GIG11ATEXQ043
the leader in intrinsically safe
shaft signaling systems
advanced technical solutions
of industrial automation for mining
Our company
MDJ ELECTRONIC - WE ARE THE SOLUTION
MDJ Electronic, as a competent supplier of automation systems for mining industry
has been present on this market since 2001.
We offer:
An Integrated Shaft Machinery Control System with the following components:
▪▪ Intrinsically safe shaft signalling and communication system.
▪▪ Intrinsically safe system for the control of skip loading and unloading.
▪▪ Intrinsically safe system for the control of coal retention silos and coal stream
automation.
▪▪ Intrinsically safe system for the control of the shaft cage station.
▪▪ Intrinsically safe system for the control of control of conveyors.
▪▪ Intrinsically safe system for the control of sump drainage and ventilation.
Intrinsically safe control systems for:
▪▪ refrigerating equipment in mining,
▪▪ hoists,
▪▪ conveyor tension system,
▪▪ conveyor transfer stations,
▪▪ hydraulic accumulators,
▪▪ conveyors
The underground gas monitoring systems tracing the concentration of methane
and other mine gases.
Our offer includes also the following equipment:
For 20 years we have been a reliable and reputable business partner, valued for providing efficient
and comprehensive solutions for industrial automation and control systems.
We design, implement and integrate industrial automation systems, computer control and monitoring systems.
We have extensive experience in many sectors of industry, such as:
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Mining
Brewing
Automotive
Food
Machine construction
Environmental protection
We are the leader in the implementation of the newest industrial automation developments onto the mining market.
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intrinsically safe PLC controllers,
flame proof computers,
intrinsically safe conveyor and tank scales,
conveyor belt velocity gauges,
intrinsically safe valve blocks,
separators,
intrinsically safe fibre optic converters.
The advanced technical solutions and well established reliability of our devices
have been the prerequisites for their application in the control system
of the underground Ex version hoist engine, developed by MWM Elektro Company.
Due to their high quality, our systems and devices have been applied in the projects
of such worldwide companies as:
▪▪ INCO Engineering,
▪▪ SIEMAG,
▪▪ BARTEC.
The MDJ Electronic systems and devices are present not only on the Polish mining
market, but also in Russia, The Czech Republic and China.
The Intrinsically Safe MDJ-100 System for Signalization and Communication in Mine Shafts.
The most important advantages of the system
are the following:
The system incorporates the following sub-systems:
IUSS – the power supply and control system for shaft
signalization
LARMO-S – the system for telephone and loud-speaking
communication
ECHO – the shaft system for wireless communication
UPSL – the system for the measurement of tensioning
forces in the head ropes
The MDJ ELECTRONIC IUSS power supply and control
system for shaft signalization is made up of the following
components:
▪▪ SIMATIC S7 controllers operated in the redundant
mode
▪▪ SIMATIC TP graphic operator touch panel
or computer
▪▪ ZI2-24 power supply modules with intrinsically
safe outputs located in the hoist building of the
shaft hoist and meant to supply all intrinsically safe
devices installed inside the shaft
▪▪ ET2000Ex intrinsically safe I/O modules provided
with three communication channels
▪▪ ETR2000 redundant I/O modules used for
communication with devices installed in the hoist
building
▪▪ Converters of RS485 signals into fibre optic signals
▪▪ Two fibre optic cables running through the shaft
and operated according to the Redundant Ring
topology
▪▪ One or two copper cables running down the shaft
and used to supply equipment on individual levels
▪▪ Hybrid opto-electrical cables as an alternative
solution for separate fibre optic and electrical cables
▪▪ Sound and light warning devices
▪▪ Sensors, switches, push buttons and indicator
lamps
▪▪ Intrinsic safety code I M1 Ex ia I enables
it to operate the equipment at any concentration
of methane
▪▪ Safe level of power voltage 24V DC
for all devices operated inside the shaft
▪▪ Top class SIMATIC S7 controllers operated
in the redundant arrangement keep the system
working even when one node of the Profibus DP
network has failed
▪▪ Intrinsically safe ET2000Ex modules
and ETR2000 modules of the redundant design
enable uninterrupted operation of the system when
one node of the Profibus DP network has failed
▪▪ Two independent Profibus DP networks,
two independent fibre optic networks
and two power supplying cables for improved safety
and to maintain the system operation when one of
the twinned components breaks down
▪▪ Solutions based on electrical transmission cables
▪▪ Hybrid opto-electrical cable as an alternative
solution to separate optical and electrical cables
▪▪ Graphic visualization on the operator panel
or a computer enables one to locate reasons
for interlocks, sources of alarms, diagnostic
and monitoring of the control system
▪▪ Quick installation and start-up, easy extension
owing to the modular design
▪▪ Programming with use of the standard software
tools, or others Allan Bradley, ABB etc.
