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DBTGmbH,Lünen2006 E
Aboutthismanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthesymbolsandcharactersused.
Beforestartingwork
Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofelektrohydrauliccontrolunitused.Failure todosocanresultinasafetyhazardforyourselfandothers.Ensure thatthedataontheelektrohydrauliccontrolunitcomplywiththe datagivenintheoperatingmanual.
Thisoperatingmanualisdesignedfor Elektrohydrauliccontrolunit-16functionswiththeorderNo.:81541190000000 andisonlypermittedtobeusedforelektrohydrauliccontrolunitsof thistype.
Anoperatingmanualfortheelektrohydrauliccontrolunitmust alwaysbeavailable.Askforanewmanualimmediatelyiftheexistingmanualisnolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforallpersonsinvolvedinthe J installation, J maintenance, J repair, J operationand J dismantling oftheelektrohydrauliccontrolunit.
Inaddition,thesupervisorypersonnelwhoinitiateand/orsupervise theactivitiesjustindicatedmustalsoobservethisoperatingmanual.
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonallthe activitiesrelatedtotheelektrohydrauliccontrolunit.
Readthisoperatingmanualcompletelyandatease.Payspecial attentiontothesafetyinstructions.Trytomemorizetheappearance andthemeaningofthesafetyandinstructionsymbols.
Readthechapter2”Foryoursafety”withspecialattention.This chaptercontainsimportantinformationindicatingpossiblehazards.
Observetheinformationgivenandfollowtheproceduralinstructions.Thisistheonlywaytominimizeoperatingcostsandtoassert warrantyclaims.
Beforestartingwork
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructionsandimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattention toimmediatelyimpendingdanger.Possibleconsequencesare: Veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations. Possibleconsequencesare: Veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare: Lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentionto harmfulsituations.Possibleconsequencesare:Minormachine damageordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultips andinformationintendedtofacilitateworkforyou.Theydonot warnaboutharmfulordangeroussituations.
Listsaremarkedwithbullets.
Sub-listsaremarkedwithalongdashatthestartoftheline. Thesymbolofthehandasksyoutodosomething.Severalsuccessiveparagraphsmarkedwiththesymbolofthehandrepresenta stringofactionswhichmustbeexecutedintheorderspecified. Followtherespectiveinstructionsstep-by-steptoperformthework safelyandefficiently.
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.
Payspecialattentiontothischapter.Thesafetyinstructionsand rulesofprocedurewillhelpyoutoavoidhazardoussituationsandto performthenecessaryworkassafelyaspossible.
Theelectrohydrauliccontrolunithasbeenmanufacturedinaccordancewiththestateoftheartandgenerallyrecognizedsafetystandardsandregulations.However,acertainriskremainswhichmight getyouintohazardoussituationswhenworkingwithorontheelectrohydrauliccontrolunit.Thesemay,forexample,becausedby unforeseeableexternalinfluences,machinedamageoroperating errors.
Inadditiontothisoperatingmanual,alsobesuretoobservethe respectivelegalprovisionsandregulationsforaccidentpreventionin yourcountry.
Observethesafetyandaccidentpreventionregulations:
J oftheminingcompany, J oftheminingauthority,and
J oftheminers’accidentinsuranceassociation.
Personnel
Personsemployedintheoperation,repair,andoverhaulofhydraulic and/orelectrohydrauliccontrolunitcomponentsmusthavespecial qualifications.Inadditiontohavingreceivedtraininginminingskills thefollowingminimumrequirementsshallbemet.
Operation
Operationandmaintenanceoftheshieldcontrolisonlyallowedto beperformedbytrainedpersonnel.Thetrainingshallbematchedto thetypeofshieldcontrolactuallyused.Thecontentoftheoperating manual,especiallythechapteronsafety,shallconstituteapartof thistraining.
Theyshallpossessandfurnishproofofadequatefamiliaritywiththe J mechanical, J hydraulic,and J controlsystems.
Repair
Ingeneral,repairworkshallbeperformedonlybypersonswhohave therespectiveknowledgeandskillstomeetthespecialrequirementsandhavebeenadequatelytrainedintherepairoftheequipment.Repairworkonandoverhaulof J controlblocks, J workingvalves, J pilotcontrolvalves, J safetycomponents,e.g.pressurereliefvalves,etc. shallbeperformedonlybyDBTservicetechniciansorbyspecially trainedpersonneloftheminingcompany.
Conditionsofoperation
Useinconformancewithspecifications
Theelectrohydrauliccontrolunithasbeendesignedandmanufacturedexclusivelyaspartofthecontrolsystemforshields.Itisonly allowedtobeusedinconnectionwithanelectroniccontrolunit,such asforexampleaPMC® -R.
Usetheelectrohydrauliccontrolunitonlyasintended.
Intendedusesare:
J Theelectrohydrauliccontrolunitiscombinedwithanelectronic controlunit-asforexampleasinglecontrolunitoftype PMC® -R.Togethertheyformacontrolunitdesignedtooperate thefunctionsofashieldsupport.Thetwodevicesarepartofan adjacentcontrolsystemforelectrohydraulicshieldsupportsfor useinundergroundmining.
Theelectrohydrauliccontrolunitisanessentialcomponentof thiselectrohydraulicshieldcontrol.Operationofthefunctionsis notallowedtobemadedirectbypressingthebuttonsofthe electrohydrauliccontrolunit,butviatherespectivesinglecontrol unitwhichmustbelocatedinoneoftheadjacentshields.By meansofthiscontrolunitthepilotvalvesofthecontrolblockare actuatedmanuallyorprogram-controlled.
J Additionally,therearetwoexceptionalcircumstancesunder whichthecontrolblockalsoservesasdirect”controlunit”: -emergencyoperationand -repairoperation.
Inthesecasestheindividualfunctionsoftheelectrohydraulic shieldsupportareexecuteddirectatthepilotvalveoftheelectrohydrauliccontrolunit.Thus,thefunctionsoftheshieldcanbe operatedevenifthesinglecontrolunitislockedoutorhasfailed -butonlyinwell-foundedexceptionsandunderstrictobservanceofthespecialsafetyregulationsofthemineoperatorfor thesecases.
Unauthorizeduse
Useswhicharenotexpresslystatedasintendedareregardedas unauthorizedusesandarenotpermissible.
Unauthorizeduse:
J Useoftheelectrohydrauliccontrolunitas”controlunit”tooperatethefunctionsoftheshieldinnormaloperation. Actuatingtheshieldsexclusivelybypushingabuttononthepilot valveblockisunauthorizedusesinceoperationoftheshield functionsmustbeperformedfromanadjacentshield.
Byunauthorizedusesyouendangeryourselfandothers.Youcould beseverelyinjuredorevenkilled.Thereforeonlyusetheelectrohydrauliccontrolunitasintended!
DBTdoesnotacceptanyliabilityfortheconsequencesofunauthorizeduses.
Safetyinstructions
Basicprinciples
Alwaysconcentrateonyourwork.
Pleasealsoobservetheoperatingmanualsfortheshieldsupport andthecontrolunit.
Alwaysfamiliarizeyourselfwithyourworkingenvironmentfirst beforetakingupwork.
Neverstayunderashieldthatisnotsecured.
Alwayswearyourpersonalprotectiveclothingandequipment.
Pleaseobservethevisualandaudiblepre-startwarnings.Particularlyobservethepre-startwarningsignalsoftheconveyorandthe miningmachine.
Employonlyelectrohydrauliccontrolunitswhichareinatechnically flawlesscondition.
