Home

user manual

1. 11 Pre start alarm controller type AP SA2 2888 9 11 15 PILE LY OG 17 19 Intercom type ABMA4 Handset 889909 iaaa 0 Legacy intercom DAC type Stage 22 Tailend unit type ct cnt oeaennceindaeennnccaieianan dali eaa Aa aa a aaia aAA ra 23 Tailend unit type TEUZ 24 Inter systems Coupler type 25 DIMF keyboard TV PCAN Bo sirieias inai a aA Ea AAA aAA 26 COET EEE E EE E R 28 Audio surface barrier type 0 0
2. 29 GEO e E E EE EE EEE EE EA E E E E E E 29 PRE START ALARM AND 2 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 PHOTOGRAPHS Photograph 1 PSACS1 family members 4 Photograph 2 Pre start alarm controller type APSA2 front 11 Photograph 3 Intercom type ABMAS front view 15 Photograph 4 Intercom type ABMAS rear 16 Photograph 5 Battery type 5 NC 1 N side 16 Photograph 6 Intercom type ABMA3S 1 front 17 Photograph 7 Intercom type ABMA3 1 rear
3. es a i F x x d i gt a b E y p gt a A 4 m e J h an 1 j 4 T F w 4 p ee 7 a e 7 8 wite fp a 5 4 A b 1 5 7 tpa ms 4 v gt e E AUS Ex 01 37455 58 IPSS o ai el Sieur 3 31 OOK 9898 Be e AUNVHeYM OvaLsny LOCAL INTERCOM TYPE ABMA3 Photograph 3 Intercom type ABMAS front view The intercom type ABMAS has three front panel mounted push buttons a front panel microphone and two side mounted speakers to provide the voice communications interface for staff working along the conveyor belt A conversation with another worker along the conveyor belt can be initiated by pressing the local call button once or several times The local call button is used to signal or attract the attention of workers along the conveyor The local call button can be pressed and released to sound a series of beeps along the conveyor The patterns and meaning of these beeps can be used to tran
4. 18 Photograph 8 Battery type 5 NH 1 N ee 18 Photograph 9 Intercom type ABMA4 front ccccccssseeecseeeeeeeeeeeeceeeeesseaeeeeseaeeeesaaseeessesesssaeees 19 Photograph 10 Intercom type ABMAG4 rear view cccccccescecceeeeeecaeeeeeeseeeeeeseaeeesseaeeessaeeessaneeseaaeeess 20 Photograph 11 Intercom type ABMA4 with handset 1 Photograph 12 Intercom type ABMA4 interior with handset ready for control panel installation 21 Photograph 13 Intercom DAC type stage front cceecceeeceeeeeeeeceeeeeceeeeseeeeceeesseaeeeeeesaaeeeeeeeas 22 Photograph 14 Tail end unit type TEU100 front 23 Photograph 15 Tail end unit type TEU2 side VIEW cee ccccccceeecceeceeeeeeeeeseaeeeceeeesaeeeeeesseaseeesensaeeeeeeaas 24 Photograph 16 Inter systems coupler type ISC2 top 25 Photograph 17 DTMF keypad type AKB1 front VIOW c cceececeeeeeeeeeeeeeeaeeeeeeeeeaeeeeeeeeaaeeeee
5. av a L Uo 3 iT pal 27 L RO 11 0 AUDIO SURFACE BARRIER TYPE TIAB1 Photograph 20 Surface audio barrier type TIAB1 The surface audio barrier tyoe ASCU is completely encapsulated and contains no user serviceable components The coupler is completely symmetrical and is not sensitive to polarity The coupler has a coupling ratio of 1 1 an insertion loss of less than 2dB characteristic impedance of 6009 and frequency range of 300Hz to 4000 17 The Pre start alarm and communications system is covered by several AUS Ex certificates Some items have individual certification but all are included in the system certification AUS Ex 02 3829X Table 10 below shows the certification of all the PSACS1 system components PRE START ALARM CONTROLLER APSA 02 3110X S Ex 02 3829X INTERCOM ABMA3 AUS Ex01 3745X AUS Ex 02 3829X INTERCOM WITH DISPLAY ABMA4 PENDING AUS Ex 02 3829X Table 11 PSACS1 Pre start alarm and communications system certification details The pre start alarm system is also covered by IECEx certification TSA 07 0021X
6. 2 35A Uo 3 55 lo 503 Ci Li OmH Co 3 2uF Lo 1 MANUFACTURED BY AUSTDAC PTY LTD SERIAL N 04051198 COUPLER TYPE ASCU Photograph 19 Coupler type ASCU front view The safety coupling unit type ASCU is completely encapsulated and contains no user serviceable components The coupler is completely symmetrical and is not sensitive to polarity The coupler has a coupling ratio of 1 1 an insertion loss of less than 248 characteristic impedance of 6009 and frequency range of 300Hz to 40001 2 Voice frequency audio port with 600Q characteristic impedance 1 008 VEON Voice frequency audio port with characteristic impedance oe Table 10 Safety coupling unit type ASCU termination details The audio surface barrier type TIAB1 is housed within a DIN rail mounting enclosure measuring 45mm x 75mm x 110mm It is used to provide DC galvanic isolation and AC voltage and current limitation between the surface safe area and the surface pair from the underground located PSACS1 All voice signals and tones between the surface exchange and the underground located PSACS1 system must pass via the audio surface barrier The audio surface barrier allows the surface pair to be part of an Ausidac telephone system multi pair cable without compromising the intrinsic safety of either system Um 250V TYPE 54 SURFACE AUDIO BARRIER 7 mia Izi 18
7. ac PTY LTD austa Title PRE START ALARM AND COMMUNICATIONS SYSTEM TYPE PSACS1 USER S MANUAL Document Number 20 0 9 12 Issue 03 PRE START ALARM AND 1 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 REVISION CONTROL 03 Add ABMA4 Handset TEU2 2007 11 19 MC ABMAS3 1 5 NH 1 N 006 PB 2004 08 26 writen Approved Austdac Pty Ltd Unit 1 4 Packard Avenue Castle Hill NSW 2154 Australia PO Box 6486 Baulkham Hills Business Centre NSW 2153 Australia Phone 61 2 8851 5000 Fax 61 2 9899 2490 Website www austdac com au Copyright 2004 10 27 Copyright 2007 11 23 This document remains the property of Austdac Pty Ltd It is subject to its recall and must not be reproduced in part or whole or its contents divulged to third parties without prior written approval from Austdac Pty Ltd TABLE OF CONTENTS 1 11 SCO 11111 9 2 25 922 22 9 29 2 9 2 9 0 922 2 2 2 9 2 0 7 007 4 System layout scalable architecture 8 55 5 11 OIC o 8 1 1 1
