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5 Operation

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___________________________________________________ Operation

______________________________________________________________ BI636364 REV 00 5.3

Operation

This chapter contains important information on the operation and maintenance of the system, an overview of the electrical, hydraulic, and mechanical components, how to adjust the system, and instructions on the replacement of wear parts. Read this chapter carefully and thoroughly paying particular attention to the safety instructions in Chapter 2, “Your safety”.

How to operate the conveyor system

DANGER! Incorrect operation endangers yourself and others! Incorrect op-eration of the system can be the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the system and have read and understood this operating manual. Should anything be unclear, please contact your immediate super-visor.

Who is allowed to operate the conveyor system?

The conveyor system is only allowed to be operated by persons with adequate knowledge of the complete system. This also includes: ■ what safety devices are installed on the system, ■ where these safety devices are located, and ■ how these safety devices are to be operated.

When can conveying be started?

Operation must not be started until the safe condition and proper func-tion of the complete system has been checked and the daily mainte-nance operations have been carried out.

Operation____________________________________________________

________________________________________________________________ 5.4 BC 200 OMM

Controls and indicators

Drive VFD operator’s station

The Drive controls for the system are located on the VFD cabinet. The Drive operator’s station (Fig. 9) consists of the following controls and indicators: Emergency Stop Power Disconnect ACS 800 DTC control

Fig. 9: Drive VFD operator’s station ACS 800 DTC

programmable controller

Drive E Stop

Power Disconnect

ACS 800 DTC Programmable controller

NOTICE! Before preforming any maintenance or service on the drive sys-tem. The power disconnect must be locked out in accordance with mine, local and regional rules and laws. The power disconnect is located to the right of the ACS 800 display and must be activated in order for the system to function. Belt conveyor start up sequences vary greatly due to mine conditions, follow mine supplied sequence for safe startup and shut down.

___________________________________________________ Operation

______________________________________________________________ BI636364 REV 00 5.5

This programmable controller (fig:10)has an extensive operations man-ual covering all features, programing and safety protocols please refer to vendor manual package and locate the “ACS800 –Firmware Manu-al—ACS800 Standard Control Program 7.x” The E STOP (Fig. 10) is used to break the control circuit in emergency situations. Striking the E Stop with a small amount of force will actuate the E STOP: all Drive system functions are shutdown immediately. The system fire suppression system for the belt conveyor is provided by the mine and follows all applicable mine, local and regional safety, actuation and resetting rules and laws. WARNING! The fire suppression actuator is actuated, the system must be completely reset before initiating a start sequence on the belt con-veyor system. IMPORTANT! PLC Programing for the drive and feeder systems was completed by mine personnel. There is no further information available on parameters or operational settings. All questions and concerns must be directed to the mine foreman.

E Stop

Fig. 10: ACS 800 Programmable controller

fire suppression

Operation____________________________________________________

________________________________________________________________ 5.6 BC 200 OMM

Fig. 11: Controls and indicators

Transformer

Profibus DP RPBA-01

ACS 800 Main Module

Breakers

Operation____________________________________________________

________________________________________________________________ 5.7 BC 200 OMM

Winch operator’s station

The Winch operator’s station (Fig. 14) is located near the winch take up system. The winch operator’s station consists of the following controls and indicators: Touch Screen Display Power Disconnect ACS 800 Programmable Controller E Stop Fig. 12: Winch operator’s station

E STOP

Touch Screen Display

Power Disconnect

ACS 800 Programmable Controller

___________________________________________________ Operation

______________________________________________________________ BI636364 REV 00 5.8

Winch operator’s station (Internal View)

The winch operator’s station consists internal view shows: Network Switch 120V Receptacle Communication Modules Circuit Breakers ACS 800 Controller Profibus DP RPBA-01 Transformers Fig. 13: Winch Operators Station

Communication Modules

Profibus DP RPBA-01

120 V

ACS 800 Controller

Circuit

Breakers

Transformers

Network Switch

___________________________________________________ Operation

______________________________________________________________ BI636364 REV 00 5.9

Starting procedure

After reading the previous descriptions and locating each control and completing the hands on operator training the operator is ready to oper-ate the conveyor system. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! The system should not be started if it’s core temperature is below 30° Fahrenheit. If the system is started at extremely low tempera-tures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the system.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the system.

Shutdown procedure

The best method for of shutting down the conveyor system is as de-scribed in operator training. Allow the system to run until the belt is empty. Continue to run the

system until all material that has been carried back into the return line has been cleaned out.

IMPORTANT! If material is very wet or sticky, it is recommended that the return line be flushed with water and the conveyor be allowed to run and clean out the return line before shutting the system down.

_____________________________________________ Electrical system

______________________________________________________________ BI636364 REV 00 5.10

Electrical system

The following pages contain a brief description of the major electrical components and assemblies that are on the conveyor system. The system receives electrical power through a heavy-duty cable. Be sure that the box connector is correctly identified and is securely con-nected; also check that the cable entrance is in good mechanical condi-tion. Walk along the cable from the power center to the conveyor sys-tem and check the condition of the cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment. Never use a cable with exposed wires or splices which heat up or spark under load. WARNING! This section is intended only to familiarize the user with the major electrical components of the conveyor system. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved. WARNING! Before removing the cover from the starter enclosure and attempt-ing any maintenance or troubleshooting on the system, the main power must be disconnected and locked and tagged out at the main power center.