Presstheemergencystopswitchimmediatelyintheeventofmalfunctionsorirregularitiesinoperation.Notifyyourforemanofany peculiarity,inorderthatnecessaryactionbetakenimmediately.
Iftheshieldisequippedwithanelectrohydrauliccontrolunityou havetooperatethesupportlock-outswitch(repairswitch)inorder tolockouttheshield.Afterthishasbeendone,theshieldcannotbe operatedfromthecontrolunit.
Actuatethesupportlock-outswitchbeforeperforming.
J maintenancework, J inspectionwork,
J repairwork,andbefore J prolongedpresenceintheshield.
Neverreachintoorenterareasbetweenmachinecomponents whichcanmove.Thisappliesespeciallytothe:
J sideseals, J baseskids, J shiftingunits, J lemniscaticlinks, J hydraulicpropsandcylinders, J canopiesand J flippers.
StorageandTransport
Neverstorematerialsofanykindinthetravelwayorinyourworking area.
Immediatelyremovedefectivecomponentsfromthefaceinorder nottohinderthefacecrewandtopreventthesepartsbeingreinstalledelsewhere.
Passthemonforservicingwithoutdelay.
Observethespecifiedstoragetimelimitsandthestorageinstructions.
Safetyinstructions
Installation
Alwayssecureallmovingcomponentsmechanicallybeforerelieving thepressureinthehydraulicsystem.
Alwaysdepressurizethehydraulicsystemsbeforestartingworkon them.
Ensurethatnodirtentersthehydraulicsystem.
Removetheprotectioncapsontheportsonlyimmediatelybefore installingthecontrolblock.
Operation
Operatethemanualrepaircontrolonlywhenitisabsolutelynecessary.Wheneverpossible,controlashieldbytheelectroniccontrol unitofanadjacentshield.
Checkthatallprotectivedevicesontheshieldareinplaceandfunctionproperly.
Makesurethatnopersonsarepresentintheareaoftheshield beingactuated.
Observetheentirezoneofmotionoftheshield,inordertorecognizeandavoidhazardsinduetime.
Maintenance
Informthesupervisorypersonnelandthecoalfacecrewabout maintenanceandrepairwork.Providethemwithinformationonthe intendedworkandtheprobableduration.
Secureyourworkingareaoverawiderangeinordertoavoid endangeringyourselfandothers.
Closeoffyourworkingareatopreventtheminingmachinegoing there.Stopandlockouttheminingmachineandtheconveyortopreventrestarting.
Securetheshieldmechanicallytopreventitfromloweringunderits ownweightbeforestartingwork,e.g.by:
J supportingthecanopies,
J positioningwoodenwedgesbetweenthelemniscaticlinks.
Stopworkontheshieldimmediatelyifconveyingandminingworkis beingcarriedoutinyourworkingarea.
Refitanyprotectivedevicesremovedimmediatelyaftercompletion oftheworkandcheckthattheyfunctionproperly.
Ensurethattheprescribedmaintenanceandinspectionintervalsare observed.Seealsochapter5”Operation”.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements.ThisisbestensuredwithoriginalDBTspareparts. Pleaserefertothesparepartscatalogfortheordernumbers.
Donotcarryoutmodificationsorconversions.Modificationsand conversionsmustbeapprovedbyDBT.
Neverusethecontrolblockwithoutfiltercartridge.Failuretofita filterorusingafilterwithinsufficientmeshsizecouldcausemalfunctionsanddamageofthecontrolblock.
handlingof hydraulic fluids
protectiveequipment -hydraulic
Hydraulics
Avoiddirectcontactbetweentheskinandhydraulicfluids. Hydraulicfluidcanpenetratetheskinandcauseseriousinfections. Whenremovingprotectiveequipmentwhichincludeshydrauliccomponentskeepinmindthatthesecomponentsmaybepressurized. Youcouldbeseverelyinjuredbyhydraulicfluidjettingoutinan uncontrolledmanner.Thereforeitisimperativethatyoudepressurizethehydrauliccomponentsbeforeremovingtheprotectiveequipment.
Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids representaveryseriousdangertohealth.
maintenance,repair
pressurerelief valves
permissablehoses
Onlypersonswhohaveandcandemonstrateaspecialknowledge ofhydraulicsareallowedtoworkonthehydraulicsystem.
Makesurethatpressurereliefvalvesarealwaysprovidedwith protectioncaps.Replacedefectivecapswithoutdelay.
Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Inparticularcheckthat:
J Thehosesarenotpinchedortrapped.
J Thehoseshavenobubblesorblisters.
J Thehosesortheoutersheathesofthehosesarenotabnormallyrigidorhard.
J Theoutersheathofthehoseisnotdamaged.
J Theconnectorsaresecurelyinsertedintothesockets.
J Theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamageinthewhole system!Flushoutthehydrauliclinesthoroughlybeforeconnecting.
Beforeremovingstaplelockstodisconnecthydraulichosesturnthe hoseatthecouplingtocheckwhetherthelineisstillpressurised.If thehoseisdifficulttoturnordoesnotturnatallthelineisstillpressurised.Besuretodepressurisetheline.
Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurised.Besureto depressurisethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththe propercouplingclamps.Alwaysfastentheclampscompletely. Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressuringthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures. Donotuseanyhydraulichoseswithdamagedconnectorsorworn O-rings.
Replacehydraulichosesonlywithhosesofthesameorahigher quality.
Observethedateofmanufacturestampedonthehydraulichoses. Neverusehydraulichoseswhicharemorethan2yearsold,evenif theyhavenovisiblesignsofdamage.
Safetyinstructions
Fig.1:Example:4SPhydraulichose,designation
layinghydraulichoses
1manufacturer
2hosetype
3dateofmanufacture, 1stquarter2002
Nevertrytoholdapulsinghydraulichose.Depressurisethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses. Replacehydraulichosesatthefirstsuspicionofdamage. Laythehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Fig.2:Layinghydraulichoses,slack
Alwayslayhydraulichosessothatthey: J alwayshavealittleslack, WRONG RIGHT
J arenottwisted,
Fig.3:Layinghydraulichoses,twisting RIGHT WRONG
J arenotbentdirectlybehindtheconnections (distancemin.1.5xnominaldiameter),
Fig.4:Layinghydraulichoses,bending RIGHT WRONG
J cannotchafe,
Fig.5:Layinghydraulichoses,crossing RIGHT WRONG
J arenotkinked,
J donothavetowithstandtensilestrains, J areprotectedagainstthermalradiation, J areaccessibleatalltimes.
Pushhydraulichosesintothesocketsonlybyhand.Nevertryto drivethehydraulichosesinwithatoolasthiswilldamagetheconnections.
Wheninstallingthehydraulichoses,ensurethattheycannotbe:
J tornout,
J kinked,
J crushed, J drivenoveror
J twisted(Fig.:6)bythemovementoftheequipment.
Fig.6:Layinghydraulichoses,connectionsonmovingparts RIGHT WRONG
Overviewofthesafetyinstructions
Overviewofthesafetyinstructions
Thisisasummaryofallsafetyinstructionsgivenintheindividual chaptersofthisoperatingmanual.Asthesesafetyinstructionsare citedoutoftheircontextthemeaningisnotalwaysobvious.
Chapter3:Storageandtransport
NOTICE!
Dirtinthehydraulicsystemcanresultinfailureofthewholesystem andnecessitatecostlyrepairs. Removetheplugsjustimmediatelybeforeconnectionoftheelectrohydrauliccontrolunit.
Chapter4:Installation
DANGER!