8. COLOUR O R S LINE NO CONNECTION TO AKB POWER SUPPLY NEGATIVE 0V Table 9 Keypad type AKB1 connection details BLACK The keyboard is connected to the PSACS1 4 wire network via a four pin molex mini fit jnr connector The PSACS1 network wiring connections to this connector are shown in photograph 11 below The DTMF keyboard type AKB1 may be mounted within any suitable enclosure that provides a minimum IP55 ingress protection rating The keyboard is typically mounted within a standard lockout enclosure or within a conveyor station enclosure along with a suitable intercom such as the intercom type ABMA4 The actual enclosure will depend on the system design and functionality requirements The AKB1 keyboard is an optional device that is only required when direct dial facilities are required for the installation PRE START ALARM AND 26 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 5 RED Photograph 18 DTMF keyboard type AKB1 rear view The safety coupling unit type ASCU is used to provide DC galvanic isolation between the PSACS1 system and the surface pair All voice signals and tones between the surface and the intercom string must pass via the safety coupling unit The safety coupling unit allows the surface pair to be part of an Austdac telephone system multi pair cable without compromising the intrinsic safety of either system BARROO7 SAFETY COUPLING UNIT TYPE ASCU AUS Ex 02 3254X Exia Ui 12 8
9. 2 WIRES POWER SUPPLY Figure 6 shows the inter system coupler type ISC2 that allows the addition of a boot end located power supply to allow a conveyor between 4000m and 8000m to be protected by a pre start alarm and have voice communications along the entire length of the conveyor UP TO 40 INTERCOMS UP TO 40 INTERCOMS 2 WIRES PRE START INTERCOM INTER INTERCOM TAIL END ALARM TYPE SYSTEMS TYPE UNIT CONTROLLER ABMA3 COUPLER ABMA3 TYPE TYPE APSA2 ABMA4 TYPE ISC2 ABMA4 TEU100 4 WIRES 4 WIRES 4 WIRES 4 WIRES 2 WIRES POWER CONVEYOR POWER SUPPLY FIGURE 6 VOICE COMMUNICATIONS AND PRE START ALARM SYSTEM WITH INTER SYSTEMS COUPLER The inter systems coupler provides galvanic isolation between the two power supplies connected to the system This preserves the explosion protected properties of the PSACS1 system The inter systems coupler type ISC2 may be located anywhere within the general centre of the conveyor The inter systems coupler divides the PSACS1 system into two separately powered segments The additional power supply may be located at the boot end of the conveyor or any convenient location in the inbye powered segment of the conveyor Refer to section 10 of this document for a more detailed description of the inter systems coupler Finally DTMF keyboards type AKB1 may be added to the intercom string to allow direct dialling via a telephone line connected via a surfac
10. Intercom type ABMA3 1 rear view The above photograph shows the rear of the ABMAS3 intercom with its battery removed to expose the battery charge current select jumper In the LO position the battery charge current is 11mA and 22mA in the HI position Refer to the system drawing for the correct charge rate for your intercoms Generally the HI position is used in systems with short powered segments and fewer intercoms the LO position is used in long powered segments with more intercoms Photograph 8 Battery type 5 NH 1 N side view 8 INTERCOM TYPE ABMA4 The intercom type ABMA4 provides the audio communications and pre start alarm sounding facilities of the PSACS1 system Intercoms are distributed along the conveyor at fixed distances apart to provide complete sound coverage along the conveyor During a pre start sequence the intercom sounds the pre start alarm through its two sideways facing speakers These same speakers and the front panel mounted microphone are used to carry out a half duplex voice conversation with other intercoms on the conveyor or a surface located BMA exchange operator Photograph 4 below shows the front panel of a type ABMA4 intercom I S INTERCOM ABMA4 AUS Ex 01 3745 MOA Exia 10220 6 61 6 5 INTERCOM TYPE ABMA4 Photograph 9 Intercom type ABMA4 front view The intercom type ABMA4 has seven front panel mounted push buttons a front panel microphone an LCD display and two side mounted s
11. The local call button is used to signal or attract the attention of workers along the conveyor The local call button can be pressed and released to sound a series of beeps along the conveyor The patterns and meaning of these beeps can be used to transmit messages to others along the belt The call exchange button is pressed to attract the attention of the BMA exchange operator at the surface Once the operator has acknowledged the call further instructions such as patching requests can be given from the intercom The voice communications of the PSACS1 system is half duplex i e only one party can speak at a time The speak button of the intercom must be pressed whenever the user wishes to speak It is important to get used to pressing the speak button just before speaking and releasing it just after finishing speaking Failure to control the speak button correctly will result in the beginning or end of a statement being cut off The ABMAS intercom when connected to the system cable will continually charge its rear mounted battery type 5 NH 1 N so that the intercom will have sufficient energy to sound a pre start alarm or broadcast a conversation PRE START ALARM AND 17 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 IS INTERCOM TYPE ABMA3 1 AUSTDAC LTO gt LOAD CHARGE AMBAS IS ONLY TO BE POWERED BY BATTERY TYPE 57NH71 N LO SPEAKERS aa SERIAL NUMBER TESTED era cn Photograph 7
12. end unit will divide this tone frequency by eight and return the new lower tone back to the controller via the S line This process of modifying the pre start tone and returning it to the controller allows the controller to verify that the pre start alarm tone did reach the boot end of the conveyor a TAIL END UNIT TYPE TEU100 Photograph 14 Tail end unit type TEU100 front view R BLUE POSITIVE POWER SUPPLY INPUT 12 6 9 VOLTS YELLOW VOICE LINE INPUT TO TONE DETECTOR S LINE OUTPUT FROM TONE DIVIDER TRANSMITTER X4 M BLACK NEGATIVE POWER SUPPLY INPUT Table 5 Tail end unit tyoe TEU100 termination details 12 TAIL END UNIT TEU2 The tail end unit type TEU2 as the name implies is situated at the boot end of the conveyor with the sole purpose of monitoring the pre start alarm tones on the V line from the controller at the drive head Ifa valid pre start alarm tone is received from the controller the tail end unit will divide this tone frequency by eight and return the new lower tone back to the controller via the S line This process of modifying the pre start tone and returning it to the controller allows the controller to verify that the pre start alarm tone did reach the boot end of the conveyor The TEU2 has two additional functions as follows e Provide a pre start alarm detected confirm output that can be used to drive a Dupline field bus standard single channel digital transmitter or a safety transmitter This