Fig. 14: Major electrical component locator

Drive VFD Incoming Power Connection

Take Up VFD Incoming Power Connection

Electrical system _____________________________________________

________________________________________________________________ 5.11 BC 200 OMM

Drive panel - front side The Drive panel (Fig. 15) is accessed by opening the door on the en-closure. Located on the Drive panel are: ACS 800 controller, relays, transformers, circuit breakers and the main disconnect.

Fig. 15: Drive panel (front side) and main circuit breaker

Main Disconnect Main Disconnect is the main power control for the drive system. The control knob on the front of the enclosure panel is used to control the disconnect when the enclosure door is closed When looking directly at the main disconnect, when the shaft “T” han-dle is horizontal the power is ON. When the main disconnect “T” han-dle is vertical the power is OFF .

10A Breaker

Control Relays

Profibus communication adaptor

Main fuses

DIN Terminal blocks

Heavy Duty Bus chopper Transformer

Regulated Power supply

Main Disconnect

20A Breaker

_____________________________________________ Electrical system

______________________________________________________________ BI636364 REV 00 5.12

Drive panel - front side The Take up Panel (Fig. 16) is accessed by opening the doors on the enclosure. Located on the Take Up panel are: ACS 800 controller, re-lays, transformers, circuit breakers and the main disconnect.

Fig. 16: Take Up panel (inside view)

Main Disconnect

Main Disconnect is the main power control for the drive system. The control knob on the front of the enclosure panel is used to control the disconnect when the enclosure door is closed When looking directly at the main disconnect, when the shaft “T” han-dle is horizontal the power is ON. When the main disconnect “T” han-dle is vertical the power is OFF .

Control Relays

Profibus communication adaptor

Main fuses

DIN Terminal blocks

Heavy Duty Bus chopper

Transformer

Regulated Power supply

Main Disconnect

Breakers

Configurable Input/ Output Communication Module

____________________________________________ Hydraulic system

______________________________________________________________ BI636364 REV 00 5.13

Hydraulic system

The following pages contain a brief description of the hydraulic compo-nents and assemblies that are on the conveyor system. The Manual hydraulic system for this system has been designed to pro-vide manual hydraulic power for the Feeder Take up WARNING! This section is intended only to familiarize the user with the hy-draulic components of the conveyor system. All hydraulic mainte-nance should be performed only by a qualified technician with the knowledge of the function of the components involved. WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the system or serious injury or death to you or other workers.

Fig. 17: Hydraulic component locator conveyor system

Feeder

Manual

Hydraulic

Take Up

Hydraulic system _____________________________________________

________________________________________________________________ 5.14 BC 200 OMM

Major hydraulic components

The hand pump is located on the side of the take up section of the sys-tem, and is used to manually extend and retract the take up cylinders. The hydraulic cylinders are located on the feeder take up system. Each cylinder is individually controlled by the 4 way valve on the hand pump. WARNING! Do not replace the take up hydraulic cylinders with different style cylinders or the system may fall. The system could be damaged or you or other personnel could be seriously injured or killed by the failing system.

Take up hydraulic cylinders

take up hand pump

____________________________________________ Hydraulic system

______________________________________________________________ BI636364 REV 00 5.15

Fig. 18: Hydraulic schematic

Hydraulic

Cylinder

Hydraulic

Cylinder

Cylinder

fittings

Cylinder

fittings

Hydraulic

lines

Pump

fittings Selector

Valve

Manual

Pump

Mechanical assemblies ________________________________________

________________________________________________________________ 5.16 BC 200 OMM

Feeder power unit

The feeder power unit drives Feeder(s) (Fig. 19). It consists of a 55KW electric motor coupled to a gearbox via fluid coupling. The power unit has been assembled as a unit and can be removed as a unit or as indi-vidual components (see Replacement of wear parts section of this chapter).

Fig. 19: Feeder power unit main components

Motor (125 HP)

Connecting tube

Gearbox

Rigid Coupling

Fluid Coupling

_______________________________________ Mechanical assemblies

______________________________________________________________ BI636364 REV 00 5.17

Motor Cooling Fan

Winch Drum gearbox

Coupling Guard

Flex Coupling

Motor

Drum Guard

Brake

Winch power unit assembly

The Winch power unit (Fig. 20) is assembled so that it can be installed and removed as separate assemblies. Fig. 20: Winch power unit assembly

Mechanical assemblies ________________________________________

________________________________________________________________ 5.18 BC 200 OMM

Conveyor chain not shown

Drive power unit The drive power unit (Fig. 21) drives the belt. It consists of a 150 HP electric motor coupled to a reducer. The power unit has been assem-bled as a unit and can be removed as a unit or as individual compo-nents (see Replacement of wear parts section of this chapter). Fig. 21: feeder power unit

