flipp.ret T1

* 1800

flipp.ret T2

* 150

flp.ret.ram * 2

Newlands V521 PM4 Parameters Manual 1.0.doc

Target extension for the flipper to reach when extending. Solenoid deactivates when this extension is achieved. (min 0, max 100) Medium level password Time for flipper to retract. (min 0, max 4000) Low level password Time for flipper extension to retract prior to flipper being retracted (see T1 above). This timer allows the flipper extension to be retracted clear of the face to prevent it catching during the flipper retraction. (min 0, max 4000) Low level password Target extension for the flipper to reach when retracting. Solenoid deactivates when this extension is achieved.

Flipper Anti-collision is active if the flipper extension is greater than flp.ret.ram + 10% (Fixed Value) (min 0, max 100) Medium level password

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Emergency Stop In the case where more than one E-stop button is pressed at the same time, the PM4 display shows the address of the SCU where the closest E-Stop button is pressed.

In this menu you can read all other SCUs where an E-stop button has been pressed.

Menu Display EMSTOP no.

xxx

Newlands V521 PM4 Parameters Manual 1.0.doc

EMERGENCY STOP

Description E-Stop button pressed in shield number xxx

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Operational Software Changes This lists the software changes completed from version Newlands V5.17 1.

Water Spray All Water Spray functions have been removed to create free space for the following changes. This includes the Water Spray Menu and ASQ Parameter Y5 water + Adv.

2.

DA Cylinder Stroke The DA cylinders have been fitted with a spacer to limit the stroke to 850mm but the original 1050mm reed rod is still installed.

The scaling has been reconfigured to achieve: 0% 0mm with shield fully advanced 100% 850mm with conveyor fully pushed.

3.

Flipper Monitoring The Flipper switched have been replaced by Reed Rods in the PM4 port D1.

Flipper retracted = 0% Flipper Extended = 100% Flipper monitoring is included in Anti-Collision and a flipper is regarded as being extended if the reading is greater than Flipper parameter flp.ret.ram + 10%.

The Flipper Reed Rod is included in the default display.

4.

Prohibited Actions To allow quick changes to the following parameters during operations the password protection has been removed.

BankFlipper SRB_ASQ

5.

Bank Flipper in shearer Zone To ensure that flippers are clear of the shearer during SRB operations the Auto flipper retract has been improved to keep the Retract Solenoid on in the shearer zone.

S_flp ret.dist

S_flp ext.dist S_ctd TAIL

S_ctd MAIN =4

S_safety zone

S_safety zone S_safety zone

Flipper Retract active zone’s Newlands V521 PM4 Parameters Manual 1.0.doc

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The zone is defined by the shearer length of: S_ctd Main + S_ctd Tail Plus the distance S_safety zone for the MG and TG Drums.

There is an additional 1 shield active in front of the leading drum safety zone.

The first flipper to retract is defined by S_flp ret.dist and this will remain active until the distance flp.ret.ram is reached. The flipper will remain OFF until it enters the shearer zone. It will then be energized until it is outside the shearer zone.

The Flipper will then be extended when the distance S_flp ext.dist is reached.

These operations are dependent on: SRB must be Active.

Shearer position must be present.

SRB Flipper Retract switches S_flpret. M>T = ON S_flpret. T>M = ON If the Flipper retract is only ON for one direction then the flipper retract in the shearer zone will only be active in that single direction.

6.

SRB_ASQ Hot Key To prevent a shield from advancing in SRB a hot key has been assigned.

Aux Batch (Key 9) has now been assigned two functions.

On the first press it will enter the standard Aux Batch Menu and its functionality has not changed.

On the second Press it will jump to the Prohibited Actions SRB_ASQ menu and toggle its parameter Value.

If SRB_ASQ was Off it will now be ON If SRB_ASQ was On it will now be OFF If the Aux Batch key is pressed again it will return to the standard Aux Batch Menu.

When in the Prohibited Actions SRB_ASQ menu it is still possible to toggle the parameter using the M key. This parameter no longer has password protection.

To provide clear indication of the status of the SRB_ASQ setting the Aux batch (key 9) LED will illuminate.

SRB_ASQ = ON SRB_ASQ = OFF

The shield is allowed to Advance LED 9 = OFF The shield is NOT allowed to Advance LED 9 = ON

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7.

SRB Gate End Reverse Push To assist in creep control parameters have been included in the SRB menu to change the direction of the gate end Bank push when operating in SRB. These parameters are S_BP MAIN and S_BP TAIL With a parameter value of 1 a normal push sequence is activated. The first DA Cylinder to go on Push will be at the gate end it will then travel into the face at a rate determined by BP_delay until it reaches S_push MAIN or S_push TAIL. With a parameter value of 2 a reverse push sequence is activated. The first DA cylinder to go on push will beat S_push MAIN or S_push TAIL and it will travel out to the gate ends at a rate determined by BP-delay.

Each gate can be configured seperatly.

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