CAT Armored Face Conveyor Hydraulic chain tensioning for parameter 115 Operation & Maintenance Manua

BI622549

Operating manual

Translation of the original operating manual

Hydraulic chain tensioner for parameter 115 Doc. No.: 1955 115 000 BA 00

Bucyrus Europe GmbH Industriestr. 1 D-44534 Lünen,

Phone: +49 (0) 23 06 / 709 - 0 Email: info@de.bucyrus.com Fax: +49 (0) 23 06 / 709 - 1421 Web: www.bucyrus.com

BI622549

Translation of the original operating manual.

Amendments and alterations to this publication are not subject to notification. Bucyrus reserves all rights to this publication.

Its content is protected by copyright laws. No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Bucyrus.

Bucyrus assumes no liability for direct or indirect consequences of misprints.

We reserve the right to introduce modifications as a result of technical developments without previous notice.

Bucyrus Europe GmbH, Lünen 2011E

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Contents

Contents 1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Persons for whom the operating manual is intended . . . .

Purpose of this operating manual . . . . . . . . . . . . . . . . . . . .

Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.4 1.4

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2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 2.5 2.5 2.6

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

3. Storage and transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Storing the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.4

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Load units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 3.4 3.6

4. Installation

Doc. No.: 1955 115 000 BA 00

What you need to observe prior to installation . . . . .

4.3

Who is allowed to perform the installation? . . . . . . . . . . . .

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 4.3

Chain tensioner overview . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Chain tensioner attachment options . . . . . . . . . . . . . . . . . .

4.6

How to install the chain tensioner . . . . . . . . . . . . . . . . .

4.7

How to install the electrohydraulic control unit . . . . .

4.8

Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10

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Contents

5.3

Switch positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Pretensioning conveyor chains . . . . . . . . . . . . . . . . . . .

5.6

Chain tensioner functions . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum reachable torques . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and operating force of the chains . . . . . . . . . .

5.7 5.7 5.7

How to tension, extend or shorten chains . . . . . . . . . .

5.8

Auxiliary devices for holding the chain . . . . . . . . . . . . . . . .

Before operating the chain tensioner . . . . . . . . . . . . . . . . . .

Tensioning the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shortening/lengthening the chain . . . . . . . . . . . . . . . . . . . . .

Connecting the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disengaging the ratchet pawl . . . . . . . . . . . . . . . . . . . . . . . .

Releasing the chain locking device . . . . . . . . . . . . . . . . . . .

Putting the chain tensioner out of operation . . . . . . . . . . . .

Tensioning the chain with drive frame, size 115 . . . . . . . .

5.8 5.9 5.10 5.10 5.10 5.11 5.11 5.11 5.12 5.12

How to maintain the chain tensioner . . . . . . . . . . . . . . 5.13 Tensioning gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrohydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 5.13 5.13

6. Technical data Technical data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.5

Control gear with electrical interlock . . . . . . . . . . . . . .

6.6

Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Permissible media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quality of the process water . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 6.9

Identification of the chain tensioner . . . . . . . . . . . . . . . 6.11

7. For your information Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Referenced standards and guidelines . . . . . . . . . . . . . . . . .

7.3

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Operation information . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5. Operation

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About this manual

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Before starting work

About this manual This chapter contains important information that makes it easier for you to use this manual. It provides you with information about the structure of the manual and the symbols and characters used in it.

Before starting work applicable operating manual

model

You will endanger yourself and others if you use an operating manual which is not intended for the existing tensioner.

Ensure that the data on the tensioner complies with the data given in the operating manual.

This operating manual belongs to the: Hydraulic chain tensioner ID No.: 1955 115 000 00 00 It is only permissible for tensioners of this type.

category according to Atex directive

The operating manual must be accessible at all times to all persons working on or with the chain tensioner.

An operating manual for the chain tensioner should always be available at the place of operation.

E Bucyrus Europe GmbH, Lünen 2011

According to European Directive 94/9/EC, the chain tensioner is a Group I, Category M2 device.

new operating manual

Request a new operating manual immediately if the current operating manual is no longer complete or has become illegible.

Persons for whom the operating manual is intended This operating manual is intended for those persons who work with the tensioner.

All persons working on the face, at the edge of the face or at the entry must read this operating manual.

This includes persons who: J are in charge of transport, J prepare the rise heading, J perform installation/removal work, J operate the conveyor, J correct malfunctions, J carry out daily routine work on the face or in the entry, J perform maintenance work, J perform repair work.

Supervisory personnel who: J initiate the activities mentioned above and/or J supervise the activities mentioned above.

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Before starting work Purpose of this operating manual economic efficiency

This operating manual is intended to help you work economically and safely with our product. It contains important information on all the activities related to the tensioner.

Read this operating manual completely and at your leisure. Pay special attention to the safety instructions in each section.

Try to memorize the appearance and meaning of the safety and instruction symbols.

service

Should you have any questions, please contact our Service department. Our service address can be found in chapter 7, “For your information”.

safety

Pay special attention to chapter 2, “Your safety”. This chapter contains important information indicating possible hazards.

Observe this information and follow the instructions.

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Danger!

Passages in the text marked with this symbol indicate an imminent danger. Possible consequences are very serious injury or even death.

Warning!

This symbol indicates hazardous situations.

Possible consequences are very serious injury or even death.

Caution!

This symbol draws attention to dangerous situations. Possible consequences are light to minor injuries and damage to machinery.

Notice!

Passages in the text marked with this symbol draw attention to harmful situations. Possible consequences include: The tensioner or the immediate surroundings could be damaged.

Important!

Passages in the text marked with this symbol contain useful tips and information intended to make work easier for you.

They do not warn about harmful or dangerous situations.

J Items in lists are indicated by bullets.

– Items in sub-lists are marked with a long dash at the start of the line.

. Text passages indicated in this way describe individual work steps. Follow these instructions step-by-step. This will help you carry out your work faster and, more importantly, more safely.

1.4

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Memorize the symbols and their meanings.

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2

Your safety

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Personnel

Your safety This chapter provides you with important information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and perform the necessary work as safely as possible. state-of-the-art technology

The tensioner has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless still be exposed to dangerous situations, e.g. as a result of environmental influences, machine damage or operating errors.

Do not make any modifications or carry out conversions which could impair the safety of the chain tensioner. All modifications and conversions must be approved by Bucyrus.

Only use original spare parts from Bucyrus. Note that using parts from other manufacturers will void the guarantee.

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The European guidelines/standards which appear in this operating manual must be applied when the chain tensioner is being used within the member states of the European Union. When used outside the EU, the applicable directives and standards must be observed in those respective countries.

In addition to this operating manual, make sure you also observe the legal provisions and regulations for accident prevention in your country.

Observe the safety and accident prevention regulations: J of the mine, J of the mines inspectorate and J of mining supervisory authorities. additional operating manuals

Please also read the operating manuals of the components required for operation, e.g. for gearboxes, E-motors, conveyors, etc. carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation training

The tensioner may only be operated by trained personnel.

Reading the operating manual, especially the chapter on safety, must constitute a part of this training.

Personnel must possess sufficient knowledge of the J mechanical system, J hydraulic system and J control technology.

and be able to provide proof of this.

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Personnel Installation and repairs As a basic rule, installation and repair work may only be carried out by personnel who have been trained adequately for these particular requirements.

