DOWNLOAD PDF CAT Moolarben PMC-R Operating Manual EM027826

Operating Manual _________________________ Moolarben PMC-R Manual # EM027826 (MAN-000617)

_________________________

Caterpillar Australia Operating Manual

ISSUE INFORMAITON Machine model:

Roof Support (RSF)

First Issue Date: 21/07/2017

Machine serial #

Revision Date:

All

16/11/2017

Prepared by

Chad Davis

Electrical Engineer

Checked by

Rainer Bartkowiak

LW Aut. Onsite Tech. Sls. Sup

Approved by

Armin Jacobs

LW Automation Doc. & Testing

Rev 02

This document is the property of Caterpillar Australia. It shall not be copied or reproduced in any way whatsoever and/or passed on to any third party without the written authority of Caterpillar Australia.

Copyright © Caterpillar Australia. All paper copies are uncontrolled.

Disclaimer: Caterpillar has made every effort to ensure that all instructions contained within this document are accurate and safe, and cannot accept liability for any resulting injury, damage or loss to persons or property arising from the use thereof or otherwise. Contact Caterpillar Australia to obtain the latest updates for this document.

NOTE: Unauthorised document if not accessed from the Caterpillar Document Control System

DOCUMENT REVISION HISTORY Revision Id 00

Date 21/07/2017

Description of Change Initial release for PMC-R software V5 Moolarben V6 Build 10055

01

21/08/2017

Minor corrections to grammar and graphics for readability Missing deadman operations added to ‘Initiate Adjacent Control’ Section Update for V8 Added Push to target information

02

16/11/2017

Note: V8 onwards contains push to target on the Gate end shields refer to information added in this revision for push to target operation.

03

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TABLE OF CONTENTS ISSUE INFORMAITON .......................................................................... 2 DOCUMENT REVISION HISTORY........................................................ 2 TABLE OF CONTENTS......................................................................... 3 ABOUT THIS MANUAL ......................................................................... 6 Before starting work ................................................................................................6 Who is this operating manual intended for ..................................................................... 6 Purpose of this manual .................................................................................................. 6 Signs and symbols used................................................................................................ 7 Reference Documents ................................................................................................... 7 Definitions ..................................................................................................................... 7 Applicability ................................................................................................................... 7

YOUR SAFETY ..................................................................................... 8 PMC-R KEYBOARD BUTTONS ............................................................ 9 PMC-R Menu structure....................................................................... 13 PMC-R MAIN MENU............................................................................ 14 PMC-R DISPLAY ................................................................................. 15 PMC-R Default Displays. ......................................................................................15 Safety Function Module (SFM) States in Default Display......................................16

PMC-R STOP FUNCTIONS ................................................................. 17 Stop Key ...............................................................................................................17 Emergency Stop....................................................................................................17 Emergency Stop (Bootend) ...................................................................................18 BSL Stop ...............................................................................................................18 Local Lockout Button.............................................................................................18

CHANGING PARAMTERS .................................................................. 19 SAFETY FUNCTION MODULE CONFIRM CONFIG ........................... 21 SHIELD CONTROL METHODS........................................................... 23 START SHEARER RUNNING BATCH – SRB .................................... 24 Initiate an SRB Newstart – Shearer communications tracking ..............................25 Initiate an SRB Newstart – Manual mode .............................................................26 Initiate an SRB restart ...........................................................................................27 Reversing the shearer during SRB operations ......................................................28

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INITIATE A TRAVEL ZONE ................................................................. 29 Start a travel zone .................................................................................................29 Moving the Travel Zone. .......................................................................................30 Stop or De-activate the Travel zone. .....................................................................30

INITIATE AN AUTO SEQUENCE (SUPPORT ADVANCE) ................. 32 INITIATE ADJACENT CONTROL FUNCTIONS .................................. 33 INITIATE AUXILIARY FUNCTIONS..................................................... 35 INITIATE A BATCH FUNCTION (SUPPORT ADVANCE) ................... 39 INITIATE A TAPER BATCH FUNCTION (SUPPORT ADVANCE) ...... 41 INITIATE A BANKPUSH...................................................................... 43 UNDERSTANDING THE OUTCOMES OF BANKPUSH DIRECTION SELECTION ......................................................................................... 45 TYPES OF BANKPUSH ...................................................................... 46 (S) Snake ..............................................................................................................46 (T) Taper ...............................................................................................................46 (All) All...................................................................................................................47 Protection zones ...................................................................................................47

INITIATE A LOCK ON PUSH............................................................... 49 INITIATE A CONVEYOR PULLBACK ................................................. 50 INITIATE A CONVEYOR PULLBACK DEADMAN GROUP ................ 51 INITIATE AN ADJACENT FLIPPER GROUP ...................................... 52 INITIATING A FLIPPER EXTEND / RETRACT FROM-TO GROUP .... 53 INITIATE ADJACENT CANOPY SPRAY GROUP ............................... 54 INITIATE ADJACENT SIDE SPRAY GROUP...................................... 55 POSITIVE SET FUNCTION.................................................................. 56 Guaranteed Set .....................................................................................................56 Disabling Positive Set ...........................................................................................56

LEG SET FUNCTION........................................................................... 58 Guaranteed Leg Set ..............................................................................................58 Disabling Leg Set ..................................................................................................58

SHEARER REMOTE STOP OPERATION ........................................... 59 ANTI-COLLISION OVER-RIDES ......................................................... 60 MOTION MONITORING MAXIMUM TRAVEL ERROR RESET. .......... 61 COMPENSATION CYLINDER STOP ERRORS. ................................. 62

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CompCylinder Stop # ............................................................................................62 MM MaxCmpAng ..................................................................................................62

ROOF / FLOOR HEIGHT CUTTING ADJUSTMENTS......................... 63 Roof Height Adjustment ........................................................................................63 Floor Height Adjustment ........................................................................................63

PMCR SHORTCUTS ........................................................................... 64 B key .....................................................................................................................64 P key .....................................................................................................................64

Gate End Sequence With Target Line ............................................... 65 Previous Sequence (Before V8) ............................................................................65 Push to Target Sequence (V8 Onwards) ..............................................................67

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ABOUT THIS MANUAL This chapter contains important information which will simplify work with this manual for you.