13. is possible for the pre start alarm to initially function issue a confirmation and then malfunction during the later part of the sounding period prior to the request being removed The pre start alarm request will immediately override any sounds being broadcast via the sound card input or synthesiser input The broadcasting of these sounds will resume three seconds after the request for the pre start alarm has been removed It is important that the end user or overall system designer conduct a risk analysis on the time it takes Staff to move away from the plant that is about to be started The analysis should determine the longest exit time and ensure that the pre start alarm sounds for that time period before any command to start is issued to the plant PRE START ALARM AND 14 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 The intercom type ABMAS provides the audio communications and pre start alarm sounding facilities of the PSACS1 system Intercoms are distributed along the conveyor at fixed distances apart to provide complete sound coverage along the conveyor During a pre start sequence the intercom sounds the pre start alarm through its two sideways facing speakers These same speakers and the front panel mounted microphone are used to carry out a half duplex voice conversation with other intercoms on the conveyor or a surface located BMA exchange operator Photograph 3 below shows the front panel of a type ABMAS intercom
14. AND 4 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 2 SYSTEM LAYOUT SCALEABLE ARCHITECTURE The pre start alarm and communications system can be implemented in several ways starting with a pair of intercoms and a power supply ranging up to a fully optioned pre start alarm system with telephone dialling and answering facilities Figure 1 shows the general system interconnection details for a fully optioned system This figure shows the four wire interconnecting cable of the powered segment that forms the backbone of the Pre start alarm and communications system type PSACS1 1 SYSTEM TYPE PSACS1 B SHA WITHIN ZONE 2 POWER SUPPLIES SHALI x ib i OUTPUT PARAN TION MAIN 5 IF THE INSTALLATION IS TEMPORARILY GASED OUT O OUTBURST POWER LIES SHALL BE REMOVED POWER BA i M 5 ND SUITAB SUPPLY MAXIMUM TED B NTERSYSTEMS AFE AREA RTIFIEL NUMBEI 10 INTERCOMS alt POWERED SEGMENT Ex ib UIT THE UT PARAMETERS OF THE ER SUPPLY FEE THAT POWERED SEGMENT POWER HALL ONLY BE STAN TELEPHONE CABL r Imm OR 0 9 ETE ad RATIO NOT EXCEEDING 40uH OH N Nemko O ATEX112 THIS DOCUMENT DESCRIBES AN Ex CERTIFIED PRODUCT THIS DOCUMENT OR THE
15. BMA3 or ABMA4 or a combination of both The ABMAS provides a simple operator interface while the ABMA4 provides an LCD and keypad interface for system monitoring and maintenance purposes See sections 6 and 7 for a more detailed description of the intercoms and their capabilities 6 6 LUI LU PRE START INTERCOM UP TO 40 INTERCOMS INTERCOM ALARM CONTROLLER ABMA3 4 WIRES ABMA3 TYPE APSA2 ABMA4 ABMA4 TEU100 2 WIRES CONVEYOR FIGURE 4 SIMPLE VOICE COMMUNICATIONS WITH PRE START ALARM SYSTEM POWER SUPPLY The pre start alarm and communications system can also be connected to the surface via the surface pair as indicated in earlier configurations This configuration shown in figure 5 below represents the most frequently used configuration of the PSACS1 system It provides voice communications and monitored pre start alarm facilities along the entire length of the host conveyor PRE START ALARM AND 6 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 TO BMA EXCHANGE OR 2 WIRES OR SURFACE MOUNTED INTERCOMS TIAB1 SURFACE SAFE AREA UNDERGROUND HAZARDOUS AREA LU PRE START INTERCOM UP TO 40 INTERCOMS INTERCOM TAIL END ALARM TYPE TYPE lt UNIT CONTROLLER ABMA3 4 WIRES ABMA3 TYPE TYPE APSA2 ABMA4 CONVEYOR 2 FIGURE 5 VOICE COMMUNICATIONS WITH PRE START ALARM SYSTEM ABMA4 TEU100
16. E MOUNTED INTERCOMS 12V I S POWER VOICE AND DTMF LOCAL CALL TONE CALL EXCHANGE TONE PRE START ALARM TONES CONFIRM TONES PRE START INTERCOM ALARM TYPE ABMA3 ABMA4 CONVEYOR FIGURE 8 PSACS1 SYSTEM SIGNAL PATHS INTERCOM TAIL END TYPE UNIT ABMA3 TYPE ABMA4 TEU100 POWER SUPPLY PRE START ALARM TONE FREQUENCIES The pre start alarm tones are a HEE HAW type sound designed to attract maximum attention of workers along the entire length of the protected conveyor Different pre start alarm tone sets are available so that when one conveyor is near another the starting conveyor can be determined from the tones The tail end unit simply divides the pre start alarm tones by eight and returns them to the controller for detection and the subsequent generation of the confirm signal Table 2 lists the typical tone sets and their application PSACS1 PRE START ALARM SYSTEM TONE SETS SET PRE START TONES CONFIRMATION TONES APSA2 SOURCE CODE WHERE X VERSION Table 2 PSACS1 Pre start alarm tone sets PRE START ALARM AND 10 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 The system cable forms an important part of the pre start alarm and communications system type PSACS1 It carries all the signals and distributes power to all the system components The system cable basically consists of four conductors within one outer sheath Of the conductors two are larger in cross sectional a
17. ER S MANUAL Issue 03 The power supply is typically 12 6 volts DC Table 1 shows the function and name of the conductors in the system backbone cable POSITIVE SUPPLY or R LINE The positive supply line provides positive power from the power supply to all the components distributed along the system cable The return for this supply is the negative supply line The positive supply is typically 12 volts DC The positive supply line is also the common for all tones and speech signals within the system VOICE LINE or V LINE The voice line is primarily for conveying any voice or pre start alarm signals along the entire length of the installation The voice signal may originate from any intercom along the conveyor and would travel in both directions until it reaches the controller type APSA2 inter systems coupler type ISC2 or the tail end unit type TEU100 The voice signal may also originate from the surface pair connected to the APSA2 controller In this case the voice line would carry the voice signal from the controller towards the tail end unit The voice line can also transfer the pre start alarm tones from the controller to all the intercoms and finally to the tail end unit All voice or tone signals on the voice line are with respect to the positive supply line or R line The voice line may also be used by some legacy intercoms BMAs type STAGE II to request a call exchange tone from the controller by changing the DC level of the voic
