DOWNLOAD PDF CAT DBT-Electrohydraulic Control Unit 12 Function Operating Manual EM026801

EM026801-0 (EN-US)

Operating Manual DBT - Electrohydraulic Control Unit, 12 Functions Doc. No.: 8154 120 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 e-mail: infodbt@dbt.de Telefax: +49 (0) 23 06 / 709 - 1421 Internet: www.dbt.de

EM026801-0 (EN-US)

Amendments and alterations to this publication are not subject to notification. DBT GmbH (DBT) reserves all rights to this publication.

Its content is protected by copyright laws, both domestic and international. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of the DBT. DBT declines all liability for direct or indirect consequences of printing errors.

We reserve the right to introduce modifications obtained by technical development without previous notice!

DBT GmbH, Lünen 2006 E

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Contents

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

1.3

Who is this operating manual intended for? . . . . . . . . . . . .

What is the purpose of this operating manual? . . . . . . . . . .

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

1.3 1.3 1.4

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

2.3

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

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 2.4

Conditions of operation . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Use in conformance with specifications . . . . . . . . . . . . . . . .

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

2.5 2.5

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

2.6

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Overview of the safety instructions . . . . . . . . . . . . . . . . 2.12

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

3.3

Storage of new equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Used equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.4

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

3.5

Transport crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Holder with Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.5 3.5

4. Installation Requirements to the face hydraulic system . . . . . . . .

4.3

Installation of the elektrohydraulic control . . . . . . . . .

4.4

Removal of the elektrohydraulic control . . . . . . . . . . . . . . . .

Installation of the elektrohydraulic control . . . . . . . . . . . . . .

4.4 4.5

5. Operation

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Operation and function of the pilot valves . . . . . . . . . .

5.4

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

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 5.4

Filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 5.6

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Contents Accumulator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

Replacing the accumulator cartridge . . . . . . . . . . . . . . . . . .

5.8

6.3

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.4 6.4 6.4 6.5 6.5 6.5

Hydraulic flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

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

6.9

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

Lubricating greases and pastes . . . . . . . . . . . . . . . . . . . . . .

6.9 6.12

7. For your information Service addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Northamerica, Canada, Southamerica . . . . . . . . . . . . . . . . .

Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

South Africa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 7.4 7.4 7.4 7.5

DBT - Electrohydraulic Control Unit - 12 Functions

DBT GmbH, Lünen 2006

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6. Technical data

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1

About this manual

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Before starting work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting work Take care to ensure that the operating manual available to you is applicable for the type of elektrohydraulic control unit used. Failure to do so can result in a safety hazard for yourself and others. Ensure that the data on the elektrohydraulic control unit comply with the data given in the operating manual.

This operating manual is designed for Elektrohydraulic control unit - 12 functions with the order No.: 8154 120 000 00 00 and is only permitted to be used for elektrohydraulic control units of this type.

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operating manual

An operating manual for the elektrohydraulic control unit must always be available. Ask for a new manual immediately if the existing manual is no longer complete or has become illegible.

DBT GmbH, Lünen 2006

Who is this operating manual intended for?

This operating manual is intended for all persons involved in the J installation, J maintenance, J repair, J operation and J dismantling

of the elektrohydraulic control unit.

In addition, the supervisory personnel who initiate and/or supervise the activities just indicated must also observe this operating manual.

What is the purpose of this operating manual? efficiency

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

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

safety

Read the chapter 2 ”For your safety” with special attention. This chapter contains important information indicating possible hazards.

operating cost warranty

Observe the information given and follow the procedural instructions. This is the only way to minimize operating costs and to assert warranty claims.

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1.3

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

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: Very serious injury or even death.

WARNING! These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

1.4

J

Lists are marked with bullets.

–

Sub-lists are marked with a long dash at the start of the line.

.

The symbol of the hand asks you to do something. Several successive paragraphs marked with the symbol of the hand represent a string of actions which must be executed in the order specified.

Follow the respective instructions step-by-step to perform the work safely and efficiently.

DBT - Electrohydraulic Control Unit - 12 Functions

DBT GmbH, Lünen 2006

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: Minor machine damage or damage in the immediate vicinity.

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CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: Light to moderately serious injuries and machine damage.

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2

Your safety

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Personnel

Your safety This chapter provides vital 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 to perform the necessary work as safely as possible. residual risk

The electrohydraulic control unit has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. However, a certain risk remains which might get you into hazardous situations when working with or on the electrohydraulic control unit. These may, for example, be caused by unforeseeable external influences, machine damage or operating errors.

supplementary regulations

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

Observe the safety and accident prevention regulations: J of the mining company, J of the mining authority, and

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J of the miners’ accident insurance association.

Personnel Persons employed in the operation, repair, and overhaul of hydraulic and/or electrohydraulic control unit components must have special qualifications. In addition to having received training in mining skills the following minimum requirements shall be met.

Operation qualification

Operation and maintenance of the shield control is only allowed to be performed by trained personnel. The training shall be matched to the type of shield control actually used. The content of the operating manual, especially the chapter on safety, shall constitute a part of this training.

They shall possess and furnish proof of adequate familiarity with the J mechanical, J hydraulic, and J control systems.

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2.3

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Personnel Repair In general, repair work shall be performed only by persons who have the respective knowledge and skills to meet the special requirements and have been adequately trained in the repair of the equipment. Repair work on and overhaul of J control blocks, J working valves, J pilot control valves, J safety components, e.g. pressure relief valves, etc.

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shall be performed only by DBT service technicians or by specially trained personnel of the mining company.

2.4

DBT - Electrohydraulic Control Unit - 12 Functions

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Conditions of operation Conditions of operation Use in conformance with specifications The electrohydraulic control unit has been designed and manufactured exclusively as part of the control system for shields. It is only allowed to be used in connection with an electronic control unit, such as for example a PMC®-R. Use the electrohydraulic control unit only as intended.