Installation and repair work on: J the safety components (pressure relief valves, etc.), J electrical systems (control systems, etc.), J the hydraulic system

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may only be carried out by Bucyrus service engineers or by specially trained personnel of the mining company.

2.4

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Operating conditions Operating conditions Intended use The hydraulic chain tensioner is designed and manufactured exclusively as a tail gate for slowly turning a conveyor drive.

It is for tensioning a conveyor chain or for coupling the chain ends of an open conveyor chain using a suitable chain locking device.

Intended use includes: J coupling the chain ends of an open conveyor chain, J tensioning a conveyor chain, J holding a tensioned conveyor chain.

Only use the hydraulic chain tensioner as intended!

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the hydraulic chain tensioner.

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Bucyrus will not accept any liability for damage resulting from any such unauthorized use.

Ambient conditions Appropriate measures must be taken by the operator to combat the potential hazards in mines due to firedamp or the ignition of dust (see DIN EN1710).

These include: J sufficient and consistent ventilation, J spraying with water.

The M2 equipment must be switched off if the firedamp concentration in the free cross section of the continuously ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL) defined by national legislation.

It may only be restarted by authorized persons.

The atmosphere in the mine should be monitored at hazardous points to allow the power supply of all devices to be switched off, except for those which are relevant to safety and suitable for use in explosive atmospheres.

The M2 equipment must be stopped immediately and secured against restarting (locked out) if firedamp protection facilities are found to be damaged.

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Operating conditions Prerequisites for operation Putting the chain tensioner into operation is prohibited until the machine in which this chain tensioner is installed meets the requirements of European Directive 94/9/EC and of the standard DIN EN1710.

Since the device supplied is only part of an overall system, the operating company must meet the safety requirements or install the required safety systems for the devices/components not included in the scope of supply of this device and/or other devices/components required for operation. These shall be identified according to the legal provisions applicable at the time they are placed on the market.

The M2 equipment/chain tensioner may only be operated when the safety requirements have been met in accordance with DIN EN 1552. These include: J equipment for preventing unauthorized starting, J startup warning systems, J water spraying systems,

J EMERGENCY STOP systems, J dust extraction systems, J noise protection, J warning notices etc.

All electrical equipment required to operate the chain tensioner must be marked according to the legal provisions applicable at the time when it is placed on the market.

2.6

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J safe shutdown command systems,

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Safety instructions Safety instructions Basic principles general

Always work with the utmost concentration.

Familiarize yourself with your working environment.

Always wear personal protective equipment. This includes wearing ear protection since the noise emitted by the conveyor may at times exceed 85 dB(A) (e.g. when the conveyor is being emptied).

Inform your colleagues of the following: J your exact location, J the work you are carrying out, J the amount of time you will probably require.

Before switching on the chain tensioner, all electric motors of the conveyor system must be disconnected and secured against being reactivated.

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Only start the chain tensioner when it is in a technically perfect condition. protective device notice signs cordoning off the working area moving parts

Keep the signaling and lighting systems in proper working order.

Observe the notice signs on the conveyor.

Block off a wide area around the working area.

Never allow parts of your body to come between components which could move, e.g.: J conveyor chains, J flights, J spill plates, J chain sprockets, J locking devices.

danger of explosion

Be sure to observe the intervals specified for maintenance and checks of the chain tensioner as hot surfaces may ignite explosive atmospheres and dust.

Storage and transport Observe the prescribed storage periods and the storage instructions.

Do not store materials or parts in the travel path or in your working area.

Inform the persons concerned about the intended transport route and the probable duration of transport.

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Safety instructions transport safety device

Make sure that the transport safety devices have been correctly installed.

Lock all movable components in place.

Never stay under unsecured components or suspended loads.

means of attachment

Attach the lifting gear only to the lifting points provided for that purpose.

Only use means of attachment which are in perfect condition and have been designed for the loads concerned.

Installation and startup

inclined face

environmental acceptability

Use chains to secure all individual parts on inclined faces, e.g. on the supports.

When working with oils, greases and other chemical substances, observe the safety regulations that apply to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

Check that all protective devices are installed on the conveyor and are in working order.

Before tensioning or releasing the chain, make sure that there are no persons in the conveyor.

Make sure that the operating symbols are clearly recognizable in order to avoid any operator errors and accidents that could result.

Maintenance and repairs Make sure you observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew about maintenance and repair work. Provide them with information on the intended work and its expected duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Secure the conveyor against unauthorized and unintentional restarting before all operations.

2.8

Hydraulic chain tensioner / parameter 115

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Operate the control system only if you have comprehensive knowledge of the operating elements and their method of operation. You need to have been instructed on the control system concerned.

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Operation

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Safety instructions working in the mining area

You may only carry out work in the mining area if: J the roof has been secured against falling rock, J the coal face has been secured against collapsing and J the mining equipment and conveyor have been shut down and

secured against being switched back on.

Remove any defective components from the face immediately to avoid hindering the face crew. In addition, this measure prevents any unintentional reinstallation of these components elsewhere.

Pass on these components for servicing without delay.

Secure the spare parts against slipping on inclined faces by using chains or lifting gear, for example. original parts

protective devices

Only use spare parts which meet the technical requirements. This is only ensured with original Bucyrus spare parts.

Please refer to the spare parts lists for the order numbers.

Refit any removed protective devices immediately after completing the work, and check that they work properly.

Hydraulic system

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handling hydraulic fluids

Avoid direct skin contact with hydraulic fluids.

Hydraulic fluid which penetrates the skin can cause serious infections.

Never use hydraulic fluids for backflushing or cleaning. Hydraulic fluids are very harmful to your health.

protective equipment hydraulic system

When removing protective devices which include hydraulic components, keep in mind that these hydraulic components may be pressurized. You could be seriously injured by hydraulic fluid squirting out in an uncontrolled manner. It is therefore imperative that you depressurize the hydraulic components before removing the protective devices.

maintenance, repairs

You may only work on the hydraulic system if you can demonstrate special knowledge of hydraulics.

pressure relief valves

Make sure that pressure relief valves are always fitted with protective caps. Replace any defective protective caps immediately.

Carry out a visual inspection on all the hydraulic components at regular intervals. Check, in particular, that: J the hoses are not pinched.

J the hoses have no swelled parts or blisters.

J the hoses or the outer sheaths of the hoses are not abnormally-

rigid or hard, J the outer sheath of the hose is not damaged.

J the connectors are securely inserted into the coupling sockets.

J the connections are leak-tight.

Make sure no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage to the whole system. Flush the hydraulic lines thoroughly before installing them.

If staples are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Make sure that you depressurize the line.

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Safety instructions Always secure the plug connectors of the hydraulic elements with the proper staples. Always fasten the staples completely with both sides.

Never use nails, wire, etc.

Check all connectors and connections of the depressurized system for leaks after finishing repair work. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn O-rings.

Replace hydraulic hoses only with hydraulic hoses of the same or higher quality.

Observe the date of manufacture stamped on the hose fittings of the hose line. Never use hose lines which are more than 2 years old even if they exhibit no visible signs of damage.

