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Amendmentsandalterationstothispublicationarenotsubjectto notification.DBTGmbH(DBT)reservesallrightstothispublication. Itscontentisprotectedbycopyrightlaws,bothdomesticandinternational.Nopartofthispublicationmaybereproducedortransmittedinanywayorformwithoutthepriorwrittenapprovalofthe DBT. DBTdeclinesallliabilityfordirectorindirectconsequencesofprintingerrors.
Wereservetherighttointroducemodificationsobtainedby technicaldevelopmentwithoutpreviousnotice!
DBTGmbH,Lünen2005 E
3.Storageandtransport
5.Operation
6.Technicaldata
Aboutthismanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyou tousethismanual.Youwillalsobegiveninformationonthestructureofthemanualandthesymbolsandcharactersused.
Beforestartingwork
Takecaretoensurethattheoperatingmanualavailabletoyouis applicableforthetypeofelektrohydrauliccontrolunitused.Failure todosocanresultinasafetyhazardforyourselfandothers.Ensure thatthedataontheelektrohydrauliccontrolunitcomplywiththe datagivenintheoperatingmanual.
Thisoperatingmanualisdesignedfor Elektrohydrauliccontrolunit-14functions-withthe orderNo.:81541170000000
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.
Readthechapter”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.
Operationandmaintenance
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.Theelectrohydrauliccontrolunitis anessentialcomponentofthiselectrohydraulicshieldcontrol. Operationofthefunctionsisnotallowedtobemadedirectby pressingthebuttonsoftheelectrohydrauliccontrolunit,butvia therespectivesinglecontrolunitwhichmustbelocatedinoneof theadjacentshields.Bymeansofthiscontrolunitthepilot valvesofthecontrolblockareactuatedmanuallyorprogramcontrolled.
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.You couldbeseverelyinjuredorevenkilled.Thereforeonlyusethe electrohydrauliccontrolunitasintended!
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.
Hydraulics
Avoiddirectcontactbetweentheskinandhydraulicfluids. Hydraulicfluidcanpenetratetheskinandcauseseriousinfections. Neverusehydraulicfluidsforrinsingorcleaning.Hydraulicfluids representaveryseriousdangertohealth.
Onlypersonswhohaveandcandemonstrateaspecialknowledge ofhydraulicsareallowedtoworkonthehydraulicsystem.
Carryoutavisualinspectionofallthehydrauliccomponentsatregularintervals.Inparticularcheckthat:
J thehosesarenotpinchedortrapped.
J thehoseshavenobubblesorblisters.
J thehosesortheoutersheathesofthehosesarenotabnormally rigidorhard.
J theoutersheathofthehoseisnotdamaged.
J theconnectorsaresecurelyinsertedintothesockets.
J theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork. Dirtinthehydraulicsystemcancauseseriousdamageinthewhole system!Flushoutthehydrauliclinesthoroughlybeforeconnecting. Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurised.Besureto depressurisethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththe propercouplingclamps.Alwaysfastentheclampscompletely. Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressuringthesystemagain.
Useonlyhydraulichosesapprovedfortheprevailingpressures. Donotuseanyhydraulichoseswithdamagedconnectorsorworn O-rings.
Replacehydraulichosesonlywithhosesofthesameorahigher quality.
Observethedateofmanufacturestampedonthehydraulichoses. Neverusehydraulichoseswhicharemorethan2yearsold,evenif theyhavenovisiblesignsofdamage.
Fig.1:Example:4SPhydraulichose,designation
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Safetyinstructions
layinghydraulichoses
Nevertrytoholdapulsinghydraulichose.Depressurisethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses. Replacehydraulichosesatthefirstsuspicionofdamage. Laythehydraulichosesproperlybehindthebracketsandclamps providedforthem.
Alwayslayhydraulichosessothatthey:
J alwayshavealittleslack,
Fig.2:Layinghydraulichoses,slack
J arenottwisted,
Fig.3:Layinghydraulichoses,twisting RIGHT
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
Thisisasummaryofallsafetyinstructionsgivenintheindividual chaptersofthisoperatingmanual.Asthesesafetyinstructionsare citedoutoftheircontextthemeaningisnotalwaysobvious.
Chapter3:Storageandtransport
NOTICE!
