Documento Recuperado

SERRA SUL PROGRAM
N1030-01
MINE/PLANT DESIGN
TITLE
SERRA SUL PROGRAM MINE/PLANT DESIGN
PRODUCT STOCK YARD
TEACHING MATERIAL FOR TRAINING
BUCKET WHEEL RECLAIMER RC-2092KS-01 TO 04VALE No.
DF-MO-2092KS-M-501E-E-002PAGE
1/73DHI No.
REV.
1REVISIONSRP: REVISION PURPOSEA PRELIMINARY
B
FOR APPROVALC FOR INFORMATION
D
FOR QUOTATIONE FOR CONSTRUCTION
F
AS PURCHASEDG AS BUILT
H
CANCELLEDRev.RP
Revision DescriptionPrep.Che.Appr.Aut.Date0B
FOR APPROVALWZJTANMAVM30/07/101ECERTIFIEDWZJTANMAVM21/12/12
QLK11000.50 Reclaimer
RC-2092KS-01 TO 04
TEACHING MATERIAL FOR TRAINING
VALE s No. DF-MO-2092KS-M-501E-E-002-R0

Foreword
Dear customer,
Thank you for choosing our product?
For proper erection and installation, safe handling and failure-free operatio
n of the bucketwheel reclaimer/reclaimer, please read carefully Operation Manual f
or the machine, with special care to the safety warnings and safe specification
sections.
Please store this Operation Manual for the machine at a convenient place for ea
sy availability and timely reference in case of questions.
This Operation Manual is delivered to the equipment user, with preserved propri
etary right by DHIDCW Group Co., Ltd. Without our authorization or permission, th
e provided technical specifications, drawings and sketches may not be all or par
tly photocopied, distributed, used for competition or provided to a third party.
Please properly maintain the Operation Manual within the lifetime of the equip
ment.
This Operation Manual is applicable for bucketwheel reclaimer/reclaimer produc
t.
This Operation Manual includes the following parts:
Chapter 1 Summary;
Chapter 2 Safety;
Chapter 3 installation, commissioning;
Chapter 4 Usage and operation;

Chapter 5 Service and maintenance;
This document is electrical part.
If your questions can not be answered in this document, please contact us and we
will be pleased to provide any help to you.
Our contact information:
Address: No.169, bayi road, xigang district, Dalian city, Liaoning province
Postal code: 116013
Website?http://www.dhidcw.com
Contact telephone no.:0411-86852188 E-mail:[email protected]
Customer service center: 0411-62999688
Fax no.:0411-86852553 E-mail:[email protected]
CHAPTER 1 SUMMARY
CONTENTS
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1.1 Main application and scope of operation
PAGEREF
1.1.1 Main application
PAGEREF _Toc257732335 \h
1.1.2 Scope of operation
1.1.3 Parameters of reclaimer
PAGEREF _Toc2577
1.1.4 Material and Physical Characteristics

1.2 Technical Characteristics
PAGEREF _Toc2577
1.2.1 The type of power supply and power

1.2.2 Capacity of power
PAGEREF
PAGEREF
1.2.3 Operating Environment Conditions
PAGEREF
1.2.4 Operating Condition PAGEREF _Toc257732343 \h

1.3 Composition of electrical system
PAGEREF
1.3.1 Drive
PAGEREF _Toc257732345 \h 3
1.3.2 Transformer PAGEREF _Toc257732346 \h 3
1.3.3 Panel box and desk PAGEREF _Toc257732347 \h
1.3.4 Field instruments
1.3.5 Light
1.3.6 Anti fire system
1.3.7 Vibration management system PAGEREF _Toc2577
1.3.8 Position and anti-collision system
PAGEREF
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1.3.9 Local operation components
PAGEREF _Toc2577
1.3.10 Telecommunication system
PAGEREF _Toc2577
1.3.10.1 CCTV
1.3.10.2 Access
1.3.10.3 Communication system
PAGEREF _Toc2577
1.3.11 Safety protection
1.3.11.1 Interlock between different structures

1.3.11.2 Process limit
1.3.11.3 Emergency switch PAGEREF _Toc257732361 \h

1.3.11.4 Anti-collision protection
1.4 Function of working
PAGEREF _Toc2577

SUMMARY
Attention: This Instructions is for control and Operation of QLK11000.50 reclaim
er only.
1 General
1.1 Main application and scope of operation
Reclaimers are widely used for handling and conveying bulk materials such as ore
, coal and coke in stockyards of mines, ports, thermal power plants, steel plant
s, coke oven plants, cement plants and chemical plants. They are large size, hig
h efficiency and mobile mechanical equipment that continuously handle and convey
bulk materials. The operators can operate the equipment by way of manual, semia
utomatic and automatic operation (unmanned operation) as well as manual unit ope
ration at machine side.
1.1.1 Main application
This reclaimer is designed to run on the runway rails in the bulk material stock
yard. Its
main function is to reclaim the material from the stockpile at both sides of rai
ls and convey
it to the designated place via the yard belt conveyer.
The manual operation and semiautomatic operation of bucket-wheel reclaimer will
be
achieved by the operator in the operator s cabin or from CCR.
It is forbidden that the reclaimer being used for another function, such as auxi
liary hauling and hoisting equipment.
1.1.2 Scope of operation
QLK11000 50 type reclaimer is designed and manufactured for Vale S11D project for
reclaiming operation of ore material of the project.
While in reclaiming operation, the height of pile is 18m and shall be separated
to 3 layers for reclaiming, the thickness of each layer is 6m, each layer of pil
e shall be reclaimed via the bucketwheel turning.
Control modes of the reclaimer include: manual and full automatic (unmanned) ope
ration.
1.1.3 Parameters of reclaimer
Reclaimer capacity?Nominal capacity: 8000t/h
Design capacity : 11000t/h
Slewing Radius:
50m
Slewing Angle:
175
Slewing speed:
0-0.14r/min
Belt Speed:
4.6m/s
Luffing Angle:
-14~13
Luffing speed(boom tail pulley):
4.5m/min
Travelling speed:
0~25m/min
Mode of power supply: power cable reel
Mains voltage: 4160 V
Mains frequency: 60 Hz
Position of power supply: middle of whole travel of reclaimer
1.1.4 Material and Physical Characteristics
Sort of material: sinter feed/pellet feed
Grain size of material: 13+.015/-0.15 mm
Bulk density: 2.6/2.05 t/m3
Moisture content: 10?
Angle of repose: 33~38
1.2 Technical Characteristics
For detail please refer to mechanical manual DF-MM-2092KS-M-501E-M-001, item 1.3
.3
1.2.1 The type of power supply and power
power supply feed to high-voltage power distribution system via HV-cable from su
bstation connecting to cable reel, please refer to the diagram: DF-2092KS-M-501E
-E-002----GENERAL SINGLE LINE DIAGRAM.
Power supply?
AC4.16KV?60Hz
LV power supply?
AC480V?60Hz
Control feeding?
AC120V?60Hz
Lighting Power Supply?
AC380/220V?60Hz
Maintenance power supply?
AC480V?60Hz
AC220V?60Hz
PLC feeding?
AC120V?60Hz
PLC input?
AC120V?60Hz
PLC output?
AC120V?60Hz
1.2.2 Capacity of power
Table 1.1
Total capacity
About1520kWMax.demand1370kW1.2.3 Operating Environment Con
ditions
For detail please refer to mechanical manual DF-MM-2092KS-M-501E-M-001, item
1.4
When the wind speed is more than 80 km/h during operation, the material m
ust be
emptied from the equipment system and the ore reclaimer stopped and the rail cla
mps and
wheel brakes in the traveling mechanism are safely applied on the rails.
When the wind speed is more that 120 km/h during operation, the ore reclaimer mu
st be driven to
the parking position, and horizontally fixed and dragged. The anchoring devices
and rail clamps
must be locked in order to ensure that the reclaimer can not be moved by the
wind. All the joysticks
in the operator s cabin are returned to zero. All the power supplies are disco
nnected and the main
circuit breaker is powered off. All the doors and windows are closed. The or
e reclaimer can not be
used if it is forecasted that the earthquake will occur.
1.2.4 Operating Condition
The following requirements must be met during normal operation of ore reclaimer.
If any of the
requirements as specified are not satisfied, use of the ore reclaimer is forbidd
en.
The operating environment conditions of equipment are within normal range;
All components and parts of mechanical, electrical and hydraulic systems in the
equipment are in
normal operating condition;
The safety and protective devices located in the equipment and on the ground are
in normal operating condition;
The system area where the equipment is located is in normal operating condition;
It must be ensured that there is no risk in the working area of equipment and it
s components.
The reclaimer operator must hold the qualification certification for operating t
his equipment;
Operator of reclaimer/reclaimer should operate strictly in accordance with opera
etoian process?
It is only allowed to use reclaimer and its onboard equipment for its original f
unctional activities and strictly forbidden to use reclaimer and its onboard equ
ipment for activates irrelevant to reclaiming operation and equipment maintenanc
e;
During operation it is strictly forbidden for operator to leave his post, sleep,
be absent minded and do other activities, and should make timely treatment in c
ase finding fault.
Treatment of fault without any description should follow essential electric comm
on sense and fundamental logic and rational principle, and consultancy to specia
lized service people and equipment manufacturer should be made.
1.3 Composition of electrical system
Reclaimer has 2 E-house,1 cabin,the E-house on under part of machine(+R3) were s
eparated into LV part, MV part and transformer part; the E-house on upper part o
f machine(+R2) were separated into LV part and MV part, the cabin is located in
the top end of boom. All routine operation can be done on the console desk insid
e cabin, necessary signal for operation and maintenance can be displaied on HMI,
all panels were layout in the E-house reasonably. For detail please refer to th
e drawings
DF-2092KS-M-501E-E-053---- LAYOUT OF UNDER E-HOUSE,
DF-2092KS-M-501E-E-045---- LAYOUT OF UPPER E-HOUSE
DF-2092KS-M-501E-E-054----LAYOUT OF CABIN

Picture 1.1 general layout
Local operation, semi-automation operation and maintenance operation can be done
on the machine.
?Under E-house, MV part
MV distribute panel(QD-2092KS-100)-----MV incoming and power feeding for power t
ransformer
Lighting transformer feeder(QD-2092KS-100)-----Power feeding for illuminate tran
sformer
?Under E-house, LV part
MCC(MC-2092KS-102)----MCC for clamp,lubrication and other under driving except t
ravelling and cable reel.
1,2# travelling panel(RF-2092KS-100/101)
Cable reel driver(RF-2092KS-103)
2# Illumination panel(QL-2092KS-100)----Power feeding for under part lighting of
machine
DC Panel(QD-2092KS-102)----Power feeding for MV control
Control panel(QD-2092KS-101)----Power feeding for control system
Under PLC panel(PL-2092KS-101)
Brake resistor(RC-2092KS-01-BR0501/0502)---- Brake resistor for travelling
Brake resistor(RC-2092KS-01-BR0505)---- Brake resistor for cable reel
125V battery panel(QD-2092KS-103)----Battery for DC panel
?Under E-house, Transformer part
Power transformer(TF-2092KS-100)
Illuminate transformer(TL-2092KS-100)
Ground resistor(RS-2092KS-100)------combined with power transformer
?Upper E-house, MV part
MV belt feeder(MC-2092KS-100)----Power feeding for boom conveyor motor

MV bucketwheel feeder(MC-2092KS-101)----Power feeding for bucketwheel motor
?Upper E-house, LV part
MCC(MC-2092KS-103)----MCC for luffing,lubrication and other upper driving except
slewing.
1,2# slewing panel(RF-2092KS-102/103)
Upper PLC panel(PL-2092KS-100)
Brake resistor(RC-2092KS-01-BR0503/0504)---- Brake resistor for slewing
?Cabin
Console desk(PO-2092KS-100)
1# illumination panel(PI-2092KS-100)----Power feeding for upper part lighting of
machine
1.3.1 Drive
Different drivings met matched system, for detail please refer to following tabl
e:
Table 1.2
SystemModelQuantitySpecificationRemarkTraveling
Integrated with gear box12AC440V?15kWVVVF drivingClamp motorIntegrated with clam
p4AC440V?1.73kWCable ReelIntegrated with cable reel1AC440V?1.5kWVVVF drivingSlew
ingIntegrated with gear box4AC440V?15kWVVVF drivingBelt conveyor1AC4kV?500kWBuck
etwheel1AC4kV?400kWLuffingIntegrated with pump3AC440V?55kWTwo for running, anoth
er for spareElectric hoist1AC440V?7.8kW1.3.2 Transformer
Power transformer?TF-2092KS-100??AC4.16kV/AC0.48kV,500kVA;
Illumination transformer?TL-2092KS-100??AC0.48kV/AC0.38kV,50kVA;
1.3.3 Panel box and desk
Table 1.3
No.TagLocationDescriptionreference1+R1Operator cabinDF-2092KS-M-501E-E-0542PO-20
92KS-100/200/300/400+R1Operation tableDF-2092KS-M-501E-E-038PI-2092KS-100/200/30
0/400+R1Illumination panel +C9ADF-2092KS-M-501E-E-0433+R3Under E-houseDF-2092KSM-501E-E-0534MC-2092KS-102/202/302/402+R3Under MCCDF-2092KS-M-501E-E-033RF-2092K
S-100/200/300/400+R3Long travelling panel +C2ADF-2092KS-M-501E-E-034RF-2092KS-10
1/201/301/401+R3Long travelling panel +C2BDF-2092KS-M-501E-E-035PL-2092KS-101/20
1/301/401+R3PLC Panel +C6BDF-2092KS-M-501E-E-042QL-2092KS-100/200/300/400+R3Illu
mination panel +C9BDF-2092KS-M-501E-E-039QD-2092KS-101/201/301/401+R3Control Pan
el +C0ADF-2092KS-M-501E-E-044QD-2092KS-102/202/302/402+R3DC PanelDC Panel maualQ
D-2092KS-103/203/303/403+R3Battery PanelDC Panel maualRS-2092KS-100/200/300/400+
R3Earthing resistor panelResistor panel maualQD-2092KS-100/200/300/400+R3MV Dist
ribution panelDF-2092KS-M-501E-E-004RF-2092KS-103/203/303/403+R3Cable reel inver
ter panelCable reel manualTF-2092KS-100/200/300/400+R3Power transformerDF-2092KS
-M-501E-E-005TL-2092KS-100/200/300/400+R3Illuminate transformerDF-2092KS-M-501EE-006RC-2092KS-01/02/03/04-BR0501/0502+R3Brake resistor for long travellingResis
tor manualRC-2092KS-01/02/03/04-BR0505+R3Brake resistor for cable reelCable reel
manual3+R2Upper E-houseDF-2092KS-M-501E-E-053PL-2092KS-100/200/300/400+R2PLC Pa
nel +C6ADF-2092KS-M-501E-E-041RF-2092KS-102/202/302/402+R2Slewing panel +C4ADF-2
092KS-M-501E-E-070RF-2092KS-103/203/303/403+R2Slewing panel +C4BDF-2092KS-M-501E
-E-071MC-2092KS-103/203/303/403+R2Upper MCC +C5DF-2092KS-M-501E-E-068MC-2092KS-1
00/200/300/400+R2MV boom conveyor feeding panelDF-2092KS-M-501E-E-061MC-2092KS-1
01/201/301/401+R2MV bucketwheel feeding panelDF-2092KS-M-501E-E-063RC-2092KS-01/
02/03/04-BR0503/0504+R2Brake resistor for slewingResistor manual+FField on machi
neDF-2092KS-M-501E-E-057/058/046JB-2092KS-120/220/320/420+FLeft LT junction boxJ
B-2092KS-121/221/321/421+FRight LT junction boxJB-2092KS-123+FTripper car juncti
on boxJB-2092KS-122/222/322/422+FBoom junction boxJB-2092KS-125/225/325/425+FLuf
fing hydraulic junction boxJB-2092KS-124/224/324/424+FCabin level hydraulic junc
tion box
JB-2092KS-117/217/317/417
+F
Left rail clamp local control station
JB-2092KS-118/218/318/418
+F
Right rail clamp local control station
JB-2092KS-116
+F
Cable reel local control station
JB-2092KS-115/215/315/415
+F
Boom conveyor local control stationJB-2092KS-119/219/319/419+FCabin level local
control stationJB-2092KS-102+FLeft travel maintenance box(AC440V)JB-2092KS-103+F
Left travel maintenance box(AC220V)JB-2092KS-104+FRight travel maintenance box(A
C440V)JB-2092KS-105+FRight travel maintenance box(AC220V)JB-2092KS-106+FSlew pla
teform maintenance box(AC440V)JB-2092KS-107+FSlew plateform maintenance box(AC22
0V)JB-2092KS-108+FBoom maintenance box(AC440V)JB-2092KS-109+FBoom maintenance bo
x(AC220V)HSS-2092KS-2005/2205/2405/2605+FLeft travel emergency stationHSS-2092KS
-2006/2206/2406/2606+FRight travel emergency stationHSS-2092KS-2008/2208/2408/26
08+FLuffing emergency stationHSS-2092KS-2009/2209/2409/2609+FBucketwheel emergen
cy stationHSS-2092KS-2007/2207/2407/2607+FSlewing emergency station1.3.4 Field i
nstruments
Several type of instruments were set on the machine for detection and protection
, For detail of that please refer to DF-LR-2092KS-M-501E-E-005---MAIN COMPONENT
LIST; DF-2092KS-M-501E-E-058---INTERCONNECTION DRAWING; DF-2092KS-M-501E-E-057--TRAVELLING PART LAYOUT;
DF-2092KS-M-501E-E-065--- UPPER PART OF SLEWING LAYOUT
The instrumentsare listed and described below
?1.4
No.NameTagFunctionReference1Illumination system1.1Light sensorRS-2092KS-2001Dete
ct light to ON/OFF lights DF-2092KS-M-501E-E-0062Long travelling system2.1FWD op
erational end limitZS-2092KS-2053Forward operational LS for travellingDF-2092KSM-501E-E-0082.2FWD emergency end limitZS-2092KS-2054Forward emergency LS for tra
vellingDF-2092KS-M-501E-E-0082.3REV emergency end limitZS-2092KS-2055Backward em
ergency LS for travellingDF-2092KS-M-501E-E-0082.4REV operational end limitZS-20
92KS-2056Backward operational LS for travellingDF-2092KS-M-501E-E-0082.5Left anc
hor limit switchZS-2092KS-2057NO----left anchor locked OFF----left anchor unlo
ckedDF-2092KS-M-501E-E-0082.6Right anchor limit switchZS-2092KS-2058NO----Right
anchor locked OFF----Right anchor unlockedDF-2092KS-M-501E-E-0082.7Left travel
ling brake limit switch 1~6#ZS-2092KS-2001~2006NO----The brake released OFF---The brake closedDF-2092KS-M-501E-E-0082.8Right travelling brake limit switch 1~
6#ZS-2092KS-2007~2012NO----The brake released OFF----The brake closedDF-2092KS
-M-501E-E-0082.9Left travelling emergency stopHSS-2092KS-2005Emergency switch on
left side of travelingDF-2092KS-M-501E-E-0082.10Right travelling emergency stop
HSS-2092KS-2006Emergency switch on right side of travelingDF-2092KS-M-501E-E-008
2.111# travelling rotary encoderZT-2092KS-2001Detect the absolute position for t
ravellingDF-2092KS-M-501E-E-0082.122# travelling rotary encoderZT-2092KS-2002Det
ect the absolute position for travelling(compare the value with 1#)DF-2092KS-M-5
01E-E-0082.13Derailing detectorZS-2092KS-2119Detect the balance of gantryDF-2092
KS-M-501E-E-0082.14RFIDZE-2092KS-2011Detect the section of travelling DF-2092KSM-501E-E-0083Rail clamp system3.1Left rail clamp valvePV-2092KS-2021?2022When it
is acting, the clamp should be openedDF-2092KS-M-501E-E-0093.2Right rail clamp
valvePV-2092KS-2023?2024When it is acting, the clamp should be openedDF-2092KS-M
-501E-E-0093.3Lifted limit switch for left rail clampZS-2092KS-2069?2071Lifted l
imit switch for left rail clampDF-2092KS-M-501E-E-0093.4Falled limit switch for