Beforestartinganyworkonthehydraulicsystemtakecareto ensurethattherespectivesectionofthesystemhasbeencompletelydepressurized.Youcouldbeheavilyinjuredorevenkilledby hydraulichoseswhippingaroundorbyhydraulicfluidescaping underpressure.
Therefore,itisabsolutelyimperativethatyoudepressurizethe hydrauliclinebeforestartingtodismantlethem. Incase,anyofthestaplesaredifficulttoremoveorcannotbe removedatallpleasebeextremelycareful.Itmayindicatethatthe hydrauliclineisstillpressurized.
Hydraulichoseswhippingaroundcancauseseriousinjuryoreven death. Onlyusesuitablestaplesforsecuringtheconnectors.Makesureto insertbothendsofthestaplesandpushthemincompletely.
WARNING!
Improperorincorrectinstallationendangersyouandothers. Carryouttheinstallationonlywhenyouhavethenecessaryspecial knowledgetodosoandcanproveit!
Releasetheshieldforoperationagainonlywhenyouhavechecked thefunctionandobservednomalfunctions.
CAUTION!
Priortoassembly,socketsandnipplesoftheplug-typeconnectors mustbetreatedwithlubricatingpasteB3toEWN7068whichdoes notcontainmolybdenumdisulfide,seechapter6,section”Lubricatinggreasesandpastes”.
NOTICE!
Theelectrohydraulicandelectronicpartsoftheelectrohydraulic shieldcontrolsystemarecoveredbytwoseparatemanuals.The informationrequiredforstart-upandoperationoftheelectrohydrauliccontrolunitisgiveninthemanualfortherespectivecontrol systemused.
Donotsecuretheelektrohydrauliccontrolwithchainsorsteelropes inordertoavoidanydangerofinjury. Useonlytransportbeltsastheyfitcloselytotheelektrohydraulic controlandpreventslipping.
Chapter5:Operationsandmaintenance
DANGER!
Safetyhazardduetoshieldmovements. Personsmaybeseverelyinjuredorevenkilled,forexampleby unexpectedmovementsoftheshield,ifthecontrolunitisoperated bysomebodywhodoesnothavesufficientknowledgeofhowtoperformthiswork.
Onlyoperatethecontrolsoftheelectrohydrauliccontrolunitifyou havetherequiredknowledge.
Pushbuttonsthatarejammedorfixedcouldleadtouncontrolled movementsoftheshield.Thesemaycausesevereinjuriesoreven death.Thereforeneverfixthepushbuttons.
WARNING!
Greatlikelihoodofinjuryduetohydraulicfluidescapingunderpressure.Youmaybeseverelyinjuredorevenkilled.Itisimperativethat youdepressurizethehydrauliccircuitbeforeworkingonit.Donot performanyworkonahydrauliccircuitbeforehavingmadesure thatthepressurehasbeenisolated.
Donotoperatethecontrolvalveblockwithoutanyorwithadefectiveaccumulatorcartridge.Failuretocomplycanleadtomalfunctionsofthecontrolvalveblockortheshield.Thiscouldresultin injuryordeathtoyourselforothers.Itisimperativethatyoureplace defectiveaccumulatorcartridgeswithoutdelay.
Hydraulicfluidsescapingunderhighpressurecancauseserious injuryordeath.Besuretodepressurizethehydraulicsystembefore startingwork.
Ifstaplelocksareimpossibleordifficulttopulloutbeextremely carefulasthismayindicatethatthehydrauliclineisstillunderpressure.Besuretodepressurizethehydraulicline.
CAUTION!
Onlyuseeachfiltercartridgeonceanddonotattempttocleanit. Dirtinthehydraulicsystemisafrequentcauseofcostlyrepairs.You shouldgenerallyonlyusenewfiltercartridgesandseals.
Soilinginthehydraulicsystemcanresultinseriousdamagetothe wholehydraulicsystem!
Alwaysensurethatyourworkingareaisclean.
Impuritiesinthehydraulicmediumcanresultinseriousdamageto thewholehydraulicsystem!
Alwaysensurethatyourworkingareaisclean.
IMPORTANT!
Themaintenanceintervalsrecommendedarestandardvalues. Specialoperatingconditionsmayrequiredifferentmaintenance intervals.Itisabsolutelynecessarythatyouadaptthemaintenance intervalstotheindividualoperatingconditions.
Thefiltercartridgeissoiledwithemulsionresiduesanddeposits. Disposeofthefiltercartridgeinaccordancewiththeenvironment protectionregulations!
Theaccumulatorcartridgeisnotincludedinthescopeofsupplyof thecontrolvalveblock.Pleaserememberthisinformationwhen orderingreplacementparts.
Overviewofthesafetyinstructions
Aspecialdeviceisrequiredforchargingandtestingaccumulator cartridges.PleasecontactyournearestDBTrepresentationfor informationandhelpifsuchadeviceisnotavailableatyoursite.
Chapter6:Technicaldata
WARNING!
Assoonasthecurrentdropstoalevelbelow40mA,theswitching positionsbecomeunstable.Thisresultsinmalfunctionsorevenfailureoftheshieldcontrol.
NOTICE!
UseonlyhydraulicfluidsforwhichavalidcertificateissuedbyDBT GmbHhasbeenmadeavailabletoyou.Otherwise,thereisthe dangerofseriousdamagetothehydraulicequipmentandtheloss ofwarrantyclaims.
IMPORTANT!
Pleaseusethesparepartscatalogsuppliedwhenorderingspare parts.
Thelubricant,whichistobeused,isspecifiedintherespective chapter,e.g.assembly,maintenance....
Thegreaseslistedinthesametablecanbemixed.Otherproducts mayonlybeusedifthesuppliercanguaranteethattheyareequivalent.
Differentlycomposedlubricatinggreasesmustnotbemixedasthis maychangetheconsistency,i.e.themixturecanbecomethinnerso thatthelubricationeffectisnotsufficient.Itmayalsobedangerous touselubricatinggreaseshavingthesamesaponificationbasebut differentorigins.
Incaseofdoubt,themanufacturerofthelubricatinggreasetobe usedshouldbecontactedastothecompatibilityofthegreasein question.
Theinstructionsfortheuseofthelubricatinggreasesgivenunder ”important”alsoapplytothelubricatingpastes.
Storageandtransport
Storageandtransport
Thischaptercontainsimportantinformationonthecorrectstorage andtransportoftheelektrohydrauliccontrol.
Observanceoftheinstructionsandtipswillincreasetheservicelife oftheelektrohydrauliccontrol.Youwillalsobeabletocarryoutthe transportworkquickerandmoresafely.
Carefulattentiontothepointsinthischapterwillhelpyoutosimplify yourday-to-daywork.
Storage
Storageofnewequipment
Thesurfacesoftheequipmentareprovidedwithatemporarycorrosionprotection.Ifstoredproperly,theequipmentpartswillbeprotectedforsixmonthsreferredtothedateofdelivery.
Priortodeliverythehydraulicallyoperatedequipmentwillbetested andoperatedattheDBTsiteusingtheanticorrosiveandantifreezingfluidHYDROCOR® CV50*).Thisfluidremainsinthehydraulic systemfortransportandafollowingshort-timestorageperiod.
HYDROCOR® CV50isfreeze-proofdownto-40degreesCelsius andprotectsthemetallicmaterialsagainstcorrosion.
HYDROCOR® CV50isequippedwithacolorindicator,whichis responsiveonthepH-valueofthefluid.Thecolorofthefluidwill changefrom”red”to”yellow”incasethepH-valuedrops.Ayellow coloredfluidindicatesinsufficientcorrosionprotection.