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

Before starting work Using a manual that is not written for the equipment at hand can result in a safety hazard for yourself and others. Make sure the information on the equipment complies with that given in the manual. The manual must be accessible at all times to all persons working on or with the equipment. There should, if possible, always be a manual for the equipment available at the place of operation. Request a new manual immediately if the current manual is no longer complete or has become illegible.

Who is this operating manual intended for This manual is intended for those persons who work with or on the equipment specified.

All persons working on the face, at the edge of the face or at the entry must read this manual.

This includes persons who: • Are in charge of transport • Set up the rise heading • Perform installation/ removal work • Operate the shields • Correct malfunctions • Perform daily routine work on the face • Monitor/ look after the hydraulic system • Carry out maintenance work • Carry out repair work Supervisory personnel who: • Initiate the activities mentioned above • Supervise them

Purpose of this manual This manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the equipment. Read this manual completely and at your leisure. Pay special attention to the corresponding safety instructions. Memorise the appearance and meaning of the safety and instruction symbols.

Should you have any questions, please contact our service department. Pay special attention to the section, “Your safety”. Observe this information and follow the procedural instructions.

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Signs and symbols used The following signs and symbols are used for safety instructions and important information in this operating manual. Memorize the symbols and their meanings.

WARNING Text passages indicated with this symbol draw your attention to imminent hazards. Possible consequences are; very serious injury or even death.

CAUTION This symbol draws your attention to hazardous situations. The possible consequences are light to minor injuries and damage to machinery.

NOTICE Sections marked with this symbol draw your attention to harmful situations. Possible consequences are damage to the equipment or damage in its immediate vicinity.

IMPORTANT Passages in the text marked with this symbol contain useful tips and information intended to make work easier for you. They do not warn about harmful or hazardous situations.

Reference Documents

Definitions

Applicability

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YOUR SAFETY This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of this procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.

CAUTION • • • • • •

• • • • •

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Isolation procedures must be followed when working on equipment.

Isolate any other related equipment where its operation will cause danger to personnel or damage to equipment.

Before operating equipment make sure that nobody is inside or in the immediate area of the equipment.

Maintenance and repair should be undertaken by trained personnel.

Always wear correct PPE when working on hydraulic systems.

Ensure that any relevant circuits are depressurised. Release of high pressure fluids can be fatal. As a final check twist the hose to ensure it is loose before disconnecting fittings.

Always be aware of E-Stop locations, in case of an emergency.

Walkways with anti slip plates and handrails are provided. When using the walkway, operators should monitor face conditions to ensure they do not encounter falling coal.

All guards have to be in place when system is in operation.

High pressure fluids can penetrate skin and enter a human body.

These fluid injections may cause severe tissue damage and loss of limb. If a fluid injection accident occurs, see a doctor immediately.

DO NOT DELAY OR TREAT AS A SIMPLE CUT!

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PMC-R KEYBOARD BUTTONS Keyboard symbol

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Idle mode

Work mode

Input mode

Stops all automatic functions on the face

Stop of all automatic functions on the face

Cancel of the input

No function

Start key for automatic/adjacent auto sequence functions

No Function

Select the adjacent SCU to the LEFT. Accesses Auxiliary Functions Menu

Select the adjacent SCU to the LEFT. Adjacent SCU goes into slave mode

No Function

Select the adjacent SCU to the RIGHT. Accesses Auxiliary Functions Menu

Select the adjacent SCU to the RIGHT. Adjacent SCU goes into slave mode

No Function

Switches `Positive Set No function Automatic’ (PSA) on / off.

Selects the PSA menu.

Input of number 0

No Function

Selects Batch group to the LEFT (View to SCU)

No Function

No Function

Selects batch group to No Function the RIGHT (View to SCU)

Shortcut to bankpush menu

No Function

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Automatic key

Input of number 6

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Keyboard symbol

Idle mode

Selects SRB operation and menu Press twice = Shearer Control

Work mode

Input mode

No Function

Input of number 9 Automatic key

Side Seal Extend

No Function

(Deadman Key)

Shortcut to Auxiliary Batch No Function function and menu

Retracts legs (Deadman Key)

No Function

Saves a shortcut to the currently displayed menu item which can be accessed from 10 shields left + right

Advances shield (Deadman Key)

Input of number 3

Input of number 7 Automatic key

No Function

No Function

Hot Key: Press 1x = Net details

Extends legs

Press 2x = Net details

(Deadman Key)

No Function

Press 3x = Net details Press 4x = Time and date Canopy tip down Shortcut to Position spray menu

Retracts comp cylinder on No Function run of face shields.

(Deadman Key) Canopy tip up

Shortcut to current errors

Extend comp cylinder on run of face shields.

No Function

(Deadman Key)

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Keyboard symbol

Idle mode

Shortcut to flipper menu

No Function

Shortcut to diagnostics menu

No Function

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Work mode

No Function (Type 1) Flipper in (Type 2,3,4)

No Function (Type 1) Flipper out (Type 2,3,4)

Baselift Extend (Deadman Key)

Side Seal Retract (Deadman Key)

Shortcut to conveyor pullback menu

Conveyor Pullback

Lock On Push (toggle)

No Function

Changes to left menu

Changes to left menu

(View to SCU)

(View to SCU)

Changes to previous menu item

Changes to previous menu item

(Deadman Key)

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Input mode

No Function

Input number 1

No Function

Input number 2

Input number 4

Input number 5

No Function

Changes to previous menu item

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Keyboard symbol

Idle mode

Work mode

Input mode

Changes to next menu item

Changes to previous menu item

Changes to next menu item

No function

Executes the function shown in the display

No function

(Deadman Key)

Hot key: Memory from last input

Changes to right menu (View to SCU)

Display version

Set or delete Travel Zone

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Executes the function shown in the display

No function

(Deadman Key) Changes to right menu No function

(View SCU)

Remote distance

Enter key inserts manual inputs into the program

No function

Input number 8

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PMC-R Menu structure

The corresponding menu column is selected with the keys K (column to the left) and R (column to the right). The following list shows the headings of the menus.

Scrolling up and down in the menus is done with the keys L and M.