left rail clampZS-2092KS-2070?2072Falled limit switch for left rail clampDF-2092
KS-M-501E-E-0093.5Oil pressure alarm for left rail clampPS-2092KS-2017?2018Detec
t high oil pressure and send the signal to PLCDF-2092KS-M-501E-E-0093.6Lifted li
mit switch for right rail clampZS-2092KS-2073?2075Lifted limit switch for right
rail clampDF-2092KS-M-501E-E-0093.7Falled limit switch for right rail clampZS-20
92KS-2074?2076Falled limit switch for right rail clampDF-2092KS-M-501E-E-0093.8O
il pressure alarm for right rail clampPS-2092KS-2019?2020Detect high oil pressur
e and send the signal to PLCDF-2092KS-M-501E-E-0094Cable reel------please refer
to the manual of cable reel Under lubrication system5Under lubrication system5.1
Travelling 1# lubrication station alarmZS-2092KS-2181Fault signal of 1# travelli
ng lubrication stationDF-2092KS-M-501E-E-0125.2Low oil level travelling 1# lubri
cation stationZS-2092KS-2182Low oil level of 1#travelling lubrication stationDF2092KS-M-501E-E-0125.3Travelling 2# lubrication station alarmZS-2092KS-2183Fault
signal of 2# travelling lubrication stationDF-2092KS-M-501E-E-0125.4Low oil lev
el travelling 2# lubrication stationZS-2092KS-2184Low oil level of 2#travelling
lubrication stationDF-2092KS-M-501E-E-0125.5Travelling 3# lubrication station al
armZS-2092KS-2185Fault signal of 3# travelling lubrication stationDF-2092KS-M-50
1E-E-0125.6Low oil level travelling 3# lubrication stationZS-2092KS-2186Low oil
level of 3#travelling lubrication stationDF-2092KS-M-501E-E-0125.7Travelling 4#
lubrication station alarmZS-2092KS-2187Fault signal of 4# travelling lubrication
stationDF-2092KS-M-501E-E-0125.8Low oil level travelling 4# lubrication station
ZS-2092KS-2188Low oil level of 4#travelling lubrication stationDF-2092KS-M-501EE-0125.9Traveling lubrication end pressureZS-2092KS-2010~2013Over normal End pre
ssure DF-2092KS-M-501E-E-0126Substructure auxiliary system6.11#funnel thruster e
xtend LSZS-2092KS-2120DF-2092KS-M-501E-E-0136.21#funnel thruster shrink LSZS-209
2KS-2121DF-2092KS-M-501E-E-0136.32#funnel thruster extend LSZS-2092KS-2122DF-209
2KS-M-501E-E-0136.42#funnel thruster shrink LSZS-2092KS-2123DF-2092KS-M-501E-E-0
136.5Left chute thruster extend LSZS-2092KS-2124DF-2092KS-M-501E-E-0136.6Left ch
ute thruster shrink LSZS-2092KS-2125DF-2092KS-M-501E-E-0136.7Left chute jammed L
SZS-2092KS-2109DF-2092KS-M-501E-E-0136.8Left rip cord detector for ground beltZS
-2092KS-2101~2104DF-2092KS-M-501E-E-0136.9Right chute thruster extend LSZS-2092K
S-2126DF-2092KS-M-501E-E-0136.10Right chute thruster shrink LSZS-2092KS-2127DF-2
092KS-M-501E-E-0136.11Right chute jammed LSZS-2092KS-2110DF-2092KS-M-501E-E-0136
.12Right rip cord detector for ground beltZS-2092KS-2105~2108DF-2092KS-M-501E-E0137Slewing system7.11#slew brake openZS-2092KS-2065The signal of brake openDF-2
092KS-M-501E-E-0147.22#slew brake openZS-2092KS-2066The signal of brake openDF-2
092KS-M-501E-E-0147.5Slew left operational end limitZS-2092KS-2025Left operation
al LS of slewingDF-2092KS-M-501E-E-0147.6Slew left emergency end limitZS-2092KS2026Left emergency LS of slewingDF-2092KS-M-501E-E-0147.7Slew right operational
end limitZS-2092KS-2027Right operational LS of slewingDF-2092KS-M-501E-E-0147.8S
lew right emergency end limitZS-2092KS-2028Right emergency LS of slewingDF-2092K
S-M-501E-E-0147.9Slew across belt limit switchZS-2092KS-2064If it is avaliable c
ombined with the signal ZS-2092KS-2063---Luff level limit switch, slewing across
belt shoud be forbiddenDF-2092KS-M-501E-E-0147.10Over temp70---slew 1# reductio
n gearTS-2092KS-2002The signal of over temp of 1# slewing reducerDF-2092KS-M-501
E-E-0147.11Over temp70---slew 2# reduction gearTS-2092KS-2003The signal of over
temp of 2# slewing reducerDF-2092KS-M-501E-E-0147.12Over temp70---slew 3# reduct
ion gearTS-2092KS-2004The signal of over temp of 3# slewing reducerDF-2092KS-M-5
01E-E-0147.13Over temp70---slew 4# reduction gearTS-2092KS-2005The signal of ove
r temp of 4# slewing reducerDF-2092KS-M-501E-E-0147.14Slew emergency stopHSS-209
2KS-2007Emergency switch near slewing systemDF-2092KS-M-501E-E-0147.15Slew 1#
encoderZT-2092KS-2003Detect the absolute angle for slewingDF-2092KS-M-501E-E-01
47.16Slew 2#
encoderZT-2092KS-2004Detect the absolute angle for slewing(compare the value wi
th 1#)DF-2092KS-M-501E-E-0148Luffing system8.1Luff local emergency stopHSS-2092K
S-2008Emergency switch near luffing systemDF-2092KS-M-501E-E-0158.2Luff up opera
tional end limitZS-2092KS-2059Luffing up operational LSDF-2092KS-M-501E-E-0158.3
Luff up emergency end limitZS-2092KS-2060Luffing up emergency LSDF-2092KS-M-501E

-E-0158.4Luff down operational end limitZS-2092KS-2061Luffing down operational L
SDF-2092KS-M-501E-E-0158.5Luff down emergency end limitZS-2092KS-2062Luffing dow
n emergency LSDF-2092KS-M-501E-E-0158.6Luff level limit switchZS-2092KS-2063See
Item 6.7DF-2092KS-M-501E-E-0158.7Luff 1# ball valve stateZS-2092KS-2137For detai
l refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.8Luff 2# ball v
alve stateZS-2092KS-2138For detail refer to the manual of hydraulic systemDF-209
2KS-M-501E-E-0158.9Luff 3# ball valve stateZS-2092KS-2139For detail refer to the
manual of hydraulic systemDF-2092KS-M-501E-E-0158.10Luff 4# ball valve stateZS2092KS-2140For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E0158.11Luff 5# ball valve stateZS-2092KS-2141For detail refer to the manual of h
ydraulic systemDF-2092KS-M-501E-E-0158.12Luff 6# ball valve stateZS-2092KS-2142F
or detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.13Luff
pump 1# butterfly valve stateZS-2092KS-2131For detail refer to the manual of hyd
raulic systemDF-2092KS-M-501E-E-0158.14Luff pump 2# butterfly valve stateZS-2092
KS-2132For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158
.15Luff pump 3# butterfly valve stateZS-2092KS-2133For detail refer to the manua
l of hydraulic systemDF-2092KS-M-501E-E-0158.16Luff pump 4# butterfly valve stat
eZS-2092KS-2134For detail refer to the manual of hydraulic systemDF-2092KS-M-501
E-E-0158.17Luff pump 5# butterfly valve stateZS-2092KS-2135For detail refer to t
he manual of hydraulic systemDF-2092KS-M-501E-E-0158.18Luff pump 6# butterfly va
lve stateZS-2092KS-2136For detail refer to the manual of hydraulic systemDF-2092
KS-M-501E-E-0158.19Oil return filter jammedPS-2092KS-2007For detail refer to the
manual of hydraulic systemDF-2092KS-M-501E-E-0158.201# High pressure filter jam
medPS-2092KS-2008For detail refer to the manual of hydraulic systemDF-2092KS-M-5
01E-E-0158.212# High pressure filter jammedPS-2092KS-2009For detail refer to the
manual of hydraulic systemDF-2092KS-M-501E-E-0158.22Temperature measuring hydra
ulic stationTS-2092KS-2007Analog signal of hydraulic station temperatureDF-2092K
S-M-501E-E-0158.23Pump exit pressure measuringZS-2092KS-2002Analog signal of out
put pressure of pumpDF-2092KS-M-501E-E-0158.24Oil level measuringPS-2092KS-2089A
nalog signal of oil levelDF-2092KS-M-501E-E-0158.25Pressure measuring 1 left hyd
raulic cylinderPS-2092KS-2003Analog signal of pressure of left hydraulic cylinde
rDF-2092KS-M-501E-E-0158.26Pressure measuring 2 left hydraulic cylinderPS-2092KS
-2004Analog signal of pressure of left hydraulic cylinderDF-2092KS-M-501E-E-0158
.27Pressure measuring 1 right hydraulic cylinderPS-2092KS-2005Analog signal of p
ressure of right hydraulic cylinderDF-2092KS-M-501E-E-0158.28Pressure measuring
2 right hydraulic cylinderPS-2092KS-2006Analog signal of pressure of right hydra
ulic cylinderDF-2092KS-M-501E-E-0158.29Luffing 1# encoderZT-2092KS-2005Detect th
e absolute angle for luffingDF-2092KS-M-501E-E-0158.30Luffing 2# encoderZT-2092K
S-2006Detect the absolute angle for luffing(compare the value with 1#)DF-2092KSM-501E-E-0158.311# Spill valvePV-2092KS-2001DF-2092KS-M-501E-E-0158.322# Spill v
alvePV-2092KS-2002DF-2092KS-M-501E-E-0158.33Directional control valvePV-2092KS-2
0034/3 way directional valveDF-2092KS-M-501E-E-0158.34Directional control valveP
V-2092KS-20044/3 way directional valveDF-2092KS-M-501E-E-0158.35Proportional val
vePV-2092KS-20054/3 way proportional valveDF-2092KS-M-501E-E-0158.36Proportional
valvePV-2092KS-20064/3 way proportional valveDF-2092KS-M-501E-E-0159Boom convey
or system9.1Boom conveyor left anti collision switchZS-2092KS-2051Anti collision
signal ---left side of boomDF-2092KS-M-501E-E-0169.2Boom conveyor right anti co
llision switchZS-2092KS-2052Anti collision signal ---right side of boomDF-2092KS
-M-501E-E-0169.3Belt misalignmentZS-2092KS-2077~2080Signal of belt misalignmentD
F-2092KS-M-501E-E-0169.4Speed sensorSS-2092KS-2001The signal of belt speedDF-209
2KS-M-501E-E-0169.5Belt tension LSSS-2092KS-2111The signal of belt tensionDF-209
2KS-M-501E-E-0169.6Boom conveyor brake openZS-2092KS-2021DF-2092KS-M-501E-E-0169
.7Boom conveyor brake closedZS-2092KS-2022DF-2092KS-M-501E-E-0169.8Under speed s
witchSS-2092KS-2002The signal of lower speed of beltDF-2092KS-M-501E-E-0169.9Ove
rhaul bracket limit switchZS-2092KS-2116DF-2092KS-M-501E-E-0169.10Oil temp measu
ring boom belt reduction gearTS-2092KS-2006The analog signal of belt reducer tempe
ratureDF-2092KS-M-501E-E-0169.11Coupling temperature sensorTS-2092KS-2001The ana
log signal of belt coupling temperatureDF-2092KS-M-501E-E-0169.12Distance measur
ing device ZS-2092KS-2115The signal of pile heightDF-2092KS-M-501E-E-0169.13Saft
y pull line on left sideHSS-2092KS-2001Emergency switch on left side of beltDF-2