Fig. 1:

Example: Hose line, identification 3

1 1 manufacturer 2 calendar week

4 3 year 4 max. working pressure

Never try to hold a hydraulic hose that is thrashing about. Immediately depressurize the section in question.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. installing hydraulic hoses

Install the hydraulic hoses properly behind the brackets and clips provided for them.

Install the hydraulic hoses so that: J they always have a little slack, Fig. 2:

Installing hydraulic hose, slack CORRECT

2.10

WRONG

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Safety instructions J they are not twisted, Fig. 3:

Installing hydraulic hose, twist CORRECT

WRONG

J they are not bent directly behind the connections (distance min-

imum 1.5 x nominal diameter) Fig. 4:

Installing hydraulic hose, bend WRONG

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CORRECT

J they cannot chafe Fig. 5:

Installing hydraulic hose, crossing CORRECT

WRONG

J they are not kinked, J they do not have to withstand tensile loads, J the they are protected against thermal radiation, J they are accessible at all times.

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Safety instructions Only push hydraulic hoses into the sockets by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connectors.

When installing the hydraulic hoses, make sure they cannot be: J torn out, J kinked, J crushed, J driven over or J twisted by the movement of the equipment (Fig.: 6).

Fig. 6:

Installing hydraulic hose, connections on moving parts WRONG

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CORRECT

2.12

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Storage and transport

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Storage

Storage and transport This chapter contains important information on correct storage and transport. Following the instructions and tips will increase the service life of the chain tensioner. You will be able to carry out transport work more safely and quickly. Paying careful attention to the points in this chapter will also help you to make your day-to-day work easier.

Storage Storing the equipment anticorrosion protection

Components with temporary anticorrosion protection are protected for about six months.

The hydraulically actuated equipment is run with a test fluid before delivery and is emptied as thoroughly as possible before shipping.

The internal parts are also protected against corrosion by the residual film for at least six months.

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no direct exposure to sunlight

dirt and moisture

Protect the equipment from direct exposure to sunlight.

Only store the electrical equipment, electronic components, spare parts made out of rubber or plastic, such as seals and hoses, as well as hydraulic fluids in closed rooms at 15C to 25C. Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. with tarpaulins.

Seal the connection surfaces of the components with blind plates.

Beforehand, apply an anticorrosive to the surfaces.

Protect the hydraulic plug-type connectors and the electrical connectors with the appropriate caps and plugs.

short-term storage

long-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components do not need to be removed. These components must be specially protected against high temperatures, dirt and moisture.

For long-term storage (more than 4 weeks), the equipment must not be stored outdoors. It needs to be stored in a dry, well-ventilated room.

If storage exceeds a period of six months, the hydraulic components must be filled completely with a corrosion inhibitor. This fluid must have anticorrosive and antifreeze properties, such as CV 50.

storage period

natural aging

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An inspection must be carried out after a storage period of approximately two years. This will make it possible to determine whether the measures taken and the type of storage used have prevented any damage.

This inspection can be carried out by Bucyrus upon request.

Even with proper storage, seals and hoses are subject to natural aging. Do not use these components if they have been stored for more than two years.

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Transport HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in the section “Hydraulic fluids in the HFA group” of this operating manual.

Important!

Make sure during storage that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

Storing used equipment The points listed above, with the exception of the one concerning corrosion protection, can be applied in the same way to the storage of hydraulic components that have already been in use.

Parts for conveying water, such as the parts for the water spraying system of a shield, must be completely drained, and possibly also filled with an antifreeze fluid, if required.

Transport Load units Observe the separate transport sheets for the respective transport units. It includes information on: J dimensions J weight J lifting points J center of gravity, etc.

The load units are provided with suitable lifting points for transport and installation as far as technically feasible.

Warning!

Use only load handling devices which comply with the technical and legal regulations for transporting loads.

Falling components can cause serious injury and death.

Only use suitable load handling devices.

Before transport freezing temperature

Before transporting the equipment at temperatures below freezing, all hydraulic components that are operated with emulsion (HFAE and HFAS) must be completely drained and filled with a corrosion inhibitor (e.g. CV 50).

*

3.4

HYDROCOR® CV50 is a commercial trademark used by Theunissen Chemische Fabriken GmbH, Wuppertal, Germany

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If the hydraulics system is to be temporarily put out of operation, the entire hydraulic system must be thoroughly flushed out in advance and then filled with a suitable corrosion inhibitor (e.g.

HYDROCOR® CV 50*) If this is not done, then the hydraulic components may suffer considerable damage within a short time, because the properties of the medium used can undergo very rapid, very negative changes, e.g. due to microbial infestation.

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anticorrosion protection

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Transport Transporting equipment at temperatures between -21°C and -40°C is only permitted if certain measures were already taken for these conditions during the design and production. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor conveying devices at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden loads.

At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to maximum 25 km/h for truck transport.

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors, unless these components or the complete equipment is protected against harmful environmental influences by suitable packaging.

The electrical cables remain in the equipment. They must be protected carefully against transport damage and the connectors must be protected against dirt.

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electrical and electronic components

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Transport Transport sheet Transport dimensions, chain tensioner - complete illustration in mounting position

328

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645

383

431

Fig. 7:

490

710 530

570

a

b

a thread M16x35 deep for lifting point b lifting point weight = 380 kg

3.6

b

Hydraulic chain tensioner / parameter 115

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4

Installation

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What you need to observe prior to installation

Installation What you need to observe prior to installation Who is allowed to perform the installation?

Installation work may only be carried out by persons who have been adequately trained for these specific requirements.

J the safety components (pressure relief valves, etc.), J electrical systems (control systems, etc.) and J the hydraulics (directional control valves, hoses, etc.)

may only be carried out by service engineers from Bucyrus or by specially trained personnel. drive connection

Before the chain tensioner can be attached, the drive connection must be installed.

Installation instructions

Bucyrus Europe GmbH, Lünen 2011

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Caution!

Serious damage can be caused to the chain tensioner and the drive connection as a result of incorrect installation.

Install the chain tensioner only according to the instructions of Bucyrus technicians.

J All flange surfaces, centering bores and grooves must be clean

and burr-free.

J Before mounting the flange, the gearing must be well greased -

lubricating paste B3 in accordance with chapter 6, section “Lubricating greases and pastes”.

J During attachment, the chain tensioner must be exactly placed

on the outer casing of the protection cover of the drive connection.

J The gearing must be aligned so that tooth and tooth gap are

exactly opposite one another to ensure that they mesh smoothly. Damage to the gearing and tilting of the chain tensioner must be prevented when mounting!

Notice!

It is very important that you observe the associated, separate operating instructions for the conveyor, the gearboxes and the PMC-R control.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

4.3

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Chain tensioner overview Chain tensioner overview Fig. 8:

Chain tensioner overview

1

3

Bucyrus Europe GmbH, Lünen 2011

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2

4

1 tensioning gearbox 115 2 hydraulic brake motor

4 retaining panel for electrohydraulic control unit 5 protection cover for electrohydraulic control unit

5

3 electrohydraulic control unit

Notes on installation The drain line, depressurized - disconnected from the return line must be discharged so that the motor housing always remains filled.

Notice!

Before starting up the hydraulic brake motor, check drain line “L” for free flow.