Dirtinthehydraulicsystemcanresultinfailureofthewholesystem andnecessitatecostlyrepairs. Removetheplugsjustimmediatelybeforeinstallationandconnectionofthecontrolblock.
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”Recommendedlubricatinggreasesandpastes”.
NOTICE!
Theelectrohydraulicandelectronicpartsoftheelectrohydraulic shieldcontrolsystemarecoveredbytwoseparatemanuals.The informationrequiredforstart-upandoperationoftheelectrohydrauliccontrolunitisgiveninthemanualfortherespectivecontrol systemused.
Donotsecuretheelectrohydrauliccontrolunitwithchainsorsteel ropesinordertoavoidanydangerofinjury. Useonlytransportbeltsastheyfitcloselytotheelectrohydraulic controlunitandpreventslipping.
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Chapter5:Operationsandmaintenance
DANGER!
Safetyhazardduetoshieldmovements. Personsmaybeseverelyinjuredorevenkilled,forexampleby unexpectedmovementsoftheshield,ifthecontrolunitisoperated bysomebodywhodoesnothavesufficientknowledgeofhowtoperformthiswork.
Onlyoperatethecontrolsofthecontrolblockifyouhavethe requiredknowledge.
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.
Usefiltercartridgesonlyonceanddonottrytocleanthem. Soilinginthehydraulicsystemisafrequentcauseofcostlyrepairs. Alwaysuseonlynewfiltercartridgesandseals.
Soilinginthehydraulicsystemcanresultinseriousdamagetothe wholehydraulicsystem!
Alwaysensurethatyourworkingareaisclean.
Impuritiesinthehydraulicmediumcanresultinseriousdamageto thewholehydraulicsystem!
Alwaysensurethatyourworkingareaisclean.
NOTICE!
Therecommendedmaintenanceintervalsmustbeunderstoodasa guidelineandmustbeadaptedtotheindividualoperatingconditions .Dependingontheactualoperatingconditionsthemaintenance intervalspossiblymustbeshortenedorcanbeprolonged.
Overviewofthesafetyinstructions
IMPORTANT!
Thefiltercartridgeissoiledwithemulsionresiduesanddeposits. Disposeofthefiltercartridgeinaccordancewiththeenvironment protectionregulations!
Theaccumulatorcartridgeisnotincludedinthescopeofsupplyof thecontrolvalveblock.Pleaserememberthisinformationwhen orderingreplacementparts.
Aspecialdeviceisrequiredforchargingandtestingaccumulator cartridges.PleasecontactyournearestDBTrepresentationfor informationandhelpifsuchadeviceisnotavailableatyoursite.
Chapter6:Technicaldata
WARNING!
Assoonasthecurrentdropstoalevelbelow40mA,theswitching positionsbecomeunstable.Thisresultsinmalfunctionsorevenfailureoftheshieldcontrol.
NOTICE!
UseonlyhydraulicfluidsapprovedbyDBT! ThesefluidshavebeentestedatDBTandguaranteeareliable operationofthehydraulicsystem.
IMPORTANT!
Pleaseusethesparepartscatalogsuppliedwhenorderingspare parts.
Weexpresslypointoutthattheapprovalofthelistedproducts relatesonlytothepuretechnicaluseinourhydraulicsystems.Only themanufacturersareresponsiblefortheconstituentsusedinthe hydraulicfluidconcentrates.
Besuretoobservethemanufacturer’sinstructionsforuse. FurtherinformationiscontainedinDIN24320.
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 onlyinclosedroomsattemperaturesof15 °Cto25 °C.
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 informationisgiveninthesection”PressurefluidsofgroupHFA”in thismanual.
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-20°Cduringtransportspecialmeasuresarerequired.Inthis case,pleasecontacttheDBTservicedepartmentpriortothecommencementoftransporttoclarifytherequirements.
Dimensionsandweight
Plugs
Theconnectionsoftheindividualelectrohydrauliccontrolunitsare sealedwithplasticplugstoprotectthesefromdamp,dirtanddamage.
NOTICE!
Dirtinthehydraulicsystemcanresultinfailureofthewhole systemandnecessitatecostlyrepairs. Removetheplugsjustimmediatelybeforeconnectionofthe electrohydrauliccontrolunit.
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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”Operatingmedia”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.
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