092KS-M-501E-E-0169.14Safty pull line on right sideHSS-2092KS-2002Emergency swit
ch on right side of beltDF-2092KS-M-501E-E-01610Bucketwheel system10.1Bucketwhee
l emergency stopHSS-2092KS-2009Emergency switch near bucketwheel systemDF-2092KS
-M-501E-E-01710.2Brake LSZS-2092KS-2023The signal of brake openDF-2092KS-M-501EE-01710.3Reducer oil flow detecterPS-2092KS-2023DF-2092KS-M-501E-E-01710.4Reduce
r filter jammingPS-2092KS-2024DF-2092KS-M-501E-E-01710.5Oil temp measuring bucke
twheel reducerTS-2092KS-2010DF-2092KS-M-501E-E-01710.6Coupling temperature senso
rTS-2092KS-2009The analog signal of bucketwheel coupling temperatureDF-2092KS-M501E-E-01711Cabin level system11.11# ball valve state cabin levelingZS-2092KS-2143
The state of 1# ball valve for cabin levelDF-2092KS-M-501E-E-01811.22# ball valv
e state cabin levelingZS-2092KS-2144The state of 1# ball valve for cabin levelDF-2
092KS-M-501E-E-01811.3Feed back oil filter jammedPS-2092KS-2022DF-2092KS-M-501EE-01811.4Cabin level detecterZS-2092KS-2118The analog signal of cabin levelDF-20
92KS-M-501E-E-01811.5Station Temp/level measuringTS-2092KS-2008DF-2092KS-M-501EE-01811.6Spill valve for cabin levelPV-2092KS-2007DF-2092KS-M-501E-E-01811.7The
valve for cabin luffing upPV-2092KS-2008The valve for cabin luffing upDF-2092KSM-501E-E-01811.8The valve for cabin luffing downPV-2092KS-2009The valve for cabi
n luffing downDF-2092KS-M-501E-E-01812Upper lubrication system12.1Slew lubricate
station alarmZS-2092KS-2191Alarm signal of slewing lubricationDF-2092KS-M-501EE-01912.2Slew lubricate station low levelZS-2092KS-2192The signal of low oil lev
el of slewing lubricationDF-2092KS-M-501E-E-01912.3Boom lubricate station alarmZ
S-2092KS-2193Alarm signal of boom lubricationDF-2092KS-M-501E-E-01912.4Boom lubr
icate station low levelZS-2092KS-2194The signal of low oil level of boom lubrica
tionDF-2092KS-M-501E-E-01912.5Bucketwheel lubricate station alarmZS-2092KS-2195A
larm signal of bucketwheel lubricationDF-2092KS-M-501E-E-01912.6bucketwheel lubr
icate station low levelZS-2092KS-2196The signal of low oil level of bucketwheel
lubricationDF-2092KS-M-501E-E-01912.7slewing lubrication end pressurePS-2092KS-2
014Over normal End pressureDF-2092KS-M-501E-E-01912.8Boom lubrication end pressu
rePS-2092KS-2015Over normal End pressureDF-2092KS-M-501E-E-01912.9Bucketwheel lu
brication end pressurePS-2092KS-2016Over normal End pressureDF-2092KS-M-501E-E-0
1913Anemometer system13.1AnemometerST-2092KS-2002The analog signal of wind speed
DF-2092KS-M-501E-E-02213.2Wind direction sensorST-2092KS-2001The analog signal o
f wind directionDF-2092KS-M-501E-E-02214Belt scale system14.1Belt scale controll
erWT-2092KS-2001DF-2092KS-M-501E-E-02414.2Weighting sensorWT-2092KS-2002DF-2092K
S-M-501E-E-02414.3speed sensorWT-2092KS-2003DF-2092KS-M-501E-E-0241.3.5 Light
For the location of all lights please refer to the drawing
DF-2092KS-M-501E-E-055---- ILLUMINATION LAYOUT.
1.3.6 Anti fire system
The wire temperature detectors are set in the cable closet of MCC, it can detect
the high temperature of power cable and send the signal to fire fighting system
(For detail of fire fighting system please refer to the appendix 3-manual of wir
e detector and drawing DF-2092KS-M-501E-E-023--- FIRE DETECTER SYSTEM). The term
inal connectors are located in CONTROL PANEL +C0A. In case cable temperature in
MCC cable room gets too high,the terminal connector will send out alarm signal t
o fire fightingsystem, fire fightingsystem will automatically send out alarm and
start to extinguish fire.
SHAPE \* MERGEFORMAT
Picture 1.2 Application example of wire temperature detector
1.3.7 Vibration management system
Some vibration/temprature detectors are set for important part of machine,it can
detect abnormal temperature rise and vibration change. Please refer to the tabl
e 1.5 and drawing DF-2092KS-M-501E-E-067--- V/T DETECTOR LAYOUT and DF-2092KS-M501E-E-029--- ASSET MANAGEMENT DIAGRAM for detail position of sensors. For detai
l of system, please refer to the manual.
Table 1.5 vibration detectors
NO.POSITIONSIGNALSENSOR MODELQUANTITYTAG1BEND PULLEYAccelerometerCMPT23104*6VE-2
092KS-3001/3201/3401/3601 TO 3006/3206/3406/3606Accelerometer/Temp.CMPT2310T4*6U
E-2092KS-3001/3201/3401/3601 TO 3006/3206/3406/36062TAKE UP PULLEYAccelerometerC
MPT23104*2VE-2092KS-3007/3207/3407/3607 TO 3008/3208/3408/3608Accelerometer/Temp
.CMPT2310T4*2UE-2092KS-3007/3207/3407/3607 TO 3008/3208/3408/36083BOOM CONVEYOR
DRIVE PULLEYAccelerometerCMPT23104*2VE-2092KS-3009/3209/3409/3609 TO 3010/3210/3
410/3610Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3009/3209/3409/3609 TO 3010/321
0/3410/36104BOOM CONVEYOR DRIVE REDUCERAccelerometerCMPT23104*4VE-2092KS-3011/32
11/3411/3611 TO 3014/3214/3414/3614Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3011
/3211/3411/3611 TO 3012/3212/3412/36125BOOM CONVEYOR DRIVE MOTORAccelerometerCMP
T23104*2VE-2092KS-3015/3215/3415/3615 TO 3016/3216/3416/3616 Accelerometer/Temp.
CMPT2310T4*2UE-2092KS-3013/3213/3413/3613 TO 3014/3214/3414/36146SLEWING DRIVE R
EDUCERAccelerometerCMPT23104*4VE-2092KS-3017/3217/3417/3617 TO 3020/3220/3420/36
20Accelerometer/Temp.CMPT2310T4*4UE-2092KS-3015/3215/3415/3615 TO 3018/3218/3418
/36187BUCKET WHEEL MOTORAccelerometerCMPT23104*2VE-2092KS-3021/3221/3421/3621 TO
3022/3222/3422/3622Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3019/3219/3419/3619
TO 3020/3220/3420/36208BUCKET WHEEL SHAFTAccelerometerCMPT23104*2VE-2092KS-3023
/3223/3423/3623 TO 3024/3224/3424/3624Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3
021/3221/3421/3621 TO 3022/3222/3422/36229BUCKET WHEEL DRIVE REDUCERAcceleromete
rCMPT23104*4VE-2092KS-3025/3225/3425/3625 TO 3028/3228/3428/3628Accelerometer/Te
mp.CMPT2310T4*2UE-2092KS-3023/3223/3423/3623 TO 3024/3224/3424/36241.3.8 Positio
n and anti-collision system
Redundant encoders are provided for position detecting of travelling (ZT-2092KS2001/2002), slewing(ZT-2092KS-2003/2004) and luffing(ZT-2092KS-2005/2006). Posit
ion signals are communicated to CCR via optical fiber ethernet(the radio is set
for spare). CCR can learn the exact position of each machine and calculate the d
istance between two machines on the same rail, CCR should command the machine to
stop, if its distance is within dangerous scope.
Two wire type protectors(ZT-2092KS-2051/2052) are also provided along both side
of the boom, they can act when boom is going to touch some obstruction. When the
boom luffs down, the pile laser detector---( ZS-2092KS-2115) can detect if the
boom shall be touching the pile and send the signal to control system to stop th
e action.
1.3.9 Local operation components
?Console desk
Picture 1.3 Console desk

Console desk is in operator s cabin, arrangement refer to drawing DF-2092KS-M-501E
-E-054---LAYOUT OF CABIN. For console top arrangement please refer to Picture 4
and 5 as shown below.
Left desk

Picture 1.4 Left desk
-JS1201,1301 is joystick for boom luffing and slewing, the symbol is same with t
hat in the circuit diagram.
-SB0201,0202 are pushbuttons for main LV power ON/OFF.
Right desk

Picture 1.5 Right desk
-JS0501 is joystick for long travelling.
-SA2401 is turnbutton for rain wiper ON/OFF, -SA2402 is turnbutton for wash spra
yer ON/OFF.
-SE0202 is emergency mushroom button, when the operator finds danger, he can pus
h it to cut off all power.
All other function can be operated or displayed on HMI,Please refer to chapt
er 4.
?HMI
HMI model is ABB PP865, In addition to the founction of joysticks and the button
s above, all operation, monitoring and trouble shooting can be done on HMI, whic
h can also display history record print report and shoot fault etc, the start pi
cture is showed below, for detail please refer to chapter 4.

Picture 1.6 Start picture of HMI
1.3.10 Telecommunication system
1.3.10.1 CCTV
There are 6 cameras on the machine, all the cameras are controled by CCR via Eth
ernet, and the pictures are displayed on the screen in CCR, please refer to the
picture below.
For detail please refer to the manual of CCTV.

Picture 1.7 Scheme of CCTV
1.3.10.2 Access
For the layout of access system, please refer to.
DF-2092KS-M-501E-E-053----LAYOUT OF UNDER E-HOUSE.
DF-2092KS-M-501E-E-045----LAYOUT OF UPPER E-HOUSE.
DF-2092KS-M-501E-E-054----LAYOUT OF CABIN.
For detail please refer to the manual
1.3.10.3 Communication system
Normally the communication between machine and CCR should be done via optical fi
ber, the automation systen and telecom system are separated by using different o
ptical fibers. There are two sets of radio on the machine as spare, one for auto
mation and the other for telecom, which should be avaliable in case the optical
fiber fails. For detail please refer to the drawing DF-2092KS-M-501E-E-036---PLC
AND TELECOMMUNICATION ARCHITECTURE.
Main components of communication system
?Switch for automation:
Model: RS30-16020606SDAEHC, specification: 16*100Mbit ports, 2*1000Mbit uplink p
orts(for optical fiber).
?Switch for telecom:
Model: WS-C2960-8TC-L, specification: 8*100Mbit ports, 1*1000Mbit uplink ports(f
or optical fiber).
?Radio sets
Model: AIR-LAP1522AG-A-K9?specification: Ethernet TCP/IP, Data transfer rate 54Mbp
s, Operating frequency 5.8 GHz
1.3.11 Safety protection
1.3.11.1 Interlock between different structures
? Interlock between drive and brake, all the drives must be started after respec
tive brake opens
? Interlock between Travelling, cable reel, anchor, clamp and boom position
The anchors and clamps must be open, the cable reel must be started, before trav
elling starts; the boom must be parallel to rail when the machine travels in hig
h speed.
? Interlock between slewing and luffing, when the switch ZS-2092KS-2063----LUFF
LEVEL LIMIT SWITCH is available, slewing should be limited to the right part or
left part of rail, can t slew across the ground belt(ZS-2092KS-2068---- SLEW ACROS
S BELT LIMIT SWITCH should be available, the boom slewing across the ground belt
is restricted), if the operator want to slew across the ground belt, he must li
ft the boom up untill the signal of LUFF LEVEL LIMIT SWITCH is eliminated.
? Interlock between boom belt, Bucketwheel and ground belt.
When reclaiming is started, the boom belt can t be started untill the ground belt
running; the bucketwheel can t be started untill the boom belt running. If the gro
und belt is failed to running, the boom belt must stop immediately, and same bet
ween boom belt and bucketwheel.
1.3.11.2 Process limit
?Long travelling
Forward operational LS for travelling----------------------- ZS-2092KS-2053
Backward operational LS for travelling--------------------- ZS-2092KS-2056
?Slewing
Left operational LS of slewing------------------------------- ZS-2092KS-2064
Right operational LS of slewing------------------------------ ZS-2092KS-2066
Slew-across-belt limit switch-------------------------------- ZS-2092KS-2068
?Luffing
Luffing up operational LS------------------------------------- ZS-2092KS-2059
Luffing down operational LS--------------------------------- ZS-2092KS-2061
Luff level limit switch----------------------------------------- ZS-2092KS-20
63
1.3.11.3 Emergency switch
?Boom conveyor
Emergency switch---- HSS-2092KS-2001,2002, these wire switches are provided alon
g both sides of belt, when the person on the boom notice danger, he can pull the
wire to stop the conveyor immediately.
?Long travelling
Left side emergency button station------------- HSS-2092KS-2005
Right side emergency button station----------- HSS-2092KS-2006
Forward emergency LS for travelling----------------------- ZS-2092KS-2054
Backward emergency LS for travelling--------------------- ZS-2092KS-2055
?Slewing
Slewing emergency button station--------------- HSS-2092KS-2007
Left emergency LS of slewing-------------------------------- ZS-2092KS-2065
Right emergency LS of slewing------------------------------ ZS-2092KS-2067
?Luffing
Luffing emergency button station -------------- HSS-2092KS-2008
Luffing up emergency LS------------------------------------ ZS-2092KS-2060
Luffing down emergency LS-------------------------------- ZS-2092KS-2062
1.3.11.4 Anti-collision protection
Anti-collision detector---- ZT-2092KS-2051/2052, these wire detectors are provid
ed along both sides of boom, when it touchs some obstacle, a signal will be sent
to the control system to stop boom slewing.
Traveling encoder(ZT-2092KS-2001/2002), slewing encoder(ZT-2092KS-2003/2004) and
luffing encoder(ZT-2092KS -2005/2006) respectively detects traveling distance,
slewing angle and luffing angle, and sends signal to CCR, centeral control syste
m will determine based on such information if the machine is going to run into a
ny obstacles and send stop order to the reclaimer in advance to prevent accident
s.
1.4 Function of working
Abbreviation
PLC-------------Programmable Logic Controller
HMI-------------Human Machine Interface. A graphical personal computer system pr
oviding operator controls, Alarms and status indication.
E-House------Electrical Switchroom
LCS------------Local Control Station, which is the individual control station ad
jacent to each drive or drive system.
CCR-----------Central Control Room
The discription for the code on all drawing:
Function code: =XXXX
Position code: +XXXX
Component code: ?XXXX
Table 1.6
System drawing NO.Function codeEnglish descriptionChinese description DX01=HVHig
h voltage system??????DX02=LV
Low voltage system??????DX03=IL
Illuminatin
g system??????DX04=PC PLC control system PLC????DX05=LT Long travel system??????

DX06=RCRail Clamp system???????DX07=WHCWheel Clamp system???????DX08=CR Cable re
el system????????DX09=DS Dust suppression system????????DX10=LBBSubstructure lub
ricate system????????DX11=ASBSubstructure auxiliary system????????DX12=SL?RK?Sle
wing?Rake? system??(??)????DX13=LF
?TR?Luffing?Trolly? system??????????DX14=BCBoom conveyor system????????DX15=ICIn
termediate Conveyor system????????DX16=BTBelt tension system????????DX17=BWBucke
t wheel system ??(??)????DX18=TCTripper car system??????DX19=YCLYard conveyor li
fting system???????DX20=CMCar moving system????????DX21=CLCabin levelling system
?????????DX22=LBPSuperstructure lubricate system????????DX23=ASPSuperstructure a
uxiliary system????????DX24=WSWashing system??????DX25=AMAnemometer system??????
?DX26=FRFire Detection system????????DX27=BSBelt scale system???????DX28=CSCommu
nication system??????DX29=ITVIndustrial TV system??????DX30=ASMAsset management
system??????DX31=ASMAccess control system????
Table 1.7 Position code
Code NO. of box, console and cabinetFunction code English descriptionChinese des
cription+R1=SRCabin???+R2=SRUpper E-house???????+R3=SRUnder E-house???????????+D
1=SRLeft console desk????+D2=SRRight console desk????+C0=SRControl panel???+P1=S
RInstrument panel???+C1=SRLV distribute panel?????+C2=SRTraveling driving panel?
????+C3=SRAuxiliary driving panel?????+C4=SRSlewing driving panel???????????+C5=
SRLV Belt & luffing driving panel???????+C6=SRPLC panelPLC???+C7=SREngineer stat
ion?????(PC????)+C8=SRLV Bucketwheel driving panel?????+C9=SRIllumination panel?
????+HA01=SRMV income panel?????????+HA02=SRMV distributing panel?????????+HA03=
SRMV belt driving panel?????+HA04=SRMV Bucketwheel driving panel?????+HA05=SRMV
illumination feeder?????+HA06=SRPower fact compensation????? +MB1=SRMaintenance box
?????+MB2=SRMaintenance box?????+MB3=SRMaintenance box?????+GB1=SRMV yard power
junction box???????+CB1=SRYard control junction box???????+OB1=SROpital Junction
box?????+TEJB=SRLT Encoder Junction box????????+SEJB=SRSL Encoder Junction box?
???????+LEJB=SRLF Encoder Junction box????????+SL.JB=SRSL Junction box?????+LF.J
B=SRLF Junction box?????+LT.JB1=SRLT Junction box 1???????+LT.JB2=SRLT Junction
box 2???????+BC.HEAD=SRBC HEAD Junction box???????+BC.TAIL=SRBC TAIL Junction bo
x???????+CL.JB=SRCL Junction box????????+DS.JB=SRDS Junction box?????+CRP.JB=SRC
RP Junction box???????+CRC.JB=SRCRC Junction box???????+IL.JB=SRIL Junction box?
????+LF.LCS=SRLocal Control Station?????+BC.LCS=SRLocal Control Station?????+BW.
LCS=SRLocal Control Station?????+LT.LCS=SRLocal Control Station?????+SL.LCS=SRLo
cal Control Station?????????+CRP.LCS=SRLocal Control Station???????+CRC.LCS=SRLo
cal Control Station???????+RC.LCS=SRLocal Control Station??????+YCL.LCS=SRLocal
Control Station?????+DS.LCS=SRLocal Control Station?????+IL.LCS1=SRLocal Control
Station???????+IL.LCS2=SRLocal Control Station???????+LF.LES=SRLocal emergency
station??????+BC.LES=SRLocal emergency station??????+BW.LES=SRLocal emergency st
ation??????+LT.LES1=SRLocal emergency station????????+LT.LES2=SRLocal emergency
station????????+SL.LES=SRLocal emergency station??????+YCL.LES=SRLocal emergency
station??????+R2.LES=SRLocal emergency station???????+R3.LES=SRLocal emergency
station???????+LF.HB=SRLF Hydraulic box???????+YCL.HB=SRYCL Hydraulic box?????+C
L.HB=SRCL Hydraulic box???????+RC.HB1=SRLeft RC Hydraulic box????????+RC.HB2=SRR
ight RC Hydraulic box????????+BW.HB=SRBW Hydraulic box???????+BW_CH.HB=SRBW chut
e Hydraulic box??????????+IC_CH.HB=SRIC chute Hydraulic box??????????+CT_CH.HB=S
RCenter chute Hydraulic box?????????
CHAPTER 2 SAFETY
CONTENTS
TOC \o "1-3" \h \z \u
HYPERLINK \l "_Toc257733363" 2.1 General description
3
HYPERLINK \l "_Toc257733364" 2.2 Items to be complied with and forbidden
PAGEREF
_Toc257733364 \h 3
HYPERLINK \l "_Toc257733365" 2.3 Definition and position of warning signs and warn
ing labels
HYPERLINK \l "_Toc257733366" 2.3.1 Definition of signs and labels
PAGEREF _Toc2577
33366 \h 3
HYPERLINK \l "_Toc257733367" 2.3.2 Positions for hanging indication and sign