18. ESSED ARGE YELLOW DETECTED IN TAIL END UNIT POWERED SEGMENT Table 8 Inter systems coupler type ISC2 LED indicator details 14 DTMF KEYBOARD TYPE The DTMF keyboard type AKB1 can be used to dial telephone numbers via an interface located in the safe area at the end of the surface pair The keyboard is typically co located with an intercom to provide a complete half duplex voice communications system between the PSACS1 system and any remote telephone even one located in the public switched telephone network The keyboard also allows for telephone calls to be answered The keyboard type AKB1 produces standard Dual Tone Multi Frequency DTMF tone signals compatible with most telephone systems PSTN and private networks PAX The AKB1 keyboard has twelve keys 0 9 and in a standard telephone keypad layout The keyboard connects to the four wire PSACS1 network to derive its power and transmit the DTMF tones in response to key presses The DTMF tones are transmitted via the V line to the pre start alarm controller type APSA2 and then onto the surface via the coupler type ASCU the surface pair and the surface barrier The actual operation of the keyboard and the key sequences to commence and end phone calls is dependent on the surface located phone system interface therefore the operation of the keypad and the key sequences will be described in the phone line interface equipment manual and is beyond the scope of this manual
19. ICATIONS ONLY SYSTEM Figure 3 below shows the simple communications system with a surface pair connection to a BMA exchange or surface located intercoms This configuration allows communications along the length of the conveyor and with the surface or with another conveyor if patched through the surface exchange The PRE START ALARM AND 5 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 surface exchange may be a hardware based BMA exchange or an Austdac computer based exchange The intercom type ABMAS is best suited for this application as it can generate local call and exchange call tones without requiring a system controller TO BMA EXCHANGE OR 2 WIRES OR SURFACE MOUNTED INTERCOMS TIAB1 SURFACE SAFE AREA UNDERGROUND HAZARDOUS AREA INTERCOM TYPE INTERCOM TYPE ABMA3 UP TO 40 INTERCOMS POWER SUPPLY 4 WIRES CONVEYOR FIGURE 3 VOICE COMMUNICATIONS SYSTEM WITH CONNECTION TO SURFACE The next configuration of the system shown in figure 4 below involves the addition of the pre start alarm controller type APSA2 and the tail end unit type TEU100 to the intercom string along the conveyor This adds the ability to issue an audible pre start alarm along the entire length of the conveyor The simple speech communications of the earlier configurations remain in this configuration to provide a full conveyor voice communications and pre start alarm system The intercom can be type A
20. PRODUCT IT DESCRIBES SHALL NOT BE MODIFIED WITHOUT REFERENCE TO THE Ex CERTIFYING BODY 2 COUPLER TYPE O teen O Q S 2 BARRIER S COMPANION 2 a ye SYSTEM OO BARRIFR SYSTEM gt 0 6uF Lo Ro gt 40 0 56 16 END ONE POWERED SE E POWEREI MENT UNIT TYPE TEU2 R BLUE O a 2 R Iut E amp tance ELLO Ou ne RED 5 RED lt TEU100 BL ile 2 ACK S 2 L 1 OOO 5 INTERCOM NPE ABMA 01 3745xX Ex ib OR POWER TYPE ABM 618254 DI j 0 7 5 KEYBOARD a AUS 38 2 3829 02 382 SAFE AREA ADDITIONAL POWER SUPPLY Figure 1 Pre start alarm and Communication system general system interconnection details The simple communications system is useful in single entry type work where a conveyor is not present to provide simple and effective broadcast type communications over a large area Any number up to forty intercoms can be connected in a communications only system with a single power supply The intercom type ABMAS is best suited for this application as it can generate local call tones without requiring a system controller Figure 2 shows the simple stand alone voice communications only system INTERCOM UP TO 40 INTERCOMS POWER TYPE INTERCOM TYPE SUPPLY ABMA3 4WIRES 0 ABMA3 CONVEYOR FIGURE 2 SIMPLE VOICE COMMUN
21. PSA2 Whenever a pre start alarm sounds along the length of the conveyor the tail end unit divides the pre start alarm tone frequency by eight and returns it to the controller as a means of confirming that the pre start alarm made it along the entire length of the conveyor The controller looks for the returned lower frequency tones and energises the confirm relay signifying that the pre start alarm was sounded along the entire length of the installation The S line may also be used by some legacy intercoms BMAs type STAGE to request a local call tone from the controller by changing the DC level of the signal line The signal line normally sits at a DC voltage level between the system supply voltage and the supply voltage less one volt If the DC voltage level on the S line with respect to the R line is changed to a value greater than six volts the pre start alarm controller will issue 8 local call tone 1 200 2 for as long as the local call button is pressed A local call tone can be requested from any intercom or BMA along the length of the conveyor The local call tone is used to attract attention of personnel along the conveyor The local call tone is not passed to the surface pair and therefore will not attract the attention of the surface exchange operator This multiplexing of the S line allows AC type low frequency PSA confirmation signals to be conveyed from the tail end unit to the controller and DC type level sig
22. be on at any one time The switch that must be on is selected by testing the local call buttons on an intercom at each end of the conveyor The correct switch setting is the one that provides the most reliable start to a local call tone and the local call tone that is not modulated or motorboating The primary responsibility of the PSA controller is the sounding of the pre start alarm when requested monitoring the return pre start signal from the tail end unit issuing the confirmation contact closure and controlling the throughput of tones to the surface pair The secondary responsibility is the detection of DC level shifts on the voice and signal lines with respect to the R power supply line and the subsequent generation of call exchange and local call tones respectively Table 4 below shows the connection details to the pre start alarm controller type APSA2 Balanced twisted surface pair VF communications port Must be connected to the surface pair via a coupler type ASCU 3 8 0 Positive power connection intercom string andtailendunit 4 0 Voice line connection intercom string andtailendunit 5 S Signal line connection intercom string and tailend N Intrinsically safe pre start alarm request input Requires a voltage free 8 LS PSAREQUEST contact closure to initiate a pre start alarm 9 PWR Positive power input for system from power supply 0 Conf