Intended uses are: J The electrohydraulic control unit is combined with an electronic

control unit - as for example a single control unit of type PMC®-R. Together they form a control unit designed to operate the functions of a shield support. The two devices are part of an adjacent control system for electrohydraulic shield supports for use in underground mining.

The electrohydraulic control unit is an essential component of this electrohydraulic shield control. Operation of the functions is not allowed to be made direct by pressing the buttons of the electrohydraulic control unit, but via the respective single control unit which must be located in one of the adjacent shields. By means of this control unit the pilot valves of the control block are actuated manually or program-controlled.

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J Additionally, there are two exceptional circumstances under

DBT GmbH, Lünen 2006

which the control block also serves as direct ”control unit”: - emergency operation and - repair operation.

In these cases the individual functions of the electrohydraulic shield support are executed direct at the pilot valve of the electrohydraulic control unit. Thus, the functions of the shield can be operated even if the single control unit is locked out or has failed - but only in well-founded exceptions and under strict observance of the special safety regulations of the mine operator for these cases.

Unauthorized use Uses which are not expressly stated as intended are regarded as unauthorized uses and are not permissible.

Unauthorized use: J Use of the electrohydraulic control unit as ”control unit” to oper-

ate the functions of the shield in normal operation.

Actuating the shields exclusively by pushing a button on the pilot valve block is unauthorized use since operation of the shield functions must be performed from an adjacent shield.

By unauthorized uses you endanger yourself and others. You could be severely injured or even killed. Therefore only use the electrohydraulic control unit as intended!

DBT does not accept any liability for the consequences of unauthorized uses.

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2.5

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Safety instructions Safety instructions Basic principles general

Always concentrate on your work.

Please also observe the operating manuals for the shield support and the control unit.

Always familiarize yourself with your working environment first before taking up work.

Never stay under a shield that is not secured.

Always wear your personal protective clothing and equipment.

Please observe the visual and audible pre-start warnings. Particularly observe the pre-start warning signals of the conveyor and the mining machine.

support lock-out switch

Press the emergency stop switch immediately in the event of malfunctions or irregularities in operation. Notify your foreman of any peculiarity, in order that necessary action be taken immediately.

If the shield is equipped with an electrohydraulic control unit you have to operate the support lock-out switch (repair switch) in order to lock out the shield. After this has been done, the shield cannot be operated from the control unit.

Actuate the support lock-out switch before performing.

J maintenance work, J inspection work, J repair work, and before J prolonged presence in the shield.

moving parts

Never reach into or enter areas between machine components which can move. This applies especially to the: J side seals, J base skids, J shifting units, J lemniscatic links, J hydraulic props and cylinders, J canopies and J flippers.

Storage and Transport Never store materials of any kind in the travelway or in your working area.

Immediately remove defective components from the face in order not to hinder the face crew and to prevent these parts being reinstalled elsewhere.

Pass them on for servicing without delay.

Observe the specified storage time limits and the storage instructions.

2.6

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EMERGENCY STOP

Employ only electrohydraulic control units which are in a technically flawless condition.

DBT GmbH, Lünen 2006

prerequisite

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Safety instructions Installation Always secure all moving components mechanically before relieving the pressure in the hydraulic system.

Always depressurize the hydraulic systems before starting work on them.

Ensure that no dirt enters the hydraulic system.

Remove the protection caps on the ports only immediately before installing the control block.

Operation Operate the manual repair control only when it is absolutely necessary. Whenever possible, control a shield by the electronic control unit of an adjacent shield.

Check that all protective devices on the shield are in place and function properly.

Make sure that no persons are present in the area of the shield being actuated.

Observe the entire zone of motion of the shield, in order to recognize and avoid hazards in due time.

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Maintenance Inform the supervisory personnel and the coal face crew about maintenance and repair work. Provide them with information on the intended work and the probable duration.

Secure your working area over a wide range in order to avoid endangering yourself and others.

Close off your working area to prevent the mining machine going there. Stop and lockout the mining machine and the conveyor to prevent restarting.

Secure the shield mechanically to prevent it from lowering under its own weight before starting work, e.g. by: J supporting the canopies, J positioning wooden wedges between the lemniscatic links.

Stop work on the shield immediately if conveying and mining work is being carried out in your working area.

Refit any protective devices removed immediately after completion of the work and check that they function properly.

Ensure that the prescribed maintenance and inspection intervals are observed. See also chapter 5 ”Operation”.

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Safety instructions original spare parts

Use only spare parts which satisfy the specified technical requirements. This is best ensured with original DBT spare parts.

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

Do not carry out modifications or conversions. Modifications and conversions must be approved by DBT. Never use the control block without filter cartridge. Failure to fit a filter or using a filter with insufficient mesh size could cause malfunctions and damage of the control block.

Hydraulics

handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

protective equipment -hydraulic

When removing protective equipment which includes hydraulic components keep in mind that these components may be pressurized.

You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

pressure relief valves

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Make sure that pressure relief valves are always provided with protection caps. Replace defective caps without delay.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: J The hoses are not pinched or trapped.

J The hoses have no bubbles or blisters.

J The hoses or the outer sheathes of the hoses are not abnor-

mally rigid or hard.

J The outer sheath of the hose is not damaged.

J The connectors are securely inserted into the sockets.

J The connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work.

Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

Before removing staple locks to disconnect hydraulic hoses turn the hose at the coupling to check whether the line is still pressurised. If the hose is difficult to turn or does not turn at all the line is still pressurised. Be sure to depressurise the line.

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurised. Be sure to depressurise the line before disconnecting couplers.

2.8

DBT - Electrohydraulic Control Unit - 12 Functions

DBT GmbH, Lünen 2006

maintenance, repair

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Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health.

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Safety instructions Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely.

Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressuring the system again. permissable 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 hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Fig. 1:

Example: 4SP hydraulic hose, designation 3 2

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1

DBT GmbH, Lünen 2006

6 1 manufacturer 2 hose type 3 date of manufacture, 1st quarter 2002

5

4

4 standard 5 nominal diameter 6 flame-resistant and antistatic

Never try to hold a pulsing hydraulic hose. Depressurise the line in question immediately.

Never try to repair damaged hydraulic hoses.

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

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

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

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Laying hydraulic hoses, slack RIGHT

WRONG

2.9

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Safety instructions J are not twisted, Fig. 3:

Laying hydraulic hoses, twisting RIGHT

WRONG

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter),

Fig. 4:

Laying hydraulic hoses, bending WRONG

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RIGHT

J cannot chafe, Fig. 5:

Laying hydraulic hoses, crossing RIGHT

WRONG

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

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

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

2.10

DBT - Electrohydraulic Control Unit - 12 Functions

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Safety instructions Fig. 6:

Laying hydraulic hoses, connections on moving parts WRONG

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RIGHT

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2.11

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Overview of the safety instructions Overview of the safety instructions This is a summary of all safety instructions given in the individual chapters of this operating manual. As these safety instructions are cited out of their context the meaning is not always obvious.

Chapter 3: Storage and transport NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before connection of the electrohydraulic control unit.

IMPORTANT! Ensure when transporting the shield that the holder with the control unit is fixed in position in such a way that it will not collide with other components when the shield is being lowered.

Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

Release the shield for operation again only when you have checked the function and observed no malfunctions.

CAUTION! Prior to assembly, sockets and nipples of the plug-type connectors must be treated with lubricating paste B3 to EWN 7068 which does not contain molybdenum disulfide, see chapter 6, section ”Lubricating greases and pastes”.

NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals. The information required for start-up and operation of the electrohydraulic control unit is given in the manual for the respective control system used.

Do not secure the elektrohydraulic control with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the elektrohydraulic control and prevent slipping.

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DBT - Electrohydraulic Control Unit - 12 Functions

DBT GmbH, Lünen 2006

DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

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Chapter 4: Installation

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Overview of the safety instructions IMPORTANT! Before commissioning the shield, take care to ensure that the symbol plate is positioned such that the symbols are clearly legible.

Chapter 5: Operations and maintenance DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the electrohydraulic control unit if you have the required knowledge.

Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

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Do not operate the control valve block without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the control valve block or the shield. This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

CAUTION! Only use each filter cartridge once and do not attempt to clean it.

Dirt in the hydraulic system is a frequent cause of costly repairs. You should generally only use new filter cartridges and seals.

Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

Impurities in the hydraulic medium can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

IMPORTANT! The maintenance intervals recommended are standard values.

Special operating conditions may require different maintenance intervals. It is absolutely necessary that you adapt the maintenance intervals to the individual operating conditions.

The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

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Overview of the safety instructions The accumulator cartridge is not included in the scope of supply of the control valve block. Please remember this information when ordering replacement parts.

A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

Chapter 6: Technical data WARNING! As soon as the current drops to a level below 40 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

NOTICE! Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

2.14

DBT - Electrohydraulic Control Unit - 12 Functions

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The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

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IMPORTANT! Please use the spare parts catalog supplied when ordering spare parts.

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3

Storage and transport

EM026801-0 (EN-US)

EM026801-0 (EN-US)

Storage

Storage and transport This chapter contains important information on the correct storage and transport of the elektrohydraulic control.

Observance of the instructions and tips will increase the service life of the elektrohydraulic control. You will also be able to carry out the transport work quicker and more safely.

Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage Storage of new equipment corrosion protection

Prior to delivery the hydraulically operated equipment will be tested and operated at the DBT site using the anti corrosive and anti freezing fluid HYDROCOR® CV50*). This fluid remains in the hydraulic system for transport and a following short-time storage period.

HYDROCOR® CV50 is freeze-proof down to - 40 degrees Celsius and protects the metallic materials against corrosion.

HYDROCOR® CV50 is equipped with a color indicator, which is responsive on the pH-value of the fluid. The color of the fluid will change from ”red” to ”yellow” in case the pH-value drops. A yellow colored fluid indicates insufficient corrosion protection.

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DBT GmbH, Lünen 2006

The surfaces of the equipment are provided with a temporary corrosion protection. If stored properly, the equipment parts will be protected for six months referred to the date of delivery.

For further particulars on the properties of HYDROCOR® CV50 please refer to the respective data sheet of the manufacturer. exposure to sunlight

Protect the equipment against direct exposure to sunlight.

Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15 ºC to 25 ºC.

natural ageing

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore recommended for these parts.

moisture and dirt

Protect all hydraulic elements during storage in a suitable manner against the ingress of dirt and moisture. The connecting surfaces of the hydraulic components must be protected against corrosion and closed with blind plates. Hydraulic plug-type connections and the connectors of the electric cables must be closed with suitable caps or plugs.

short-term storage

During short-term storage (approx. 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must, however, be particularly protected against environmental influences, including high temperatures, for example by suitable covers or sheathings for the controls and by additionally covering the equipment.

*)

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If the equipment is to be stored for more than 6 months, the cavities in the hydraulic components must be completely filled with a preserving fluid such as e.g. HYDROCOR® CV 50. This fluid must have corrosion-protection properties and should be frost-proof within the respective temperature range of the application. All ports must be sealed with durable and suitable plugs.

It is highly recommended not to store the equipment outdoors but in a well ventilated room. If it is not possible to store the complete equipment indoors, remove the hydraulic and electronic components and store them separately.

plastic deformation

During long-term storage, the sealing elements may suffer plastic deformation due to the weight of the components. This may render the seals useless or reduce the life of the seals. Therefore, props and cylinders, for example, should only be stored in an upright position. If this is not possible with the components installed, they have to be dismantled.

random sample inspection

After a storage period of approx. two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by DBT. The cost will be borne by the mine.