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PMC-R MAIN MENU AUXILIARY FUNCTIONS IDLE DISPLAY MEASURED VALUES SYSTEM PARAMETER ERROR MESSAGES GLOBAL PARAMETER LOCAL VALUES SERVICE SRB PARAMETERS ASQ PARAMETER BATCH PARAMETER BANKPUSH PARAM. CONV PULLBACK PSA PARAMETER FLIPPER PARAMETERS POSITION SPRAY SIDE WATERSPRAY TRAVEL ZONE PARAMETER ANTICOLLISION LINE PARAMETER MOTION MONITOR WINDBLAST PARAMETER VALVE CYCLE COUNT EMERGENCY STOP DIAGNOSTIC SAFETY FUNCTION MODULE

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PMC-R DISPLAY The PMC-R Display is a two row display.

In case of available global or adjacent information, the bottom row gives you hints and explanation during inputs, global messages (such as E-Stop, Local Lockout, and so on).

Figure 1 - Typical PMC-R Display

PMC-R Default Displays.

The default display on a face shield SCU is shown below.

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Safety Function Module (SFM) States in Default Display When an emergency stop is pressed the Ⓔ symbol is shown SFM configuration Invalid shown by

☹

The SFM can lock actuators by disabling power to E & F ports because of an emergency stop condition indicated by

☀

The SFM module can terminate actuators by disabling power to E & F ports until power is reset, this is indicated by

☀☀☀☀

If the high side FET and any low side FET of port E1, E2 or F2 has a failure, the PMC-R shows the Fatal Error message and does not respond to key presses.

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PMC-R STOP FUNCTIONS The PMC-R’s have a number of keys and buttons that provide the user with control to stop automatic and manual functions and/or remove electrical and/or fluid power to the Shields actuators.

• • • • •

Stop key Emergency Stop Button Emergency Stop Button (Bootend) Local Lockout Button BSL Stop

Stop Key When the “Stop” key is pressed all electrical operations on the PMC-R system are cancelled.

The Stop Key is used to cancel all automatic functions including Batch, Bankpush, Conveyor Pullback, Auto Sequence (ASQ) and suspends SRB operations. The stop key will also cancel any PMC-R that is currently in slave mode when using Adjacent Control or Remote Control. The Dump Valve solenoid connected to the Server PMC-R will remain energised when the Stop Key is pressed.

Emergency Stop When the Emergency Stop Button is pressed all operations are ceased including Adjacent Control, Remote Control, all automatic functions and SRB will be stopped. An SRB new start will be required after an Emergency Stop has been pressed. The Dump Valve solenoid connected to the Server PMC-R will be de-energised when an Emergency Stop is pressed.

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Emergency Stop (Bootend) If communications are active between the Bootend PMC-R and the Face Server PMC-R then the Bootend PMC-R Emergency Stop Button will cause the same actions as operating an Emergency Stop on the Face PMC-R’s.

BSL Stop External stop buttons can be connected to the Face Server PMC-R these are referred to as a BSL Stop and when operated will cause the same actions as operating an Emergency Stop on the Face PMC-R’s.

Local Lockout Button The Local Lockout Button is used to prevent any electrical operation of the SCU. An additional feature is that when a Local Lockout Button is pressed, the two adjacent SCUs are also to protect operators when standing on or in front of the supports. Power is removed from the solenoid driver outputs on the shield with the Local Lockout Button pressed ‘Locked Out’ while the two adjacent Shields solenoid drivers remain powered but all functions are disabled ‘Soft Locked’. If the Local Lockout Button is pressed on the Face Server PMC-R then only the Face Server will be locked out and the Dump Valve will be de-energised as power is removed from the Face Server’s Solenoid Driver.

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CHANGING PARAMTERS Many of the menu displays in the PMC-R menu are adjustable parameters that affect the way the supports operate. There are two types of parameters in the PMC-R program.

•

Numeric parameters (those preceded by a * symbol)

•

Text parameters

Parameters can be changed following the procedures below.

Numeric parameters can be changed by 1. Navigate to the menu item you wish to change 2. Press

.

3. If the parameter is password protected the screen will show PASSWORD? 4. Enter the password with the Numeric keys and press

.

5. Press the Numeric keys to enter the new value for the parameter 6. Press

to save the new parameter.

Text parameters can be changed by 1. Navigate to the menu item you wish to change 2. Press

or for some parameters maybe the

if prompted.

3. If the parameter is password protected the screen will show PASSWORD? 4. Enter the password with the Numeric keys and press 5. Press

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.

to scroll through the parameter options to the desired setting

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DANGER: Many of the parameters are password protected from view and to prevent inadvertent altering of parameters. Changes too many of the parameters could result in damage to equipment and / or danger to personnel.

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SAFETY FUNCTION MODULE CONFIRM CONFIG The Safety Function Module (SFM) provides additional networking, actuator monitoring and emergency stop features that are compliant with the principles of functional safety. This module involves additional steps when establishing a PMC-R network. Within the System Parameter Menu there are items associated with the Safety Function Module that allow the user to view the network status and confirm the current network configuration.

Note: The network configuration will need to be confirmed by the user whenever changes are made to the network parameters, when a PMCR is moved or when a PMC-R is replaced.

When the network is not setup with the correct parameters the display will show the ‘no network’ message. The network parameters need to be setup according to the face layout. |$$~~~ (no network) |

|

|

When the network parameters are setup correctly the SFM menu item displays a number of symbols that indicate the network state, solenoid driver port status and emergency stop operation. |  100 ☹ 20 }  ☀ |

Ⓔ

|

Smiley Characters indicate different network status •

☹ = Network configuration Invalid

•

 = Network configuration valid, not confirmed

•

☻ = Network configuration valid, confimred

Status of the shorting caps is indicated •

 = Loop Connector fitted to F1

•

 = Loop Connector fitted to A1

•

{ = Loop Connector not fitted to F1

•

} = Loop connector not fitted to A1

•

 = Network Split

The SFM can lock actuators by disabling power to E & F ports because of an emergency stop condition indicated by ☀

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The SFM module can terminate actuators by disabling power to E & F ports until power is reset, this is indicated by ☀☀☀☀ When an emergency stop is pressed the Ⓔ symbol is shown The number on the left of the smiley character i.e. 100 indicates how many neighbour PMCR’s are on the F1 side of viewed PMC-R. The number on the right of the smiley character i.e. 46 indicates how many neighbour PMCR’s are on the A1 side of viewed PMC-R

Note: A loop connector must be installed at each end of the PMC-R network on the unused A1 and F1 ports of the first and last PMC-R’s in the network.

|

 100  46 

| Confirm Config ?