▪▪ Easy integration with control systems
of the shaft winder, control systems for loading
and unloading of skip conveyances
as well as all the shaft-related equipment
▪▪ Monitoring of loading skip or cage conveyances
by means of the UPSL-02 i z unit or others systems
for measurements of tensioning forces in ropes of
hoisting winders
▪▪ Maintaining archives of the system signals
(system log) on the operator panel, an external
computer or an independent log device
▪▪ Easy integration with IT systems
▪▪ Visualization and monitoring of the shaft
communication system LARMO-S
▪▪ Remote service and monitoring of the system
More than 50 systems have been provided for mines
in Poland, Russia and The Czech Republic.
System ECHO
System LARMO-S
LARMO-S - the intrinsically safe system for mine shaft phone and
loud speaker-phone communication.
The wireless shaft communication devices ECHO-S is designed
to communicate between the crew in conveyance (cage or skip)
and the hoist operator in the mine shaft.
The LARMO-S system has been specifically designed for
applications associated with intrinsically safe shaft signaling.
It can communicate via fiber optics, copper tele-transmission cables
or standard phone cables. The loud speaker-phone functions
can be either integrated into the shaft phone system,
or executed by a separate set of devices.
The basic advantages of this system are the following:
▪▪ two-way half duplex audio communication,
▪▪ sending remote control signals from the cage to the hoist,
▪▪ receiving information signals from the hoist to the cage.
The cage unit is made as part of the intrinsically safe device group I,
category M1. The device is intended to be used during the time
of shaft inspection; conveyance of people, emergency exiting
as well as maintenance in the shaft. The principle involved
in this device is the use of rope as a carrier to convey
electromagnetic waves.
The carrier is created with:
▪▪ head-rope, tail-rope and conveyances
(in case of friction on the hoist),
▪▪ guide-rope and earth (in the case of a drum hoist),
▪▪ additional rope and earth (in other cases).
The electric continuity of such a loop is the main condition
for the correct working of this device. An electromagnetic wave
is generated to the loop and then received back from it by inductive
couplers. In the head-frame there are two inductive couplers fixed
(transmitter and receiver) in such a way, that the head-rope crosses
through their center. There are also fixed another pair of couplers
over the cage.
The head-frame unit sends a signal by the inductive coupler
(transmitter) to the rope and then the cage unit receives signals
from the rope by another inductive coupler (receiver). Communication
from the cage unit to the head-frame unit is performed in the same
way by another pair of couplers. Only one device can work in one
loop. The device has 4 frequency performances: A, B, C, D
thanks to which, it is possible to use four devices in one shaft.
The LARMO-S comprises a system independent of the IUSS
intrinsically safe shaft signalling control one, but it uses the same
transmission cables and the ET2000Ex device cases to connect
the optical fiber cables.
Operator’s
telephone
Hoist room
The most important system features are as follows:
▪▪ Simple and clear system structure.
▪▪ Intuitive usage.
▪▪ Easy communication with the hoist operator.
▪▪ Conference call option.
▪▪ Optional simultaneous phone and speaker-phone calls.
▪▪ Possibility of transmitting independent acoustic and optical
signals.
▪▪ Shaft communication system visualization and testing
on the hoist operator’s control panel.
▪▪ It doesn’t allow any connection to other phone systems.
Ground level
The MDJ-100 intrinsically safe shaft signaling device
can also be used with traditional shaft phone systems
or standard loud speaker-phone communication systems.
Level 1
Level N
Shaft sump
The UPSL-02i device has been designed to eliminate unequal rope
loads in multi-rope mine hoists. It can also be applied
to measure the output mass in a skip bucket, or the weight
of people in an elevator cage. It is also possible to use the device
either to detect, if a skip is unloaded or to prevent double-loading,
and as a security measure against any cage hoist overload.
The device is radio-linked to ET2000Ex or MDJ315-2DPEx
controllers located at the shaft bottom, collar or pit bank.