23. d 22mA in the HI position Refer to the system drawing for the correct charge rate for your intercoms Generally the HI position is used in systems with short powered segments and fewer intercoms the LO position is used in long powered segments with more intercoms BATTERY TYPE 5 NC 1 N FOR INTERCOM TYPE ABMA3 Photograph 5 Battery type 5 NC 1 N side view T INTERCOM TYPE ABMA3 1 The intercom type ABMAS provides the audio communications and pre start alarm sounding facilities of the PSACS1 system Intercoms are distributed along the conveyor at fixed distances apart to provide complete sound coverage along the conveyor During a pre start sequence the intercom sounds the pre start alarm through its two sideways facing speakers These same speakers and the front panel mounted microphone are used to carry out a half duplex voice conversation with other intercoms on the conveyor or a surface located BMA exchange operator Photograph 3 below shows the front panel of a type ABMAs intercom Austdac CONNECT BATTERY PRIOR TO INSTALLATION Photograph 6 Intercom type ABMA3 1 with 5 NH 1 N battery The intercom type ABMAS has three front panel mounted push buttons a front panel microphone and two side mounted speakers to provide the voice communications interface for staff working along the conveyor belt A conversation with another worker along the conveyor belt can be initiated by pressing the local call button once or several times
24. e amounts of power so the two powered segments that it separates can be powered from the extreme ends of the conveyor where power is generally available Photograph shows the inter systems coupler in its enclosure The inter systems coupler type ISC2 is provided with two gland entries one on each side of the enclosure The inter systems coupler type ISC2 has two ports one port for connection to the controller out bye powered segment the other port is for connection to the boot end in bye powered segment The two ports are not the same so the inter systems coupler must be connected into the intercom string the correct way X4 1 BLUE X1 1 BLUE Table 7 Inter systems coupler type ISC2 termination details The inter systems coupler type ISC2 has four LED indications to aid in system commissioning and fault finding The first LED indicates power status on the controller side powered segment the second indicates power status on the tail end unit side powered segment The third and fourth LEDs provide indication of a call exchange or local call request in the boot end segment respectively INTER SYSTEMS COUPLER TYPE ISC2 LED INDICATOR DETAILS NAME COLOUR FUNCTION INDICATION CONTROLLER SIDE POWERED SEGMENT POWER 101 V2 POWER GREEN TAIL END UNIT SIDE POWERED SEGMENT POWER 1002 V1 POWER GREEN LD1 LD2 LOCAL CALL REQUEST BUTTON PRESED ARE DETECTED IN TAIL END UNIT POWERED SEGMENT CALL EXCHANGE REQUEST BUTTON PR
25. e line The voice line normally sits at a DC voltage level between the system supply voltage and the supply voltage minus one volt If the DC voltage level on the V line with respect to the R line is changed to a value greater than six volts the pre start alarm controller will issue a call exchange tone 400112 for about 4 seconds This call exchange tone is transmitted to all intercoms and the surface exchange pair This tone triggers a tone detector in the surface exchange that in turn rings an alarm to attract the exchange operator s attention This multiplexing of the V line allows AC type voice or audio signals to be conveyed along the entire length of the system and DC type level signals to request a call exchange tone from the controller by pressing a button on any one of the BMAs Once a call exchange tone has been requested all intercoms on the system will sound the tone until the controller has timed out The later model intercoms type ABMA3 and ABMA4 can be configured to request tones from the pre start alarm controller to maintain backwards compatibility with BMAs type STAGE or generate the tone internally using the intercom onboard battery This later method has the advantage of functioning during mains power failures as the pre start alarm controller is not battery backed SIGNAL LINE or S LINE The signal line is primarily for conveying pre start alarm confirmation tones from the tail end unit to the pre start alarm controller tyoe A
26. e located interface connected to the surface pair This interface can be a TARA or an Austdac computer based exchange and PABX PRE START ALARM AND 7 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 TARA PABX INTERFACE 2 WIRES OR LINE CONTROL UNIT TIAB1 SURFACE SAFE AREA UNDERGROUND HAZARDOUS AREA 31 KEYBOARD TYPE AKB1 DTMF KEYBOARD TYPE AKB1 UP TO 20 INTERCOMS AND 20 KEYBOARDS INTERCOM TYPE INTERCOM i 4 WIRES ABMA3 POWER SUPPLY FIGURE 7 VOICE COMMUNICATIONS SYSTEM WITH TELEPHONE DIALLING FACILITY This configuration with DTMF keypads type AKB1 allows telephone calls to be originated and answered from the PSACS1 system underground without surface operator intervention An incoming phone call will broadcast ring tone along the entire length of the conveyor allowing the call to be answered from any type AKB1 keypad located along the conveyor A phone call can be originated from any type AKB1 keypad by entering a code followed by the required phone number Configurations can be provided that answer incoming phone calls automatically and broadcast them along the conveyor belt without any tyoe AKB1 keypads in the system Other configurations can be provided that allow pre allocated phone numbers to be stored in the phone line interface to allow quick and convenient connection to emergency operations manager or other conveyo
27. eesseneeeeeenas 27 Photograph 11 DTMF keypad type AKB1 rear VICW cccceececeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeesaaeeeeeesaaneeeeeenas 27 Photograph 12 Coupler type ASCU front vi W 84 5 28 Photograph 13 Audio surface barrier type 11 51 29 FIGURES Figure 1 PSACS1 general system interconnection CetallS cccccccccssssseeeeeeeeeseeeeeeeeeeseeeeeeeeeeeeeeeeaas 5 Figure 2 Simple communications only system 5 Figure 3 Voice communications system with connection to the 5 6 Figure 4 Simple voice communications with pre start alarm 6 Figure 5 Voice communications with pre start alarm 7 Figure 6 Voice communications and pre start alarm system with inter systems coupler 7 Figure 7 Voice communications system with telephone dialling facility cccccsseccesseeeeseeeeeeeeeeeeens 8 Figure 8 PSACS1 sys
