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[email protected] www.pbegrp.com PH +61 7 3890 8113 FAX +61 7 3890 7489 PBE Australia 2/1631 Wynnum Rd Tingalpa Queensland 4173 AUSTRALIA Leaky Feeder System Manual VHF and UHF Leaky Feeder System Manual Copyright © PBE Australia Pty Ltd (ABN 11 156 073 871), All rights reserved. No section or element of this document may be removed from this document, reproduced, electronically stored or transmitted in any form without the written permission of PBE Australia. The information contained in this document produced by PBE, is solely for the use of the client(s) for the purpose for which it has been prepared and PBE undertakes no duty to, nor accepts any responsibility to, any third party who may rely upon this information contained in this document. 11/07/12 Date D Rev no MAN-41-00001 Document number SL Prepared JF Approved by PBE Leaky Feeder System Manual Table of Contents 1. INTRODUCTION ........................................................................................................................................ 4 1.1 1.2 1.3 WARNINGS AND WARRANTY.................................................................................................................. 4 COMPLIANCE .......................................................................................................................................... 5 FREQUENCY ALLOCATION .............................................................................................................................5 2. GLOSSARY .................................................................................................................................................. 6 3. SYSTEM OVERVIEW ................................................................................................................................ 8 3.1 COMMUNICATIONS RACK ..................................................................................................................... 10 3.2 HEAD END UNIT ................................................................................................................................... 10 3.2.1. Head End Combiner (VHF: 02-00144, UHF: 03-00145, UHF: 03-00146) ............................... 10 3.3 LEAKY FEEDER POWER SUPPLY ........................................................................................................... 10 3.4 BASE RADIO EQUIPMENT...................................................................................................................... 11 3.4.1. Voice Channels ........................................................................................................................... 11 3.4.2. Data Channels ............................................................................................................................ 11 3.4.3. Telephone Interconnect Unit....................................................................................................... 11 3.4.4. Voice Message Alerting .............................................................................................................. 11 3.5 ABOVE GROUND ANTENNA SYSTEM .................................................................................................... 12 3.6 AUDIO BRIDGE (02-00138)................................................................................................................... 12 3.7 SURGE ARRESTER (24-00001) .............................................................................................................. 12 3.8 REPEATER (VHF: 05-00074, UHF: 05-00086) ..................................................................................... 13 3.9 ISOLATOR (VHF: 24-00007, UHF: 24-00017)...................................................................................... 13 3.10 MODEL 1925 POWER SUPPLY (FOR IS SYSTEMS ONLY) ........................................................................ 13 3.11 MODEL 1953 AND 1955 BATTERY BACKUP UNIT (FOR IS SYSTEMS ONLY) .......................................... 13 3.12 UNDERGROUND COMPONENTS................................................................................................... 15 4. LAYOUT ..................................................................................................................................................... 16 4.1 COMPONENT LAYOUT .......................................................................................................................... 16 4.1.1. Head End Combiner ................................................................................................................... 16 4.1.2. Amplifiers .................................................................................................................................... 16 4.1.3. Single Branch Units .................................................................................................................... 16 4.1.4. Dual Branch Units ...................................................................................................................... 17 4.1.5. Power Couplers .......................................................................................................................... 17 4.1.6. Joiner Boxes................................................................................................................................ 18 4.1.7. Termination Boxes ...................................................................................................................... 18 4.2 LAYOUT INSTRUCTIONS ....................................................................................................................... 18 4.3 POWERING THE SYSTEM........................................................................................................................ 19 4.4 UNPLANNED TOPOLOGY CHANGES ...................................................................................................... 19 4.5 EXAMPLE LAYOUT DIAGRAM .......................................................................................................................20 5. INSTALLATION ....................................................................................................................................... 21 5.1 INSTALLATION GUIDELINES .................................................................................................................. 21 5.2 COMMUNICATIONS RACK INSTALLATION ...................................................................................................21 5.2.1. Head End Combiner Mounting ................................................................................................... 21 5.2.2. Head End Combiner Connections............................................................................................... 21 5.3 LEAKY FEEDER CABLE INSTALLATION .......................................................................................................22 5.3.1. Catenary recommendations ........................................................................................................ 23 5.4 DISTRIBUTION EQUIPMENT (COMPONENTS) .......................................................................................... 24 5.4.1. General Component Connection ................................................................................................. 24 5.4.2. Head End Combiner Connection or Isolation Barrier Connection (for IS systems only) ........... 27 6. TUNING (FOR GEN-3 AMPLIFIERS) ................................................................................................... 29 6.1.1. 6.1.2. 7. Order of Tuning .......................................................................................................................... 29 Configuration of Amplifier Attenuator Settings .......................................................................... 29 MAINTENANCE ....................................................................................................................................... 32 7.1 MINECOM WEEKLY MAINTENANCE CHECKLIST ........................................................................................32 MAN-41-00001-D Minecom Leaky Feeder System Manual Page 2 of 42 PBE Leaky Feeder System Manual 7.2 7.3 7.4 7.5 7.6 8. FAULT FINDING ...................................................................................................................................... 34 8.1 8.2 8.3 8.4 9. OPERATIONAL TRAINING...................................................................................................................... 32 MAINTENANCE TRAINING .................................................................................................................... 33 SYSTEM DRAWING ............................................................................................................................... 33 DOCUMENTATION ................................................................................................................................ 33 TEST EQUIPMENT REQUIRED ................................................................................................................ 33 IDENTIFY THE LOCATION OF THE FAULT .....................................................................................................34 HEAD END COMMUNICATIONS RACK FAULT..............................................................................................34 RADIO FAULT................................................................................................................................................34 SYSTEM FAULT .............................................................................................................................................34 PREVENTATIVE MAINTENANCE ....................................................................................................... 36 9.1 PROGRAM MAINTENANCE .................................................................................................................... 36 9.1.1. Communications Rack ................................................................................................................ 