HYPERLINK \l "_Toc257733368" 2.3.3 Symbols for instruction reader
PAGEREF _Toc2577
33368 \h 3
HYPERLINK \l "_Toc257733369" 2.4 Indication of hazardous areas and cautions for en
tering such areas
HYPERLINK \l "_Toc257733370" 2.5 Notes for safe operation
3
HYPERLINK \l "_Toc257733371" 2.6 Notice before operation
3
HYPERLINK \l "_Toc257733372" 2.7 Safety notice during operation
PAGEREF _Toc2577
33372 \h 3
HYPERLINK \l "_Toc257733373" 2.8 Safety notice when operation is finished
PAGEREF
_Toc257733373 \h 3
HYPERLINK \l "_Toc257733374" 2.9 Other safety notice and measures
PAGEREF _Toc2577
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SAFETY
2.1 General description
The safety content specified in this part is to ensure equipment and personal sa
fety, so as to realize safe production. During operation of the equipment, in ad
dition to the terms listed by such specification, the regulations specified by t
he national law and regulations related to the equipment also must be complied w
ith. Using, checking and servicing of the electrical devices on the equipment mu
st comply with requirement specified in law and regulations of corresponding tra
de.
2.2 Items to be complied with and forbidden
Companies undertaking site installation and commissioning and end user should co
mply with the following items:
Only personnel who have received proper training of reclaimer operation and under
stand basic safety and accidental prevention specification are authorized to ope
rate this equipment. Operators must be professionals who have been trained and p
assed the examination. Other unauthorized people should stay away from the equip
ment and installation area. and professional may operate the equipment only when
it is necessary for the job and should strictly follow all operation procedures
.
Only personnel who have relative knowledge on safe operation of equipment and hav
e read and understood the safety regulations and warning notes in this documents
are authorized to work on reclaimer. Other unauthorized people should stay away
from the equipment and installation area.
This equipment is to be operated by professional operators, either in mode of onb
oard operation and remote operation. Therefore without permission, no one should
stay in the perimeter of the equipment, even when the equipment is not in opera
tion, because the equipment may start and operate at any time.
During installation, commissioning, and operation, unauthorized people should sta
y away from the equipment and equipment working area.
For the authorized personnel working on reclaimer, the end user and installation
and commissioning company will provide necessary safety protection equipment (sa
fety helmet, safety harness, working suit, gas mask, special protection equipmen
t, etc.), and provide special instructions.
Personnel working on the reclaimer should comply with the requirement and put on
safety protection equipment, the best is do not ware long hair (long hair is to
be done up) and do not ware loose suits or jewelries, because these items may ea
sily caught up by the equipment and result in personal injury.
End user and installation and commissioning company should check from time to tim
e if their workers comply with safety operation regulations.
End user and installation and commissioning company should ensure safety document
s are always stored on the reclaimer for reference on occasions.
End user and installation and commissioning company should provide instructions a
bout laws and other accident prevention and environmental protection safety spec
ifications to be followed (e.g. Specifications for handling hazardous materials,

etc.).
End user and installation and commissioning company should supplement the documen
ts with other internal instructions of the company(e.g. Supervision and reportin
g function, factory features, working organization, working cycles, employed per
sonnel, etc.).
Regularly check if all safety devices are installed correctly and in proper wor
king condition.
During operation of the equipment, it is forbidden to stay within the following d
angerous area:
areas within reach of the boom;
front of the equipment;
material transit area;
belt conveyor area.
Under the following condition, the safety devices may be dismantled:
after confirming power for the mechanism is shut down;
when taking appropriate measures, the reclaimer is sure not to have accidents
again;
being maintenance or serviced by trained professionals;
all existing safety devices must be regularly checked.
Do not take fire lightly, it may happen occasionally. Make sure fire extinguisher
s are provided in inflammable area, and working personnel onboard must exactly k
now the position of fire extinguisher (operator s cabin, electric room, hydraulic
room, and hydro-chamber).
Make sure reclaimer is in safe condition and at good technical level, which are t
he basic conditions for safe operation, make sure all safety equipment and devic
es (safety protective device, safe position limit, emergency stop pushbutton, so
und damper, explosion proof facilities, etc.) Are in normal mounting position an
d running normally before the reclaimer is allowed to be started.
Before starting reclaimer, make sure no one is likely to be hurt when reclaimer i
s started and running.
Check external hazards warning indications?and safety devices are working normall
y, at least once a day.
Any potential changes, including change of operation situations, should be immedi
ately reported to responsible person of respective sections. If necessary, immed
iately stop the machine and protect the reclaimer (e.g. Shut off main switch or
push down emergency stop switch, etc.).
In case of fault, immediately cut off main switch of the reclaimer, and take prop
er measures to prevent reconnection of reclaimer main switch, immediately elimin
ate the fault.
Comply with specification in the document; follow switching procedures of indicat
or lights and indicator, etc.
After starting the controller, keep hands away from all switches or pushbuttons,
lest pushing causes mal-operation.
During normal operation of the reclaimer, do not turn on any safety devices.
Installation, commissioning, maintenance, etc. of the electrical equipment of the
reclaimer should only be done by qualified electricians, or by personnel who ha
ve received proper training under the supervision of a qualified electrician, ac
cording to electrical engineering specification and regulation.
Regularly check electrical equipment of reclaimer, tighten all loose connections,
and replace any aged or damaged cable.
Always keep electrical cabinet locked and only authorized personnel with keys or
relevant tools may open the electrical cabinet.
Certified fuse product with appropriate ampere must be used.
In case of power failure or power outage, immediately shut off mains control box
of the reclaimer.
Before making service, maintenance or repair work to equipment components, the co
mponents must be discharged. First use electrical instruments to check if the co
mponents have finished discharging, then earth it and short circuit it, to separ
ate with adjacent electrified components.
Working on electrified components is fatal. If it is a must, then there must be t

he presence of another person, and in case of emergency, this person should pres
s down emergency shutoff switch or cut off main switch, to shut down power. The
working area should be enclosed by warning line and warning sign must be provide
d. Insulated tools must be used for operation.
For carrying out installation and maintenance, shop should be provided with relev
ant tools necessary for the work.
Timely make specified adjustment, maintenance and service to the equipment, which
should be done by qualified personnel.
Before commencing any service or repair work, operator must be noticed and one su
pervisor appointed for the work.
During maintenance, service and repair, power supply for the reclaimer should be
cut off and proper measures taken to ensure no mal-operation will reconnect the
power. Procedures as below:
lock main control device, take away the key to be kept by the personnel doing main
tenance or repair.
if due to some reasons the main control device can not be locked, the main switch
and emergency cutoff switch should be cut off, with warning signs provided at bo
th switches.
at necessary positions, warning line should be used to enclose the maintenance
area.
If it is necessary to mount or replace single component or large item, it must be
carefully tied to appropriate lifting equipment and protected to ensure no dang
er will happen. It is a must to use suitable lifting equipment and tools and ens
ure they have enough load carrying capacity and are in good technical condition.
It is not allowed to stand below the lifted item or to work under the lifted go
ods. The specified lifting equipment in installation manual must be used for lif
ting up goods.
The goods must be tied by experienced person, and instructions are sent to crane
driver. The person giving instructions must be able to see the operator or must
be able to get in contact with the operator.
When doing mounting work in the air, ladders, platforms and other climbing tools
should be used to ensure safety. It is not allowed to climb onto components or e
quipment. During assembly or inspection, proper measures should be taken to prot
ect the installed or dismantled components and tools to prevent it from falling.
If it is necessary to remove safety device/safety equipment in order to carry out
installation, maintenance or repair, then the safety device/safety equipment mu
st be reinstalled as soon as the maintenance or repair work is finished, also mu
st check if they are in good working condition.
make sure all loosened bolts connections are retightened;
make sure the consumables and replaced items are handled in proper and safe si
tuation;
protect the switches and control devices to prevent from influence by water or
dust;
it is mandatory to use tools of qualified performance, appropriate tools and under
some circumstances specified tools (such as electrical installation tools, etc.
);
all rotating or open components may cause dangers of crushing or jamming, so speci
al attention should be paid;
tools or other external materials should not be stored on the equipment.
Due to danger of fire and explosion, it is only allowed to weld, flame cut or gri
nd on the reclaimer when there is definite requirement for it, and with approval
of safety department and monitoring by safety personnel. Before making any weld
ing, flame cutting or grinding, clean the reclaimer and its adjacent area, remov
e all scale or inflammable material, and keep good ventilation.
During welding work, earthing must be directly connected to the welding position;
otherwise electrical component may be damaged.
For working in narrow areas, current national laws and regulations should be
complied with.
When handling oil, glycerol and other chemical materials, pay attention to the cu
rrent safety regulation and requirement of the product.

2.3 Definition and position of warning signs and warning labels
2.3.1 Definition of signs and labels
During installation, commissioning and operation of the reclaimer, some position
s are necessary to put on relative warning signs and attention labels in order t
o prevent safety accidents, symbols and definitions refer to table 2.1.
Table 2.1 Symbols and definitions of warning signs and attention labels

A sign that safety helmet must be worn, and if not followed, head or othe
r part of the body may have danger of bruising or scuffing by fallen items from
height, or by equipment edges or corners, in serious cases may jeopardize life.

A sign that working suit must be worn, and if not followed, clothes may b
urn, leak or be scraped, other part of the clothes may have danger of being suck
ed in by rotating parts, in serious cases may jeopardize life.

A sign that
flame is forbidden, and if not followed, surrounding flammables may catch fire,
equipment or person may be hurt, in serious cases may jeopardize life and damag
e equipment.

A sign that flame is forbidden, and if not followed, surroun
ding flammables may catch fire, equipment or person may be hurt, in serious case
s may jeopardize life and damage equipment.
A sign that touch is forbidden,
indicating no direct or indirect contact with item is forbidden, and if not foll
owed, there will be danger of electric shock, liquid corrosion, burning, sucked
in by rotating part, or scuffed by such items, etc., in serious cases may jeopar
dize life and damage equipment.

A sign that passing through is forbidden,
indicating such area is dangerous, and if not followed, there will be potential
personal injury, in serious cases may jeopardize life.

A sign that saf
ety should be noted, the appearance of such sign means there are danger or possi
bility to have danger in such area or during operation process, and if not follo
wed, there will be danger that equipment or person may be hurt, in serious cases
may jeopardize life and damage equipment.

A sign that falling should be
noted, and if not followed or not careful, there will be danger of falling from
platform, handrail, high level platform, in serious cases may jeopardize life.

A sign that fire should be noted, indicating the area or articles are po
ssible to catch on fire, and if not followed, there will be fire, and in serious
cases may jeopardize life and damage equipment.

A sign that electric sho
ck should be noted, indicating the area or articles are possible to be electrica
lly charged or leaking, and if not followed, there will be electric shock, causi
ng equipment short circuit and personal injury, and in serious cases may jeopard
ize life and damage equipment.

A sign that corrosion should be noted, ind
icating the articles are possible to corrode equipment, human body, environment,
etc., and if not followed or noted, there will be possibility of equipment dama
ge, personal injury, and environment pollution, and in serious cases may jeopard
ize life and damage equipment.
2.3.2 Positions for hanging indication and sign
Positions for hanging indication and sign refer to table 2.2, and indication and
sign should be provided by Installation Company or end user.
Table 2.2 Positions for hanging indication and signs
Indication and signsDescription
Hanging position
Ware safety helmet, w
ear working suitAll stairs entry to the reclaimer
Caution of falling, note saf
etyBy the edge of all platform, passage and handrail
No flame, no smokingOper
ator s cabin
Note safety, caution of fireElectric room
Caution of electric s
hock, no touching
High temperature and inflammable, caution of corrosionHydra
ulic room
Caution of electric shock, no through passingAll stairs entry to po
wer supply devices
No through passingUnfinished areas such as platform and han
drail, lifting area, mechanism moving area and passage area where component asse
mbly is carrying on overhead, etc., and use warning line to isolate.
2.3.3 Symbols for instruction reader
This instruction will include the following symbols, please learn carefully abou
t the definition and purpose of all indication symbols, see table 2.3.
Table 2.3 Definition and purpose of indication symbols
Indication symbols
Definition
Appearance of such symbols indicates there are
important content to warn relevant people, if not followed it may result in ins
tallation fault, equipment damage during equipment installation, commissioning,
operation and maintenance, and in serious cases injury or death may happen.

Appearance of such symbols indicates there are important content to warn relev
ant people, if not followed it may result in equipment damage or personal injury
during equipment installation, commissioning, operation and maintenance.
A
ppearance of such symbols indicates there are important content to warn relevant
people, if not followed it may result in major equipment damage or personal inj
ury accident during equipment installation, commissioning, operation and mainten
ance.
Appearance of such symbols indicates there are proposing content to
warn relevant people, if not followed it may result in unsatisfactory operation
of equipment, improper maintenance, untimely service, etc.
2.4 Indication of hazardous areas and cautions for entering such areas
Personnel authorized to work on reclaimer must know about the hazardous areas of
the equipment, learn by heart the location of such areas to prevent personal in
jury. Hazardous areas of the reclaimer see table 2.4.
Table 2.4 hazardous areas of the reclaimer
Hazardous areas Location Cautions to prevent dangerPotential injuryBelt conveyor
Notice operating belt conveyorSlewing deviceNotice operating slewing deviceLuffi
ng deviceNotice operating luffing deviceTraveling deviceNotice operating traveli
ng devicePotential falling dangerAll stairs to the equipmentHold on handrail tig
htEdge of all platforms close to handrail Never extend your body out over top of
the handrail Potential jammingMaterial transmit areaNo entry into such area dur
ing operationPotential electric shockingTransformer room, inside electric cabine
t in electric room, external electric components No touching of electric compone
nts Potential dust explosionMaterial transmit areaNo welding allowed during oper
ation, no smoking and flame allowed in the periphery, maintenance only allowed a
fter thoroughly clean the dust and keep ventilation. Inflammables existsInside h
ydraulic room(if use flammable hydraulic oil) No smoking and flame allowed regul
arly check wire for ageing signs.
Around lubrication pumpNo smoking and flam
e allowed regularly check wire for ageing signs.
2.5 Notes for safe operation
Only personnel with relevant operation qualification are allowed to operate this
reclaimer.
If current for traveling, slewing, luffing and belt conveyor are obviously larger
than normal value, relevant leader should be reported to timely.
In case of abnormal situation of reclaimer (such as intense vibration, operator i
n the operator s cabin can feel apparent vibration),operator should notice service
personnel to find out the reason after finishing this operation cycle, to deter
mine if the problem is electrical, mechanical or hydraulic issue.
In case of the following situations, the reclaimer operator must immediately repo
rt to his manager, to get it handled by service people: Severe vibration, comple
te machine power outage and switch tripped, luffing goes down by itself, reclaim
er slides off in stopped state, etc.
Do no push down emergency stop pushbutton at will unless in special situation.
No people other than operators are allowed to go aboard the reclaimer before
permitted by the onboard operator.
Accessing and alighting from the reclaimer are only allowed when reclaimer is in
idle state.
Operator should not let irrelevant people go aboard the reclaimer.
In case of major fault of reclaimer, no one is allowed to operate the reclaimer
before the fault is eliminated, and the reclaimer should be in a locked status.
Requirement for electrical service people:
It is forbidden to operate with out qualification or service by people without fu
ll scale professional training, and service must be done by professional technic
ians.
It is forbidden to short circuit with power switched on.
It is forbidden to use megohmmeter to directly measure insulation on thyristor /I
GBT.
Before touching circuit board, personnel should discharge to earth to prevent sta
tic electricity from damaging circuit board.
Only when operator has confirmed all power supply and signal indications are norm
al, can reclaimer operation be carried out.
It is forbidden for personnel without HV operation certificate to service or main
tain on HV electrical equipment such as HV transformer, HV switchgear, etc., oth
erwise it may cause personal injury, death and equipment damage.
All rectifier, inverter and relevant equipment must be earthed.
It is forbidden to service rectifier and inverter with power switched on. If faul
t searching involves internal structure of modules, motor or motor cable, then m
ain power must be cut off for at least five minutes, until intermediate circuit
capacitor has finished discharging before making operation on converter, motor o
r motor cable. It is the best to check if converter has finished discharging bef
ore conducting work (use voltmeter).
When main power is switched on, no matter the motor is running or not, the VF mot
or cable terminals are always with dangerous high voltage.
When main circuit of converter is cut off, inside converter, dangerous voltage fr
om external control circuits still exists. Great prudence and attention should b
e paid during operation. Otherwise neglecting these safety instructions would ca
use personal injury or death.
Do not make any measure, change of spares or other service work other than those
referred to in converter manual.
2.6 Notice before operation
Check reclaimer traveling rail and ground make sure there are no obstacles.
Check drive part for any obstacles, check fastening of brake, coupling, etc., bra
ke should make good braking.
Check reclaimer track: if that the track is level and normal, ground brush is
good.
Check if metal structure and all mechanisms are normal, check if there are loose
bolts, nuts fallen on the platform.
Check lubrication of reclaimer, check if hydraulic pipeline leaks oil.
Check if reclaimer is interlocked with central control.
Check if switches and joysticks of all electrical devices are at normal positi
on.
Check if reclaimer initial position status information is correct.
Check if reclaimer power voltage is normal, if voltage exceeds normal value by10??
the machine must be stopped.
Only when it is sure the reclaimer is in normal status before the machine can be
started for operation.
2.7 Safety notice during operation
During normal operation it is not allowed any people (including operators) to be
at reclaimer track, belt conveyor, stockyard, if there is any one, all operation
must be stopped to prevent personal injury accident.
Under any circumstances, operator must pay special attention to warning system, t
o prevent damage of equipment. Before start reclaimer traveling, operator must s
end out photo acoustic alarm signal and real time warning.
Even when belt conveyor, slewing and traveling operation are in automatic operati
on mode, the operator should also carefully observe the operation status.
2.8 Safety notice when operation is finished
When finishing operation, operator should make sure of the position of long trave
l, slewing angle, luffing angle before cutting off main switch, and in addition
to that, cut off motor power as necessary.
Before operator leaving reclaimer, the machine must be stopped, and all tasks to
be done for stopping of the machine must be properly done, operator should make
proper operation log and other records.
When stopping the machine under normal situation, reclaimer should be parked at a
position that boom is parallel to the track. Properly shut the door and windows
of hydraulic room, electric room, operator s cabin and turn off illuminating ligh
t.
If without hydraulic system warning and oil cylinder speed has obvious change, th
e system should be stopped after this cycle of operation and service people for
hydraulic system should be requested to come to site to check and only after pro
blem has been dealt with before restarting of the equipment is allowed.
2.9 Other safety notice and measures
During operation, the operator should follow instruction of central control room
personnel and the interlocked information of central control room. Only when es
pecially emergent situation happens at site, can operators take relevant measure
s based on specific situation.
Overloading during commissioning is only a testing operation, and carried out wit
h all preparations, so it does not mean the machine can be overloaded during ope
ration. In case of overloading at any mechanisms, operation should be stopped in
time, and only when fault has been dealt with and situation is normal before op
eration can be continued.
When safety limit switch of a mechanism is loose, technicians should be requested
to deal with the accident immediately to find out fault reason and only after f
ault has been eliminated before the fault signal is by-passed by the bypass swit
ch installed in control cabins of all mechanisms, and restart power, move the fa
ult mechanism in opposite direction, to move out of safety limit switch activati
ng area, then reset the bypass switch and resume normal operation.
During operation the operator should always pay attention to abnormal phenomena s
uch as abnormal noise, vibration and heating, etc., in case of such abnormal phe
nomena happening, operation should be immediately stopped and reason is to be fo
und out before making any relevant handling or operation.
The operation limit switch of reclaimer is to ensure safety, during operation, th
e operator should not only use limit switches to control movement of mechanisms,
but to stop movement before the mechanism arrives at finish position. After th
e mechanism moves into deceleration area, operator should put joystick to low sp
eed position to prevent failure of deceleration from causing fault.
Operator should not leave operation position when reclaimer is in operation.
During operation of reclaimer, it is not allowed to fill oil, make adjustment, re
pair or carry out cleaning and service work. Only after power switch is cut off,
can electric equipment be serviced, and signs warning do not switch on should b
e hanged at the switch. It is not allowed to make separate movement of reclaimer
without the permission of central control interlocking information; otherwise i
t would cause major accidents.
Reclaimer must be immediately stopped in case of fault.
When reclaimer is in operation at night, the outdoor illuminating lamp should
be turned on.
CHAPTER 3 INSTALLATION,COMMISSIONING
CONTENTS
TOC \o "1-3" \h \z \u
HYPERLINK \l "_Toc258479334" 3.1 Installation conditions and technical requirement