ForfurtherparticularsonthepropertiesofHYDROCOR® CV50 pleaserefertotherespectivedatasheetofthemanufacturer.
Protecttheequipmentagainstdirectexposuretosunlight. Storetheelectricalequipment,electroniccomponents,sparepartsof rubberorplastic-suchassealsandhoses-andhydraulicfluids onlyinclosedroomsattemperaturesof15ºCto25ºC.
Evenwithproperstorage,sealsandhosesaresubjecttonatural ageing.Astorageperiodofapprox.twoyearsisthereforerecommendedfortheseparts.
Protectallhydraulicelementsduringstorageinasuitablemanner againsttheingressofdirtandmoisture.Theconnectingsurfacesof thehydrauliccomponentsmustbeprotectedagainstcorrosionand closedwithblindplates.Hydraulicplug-typeconnectionsandthe connectorsoftheelectriccablesmustbeclosedwithsuitablecaps orplugs.
Duringshort-termstorage(approx.4weeks)ofequipmentoutdoors, butattemperatures above freezing,electricalcomponentsneednot beremoved.Suchcomponentsmust,however,beparticularlyprotectedagainstenvironmentalinfluences,includinghightemperatures,forexamplebysuitablecoversorsheathingsforthecontrols andbyadditionallycoveringtheequipment. *) HYDROCOR® CV50isatradenameofTheunissen,ChemischeFabriken GmbH,Wuppertal/Germany
Storage
Iftheequipmentistobestoredformorethan6months,thecavities inthehydrauliccomponentsmustbecompletelyfilledwithapreservingfluidsuchase.g.HYDROCOR® CV50.Thisfluidmusthave corrosion-protectionpropertiesandshouldbefrost-proofwithinthe respectivetemperaturerangeoftheapplication.Allportsmustbe sealedwithdurableandsuitableplugs. Itishighlyrecommendednottostoretheequipmentoutdoorsbutin awellventilatedroom.Ifitisnotpossibletostorethecomplete equipmentindoors,removethehydraulicandelectroniccomponents andstorethemseparately.
Duringlong-termstorage,thesealingelementsmaysufferplastic deformationduetotheweightofthecomponents.Thismayrender thesealsuselessorreducethelifeoftheseals.Therefore,props andcylinders,forexample,shouldonlybestoredinanuprightposition.Ifthisisnotpossiblewiththecomponentsinstalled,theyhave tobedismantled.
Afterastorageperiodofapprox.twoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyDBT.Thecostwill bebornebythemine.
WithrespecttothestorageofHFAfluidsorconcentratesfortheproductionofHFAfluidsinanycasetheregulationsofthemanufacturer orsupplierofthosemediahavetobeobservedfirst.Supplementary informationisgiveninthechapter6,inthesection”Permissiblemedia”.
Takecaretoensurethatnewsuppliesarestoredseparatelyfrom existingstockandthatremovaltakesplaceonthe”firstin,firstout” principle.Markthecontainersaccordingly.
Usedequipment
Ifthereisanyneedtostorehydraulicequipmentthathasbeenin usebeforetheitemsspecifiedaboveapplyanalogously,withthe exceptionoftheitemcorrosionprotection.
Incasethehydraulicsystemistobeputoutofoperationtemporarily thecompletesystemhastobeflushedthoroughlyandfilledwitha suitablepreservingfluid(e.g.HYDROCOR® CV50).Ifthisisnot done,considerabledamagetothehydrauliccomponentsmaybe causedwithinashorttimesincethepropertiesofthemediumused maychangeveryfastandnegatively,e.g.duetomicrobialattack.
Transport Transportcrates
Severalelektrohydrauliccontrolsarepackedtogetherintransport crates.Theyshouldremaininthesecratesuntiltheyreachtheirfinal placeofinstallationinordertoprotectthemfromdamage.
Ensurethatthecratesarenotdamagedduringtransport.Payattentioninparticularthattheydonot:
J fallor
J burstopen duringtransport.
Protectthetransportcratesfrommoisture.
Beforetransportingtheelektrohydrauliccontrolattemperatures belowfreezing,theblockmustbecompletelyemptiedandthenfilled withasuitablepreservingfluid(e.g.HYDROCOR® CV50).
Iftheelectrohydrauliccontrolunitissubjectedtotemperatures below-20ºCduringtransportspecialmeasuresarerequired.Inthis case,pleasecontacttheDBTservicedepartmentpriortothecommencementoftransporttoclarifytherequirements.
Dimensionsandweight
Plugs
Theconnectionsoftheindividualelectrohydrauliccontrolunitsare sealedwithplasticplugstoprotectthesefromdamp,dirtanddamage.
NOTICE!
Dirtinthehydraulicsystemcanresultinfailureofthewhole systemandnecessitatecostlyrepairs. Removetheplugsjustimmediatelybeforeconnectionofthe electrohydrauliccontrolunit.
4 Installation
Installation
Thischaptercontainsinformationontheinstallationandremovalof theelektrohydrauliccontrol.Pleasepayparticularattentiontothe warningsandtips.
WARNING!
Improperorincorrectinstallationendangersyouandothers. Carryouttheinstallationonlywhenyouhavethenecessary specialknowledgetodosoandcanproveit!
Requirementstothefacehydraulicsystem
NOTICE!
Theelectrohydraulicandelectronicpartsoftheelectrohydraulicshieldcontrolsystemarecoveredbytwoseparate manuals.Theinformationrequiredforstart-upandoperationof theelectrohydrauliccontrolunitisgiveninthemanualforthe respectivecontrolsystemused.
Forallhydrauliccomponentsincludedinthescopeofsupplyof DBT,thehydraulicmediummustmeetthefollowingrequirements:
J Pressurefluidaccordingtolistofapprovedproducts,seesection”Permissiblemedia”inchapter6ofthismanual.
J Purityclass18/14toISO4406.
Installationoftheelektrohydrauliccontrol
Removaloftheelektrohydrauliccontrol
Beforestartingtheinstallationorreplacementofelektrohydraulic controls,youmusttakesafetyprecautions:
. Closeoffyourworkingareatopreventotherpersonsgetting there.
. Arrangefortheminingworktobestoppedinthisarea.
. Informyourcolleaguesaboutthetypeanddurationofthe repairworkandaboutyourexactlocation.
. Actuatethesupportlock-outswitch.
. Securetheshieldtopreventitfromloweringunderitsown weight;e.g.byplacinghardwoodwedgesbetweenthepairsof lemniscaticlinksorbysupportingthecanopyotherwise.
. Depressurizethehydraulicsystemoftheshieldin question.
. Checkthatthehydrauliclinesarereallydepressurized. WheneverythingisOK,youcanproceedwiththenextsteps.
. Marktheconnectingcablesandhydraulichosestoprevent confusions.
. Pulltheconnectingcablesfromthecoversofthepilotcontrol valves.
Installationoftheelektrohydrauliccontrol
DANGER!
Beforestartinganyworkonthehydraulicsystemtakecareto ensurethattherespectivesectionofthesystemhasbeencompletelydepressurized.Youcouldbeheavilyinjuredoreven killedbyhydraulichoseswhippingaroundorbyhydraulicfluid escaping underpressure. Therefore,itisabsolutelyimperativethatyoudepressurizethe hydrauliclinebeforestartingtodismantlethem. Incase,anyofthestaplesaredifficulttoremoveorcannotbe removedatallpleasebeextremelycareful.Itmayindicatethat thehydrauliclineisstillpressurized.
. Loosenallhydraulicconnectionsontherearoftheelektrohydrauliccontrolandensurethattheconnectionsarenotdamagedorsoiled.