The line connections are marked as follows: J “1” = pressure port J “2” = return connection J “L” = drain connection J “S1” = control line connection to the brake

4.4

Hydraulic chain tensioner / parameter 115

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Chain tensioner overview Fig. 9:

Overview of connections 2

S1

a b

1

Bucyrus Europe GmbH, Lünen 2011

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L1+L2

P t

a filling breather filter M12x1.5 b drain connection brake M12x1.5 1 connection for electrohydraulic control unit (rotational direction clockwise: for flow from connection 2 to 1) 2 connection for electrohydraulic control unit (rotational direction counterclockwise: for flow from connection 1 to 2)

L1+L2 drain connections fed together, lead to “Tank” depressurized S1 brake control connection P pressure line to the electrohydraulic control unit, can be shut off via HP ball valve T return line with check valve DN 12

Removal instructions The hydraulic brake motor with connected control unit must be removed so that no emulsion can flow out of the components.

Corrosion protection is only ensured if the applied film is sufficient.

Connections “1”, “2” and “L” must be sealed with the provided blind plugs.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

4.5

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Chain tensioner overview Chain tensioner attachment options The hydraulic chain tensioner is designed for gearboxes with the parameter 115. There is the option of mounting the control unit with bracket and protection cover to the drive connection from both sides.

In the following figure, the various gearbox designs are shown in connection with the mounted chain tensioner.

Caution!

Gearboxes and drive connections which aren't included in the scope of delivery from Bucyrus may only be installed after previously consulting with us.

Fig. 10: Mounting options of the hydraulic chain tensioner

1

D

3

Bucyrus Europe GmbH, Lünen 2011

A

2

1 C B

3

D

2

1 mounting option of the electrohydraulic control unit, right 2 mounting option of the electrohydraulic control unit, left 3 tensioning gearbox 115 with hydraulic brake motor

4.6

a B C D

E

C

gearbox P-115 CST gearbox KP-115 CST drive connection motor

Hydraulic chain tensioner / parameter 115

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How to install the chain tensioner How to install the chain tensioner The hydraulic chain tensioner is fastened to the outer casing of the protection cover of the drive connection with ten hex. head screws and centered with two spring dowel pins.

. Remove the hex. head screws (2) and remove the cover (3) from the drive connection.

. Place the chain tensioner in the drive connection. . Insert the spring dowel pins (4) and the cyl. head screws (5) and screw the chain tensioner firmly in place.

Fig. 11: Mount the chain tensioner to the drive connection 2 1

4

3

b

Bucyrus Europe GmbH, Lünen 2011

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a

5

c

d 1 2 3 4 5

Doc. No.: 1955 115 000 BA 00

VUSS / 01

drive connection hex. head screw M 12x30-8.8 cover spring dowel pin 12x30 cyl. head screw M 12x30-8.8

a b c d

gearbox side motor side control wheel, 22 teeth crown gear, 78 teeth

4.7

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How to install the electrohydraulic control unit How to install the electrohydraulic control unit The control unit is mounted to the drive connection on the side above the retaining panel. Depending on the spatial requirements, this can be mounted to the drive connection on either side.

. Mount the retaining panels (2) to the rear side of the control unit (1) with the hex. head screws (3).

Fig. 12: Mounting the electrohydraulic control unit to the retaining panel 1

3 1 electrohydraulic control unit 2 retaining panel for electrohydraulic control unit

3 hex. head screw M16x35-8.8

. Mount the retaining panel with the control unit to the side of the drive connection (4) with the hex. head screws (5).

Fig. 13: Mounting the electrohydraulic control unit with retaining panel to the drive connection

6

4 4 drive connection 5 hex. head screw M20x30-8.8

4.8

5 6 motor

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

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2

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How to install the electrohydraulic control unit . Connect the hose lines (7) to the connections of the control unit (see connection overview Fig. 9).

Secure the connections with staples.

. Mount the protection cover (8) to the retaining panel with the hex. head screws (9) and the hex nuts (10).

Fig. 14: Mounting the protection cover

Bucyrus Europe GmbH, Lünen 2011

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7

8 10

7 hose lines 8 protection cover for electrohydraulic control unit

Doc. No.: 1955 115 000 BA 00

VUSS / 01

9

9 hex. head screw M16x35-8.8 10 hex. nut M16-8

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How to install the electrohydraulic control unit Hydraulic circuit diagram Fig. 15: Hydraulic circuit diagram of the electrohydraulic control unit connections from PMC-R control unit

2 4

1

2

1/2 HP

right

left

break away

S1 release brake

2

11

connections to the hydraulic brake motor

13 14

8

S1 6

13 15 12

10

L2 2 3

10

10 1 L1 10

16 12

P

T

2 double 3/2 way magnetic pilot solenoid valve 3 pressure relief valve, 250 bar 4 accumulator cartridge 5 pressure-reducing valve (permanently set) 6 pressure-reducing valve (controllable from 30 to 170 bar) 8 pressure gauge

4.10

10 11 12 13 14 15 16

control valve cartridge NG 13 control valve cartridge DN 6 check valve DN 12 shuttle valve NG 2 check valve NG 2 screw-in throttle filter element DN 12

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

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5

Operation

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Operation information

Operation Operation information With the hydraulic chain tensioner, the necessary work on the chains during the operation of the conveyor systems can be carried out safely and reliably.

The pretension forces required for operation can be built up with the hydraulic chain tensioner.

Danger!

Towing chains which are under tension can break when you exceed the load limit. This could seriously injure or kill you.

Never load a chain above its load limit.

Always work from alongside of the chain. This way you can avoid being hit by the chain should it break.

The hydraulic chain tensioner can be used for the following work: J holding and tensioning the chains, E

J shortening and extending the conveyor systems on the head Bucyrus Europe GmbH, Lünen 2011

gate, J retensioning the chains, J installation after chain break, J breaking away the conveyor (freeing the chains).

The hydraulic chain tensioner is designed for parameter 115 mining gearboxes and may only be used for this parameter.

The main advantages of this method include: J smooth and secure tensioning of the chains, J secure holding of the pretensioned chains using the chain

locking device, ratchet pawl and the hydraulic chain tensioner during the installation operation, J gradual reduction to a certain pretension force after joining

the ends of the chain, thus conserving the chains and chain sprockets, J installation and start-up help, J moving the shear crown boresover one another to safely insert

the shear pins.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.3

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Operation information Requirements for a smooth tensioning procedure: J The chain tensioner is specified for the translation ratio and the

type of main gearbox.

J The hose lines between the control unit and hydraulic brake

motor are correctly mounted.

J The pressure and return lines to the control unit are mounted.

J The working pressure must be at least p = 320 bar to ensure

that the valves switch reliably.

J The pressure required for tensioning must be set by an expert

according to the available equipment and secured against maladjustment.

Important!

Information about the tensioning procedure can be found in the "Pretensioning conveyor chains" section on the following pages. The pressure must be set while the chain tensioner is running.

J The overload protection systems lying in the force flow are de-

activated.

Caution!

Observe the operating manuals and the safety regulations of the respective electric motor manufacturers.

5.4

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

the tail gate is designed so that all associated electric motors on the conveyor and mining equipment are disconnected before switching on the hydraulic chain tensioner and are secured against being switched on again.

E

J The electric control of the electric motors of the head gate and

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Operation information Switch positions The pinion is engaged/disengaged via the operating lever on the tensioning gearbox of the chain tensioner. To do this, the operating lever is pulled up and turned to the desired switch position.