HFA fluids

With respect to the storage of HFA fluids or concentrates for the production of HFA fluids in any case the regulations of the manufacturer or supplier of those media have to be observed first. Supplementary information is given in the chapter 6, in the section ”Permissible media”.

Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the ”first in, first out” principle. Mark the containers accordingly.

Used equipment If there is any need to store hydraulic equipment that has been in use before the items specified above apply analogously, with the exception of the item corrosion protection. corrosion protection

3.4

In case the hydraulic system is to be put out of operation temporarily the complete system has to be flushed thoroughly and filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50). If this is not done, considerable damage to the hydraulic components may be caused within a short time since the properties of the medium used may change very fast and negatively, e.g. due to microbial attack.

DBT - Electrohydraulic Control Unit - 12 Functions

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long-term storage

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Storage

EM026801-0 (EN-US)

Transport Transport Transport crates Several elektrohydraulic controls are packed together in transport crates. They should remain in these crates until they reach their final place of installation in order to protect them from damage.

Ensure that the crates are not damaged during transport. Pay attention in particular that they do not: J fall or J burst open

during transport.

Protect the transport crates from moisture. temperatures below freezing

Before transporting the elektrohydraulic control at temperatures below freezing, the block must be completely emptied and then filled with a suitable preserving fluid (e.g. HYDROCOR® CV 50).

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If the electrohydraulic control unit is subjected to temperatures below -20 ºC during transport special measures are required. In this case, please contact the DBT service department prior to the commencement of transport to clarify the requirements.

DBT GmbH, Lünen 2006

Dimensions and weight depth: . . . . . . . . . . . . . . . . . . . . width: . . . . . . . . . . . . . . . . . . . . . height: . . . . . . . . . . . . . . . . . . . . weight:

271,5 mm 340 mm 140 mm 53,50 kg

Plugs The connections of the individual electrohydraulic control units are sealed with plastic plugs to protect these from damp, dirt and damage.

NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs.

Remove the plugs just immediately before connection of the electrohydraulic control unit.

Holder with Control unit IMPORTANT! Ensure when transporting the shield that the holder with the control unit is fixed in position in such a way that it will not collide with other components when the shield is being lowered.

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Transport

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4

Installation

EM026801-0 (EN-US)

EM026801-0 (EN-US)

Requirements to the face hydraulic system

Installation This chapter contains information on the installation and removal of the elektrohydraulic control. Please pay particular attention to the warnings and tips.

WARNING! Improper or incorrect installation endangers you and others.

Carry out the installation only when you have the necessary special knowledge to do so and can prove it!

Requirements to the face hydraulic system NOTICE! The electrohydraulic and electronic parts of the electrohydraulic shield control system are covered by two separate manuals. The information required for start-up and operation of the electrohydraulic control unit is given in the manual for the respective control system used.

For all hydraulic components included in the scope of supply of DBT, the hydraulic medium must meet the following requirements: J Pressure fluid according to list of approved products, see secDBT GmbH, Lünen 2006

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tion ”Permissible media” in chapter 6 of this manual.

J Purity class 18 / 14 to ISO 4406.

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Installation of the elektrohydraulic control Installation of the elektrohydraulic control Removal of the elektrohydraulic control Before starting the installation or replacement of elektrohydraulic controls, you must take safety precautions: safety

. Close off your working area to prevent other persons getting there.

. Arrange for the mining work to be stopped in this area. . Inform your colleagues about the type and duration of the repair work and about your exact location.

. Actuate the support lock-out switch. . Secure the shield to prevent it from lowering under its own

weight; e.g. by placing hardwood wedges between the pairs of lemniscatic links or by supporting the canopy otherwise.

When everything is OK, you can proceed with the next steps.

. Mark the connecting cables and hydraulic hoses to prevent confusions.

. Pull the connecting cables from the covers of the pilot control valves.

DANGER! Before starting any work on the hydraulic system take care to ensure that the respective section of the system has been completely depressurized. You could be heavily injured or even killed by hydraulic hoses whipping around or by hydraulic fluid escaping under pressure.

Therefore, it is absolutely imperative that you depressurize the hydraulic line before starting to dismantle them.

In case, any of the staples are difficult to remove or cannot be removed at all please be extremely careful. It may indicate that the hydraulic line is still pressurized.

. Loosen all hydraulic connections on the rear of the elektrohydraulic control and ensure that the connections are not damaged or soiled.

. Secure the elektrohydraulic control with hoists and transport belts.

NOTICE! Do not secure the elektrohydraulic control with chains or steel ropes in order to avoid any danger of injury.

Use only transport belts as they fit closely to the elektrohydraulic control and prevent slipping.

. Loosen the bolts of the elektrohydraulic control mounting. . Pull the elektrohydraulic control out of the mounting.

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remove elektrohydraulic control

. Depressurize the hydraulic system of the shield in question. . Check that the hydraulic lines are really depressurized.

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shut off hydraulic pressure

EM026801-0 (EN-US)

Installation of the elektrohydraulic control Installation of the elektrohydraulic control To install the control unit,

. place the elektrohydraulic control into the mounting and tighten the bolts (M10) properly.

Fig. 7:

Installation example 2 6

5

1

12 15 8 7

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1, 2 holder 5 staple DN10 6 pin 7 symbol plate

11

8 symbol plate mounting bracket 11 hex. head bolt M6x8 12 hex. head bolt M10x20 15 spring clip

IMPORTANT! Before commissioning the shield, take care to ensure that the symbol plate is positioned such that the symbols are clearly legible.

CAUTION! Prior to assembly, sockets and nipples of the plug-type connectors must be treated with lubricating paste B3 to EWN 7068 which does not contain molybdenum disulfide, see chapter 6, section ”Lubricating greases and pastes”.