36 9.1.2. Down Line System ....................................................................................................................... 36 9.1.3. Portable Radios .......................................................................................................................... 36 9.1.4. Vehicle and Desktop Radios ....................................................................................................... 36 9.2 TEST EQUIPMENT REQUIRED ................................................................................................................ 37 10. AFTER SALES SERVICE ........................................................................................................................ 38 11. INDEX ......................................................................................................................................................... 39 12. APPENDICES ............................................................................................................................................ 40 12.1 APPENDIX A - MINE-WIDE SYSTEM TUNING (AMPLIFIER ATTENUATOR SETTINGS) .................................40 12.1.1. Order of Tuning (for Gen-2 Amplifiers)...................................................................................... 40 12.1.2. Configuration of Amplifier Attenuator Settings (for Gen-2 Amplifiers)...................................... 40 12.1.3. Unplanned Topology Changes (for Gen-2 Amplifiers) ............................................................... 41 12.2 APPENDIX B - MINECOM SYSTEM DESIGN GUIDE DWG-41-00005-01 ................................................ 42 MAN-41-00001-D Minecom Leaky Feeder System Manual Page 3 of 42 PBE Leaky Feeder System Manual 1. INTRODUCTION The PBE Leaky Feeder System Manual contains procedures and information for authorized personnel to work with a PBE VHF or UHF Leaky Feeder underground communications system and all their components. PBE part numbers are listed in parentheses. This document provides maintenance personnel with adequate information on the PBE Leaky Feeder Systems and equipment to properly install, operate, and maintain the system, using minimal test equipment. This document relates to non-intrinsically safe systems only. PBE produces a separate intrinsically safe communications system with appropriate documentation, and products. 1.1 Warnings and Warranty Before using the PBE Leaky Feeder System ensure you have read this manual and any accompanying operating manuals or datasheets for all components in the system. To comply with PBE guidelines you must: Install the system in accordance with the PBE System Design Guide (DWG-41-00005-01 - Appendix B). Avoid intermingling the PBE Leaky Feeder cable with any other electric cable, where possible. Maintain 2.5 m spacing between leaky feeder cable and blasting circuits. Not modify or replace any PBE approved component with any other non- PBE component. To comply with MSHA guidelines you must also: install the system in accordance with the PBE System Design Guide (S19… Appendix A). not intermingle the battery backup supply cable with Leaky Feeder cable or any other electric cable. de-energize the Model 1925 power supplies located on the surface when underground mine power is de-energized. charge the battery of the Model 1955 or 1953 backup battery supply on the surface or in an area where permissible equipment is not required (fresh air). locate the Leaky Feeder cable and all series connected components of the system greater than eight feet from blasting circuits. MAN-41-00001-D PBE Leaky Feeder System Manual Page 4 of 42 PBE Leaky Feeder System Manual 1.2 Compliance The PBE 01-20001, 01-20002 and S01-01 (previously 0200156, 02-00149, 03-00041) amplifiers comply with Part 15 of the FCC Rules. Operation is subject to the following two conditions (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. MSHA Approval 23-A090003-0 for VHF systems MSHA Approval 23-A090001-0 for UHF systems Commonwealth of Pennsylvania Approval BFE23-10 for 01-20001, 01-20002 and GEN-2 UHF Leaky Feeder system Commonwealth of Pennsylvania Approval BOTE for GEN-2 VHF Leaky Feeder system European Conformity approval for S01-01 (previously 02-00156, 0200149, 03-00041) C-Tick approval for S01-01 (previously 02-00156, 02-00149, 0300041) Canadian Standards Association (CSA) approval for S01-01 (previously 02-00156, 02-00149, 03-00041) 1.3 Frequency allocation End-users are responsible for organizing all frequency allocation requirements. PBE assumes end-users have already obtained current and appropriate licenses from their local authorities. Please contact PBE or your local distributor if you have any questions regarding frequencies. MAN-41-00001-D PBE Leaky Feeder System Manual Page 5 of 42 PBE Leaky Feeder System Manual 2. GLOSSARY AGC: Automatic Gain Control Attenuation: gradual loss in intensity of a signal through a medium Audio Bridge: a configurable switching matrix that selectively merges audio between devices or channels AWG: American Wire Gauge Audio Bridge: a configurable switching matrix that selectively merges audio between devices or channels Bandwidth: range of radio frequencies Base Station: non portable radio that can transmit with a high duty cycle (located in the Communications Rack) BDA: Bidirectional Line Amplifier BNC: type of RF coaxial cable connector dB: decibel Downlink: the frequency that a duplex radio channel receives on (transmitted by repeater) Duplex: (a radio channel) when transmitting is on one frequency (uplink), but receives on a different frequency (downlink). Used in conjunction with a repeater that receives the uplink audio in real time and re-broadcasts it on a separate downlink frequency. Voice Message Alerting: a device which plays a pre-recorded audio message onto a desired radio channel in response to an external input E & M ports: Ear and Mouth port – standard interface (found on repeaters, audio bridges, telephone interconnects, page phone couplers, enunciators, VoIP bridges and other equipment) for receiving and transmitting audio Gen-1: First generation PBE amplifier (with attenuator settings common to both uplink and downlink) Gen-2: Latest generation PBE amplifier (with local diagnostics, and separate uplink and downlink attenuator settings) GEN-3: Third generation PBE amplifier (with remote diagnostics, and separate uplink and downlink attenuator settings) Inby: (American mining term) away from the shaft or mine entrance and therefore toward the working face Insertion Loss: the ratio of energy that enters a device compared to the energy that exits a device IP55: (Enclosure rating) protects against limited dust ingress and low pressure water jets from any direction. IS: Intrinsic Safety (Safe operation of electronic equipment in explosive atmospheres. IS equipment won't ignite flammable methane gas or coal dust.) MSHA: Mine Safety and Health Administration, an agency of the United States Department of Labor which certifies IS accreditation. Non-IS: Non Intrinsic Safety (not intrinsically safe e.g. Hard Rock) MAN-41-00001-D PBE Leaky Feeder System Manual Page 6 of 42 PBE Leaky Feeder System Manual N-T ype: A coaxial cable connector type Outby: (American mining term) towards the shaft or mine entrance and therefore away from the working face PABX: Private Automatic Branch Exchange Page Phone Coupler: a device which links audio between an existing wired intercom system and a given radio channel PLC: Programmable Logic Controller (a computer used to control electronic processes) Polyswitch: an electronic component that protects against short circuits PTT: Push To Talk Repeater: a device which receives the uplink audio in real time and re-broadcasts it on a separate downlink frequency. Used in conjunction with duplex radio channels. RF: Radio Frequency Rx (RX): Receive Saddle: PBE Leaky Feeder connector Trunking: a concept by which a communications system can provide network access to many clients by sharing a pool of lines or frequencies instead of providing them individually Telephone interconnect: a device which connects a given telephone line to a given radio channel. Depending on configuration can receive and make calls remotely. Tx (TX): Transmit Uplink: the frequency that duplex radio channel transmits on (received by the repeater) VoIP bridge: a device which (via a TCP/IP computer network) connects audio of one repeater to another remote repeater(s). A VoIP bridge creates a shared channel allowing conversations between numerous facilities over very large distances. VSWR: Voltage Standing Wave Ratio (used to measure the quality of the match of transmission line between the antenna and the radio). MAN-41-00001-D PBE Leaky Feeder System Manual Page 7 of 42 PBE Leaky Feeder System Manual 3. SYSTEM OVERVIEW The PBE VHF and UHF Leaky Feeder Systems provide a comprehensive and reliable communications system in underground mining and tunnel environments. The PBE Leaky Feeder Systems acts as a distributed antenna system which consists of the following components: Head End Unit Communications Rack Power Supply Base Station Radio Receivers and Transmitters up to 32 channels Above ground antenna system, to provide surface coverage Leaky Feeder Cable Bidirectional Amplifiers Branch Units (Single and Dual) Power Couplers Termination Boxes Joiner Boxes Isolation Barrier In-Line Barriers (IS systems only) Field radio equipment. Note: UHF amplifiers and repeaters are not compatible within a VHF system and vice versa. MAN-41-00001-D PBE Leaky Feeder System Manual Page 8 of 42 PBE Leaky Feeder System Manual Figure 1 shows an overview of the sequence of some of the components used in a typical PBE Leaky Feeder System. Each PBE Leaky Feeder System will be tailored to specific site requirements to provide the best radio coverage. The spacing, design layout and components used will differ from this illustration. For a full System Design Guide see Appendix B. Figure 1: Overview of a v UHF Leaky Feeder System (IS) MAN-41-00001-D PBE Leaky Feeder System Manual Page 9 of 42 PBE Leaky Feeder System Manual 3.1 Communications Rack The Communications Rack is the hub of the Leaky Feeder System and contains: Head End Unit interfacing Leaky Feeder cable and base radios Leaky Feeder Power Supply and Battery Backup Base Radio Equipment Connections to surface coverage antenna system Audio Bridge interfacing and controlling the audio channels Surge arresters Repeaters Isolators. The above components, along with a circuit breaker panel, are all housed in a standard or high IP rated rack. 3.2 Head End Unit The Head End Combiner is the core of each PBE Leaky Feeder System. Its purpose is to combine the RF outputs and inputs of the receivers. The Head End Combiner provides the necessary interface between the base radios and the Leaky Feeder cable. See DAT-4100002-01 Head End Combiner Datasheet for details. 