The Intrinsically Safe Shaft Signaling and Communication System
MDJ Electronic Company has been active in the shaft
signalling area since 2001. A modern, intrinsically safe
shaft signalling system developed by our engineers,
and based on PLC controllers and fiber optic transmission
technology, has became the standard for newly-built
and modernized shaft hoists. The first intrinsically safe
shaft signalling system based on the MDJ Electronic
technology was assembled in the Paweł shaft of the
Knurów Coal Mine in Poland.
Since that time 28 cage hoist signaling systems have
been implemented in Poland, 11 skip hoist ones
and one installation in a shaft sinking hoist, all based
on our technical solutions. Moreover, two shaft signaling
installations for cage hoists, based on our know-how,
operate in The Czech Republic, whilst in Russia 2 cage
elevators, 2 skip hoist and 2 shaft sinking hoist signaling
systems have been implemented. Several other shaft
signaling installations are awaiting start-up in Russia.
Due to the large scope of options together with
the implementation of standard communication protocols,
the shaft signaling installations based on our know-how
are applicable to all hoist engines present on the Polish
mining market, and manufactured by companies such as:
▪▪ ELCAM
▪▪ MWM Elektro
▪▪ INCO Engineering
▪▪ SIEMAG Tecberg
▪▪ ABB
Due to advanced technology, high reliability and friendly
collaboration with the hoist engine manufacturers, more
than 90% of newly-built and modernized shaft signaling
systems in Poland are based on our technical solutions
and devices.
On the Russian market all six shaft signaling systems
completed so far have been incorporated into
the installations of INCO Engineering Praha hoist engines
(The Czech Republic).
Our experience in shaft signaling refers to both
manufacturing of highly specialized equipment
and software, and technological aspects related
to cage, skip, emergency and shaft sinking hoists.
Common operational system between
intrinsically safe shaft signalization,
based on MDJ Electronic technology with
hoisting machines of specified producers:
No.
Hoisting
machine
producers
Mine
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2. MWM Elektro ▪▪
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3. INCO
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Engineering
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1. ELCAM
4. SIEMAG
Tecberg
5. ABB
6. Other
producers
of hoisting
machines
Budryk
Halemba
Jankowice
Murcki
Sośnica
Rydułtowy
Knurów
Szczygłowice
Chwałowice
Jas-Mos
Budryk
Bogdanka
Lubin
Wesoła
Wieliczka
Kłodawa
Makoszowy
Jankowice
Darkov
Rydułtowy – Polska
Gajskij Gok – Rosja
Krasnokamensk –
Rosja
Wołgakalij – Rosja
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▪▪ Silesia
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Jankowice
Pniówek
Pniówek
Bielszowice
Marcel
Borynia
Brzeszcze
Integrated shaft operating control systems, including:
▪▪ Intrinsically safe shaft signaling equipment.
▪▪ Intrinsically safe systems for the control of the skip loading.
▪▪ Intrinsically safe systems for the control of the skip discharge.
▪▪ Intrinsically safe systems for the control of coal retention and silos and coal stream automation.
▪▪ Intrinsically safe systems for the control of by-the-shaft equipment in cage hoist shaft bottoms.
▪▪ Intrinsically safe systems for the control of shunting railways.
▪▪ Intrinsically safe systems for the control of the sump drainage.
The most important features:
▪▪ A single integrated data base for software, visualization, archiving and diagnostics (TIA Portal, Step7, WinCC),
▪▪ Programming is possible from the mine surface facilities, but also long distance via phone or Ethernet.
▪▪ Visualization and diagnostics is available at the hoist room, or any other mine’s location.
▪▪ A common family of devices for all systems.
The Intrinsically safe system for skip loading control. MDJ 200
The Intrinsically safe system for skip unloading control. MDJ 210
The Intrinsically safe system for skip loading control MDJ 200
▪▪ A single MDJ315-2DPEx PLC controller for the complete skip loading control system, which simplifies programming,
update and monitoring/diagnostics of the system.
▪▪ Integration of the REX-01 scales with the controller ensures minimization of assembly elements, full visualization,
diagnostics and an extensive range of implementation capabilities for complex weighing algorithms.
▪▪ Full visualisation, monitoring and diagnostics of the system, with data archiving in MDJ7001 computers, also in the hoist
house or other locations designated by the mine’s management.
▪▪ Optional data transfer to the mine computer systems.