. Connect the hydraulic hoses, ensuring that the connections are not confused.

Observe the hose connection plan and the markings on the hoses.

DANGER! Hydraulic hoses whipping around can cause serious injury or even death.

Only use suitable staples for securing the connectors. Make sure to insert both ends of the staples and push them in completely. safety

. Check the hose connections again. The hose nipples must fit

tightly in the sockets and be secured with staples. Make sure to insert both ends of the staples and push them in completely.

Ensure that the connections are leak-tight.

. After connecting the hoses and checking the connections, plug

the connecting cable of the electrohydraulic control unit into the respective sockets of the pilot valves. Observe the circuit diagram and the markings on the cables.

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Installation of the elektrohydraulic control . Check all the connections once more against the hose connection diagram.

. Test all functions of the shield and remove the securing devices installed at the beginning of the work.

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WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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5

Operation

EM026801-0 (EN-US)

EM026801-0 (EN-US)

Operation This chapter contains information on the operation of the electrohydraulic control unit and on its functions. Be sure to also observe the operating manuals for the support and the control unit.

DANGER! Safety hazard due to shield movements.

Persons may be severely injured or even killed, for example by unexpected movements of the shield, if the control unit is operated by somebody who does not have sufficient knowledge of how to perform this work.

Only operate the controls of the electrohydraulic control unit if you have the required knowledge.

Fig. 8:

Electrohydraulic control unit, 12-functions a

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1

9

10

2 b

3

1 manifold block 2 double 3/2 way-solenoid-valve 3 screw-in socket NG 20 9 plug M 16x1

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10 plug M 18x1 a accumulator cartridge b staple

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Operation and function of the pilot valves Operation and function of the pilot valves Control of the shields is particularly dangerous in repair mode, as you then directly control the shield under which you are working. It is therefore extremely important that you know and understand the different functions and sequences of movement of the shield control.

If you are operating the shield in repair control mode, no one else is allowed to remain in the movement area of the shield.

Operation Two push buttons are provided on the cover of each pilot valve. By pressing a button you directly actuate the respective directional valves.

The function is terminated as soon as you release the button.

DANGER! Push buttons that are jammed or fixed could lead to uncontrolled movements of the shield. These may cause severe injuries or even death. Therefore never fix the push buttons.

Push buttons

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Fig. 9:

Function variable functions

5.4

The function of the individual pilot valves is variable and depends on the external connections. The function/push-button assignment is shown on a symbol plate. This symbol plate should be attached to the electrohydraulic control unit underneath or above the pilot valves. Please observe the hydraulic diagram in the separate operating manual for the shield.

DBT - Electrohydraulic Control Unit - 12 Functions

EM026801-0 (EN-US)

Filter cartridge Filter cartridge A filter cartridge (item 6, fig. 10) is provided in the manifold section of the electrohydraulic control unit. It protects the valves of the control unit against damage from impurities in the hydraulic medium.

Maintenance intervals IMPORTANT! The maintenance intervals recommended are standard values.

Special operating conditions may require different maintenance intervals. It is absolutely necessary that you adapt the maintenance intervals to the individual operating conditions. after one week

The filter cartridge in the manifold section should be checked for soiling one week after start-up of an electrohydraulic control system, at the latest. Replace the filter cartridge, if soiled.

If a large number of electrohydraulic control units have been placed in service on a face at the same time, it is sufficient to examine the filter cartridges randomly. If the inspection reveals that there is a high probability of failures due to soiled filter cartridges all filter cartridges on the face must be replaced.

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When extensive work has been performed on the hydraulic system or after start-up of a new face there is an increased risk of dirt having entered the hydraulic system. Depending on the degree of contamination this may lead to the filter cartridges on the whole face being soiled. This, in turn, results in the functions being operated slower or not at all. We therefore recommend that you take the measure described above in order to prevent failures occurring during operation of the shield hydraulics. according to schedule

If problems occur in the preparation of the medium there will be an increased risk of failures due to clogged filters. To maintain the operational reliability of the installation, certain measures may then have to be taken regularly. For example, you should take the precaution to maintain regular random inspections of the filter cartridges of all electrohydraulic control units on the face. It may be necessary to replace the filter cartridges at regular intervals as a precaution.

A filter cartridge is provided in the manifold block of the electrohydraulic control unit to protect the valves in the pilot circuit of the control unit against damage from impurities in the medium. This filter cartridge requires maintenance. Regular replacement, however, is only necessary when the filtration in the face supply unit is insufficient. Therefore, take care to ensure a high level of quality when processing the hydraulic medium.

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Filter cartridge Replacing the filter cartridge CAUTION! Only use each filter cartridge once and do not attempt to clean it. Dirt in the hydraulic system is a frequent cause of costly repairs. You should generally only use new filter cartridges and seals.

Preparation

. Secure the shield mechanically to prevent it from lowering under its own weight.

WARNING! Great likelihood of injury due to hydraulic fluid escaping under pressure. You may be severely injured or even killed. It is imperative that you depressurize the hydraulic circuit before working on it. Do not perform any work on a hydraulic circuit before having made sure that the pressure has been isolated.

. Close the shut-off valve in the pressure feed line P. . Check the system for any residual pressure. This pressure can

nection diagram and hydraulic circuit diagram.

When the hydraulic circuit has been depressurized, you can continue with the next working steps.

Unscrew the filter cartridge

. Remove any dust and dirt from the electrohydraulic control unit.

CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Unscrew the filter cartridge using a screwdriver.

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. Depressurize the system. Make sure to observe the hose con-

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build up in the hydraulic system as a result of the loads on the props and cylinders.

EM026801-0 (EN-US)

Filter cartridge Fig. 10: Unscrew the filter cartridge

8

5 6

7 screw fitting 8 screw fitting

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5 check valve NG 2 6 filter cartridge

7

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits.