Motor (125 HP)

Connecting tube

Gearbox

Rigid Coupling

Fluid Coupling

_______________________________________ Mechanical assemblies

______________________________________________________________ BI636364 REV 00 5.19

Take Up Assembly

The Take Up assembly (Fig. 22) attaches to the end of the Feeder sys-tem frame. It consists of a return belt pulley, pillow block bearing and take up cylinders. The belt runs around the belt pulley and over the impact bed. The take up cylinders are used to tension the belt to correct for misa-lignment between the belt and the conveyor system. The take up assembly, when attached to the conveyor system, pro-vides a means for quickly tensioning the belt. Fig. 22: Take up assembly

Take up cylinder

Pillow block bearing

Belt pulley

Mechanical assemblies ________________________________________

________________________________________________________________ 5.20 BC 200 OMM

Carriage assembly

The carriage assembly (Fig. 23) attaches to the storage unit of the con-veyor system. It consists of pulley carriage and pulley. The carriage assembly is used to tension the belt during system advancement and retreat.

Fig. 23: carriage assembly

Upper belt spreader cylinder

Pillow Block Bearing

Winch Connection

Carriage Pulley Greasing Manifold

V-Groove Tracking wheel Assembly

Pulley Carriage Frame

________________________________________________ Maintenance

______________________________________________________________ BI636364 REV 00 5.21

Instructions on the maintenance

Maintenance at regular intervals increases the operational safety and prolongs the service life of the system. In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes

Please observe the following:

■ In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the system as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■ Inadequate maintenance can result in system damage which leads to considerable costs.

■ Use only suitable and approved tools for maintenance work.

■ Use only original Caterpillar spare parts when replacing components.

■ All electrical work must be supervised and inspected by a certified electrician.

■ Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Caterpillar guide.

Before maintenance

Please observe the following:

■ Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Follow all Federal and mine safety regulations for lockout/tagout procedures.

WARNING! Before performing maintenance on the system, the circuit breaker must be in the “OFF” position and the power should be discon-nected at the main power source. Follow all Federal and mine safety regulations for lockout/tagout procedures. Electrical shock and accidental system movement can cause serious injuries or even death to you or the maintenance person.

■ Test the controls to ensure that the unit will not move.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any system movement. Acci-dental system movement can cause serious injuries or even death to you or the maintenance person.

Maintenance _________________________________________________

________________________________________________________________ 5.22 BC 200 OMM

■ Do not perform maintenance on a hydraulic cylinder while there is a

load resting on the hydraulic cylinder. Loads must be securely blocked if maintenance is to be performed with a load on the hydraulic cylinder. Follow all Federal and mine safety standards for blocking the load.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load may fall, causing damage to the system or serious injury or death to you or other workers. Always block or place a mechanical lock on the load. Follow all Federal and mine safety standards for blocking the load. WARNING! You could be seriously injured or even killed by falling loads. Ob-serve the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads. ■ Do not perform maintenance in a congested area. This could

endanger the maintenance person or others in the vicinity. ■ Whenever a potential problem is uncovered during a periodic

maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■ Cleanliness can not be overemphasized as the essential ingredient

of a good maintenance program. System should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

Maintenance _________________________________________________

________________________________________________________________ 5.23 BC 200 OMM

Lubrication and inspection

Maintenance includes:

■ lubrication of the system in accordance with the lubrication schedule.

■ inspection of the system for faults and proper function. ■ inspection of wear parts.

Lubrication

IMPORTANT! The is equipped with lubrication manifolds on the system. The manifolds (Fig. 24) are located through out the conveyor system. This allows the following to be easily lubricated from a central point; he pulley bearings, and idler bearings. Fig:24 grease manifold

lubrication manifold

Grease Manifold

Maintenance _________________________________________________

________________________________________________________________ 5.24 BC 200 OMM

Inspection of the conveyor system

CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor. Prior to each shift the following points should be inspected: Clean and remove any foreign material from the operator’s station. Inspect all electrical cables, conduits, hydraulic hoses, fittings and

warning devices for signs of wear or damage. Visually inspect the condition and readability of all tags, labels and

reflectors. Check the “STOP” button (s) for correct operation. Check oil level in all reducers. Inspect the condition of all electrical and hydraulic components. Check for proper conveyor belt tensioning. Lubricate per the lubrication schedule. Check power input cable to power source insuring that the voltage

and breaker settings are correct. Check that all covers are installed and secure. Check the tightness of all connecting elements.

________________________________________________ Maintenance

______________________________________________________________ BI636364 REV 00 5.25

Inspection of wear parts on the conveyor

In order to be able to determine in good time when a repair shift has to be scheduled, and to avoid damage to other components, it is essential to inspect all the following wear parts as to their degree of wear: ■ the conveyor tail pulley ■ the idler rollers ■ the return rollers ■ the belt wipers ■ the belt cleaners ■ the plugged chute sensor

Inspection of fire suppression system on the conveyor

system

To provide maximum assurance that your fire suppression system will operate effectively and safely, the system should be inspected weekly, in accordance with mine safety procedures.