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Unicon - Universal Conveyor Signalling, Communication and Monitoring System

CENELEC certified
Expandible for different Applications
One or Two Signalling and Control Systems
Monitored Pre-start Alarm
Applicable to all Types of AFC, Development, Gate and Trunk Conveyors
Remote Control Telemetry Option to BS6556 Parts 2 & 3
Optional Analogue and Digital Transducer Monitoring
Underground to Surface Audio Communications Link
Up to 50 Intrinsically safe Loudspeaker Amplifiers
User Programmable with Key Pad Configuration

The Unicon system is a flexible low cost CENELEC certified dual pilot signalling and control system for controlling coal face, development and roadway conveyors in coal mines.

The system comprises a flameproof console containing power supplies and control relays with an intrinsically safe compartment which houses a microprocessor, the signalling circuitry and the telemetry circuitry. The design concept was to maximise the use of intrinsically safe circuitry to reduce both cost and weight whilst at the same time providing enhanced features and simplifying maintenance. In addition to the console, the system comprises up to 50 remote amplifiers, two pre-start warning generators and up to 63 signalling keys for each pilot circuit.

System Features

The Unicon system is extremely flexible and may be used as a universal conveyor control system in coal mines for all types of conveyor including armoured face conveyors. It has facilities to control up to two conveyors.

The system provides signalling, loudspeaker communications and monitored pre-start alarm for one or both controlled, conveyors. The system can provide optional transducer monitoring facilities for a further 16 line proved digital inputs and up to 12 analogue inputs. In addition to the two P130 or BZ1/PRI3 pilot outputs, the console has optional facilities for up to 4 intrinsically safe relay outputs. The console also has optional telemetry facilities complying with BS6556 Part 2 'Low S Digital Signals in Coal Mines'.

System Block Diagram

Signalling Systems

The Unicon console may be equip with one or two signalling systems each with numerical indication of lock-out position catering for up to 63 signalling keys. Each signalling key has visual indication of lockout by means of an LED indicator (or indicators) depending on the type of signalling key.

Loudspeaker Communications

The Unicon system is equipped with the Davis Derby DIS 5 Loudspeaker communication system.

The Unicon console is fitted with two 12Vdc power supplies (one of which is for the communication systems and the other to power the microprocessor circuitry) and an intrinsically safe loudspeaker amplifier which is fitted with a telephone handset and a rechargeable battery. Up to 50 remote DIS 5 intrinsically safe loudspeaker amplifiers can be connected to the console, which can be split into two sections to provide communication and pre-start warning along two conveyors if required. The audio system can be extended to the surface or to other compatible communication systems.

System Components

Unicon Console Type 26850

The Unicon Console is a rugged compact conveyor control unit which is certified flameproof and intrinsically safe to European Standards EN50 014, EN50 018 and EN50 020. The unit is extremely versatile and a number of different versions are available.

Construction

The unit comprises a steel enclosure the lower section of which is flameproof. The enclose has four compartments:

The main FLP compartment housing two plug-in 12VDC power supply chassis and a plug-in control chassis equipped with interposing relays for the two pilot circuits and the section switch trip circuit.
The FLP isolator compartment containing the mains isolator which is mechanically interlocked with the front door.
The main intrinsically safe compartment which houses a number of electronic plug-in modules and up to two signalling system printed circuit boards. The compartment has a hinged front door which carries the processor module in addition to other optional electronic modules, start stop and test switches and the display pcb containing the Liquid Crystal Display (LCD) and the Light Emitting Diodes (LEDs).
The intrinsically safe amplifier and terminal chamber containing the optional console amplifier and the intrinsically safe terminals for connection of the signalling and communication circuits and also the transducer inputs and telemetry connections.

Console Displays

The console is equipped with LCD and LED indicators which are visible through a window in the front door of the main intrinsically safe compartlnent. These indicators show the status of the Unicon system, including the signalling systems, the transducer inputs and the various diagnostic displays.

Programming and Configuration

The Unicon Console incorporates a powerful Programmable Logic Controller (PLC) function within its software, which is programmed using a computer program developed by Davis Derby Which runs on a personal computer. A standard conveyor control program has been developed for the Unicon Console, hwever this can easily be modified using the programming package.

The Unicon Console is provided with a 16 button keypad which allows online configuration of certain operating parameters such as various timers for pre-start warning times, analogue set points and the function of some transducers.