HYPERLINK \l "_Toc258479335" 3.1.1 Inspection before installation
PAGEREF _Toc2584
79335 \h 3
HYPERLINK \l "_Toc258479336" 3.1.2 Cable reel PAGEREF _Toc258479336 \h 3
HYPERLINK \l "_Toc258479337" 3.1.3 Installation requirement for electrical control
cabinet and junction boxes
HYPERLINK \l "_Toc258479338" 3.1.4 Installation requirement for field instrumrnts
and limit switchs
HYPERLINK \l "_Toc258479339" 3.1.5 Technical requirement for resistor installtion

HYPERLINK \l "_Toc258479340" 3.1.6 Wire, cable and laying requirement PAGEREF
_Toc258479340 \h 3
HYPERLINK \l "_Toc258479341" 3.1.7 Laying of wire conduit and cable tray
PAGEREF
_Toc258479341 \h 3
HYPERLINK \l "_Toc258479342" 3.1.8 Protection earthing requirement
PAGEREF
_Toc258479342 \h 3
HYPERLINK \l "_Toc258479343" 3.1.9 Limit switch
HYPERLINK \l "_Toc258479344" 3.1.10 Lighting equipment PAGEREF _Toc258479344 \h
3
HYPERLINK \l "_Toc258479345" 3.1.11 Other electrical equipment PAGEREF _Toc2584
79345 \h 3
HYPERLINK \l "_Toc258479346" 3.2 Installation procedure, method and cautions

HYPERLINK \l "_Toc258479350" 3.2.1 Assembly of electrical equipment
PAGEREF
_Toc258479350 \h 3
HYPERLINK \l "_Toc258479385" 3.2.2 Fixing of electrical equipment
PAGEREF _Toc2584
79385 \h 3
HYPERLINK \l "_Toc258479386" 3.2.3 Fixing of cable and wire conduit and laying of
cable in cable tray and metal conduit
HYPERLINK \l "_Toc258479387" 3.2.4 Earthing
HYPERLINK \l "_Toc258479388" 3.2.5 Wire and cable connection
PAGEREF _Toc2584
79388 \h 3
HYPERLINK \l "_Toc258479389" 3.2.6 Wiring inspection and insulation test
PAGEREF
_Toc258479389 \h 3
HYPERLINK \l "_Toc258479390" 3.2.7 Drawing and document for installation
PAGEREF
_Toc258479390 \h 3
HYPERLINK \l "_Toc258479391" 3.2.8 Installation and acceptance requirement

HYPERLINK \l "_Toc258479393" 3.3 Commissioning condition, cautions and commissioni
ng method
HYPERLINK \l "_Toc258479394" 3.3.1 Commissioning condition
PAGEREF _Toc2584
79394 \h 3
HYPERLINK \l "_Toc258479395" 3.3.2 Cautions
HYPERLINK \l "_Toc258479396" 3.3.3 Commissioning method
3
HYPERLINK \l "_Toc258479397" 3.3.3.1 Commissioning preparation PAGEREF _Toc2584
79397 \h 3
HYPERLINK \l "_Toc258479398" 3.3.3.2 Circuit test
HYPERLINK \l "_Toc258479399" 3.4 Items, method and criterion of acceptance test af
ter commissioning
HYPERLINK \l "_Toc258479400" 3.5 Preparation before test run, start of test run an
d test run
HYPERLINK \l "_Toc258479401" 3.5.1 Preparation before test run PAGEREF _Toc2584
79401 \h 3
HYPERLINK \l "_Toc258479403" 3.5.1.1 Power system
HYPERLINK \l "_Toc258479404" 3.5.1.2 Hydraulic system PAGEREF _Toc258479404 \h
3
HYPERLINK \l "_Toc258479405" 3.5.1.3 Lubrication system
3
HYPERLINK \l "_Toc258479406" 3.5.1.4 Initial position of all systems
PAGEREF
_Toc258479406 \h 3
HYPERLINK \l "_Toc258479407" 3.5.2 Start of test run, test run PAGEREF _Toc2584
79407 \h 3

INSTALLATION,COMMISIONING
3.1 Installation conditions and technical requirement
This section only gives general requirement for installation of electrical equip
ment of reclaimer. For some electrical equipment with special requirement, refer
to additional drawing and electrical system instruction delivered with machine.
3.1.1 Inspection before installation
a) Clean and remove dirt and defects from electrical equipment and components,
replace damaged parts and components;
b) All movable parts and components should move freely without jamming, sticking
or loosing phenomenon;
c) All wiring fasteners are complete, and wired screws should be tightened;
d) Nonmetal part of electrical equipment installation fasteners, structures, st
eel pipe and joint, connecting parts, electricity conducting device, supports, e
tc. Should all be galvanized or coated for corrosion prevention or galvanized pr
oduct should be used.
3.1.2 Cable reel
Power supply of this machine is fed on board by flexible cable through cable ree
l, cable reels are provided on the platform of the tripper car, and interlocked
with travel drive device. Cable reels include two sets, one is power cable reel
and the other is control cable reel, both are magnetic hysteresis type, for deta
il usages see cable reel instruction.
A) Arrangement, installation and connection of cable reel assembly should f
ollow design drawing.
B) Installation of cable reel should comply with the above mentioned regulations
, and in addition, HV cable should make withstand voltage test before connection
and installation and should company with relevant specification of current issu
e of electrical equipment handover test standard for electrical device installati
on project .
3.1.3 Installation requirement for electrical control cabinet and junction boxes
A) Installation of control cabinet (panel) should comply with relevant speci
fication of VALE
B) Control cabinet (panel) should be installed inside electric room and operator s
cabin according to mechanical arrangement drawing.
C) Installation of control cabinet (panel) should be secure and reliable, to min
imize its vibration during equipment operation, and if necessary, bracing should
be added. Screen of control cabinet (panel) should have verticality error less
than 12 .
D) use 500V megohmmeter (working voltage?48V) or 250V megohmmeter (working volta
ge <48V)to measure insulation resistance between all phases and between phases t
o earth of main circuit, control circuit of the control cabinet (panel), which s
hould be not less than 0.8M? under normal environment and in humid environment n
ot less than 0.4M?. During dielectric test, insulation resistance should be not
less than 1 M?. Those electrical components (such as semiconductors, capacitors,
etc.) That can not withstand high voltage impact of megohmmeter, should be dism
antled or short circuited before testing.
3.1.4 Installation requirement for field instrumrnts and limit switchs
A) Installation height
LV electrical device should be installed at a height complying with design speci

fication, and when there is no specification in design, should meet with the fol
lowing requirement:
-- for LV electrical device mounted on the ground, its bottom should be higher t
han the ground by 50?100mm.
-- center of rotating shaft of the operating handle should be at a distance of 1
200?1500mm from ground; and operation handle on the side should be not less than
200mm away from buildings or equipment.
B) Fixing
-- LV electrical devices may be fixed to wall, column or other construction memb
ers with supports, metal plate, and insulation plate as appropriate according to
their various constructions. When using expansion bolt for fixing, the bolt siz
e should be selected according to product technical requirement, its drilling di
ameter and embedded depth should match the size of the bolt.
-- Fasteners should be galvanized products, bolt size should be chosen properly
and fixing of electrical devices should be secure and leveled. For those with an
ti-shock requirement, the fixing bolts should have anti-loosening measures.
C) External wire connection
-- Wire connection should be done according to the wire end marking. Wiring arra
ngement should be tidy, distinct and neat; conductor insulation should be good w
ithout any damage.
-- side incoming line should be connected at incoming end, i.e. Fixed contact wi
ring end; loaded side outgoing line should be connected at outgoing end, i.e. Mo
vable contact wiring end.
-- wiring of electrical device should use bolts and screws of copper material or
with electroplated metal antirust coat, which should be tightened when connecte
d and should have anti-loosen device.
-- When busbar is connected with electrical device, contact surface should compl
y with relevant specification of current national standard construction and accep
tance specification for busbar device in electrical device installation project .
Minimum electric clearance between different phases at the connection should mee
t requirement of table 3.1.
Table 3.1
Rated voltage(V)Minimum electric clearance (mm)Rated voltage (V)Minimum electric
clearance (mm)U?50010500?U?120014
-- Connection with zero point or earthing of electrical device s metal casing and
frame should meet construction and acceptance specification for earthing device i
n electrical device installation project .
-- measuring of insulation resistance between electrically charged parts and met
al frames for main circuit, control circuit and auxiliary circuit, etc. Should m
eet relevant specification of current national standard handover test standard fo
r electrical equipment in electrical device installation project .
3.1.5 Technical requirement for resistor installtion
A) Resistor element should be positioned in vertical plane. Vertical stacking of
resistor should not be more than 4 cases. When exceeding, supports should be us
ed for fixing and appropriate distance should be kept between each other; for re
sistor with special requirement, the installation method should comply with desi
gn specification. Between resistor bottom and ground there should have space int
erval of not less than 150mm.
B) When resistor is vertically arranged to other electrically devices, it should
be installed above the other electrical devices and there should have a space i
nterval between them.
C) Wiring of resistor should meet the following requirement:
-- Resistor should be wired according to terminal numbers provided on circuit di
agram, wring diagram (list). Holding plate or bolt of resistor outgoing line sho
uld have indication corresponding to equipment wiring diagram; when connecting w
ith insulating conductor, measures should be taken to prevent temperature rise a
t connection from lowering the conductor insulation strength.
-- Outgoing wire for resistor boxes stacked in multiple layers should be fixed w
ith support which should not interfere with replacement of resistor elements.
Inside of resistor should not have break circuit or short circuit; error of its
DC resistance should comply with specification of product technical document.
Cover plate or protection shield of resistor should be correctly installed, and
securely fixed.
-- wire or cable connecting resistors should have its vertical part arranged on
both left and right side of the resistor, however should not interfere with inst
alling and dismantling of resistor, and horizontal part may be wrapped up with h
eat resistance material such as asbestos rope, etc. To prevent insulation from a
geing easily by heating due to its close distance to the resistor element.
-- Actual working temperature of resistor should not be more than 350?.
3.1.6 Wire, cable and laying requirement
A) All wirings on reclaimer equipment except for light current system should use
multiple strand copper core wire or cable with rated voltage not less than 500V
. Sectional area of multiple strand wire should not be less than 1.5mm2;And sect
ional area of multiple strand cable should not be less than 1.0mm2.
B) At positions where easily have mechanical damage, heat radiation or lubricati
on oil dripping, wire or cable should be installed in steel conduit, trough, and
protection shield or take heat insulation protection measures.
C) When wire or cable is going through holes in steel structure, the holes shoul
d be deburred and protection measures should be taken.
D) Laying of cable should comply with the following requirement:
1) Cables should be arranged tidily according to the sequence of laying and shou
ld not be crossed; Cable for strong current and light current should be laid sep
arately, both ends of the cable should have tags;
2) Fixed cables should be securely held, distance between supporting points shou
ld not be more than 1m;
3) For fixed cable arrangement, its bending radius should be more than 5 times o
f cable O.D.; for movable cable arrangement, its bending radius should be more t
han 8 times of cable O.D.
4) When wire and cable are laid or protected using water pipe or gas pipe of ste
el material, total sectional area of conductors in the steel pipe (except two ca
bles) should not be more than 40% of I.D. sectional area of the steel pipe. and
I.D. of pipe should not be less than 1.5 time of cable O.D.; for relatively shor
ter pipe or larger bending radius, the requirement may be loosened as appropriat
e if it does not interfere with cable laying
5) Wire and cables laid on equipment should not have connections in the middle.
6) Both ends of all wire and cable should use corresponding copper cold welding
connectors for connection with wiring terminal of components of electrical equip
ment. For cold welding of connectors, special connector crimping tool should be
used and general purpose wire cutters are not allowed to use for pressing.
7) Laying of wire and cable should be arranged tidily and sorted in bundle to av
oid crossing. Each bundle of conductor or cable should have tags indicating bund
le number or cable number, both ends of conductor should has insulation marking
corresponding to circuit diagram and wiring diagram (list). Marking on insulatio
n conductor may be in mathematical numbers, colors or other type.
8) Cable core wire transmitting low voltage, low power signals should not be usi
ng the same cable as power cable core wire or that of different voltage ratings,
but should use a separate cable and if necessary should use shielded cables to
avoid interference.
9) Quantity of conductors on wiring terminal normally is one conductor crimped t
o one wiring screw.
3.1.7 Laying of wire conduit and cable tray
A) Steel conduit and cable tray should be securely fixed.
B) For steel conduit laying in open air, pipe opening should face downward or ta
ke other water prevention method.
C) All pipe openings should be provided with protection gland.
D) Installation of cable tray should meet requirement for laying wire or cable,
and at entry and exit of wire or cable, protection measures should be taken.
E) For AC circuit going through metal conduit or metal tray, all phase line and
N line should be put in one same enclosure, lines for different circuits should
not be going through the same conduit, except for the following cases.
-- Circuit with nominal voltage below 50V
-- Power circuit for the same equipment and control circuit without anti-in
terference requirement
-- Several circuits for the same lighting fixture
-- Several circuits for the same type of lighting, however total number of insul
ated conductors inside conduit should not be more than 8.
-- When there are several circuits in the same conduit, all insulated conductors
should have the same insulation as that for the maximum nominal voltage circuit
.
F) When laying, stator wire and rotor wire of the same motor, 3 phase AC conduct
or or DC two poled wire exceeding 25A, should be laid in the same conduit; wires
for different mechanisms or AC and DC or wires of different voltage ratings sho
uld be separately arranged in bundles, and separately laid as possible; single c
ore conductors with current-carrying capacity of over 25A are not allowed to go
through metal conduit alone; lighting circuit should be separately laid.
3.1.8 Protection earthing requirement
A) Earthing
-- earthing of reclaimer traveling track is the responsibility of end user, and
should comply with requirement of relevant specification.
-- for AC power, when supplied by slide contact line, earthing protection slide
contact line, collector ring or earthing wire should be provided.
B) Earthing of electrical equipment
-- In all electrical equipment, those may become electrically charged due to ins
ulation damage must have protection earthing provided for its metal part. Under
normal circumstances, uncharged metal casing, metal conduit, cable metal sheath,
cabinet s (panel, box) frame, body, door and LV side of lighting transformer shou
ld all be reliably earthed.
-- Connection between earthing wire and metal structure or electrical equipment
may use welding or bolt connection. For bolt connection, protection measures sho
uld be provided to ensure reliable connection. It is not allowed to use unreliab
le methods such as twisting or soldering for connection.
-- The earthing part of all electrical equipment should use separate earthing wi
re to connect with earthing busbar. It is strictly forbidden to use earthing wir
e as current carrying zero wire.
-- Fasteners for earthing device should all be galvanized parts.
C) Sectional area and resistance of earthing body
-- connection of steel earthing wire (body) should use overlap welding, welding
length should be 2times of flat bar width and welded in three sides, or 6 times
of round bar diameter and welded in two sides.
-- Sectional area of circuit earthing conductor should meet the following re
quirement, see table 3.2.
Table 3.2
Circuit sectional area (mm2 )Earthing wire sectional area (mm2 )Circuit sectiona
l area (mm2 )Earthing wire sectional area (mm2 )S?16SS ?35S/2?but earthing busba
r ;not more than 50 mm2 for copper16?S?3516Not more than 800 mm2 for steel
-- connection resistance between metal casing of all electrical equipment, poten
tial charged metal parts and components, and earthing bolts should not be more t
han 0.1?.
-- earthing resistance at any point of the equipment should not be more than 4?.
3.1.9 Limit switch
A) Ram bar installation and determine of its dimension should ensure the limit s
witch activate reliably, the ram bar and its support should not jiggle during eq
uipment operation. Ram bar s width should meet requirement of machinery (bridge an
d trolley) lateral movement range, ram bar s length should meet requirement of mac
hinery (bridge and trolley) maximum braking distance, and should not interfere w
ith movement of mechanical parts.
B) Ram block or ram bar should be installed on the movement axis of switch rolle
r or push bar. For electronic limit switch, movable equipment distance should be
adjusted according to product technical document.
C) Acting force of ram block on the switch or movement distance of the switch sh
ould not be more than allowed value.
3.1.10 Lighting equipment
A) Light fixtures should have complete fittings, and securely suspended, without
sever swing during operation.
B) Lighting circuit should have special zero line or isolation transformer, it i
s not allowed to use the earthing wire of wire conduit or equipment itself as ze
ro line.
3.1.11 Other electrical equipment
A) Other equipment not mentioned should have type no. and specification in accor
dance with the design drawing.
B) Its installation should meet relevant specification and standard.
C) refer to machine attached product Operation Manual for such equipment install
ation, adjustment and testing requirement regarding converter device, measuring
device, PLC, communication device, transformer, protection device, etc. Used on
the equipment.
It is strictly forbidden to use megameter on electronic equipment PLC, converter
, and frequency carrier, etc.
3.2 Installation procedure, method and cautions
Product installation should meet relevant content of 3.1 installation condition a
nd technical requirement .
Before commencing installation, read carefully installation instruction and deta
iled instruction of specific equipment and manufacturer s manual; carefully read d
rawing, document, know about electrical equipment working principle, cautions fo
r installation, list in detail the steps and process of installation and commiss
ioning work, and safety measures.
Installation of mechanical and electrical equipment of reclaimer must be underta
ken by companies with installation license and business license, and must be con
structed by skilled electricians in cooperation with other professions.
During installation of electrical equipment, all original records should be care
fully made. After completion of installation, there should be complete installat
ion record, and any change to original design should be indicated.
3.2.1 Assembly of electrical equipment
Installation of electrical equipment should be carried out according to installa
tion schedule; some installation should be conducting at the same time as mechan
ical assembly work:
Assembly?
Assembly is to fix and install the installation attachment of electrical equipme
nt and cable on to the equipment structure of reclaimer.
Before assembly, carefully read electrical equipment arrangement drawing and ins
tallation attachment drawing, determine the position of electrical equipment, in
cluding appropriate fixing plan. Fixing plan for LV equipment, cable trough and
limit switches should be indicated on respective mechanical drawings.
Note: in order to avoid welding current going through pivot point, the structure
must be earthed before starting welding job on the steel structure!
Fixing by welding method must be carried out before applying the top coat of equ
ipment.
1) Installation of bases or support of control cabinet, junction box