. Securetheelektrohydrauliccontrolwithhoistsandtransport belts.
NOTICE!
Donotsecuretheelektrohydrauliccontrolwithchainsorsteel ropesinordertoavoidanydangerofinjury. Useonlytransportbeltsastheyfitcloselytotheelektrohydrauliccontrolandpreventslipping.
. Loosentheboltsoftheelektrohydrauliccontrolmounting.
. Pulltheelektrohydrauliccontroloutofthemounting.
Installationoftheelektrohydrauliccontrol
Toinstallthecontrolunit,,
. placetheelektrohydrauliccontrolintothemountingandtighten thebolts(M10)properly.
Fig.7:Installationexample
CAUTION!
Priortoassembly,socketsandnipplesoftheplug-typeconnectorsmustbetreatedwithlubricatingpasteB3toEWN7068 whichdoesnotcontainmolybdenumdisulfide,seechapter6, section”Lubricatinggreasesandpastes”.
. Connectthehydraulichoses,ensuringthattheconnectionsare notconfused.
Observethehoseconnectionplanandthemarkingsonthe hoses.
DANGER!
Hydraulichoseswhippingaroundcancauseseriousinjuryor evendeath.
Onlyusesuitablestaplesforsecuringtheconnectors.Make suretoinsertbothendsofthestaplesandpushthemincompletely.
. Checkthehoseconnectionsagain.Thehosenipplesmustfit tightlyinthesocketsandbesecuredwithstaples.Makesureto insertbothendsofthestaplesandpushthemincompletely. Ensurethattheconnectionsareleak-tight.
. Afterconnectingthehosesandcheckingtheconnections,plug theconnectingcableoftheelectrohydrauliccontrolunitintothe respectivesocketsofthepilotvalves.Observethecircuitdiagramandthemarkingsonthecables.
. Checkalltheconnectionsoncemoreagainstthehoseconnectiondiagram.
. Testallfunctionsoftheshieldandremovethesecuringdevices installedatthebeginningofthework.
WARNING!
Releasetheshieldforoperationagainonlywhenyouhave checkedthefunctionandobservednomalfunctions.
5 Operation
Operation
Thischaptercontainsinformationontheoperationoftheelectrohydrauliccontrolunitandonitsfunctions.Besuretoalsoobservethe operatingmanualsforthesupportandthecontrolunit.
DANGER!
Safetyhazardduetoshieldmovements.
Personsmaybeseverelyinjuredorevenkilled,for exampleby unexpectedmovementsoftheshield,ifthecontrolunitisoperatedbysomebodywhodoesnothavesufficientknowledgeof howtoperformthiswork.
Onlyoperatethecontrolsoftheelectrohydrauliccontrolunitif youhavetherequiredknowledge.
Fig.8:electrohydrauliccontrolunit,16-functions
1manifoldblock
2double3/2way-solenoid-valve 3screw-insocketDN20 9plugM16x1 10plugM18x1 aaccumulatorcartridge bstaple
Controloftheshieldsisparticularlydangerousinrepairmode,as youthendirectlycontroltheshieldunderwhichyouareworking.It isthereforeextremelyimportantthatyouknowandunderstandthe differentfunctionsandsequencesofmovementoftheshieldcontrol.
Ifyouareoperatingtheshieldinrepaircontrolmode,nooneelseis allowedtoremaininthemovementareaoftheshield.
Operationandfunctionofthepilotvalves
Operation
Twopushbuttonsareprovidedonthecoverofeachpilotvalve.By pressingabuttonyoudirectlyactuatetherespectivedirectional valves.
Thefunctionisterminatedassoonasyoureleasethebutton.
DANGER!
Pushbuttonsthatarejammedorfixedcouldleadtouncontrolledmovementsoftheshield.Thesemaycausesevere injuriesorevendeath.Thereforeneverfixthepushbuttons.
Fig.9:Pushbuttons
Function
Thefunctionoftheindividualpilotvalvesisvariableanddepends ontheexternalconnections.TheassignmentFunction/Push-button isshownonasymbolplate.Thissymbolplateshouldbeattached totheelectrohydrauliccontrolunitunderneaththepilotvalves.
Filtercartridge
Afiltercartridge(item6,fig.10)isprovidedinthemanifoldsection oftheelectrohydrauliccontrolunit.Itprotectsthevalvesofthecontrolunitagainstdamagefromimpuritiesinthehydraulicmedium.
Maintenanceintervals
IMPORTANT!
Themaintenanceintervalsrecommendedarestandardvalues. Specialoperatingconditionsmayrequiredifferentmaintenanceintervals.Itisabsolutelynecessarythatyouadaptthe maintenanceintervalstotheindividualoperatingconditions.
Thefiltercartridgeinthemanifoldsectionshouldbecheckedfor soilingoneweekafterstart-upofanelectrohydrauliccontrolsystem,atthelatest.Replacethefiltercartridge,ifsoiled.
Ifalargenumberofelectrohydrauliccontrolunitshavebeenplaced inserviceonafaceatthesametime,itissufficienttoexaminethe filtercartridgesrandomly.Iftheinspectionrevealsthatthereisa highprobabilityoffailuresduetosoiledfiltercartridgesallfiltercartridgesonthefacemustbereplaced.
Whenextensiveworkhasbeenperformedonthehydraulic system orafterstart-upofanewfacethereisanincreasedriskofdirthavingenteredthehydraulicsystem.Dependingonthedegreeofcontaminationthismayleadtothefiltercartridgesonthewholeface beingsoiled.This,inturn,resultsinthefunctionsbeingoperated slowerornotatall.Wethereforerecommendthatyoutakethe measuredescribedaboveinordertopreventfailuresoccurringduringoperationoftheshieldhydraulics.
Ifproblemsoccurinthepreparationofthemediumtherewillbean increasedriskoffailuresduetocloggedfilters.Tomaintainthe operationalreliabilityoftheinstallation,certainmeasuresmaythen havetobetakenregularly.Forexample,youshouldtaketheprecautiontomaintainregularrandominspectionsofthefiltercartridgesofallelectrohydrauliccontrolunitsontheface.Itmaybe necessarytoreplacethefiltercartridgesatregularintervalsasa precaution.
Afiltercartridgeisprovidedinthemanifoldblockoftheelectrohydrauliccontrolunittoprotectthevalvesinthepilotcircuitofthe controlunitagainstdamagefromimpuritiesinthemedium.This filtercartridgerequiresmaintenance.Regularreplacement,however,isonlynecessarywhenthefiltrationinthefacesupplyunitis insufficient.Therefore,takecaretoensureahighlevelofquality whenprocessingthehydraulicmedium
Replacingthefiltercartridge
CAUTION!
Onlyuseeachfiltercartridgeonceanddonotattempttoclean it.Dirtinthehydraulicsystemisafrequentcauseofcostly repairs.Youshouldgenerallyonlyusenewfiltercartridgesand seals.
Filtercartridge
Preparation
. Securetheshieldmechanicallytopreventitfromlowering underitsownweight.
WARNING!
Greatlikelihoodofinjuryduetohydraulicfluid escaping under pressure.Youmaybeseverelyinjuredorevenkilled.Itis imperativethatyoudepressurizethehydrauliccircuitbefore workingonit.Donotperformanyworkonahydrauliccircuit beforehavingmadesurethatthepressurehasbeenisolated.
. Closetheshut-offvalveinthepressurefeedlineP.
. Checkthesystemforanyresidualpressure.Thispressurecan buildupinthehydraulicsystemasaresultoftheloadsonthe propsandcylinders.