▪▪ Easy integration with other systems.
▪▪ Programming with the Step7 software package.
▪▪ The components compatible with the shaft signalling system and skip loading/discharge one.
▪▪ Automation of coal retention silos and coal stream automation
▪▪ Information exchange with the hoist control system.
The Intrinsically safe skip unloading control system MDJ-210
▪▪ A single MDJ315-2DPEx PLC controller for the complete skip loading control system, which simplifies programming,
update and monitoring/diagnostics of the system.
▪▪ Full visualisation, monitoring and diagnostics of the system, with data archiving in MDJ7001 computers.
▪▪ Optional data transfer to the mine computer systems.
▪▪ Easy integration with the shaft signaling and hoist control systems, to visualise the loading system
at the hoist engine display.
▪▪ Programmable with the Step7 (Siemens) tool package.
▪▪ Radio-link with the rope force gauge ensures the skip discharge control.
The system for the control of skip loading includes controlling of the following equipment:
▪▪ Belt and push-plate conveyors
▪▪ Retention bunker discharging flaps
▪▪ Conveyor or bunker scales
▪▪ Upper adjustable flap
▪▪ Calibrated tank bottom flaps
▪▪ Isotope gauges
▪▪ Material level gauges
▪▪ Air pressure sensors
▪▪ Skip position sensors
▪▪ Pulsators
Monitoring of mine atmosphere parameters and control of production MORS
MDJ 250 intrinsically safe cage shaft bottom control system
Dispatcher’s station
Dispatcher’s station is a computer with pre-installed SCADA software, which allows:
▪▪ visualization of data acquired from control and measurement equipment
▪▪ control of monitoring and measuring instruments
▪▪ generation of reports
▪▪ sharing data with other systems, etc.
System power supply and communication
Power supply and communication within the system is available in two variants:
Variant 1 Underground equipment is centrally supplied from a surface-based power supply and transmission modules.
Power supply and transmission modules MZT-10/60M provide an intrinsically safe power supply to control and monitor
instruments and mediate between the surface and underground sections of the system.
Parameters of telemetric line of module MZT-10/60M:
▪▪ 60 V DC, 40 mA,
▪▪ modem type telecommunications V23, 1200 bps,
▪▪ maximum line length: 10 km.
Variant 2 Underground equipment is supplied via local power supplies and communication between the surface
and underground sections is maintained based on PROFIBUS DP communication protocol.
Underground control and monitoring instruments
Underground equipment comprises, among others, the following:
▪▪ detectors allowing ongoing monitoring of coal mine atmosphere parameters, such as CH4, O2, CO, CO2, temperature,
humidity, pressure, differential pressure, air flow rate;
▪▪ control and monitoring stations;
▪▪ underground computers.
SCADA
Wonderware InTouch
INDUSTRIAL ETHERNET
SCADA
Wonderware InTouch
INDUSTRIAL ETHERNET
OTHER
SYSTEMS
STATION LEVEL
INDUSTRIAL
ETHERNET
Dispatcher`s level
Visualization
ARCHIVING
CONTROL
REPORTING ITP..
SIMATIC PLC
Module power supply and transmission
MZT-10 / 60M
SURFACE
MDJ-250 intrinsically safe shaft cage station control system
UDERGROUND
0,4-2V
Mo2
MCH
MRC
MEASURING/CONTROL
UNDERGROUND DEVICES LEVEL
DCH IR
DRC
DHT
DOX
ZCZ-MP
DCO
DCD IR
DCH
PROFIBUS DP (OPTICAL LUB Cu)
MDJ315-2DPEx
MDJ7001
PROFIBUS DP (OPTICAL LUB Cu)
MCO
MM-4
Telemetric LINE MAX. Length 10km, Supply 60VDC / 40mA, COMMUNICATION 1200bps V23
AS-3ES
0,4-2V
0,4-2V
0,4-2V
MCCD-01
MDJ7001
Power supply
MDJ6001
0,4-2V
AS-3ES
MRC
MCH
ET2000Ex
MDJ6001
V23
ZCZ-MP
ZCZ-MP
MDJ315-2DPEx
0,4-2V
Mo2
AS-3ES
ET2000Ex
MHT
MCO
MRC
MCH
- SIGNAL SHAFTS
- AUTOMATIC CONVEYOR SCALE
- LOADING AND UNLOADING SKIPS
- CONTROL BELT CONVEYORS
- CLIMATE CONTROL
- CONTROL AUXILLARY DEVICES
- CONTINUOUS MONITORING MINE ATMOSPHERE PARAMETERS
- IMPLEMENTATION OF AUTOMATIC EXEMPTION EN. ELECTRIC.