28. feature can be used to monitor the pre start alarm signal via an alternate return path Provide a pre start alarm system end of line under voltage detected output that can be used to drive a Dupline field bus standard single channel digital transmitter or a safety transmitter This feature can be used to continuously monitor the integrity of the pre start alarm hardware and cabling instead of just during a pre start alarm The TEU2 printed circuit board is fitted with connectors terminals and switches allowing the unit to be configured as required Table x below shows the various configuration options PRE START ALARM SYSTEM R V S M ee DUPLINE FIELDBUS SIG COM SW2 in 8150 position Table 6 Configuration of tail end unit type TEU2 Photograph 15 Tail end unit type TEU2 side view PRE START ALARM AND 24 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 The inter systems coupler type ISC2 can be used to divide the intercom string into two segments with each segment having up to 40 intercoms and DT MF keypads This allows conveyors up to 6000 metres long to be protected by the pre start alarm system An additional power supply is required to power the boot end powered segment INTER SYSTEMS COUPLER TYPE ISC2 Photograph 16 Inter systems coupler type ISC2 top view The inter systems coupler should generally be placed in the centre of the intercom string The inter systems coupler does not require larg
29. g the switch mounted in the grip section of the handset The front panel mounted microphone and speak button are disabled whenever the handset is connected to the intercom type ABMA4 The display and other controls still function as in the standalone ABMA4 The two side mounted speakers will also broadcast whatever is received from line unless they are optionally disabled Photograph 12 Intercom type ABMA4 interior with handset ready for control panel installation PRE START ALARM AND 21 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 Some earlier PSACS1 systems may be fitted with DAC type stage battery mini amplifiers These intercoms will only function fully when they are connected to a system with a type APSA2 controller The stage intercom will loose some functionality when power to the APSA2 controller is lost BATTERY MINI A sj MFT eal jo Aus td ac CONNECT BATTERY PRIOR TO INTERCOM DAC TYPE STAGEII Photograph 13 Intercom DAC type stage front view For more detail refer to the individual manual on the DAC stage intercom The tail end unit tyoe TEU100 as the name implies is situated at the boot end of the conveyor with the sole purpose of monitoring the pre start alarm tones on the V line from the controller at the drive head If a valid pre start alarm tone is received from the controller the tail
30. in until a confirmation is received from the controller The shortest time between the request and the receipt of the confirmation is 10 seconds The request can be negated any time after the receipt of the confirmation If a longer pre start alarm is required then the request should remain asserted for the required time Once the request has been negated the sounding of the alarm will cease within one second The controller will negate the confirm output within one second of the request being removed PSA REQUEST 1 8 PSA SOUND OUTPUT PSA CONFIRM 3 6 10 110 ale Lace Ai 0 1 2 3 4 5 6 7 8 1 PRE START REQUEST ASSERTED BY HOST PLC 4 PRE START ALARM SOUND ENDS 2 PRE START ALARM SOUND BEGINS 5 PRE START REQUEST NEGATED BY HOST PLC 3 PSA CONFIRM IS NOT ASSERTED FIGURE 10 PRE START ALARM FAIL INTERFACE TIMING DIAGRAM Figure 10 above shows a failed pre start alarm sequence where the fault output was asserted three seconds after the request was issued The host PLC should remove the request after the receipt of a fault The host may have several attempts before raising an alarm PRE START ALARM AND 13 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 For extended pre start alarm sounding periods the host PLC should continue to monitor the confirm and fault outputs to ensure that the pre start alarm functioned correctly for the entire period It
31. irm relay changeover contact set 1 Relay is energised on valid confirmation of pre start alarm Confirm relay changeover contact set 2 Relay is energised on valid confirmation of pre start alarm Non intrinsically safe pre start alarm request input Requires application of 24 volts to initiate pre start alarm Um 250V Table 4 Pre start alarm controller tyoe APSA2 termination details PRE START ALARM INTERFACE The pre start alarm interface consists of one input and one output from the APSA2 controller The input is the pre start alarm request and the output is the pre start alarm confirm relay contact The pre start alarm interface allows the host PLC to request that a pre start alarm be sounded along the conveyor and to determine if the pre start alarm was valid The controller tyoe APSA actually has two pre start alarm request inputs a intrinsically safe request input and a non intrinsically safe request input but only one is ever used in any one installation The intrinsically safe request input requires a contact closure to initiate a pre start alarm The non intrinsically safe request input requires the application of 24V DC to initiate a pre start alarm The host PLC should assert the pre start alarm request input whenever a pre start alarm is required The host PLC should continue to assert the request until one of the following has occurred 9 A confirmation has been received via the pre start alarm confirm contact No resp