Dispose of the filter cartridge in accordance with the environment protection regulations!

Screw in the new filter cartridge

. Screw in the new filter cartridge. . Tighten the cartridge finger-tight (15 Nm). . Check that the cartridge is fitted leak-tight.

When you have completed the check without finding any faults, the electrohydraulic control unit can be pressurized again. Remove the securing elements only when you are sure that the hydraulic components function properly.

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Accumulator cartridge Accumulator cartridge WARNING! Do not operate the control valve block without any or with a defective accumulator cartridge. Failure to comply can lead to malfunctions of the control valve block or the shield. This could result in injury or death to yourself or others. It is imperative that you replace defective accumulator cartridges without delay.

IMPORTANT! The accumulator cartridge is not included in the scope of supply of the control valve block. Please remember this information when ordering replacement parts.

The accumulator cartridge is located at the front of the manifold block, to the left of the solenoid pilot valves, see item a Fig. 8.

Replacing the accumulator cartridge Preparations

. Secure the shield mechanically to prevent it from lowering under its own weight.

WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurize the hydraulic system before starting work.

. Close the shut-off valve in the pressure feed line. . Operate the opposite acting pairs of hydraulic functions several times alternatively to depressurize the hydraulic system of the shield support.

. Check the control valve block for any residual pressure by turning the accumulator cartridge. Observe the hose connection plan and/or the hydraulic circuit diagram given in the separate operating manual for the shield.

Only when you are sure the system has been depressurized, you can continue with the next working steps.

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Accumulator cartridges must be checked for correct operation at regular intervals. We recommend to perform this test on a random sample basis. For this purpose, select a few samples and replace them by new cartridges. Test the samples to make sure they function properly. If they do, they can be installed again.

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IMPORTANT! A special device is required for charging and testing accumulator cartridges. Please contact your nearest DBT representation for information and help if such a device is not available at your site.

EM026801-0 (EN-US)

Accumulator cartridge Removing the accumulator cartridge CAUTION! Impurities in the hydraulic medium can result in serious damage to the whole hydraulic system!

Always ensure that your working area is clean.

. Remove any dust and other impurities from the accumulator

cartridge and the surroundings in order to prevent dirt entering the hydraulic system during assembly / disassembly of the accumulator cartridge.

WARNING! If staple locks are impossible or difficult to pull out be extremely careful as this may indicate that the hydraulic line is still under pressure. Be sure to depressurize the hydraulic line.

Replacing the accumulator cartridge

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Fig. 11:

b

a

a accumulator cartridge

b staple

. Pull the staple (b) out sideways. . Pull the accumulator cartridge (a) out to the front.

Installing the accumulator cartridge The new accumulator cartridge is installed in the reverse order of removal. Prior to installation, apply a separating agent/lubricant (B6 acc. to EWN 7068) to the surfaces to be joined, see also chapter 6, section ”Lubricating greases and pastes”.

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Accumulator cartridge

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6

Technical data

EM026801-0 (EN-US)

EM026801-0 (EN-US)

Description

Technical data This chapter contains important and useful information on the design and materials used. Information on permissible hydraulic fluids and recommendations on lubricants can be found at the end of the chapter.

IMPORTANT! Please use the spare parts catalog supplied when ordering spare parts.

Description Functions The electrohydraulic control unit permits to control 12 independent functions. The directional valves of the control block are actuated via solenoid-operated pilot valves. Operation of the pilot valves requires an electronic control unit such as for example a shield control unit of type PMC®-R. Fig. 12: Electrohydraulic control unit, front view

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a

b

c

a accumulator cartridge port, DN20 b manifold block

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c pilot control valves

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Description Design The main components of the electrohydraulic control unit are: J manifold block with

– directional valves, – check valve, – filter cartridge, – accumulator cartridge port and – connecting sockets, J pilot control valves.

Fig. 13: Electrohydraulic control unit d a

3

2

b

1 manifold block 2 double 3/2 way-solenoid-valve 3 screw-in socket DN20 a accumulator cartridge, connection

c

b push buttons c plug contact, electrical connection to the control unit d rear connecting sockets

Materials employed The electrohydraulic control unit is made of corrosion-resistant materials such as stainless steel, brass, bronze, etc.

The seal materials are designed for operation with HFA hydraulic fluids (oil-in-water emulsions).

Dimensions and weight depth: . . . . . . . . . . . . . . . . . . . . . . width: . . . . . . . . . . . . . . . . . . . . . . height: . . . . . . . . . . . . . . . . . . . . . weight: . . . . . . . . . . . . . . . . . . . . .

271,5 mm 340 mm 140 mm 53,50 kg

Pressure permissible working pressure: . test pressure: . . . . . . . . . . . . . . .

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1

EM026801-0 (EN-US)

Description Filter The filter cartridge protects the pilot control circuit against impurities. Use only new filter cartridges, never ”cleaned” cartridges.

Only new filter cartridges have the necessary filtration properties (mesh size = 25 µm), see also chapter 5 ”Operation”, section “Replacing filter cartridge”.

Mountings A total of 8 threaded holes (M10) are provided in the control unit which can be used for the attachment to different holders.

4 threaded holes (a) are located at the top and 2 holes (b) each at the side of the manifold block.

Fig. 14: Threaded bores a

a

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b

b

a, b thread M10

Valves Directional valves: J 3 x 3/2-way directional control valves (NG 20) J 10 x 3/2-way directional control valves (NG 13)

They are controlled by pilot control valves.

Pilot control valves: J 6 x double 3/2-way directional control valves (NG 0.5)

The pilot control valves are operated by a control unit (e.g.

PMC®-R). They can also be operated direct in an emergency or for repair purposes. To this end, the valve covers are provided with 2 push buttons each.