IN THE EVENT OF THREATS
power
▪▪ A single MDJ315-2DPEx PLC controller for the complete automation system of cage hoist shaft bottoms,
which simplifies programming, update and monitoring/diagnostics of the system.
▪▪ Full visualization, monitoring and diagnostics of the system, with data archiving in MDJ7001 computers.
▪▪ Optional data transfer to the mine computer systems.
▪▪ Easy integration with the shaft signaling and hoist control systems, to visualize the loading system
at the hoist engine display.
▪▪ Programming with the standard Step7 software package.
▪▪ The components compatible with the shaft signaling system and skip loading/discharge one.
▪▪ Radio-link with the rope force gauge allows controlling the weight of the cage load.
Implementation of reliable automation standards in the mining industry
MDJ315-2DPEx intrinsically safe PLC controller
▪▪ It can operate in areas with methane and coal dust explosion hazards (mining
industry).
▪▪ The controller is programmable with the Step7 (Siemens) tool package.
▪▪ The MDJ315-2DPEx controller may act as the master for ET2000Ex controllers,
which allows for expansion of the number of output-input signals to be processed.
▪▪ The controller’s highly advanced computing power and its communication
capabilities allow meeting the requirements applicable to all automation systems
being used in the mining industry.
▪▪ It is mainly used in skip loading and discharge automation systems, control of
shaft bottom equipment for cage hoists, conveyors’ control, intrinsically safe shaft
signaling systems and control systems for Ex-version hoist.
REX-01 intrinsically safe automatic conveyor scales
▪▪ The REX-01 scales is an intrinsically safe device designated for
underground mine applications. It can work, depending on the
implemented software and sensors, either as a conveyor,
or bunker scales.
▪▪ The scales are integrated with a MDJ315-2DPEx or ET2000Ex
intrinsically safe controller, and its configuration
and programming can be performed with the Step7 (Siemens) tool
package.
Intrinsically safe input/output module with Profibus DP communication ET2000Ex
▪▪ It can operate in areas with methane and coal dust explosion hazards (mining
industry)
▪▪ Main features: redundancy, reliability, modular structure, configuration flexibility.
▪▪ It may function as a remote input-output gate for a PLC controller, or operate as an
autonomous (off-line) controller.
▪▪ It provides comprehensive support for all levels of shaft signaling (transmitters,
sensors, acoustic and light signals, visualisation).
▪▪ The device is mainly used in intrinsically safe shaft signaling installations, and also
in skip loading and unloading systems, cage hoist shaft bottom equipment control,
and control systems for Ex-version winders.
MDJ7001 flame proof mine computer
▪▪ Visualisation of technological processes in underground
automation systems.
▪▪ Compatible with MDJ315-2DPEx, ET2000Ex, MDJ6001
and other brand intrinsically safe controllers.
▪▪ Compatibility with reliable communication protocols, well
established in the industry for years, ensures safe data transfer
with other elements of the automation system.
▪▪ Two keyboard types: standard QWERTY or 9-key one.
▪▪ Large and legible 19” monitor.
MDJ6001 intrinsically safe controller
▪▪ It can operate in spaces with methane and coal dust explosion hazards
(mining industry)
▪▪ Dedicated to monitor and control moderately complex technological systems.
▪▪ It can function as a long distance remote input-output gate in more complex control
or data collection systems.
▪▪ The MDJ6001 controller is applied to control mining conditioning systems, pump
stations, sump drainage systems, by-the-shaft equipment,
and shunting railways and skip loading systems.
SEP-16 separator of intrinsically safe and non intrinsically safe signals
▪▪ It ensures separation between ia or ib intrinsically safe circuits,
and the non intrinsically safe ones.
▪▪ Two-way signal transmission.
▪▪ Max. 16 separated input/output bistate connections.
▪▪ Wide range of power supply voltages.
wrzesień 2014
MDJ Electronic LTD., ul.Gliwicka 233, 43-190 Mikołów, Poland
tel. +48 32 322 59 42, +48 32 326 00 40, fax. +48 32 326 00 41
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biuro@mdj pl
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www
mdj
pl