(P) |

When the network is setup correctly and loop connectors are fitted the SFM menu item will give the user the option to confirm the configuration by pressing the key. When the network has been confirmed the smiley will change to ☻ indicating a valid and confirmed network configuration which will allow all program functions.  100 ☻ 20  | Destroy Config ?

(N) |

|

When the network has been accepted the smiley will be displayed as ☻, in this state the user will have the option to destroy the configuration by pressing the

key. After the

smiley will be displayed as ☹ indicating the network configuration is invalid. This will disable all program functions, the network can be confirmed again as long as the network parameters are valid.

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SHIELD CONTROL METHODS •

SRB Serial Tracking

•

SRB Manual

•

Batch or Group Functions

•

Adjacent Automatic

•

Manual Adjacent

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START SHEARER RUNNING BATCH – SRB There are two SRB Operating Modes: • •

Shearer communication tracking, Manual

To operate in full automatic SRB (that is, tracking of Shearer position via a PLC interface) the following conditions must be met: • •

‘S_track’ parameter must be set to ‘S_MG’ The shearer must be turned to ‘ON’ and communication established between the shearer and PMC-R server, to register a shearer position to the system.

An SRB New start is used when SRB is: • • • •

Initiated for the first time, After a power outage, After an Emergency Stop, or If the operator needs to clear the PMC-R memory so that SRB can start again from the point of initiation.

The limited start area is defined by parameter “S_offset”, behind this the shields are not included in the SRB group.

An SRB restart is used when SRB has been temporarily stopped by pressing

.

When SRB restart is initiated, SRB continues from the last automatic operation.

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Initiate an SRB Newstart – Shearer communications tracking

To initiate SRB, the operator must be adjacent to the shearer, where the flashing.

1. Press

key is

to select SRB automatic operation.

2. Then select the Direction that the shearer will travel, by pressing either

or

.

3. Start SRB by pressing

Note: If the

.

and

keys LED’s are lit, SRB is running.

Now that the SRB automatic is started, if the Shearer Running Batch (SRB) is cancelled (for example, the Stop key was pressed), the SRB can be ‘Restarted’ from a group of supports near the shearer, indicated by a flashing

and

The sequence can be ‘Restarted’ by pressing

To stop SRB press

keys LED’s.

, then

and then

.

.

Note: It is important to ‘Restart’ SRB and not to initiate e new start unless the shearer is at the beginning of its main to tail, or tail to main sequence.

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Initiate an SRB Newstart – Manual mode SRB manual mode is only used if the shearer data is lost due to a fault. The manual SRB mode can be started the same way as the serial mode.

1. Switching from SHEARER COMMUNICATIONS to MANUAL tracking is done by accessing the SRB PARAMETERS menu, and using the ‘L’ or ‘M’ keys to change the display to:

S track 280

S_MG 98

280

SA-Idle

Using the ‘P’ key will change display to either ‘NONE’, ‘S_MG’, or ‘MANUAL”.

2. Press

and then select shearer direction by pressing either

3. Press

to activate SRB.

or

.

4. In ‘Manual’ mode, the shearer position is given manually to the PMC-R system by the shearer operator.

5. The operator has to press and then the key, which is adjacent to the MG drum of the shearer, and defined by a parameter (usually set 4-5 shields from centre of shearer).

6. In 'Manual’ mode the

and

key LED’s are lit throughout the face.

7. To stop SRB press

DANGER: It is extremely important that the operator constantly updates the machine position to ensure collision between the Shearer and Shields do not occur.

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Initiate an SRB restart

When SRB is suspended using the where they were suspended.

key it is possible to resume SRB operations from

This feature is useful when the operator has to manually operate the shearer outside f the normal cutting sequence. E.g. reverse the shearer. But before SRB can be re-started the shearer position must be returned to the position where SRB was suspended or further.

1. SRB can only be ‘Restarted’ from a group of supports near the shearer, indicated by a flashing

and

keys LED’s.

2. The SRB sequence can be ‘Restarted’ by pressing

, then

and then

.

DANGER: When SRB is re-started shields will commence to advance or push the conveyor where the sequence was suspended regardless of the shied operations distance from the shearer. S_Offset is not used for an SRB restart.

Note: SRB can only be re-started within a time determined by the parameter S_restart from when SRB was suspended using the

key.

Note: It is important to ‘Restart’ SRB and not to initiate e new start unless the shearer is at the beginning of its main to tail, or tail to main sequence.

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Reversing the shearer during SRB operations To reverse the direction of travel of the shearer out of normal cutting sequence when in SRB, such as when out of the gate ends clean up area, the SRB must be suspended by pressing

.

The shearer may then be reversed to clear blockages, re-cut roof or floor etc.

The Shearer must be returned to its position in the sequence where SRB was suspended, and a ‘Restart’ performed to resume operation within the maximum time limit for an SRB restart.

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INITIATE A TRAVEL ZONE The travel zone is to permit persons unfamiliar with longwall mining operations to cross the face within a defined, moving zone, without experiencing shield operations in that zone.

It disables all auto sequence operations so shields don’t lower, advance or set in that area.

However an AFC bankpush is allowed to continue.

The Travel Zone is accessible when the SCU shows the Default Display.

Start a travel zone 1. To initiate a travel zone Press

.

The display will show:

Set trav.zone 280

2. Press

98

(ENTER) SA-Idle

280

.

The travel zone will now be initiated.

#15 TZONE!!!

280

98

<85 280

SF-Idle

The SCU at the ends of the travel zone have the ‘A’, ‘B’, ‘C’, ‘D’, ‘E’, ‘#’, ‘G’, ‘I’, ‘P’, & ‘N’ Keys flashing.