Installation of electrical cabinet should comply with relevant specification of
current national standard specification for tie line construction and acceptance
of panels, cabinets and secondary circuit in electrical device installation proj
ect , and should comply with relevant requirement in article 3.1.4.
-- General inspection on control cabinet, junction box
Check type, specification and quantity of control cabinet are complying with des
ign drawing requirement, protection type and degree should comply with relevant
standard and requirement of operation site.
-- Assembly of base or support of control cabinet, junction box
When lifting up equipment, designated lifting points should be used; care should
be taken not to damage the frame.
Drill in the base after control cabinet is placed at the appropriate position on
the base. Securely weld or bolt connect the control base and junction box suppo
rt to the appropriate position on the structure.
2) Assembly of resistor
Make general inspection on resistor before installation, and should meet 3.1.7 r
egarding technical requirement for installation of resistor .
-- Arrangement of resistor frame should be good for heat emission, easy for serv
ice and replace of resistor element.
-- a service passage of not less than 500mm should be kept in front of resistor,
distance between resistor element and floor and walls should not be less than 1
50mm.
-- Resistor frame should be secure, if necessary top of the frame may add draw p
late or tie bar.
3) Assembly of lighting and auxiliary apparatus
Before installation, please read equipment arrangement drawing, lighting circuit
diagram and installation attachment drawing.
-- check if type, specification and quantity of lighting and auxiliary equipment
are in accordance with design drawing requirement, protection type and degree s
hould comply with relevant standard and requirement of operation site.
-- fixing of installation support
Securely weld and bolt connect the supports to respective positions according to
installation and arrangement drawing, and comply with technical requirement on
the drawing.
4) Installation of limit switch and support
Assembly of limit switch is indicated on mechanical drawing.
-- before installation, check if its type, specification and quantity comply wit
h design drawing requirement, and protection type and degree should meet require
ment of relevant standard and operation site. Ram rod should move freely, rotati
ng limit switch should have correct speed ratio, and there is no damage to the p
arts.
-- Securely weld support and ram scale to the designated position according to d
rawing technical requirement.
5) Assembly of electrical conduit and cable tray
Before installation, read cable piping drawing and general drawing of electrical
equipment, to determine cable route and size of cable tray, conduit and pipe.
Assembly of route of electric conduit and cable tray should meet requirement of
GB50256-96: comply with 3.1.8 regarding technical requirement for laying of elect
ric conduit and cable tray .
-- Electric conduit, cable tray
Electric conduit and cable tray may be fixed by mechanical method or electric we
lding. When using electric welding method, welding spot should be secure to prev
ent cracking and damage at welding spot due to operation vibration and deformati
on.
-- bending of electric conduit
Electric conduit should be bended according to actual situation. Bending radius
should not be less than 5 times of O.D. of the conduit, and bending angle not le
s than 90. After bending, the conduit should not have obvious flattening defect
(flattening defect not more than 10% of pipe O.D.). When there is one 90 bend in
the line, the distance between two pulling points should not be more than 20m;an
d when there are two 90, the distance between two pulling points should not be mo
re than 15m;and when there are three 90bends, the distance between two pulling po
ints should not be more than 8m;Otherwise pipe of larger diameter should be used
.
3.2.2 Fixing of electrical equipment
1) Electrical equipment such as control cabinet, junction box, lighting, and
limit switches, etc.
-- electrical equipment must be securely fixed with hot dip galvanized or stainl
ess steel screw and nut, and using double nuts or lock nuts for reliable fixing.
Screw length must be long enough for nut or screw to appear on the other sid
e.
-- Control cabinet, junction box, lighting fixture, socket of electric room shou
ld be fixed according to arrangement drawing of electric room .
-- Equipment of operator s cabin should be arranged and fixed according to arrangem
ent drawing of operator s cabin
2) Nameplate of electrical equipment
Nameplate of electrical equipment must be fixed to the structure near the equipm
ent.
3) Cable entry of electrical equipment
Laying of equipment cable must be going in to the cabinet and electrical equipme
nt from the bottom. Protection measures should be provided at cable entry.
3.2.3 Fixing of cable and wire conduit and laying of cable in cable tray and met
al conduit
Fixing of cable and wire conduit and laying of cable in cable tray should me
et 3.1.8 technical requirement
A) General check before laying
-- Before laying cables, check cable type, specification, quantity according to
packing list, visually check for damage.
-- check if cable or wire ( except for light current system) have nominal voltag
e of not less than 1000V?and are copper core multiple strand wire or cable.
B) Installation of cable (in cable trench or cable tray)
-- cutting of cable
On site, cable should be cut to correct length. Before cutting, measure must be
done on overall structure for correct length.
-- laying of cables
Use cable tie specified in contract, fix cable in bundles inside cable tray.
According to wiring list and the requirement of separating HV, LV power, control
and lighting, arrange cables in cable tray by varieties.
To prevent cable from moving, cable tie must be pulled tight enough but not too
tight. Do not use cable ties that are too long.
-- fixing of cables?
For vertical laying, the top three fixing places at the vertical cable tray must
use two cable ties side by side, fix at other places with cable tie at every 1.
5m~2m; for horizontal laying, in addition to fixing at front, end and middle of
the cable, fix at other places with cable tie at every 5m~10m.
-- ratio of total cable area and that of cable tray should be not more than 40%
for power cable; and not more than 50% for control cable.
-- Bundle of cables in cable tray
3~10kv medium voltage cables are laid in separate cable tray.
400V-1000V cable (motor, brake and other main circuit cables):
Tie in bundles; diameter of each bundle must be less than 60mm; distance between
two bundles at least 10mm?
24V-240V cable (control cable):
Diameter of each bundle must be less than 60mm; 24V cable must be separately bun
dled with 240V cable.
Shielded cable must be separately arranged with other cables on the other side o
f cable tray, and keep a distance of at least 10cm from cables of over 24V.
Cable and bundled cable must not intersect with each other.
End of cable tray must lay rubber plate to protect cable.
C) Installation of cable in metal conduit

Laying and installation of cable in metal conduit should meet relevant requi
rement of 3.1.7.
D) Installation at pivot point
Flexible cable should be used when going through structure pivot point.
Cable loop at pivot point should be long enough to ensure free movement.
E) Installation of shielded cable
Shielded cable (shielding layer) should be connected according to wiring list. U
nless specially indicated, it is a principle to earth the cable shielding layer
at power supply end.
F) Cable exit
-- Both ends of metal conduit must be added with plastic sleeve.
-- Cable exit at electric room, HV room, main girder, operator s cabin, etc. Must
be ground smooth and protected with rubber plate.
-- When cable entry requires sealing, stainless steel or nylon cable gland s
hould be used.
-- When the interface between flexible hose and equipment requires sealing, stai
nless steel hose connector should be used.
G) Installation of cable for limit switch or lighting equipment
-- When going into limit switch or lighting equipment, some redundancy should be
reserved at its ends for the convenience of possible forming of new cable ends
(in the future). Lighting cable on inside walls and on the ceiling must be laid
inside conduit.
-- Cable ends going into limit switch or lighting equipment should have glan
ds at cable ends.
-- On both ends of conductor conduit, plastic sleeve must be added to eliminate
sharp cutting edge of the conductor conduit.
-- Flexible hose must be fixed to the cable tray with cable tie.
H) Temperature
It is forbidden to install under -10?. If stored less than zero, before laying,
cable must be preheated in a store at least 15? for 24 hours, otherwise cable wo
uld be too stiff to handle and bending may damage insulation.
Fluctuation of temperature will cause cable length change; therefore long cable
must be laid with slight bending.
I) cable wire connector
-- Conductor of cable is connected to equipment by crimped cable connector. For
crimping, special pliers must be used. And plier opening dimension must be chose
n properly according to the dimension of cable connector.
-- Size of cable connector must be chosen according to sectional area of con
ductor.
-- Motor cable of all sizes and cables going into isolating switch and big conta
ctor must use cable connector.
-- when connecting very fine strand of wire to junction box, end crimping tools
must be used to crimp and harden the end of wire.
J) Wire not used
Length of wires not used must be long enough to reach terminals in the cabinet a
nd should be tied into bundled with plastic cable tie or connected to earthing b
ar.
K) Cable marking: cable should be marked with plastic tags; cable number should
be indicated as cable list.
Note: PE wire (yellow and green) are not to be marked with terminal number.
L) Cable core wire marking
-- Wire core is to be marked with plastic wire marking sleeve, marking symbo
l should be nonfading.
-- Each core of cable must be marked with terminal number to be connected wi
th it.
-- Wire number starts from end of wire.
-- peeling length of wire end should be appropriate.
3.2.4 Earthing
Earthing of reclaimer equipment should meet 3.1.8 technical requirement.

All metal parts of electrical equipment (non-conducting part) must be earthed. F
ixed type of electrical equipment must be earthed with external earthing wire or
earthed with yellow/green wire of cable. For cables with out yellow/green color
wire, earthing conductor should be marked by yellow/green color tape.
1) Earthing bolt and nut
Pivoting place or pivoting point must be earthed with earthing bolt set and
jumper wire.
2) Earthing of electrical cabinet, metal structure, and electrical equipment ref
er to earthing drawing or earthing requirement for electrical system.
3) Earthing nut and screw must be hot dip galvanized, acid preventing or mad
e from stainless steel.
4) sectional area of earthing conductor ?
Sectional area of earthing conductor should meet relevant technical requirem
ent of 3.1.9.
3.2.5 Wire and cable connection
Wire and cable connection include wiring of parts and between parts, accordi
ng to wiring list.
A) Wiring of parts
-- wiring of equipment in electric room
Wiring of control cabinet in electric room(according to electrical equipment arr
angement diagram, electric room cable list)
Wiring of lighting equipment
Wiring of resistor(according to electric room cable list)
Wiring of air conditioner set(according to electric room cable list)
Wiring of transformer assembly(according to electric room cable list)
-- wiring between outdoor electrical equipment
-- wiring of electrical equipment in machinery room
-- wiring of electrical equipment in operator s cabin
B) Wiring between parts
-- From control console, control box in operator s cabin to control cabinet in
electric room
-- From electrical equipment to control cabinet in electric room
-- From cable reel and HV switchgear cabinet
-- From HV switchgear to HV transformer and HV motor, etc.
-- From HV transformer to power distribution cabinet in electric room
3.2.6 Wiring inspection and insulation test
1) After wring of cable, check wiring according to schematic diagram, make marki
ng properly on schematic diagram for site archiving.
2) Test power bus bar insulation and make proper record.
3) Test motor insulation
-- use 1000V megohmmeter to measure insulation resistance between all windings o
f electric motor and between windings to earth. Stator winding may be measured t
ogether with the connected cables, rotor winding may be measured together with t
he connected starting equipment, and in case winding terminals of each phase are
separately led out, insulation resistance between winding phases should also be
measured.
-- If motor is installed with embedded temperature switch or temperature detecto
r, 250V megohmmeter should be used to measure winding insulation resistance.
Measuring result should be filled in respective tables, together with the fin
ishing date, and filed into site archive.
For electric motors driven by thyristor and VFC device, before measuring insulat
ion, cables must be loosened from the device! And power should not be connected
until wiring inspection is finished.
3.2.7 Drawing and document for installation
Reclaimer has two E-houses and a cabin, the under E-house were separated into LV
part, MV part and transformer part; the upper E-house were separated into LV pa
rt and MV part. All routine operation can be done on the console desk inside cab
in, necessary signal for operation and maintenance can be displaied on HMI, all
panels were layout in the E-house reasonably. For detail please refer to the dra
wings DF-2092KS-M-501E-E-053---- LAYOUT OF UNDER E-HOUSE
DF-2092KS-M-501E-E-045----LAYOUT OF UPPER E-HOUSE
DF-2092KS-M-501E-E-054----LAYOUT OF CABIN

Picture 3.1
2 parts for total electrical installation
DF-2092KS-M-501E-E-057-------- TRAVELLING PART LAYOUT
DF-LM-2092KS-M-501E-E-057----- MATERIAL LIST OF TRAVELLING PART LAYOUT
DF-2092KS-M-501E-E-065-------- UPPER PART OF SLEWING LAYOUT
DF-LM-2092KS-M-501E-E-065----- MATERIAL LIST OF UPPER PART OF SLEWING LAYOUT
All components will be arranged as per above scheme drawings, for detail install
ation of components, please refer to the mechanical drawings DF-2092KS-M-501E-M694---- detetor and protection device
All cable connection shall be performed as per DF-LB-2092KS-M-501E-E-003-----CAB
LE LIST, the conduit and accessory for the cable shall be performed as per DF-20
92KS-M-501E-E-069-----ELECTRICAL CONNECTION ROUTE?the layout of cable tray shall
be performed as per DF-2092KS-M-501E-M-746, please refer to DF-2092KS-M-501E-E058-----INTERCONNECTION DRAWING for total cable connection.
Please refer to following drawings for detail circuit diagrams
DF-2092KS-M-501E-E-004-----MV DISTRIBUTION SYSTEM
DF-2092KS-M-501E-E-060-----MV POWER TRANSFORMER FEEDING
DF-2092KS-M-501E-E-061-----MV BELT DRIVING FEEDING
DF-2092KS-M-501E-E-062-----MV LIGHTING TRANSFORMER FEEDING
DF-2092KS-M-501E-E-063-----MV BUCKET WHEEL DRIVING FEEDING
DF-2092KS-M-501E-E-005-----LV DISTRIBUTION SYSTEM
DF-2092KS-M-501E-E-006-----ILLUMINATING SYSTEM
DF-2092KS-M-501E-E-007-----PLC SYSTEM
DF-2092KS-M-501E-E-008-----LONG TRAVELING SYSTEM
DF-2092KS-M-501E-E-009-----RAIL CLAMP SYSTEM
DF-2092KS-M-501E-E-010-----CABLE REEL SYSTEM
DF-2092KS-M-501E-E-011-----DUST CLEARING SYSTEM
DF-2092KS-M-501E-E-012-----UNDER LUBRICATION SYSTEM
DF-2092KS-M-501E-E-013-----UNDER AUX SYSTEM
DF-2092KS-M-501E-E-014-----SLEWING SYSTEM
DF-2092KS-M-501E-E-015-----LUFFING SYSTEM
DF-2092KS-M-501E-E-016-----BOOM CONVEYOR SYSTEM
DF-2092KS-M-501E-E-017-----BUCKETWHEEL SYSTEM
DF-2092KS-M-501E-E-018----- CABIN LEVEL SYSTEM
DF-2092KS-M-501E-E-019----- UPPER LUBRICATION SYSTEM
DF-2092KS-M-501E-E-020----- UPPER AUX SYSTEM
DF-2092KS-M-501E-E-021----- WIPER SYSTEM
DF-2092KS-M-501E-E-022----- ANEMOMETER SYSTEM
DF-2092KS-M-501E-E-023----- FIRE DETECTER SYSTEM
DF-2092KS-M-501E-E-024----- BELT SCALE SYSTEM
DF-2092KS-M-501E-E-025----- COMMUNICATION SYSTEM
DF-2092KS-M-501E-E-026-----CCTV DIAGRAM
DF-2092KS-M-501E-E-027----- ASSET MANAGEMENT DIAGRAM
DF-2092KS-M-501E-E-028----- ACCESS SYS DIAGRAM
DF-2092KS-M-501E-E-003----- MV NETWORK
DF-RE-2092KS-M-501E-J-001----- I/O LIST
When all electrical installation are finished, the cable connection checking sha
ll be performed as per above drawings before power feeding and commisioning, che
cking report shall be released.
DF-2092KS-M-501E-E-056---- GROUNDING SCHEME shall be as a guide for groundin
g performance.
For another related documents, please refer toDF-LD-2092KS-M-501E-G-0011----DOCUMENTS LIST