Switch position “ON” In this switch position, the control wheel of the hydraulic chain tensioner is engaged in the crown gear of the drive connection. The electric motors on the conveyor and mining equipment are locked out.

Fig. 16: Switch position “ON”

Bucyrus Europe GmbH, Lünen 2011

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Control wheel engaged

Switch position “OFF” In this position, the control wheel of the hydraulic chain tensioner is disengaged. The contact in the electrical circuit of the control contactor is closed again. The conveyor and mining equipment can be put back into operation.

Fig. 17: Switch position “OFF”

Control wheel disengaged

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.5

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Pretensioning conveyor chains Pretensioning conveyor chains slack chain - conveyor

Chains must be pretensioned in the empty conveyor so that only a tolerable degree of slack chain is formed when the conveyor is operating with a load. Experience indicates that the chain may not exhibit more than a hand's width of slack at the head gate during operation when under the influence of the load. Otherwise the chain will hit too strongly against the entry edge of the lower chain channel. This leads to high noise levels and increased wear. Also, chain climbing/jumping on the chain sprockets is promoted when too much slack chain forms.

Excessive chain tensioning results in a loss in power as the chains pass around the chain sprockets. This will lead to increased wear on the chains and chain sprockets, increased noise levels and higher input power.

pretension change during operation

As the face advances, the pretension in the chains may change when the conveyor takes on other curves in both horizontal and vertical direction. Changes can be caused by greater compression or stretching of the pan line and by changes in the face angle. In addition, load changes due to fluctuations in the properties of the transported material are possible, e.g., due to fluctuations in the minability of the face and the required loading work.

permanent elongation monitoring the chain

pretensioning the chain

The chain itself changes due to increasing permanent elongation.

In order to ensure trouble-free operation with a favorable power rating and long service lives of chains and chain sprockets, the run of the chain must be constantly monitored with respect to the criteria slack chain and noise level. In this way it is possible to know when a chain needs to be lengthened or shortened.

Guide values for pretensioning chains in face conveyors can be requested from Bucyrus.

The information is based on empirical values for average operating conditions and for the uniform loading of conveyors which are most often used for the individual chain sizes. The pretension might therefore have to be corrected according to the respective operational conditions observed.

5.6

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

excessive chain tensioning

E

During operation, the horizontally lying chain links must not be hit by the tooth heads on the driving drum of the tail gate. The chains links might also jam together, which could damage the pans and cause chain breaks.

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Pretensioning conveyor chains Chain tensioner functions Notice!

The chain tensioner functions are actuated on the PMC-R control unit. Please observe the separate operating manual of the PMC-R control unit.

Tab. 1: Chain tensioner functions

E

Function

Remarks

Clockwise rotation

The hydraulic brake motor is driven between 30 and 170 bar

Counterclockwise rotation

The hydraulic brake motor is driven between 30 and 170 bar

“Break-away” clockwise rotation at high pressure

Hydraulic brake motor is driven at 230 bar

“Break-away" counterclockwise rotation at high pressure

Hydraulic brake motor is driven at 230 bar

Release brake

Hydraulic brake motor is not driven.

Brake is released (230 bar)

Setting the pressure-reducing valve

If the function is actuated, the setting pressure can be read off the pressure gauge

Bucyrus Europe GmbH, Lünen 2011

Maximum reachable torques Tab. 2: Maximum reachable torques Ratio of the Hydraulic brake motor main gearbox type i

Maximum reachable torques at the output in kNm Gearbox parameter

i = 33 i = 39

RM 160 NKAD 12 FS94-LBD124 HF

963 kNm 1138 kNm

Dimensions and operating force of the chains Caution!

The chain forces can be reduced by up to 50% along the chain up to the locking device depending on the length, type and position of the system.

Tab. 3: Dimensions and operating forces of the chains Chain

according to DIN 22252 quality class 2

dxt

Operating force

Breaking strength

(mm)

(kN)

(kN)

60/135x181/197 F-Class

2310

3300

Power Chain 60 x 200

3070

4910

For chain assemblies with two chains, twice the operating force is permissible.

Important!

The respectively used chain can be found in the conveyor operating manual.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.7

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How to tension, extend or shorten chains How to tension, extend or shorten chains Auxiliary devices for holding the chain Danger!

Never use the drives to tension the chain or couple it. The drives generate chain forces which could irreparably damage the chain locking device or the ratchet pawl! This could result in serious injury or death.

If the chain is equipped with a chain locking device, only use a chain tensioner device to move it.

Caution!

Take care to ensure that the tensioner cylinder in the tensionable drive frame still has sufficient residual stroke to be able to retighten the chain during operation.

The following auxiliary devices are to be used to hold the uncoupled chain when extending or shortening it: J chain locking device

There is a reverse lock or retaining pawl to keep the chain on the chain sprocket from running back during the tensioning procedure.

J chain ratchet pawl device at the head gate J chain ratchet pawl on the baffle plate of the tail gate.

Fig. 18: Schematic diagram for tightening the chain (ratchet pawl and chain locking device are installed on the head gate) d a c e b

a drive 1 (head gate) b drive 2 (tail gate) c chain locking device

d ratchet pawl e tractive direction

Notice!

The manufacturer information is to be observed for gearboxes with overload protection systems.

5.8

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

Notice!

Please observe the separate operating manual of the PMC-R control unit.

E

Notice!

Make sure you observe the separate operating manual for the used conveyor.

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How to tension, extend or shorten chains Before operating the chain tensioner Danger!

Always work only from alongside of the chain.

Caution!

Before startup, make sure that the drain line “L” of the hydraulic brake motor has a free flow.

Warning!

Before startup, make sure that the HP ball valve for the pressure line (P) is open.

Danger!

Before tensioning the chain, the chain locking device must be installed on the conveyor chain.

Caution!

In normal operation, the chain tensioner is operated exclusively with the electronic control unit.

Please observe the separate operating manual of the PMC-R control unit.

Bucyrus Europe GmbH, Lünen 2011

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Please proceed as follows:

. Run the conveyor empty. . Move the adjusting chains of the conveyor chain to the head gate.

. Pull the operating lever of the chain tensioner upward and then move the operating lever from the switch position “OFF” to switch position “ON” (see 5.5 “Switch positions” page).

Notice!

The electrohydraulic control unit can lose a little hydraulic fluid after every executed function.

This condition is not a defect.

Collect the escaped fluid in a suitable container and dispose of it according to the environmental regulations of your country.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.9

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How to tension, extend or shorten chains Tensioning the chain

. Press the respective function on the PMC-R (clockwise or counterclockwise rotation) in which you would like to tension the chain.

Important!

You can find the required information for setting the required pressure for tensioning the conveyor chain in chapter 6, “Pressure control” on page 6.5.

. Engage the ratchet pawl on the conveyor after the set working pressure has been reached and the hydraulic brake motor is at a standstill.

Important!

It might be necessary to throttle the hydraulic brake motor until the ratchet pawls can engage behind a vertical chain link.

. Move the chain tensioner in the opposite direction via the

J disconnected J shortened/extended or J connected

Notice!

To join chains with chain connectors, e.g. with U-locks, tensioning must be initially greater during pretensioning than the desired pretension required after joining. In order to be able to insert a chain connector, the two end links must be touching one another, i.e. a minimum of approx. one chain pitch “t” is required as slack.