Cable Connections

The Unicon Console has facilities for fitting up to four FLP spigot type cable glands for the mains input and pilots circuits. The intrinsically safe compartment has facilities for up to four catch restrained plugs for connection of the signalling keys and loudspeaker amplifiers. In addition there are facilities for fitting 2 CM25 cable glands and 32 CM20 cable glands for the remaining Iitrinsically safe inputs and outputs.

Additional Features

The Unicon system is extremely flexible and the console can be fitted with a number of optional modules to enhance its capability which must generally be specified when ordering.

Signalling Systems

Both signalling systems provide lockout facilities over distances of up to 5km with up to 63 signalling keys connected to each system. When a signalling key is locked out, LOCKOUT is indicated by the LCD indicator on the Unicon Console and the number of the locked out signalling key is also displayed. If more than one key is locked out on the same system, the number of the signalling key nearest to the console is displayed. When this key has been reset the number of the next signalling key will then redisplayed. Each signalling key is fitted with a high intensity LED which glows when the signalling key is locked out. In addition an audible tone is broadcast for 3 seconds from the loudspeaker amplifiers. Various types of signalling key are available designed for coal face or roadway conveyor applications

signalling key type 26825

Signalling key type 26825 is intended for coal face applications and is ruggedly constructed from cast-iron and housed in a steel channel.

It is fitted with sealed micro-switches and has two 6 pole catch restrained plugs for connection of the incoming and outgoing cables. This signalling key has a large push and turn lock-out knob which when operated causes the controlled conveyor to stop. A high intensity LED on the front of the signalling key glows when the lock-out knob is operated.

The unit is fitted with an encapsulated electronic module which causes a number to be displayed on the Unicon Console when the signallinq key is locked out.

Signalling Key Type 26831

Signalling key type 26831 is designed for use on stage loaders and roadway conveyors. It is equipped with a rotary action lock-out knob and has double-ended pullwire facilities. Manufactured from lightweight alloy approved for use in coal mines, it is fitted with sealed microswitches and an electronic module which is encapsulated to prevent water ingress.

The pullwire mechanism is contained in a separate compartment and is mechanically linked to the microswitches which are arranged to mechanically latch in the off position when the signalling key is operated.

A pin within the signalling key can be removed to prevents the switches latching when the pullwire is operated if required thus giving automatic reset. However, the switches retain the latch facility when the rotary lockout knob is used to operate the signalling key.

A high intensity LED is mounted on each end of the signalling key these are illuminated when the signalling key is locked out. Signalling key type 26831 is available fitted with two 6 pole catch restrained plugs or with facilities for up to two 20mm cable glands.

Remote Oscillator Type 26827

This unit is installed at the remote end of the system, its enclosure houses an electronic oscillator circuit producing a signal which is detected by failsafe circuitry in the Unicon Console, which monitors the condition of the signalling key circuitry and causes the Unicon Console to give the appropriate display. For installations where a singled core cable is used for signals and communications, the electronic oscillator module is installed within the pre-start warning generator type 26822 or 26822/S.

The Termination Unit type 26827 is available fitted with one 6 pole catch restrained plug or with facilities for one 20mm cable gland. The Termination Unit measures 96mm x 135mm x 63mm (w x h x d) and weighs 1 .36kg (excluding the catch restrained plug).

Communication System

The DI5 5 loudspeaker system which is incorporated within the Unicon system provides loudspeaker communication and pre-start warning facilities over very long distances allowing up to 50 amplifier units to be connected to a Unicon console via a 4-core cable. For applications using a single cable for signals and communications, a 6 core cable is used.

Each amplifier is equipped with a trickle charged nickel cadmium battery giving standby facilities for up to 5000 hours in the event of power failure. The system can be used to broadcast speech, pre-start warning for conveyors or other items of plant or other warning tones.

Console Amplifier Type 26823

The plug-in console amplifier which is fitted to the Unicon Console is equipped with a durable telephone handset, a plastic cone loudspeaker, a call tone pcb and an audio coupling transformer which allows the unit to be connected to other audio systems. The unit incorporates a plug-in replaceable nickel cadmium rechargeable battery which provides stand-by power when fully charged for up to 5000 hours in the event of a mains failure.

The front panel of the amplifier unit is equipped with a light emitting diode battery state indicator and 3 push-button switches:

LOCAL Which allows communication to the remote amplifier units

SURFACE Which allows private speech to the surface control room

CALL Which generates a call tone of skill used to alert the operator in the surface control room and also to activate the internal battery test facility.