. Depressurizethesystem.Makesuretoobservethehoseconnectiondiagramandhydrauliccircuitdiagram.
Whenthehydrauliccircuithasbeendepressurized,youcancontinuewiththenextworkingsteps.
Unscrewthefiltercartridge
. Removeanydustanddirtfromtheelectrohydrauliccontrolunit.
CAUTION!
Soilinginthehydraulic systemcanresultinseriousdamageto thewholehydraulicsystem! Alwaysensurethatyourworkingareaisclean.
. Unscrewthefiltercartridgeusingascrewdriver.
Fig.10:Unscrewthefiltercartridge
IMPORTANT!
Thefiltercartridgeissoiledwithemulsionresiduesand deposits.
Disposeofthefiltercartridgeinaccordancewiththeenvironmentprotectionregulations!
Screwinthenewfiltercartridge
. Screwinthenewfiltercartridge.
. Tightenthecartridgefinger-tight(15Nm).
. Checkthatthecartridgeisfittedleak-tight.
Whenyouhavecompletedthecheckwithoutfindinganyfaults,the electrohydrauliccontrolunitcanbepressurizedagain.Removethe securingelementsonlywhenyouaresurethatthehydrauliccomponentsfunctionproperly.
Accumulatorcartridge
WARNING!
Donotoperatethecontrolvalveblockwithoutanyorwitha defectiveaccumulatorcartridge.Failuretocomplycanleadto malfunctionsofthecontrolvalveblockortheshield.This couldresultininjuryordeathtoyourselforothers.Itis imperativethatyoureplacedefectiveaccumulatorcartridges withoutdelay.
IMPORTANT!
Theaccumulatorcartridgeisnotincludedinthescopeofsupplyofthecontrolvalveblock.Pleaserememberthisinformationwhenorderingreplacementparts.
IMPORTANT!
Aspecialdeviceisrequiredforchargingandtestingaccumulatorcartridges.PleasecontactyournearestDBTrepresentation forinformationandhelpifsuchadeviceisnotavailableat yoursite.
Accumulatorcartridgesmustbecheckedforcorrectoperationat regularintervals.Werecommendtoperformthistestonarandom samplebasis.Forthispurpose,selectafewsamplesandreplace thembynewcartridges.Testthesamplestomakesuretheyfunctionproperly.Iftheydo,theycanbeinstalledagain.
Theaccumulatorcartridgeislocatedatthefrontofthemanifold block,totheleftofthesolenoidpilotvalves,seeitemaFig.8.
Replacingtheaccumulatorcartridge
Preparations
. Securetheshieldmechanicallytopreventitfromlowering underitsownweight.
WARNING!
Hydraulicfluidsescaping underhighpressurecancauseseriousinjuryordeath.Besuretodepressurizethehydraulicsystembeforestartingwork.
Filtercartridge
. Closetheshut-offvalveinthepressurefeedline.
. Operatetheoppositeactingpairsofhydraulicfunctionsseveral timesalternating,todepressurizethehydraulic systemofthe shieldsupport.
. Checkthecontrolvalveblockforanyresidualpressure. Observealsothehoseconnectiondiagramandhydrauliccircuit diagram.
Onlywhenyouaresurethesystemhas beendepressurized,you cancontinuewiththenextworkingsteps.
Removingtheaccumulatorcartridge
CAUTION!
Impuritiesinthehydraulicmediumcanresultinseriousdamagetothewholehydraulicsystem! Alwaysensurethatyourworkingareaisclean.
. Removeanydustandotherimpuritiesfromtheaccumulator cartridgeandthesurroundingsinordertopreventdirtentering thehydraulicsystemduringassembly/disassemblyofthe accumulatorcartridge.
WARNING!
Ifstaplelocksareimpossibleordifficulttopulloutbe extremelycarefulasthismayindicatethatthehydrauliclineis stillunderpressure.Besuretodepressurizethehydraulicline.
Fig.11:Replacingtheaccumulatorcartridge
aaccumulatorcartridgebstaple
. Pullthestaple(b)outsideways.
. Pulltheaccumulatorcartridge(a)outtothefront.
Installingthe accumulatorcartridge
Thenewaccumulatorcartridgeisinstalledinthereverseorderof removal.Priortoinstallation,applyaseparatingagent/lubricant(B6 acc.toEWN7068)tothesurfacestobejoined,seealsochapter6, section”Lubricatinggreasesandlubricatingpastes”.
6 Technicaldata
Technicaldata
Thischaptercontainsimportantandusefulinformationonthe designandmaterialsused.Informationonpermissiblehydraulic fluidsandrecommendationsonlubricantscanbefoundattheend ofthechapter.
IMPORTANT!
Pleaseusethesparepartscatalogsuppliedwhenordering spareparts.
Description Functions
Theelectrohydrauliccontrolunitpermitstocontrol16independent functions.Thedirectionalvalvesofthecontrolblockareactuated viasolenoid-operatedpilotvalves.Operationofthepilotvalves requiresanelectroniccontrolunitsuchasforexampleashieldcontrolunitoftypePMC® -R.
Fig.12:Electrohydrauliccontrolunit,frontview
aaccumulatorcartridgeport,DN20 bmanifoldblock cpilotcontrolvalves
Design
Themaincomponentsoftheelectrohydrauliccontrolunitare: J manifoldblockwith –directionalvalves, –checkvalve, –filtercartridge, –accumulatorcartridgeportand –connectingsockets, J pilotcontrolvalves.
Fig.13:Electrohydrauliccontrolunit
1manifoldblock
2double3/2way-solenoid-valve 3screw-insocketDN20 aaccumulatorcartridge
Materialsemployed
bpushbuttons cplugcontact,electricalconnection tothecontrolunit drearconnectingsockets
Theelectrohydrauliccontrolunitismadeofcorrosion-resistant materialssuchasstainlesssteel,brass,bronze,etc.
ThesealmaterialsaredesignedforoperationwithHFAhydraulic fluids(oil-in-wateremulsions).
Dimensionsandweight
Pressure permissibleworkingpressure:.350bar testpressure:...............400bar
Filter
Thefiltercartridgeprotectsthepilotcontrolcircuitagainstimpurities.Useonlynewfiltercartridges,never”cleaned”cartridges.
Onlynewfiltercartridgeshavethenecessaryfiltrationproperties (meshsize=25 µm),seealsochapter5”Operation”,section “Replacingfiltercartridge”.
Mountings
Atotalof8threadedholes(M10)areprovidedinthecontrolunit whichcanbeusedfortheattachmenttodifferentholders.
4threadedholes(a)arelocatedatthetopand2holes(b)eachat thesideofthemanifoldblock.
Fig.14:Threadedbores
a,bthreadM10
Valves
Directionalvalves:
J 3x3/2-waydirectionalcontrolvalves(NG20)
J 14x3/2-waydirectionalcontrolvalves(NG13)
Theyarecontrolledbypilotcontrolvalves.
Pilotcontrolvalves:
J 8xdouble3/2-waydirectionalcontrolvalves(NG0.5)
Thepilotcontrolvalvesareoperatedbyacontrolunit(e.g. PMC® -R).Theycanalsobeoperateddirectinanemergencyorfor repairpurposes.Tothisend,thevalvecoversareprovidedwith2 pushbuttonseach.
Powerissuppliedfromthesinglecontrolunit.Afour-pinconnector isprovidedonthehousingcoverofeachpilotvalveforconnection oftherequiredcables.