The display will also indicate that it is the last shield that forms the travel zone by indicating ‘TZONE>-0’ or ‘<TZONE-0’ meaning that there are no more shields that form the travel zone group in the direction away from the PMCR of initiation.

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Any shields within the Travel zone with an active ASQ, will be interrupted by re-setting the Shield. A conveyor pullback is also stopped in a travel zone however a Bankpush is possible. If the Travel Zone is stopped or moved away from a shield with an interrupted ASQ within this time, the ASQ will then resume.

Moving the Travel Zone.

To move the Travel zone as you travel across the face you must be within the travel zone.

Press

twice.

The Travel zone will be advanced with you and SCU’s with respect to your shield address will be released from the Travel zone.

Shields released from the Travel zone that had its ASQ interrupted, will resume its ASQ providing the Travel Zone Timer has not expired.

Stop or De-activate the Travel zone.

On any SCU that is in the Travel zone,

Press

.

The display will show,

Stop trav.zone 280

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98

(ENTER) 280

SA-Idle

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Press

.

The SCU display will return to the normal Default Display: Shields released from the Travel zone that had its ASQ interrupted, will resume its ASQ providing the Travel Zone Time has not expired.

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INITIATE AN AUTO SEQUENCE (SUPPORT ADVANCE)

DANGER: Mine safety procedures in regards to shield movement MUST be observed.

This function is in the event that an SRB is not operational or a shield requires advancing ahead of the SRB sequence. It is an automatic function that is manually initiated and controlled by PMC-R system.

1. Press

or

to select the adjacent shield.

2. Press Pressing the stop key, at any time will stop the ASQ and any other automatic functions on the face including SRB.

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INITIATE ADJACENT CONTROL FUNCTIONS DANGER: Mine safety procedures in regards to shield movement MUST be observed.

Adjacent control of a neighbouring support is usually used when close supervision of an action or operation is required. The adjacent functions are generally used if the roof is poor or maintenance is being done on the neighbouring support.

1. Select direction by using

or

2. While the SCU is in ‘Master Mode’ the function required on the adjacent shield can be selected. The function will stop when the key is released (a Deadman function).

The following keys are Deadman keys:

Legs lower.

Shield Advance.

Legs raise.

Base lift.

Canopy tip up.

Canopy tip down.

Flipper Retract.

Flipper Extend.

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Side Seal Retract.

Side Seal Extend.

Conveyor pullback deadman group.

If the key is released, the timer (the “mastertime“counter) starts from zero again. The function stops when the key is released (a Deadman function).

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INITIATE AUXILIARY FUNCTIONS DANGER: Mine safety procedures in regards to shield movement MUST be observed.

The main shield functions have their own PMC-R key assigned to them, however there are not enough keys for all the functions on the supports, so the additional functions are accessed using this menu.

1. Select the adjacent shield using or keys. The adjacent shield will be placed in slave mode and the master shield will display the “Auxiliary Functions” menu.

2. Press

until the required auxiliary function is displayed if necessary.

3. Individual functions can now be made by pressing the applicable.

or

keys if

All possible operations are listed below.

ram out

ON

Leg press.

SET

PS Spray

ON

Pressing the key operates the front AFC ram cylinder, which pushes the front AFC across.

Pressing the

Side Spray

Antitopple

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ON

IN

key operates the Leigh Pressure Set valve.

Pressing the key activates the shearer water curtain spray mounted under the canopy tip.

Pressing the

key activates the shield side sprays

TG shields only.

Pressing the key activates the Anti-topple Cylinder

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BP MAIN

ON

OFF

BP Solid MG group Pressing the key activates the Bankpush solid ON at MG Pressing the

key activates the Bankpush solid ‘OFF’ at MG

BP Solid TG group BP TAIL

ON

OFF

Warn.Lamp LED1 LED2

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Pressing the Pressing the

key activates the Bankpush solid ON at TG key activates the Bankpush solid ‘OFF’ at TG

Pressing the Pressing the

key activates the red warning lamp key activates the green warning lamp

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INITIATE A REMOTE SUPPORT FOR SLAVE OPERATION DANGER: Mine safety procedures in regards to shield movement MUST be observed.

This feature allows operation of a support up to 5 supports away from the operator using the remote adjacent control functions of the PMC-R. 1. To operate an auxiliary function an adjacent support must be selected pressing the

or

keys.

2. If remote operation is enabled then the desired remote shield may be selected by first pressing

.

3. The display on the master PMCR then changes and shows the default remote distance value:

Remote dist. r0 280

c100 98

2 s100 280

SA-Idle

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

In this example the

has been pressed once. (Assuming NbManDist = 2)

Remote dist. r0 280

5. Finally to select the shield press the

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3 s100 280

SA-Idle

key.

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In this example the shield that is 3 shields away in the direction initially selected by the or key will be placed into slave mode. The beeper will be heard and the shield can be operated from the Master PMCR.

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INITIATE A BATCH FUNCTION (SUPPORT ADVANCE) DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1. Press

to select the support advance operation in Batch group.

2. To select the neighbour group of shields you want the function to operate, press

or

.

3. The PMC-R display shows: Sequence mode

BA: SEQU 280 r2

98 c100

Direction

40

< 36 280 s100

SA-Idle

4. Pressing RABB.

, the operator can toggle between the operating modes SEQ, RAN and

5. Pressing operate.

, the operator can toggle between the directions that the group function will

6. Press

to initiate the Batch support advance sequence.

In the above example a Batch support advance has been selected from shield 41. The supports will advance in sequential order starting with No.36 assuming the batch group is 5.

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Pressing the stop key, at any time will stop the batch support advance and any other automatic functions on the face including SRB.

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INITIATE A TAPER BATCH FUNCTION (SUPPORT ADVANCE) DANGER: Mine safety procedures in regards to shield movement MUST be observed.

The parameters are changed as for any parameter, however to ‘commence’ the operation:

1. Press

to select the support advance operation in Batch group.

2. Press

and you will be prompted to enter the Password. Once the password is

entered using the numeric keys press

.

3. Press and navigate to the taper start parameter. This is the shield that you wish the taper batch to start. Enter the shield number using the numeric keypad and press

.

4. Press and navigate to the taper 0 ext parameter. This is the final value of the ramstroke that you wish the shield at taper start to achieve. Enter the ram stroke target value using the numeric keypad and press

.