Power is supplied from the single control unit. A four-pin connector is provided on the housing cover of each pilot valve for connection of the required cables.

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Description Specification of the double 3/2-way directional control valves Classification according to directive 94/9/EG (ATEX): . . . . . . . . . . . . . . . . protection type: . . . . . . . . . . . . . . . . . . connectors: . . . . . . . . . . . . . . . . . . . . . solenoid design: . . . . . . . . . . . . . . . . . rated voltage: . . . . . . . . . . . . . . . . . . . perm. deviation: . . . . . . . . . . . . . . . . . switching current: . . . . . . . . . . . . . . . . current reduction: . . . . . . . . . . . . . . . .

group I, category M2 EExib l OS4 solenoid, round, 57 ohm type: DMA3 12 V, DC -2%/+10% approx. 190mA down to approx. 40 mA

WARNING! As soon as the current drops to a level below 40 mA, the switching positions become unstable. This results in malfunctions or even failure of the shield control.

Tab. 1: Certified Dust-Ex unit certification body

approval no.

Europe

INERIS, ATEX

05 ATEX 0049

USA

MSHA

18-ISA050002-0

Australia

Telesafe, ANZEx

05.4015X DBT GmbH, Lünen 2006

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area of application

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Hydraulic flow diagram Hydraulic flow diagram

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Fig. 15: Electrohydraulic control unit, 12 functions

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Connections Connections The connection ports for the hydraulic lines are located on the rear of the control valve block.

Fig. 16: Electrohydraulic control unit, rear view

12

4

6

8

10

2

1

2

P 11

9

7

5

3 T

connections: . . . . . . . . . . . . 3 x DN 20 socket, plug-type 1, 2, 2, SP (accumulator cartridge marking: . . . . . . . . . . . . . . . . port, front) flow rate: . . . . . . . . . . . . . . . . max. 340 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . large-volume consumers

medium-volume consumers

connections: . . . . . . . . . . . . 2 x DN 12 and 8 x DN 10 socket, plug-type marking: . . . . . . . . . . . . . . . . DN 12: 3, 12 DN 10: 4, 5, 6, 7, 8, 9, 10, 11 flow rate: . . . . . . . . . . . . . . . . max. 180 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . medium-volume consumers

pressure supply and tank line

6.8

connections: . . . . . . . . . . . . 2 x DN 25 socket, plug-type marking: . . . . . . . . . . . . . . . . P pressure supply T tank line flow rate: . . . . . . . . . . . . . . . . max. 340 l/min at ∆p = 100 bar application: . . . . . . . . . . . . . . P pressure supply to the system T return line to the tank

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Hydraulic connections

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Permissible media Permissible media Hydraulic fluids Permissible hydraulic fluids NOTICE! Use only hydraulic fluids for which a valid certificate issued by DBT GmbH has been made available to you. Otherwise, there is the danger of serious damage to the hydraulic equipment and the loss of warranty claims.

For the operation of hydraulic components of DBT GmbH generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWM 8350 or an exemption permit of DBT GmbH is available to the respective operator. DBT GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

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

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If a mine only uses individual hydraulic components without applying DBT shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid as is used for the existing shield support shall be allowed to be used for these individual components, subject to approval by DBT. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by DBT GmbH upon request.

Suitability test Before the certificate of DBT GmbH 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.

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

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

In addition, a chemical ”fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive the respective certificate by DBT GmbH.

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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 hydraulic systems of DBT GmbH for each product tested. The respective certificate shall be valid for a period of one year and, after a simplified test, can be extended for an additional year each. The certificate shall become invalid if one or several of the prerequisites 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.

DBT GmbH, Lünen 2006

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Fig. 17: Typical certificate

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EM026801-0 (EN-US)

Permissible media Hydraulic fluid maintenance A 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 but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects.

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

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual 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

– Target value: 7.5 to 9.5 J Concentrate ratio

– Target value: see certificate DBT GmbH, Lünen 2006

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J Microbial load

– Target value: < 105 Kol/m In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

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

Quality of the process water The quality of the water used for the preparation of 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.

The following table 2 lists limit values for the essential properties and components of the water.

If the limit values shown are maintained it can be assumed that the water is basically suitable.

If one or several of the limit values mentioned are not met this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, 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 also lead to the loss of the certificate even if they are within the limit values mentioned.

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Permissible media Tab. 2: Properties of the process water, limit values Test criterium

Limit value

Appearance, color, smell

no peculiarities permissible, e.g. turbidity, bad smell etc.

electrical conductivity

< 1800 µS/cm

pH-value

6,5 ..... 8,5

Na+ - content

not specified

Mg+ - content

not specified

water hardness

< 750 mg/l CaCO3 - äquivalent (≤ 42° dH)

Cl- - content

≤

201 mg/l

SO42- - content NO3- - content

≤

145 mg/l

≤

20 mg/l

Fe - content

≤

1 mg/l

Bacteriological requirements

≤

105 Kol/ml

Ratio of solid foreign matter at 1,2 µm filtering in conformity with DIN EN 12662

≤

10 mg/l

Contamination class according to ISO 4406: 1999

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Lubricating greases general properties

base: . . . . . . . . . . . . . . . . . . . . . . . . . lithium soap NLGI class: . . . . . . . . . . . . . . . . . . . 2 worked penetration: . . . . . . . . . . . . 265 to 295 (0.1 mm) behavior in the presence of water: practically non-soluble in water temperature of application : . . . . . -20 to +120 °C flash point: . . . . . . . . . . . . . . . . . . . . ≧ 200 °C

lubricating greases A1

Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN 1) 7068.

Tab. 3: Lubricating greases for general application

lubricating greases A2

Supplier

Type

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

Flash point in °C

Lubricating greases containing additives for application under high pressure e.g. for roller bearings and bearing locations subject to extreme load.