Disconnecting the chain

. Pull the slack chain laterally out of the conveyor. . Disconnect the chain and remove the adjusting chain/chain links.

Shortening/lengthening the chain

. Pull off the head gate with the equipment for installing or removing the pans.

. Now you can install or remove conveyor pans. . Afterwards, pull the head gate back toward the conveyor. . Shorten or lengthen the chainaccordingly.

5.10

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

Once the chain is tensioned, the chain can be safely:

E

PMC-R so that the ratchet pawl on the conveyor can engage in the chain.

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How to tension, extend or shorten chains Connecting the chain

. Connect the chain with the corresponding chain connectors (e.g. U-locks).

. Place the slack chain in the conveyor from the side.

Disengaging the ratchet pawl After tensioning the chain the ratchet pawl must be disengaged and secured.

. Briefly retension the chain. . Lift and disengage the ratchet pawl.

E

Danger!

If the ratchet pawl cannot be lifted out easily, it is still engaged too firmly in the chain.

Never attempt to free the ratchet pawl from the chain using a hammer or something similar.

The pawl can be lifted out of the chain link by retensioning the chain again by a small amount.

Afterwards, you can lift out the ratchet pawl.

Bucyrus Europe GmbH, Lünen 2011

. Secure the ratchet pawl against re-engaging.

Releasing the chain locking device Notice!

Considerable damage to the drives can be caused by starting the blocked conveyor.

Remove the chain locking device before putting the conveyor back into service.

. Remove the chain locking device from the conveyor.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

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How to tension, extend or shorten chains Putting the chain tensioner out of operation

. Switch the chain tensioner off by switching the operating lever to the “OFF” switch position. This also unlocks the electric lock of the electric motors.

Warning!

You may only put the system back into operation after you have checked the entire conveyor without finding any deficiencies.

Tensioning the chain with drive frame, size 115 Notice!

In the case of conveyor systems with drive frames of size 115, the max. permitted working pressures might not be sufficient if the chain is only to be tensioned on the head gate.

For this reason, you must tension the chain separately on the upper and bottom races or on the head and tail gates.

Fig. 19: Schematic diagram - Tensioning the chain with drive frame, size 115 1. Tensioning the chain in the upper race - tail gate

ratchet pawl Bucyrus Europe GmbH, Lünen 2011

E

locking device

pulling direction of the chain

rotational direction of the chain tensioner

2. Tensioning the chain in the bottom race - head gate

ratchet pawl

locking device

holding the pretension with the chain tensioner

pulling direction of the chain

rotational direction of the chain tensioner

Proceed as described in the “Tensioning the chain” and “Shortening/ lengthening the chain” sections.

J Insert the locking device J Tension the chain in the upper race on the tail gate.

J Maintain the pretension on the tail gate with the chain ten-

sioner.

J Tension the chain bottom race on the head gate.

5.12

Hydraulic chain tensioner / parameter 115

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How to maintain the chain tensioner How to maintain the chain tensioner Put the chain tensioner into operation at least twice a week for a short time and make sure the surfaces of the chain tensioner are kept clean.

Important!

The recommended maintenance intervals are for guidance only. Particular operating conditions may require other maintenance intervals. Be sure to modify the maintenance intervals to the specific operating conditions.

Danger!

Be sure to observe the intervals specified for maintenance and checks of the chain tensioner as hot surfaces may ignite explosive atmospheres and dust. danger of explosion

Also observe the information about the maintenance intervals in the separate operating manuals of the used components.

Tensioning gearbox

Bucyrus Europe GmbH, Lünen 2011

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The tensioning gearbox has life-time lubrication and is therefore maintenance-free. Together with the hydraulic brake motor, the tensioning gearbox must be put into operation at least twice a week for a short time.

Hydraulic brake motor The hydraulic brake motor is maintenance-free and is lubricated by the fed pressure fluid. Together with the tensioning gearbox, the hydraulic brake motor must be put into operation at least twice a week for a short time. Check the leaked brake oil after every tensioning procedure.

Notice!

To avoid corrosion damage, the hydraulic brake motor must constantly remain full of emulsion. Make sure that this emulsion cannot leak through the oil drain line.

Electrohydraulic control unit The electrohydraulic control unit is subject to regular maintenance.

The corresponding components and maintenance points are listed and explained below.

Danger!

The hydraulic components are constantly under pressure!

You could be seriously injured or even killed by pressurized components and escaping hydraulic fluid. Therefore, before starting work, make absolutely certain that the hydraulic system is depressurized. Close the shut-off valve in the pressure supply line to the chain tensioner.

Warning!

Alternately actuate the opposing pressure keys of the control unit 10 times to reduce the remaining pressure in the hydraulic system. Only once the pressure has been relieved can you begin with maintenance.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.13

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How to maintain the chain tensioner The following components on the electrohydraulic control unit require maintenance: J the accumulator cartridge J the screw-in throttle J the filter element J the pressure relief valves Fig. 20: Maintenance of the electrohydraulic control unit 4

1

3 2

1 accumulator cartridge 2 screw-in throttle 3 filter element DN 12

4 pressure relief valve, 250 bar a push-button

Accumulator cartridge The accumulator cartridge is used to stabilize the pressure in hydraulic control circuits. It is pretensioned with nitrogen and is connected directly with the system pressure of the control circuit.

If there is a drop in pressure within the control circuit, fluid will be topped up from the accumulator cartridge and the control pressure will be stabilized.

Danger!

Do not operate the control unit without an accumulator cartridge or with a damaged accumulator cartridge. Otherwise there could be malfunctions on the chain tensioner. You could be seriously injured or killed by this.

Immediately replace a faulty accumulator cartridge.

Important!

Accumulator cartridges may only be tested and filled by specialist Bucyrus personnel. Contact your local Bucyrus supplier.

Accumulator cartridges must be checked every year to make sure they work. For this purpose, the selected accumulator cartridge must be exchanged for a new one and then tested. The tested accumulator cartridges can be put back if no faults were found.

5.14

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

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How to maintain the chain tensioner Screw-in throttle The screw-in throttle ensures the necessary flow rate to ensure the complete function of the pressure-reducing valve.

If the screw-in throttle is contaminated, the pressure-reducing valves do not have a sufficient flow through them and the pressure rises above the setting pressure. Check the screw-in throttle regularly for contamination. The cleaned screw-in throttle can be put back.

Filter element There is a filter element at pressure port “P” of the control unit. The filter element protects the control unit's valves from damage caused by impurities in the hydraulic fluid.

If the filter element is contaminated, it is possible that functions run slowly or even can no longer be carried out. Replace the filter element when it is contaminated. However, it only has to be replaced regularly, if the face supply unit filtering system is inadequate. You must thus put great emphasis on the quality of the preparation of the hydraulic fluid.

Bucyrus Europe GmbH, Lünen 2011

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Caution!

Only use the filter element once and do not attempt to clean it.

Contamination in hydraulic systems is a common reason for expensive repairs.

You must always only use new filter elements and seals.

Pressure relief valves The pressure relief valves must be checked every year to make sure they work properly.

Caution!