5. Press and navigate to the taper end parameter. This is the shield that you wish the taper batch to end. Enter the shield number using the numeric keypad and press

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6. Press and navigate to the taper 1 ext parameter. This is the final value of the ramstroke that you wish the shield at taper end to achieve. Enter the ram stroke target value using the numeric keypad and press

.

7. Press

8. The PMC-R display shows (for example):

BA: SEQU 280 r2

9. Press

98 c100

40

T 30 280 s100

SA-Idle

to initiate the Batch support advance sequence.

Pressing the stop key, at any time will stop the batch support advance and any other automatic functions on the face including SRB.

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INITIATE A BANKPUSH DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1. Press

.

2. Select on which side of the local support to operate the bankpush by pressing either or

.

Direction Operating mode

3. Pressing TAPER).

BP: SNAKE 158

< 134

280 r2

s100 280

c100 98

SA-Idle

, the operator can toggle between the operating modes (ALL, SNAKE,

All =all supports will push until it reaches the target stroke.

Snake = The AFC will push to form a snake.

Taper = AFC will push over with an evenly calculated Taper between the supports in the display.

4. Pressing operate.

, the operator can toggle between the directions that the group function will

Note: The default direction assumes that when snake mode is selected the operator wishes to bring the snake towards him.

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5. Press

to begin the AFC advance.

The supports will push the AFC in the group range to the target stroke.

Pressing the stop key, at any time will stop the batch support advance and any other automatic functions on the face including SRB.

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UNDERSTANDING THE OUTCOMES OF BANKPUSH DIRECTION SELECTION When performing a Bankpush group function in either snake or taper mode it is important that the correct direction (< or >, toggled by the N key) is selected. The direction will determine which end of the group will try to meet the ‘BP extens’ parameter value first.

The example below would shows typical values to perform a TG push.

Example 1.

BP: SNAKE 158

> 134

280 r2

s100 280

c100 98

SA-Idle

This shows a correctly selected direction, this is also the default direction as the system assumes that the operator wishes to work the snake towards him.

In the above example shield 158 ram stroke will attempt to meet the value of ‘BP extens’. A snake will be formed between 134 and shield 134 + ‘BP snake’. 134 + ‘BP snake’ will target ‘BP extens’ as its final ram stroke.

Example 2.

BP: SNAKE 158 280 r2

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TYPES OF BANKPUSH This parameter is in the Bankpush parameter menu. This parameter sets the default type of push displayed when a bankpush is initiated. The bankpush may also be toggled between the three modes once initiated by using the ’P’ key on the PMC-R keypad.

There are three types of bankpush:

(S) Snake This mode is designed to be used in lieu of the SRB Bank Push and will provide a defined snake over a number of shields. Note that the snake is the last 13 pans in the bankpush group. If you are bank pushing the entire face the bankpush groups must be overlapped to push out the snake.

(T) 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 push 100%.

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(All) All Every shield is activated for Bankpush. All shields in group try to reach BP extend or push for BP timeout.

Protection zones During a bank push there is the possibility that a shield is left back causing a neighbour difference between adjacent shields. If this is the case, and a bank push is allowed then physical damaged could be caused to the shield/s. In the following example shield #49 could be damaged by the Bank Push advancing from Left to Right.

To prevent damage to the shields Protection zones are provided. PMC-R software will examine the reading of reed rods. If the linear movement of a reed rod is not in the predefined tolerance the Bank Push will be suspended and reed rod reading re-examined. If however the neighbour difference is in excess of tolerable limits the Bank Push will abort.

This will form a protective curve in the AFC over the group of shields surrounding the shield that had been left back.

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INITIATING A BANKPUSH FROM-TO GROUP DANGER: Mine safety procedures in regards to shield movement MUST be observed.

If specific ‘start’ and ‘end’ points are required for the Bankpush, especially if the same range is required on every push and is required to be initiated from the same point each time, the range can be set in the Bankpush menu using the BP start and BP end parameters. These parameters are then stored in the local PMCR. This is useful if a Bankpush operation is repetitive from a particular PMCR. The parameters are changed as for any parameter, however to ‘commence’ the operation:

1. Press

.

The display will show the locally set ‘BP start’ and ‘BP end’ parameters that have been selected in the shield.

2. Pressing TAPER).

BP: SNAKE 158

< 134

280 r2

s100 280

c100 98

SA-Idle

, the operator can toggle between the operating modes (ALL, SNAKE,

All =all supports will push until it reaches the target stroke.

Snake = The AFC will push to form a snake.

Taper = AFC will push over with an evenly calculated Taper between the supports in the display.

3. Press

to begin the bankpush.

Pressing the stop key, at any time will stop the bankpush and any other automatic functions on the face including SRB.

Note: Consideration should be taken when operating from – to functions for the hydraulic pump system. Oversized groups can create an over demand for fluid that can cause significant drops in system pressure.

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INITIATE A LOCK ON PUSH

DANGER: Mine safety procedures in regards to shield movement MUST be observed.

If a lock on push is initiated in a support the DA ram will push the AFC until the ram stroke meets the target ‘BP LockOnP. Ext’ or until the ‘BP LockOnP.tmo’ timer expires.

1. Press

to activate the lock on push.

2. Press

to turn off the lock on push.

DANGER: During a lock on push all ram stroke protection is disabled. Use of lock on push can result in damage to the equipment.

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INITIATE A CONVEYOR PULLBACK

DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1. Press

to select Conveyor Pullback Operation.

2. Select the side you want the function to operate with the

or

key.

Direction Target Extension

CP: 280

80 98

36

<

17

280

SF-Idle

The display shows Conveyor Pullback will start at support 17 and work towards support 36 and stroke will be 80% after Pull Back.

3. Pressing operate.

4. Press

, the operator can toggle between the directions that the group function will

to begin the conveyor pullback.

Pressing the stop key, at any time will stop the conveyor pullback and any other automatic functions on the face including SRB.

Note: Global parameters in the conveyor pullback menu determine the adjacent group size ‘CP group’ and the target extension ‘CP extens’. These are configurable under Level 1 password control.