Tab. 4: Lubricating greases for general application Supplier

Type

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

Flash point in °C

1) EWN = DBT standard

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IMPORTANT! The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

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Lubricating greases and pastes

EM026801-0 (EN-US)

Permissible media IMPORTANT! The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

Lubricating pastes lubricating pastes B3

Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centerings and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Tab. 5: Lubricating pastes free from molybdenum disulfide

Type

Base

NLGI class

flash point °C

gleitmolybdän

gleitmo 805 *)

Li

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the DBT works standard EWN 7068 is:

E DBT GmbH, Lünen 2006

Supplier

gleitmolybdän ”gleitmo 805” lubricating pastes B6

Separating agents and lubricants with organic lubricating media on a synthetic base for lubricating thread areas and fits of props and hydraulic cylinders, of bolted connections and similar connecting elements of roof supports.

Behavior in the presence of water: . . . . non-soluble in water Temperature of application: . . . . . . . . . . . -34 to +120 ºC When the equipment is lubricated in our works for the first time, the lubricant type used as lubricant B 6 according to the DBT works standard EWN 7068 is : Chesterton separating agent and lubricant 785 (flash point 132 ºC) IMPORTANT! The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

*)

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The products listed in table 3 are suitable lubricating greases for filling of adjacent cavities.

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Permissible media

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For your information

EM026801-0 (EN-US)

EM026801-0 (EN-US)

Service addresses

For your information If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct (Homepage: www.dbt.de).

Service addresses Europe Germany

DBT GmbH (Headquarters) Industriestraße 1 D-44534 Lünen Tel: +49 / 23 06 70 9 - 0 Fax: +49 / 23 06 70 9 - 1421 E-mail: infodbt@dbt.de

Great Britain

DBT GB Limited Hallam Fields Road Ilkeston, Derbyshire DE7 4BS England

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Tel: +44 / 11 59 51 - 2500 Fax: +44 / 11 59 32 - 9683 E-mail: martin.daldrup@dbtgb.com DBT GB Limited Engineering Pioneer House 2 Renshaw Place Europoint Office Park Eurocentral Lanarkshire, ML1 4UF Scotland Phone: +44 / 16 98 83 5 - 000 Fax: +44 / 16 98 83 5 - 038 Poland

DBT POLSKA Sp. z. o.o. ul. Fabryczna 6, 41-404 Myslowice Tel: +48 / 32 31 70 - 500 Fax: +48 / 32 31 70 - 509 E-mail: dbtpolska@dbtpolska.com

Russia

DBT Office Moskau Bolschoi Tscherkassi Per. No. 15, Office 310 103626 Moskau Tel: +7 / 49 56 23 - 5396 Fax: +7 / 49 59 24 - 8363 E-mail: dbt@co.ru

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Service addresses OOO DBT RUS ul. Grdiny, 4 office 1 654066 Novokuzneck, Kemerovskaja obl.

Tel: +7 / 38 43 35 - 3441 Fax: +7 / 38 43 35 - 3442 E-mail: office@dbtrus.ru

Northamerica, Canada, Southamerica USA

DBT America Inc. 2045 West Pike Street Houston, PA 15342 - 1010 Tel: +1 / 72 47 43 - 1200 Fax: +1 / 72 47 43 - 1201 E-mail: info@dbtamerica.com DBT America Inc. 4041 Wurno Road Pulaski, VA 24301

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+1 / 54 09 80 - 4530 +1 / 54 09 94 - 3889

Australia DBT Australia Pty Ltd / DBT Diesel Pty Ltd 537 Lake Road Argenton, New South Wales 2284 P.O. Box 102 Boolaroo, New South Wales 2284 Tel: +61 / 24 95 8 - 3133 Fax: +61 / 24 95 8 - 5754 E-mail: tim.clark@dbtaustralia.com DBT Customer Service Center Mackay 14 Commercial Avenue Paget M.M.C Box 5182 Mackay Queensland 4741 Tel: Fax:

+61 / 74 95 2 - 0000 +61 / 74 95 2 - 0099

South Africa Südafrika

DBT Africa Pty. Ltd. Corner of Gamma and Zeta Roads Industries West Germiston 1401 Tel: + 27 / 11 82 5 - 8212 Fax: + 27 / 11 82 5 - 7389 E-mail: zelda.stephens@dbtafrica.com

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Tel: Fax:

EM026801-0 (EN-US)

Service addresses Asia China

DBT China Beijing Representative Office Suite 1112, Tower B Full Link Plaza No. 18 Chaowai Street Beijing 100020 Tel: +86 / 10 65 88 - 2998 Fax: +86 / 10 65 88 - 6570 E-mail: Info.beijing@dbtchina.com DBT (Langfang) Mine Technik Co. Ltd. Jinyua. Road - Langfang Economic and Technical Development Zone Hebei Province 065001 Tel: + 86 / 31 66 08 6 - 840 (& 841, 842, 843) Fax: + 86 / 31 66 08 6 - 845 E-mail: Info.langfang@dbtchina.com DBT Tangshan Machinery Ltd.

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No. 4 Gangyao Road Tangshan 063027 Hebei Province Tel: +86 / 31 53 20 - 3117 (& 3445, 3404) Fax: +86 / 31 53 20 - 3438 E-mail: Info.tangshan@dbtchina.com Shenhua DBT Belt Conveyor Co. Ltd. Bulianta, Yiqi County, Erdos City Inner Mongolia 017209 Tel: +86 / 47 78 28 - 7245 (& 7514, 7290) Fax: +86 / 47 78 28 - 7431 E-mail: Info.shenhua@dbtchina.com India

DBT Representative Office Calcutta c/o Thaphar House 25, Brabourne Road Calcutta 700 001 Tel: Fax:

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+91 / 33 24 2 - 0272 +91 / 33 24 2 - 8684

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Service addresses

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