32. nals to request a local call tone from the controller by pressing a button on any one of the BMAs The local call tone will only sound while the local call button is pressed The later model intercoms type ABMA3 and ABMA4 can be configured to request tones from the pre start alarm controller to maintain backwards compatibility with BMAs type STAGE II or generate the tone PRE START ALARM AND 9 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 internally using the intercom onboard battery This later method has the advantage of functioning during mains power failures as the pre start alarm controller is not battery backed NEGATIVE SUPPLY or M LINE Negative supply line provides the supply current return for the positive supply line The negative supply line only has one function MONITORED PRE START ALARM The pre start alarm is monitored to ensure that the pre start alarm tones reach the entire length of the conveyor installation For a pre start alarm to be confirmed or successful it must make its way from the controller through all the intercoms or BMAs that sound the pre start alarm and onto the tail end unit The tail end unit detects the pre start alarm tones and returns a confirmation set of tones to the controller so that a confirmation or successful signal can be passed onto the host PLC or conveyor controller Figure 8 shows where all the signals soeech tones and power go in a typical installation TO BMA EXCHANGE OR OR SURFAC
33. onse of any kind within 35 seconds of asserting the request PRE START ALARM AND 12 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 The pre start alarm confirm output is a voltage free changeover contact that is asserted whenever a pre start alarm is successful A successful pre start alarm is one that has been confirmed by the tail end unit type TEU100 The confirmation will not be asserted if the system cable is damaged open circuit short circuit or if the tail end unit supply voltage is out of tolerance or if the pre start request is negated prematurely PSA REQUEST 1 5 2 1 PRE START REQUEST ASSERTED BY HOST PLC 5 PRE START REQUEST NEGATED BY HOST PLC 2 PRE START ALARM SOUND BEGINS 6 PRE START ALARM SOUND ENDS 3 PSA CONFIRMED BY CONTROLLER EARLIEST 7 PSA CONFIRM NEGATED BY CONTROLLER 4 PSA CONFIRMED BY CONTROLLER LATEST FIGURE 9 PRE START ALARM SUCCESSFUL INTERFACE TIMING DIAGRAM Figure 9 above shows a timing diagram for a successful pre start alarm sequence The sequence is started by the host PLC requesting a pre start alarm Assuming that the intercom string and tail end unit have no cable faults the controller tyoe APSA2 will issue assert a confirm signal within two seconds It is important that the host PLC does NOT negate its request for a pre start alarm during this delay period The pre start alarm will continue to sound as long as the request is asserted The request should rema
34. peakers to provide the voice communications interface for staff working along the conveyor belt The LCD display allows the operator to view operational and maintenance information about the intercom and the PSACS1 system A conversation with another worker along the conveyor belt can be initiated by pressing the local call button once or several times The local call button is used to signal or attract the attention of workers along the conveyor The local call button can be pressed and released to sound a series of beeps along the conveyor The patterns and meaning of these beeps can be used to transmit messages to others along the belt The call exchange button is pressed to attract the attention of the BMA exchange operator at the surface Once the operator has acknowledged the call further instructions such as patching requests can be given from the intercom The voice communications of the PSACS1 system is half duplex i e only one party can speak at a time The speak button of the intercom must be pressed whenever the user wishes to speak It is important to PRE START ALARM AND 19 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 get used to pressing the speak button just before speaking and releasing it just after finishing speaking Failure to control the speak button correctly will result in the beginning or end of a statement being cut off The ABMA4 intercom when connected to the system cable will continually charge its rear mo
35. r type ISC2 LED indicator 5 26 Table 9 DTMF keypad type AKB1 connection details 5 44 4594 26 Table 10 Safety coupling unit type ASCU termination details 4 28 Table 11 PSACS1 Pre start alarm and communications system certification details 29 PRE START ALARM AND 3 OF 29 20 079 12 COMMUNICATIONS USER S MANUAL Issue 03 1 GENERAL DESCRIPTION The Austdac voice communications and pre start alarm system type PSACS1 is designed to be used with conveyors of all tyoes where voice communications and pre start alarm facilities are required along the entire length of the conveyor or belt The voice communications subsystem allows crew to communicate with each other or communicate with a surface located control room while the pre start alarm subsystem provides an audible warning that the conveyor is about to start moving The various components of the system are located along the length of the conveyor to provide continuous audible coverage of the conveyor and associated plant The controller is typically located at or within the conveyor control cubicle the intercoms are placed at strategic locations along the conveyor and the tail end unit is located at the boot end of the bel
36. rea than the other two The two larger cross sectional area conductors are used to distribute power to the system components while the smaller conductors are used to convey signals between the various system components iT N POWER BLUE ig 8 IR SPARE 25 652 Table 3 PSACS1 typical system cable details The pre start alarm controller tyoe APSA2 forms the central part of the PSACS1 system when pre start alarm facilities are required It provides a connection point between the power supply the intercom string the surface pair and the host belt controller or PLC 2 ausidac PSA CONTROL BOARD TYPE APSA2 APPROVALS AUS Ex 07 3110 PART NO PSAI2 MANUFACTURED AUSTOAC PTY LTO SERIAL N 03096165 PSA CONTROLLER TYPE APSA2 Photograph Pre start alarm controller type APSA2 front view The pre start alarm controller is housed within a plastic enclosure measuring 150mm x 150mm x 65mm The front cover of the enclosure is clear allowing a clear view of the internal switch settings and LED indicators The pre start alarm controller has two LED indicators one green LED LD1 flashes continuously to indicate system powered up and functioning the other green LED LD2 is illuminated whenever the confirm signal is asserted All eight switches of SW1 must be in the off position SW2 controls the threshold level of the local call detect circuit Only one switch of SW2 shall