3.2.1. Head End Combiner (VHF: 02-00144, UHF: 03-00145, UHF: 03-00146) Figure 2: Head End Combiner (02-00144) 3.3 Leaky Feeder Power Supply The Leaky Feeder Power Supply is a critical component of the system, providing a regulated 12 volts DC to power all electronic devices in the system. The HEC works at 12, 24 and 48 V. The power supply is capable of handling large load fluctuations, without MAN-41-00001-D Minecom Leaky Feeder System Manual Page 10 of 42 PBE Leaky Feeder System Manual failing. This Power Supply consists of an input AC voltage ranging from 105 - 125 VAC to a DC voltage rated at 13.8 VDC with a current rating appropriate to the current drain of all equipment included in the Communications Rack (Head End, base station radios, etc). The power supply is equipped with a battery backup. Battery(s) backup are supplied with the Leaky Feeder power supply to provide continuous operation of the communications system under power failure. The power supply charges the battery at 13.8 VDC when external power is available and switches automatically during a power failure. Figure 3 : Communications Rack Power Supply (example only) 3.4 Base Radio Equipment The Leaky Feeder communication systems require dual port repeaters individually interfaced into the Head End Unit. The repeaters can be configured for either conventional use or trunking use by the addition of a T1810 Trunking Interface unit or similar. The PBE Head End Unit can be expanded to accommodate from 1 to 32 operational channels, which can be used for Voice and/or Data operation. Base station radio repeaters are colocated with the PBE Head End Unit in equipment housing, which can be either a 19 inch rack cabinet, or a standard lock up cabinet. Operating frequencies for the UHF base radio equipment are 435 - 490 MHz. Operating frequencies for the VHF base radio equipment are 151 – 157.5 MHz base transmit, 170 – 174.5 MHz base receive. In most situations radio channels would be configured in a talk-through-repeater mode, whereby all information received at the Head End would be automatically re-transmitted on a different frequency. The radio channels can be configured as: 3.4.1. Voice Channels Repeater (Talk-Through-Repeater) Providing underground-to-underground, underground-to-surface communications (portableto-portable, vehicle-to-vehicle, vehicle-to-portable). 3.4.2. Data Channels Repeater Providing underground-to-underground, or underground-to-surface communications. 3.4.3. Telephone Interconnect Unit This unit provides the interface between the audio connections of a voice radio transmitter/receiver and a telephone extension of the site’s PABX system, or directly into the public telephone network. 3.4.4. Voice Message Alerting This unit provides the interface between the audio connections of a voice radio transmitter/receiver and a PLC or personal computer to broadcast pre-recorded voice messages (or alarm) over a voice channel when activated. MAN-41-00001-D PBE Leaky Feeder System Manual Page 11 of 42 PBE Leaky Feeder System Manual 3.5 Above Ground Antenna System Surface coverage is dependent on a number of parameters, such as the surrounding terrain, the height of antenna above ground, the gain of the antenna, the type and size of coaxial cable used, the power output of the transmitter used (2/5/25/50 watts), etc. The Leaky Feeder System can provide above ground communications by splitting the inputs and outputs of the base radio receivers and transmitters, and coupling them to two or more conventional antennas. Note: All licensing, regulations, and local frequency regulators must be consulted before working with above ground antenna systems. PBE individually review each customer’s requirements and recommends the most appropriate antenna configuration. Example of the equipment required for a Conventional Antenna System: One antenna - one for transmitting and one for receiving (due to the large split between TX and RX frequencies). Low loss coaxial cables from the Communications Rack up to the antenna. Transmitter power divider (divides the transmitter output power 24/1 watt). 24 watts up the antenna to the surface, 1 watt into the Head End Unit. Transmitter combiner (combines the output power of two or more transmitters into one antenna). Receiver splitter (combines two or more receivers into one antenna). 3.6 Audio Bridge (02-00138) The Audio Bridge is used for interfacing and control of audio channels. The primary function of the Audio Bridge is the combining and linking of repeaters, links and other audio sources at remote sites. The audio wires from each Transmitter and Receiver are wired into the Audio Bridge. The Audio Bridge is programmed to interlink the audio feeds of two or more of the voice repeaters when activated by a remote wireless command or manually operated at the Communications Rack. This Audio Bridge has four or six independent 4 Wire plus E & M ports. Each of the ports is provided with input level adjustment and output level adjustment. The E & M lines are fully configurable for the various combinations of electrical protocol. The selection of these electrical protocols is accessed via removal of the panel. An LED level meter and individual LEDs for each Mute and PTT input or output provides a visual interface on the front panel. 3.7 Surge Arrester (24-00001) Each Leaky Feeder cable should have a Surge Arrester installed immediately before the Head End Unit to protect the unit from power surges. MAN-41-00001-D PBE Leaky Feeder System Manual Page 12 of 42 PBE Leaky Feeder System Manual 3.8 Repeater (VHF: 05-00074, UHF: 05-00086) The Repeater receives audio from one channel in the uplink band and rebroadcasts it simultaneously on one channel in the downlink band. Duplex radios are programmed to receive on the downlink and automatically retune to broadcast on the uplink. Refer to the Tait 7100 Repeater manual for more information. 3.9 Isolator (VHF: 24-00007, UHF: 24-00017) The Isolator (found with each Repeater) permits the transmission of an RF signal in one direction and attenuates a signal flowing in the opposite direction. 3.10 Model 1925 Power Supply (for IS Systems only) Each 1925 (Power Supply) has two independent 24 V, 1.25 A outputs. Each of these may be used to power two amplifiers and 1955 battery backup units. This allows a total of four amplifiers to be powered from a single 120 V single phase source. MSHA approval requires the two output cables to maintain a 2” separation once it leaves the power supply. AC power supplying all 1925 DC power supplies must be de- energized in a fan-down situation. This includes any power supplies on the surface supplying underground components. 3.11 • • • • • Figure 4: Model 1925 Model 1953 and 1955 Battery Backup Unit (for IS Systems only) Intrinsically safe when AC power is de-energized Eliminates the need for expensive XP enclosures Lightweight Utilizes a durable Sure-Seal Interconnect for connection to the line amplifiers designed for harsh environments Allows amplifiers to continue operation when there is a break in the Leaky Feeder cable MAN-41-00001-D PBE Leaky Feeder System Manual Page 13 of 42 PBE Leaky Feeder System Manual The PBE intrinsically safe 1953 and 1955 battery backup devices provide power for all leaky feeder line amplifiers. They also allow amplifiers to continue operation during system maintenance (when depowering individual section) or when there is a cable fault. For more information please refer to the PBE manual. Figure 5: Model 1955 MAN-41-00001-D PBE Leaky Feeder System Manual Page 14 of 42 PBE Leaky Feeder System Manual 3.12 UNDERGROUND COMPONENTS Leaky Feeder Cable (20-00007) (20-00008) (20-00041) Leaky Feeder Cable is used to distribute power and RF signals throughout an underground tunnel system. Datasheet: DAT-41-00007-02 Bidirectional Line Amplifier (02-00149) (02-00156) (03-00041) Bidirectional Line Amplifiers are used to restore the radio signals as they pass along the leaky feeder system. Datasheet: DAT-41-00003-01 Single Branch Unit (02-00030) Datasheet: DAT-02-00030-01 Dual Branch Unit (02-00029) Datasheet: DAT-02-00029-01 Power Coupler Module (02-00069) Single Branch Units are used to split an additional path, tunnel or level from the main Leaky Feeder cable. Dual Branch Units are used to split two additional paths, tunnels or levels from the main Leaky Feeder cable. Power Coupler Modules are used to inject power through Leaky Feeder cable to power amplifiers. Datasheet: DAT-02-00069-01 Joiner Box (02-00039) Joins two ends of Leaky Feeder cable together to prevent losses and damage to the cable. Datasheet: DAT-02-00039-01 Termination Box (02-00048) Datasheet: DAT-02-00048-01 MAN-41-00001-D Termination Boxes are used to seal the end of the cable and protects against harsh mine environments. PBE Leaky Feeder System Manual Page 15 of 42 PBE Leaky Feeder System Manual 4. LAYOUT The PBE Leaky Feeder System acts as a Distributed Antenna System where the Leaky Feeder Cable, together with a series of line components, can be joined together to provide flexible mine-wide coverage. PBE products have been designed to be run down the left hand side of a tunnel but can be installed either way. The PBE Leaky Feeder System has the ability to scale and grow with a changing environment throughout any mine or tunnel. The system has been specifically designed with the minimum of DC injection points. For full details on layout please refer to DWG-41-00005-01 (Appendix B). 