3.2.8 Installation and acceptance requirement
At the time of acceptance and handover of electrical installation work of reclai
mer equipment, the electrical equipment should be?
1)electrical installation are completely finished.
2)electric circuit wiring is correct, terminal securely fixed, well contact
ed, clearly marked.
3)insulation resistance of electrical equipment and circuit meet relevant regula
tion of the current national standard standard for handover test of electrical eq
uipment in electrical installation project .
4)power capacity, voltage, frequency meet requirement of design and operati
on of the equipment.
5)protective earthing or connection to zero is properly done.
6) Has finished inspection and adjustment of electrical equipment such as electr
ic motor, controller, contactor, brake, voltage relay and current relay, etc.
7) Safety protection device has finished simulating test and adjustment, an
d has passed inspection.
8) Installation company should provide relevant documents of electrical instilla
tion inspection and adjustment record. Records required to be provided in the do
cument should be clearly, correctly, and completely recorded, with date and resp
onsible person.
3.3 Commissioning condition, cautions and commissioning method
3.3.1 Commissioning condition
1)drawing and documents
Drawing?schematic diagram, arrangement drawing, configuration diagram, interconn
ection list, drawings for panels, consoles, boxes and cabinets.
Documents?instruction book, special parts instruction and relevant documents, et
c.
2)tools and instruments
Common electrical tools, megohmmeter, multimeter, pincers, tachometer, walkie ta
lkie, etc.
3)various caution signs, warning signs.
4)compile commissioning plan.
Including commissioning content, personnel organization and job division, safety
measures, commissioning steps, contents to be tested and requirement of recordi
ng, scheduling program, etc.
3.3.2 Cautions
1) dangerous area should hang warning sign and provide safety handrail.
2) observe passage, handrail and surrounding environment, and in case unsafe ele
ments are found, take necessary measures.
3) check or repair of electrical equipment (such as motor, limit switches, etc.)
Must be done when de-energized.
4) on first time energizing, must confirm voltage rating, confirm load side has
no abnormal phenomenon such as short circuit and earthing etc.
5) test run and mechanical interlocked operation must be done together with mech
anical personnel and relevant personnel.
6) master normal stop and emergency stop method for equipment operation, in case
of abnormality, immediately stop the equipment to prevent accident from happeni
ng and extending.
7) Installation personnel must participate and assist with the commissioni
ng.
3.3.3 Commissioning method
Installation company must provide: repair items and content during installation,
test record that have been tested, repaired devices and parts and handling conc
lusion, and remaining problems unable to be dealt with.
3.3.3.1 Commissioning preparation
1) cleaning up and inspection
Make cleaning and inspection on areas surrounding electrical elements and
parts, including:
Clean surrounding areas, clear articles interfering with commissioning, clean

up dirt.
If components are damaged, if installation is secure
Movement of element and apparatus do not have abnormal situation of blockag
e.
Setting value of time relay and thermal relay are complying with drawing require
ment, measure and record such value.
Confirm is wiring work has finished, check for any omission, all terminals are se
cure, terminal and protective hood are intact.
2) Motor, brake, etc.
Winding motor, check collecting device, if slip ring surface is smooth, dam
aged or corroded, coordination of brush frame and brush, and contacting status o
f the brush and slip ring.
Check and adjust brake for proper tightness and lock.
Manually rotate motor to confirm there is no abnormality.
Except for special mechanisms, motor should be disconnected with mechanical part
and after separately run the motor without load, and confirm by both electrical
and mechanical parties, then reconnect.
3) Check devices
Check if limit switch, proximity switch, magnetic switch, travel controller comp
ly with drawing requirement, confirm if their installation are correct, wiring o
f circuit is in accordance with drawing requirement.
4) Check wiring
Check cable type, specification and quantity, correct wiring, any misconnected
and omitted wire, according to interconnection list.
5) Routine testing
Re-measuring of insulation resistance.
Use 1000V megameter.
Measure power circuit between phases and to earth (except for converter, re
gulator, etc.)
Measure motor, transformer, brake, resistor between primary and secondary p
hase and to earth.
Control circuit to earth (except for electronic circuits PLC and I/O etc.).
Measure of DC resistance of coil of motor, transformer, brake, resistor (bridge m
easurement allowed).
PLC, converter, regulator, etc. Must not be measured with megameter.
Note: on measuring, record measuring date, time, environmental conditions, and n
atural conditions such as weather, temperature, humidity, etc., make detailed r
ecord of the measured object.
3.3.3.2 Circuit test
Is to test circuit when main circuit is cut off (mechanical and motor are not ru
nning), and test its correctness of controlling circuit and protecting circuit,
to confirm the circuit is correct and elements and devices are intact.
Confirm before testing
If environmental condition is safe, passage through, safety facilities arranged a
nd implemented.
All power switches are at off position; load side has no short circuit and earthi
ng.
All operation devices (pushbutton selector switch, cam switch) are at safe status
(initial position).
All elements with polarity (such as triode) should be tested to check if wiring i
s correct.
Passive control circuit (power supplied from converter) directly connected into c
onverter should be tested to check correctness.
Current transformer circuit should not be open circuit; voltage transformer shoul
d not have short circuit.
Power source for commissioning
For the unsafe element caused by feeding in of commissioning power source, corres
ponding safety measures should be taken, and conductor s specification and size sh
ould meet commissioning requirement.
Measure voltage of power supply, switch on main power switch.
Put in respective control power switch according to test circuit, and test voltag
e.
Test with operation elements or make simulation test on circuits not included in
PLC control according to schematic diagram.
At the same time check if its interlocking circuit and protection circuit are co
rrect.
Test on PLC control circuit, input/output interface circuit
Understand and get familiarize with PLC, PLC programming software, application s
oftware and relevant documents.
Check PC configuration, module construction, CPU module, power module and /O modu
le if voltage rating, switch setting and earthing are correct according to drawi
ng and document.
Switch on and off PLC, I/O module power, measure if voltage of the supply power i
s normal, and comply with requirement, then connect and put in according to the
sequence of need of testing process.
Connect PLC power line, put in PLC power, use programmer and application software
to load configuration into PLC through communication cable, start PLC, monitor
with programmer.
Check input interface circuit (some simple program may be programmed to observe i
f interface corresponds with respective address number).
Check output interface circuit (may force output).
Based on test result, about those not complying with drawing requirement or have
problem, timely contact should be made and in cooperation with relevant personn
el make treatment and modification, and make proper record.
Cares to be taken during testing
Carry on according to schematic diagram; make proper record to avoid omission.
Interlock and protection are to be done together or make simulation test.
During test if all components movement have no abnormality.
If mating with mechanical part (such as valves) are good.
Testing or action of each circuit should be tested for at least 2~3 times, to mak
e sure there is no mistake.
3.4 Items, method and criterion of acceptance test after commissioning
Preparation of drawing and document
Cooperation of personnel(carry out together with mechanical personnel).
Safety facility?according to site requirement, necessary safety facilities shoul
d be provided.
Use programmer to load application software into PLC, and operate. Put in contro
l power, notice if equipment are normal, and indication are normal.
Test run of motor equipment
If interlocking condition is not met, commissioning switch or short circuit may
be used to meet requirement.
Put in respective power switch, jog control element, check if rotation direction
is correct (for those driven by two motors should determine rotation direction
according to mechanical requirement). If direction is not correct, change phase
and try again.
Determination of direction. Run without load for some time; observe for abnormal
ity, measure and record no-load current, rotation speed, etc.
When trial run is finished, cut off respective motor power supply, if safety is
ensured, motor and machinery may be connected.
This test includes motors and hydraulic thrust brake motor still connected with
mechanical part, and must be done with cooperation of mechanical personnel.
Test run of oil pump
Such operation also must be done with cooperation of relevant personnel.
Start oil pump, adjust and confirm temperature, pressure, to meet requirement.
Test run of oil cylinder, steam cylinder and limit switches
Under the condition that equipment and pipelines are intact, start oil pump and
air compressor.
If action has no blockage, and interlocking condition is met or provided, use ma
nual mode to carry out each movement, observe and adjust its speed (flow rate) a
nd relevant limit switch and indicator light.
Observe pump with load and situation of load, make load adjustment.
Others
Lamp test, warning, alarm, contact signal, protection circuit may have respectiv
e simulation operation.
Test run of special devices
Carry out according to instruction for special devices.
Frequency converter
Test and determine correctness of self control circuit and relevant control circu
it
Data setting
Determine rotation direction, make no-load operation, observe and record all leve
l of rotation speed, current, starting and braking and acceleration. When finish
ing test run, connect motor with machine.
Industry TV
Operate according to instruction.
3.5 Preparation before test run, start of test run and test run
Before operate stack for production, operator should make preparation before pro
duction, check all mechanisms, and make immediate service in case of any problem
s found, it is not allowed to operate with problem unsolved, otherwise it may ca
use operation accident, and equipment supplier will not be responsible for any a
ccidents caused under such circumstances. In the following chapters we introduce
d detail preparation work. Operator must finish the following job properly on ha
ndover to the next shift.
3.5.1 Preparation before test run
Organization of personnel, all relevant personnel should participate.
Safety facilities provide necessary safety facilities, and supervision.
Test interlock circuit and protection circuit, test their functions.
Adjust again the traveling device and limit switches, etc.
Adjust time of timer.
Observe and adjust brake, oil pressure and flow rate, etc.
For successful joint movement, test should be done at least for three times
, and result correct.
1) Appearance is perfect and without abnormality, all open circuit or short circ
uit done for previous tests should be all resumed, except for those circuits tha
t can not be put in due to some special reasons.
2) Put in power and connect control power, make PLC self starting, lamp test, st
art oil pump, air compressor and necessary communication facilities, auxiliary e
quipment. Observe if indications are normal, and in case of abnormality find out
the reason.
Operate according to drawing, instruction, flow process and block diagram.
3.5.1.1 Power system
First check power system is normal, which is the basic condition for operation o
f the machine, check power system mainly at three places:
1) Motor power system
Power indicator of HV switchgear, if indicator light is on it means power circui
t is energized, in the cabinet is provided with integrated relay protector for o
ver current and quick disconnect protection, etc., and automatic trip protection
should be activated in case of fault.
There are motor power indicating light on LV power cabinet, if indicator light i
s on it means power circuit is energized; in the power cabinet there also are vo
ltage measuring device, for measuring voltage, check faults of phase sequence, p
hase loss, etc., and power system fault should be immediately taken care of in c
ase of any fault.
2) Control power system
Start and stop of control power is controlled from control console, before opera
tion start and stop control power once, to check if control system is normal, mo
nitor by HMI touch screen.

3) UPS power system
UPS power is installed in UPS cabinet, and its condition may be determined by us
ing screen on UPS, check if there is any alarm information, if voltage is stable
, and if any bypass exists. In case of fault, professional technicians should be
contacted for service, never open machine case for service by yourself.
3.5.1.2 Hydraulic system
Pump station and valve station are all installed inside hydraulic room, when goi
ng into hydraulic station first check the following items:
If there is any oil leakage
If oil level meet operation requirement
If oil temperature is normal
If indication of pressure sensor indicating light of all oil lines are normal (gr
een is normal, red is abnormal)
If indoor air conditioner works normally
If valve station has any valve in operation (valve head indicator light is on mea
ns in operation, before system starts operation, no indicator light should be on
, otherwise it means abnormality)
If the above mentioned items are no problem, the mode selector turn button at lo
cal control box of hydraulic station may be switched to service mode (detail pro
cess of service mode operation are detailed in the following chapters), then tur
n oil pump start/stop turn button to start position, oil pump will be started, o
bserve if system pressure is normal (detail data refer to hydraulic system instr
uction), if sound of oil pump motor is normal, if every thing is normal, hydraul
ic system may be put into operation, handle timely in case of any fault.
3.5.1.3 Lubrication system
Lubrication system is provided with local control and automatic control operatio
n, lubrication system has independent local control box. Operation and fault sig
nal is monitored through HMI.
First check grease tank liquid level, fill in grease timely if needed; then star
t lubrication pump under service mode, observe if operation is stable; finally p
ush down direction changeover pushbutton under service mode to observe if revers
ing valve change direction.
If everything is normal, lubrication system may be put in operation.
3.5.1.4 Initial position of all systems
Before equipment is put in operation, all activating mechanisms should be at ini
tial position, if not, some actions may be impossible to realize due to interloc
k of program, if operate under service mode by removing interlocking, accidents
may be caused, therefore before reclaimer starts operation, make sure all activa
tion mechanisms are at initial position, below are the initial position of all s
ystem activation mechanisms:
1) slewing system
Boom is parallel to ground belt conveyor, slewing angle zero
2) luffing system
Boom is parallel to ground belt conveyor, luffing angle zero
3) rail clamp system
Clamped
Above is the initial positions of all system mechanisms, before starting op
eration, first of all check each initial position, if any mechanism is not at in
itial position, move it to initial position under manual mode, so reclaimer can
make automatic operation.
3.5.2 Start of test run, test run
If site condition allows, remove temporary power source for commissioning, and c
onnect normal power supply.
1) test phase sequence, same as commissioning power supply.
2) repeat no-load operation
3) make test on reclaimer, adjust and make proper record.
Travel on tracks, manual operation, check traveling speed at all levels of gears
, check motor speed, current, voltage, start and brake, acceleration and deceler
ation, finally adjust parameter, make record, adjust brake.
Make slew movement, manual operation, check traveling speed at all levels of gea
rs, check motor speed, current, voltage, start and brake, acceleration and decel
eration, finally adjust parameter, make record, adjust brake.
Test signal of luffing hydraulic system, start oil pump, check hydraulic station
operation, adjust lifting and lowering speed, make record.
Test belt protection switch signal, test belt motor rotation direction comply wi
th process requirement, start belt, test work condition at the highest and lowes
t point.
Trial run in coordination with central control room
Interlock, send and receive situation index.
Others, test sending and receiving of contacting signal through cable on control
cable reel, and contacting signals of other properties.
Commissioning is basically finished; operators make operation under supervision
of commissioning personnel, make operation for some time to make operators get f
amiliarized and master operation, and for equipment to run in. During trial prod
uction, make further modification of some data. Finally record no-load, load, st
art, maximum current; speed, rotation speed; timer s setting; power voltage; data
setting and status report of interlocking, protection, communication etc. Such d
ata may be used as equipment original archive.
CHAPTER 4 USAGE AND OPERATION

CONTENTS
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3
_Toc258857401 \h 3
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_Toc258857404 \h 3
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57410 \h 3
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3

4.1 Operation mode

4.1.1 Maintenance Mode

4.1.2 Local Mode PAGEREF _Toc258857398 \h 3

4.1.2.1 Manual mode
4.1.2.2 Semi automation mode
4.1.3 Remote automatic operation mode
PAGEREF
4.2 Operation information PAGEREF _Toc258857402 \h

4.2.1 Rule of information display PAGEREF _Toc2588
4.2.2 Description of each system operation
4.2.2.1
4.2.2.2
4.2.2.3
4.2.2.4
PAGEREF
Travelling
Slewing
Luffing
Boom belt conveyor
4.2.2.5 Bucketwheel
4.3 Operational control description
PAGEREF _Toc2588
4.3.1 Maintenance operation
4.3.2 Cabin operation
4.3.3 HMI touch screen menu operational control
USAGE AND OPERATION

4.1 Operation mode
Reclaimer operation include local operation and remote opeartion based on operat
ing location, both locations may carry out all operations.