Specificationofthedouble3/2-waydirectionalcontrolvalves
Classificationaccordingtodirective 94/9/EG(ATEX):................groupI,categoryM2 protectiontype:..................EExibl connectors: .....................OS4 solenoiddesign: .................solenoid,round,57ohm type:DMA3
ratedvoltage: ...................12V,DC perm.deviation:.................-2%/+10% switchingcurrent:................ approx.190mA currentreduction:................downto approx.40mA
WARNING!
Assoonasthecurrentdropstoalevelbelow40mA,the switchingpositionsbecomeunstable.Thisresultsinmalfunctionsorevenfailureoftheshieldcontrol.
Tab.1:CertifiedDust-Exunit areaofapplicationcertificationbody approvalno.
Europe INERIS,ATEX 05ATEX0049
USA MSHA 18-ISA050002-0
Australia Telesafe,ANZEx 05.4015X
Hydraulicflowdiagram
Fig.15:Electrohydrauliccontrolunit,16functions
large-volumeconsumers
Connections
Theconnectionportsforthehydrauliclinesarelocatedontherear ofthecontrolvalveblock.
Fig.16:Electrohydrauliccontrolunit,rearview
medium-volumeconsumers
Hydraulicconnections
connections: ............3xDN20socket,plug-type
marking:................ 1,2,2,SP(accumulatorcartridge port,front)
flowrate:................max.340l/minat ∆ p=100bar application:..............large-volumeconsumers
connections: ............2xDN12and12xDN10socket, plug-type
marking:................
DN12:3,16
DN10:4,5,6,7,8,9,10,11,12,13, 14,15
flowrate:................max.180l/minat ∆ p=100bar application:..............medium-volumeconsumers
pressuresupplyandtankline
connections: ............2xDN25socket,plug-type marking:................Ppressuresupply Ttankline
flowrate:................max.180l/minat ∆ p=100bar application:..............Ppressuresupplytothe system Treturnlinetothetank
Permissiblemedia
Hydraulicfluids
Permissiblehydraulicfluids
NOTICE!
Useonlyhydraulicfluidsforwhichavalidcertificateissuedby DBTGmbHhasbeenmadeavailabletoyou.Otherwise,thereis thedangerofseriousdamagetothehydraulicequipmentand thelossofwarrantyclaims.
FortheoperationofhydrauliccomponentsofDBTGmbHgenerally onlysuchhydraulicfluidsareallowedtobeusedforwhichavalid certificateinaccordancewithEWM8350oranexemptionpermitof DBTGmbHisavailabletotherespectiveoperator.DBTGmbHwill notacceptanyclaimsunderwarrantyforcomponentswhichhave beenorareoperatedwithadifferenthydraulicfluid.
Inaddition,national-andsometimesalsoregional-regulationson healthandsafetyatworkandanyenvironmentalregulationsmust beobservedforoperation.
IfamineonlyusesindividualhydrauliccomponentswithoutapplyingDBTshieldsupportsorifobtainingavalidcertificatewould requiretoomucheffort,thesamehydraulicfluidasisusedforthe existingshieldsupportshallbeallowedtobeusedfortheseindividualcomponents,subjecttoapprovalbyDBT.Thesameappliese.g. tohydraulicchaintensioners,hydraulicallytensionabledriveunits etc.TherespectiveexemptionpermitwillbeissuedbyDBTGmbH uponrequest.
Suitabilitytest
BeforethecertificateofDBTGmbHisissuedforahydraulicfluid therespectivefluidhastobesubjectedtoasuitabilitytest.However,thissuitabilitytestonlyreferstothetechnologicalproperties ofthehydraulicfluidanddoesnotallowanyconclusionstobe drawnwithrespecttoitspropertiesregardinghealthandsafetyand environmentalprotection.
Originalsamplesoftheconcentrateandthewaterwhichwillbe usedlaterwhenpreparingthehydraulicfluidatthemineare requiredtoperformthesuitabilitytest.
Thesuitabilitytestwillbecarriedoutbyanindependenttesting instituteauthorizedbyDBTGmbH.Forthetests,thecriteriaas specifiedinEWN8350willbeapplied.Thesuitabilitytestmainly servestoclarifythepropertiesofthehydraulicfluidwithrespectto
J stability,
J sealingmaterials, J corrosion.
Inaddition,achemical”fingerprint”oftheconcentratewillbepreparedinordertoexcludeorproveanypossiblechangesinthe compositionoftheconcentrate,ifrequired.
Ifthesuitabilitytestshowsthatthehydraulicfluidmeetsthe requirements,theoperatorwillreceivetherespectivecertificateby DBTGmbH.
Certificate
Thecustomerwillbegivenacertificateattestingthesuitabilityof thehydraulicfluidfortheoperationofhydraulic systemsofDBT GmbHforeachproducttested.Therespectivecertificateshallbe validforaperiodofoneyearand,afterasimplifiedtest,canbe extendedforanadditionalyeareach.Thecertificateshallbecome invalidifoneorseveraloftheprerequisitesforobtainingthecertificatearenolongerfulfilled.Thisisthecase,forexample,ifthe qualityofthewaterhaschangedsubstantiallyand/orthecompositionoftheconcentratehasbeenchanged,adifferentconcentrateis usedortheconcentrateandwatermixtureratiodoesnotcorrespondtothedatagivenonthecertificate.Forfurtherinformation, pleaserefertoEWN8350,part1.
Thefollowingillustrationshowsatypicalcertificate.
Fig.17:Typicalcertificate
Hydraulicfluidmaintenance
Aconsistentgoodqualityofthehydraulicfluidisessentialforthe operationalreliabilityofhydraulic systems.Therefore,maintenance ofthehydraulicfluidmustnotbeneglectedbutshouldbeperformedwithspecialcare.Themostimportantpropertiesofthe hydraulicfluidshouldideallybemonitoredautomaticallyand recordedinordertobeabletodirectlycounteranyharmfuleffects. Thesepropertiesinclude:temperature,foaming,pH-value,concentrateratio,andmicrobialload.
Theoperatoroftheequipmenthastoprepareahydraulicfluid maintenanceconceptforanyindividualapplication.Themaintenanceconceptshouldbepreparedinclosecooperationwiththe manufactureroftheconcentrateandhastobeappliedconsistently.
Ifitisnotpossibletomonitorthehydraulicfluidcontinuouslythe propertieslistedinthefollowingshouldbecheckedatleastonce everyweek:
J pH-value
–Targetvalue:7.5to9.5
J Concentrateratio
–Targetvalue:seecertificate
J Microbialload
–Targetvalue:<105 Kol/m
Inaddition,theelectricalconductivity,foamingandtheoperating temperatureofthehydraulicfluidshouldbemonitoredregularly.
Thepermissiblemax.temperatureofthehydraulicfluidis55°C. Duringnormaloperation,however,anoperatingtemperatureof 45°Cshouldnotbeexceeded.Ahigheroperatingtemperaturewill reducethestabilityoftheemulsionandshortenthelifeofthesealingmaterial.
Qualityoftheprocesswater
Thequalityofthewaterusedforthepreparationofthehydraulic fluidhasanenormousinfluenceonthepropertiesofthehydraulic fluid.Accordingly,therequirementsformonitoringthewaterquality areveryhigh.
Thefollowingtable2listslimitvaluesfortheessentialproperties andcomponentsofthewater.
Ifthelimitvaluesshownaremaintaineditcanbeassumedthatthe waterisbasicallysuitable.
Ifoneorseveralofthelimitvaluesmentionedarenotmetthis shouldbetakenintoconsiderationwhenselectingaconcentrate. Additionalwatertreatmentmayalsoberequired.
Thecustomershallinanycase,however,provideasampleofthe originalwatertopermitperformingthetestsrequiredfortheissue ofthecertificate.