4.1 Component Layout 4.1.1. Head End Combiner The Head End Combiner (HEC) is typically installed in a Communications Rack with other equipment such as repeaters. The HEC is usually located on the surface or at some central point within the mine. The HEC must be housed in a weather tight enclosure of building exceeding IP55 rating. The first amplifier should be placed directly after the Communications Rack. 4.1.2. Amplifiers The arrow pointing to the base on each amplifier must point back to the Communications Rack. The spacing of the amplifiers will vary depending on the number and type of devices installed between them. Amplifiers should be installed the typical distance shown below. Frequency UHF (& VHF) VHF Minimum 270 m 360 m Maximum 385 m 550 m 4.1.3. Single Branch Units The arrow pointing to the base on each Branch Unit must point back to the Communications Rack. The cable length between amplifiers must be reduced by: Frequency UHF VHF Typical 350 m 500 m Reduction 40 m 90 m It is possible to install more than one Branch Unit between amplifiers as long as distances are compensated for. Two Branch Units = 2 X 90 m cable length reductions or 500 – 180 = 320 m cable distance between amplifiers in a VHF system. MAN-41-00001-D PBE Leaky Feeder System Manual Page 16 of 42 PBE Leaky Feeder System Manual AMP 4.1.4. Dual Branch Units The arrow pointing to the base on the Branch Unit must point back to the Communications Rack. The cable length must be reduced by: Frequency UHF VHF Tunnel 95 m 90 m It is possible to install more than one Branch Unit between amplifiers as long as distances are compensated for. Tunnel Communications Rack AMP Branch 1 & 2 160 m 180 m AMP 4.1.5. Power Couplers The arrow pointing to the base on the Power Coupler must point back to the Communications Rack. Each leg of a Power Coupler (PC) can support up to the following number of amplifiers: System Voltage 12 24 48 VHF Amplifiers (500 m spacing) 3 (5) 6 (10) 13* (19) UHF (& VHF) Amplifiers (350 m spacing) 4 (7) 7 (13) 15* (23) *The figures quoted above are the theoretical maximum and may be reduced by system issues. BDA-4 figures are in parenthesis. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 17 of 42 PBE Leaky Feeder System Manual PCs should be DC isolated from each other. 4.1.6. Joiner Boxes Up to four Joiner Boxes can be used between amplifiers. Tunnel Tunnel Communications Rack Tunnel 4.1.7. Termination Boxes Termination Boxes must be used at the end of a cable run. Communications Rack Communications Rack 4.2 Layout Instructions A Leaky Feeder System should be designed prior to installation to provide the most effective communications. Your local dealer or PBE representative can help you with this process; however the basic ideas are presented below. 1. Create a map where communications are required. Ensure a minimum separation distance of 20 metres from different tunnel legs is maintained during cable layout at all times to ensure adequate system performance. 2. On the map add inline devices starting at the Communications Rack and work your way down the communications path. The first amplifier should be placed at the Communications Rack. Add amplifiers and branch units as required. Remember to follow the rules above for shortening cable lengths around branch units. 3. Add power couplers MAN-41-00001-D Minecom Leaky Feeder System Manual Page 18 of 42 PBE Leaky Feeder System Manual 4.3 Powering the system The system can be powered in two ways, from the Head End Combiner and/or from a Power Coupler. Large systems will need to use several Power Couplers. Each Power Coupler can supply a certain number of amplifiers, stated above. Once the system layout has been completed go back and insert Power Couplers as required, making sure the maximum number of BDA per leg isn’t exceeded. For best performance the Power Couplers should not have a DC connection between them. To stop this, internal jumpers should be removed from certain points in the system. The last amplifier to be powered from a Power Coupler should have its jumper removed. BU1, BU2 also have jumpers to block DC. 4.4 Unplanned Topology Changes While strongly discouraged, a limited number of Branch Units may be inserted into an existing properly balanced system. If you believe an unused drive may become viable in the future it is best to add a Branch Unit inline and adjust the system topology to match at initial design time. o Insert 3 meters (10 feet) of cable and a Termination Box. o Think about how you would like to power any amplifiers required from existing or planned infrastructure. That way correct system balance is always maintained. If possible use a Single Branch Unit and make further branches after an amplifier. Do not run additional amplifiers from the existing system, unless there is excess power from PC available. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 19 of 42 PBE Leaky Feeder System Manual 4.5 Example layout diagram MAN-41-00001-D Minecom Leaky Feeder System Manual Page 20 of 42 PBE Leaky Feeder System Manual 5. INSTALLATION 5.1 Installation Guidelines Connecting the leaky feeder cable to components and peripherals is simple, ensuring easy assembly underground, as well as ongoing maintenance and system scalability, without the need for specialized tools or skills. It is essential to refer to the System Design Guide (DWG-41-00005-01 - Appendix B) when modifying system topology and for device spacing. Care should be taken when installing a leaky feeder cable in a mine and strict rules must be followed as to who is authorized to install or make modifications. Note: UHF amplifiers and repeaters are not compatible within a VHF system and vice versa. 5.2 Communications Rack Installation The Communications Rack can be sited either above or below ground in a non-IS environment. 5.2.1. Head End Combiner Mounting The Head End Combiner and its ancillary equipment must be protected from the environment by installing them in an IP rated rack enclosure or in a standard rack in a clean air-conditioned room. The Head End Combiner should be installed in the top of the enclosure. The Head End Combiner is 3RU high and fits into any standard 19 inch rack. See section 5.3 for cable connection details. 5.2.2. Head End Combiner Connections To minimize loss from the Head End Combiner only use RG400 coaxial cable or better. Use high quality BNC connectors to reduce losses and keep the coaxial cables as short as possible. See section 5.3 for cable connection details. Arterial Connections The Leaky Feeder cables are connected to the Head End Combiner using four N-type sockets. The Leaky Feeder cable must be connected with a ½ inch N-type coaxial plug (10D-FB or 9005 type). DC Power Connection DC Power is required for the Head End Combiner to function. It can be connected via the rear panel using binding post type connectors (banana plugs) to the correct 12/24 or 48 Volts DC power source. The power source must be suitably rated to handle the current of the arterial ports. The Head End Combiner is protected by a M205 size 12.5 Amp slow blow fuse. The fuse can be removed with a quarter turn using a flat head screwdriver. If the POWER LED above the port on the rear panel is on, DC is present. It is recommended that DC be switched off to the arterial while the Leaky Feeder cable is being connected. Unused arterials should be protected with dust covers. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 21 of 42 PBE Leaky Feeder System Manual RF connections The Head End Combiner has eight BNC ports for transmitting (BASE TX) on Leaky Feeder and eight BNC ports for receiving (BASE RX). Unused BNC ports must always be terminated with 50 ohm terminators. LOOP The default configuration is to have the loop IN and OUT ports connected to each other as shown below. The loop ports can be used to connect Head End Combiners together to provide more channels, where OUT is the combined BASE TX and BASE RX signal and IN connects to the arterial ports. Figure 6: Head End Combiner (02-00144) – rear view 5.3 Leaky Feeder Cable Installation Leaky feeder cable radiates 360 degrees from the cable and must be installed using the following guidelines: Where the leaky feeder cable cannot be supported at least every 3 meters by preexisting fixings, PBE recommend a catenary cable be installed to support it. Leaky feeder cable shall be installed with a separation of at least 300 mm from high voltage (>1100 Volts) cables. VHF leaky feeder cable requires no separation from low voltage cable (<1100 Volts), where the cable is screened or steel wire armored, and is earthed. UHF leaky feeder cable requires at least 100 mm clearance from low voltage cable (<1100 Volts), where the cable is screened or steel wire armored, and is earthed. For best coverage the leaky feeder cable shall be installed at least 4 meters above the backfilled drive floor. Where multiple cables are located on the same cable support system or catenary, the leaky feeder cable must be located on the outside of the bundle so as to be seen with the naked eye. UHF leaky feeder cable requires at least 100 mm clearance from any conductive or grounded object. When it is required to run leaky feeder cable in a cable tray, ensure leaky feeder is located on the outside (underside) of the cable tray, within clear view. UHF leaky feeder cable requires at least 100 mm clearance from any conductive or grounded object. Minimum bending radius of leaky feeder cable is 100 mm. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 22 of 42 PBE Leaky Feeder System Manual The leaky feeder cable must be pulled off the drum using pull ropes attached every 30 m. Alternatively the cable drum may be towed on a suitable trailer and manually pulled off the drum directly to the final support structure or catenary. Where a leaky feeder cable enters an inline device, a coil of cable no less than one meter shall be made such that moisture is not allowed to run down the cable into the cable gland, and enough cable is available so that terminations can be made without need to install new cable or joints. Where shotcreting operations are to be undertaken after leaky feeder installation, leaky feeder cable shall be re-routed so that no shotcrete is allowed to collect on, or drip onto, the leaky feeder cable. Leaky feeder cable must not be covered by shotcrete or mesh for any part of the installation. Where water is dripping from the backs of the tunnel, the cable must be either redirected to avoid the water, or be protected by a PVC (or similar non conducting) splash guard which provides a minimum of 25 mm separation between the top of the splash guard and the top of the radiating coaxial cable. Where the leaky feeder cable is to be installed into shafts or other vertical rises, the cable must be secured to a catenary cable (or similar) at intervals of not less than 1000 mm. Note: MSHA officials may require shotcreting of the leaky feeder cable in extreme situations if the cable cannot be re-routed to avoid a specific area. If you must do this consider replacing the cable with approved shielded coaxial cable (p/n 138-0006-009) prior to shotcreting or adjust the gain of the inby and outby amplifiers to attempt to compensate for signal loss. If the affected section is longer than 30 m (100 feet) between two amplifiers it may not be possible to balance the signal loss. 5.3.1. Catenary recommendations Where catenary cable is used to support the leaky feeder cable, the catenary supports must be installed such that the cable is not more than 150 mm from the backs. When a VHF leaky feeder cable is mounted on a catenary support it must not be closer than 50 mm from the backs. When a UHF leaky feeder cable is mounted on a catenary support it must be installed such that the cable is not less than 100 mm from the backs. If the catenary cable is conductive then the Leaky Feeder cable needs to be separated by a further 100 mm from the catenary wire. Catenary supports shall be installed at intervals of at least every 20 meters. Spacing will decrease for bends and curves, but should not be less than 1 meter. Catenary cable shall be stainless steel and shall have a minimum diameter of 3.5 mm (0.14 inch). The catenary cable shall be tensioned so that there is no visible sag in the cable. While maximum cable support separation is 3 meters (10 feet) when strapped to a solid support, this is not always the case when a catenary wire is used. The Leaky Feeder needs to be supported every 1.5 m (5 feet) when strapped to a catenary wire to avoid it sagging when routed around corners or changes in height. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 23 of 42 PBE Leaky Feeder System Manual 5.4 Distribution Equipment (Components) Distribution devices are to be installed on the cable support structure, or catenary. The top cover of the device shall be installed so as to be seen easily from the ground. Amplifiers are to be installed with the Base pointing to the cable coming from the Head End. Generally amplifiers are spaced every 500 meters (1640 feet) for a VHF system using 5/8 inch mine quality coaxial cable and 350 meters (1148 feet) for a UHF system. When installing branches, ensure that the arrow on the circuit board is pointing to the cable coming from the Head End. Also ensure that the opposite end of the arrow is pointing to the main leg continuing through the branch unit. The main line shall go straight through the device. Leaky Feeder cable loops of at least 1 m are required on all terminations of distribution devices (see Figure 7). Loops are to be secured to the cable support structure or catenary with cable-ties. Figure 7: Service loop After the cable has been terminated into the distribution device, secure the cable approximately 300 mm back from the device. Lid screws and gland nuts should be manually tightened; mechanized tools should not be used. Where distribution devices are to be installed in shafts, a shield must be installed over the device so as to protect the device from falling debris. The shield must also cover the cable entry points of the device. Each Power Coupler Complete is connected to a power supply. When installing a Power Coupler ensure the local 1925 power supply has its AC inputs isolated. Refer to the Section 5.3 General Component Connection for cable preparation methods. 5.4.1. General Component Connection There are two types of connections required with the PBE Leaky Feeder cable; one for connecting Leaky Feeder cable to the Head End Unit and one for most of the other components. They are described separately below. The following instructions should be used for connecting most components (except for the Head End Unit, covered below) within the PBE Leaky Feeder System: MAN-41-00001-D Minecom Leaky Feeder System Manual Page 24 of 42 PBE Leaky Feeder System Manual Strip the Leaky Feeder cable to the dimensions outlined in the figure below. Figure 8: Slicing dimensions Separate the outer braid into two sets, eight conductors per side, and twist tightly together. Figure 9: Twist braids into 2 strands Place the gland nut, any plastic washers, and the rubber compression seal onto the cable and insert the cable through the gland. Align the center conductor to fit into the center brass block of the device. Ensure that the white center dielectric is hard up against the center brass block. Figure 10: Attach to brass block Tightly wrap each strand of outer conductors around the threaded studs of the ground block, one each side of the cable. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 25 of 42 PBE Leaky Feeder System Manual Figure 12: Tightly wrap conductors around studs Tighten the two screws on the center block to clamp the center conductor into place. Place the top ground block into place, and tighten the nuts onto the wrapped outer conductors to clamp them onto the threaded studs. Figure 13: Place the top ground block into place Figure 14: Typical installation without shielding (terminal block not shown) MAN-41-00001-D Minecom Leaky Feeder System Manual Page 26 of 42 PBE Leaky Feeder System Manual Figure 15: Typical installation with shielding (terminal block not shown) 5.4.2. Head End Combiner Connection or Isolation Barrier Connection (for IS systems only) When installing an Isolation Barrier, ensure that the ‘blue end’ is facing the hazardous area and that the ground screw is properly grounded. The following instructions should be used for connecting Leaky Feeder cable to the Head End Combiner: 1. Strip the Leaky Feeder cable to the dimensions outlined in the figure below. Figure 16: Slicing dimensions 2. Using a NP-10DFB, slide the clamp nut, metal washer, plain gasket, and metal ferrule over the stripped cable as shown in Figure 17 and 18. Figure 17 MAN-41-00001-D Minecom Leaky Feeder System Manual Page 27 of 42 PBE Leaky Feeder System Manual Figure 18 3. Fold back the cable braid over the ferrule, taking care not to overlap the braid conductors. Trim off surplus braid. 4. Fit the male pin contact onto the centre conductor. Hold the cable and contact tightly together and crimp/solder. Figure 19 5. Press the sub-assembly into the body as far as possible and engage, then tighten the clamp nut. Figure 20 MAN-41-00001-D Minecom Leaky Feeder System Manual Page 28 of 42 PBE Leaky Feeder System Manual 6. TUNING (for GEN-3 amplifiers) As the topology of the mine changes over time, it becomes necessary to expand communications coverage. Due to differences in cable and tunnel geometry, as well as cable variance, it may be necessary to slightly adjust amplifier gains as new amplifiers are installed. Note: It is recommended that DC is disconnected before working on equipment. Always use your PBE System Design Guide (S-19…) when expanding your coverage to ensure proper device to device spacing. Due to differences in cable and tunnel geometry, as well as cable variance, it may be necessary to slightly adjust amplifier gains as new amplifiers are installed. 6.1.1. Order of Tuning When tuning a new system, identify the Main Routes of the mine. The main decline or tunnel is a good place to start. You should be able to identify the longest routes within a mine, and the sub branches that feed from it. The tuning (of amplifier gain adjustment) is dependant not only on the receiving amplifier but also the transmitting amplifier. It is therefore important to tune the main legs first, and any compromises to be made on the shorter legs. It is generally better to make a series of slight attenuator adjustments in several places than a single large change in one place. However, when connecting a new drive to a previously balanced main drive, the main drive’s balance has priority. 