Always replace pressure relief valves with new valves having the same properties. Always compare with the hydraulic system circuit diagram. Noncompliance endangers the operational safety of the hydraulic system and can cause serious and sometimes irreparable damage to components.

Notice!

Always fit new seals when replacing a pressure relief valve.

Noncompliance can lead to leaks on the staple locks and compromise the operational safety of the hydraulic system.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

5.15

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How to maintain the chain tensioner

5.16

Hydraulic chain tensioner / parameter 115

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6

Technical data

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Technical data sheet

Technical data This chapter contains the most important technical data for the chain tensioner. At the end of the chapter you will find further information about tightening torques, approved oils, HFA fluids, etc.

Read this chapter through carefully and at your leisure. Pay special attention to any safety instructions.

Technical data sheet Main components The hydraulic chain tensioner consists of: J the tensioning gearbox, J the hydraulic brake motor, J the electrohydraulic control unit, J the electronic control unit (PMC-R).

Bucyrus Europe GmbH, Lünen 2011

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Tab. 4: Maximum reachable torques Ratio of the Hydraulic brake motor main gearbox type i

Maximum reachable torques at the chain wheel in kNm Gearbox parameter

i = 33 i = 39

RM 160 NKAD 12 FS94-LBD124 HF

963 kNm 1138 kNm

Tab. 5: Main dimensions, tensioning gearbox and hydraulic brake motor

Length: . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . .

L B H M

= = = =

710 mm 570 mm 431 mm 270 kg

Tab. 6: Main dimensions, electrohydraulic control without protection cover

Length: . . . . . . . . . . . . . . . . .

Width: . . . . . . . . . . . . . . . . . .

Height: . . . . . . . . . . . . . . . . .

Weight: . . . . . . . . . . . . . . . . .

L B H M

= = = =

308 mm 350 mm 528 mm 75 kg

Ratio tensioning gearbox with crown gear: i = 53.3 Hydraulic brake motor The hydraulic brake motor consists of a radial piston motor with a downstream hydraulically ventilated, spring-loaded multi-disk brake.

Geometric displacement: . . . . . . V = 160 cm3/U Specific torque: . . . . . . . . . . . . . . T = 2.38 Nm/bar Max. speed: . . . . . . . . . . . . . . . . . . . . . . n = 800 rpm Brake air pressure: . . . . . . . . . . . . . . . . p = 30 bar

Doc. No.: 1955 115 000 BA 00

VUSS / 01

6.3

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Technical data sheet Functional description The chain tensioner is controlled via the PMC-R control unit. The pressure is supplied via the electrohydraulic control unit. The possible control range for tensioning lies between 30 and 170 bar. The “break-away” function is executed with a permanently set pressure of 230 bar.

The pressure fluid goes via the pressure filter to pressure port “1” of the control unit. The connection for the return line is labeled with “2”. The multi-disk brake is hydraulically opened via pilot line “S1”.

The drain line from the hydraulic brake motor must not be connected to the return line. The leaked oil is to be drained freely, depressurized, via a siphon-like installed hose line or is to be fed separately to the tank. The drain line must be installed so that the motor housing always remains full of pressure fluid.

The leaked brake oil is to be checked after every tensioning and, if necessary, is to be drained via the “brake drain connection” on the brake housing. The connection for the drain line on the hydraulic brake motor is labeled with “L”. All components are suitable for operation with 2 to 5% oil-in-water emulsion.

E

S1 a

b 1

L1+L2

P T

a filling breather filter M12x1.5 b drain connection, brake M12x1.5 1 connection for electrohydraulic control unit (rotational direction clockwise: for flow from connection 2 to 1) 2 connection for electrohydraulic control unit (rotational direction counterclockwise: for flow from connection 1 to 2)

6.4

L1+L2 drain connections fed together, lead to “Tank” depressurized S1 brake control connection P pressure line to the electrohydraulic control unit, can be shut off via HP ball valve T return line with check valve DN 12

Hydraulic chain tensioner / parameter 115

Bucyrus Europe GmbH, Lünen 2011

Fig. 21: Overview of connections 2

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Technical data sheet Pressure control The pressure range from 30 bar to 170 bar is set on the set screw on the right pressure-reducing valve. The amount of pressure depends on the operating conditions. Depending on events and the operating state, the pressure must be corrected according to observations. The “break-away” of the conveyor is executed with a permanently set pressure of 230 bar.

Important!

Guide values for pretensioning chains in face conveyors can be requested from Bucyrus.

Caution!

The max. permissible pressure is 230 bar.

If pressures are higher, the seals on the hydraulic motor will be destroyed.

The pressure is adjusted to the desired value via the set screw on the right pressure-reducing valve (2). Depending on the rotational direction of the set screw, you can set the permissible pressure higher or lower.

J Screw in set screw = increase pressure Bucyrus Europe GmbH, Lünen 2011

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J Screw out set screw = lower pressure

In order to be able to read off the set pressure from the pressure gauge, the “Set pressure” function on the PMC-R must be actuated.

Fig. 22: Pressure control on the electrohydraulic control unit

1

3

1 pressure gauge 2 pressure-reducing valve adjustable (30 to 170 bar)

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3 pressure-reducing valve permanently set (230 bar)

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Control gear with electrical interlock Control gear with electrical interlock The electric control is designed such that all associated electric motors on the conveyor system are disconnected before switching on the hydraulic chain tensioner and are locked out.

Functional description The pulse switch (item a) looped into the electrical circuit is actuated by switching off the hydraulic chain tensioner. By moving the operating lever (item b) with the permanent magnet (item c) in the direction of the arrow, a flat spring of the protective gas contact is acted upon by a pole (north or south pole) of the cross-polarized permanent magnet. The contact in the electrical circuit of the control contactor is thus closed.

In this “OFF” switch position, the drive motors can be started. The contact opens again when the permanent magnet moves away and the affected contact tongue is no longer magnetically influenced.

The electric motors on the conveyor system are locked out at the same time the hydraulic chain tensioner is switched on.

Fig. 23: Electric locking mechanism

c

b

Switch position “OFF”

Switch position “ON”

a pulse switch b operating lever

6.6

c switching magnet

Hydraulic chain tensioner / parameter 115

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a

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids Notice!

Only use hydraulic fluids for which you have a valid certificate issued by Bucyrus. Otherwise, there is a danger that the hydraulic equipment can be seriously damaged and could result in the loss of warranty claims.

Only those hydraulic fluids may be used for the operation of hydraulic components from Bucyrus for which the respective operator has a valid certificate in accordance with EWN 8350 or an exemption permit from Bucyrus. Bucyrus will not accept any warranty claims for components which have been or are operated using a different hydraulic fluid.

Furthermore, the national - and sometimes also regional - regulations on health and safety at work and environmental regulations must be observed for operation.

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If a mine only uses individual hydraulic components without using Bucyrus shield supports, or if obtaining a valid certificate would require too much effort, the same hydraulic fluid which is used for the existing shield support may be used for these individual components, subject to approval by Bucyrus. The same applies to hydraulic chain tensioners, hydraulically tensionable drive units, etc. The respective exemption permit is issued by Bucyrus on request.

Suitability test Before the certificate of Bucyrus is issued for a hydraulic fluid, the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid, and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

To perform the suitability test, original samples are required of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine.