Changesinthecompositionofthewaterwillalsoleadtothelossof thecertificateeveniftheyarewithinthelimitvaluesmentioned.
Tab.2:Propertiesoftheprocesswater,limitvalues
TestcriteriumLimitvalue
Appearance,color,smell nopeculiaritiespermissible,e.g. turbidity,badsmelletc.
electricalconductivity
<1800 µS/cm
pH-value 6,5.....8,5
Na+ -content notspecified
Mg+ -content notspecified
waterhardness
<750mg/lCaCO3 -äquivalent (≤ 42°dH)
Cl- -content ≤ 201mg/l
SO42- -content ≤ 145mg/l
NO3- -content ≤ 20mg/l
Fe-content ≤ 1mg/l
Bacteriologicalrequirements ≤ 105 Kol/ml
Ratioofsolidforeignmatterat1,2 µmfilteringinconformitywithDINEN12662
generalproperties
≤ 10mg/l
Contaminationclassaccordingto ISO4406:1999 -/18/14
Lubricatinggreasesandpastes
IMPORTANT!
Thelubricant,whichistobeused,isspecifiedintherespectivechapter,e.g.assembly,maintenance....
Lubricatinggreases
base:lithiumsoap
NLGIclass:2
workedpenetration:265to295(0.1mm) ............
behaviorinthepresenceofwater:practicallynon-solubleinwater temperatureofapplication:-20to+120°C .....
flashpoint: ≧ 200°C
Lubricatinggreasesforgeneralapplicatione.g.forrollerbearings subjecttonormalload,forlabyrinthsandforassemblyaccordingto EWN 1) 7068.
Tab.3:Lubricatinggreasesforgeneralapplication
SupplierType
Lubricatinggreasescontainingadditivesforapplicationunderhigh pressuree.g.forrollerbearingsandbearinglocationssubjectto extremeload.
Tab.4:Lubricatinggreasesforgeneralapplication
SupplierType
1) EWN=DBTstandard
IMPORTANT!
Thegreaseslistedinthesametablecanbemixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethatthey areequivalent.
Differentlycomposedlubricatinggreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmay alsobedangeroustouselubricatinggreaseshavingthesame saponificationbasebutdifferentorigins.
Incaseof doubt,themanufacturerofthelubricatinggreaseto beusedshouldbecontactedastothecompatibilityofthe greaseinquestion.
Lubricatingpastes
Lubricatingpastesfreefrommolybdenumdisulfide,containingsolid lubricantsforlubricatingcenteringsandconnectionsofsplined shaftsofsprocketdrumsandchainsprocketsduringassembly.
Tab.5:Lubricatingpastesfreefrommolybdenumdisulfide
SupplierType
Whentheequipmentislubricatedinourworksforthefirsttime,the lubricanttypeusedaslubricatingpasteB3accordingtotheDBT worksstandardEWN7068is:
gleitmolybdän”gleitmo805”
Separatingagentsandlubricantswithorganiclubricatingmediaon asyntheticbaseforlubricatingthreadareasandfitsofpropsand hydrauliccylinders,ofboltedconnectionsandsimilarconnecting elementsofroofsupports.
Behaviorinthepresenceofwater:non-solubleinwater Temperatureofapplication:-34to+120ºC
Whentheequipmentislubricatedinourworksforthefirsttime,the lubricanttypeusedaslubricantB6accordingtotheDBTworks standardEWN7068is:
Chestertonseparatingagentandlubricant785 (flashpoint 132ºC)
IMPORTANT!
Theinstructionsfortheuseofthelubricatinggreasesgiven under”important”alsoapplytothelubricatingpastes.
*)Theproductslistedintable3aresuitablelubricatinggreasesforfillingofadjacentcavities.
7
Foryourinformation
Foryourinformation
Ifyouneedtoordersparepartsoriftechnicalproblemsoccur, pleasecontactourafter-salesservicepersonnelorcontactus direct(Homepage: www.dbt.de).
Serviceaddresses
Europe
DBTGmbH(Headquarters)
Industriestraße1 D-44534Lünen
Tel:+49/2306709-0 Fax:+49/2306709-1421
E-mail:infodbt@dbt.de
DBTGBLimited
HallamFieldsRoad Ilkeston,DerbyshireDE74BS England
Tel:+44/115951-2500
Fax:+44/115932-9683
E-mail:martin.daldrup@dbtgb.com
DBTGBLimitedEngineering
PioneerHouse 2RenshawPlace
EuropointOfficePark Eurocentral Lanarkshire,ML14UF Scotland
Phone:+44/1698835-000 Fax:+44/1698835-038
DBTPOLSKASp.z.o.o. ul.Fabryczna6, 41-404Myslowice
Tel:+48/323170-500
Fax:+48/323170-509
E-mail:dbtpolska@dbtpolska.com
DBTOfficeMoskau
BolschoiTscherkassiPer.No.15,Office310 103626Moskau
Tel:+7/495623-5396
Fax:+7/495924-8363
E-mail:dbt@co.ru
OOODBTRUS
ul.Grdiny,4 office1
654066Novokuzneck,Kemerovskajaobl.
Tel:+7/384335-3441
Fax:+7/384335-3442
E-mail:office@dbtrus.ru
Northamerica,Canada,Southamerica
DBTAmericaInc.
2045WestPikeStreet Houston,PA15342-1010
Tel:+1/724743-1200
Fax:+1/724743-1201
E-mail:info@dbtamerica.com
DBTAmericaInc.
4041WurnoRoad Pulaski,VA24301
Tel:+1/540980-4530
Fax:+1/540994-3889
Australia
DBTAustraliaPtyLtd/DBTDieselPtyLtd 537LakeRoad Argenton,NewSouthWales2284
P.O.Box102
Boolaroo,NewSouthWales2284
Tel:+61/24958-3133
Fax:+61/24958-5754
E-mail:tim.clark@dbtaustralia.com
DBTCustomerServiceCenterMackay 14CommercialAvenuePaget M.M.CBox5182 MackayQueensland4741
Tel:+61/74952-0000
Fax:+61/74952-0099
SouthAfrica
DBTAfricaPty.Ltd. CornerofGammaandZetaRoads IndustriesWest Germiston1401
Tel:+27/11825-8212
Fax:+27/11825-7389
E-mail:zelda.stephens@dbtafrica.com
Südafrika
Asia
DBTChinaBeijingRepresentativeOffice
Suite1112,TowerB FullLinkPlaza No.18ChaowaiStreet Beijing100020
Tel:+86/106588-2998
Fax:+86/106588-6570
E-mail:Info.beijing@dbtchina.com
DBT(Langfang)MineTechnikCo.Ltd. Jinyua.Road -LangfangEconomicandTechnicalDevelopmentZoneHebeiProvince065001
Tel:+86/3166086-840(&841,842,843)
Fax:+86/3166086-845
E-mail:Info.langfang@dbtchina.com
DBTTangshanMachineryLtd. No.4GangyaoRoad Tangshan063027
HebeiProvince
Tel:+86/315320-3117(&3445,3404)
Fax:+86/315320-3438
E-mail:Info.tangshan@dbtchina.com
ShenhuaDBTBeltConveyorCo.Ltd. Bulianta,YiqiCounty,ErdosCity InnerMongolia017209
Tel:+86/477828-7245(&7514,7290)
Fax:+86/477828-7431
E-mail:Info.shenhua@dbtchina.com
DBTRepresentativeOfficeCalcutta c/oThapharHouse 25,BrabourneRoad Calcutta700001
Tel:+91/33242-0272
Fax:+91/33242-8684
India