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INITIATE A CONVEYOR PULLBACK DEADMAN GROUP DANGER: Mine safety procedures in regards to shield movement MUST be observed.

This function initiates an adjacent group of shields to pull the conveyor back under Deadman control.

1. Press or to select the direction of the adjacent group of shields that require the conveyor pulling back.

2. Press to initiate the conveyor pullback deadman group. The number of shields that will attempt to pull the conveyor back will default to the CP group parameter setting.

3. Release

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INITIATE AN ADJACENT FLIPPER GROUP

DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1.

Press

to select Flipper Operation.

2.

Select the side you want the function to operate with the

or

key.

Direction Extend or Retract

FLP: EXT r0 280

80 c100 98

>

30

s100 280

SA-Idle

In this example the ‘G’ key was pressed in No.16 support to select the adjacent flipper group. The display informs the operator that the currently selected group is shields 21 to 17 and the sequence will start at 21 and work towards 17.

3.

Pressing , the operator can toggle between the directions that the flipper group function will operate.

4.

Pressing

5.

Press

Press

, the operator can toggle between Extend and Retract.

, to begin the flipper group operation.

to stop the flipper group operation at anytime.

DANGER: If Anti-Collision is inactive it is possible to extend and retract the flippers in the shearer zone.

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INITIATING A FLIPPER EXTEND / RETRACT FROM-TO GROUP

DANGER: Mine safety procedures in regards to shield movement MUST be observed.

If specific ‘start’ and ‘end’ points are required for the Flipper Extend or retract, the range can be set in the flipper menu using the flipper start and flipper end parameters. These parameters are not stored in the local SCU. The parameters are changed as for any parameter, however to ‘commence’ the operation the following key stroke combination should be followed immediately after entering the start and end parameters.

1. Press The display will show the locally set ‘Flipper start’ and ‘Flipper end’ parameters that have been selected in the shield and the direction that the group function will operate.

FLP: EXT 80 > r0 c100 s100

6.

Pressing

7.

Press

Press

30 SA-Idle

, the operator can toggle between Extend and Retract.

, to begin the flipper group operation.

to stop the flipper group operation at anytime.

DANGER: If Anti-Collision is inactive it is possible to extend and retract the flippers in the shearer zone.

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INITIATE ADJACENT CANOPY SPRAY GROUP DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1. Press

.

2. Select on which side of the local support to operate the Canopy Sprays by pressing either or

.

In this example the adjacent group is selected from shield 19 and Position Sprays parameter WSP group = 5.

3. Press

to initiate the Canopy Spray Group.

All selected sprays will initiate and remain energised for the time determined by Position Spray parameter WSP GRP tmo[min] or until cancelled for other reason (e.g. Stop key is pressed).

Pressing the stop key, at any time will stop the Canopy spray group including other automatic functions on the face including SRB.

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INITIATE ADJACENT SIDE SPRAY GROUP DANGER: Mine safety procedures in regards to shield movement MUST be observed.

1. Navigate to the Side Waterspray Menu using the K & R keys

2. Then press the

Key to access the group function menu

3. Select a direction using the

WSS1000 300 100

4. Press

or

key

20 > 25 300 SA-Idle

to initiate the Side Spray Group.

The number of sprays selected is determined by the ‘WSS Group’ parameter and the time the sprays remain energised is determined by the ‘WSS timeout’ parameter, both are available in the Side Waterspray menu.

Pressing the stop key, at any time will stop the Side Spray Group including other automatic functions on the face including SRB.

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POSITIVE SET FUNCTION Positive Set is a function that allows the roof support or shield to reset to the roof or set to the roof after a preset pressure is reached, approximately 120 Bar in most cases.

Positive Set is also used to maintain shield leg pressures within a defined pressure range once the shield has been properly set to the roof.

The positive set function monitors the hydraulic pressure in the shield leg and utilises timers to initiate the positive set function

Guaranteed Set The guaranteed set uses the measured leg pressure in a shield and the measured system hydraulic pressure to calculate when to initiate the positive set. In a shield, if measured system pressure is greater than measured leg pressure + parameter PSA p.diff then the positive set activates.

Disabling Positive Set DANGER: Positive Set must be turned off if there is poor roof over the rear of the support, or the support is used for maintenance purposes.

It is possible to switch the positive set ON or OFF by pressing With a single push on key `0’ it is possible to switch positive set ON, another push switches the positive set OFF on the support on which you are standing.

If the

LED is On, positive set is ON.

If the

LED is Off, positive set is OFF.

Note:The ‘0’ key is intended to allow the operator to switch OFF PSA easily if a changing roof condition is noticed local to the shield that requires PSA to be turned off. If PSA is to be more permanently switched off in local shields it is recommended that the local parameter ‘PSA’ is switched OFF It is possible to switch positive set ON or OFF on an adjacent group of shields by pressing then the

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or

followed by

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Alternatively, it is possible to lockout the positive set for all supports in the Global Parameter menu.

Note: If LED is flashing, there was a positive set error registered on the shield. This means that the shield has had multiple attempts to reach the positive set setting pressure and has failed.

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LEG SET FUNCTION The Leg Set function is incorporated with the Positive Set Function however pressure is supplied from a separate delivery system to ensure the Shield’s leg cylinder pressures are topped up to adequately support the roof. The Leg Set function will operate after the completion of the Positive Set Function. Similar to the Positive Set function the Leg Set Function monitors the hydraulic pressure in the shield leg and utilises timers to initiate the Leg Set function however generally with slightly higher pressure parameters. If the Positive Set Function is disabled then the Leg Set Function will be disabled. The Leg Set Function can be disabled without affecting the Positive Set function.

Guaranteed Leg Set The guaranteed Leg Set uses the measured leg pressure in a shield and the measured Leg Set system hydraulic pressure to calculate when to initiate the positive set. In a shield, if measured Leg Set system pressure is greater than measured leg pressure + parameter PSA LegSet_p.diff then the Leg Set Functions activates.

Disabling Leg Set It is possible to switch the Leg Set ON or OFF on the local Shield by going to the PSA Parameter menu then press

to access the LegSet loc. parameter and using the

key to toggle the Leg Set ON or OFF.