The suitability test is carried out by an independent testing institute authorized by Bucyrus. The criteria as specified in EWN 8350 will be applied for the test. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to: J stability, J sealing materials, J corrosion.

Furthermore, a chemical “fingerprint” of the concentrate is created in order to rule out or verify any possible changes in the composition of the concentrate if necessary.

If the suitability test shows that the hydraulic fluid meets requirements, the operator will receive a corresponding certificate from Bucyrus.

Doc. No.: 1955 115 000 BA 00

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Permissible media Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of Bucyrus hydraulic systems for each product tested. Certificates shall be valid for a period of one year and, after a simplified test, can each be extended for an additional year. The certificate is no longer valid if one or several of the requirements for obtaining the certificate are no longer fulfilled.

This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, Part 1.

The following illustration shows a typical certificate.

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Fig. 24: Typical certificate

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Permissible media Hydraulic fluid maintenance The consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected and should be performed with special care. Ideally, the most important properties of the hydraulic fluid are monitored automatically and documented continuously in order to directly counter any harmful development.

These properties include: temperature, foaming, pH value, concentrate ratio and microbial load.

The operator of the equipment must prepare a hydraulic fluid maintenance plan for the specific application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

If it is not possible to monitor the hydraulic fluid continuously, the properties listed in the following should be checked at least once every week: J pH value

– setpoint: 7.5 to 9.5 J Concentrate content Bucyrus Europe GmbH, Lünen 2011

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– setpoint: see certificate J Microbial load

– setpoint:  105 col/ml.

In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible maximum temperature of the hydraulic fluid is 55°C. During normal operation, however, an operating temperature of 45°C should not be exceeded. A higher working temperature will reduce the stability of the emulsion and shorten the service life of the sealing material.

Quality of the process water use for hydraulic fluids

The quality of the water used to create the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid.

Accordingly, the requirements for monitoring the water quality are very high.

If the limits shown in the Table 7 are maintained, it can be assumed that the water is basically suitable.

If one or several of the limits mentioned are not complied with, this should be taken into consideration when selecting a concentrate.

Furthermore, water treatment may also be necessary.

However, the customer shall in any case provide a sample of the original water to permit performing the tests required for the issue of the certificate.

Changes in the composition of the water will lead to the loss of the certificate even if they are within the limit values mentioned.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

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Permissible media for use as spraying water

limit values

Water used for this purpose may not contain aggressive components and dirt particles. In order to guarantee perfect long-term operation, the water must be filtered with a prefilter, with a minimum of 100m. In order to protect the components, the limit values listed in the table must not be exceeded The following table lists limit values for the essential properties and components of the process water.

Caution!

Using water which is not of the specified quality can cause serious damage to component surfaces and the entire hydraulic system. Only use water that complies with the specified limit values.

Limit value

Appearance, color, odor

No peculiarities permissible, e.g.turbidity, bad odor, etc.

Electrical conductivity

< 1800 S/cm

pH value

6.5 ..... 8.5

Na+ content

Not specified

Mg+

Not specified

content

Water hardness

< 750 mg/l CaCO3 equivalent ( 42° dH)

Cl- content



201 mg/l

SO42- content



145 mg/l

NO3- content



20 mg/l

Fe content



Bacteriological requirements



105 col/ml 1)

Ratio of solid foreign matter with 1.2 m filtration in accordance with DIN EN 12662



10 mg/l1)

Contamination class according to ISO 4406: 1999

- / 18 / 14 1)

1 mg/l

1) The values listed must be observed during the production of hydraulic fluids.

They do not apply when the water is used exclusively as spraying water.

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Test criterion

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Tab. 7: Properties of the process water, limit values

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Identification of the chain tensioner Identification of the chain tensioner Manufacturer: . . . . . . . . . . . . . Bucyrus Europe GmbH Type: . . . . . . . . . . . . . . . . . . . . Hydr. chain tensioner Year of manufacturing: . . . . . MM/YY (e.g.: 08/10 ≙ August 2010) ID No.: . . . . . . . . . . . . . . . . . . . 1955 115 000 00 00 Weight: . . . . . . . . . . . . . . . . . . approx. 380 kg The chain tensioner is labeled with the following information.

Fig. 25: Identification markings on the chain tensioner Chain tensioner data

Hydr. chain tensioner 1 type 2 ID number 3 serial no. / year of manufacturing

1 2

1955 115 000 00 00

4 weight

3 4

No. xxx/ xx

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G = 380 kg CE-marking

The design of the chain tensioner meets the requirements of the European Directive 94/9/EC and DIN EN1710. It is suitable for use in potentially explosive atmospheres.

Doc. No.: 1955 115 000 BA 00

VUSS / 01

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Identification of the chain tensioner

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7

For your information

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Standards and directives

For your information If you should require spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly (homepage: www.bucyrus.com).

Standards and directives Referenced standards and guidelines Tab. 8: Standards and guidelines, extract

Bucyrus Europe GmbH, Lünen 2011

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Designation

Date of issue

Title

Directive of the European Parliament and the Council on Directive 2006/42/EC the approximation of the laws of the Member States relat2006-05-17 ing to machinery Directive of the European Parliament and the Council on the laws of the Member States concerning equipment and Directive 94/9/EC 1994-03-23 protective systems intended for use in potentially explosive atmospheres DIN EN ISO 2004-04 Safety of machinery 12100-1/A1 2009-07 DIN EN ISO 12100-2 Safety of machinery 2004-04 Petroleum products and bituminous materials DIN ISO 3733 2003-02 - Determination of water - Distillation method Non-electrical equipment for potentially explosive atmoDIN EN 13463-1 2009-07 spheres - Part 1: Basic method and requirements Electrical apparatus for explosive gas atmospheres DIN EN 60079-0 2010-03 - Part 0: General requirements DIN EN 60445 Basic and safety principles for man - machine interface 2007-11 Underground mining machinery - Specification for the DIN EN 12321 2009-07 safety requirements for armoured face conveyors Equipment and components intended for use in potentially DIN EN 1710 2008-08 explosive atmospheres in underground mines Mobile extracting machines at the face - safety requireDIN EN 1552 2003-09 ments for shear loaders and plough systems DIN EN 1804-1,-2,-3 Safety requirements for hydraulic powered roof supports 2010-05 Preparation of instructions DIN EN 62079 2001-11 - Structuring, content and presentation DIN 2000 Quality of drinking water 2000-10 DIN 6789 Documentation System 1990-09 DIN 20043 Plug connectors for hydraulics 2003-09 DIN 24320 Fire-resistant hydraulic fluids 2006-12 DIN 24343 Maintenance and inspection list for hydraulic systems 1982-02 DIN 51558-1 Determination of the acid number 1979-07 DIN 51575 Determination of sulfated ash 2011-01

Doc. No.: 1955 115 000 BA 00

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Standards and directives Date of issue

Designation

Title

EWN 6003 1)

Tensioning force, tightening torques and surface pressure for bolts Hammer head bolts Lubricating greases & solid lubricants Non-metallic (coating) surface protection Approval procedure for fire-resistant HFA-fluids in mining

1985-02 1992-06 1985-02 2008-01

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EWN 6110 1) EWN 7068 1) EWN 7069 1) EWN 8350-1 1)

1985-02

1) EWN = Bucyrus works standard

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Hydraulic chain tensioner / parameter 115