4.1.1 Maintenance Mode
Allows for equipment operation by switches arranged close to drive sets, in a no
n-interlocked way, with their protections remained. Such mode shall be designed
only for maintenance operation.
4.1.2 Local Mode
Local operation include manual mode, semi automation mode and automation mo
de.
4.1.2.1 Manual mode
The manual operation, i.e. hand operation, is the most popularly control mode ad
opted for controlling the reclaimer, The operators manually operate the mechanis
ms in the cab and complete the unit or system running operation. The safe and re
liable interlocking is provided for various mechanisms. The running speed of mec
hanism is corresponding to the displacement angle of the joystick which has the
zero position protection (including the mechanical and electrical protections).
4.1.2.2 Semi automation mode
Semi automation shall be performed by operator in the cabin, the reclaiming proc
ess can be performed automatically after layer and width of pile setting, the op
erator shall monitor the process and interfere the process if some trouble occur
red, the operator shall obey the command from CCR.
At start, the operator shall drive the reclaimer to the start position, drive th
e boom to the right position, set the width of pile, then push the button autimat
ion start on the touch screenof HMI, the automatical process shall be start, when
end command is released from CCR, the operator can push button automation stop to
end the reclaiming process.
4.1.3 Remote automatic operation mode
Await for remote operation mode selection by machine operation cabin operator;Th
en, select manual operation mode;Displace reclaimer to pile start position (syst
em shall actuate sound alarm before machine translation is started); Select semi
-automatic mode; Set pile limits; Define iron ore reclaiming rate;Thoroughly def
ine parameters such as translation speed, maximum rotation angle, reclaimer adva
nce, boom slope, etc.;Send semi-automatic release command; After yard reclaiming
circuit conveyor is started and once its nominal speed is reached, operator sha
ll command reclaiming operation start by sending automatic release command.
Equipment shall operate in automatic sequence as follows: Boom belt conveyor sou
nd alarm shall be actuated; Boom belt conveyor shall be started; After boom belt
conveyor reaches its nominal speed, bucket wheel shall be started; Then, boom l
owering, table rotation and machine advance movements may be started. Table rota
tion speed shall be automatic and continuously controlled by control system, so
as to keep reclaiming rate as constant as possible during boom movement; Machine
translation start shall follow this sequence: Translation sound alarm shall be
actuated; Rail clamps shall be opened (in case they are closed); Motor brake ope
ning shall be actuated; Cable reel shall be started; Motor inverter shall be sta
rted, according to ramp up to nominal translation speed; Step translation shall
be started for preset pile charges.
The safety detecters are avaliable in Automatic Start Sequence
Refer to following picture for the sequence of reclaiming from 1 to 24.

Picture 4.1
4.2 Operation information
4.2.1 Rule of information display
The normal information of state, running and start touch buttons are in gree
n color,
Example:
The normal information of alarm, fault and stop touch buttons are in red col
or
Example:
If any trouble occurs and the machine can t operate normally, the information shou
ld be in bright red color and blinking simultaneously.
Example:
If the state of information is avaliable, the color is bright.
Example:
If the action is being carried out, the information blinks and the color is
bright.
4.2.2 Description of each system operation
4.2.2.1 Travelling
Please refer to picture 4.2 for travelling flow scheme.
Picture 4.2 Travelling flow scheme

Interlock for travelling?
* Emergency stop button

* Traveling limits
* Traveling emergency stop limits
* Overload and overheat protection for traveling motor
* Low oil level, high oil temperature failure of the hydraulic unit for rail cla
mper
* Rail clamper release
* Cable reel loose cable protection
* Cable reel s full reel and empty reel
* Cable reel motor overload
* Anchor limits
* Frequency converter failure
* Boom anti-collision detection
* High wind
4.2.2.2 Slewing
Please refer to picture 4.3 for slewing flow scheme.
Picture 4.3 Slewing flow scheme

Slewing interlocking protection signals:
* Slewing limits
* Slewing emergency stop limits
* Encoder position data accuracy
* Slewing motor overload & overheat protection
* Frequency converter failure
* High wind
4.2.2.3 Luffing
Please refer to picture 4.4 for luffing flow scheme.
Picture 4.4 Luffing flow scheme

Luffing interlocking protection signals:
* Luffing limits
* Luffing emergency stop limits
* Luffing motor overload & overheat protection
* Hydraulic unit low oil level
* Hydraulic unit high oil temperature
* High wind
4.2.2.4 Boom belt conveyor
Please refer to picture 4.5 for boom belt conveyor flow scheme.
Picture 4.5 boom belt conveyor flow scheme

Belt conveyor interlocking signals:
* Motor overload &overheat protection
* Brake limit
* Belt misalignment
* Belt speed detection
* Pull rope protection switch
* Chute blocking
* Ground conveyor running
4.2.2.5 Bucketwheel
Please refer to picture 4.6 for bucketwheel flow scheme.
Picture 4.6 bucket wheel flow scheme

Bucket wheel interlocking signals:
* Motor overload &overheat protection
* Brake limit
* Coupeling temperature
* Boom conveyor running
4.3 Operational control description
This chapter gives the descriptions for the local control, the operator desk con
trol and HMI touch screen control of main mechanisms.
4.3.1 Maintenance operation
The maintenance operation boxes are set for clamper, belt conveyor and cab
in level with start/stop buttons and emergency stop buttons.
4.3.2 Cabin operation
All operation shall be performed via HMI beside joystick ,emergency button and p
ower ON/OFF button,please refer to item1.3.9.
4.3.3 HMI touch screen menu operational control
According to the features of project, pictures are established with complete fun
ctional information which is satisfactory to the relevant specification and stan
dards, and the operators of user can operate the menu pictures via the touch scr
een. The following is a brief introduction for some simple pictures for referenc
e.
The pictures are composed of pictures for logging in, major parameters, main mec
hanisms, communication control and fault & alarms.
1?Picture for logging in?

2?Picture of major parameters

3?Picture of communication control

4?Picture of traveling unit

5?Picture of luffing unit

6?Picture of cabin level unit

7?Picture of slewing mechanism

8?Picture of PLC

9?Picture of conveyor & bucket wheel units

10?Picture of lubrication mechanism

11?Picture of clamper mechanism

12?Picture of cable reel mechanism

13?Picture of main operation

CHAPTER 5 SERVICE AND MAINTENANCE
CONTENTS
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5.1 Daily service, maintenance and calibration

5.2 Regular inspection and service
5.3 Temporary service
PAGEREF _Toc2588
5.4 Fault reason and handling
PAGEREF _Toc2588
5.5 Service and maintenance during long time stop
SERVICE AND MAINTENANCE

5.1 Daily service, maintenance and calibration
In case of fault of equipment that can not be eliminated in time, immediately st
op the machine to find out the fault or change to spare machine to maintain prod
uction, otherwise equipment supplier will not take any responsibility for damage
to the equipment. In order to successfully eliminate fault, in addition to regu
larly service equipment, master equipment operation condition, an abundant store
of ware parts should be kept.
Table 5.1 list rules and handling method for service, commissioning and op
eration for reference.
Table 5.1 Daily service and maintenance
Service typeOperation statusService intervalService contentDaily Mainly in opera
tion
When energized, also include machine stop time everyday Daily
Normally service with door closed, and open door for service every two weeks to
one month Daily inspection mainly visually
Service before starting, check for abnormality during operation Regular Stop ope
ration, cut off power One monthVisual and contact inspection, determine service
plan according to inspection result TemporaryStop operation, cut off power In ca
se of abnormality or anticipate to have abnormality Find reason, determine servi
ce method correspondingly, to resume production a.s.a.p. Note: service period di
ffers with environmental condition, operation years and equipment importance, wh
at listed in table only for reference.
Daily service
1) during general daily inspection, do not take off equipment cover, only observ
e from outside to check for abnormal sound, smell, damage, color change, etc., a
nd immediately make service in case of abnormality.
2) in case of abnormality, determine the degree of abnormity, i.e. Confirm if op
eration may proceed, and make immediate service if operation can not be proceede
d.
3) make careful service record.
5.2 Regular inspection and service
1) before making regular service, investigate according to drawing and site situ
ation, confirm power system construction for cabinet and consoles, and earthing
condition, etc., determine detail working content.
2) based on service list, check abnormal sound and vibration, confirm operation
condition and abnormality before power is cut off.
3) based on service list, mainly the items not possible to make daily service ch
eck for abnormality visually or by contact.
4) when abnormality is found, use correct method to dismantle and replace, do no
t hammer or make intense shaking, or impact, etc.
5) confirm screws and bolts are tightened, tools are returned to their position.
6) carefully make service record.
5.3 Temporary service
In case of finding or anticipating abnormality of cabinet or machine, or protect

ion element of internal machine get loose, service should be made according to r
egular service requirement, dismantle and replace the abnormal part.
Note: operation and service of all electrical equipment should strictly follow t
he safe operation requirement in its Operation Manual.
Table 5.2 service inspection examples
Service locationService contentService periodDailyRegularService spaceCheck if w
aste articles, tools, hazardous article are stored ??Control cabinet body?check
for damage, color change, rust
?vibration, abnormal sound
?tilting due to ground subsidence or elevation
?bolts loose or fallen
?water ingression, condensation or other trace in cabinet
?attach of dirt, foreign object, dust?
?
?
?
?
?
?
?
?
?Power voltageIf voltage of main circuit, control circuit are normal??Door?smoot
h open/close
?handle good to use
?loose bolt in hinge and latch ?
??
?
?Name plate?loose, falling, damage
?blur letter due to dirt?
??
?Main circuit feed in?loose or falling bolt
?broken or deformed electrical porcelain, clamp plate, insulator
?deterioration and color change due to overheat at wiring connection or insulati
on
?attachment of foreign object, dust
?abnormal insulation distance between conductors and for metal parts ?
?
?
?
?
?
?Control circuit and terminal?loose terminal wiring
?insulator broken or damage
?color change due to overheat
?terminal broken or attached with foreign object
?if terminal number on terminal block and number on wire sleeve are clear and re
adable
?
?
?
?
?
?Earthing circuit?loose earthing due to vibration, and proper connection
? corroded or broken wire ?
?
?Cable entry and exit?loose bolts

?broken cable sheath
? trace of ingression of mice, etc.
??
?
?Circuit breaker for wiring, electromagnetic contactor? abnormal sound
?loose bolt at terminal
?color change at terminal and contacting area
?attachment of foreign object, dust on insulation, any damage or deformation
?normal on/off action, good contact at contactor
?test pushbutton for residual current circuit breaker works normally, if action
indication is obvious
? contact of electromagnetic contactor is bright and clean ??
?
?
?
?
?
?
?Transformer, reactor?abnormal sound
?loose bolt at terminal, attachment of foreign object and dust
?if iron core is rusted or damaged
? if insulator has crack, damage, deformation or color change due to overheat
?
??
?
?
?Resistor?unusual smell due to overheat
?if electrical porcelain or insulator has crack, damage, attachment of foreign o
bject and dust
?loose bolt and screw
?if wire is in proximity of heating part
?broken wire
?
?
?
?
?
?
?
Instrument indicator
?if indication is normal
?if indication deviate from mechanical zero position
?bend indicator arm, broken cover
?attachment of dust, foreign object
?loose mounting screw
?
?
?
?
?
?
?Indicator light?normal on/off indication
?if transparent cover has fallen, damaged or changed color

?attachment of dust, foreign object
?loose screw?
?
?
?
?
?Switch ?if switching action is normal
?indication on nameplate and handle, attachment of dust, foreign object
?if insulator is cracked, damaged or deformed
?loose screw
?if spring is rusted, damaged or deformed
?
?
?
?
?
?
?Confirm circuit actionWhen having external signal of switching and simulation i
nput, if speed variation mechanism in program circuit functions normally ?Note?1
.daily service ? means open door service
2.regular service ? means mandatory
3.daily and regular service ? means require service5.4 Fault reason and handling
see table 5.3.
Table 5.3
Fault phenomenonFault analysisHandling methodTraveling device
1.can not travel
2.traveling with abnormal sound and vibration?main power supply or control power
not switched on
?interlocking condition not satisfied
?motor failure
?motor fault
?converter fault?check power and overload protection
?investigate and satisfy interlocking condition
?open mechanical brake
?refer to motor Operation Manual
?refer to converter Operation ManualSlewing device
1.can not slew
2.slewing with abnormal sound and vibration?main power supply or control power n
ot switched on
?motor failure
?motor fault
?converter fault?check power and overload protection
?refer to motor Operation Manual
?refer to converter Operation ManualLuffing device
1.can not luff?main power supply or control power not switched on
?motor failure
?hydraulic system fault?check power and overload protection
?refer to hydraulic system Operation Manual Belt mechanism

1.belt do not move?main power supply or control power not switched on
?motor failure
?hydraulic system fault?check power and overload protection
?refer to hydraulic system Operation Manual PLC do not operateLook into PLC manu
alLook into PLC manualPosition data not accurate?encoder network connection faul
t
?encoder damaged, do not operate ?check encoder network
?refer to encoder Operation Manual Movement with abnormal sound and vibration? s
peed too high
?insufficient lubrication
?wheel eccentric wear?adjust
?lubricate
?repair5.5 Service and maintenance during long time stop
Electrical equipment package provide by reclaimer equipment manufacturer are onl
y for preventing rain, snow and other objects from going into electrical equipme
nt during transportation, not to guarantee for the damage and loss to electrical
equipment or apparatus. Therefore proper keeping must be timely done after elec
trical equipment has been delivered to customer s site.
Uninstalled electrical equipment must be all kept in the store, and prevent mois
ture from corroding motor, control cabinet and other parts and components of ele
ctrical equipment.
Electrical equipment that has finished installation but stopped service for long
term, it should be kept inside storehouse if condition allows, otherwise it sho
uld be put at a cool, ventilated and dry place, and customer should take measure
to prevent ingression and trapping of rain, snow, condensation, dampness in the
equipment, and should take measures to prevent exposing to sunlight for a long
time.
Equipment stored for long time should regularly switch on power to expel humidit
y or switch on heater on the equipment, especially in rainy season.
Note: the storing and keeping temperature for electrical equipment should comply
with requirement for equipment storage condition.
QLK11000.50ReclaimerTeaching Material For Training
M-501E-E-002
Page PAGE 14 /73
No.: DF-MO-2092KS-

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SERRA SUL PROGRAM

Chapter 4 Usage and operation;

1.1 Main application and scope of operation

1.1.1 Main application

1.1.2 Scope of operation

1.1.3 Parameters of reclaimer

1.1.4 Material and Physical Characteristics

1.2.1 The type of power supply and power

1.2.3 Operating Environment Conditions

1.2.4 Operating Condition  PAGEREF _Toc257732343 \h

1.3.9 Local operation components

1.3.10 Telecommunication system

1.3.11.1 Interlock between different structures

1.3.11.3 Emergency switch  PAGEREF _Toc257732361 \h

MV belt feeder(MC-2092KS-100)----Power feeding for boom conveyor motor

imit switch for left rail clampDF-2092KS-M-501E-E-0093.4Falled limit switch for

Luff up emergency end limitZS-2092KS-2060Luffing up emergency LSDF-2092KS-M-501E

y pull line on left sideHSS-2092KS-2001Emergency switch on left side of beltDF-2

Picture 1.3 Console desk

g system??????DX04=PC PLC control system PLC????DX05=LT Long travel system??????

ifications to be followed (e.g. Specifications for handling hazardous materials,

Working on electrified components is fatal. If it is a must, then there must be t

rrent safety regulation and requirement of the product.

 PAGEREF _Toc258479334 \h 3

LV electrical device should be installed at a height complying with design speci

1) Installation of bases or support of control cabinet, junction box

C) Installation of cable in metal conduit

Earthing of reclaimer equipment should meet 3.1.8 technical requirement.

For another related documents, please refer toDF-LD-2092KS-M-501E-G-0011----DOCUMENTS LIST

Clean surrounding areas, clear articles interfering with commissioning, clean

nitor by HMI touch screen.

CHAPTER 4 USAGE AND OPERATION

4.1 Operation mode

 PAGEREF _Toc258857396 \h 3

4.1.2 Local Mode  PAGEREF _Toc258857398 \h 3

4.2 Operation information  PAGEREF _Toc258857402 \h

4.3.3 HMI touch screen menu operational control

USAGE AND OPERATION

ing location, both locations may carry out all operations.

Picture 4.2 Travelling flow scheme

* Emergency stop button

Picture 4.3 Slewing flow scheme

Picture 4.4 Luffing flow scheme

Picture 4.5 boom belt conveyor flow scheme

Picture 4.6 bucket wheel flow scheme

4?Picture of traveling unit

6?Picture of cabin level unit

7?Picture of slewing mechanism

10?Picture of lubrication mechanism

5.1 Daily service, maintenance and calibration

5.4 Fault reason and handling

5.5 Service and maintenance during long time stop 

SERVICE AND MAINTENANCE

In case of finding or anticipating abnormality of cabinet or machine, or protect

?Cable entry and exit?loose bolts

?if transparent cover has fallen, damaged or changed color

?refer to hydraulic system Operation Manual Belt mechanism

Page  PAGE 14 /73

You might also like

1.1 Main application and scope of operation

1.1.1 Main application

1.1.2 Scope of operation

1.1.3 Parameters of reclaimer

1.1.4 Material and Physical Characteristics

1.2.1 The type of power supply and power

1.2.3 Operating Environment Conditions

1.2.4 Operating Condition PAGEREF _Toc257732343 \h

1.3.9 Local operation components

1.3.10 Telecommunication system

1.3.11.1 Interlock between different structures

1.3.11.3 Emergency switch PAGEREF _Toc257732361 \h

PAGEREF _Toc258479334 \h 3

4.1 Operation mode

PAGEREF _Toc258857396 \h 3

4.1.2 Local Mode PAGEREF _Toc258857398 \h 3

4.2 Operation information PAGEREF _Toc258857402 \h

4.3.3 HMI touch screen menu operational control

5.1 Daily service, maintenance and calibration

5.4 Fault reason and handling

5.5 Service and maintenance during long time stop

Page PAGE 14 /73