The circuitry of the amplifier and the battery are each separately encapsulated and mounted on the plug-in front panel. For ease of maintenance either item can be individually replaced once the front panel has been removed.

Amplifier Type 26821

The amplifier unit comprises a die cast front panel housed in a rugged sheet metal enclosure designed to enhance the acoustic performance of the twin sealed Mylar done loudspeakers. Each end of the amplifier enclosure has an aperture to direct sound along the roadway or coal face.

The amplifier unit is equipped with an encapsulated amplifier module and a separate plug-in encapsulated nickel cadmium rechargeable battery which provides stand-by power when fully charged for up to 5000 hours in the event of a mains failure

The amplifier unit provides an output in excess of 95 dB and has been vibration tested at 5g. In addition to two loudspeakers, the unit is equipped with a microphone and a light emitting diode battery state indicator. A three position lever switch - NORMAL, CALL and SPEECH is also provided. Versions of the amplifier unit are available fitted with either two 4 pole catch restrained plugs or facilities for two 20mm cable glands.

Combined Key Amplifier Type 26824

The Combined Key Amplifier Unit type 26824 is similar to Amplifier Unit Type 26821, but it is fitted with a rotary lockout knob and associated switches. It has a small encapsulated electronic module that displays a number on the Unicon Console showing its position on the system when the lockout knob is operated.

There are two high intensity LED'S fitted, one on each end of the Key Amplifier Unit, which glow when the lockout knob is operated, an audio tone is also broadcast from the communication system. The Key Amplifier Unit is supplied fitted with two 6 pole catch restrained connectors. Overall dimensions are similar to Amplifier Unit type 26821 and the weight is 8.7kg.

Pre-Start Warning Generator Type 26822/S

The construction of the Pre-start Warning Generator type 26822/5 is similar to the remote amplifier unit type 26821 . The unit is equipped with separate encapsulated amplifier and battery units, two sealed Mylar cone loudspeakers, pre-start warning tone generator circuitry, a meter mounted on the front panel and a 3 position lever switch.

The loudspeakers broadcast pre-start warning tone when the unit has been initiated but do not operate for speech. The three position switch enables the meter to read line voltage, pre-start warning initiate voltage and battery voltage.- The pre-start warning generator unit is equipped with a relay which energizes when pre-start warning is sounding. A relay contact is provided which can be used to interrupt the outbye audio line or to provide a set of voltage free contacts for other switching functions within the audio system. A plug-in link is provided to determine the function of the relay contact.

Versions of the pre-start warning generator are available with either plugs and sockets or cable gland facilities. A further version of the pre-start warning generator is fitted with a termination unit for the signalling system for applications where a single 6 core cable is used for signals and communications. This pre-start warning generator is fitted with one 6 pole catch restrained connector for the incoming cable and one 4 pole catch restrained connector for the outgoing audio connections. Alternatively it is available fitted with two 4 pole catch restrained connectors or with facilities for two 20mm cable glands. Overall dimensions are similar to Amplifier type 26821, the weight is 9kg.

Operation of the Communication System

When the console amplifier handset is lifted and the LOCAL button operated, speech is broadcast from each remote amplifier connected to the system. When the PRESS to SPEAK switch is operated on a remote amplifier, speech is broadcast from all amplifiers connected to the system including the console amplifier loudspeaker or telephone handset earpiece. An operator using the console amplifier can listen to the loudspeaker or use the telephone handset by using the LOCAL button.

The state of charge of batteries fitted to each unit can be checked at anytime by pressing the CALL switch, or in the case of the pre-start warning generator, the TEST switch. The LED glows to indicate that the battery is charged.

The extension audio connection of the Unicon console can be extended to the control room to a Davis Derby Surface Communication Switchboard. To use this facility, the CALL switch on an amplifier must be pressed for 3 to 4 seconds resulting in a 5kHz call tone being transmitted to the surface, where it is detected to provide an indication which is used to alert the operator. The operator on the surface can then converse with persons underground, speech will be broadcast from every amplifier connected to the system. Alternatively, a private conversation is possible using the DI5 5 Console telephone handset and pressing the SURFACE button on the console amplifier.

Extension Audio Barriers

The communication system can be extended to the surface, via a Davis Derby intrinsically safe barrier unit type 25235. Further details are available on request.