6.1.2. Configuration of Amplifier Attenuator Settings Downlink Tuning of the downlink band is useful for future observations and fault finding the system. Full tuning of the downlink band is optional, but recommended. Alternatively, please follow the Minimum Tuning Procedure below. Team Setup Downlink tuning is performed starting from the closest amplifier to Head End and then moving to each consecutive amplifier away from the Head End. A single person is able to tune the downlink band. Initial Device Setup Set the downlink attenuator settings of all amplifiers to no attenuation (0) Minimum Tuning Procedure Whilst within view of the amplifier diagnostic LEDs, key up a mobile handset to activate the downlink repeater. Ensure that all amplifiers have any one of the “Downlink AGC” LED lit during a downlink transmission. Full Tuning Procedure MAN-41-00001-D Minecom Leaky Feeder System Manual Page 29 of 42 PBE Leaky Feeder System Manual The downlink band is perfectly balanced if all amplifiers have the +6 dB“Downlink RF Power” LED lit. Whilst within view of the amplifier diagnostic LEDs, key up a mobile handset to activate the downlink repeater: LED status Attenuation 0 or +3 dB Decrease the downlink attenuator setting. +9 or +12 dB Increase the downlink attenuator setting. Repeat this procedure until the +6 dB “Downlink AGC” LED lights. Repeat this procedure for each amplifier. Caution on adjusting the attenuator settings Any adjustment will not be recognized until there is a quiet period. There should not be any other in-band data or voice communications during the adjustment. Uplink Due to the variability of uplink signal powers and the lack of a mechanism to keep the uplink amplifiers in AGC, it is necessary to tune the uplink band to minimize noise build-up during periods of no data or voice communications. Team Setup Uplink tuning is performed from the furthest amplifier (away from Head End) and then moving back towards the Head End. A two-person team is required, one amplifier apart, both walking one amplifier towards the Head End after each adjustment. The first person stands 10 m past the furthest amplifier, away from the Head End, ensuring he can still see the amplifier. The second person stands at the next amplifier towards the Head End. Initial Device Setup Set all uplink attenuator settings of all amplifiers to default (6). Aim The second person needs to adjust the uplink attenuator setting such that when an uplink transmission is active, the “Uplink AGC” LED just turns on. Test Method The first person keys up a mobile handset (for approx 10 seconds) so that the second person can observe the state of their ‘Uplink AGC’ LED. When keyed up, the first person should see his “Uplink AGC” LED flash. Once the transmission completes, the second person will adjust the uplink attenuator settings depending on their observation of the ‘Uplink AGC’ LED. LED OFF ON FLASHING MAN-41-00001-D Attenuation attenuation needs to be decreased by one step attenuation should be increased by one step, to ensure that it is at the highest setting for the LED to be active. attenuation should be increased by two steps. PBE Leaky Feeder System Manual Page 30 of 42 PBE Leaky Feeder System Manual This process is repeated until the second person has adjusted the uplink attenuator settings such that his “Uplink AGC” LED just comes on when the first person keys up. If the LED never comes on, then the uplink attenuator setting should be left at the minimum attenuation setting (0). Once tuning is achieved, re-seal the amplifiers and both men move up one amplifier towards the Head End (maintaining one amplifier spacing). This procedure is repeated until the second person reaches a previously calibrated amplifier (usually on a main leg). Caution on adjusting the attenuator settings Any adjustment will not be recognized until there is a quiet period. Therefore, it is important that the second person wait for the first person to stop transmitting before adjusting the uplink attenuator settings. There should not be any other in- band data or voice communications during the adjustment. MAN-41-00001-D PBE Leaky Feeder System Manual Page 31 of 42 PBE Leaky Feeder System Manual 7. MAINTENANCE A fully installed PBE system will operate indefinitely with the correct maintenance procedures. The PBE Leaky Feeder System has been designed and developed for ease of operation and maintenance in an underground mining environment. This section describes the procedures that should be adopted by site management to ensure that the system operates as designed during its lifetime. The amplifier’s Local Diagnostics LEDs indicate the current state of the amplifier for ease of maintenance. The Sections on Layout and Installation should be consulted before making any changes to the system. They describe how to design, install or make changes to the Leaky Feeder System. 7.1 PBE Weekly Maintenance Checklist Check Test Result Amplifier Operation Visually inspect the line voltage and amplifier current lights on all PBE Amplifiers on site LINE VOLTAGE should indicate NORMAL or HIGH Battery Supply Operation Visually inspect the PBE 1953 and 1955 units on site DC IN should be green Battery Backup Test Remove AC power from all 1925 power supplies for 15 minutes and use the Leaky Feeder System to Communicate with miner at the working section Voice communication should remain during the battery back up test AMP CURRENT should indicate NORMAL or HIGH BATTERY OUT should be green Note for IS systems: To maintain optimum battery backup capacity it is strongly recommended to replace the 1953 or 195 and Communications Rack rechargeable batteries with manufacturer approved batteries every two years. The Leaky Feeder System must be installed and maintained to the MSHA approved system diagram. 7.2 Operational Training Training in the operation and maintenance of the system is critical to the successful ongoing operation of the system. If site personnel are to use the PBE Leaky Feeder System successfully, they must understand how it works. All new personnel commencing work should cover the PBE Leaky Feeder System procedures as part of their induction training. Training should include: Operation of portable radios, vehicle radios, mini base stations, etc. MAN-41-00001-D PBE Leaky Feeder System Manual Page 32 of 42 PBE Leaky Feeder System Manual Knowing where the radios will and will not work; all staff should be aware of the radio coverage area. Procedures for the use of the system: who to call in the case of an emergency, how to report a fault in the system, warnings with respect to use of radios in the vicinity of electric detonators, fuel dumps, gaseous areas, magazine, etc. 7.3 Maintenance Training The training of maintenance staff should commence with the installation of the system. Maintenance staff will learn more quickly and have a better chance of retaining that knowledge if they are involved in the initial installation of the system. Training should be a combination of both classroom and hands-on learning. 7.4 System Drawing An accurate up to date system drawing with cable distances should be kept by the shift maintenance engineer in charge of the system. The drawing should allow maintenance staff to mark any changes to the system design (i.e. cable breaks, new branches and new power centers). It should be the responsibility of the engineer in charge to check that the work has been carried out correctly and amend the master copies of the system drawing when necessary. It is important that the manufacturer/supplier of the system be supplied with the up-to-date system drawing when you contact them. This will allow them to assist/advise site staff in the event of a fault with the system, ensuring a quick and speedy solution to the problem. A generic System Design Guide can be found in Appendix B. 7.5 Documentation Maintenance staff should have access to copies of the system documentation package, with master copies being held by the engineer in charge. Documentation is available in both hard copy and soft copy format. 7.6 Test Equipment Required The test equipment required for troubleshooting the PBE VHF and UHF systems are as follows: standard handheld voice radio(s) one multi-meter (Optional) spectrum analyzer (Not IS approved, mine specific restrictions will apply) a range of approved hand tools, long cable-ties, insulating tape, cleaning rags. MAN-41-00001-D PBE Leaky Feeder System Manual Page 33 of 42 PBE Leaky Feeder System Manual 8. FAULT FINDING 8.1 Identify the Location of the Fault Most failures are due to cable and water damage. Use Local Diagnostics or user reports to determine where to start troubleshooting. When fault finding field equipment PBE recommend taking spare units to quickly replace faulty or damaged equipment. When a system fault is reported, i.e. voice coverage is poor (below the 640 level), first determine that: the reported fault is as described and that the person’s radio is not faulty or that their battery is not flat. the reported fault, affects all communications channels, and not just one single channel. If it affects only one channel, the problem is most likely with the Head End Communications Rack. If the report is poor performance and not system failure, check: the tuning of the system as per the tuning guide that the leaky feeder cable is free of obstructions as per the installation guide. Starting at the Communications Rack work your way through the system until you get to the point that communications no longer function. Start your fault finding from this point. IMPORTANT - if the coverage is poor in a lower level, it does not necessarily mean that the fault is immediately above the area of poor or no coverage. The actual fault may be higher up (closer to the Head End). 8.2 Head End Communications Rack fault Available LED not on: Main fuse on the Head End has blown No power to Head End Combiner Arterial cluster has no LEDs on: Main power switch has not been turned on None of the arterial switches are turned on Fault LED on: A short circuit has occurred down the line. Find and repair short circuit before circuit breaker. 8.3 Radio fault If only one channel is affected, then the fault will most likely be at the Communications Rack and not in the Leaky Feeder System. 8.4 System fault If all radio channels are affected, carry out a systems check of the Leaky Feeder System. MAN-41-00001-D PBE Leaky Feeder System Manual Page 34 of 42 PBE Leaky Feeder System Manual Before you start, ensure that: both of the test portable radios work radios are tuned to the same radio channel the batteries must be at least 90% charged You have an up-to-date system drawing showing the locations of the devices. If more than one amplifier has no LEDs on there could be a: short circuit: o Remove DC isolating jumpers and reset Power Coupler to help isolate the exact location o Visual inspection for cable damage and repair with a Joiner Box o Open inline devices to check for water logging, recommend replacement of water logged devices. Always tighten glands to prevent water ingress. cable cut: o Visual inspection, repair with a Joiner Box. If one amplifier has no LEDs on: replace the amplifier, take it back to workshop for inspection if replacement amplifier doesn’t work, check for cable breaks or short circuits towards the Power Coupler. If one or more amplifiers LEDs flash on and off: most likely too many amplifiers are connected to the one PC. Review layout diagram. Insert another Power Coupler. MAN-41-00001-D PBE Leaky Feeder System Manual Page 35 of 42 PBE Leaky Feeder System Manual 9. PREVENTATIVE MAINTENANCE A preventative maintenance program will reduce the number of system faults caused by the mine environment, as well as ensuring that any backup systems work when they are required. Preventive maintenance can take many forms and is dependent on the size of the mine, the size of system installed and the level of test equipment carried at the mine. 9.1 Program Maintenance Programmed maintenance takes the form of monthly or quarterly visual and electronic testing of the various components and a log kept of the results. 