LegSet.Loc

ON

Alternatively, it is possible to lockout the Leg Set Function for all supports with the Leg Set parameter in PSA Parameter Menu, this will not affect the Positive Set Function operation.

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SHEARER REMOTE STOP OPERATION It is possible to send a stop request to the shearer from the PMCR system.

Operating the keys shearer.

will send an all MOTORS stop request to the

The PMCR’s Display SHEARER_SHUTDOWN # ‘Shield Number’.

The shearer is locked until the following keys are operated

.

The PMCR display reverts back to Normal.

Note: Shearer communications must be active and this feature enabled on the shearer for this functionality to occur..

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ANTI-COLLISION OVER-RIDES Shearer Anti-Collision Override When a shearer anti-collision function has been activated it can be cleared in various ways.

If a shield is advanced then it can be pushed back into position.

If a flipper is advanced then it can be retracted.

If the shield is set then the drum can be lowered below the minimum limit.

If the maximum lowering time is operated then the shield can be reset to the roof.

The shields display a collision warning at the server and in the shearer zone If it is not possible to do this then the anti-collision can be overridden in the shearer zone by pressing the M key

and the

key.

DANGER: Ignoring ram stroke sensors will defeat anti-collision protection related to the particular ram.

For example a flipper ram stroke sensor that has an ignored will operate to timers during its automatic extension / retraction. It is possible that the flipper can be fully extended but it will not generate an anti-collision with the shearer as its sensor is ignored.

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MOTION MONITORING MAXIMUM TRAVEL ERROR RESET. If a MaxTrDwn error, MaxTrDA error or a MaxTrFlp error occurs in a shield the dump valve will de-energised.

The error must be cleared in the local shield by using the

key to access the error

menu. The individual errors in the menu can then be cleared by pressing the

key.

DANGER: The purpose of this protection is to make the system safe in the event of a mechanical failure. A qualified person should be notified of the error before attempting a reset.

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COMPENSATION CYLINDER STOP ERRORS. CompCylinder Stop # If a MM MaxCmpAng or MM MinCmpAng error occurs in a shield then a facewide ‘CompCylinder Stop #’ will occur. The shield number is also displayed on the PMCR where the error has occurred.

This protection prevents damage to the compensation cylinder by preventing certain valve activations in the shield once the angle between the caving shield and the canopy reaches the minimum or maximum limits.

The error can only be cleared by operating the shield from manual adjacent control to correct the caving / canopy angle.

The actual angle between the caving shield and canopy can be viewed in the measured values menu. The value is in degrees.

0= tilt comp

130

MM MaxCmpAng If a shield has a MM MaxCmpAng error then the Compensation cylinder will be close to its maximum extension.

To clear the error in the shield either the legs must be lowered or the canopy tipped down.

1. Disable PSA in the shield where the compensation cylinder STOP has occured.

2. Press the

key if required and check that the LED on this key is OFF.

3. Select direction by using

or

4. While the SCU is in ‘Master Mode’ the function required on the adjacent shield can be selected. The function will stop when the key is released (a Deadman function).

5. Use either of the following keys to reduce the caving – canopy angle.

Legs lower.

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ROOF / FLOOR HEIGHT CUTTING ADJUSTMENTS From any PMC-R on the face roof cutting height and floor cutting height can be adjusted by the operator as the Shearer passes along the face. This will affect the VShearer target functionality, and in turn modify the shearer cutting height. Using visual observation the operator can apply roof or floor adjustment in increments of ± 25mm, these adjustments are available from the Shearer Control menu accessed by pressing the

key two times.

Shearer Control

Roof Height Adjustment The roof height can be increased in 25mm increments pressing the decreased in 25mm increments by pressing the

key and

key.

RoofAdj ( N- / P+ ) *0

Floor Height Adjustment The floor height can be increased in 25mm increments by pressing the decreased in 25mm increments by pressing the

key and

key.

FloorAdj ( N- / P+ ) *0

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PMCR SHORTCUTS B key Shortcut to a PMCR menu item can be created for 10 shields either side of the shield where the shortcut is created. This is useful when needing to check measured values in a group of PMCR’s.

It is only possible to create these shortcuts to menu items that are not password protected.

Example.

The measured value of the flipper ram is required to be checked in a group of shields.

1. Navigate to the measured value Flipper using the

,

,

and

keys.

2. Press the

key twice.

3. The shortcut is now saved and can be used in 10 shields either side of the shield where the shortcut was created.

4. In an adjacent shield press the the display.

key once. The measured value will be seen on

P key

Pressing the key on a PMCR at the default display provides a shortcut to the last menu item before the Master timer elapsed. This does not include auxiliary menu items or password level protected items.

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Gate End Sequence With Target Line From software version V8 onwards the way in which the Gate End shields move towards a target line has changed. Previously the Gate End Shields advanced to a set target line whereas from V8 onwards the Gate End Shields will push towards a set target line.

Previous Sequence (Before V8) Standard Gate End sequence would be the Conventional Shields advanced and all other Shields set one web back.

When the Shearer cuts into the gate and back out to the buttock then all Shields are advanced.

The next action is to push the AFC when the Shearer has left the gate. Because the DA strokes for all Shields indicate similar positions then the push will operate as expected.

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The Gate End Shields will then advance to protect the roof.

The Sequence is then complete.

When operating a target line the Gate End Shields are already advanced but the Run of Face Shields will advance to target.

The above example shows a 50% advance of the Run of Face Shields. The next step is to push the AFC as the DA difference between the first run of face shield and last gate end shield exceeds the BP Protect limit the push then the Push will abort. This issue was the motivation for implementing the push to target sequence in software version V8.

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Push to Target Sequence (V8 Onwards) The sequence change looks to address how the gate shields react to a Target Line operation and the Bank Push operation has be altered when a Target Line is set. The Following shows the push to target sequence for the Gate End Shields.

The Gate End shields are set as previous after a completed sequence.

A Target Line is set before the Shearer leaves the gate and before the Run of Face Shields advance. The Run of Face Shields then advance to achieve a Conveyor Push to the desired position.

The problem with regard to the BP Protect limit being exceeded is still present but if a Target line is active the protection will be ignored between the last conventional Shield and first run of face shield. This will allow the push to become active. Without an active Target Line the protection will remain active.

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