37. rs etc The PSACS1 pre start alarm and communications system allows up to 40 intercoms per powered segment and up to two powered segments per system Generally each powered segment can be up to 4000 metres long depending on system cable attenuation and voltage drop A complete system functional assessment must be carried out on a proposed system layout to ensure that the required system will operate correctly Austdac Pty Ltd can provide this assessment during your system design phase 3 PRINCIPLE OF OPERATION The pre start alarm and communications system uses a four wire system cable to provide power and signal paths for the entire system The system cable has two large conductors for power and two small conductors for signal The two power conductors provide power from the power supply to all the intercoms and other components distributed along the system cable PSACS1 SYSTEM CONDUCTOR NAMES AND FUNCTIONS NAME SYMBOL PRIMARY FUNCTION SECONDARY FUNCTION COLOUR POSITIVE COMMON RETURN FOR VOICE SUPPLY POSITIVE SUPPLY AND SIGNAL LINES BLUE CONVEY BEDIRECTIONAL VOICE OR VOICE LINE TONES ALONG ENTIRE LENGTH OF CALL EXCHANGE REQUEST YELLOW SYSTEM LINE CONVEY PRE START ALARM SIGNAL LINE CONFIRMATION TONES FROM THE TAIL RED END UNIT TO THE CONTROLLER NEGATIVE NEGATIVE SUPPLY BLACK Table 1 PSACS1 system conductor names and functions V S M PRE START ALARM AND 8 OF 29 20 079 12 COMMUNICATIONS US
38. smit messages to others along the belt The call exchange button is pressed to attract the attention of the BMA exchange operator at the surface Once the operator has acknowledged the call further instructions such as patching requests can be given from the intercom The voice communications of the PSACS1 system is half duplex i e only one party can speak at a time The speak button of the intercom must be pressed whenever the user wishes to speak It is important to get used to pressing the speak button just before speaking and releasing it just after finishing speaking Failure to control the speak button correctly will result in the beginning or end of a statement being cut off The ABMAS intercom when connected to the system cable will continually charge its rear mounted battery tyoe 5 NC 1 N so that the intercom will have sufficient energy to sound a pre start alarm or broadcast a conversation CHARGE 70 CURRENT Di BATTERY SELECTION 7 J E ma 5 L m U SPEAKER 2 e CONNECTIONS SYSTEM gt CABLE 138 CONNECTIONS f e AUSTDAC PTY LTO 1 REAR VIEW OF I S INTERCOM TYPE ABMA3 Photograph 4 Intercom type ABMA3 rear view The above photograph shows the rear of the ABMA3 intercom with its battery removed to expose the battery charge current select jumper In the LO position the battery charge current is 11mA an
39. t The controller is responsible for interfacing with the conveyor control system issuing the pre start alarm controlling the connection to the surface pair and distributing power to the other system components such as the intercoms and tail end unit Photograph 1 The components of the PSACS1 system The intercoms with their sideways facing speakers are distributed along the conveyor to provide continuous audible pre start alarm coverage as well as voice communications coverage Crewmembers can instigate a conversation to other crew along the belt or contact the surface operator from any of the intercoms The tail end unit is located at the boot end of the conveyor and monitors the entire system for correct operation during a pre start alarm The tail end unit monitors the pre start alarm and send s back a message to confirm that the alarm was heard along the entire length of the conveyor The inter systems coupler can be placed in the centre of a long conveyor to allow the outbye intercoms to be powered from the controller and the inbye intercoms to be powered from a separate power supply at the boot end This allows conveyors up to 8000 metres long to be protected with pre start alarm facilities The DTMF keyboard can be co located with any intercom to allow direct dialling into a PABX or analogue PSTN telephone line The keyboard will allow direct half duplex telephone conversations between the conveyor and the surface PRE START ALARM
40. tem Signal Paths ceecccccccccsseseseceeeeeeeeeeeeeeeeesseseesseeeeeeeessseaeeeeeeeeeessaaeeeeeseeees 10 Figure 9 Pre start alarm successful interface timing GiAQGrAM cccceeeeceeeceeeeeeeeeeeeeeeeeeeeaeeeeeeeaeaees 13 Figure 10 Pre start alarm fail interface timing 13 TABLES Table 1 System Conductor names and FUNCTIONS cece ccceecceeeeeeeeeeeeeeeeeeseeeeeeeeeseaeeeeeeesseaeeeeeesaaeeeeeeas 8 Table 2 Pre start alarm tone Sets ccccccsssseecccceeeceecceeusecececeeasececeseaaeeeeseeueeeeessaaaeeeeesssaeeeeeesssagseeess 10 Table 3 Typical system Cable details ccccccccsseseccccceeseeeecceeeseeeeeceeeseeeeesseaueeeesseasecesessageeeessesanseees 11 Table 4 Pre start alarm controller type APSA2 termination 5 12 Table 5 Tail end unit type TEU100 termination Aetalls ccccccccseeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesaeeeeeeeas 23 Table 6 Configuration of tail end Unit type 444 44 55 4849 4 Table 7 Inter systems coupler type ISC2 termination details 555 555 25 Table 8 Inter systems couple
41. unted battery type 5 NH 1 N so that the intercom will have sufficient energy to sound a pre start alarm or broadcast a conversation The ABMA4 uses the same battery as the ABMA3 1 The rear of the ABMA4 intercom has a two position battery charge current selection switch In the LO position the battery charge current is 11mA and 22mA in the HI position Refer to the system drawing for the correct charge rate for your intercoms Generally the HI position is used in systems with short powered segments and fewer intercoms the LO position is used in long powered segments with more intercoms fl 00 Ex Yor 0AN PYWEY 1 J OLSNY AMBAS IS ONLY TO BE POWERED BY BATTERY TYPE 57NH71 N m 1 m rE C a 1 19089 1 Photograph 10 Intercom type ABMA4 rear view For more detail refer to the individual manual on the ABMA4 intercom The intercom ABMA4 with handset fitted functions in a similar manner to the normal ABMA4 except that all voice communications are conducted through a handset The communications is still half duplex and is still over a party line with no privacy within the intercom string The handset allows the intercom to be used in an office or area where loud paging style communications is not appropriate As an additional degree of flexibility the two side facing loud speakers can remain in circuit or can be disabled depending on the actual application The press to talk function is carried out by pressin

user manual

Contents

Download Pdf Manuals

Related Search

Related Contents