9.1.1. Communications Rack Test and measure RF Power levels of the Base Radio Transmitters and the Head End Combiner. Batteries need to be replaced every two years. Visually inspect all equipment, cables and leads for deterioration. Check temperature levels inside the cabinet are <40 degrees C (104 degrees F). Check stand-by battery condition and clean battery tops. Measure and log the AC and DC voltages. It is recommended that the system revert to the stand-by battery back at least every three months to ensure that the batteries can operate the system for the required period of time. Remove any build up of dust, dirt, insects, etc. inside the enclosure and clean any vents or filters fitted to the enclosure. Log the results of all tests. 9.1.2. Down Line System Inspect the leaky feeder cable for damage. Ensure that the leaky feeder cable is secured every 3 meters (10 feet). Inspect all devices (amplifiers, branches, etc.) for damage, water ingress and condensation. Wipe down all devices. Measure and log the DC voltage at every device. Log the results of all tests. 9.1.3. Portable Radios Test all functions of the portable radio. Charge/condition the battery pack. Visually inspect the radio, including all attachments, for damage or deterioration. Check the antenna for physical damage. Clean the radio. Test the portable radio to air. Log the results of all tests. 9.1.4. Vehicle and Desktop Radios Test all functions of the radio. Check the antenna for physical damage. Carry out VSWR check of the antenna. Visually inspect the radio, all leads and connections. Clean the radio. MAN-41-00001-D PBE Leaky Feeder System Manual Page 36 of 42 PBE Leaky Feeder System Manual If the radio is fitted with a stand-by battery, operate the radio from the stand-by battery for at least 4 hours. Test to air. Log the results of all tests. 9.2 Test Equipment required The minimum test equipment required is a handheld radio, at least 90% charged radio battery, and a multi-meter. Optional test equipment include a communications test set, manufacturers’ test kit(s) for portable and vehicle radios, laptop, RF Wattmeter, and VSWR meter. MAN-41-00001-D PBE Leaky Feeder System Manual Page 37 of 42 PBE Leaky Feeder System Manual 10. AFTER SALES SERVICE The information contained in this manual and the attachments is designed as a guide to assist site staff in the maintenance and up-keep of the PBE VHF or UHF Leaky Feeder System. As additional information becomes available it will be sent to you automatically. The information is normally available in both hard and soft copy format. Note: Before contacting us, please ensure that you have followed the support processes listed above. You will need to provide the following information for us to respond to your request: 1. Your contact details Name, Company, Location, etc. 2. Support details a clear understanding of the fault condition and description of any attempts made to fix the problem an up-to-date system drawing measurements of the voltages of the devices in the area of the fault personally visited the area of the fault and verify the fault condition. For further information, please visit: www.pbegrp.com or contact your local supplier for servicing requirements. MAN-41-00001-D PBE Leaky Feeder System Manual Page 38 of 42 PBE Leaky Feeder System Manual 11. INDEX 02-00030 ............................................15 02-00039 ............................................15 02-00048 ............................................15 02-00138 ............................................12 02-00144, 03-00145, 03-00146..........10 02-00149 ............................................15 02-00156 ............................................15 03-00041 ............................................15 05-00074 ............................................13 05-00086 ............................................13 20-00007 ............................................15 20-00008 ............................................15 20-00020 ............................................15 24-00001 ............................................12 24-00007 ............................................13 24-00017 ............................................13 Above Ground ....................................12 amplifier ..............................................16 Amplifier ...................................8, 15, 21 Antenna System .................................12 Audio Bridge .......................................12 Base Radio .........................................11 Base station........................................11 Bidirectional Line Amplifiers ............ See Amplifier Branch Unit.........................................16 Catenary .............................................23 Communications Rack ...........10, 21, 36 Connecting cable .............................. 24 Connecting components ....................24 Contact ...............................................38 Data channels ....................................11 Distribution Equipment .......................24 MAN-41-00001-D Downlink Adjustments ....................... 42 Dual Branch Unit................................ 15 Fault finding ....................................... 34 Fault locating ..................................... 34 Head End Combiner .......................... 16 Head End Combiner Connections ..... 21 Head End Unit ................................... 10 Installation ......................................... 21 Isolator ............................................... 13 Joiner Boxes ...................................... 18 LAYOUT ............................................ 16 Leaky Feeder Cable .................... 15, 22 Leaky Feeder Power Supply ............. 10 Maintenance ................................ 32, 36 Portable Radios ................................. 36 Power Coupler ................................... 17 Power Coupler Module ...................... 15 Preventative Maintenance ................. 36 Radio fault ......................................... 34 Repeater ............................................ 13 Service ............................................... 38 Single Branch Unit ............................. 15 Stripping Leaky Feeder cable ............ 27 Surge Arrester ................................... 12 System Drawing ................................ 33 System fault ....................................... 34 Termination Box ................................ 15 Termination Boxes ............................. 18 Test Equipment ........................... 33, 37 Training .............................................. 32 Troubleshooting......... See Fault Finding Uplink Adjustments ........................... 42 PBE Leaky Feeder System Manual Page 39 of 42 PBE Leaky Feeder System Manual 12. Appendices 12.1 Appendix A - Mine-wide System Tuning (Amplifier Attenuator Settings) As the topology of the mine changes over time, it becomes necessary to expand communications coverage. Always use your Minecom System Design Guide (DWG-41-00005-01) when expanding your coverage to ensure proper device to device spacing. Due to differences in cable and tunnel geometry, as well as cable variance, it may be necessary to slightly adjust amplifier gains as new amplifiers are installed. Always remember to close all enclosures as you leave each unit to prevent dust build up. 12.1.1. Order of Tuning (for Gen-2 Amplifiers) When designing a system, and later tuning a new system, identify the “Main Routes” of the mine. The main decline or tunnel is a good place to start. You should be able to identify the longest routes within a mine, and the sub branches that feed from it. The tuning (of amplifier gain adjustment) is dependant not only on the receiving amplifier but also the transmitting amplifier. It is therefore important to tune the main legs first, and any compromises to be made on the shorter legs. It is generally better to make a series of slight attenuator adjustments in several places than a single large change in one place. However, when connecting a new drive to a previously balanced main drive, the main drive’s balance has priority. 12.1.2. Configuration of Amplifier Attenuator Settings (for Gen-2 Amplifiers) As each amplifier is commissioned you should see the following on the Downlink RF Power display: When adjusting downlink AGC, always adjust the amplifiers nearest the Head End first, as the adjustments have a flow on affect. 1. During downstream communications you should see the Central “0 dB” LED light. You can force downstream communications by keying up a portable radio on a mine wide channel. 2. The “-6 dB” LED should light when no one is communicating. If you don’t see this LED light periodically, confirm with someone at the Head End that none of the repeaters are active (Red TX light). (depending on configuration) you are unlikely to hear communications on any talk group other than your currently selected one. A repeater will become active the instant the person at the Head End starts to speak on a radio. If you don’t see both step 1 and step 2, adjust attenuators up or down to achieve these results. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 40 of 42 PBE Leaky Feeder System Manual Note for the first one or two amplifiers into a mine, it may not be possible to prevent the higher “+3 dB” or “+6 dB” LEDs from lighting, so just increase attenuation as far as possible. Uplink tuning is performed from the furthest amplifier (away from Head End) and then moving outby (back towards the Head End). A two-person team is required, (one amplifier apart) both walking one amplifier towards the Head End after each adjustment. The first person stands 10 m (33 feet) past the first amplifier (away from the Head End), where he can still see it. When asked, the first person then keys up a portable radio for several seconds. While not mandatory, the first person should see the “uplink AGC Active” light flash. It is important that the first person have quiet periods of no transmission, so the second person can contact them and the amplifiers can calibrate themselves. The second person stands at the next amplifier towards the Head End. The goal of the second person is to adjust the uplink attenuator settings just below the level where the “Uplink AGC active” LED comes on. Select an uplink attenuator level where the “Uplink AGC Active” LED glows when the first person is transmitting. Then increase the attenuation so it no longer glows while the first person is transmitting. Once this is achieved re-seal the amplifier furthest from the Head End and both men move up one amplifier towards the Head End (maintaining one amplifier spacing). This procedure is repeated until the first person reaches a previously calibrated amplifier (usually on a main leg). Note: the attenuator settings of an amplifier may be determined without opening the case. Disconnecting and reconnecting external power (at Power Couplers) causes the display to show the settings. A quite period (no communications) is required for the amplifiers to re-calibrate themselves (you may have to wait for this to happen). 12.1.3. Unplanned Topology Changes (for Gen-2 Amplifiers) While strongly discouraged, a limited number of branch units may be inserted into an existing properly balanced system. New deposits may be discovered and an unplanned branch may need to be added. If you believe an unused drive may become viable in the future it is best to: Add a branch unit inline and adjust the system topology to match at initial design time. Insert 3 meters (10 feet) of cable and a termination box. Think about how you would like to power any amplifiers required from existing or planned infrastructure. That way correct system balance is always maintained. If possible use a single branch unit, and make further branches after an amplifier. Do not run additional amplifiers from the existing system, unless there is excess power from Power Coupler available. MAN-41-00001-D Minecom Leaky Feeder System Manual Page 41 of 42 PBE Leaky Feeder System Manual Uplink Adjustments (for Gen-2 Amplifiers) As stated earlier, the main (longer) legs have a higher priority when it comes to correct system balance. You will probably have to decrease the attenuation on the amplifier inby from the unplanned branch. Check the uplink AGC outby of the unplanned branch to see if additional gain adjustment is required. Adjust the uplink AGC in the new drive and make a compromise. Downlink Adjustments (for Gen-2 Amplifiers) You will probably have to decrease downlink attenuation (by one stop) for the amplifier outby from the unscheduled branch. 1. This may cause the higher LEDs on the amplifier outby to light during downstream communications. This is not ideal, but is the best compromise when an unscheduled branch needs to be included. 2. The goal is for the “0 dB” LED to light during downlink communications on both amplifiers inby from unscheduled branch, however, it will still operate when the other LEDs are on. 3. Once the above step is completed examine both amplifiers inby from unscheduled branch to verify that they comply with Step 2. 4. You may have to also decrease these attenuation (by one stop) in order to show the “0 dB” LED light during downlink communications. 5. If necessary, return to the amplifier inby from the branch and reduce the downlink attenuation again. 6. It is preferable to decrease attenuation slightly in several places rather than a great deal in one place. 12.2 Appendix B - Minecom System Design Guide DWG-41-00005-01 MAN-41-00001-D Minecom Leaky Feeder System Manual Page 42 of 42 2 1 3 4 5 6 7 8 Leaky Feeder Cable Leaky Feeder cable is available in UHF (blue) and VHF (yellow) in 350 m drums (VHF is also available in 500 m drums). The cable drums are heavy and may require machinery and or multiple personnel to install. Cable strapping intervals should not exceed 3 m. Leaky Feeder cable must be installed at least 300 mm from high voltage cables. The cable requires line of sight with portable radios and hence must not be installed behind metal piping, behind corrugated iron, steel or other conductive surfaces. Yellow VHF cable can be strapped or cable-tied directly to a catenary wire. Blue UHF cable must be at least 100 mm from conductive material using spacers or hangers. A Joiner Box (JB) Amplifiers (AMP) Minecom inline Amplifiers restore radio signals to adequate retransmission levels. Amplifiers obtain DC power from an inline source (Leaky Feeder cable). This power is initially obtained from the Communications Rack, however after a certain number of amplifiers, Voltage Power Couplers are used to reintroduce power to the Leaky Feeder system. The arrow on each amplifier must point back to the Communications Rack (located on the surface or underground). Amplifiers must be A Joiner Box can be used to join the two ends of a Leaky Feeder cable where there has been a break. As Joiner Boxes introduce very little loss to the system, up to 4 Joiner Boxes can be used between amplifiers (both 350 m and 500 m cables). The Joiner Box provides an effective electrical connection with a very low signal loss (<0.5 dB). Tunnel AMP Communications Rack Communications Rack Communications Rack Tunnel JB 230 m 170m AMP Tunnel 150 m AMP restore signals. More than one BU2 can used between amplifiers. Voltage Power Couplers (PC) AMP AMP PC AMP AMP AMP D C 29/04/10 16/12/09 BU2 Tunnel 150 m AMP Branch 2 Termination Box (TB) Termination Boxes (TB) are used to terminate the Leaky Feeder cable at all ‘end of runs’. Their main function is to ensure no signal reflections are experienced in the system. At the same time the unit protects the cable from water and dust ingress as well as DC and RF isolation. 350 m Power Station TITLE DWG-41-00005-01 Design Guide Non IS Removed V from VBU System & updated images New Template AC 240 V In SL SL HM JF 29/04/10 HM JF 16/12/09 D -180 TB DC (supplied upstream, downstream o r both) PC 110 m Branch 2 60 m TB Communications Rack AMP -90 AMP AMP OR AMP 125 m TB F Communications Rack AMP E BU2 Branch 1 60 m AMP Voltage Power Couplers (PC) are used to introduce external DC voltage into the Leaky Feeder System. As the leaky feeder cable can cover many kilometers underground, over distance, voltage must be re-introduced to the system. Although PCs are AC powered, they only introduce an adequate DC voltage to the system (12/24/48). The arterial distribution of power can be selected at the PC. Upstream voltage, downstream voltage or both can be selected. Due to differences in amplifiers, system design and configuration, the specific location and intervals of PCs will vary in all systems. A maximum of 5 amplifiers (4 for VHF) can be powered from a single PC. NB: DC isolation rules apply. -180 Tunnel Branch 1 Branch 1 Communications Rack D Communications Rack AMP -90 C AMP BU1 Tunnel -90 AMP Dual Branch Units are used to split the signal into two branches (Branch 1 and 2). The cable that continues down the tunnel (or decline) is called the ‘Tunnel Branch’. BU2s experience a measurable loss across all legs. Due to the loss associated in signal splitting, the cable distance in the ‘Tunnel Branch’ will be reduced by approximately 90 m and 180 m in Branches 1 and 2. After installing a BU2 the maximum physical separation between amplifiers is now reduced to 260 m in the ‘Tunnel Branch’ (maximum distance 350 m – loss of 90 m = 260 m), 170 m along ‘Branch 1’, and 170 m along ‘Branch 2' (maximum distance 350 m – loss of 180 m = 170 m). Distances must be maintained to ensure the system can compensate for the introduced losses and adequately Branch 1 150 m BU1 JB Tunnel Communications Rack 110 m AMP JB B Dual Branch Units (BU2) Single Branch Units (BU1) are used to split the cable (and signal) into another single branch. A nominal loss of 90 m is experienced on both ‘tunnel’ and ‘branch’ legs, hence the separation between amplifiers is now reduced by 90 m. As the distance between amplifiers is normally 350 m, inserting a Branch Unit will reduce the overall amplifier separation to 260 m. It is vitally important to ensure the cable distance between amplifiers reflects the losses in the Branch Unit. Note: it is possible to install more than one Branch Unit between amplifiers as long as loss distances are compensated for. Communications Rack AMP 70 m AMP Single Branch Units (BU1) C 50 m Tunnel AMP Tunnel 350 m AMP AMP Tunnel B 350 m AMP Tunnel installed every 350 meters of UHF cable (350/500 m for VHF). Separation distances greater than 350 m (350/500 m VHF) will result in amplifiers not restoring the signal to an adequate level, and spacing too closely could potentially amplify noise. Both conditions, over distance, will exponentially degrade radio signals. Communications Rack A E Design © 201 0 This dra win g and all intel lect ual prop erty pert aini ng to it belo ngs to TR Pty Ltd. The informati on or any part thereof contained in this drawing is confidenti al and shall not be reproduc ed or JF copied in any form without TR Pty Ltd written approval. F REV DATE CN 1 DESCRIPTION 2 BY CHK APR 3 DATE DATE 09/2009 CHKD SL DATE 29/04/10 6 Joseph Street, Blackburn North, Vic 3130 Ph +61 3 9896 3000 Fx +61 3 9896 3099 SCALE TITLE DOC No. REV N\A Minecom System Design Guide SIZE DWG-41-00005-01 A3 SHEET 1 OF 1 4 5 6 7 8 D
